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REPAIR MANUAL
MECHANICAL
ELECTRICAL
ELECTRONIC
This publication describes the characteristics, the data, the
correct methodology of the repairs that can be made on each
individual component of the vehicle.
By complying with the instructions supplied and using the
specific tools it is possible to perform any repair intervention
correctly, within the specified time frames, while protecting the
technicians against incidents.
Before starting any repair work, make sure that all accident
prevention devices are ready at hand.
Check and wear the protective personal equipment provided
for by the safety standards: goggles, helmet, gloves, shoes.
Check the efficiency of all processing, lifting and transport tools
before using them.
Produced by:
Example
Furthermore, within each section, every heading or sub-heading concerning the operations to be carried out is preceded by a six
digit number. This number is the Product Code that is to be found in the repair operation described in the REPAIR TIMES CHARTS
and in the FAULT CODES.
For quick reference the indication of how to read this code is described below (see the Repair time charts also).
Product Code: 5 0
PRODUCT UNIT SUB-ASSEMBLY
COMPONENT
Example:
Product 50 = Frame;
Product 52 = Axles;
Product 53 = Gears etc.
Unit Code: 0 1
PRODUCT UNIT SUB-ASSEMBLY
COMPONENT
Figures three and four identify the ASSEMBLY within the PRODUCT
Example:
Product 50 = Frame;
Unit 01 = Chassis;
Unit 02 = Bumpers etc .
Sub-assembly Code: 4 0
PRODUCT UNIT SUB-ASSEMBLY
COMPONENT
Example:
Product 50 = Frame;
Unit 01 = Chassis;
Sub-assembly 40 = Chassis cross members etc.
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly ρ Compression ratio
Tolerance
Tighten to torque
Weight difference
Replacement
Press or caulk
Original spare parts
Regulation
Rotation
Adjustment
Warning Angle
! Note Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Oversized
Interference
Higher than….
Strained assembly
Maximum, peak
Undersized
Thickness
Less than….
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0°
Sealant
Cold
Adhesive
Winter
Temperature > 0°
Air bleeding Hot
Summer
UPDATE DATA
Section
General information 1
Engine 2
Clutch 3
Transmission 4
Propeller shafts 5
Rear axles 6
Axle 7
Steering gear 10
Scheduled Maintenance 13
Electrical/electronic system 14
Print 603.43.351
SECTION 1
General
Page
IDENTIFICATION DATA . . . . . . . . . . . . . . . . . . 3
COMPOSITION OF MODELS . . . . . . . . . . . . . . 4
REPLENISHING FLUIDS . . . . . . . . . . . . . . . . . . . 17
IDENTIFICATION DATA
Print 603.43.351
o) Place of manufacture. l) m)
* Permissible grade of smoke Made in
o)
Admissible smoke
value
Manufacturer’s plate
To identify the vehicle
according to E.E.C.
directive (on the front
cross member).
Engine
Chassis frame Stamping
Stamping (at the front on (right-hand side on the crankcase)
the right-hand structural
member of the chassis
frame).
COMPOSITION OF MODELS
Print 603.43.351/D
MODELS
35 C 10
35 C 11
35 C 12
35 C 13
35 C 15
40 C 10
40 C 11
40 C 12
40 C 13
29 L 10
29 L 11
29 L 12
35 S 10
35 S 11
35 S 12
35 S 13
35 S 15
35 C 9
35 S 9
40 C 9
29 L 9
ASSEMBLIES
8140.63.4.. (85 CV PC/NA + EGR + OXICAT) •• •• •• ••
8140.43R (90 CV ID/TCA*) o o o o
8140.43B.43XX (105 CV ID/TCA*) o o o o
8140.43C.40XX (105 CV ID/TCA + OXICAT) o o o o
8140.43S.41XX (125 CV ID/TCA* E.G.R. + OXICAT) J
8140.43S.43XX (125 CV ID/TCA*) o o o
8140.43N.43XX (150 CV ID/TCA*) o o
F1AE0481A*A (96 CV) o o o o
F1AE0481B*A (116 CV) o o o o
F1AE0481B*B (116 CV + E.G.R. + OXICAT) J
Single disc 9” 1/4 o o o o o o o o o o o o o o o
Single disc 10” 1/2 o o o o o
Single disc 11 o o
ZF 5S 200 o o o o o o o o
ZF 5S 270 o o o o o o o o
ZF 6S 300 o o o o o
FRONT AXLES:
5817 o o o o o o o o o o
5818 V V V
5819 o o o o o o o o
5823
450210 o o o o o o o o o o
450311/1 o o o o o o o o o o o
450511
450517/2
Rack-and-pinion Power steering o o o o o o o o o o o o o o o o o o o o o
FRONT MECHANICAL SUSPENSIONS:
o o o o o o o o o o o o o o o o
independent with transverse leaf spring (MK3)
independent with torsion bars (•) (•) (•) (•) (•) (•) o o o o o
REAR Parabolic Z Z Z Z Z Z Z Z Z Z Z
MECHANICAL
SUSPENSIONS: - single leaf • • • • • • • • • •
- double-leaf ◓ ◓ ◓ ◓ ◓ ◓ ◓ ◓ ◓ ◓
Semi-elliptic s s s s s s s s s s s
Semi-elliptic
with leaf spring
z zzzzz zzzzz
COMPOSITION OF MODELS
40 C 13 BUS
40 C 15 BUS
50 C 11 BUS
50 C 13 BUS
50 C 15 BUS
35 S 13 BUS
MODELS
45 C 11
45 C 13
50 C 11
50 C 13
50 C 15
60 C 15
65 C 15
ASSEMBLIES
8140.63.4.. (85 CV PC/NA + EGR + OXICAT)
8140.43R (90 CV ID/TCA*)
8140.43B.43XX (105 CV ID/TCA*) o o
8140.43C.40XX (105 CV ID/TCA + OXICAT) o o o
8140.43S.41XX (125 CV ID/TCA* E.G.R. + OXICAT)
8140.43S.43XX (125 CV ID/TCA*) o o o o o o
8140.43N.43XX (150 CV ID/TCA*) o o o o
F1AE0481A*A (96 CV)
F1AE0481B*A (116 CV)
F1AE0481B*B (116 CV + E.G.R. + OXICAT)
Single disc 9” 1/4
Single disc 10” 1/2 o o o o o o o o
Single disc 11 o o o o o
ZF 5S 200
ZF 5S 270
ZF 6S 300 o o o o o o o o o o o o o
FRONT AXLES:
5817 o
5818
5819 o o o o o o o o o o
5823 o o
450210 o
450311/1 o o
450511 o o o o o o o o
450517/2 o o
Rack-and-pinion Power steering o o o o o o o o o o o o o
FRONT MECHANICAL SUSPENSIONS:
o
independent with transverse leaf spring (MK3)
independent with torsion bars o o o o o o o
REAR Parabolic Z Z Z Z Z Z Z o o o o o
MECHANICAL
SUSPENSIONS: - single leaf o
- double-leaf
Semi-elliptic s s s s s s s
Semi-elliptic
with leaf spring
z z z z z z z
Print 603.43.351
ALPHANUMERICAL CODING FOR VEHICLE IDENTIFICATION
CUSTOMIZED VEHICLE (V.P.)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
RANGE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
PROGRAMMING FAMILY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
29 L
1 L 30
35 S
35 C
2 L 35
40 C
60 C
4 L 65
65 C
29 L
5 L 30 A
35 S
35 C
6 L 35 A
40 C
60 C
8 L 65A
65 C
PROGRAMMING FAMILY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
H F 25 29 L
M F 30 35 S
CHASSIS CABS AND
DERIVATIVES
35 C
E F 35
40 C
L F 25 A 29 L
N F 30 A 35 C
VANS AND DERIVATIVES
35 C
G F 35 A
40 C
ENGINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
B 8140 43 C.40XX
8140.43 C 40XX ID/TCA - 105 CV
E 8140 43 S.41XX
8140.43 S 41XX ID/TCA - 125 CV (MI)
ENGINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
F 8140 43 B.43XX
8140.43 B 43XX ID/TCA - 105 CV
G 8140 43 S.43XX
8140.43 S 43XX ID/TCA - 125 CV
H 8140 43 N.43XX
8140.43 N 43XX ID/TCA - 150 CV
M 8140 43 R.43XX
8140.43 R 43XX ID/TCA - 90 CV
J F1AE0481A ID/TCA - 96 CV
SUSPENSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
VERSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
35 S.9 (•) - 29 L.9 - 35 S.11 (•)
( ) - 29 L.11 - 29 L.12 (•)
29 L.10 (•) ( )
3 S.10
35 S 0 ((•)) - 35
3 SS.12
2 (•)
( ) - 35
3 SS.13
3 (•)
( )
35 S 15 (•) - 35 C.9 (•) - 35 C.10 (•)
1 CHASSIS
35 C.11
C 11 (•) - 35 C.12
C 12 (•) - 35 C.13
C 13 (•)
CAB
35 C 15 (•) - 40 C.9 - 40 C.11 - 40 C.12
45 C.11 - 45 C.13 - 50 C.11 (•)
50 C.13 (•) - 50 C.15 (•) - 60 C.15 (•)
65 C.15 (•)
VERSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
VERSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
29 L.9 C.V. - 29 L. 10 C.V. (•) - 29 L.12 C.V.
((•)) - 29 S.11 C.V. - 35 S.9 C.V. (•)( ) - 35 S.10
C
C.V. (•)
( ) - 35
3 S.11
S C
C.V. (•)
( ) - 35
3 S.12
S 2C C.V. (•)
( )
VENDOR 35 S.13 C.V. (•) - 35 S.15 C.V. (•) - 35 C.9
U VERSION CITY C.V.
C V (•) - 35 C.10C 10 C.V.
C V (•) - 35 C.11
C 11 C.V.
C V (•)
VAN - 35 C.12 C.V. (•) - 35 C.13 C.V. (•) - 35
C.15 C.V. (•) - 40 C.10 C.V. - 40 C.12 C.V. -
50 C.11 C.V. (•) - 50 C.13 C.V. (•) - 50 C.15
C.V. (•)
WHEELBASE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 3000 L mm (F35A)
WHEELBASE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
5 4100 mm (L35)
7 4100 mm (F35)
GEARBOX
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A 5 SPEED
B 6 SPEED
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Print 603.43.351/D Base - 3rd Ed. - February 2002
Revi - May 2003
14 GENERAL DAILY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
RANGE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
PROGRAMMING FAMILY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A LBU1 35 S
B LBU2 40 C
C LBU2 50 C
ENGINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
SUSPENSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
VERSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14
LBU1
F GLAZED VAN
LBU2
2 MINIBUS LBU2
3 HIRE LBU2
GEARBOX — WHEELBASE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
5 SPEED
A LBU1
3000 L mm
6 SPEED LBU1
B
3000 L mm LBU2
6 SPEED
C LBU2
3950 mm
1 2 3 4 5 6 7 8 9 10 11 12 13 14
REPLENISHING FLUIDS
Print 603.43.351/D
! Max. gradient negotiable by vehicle uphill/downhill with oil at minimum level 30%
Front axle:
5817 - -
5818 - -
5819 - -
5823 - -
Rear axles:
Tutela W140/M-DA (SAE 450210 18
1.8 15
1.5
85W140)
Print 603.43.351
95 35
50 10 SAE 40
32 0 SAE 30
SAE
14 -10 20W
SAE
5 -15
15W/40
SAE
-13 -25 10W
oF oC
SECTION 2
5401 Engines
Page
ENGINES WITH ELECTRONIC
HIGH-PRESSURE
INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . 25
- 8140.43R. 43XX
- 8140.43B. 43XX
- 8140.43S. 41XX
- 8140.43S. 43XX
- 8140.43N. 43XX
Page
MAIN SERVICING OPERATIONS TO BE PERFORMED
ON VEHICLE ENGINE . . . . . . . . . . . . . . . . . . 5
ENGINE REMOVAL-REFITTING . . . . . . . . . . . . . 7
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REPLACING BELTS . . . . . . . . . . . . . . . . . . . . . . . 17
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Page
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REPLACING INJECTORS
(ENGINE 8140.63 - 8140.43C) . . . . . . . . . . . . 21
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REPLACING INJECTION PUMP . . . . . . . . . . . . . 21
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
On vehicles equipped with 8140.43B/R/S (Common Rail) engines, follow the indications specified below before
! performing engine servicing operations that involve fuel system:
- before every engine servicing operation, perform engine/vehicle diagnosis by proper IVECO testers and print out
obtained results.
- MS6.3 control unit replacement shall be authorised by Help Desk.
- The following fuel system components shall not be overhauled but replaced: flow control devices, pressure relief
valve, fuel pressure sensor, rail, complete CPI high pressure pump, pressure control valve, electroinjectors;
- Every Common Rail system part is packed by supplier into oil paper sheets and then stored into cardboard boxes.
These parts shall be protected against dampness and shall be unpacked just before their use.
- Take utmost care to part cleanliness during filter and prefilter handling and fitting (even in case of simple
replacement) to prevent foreign matters and dirt infiltration. To this purpose, hydraulic part and sensor protective
plugs shall be removed just before refitting into place.
- Assembly direction shall be observed for all electric connections.
- Every threaded connection shall be tightened to the specified torque.
- Every quick coupling connector (on this engine find them on high pressure pump and diesel fuel draining duct) shall
be fitted properly. Operate on the tabs set at connector base to remove them.
Electroinjector:
injector body connections/unions/nuts shall never be manipulated. Nozzle body and electromagnet shall never be
disassembled, since this operation is not required and is forbidden.
When servicing operations on high pressure pipe are required, the hexagon on injector side shall be held with proper
wrench.
Before servicing pipes, check whether injector is fitted into seat on cylinder head.
When removing/refitting injector draining duct, do not remove retaining spring from its seat on injector: when pushing
the spring towards the engine and exerting a vertical force on connector, recycling is released. When refitting, put
recycle connector into its seat and exert a vertical force by pressing the retaining spring towards engine. Fitting shall
be friendly.
ENGINE
50952
Take the cap (1) off the expansion tank (3). Figure 2
Unscrew the coolant plug (10), under the radiator (11), and
drain the cooling system.
Disconnect the heat exchanger pipes (7 and 8) from the intake
manifold and from the turbocharger.
62115
Unscrew the screws (3) to free the engine cable from the
body.
Disconnect the fuel pipe (11) from the high-pressure pump.
Disconnect the fuel recovery pipes (9 and 10).
Disconnect the pipe (12) from the vacuum pump.
Place a container under the power steering pump to recover
the oil from the system. Then disconnect the oil inlet and
outlet pipes (15 and 16).
Disconnect oil vapour piping (23) from flow control valve (for
EGR versions only).
Disconnect air intake duct (22) from turbosupercharger.
Disconnect pressure pipe (24) from turbosupercharger
actuator control solenoid valve (engine 8140.43N only).
Remove the sealing from the ring nut (1), unscrew it and dis- Figure 4
connect the speedometer control cable.
Disconnect the electrical connection (4) from the reversing
light switch.
Unscrew the screws (3) securing the propeller shaft (2) to the
gearbox. Fasten the propeller shaft to the chassis frame ap-
propriately.
Unscrew the screws (6) and the screw (5). Remove the cross-
piece (7) supporting the gearbox complete with plug.
Disconnect the exhaust pipe (9) from the turbocharger outlet
pipe.
Disconnect the screws (16 and 18) securing the brackets (15
and 17) and disconnect the ”bowdens” (14 and 19) from the
gearbox.
Unscrew the screws (20), move the clutch control cylinder
(21), with its bracket, and fasten it to the chassis frame ap-
propriately.
Remove the nuts (13) for the screws securing the engine
brackets to the structural members and take out the screws.
Lift the engine assembly and take it out of the engine bay.
50955
ENGINE
Figure 5
50956
62853
51194
This differs from engine removal for the 8140.43S as there Disconnect the throttle cable (9) from the injection pump
is no engine cable or electric components connected to it and from the bracket.
and in the following. Disconnect the fuel pipes (10 and 14) from the injection
Disconnect the electric cables: pump.
- (1), from the thermostart solenoid valve; 8140.63 (aspirated) engine only:
- (2), thermostart glow plug; - (18), vacuum pipe from EGR valve;
- (3), insufficient engine oil pressure indicator; - (19), EGR potentiometer electric cable;
- (4), coolant temperature indicator;
- Disconnect the glow plug electrical connection from the
- (5), temperature switch for K.S.B. and thermostart; control unit in the engine bay, above the battery.
- (6), alternator;
- (7), temperature switch;
- (8), electric fan;
The engine should be taken out of the engine bay
- (11), starter motor; extremely carefully so as not to damage the top pipe
!
- (15) electric stop; of the power steering and the heatproof-soundproof
- (16), K.S.B.; covering of the engine bay.
- (17), engine speed sensor.
Refitting
When positioning the engine in the engine bay, take
! special care not to damage the top pipe of the power
To refit the power unit, reverse removal operations and steering and the soundproof-heatproof cladding of
observe the following indications: the engine bay.
Once positioned, meticulously check that the top
- before refitting gearbox to engine, remove thrust bearing pipe of the power steering is sound.
(2, Figure 6) from diaphragm spring (3, Figure 6) by Before using it again, check that the power steering
opening circlip (4, Figure 6). oil and coolant contain no impurities. If they do, filter
Fit thrust bearing (2, Figure 6) on input shaft cover sleeve with suitable mesh filters. For any topping up, refer
and connect it to clutch disengagement lever. Smear to the REPLENISHING FLUIDS table in the
input shaft with Molikote molybdenum disulphate ”GENERAL” section.
grease.
Engage a speed to rotate main shaft by rotating propeller
shaft flange. Push down the gearbox to properly engage
thrust bearing (2, Figure 6) into diaphragm spring; Figure 8
- take the utmost care when refitting the power unit into
engine compartment;
- check the conditions of the coolant pipes or sleeves and
of the air conveyors. Replace them if they show any sign
of deterioration;
- check the flexible mountings of the assemblies: engine
and gearbox. Replace them if they show any sign of
deterioration;
- check that the exhaust pipe members have not
deteriorated and are not about to deteriorate. If this is
so, replace them along with the flexible parts for securing
them;
- tighten the screws or nuts to the required torque;
75242
- meticulously check the state of the vacuum pipe. It must
show no sign of cracking, cutting, scoring or of being
FUEL PIPES
crushed. Replace it if there is any doubt at all about its
1. High-pressure pump fuel pipe fast coupling - 2. Fuel
soundness. When mounting it, make sure the pipe does
supply pipe fast coupling 3. Fuel return pipe fast coupling -
not come into contact with sharp metal parts or corners
4. Fuel filter mount.
or with any particularly hot parts. In addition, after
assembly, the pipe must have no bends or constrictions, If the fuel pipes (1-2-3) get disconnected from the mount (4),
its radius of curvature should be broad and it must be it is necessary, when refitting, to make sure their couplings are
secured to the vacuum pump fitting with a suitable thoroughly clean. This is to prevent getting a bad seal and fuel
clamp; leaking out as a result.
- fill the cooling system with coolant.
- make sure that the quick-coupling fittings of the fuel
pipes are carefully cleaned and that, after their Checks and tests
connection to the relevant unions of the high-pressure
pump or of the fuel filter mounting, they are fully inserted
and do not get disconnected. Start up engine, leave running at a speed slightly in
excess of idle speed and wait for coolant to heat
- bleed the fuel supply system as described in the relative sufficiently to open thermostat. Then check the fol-
paragraph (only for engines 8140.63.4... - 8140.43C.4...); lowing:
- fill the power steering circuit and bleed the air as
described in the relevant paragraph;
- check the level of oil in the engine and gearbox; - no coolant leaks from coolant hose and cab interior
heating hose connection sleeves. Tighten hose clips, if
- adjust the tension of the drive belt of the compressor for necessary;
the air-conditioner as described in ”Replacing Belts” (if - no oil leaks from between cover and cylinder head, oil
present). sump and crankcase, oil filter and housing, heat
exchanger and crankcase or from lubrication circuit lines;
- no fuel leaks from injection pump and injector lines.
Tighten fittings if necessary;
- check that the indicator lights on the instrument panel
and relating to the devices disconnected when the
engine was removed are working properly.
542011 Bleending the fuel system (see 507130 OXICAT - OXYDIZER CATALYST
Figure 7) 8140.43C - 8140.63 engines (Vehicles with 8140.43C -
only 8140.63 engines)
Description
Loosen bleed screw (12), operate priming pump lever (13)
until complete bleeding of all the air in the system, tighten The oxidizing catalyst (1) is a post-treatment device for ex-
bleed screw. haust gases. It is used to oxidize CO, HC transforming them
into carbon dioxide (CO2) and steam (H2O).
If the engine stops for lack of fuel, resulting in air This catalyst also treats saturated and aromatic hydrocarbons
! being introduced into the system (and if the bleeding forming part of the particulate, such as the carbon in the form
process described above is no sufficient), it is necess- of soot, metals, water and sulphur compounds that are ex-
ary to loosen the unions of at least two injectors, ro- hausted.
tate the engine and start it.
When the air has been bled off, close the unions The cylindrical-shaped catalyst consists of a ceramic honey-
again. comb monolith whose cells are platinum-impregnated, a ca-
talyzing substance of oxidation reactions. Its total volumetric
capacity is equal to 600 cm3 with a density of 400 cells per
square inch.
501430 Power steering system air The exhaust gases passing through the cells heat the catalyst,
bleed converting the pollutants into inert compounds.
The chemical oxidation reaction of CO, HC and of the parti-
Check the level of oil in the tank and top it up if necessary. culate is efficient with temperatures ranging between
Lift the vehicle at the front, start up the engine and let it idle 200°C ÷350°C.
for some time. With temperatures higher than 350°C it starts oxidizing the sul-
Check there is no oil leakage from the hydraulic circuit and phur contained in the diesel oil, generating sulphur dioxide
check the level in the tank. (SO2) and sulphur trioxide (SO3), which are the cause of acid
Slowly turn the flywheel in both directions of steering so that rain.
the air in the hydraulic system comes out.
Check the level of oil in the tank again and top up if necessary. Correct catalyst sizing enables limiting the temperature, ob-
taining the greatest percentage of conversion of polluting
emissions, while reducing the freezing of sulphur compounds.
Figure 9
455182
62063
Removal - remove the pipe (19) from the rear cover of the cylinder
Remove the timing belt as described under the relevant head;
heading (operation 541257). - take out the screw securing the engine electric cable
Disconnect the electrical connections from the: bracket;
- cooling temperature indicator (11); - take out the screw (20) securing the pipes (17) to the
cylinder head;
- ”KSB” temperature switch (8140.63/43C engines only)
and/or thermostart; - take out the screw (18) securing the oil vapour
condenser;
- air temperature and pressure sensor (4) (8140.43B/R/S
engine only); - remove the top (23) and side (22) soundproofing;
- expansion tank level indicator (14); - disconnect the electrical connections:
(29) from the electro-injectors (26) (8140.43B/R/S
- disconnect the coolant pipes (2, 3 and 5); engines only);
- remove the expansion tank (15); - (13) from the engine speed sensor (8140.43B/R/S and
- remove the coolant pipes (10) from the water pump and 8140.63 engines only);
from the heat exchanger pipe (9); - from the glow plugs (8140.63 engine only);
- take out the screw (1) and the nut securing the bracket - from the fuel pressure sensor (25) (8140.43B/R/S
fixing the pipes (10 and 16) to the inlet manifold; engines only);
- extract the oil vapour recirculation valve (6) from the - remove the tappet cover.
duct (8) (8140.63 engine only);
8140.43B/R/S engines only
- remove the exhaust pipes (7) from the turbocharger Disconnect fuel recovery pipe (28) from connection (24).
(8140.43C - 8140.43B/R/S engines only); Press clamps (32) and lift connections (31) at the same time,
- remove the turbocharger (8140.43B/R/S/43 C engines disconnect connections and pipes (28) from electroinjectors
only) from the inlet manifold; (26).
Disconnect the fuel pipes (28) from the electro-injectors
(26) and from the hydraulic accumulator. Take out the
screws securing the electro-injector brackets (20).
Remove the electro-injectors (26) from the cylinder head.
Disconnect the pipe (33) from the high-pressure pump and Figure 11
from the hydraulic accumulator.
8140.43B/R/S engine excluded
Disconnect the fuel pipes from the injection pump and from
the injectors.
Disconnect the fuel recovery pipes from the injectors. α
- Disconnect the LDA pipe from the inlet manifold
(8140.43 C engine only).
- Take out the screws (27) and remove the cylinder head
6448
with its gasket.
Figure 12
in three successive stages, following the order and method Clean spaces between rear cover (4) and cylinder head (3)
shown in the following figure. from sealant residues and refill with IVECO 1905685 sealant.
Fit seal (2) on tappet cover (1). Smear tappet cover corners
(⇒) with Silastic 732 RTV (approx. 10g). Refit tappet cover
on cylinder head and tighten fixing nuts (5) to the specified
The angle closure is done with tool 99395216. torque.
! Check the speed sensor is mounted as described under the
relevant heading (8140.63 - 8140.43 S engines only).
When fitting the fuel pipes, don’t use the metal clamp with
the flexible plug and fixing screw. Replace them with new
parts (8140.63 - 8140.43C engines only).
REPLACING BELTS
Figure 13
50958
Print 603.43.351/D
Figure 14
86142
Figure 15
50960
Print 603.43.351
50961
Remove the wrench (4) and the washer (3) from the water
Disassembly pump shaft (1) and take out the pulley (5). Remove the nuts
and extract the electromagnetic coupling (2).
Disassemble the compressor drive belt (if there is one) and the
water pump drive belt as described under the relevant headings. Shift the piston ring (22) downwards and insert the pipe (23)
into the thermostat box so as to remove it from the water
Remove the air manifold (20) without disconnecting the electric
pump (1).
cables and the fuel pipe from the solenoid valve - thermostart
glow plug in the engine bay. Take out the screws (24) and remove the water pump (1)
from the crankcase.
Remove the side (18) (if present) and top (19) soundproofing
covers from the cylinder head.
Remove the timing belt cover (17). Assembly
Remove the automatic tightener (14). Loosen the screw (15)
for the nut securing the alternator to the mounting. For assembly, carry out the operations for disassembly in
Take out the screw (12) securing the alternator to the water reverse order, taking the following precautions:
pump (1). - replace the seal rings of the pipe (23);
Insert a special wrench (16) between the pin (13) and the push
rod (11) so as to cancel its pressure on the tightener roller (25). - clean the thread of the screws (24) and apply IVECO
Take out the screws securing the piping (8) to the water pump 1905683 sealant on their first 15 mm.
(1).
Disconnect the electromagnetic pulley electrical connection The hub locking nut (9) has a left-hand thread. The
(10). ! nut (7) must be replaced whenever disassembled.
Stop electromagnetic pulley (5) rotation using the proper tool.
Unscrew clockwise (7) hub retaining nut (9) and remove the
hub. Phase 1, tightening with torque wrench to a torque of 40 Nm.
Phase 2, closing with an angle of 110° ± 10°.
The nut (7) retaining the hub (9) has a left-hand The angle closure is performed with tool 99395216.
! thread. !
50963
Disassembly
Remove the air manifold (10) from the inlet manifold without
disconnecting the electric cables and the fuel pipe. Remove the transverse air manifold (10) without
Put the air manifold (10) appropriately to one side in the disconnecting the fuel pipe and electric cables from the
engine bay. Take out the side soundproofing cover (if any) thermostart components. Put the transverse air manifold
and the top cover (11). Remove the injectors (17 or 13), the (10) appropriately to one side in the engine bay.
fuel recovery pipe (16) and the fuel pipes (15). For engine Remove the top (11) and side (if any) soundproofing covers.
8140.43C, take out the screws (18) securing the injector Remove the timing cover (6). Turn the crankshaft so as to
brackets and remove the injectors from the cylinder head. align the camshaft pulley mark A with the tappet cover mark
For engine 8140.63, unscrew the injectors (13). B, making it possible to insert tool 99360608 into the hole
(5) in the pulley and into the hole in the auxiliary member
assembly. If this is not possible, turn the crankshaft by one
Assembly turn.
Remove the pipe bracket for the oil dipstick (7) from the
For assembly, carry out the operations described for disas- auxiliary member assembly.
sembly in reverse order, taking the following precautions: Disconnect the following from the injection pump:
- tighten the injectors of engine 8140.63 at a torque of 60 - Electric cables:
Nm (6 kgm); D (9), KSB device.
D (14), electrostop.
- bleed the fuel air as described under the relevant heading. D (12), EGR potentiometer (if present);
- fuel pipes (3 - 7, Figure 17); Connect the electric cable to the bulb (1, Figure 18) of the
- pipes delivering fuel to the injectors (15, Figure 17); KSB device and power it with the voltage of the vehicle. This
deactivates the KSB device.
- vacuum pipe (8, Figure 17)
- bowden throttle control cable (1, Figure 17); From underneath the vehicle:
Disconnect the injection pump. - remove the soundproofing guards of the engine/gear-
box;
Having to refit the same injection pump that has - disconnect the oil dipstick pipe (7, Figure 17);
! been removed. Mark its assembly position on its - take out a nut securing the injection pump.
mounting. From the engine bay, take out the nuts securing the injection
pump and remove the pump.
Figure 18
50694
Take out the plug located on the pump closure screw and
screw down tool 99395100 (2), with the rod in contact with The KSB device is deactivated when the timing
the top of the timing piston. ! advance control lever is no longer pulled.
Preload the dial gauge 99395603 (3) by approx. 3 mm.
Figure 19 Remove the tool 99360608 from the injection pump control
pulley.
Turn the engine in the opposite direction to that of rotation
until the injection pump timing piston reaches TDC, indicated
by the dial gauge (3). Zero the dial gauge (3). Insert tool
99360608 (5) into the hole (⇒) of the gearbox cover (6).
Slowly turn the crankshaft in its direction of rotation to insert
tool 99360608 (5) into the slot in the engine flywheel (4).
In the above condition, marks A and B (Figure 17) must
coincide and the injection pump piston must have made the
required travel. If this is not so, turn the pump body in its slot
to obtain the required value shown by the dial gauge. Fully
lock the nuts securing the pump to the auxiliary member
assembly.
18941
540850 ENGINE FLYWHEEL REMOVAL-RE- Remove the flywheel fastening screws, lift pin (11) from en-
FITTING gine flywheel (13) milling and remove it.
Removal
Should rear cover leaks be found, replace the cover
This operation includes: ! as described in the relevant chapter (operation
540460).
- propeller shafts removal-refitting (see relevant section
505620)
- gearbox removal-refitting (see relevant section
530210) Refitting
- clutch removal-refitting (operation 505210).
Check on dial gauge (1) whether piston (3) is at TDC,
For engines 8140.43C-8140.43 B/R/S proceed as otherwise operate on the output shaft to position it in said
follows: condition.
Remove cylinder 1 injector (6) as specified in engine over- Position engine flywheel (13) on output shaft to fit tool pin
haul. (11) into flywheel milling and secure the fastening screws.
Tighten flywheel fastening screws to the required torque.
Fit tool 99395098 (2) with dial gauge 99395603 (1) into in- Refit injector as specified in engine overhaul.
jector seat and secure it to cylinder head by clip (5) and
screw (4).
Rotate the output shaft until reading piston (3) TDC posi- For engines 8140.63:
tion on dial gauge (1).
Apply gauge 99395214 (10) to engine block. Removal
Operate on engine flywheel (13) to fit tool 99395214 (10)
pin (11) into engine flywheel (13) milling. Set cylinder 1 piston to TDC at compression stage (valves
closed).
Lock pin (11) by screw (12). Fit tool 99395100 (8) including the dial gauge 99395603 (9)
on injection pump (7) (after removing the plug); preload and
set the dial gauge to zero.
Figure 20 Apply gauge 99395214 (10) to engine block and proceed as
described for engines 8140.43C-8140.43 B/R/S.
Refitting
62851
ENGINE 8140.43R.43XX
ENGINE 8140.43B.43XX
ENGINE 8140.43S.41XX
ENGINE 8140.43S.43XX
ENGINE 8140.43N.43XX
DAILY ENGINES 8140 27
Page
EMISSIONS VALUES . . . . . . . . . . . . . . . . . . . . . . 31
- Engine 8140.43R.43.. . . . . . . . . . . . . . . . . . . . . 31
- Engine 8140.43B.43.. . . . . . . . . . . . . . . . . . . . . 32
- Engine 8140.43S.41.. . . . . . . . . . . . . . . . . . . . . . 33
- Engine 8140.43S.43.. . . . . . . . . . . . . . . . . . . . . . 34
- Engine 8140.43N.43.. . . . . . . . . . . . . . . . . . . . . 35
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 40
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 48
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
OVERHAULING ENGINE . . . . . . . . . . . . . . . . . . 59
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 65
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 65
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 68
- Checking crankshaft . . . . . . . . . . . . . . . . . . . . . 70
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 71
Page Page
Page Page
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 97
- Timing system speed sensor . . . . . . . . . . . . . . . 107 - Checking engine coolant temperature . . . . . . . 115
Page Page