IVECO - STRALIS AS 4_5 - REPAIR MANUAL.pdf

STRALIS AS EURO 4/5REPAIR MANUALMECHANICALELECTRIC/ELECTRONIC

This document provides data, characteristics, instructions andmethodology to perform repair interventions on the vehicleand its components.

Anyhow, this document is addressed to qualified andspecialised personnel. Iveco commercial and assistancenetwork personnel as well as all Iveco authorised points ofassistance are specifically qualified and equipped to performthe repair interventions that are indicated in this document.

Before performing any intervention, check to have availablethe document relating to the vehicle model on which theintervention is being performed and also make sure that allaccident prevention devices, such as, as a rough guide, goggles,helmet, gloves, shoes, as well as work tooling, lifting andtransport tooling, etc., are available and efficient, and furthermake sure that the vehicle is put such a way that anintervention can be made in safety conditions.

Making interventions strictly observing the indications givenhere, as well as using specific tooling indicated, assures acorrect repair intervention, execution timing observance andoperators safety.

Each repair intervention must be finalised to the recovery offunctionality, efficiency and safety conditions that are providedby Iveco.Each intervention, on the vehicle, that is finalised to amodification, alteration or else, which is not authorised byIveco, involves the exclusion of any responsibility for Iveco,and, in particular, where the vehicle is covered by a guarantee,each such intervention involves an immediate lapse of theguarantee.

Responsibility for Iveco in repair intervention execution isexcluded.

Iveco is available to provide all clarifications necessary tomakeinterventions, as well as to provide indications in cases andsituations not included in this document.

Data and information contained in this document could resultnot to be updated owing to modifications made by Iveco atany moment for technical or commercial reasons, or becauseof the need to adapt the vehicle to law requirements indifferent countries.

In the case of a difference between what contained here andwhat actually found on the vehicle, please contact Iveconetwork before making any intervention.

The data contained in this publication might fail to reflect thelatest changes which the Manufacturer may introduce at anytime, for technical or sales purposes, or to meet therequirements of local legislation.

Copy, even partial, of text and drawings is forbidden.

Publication Edited by:IVECO S.p.A.Customer ServiceLungo Stura Lazio, 1510156 Torino (TO) - Italy

Print 603.93.531 - 2nd Ed. 2006

B.U. TECHNICAL PUBLISHINGIveco Technical PublicationsLungo Stura Lazio, 1510156 Torino (TO) - Italy

Produced by:

Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicatedin the general table of contents.Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.).Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections disconnections ofunits to/from the vehicle, overhauls at the bench and relating troubleshooting.On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electricschemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of theelectric system.The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,there have been defined a set of symbols to classify warnings and a set for assistance operations.

PRELIMINARY REMARKS

General dangerIt includes the dangers of above described signals.

Danger of serious damage for the vehiclePartial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimesguarantee lapse too.

Environment protectionIt indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.

Danger for personsMissing or incomplete observance of these prescriptions can cause serious danger for persons safety.

SYMBOLS - WARNINGS

It indicates an additional explanation for a piece of information.

!

NOTE

Print 603.93.531 Base - September 2006I

Base - September 2006 Print 603.93.531II

SYMBOLS - ASSISTANCE OPERATIONS

RemovalDisconnection

Intake

RefittingConnection

Exhaust

RemovalDisassembly

Operation

Fitting in placeAssembly Compression ratio

Tighten to torqueToleranceWeight difference

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

RegulationAdjustment

AngleAngular value

Visual inspectionFitting position check

Preload

MeasurementValue to findCheck

Number of revolutions

Equipment Temperature

Surface for machiningMachine finish bar

Pressure

InterferenceStrained assembly

OversizedHigher than.Maximum, peak

ThicknessClearance

UndersizedLess than.Minimum

LubricationDampGrease

SelectionClassesOversizing

SealantAdhesive

Temperature < 0 CColdWinter

Air bleedingTemperature > 0 CHotSummer

ReplacementOriginal spare parts

Each title or subtitle concerning operations being performed is preceded by a six-figure number named PRODUCT CODE.This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES andTROUBLE CODE document.As a quick reference there are shown below the guide lines to read this code (see Repair Timing, too).

Product Code:

The first and second figures identify the PRODUCT within motor vehicle.

Example :

Product 50 = Vehicle chassis;Product 52 = Axles;Product 53 = Transmission;Product 76 = Electric ssystem.

Unit Code:

The third and fourth figures identify the UNIT within the PRODUCT.

Example :

Product 50 = Vehicle chassis;Unit 01 = Chassis;Unit 02 = Bumpers;Unit 03 = Alternator.

Sub-assembly Code:

The fifth and sixth figures exactly identify the SUB-ASSEMBLY and Component of a Unit within a PRODUCT.

Example :

Product 50 = Vehicle chassis;Unit 01 = Chassis;Sub-assembly 40 = Chassis cross members;Sub-assembly 13 = Rotor.

PRODUCT CODE

5 0PRODUCT UNIT SUB-ASSEMBLY

COMPONENT

0 1

4 0

7 6

0 3

1 3

PRODUCT UNIT SUB-ASSEMBLYCOMPONENT





Print 603.93.531 Base - September 2006III

GENERAL WARNINGS

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contactimmediate superiors where a danger situation occurs which is not described.

Use both specific and general-purpose toolings according to the prescriptions contained in respective use andmaintenance handbooks. Check use state and suitability of tools not subjected to regular check.

The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and onthe path.

Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said meansis compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.

In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out fromaccidentally striking workshop personnel.

Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could bedangerous for the co-operator because of lack of visibility or of his/her not correct position.

Keep personnel not authorised to operations clear of working area.

Learn operation and safety knowledge necessary relating to the vehicle prior to each intervention on it. Scrupulouslyobserve all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repairintervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph Controlscare of user of Use and Maintenance handbook.

In lack of visibility in operating from the vehicle, charge a person on the ground with assistance. Do not leave unmanneda vehicle in motion during repair interventions.

Keep the vehicle stationary by proper chocks.

In the case of an intervention on a vehicle lifted from the ground, check the vehicle to be quite steady on special supportstands and, in the case of lifting by means of a lift, check manual/automatic safeties to be activated.

When it is necessary to perform an intervention on methane-fed vehicles, observe the indications contained inside thedocument, as well as all specific safety regulations provided.

Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressureout.

Inflammable fuel and all inflammable fluids and liquidsmust be handledwith care, according towhat contained on harmfulmaterials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flamesor sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquidsaccording to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitablecontainers.

Worn out, damaged or consumable parts must be replaced by Iveco original spares.

Duringworkshop activity, always keep thework place clean; timely clear or clean floors from accidental liquid or oil spots.Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

For every intervention on vehicle hydraulic, pneumatic, conditioning and AIR - BAG systems, scrupulously observeindications specified in relating manual sections.

!

Base - September 2006 Print 603.93.531IV

GENERAL WARNINGS

Clean units or assemblies detached from the vehicle and carefully check their integrity before overhaul. Tidy up detachedor disassembled parts with their securing elements (screws, nuts, etc.) into special containers.

Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.Self-locking nuts with an insert made of nylon must always be replaced.

Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.

Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.

Tightening screws and nuts must always be according to prescriptions; IVECO commercial and assistance network isavailable to give all clarifications necessary to perform repair interventions not provided in this document.

Before welding:

- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)and detach connectors.

- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.

- Await about 15 minutes before welding.

- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materialsflow which may catch fire easily on welding.

Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic centralunits.

The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contactwith moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,scarves, etc.

Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.

Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operateoutdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.

Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause seriousburns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,refer to 12-point cards for provisions to make.

Print 603.93.531 Base - September 2006V

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

To start up the engine, do not use fast chargers. Start upmust only be performedwith either separate batteries or specialtruck.

A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)can cause them to be destroyed.

Disconnect the batteries from the system during their recharging with an external apparatus.

On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tighteningtorque.

Before disconnecting the junction connector from an electronic central unit, isolate the system.

Do not directly supply electronic central units servo components at nominal vehicle voltage.

Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/bodystructure.

Once the intervention on the electric system has been completed, recover connectors and wiring harnesses accordingto original arrangement.

Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during keymemorisation:1 Pay attention that jamming sources are not present in the cab or near the keys.2. Keys not insered in the panel must be at least 1 meter away.

If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.

Before connecting the batteries to the system, make sure that the system is well isolated.

Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off batteryterminals.

Do not cause sparks to be generated in checking if the circuit is energised.

Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.

Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screeningbraiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenanceinterventions.

Measurements in drive electronic central units, plugged connections and electric connections to components can onlybe made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, whichwould later cause contact problems.

Connectors presentmust be seen from cable side. Connectors views contained in themanual are representative of cableside.

!

NOTE

Base - September 2006 Print 603.93.531VI

In order to prevent damage or short-circuiting of the on-board electronic control units, the following operations mustbe always carried out before starting any welding operation on the chassis.

- If electric welding has to be done on the vehicle,

isolate the electric system as follows:

a) disconnect the power lead from the battery positive terminal and connect it to the chassis earth;

b) disconnect the power lead from the battery negative terminal;

c) disconnect the electronic control unit connectors, taking care to avoid touching the control unit connector pins.

- Moreover:

a) should it be necessary to carry out welding operations close to the control unit, remove it from its location.

b) whenever possible, earth the welding machine directly to the piece that has to be welded.

112514

In the case of vehicles equipped with a DTCO digital tachograph, do not disconnect the b attery leads and then connectthem by jumpers to reset the electronic systems.

This operation should be avoided, as it could cause permanent damage to the DTCO tachograph CARD or otheron-board electronic systems.

To reset the electronic system without running risks, disconnect the vehicle battery and wait for 10 minutes.

It is strictly forbidden to carry out any modifications or connections to the electronic control unitwiring; in particular,the line interconnecting data between the control units (CAN line) must be considered as untouchable.

Diagnostic and maintenance operations can only be carried out by authorised personnel with IVECO approvedequipment.

Print 603.93.531 Base - September 2006VII

Base - September 2006 Print 603.93.531VIII

Bonding and screening

Negative leads connected to a system bonded point must be both as short and possible and star-connected to each other, tryingthen to have their centering tidily and properly made (Figure 1, re. M).

Further, following warnings are to be compulsorily observed for electronic components:

- Electronic central units must be connected to system bonding when they are provided with a metallic shell.

- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard openingbonding (avoiding serial or chain connections), and to battery negative terminal.

- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.

- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).

- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).

- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.

1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT C. CONNECTORd. DISTANCE! 0

88039

Figure 1

Figure 2

Print 603.93.531 Base - September 2006IX

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONSAccessories mounting, additions and modifications on the vehicle are to be performed complying with IVECO mountinginstructions (specific document Instructions for transformation and preparation is available at Assistance Network workshops).It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets inorder to simplify and normalise the electrical intervention that is care of preparation personnel.For any exception to mounting instructions, IVECOs authorisation is necessary.Lack of observance of above described prescriptions involves guarantee lapse.

It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,the data interconnection line between central units (CAN line) is to be considered inviolable.

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THEINTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Power1 kW = 1.36 metric HP1 kW = 1.34 HP1 metric HP = 0.736 kW1 metric HP = 0.986 HP1 HP = 0.746 kW1 HP = 1.014 metric HP

Torque1 Nm = 0.1019 kgm1 kgm = 9.81 Nm

Revolutions per time unit1 rad/s = 1 rpm x 0.10461 rpm = 1 rad/s x 9.5602

Pressure1 bar = 1.02 kg/cm2

1 kg/cm2 = 0.981 bar1 bar = 105 Pa

Where accuracy is not particularly needed:

- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1

1 kgm = 10 Nm;

- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1

1 kg/cm2 = 1 bar.

Temperature0 C = 32 F1 C = (1 x 1.8 + 32) F

Base - September 2006 Print 603.93.531X

Print 603.93.531 Base - September 2006

STRALIS AS EURO 4/5

Print 603.93.531 - 2nd editionBase - September 2006

UPDATE DATA

Section Description Page Revision date

Base - September 2006 Print 603.93.531


Section

General 1

Engine 2

Clutch 3

Gearbox 4

Hydraulic retarder 5

Propeller shafts 6

Rear axles 7

Axles 8

Suspensions 9

Wheels and tyres 10

Steering 11

Air system - brakes 12

Bodywork - Chassis frame 13

Scheduled maintenance 14

Electric/electronic system 15

INDEX OF SECTIONS

GENERAL 1STRALIS AS EURO 4/5


SECTION 1

General

Page

VEHICLE IDENTIFICATION DATA 3. . . . . . . . . .

- Vehicle identification plate 4. . . . . . . . . . . . . . . .

- Production identification plate 4. . . . . . . . . . . . .

COMMERCIAL CODING 5. . . . . . . . . . . . . . . . . .

COMPOSITION OF MODELS 7. . . . . . . . . . . . . .

P.I.C. NUMBER CODING 9. . . . . . . . . . . . . . . . . .

REPLENISHING FLUIDS 13. . . . . . . . . . . . . . . . . . .

- International lubricant designation 15. . . . . . . . . .

2 GENERAL STRALIS AS EURO 4/5


Chassis frame

Punching (front on right side member ofchassis frame).

Manufacturers plate

To identify the vehicle in accordancewith the E.E.C. directive(under the front radiator cowling).

Engine

Plate on the left rear side of the crankcase.



VEHICLE IDENTIFICATION DATA

The type and number of engine, type andnumber of chassis and manufacturers platecomprise the vehicle identification data.



Vehicle Identification Plate

Plate legend

a) Type-approval number marking (if applicable).b) Vehicle identification code number (V.I.N.).c) Total tractor weight.d) Total weight of tractor + trailer (if applicable).e) Permissible weight limit on 1st axle.f) Permissible weight limit on 2nd axle (if applicable).g) Permissible weight limit on 3rd axle.h) Permissible weight limit on 4th axle (if applicable).i) Specific identification of type.l) Wheelbase in mm.m) Engine type.n) Engine power.o) No. of axles.p) Place of manufacture.

Production identification plateThis plate shows the P.I.C. (production identification codenumber), which is needed when referring to the spareparts catalogue (electronic and/or microfiche catalogue).The P.I.C. is also given on the vehicle warranty card.Note: When consulting the catalogues, use only the first8 digits of the product identification code number.

Permissiblegrade ofsmoke

IVECO MAGIRUS AG

Kg

Kg

Kg

Kg

a)

b)

c)

d)

e)

f)

g)

h)Type

Wheelbase Correctedabsorptionvalue

Engine type

Made in

No of axles

Engine power KW

1-

2-

3-

4-

l)

m)

i)

Kg

Kg

n)

o)

p)

Unit No

Part No

Serial No

P.I.C. No

Made in Germany-Iveco Magirus AG

9843 8247

STRALIS

RANGENAME

AS 190 S 42

RANGENAME

LONG CABTYPE

Active-Space

VERSION

MODEL

Tractors 4x2

190

260

Lorries 4x2

Lorries 6x2 - 6x4

440Tractors 4x2 - 6x2- 6x4

TOTALWEIGHT

T

ENGINEPOWER

F3A VGT - 420 CV

F3A VGT - 450 CV 45

F3B VGT - 500 CV

F3B VGT - 560 CV 56

42

50

/ P

TX

TY

TZ

Y

Tractors 6x2 C(central added axle)

Tractors 6x2 P(rear added axle)

Cab-equipped 4x2

Cab-equipped 6x2 P(rear added axle)

Z Cab-equipped 6x4(rear axle in Tandem)

Vehicles 4x2 - 6x2 P - 6x2 C with air spring suspensionon rear axle and vehicles 6x2 P with single wheels liftablerigid rear axle

P

Vehicle 6x2 P with air spring suspension on rear axle andtwin wheels liftable rigid rear added axle

PT

Vehicles 6x2 Pwith air spring suspension on rear axle andsingle wheels liftable steering rear added axle

PS

Vehicles 4x2 - 6x4 - 6x2 P - 6x2C with front and rear airspring suspensions

FP

Vehicles 6x2 P with front and rear air spring suspensions,single wheels liftable steering rear added axle

FS

Vehicles 6x2 with rear mechanical and suspensions andliftable rigid rear added axle

TN

Mobile Boxes CM

Large Volumes GV

Heavy Missions HC

High Cube HM

Tractor with lowered chassis LT

Cab-equipped vehicle with lowered chassis CT

Rough Roads RR

Hub Reduction HR

Tractors 6x2(rear axle in Tandem)



COMMERCIAL CODES



COMPOSITION OF MODELSTRACTORS - MODELS 4x2 6x2c 6x2p 6x4

ASSEMBLIES

A

S

4

4

0

S

4

2

T

/

P

+

T

/

P

-

R

R

A

S

4

4

0

S

4

2

T

/

P

-

H

R

A

S

4

4

0

S

4

2

T

/

F

P

-

L

T

A

S

4

4

0

S

4

5

T

/

P

+

T

/

P

-

R

R

A

S

4

4

0

S

4

5

T

/

P

-

H

R

A

S

4

4

0

S

4

5

T

/

F

P

-

L

T

A

S

4

4

0

S

5

0

T

/

P

A

S

4

4

0

S

5

0

T

/

P

-

H

R

A

S

4

4

0

S

5

0

T

/

F

P

-

L

T

A

S

4

4

0

S

5

6

T

/

P

A

S

4

4

0

S

5

6

T

/

P

-

H

R

A

S

4

4

0

S

5

6

T

/

F

P

-

L

T

A

S

4

4

0

S

4

2

T

X

/

P

A

S

4

4

0

S

4

5

T

X

/

P

A

S

4

4

0

S

5

0

T

X

/

P

A

S

4

4

0

S

5

6

T

X

/

P

A

S

4

4

0

S

5

0

T

Y

/

P

T

A

S

2

6

0

S

5

0

T

Z

/

P

-

H

M

A

S

2

6

0

S

5

6

T

Z

/

P

-

H

M

F3AE3681D (420 CV) f f f f

F3AE3681A (450 CV) f f f f

F3BE3681B (500 CV) f f f f f f

F3BE3681A (560 CV) f f f f f

Single disc 17 f f f f f f f f f f f f f f f f f f f

16S 1920 TD f f f

16S 2220 TD f f f

16S 2220 TO f f

16S 2320 TD f f f f f

16S 2520 TO f f f f f f

12 AS1930 TD f f f

12 AS2330 TD f f f f f f f f

12 AS2330 TO f f f

12 AS2530 TO f f f f f

FRONT AXLE: 5876/4 5876/5 F F F F

5876 f f f f

ADDED AXLE: 5876/4 55080/DI

57080/DI

56082/DI f

MERITOR MS 13-175/D f f f f f f f f f f f f f

451391 HR f f f f

MERITOR MT 23-155/D f f

ZF 8098 f f f f f f f f f f f f f f f f f f f

FRONT MECHANICAL Parabolic f f f f f f f f f f f f f f fFRONT MECHANICAL Parabolic f f f f f f f f f f f f f f f

PNEUMATIC Front j j j j

Rear f f f f f f f f f f f f f f f f f f f

Added axle f f f f f = With brake calliper assembly at 57 without parking brake j = With parabolic leaf springs F = With parabolic leaf springs



COMPOSITION OF MODELSCAB-EQUIPPED VEHICLES - MODELS 4x2 6x2p 6x4

ASSEMBLIES AS

1

9

0

S

4

2

/

P

A

S

1

9

0

S

4

2

/

F

P

-

C

M

A

S

1

9

0

S

4

2

/

F

P

-

G

V

A

S

1

9

0

S

4

5

/

P

A

S

1

9

0

S

4

5

/

F

P

-

C

M

A

S

1

9

0

S

4

5

/

F

P

-

G

V

A

S

1

9

0

S

5

0

/

P

A

S

1

9

0

S

5

0

/

F

P

-

C

M

A

S

1

9

0

S

5

0

/

F

P

-

G

V

A

S

2

6

0

S

4

2

Y

/

F

P

-

C

M

A

S

2

6

0

S

4

2

Y

/

F

P

-

G

V

A

S

2

6

0

S

4

2

Y

/

F

S

-

C

M

A

S

2

6

0

S

4

2

Y

/

F

S

-

G

V

A

S

2

6

0

S

4

2

Y

/

P

A

S

2

6

0

S

4

2

Y

/

P

S

A

S

2

6

0

S

4

2

Y

/

P

T

A

S

2

6

0

S

4

5

Y

/

F

P

-

C

M

A

S

2

6

0

S

4

5

Y

/

F

P

-

G

V

A

S

2

6

0

S

4

5

Y

/

F

S

-

C

M

A

S

2

6

0

S

4

5

Y

/

F

S

-

G

V

A

S

2

6

0

S

4

5

Y

/

P

A

S

2

6

0

S

4

5

Y

/

P

S

A

S

2

6

0

S

4

5

Y

/

P

T

A

S

2

6

0

S

5

0

Y

/

F

P

-

C

M

A

S

2

6

0

S

5

0

Y

/

F

P

-

G

V

A

S

2

6

0

S

5

0

Y

/

F

S

-

C

M

A

S

2

6

0

S

5

0

Y

/

F

S

-

G

V

A

S

2

6

0

S

5

0

Y

/

P

A

S

2

6

0

S

5

0

Y

/

P

S

A

S

2

6

0

S

5

0

Y

/

P

T

A

S

2

6

0

S

5

6

Y

/

F

P

-

C

M

A

S

2

6

0

S

5

6

Y

/

F

S

-

C

M

A

S

2

6

0

S

5

6

Y

/

P

A

S

2

6

0

S

5

6

Y

/

P

S

A

S

2

6

0

S

5

6

Y

/

P

T

A

S

2

6

0

S

5

0

Z

/

P

-

H

M

A

S

2

6

0

S

5

6

Z

/

P

-

H

M

F3AE3681D (420 CV) f f f f f f f f f f

F3AE3681A (450 CV) f f f f f f f f f f

F3BE3681B (500 CV) f f f f f f f f f f f

F3BE3681A (560 CV) f f f f f f

Single disc 17 f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f

16S 1920 TD f f f f f f f f f f

16S 2220 TD f f f f f f f f f f

16S 2220 TO

16S 2320 TD f f f f f f f f f f f

16S 2520 TO f f f f f f

12 AS1930 TD f f f f f f f f f f

12 AS2330 TD f f f f f f f f f f f f f f f f f f f f f

12 AS2330 TO

12 AS2530 TO f f f f f f

FRONT AXLE: 5876/4 5876/5 F F F F F F F F F F F F F

5876

ADDED AXLE: 5876/4

55080/DI f f f f f f f f f f f

57080/DI f f f f f f f f f f f

56082/DI f f f f

MERITOR MS 13-175/D f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f

451391 HR

MERITOR MT 23-155/D f f

ZF 8098 f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f

FRONT MECHANICAL: Parabolic f f f f f f f f f f f f f f f f fFRONT MECHANICAL: Parabolic f f f f f f f f f f f f f f f f f

PNEUMATIC Front Z j Z j Z j Z j Z j Z j Z j Z j Z j Z Z

Rear f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f

Added axle f f f f f f f f f f f f f f f f f f f f f f f f f f = With brake calliper assembly at 57 without parking brake Z = With parabolic leaf springsF = With brake calliper assembly at 0 with parking brake j = With drum brakes

CAB LIVEABILITY

A A B C DB CA

TOTAL WEIGHT ON GROUND - AXLES CONFIGURATION

A A B C DB C

M = Stralis AS (Active Space)

A

C

D

E

G

= 6x2P; 26 ton

= 6x2P; 26 ton

= 6x2C; 26 ton

= 4x2T; 18-20 ton

ENGINE

A B C DB CA

D E 420

A

E 450E

Z

H

J

K

L

= 6x2P; 26 ton

= 6x4; 26 ton

= 6x4T; 26 ton

= 6x2P; 26 ton

M

N

= 6x2P; 26 ton

= 6x2C; 26 ton

F

G

E 500

E 560

A

B

= 4x2; 18-20 ton

= 4x2T; 18-20 ton

F = 4x2; 18-20 ton



P.I.C. NUMBER CODING

SUSPENSION TYPE - REAR AXLE TYPE - TYPE OF ADDITIONAL AXLE

A B C DB CA

B Pneumatic - SR - CENT/SING/TWIN

A

C

E

Integral air suspension- SR - SING

Pneumatic - SR - STER

E Pneumatic - HR (Tractor 4x2)

F Integral air suspension- SR - STER

TWIN = Twin rear wheelsCENT = Middle axle (6x2C vehicles)SING = Added axle with rear single wheelsSTER = Added axle with rear steering single wheelsHR = Double reduction rear axleSR = Simple reduction rear axle

A A C DCA B

1

K

L

= Chassis cab - STD

= Chassis cab - GRAV

B

VERSION COMBINATION - USE

= LOW CH - STD

U = CM - STD

H = Tractor - GRAV

T = LOW TR - STD

Cartran = Car transportLOW TR = Lowered tractorSTD = Standard useGRAV = Heavy duty useLOW CH = Lowered chassis cabCM = Mobile Boxes

2 = Tractor - STD



CA A C DBA B

WHEELBASE

9

8

7

6

4

3

2

1

5

L

M



VERSION WHEELBASE VERSION WHEELBASE VERSION WHEELBASE VERSION WHEELBASE

T 6 x 2 C 3800 T 4 x 2 3650 T 6 x 4 2800

T 6 x 4C 6 x 2 P 3200

C 6 x 2 PT 4 x 2C 6 x 4C 4 x 2

3800

C 6 x 46 x 2 P

C 4 x 24200

C 4 x 2C 6 x 4

6 x 2P4500

C 4 x 26 x 2 P 4800

C 4 x 26 x 2 P 5100

C 4 x 2 5500

C 4 x 26 x 2 P 5700

C 4 x 2 6300 6 x 2 P 6050

C 4 x 2 6700

GEARBOX - COMBINATION

A A DB CA B C

B

DRIVE - BRAKES COMBINATION

A A B CA B C D

2

1

A

A



GEARBOXGEARBOX

Mechanical - 16M

EuroTronic 12 MEuroTronic - 12 M

DRIVE BrakesDRIVE Brakes

Left DIS - DISLeft DIS - DIS

Left DIS - TAMLeft DIS - TAM

Right DIS - DISRight DIS - DIS

(1) IVECO recommends using these types of oil to derive benefit as far as fuel economy is concerned. IVECOprovides new vehiclesalready with these types of lubricants (also suited for cold climates minimum temperature down to -30C)

(2) Only on axles with disc brakes. Note (1) holds for these(3) Specific for cold climatesThese quantities are not decisive. An exact check must be made by verifying the levels



REPLENISHING FLUIDS

LUBRICANTS RECOMMENDED BY IVECO PARTS FOR REPLENISHINGQuantity

LUBRICANTS RECOMMENDED BY IVECO PARTS FOR REPLENISHING Litres kg

Urania FE 5W301

Urania LD7Engine F3A

Total capacity 1st filling 32 28.8

Capacity:- engine sump at minimum level- engine sump at maximum level- quantity in circulation that does not re-

turn to sump- quantity contained in cartridge filter (to

add when changing the cartridge filter)

1725

7

2.5

15.322.5

6.3

2.3

Urania FE 5W301

Urania LD7Engine F3B

Total capacity 1st filling 35 31.5

Capacity:- engine sump at minimum level- engine sump at maximum level- quantity in circulation that does not return

to sump- quantity contained in cartridge filter

(to add when changing the cartridge filter)

2028

7

3

1825.5

6.3

2.7

Tutela Truck FE-Gear1

Tutela ZC 90

* Quantity 1st filling

GearboxZF 16 S 1920/2220/2320/2520 *ZF 16 S 1921/2221/2321/2521 *(with Intarder)Eurotronic 12 AS 1930/2330/2530 *Eurotronic 12 AS 1931/2331/2531 *(with Intarder)

1321.5

1221

11,719.3

10,618,9

Tutela Truck FE-Axle2

Tutela W140/M-DATutela W90/M-DA3

Front hubs (single)FRONT AXLE 5876/4-/5ADDED AXLE:Steering central 5876/4Steering rear 57080/DIRigid rear axle 55080/DIRigid rear axle 56082/DI

0.33

0.330.330.330.33

0.30

0.300.300.300.30

Tutela TruckFE A l 2

Rear axle MS 13-175Rear axle 451391

18.516

16.614.5

FE-Axle2

Tutela W140/M-DATutela W90/M-DA3

Rear axle in tandem MT 23 - 155- middle- rear

2018.5

1816.6



LUBRICANTS RECOMMENDED BY IVECO PARTS FOR REPLENISHINGQuantity

LUBRICANTS RECOMMENDED BY IVECO PARTS FOR REPLENISHINGLitres kg

Tutela GI/A Power steering 2.7*13.5**

2.412

* Excluding vehicles with steering rear axle** For vehicles with steering rear axle only

Tutela TRUCKDOT SPECIAL

Clutch circuit(excluding vehicles with Euro Tronic gearbox)

0.5 0.45

Water+Paraflu11

Cooling systemEngine 43A Total capacity*Engine 43A with Intarder Total capacity*Engine 43B Total capacity*Engine 43B with Intarder Total capacity*

38584464

* = Protective anti-freeze(concentration 50% freezing point 35C)

Tutela TILT CAB Cab tilting system 0.6 0.54

These quantities are not decisive. An exact check must be made by verifying the levels



International lubricant designation FL products

Engine oilMeets the specifications:ACEA E4 with a totally synthetic base SAE 5W 30ACEA E7 with a mineral base SAE 15W 40

URANIA FE 5W30Urania LD7

Oil for differential gear and wheel hubsMeets the specifications:API GL5, MT-1 with a totally synthetic base SAE 75W 90API GL5 with a mineral base SAE 85W 140API GL5 with a mineral base SAE 80W 90

Tutela Truck FE-Axle (1)Tutela W140/M-DATutela W90/M-DA (2)

Oil for mechanical gearboxesContaining non-EP anti-wear additivesMeets the specifications:API GL4 with a totally synthetic base SAE 75W 80API GL3 with a mineral base SAE 80W 90

Tutela Truck FE-Gear (3)Tutela ZC90

Oil for power steering and hydrostatic transmissionsA.T.F. DEXRON II D Tutela GI/A

Grease for general greasingbased on lithium soaps, N.L.G.I. consistency no. 2

Tutela MR 2

Specific grease for bearings and wheel hubsbased on lithium soaps, N.L.G.I. consistency no. 3

Tutela MR 3

Clutch drive fluidConforming to N.H.T.S.A. standards N. 116, ISO 4925, Std. SAEJ 1703,IVECO STANDARD 18-1820

Tutela TRUCK DOT SPECIAL

Hydraulic fluid with a very high viscosity index (over 300),at performance level MIL-H- 5606 A

Tutela TILT CAB

Windscreen washer fluid, mixture of spirit, water and surfactantsCUNA NC 956-11

Tutela PROFESSIONAL SC 35

Grease for central lubrication systems based on lithium soaps,with synthetic base, N.L.G.I. no. 2.Working temperatures: from 30C to +140C

Tutela COMAR 2

Concentrated protective fluid for radiatorsbased on ethylene glycol containing corrosion inhibitors, conforming to thestandard: IVECO-STANDARD 18-1830To use diluted with water to 50%.

Paraflu11

(1) Only on axles with disc brakes. Note (3) holds for these(2) Specific for cold climates(3) IVECO recommends using these types of oil to derive benefit as far as fuel economy is concerned.

IVECOprovides new vehicles already with these types of lubricants. Also suited for cold climatesminimum (temperature downto -30C)

ENGINE 1STRALIS AS EURO 4/5


SECTION 2

Engine

Page

- F3A Engine 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

- F3B Engine 123. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Hydrocar pressure take-off on timing system(P.T.O. - Optional) 245. . . . . . . . . . . . . . . . . . . . .

- Denox Sistem 2 251. . . . . . . . . . . . . . . . . . . . . . . .

- Diagnostics 265. . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ENGINE STRALIS AS EURO 4/5


3STRALIS AS EURO 4/5 F3A ENGINE


F3A Engine

Page

VIEWS OF THE ENGINE 5. . . . . . . . . . . . . . . . . .

TECHNICAL DESIGNATION 9. . . . . . . . . . . . . . .

CHARACTERISTIC CURVES 10. . . . . . . . . . . . . . .

GENERAL CHARACTERISTICS 12. . . . . . . . . . . . .

ASSEMBLY CLEARANCE DATA 15. . . . . . . . . . . .

TIGHTENING TORQUE F3A ENGINE 22. . . . . . .

TOOLS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE REMOVAL - REFITTING 39. . . . . . . . . . .

- Removal 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Filling the cooling system 41. . . . . . . . . . . . . . . . .

- Bleeding air from the supply system 42. . . . . . . . .

- Checks and tests 42. . . . . . . . . . . . . . . . . . . . . . .

ELECTRO-MAGNETIC JOINT REPLACEMENT 43.

- Removal 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISMANTLING THE ENGINE ON THE BENCH 47

REPAIR OPERATIONS 54. . . . . . . . . . . . . . . . . . . .

CYLINDER BLOCK 54. . . . . . . . . . . . . . . . . . . . . . .

- Checks and measurements 54. . . . . . . . . . . . . . .

- Cylinder liners 55. . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing cylinder liners 56. . . . . . . . . . . . . . . . . .

- Crankshaft 57. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring the main journals and crankpins 58. . .

- Preliminary measurement of main and bigend bearing shell selection data 59. . . . . . . . . . . .

- Selecting the main and big end bearing shells 60. .

- Replacing the timing gearand oil pump 66. . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking main journal assembly clearance 66. . . .

- Checking crankshaft end float 67. . . . . . . . . . . . .

- Piston connecting rod assembly 68. . . . . . . . . . . .

- Piston rings 70. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Connecting rods 71. . . . . . . . . . . . . . . . . . . . . . .

- Bushings 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking connecting rods 72. . . . . . . . . . . . . . . .

STRALIS AS EURO 4/54 F3A ENGINE


Page

- Mounting the connecting rod piston assembly 73

- Mounting the piston rings 73. . . . . . . . . . . . . . . . .

- Fitting the big end bearing shells 73. . . . . . . . . . . .

- Fitting connecting rod - piston assembliesin the cylinder liners 74. . . . . . . . . . . . . . . . . . . . .

- Checking piston protrusion 74. . . . . . . . . . . . . . .

- Checking crankpin assembly clearance 75. . . . . . .

CYLINDER HEAD 75. . . . . . . . . . . . . . . . . . . . . . . .

- Disassembly the valves 75. . . . . . . . . . . . . . . . . . .

- Checking head bearing surface on cylinder block 75

- Valves 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing deposits and checking the valves 76. . .

- Valve seats 76. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking clearance between valve-stemand associated valve guide 77. . . . . . . . . . . . . . . .

- Valve guides 77. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing injector cases 77. . . . . . . . . . . . . . . . . .

- Checking injector protrusion 79. . . . . . . . . . . . . .

TIMING GEAR 80. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft drive 80. . . . . . . . . . . . . . . . . . . . . . . . .

- Idler gear pin 80. . . . . . . . . . . . . . . . . . . . . . . . . .

- Idler gear 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Twin intermediate gear pin 80. . . . . . . . . . . . . . . .

- Twin idler gear 80. . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing the bushings 80. . . . . . . . . . . . . . . . . . .

- Timing system 81. . . . . . . . . . . . . . . . . . . . . . . . .

- Checking cam lift and pin alignment 81. . . . . . . . .

- Bushings 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Valve springs 84. . . . . . . . . . . . . . . . . . . . . . . . . . .

ROCKER SHAFT 85. . . . . . . . . . . . . . . . . . . . . . . . .

- Shaft 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Rocker arms 86. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE ASSEMBLY ON BENCH 87. . . . . . . . . . . .

- Fitting connecting rod - piston assembliesin cylinder liners 90. . . . . . . . . . . . . . . . . . . . . . . .

ENGINE FLYWHEEL 93. . . . . . . . . . . . . . . . . . . . . .

- Fitting engine flywheel 93. . . . . . . . . . . . . . . . . . .

- Fitting camshaft 94. . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting pump-injectors 95. . . . . . . . . . . . . . . . . . . .

Page

- Fitting rocker-arm shaft assembly 95. . . . . . . . . . .

- Camshaft timing 96. . . . . . . . . . . . . . . . . . . . . . . .

- Phonic wheel timing 98. . . . . . . . . . . . . . . . . . . . .

- Intake and exhaust rocker playadjustment and pre-loading of rockerscontrolling pump injectors 99. . . . . . . . . . . . . . . .

- Completing Engine Assembly 100. . . . . . . . . . . . . .

LUBRICATION 103. . . . . . . . . . . . . . . . . . . . . . . . . .

- Oil pump 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Overpressure valve 105. . . . . . . . . . . . . . . . . . . . .

- Oil pressure control valve 106. . . . . . . . . . . . . . . .

- Heat exchanger 106. . . . . . . . . . . . . . . . . . . . . . . .

- By-pass valve 107. . . . . . . . . . . . . . . . . . . . . . . . . .

- Thermostatic valve 107. . . . . . . . . . . . . . . . . . . . . .

- Engine oil filters 107. . . . . . . . . . . . . . . . . . . . . . . .

- Valve integrated in piston cooling nozzle 108. . . . .

COOLING 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Description 109. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Operation 109. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Electromagnetic coupling 111. . . . . . . . . . . . . . . . .

- Water pump 111. . . . . . . . . . . . . . . . . . . . . . . . . .

- Thermostat 111. . . . . . . . . . . . . . . . . . . . . . . . . . .

- View of thermostat operation for versionswith Intarder 112. . . . . . . . . . . . . . . . . . . . . . . . . . .

TURBOCHARGING 113. . . . . . . . . . . . . . . . . . . . . .

- Turbocharger HOLSET HE 531 V 113. . . . . . . . . .

- Actuator 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Solenoid valve for VGT control 114. . . . . . . . . . . .

REPAIRING ACTIONS 114. . . . . . . . . . . . . . . . . . . .

- Variable geometry movement control 115. . . . . . .

- Checking the actuator 115. . . . . . . . . . . . . . . . . . .

- Checking actuator travel 116. . . . . . . . . . . . . . . . . .

- Cleaning turbine body 116. . . . . . . . . . . . . . . . . . .

FEEDING 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Overpressure valve 120. . . . . . . . . . . . . . . . . . . . .

- Feed pump 120. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Injector-pump 120. . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing injectors-pump 121. . . . . . . . . . . . . . . . .

- Pressure damper 121. . . . . . . . . . . . . . . . . . . . . . .

F3A ENGINE

Figure 1

73835



VIEWS OF THE ENGINE

RIGHT-HAND SIDE VIEW OF THE ENGINE

REAR VIEW OF THE ENGINE

115777

73527

Figure 2

Figure 3



106681

Figure 4

RIGHT-HAND SIDE VIEW OF THE ENGINE

73529

LEFT-HAND SIDE VIEW OF THE ENGINE

Figure 5



VIEW OF THE ENGINE FROM ABOVE

73834

Figure 6



Level of Gas Emissions

Engine torque and power level

ENGINE

F A E 3 6 8 1 D * P 0 0 1 -

Indicates the engine family

Progressive production number

Engine family evolution (also irrespective of the displacement)

Engine (invariable)

Number of strokes and cylinders position(3 = 4 stroke, vertical with post-treatment)

Number of cylinders

Fuel feed + injection (TCA, direct injection diesel engine)

Use (eg I = truck)

Version number within the B.o.M.

TYPE PART NUMBER

D 420 CV / 1900 Nm

A 450 CV / 2100 Nm

3

P Euro 4

M Euro 5



TECHNICAL DESIGNATION

CHARACTERISTIC CURVES OF ENGINE F3AE 3681D

108517

Max OUTPUT 310 kW at 2100 rpm

Max TORQUE 1900 Nm at 1050 1550 rpm

420 HP

174 kgm

Figure 7

rpm



CHARACTERISTIC CURVES

CHARACTERISTIC CURVES OF ENGINE F3A 3681A

108518

Max OUTPUT 330 kW at 2100 rpm

Max TORQUE 2100 Nm at 1050 1550 rpm214 kgm

450 CV

Figure 8

rpm





GENERAL CHARACTERISTICS

Type F3AE3681D F3AE3681A

Cycle 4-stroke Diesel engine

Fuel feed Turbocharged with aftercooler

Injection Direct

No. of cylinders 6 in line

Bore mm 125

Stroke mm 140

+ + +... = Total displacement cm3 10300

Compression ratio 16.5 : 1Max output KW

(HP)310(420)

330(450)

rpm 2100 2100

Max. torque Nm(kgm)

1900(193)

2100(214)

rpm 1050 1550 1050 1550

Engine idling speed,no load rpm 550 50Maximum engine speed,no load rpm 2420 50



Type F3A

A

B

VALVE TIMING

opens before T.D.C. A

closes after B.D.C. B

16

32

C

D

opens before B.D.C. D

closes after T.D.C. C

50

9

X

For timing check

mmX

mm

Running

mmX

mm

-

-

0.35 to 0.45

0.45 to 0.55

FEED Through fuel pump - filters

Injectiontype: Bosch

With electronically regulated injectors UIN3.1pump injectors controlled by overhead camshaft

Nozzle typeNozzle type _

Injection order 1 - 4 - 2 - 6 - 3 - 5

bar Injection pressure bar

Injector calibration bar

2000

296 6



Type F3A

SUPERCHARGING

Turbocharger type Variable geometry Holset HE 531 V

LUBRICATION Forced by gear pump, pressure control valve, oil filter

bar

Oil pressure with hot engine(I00C 5C):

barat idling speed bar 1.5

at maximum rpm bar 5

COOLING By centrifugal pump, regulating thermostat, viscostatic fan,radiator and heat exchangerWater pump control By belt

Thermostat N. 1

initial opening ~84C 2Cmaximum opening 94C 2COIL FILLING

Total capacityat 1st filling

litres 32

kg 28.8

Capacities- engine sump min level

litres 17

kg 15.3

Urania FE 5W30

- engine sump max levellitres 25

Urania FE 5W30Urania LD7 kg 22.5Urania LD7

- quantity in circulationthat does not flow backto the engine sump

litres 7

kg 6.3

- quantity contained inthe cartridge filter (whichhas to be added to thecartridge filter refill)

litres 2.5

kg 2.3



ASSEMBLY CLEARANCE DATA

Type F3A

CYLINDER BLOCK ANDCRANKMECHANISM COMPONENTS mm

1Bores for cylinder liners:

upper1

lower

142.000 to 142.025

140.000 to 140.025

Cylinder liners:

L

2

external diameter:upper

2lower

141.961 to 141.986

139.890 to 139.9152 length L

Cylinder liners -crankcase bores

upperlower

0.014 to 0.0640.085 to 0.135

External diameter 2 -

Cylinder sleeve3 inside diameter 3A* 125.000 to 125.013

Xinside diameter 3B* 125.011 to 125.024

Protrusion X** 0.045 to 0.075

* Selection class** Value measured under a load of 8000 kg

Pistons:1

Xmeasuring dimension X 18

X external diameter 1AF 124.861 to 124.873

2external diameter 1Bf 124.872 to 124.884

2 pin bore 2 50.010 to 50.016Piston - cylinder sleeve

A*B*

--

* Selection class

Piston diameter 1 -

X

Pistons protrusion X 0.23 to 0.53

3 Gudgeon pin 3 49.994 to 50.000

Gudgeon pin - pin housing 0.010 to 0.022

F Class A pistons supplied as spares.f Class B pistons are fitted in production only and are not supplied as spares.



F3AType

F3AType

mm

1X X1 2.098 to 2.128 *

X12

XPiston ring grooves X2 1.550 to 1.570 () 3.050 to 3.070X

32

X X3* measured on of 120 mm +0-0.15

4.020 to 4.040

Pi t iPiston rings:Piston rings:Piston rings:1S - trapezoidal seal S1* 1.929 to 1.9732S - lune seal S2 1.550 to 1.570 () 3.050 to 3.0703S - milled scraper ring with

slits and internal spring S3 3.970 to 3.990* measured at 2 mm fromouter

1 0.125 to 0.199Piston rings - grooves 2 0.050 to 0.100

3 0.030 to 0.070

Piston rings -

X1

2X

Piston ring end gapin cylinder liners

3

2X

XX1 0.35 to 0.45

3XX2 0.60 to 0.75X3 0.35 to 0.65

1 Small end bush housing 1 54.000 to 54.030

2

Big end bearinghousing 2- Class 1- Class 2- Class 3

87.000 to 87.01087.011 to 87.02087.021 to 87.030

4 Small end bush diameter

3outside 4 54.085 to 54.110

3inside 3 50.019 to 50.035

SBig end bearing shell SRedGreenYellow D

1.970 to 1.9801.981 to 1.9901.991 to 2.000

Small end bush - housing 0.055 to 0.110

Piston pin - bush 0.019 to 0.041

Big end bearing 0.127 - 0.254 - 0.508

Connecting rod weightA 4024 to 4054 g.

Class B

g

4055 to 4085 g.

C 4086 to 4116 g.

D Fitted in production only and not supplied as spares

DD Old part number



TypeF3A

Typemm

XMeasuring dimension X 125

Max. connecting rodaxis misalignmenttolerance / / 0.08

1 2

Main journals 1- nominal- class 1- class 2- class 3

Crankpins 2- nominal- class 1- class 2- class 3

92.970 to 93.00092.970 to 92.97992.980 to 92.98992.990 to 93.000

82.970 to 83.00082.970 to 82.97982.980 to 82.98982.990 to 83.000

S 1 S 2 Main bearing shells S1RedGreenYellow*

2.965 to 2.9742.975 to 2.9842.985 to 2.995

Big end bearing shells S2RedGreenYellow*

1.970 to 1.9801.981 to 1.9901.991 to 2.000

3Main bearing housings 3- nominal- class 1- class 2- class 3

99.000 to 99.03099.000 to 99.00999.010 to 99.01999.020 to 99.030

Bearing shells -main journals 0.050 to 0.090

Bearing shells -big ends

0.040 to 0.080

Main bearing shells 0.127 - 2.254 - 0.508

Big end bearing shells 0.127 - 2.254 - 0.508

X1

Main journal,thrust bearing X1 45.95 to 46.00

X2

Main bearing housing,thrust bearing X2 38.94 to 38.99

X 3 Thrust washerhalves X3 3.38 to 3.43

Crankshaft end float 0.10 to 0.30

1 2

Alignment / / 1 - 2

Ovalization 1 - 2

0.025

0.040

* Fitted in production only and not supplied as spares



Type F3A

CYLINDER HEAD - VALVE TRAIN mm

1Valve guide housingsin cylinder head

1 14.980 to 14.997

2

Valve guide 2 9.015 to 9.030

3

Va ve gu de 3 15.012 to 15.025

Valve guides - housingsin the cylinder heads 0.015 to 0.045

Valve guide 0.2 - 0.4

4 Valves:

4 8.960 to 8.975

60 30 7 30

4 8.960 to 8.97545 30 7 30

Valve stem and its guide 0.040 to 0.070

1

Valve seat inhead

1

1

44.185 to 44.220

42.985 to 43.020

2Outside diameter of valveseat; angle of valve seatin cylinder head:2 in cylinder head:

2 44.260 to 44.275

2 43.060 to 43.075

Valve guide 0.2

X

Recessing of valve0.59 to 0.91

XRecessing of valve

X 1.8 to 2.1

Between valveBetween valveseat and head 0.040 to 0.0900.040 to 0.090



Table 1

TypeF3A

Typemm

Valve spring height:

free height H 80H H 1

2under a load of:H 1

H2 660 33 N H1 621140 57 N H2 48.8

X

Injector protrusion X 0.32 to 1.14

Camshaft bushing housingin the cylinder head:1 7 88.000 to 88.030

1

2

3

Camshaft bearingjournals:1 7 82.950 to 82.968

Outer diameter ofcamshaft bushings: 88.153 to 88.183

Inner diameter ofcamshaft bushings: 83.018 to 83.085

Bushings and housingsin the cylinder head 0.123 to 0.183

Bushings and bearingjournals 0.050 to 0.135Cam lift:

9.30

H 9.458

13.376

1Rocker shaft 1 41.984 to 42.000



TypeF3A

Typemm

Bushing housing inrocker arms

45.000 to 45.016

59.000 to 59.019

46.000 to 46.016

Bushing outer diameterfor rocker arms

45.090 to 45.130

59.100 to 59.140

46.066 to 46.091

Bushing inner diameterfor rocker arms

42.025 to 42.041

56.030 to 56.049

42.015 to 42.071

Between bushings andhousings

0.074 to 0.130

0.081 to 0.140

0.050 to 0.091

Between bushings ofrocker arms and shaft

0.025 to 0.057

0.015 to 0.087

Engine brake control lever

Eccentric pin outerdiameter 1Rocker arms shaft seat 2

55.981 to 56.000

42.025 to 42.041



Type F3A

mm

Rocker arms and enginebrake control lever pin

0.030 to 0.068

Rocker arm shaft and seaton engine brake controllever

0.025 to 0.057

TURBOCHARGERType

End play

Radial movement

HOLSET HE 531 V with variable geometry

0.025 0.1270.381 0.533



TIGHTENING TORQUE F3A ENGINEPART TORQUE

Nm kgm

Capscrews, undercrankcase to crankcase (see Figure 9) M12x1.75 outer screws Stage 1: pretightening 30 3M 17x2 inner screws Stage 2: pretightening 120 12Inner screws Stage 3: angle 90Inner screws Stage 4: angle 45Outer screws Stage 5: angle 60Piston cooling nozzle union 35 2 3.5 2Capscrews, heat exchanger to crankcase (see Figure 13)

pretighteningtightening

11.519

1.15

1.9Spacer and oil sump capscrews (see Figure 14)


3845

3.84.5

M 12x1.75 screws, gear case to crankcase 63 2 6.3 0.2Cylinder head capscrews (see Figure 10) Stage 1: pretightening 60 6Stage 2 pretightening 120 12Stage 3: angle 120Stage 4: angle 60Air compressor capscrews 100 10Rocker shaft capscrew Stage 1: pretightening 80 8Stage 2: angle 60Locknut, rocker adjusting screw 39 5 3.9 0.5Capscrews, injector securing brackets 26 2.6Capscrews, thrust plates to head 19 1.9Screw fastening the engine supporting bracket to the cylinder head

Stage 1: pretightening 120 12Stage 2: angle 45Screw fastening the engine supporting bracket to the flywheel caseStage 1: pretightening 100 10Stage 2: angle 60Camshaft gear capscrews Stage 1: pretightening 60 6Stage 2: angle 60Screw fixing phonic wheel to timing system gear 8.5 1.5 0.8 0.1Exhaust manifold capscrews (see Figure 11)


40 570 5

4 0.57 0.5

Capscrews, exhaust brake actuator cylinder 19 1.9Capscrews, connecting rod caps Stage 1: pretightening 60 6Stage 2: angle 60Engine flywheel capscrews Stage 1: pretightening 120 12Stage 2: angle 90 Before assembly, lubricate with engine oilD Before assembly, lubricate with graphitized oil



F3A ENGINE

PART TORQUE

Nm kgm

Screws fixing damper flywheel: First phase pre-tightening 70 7Second phase closing to angle 50Screws fixing intermediate gear pins: First phase pre-tightening 30 3Second phase closing to angle 90Screw fixing connecting rod for idle gear 25 2.5 2.5 0.2Screws fixing oil pump 25 2.5 2.5 0.2Screw fixing suction strainer and oil pump pipe to crankcase 25 2.5 2.5 0.2Screws fixing crankshaft gasket cover 25 2.5 2.5 0.2Screws fixing fuel pump/filter 37 3 3.7 0.3Screw fixing control unit mount to crankcase 19 3 1.9 0.3Screw fixing fuel pump to flywheel cover box 19 3 1.9 0.3Screw fixing thermostat box to cylinder head 22 2 2.2 0.2Screw fixing rocker cover (see Figure 15) 8.5 1.5 0.8 0.1Screws and nuts fixing turbocharger (see Figure 12)

pre-tighteningtightening

33.5 7.546 2

3.3 0.74.6 0.2

Screws fixing water pump to crankcase 25 2.5 2.5 0.2Screws fixing spacer/pulley to fan 30 3 3 0.3Screw fixing automatic tensioner to crankcase 50 5 5 0.5Screw fixing fixed tensioner to crankcase 105 5 10.5 0.5Screws fixing fan mount to crankcase 100 5 10 0.5Screws fixing starter motor 74 8 7.4 0.8Screws fixing air heater to cylinder head 37 3 3.7 0.3Screw fixing air compressor 74 8 7.4 0.8Nut fixing gear driving air compressor 170 10 17 1Screw fixing automatic tensioner for belt driving air-conditioningcompressor to crankcase 26 2 2.6 0.2Screw fixing alternator bracket to crankcase L = 35 mm

L = 60 mmL = 30 mm

30 344 424.5 2.5

3 0.34.4 0.42.4 0.2

Screws fixing hydraulic power steering pump 46.5 4.5 4.65 0.45Screws fixing air-conditioner compressor to mount 24.5 2.5 2.5 0.25Screws fixing guard 24.5 25 2.5 0.25Filter clogging sensor fastening 55 5 5.5 0.5 Before assembly, lubricate with engine oilD Before assembly, lubricate with graphitized oil



F3A ENGINE

PART TORQUE

Nm kgm

Pressure transmitter fastener 8 2 0.8 0.2Water/fuel temperature sensor fastener 32.5 2.5 3.2 0.2Thermometric switch/transmitter fastener 23 2.5 2.5 0.2Air temperature transmitter fastener 32.5 2.5 3.2 0.2Pulse transmitter fastener 8 2 0.8 0.2Injector-pump connections fastener 1.36 1.92 0.13 0.19Screw fixing electric cables 8 2 0.8 0.2Screw fixing electric cables 8 2 0.8 0.2Exhaust brake solenoid valve fastener 32 3.2

PWM solenoid valve fastener 9 1 0.9 0.1Motor propulsor

M14x70/80 screw securing front and rear elastic blocks to chassis 192.5 19.5 19.2 1.9M16x130 screw securing front and rear elastic blocks to engine 278 28 27.8 2.8M18x62 flanged HEX screw for front engine block

Pre-tightening 1st step 120 12

Angle closing 2nd step 45

M14x60 socket cheese-head TC screw for front engine block



Flanged HEX screw for rear engine block



Before assembly, lubricate with engine oilD Before assembly, lubricate with graphitized oil

60593

FRONT SIDEstage 4:angle,

inner screws

45

60592

60594

60593

Figure 9

stage 1:pretightening,outer screws

(30 Nm)

FRONT SIDE

FRONT SIDE

stage 2:pretightenig,inner screws

(120 Nm)

stage 5:angle,

outer screws

60

60593

FRONT SIDEstage 3:angle,

inner screws

90

FRONT SIDE

DIAGRAMS OF TIGHTENING SEQUENCE FOR SCREWS FIXING CRANKCASE BASE



F3A ENGINEDIAGRAMS OF TIGHTENING SEQUENCE FOR MAIN PARTS OF ENGINE

60580

Figure 10

Figure 11

Figure 12

DIAGRAM OF EXHAUST MANIFOLD FIXING SCREWS TIGHTENING SEQUENCE

DIAGRAM OF TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING SEQUENCE

SEQUENCE: Pretightening 4 - 3 - 1 - 2Tightening 1 - 4 - 2 - 3

60581

60582

DIAGRAM OF CYLINDER HEAD FIXING SCREWS TIGHTENING SEQUENCE



F3A ENGINE

60666

Figure 13

Figure 14

DIAGRAM OF TIGHTENING SEQUENCE FOR ENGINE OIL SUMP SCREWS

60583

DIAGRAM OF TIGHTENING SEQUENCE FOR HEAT EXCHANGER SCREWS

Stage 1 from 1 to 16.

Stage 2 from 17 to 32

Figure 15

DIAGRAM OF TIGHTENING SEQUENCE FOR SCREWS FIXING ROCKER COVER

73587



F3A ENGINE

Using a torque wrench, tighten the highlighted screws with the following sequence and tightening torques:

4 screws M12 x 1.75 x 35 63 Nm

10 screws M12 x 1.75 x 100 63 Nm 1 screw M12 x 1.75 x 120 63 Nm

2 screws M12 x 1.75 x 70 63 Nm

Figure 16

60633

2 screws M12 x 1.75 x 193 63 Nm:

Figure 17

70567A

DIAGRAM OF CYLINDER HEAD FIXING SCREWS TIGHTENING SEQUENCE1st step 80 Nm

2nd step closing to angle 60



F3A ENGINE



TOOLS

TOOL NO. DESCRIPTION

99322230 Rotary telescopic stand (range 2000 daN, torque 375 daNm)

99340053 Extractor for crankshaft front gasket

99340054 Extractor for crankshaft rear gasket

99340205 Percussion extractor

99342149 Extractor for injector-holder

99342155 Tool to extract injectors



TOOLS


99346250 Tool to install the crankshaft front gasket

99346251 Tool to install the crankshaft rear gasket

99348004 Universal extractor for 5 to 70 mm internal components

99350072 Box wrench for block junction bolts to the underblock

99360144 Tools (12 + 6) holding rocker adjustment screw blocks whenremoving/refitting the rocker shaft

99360180 Injector housing protecting plugs (6)



TOOLS


99360184 Pliers for assembling and disassembling piston split rings(105-160 mm)

99360192 Guide for flexible belt

99360261 Tool to take down-fit engine valves(to be used with special plates)

99360262 Plate for take down-fit engine valves(to be used with 99360261)

99360295 Tool to fit back valve guide (to be used with 99360481)

99360314 Tool to remove oil filter (engine)



TOOLS


99360321 Tool to rotate engine flywheel (to be used with 99360325)

99360325 Spacer (to be used with 99360321)

99360328 Tool to install gasket on valve guide

99360334 Compression tool for checking the protrusion of cylinder liners(to be used with 99370415-99395603 and special plates)

99360336 Spacer (to be used with 99360334)

99360337 Cylinder liner compression plate(to be used with 99360334-99360336)



TOOLS


99360351 Tool to stop engine flywheel

99360481 Tool to remove valve guide

99360499 Tool to take down and fit back camshaft bushes

99360500 Tool to lift crankshaft

99360551 Bracket to take down and fit engine flywheel

99360553 Tool for assembling and installing rocker arm shaft



TOOLS


99360585 Swing hoist for engine disassembly assembly

99360605 Belt to insert piston in cylinder liner (60 - 125 mm)

99360612 Tool for positioning engine P.M.S.

99360613 Tool for timing of phonic wheel on timing gear

99360703 Tool to stop cylinder liners

99360706 Tool to extract cylinder liners (to be used with specific rings)



TOOLS


99360726 Ring (125 mm) (to be used with 99360706)

99361036 Brackets fixing the engine to rotary stand 99322230

99365056 Tool for injector holder heading

99370415 Base supporting the dial gauge for checking cylinder linerprotrusion (to be used with 99395603)

99378100 Tool for printing engine identification plates(to be used with special punches)

99378101 :99378102 F99378103 f99378104 j99378105 J99378106 Y99378107 B99378108 z

Drifts (A: -BF -Cf - Dj - EJ - FY - GB - Vz) for stampingengine identification plates (components of 99378130)



TOOLS


99378130 Drift set for stamping engine identification plates(consisting of: 99378101 (A) - 99378102 (B) - 99378103 (C) -99378104 (D) - 99378105 (E) - 99378106 (F) - 99378107 (G)- 99378108 (V))

99389834 Torque screwdriver for calibrating the injector solenoidvalve connector check nut

99390311 Valve guide sleeker

99390772 Tool for removing injector holding case deposits

99390804 Tool for threading injector holding cases to be extracted(to be used with 99390805)

99390805 Guide bush (to be used with 99390804)



TOOLS


99394015 Guide bush (to be used with 99394041 or 99394043)

99394041 Cutter to rectify injector holder housing(to be used with 99394015)

99394043 Reamer to rectify injector holder lower side(to be used with 99394015)

99395216 Measuring pair for angular tightening with 1/2and 3/4 square couplings

99395218 Gauge for defining the distance between the centresof camshaft and transmission gear

99395603 Dial gauge (0 - 5 mm)



TOOLS


99395687 Reaming gauge (50 - 178 mm)

99396035 Centering ring of crankshaft front gasket cap

Disconnect batteries by disconnecting the electriccables or by opening the current cut-out switch, liftthe radiator cowling and overturn the cabin.Disassemble the gearbox as described in section 4.

If washing the engine bay, adequately protect theelectric/electronic components and their connec-tions.

Operations to be carried out from the lower part:

- drain the cooling liquid in a fit container by removing thecap (8) from radiator (2);

- remove the line (10) between radiator and water pumpunion (9);

- disconnect line (5 and 6) from water pump union (9);

On the upper side:

- disconnect the air line (13) from the drier filter at union(7) after releasing it from the check clamp on the chassis;

- disconnect water lines (1 and 15) form the thermostatunit (14) (see detail A);

- disconnect the sleeve (3) connecting turbocharger toaftercooler radiator;

- if present, remove the climate control pipe (11) supportbracket (12).

- disconnect the sleeve (18) connecting air filter line toturbocharger manifold;

- disconnect the exhaust line (16).

Unscrew the screws (17) fastening the engine supports tothe flexible support (4) on the chassis.

- disconnect the connector from the electronic unit asfollows:A. lift the safety lever;B. move the connector by disconnecting it from thecontrol unit;

C. lift the connector by releasing the pawl.

Figure 18

NOTE

87381



540110 ENGINE REMOVAL - REFITTINGRemoval

Carry out the following operations from the suction side:drain the power steering system oil in a fit container bydisconnecting delivery and return lines (5 and 6). Disconnectelectric connections (9 and 12) from the engine and releasecable from the engine air suction manifold freeing it from checkclamps. Disconnect the electric cables (14) and the groundcable (4) form the starter (3). Disconnect the electric cables(15) on the alternator (11). Disconnect pipe (13) on thecompressor.Disconnect the sleeve (10) connecting aftercoolerradiator - suction manifold. Disconnect piping from tankoverpressure valve (2) and piping (16). On vehicles fitted withclimate control system, operate as follows: use the suitablewrench to operate the automatic backstand and remove theclimate control system (19) compressor control belt (17).Remove the screws (18) and the climate control systemcompressor.Without disconnecting the compressor pipes andto prevent draining the climate control system, fasten thecompressor to the vehicle so that it does not interfere with theengine removal. Tighten the chains using a hoist and swing hoist99360595 hooked to the engine brackets. Remove the enginefixing screws of the elastic engine (1) brackets from the chassis.Slowly raise the engine from its compartment by taking itbackwards so that the fan is released from the air conveyorcompartment (20) on the radiator. Operate the screws toremove the fan from the hub. Remove the engine completelywithout interferingwith the remaining fixed parts on the chassis,in particular the wiring interfering with the rear right enginesupport.

Refitting

In order to assemble the engine, carry out the operationsdescribed for disassembly in the reverse order, paying specialattention to the operations required to install the assembly in theengine department and keeping to the following instructions:check engine and gearbox group flexible supports and replacethem if damaged. Check that exhaust line parts are notdamaged or nearly damaged; if so, replace them. Tighten thescrews and/or the nuts to the prescribed torque. Fill the coolingsystem with cooling liquid. Bleed the air supply system;

112171

If washing the engine bay, adequately protect theelectric/electronic components and their connec-tions.

Fill the cooling system with coolant as described in theparagraph relevant. Blow air off the cooling system as describedin the paragraph relevant (operation 502011). Blow air off thefuel system as described in the relevant chapter (operation542011). Fill the power steering circuit, then blow air off asdescribed in the relevant chapter (operation 501030). Checkthe level of oil in the engine. Carry out the inspections andchecks as described in the chapter relevant.Connect connector (7) to control unit (8) as described below:A, insert the pawl in its housingB, connect the connectorC, push the safety lever until it stops.

Tighten the nuts fastening the electric cables to thestarting motor terminals, by applying the torquevalues below:- nut M10 x 1.5 (terminal 30):

17.6 24.5 Nm (1.8-2.5 Kgm);- nut M5 x 0,8 (terminal 50):

2.6 4.6 Nm (0.27-0.47 Kgm);

Figure 19

NOTE

NOTE



87198

Filling the system

After conscientiously following the above warnings,proceed as follows:

- Remove the cap (2) from the expansion tub (3).

- Pour the coolant into the expansion tub (3) till it is quitefull.

Bleeding air from the system

Filling the cooling system

Preliminary operations

For vehicles equipped with just the standard cab heatingsystem or manual air-conditioning:- Fully open the coolant cock on the instrument panel.

For vehicles equipped with the automatic air-conditioningsystem:- Set the temperature control in the cab on the HI position.

For vehicles equipped with an additional heater:- The heater must not be turned on.

Operations

Place a sheet of cardboard between the coolant radiator andthe intercooler radiator in order to shorten the time it takesto reach the engines working temperature (approx. 90C).

GENERAL WARNINGSFilling must be done with the engine cold.The cap (1) must not be removed for any reasonswhatsoever.To prevent pockets of air forming in the system, thefluid has to be transferred slowly (approximate flowrate 8 litres/min).For vehicles equipped with an additional heater: thepercentage of glycols in the coolant must be nogreater than 50%.

For vehicles equipped with an additional heater:- Turn on the heater.

If the tub empties completely during these first fewminutes, stop and engine and top it up at a slowerrate than before.Restart the engine.

- Start the engine and keep the speed just above idling for5 min.

- After 5 min. running, top up the level of fluid in theexpansion tub, if necessary.

- Close the expansion tub filler with the cap (2).Take the engine up to top speed so that the coolantquickly reaches the temperature of full thermostatopening (approx. 90C) and keep it in this state until allthe air is bled out of the system.This is checked by seeing there is no foam or air bubblesin the tub.The longest time it takes to bleed the air from the systemcompletely is approximately 15 minutes from themoment when the thermostat opens (opening starts852 C).

!Do not take the filler cap off the expansion tub untilthe fluid in the system has cooled completely.Any topping up must only be done with the enginecold.This is to avoid:1 - Operator burns.2 - Damage to the engine since cooling systempressurization is only created with the fluidheating from the condition of the engine cold.

NOTE

NOTE

NOTE

Figure 20



- Bleed screw (1) on the pre-filter mounting.- Bleed screw (2) on the filter mounting.- Bleed screw (4) on the front of the cylinder head.- Work the pump (3) on the pre-filter mounting till fuel

with no air bubbles in it comes out of the screw (1); closethe screw.

- Repeat this step for screw (2).- Repeat this step for screw (4).

13 2

Checks and testsStart the engine, leave it running at just a little fasterthan idling speed andwait for the temperature of thecoolant to reach the level to open the thermostat.Then, check that:

- No water leaks from the connecting sleeves of the pipesin the engine cooling and cab heating circuits, tighteningthe collars further if this is necessary.

- No oil leaks from between the cover and the cylinderhead, between the oil sump and the crankcase, betweenthe oil filter and its seat, between the heat exchanger andthe crankcase, or between the various pipes in thelubrication circuit.

- No air leaks from the pipes connected to the pneumaticcomponents involved in removal.

- The indicator lights on the instrument panel and thedevices disconnected when removing the engine all workproperly.

4

Before bleeding the fuel system connect properpipes to the bleeding screws located on prefiltersupport, filter and cylinder head front part, in orderto recover fuel in suitable containers during thisoperation.

In particular, never allow that the fuel, coming outof the cylinder head draining screw, stains thecontrol belts of the fan, the water pump, thealternator and the conditioner compressor, thusdamaging them.

Figure 21

NOTE



542011 Bleeding air from the supply system

87254

To cut off the batteries, remove the electric wires or openthe main switch.

Lift the calender and tilt the cabin. Remove the coolant fillingplug from the header tank.

Go under the vehicle and remove the plug (10) from theradiator (11) and drain the coolant fluid in the appropriatecontainer.

Remove the clip (9) and disconnect the radiator (17) sleeve(11).

Remove the climate control system pipe (6) fastening screw(if fitted) to the air conveyor (12).

Remove the air conveyor (12) fastening screws (8) from thesupport bracket.

Remove the two sleeve fastening screws to the intercoolerradiator (11).

Remove the screw (15) and the electric wire (14). Slackenthe clamp (16) and remove the air conveyor (12) from theturbocharger (13) and from the intercooler radiator (5).

Loosen the strap fastening sleeve (7) to intercooler radiator(5).

Drive in the suitable self-threading screw in the pin hole (2)taking care to partially take off and finally remove with ascrewdriver the upper clip (3) fastening the fan air (4)conveyor to the radiator guard (1).

Remove the lower clip in the same way.

Figure 22



543422 ELECTRO-MAGNETIC JOINT REPLACEMENTRemoval

RefittingTo refit the electro-magnetic joint, reverse theremoval procedure and attain to the following rules:

- check the control belt (18) conditions; replace it ifdamaged or worn out;

- tighten the screws and/or nuts to the prescribed torque;

- fill the cooling systemwith the prescribed fluid, then blowair off the cooling system as described in the respectivechapter;

The electro-magnetic joint is fitted with twothreaded holes () at 180 one from the other. Inthe event of fault, lock the joint control driving in aM8x16 mm screw in these holes. In this way it ispossible to take the vehicle to the closest dealership.

Figure 23

NOTE

107398

Disconnect the pipe (1) from the thermostat.Remove the clip (10) and disconnect the sleeve (9) from theradiator (11).Slacken the clamps (7) and remove the sleeve (6).Remove the upper and lower clip (3) as described for theleft-hand side.Remove the radiator support fastening screws on the chassisand move the radiator unit forwards.Remove the radiator support fastening screws (2) on thechassis and move the radiator unit forwards (14).Remove the fan fastening screws (2) to the electro-magneticjoint (4).Loosen belt (16) tension by acting on automaticbelt-stretcher (17), then remove the belt from the pulleys.Disconnect the electric connection (12) from theelectro-magnetic join (14).Disconnect pneumatic piping (15) from electromagneticcoupling (14).Remove the fan fastening screws (13) to theelectro-magnetic joint (14).Disconnect pneumatic piping (15) from electromagneticcoupling (14).



Figure 24

73581

ENGINE - LONGITUDINAL SECTION



Figure 25

ENGINE - CROSS SECTION

60584



- pipes (3, 4 and 7);- electrical cables (5);- sound deadening guard (6);- pipes (1 and 2).

60481

106215

106239

60484

60485

60486

On the engine right-hand side

- diesel cartridge filter (1);- power steering system tank (2);- electric connections;

- compressor (1) complete with oversteering pump (2) andfeed pump (3).

- remove the air conditioner control belt (1) using a fit tool(3) and acting in the direction shown by the arrow;

- disassemble the air conditioner (2) fitted with the enginesupport.

- oil pressure controlling valve (1).

On the engine left-hand side

- engine support (1);

Before fastening the engine on rotary stand 99322230,dismount or disconnect following parts:

Figure 26

Figure 27

Figure 28

Figure 29

F

IVECO - STRALIS AS 4_5 - REPAIR MANUAL.pdf

Documents

Transcript of IVECO - STRALIS AS 4_5 - REPAIR MANUAL.pdf