IVECO FIA FIC Engine Service Repair Manual 2006-2012

DAILY EURO 4 REPAIR MANUAL MECHANICAL ELECTRIC/ELECTRONIC

B.U. TECHNICAL PUBLISHING IvecoTechnicalPublications LungoSturaLazio,15 10156Torino(TO)-Italy Producedby: ”Thisdocumentprovidesdata,characteristics,instructionsand methodology to perform repair interventions on the vehicle anditscomponents. Anyhow, this document is addressed to qualified and specialised personnel. Iveco commercial and assistance network personnel as well as all Iveco authorised points of assistance are specifically qualified and equipped to perform therepairinterventionsthatareindicatedinthisdocument. Before performing any intervention, check to have available the document relating to the vehicle model on which the intervention is being performed and also make sure that all accidentpreventiondevices,suchas,asaroughguide,goggles, helmet, gloves, shoes, as well as work tooling, lifting and transport tooling, etc., are available and efficient, and further make sure that the vehicle is put such a way that an interventioncanbemadeinsafetyconditions. Making interventions strictly observing the indications given here, as well as using specific tooling indicated, assures a correctrepairintervention,executiontimingobservanceand operators’ safety. Eachrepairinterventionmustbefinalisedtotherecoveryof functionality,efficiencyandsafetyconditionsthatareprovided byIveco. Each intervention, on the vehicle, that is finalised to a modification, alteration or else, which is not authorised by Iveco, involves the exclusion of any responsibility for Iveco, and,inparticular,wherethevehicleiscoveredbyaguarantee, each such intervention involves an immediate lapse of the guarantee. Responsibility for Iveco in repair intervention execution is excluded. Ivecoisavailabletoprovideallclarificationsnecessarytomake interventions, as well as to provide indications in cases and situationsnotincludedinthisdocument. Dataandinformationcontainedinthisdocumentcouldresult not to be updated owing to modifications made by Iveco at anymomentfortechnicalorcommercialreasons,orbecause of the need to adapt the vehicle to law requirements in different countries. Inthecaseofadifferencebetweenwhatcontainedhereand what actually found on the vehicle, please contact Iveco networkbeforemakinganyintervention.” Thedatacontainedinthispublicationmightfailtoreflectthe latestchangeswhichtheManufacturermayintroduceatany time, for technical or sales purposes, or to meet the requirementsoflocallegislation. Copy,evenpartial,oftextanddrawingsisforbidden. PublicationEditedby: IVECOS.p.A. Customer Service LungoSturaLazio,15 10156Torino(TO)-Italy Print 603.93.651 -1 st Ed.2006

ManualsforrepairsaresplitintoSections,eachoneofwhichismarkedbyanumeral;thecontentsofthesesectionsareindicated inthegeneraltableofcontents. EachsectionisgenerallydedicatedtoamainUnit(e.g.:engine,gearbox,electricsystem,etc.). Sectionswithmechanicalcontentsincludetechnicaldata,tighteningtorquecollections,toollists,connections—disconnectionsof unitsto/fromthevehicle,overhaulsatthebenchandrelatingtroubleshooting. Ontheelectric/electronicsystemsectiontherearethedescriptionsoftheelectricnetworkandvehicleelectronicsystems,electric schemes,componentselectriccharacteristics,componentscodesand troubleshootingrelatingtothecentralunitsspecificofthe electric system. Themanualusespropersymbolsinitsdescriptions;thepurposeofthesesymbolsistoclassifycontainedinformation.Inparticular, therehavebeendefinedasetofsymbolstoclassifywarningsandasetforassistanceoperations. PRELIMINARY REMARKS General danger Itincludesthedangersofabovedescribedsignals. Danger of serious damage for the vehicle Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes guarantee lapse too. Environment protection Itindicatescorrectbehaviourinorderthatvehicleuseisenvironmentallyfriendlyasmuchaspossible. Danger for persons Missingorincompleteobservanceoftheseprescriptionscancauseseriousdangerforpersons’safety. SYMBOLS - WARNINGS Itindicatesanadditionalexplanationforapieceofinformation. ! NOTE Print 603.93.651 Base-March2006 I

Base-March2006 Print 603.93.651 II SYMBOLS - ASSISTANCE OPERATIONS Removal Disconnection Intake Refitting Connection Exhaust Removal Disassembly Operation Fittinginplace Assembly ρ Compression ratio Tightentotorque Tolerance Weight difference α Tightentotorque+anglevalue Rollingtorque Pressorcaulk Rotation Regulation Adjustment Angle Angularvalue Visual inspection Fittingpositioncheck Preload Measurement Valuetofind Check Number of revolutions Equipment Temperature Surface for machining Machine finish bar Pressure Interference Strainedassembly Oversized Higherthan…. Maximum, peak Thickness Clearance Undersized Lessthan…. Minimum Lubrication Damp Grease Selection Classes Oversizing Sealant Adhesive Temperature<0 °C Cold Winter Air bleeding Temperature>0 °C Hot Summer Replacement Originalspareparts

Eachtitleorsubtitleconcerningoperationsbeingperformedisprecededbyasix-figurenumbernamedPRODUCTCODE. This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES and TROUBLE CODE document. Asaquickreferencethereareshownbelowtheguidelinestoreadthiscode(seeRepairTiming,too). Product Code: ThefirstandsecondfiguresidentifythePRODUCTwithinmotorvehicle. Example: Product 50 = Vehiclechassis; Product 52 = Axles; Product 53 = Transmission; Product 76 = Electricssystem. Unit Code: ThethirdandfourthfiguresidentifytheUNITwithinthePRODUCT. Example: Product 50 = Vehiclechassis; Unit 01 = Chassis; Unit 02 = Bumpers; Unit 03 = Alternator. Sub-assembly Code: ThefifthandsixthfiguresexactlyidentifytheSUB-ASSEMBLYandComponentofaUnitwithinaPRODUCT. Example: Product 50 = Vehiclechassis; Unit 01 = Chassis; Sub-assembly 40 = Chassiscrossmembers; Sub-assembly 13 = Rotor. PRODUCT CODE 5 0 PRODUCT UNIT SUB-ASSEMBLY COMPONENT 0 1 4 0 7 6 0 3 1 3 PRODUCT UNIT SUB-ASSEMBLY COMPONENT PRODUCT UNIT SUB-ASSEMBLY COMPONENT PRODUCT UNIT SUB-ASSEMBLY COMPONENT PRODUCT UNIT SUB-ASSEMBLY COMPONENT PRODUCT UNIT SUB-ASSEMBLY COMPONENT Print 603.93.651 Base-March2006 III

IVECO FIA FIC Engine Service Repair Manual 2006-2012

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