Eurocargo Tector 12-26t Repair Manual

7/21/2019 Eurocargo Tector 12-26t Repair Manual

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EUROCARGO TECTOR12 TO 26 t

REPAIR MANUAL


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This publication describes the characteristics, data and correctmethods for repair operations on each component of the ve-hicle.

If the instructions provided are followed and the specifiedequipment is used, correct repair operations in the pro-grammed time will be ensured, safeguarding against possibleaccidents.

Before starting to performwhatever type of repair, ensure thatall accident prevention equipment is available and efficient.

All protections specified by safety regulations, i.e.: goggles,helmet, gloves, boot, etc. must be checked and worn.

All machining, lifting and conveying equipment should be in-spected before use.

The data contained in this publication was correct at the timeof going to press but due to possible modifications made by

the Manufacturer for reasons of a technical or commercial na-ture or for adaptation to the legal requirements of the differ-ent countries, some changes may have occurred.

No part of this publication, including the pictures, may be re-produced in any form or by any means.

Publication Edited by:

IVECO S.p.A.T.C.O. - B.U. Customer Service

Lungo Stura Lazio 15/1910156 Torino (Italy)

Print603.93.111 - 1st Ed. 2003

B.U. TECHNICAL PUBLISHING

C.so Svizzera, 185

10149 Torino (Italy)

Produced by:


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Workshop Manuals - concerning the mechanical part - are divided into several Sections. Each Section is characterised by a numberand its content is shown on the general index to be found at the beginning of each workshop manual.Each section deals generally with one of the main Assemblies (engine, transmission, etc.)Each section deals with the following topics:Specifications and technical data, Tightening torques, Special tools, Troubleshooting (fault diagnosis), Component removal/refitting,Repair operations.To facilitate manual consultation, the different subjects are generally dealt with (where possible), following the same sequence.This manual also provides graphs and symbols instead of description of parts, operations or operating procedures (see next page),

to give a more immediate and friendly reference.

Example:

1 = Housing for connecting rod small end bush

2 = Housing for big end bearings

Furthermore, within each section, every heading or sub-heading concerning the operations to be carried out is preceded by a sixdigit number. This number is theProduct Codethat is to be found in the repair operation described in the FLAT RATE MANUALSand in the FAILURE CODES publication.For quick reference the indication for reading this code is described below (see also the Flat Rate Manuals).

Product code:

The first two figures identify the PRODUCT within the vehicle.Example :Product 50 = Frame;Product 52 = Axles;Product 53 = Gearbox, etc.

Assembly code:

Figure three and four identify the ASSEMBLY within the PRODUCTExample :Product 50 = Frame;Assembly 01 = Chassis;Assembly 02 = Bumpers-Under run-bars, etc.

Subassembly code:

Figure five and six identify exactly the SUB-ASSEMBLY and the Assembly Component within the PRODUCT

Example :Product 50 = Frame;Assembly 01 = Chassis;Subassembly 40 = Chassis cross members, etc.

Tighten to torque + angle value

1

2

5 0

P RO DUCT ASS EMB LY S UB ASS EMB LYCOMPONENT

0 1

P RO DUCT ASS EMB LY S UB AS SEM BL YCOMPONENT

4 0

P RO DUCT ASS EMB LY S UBAS SE MB LYCOMPONENT

Print 603.93.111 Base - February 2003

SPECIAL REMARKS


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Base - February 2003 Print 603.93.111

Graph and symbols

RemovalDisconnection

Intake

RefittingConnection Exhaust

RemovalDisassembly

Operation

Fitting in placeAssembly

Compression ratio

Tighten to torque Tolerance

Weight difference

Tighten to torque + angle value Rolling torque

Press or caulk Replacement

Original spare parts

RegulationAdjustment

Rotation

!WarningNote

AngleAngular value

Visual inspection

Fitting position check Preload

MeasurementValue to findCheck

Number of revolutions

Equipment Temperature

Surface for machiningMachine finish bar

Pressure

Interference

Strained assembly

OversizedHigher than.Maximum, peak

ThicknessClearance

UndersizedLess than.Minimum

LubricationDampGrease

SelectionClassesOversizing

SealantAdhesive

Temperature < 0CCold

Winter

Air bleeding

Temperature > 0C

HotSummer


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EUROCARGO Tector 12-26t

Print 603.93.111 - 1st editionBase - February 2003

UPDATING DATE

Section Description Page Revision date


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Section

General Specifications 1

Engine 2

Clutch 3

Gearbox 4

Propeller shafts 5

Rear axles 6

Axles 7

Suspensions 8

Wheels and tyres 9

Steering system 10

Pneumatic system brakes 11

Body and chassis 12

Scheduled maintenance 13

INDEX OF SECTIONS



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DAILY2



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EUROCARGOTECTOR12-26 t GENERAL SPECIFICATIONS 1

Base - February 2003Print 603.93.111

SECTION 1

General Specifications

Page

COMPOSITION OF THE MODELS 3. . . . . . . . . .

IDENTIFICATION DATA AND LOCATIONON VEHICLE 11. . . . . . . . . . . . . . . . . . . . . . . . .

FILLING UP 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTERNATIONAL LUBRICANT DESIGNATION 13


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EUROCARGOTECTOR12-26 t2 GENERAL SPECIFICATIONS


Print 603.43.761


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Print 603.43.761/B

GENERAL SPECIFICATIONSCOMPOSITION OF THE MODELS

MODELS4 X 2

UNITS ML11

0EL17

ML11

0EL17/P

ML11

0EL17R

ML11

0EL17R/P

ML110EL21

ML11

0EL21/P

ML110EL21R

ML11

0EL21R/P

ML12

0EL17

ML12

0EL17/P

ML120EL17/R

ML12

0EL17R/P

ML12

0EL21

ML120EL21/P

ML12

0EL21R

ML120EL21R/P

ML12

0E18

ML120E18/P

F4AE0481A (170 HP) S S S S S S S S

F4AE0681E (180 HP) S S

F4AE0681D (210 HP) S S S S S S S S

F4AE0681B (240 HP)

F4AE0681A (275 HP)

13 S S S S S S S S

14 S S S S S S S S S Sng e p a e

13/14 S S

15/162855.6 S S S S S S

2865.6 S S S S

2870.9 S S S S S S S S S S S S S S S S S S

2895.9

FSO 5206B

MD 3060P

5845 S S S S S S S S S S S S S S S S

5842/5 S S

5851/5

5871/5

MS08-125 S S S S S S S S S S S S S S S S

MS10-144 S S

MS10-164

MS13-165

SP145E

ZF 8095 S S

ZF 8098

TRW-TAS 55 S S S S S S S S S S S S S S S S

Mechanical front S S S S S S S S S S S S S S S S S S

Mechanical rear S S S S S S S S SPneumatic front

Pneumatic rear S S S S S S S S S

Disk front S S S S S S S S S S S S S S S S S S

Disk rear S S S S S S S S S S S S S S S S S S

Drum rear

K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with frontand rear pneumatic suspension; D = Double cabin (6 + 1); RS* = Road Sweeper


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COMPOSITION OF THE MODELS

MODELS4 x 2

UNITS ML1

20E18/FP

ML1

20E18R

ML1

20E18R/P

ML1

20E18R/FP

ML1

20E18K

ML1

20E18KR

ML1

20E18D

ML1

20E18D/P

ML1

20E18DR

ML1

20E18DR/P

ML1

20E18DK

ML1

20E18DKR

ML1

20E21

ML1

20E21/P

ML1

20E21/FP

ML1

20E21R

ML1

20E21R/P

ML1

20E21R/FP

F4AE0481A (170 HP)

F4AE0681E (180 HP) S S S S S S S S S S S S

F4AE0681D (210 HP) S S S S S S

F4AE0681B (240 HP)

F4AE0681A (275 HP)

13

14 S S S S S S S S S S S S S S S S S Snge p ate

13/14 S S S S S S S S S S S S

15/16

2855.6 S S S S S

2865.6 S S S

2870.9 S S S S S S S S S S S S S S S S S S

2895.9

FSO 5206B

MD 3060P

5845

5842/5 S S S S S S S S S S S S S S S S S S

5851/5

5871/5

MS08-125

MS10-144 S S S S S S S S S S S S S S S S S S

MS10-164

MS13-165

SP145E

ZF 8095 S S S S S S S S S S S S S S S S S S

ZF 8098

TRW-TAS 55

Mechanical front S S S S S S S S S S S S S S

Mechanical Rear S S S S S S S S S

Pneumatic front S S S S S




Drum rear



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MODELS4 X 2

UNITS ML1

20E21K

ML1

20E21KR

ML1

20E24

ML1

20E24/P

ML1

20E24FP

ML1

20E24R

ML1

20E24R/P

ML1

20E24R/FP

ML1

20E24K

ML1

20E24KR

ML1

20E24D

ML1

20E24D/P

ML1

20E24DR

ML1

20E24DR/P

ML1

20E24DK

ML1

20E24DKR

ML1

20E28

ML1

20E28/P

F4AE0481A (170 HP)

F4AE0681E (180 HP)

F4AE0681D (210 HP) S S

F4AE0681B (240 HP) S S S S S S S S S S S S S S

F4AE0681A (275 HP) S S

13

14 S S S S S S S S Snge p ate

13/14

15/16 S S S S S S S S S S S S S S S S

2855.6

2865.6 S

2870.9 S S

2895.9 S S S S S S S S S S S S S S S S

FSO 5206B S S S S S S S

MD 3060P

5845


5851/5

5871/5

MS08-125


MS10-164

MS13-165

SP145E


ZF 8098

TRW-TAS 55

Mechanical front S S S S S S S S S S S S S S S S

Mechanical Rear S S S S S S S S S S S

Pneumatic front

Pneumatic rear S S S S S S S



Drum rear



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MODELS4 X 2

UNITS ML120E28/FP

ML

120E28R

ML120E28R/P

ML120E28R/FP

ML120E28K

ML120E28KR

ML130E18

ML130E18/P

ML130E18/FP

ML130E18R

ML130E18R/P

ML130E18R/FP

ML130E18K

ML130E18KR

ML130E18RS*

ML130E18D

ML130E18D/P

ML130E18DR

ML130E18DR/P

F4AE0481A (170 HP)

F4AE0681E (180 HP) S S S S S S S S S S S S S

F4AE0681D (210 HP)

F4AE0681B (240 HP)

F4AE0681A (275 HP) S S S S S S

13

14Single plate 13/14 S S S S S S S S S S S S S

15/16 S S S S S S

2855.6 S S S S S S

2865.6 S

2870.9 S S S S S S S S S S S S

2895.9 S S S S S S

FSO 5206B

MD 3060P

5845

5842/5 S S S S S S S S S S S S S S S S S S S

5851/5

5871/5

MS08-125MS10-144 S S S S S S S S S S S S S S S S S S S

MS10-164

MS13-165

SP145E

ZF 8095 S S S S S S S S S S S S S S S S S S S

ZF 8098

TRW-TAS 55

Mechanical front S S S S S S S S S S S S S S S

Mechanical Rear S S S S S S S S S S

Pneumatic front S S S S


Disk front S S S S S S S S S S S S S S S S S S S

Disk rear S S S S S S S S S S S S S S S S S S S

Drum rear



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MODELS4 X 2

UNITS ML1

30E18DK

ML1

30E18DKR

ML1

30E21

ML1

30E21/P

ML1

30E21/FP

ML1

30E21R

ML1

30E21R/P

ML1

30E21R/FP

ML1

30E21K

ML1

30E21KR

ML1

30E24

ML1

30E24/P

ML1

30E24/FP

ML1

30E24R

ML1

30E24R/P

ML1

30E24R/FP

ML1

30E24K

ML1

30E24KR

F4AE0481A (170 HP)

F4AE0681E (180 HP) S S

F4AE0681D (210 HP) S S S S S S S S

F4AE0681B (240 HP) S S S S S S S S

F4AE0681A (275 HP)

13

14 S S S S S S S Snge p ate

13/14 S S

15/16 S S S S S S S S

2855.6 S

2865.6 S S S S

2870.9 S S S S S S S S S S

2895.9 S S S S S S S S

FSO 5206B S S S S

MD 3060P

5845


5851/5

5871/5

MS08-125


MS10-164

MS13-165

SP145E


ZF 8098

TRW-TAS 55



Pneumatic front S S S S

Pneumatic rear S S S S S S S S



Drum rear



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MODELS4 X 2

UNITS M

L130E24D

M

L130E24D/P

M

L130E24DR

M

L130E24DR/P

M

L130E24DK

M

L130E24DKR

M

L130E28

M

L130E28/P

M

L130E28/FP

M

L130E28R

M

L130E28R/P

M

L130E28R/FP

M

L130E28K

M

L130E28KR

M

L150E21

M

L150E21/P

M

L150E21/FP

M

L150E21R

M

L150E21R/P

F4AE0481A (170 HP)

F4AE0681E (180 HP)

F4AE0681D (210 HP) S S S S S

F4AE0681B (240 HP) S S S S S S


13

14 S S S S SSingle plate

13/14

15/16 S S S S S S S S S S S S S S

2855.6

2865.6 S S S

2870.9 S S S S S

2895.9 S S S S S S S S S S S S S S

FSO 5206B S S S

MD 3060P S S S

5845


5851/5 S S S S S

5871/5

MS08-125

MS10-144 S S S S S S S S S S S S S S

MS10-164 S S S S S

MS13-165

SP145E


ZF 8098

TRW-TAS 55

Mechanical front S S S S S S S S S S S S S S S S


Pneumatic front S S SPneumatic rear S S S S S S S S S



Drum rear



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MODELS4 X 2

UNITS M

L150E21R/FP

ML150E21K

ML150E21KR

ML150E21RS*

ML150E24

ML150E24/P

ML150E24/FP

ML150E24R

ML150E24R/P

ML150E24R/FP

ML150E24K

ML150E24KR

ML150E28

ML150E28/P

ML150E28/FP

ML150E28R

ML150E28R/P

ML150E28R/FP

ML150E28K

F4AE0481A (170 HP)

F4AE0681E (180 HP)

F4AE0681D (210 HP) S S S S

F4AE0681B (240 HP) S S S S S S S S

F4AE0681A (275 HP) S S S S S S S

13

14 S S S SSingle plate

13/14

15/16 S S S S S S S S S S S S S S S

2855.6

2865.6 S

2870.9 S S S S

2895.9 S S S S S S S S S S S S S S S

FSO 5206B S S S S

MD 3060P S S S S S

5845

5842/5


5871/5

MS08-125

MS10-144

MS10-164 S S S S S S S S S S S S S S S S S S S

MS13-165

SP145E


ZF 8098

TRW-TAS 55



Pneumatic front S S S S S




Drum rear



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MODELS4 X 2

UNITS ML150E28KR

ML

180E21

ML

180E21/P

ML

180E21/R

ML

180E21R/P

ML

180E21K

ML

180E21KR

ML

180E24

ML

180E24/P

ML

180E24R

ML

180E24R/P

ML

180E24K

ML

180E24KR

ML

180E28

ML

180E28/P

ML

180E28R

ML

180E28R/P

ML

180E28K

ML

180E28KR

ML

260E28KE(6x4)

F4AE0481A (170 HP)

F4AE0681E (180 HP)

F4AE0681D (210 HP) S S S S S S

F4AE0681B (240 HP) S S S S S S


13

14 S S S S S Snge p ate

13/14


2855.62865.6 S S S

2870.9 S S S S S S

2895.9 S S S S S S S S S S S S S S

FSO 5206B S S S

MD 3060P S S S S S S S S S

5845

5842/5

5851/5 S


MS08-125MS10-125

MS10-164 S


SP145E S

ZF 8095 S


TRW-TAS 55

Mechanical front S S S S S S S S S S S S S S S S S S S S

Mechanical Rear S S S S S S S S S S S S S

Pneumatic front

Pneumatic rear S S S S S S S

Disk front S S S S S S S S S S S S S S S S S S S S


Drum rear S

K = Dump body; R = Trailing vehicle; T = Tractor; P = Vehicles with pneumatic suspension on rear axle; FP = Vehicles with frontand rear pneumatic suspension; D = Double cabin (6 + 1); RS* = Road Sweeper; KE = HENDRICKSON rear suspensions


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Manufacturers plate

For vehicle identification to complywith EC directions (under frontradiator grille)

Engine

Flywheel cover plate onthe box (left side)

Chassis

Marking (on right side

member front end)



IDENTIFICATION DATA AND LOCATION ON VEHICLE


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* Rear axle with mechanical suspension** Rear axle with pneumatic suspension



FILLING UP

LUBRICANTS RECOMMENDED BY IVECO PARTS TO FILLED UP Quantity

Litres kg

Urania Turbo

Urania LD5 Engine 4 cylinders

min.

max

5.3

8.3

4.8

7.5

1 0.9

Engine 6 cylinders

min.

max

8

10.8

7.2

9.7

1 0.9

Tutela ZC 90Gearbox 2855.5

2865.6

5.5

9

5

8.1

.

2895.9 8.3

.

7.5.

FSO5206B

.

7

.

6.5

MD3060P 28

.

25

Tutela W140/M - DA Front hubs (individual) 0.2 0.18

Rear axle MS08-125MS10-125MS10-164MS13-165SP145EIntermediateRear

6.5**11.5/12***12.2/11.7*

**18/19*

16.212.2

5.85**10.3/10.8***10/10.5*

**16.2/16.7*

14.511

Tutela GI/A Power

steering

ZF 8095ZF 8098TRWTAS5

---

---

Tutela TRUCK DOT

SPECIAL

Clutch circuit - -

Paraflu11 Cooling system

Total capacity - -

Tutela LHM Cab tipping system

- -


21/884



INTERNATIONAL LUBRICANT DESIGNATION

Description FL Products

Engine oilCompliant with ACEA E2 specifications

Urania Turbo

Engine oilCompliant with ACEA E3 and ACEA E5 specifications

Urania LD5

Differential and wheel hub oil SAE 80W/90Compliant with MIL-L-2105 C SAE 85W/140and API GL-5 specifications

Tutela W 90/M-DA (Cold climates)Tutela W140/M-DA (Hot and temperate

climates)

Manual gearbox oil SAE 80W/90Contains non EP wear resistant additivesCompliant with MIL-L2105 or API GL 3 specifications

Tutela ZC 90

Automatic gearbox and power steering oilCompliant with A.T.F. DEXRON II specifications

Tutela GI/A

Grease for general useLithium-soap base grease, N.L.G.I. n. 2 Tutela MR 2

Specific grease for bearings and wheel hubsLithium-soap base grease, N.L.G.I. n. 3

Tutela MR 3

Non-mineral base grease, compatible with brake system materials andsuitable to lubricate brake system components

SP 349

Grease for general use, suitable for components not requiring specialgrease (e.g., joints, pins and pivots, levers, tie rods, sliding shoes, brakecallipers, etc.)Lithium-soap base grease, N.L.G.I. n. 2

Tutela Zeta 2

Hydraulic brakes and clutch fluidCompliant with N.H.T.S.A. N. 116 ISO 4295 SAE J 1703 CUNA NC956-01 specifications and IVECO STANDARD 18-1820

Tutela TRUCK DOT SPECIAL

Mineral oil for hydraulic circuitsWear resistant and very low pour point

Tutela LHM

Window liquid, mixture of alcohols, water and surface-actives,CUNA NC 956-11

Arexons DP1

Antifreeze, 50% concentration for temperatures up to 35C Paraflu 11


22/884




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EUROCARGO TECTOR12-26 t ENGINE 1


SECTION 2

Engine

Page

ENGINE IDENTIFICATION CODES 3. . . . . . . . . . .

MAIN SERVICING OPERATIONS TO BEPERFORMED ON ENGINE FITTED ONVEHICLE 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARNINGS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- High pressure CP3 pump 4. . . . . . . . . . . . . . . .

- Rail and fittings 4. . . . . . . . . . . . . . . . . . . . . . . .

- Injector 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Low pressure tubing 4. . . . . . . . . . . . . . . . . . . .

- High pressure tubing 4. . . . . . . . . . . . . . . . . . . .

ENGINE REMOVAL-REFITTING 5. . . . . . . . . . . . . .

- Removal 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Tests and checks 7. . . . . . . . . . . . . . . . . . . . . . .

- Engine cooling filling system 7. . . . . . . . . . . . . .

- Air bleeding from fuel system 8. . . . . . . . . . . . .

- Air bleeding from hydraulic powersteering system 8. . . . . . . . . . . . . . . . . . . . . . . .

INJECTORS REPLACEMENT 9. . . . . . . . . . . . . . . . .

- Removal 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Tests and checks 11. . . . . . . . . . . . . . . . . . . . . . .

REPLACING SEAL RING FRONT COVERDRIVING SHAFT 11. . . . . . . . . . . . . . . . . . . . . . .

REPLACING SEAL RING FLYWHEELHOUSING BOX 12. . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD REMOVAL/REFITTING 13. . . . . .

- Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Tests and checks 15. . . . . . . . . . . . . . . . . . . . . . .

ENGINE F4 AE 0481 19. . . . . . . . . . . . . . . . . . . . . . .

ENGINE F4 AE 0681 115. . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING GUIDE 141. . . . . . . . . . . . . . .


24/884

EUROCARGOTECTOR12-26 t2 ENGINE



25/884

Engine series

Engine series evolution

Engine

Exhaust emission level

Homologation power

Duty No.

Injection

Cylinder No.

Engine cycle cylinder position

0= 4-stroke,vertical

4 = 4 cylinders6 = 6 cylinders

8 = DI. TCA

1 = Truck2 = Bus4 = M.T. vehicles

and tractors6 = Marine9 = Army

0681 A = 202 kW - (275 HP) 2700 rpm - 930 Nm / 1250 rpm

0481 A = 125 kW - (170 HP) 2700 rpm - 560 Nm / 1200 rpm0681 B = 176 kW - (240 HP) 2700 rpm - 810 Nm / 1250 rpm0481 C = 110 kW - (150 HP) 2700 rpm - 490 Nm / 1200 rpm0681 D = 154 kW - (210 HP) 2700 rpm - 680 Nm / 1200 rpm0481 D = 95 kW - (130 HP) 2700 rpm - 430 Nm / 1200 rpm0681 E = 134 kW - (182 HP) 2700 rpm - 600 Nm / 1200 rpm0681 F = 202 kW - (275 HP) 2500 rpm - 930 Nm / 1250 rpm

Model No. within D.B. Model No. within D.B.

F 1860EA4 CA * +



ENGINE IDENTIFICATION CODES


26/884

WARNINGS

High pressure CP3 pumpNever operate on the pressure control.

When servicing operations on high pressure pipe arerequired, the hexagon on pump side shall be held with properwrench.

Rail and fittingsThe flow limiter and the pressure limiting valve can beassembled 5 times consecutively before being replaced. Theyshall be lubricated with a little oil before assembling.

Lubricate the overpressure valve as well before assemblingand always replace its gasket.

Injector

It is not necessary and permitted to disassemble the fuelnozzle or the electromagnet.

!

Follow warnings below before operationsconcerning or involving fuel system components.

- Before any engine intervention always carry out

the engine/vehicle test with the proper IVECOtest equipment, then print the results.

- To replace the EDC7 control unit follow theIveco procedure for electronic control unit runengines.

- It is possible to replace but not recondition thefollowing fuel system parts: flow limiter, pressurelimiting valve, fuel pressure sensor, hydraulicaccumulator, fuel pump, high pressure CP3pump with pressure adjustment valve.

- All theCommon Rail system partsare packed bythe supplier in oilpaper sheet and then incardboard boxes. They shall be protected fromhumidity and unpacked just before assembling.

- The parts shall always be clean during theirhandling and assembling (even for simpleoperations such as filter or pre-filterreplacement) to avoid dust or filth. Therefore,the hydraulic part protection caps shall beremoved only immediately before the partassembling.

- Always follow assembling direction for electricalconnections.

- Threaded connections shall be clamped to theprescribed coupling.

Low pressure tubing

70126

Figure 1

AConnector properly locked

BConnector released for removal-refitting

All connectors shall be in the blocking position (see Figure1-A) with the clip (1).

To disconnect the low pressure system tubing, press on theclip (1) (as described in 1-B) to free the connector.

After disconnecting, bring again the spring clip (1) in theblocking position (Figure 1-A) to avoid deformations.

When the low pressure system is restored, press the clip (1)(as described in 1-B) and connect the union to its connector.Bring the clip (1) in the blocking position A to guarantee theconnection between the tubing and its component.

The non-observance of the above mentioned connectingprocedure may cause a sudden tubing disconnection duringthe vehicle starting or engine working, due to pressure.

High pressure tubingSince this hydraulic system contains high pressures, observethe following norms to avoid any risks:

- Do not connect the high pressure tubing unions with arough clamping;

- Do not disconnect the high pressure tubing while theengine is working;

Always replace each high pressure tubing after disassemblingit once.

- Replace each fuel manifold after disassembling it once.

In case of clamping or loosening of the fixing connections,keep fuel manifolds, hydraulic accumulator (rail) and highpressure pump firmly fixed and the component-side hexagonfirm, if there is enough space.

- Replace involved piping in case of drippings.



MAIN SERVICING OPERATIONS TO BE PERFORMED ON ENGINE FITTED ON VEHICLE


27/884

Figure 2

Removal

!Before removal/refitting disconnect battery cablesand place the vehicle in safety conditions.

Lift the radiator cowling and overturn the cab.Remove gearbox as described in the relevantsection and proceed as follows:

- Drain the engine coolant in a proper container.

- Drain the hydraulic steering system oil in a propercontainer.

From the engine left side:

- Disconnect tubings (18) from the compressor (13), theair cleaner and the turbine suction tubing (on the rightside).

- Remove the suction tube (16) and its support byunscrewing the frame fastening nuts.

- Disconnect air tubing (15).

- Unscrew fastening screws (6), the nut (5), remove theclamp (4) and move the gear lever rightwards (17).

- Disconnectdelivery(11)and return(10) tubingfromthehydraulic steering pump.

- Loosen clamps (1) and remove the after-cooler tube(2).

- Disconnect fuel tubings; delivery tubings (9) from the

control unit support and return ones (12) from the fuelfilter support.

- Disconnect the oil pan tubing (3).

- Disconnect the connector (8) from the control unitandall those connections coming from the harness.

EUROCARGOTECTOR12-26 t ENGINE 5


ENGINE REMOVAL-REFITTING


28/884

Figure 3From the engine right side:

- Move the gear control lever (1) leftwards.

- Loosen clamps (14) and remove the after-cooler tubing(15).

- Loosen the tightener (16) and undermine the belt.

- Unscrew relevant fastening screws, remove theconditioner (17) compressor and place it on thecondenser, tightly fastened to prevent it form dropping.

- Remove the exhaust brake throttle valve (9) guard (12).

- Disconnect the tubing (10) , unscrew the exhaust pipe

fastening screws (7) and remove the throttle valve (9).- Unscrew the elastic support (silent block) fastening nut

that fixes the exhaust pipe (8) to the frame and removeit.

- Disconnect air tubing (4).

- Loosen clamps from the radiator and the thermostatand remove the cooling fluid tubing (18).

!During the refitting, do not invert the tubing (18)position, because it will interfere with the fan.

- Disconnect the tubing (2) from the clamp that fixes it tothe head and free it from t he check clamps.

- Disconnect the tubing (3) from the clamp placed as

shown ().- Loosenthe clamp anddisconnect thecooling fluidtubing

(11).

- Disconnect the alternator, starter and ground cableelectrical connections.

- Remove the clamp (5) that fixes the harness to theengine support bracket and disconnect all thoseconnections coming from the harness.

- Place the lifting arm (99360595) to the engine andtension it with a proper lifting device.

- Unscrew fastening nuts (7 and 14, Figure 2) and (6 and13, Figure 3); then, lift the engine moving it at the same

time towards the rear part and remove it from thecompartment.

!

Depending on the kind of vehicle cab, the cab reartraverse might be removed, too.




29/884

- There are no oil drippings between cover and headcylinders, oil pan and base, heat exchanger oil filter andits seatings and between the different lubrication circuits;

- There are no fuel leakages from fuel tubings;

- There are no air losses from pneumatic tubings;

- The warning lights on the instrument panels and thedevices disconnected during the engine removal workcorrectly.

- There are no water drippings from the connectingmanifolds of the engine cooling tubing and the cabheating, and in case fasten by blocking collars further;

Refitting

Invert the operations requested for removal and observe thefollowing directions:

- Take great care during the engine assembling;- Check cooling fluid and air-conveyor coupling

conditions and in case they are damaged, replace themimmediately;

- Check engine and speed gear unit elastic supports; incase they are damaged, replace them immediately;

- Check if the exhaust pipe parts or its fastening elementsare damaged or about to be damaged and replace them;

- Fasten screws or nuts to the prescribed torque;

- Check accurately that the connections of the lowpressure fuel tubings to its unions are correct, as

specified in the notes concerning main serviceoperations to be performed on engine fitted on vehicle.

- Fill thecoolingsystem with thecoolingfluid and carry outthe bleeding as described in the relevant chapters;

- Fill the hydraulic steering circuit and carry out thebleeding as described in the relevant chapter;

!Check that hydraulic steering oil and the cooling fluiddo not contain filth before using them; if they do,filter with appropriate net filters; in case of filling-ups,see the table REFUELING in the sectionGENERAL.

- Check the engine and speed gear oil level; in case offilling-ups, see the table REFUELING in the sectionGENERAL.

Tests and checks

Start the engine, leave it in motion at running ratelittlemore than theminimal and wait that the coolingfluid temperature reaches the rate for thethermostat to be opened , then check that:

Engine cooling filling system

General rules

Figure 4

70469

- These operations shall be carried out when the engineis cool.

- The cap (1) is sealed and shall never be tampered by theuser.To empty or fill it use only the cap (2).

- To avoid air locks in the system, the fluid shall be pouredvery slowly (about 8 l per minute).

- The antifreeze contained in the cooling fluid shall notexceed 50%.

Figure 5

79450

- Open the heating fluid tap knob (1) completely.

- Remove the cap (2, Figure 4) and refuel as describedbefore until the expansion cup is full.

O

1 2

3

4




30/884

70471

Figure 6

The bleeding shall be performed as follows:

- Insert in the bleeding screw (1) its proper small tube (1)

to drain the fuel in the appropriate container;

- Loosen the screw (1).

Check the fuel level in the tank and in case increase it.

Lift the vehicle from the front part, start the engine and letit rotate at its minimum for some time.

Check that there are no oil drippings from the hydrauliccircuit and check its level in the tank.

Turn the steering wheel slowly in both directions to let outthe air contained in the hydraulic system.

Check again the oil level in the tank and increase it, ifnecessary.

Air bleeding

- Start air bleeding from the cooling system immediatelyafter filling operations.

- Start the engine at the minimum speed for at least 5minutes.

- Fill the fluid up after this time.- Close the cap 2, Figure 4, accurately and take the engine

at high revolutions to simplify fluid cooling until thethermostat opens.

- Note: Screen the radiator with a cardboard between itand the intercooler to quicken the operation.

- Take the fluid temperature to 90C (to be sure thatthe thermostat will open) checking the on boardthermometer.

- When the fluid reaches the right temperature, keep theengine at max. revolutions possible to let the air outcompletely.

- Check that in the expansion cup there are no more airbubbles or foam.

- The max complete deareation time is 15 minutes fromthe thermostat opening.

Important warnings

- From the moment the cap (2, Figure 4) is closed and theengine heating starts, do not remove the cap until theengine is completely cooled.Consequently, in case of filling, wait until the engine iscool.This will avoid two consequences:

- Scalds to the operator;- Engine damages, since thesystemcan bepressurized

only with a cool engine heating.

542011 Air bleeding from fuel system

- Start priming pump hand control (2) until fuel goes outfrom the bleeding screw (1) without air;

- Close the screw (1);

- Operate on the hand control until the priming pump (2)starts idle working;

- Start the engine and let it rotate at its minimum for someminutes to eliminate air residuals.

!

Fire danger: always close the bleeding screw to avoidfuel leakages.

501430 Air bleeding from hydraulicpower steering system




31/884

70472

70131

70473

70133

Figure 7

Figure 8

Figure 9

Figure 10

Place the vehicle in safety conditions.

Disconnect battery terminals, lift the radiator cowling,overturn the cab and operate as follows:

- Disconnect oil tubings (5 and 6) from the tappet cover(7) and remove it;

- Remove ignition harness clamps (1);

- Disconnect ignition harness (1) from injectorconnectors, overpressure and temperature/pressuresensors (4);

- Remove tubings (9) from the hydraulic accumulator (3)and fuel manifolds for injectors.

Remove nuts (7) and disconnect electrical cables frominjectors (8).Remove screws (1) and injector harness support (2) with thegasket.Remove screws (5) and air temperature/pressure sensor (6).

Remove nuts (3) and fuel manifolds (4).

Refitting

!During unlocking of the fitting (3) fastening pipe (9)to rail (3), avoid flow limiters (8) rotation with anappropriate wrench.

Loosen fastening tappet register nuts (1) and unscrewregisters.Remove screws (2), rocker unit (3) consisting of support (6),rockers (4) and shafts (5) and remove bonds (7) from thevalves.

70338

Figure 11

Assemble a new ring (2) lubricated with vaseline and a newwasher (3) on the injector (1).

Remove injector fastening screws and with the tool99342101 (1) remove also the injectors (2) from cylinderheads.

!

The disassembled fuel manifolds (4) shall never beused again but replaced with new ones.



INJECTORS REPLACEMENTRemoval


32/884

8

70339

70341

70342

70346

Assemble the injectors (1) on the cylinder heads, in a waythat the fuel entrance hole (2) is turned towards the fuel

manifolds housing (3).Screw fastening screws without clamping them.

Assemble a new ring (3), lubricated with vaseline, on the fuelmanifold (2) and insert it in the cylinder head housing so thatthe position ball (5) clashes with its housing (4).

Screw fastening nuts without clamping them.

Fasten gradually and alternatively the injector fasteningscrews (1) to 8.50.8 Nm torque with a dynamometricalwrench.

Fasten fuel manifold (3) fastening screws (2) to the 50 Nmtorque.

Check that the tappet registers (1) are unscrewed to avoidproblems with rods (7) during rocker unit (2) assembling.Place the bond on the valve (6).

!

To fit down injectors use the tool 99342101(Figure 10).

!

During this operation, move the injector (1) so thatthe manifold (2 Figure 13) can be placed correctlyinto the fuel entrance hole (2, Figure 12)

!

The notches () on the bonds shall be turnedtowards the exhaust manifold.

After, assemble rockerunits (2) consisting of support(5),rockers (3) and shafts (4) and fix them tocylinderheads fastening the screws (8) to the Nm 36 torque.

Figure 12

Figure 13

Figure 14

Figure 15

!

The disassembled fuel manifolds (2) shall never beused again but replaced with new ones.




33/884

70520

Figure 16

Adjust clearance between rockers and valves through a

setscrew wrench (1), box wrench (3) and feeler gauge (2).

The clearance amounts to:

- 0.05

- suction valves 0.25 0.05

- exhaust valves 0.51 0.05

Complete assembling inverting the operations requested forremoval, bearing in mind to:

- Fasten injector connector nuts to the prescribed torque;

- Assemble high and low pressure tubings according tothe procedures described in the paragraph main

service operations to be performed on engine fittedon vehicle ;

- Fill the cooling system with cooling fluid and bleed asdescribed before.

!

To adjust more quickly the rocker-valve clearance,operate as follows:Rotate driving shaft, balance cylinder No. 1 valvesand adjust the valves marked with * as described inthe tables:

4- cylinder engine

Rotate driving shaft, balance cylinder No. 4 valvesand adjust the valves marked with * as described inthe tables:

Rotate driving shaft, balance cylinder No. 6 valvesand adjust the valves marked with * as described inthe tables:

!

Check that the cooling fluid does not contain filthbefore using it; if it does, filter with appropriate netfilters; in case of filling-ups, see the table REFUELINGin the section GENERAL.

Tests and checks

Start the engine, leave it in motion at a running ratelittle more than the minimum and wait that thecooling fluid temperature reaches the rate for thethermostat to be opened , then check that:

- There are no water drippings from the connectingmanifolds of the engine cooling tubing and the cabheating, fasten blocking collars further if necessary.

6-cylinder engine

Figure 16/1

REPLACING SEAL RING FRONT COVERDRIVING SHAFT

78256

Apply on the front tang (2) of the driving shaft fixture99340055 (4) and through the guiding holes of the fixtureitself, drill the internal seal ring (1) with a drill (3,5 mm) toa depth of 5 mm..Fix fixture (4) to the ring (1) by means of the 6 screws in thekit e proceed with the removal of the ring by screwing up thescrew (3).



Cylinder No. 1 2 3 4

Suction - - * *

Exhaust - * - *

Cylinder No. 1 2 3 4

Suction * * - -

Exhaust * - * -

Cylinder No. 1 2 3 4 5 6

Suction - - * - * *

Exhaust - * - * - *

Cylinder No. 1 2 3 4 5 6

Suction * * - * - -

Exhaust * - * - * -


34/884

78257

Figure 16/2

Apply the proper rod (3) of fixture 99363204 to theexternal

seal ring (2) as shown in the figure and use lever (4), toremove it from the front cover (1).

Figure 16/3

REPLACING SEAL RING FLYWHEELHOUSING BOX

78258

Apply fixture 99340056(3) on the rear tang (5) of thedrivingshaft and through the guiding holes of the fixture, drill theinternal seal ring (1) with a drill (3,5 mm) to a depth of 5mm.Fix fixture (3) to the ring (1) by means of the 6 screws (4)in the kit e proceed with the removal of thering by tighteningthe screw (2).Perform the removal of the external seal ring as shown anddescribed in figure 16/2.

Figure 16/4

Apply on the front tang (6) of the driving shaft part (5) offixture 99346252, fix it with screws (4) and key on it the new

seal ring (3). Position part (1) on part (5), tighten nut (2) tillcomplete assembly of seal ring (3) on the front cover (7).

70225

Figure 16/5

Apply on the rear tang (6) of the driving shaft part (5) offixture 99346253, fix it with screws (4) and key on it thenewseal ring (3).

Position part (1) on part (5) tighten nut (2) until seal ring (3)is fully assembled into the flywheel housing box (7).

70216




35/884

Figure 17

!Before removal/refitting operations disconnectbattery terminals and place the vehicle in safetyconditions.

Lift the radiator cowling, overturn the cab and operateas follows:

- Drain partially the coolingfluid in an appropriatetin;

- Disconnect the cooling fluid tubing (2) fromthermostat cover;

- Disconnect the air tubing (3) from the suctionmanifold;

- Disconnect electrical connections;

(4), for heater

(12), for injectors

(13), for water temperature sensor;

(5) air temperature/pressure sensor;

(14), air from the rail pressure sensor;

- Remove the part of air tubing (15) from theremaining tubing, from the compressor (8) andfrom the bracket;

- Remove the cooling fluid tubing (9) from thecompressor (8);

- Remove oil breathe pipes (11) from tappet cover

(1);

- Disconnect exhaust fuel tubing (10) from pressureadjusting valve;

- Remove high pressure tubing (7) from the rail andhigh pressure pump (6).

EUROCARGOTECTOR12-26 t ENGINE 13


CYLINDER HEAD REMOVAL/REFITTINGRemoval


36/884

Figure 18- Remove air-conveyor (9) from turbosupercharger (3)and intercooler radiator (10);

- Disconnect cooling fluid tubings (1)

For vehicles with air-conditioning:

- Operating on the automatic tightener (11), loosen thecompressor (13) belt tension (12);

- Remove compressor fastening screws (13) to thesupport and fix the compressor (13) accurately to avoidgas tubing damages in the air-conditioning system;

For all types of vehicles:- Remove heat protection (8);

- Remove exhaust tubingfasteningscrews (5) andexhaustbrake throttle valve (4) from the turbosupercharger (3),

taking care to fasten the latter to the frame;

- Remove the air tubing bracket fastening screws (2);

- Disconnect oil tubing from the turbosupercharger (3);

- Remove exhaust manifold fastening screws (14) fromthe cylinder heads and remove it with theturbosupercharger (3).

!Close the oil and air inlet/outlet holes in the

turbosupercharger to avoid damages caused by

external bodies in it.

!Place the rocker 99360585 to the cylinder headlifting bracket. Hook it to the lifter and removecylinder heads.

- Remove injectors as described before;

- Remove rocker control rods (6);

- Remove cylinder head fastening screws (7).



,


37/884

Fastening screws closing order chart:

- 1st pre-closing step, with dynamometrical wrench:Screw 12x1.75x130 ( ) 35 5 NmScrew12x1.75 x 150 ( ) 55 5 Nm

A= Front side- 2nd 905 angle closing step

- 3rd 905 angle closing step

- There are no water drippings from the connectingmanifolds of the engine cooling tubing and the cabheating, and fasten by blocking collars further ifnecessary.

- Low pressure fuel tubing connections and its unions arecorrect, as described in main interventions on anassembled vehicle.

- There are no oil drippings between cylinder cover andhead, oil pan and base, heat exchanger oil filter andlubrication circuit tubings.

- There are no fuel leakages from fuel tubings.

- There are no air losses from pneumatic tubings.

- The warning lights on the instrument panel and thedevices disassembled during the engine removal workcorrectly.

Refitting

For refitting invert the operations requested for removal andfollow these warnings:Check that the cylinder head attack surface and the base areclean;Do not dirty the cylinder head gasket;

Assemble cylinder head, fasten and clamp the screws in threesteps, as described in the following figures.

!

Carry out the angle closing with the tool 99395216.

Figure 19

Figure 20

4-cylinder engine

6-cylinder engine

Tests and checks

!

Check that the cooling fluid does not contain filthbefore using it; if it does, filter with appropriate netfilters; in case of filling-ups, see the table REFUELINGin the section GENERAL.

Start the engine, leave it in motion at a running ratelittle more than the minimum and wait that thecooling fluid temperature reaches the rate for thethermostat to be opened , then check that:

Assemble injectors as described in the appropriate chapter.

Assemble high and low pressure tubing as described in theparagraph main service operations to be performed onengine fitted on vehicle.

- Check manifold, cooling fluid and air-conveyor

conditions and replace them in case of damage;- Fasten the screw to the prescribed torque;

- Fill the cooling system with cooling fluid and bleed asdescribed before.

70476

70337

A

A




38/884




39/884

ENGINE F4 AE 0481

70756


40/884


41/884

EUROCARGO TECTOR12-26 t ENGINE F4 AE 0481 19


Engine F4 AE 0481

Page

GENERAL SPECIFICATIONS 21. . . . . . . . . . . . . . .

ASSEMBLY DATA CLEARANCES 24. . . . . . . . .

TIGHTENING TORQUE 30. . . . . . . . . . . . . . . . . .

AUXILIARY COMPONENTS 32. . . . . . . . . . . . . . .

TOOLS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OVERHAUL 40. . . . . . . . . . . . . . . . . . . . .

DISASSEMBLY OF THE ENGINE AT THE BENCH 40

REPAIR INTERVENTIONS 48. . . . . . . . . . . . . . . . .

CYLINDER GROUP 48. . . . . . . . . . . . . . . . . . . . . .

- Controls and measurements 48. . . . . . . . . . . . . .

- Head face check on the cylinder group 49. . . . .

TIMING SYSTEM 49. . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Cam lift check and pin alignment check 50. . . . .

BUSHES 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Bush replacement 51. . . . . . . . . . . . . . . . . . . . . .

- Tappets 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting tappets camshaft 51. . . . . . . . . . . . . . . .

OUTPUT SHAFT 52. . . . . . . . . . . . . . . . . . . . . . . .

- Measuring journals and crankpins 52. . . . . . . . . .

- Replacing oil pump control gear 54. . . . . . . . . . .

- Fitting main bearings 54. . . . . . . . . . . . . . . . . . . .

- Finding journal clearance 54. . . . . . . . . . . . . . . . .

- Checking output shaft shoulder clearance 55. . .

CONNECTING ROD PISTON ASSEMBLY 55. .

- Pistons 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring piston diameter 56. . . . . . . . . . . . . . .

- Piston pins 57. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Conditions for proper pin-piston coupling 57. . .

- Split rings 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Connecting rods 58. . . . . . . . . . . . . . . . . . . . . . .

- Bushes 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking connecting rods 59. . . . . . . . . . . . . . . .

- Checking torsion 59. . . . . . . . . . . . . . . . . . . . . . .


42/884

EUROCARGOTECTOR12-26 t20 ENGINE F4 AE 0481


Page

- Checking bending 59. . . . . . . . . . . . . . . . . . . . . .

- Fitt ing connecting rod-piston assembly 59. . . . . .

- Connecting rod-piston coupling 59. . . . . . . . . . .

- Fitting split rings 60. . . . . . . . . . . . . . . . . . . . . . . .

- Fitting connecting rod-piston assembly intocylinder barrels 60. . . . . . . . . . . . . . . . . . . . . . . .

- Finding crankpin clearance 61. . . . . . . . . . . . . . . .

- Checking piston protrusion 62. . . . . . . . . . . . . . .

- Timing gear case 62. . . . . . . . . . . . . . . . . . . . . . .

- Timing 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Flywheel housing 63. . . . . . . . . . . . . . . . . . . . . . .

ENGINE FLYWHEEL 64. . . . . . . . . . . . . . . . . . . . . . .

- Replacing engine flywheel ring gear 64. . . . . . . . .

CYLINDER HEAD 68. . . . . . . . . . . . . . . . . . . . . . . . .

- Removing the valves 68. . . . . . . . . . . . . . . . . . . .

- Checking cylinder head wet seal 69. . . . . . . . . . .

- Checking cylinder head supporting surface 69. . .

VALVES 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing carbon deposits, checking and grinding valves 70

- Checking clearance between valve stem andvalve guide and valve centering 70. . . . . . . . . . . .

VALVE GUIDE 71. . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE SEATS 71. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Regrinding replacing the valve seats 71. . . . . . .

VALVE SPRINGS 73. . . . . . . . . . . . . . . . . . . . . . . . . .

FITTING CYLINDER HEAD 73. . . . . . . . . . . . . . . . . .

- Refitting the cylinder head 73. . . . . . . . . . . . . . . .

- Fitting injectors 74. . . . . . . . . . . . . . . . . . . . . . . .

RODS 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Rocker assembly 75. . . . . . . . . . . . . . . . . . . . . . .

- Tappet clearance adjustment 76. . . . . . . . . . . . .

- Intake manifold 77. . . . . . . . . . . . . . . . . . . . . . . .

- Wiring support 79. . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION 83. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PUMP 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEAT EXCHANGER 85. . . . . . . . . . . . . . . . . . . . . . .

- Oil pressure relief valve 86. . . . . . . . . . . . . . . . . .

Page

- Oil vapour recycling 87. . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 89. . . . . . . . . . . . . . . . . . . . . . . .

- Water Pump 91. . . . . . . . . . . . . . . . . . . . . . . . . .

- Viscous fan 91. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Thermostat 92. . . . . . . . . . . . . . . . . . . . . . . . . . .

BOOSTER 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Turbosupercharger 92. . . . . . . . . . . . . . . . . . . . .

- Description 92. . . . . . . . . . . . . . . . . . . . . . . . . . .

TURBOSUPERCHARGER ACTUATOR 93. . . . . . . .

- Check and adjustment 93. . . . . . . . . . . . . . . . . .

- Actuator replacement 93. . . . . . . . . . . . . . . . . . .

TURBOSUPERCHARGER LAYOUT 95. . . . . . . . . . .

COMMON RAIL 97. . . . . . . . . . . . . . . . . . . . . . . . . .

- General Specifications 97. . . . . . . . . . . . . . . . . . .

FEED SYSTEM 99. . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEED SYSTEM LAYOUT 101. . . . . . . . . . . . . . . . . . . .

FUEL PREFILTER 103. . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL FILTER 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MECHANICAL SUPPLY PUMP 104. . . . . . . . . . . . . . .

- Normal operating conditions 104. . . . . . . . . . . . .

- Overpressure condition at outlet 104. . . . . . . . . .

- Drain conditions 104. . . . . . . . . . . . . . . . . . . . . . .

CP3 HIGH-PRESSURE PUMP 105. . . . . . . . . . . . . . . . .

HIGH-PRESSURE PUMP - INSIDE STRUCTURE 106. . . . . . . . . . . . . . . . . . . . . . . . . .

- Operating principle 107. . . . . . . . . . . . . . . . . . . . .

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

RAIL 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERPRESSURE VALVE 110. . . . . . . . . . . . . . . . . . . .

FLOW LIMITERS 110. . . . . . . . . . . . . . . . . . . . . . . . . .

INJECTOR 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Injector in rest position 111. . . . . . . . . . . . . . . . . .

- Injection start 111. . . . . . . . . . . . . . . . . . . . . . . . .

- Injection end 111. . . . . . . . . . . . . . . . . . . . . . . . . .

PRESSURE LIMITER FOR FUEL RETURN 111. . . . . . .


43/884

EUROCARGOTECTOR12-26 t ENGINE F4 AE 0481 21


GENERAL SPECIFICATIONS

Type F4AE0481A

(.17)

Cycle 4 stroke Diesel

Power Supply Intercooler supercharged

Injection Direct

Cylinder number 4 in line

Bore mm 102

Stroke mm 120

+ + +.. = Total displacement cm3 3900

Compression ratio 17 : 1Max power kW

(CV)

rpm

125(170)

2700

Max. torque Nm(kgm)

rpm

560(57.1)

1200Idle engineminimum rpm

rpm 750

Idle engine peakrpm

rpm 3000


44/884



Type F4AE0481A

(.17)

SUPERCHARGER

Turbosupercharger type

With intercooler

GARRETT GT 22

Turbosupercharger shaft radial backlashTurbosupercharger shaft end playPressure relief valve min. opening stroke:

mmPressure relief valve max. opening stroke:

mmPressure corresponding to min. stroke: bar Pressure corresponding to max. stroke: bar

--

-

---

LUBRICATION Forced by gear pump , pressure relief valve, double

stage oil filter

barOil pressure with warmengine:- idling bar - peak rpm bar

1.23.8

COOLING By centrifugal pump, regulatingthermostat, radiator, heat exchanger,

intercooler

Water pump control Through belt

Thermostat- start of opening- maximum opening

81 2 C96 C

Urania TurboUrania LD5

FILLINGTotal capacity1st filling:

literskg

--

-engine sumpliterskg

Min. level.

5.34.8

Max. level

8.37.5

- engine sump + filterliters

kg

6.3

5.7

9.3

8.4


45/884



Type F4AE0481A

(.17)

TIMING

start before T.D.C. Aend after B.D.C. B

8.58.5

start before T.D.C. Dend after B.D.C. C

5112.5

X

Checking timingmm

Xmm

Checking operationmm

Xmm

-

-

0.20 0.30

0.46 0.56

FUEL FEED

InjectionType: Bosch

high pressure common railEDC7 ECU

Nozzle type Injectors

Injection sequence 1 - 3 - 4 - 2

bar

Injection pressure bar 250 - 1450


46/884



ASSEMBLY DATA CLEARANCES

Type F4AE0481A

(.17)

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

1

X Cylinder barrels 1 102.009 102.031

1

X

2

Spare pistonstype:Size XOutside diameter 1Pin housing 2

60,5101.781 101.799

40.008 40.014

Piston cylinder barrels 0.116 0.134

Piston diameter 1 0.5

X

Piston protrusion X 0.28 0.52

3 Piston pin 3 39.9938 40.0002

Piston pin pin housing 0.0078 0.0202


47/884



Type F4AE0481A

(.17)


X

1

3

2

X

X

X1*Split ring slots X 2

X 3

2.705 2.7352.420 2.4404.020 4.040

1

3

2S

S

S

S 1*Split rings S 2

S 3

* measured on 98 mm

2.560 2.6052.350 2.3803.975 4.000

1Split rings - slots 2

3

0.100 0.1750.040 0.90

0.020 0.065

Split rings 0.5

X1

3

2X

X

Split ring end openingin cylinder barrel:

X 1X 2X 3

030 0.400.60 0.800.25 0.55

1

2

Small end bushhousing 1Big end bearinghousing 2

42.987 43.013

72.987 73.013

S

4

3 Small end bush diameterOutside 4Inside 3Spare big end halfbearings S

43.279 43.55340.019 40.033

1.955 1.968

Small end bush housing 0.266 0.566

Piston pin bush 0.0188 0.0392

Big end half bearings 0.250 0.500


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Type F4AE0481A

(.17)


X

Size X

Max. toleranceon connecting rodaxis alignment

-

-

1 2

S1 S 2

Journals 1Crankpins 2

Main half bearings S 1

Big end half bearings S 2

*provided as spare part

82.99 83.0168.997 69.013

2.456 2.464

1.955 1.968

3Main bearingsNo. 1-3-4-5 3No. 2 3

87.982 88.00887.982 88.008

Half bearings JournalsNo. 1-3-4-5No. 2

0.041 0.1030.041 0.103

Half bearings - Crankpins 0.033 0.041

Main half bearingsBig end half bearings

0.250 ; 0.500

1X

Shoulder journal X 1 37.475 37.545

X 2

Shoulder main bearing X 2 32.23

X 3Shoulder half-rings X 3 32.30

Output shaft shoulder 0.07


49/884



Type F4AE0481A

(.17)

CYLINDER HEAD TIMING SYSTEM mm

1

Valve guide seats oncylinder head 1 7.042 7.062

4 Valves:

2

2

6.970 6.99060o 0.25o

6.970 6.990

45

o 0.25

o

Valve stem and guide 0.052 0.092

1

Housing on head forvalve seat:

1

1

34.837 34.863

34.837 34.863

2

Valve seat outside diameter;valve seat angle on cylinderhead:

2

2

34.917 34.93160o

34.917 34.93145o

X

X

Sinking X

0.59 1.11

0.96 1.48

Between valve seatand head

0.054 0.094

0.054 0.094

Valve seats -


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Type F4AE0481A

(.17)


H H 1H 2

Valve spring height:

free spring H

under a load equal to:339.8 19 N H1741 39 N H2

47.75

35.3325.2

X

Injector protrusion X It cannot be adjusted

1 2 3 4 5

Camshaft bushhousings No. 1-5

Camshaft housingsNo. 2-3-4

59.222 59.248

59.222 59.248

1

2

3

Camshaft journals:1 5 1-2-3 53.995 54.045

Camshaft bush outsidediameter with a loadof 3.3 kN: 59,222 59,248

Bush inside diameter

after ramming 54.083 54.147

Bushes and housingson block

0,113 0,165

Bushes and journals 0.038 0.152

H

Cam lift:

H

H

6.045

7.582


51/884



Type F4AE0481A

(.17)


1Tappet cap housingon block 1 16.000 16.030

2

3

2

Tappet cap outsidediameter: 2

315.924 15.95415.960 15.975

Between tappets and housings 0.025 0.070

Tappets -

1

Rocker shaft 1 21.965 21.977

2

Rockers 2 22.001 22.027

Between rockers and shaft 0.024 0.162


52/884



TIGHTENING TORQUE

PART TORQUE

Nm kgm

Cylinder barrel lubrication nozzle fixing screw M8 15 3 1.5 0.3

Engine shaft cap fixing screw M12 1st phase2nd phase

50 680 6

5 0.68 0.6

3rd phase 90 5

Stud bolts M6 for camshaft sensors 8 2 0.8 0.2

Stud bolts M8 for power supply pump 12 2 1.2 0.2

Rear gearcase fixing screw M12Rear gearcase fixing screw M10Rear gearcase fixing screw M8

77 1247 524 4

7.7 1.24.7 0.52.4 0.4

Camshaft sensor fixing nut M6 10 2 1 0.2

Oil pump fixing screw M8 1st phase

2nd phase

8 124 4

0.8 0.12.4 0.4

Front cover fixing screw M8 24 4 2.4 0.4

Screw M8 for camshaft longitudinal check plate fixing 24 4 2.4 0.4

Camshaft gear fixing screw M8 36 4 3.6 0.4

Connecting rod cap fixing screw M11 1st phase 60 5 6 0.5

2nd phase 60 5

Underblock plate fixing screw M10 43 5 4.3 0.4

Nut M8 for high pressure pump gear fixing 105 5 10.5 0.5

Fuel pump fixing nuts M8 24 4 2,4 0,4

inch plug on the cylinder head inch plug on the cylinder head inch plug on the cylinder head

24 436 512 2

2.4 0.43.6 0.51.2 0.2

8.5 0.35 0.35 0.035n ector x ng screws

75 5

Union fixing nut for injector power supply 50 5 5 0.5Pre-heating grid nut M6 on the suction manifold 8 2 0.8 0.2

Suction manifold fixing screw M8 24 4 2.4 0.4

Rear bracket fixing screw M12 for engine lifting 77 12 7.7 1.2

Common rail fixing M8 screws 24 4 2.4 0.4

High-pressure fuel pipe unions M14 20 2 2 0.2

Cylinder head fixing M12 screw (12x1.75x 130) 35 5 3.5 0.5

Cylinder head fixing M12 screw (12x1.75x 150) 1st phase

55 5 5.5 0.5

2nd phase 90 5

3rd phase 90 5

Equalizer support fixing screw 36 5 3.6 0.5

Valve clearance adjustment nut 24 4 2.4 0.4

Power supply pipe fixing nuts M14 from common rail high pressure pump 20 2 2 0.2

High pressure pipe union fixing screw M8 24 4 2.4 0.4

Head bulkhead fixing screw M6 for harness 10 2 1 0.2

Electric harness support fixing screw M8 for injector power supply 24 4 2.4 0.4

Harness fixing nuts on individual injector 1.5 0.25 0.15 0.025

Fuel filter-holder bracket fixing screw M8 77 8 7.7 0.8

Fuel filter-holder fixing screw M8 24 4 2.4 0.4

Fuel filter contact + turn

Oil pressure adjustment valve fixing screw M22 on the oil fi lter support 80 8 8 0.8

Oil filter support and gasket radiator fixing screw M8 24 4 2.4 0.4Oil filter contact + turn


53/884



PART TORQUE

Nm kgm

11/8 inch connection on filter support for turbine lubrication 24 4 2.4 0.4

Pipe fixing nut M12 for turbine lubrication 10 2 1 0.2

Engine coolant input connection fixing screw M10 43 6 4.3 0.690curve fixing (as necessary) on engine fluid input connection 24 4 2.4 0.4

Pipe on cylinder head for supercharger cooling 22 2 2.2 0.2

Union fixing screw M6 for engine coolant exhaust 10 2 1 0.2

Pin fixing on engine block for exhaust manifold 10 2 1 0.2

Exhaust manifold fixing screw M10 on cylinder head 53 5 5.3 0.5

Adapter fixing screw M12 for damper 1st phase 50 5 5 0.5

and damper on engine shaft 2nd phase 90

Pulley fixing screw M10 on engine shaft 68 7 6.8 0.7

Water pump fixing screw M8 24 4 2.4 0.4

Auxiliary part control belt screw coupling fixing screw M10 43 6 4.3 0.6

Fixed pulley fixing screw M10 for auxiliary part control belt 43 6 4.3 0.6Flywheel housing fixing screw M10Flywheel housing fixing screw M12

85 10

49 5

8.5 1

4.9 0.5

Heating exchanger fixing screw M6 for control unitHeating exchanger fixing screw M8 for control unit

10 2

24 4

1 0.2

2.4 0.4

Input-output connection M12 for fuel on the heating exchanger 12 2 1.2 0.2

Valve cover fixing nut M8 24 4 2.4 0.4

Camshaft sensor fixing screw M6 8 2 0.8 0.2

Engine shaft sensor fixing screw M6 8 2 0.8 0.2

Engine coolant temperature sensor fixing screw M14 20 3 2 0.3

Oil temperature-pressure sensor fixing screw M5 6 1 0.6 0.1

Fuel pressure sensor fixing screw 35 5 3.5 0.5Fuel temperature sensor fixing screw M14 20 3 2 0.3

Air pressure/temperature sensor fixing screw on suction manifold 6 1 0.6 0.1

Engine oil level sensor fixing screw M12 12 2 1.2 0.2

pins M106 cylinders

7 1 0.7 0.1

Turbine fixing to the exhaust manifoldnu s 43 6 4.3 0.6

0.7 0.14 cylinders {p nsnuts M8

24 4

. .

2.4 0.4

Adapter M12 on turbine for (input) lubricant oil pipes 35 5 3.5 0.5

Pipe fixing on adapter M10 for turbine lubrication 35 5 3.5 0.5

Oil pipe fixing on adapter M10 for block turbine lubrication 43 6 4.3 0.6

M8 oil exhaust pipe fixing on turbine 24 4 2.4 0.4Fixing union M6 for oil return from the cylinder head to the flywheel housing 10 2 1 0.2

Engine flywheel fixing screw M12 1st phase 30 4 3 0.4

2nd phase 60 5

Front bracket fixing screw M8 for engine lifting 24 4 2.4 0.4

Engine oil torque fixing screw 24 4 2.4 0.4


54/884



AUXILIARY COMPONENTS

PART TORQUE

Nm kgm

Air supercharger:

Control gear 5/8 inch fixing nut on the supercharger shaft 125 19 12.5 1.9

Fixing nut M12 to the flywheel housing 77 12 7.7 1.2Alternator:

Bracket fixing nut M12 on the water input union 43 6 4.3 0.6

Alternator fixing nut M10 43 6 4.3 0.6

Climate control:

Bracket fixing screw M10 43 6 4.3 0.6

Supercharger fixing screw M10 24 4 2.4 0.4

Starter:

Starter fixing screw 43 6 4.3 0.6


55/884



TOOLS

TOOL No. DESCRIPTION

99305018 Kit with tooling complete of valve seat grinding tools

99305047 Spring load device

99322205 Revolving stand for group overhaul (capacity 1000 daN, torque

120 daNm)

99340055 Engine shaft front gasket extraction tool

99340056 Engine shaft rear gasket extraction tool

99341001 Double effect lift


56/884



TOOLS


99341009 Bracket pair

99342101 Injector extraction tool

99346252 Tool for engine shaft front gasket assembly

99346253 Tool for engine shaft front gasket assembly

99355019 Wrench (10mm) for hydraulic power steering pump check screw

99360076 (engine) oil filter removal tool


57/884



TOOLS


99360183 Pliers for piston ring removal and assembly (65-110mm)

99360268 Engine valve assembly and removal tool

99360330 Engine flywheel rotation tool

99360351 Engine flywheel check tool

99360362 Beater for camshaft bush removal and assembly

(use with tool 99370006)

99360500 Engine shaft lifting tool


58/884



TOOLS


99360595 Engine removal and assembly rocker arm

99360605 Band for piston insertion into the cylinder barrel (60-125 mm)

99361037 Engine fixing bracket to the revolving stand 99322205

99363204 Gasket extraction tool

99370006 Interchangeable beater grip

99370415 Gauge-holder block for various relieves (use with tool 99395603)


59/884



TOOLS


99389834 Dynamometric screwdriver for injector solenoid valve connectorcheck nut adjustment

99395216 Measurer pair for angular tightening with and square

99395363 Square complete for connecting rod quadrature control

99395603 Gauge (0 5 mm)

99395687 Bore meter


60/884

70477

Figure 1

ENGINE F4AE0481 CROSS SECTION




61/884

70478

Figure 2

ENGINE F4AE0481 LONGITUDINAL SECTION




62/884

70125

70126

70127

70128

Figure 3

Figure 4

Figure 5

Figure 6

In order to apply to the engine block the engine fixingbrackets99341009 to the stand for the overhaul, operating on the

engine left side, it is necessary:- to remove the fuel filter (5) from the support (1) by

means of tool 99360076;

- to remove the low pressure fuel pipe (2-3-4) from thesupport (1)

- to remove the support (1) bracket from the block

The pipe (3) from the union (4) and from the supercharger(8).

Remove the fuel pipe (2) from the rail and from thehigh-pressure pump (9) and remove it from the engine block,by removing the fixing screws (4 and 6)

On the right side

Remove the screws (2) and remove the oil pipe (3) from thesupercharger pipe (1) and from the engine block.

Remove the starting engine (5) from the flywheel cover (4).

Apply to the block the bracket 99361037 and fix by means of

these latter the engine to the revolving stand 99322205. Drainthe engine oil by removing the plug from the sump.

Remove the fan from the engine shaft pulley.

!

In order to remove the low-pressure fuel pipe (2-3-4,Figure 3) from the relevant connection unions, it isnecessary to press the fastener (1) as shown in figureB.

After removing the pipe, position the fastener (1) into

its lock position, figure A , in order to avoid possibledeformations.

!

When unlocking the pipe (2) union (7), it is necessaryto prevent the union (10) rotation of the high-pressurepump (9), by using the proper wrench.



ENGINE OVERHAUL540110 DISASSEMBLY OF THE ENGINE AT

THE BENCH


63/884

78670

70236

Figure 7

Figure 8

1. Connections for injectors - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil pressure andtemperature sensor - 5. Engine shaft sensor - 6. Injector - 7. Temperature-air pressure sensor - 8. Timing phase sensor -

9. Fuel temperature sensor and fuel heater - 10. Pressure adjuster - 11. Control unit EDC7

Disconnect the engine wire by disconnecting theconnectors:(1) from the injector harness (6); (7) air temperature/pressure sensor: (3) fuel pressure sensor; (11) control unit;(10) high pressure pump sensor; (8) timing phase sensor; (2)engine coolant temperature sensor on thermostat (5) rpmsensor;

Remove the screws (1) and the rail (2).

Remove from the rail: the fuel pipe (7) according to theprocedures described in Figure 4. Remove the fuel pipe (5)from the rail (2) and from the manifolds (6) for injectors.

!

During the unlocking operation of the pipe (6) fixingunions (4) from the rail (2), it is necessary to preventthe possible flow limiting device rotation (3) by

means of a proper wrench.

EUROCARGO TECTOR12-26 t ENGINE F4 AE 0481 41



64/884

70130

70131

70132

70133

70134

Remove from the fuel return pressure limiting device (1), thepipe (2) as described in Figure 4.

Remove the pipe (4) from the air supercharger (3) and fromthe union (5). Remove the nut (10) Loosen the elastic hoseclamp (6) and remove the oil vapor pipe (9).

Remove the unions (13-11) and remove the pipe (12).

Remove the nuts (7) and remove the tappet (8) covercomplete of gasket.

Remove the nuts (7) and disconnect the electric wires fromthe injectors (8).

Remove the screws (1) and remove the injector harnesssupport (2) complete of gasket.

Remove the screws (5) and remove the air pressure/temperature sensor (6).

Remove the nuts (3) and withdraw the fuel manifolds (4).

Loosen the tappet adjuster fixing nuts (1) and unscrew theadjuster.Remove the screws (2), remove the equalizer unit (3)

composed by the support (6), equalizers (4), shafts (5) andremove the bonds (7) from the valves. Remove the rods (8)

Remove the injector fixing screws and by means of tool99342101 (1) withdraw the injectors (2) from the cylinderhead.

Remove the screw (4), loosen the clamp (2) and remove theair conveyor (1) from the turbosupercharger (3)

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

!The removed fuel manifold (4) shall not be usedagain and they must be replaced by new ones.




65/884

70135

70136

70137

70138

70139

Figure 14

Figure 15

Figure 16

Figure 17

Figure 18

Remove the oil pipe (5) check clamp fixing screw (4) fromthe exhaust manifold (1).

Remove the oil pipe (5) from the oil filter/ heating exchangersupport (7).

Remove the nuts (2) and remove the turbosupercharger (3)from the exhaust manifold (1).

Remove the screws (6) and remove theexhaust manifold (1)from the cylinder head.

Remove the screws (1) and remove the air conveyor (2)complete of heater. Remove the screws (4), remove thecover (3) and the relevant thermostat.

Remove the head cylinder (6) fixing screws (5).

Hook the brackets (1) with metal ropes and remove thecylinder head (2)

Eurocargo Tector 12-26t Repair Manual

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Transcript of Eurocargo Tector 12-26t Repair Manual