2010 IVECO DAILY 4 Service Repair Manual

DAILY EURO 4
REPAIR MANUAL
MECHANICAL
ELECTRIC/ELECTRONIC

B.U. TECHNICAL PUBLISHING
Iveco Technical Publications
Lungo Stura Lazio, 15
10156 Torino (TO) - Italy
Produced by:
”This document provides data,characteristics, instructions and
methodology to perform repair interventions on the vehicle
and its components.
Anyhow, this document is addressed to qualified and
specialised personnel. Iveco commercial and assistance
network personnel as well as all Iveco authorised points of
assistance are specifically qualified and equipped to perform
the repair interventions that are indicated in this document.
Before performing any intervention, check to have available
the document relating to the vehicle model on which the
intervention is being performed and also make sure that all
accident prevention devices, such as, as a rough guide, goggles,
helmet, gloves, shoes, as well as work tooling, lifting and
transport tooling, etc., are available and efficient, and further
make sure that the vehicle is put such a way that an
intervention can be made in safety conditions.
Making interventions strictly observing the indications given
here, as well as using specific tooling indicated, assures a
correct repair intervention, execution timing observance and
operators’ safety.
Each repair intervention must be finalised to the recovery of
functionality, efficiency and safety conditions that are provided
by Iveco.
Each intervention, on the vehicle, that is finalised to a
modification, alteration or else, which is not authorised by
Iveco, involves the exclusion of any responsibility for Iveco,
and, in particular, where the vehicle is covered by a guarantee,
each such intervention involves an immediate lapse of the
guarantee.
Responsibility for Iveco in repair intervention execution is
excluded.
Iveco is available to provide all clarifications necessary to make
interventions, as well as to provide indications in cases and
situations not included in this document.
Data and information contained in this document could result
not to be updated owing to modifications made by Iveco at
any moment for technical or commercial reasons, or because
of the need to adapt the vehicle to law requirements in
different countries.
In the case of a difference between what contained here and
what actually found on the vehicle, please contact Iveco
network before making any intervention.”
The data contained in this publication might fail to reflect the
latest changes which the Manufacturer may introduce at any
time, for technical or sales purposes, or to meet the
requirements of local legislation.
Copy, even partial, of text and drawings is forbidden.
Publication Edited by:
IVECO S.p.A.
Customer Service
Lungo Stura Lazio, 15
10156 Torino (TO) - Italy
Print 603.93.651 - 1st Ed. 2006

Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated
in 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 of
units 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, electric
schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the
electric 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 danger
It includes the dangers of above described signals.
Danger of serious damage for the vehicle
Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes
guarantee lapse too.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
Danger for persons
Missing 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 603.93.651 Base - March 2006I

Base - March 2006 Print 603.93.651II
SYMBOLS - ASSISTANCE OPERATIONS
Removal
Disconnection
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fitting in place
Assembly
Compression ratio
Tighten to torque
Tolerance
Weight difference
Tighten to torque + angle value Rolling torque
Press or caulk Rotation
Regulation
Adjustment
Angle
Angular value
Visual inspection
Fitting position check
Preload
Measurement
Value to find
Check
Number of revolutions
Equipment Temperature
Surface for machining
Machine finish bar
Pressure
Interference
Strained assembly
Oversized
Higher than .
Maximum, peak
Thickness
Clearance
Undersized
Less than .
Minimum
Lubrication
Damp
Grease
Selection
Classes
Oversizing
Sealant
Adhesive
Temperature < 0 C
Cold
Winter
Air bleeding
Temperature > 0 C
Hot
Summer
Replacement
Original 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 and
TROUBLE 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 :
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 :
Unit 01 = Chassis;
Sub-assembly 40 = Chassis cross members;
Sub-assembly 13 = Rotor.
PRODUCT CODE
5 0
PRODUCT UNIT SUB-ASSEMBLY
COMPONENT
0 1
4 0
7 6
0 3
1 3
COMPONENT
COMPONENT
COMPONENT
COMPONENT
COMPONENT
Print 603.93.651 Base - March 2006III

GENERAL WARNINGS
Warnings shown cannot be representative ofall danger situations possibly occurring. Therefore,it is suggested tocontact
immediate 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 and
maintenance 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 on
the 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 means
is 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 from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous 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. Scrupulously
observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair
intervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph “Controls
care 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 unmanned
a 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 support
stands 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 the
document, 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 pressure
out.
Inflammable fuel andall inflammable fluids andliquids must be handled with care, according to what contained onharmful
materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according 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 suitable
containers.
Worn out, damaged or consumable parts must be replaced by Iveco original spares.
During workshopactivity, always keepthe work place clean; timely clear or clean floors from accidental liquidor 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 observe
indications specified in relating manual sections.
!
Base - March 2006 Print 603.93.651IV

GENERAL WARNINGS
Clean units or assemblies detachedfrom the vehicle and carefully check their integrity before overhaul. Tidy updetached
or 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 is
available 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 materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80 C (dryer ovens), disassemble drive electronic central
units.
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; contact
with 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; operate
outdoors 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 serious
burns. 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 603.93.651 Base - March 2006V

GENERAL WARNINGS ON THE ELECTRIC SYSTEM
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
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 tightening
torque.
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/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during key
memorisation:
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 battery
terminals.
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 screening
braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance
interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be 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, which
would later cause contact problems.
Connectors present must be seen from cable side. Connectors views containedin the manual are representative ofcable
side.
!
NOTE
Base - March 2006 Print 603.93.651VI

Print 603.93.651 Base - March 2006VII
Bonding and screening
Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying
then 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 opening
bonding (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. CONNECTOR
d. DISTANCE ! 0
88039
Figure 1
Figure 2

Base - March 2006 Print 603.93.651VIII
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
Accessories mounting, additions and modifications on the vehicle are to be performed complying with IVECO mounting
instructions (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 in
order to simplify and normalise the electrical intervention that is care of preparation personnel.
For any exception to mounting instructions, IVECO’s 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 THE
INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 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.
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F

Base - March 2006 Print 603.93.651

Print 603.93.651 Base - March 2006
Section
General information 1
Engine 2
Clutch 3
Gearbox 4
Propeller shafts 5
Rear axles 6
Front axle 7
Front and rear suspensions 8
Wheels and tyres 9
Steering system 10
Pneumatic system - Brakes 11
Bodywork and chassis frame 12
Maintenance 13
Electric/Electronic System 14
INDEX OF SECTIONS

GENERAL 1DAILY EURO 4
Print 603.43.671
SECTION 1
General
Page
IDENTIFICATION DATA 3. . . . . . . . . . . . . . . . . .
- Vehicle Identification Plate 3. . . . . . . . . . . . . . . .
COMPOSITION OF MODELS 4. . . . . . . . . . . . . .
ALPHANUMERICAL CODING FOR
BUS IDENTIFICATION 6. . . . . . . . . . . . . . . . .
REPLENISHING FLUIDS 13. . . . . . . . . . . . . . . . . . .

Vehicle identification plate
Plate legend
Manufacturer tag
For vehicle identification according
to the EC directive
(on the front crosspiece)
Chassis
Stamping
(at the front on the chassis right-hand side-member)
Engine
Stamping
(on the right side on the engine base)
1) Approval number
2) Chassis number
3) PTT - Total weight on ground
4) MTC - Total combined weight
5) Max. weight permitted on the front axle
6) Max. weight permitted on the rear axle
7) Specific indication of type
8) Wheelbase (mm)
9) Type of engine
10) Engine rating
11) Permitted smoke level
12) Place of manufacture
13) Number of vehicle axles
Figure 1
Figure 2
108533
108534
IDENTIFICATION DATA

4 GENERAL DAILY EURO 4
COMPOSITION OF MODELS
ASSEMBLIES
MODELS
F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV o o o o
F1AE0481G*A - F1AE0481G*B (OPT. DPF) 116 CV o o o o
F1AE0481H*A - F1AE0481H*B (OPT. DPF) 136 CV o o o
F1CE0481F*A - F1CE0481F*B (OPT. DPF) 146 CV o o
F1CE0481F*C (DPF series) 146 CV
F1CE0481H*A - F1CE0481H*B (OPT. DPF) 176 CV o o
F1CE0481H*C (DPF series) 176 CV o
Single disk 9” 1/4 o o o o o o o o
Single disk 10” 1/2
o o o o
Single disk 11 o o o o o
ZF 5 S300 V V V V V V V V V V V
ZF 6 S400 O.D. V V V V V
ZF 6 S400A O.D. V V V V V V V V V V V V V V V V
5817 o o o o o o o
5818
5819 o o o o
5823
NDA R.S. o o o o o o o
NDA R.G. o o o o o
450511 o o o o
450517/2
Rack-and-pinion Powered steering o o o o o o o o o o o o o o o o
FRONT MECHANICAL SUSPENSIONS:
independent with transverse leaf spring (MK3)
o o o o o o o o o o o
independent with torsion bars ( ) ( ) ( ) ( ) ( ) o o o o
REAR
MECHANICAL
Parabolic o o o o o o o Z Z Z Z Z Z Z Z Z
MECHANICAL
SUSPENSIONS:
- single leaf o o o o o o o
SUSPENSIONS:
- reinforced o o o o o o o
Semi-elliptical s s s s s s s s s
Semi-elliptic
with leaf spring
z z z z z z z z z
REAR AIR SUSPENSIONS V V V V V V V V V V V V V V V V
O.D. = Over Drive
( ) Optional extra (with max load of 1900 kg)
o Standard
with ZF 6 S 400 A O.D. gearbox
V Alternative
Vehicles with front suspension with transverse leaf spring
Vehicles with front suspension with torsion bars
z Chassis cabs only, as an alternative
s Standard on chassis cabs, Alternatively on Vans — Chassis Cowls
and Cut Aways
Z Standard on Vans, Chassis Cowls and Cut Aways — Alternatively
on Chassis Cabs
S Single rear wheels
L Light with single rear wheels
C Twin rear wheels

COMPOSITION OF MODELS
ASSEMBLIES
MODELS
F1AE0481A*A - F1AE0481A*B (OPT. DPF) 96 CV
F1AE0481G*A - F1AE0481G*B (OPT. DPF) 116 CV
F1AE0481H*A - F1AE0481H*B (OPT. DPF) 136 CV
F1CE0481F*A - F1CE0481F*B (OPT. DPF) 146 CV
F1CE0481F*C (DPF series) 146 CV o o o o
F1CE0481H*A - F1CE0481H*B (OPT. DPF) 176 CV
F1CE0481H*C (DPF series) 176 CV o o o o
Single disk 11 o o o o o o o o
ZF 5 S300
ZF 6 S400 O.D. V V V V V V V V
ZF 6 S400A O.D. V V V V V V V V
5817
5818
5819 o o o o
5823 o o o o
NDA R.S.
NDA R.G.
450511 o o o o
450517/2 o o o o
Rack-and-pinion Power steering o o o o o o o o
FRONT MECHANICAL SUSPENSIONS:
independent with transverse leaf spring (MK3)
independent with torsion bars o o o o o o o o
Parabolic Z Z Z Z Z Z Z Z
- single leaf
- reinforced
Semi-elliptical s s s s s s s s
Semi-elliptic
with leaf spring
z z z z z z z z
REAR AIR SUSPENSIONS V V V V V V V V
O.D. = Over Drive
( ) Optional extra (with max load of 1900 kg)
o Standard
V Alternative
Vehicles with front suspension with transverse leaf spring
Vehicles with front suspension with torsion bars
z Chassis cabs only, as an alternative
s Standard on chassis cabs, Alternatively on Vans — Chassis Cowls
and Cut Aways
Z Standard on Vans, Chassis Cowls and Cut Aways — Alternatively
on Chassis Cabs
S Single rear wheels
L Light with single rear wheels
C Twin rear wheels

ALPHANUMERICAL CODING FOR VEHICLE IDENTIFICATION
A LIGHT ROAD VEHICLES
A T 25C 29 L
B T 30C 35 S
C T 35C 35 C
D T 40C 40 C
E T 50C
50 C
45 C
F T 65C
60 C
65 C
CUSTOMIZED VEHICLE (V.P.)
PROGRAMMING FAMILY
MARKET VEHICLE (V.M.)
STANDARD VEHICLE (V.C.B.)
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14
CHASSIS CABS AND DERIVATIVES

H T 25V 29 L
K T 30V 35 C
J T 35V 35 C
L T 40V 40 C
M T 50V
50 C
45 C
N T 65V
60 C
65 C
A F1A E4 LD - 96 CV
B F1A E4 LD - 116 CV
C F1A E4 LD - 136 CV
D F1C E4 HD - 146 CV
E F1C E4 HD - 176 CV
E4 = Euro 4
LD = Light Duty
HD = Heavy Duty
ENGINE
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
VANS AND DERIVATIVES

A Mechanical suspension: front with transverse leaf spring.
B Mechanical suspension: front with torsion bars.
C Mechanical front suspension with transverse leaf spring — rear air suspension.
D Mechanical front suspension with torsion bars — rear air suspension.
29 L10 ( ) - 29 L12 ( ) - 29 L14 ( )
35 S10 ( ) - 35 S12 ( ) - 35 S14 ( ) - 35 S18 ( )
1
CHASSIS
35 S10 ( ) - 35 S12 ( ) - 35 S14 ( ) - 35 S18 ( )
35 C10 ( ) - 35 C12 ( ) - 35 C15 ( ) - 35 C18 ( )
40 C10 ( ) - 40 C15 ( ) - 40 C18 ( )1
CHASSIS
CAB
40 C10 ( ) - 40 C15 ( ) - 40 C18 ( )
45 C15 ( ) - 50 C15 ( ) - 50 C18 ( )
60 C15 ( ) 60 C18 ( )60 C15 ( ) - 60 C18 ( )
65 C15 ( ) - 65 C18 ( )
29 L10 D ( ) - 29 L12 D ( ) - 29 L14 D ( ) -
35 S10 D ( ) - 35 S12 D ( ) - 35 S14 D ( ) -
6
CHASSIS
CAB
35 S10 D ( ) - 35 S12 D ( ) - 35 S14 D ( ) -
35 S18 D ( ) - 35 C10 D ( ) - 35 C12 D ( ) -
35 C15 D ( ) 35 C18 D ( ) - 40 C10 D ( ) -6 CAB
6 + 1
35 C15 D ( ) - 35 C18 D ( ) - 40 C10 D ( ) -
40 C12 D ( ) - 45 C15 D ( ) - 45 C18 D ( )
50 C18 D ( ) 60 C15 D ( ) 60 C18 D ( )50 C18 D ( ) - 60 C15 D ( ) - 60 C18 D ( ) -
65 C15 D ( ) - 65 C18 D ( )
35 S12 CC ( ) - 35 S 14 CC ( ) - 35 S18 CC ( ) -
35 C12 CC ( ) 35 C15 CC ( ) 35 C18 CC ( )
0
CHASSIS
35 C12 CC ( ) - 35 C15 CC ( ) - 35 C18 CC ( ) -
40 C12 CC - 40 C15 CC ( ) - 40 C18 CC ( )
0
CHASSIS
COWL
40 C12 CC 40 C15 CC ( ) 40 C18 CC ( )
45 C15 CC - 45 C18 CC ( )
50 C15 CC ( ) - 50 C18 CC ( )50 C15 CC ( ) - 50 C18 CC ( )
60 C18 CC ( ) - 65 C18 CC ( )
35 S12 CCR ( ) - 35 S14 CCR ( ) - 35 S18 CCR( )
35 C12 CCR ( ) 35 C15 CCR ( ) 35C18CCR( )
R
CHASSIS
COWL
35 C12 CCR ( ) - 35 C15 CCR ( ) - 35C18CCR( )
40 C12 CCR ( ) - 40 C15 CCR ( ) - 40C18CCR( )R COWL
SHORT
40 C12 CCR ( ) 40 C15 CCR ( ) 40C18CCR( )
45 C15 CCR ( ) - 45 C18 CCR ( )
50 C15 CCR ( ) - 50 C18 CCR ( )50 C15 CCR ( ) - 50 C18 CCR ( )
60 C18 CCR ( ) - 65 C18 CCR ( )
( ) Also available in the A (automatic transmission) and /P (pneumatic rear suspensions) versions.
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 C10 CA ( ) - 35 C12 CA ( )
A CUT-AWAY
35 C10 CA ( ) - 35 C12 CA ( )
40 C10 CA ( ) - 40 C12 CA ( )
A CUT-AWAY
40 C10 CA ( ) 40 C12 CA ( )
45 C18 CA ( ) - 50 C18 CA ( )
60 C18 CA ( ) 65 C18 CA ( )
( ) ( )
60 C18 CA ( ) - 65 C18 CA ( )
29 L10 V ( ) - 29 L12 V ( ) - 29 L14 V ( )
35 S10 V ( ) - 35 S12 V ( ) - 35 S14 V ( )
35 S18 V ( )
4 VAN
35 S18 V ( )
35 C10 V ( ) - 35 C12 V ( ) - 35 C15 V ( )
35 C18 V ( )
4 VAN
35 C18 V ( )
40 C12 V ( ) - 40 C15 V ( ) - 40 C18 V ( )
45 C15 V ( ) - 45 C18 V ( )
50 C15 V ( ) - 50 C18 V ( )50 C15 V ( ) - 50 C18 V ( )
60 C15 V ( ) - 60 C18 V ( )
65 C15 V ( ) - 65 C18 V ( )
29 L10 SV ( ) - 29 L12 SV ( ) - 29 L14 SV ( )
35 S10 SV ( ) - 35 S12 SV ( ) - 35 S14 SV ( ) -
35 S18 SV ( )
V
SEMI-GLAZE
35 S18 SV ( )
35 C10 SV ( ) - 35 C12 SV ( ) - 35 C15 SV ( ) -
35 C18 SV ( )
V
SEMI GLAZE
D VAN
35 C18 SV ( )
40 C10 SV ( ) - 40 C12 SV ( ) - 40 C15 SV ( ) -
40 C18 SV ( ) -
45 C15 SV ( ) - 45 C18 SV ( )45 C15 SV ( ) - 45 C18 SV ( )
50 C15 SV ( ) - 50 C18 SV ( )
VENDOR 35 S12 CV ( ) - 35 S14 CV ( )
U
VENDOR
VERSION
35 S12 CV ( ) - 35 S14 CV ( )
35 C12 CV ( ) - 40 C12 CV -
U
VERSION
CITY
35 C12 CV ( ) 40 C12 CV
45 C15 CV ( ) - 45 C18 CV ( )
50 C15 CV ( ) 50 C18 CV ( )VAN
( ) ( )
50 C15 CV ( ) - 50 C18 CV ( )
5 COMBI 29 L14 C ( ) - 35 S14 C ( )5 COMBI 29 L14 C ( ) - 35 S14 C ( )
8 CAMPER
35 S14 ( ) - 35 S18 ( )
8 CAMPER
35 S14 ( ) 35 S18 ( )
35 C14 ( ) - 35 C18 ( )35 C14 ( ) 35 C18 ( )
CHASSIS-
COWL
9
COWL
SHORT
VERSION FOR
35 S14 CCRC ( ) - 35 S18 CCRC -
35 C14 CCRC ( ) - 35 C18 CCRC
VERSION FOR
CAMPER VAN
35 C14 CCRC ( ) 35 C18 CCRC
( ) Also available in the A (automatic transmission) and /P (pneumatic rear suspensions) versions.
VERSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14

1
3000 mm
(T25C - T30C - T35C - T40C - T25V - T30V -
T35V - T40V - T50V)
2
3000 L mm
(T25V - T30V - T35V - T40V - T50V)
3
3300 mm
(T25V - T30V - T35V - T40V - T50V)
4
3450 mm
(T25C - T30C - T35C - T40C - T50C - T65C)
5
3750 mm
(T30C - T35C - T40C - T50C - T65C)
6
3950 L mm
(T30V - T35V - T40V - T50V - T65V)
7
4100 mm
(T35C - T40C)
8
4350 mm
(T50C - T65C)
9
4750 mm
(T50C - T65C)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
WHEELBASE

A 5 SPEED (5 S 300)
B 6 SPEED (6 S 400 O.D.)
C 6 SPEED (6 S 400 A O.D.)
A Automated
O.D. Over Drive
1 2 3 4 5 6 7 8 9 10 11 12 13 14
GEARBOX

LEFT-HAND DRIVE
(T25C - T30C - T35C - T40C - T50C)
1
LEFT-HAND DRIVE AND INTERNAL HEIGHT OF
LOADING BAY H1 = 1545 mm
(T25V - T30V - T35V - T40V - T50V)
1
(T25V - T30V - T35V - T40V - T50V)
2
(T30V - T35V - T40V - T50V)
3
RIGHT-HAND DRIVE
(T25C - T30C - T35C - T40C - T50C)
A
RIGHT-HAND DRIVE AND INTERNAL HEIGHT OF
(T25V - T30V - T35V - T40V - T50V)
A
(T25V - T30V - T35V - T40V - T50V)
B
(T30V - T35V - T40V - T50V - T65V)
C
DRIVE — INTERNAL HEIGHT OF LOADING BAY
1 2 3 4 5 6 7 8 9 10 11 12 13 14
MANDATORY MARKET OPTIONAL EXTRAS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
OPTIONAL EXTRAS REQUIRED BY THE CUSTOMER
1 2 3 4 5 6 7 8 9 10 11 12 13 14

REPLENISHING FLUIDS
IVECO RECOMMENDED LUBRICANTS PARTS TO BE REPLENISHED Quantity
Litres kg
Quantity of oil in circulation in the car-
tridge filter and heat exchanger
1.4 1.23
Total dry engine capacity 5.7 5.02
Urania Daily
Urania LD 5
Sump capacity:
- max level
- min level
4.3
3
3.78
2.65y
Urania LD 5
Quantity of oil in circulation in the car-
tridge filter and heat exchanger 1 0.88
Total dry engine capacity 7.6 6.79
Sump capacity:
- max level
- min level
6.6
4.29
5.81
3.78
Max. gradient negotiable by vehicle uphill/downhill with oil at minimum level 30%!
Gearbox
ZF 5S 300 2 1.8
Tutela TRUCK GEARLITE
ZF 6S 400 O.D. 2.2 1.98
ZF 6S 400 A O.D. 2.7 2.43
Front axle:
5817 - -
5818 - -
5819 - -
5823 - -
Rear axles:
Tutela W140/M-DA (SAE 80W90) NDA R.S. 1.35 1.21
Tutela W90/M-DA (SAE 80W90) NDA R.G. 1.35 1.21
Tutela W140/M-DA (SAE 85W140) 450511 1.9 1.65
Tutela W140/M-DA (SAE 85W140) 450517/2 3 2.7
Tutela GI/A Power steering 1.4 1.3
Tutela TRUCK DOT SPECIAL Brake circuit 1.11 1
Arexons DP1 Windscreen washer 5 4.5
Paraflu11 * Cooling system 9 -
* = Protective anti-freeze (concentration 50%, freezing point —35 C)

International lubricant description FL Group products
Engine oil meets specifications:
ACEA B5 with synthetic base SAE 5W30
ACEA E3/E5 with mineral base SAE 15W40
Urania Daily
Urania LD5
Differential and wheel hub oil meets specifications:
API GL-5 with mineral base SAE 85W140
API GL-5 with mineral base SAE 80W90
Tutela W 140/M - DA (1)
Tutela W 90/M - DA (2)
Mechanical gearbox oil containing non-EP anti-wear additives
Meets specification API GL 4 SAE 75W80
Tutela Truck Gearlite
Hydrostatic transmission and power steering oil
Meets specifications: ATF-DEXRON II D
Tutela GI/A
General-purpose grease
lithium soap based grease N.L.G.I. fluidity no. 2
Tutela MR 2
Specific grease for wheel hubs and bearings
lithium soap based grease N.L.G.I. fluidity no. 3
Tutela MR 3
Hydraulic brake and clutch control fluid
In conformity with N.H.T.S.A. standards No. 116, ISO 4925
Standard SAE J 1703, IVECO STANDARD 18-1820
Tutela TRUCK DOT SPECIAL
Windscreen washer liquid
Mixture of spirits, water and surfactants CUNA NC 956-11
Tutela Professional SC 35
Concentrated protective radiator fluid
ethylene glycol based containing corrosion inhibitors,
in conformity with Iveco Standard 18-1830
Paraflu11(3)
(1) Hot or temperate climate
(2) Specific for cold climes.
(3) 100% Paraflu to be diluted with water to 50%
3595
50 10
032
14 -10
-15
-25
oCoF
-13
5
SAE 40
SAE 30
SAE
20W
SAE
10W
SAE
15W/40
SAE 5W 30
Figure
108535

F1A ENGINE 1DAILY EURO 4
Base - March 2006Print 603.93.651
SECTION 2
5401 Engine
Page
F1A ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
F1C ENGINE 157. . . . . . . . . . . . . . . . . . . . . . . . . . . .

F1A Engine
Page
MAIN OPERATIONS ON ENGINE MOUNTED
ON VEHICLE 7. . . . . . . . . . . . . . . . . . . . . . . . .
- Service procedures to be performed after replacing
high-pressure feeding system and/or exhaust gas post-
treatment system components 8. . . . . . . . . . . .
POWER UNIT REMOVAL/REFITTING 9. . . . . . . .
- Removal 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checks and tests 13. . . . . . . . . . . . . . . . . . . . . . .
- Power steering system air bleed 13. . . . . . . . . . .
REPLACING BELTS 14. . . . . . . . . . . . . . . . . . . . . . .
- Power steering pump-alternator belt replacement 14
- Disassembly 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing air-conditioning compressor drive belt 14
- Disassembly 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembly 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing timing drive belt 15. . . . . . . . . . . . . . . .
- Disassembly 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Assembling 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE ELECTRIC INJECTORS 17. . . . .
- Removal 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD REMOVAL AND REFITTING 19
- Removal 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING HIGH-PRESSURE PUMP CPH1 22. . .
- Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING WATER PUMP 22. . . . . . . . . . . . . . .
- Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREHEATING PLUG REMOVAL/REFITTING 23. . .
- Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE VALVE ASSEMBLY REMOVAL-REFITTING 23

4 F1A ENGINE DAILY EURO 4
Page
- Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E.G.R. VALVE REMOVAL/REFITTING 24. . . . . . . . .
- Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT EXCHANGER REMOVAL/REFITTING 24. . .
- Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BURNT GAS EXHAUST SYSTEM 25. . . . . . . . . . . .
- Description 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
OXICAT - OXYDIZER CATALYST 25. . . . . . . . . .
- Description 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE ASSEMBLY REMOVAL/REFITTING 27
- Removal 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL/REFITTING OF EXHAUST PIPE ASSEMBLY
COMPONENTS (SYSTEMS EQUIPPED WITH D.P.F.
CATALYST) 28. . . . . . . . . . . . . . . . . . . . . . . . . .
- Exhaust silencer removal 28. . . . . . . . . . . . . . . . .
- Replacing D.P.F. catalyst 29. . . . . . . . . . . . . . . . . .
- Refittingl 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- D.P.F. catalyst removal 28. . . . . . . . . . . . . . . . . . .
- Replacing differential sensor (delta-p) 29. . . . . . . .
ENGINE VIEWS 30. . . . . . . . . . . . . . . . . . . . . . . . . .
EMISSIONS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE IDENTIFICATION CODE 34. . . . . . . . . . .
CHARACTERISTICS CURVES 35. . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS 39. . . . . . . . . . . . . . .
ASSEMBLY DATA — CLEARANCES 40. . . . . . . . . .
TOOLS 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXPERIMENTAL TOOLS 52. . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE 63. . . . . . . . . . . . . . . . . . .
OVERHAULING ENGINE 68. . . . . . . . . . . . . . . . . .
DISASSEMBLING THE ENGINE AT THE BENCH 68
REPAIRS 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER BLOCK 78. . . . . . . . . . . . . . . . . . . . . . .
- Checks and measurements 78. . . . . . . . . . . . . . . .
- Checking head mating surfae on cylinder block 78
CRANKSHAFT 79. . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Measuring main journals and crank pins 79. . . . . .
- Checking crankshaft 80. . . . . . . . . . . . . . . . . . . . .
- Replacing timing control gear 82. . . . . . . . . . . . . .
ENGINE ASSEMBLY 82. . . . . . . . . . . . . . . . . . . . . .
- Assembling main bearings 82. . . . . . . . . . . . . . . . .
- Measuring main journal assembly clearance 82. . .
- Checking crankshaft end float 83. . . . . . . . . . . . . .
- Assembling rear seal 84. . . . . . . . . . . . . . . . . . . . .
ENGINE FLYWHEEL 85. . . . . . . . . . . . . . . . . . . . . .
- Replacing bearing supporting gearbox input shaft 85
CONNECTING ROD — PISTON ASSEMBLY 86. . .
- Pistons 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly 86. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring piston diameter 87. . . . . . . . . . . . . . . .
- Piston pins 87. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Conditions for correct pin-piston coupling 87. . . .
- Piston rings 87. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connecting rods 88. . . . . . . . . . . . . . . . . . . . . . . .
- Bushes 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking connecting rod 89. . . . . . . . . . . . . . . . .
- Checking bending 89. . . . . . . . . . . . . . . . . . . . . . .
- Assembling connecting rod-piston assembly 89. . .
- Checking for connecting rod — piston distortion 90
- Fitting piston rings 90. . . . . . . . . . . . . . . . . . . . . . .
- Assembling connecting rod — piston assemblies
in cylinder barrels 90. . . . . . . . . . . . . . . . . . . . . . .
- Measuring crankpin assembly clearance 91. . . . . .
- Checking piston protrusion 91. . . . . . . . . . . . . . .
CYLINDER HEADS 92. . . . . . . . . . . . . . . . . . . . . . .
- Disassembly 92. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing valves 92. . . . . . . . . . . . . . . . . . . . . . . .
- Checking cylinder head seal 93. . . . . . . . . . . . . . .
- Checking cylinder head mating surface 93. . . . . . .
VALVES 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing deposits, refacing and checking valves 93
- Checking clearance between valve stem and valve
guide and centring valves 94. . . . . . . . . . . . . . . . .
VALVE GUIDE 94. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing valve guide 94. . . . . . . . . . . . . . . . . . . .

Page
- Boring valve guides 94. . . . . . . . . . . . . . . . . . . . . .
VALVE SEATS 95. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Recutting and replacing valve seats 95. . . . . . . . . .
VALVE SPRINGS 96. . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARMS — TAPPETS 96. . . . . . . . . . . . . . . .
- Checks 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING CYLINDER HEADS 97. . . . . . . . . . .
- Overhead 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Overhead removal 98. . . . . . . . . . . . . . . . . . . . . .
TIMING SYSTEM 99. . . . . . . . . . . . . . . . . . . . . . . . .
- Description 99. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checks 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking cam lift and pin alignment 100. . . . . . . . .
- Assembling overhead 102. . . . . . . . . . . . . . . . . . . .
- Assembling front seal ring 103. . . . . . . . . . . . . . . . .
- Refitting cylinder head 106. . . . . . . . . . . . . . . . . . .
- Camshaft drive 107. . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION 115. . . . . . . . . . . . . . . . . . . . . . . . . .
- General 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL VACUUM PUMP ASSEMBLY (GPOD) 117. . . . .
- Oil pump 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Characteristic data 117. . . . . . . . . . . . . . . . . . . . . .
- Vacuum pump 117. . . . . . . . . . . . . . . . . . . . . . . . .
- Oil pressure control valve 118. . . . . . . . . . . . . . . .
- Oil filter 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Modine heat exchanger 118. . . . . . . . . . . . . . . . . .
- Oil vapour recirculation system 119. . . . . . . . . . . .
- Description 119. . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Description 121. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation 121. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electromagnetic pulley 123. . . . . . . . . . . . . . . . . . .
- Water pump 123. . . . . . . . . . . . . . . . . . . . . . . . . .
- Thermostat 123. . . . . . . . . . . . . . . . . . . . . . . . . . .
TURBOCHARGING 124. . . . . . . . . . . . . . . . . . . . . .
- Description 124. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Turbocharger (KKK K03-2074-CCB 5.88 type) 125
REPAIRS 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Pressure relief valve 126. . . . . . . . . . . . . . . . . . . . .
- Checking pressure relief valve 126. . . . . . . . . . . . . .
- GARRET GT 17 variable geometry
turbosupercharger 127. . . . . . . . . . . . . . . . . . . . . .
- General 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation at low engine rpm 127. . . . . . . . . . . . . .
- Operation at high engine rpm 127. . . . . . . . . . . . .
- Proportional solenoid valve controlling turbocharger
actuator 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Actuator 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIRS 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking and adjusting the actuator 129. . . . . . . . .
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
(EXHAUST GAS RECIRCULATION) 130. . . . . . .
- EGR system operation 130. . . . . . . . . . . . . . . . . . .
- Main system components 131. . . . . . . . . . . . . . . . .
- E.G.R. valve 131. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Modulator solenoid valve 131. . . . . . . . . . . . . . . . .
- Air flow rate meter (flow meter) 131. . . . . . . . . . .
- Heat exchanger 132. . . . . . . . . . . . . . . . . . . . . . . .
- Throttle valve assembly 132. . . . . . . . . . . . . . . . . .
EXHAUST POLLUTANT REDUCTION SYSTEM WITH
DPF CATALYST (ON REQUEST) 133. . . . . . . . .
- General 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D.P.F. (DIESEL PARTICULATE FILTER) CATALYST 134
- Description 134. . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTICULATE FILTER REGENERATION SYSTEM 135
- Operation 135. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Forced regeneration 136. . . . . . . . . . . . . . . . . . . . .
- Refilling engine oil 136. . . . . . . . . . . . . . . . . . . . . . .
FUEL SUPPLY 137. . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH-PRESSURE ELECTRONIC
INJECTION SYSTEM (MS 6.3 - EDC 16) 137. . . .
- General 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM OPERATION 139. . . . . . . . . . . . . . . . . . . .
- Self-diagnosis — BLINK CODE 139. . . . . . . . . . . . .

Page
- Immobilizer recognition 139. . . . . . . . . . . . . . . . . .
- Checking fuel temperature 139. . . . . . . . . . . . . . . .
- Checking engine coolant temperature 139. . . . . . .
- Checking quantity of fuel injected 139. . . . . . . . . . .
- Checking idling adjustment 139. . . . . . . . . . . . . . . .
- Fuel cut-off in release phase 139. . . . . . . . . . . . . . .
- Checking cylinder balancing on idling 139. . . . . . . .
- Checking regular engine rotation (anti-sawing) 139.
- Checking smokiness at exhaust on acceleration 139
- Checking exhaust gas recirculation (E.G.R.) 139. . .
- Checking top speed limit 139. . . . . . . . . . . . . . . . .
- Checking regular rotation on acceleration 139. . . .
- Checking glow plug control unit 139. . . . . . . . . . . .
- Checking activation of air-conditioning system 139.
- Checking fuel pump 139. . . . . . . . . . . . . . . . . . . . .
- Checking diesel warming 140. . . . . . . . . . . . . . . . .
- Checking cylinder position 140. . . . . . . . . . . . . . . .
- Checking pilot and main injection timing 140. . . . .
- Checking injection pressure closed cycle 140. . . . .
- Fuel supply 140. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Correcting flow rate according to water
temperature 140. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Correcting flow rate to avoid noise, smoke
or overloading 140. . . . . . . . . . . . . . . . . . . . . . . . .
- De-rating 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Injection timing electronic test 140. . . . . . . . . . . . .
- Speed governor 140. . . . . . . . . . . . . . . . . . . . . . . .
- Engine starting 140. . . . . . . . . . . . . . . . . . . . . . . . .
- Cold starting 141. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Warm starting 141. . . . . . . . . . . . . . . . . . . . . . . . .
- Run up 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- After run 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cut-off 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cylider balancin 141. . . . . . . . . . . . . . . . . . . . . . . .
- Synchronisation search 141. . . . . . . . . . . . . . . . . . .
OPERATION 143. . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEM 146. . . . . . . . . . . . . . . . . . . . .
Page
- Fuel pump 146. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fuel filter “UFIfilters” 147. . . . . . . . . . . . . . . . . . . .
- Fuel filter “Filtrauto” 148. . . . . . . . . . . . . . . . . . . . .
- Fuel pipes 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- High-pressure pump CPH1 149. . . . . . . . . . . . . . .
- Pressure control valve 150. . . . . . . . . . . . . . . . . . .
- Replacing pressure regulator 150. . . . . . . . . . . . . . .
- Hydraulic accumulator (rail) 151. . . . . . . . . . . . . . .
ELECTRO-INJECTORS 152. . . . . . . . . . . . . . . . . . . .
- Operation 152. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing an electrical injector 152. . . . . . . . . . . . .
ELECTRIC/ELECTRONIC COMPONENTS 153. . . . .
- Electronic control unit EDC 16 153. . . . . . . . . . . .
- Glow plug electronic control unit 154. . . . . . . . . . .
- Glow plugs 154. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSORES 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Engine speed sensor 154. . . . . . . . . . . . . . . . . . . . .
- Camshaft timing sensor 154. . . . . . . . . . . . . . . . . .
- Air temperature and pressure sensor 155. . . . . . . .
- Fuel temperature sensor 155. . . . . . . . . . . . . . . . .
- Fuel pressure sensor 155. . . . . . . . . . . . . . . . . . . . .
- Atmospheric pressure sensor 155. . . . . . . . . . . . . .
- Engine coolant temperature sensor 155. . . . . . . . .
- Throttle pedal position sensor 155. . . . . . . . . . . . .
- Clutch pedal position sensor 155. . . . . . . . . . . . . .
- Brake pedal position sensor 155. . . . . . . . . . . . . . .
- Vehicle speed sensor 155. . . . . . . . . . . . . . . . . . . .
- Differential pressure sensor - deltap ( p 155. . . .
- Exhaust gas temperature sensor 155. . . . . . . . . . . .
ACTUATORS 156. . . . . . . . . . . . . . . . . . . . . . . . . . .
- PWM (Pulse Width Modulation) controls 156. . . .

MAIN OPERATIONS ON ENGINE MOUNTED ON VEHICLE
Keep to the following instructions before doing any work on the engine involving components of the fuel supply system.
- Before doing any work on the engine, perform the engine/vehicle fault diagnosis with specific IVECO diagnosis
equipment and print out the results.
- Replacement of the MS6.3 or EDC 16control unit must be authorized by the Help Desk. Replacing operation
requires reprogramming as described in specific section.
- Following components in feed system cannot be overhauled but have to be replaced:pressure reliefvalve, ifpresent,
fuel pressure sensor, hydraulic accumulator, complete CP1H high pressure feed pump, pressure control valve,
electric injectors.
- All the parts of the Common Rail system are packaged by the supplier in sheets of oiled paper and are stored in
cardboard boxes. They must therefore be protected against moisture and unpacked just prior to assembly.
- The greatest care must be taken over the cleanliness of parts, making sure that when handling or assembling
(starting with straightforward filter and pre-filter replacement) no dirt of foreign bodies can get inside. For this
reason, the plugs protecting the hydraulic parts and sensors must be removed just prior to positioning in theirseats.
- Take care over the direction of assembly for all electrical connections.
- All threaded connections must be tightened to the prescribed torque.
- All the quick-coupling connectors (on the engine they are found on the high-pressure pump and on the diesel drain
manifold) must be fully inserted. To drive them out, press on the tabs at the base of the connectors.
Electro-injector
None of the couplings/unions/nuts on the injector body may be handled. It is neither necessary nor permitted to
dismantle the nozzle body or the electromagnet.
If working on the high-pressure pipe, the hexagon on the injector side must be kept stationary with a wrench.
Before working on pipes, make sure the injector is stationary in its seat on the cylinder head.
When assembling/disassembling the injector drain, the retaining spring must not be removed from its seat in the injector:
pushing the spring towards the engine and applying a vertical force on the connector frees the recirculation. When
assembling, rest the recirculation connector in its seat and apply a vertical force while keeping the retaining spring
pressed in the direction of the engine. Fitting in has to be easy.
Replacing one or more electrical injectors requires central unit programming as described in specific section.
CP1H High-pressure pump
If working on the high-pressure pipe, the hexagon on the pump side must be kept stationary with a wrench.
Before working on the high-pressure pipe, make sure the pump is secured in its seat.
High-pressure pipes
Each high-pressure pipe must be replaced after disassembly operations.
The couplings must be tightened or loosened with the injectors, hydraulic accumulator (rail) and high-pressure pump
well secured and taking care to keep the hexagon on the component side stationary, space permitting.
Hydraulic accumulator (rail) and accessories
The pressure sensor can be assembled five consecutive times; after that, it must be replaced. They must be lubricated
with a thin layer of oil before being mounted..
Replacing the sensor requires central unit programming as described in specific section.

Service procedures to be performed after
replacing high-pressure feeding system and/or
exhaust gas post-treatment systemcomponents
To ensure correct operation of the engine, the CP1 control
unit 16 stores, in the memory non-labile area, the information
relative to the engine parameters originally set or acquired
during engine operation.
As a result, after any of the operations below is carried out:
- replacing one or several injectors,
- replacing all the injectors,
- replacing the air flow meter,
- replacing the hydraulic accumulator pressure sensor
(common rail),
- replacing the EDC control unit 16;
- changing the engine oil,
- replacing the D.P.F. catalyst,
- replacing the filter differential pressure (Dp) sensor,
- replacing any significant component as regards emission
levels,
- performing forced regeneration,
the control unit shall be programmed again by means of the
IVECO MODUS- E.A.SY.- IT 2000 diagnosis instrument, and
the replacement procedure for the concerned component
shall be performed, in accordance with the indications of the
diagnosis instruments used.

Refitting
To refit the engine assembly, carry out the operations
described for removal in reverse order, following these
instructions:
- Before refitting the gearbox to the engine, it is necessary
to remove the pressure plate bearing from the
diaphragm spring by opening out the retaining circlip.
Fit the pressure plate bearing on the sleeve of the drive
input shaft cover, connecting it to the clutch release
lever. Spread the gearbox input shaft with Molikote
molybdenum disulphide grease.
As regards the 5 S 300 - 6 S 400 O.D. gearbox units,
proceed as follows.
Engage a gear to let the main shaft turn, rotating the
propeller shaft connecting flange. Push the gearbox fully
in so that the pressure plate bearing couples with the
diaphragm spring correctly.
As regards the 6 S 400 O.D. gearbox units, follow the
procedures described in the specific chapter.
- Pay special attention to the operations needed to install
the engine assembly in the engine bay.
- Check the conditions of the coolant pipes or sleeves and
of the air ducts. 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.
- Meticulously check the state of the vacuum pipe. It must
show no sign of cracking, cutting, scoring or of being
crushed. Replace it if there is any doubt at all about its
soundness. When mounting it, make sure the pipe does
not come into contact with sharp metal parts or corners
or with any particularly hot parts. In addition, after
assembly, the pipe must have no bends or constrictions,
its radius of curvature should be broad and it must be
secured to the vacuum pump fitting with a suitable
clamp.
- make sure that fuel pipes rapid engagement fittings are
accurately clean, and result to have been fully inserted
and not going to be disconnected after their being
connected to relating engagement unions.
- Fill the cooling system with coolant.
- Fill the hydraulic power steering circuit and bleed the air
as described under the relevant heading.
- Check the level of oil in the engine and gearbox.
- recharge climate control system (if present) as described
in chapter relating to section ”Body and chassis”;
- check the inclination of light from headlights, if needed.
- no coolant leaks from coolant hose and cab interior
heating hose connection sleeves. Tighten hose clips, if
necessary;
- no oil leaks from between cover and cylinder head, oil
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 injection pump control linkage allows the flow
regulation to perform its full travel in both directions.
Otherwise adjust the travel by acting on nuts (1-2, Fig.
6);
- check that the engine shut-off device is working properly;
- check that the indicator lights on the instrument panel
and relating to the devices disconnected when the
engine was removed are working properly.
Check the level of oil in the tank and top it up if necessary.
Lift the vehicle at the front, start up the engine and let it idle
for some time.
Check there is no oil leakage from the hydraulic circuit and
check the level in the tank.
Slowly turn the steering wheel in both directions of steering
so that the air in the hydraulic system comes out.
Check the level of oil in the tank again and top up if necessary.
501430 Power steering system air
bleed
Checks and tests
Start up engine, leave running at a speed slightly in
excess of idle speed and wait for coolant to heat
sufficiently to open thermostat. Then check the fol-
lowing:
When positioning the engine in the engine bay,
take special care not to damage the top pipe of the
power steering and the soundproof-heatproof
cladding of the engine bay.
Once positioned, meticulously check that the top
pipe of the power steering is sound.
Before using it again, check that the power steering
oil and coolant contain no impurities. If they do,
filter with suitable mesh filters. For any topping up,
refer to the REPLENISHING FLUIDS table in the
“GENERAL” section.
NOTE

75248
Figure 5
Disassemble the compressor drive belt, if there is one, as
described under the relevant heading.
Slacken off the tension of the belt (1) using a specific wrench
on the automatic tightener (2) and remove the belt.
543910 Power steering pump-alternator
belt replacement
Disassembly
Assembly
Mount the drive belt (1) taking care to position its
ribs correctly in the respective races of the pulleys.
Release the automatic tightener (2). Turn the
crankshaft by one turn to settle the belt.
Mount the compressor drive belt, if there is one, and
adjust the tension as described under the relevant
heading.
Fit the middle soundproofing guard back on.
543910 Replacing air-conditioning
compressor drive belt
Disassembly
90155
Cut elastic belt (3), as it cannot be reused.
Figure 6
Assembly
Fit the flexible belt (3) equipped with tool 99360191 (2)
on the pulley (4) and apply the tool on the pulley (1).
Fit the drive ring (5) on the flexible belt (3) and fasten
the ring on the compressor support.
Turn the drive shaft clockwise until the belt fits
perfectly on the pulley (1).
REPLACING BELTS

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2010 IVECO DAILY 4 Service Repair Manual

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2010 IVECO DAILY 4 Service Repair Manual