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

GENERAL WARNINGS Warningsshowncannotberepresentativeofalldangersituationspossiblyoccurring.Therefore,itissuggestedtocontact immediatesuperiorswhereadangersituationoccurswhichisnotdescribed. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenancehandbooks.Checkusestateandsuitabilityoftoolsnotsubjectedtoregularcheck. Themanualhandlingofloadsmustbeassessedinadvancebecauseitalsodepends,besidesweight,onitssizeandon the path. Handlingbymechanicalmeansmustbewithhoistersproperasforweightaswellasforshapeandvolume.Hoisters, ropesandhooksusedmustcontainclearindicationsonmaximumcarryingcapacityacceptable.Theuseofsaidmeans iscompulsorilypermittedtoauthorisedpersonnelonly.Staydulyclearoftheload,and,anyhow,neverunderit. In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentallystrikingworkshoppersonnel. Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerousfortheco-operatorbecauseoflackofvisibilityorofhis/hernotcorrectposition. Keeppersonnelnotauthorisedtooperationsclearofworkingarea. Learnoperationandsafetyknowledgenecessaryrelatingtothevehiclepriortoeachinterventiononit.Scrupulously observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair interventionhasbeencompleted,beforestartingupthevehicle,performallchecksindicatedonparagraph“Controls careofuser”ofUseandMaintenancehandbook. Inlackofvisibilityinoperatingfromthevehicle,chargeapersononthegroundwithassistance.Donotleaveunmanned avehicleinmotionduringrepairinterventions. Keepthevehiclestationarybyproperchocks. Inthecaseofaninterventiononavehicleliftedfromtheground,checkthevehicletobequitesteadyonspecialsupport standsand,inthecaseofliftingbymeansofalift,checkmanual/automaticsafetiestobeactivated. Whenitisnecessarytoperformaninterventiononmethane-fedvehicles,observetheindicationscontainedinsidethe document,aswellasallspecificsafetyregulationsprovided. Onlyremoveradiatorcapwhentheengineiscoldbycautiouslyunscrewingitinordertoletsystemresidualpressure out. Inflammablefuelandallinflammablefluidsandliquidsmustbehandledwithcare,accordingtowhatcontainedonharmful materials12-pointcards.Refuellingmustbeperformedoutdoorswiththeengineoff,avoidinglitcigarettes,freeflames orsparksinordertopreventsuddenfires/bursts.Adequatelystoreinflammable,corrosiveandpollutingfluidsandliquids accordingtowhatprovidedbyregulationsinforce.Compulsorilyavoidtousefoodcontainerstostoreharmfulliquids. Avoidtodrillorborepressurisedcontainers,andthrowclothsimpregnatedwithinflammablesubstancesintosuitable containers. Wornout,damagedorconsumablepartsmustbereplacedbyIvecooriginalspares. Duringworkshopactivity,alwayskeeptheworkplaceclean;timelyclearorcleanfloorsfromaccidentalliquidoroilspots. Electricsocketsandelectricequipmentnecessarytoperformrepairinterventionsmustmeetsafetyrules. For every intervention on vehicle hydraulic, pneumatic, conditioning and AIR - BAG systems, scrupulously observe indicationsspecifiedinrelatingmanualsections. ! Base-March2006 Print 603.93.651 IV

GENERAL WARNINGS Cleanunitsorassembliesdetachedfromthevehicleandcarefullychecktheirintegritybeforeoverhaul.Tidyupdetached ordisassembledpartswiththeirsecuringelements(screws,nuts,etc.)intospecialcontainers. Checkfortheintegrityofthepartswhichpreventscrewsfrombeingunscrewed:brokenwashers,dowels,clips,etc. Self-lockingnutswithaninsertmadeofnylonmustalwaysbereplaced. Avoidcontactofrubberpartswithdieseloil,petrolorothernotcompatiblesubstances. Beforewashingunderpressuremechanicalparts,protectelectricconnectors,andcentralunits,ifpresent. Tighteningscrewsandnutsmustalwaysbeaccordingtoprescriptions;IVECOcommercialandassistancenetworkis availabletogiveallclarificationsnecessarytoperformrepairinterventionsnotprovidedinthisdocument. Before welding: - Disconnectallelectroniccentralunits,takepowercableoffbatterypositiveterminal(connectittochassisbonding) anddetachconnectors. - Removepaintbyusingpropersolventsorpaintremoversandcleanrelevantsurficeswithsoapandwater. - Awaitabout15minutesbeforewelding. - Equipwithsuitablefireresistantprotectionstoprotecthosesorothercomponentswherefluidsorothermaterials flowwhichmaycatchfireeasilyonwelding. Shouldthevehiclebesubjectedtotemperaturesexceeding80°C(dryerovens),disassembledriveelectroniccentral units. Thedisposalofallliquidsandfluidsmustbeperformedwithfullobservanceofspecificrulesinforce. Puton,whererequiredbytheintervention,garmentsandprotectionsprovidedinaccidentpreventionrules;contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc. Donotleavetheengineinmotionatworkshoplocationsnotprovidedwithapipetoscavengeexhaustgasoutside. Avoidtobreathefumescomingfromheatingorfrompaintweldingbecausetheycancausedamagestohealth;operate outdoorsorinsuitablyventilatedareas.Putonproperinspiratorifpaintpowderispresent. Avoidcontactwithhotwaterorsteamcomingfromtheengine,radiatorandpipingsbecausetheycouldcauseserious burns.Avoiddirectcontactwithliquidsandfluidspresentinvehiclesystems;whereanaccidentalcontacthasoccurred, referto12-pointcardsforprovisionstomake. Print 603.93.651 Base-March2006 V

GENERAL WARNINGS ON THE ELECTRIC SYSTEM Tostartuptheengine,donotusefastchargers.Startupmustonlybeperformedwitheitherseparatebatteriesorspecial truck. Awrongpolarisationofsupplyvoltageindriveelectroniccentralunits(forinstance,awrongpolarisationofbatteries) cancausethemtobedestroyed. Disconnectthebatteriesfromthesystemduringtheirrechargingwithanexternalapparatus. On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening torque. Beforedisconnectingthejunctionconnectorfromanelectroniccentralunit,isolatethesystem. Donotdirectlysupplyelectroniccentralunitsservocomponentsatnominalvehiclevoltage. Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure. Oncetheinterventionontheelectricsystemhasbeencompleted,recoverconnectorsandwiringharnessesaccording tooriginalarrangement. Keymemorisationproceduresareinfluencedbyelectromagneticjamming(mobilephones,etc.).Therefore,duringkey memorisation: 1 Payattentionthatjammingsourcesarenotpresentinthecabornearthekeys. 2. Keysnotinseredinthepanelmustbeatleast1meteraway. Ifaninterventionhastobemadeontheelectric/electronicsystem,disconnectbatteriesfromthesystem;inthiscase, alwaysdisconnect,asafirstone,thechassisbondingcablefrombatteriesnegativeterminal. Beforeconnectingthebatteriestothesystem,makesurethatthesystemiswellisolated. Disconnecttheexternalrechargingapparatusfromthepublicutilitynetworkbeforetakingapparatuspinsoffbattery terminals. Donotcausesparkstobegeneratedincheckingifthecircuitisenergised. Donotuseatestlampincheckingcircuitcontinuity,butonlyusepropercontrolapparatuses. Makesurethattheelectronicdeviceswiringharnesses(length,leadtype,location,strapping,connectiontoscreening braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance interventions. Measurementsindriveelectroniccentralunits,pluggedconnectionsandelectricconnectionstocomponentscanonly bemadeonpropertestinglineswithspecialplugsandplugbushes.Neveruseimpropermeanslikewires,screwdrivers, clipsandthelikeinordertoavoidthedangerofcausingashortcircuit,aswellasofdamagingpluggedconnections,which wouldlatercausecontactproblems. Connectorspresentmustbeseenfromcableside.Connectorsviewscontainedinthemanualarerepresentativeofcable side. ! NOTE Base-March2006 Print 603.93.651 VI

Print 603.93.651 Base-March2006 VII Bonding and screening Negativeleadsconnectedtoasystembondedpointmustbebothasshortandpossible and“star“-connectedtoeachother,trying thentohavetheircenteringtidilyandproperlymade(Figure1,re.M). Further,followingwarningsaretobecompulsorilyobservedforelectroniccomponents: - Electroniccentralunitsmustbeconnectedtosystembondingwhentheyareprovidedwithametallicshell. - Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening bonding(avoiding“serial“or“chain“connections),andtobatterynegativeterminal. - Analogbonding(sensors),althoughnotconnectedtobatterynegativesystem/terminal bonding,musthaveoptimalisolation. Consequently,particularlyconsideredmustbeparasiticresistancesinlugs:oxidising,clinchingdefects,etc. - Screenedcircuitsbraidingmustonlyelectricallycontacttheendtowardsthecentralunitenteredbythesignal(Figure2). - Ifjunctionconnectorsarepresent,unscreenedsection d,nearthem,mustbeasshortaspossible(Figure2). - Cablesmustbearrangedsuchastoresulttobeparalleltoreferenceplane,i.e.ascloseaspossibletochassis/bodystructure. 1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M 2. SCREENINGTHROUGHMETALLICBRAIDINGOFACABLETOANELECTRONICCOMPONENT— C. CONNECTOR d. DISTANCE ! 0 88039 Figure 1 Figure 2

Base-March2006 Print 603.93.651 VIII OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Accessories mounting, additions and modifications on the vehicle are to be performed complying with IVECO mounting instructions(specificdocument“Instructionsfortransformationandpreparation”isavailableatAssistanceNetworkworkshops). Itisremindedthat,especiallyabouttheelectricsystem,severalelectricsocketsareprovidedforasseries(oroptional)socketsin ordertosimplifyandnormalisetheelectricalinterventionthatiscareofpreparationpersonnel. Foranyexceptiontomountinginstructions,IVECO’sauthorisationisnecessary. Lackofobservanceofabovedescribedprescriptionsinvolvesguaranteelapse. Itisabsolutelyforbiddentomakemodificationsorconnectionstoelectriccentralunitswiringharnesses;inparticular, thedatainterconnectionlinebetweencentralunits(CANline)istobeconsideredinviolable. CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES Power 1kW = 1.36metricHP 1kW = 1.34HP 1metricHP = 0.736kW 1metricHP = 0.986HP 1HP = 0.746kW 1HP = 1.014metricHP Torque 1Nm = 0.1019kgm 1kgm = 9.81Nm Revolutions per time unit 1rad/s = 1rpmx0.1046 1rpm = 1rad/sx9.5602 Pressure 1bar = 1.02kg/cm 2 1kg/cm 2 = 0.981bar 1bar = 10 5 Pa Whereaccuracyisnotparticularlyneeded: - Nmunitisforthesakeofsimplicityconvertedintokgmaccordingtoratio10:1 1kgm = 10Nm; - barunitisforthesakeofsimplicityconvertedintokg/cm 2 accordingtoratio1:1 1kg/cm 2 = 1bar. Temperature 0° C = 32° F 1° C = (1x1.8+32) ° F

IVECO FIA FIC Engine Service Repair Manual 2006-2012

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