Iveco Daily Service Manual / Repair Manual View larger

Iveco Daily Service Manual / Repair Manual

English Service Manual / Repair Manual to vehicles Iveco Daily.

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LANGUAGE: English.
FORMAT: PDF file
PAGES: 1898
COMPATIBILITY: All Versions of Windows, Mac, iOS, BB, Android, etc..
PRINTABLE: Yes

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IVECO DAILY - REPAIR MANUAL

- English Service Manual to vehicles Iveco Daily.
 

INDEX:


SECTION 1 - GENERAL
- General
- Identification Data
- Vehicle Identification Plate
- Composition Of Models
- Alphanumerical Coding For Vehicle Identification
- Alphanumerical Coding For Bus Identification
- Replenishing Fluids

SECTION 2 - ENGINES
- Engines
- engines 8140.xxx
- main servicing operations to be performed on vehicle engine
- engine removal-refitting
- removal (engine 8140.43b/r/s)
- removal (engine 8140.43c - 8140.63)
- refitting
- checks and tests
- bleending the fuel system
- power steering system air bleed
- oxicat - oxydizer catalyst (vehicles with 8140.43c - 8140.63 engines)
- description
- cylinder head removal and refitting
- removal
- refitting
- replacing belts
- replacing air-conditioning compres- sor drive belt
- disassembly
- assembly and adjusting belt tension
- replacing water pump - alternator drive belt
- disassembly
- assembly and adjusting belt tension
- changing the timing system driving belt
- disassembly
- removal
- refitting
- replacing water pump
- disassembly
- assembly
- replacing injectors (engine 8140.63 - 8140.43c)
- disassembly
- assembly
- replacing injection pump
- disassembly
- assembly and injection pump adjustment
- engine flywheel removal-refitting
- removal
- refitting
- removal
- refitting
- engines with electronic high-pressure injection system
- emissions values
- engine 8140.43r.43xx/44xx
- engine 8140.43b.43xx/44xx
- engine 8140.43s.41..
- engine 8140.43s.43xx/44xx
- engine 8140.43n.43xx/44xx
- general specifications
- assembly data - clearances
- tightening torques
- tools
- overhauling engine
- disassembling the engine at the bench
- repair operations
- cylinder block
- checks and measurements
- checking head mating surface on cylinder block
- spare cylinder barrel assembling
- crankshaft
- measuring main journals and connecting rods
- checking crankshaft
- replacing gearbox input shaft centering ring
- replacing timing control gear
- engine assembly
- assembling main bearings
- measuring main journals assembly clearances
- checking crankshaft end float
- checking alignment pulley crankshaft
- rear crankshaft cover
- front crankshaft cover
- engine flywheel
- replacing bearing supporting gearbox input shaft
- replacing engine flywheel ring gear
- connecting rod - pistonas- sembly
- pistons
- measuring the pistons diameter
- piston gudgeon pins
- conditions for correct pin-piston coupling
- piston rings
- connecting rods
- bushes
- checking connecting rod for distortion
- checking torsion
- checking bending

- assembling connecting rod - piston assembly
- coupling connecting rod - pistons
- checking for connecting rod - piston distortion
- assembling piston rings
- assembling connecting rod - piston assemblies in cylinder barrels
- measuring connecting rod assembly clearance
- checking piston protrusion
- flywheel adjustment
- cylinder heads
- disassembling camshaft
- checks
- checking cam lift and journal alignment
- valve tappet
- disassembling valves
- checking cylinder head seal
- checking cylinder head mating surface
- valves
- removing deposits, refacing and checking valves
- checking clearance between valve stem and valve guide and centring valves
- valve guides
- replacing valve guides
- reaming valve guides
- valve seats
- regrinding and replacing valve seats
- valve springs
- assembling cylinder heads
- assembling valves
- assembling tappets
- assembling camshaft
- adjusting tappet clearance
- refitting cylinder head
- auxiliary member assembly
- disassembling auxiliary member assembly
- oil pressure control valve
- oil pump
- assembling auxiliary member assembly
- 6-element heat exchanger
- lubrication
- general
- oil vapour recycling system
- cooling
- description
- operation
- electromagnetic pulley
- water pump
- thermostat
- timing and auxiliary member control
- setting the timing system
- checking and aligning electromagnetic coupling pulleys
- checking alternator pulley alignment
- checking compressor pulley alignment
- adjusting alternator - water pump drive belt tension
- adjusting compressor - air-conditioner drive belt tension
- timing system speed sensor
- engine speed sensor
- supercharging
- description
- turbocharger
- repairs
- pressure relief valve
- checking and adjusting the pressure relief valve
- changing the pressure relief valve
- garret gt 2256 t variable geometry turbosupercharger
- general
- operation at low engine rpm
- operation at high engine rpm
- proportional solenoid valve controlling turbocharger actuator
- actuator
- repairs
- checking the actuator
- fuel supply
- high-pressure electronic injection system (common rail ms 6.3 or edc.16)
- general
- system operation
- self-diagnosis - blink code
- immobilizer recognition
- checking fuel temperature
- checking engine coolant temperature
- checking quantity of fuel injected
- checking idling adjustment
- fuel cut-off in release phase
- checking cylinder balancing on idling
- checking regulator engine rotation (anti-sawing)
- checking smokiness at exhaust on acceleration
- checking exhaust gas recirculation (e.g.r. If present)
- checking top speed limit
- checking rotation regularity during acceleration
- checking thermostart
- checking activation of air-conditioning system
- checking fuel pump
- checking diesel warming
- checking cylinder position
- checking pilot and main injection timing
- checking injection pressure closed cycle
- fuel supply
- correcting flow rate according to water temperature
- correcting flow rate to avoid noise, smoke or overloading
- de-rating
- adjusting turbine speed (for variable geometry turbocharger - when present)
- injection timing electronic test
- speed governor
- engine starting
- cold starting
- warm starting
- run up
- after run
- cut-off
- cylinder balancing
- synchronization search
- operation
- hydraulic system
- fuel pump
- specifications
- fuel filter
- tightening torques
- fuel pipes
- high-pressure pump
- 3rd pumping element exclusion device
- pressure regulator
- hydraulic accumulator (rail)
- flow limiters
- pressure relief valve
- fuel recirculation and supply system
- electro-injectors
- operation
- electric/electronic components
- electronic control unit ms6.3 or edc 16
- sensors
- engine speed sensor
- camshaft timing sensor
- air temperature and pressure sensor
- fuel temperature sensor
- fuel pressure sensor
- atmospheric pressure sensor
- engine coolant temperature sensor
- throttle pedal position sensor
- clutch pedal position sensor
- brake pedal position sensor
- vehicle speed sensor
- actuators
- pwm (pulse width modulation) controls
- exhaust gas recirculation system e.g.r. (vehicles with homologation mi)
- guide to troubleshooting
- engines with rotary mechanical injection pump
- troubleshooting
- engine 8140.43c.43xx
- gas emissions
- smokiness
- noise emissions
- general specifications
- assembly data - clearances
- tightening torque
- tools
- engine overhaul
- dismantling engine on bench
- cylinder head
- engine assembling at the bench
- setting the timing system
- injection pump assembling and timing
- cooling
- feeding
- injection pump test values
- cold injection advance automatic device (ksb) [kalt start betriebseinrichtung]
- description
- operation
- engine 8140.63.40xx
- emissions values
- gas emissions
- smokiness
- noise emissions
- general specifications
- assembly data - clearances
- tightening torques
- tools
- 8140.63 engine overhaul
- disassembly engine on bench
- pistons - pins - snap rings
- assembling connecting rod-piston assembly
- fitting connecting rods-pistons
- cylinder heads
- camshaft
- checking cam lift and journal alignment
- checking cylinder head mating surface
- precombustion chambers
- disassembly
- assembly
- glow plugs
- disassembly
- checking glow plugs continuity
- assembly
- lubrication
- heat exchanger
- oil vapour full recirculation system (blow-by)
- cooling system
- thermostat
- exhaust gas recirculation system e.g.r.
- general information
- operation
- modulating solenoid valve
- potentiometer on injection pump lever
- engine rpm sensor
- engine coolant temperature sensor
- absolute pressure sensor
- vacuum sensor
- electronic control unit
- operation logics
- air conditioner interface operation logic
- pre-post heating operating logic
- engine cooling fan operating logic
- ksb operating logic
- feeding
- injection pump test values
- f1a engine
- main operations on engine mounted on vehicle
- engine removal-refitting
- removal
- refitting
- checks and tests
- power steering system air bleed
- replacing belts
- replacing air-conditioning compressor drive belt (version with belt tensioner)
- disassembly
- assembly and adjusting belt tension
- replacing air-conditioning compressor drive belt (version with elastic belt)
- disassembly
- assembly
- power steering pump-alternator belt replacement
- disassembly
- assembly
- replacing timing drive belt
- disassembly
- assembly
- replacing electro-injectors
- disassembly
- assembly
- cylinder head removal and refitting
- removal
- refitting
- replacing high-pressure pump cp3
- removal
- refitting
- replacingwater pump
- removal
- refitting
- emissions
- engine identification code
- characteristic curves
- general specifications
- assembly data - clearances
- tools
- experimental tools
- tightening torque
- overhauling engine f1a
- disassembling the engine at the bench
- repairs
- cylinder block
- checks and measurements
- checking head mating surface on cylinder block
- crankshaft
- measuring main journals and crank pins
- checking crankshaft
- replacing timing control gear
- engine assembly
- assembling main bearings
- measuring main journal assembly clearance
- checking crankshaft end float
- assembling rear seal
- engine flywheel
- replacing bearing supporting gear- box input shaft
- connecting rod - piston assembly
- pistons
- measuring piston diameter
- piston pins
- conditions for correct pin-piston coupling
- piston rings
- connecting rods
- bushes
- checking connecting rods
- checking torsion
- checking bending
- assembling connecting rod-piston assembly
- checking for connecting rod - piston distortion
- assembling piston rings
- assembling connecting rod - piston assemblies in cylinder barrels
- measuring crankpin assembly clearance
- checking piston protrusion
- cylinder head
- disassembly
- removing valves
- checking cylinder head seal
- checking cylinder head mating surface
- valves
- removing deposits, refacing and checking valves
- checking clearance between valve stem and valve guide and centring valves
- valve guides
- replacing valve guides
- boring valve guides
- valve seats
- regrinding - replacing valve seats
- valve springs
- rocker arms - tappets
- checks
- assembling cylinder heads
- overhead
- overhead removal
- timing system
- description
- camshaft
- checks
- checking cam lift and pin alignment
- assembling overhead
- assembling front seal ring
- refitting cylinder head
- adjusting air-conditioner - compressor drive belt tension
- timing speed sensor
- engine speed sensor
- lubrication
- general
- oil vacuum pump assembly (gpod)
- oil pump
- characteristic data
- vacuum pump
- oil pressure control valve
- oil filter
- modine heat exchanger
- oil vapour recirculation system
- description
- cooling
- description
- operation
- electromagnetic pulley
- water pump
- thermostat
- turbocharging
- description
- turbocharger
- repairs
- pressure relief valve
- checking and adjusting pressure relief valve
- replacing pressure relief valve
- exhaust gas recirculation (egr) system
- egr system operation
- operating principles
- air flow meter
- fuel supply
- high-pressure electronic injection system (ms 6.3 - edc 16)
- general
- system operation
- self-diagnosis - blink code
- immobilizer recognition
- checking fuel temperature
- checking engine coolant temperature
- checking quantity of fuel injected
- checking idling adjustment
- fuel cut-off in release phase
- checking cylinder balancing on idling
- checking regular engine rotation (anti-sawing)
- checking smokiness at exhaust on acceleration
- checking exhaust gas recirculation (e.g.r. If present)
- checking top speed limit
- checking regular rotation on acceleration
- checking glow plug control unit
- checking activation of air-conditioning system
- checking fuel pump
- checking diesel warming
- checking cylinder position
- checking pilot and main injection timing
- checking injection pressure closed cycle
- fuel supply
- correcting flow rate according to water temperature
- correcting flow rate to avoid noise, smoke or overloading
- de-rating
- injection timing electronic test
- speed governor
- engine starting
- cold starting
- warm starting
- run up
- after run
- cut-off
- cylinder balancing
- synchronization search
- operation
- hydraulic system
- fuel pump
- specifications
- fuel filter
- tightening torques
- fuel pipes
- high-pressure pump
- high-pressure pump internal structure
- working principle
- pressure control valve
- replacing pressure regulator
- mechanical supply pump
- hydraulic accumulator (rail)
- overpressure valve (for forged hydraulic accumulator)
- electro-injectors
- operation
- electric/electronic components
- electronic control unit ms6.3 or edc 16
- glow plug electronic control unit
- glow plugs
- sensors
- engine speed sensor
- camshaft timing sensor
- air temperature and pressure sensor
- fuel temperature sensor
- fuel pressure sensor
- atmospheric pressure sensor
- engine coolant temperature sensor
- throttle pedal position sensor
- clutch pedal position sensor
- brake pedal position sensor
- vehicle speed sensor
- actuators
- pwm (pulsewidth modulation) controls

- guide to troubleshooting
- f1c engine
- main operations on engine mounted on vehicle
- engine removal-refitting
- removal
- refitting
- checks and tests
- power steering system air bleed
- replacing air-conditioning compressor drive belt (version with belt tensioner)
- disassembly
- assembly
- power steering pump-alternator belt replacement
- disassembly
- assembly
- replacing the water pump
- removal
- refitting
- replacing the high-pressure pump
- removal
- refitting
- replacing the power steering pump
- removal
- refitting
- replacing the drive shaft seal ring and the front cover gasket
- removal
- refitting
- replacing the vacuum pump oil pump assembly (gpod)
- removal
- refitting
- replacing the drive shaft rear seal ring
- removal
- refitting
- replacing electro-injectors
- removal
- refitting
- detaching/re-attaching the cylinder head
- removal
- refitting
- engine views
- engine identification code
- characteristic curves
- general specifications
- assembly data - clearances
- tools
- experimental tools
- tightening torque
- overhauling engine f1c
- disassembling the engine at the bench
- repairs
- cylinder block
- checks and measurements

- checking head mating surface on cylinder block
- crankshaft
- measuring main journals and crank pins
- checking crankshaft
- replacing timing control gear
- engine assembly
- assembling main bearings
- measuring main journal assembly clearance
- checking crankshaft end float
- assembling rear seal
- engine flywheel
- replacing bearing supporting gearbox input shaft
- connecting rod - piston assembly
- pistons
- measuring piston diameter
- piston pins
- conditions for correct pin-piston coupling
- piston rings
- connecting rods
- bushing
- checking connecting rods
- checking torsion
- checking bending
- assembling connecting rod-piston assembly
- checking for connecting rod - piston distortion
- assembling piston rings
- assembling connecting rod - piston assemblies in cylinder barrels
- measuring crankpin assembly clearance
- checking piston protrusion
- cylinder head
- disassembly
- disassembling valves
- checking cylinder head seal
- checking cylinder head mating surface
- valves
- removing deposits, refacing and checking valves
- checking clearance between valve stem and valve guide and centring valves
- valve guides
- replacing valve guides
- boring valve guides
- valve seats
- regrinding - replacing valve seats
- valve springs
- rocker arms - tappets
- checks
- assembling cylinder heads
- overhead
- overhead removal
- timing system
- description
- camshaft
- checks
- checking cam lift and pin alignment
- assembling overhead
- auxiliary organ controls
- cylinder head refitting
- timing system control
- replacement of alternator free wheel
- timing speed sensor
- engine speed sensor
- lubrication
- general
- oil pump/depressor unit
- oil pump
- characteristic data
- vacuum pump
- oil pressure adjusting valve
- disassembly
- assembly
- oil filter
- heat exchanger
- disassembly
- assembly
- oil vapour recirculation (blow-by)
- operation
- cooling
- description
- operation
- electromagnetic pulley
- water pump
- thermostat
- turbocharging
- description
- turbocharger type mitsubishi td 4 hl-13t - 6
- repairs
- pressure relief valve
- checking and adjusting pressure relief valve
- changing the pressure relief valve
- garret gt 2256 t variable geometry turbosupercharger
- general
- operation at low engine rpm
- operation at high engine rpm
- proportional solenoid valve controlling turbocharger actuator
- actuator
- repairs
- checking and adjusting the actuator
- fuel supply
- high-pressure electronic injection system (edc 16)
- general
- system operation
- self-diagnosis - blink code
- immobilizer recognition
- checking fuel temperature
- checking engine coolant temperature
- checking quantity of fuel injected
- checking idling adjustment
- fuel cut-off in release phase
- checking cylinder balancing on idling
- checking regular engine rotation (anti-sawing)
- checking smokiness at exhaust on acceleration
- checking exhaust gas recirculation (e.g.r. If present)
- checking top speed limit
- checking regular rotation on acceleration
- checking glow plug control unit
- checking activation of air-conditioning system
- checking fuel pump
- checking diesel warming
- checking cylinder position
- checking pilot and main injection timing
- checking injection pressure closed cycle
- fuel supply
- correcting flow rate according to water temperature
- correcting flow rate to avoid noise, smoke or overloading
- de-rating
- injection timing electronic test
- speed governor
- engine starting
- cold starting
- warm starting
- run up
- after run
- cut-off
- cylinder balancing
- synchronization search
- operation
- hydraulic system
- fuel pipes
- fuel pump
- specifications
- fuel filter
- tightening torques
- high-pressure pump
- high-pressure pump internal structure
- working principle
- pressure regulator
- replacing pressure regulator
- mechanical supply pump
- hydraulic accumulator (rail)
- electro-injectors
- operation
- electric/electronic components
- electronic control unit edc 16
- glow plug electronic control unit
- glow plugs
- sensors
- engine speed sensor
- camshaft timing sensor
- air temperature and pressure sensor
- fuel temperature sensor
- fuel pressure sensor
- atmospheric pressure sensor
- engine coolant temperature sensor
- throttle pedal position sensor
- clutch pedal position sensor
- brake pedal position sensor
- vehicle speed sensor
- actuators
- pwm (pulsewidth modulation) controls
- troubleshooting guide

SECTION 3 - CLUTCH
- Clutch
- Description
- Diagnostics
- Characteristics And Data
- Tightening Torques
- Tools
- Clutch Removal And Refitting
- Removal
- Checks
- Refitting
- Thrust Bearing Removal And Refitting
- Hydraulic Clutch Drive
- Hydraulic Clutch Drive Removal - Refitting
- Removal
- Refitting
- Pedal Board Removal - Refitting
- Removal
- Refitting
- Pedal Board
- Clutch With Automaticwear Recovery - Combined With 6 As’300 Vd Gearbox
- Description
- Operation
- Removal And Refitting Of Clutch With Device Recovery Combined
- Removal
- Checks
- Refitting

SECTION 4 - TRANSMISSION
- Transmission
- Diagnostics
- Transmission Removal - Refitting
- Removal
- Refitting
- Gear Control
- 5 S 200 - 5 S 270 - 5 S 300 Transmissions
- General
- Gear Selection And Engagement Control
- Safety Devices
- Engagement locking device
- Reverse gear anti-engagement device
- Specifications And Data
- Tightening Torques
- Tools
- Overhauling The Transmission
- Gear control box
- Disassembly
- Assembly
- Disassembling the transmission
- Disassembling the rear cover bearings
- Disassembling the transmission bearings
- Disassembling the main shaft
- Drive input shaft
- Disassembling the transmission shaft
- Checks
- Transmission
- Hubs - sliding sleeves - forks
- Bearings
- Shafts - gears
- Synchronizing devices
- Mounting the transmission shaft
- Mounting the main shaft
- Rods - forks - selector - driver
- Disassembly - assembly
- Mounting the transmission
- Adjusting the transmission shaft bearing end float
- 6 S 300 Transmission
- General
- Gear Selection And Engagement
- Specifications And Data
- Tightening Torques
- Tools
- Overhauling The Transmission
- Gear control box
- Disassembly
- Assembly
- Check levers mounting
- Disassembling the transmission
- Disassembling the rear cover bearings
- Disassembling the transmission bearings
- Disassembling the main shaft
- Disassembling the drive input shaft
- Disassembling the transmission shaft
- Checks
- Transmission
- Hubs - sliding sleeves - forks
- Bearings
- Shafts - gears
- Synchronizing devices
- Mounting the transmission shaft
- Mounting the main shaft
- Rods - forks - selector - driver
- Disassembly - assembly
- Mounting the transmission
- Adjusting the transmission shaft bearing end float
- 6 S 380 O.D. Transmission
- General
- Gear Selection And Engagement
- Specifications And Data
- Tightening Torques
- Tools
- Overhauling The Transmission
- Gear control box
- Disassembly
- Assembly
- Check levers mounting
- Disassembling the transmission
- Disassembling the rear cover bearings
- Disassembling the transmission bearings
- Disassembling the main shaft
- Disassembling the drive input shaft
- Disassembling the transmission shaft
- Checks
- Transmission
- Hubs - sliding sleeves - forks
- Bearings
- Shafts - gears
- Synchronizing devices
- Mounting the transmission shaft
- Mounting the main shaft
- Rods - forks - selector - driver
- Disassembly - assembly
- Mounting the transmission
- Adjusting the transmission shaft bearing end float
- 6 As 300 Vd Transmission
- General
- Gear Selection And Engagement
- Neutral arrangement and/or 3rd/4th gear selection and engagement arrangement
- 1st/3rd gear selection election and engagement arrangement
- 5th/6th gear selection and engagement arrangement
- Reverse gear selection and engagement arrangement
- Safety device
- Specifications And Data

- Motion Transmission Gear Sequence
- Diagnosis Equipment
- Modus - It 2000 - E.A.Sy. Connection
- Tightening Torques
- Tools
- Gearbox Removal/Refitting
- Removal
- Refitting
- Repair Work
- Control Unit
- Removal
- Refitting
- Clutch Actuator
- Removal
- Refitting
- Gearbox Actuator
- Removal
- Refitting
- Chassis Wiring - Gearbox
- Removal
- Refitting
- Gearbox Wiring - Gearbox
- Removal
- Refitting
- Calibration
- Power Take Off
- Specifications And Data
- Tightening Torques
- Assembly Standards
- Power Take Off Electric Actuator
- Description
- Operation

SECTION 5 - PROPELLER SHAFTS
- Propeller shafts
- Specifications And Data
- Diagnostics
- Tightening Torques
- Tools

- Propeller Shaft Removal And Refitting
- Removal
- Refitting
- Checking Propeller Shafts On Vehicle

SECTION 6 - REAR AXLES
- Rear axles
- Diagnostics
- Rear Axle 450210
- Rear Axle Removal - Refitting
- Removal
- Refitting
- Description
- Specifications And Data
- Tightening Torques
- Tools
- Overhauling The Rear Axle Assembly
- Air breather disassembly - assembly
- Wheel hub overhaul
- Assembly
- Repairing The Differential
- Disassembling the differential unit
- Gear housing removal
- Checking the parts comprising the differential
- Assembly
- Assembly of gear housing
- Assembling the bevel pinion assembly
- Assembly of differential unit
- Rear Axles 450311/1 450511
- Rear Axle Removal - Refitting
- Removal
- Refitting
- Description
- Specifications And Data
- Tightening Torques
- Tools
- Overhauling The Rear Axle Assembly
- Wheel hub overhaul
- Replacing the wheel hub bearing
- Differential Repair Operations
- Disassembly of differential locking
- Differential locking removal
- Assembling the differential locking device
- Differential locking refitting
- Adjusting the differential locking device
- Disassembling the differential unit
- Disassembly of gear housing
- Assembly of gear housing
- Assembling bevel pinion unit
- Differential unit refitting
- Rear Axle 450517/2
- Rear Axle Removal - Refitting
- Removal
- Refitting
- Description
- Specifications And Data
- Tightening Torques
- Tools
- Overhauling The Rear Axle Assembly
- Air breather disassembly - assembly
- Overhaul of wheel hubs
- Removal
- Stud replacement
- Refitting
- Refitting
- Differential Repair Operations
- Differential locking
- Differential Repair Operations
- Differential unit removal
- Gearing case removal
- Differential components check
- Rear axle casing check
- Gearing case refitting
- Differential unit refitting
- Rear Axles 450310
- Description
- Specifications And Data
- Tightening Torques
- Tools
- Overhauling The Rear Axle Assembly
- Air breather disassembly - assembly
- Wheel hub overhaul
- Replacing the wheel hub bearing
- Repairing The Differential
- Disassembling the differential unit
- Gear housing removal
- Checking the parts comprising the differential
- Assembly
- Assembly of gear housing
- Assembling the bevel pinion assembly
- Assembly of differential unit

SECTION 7 - AXLES
- Axles
- Diagnostics
- Axle 5817
- Description
- Specifications And Data
- Tightening Torques
- Tools
- Removing And Refitting Axle 5817
- Removal
- Refitting
- Repairs
- Overhauling Axle 5817
- Wheel hub removal and refitting
- Removal
- Replacing phonic wheel
- Refitting
- Stub Axle Removal-Refitting
- Removal
- Refitting
- Axle 5818
- Description
- Specification And Data
- Tightening Torques
- Tools
- Overhauling Axle 5818
- Replacing phonic wheel
- Refitting
- Stub Axle Removal And Refitting
- Axle 5819
- Description
- Specification And Data
- Tightening Torques
- Tools
- Repair Operations
- Axle 5819 Overhaul
- Stub axle removal and refitting
- Removal
- Refitting
- Axle 5823
- Description
- Specification And Data
- Tightening Torques
- Tools
- Removing And Refitting Axle 5823
- Removal
- Refitting
- Axle 5823 Overhaul
- Wheel hub removal and refitting
- Removal
- Replacing phonic wheel
- Re-fitting
- Wheel Geometry
- Description
- Wheel Geometry
- Specifications And Data
- Tightening Torques
- Tools
- Checking Characteristic Angles
- Positioning jaws and projectors
- Electronic balancing of rim eccentricity
- Wheel alignment
- Checking toe-in
- Front wheel deviation test (vehicle wheelbase check)
- Checking camber
- Checking king-pin angle and caster angle
- Checking steering angles
- Checking rear axle alignment
- Calculating thickness of spacers to be fitted between tie rod mountings and chassis side members
(with the exception of vehicles equipped with 5-mm thick chassis or with transverse leaf-spring suspension)

SECTION 8 - SUSPENSIONS
- Suspensions
- front and rear mechanical suspensions
- diagnostics
- front mechanical suspensions
- description
- articulated quadrilateral suspension with transverse leaf spring
- specifications and data
- front leaf spring
- front suspension stabilizer bar (axle 5817)
- front shock absorbers
- tools
- vehicle suspensions 29 l - 35 s without sway bar
- shock absorber data
- tightening torques
- vehicles 29 l - 35 s (without sway bar)
- tightening torques
- vehicles 29 l - 35 s
- tightening torques
- vehicles 35 c
- tightening torques
- vehicles 29 l - 35 s - 35c
- repairs
- check the clearance of upper swinging arm articulated
- check the clearance of lower swinging arm articulated head
- overhauling the suspension
- suspension arms
- removal
- replacing suspension arm bushings disassembly
- disassembly
- assembly
- refitting
- stabilizer bar
- removal
- refitting
- front shock absorbers
- removal
- refitting
- leaf spring
- removal
- refitting
- torsion bar suspension
- (axle 5819 - vehicles 35c - 40c - 45c - 50c)
- description
- specifications and data
- front shock absorbers
- stabilizer bar diameter
- tools
- tightening torques
- vehicles 35 c - 40 c - 45 c - 50 c
- repairs
- check the clearance of upper swinging arm articulated head
- check the clearance of lower swinging arm articulated head
- overhauling the suspension
- tie rods
- removal
- replacing swivel heads
- refitting
- torsion bars
- removal
- replacing silentbloc and limit stops
- replacing link pins
- refitting
- adjusting torsion bar pre-load
- stabilizer bar
- removal
- refitting
- front shock absorbers
- removal
- refitting
- torsion bar suspension
- (axle 5823 - vehicles 60c - 65c)
- description
- specifications and data
- front shock absorbers
- stabilizer bar
- tightening torques
- equipment
- repair operations
- suspension overhaul
- lower tie rod articulated heads replacement
- torsion bars
- removal
- rubber bush replacement
- removal
- refitting
- torsion bar preload adjustment
- rear mechanical suspensions
- description
- characteristics and data
- rear leaf spring
- rear shock absorbers
- tools
- tightening torques
- vehicles 29 l - 35 s
- vehicles 35 c - 40 c - 45 c- 50 c
- vehicles 60c - 65c
- rear leaf spring
- vehicles: 29 l - 35 s
- removal
- refitting
- vehicles: 35 c - 40 c - 45 c - 50 c - 60 c - 65 c
- removal
- refitting
- repairs
- disassembling the leaf spring
- checks
- assembling the leaf spring
- replacing the bushings
- rear shock absorbers
- removal
- refitting
- stabilizer bar
- removal
- refitting
- rear air suspensions
- diagnostic
- rear pneumatic suspensions - vb-techniek type
- blink - code
- rear pneumatic suspensions -wabco type
- blink-code
- failure code table
- general
- pneumatic suspensions -wabco type (for 29l - 35s vehicles)
- specifications and data
- air system components
- rear leaf spring
- rear shock absorbers
- stabilizer bar
- levelling and height values
- electric system wabco (ecas)
- pneumatic systemwabco (ecas)
- pneumatic system on vehicle
- vehicles without abs
- vehicles with abs
- chassis self-levelling, lifting and lowering
- operation
- main system components
- pneumatic supply unit
- specifications and data
- electroniccontrolunit
- ecu programming/setting
- level sensor
- level sensor replacement
- removal
- refitting
- level sensor adjustment
- air spring
- air spring replacement
- removal
- refitting
- load sensing valve
- load sensing valve replacement
- removal
- refitting
- load sensing valve adjustment on vehicle !
- rear suspension overhaul
- leaf spring
- removal
- refitting
- rear shock absorbers
- removal
- refitting
- rear stabilizer bar
- removal
- refitting
- panhard reaction bar
- removal
- refitting
- air suspensions type vb-techniek (for vehicles 35c - 40c - 45c - 50c - 60c - 65c)
- general information
- specifications and data
- pneumatic system (for vehicles 35 c - 50 c)
- rear leaf spring (vehicles 35 c - 40 c)
- rear leaf spring (vehicles 45 c - 50 c)
- rear shock absorbers
- levelling and height values
- vb techniek electric system
- pneumatic system
- vb-techniek electrical system (60 c - 65 c vehicles)
- pneumatic system (vehicles: 60 c - 65 c)
- pneumatic system on vehicle
- vehicles without abs (35c - 40c - 45 c - 50 c)
- vehicles with abs (35c - 40c - 45 c - 50 c)
- 60 c - 65 c vehicles without abs
- 60 c - 65 c vehicles with abs
- chassis self-levelling, lifting and lowering
- operation
- main system components
- electrocompressor
- electroniccontrolunit
- ecu programming/setting
- level sensor
- level sensor replacement
- refitting
- level sensor adjustment
- removal
- air spring
- air spring replacement
- removal
- refitting
- load sensing valve
- load sensing valve replacement
- refitting
- removal
- load sensing valve adjustment on vehicle
- rear suspension overhaul (vehicles 30 c - 35c - 40c - 45 c)
- leaf spring
- removal
- refitting
- rear shock absorbers
- removal
- refitting
- panhard reaction bar
- removal
- refitting
- rear stabilizer bar
- removal

- refitting

SECTION 9 - WHEEL AND TYRES
- Wheel and Tyres
- Description
- Tyre Pressure
- Tools
- Diagnostics
- Static Wheel Balancing
- Tyre Pressure
- How Tyre Behaviour Depends On Pressure

SECTION 10 - STEERING GEAR
- Steering gear
- Steering Gear
- General
- Power Steering Specifications And Data
- Steering Gear
- Tightening Torques
- Specific Tools
- Diagnostics
- Power Steering
- Description
- Power Steering Type Trw
- Operation
- Power Steering Type Zf
- Operation
- Checks And Operations On The Vehicle
- Checking Maximum Pressure
- Checking Hydraulic Steering Centre (For ”Zf” Power Steering Only)
- Bleeding The Air From The Hydraulic System
- Swivel Heads
- Protection Casings
- Steering Gear Control
- Vehicles Equipped With An Air-Bag
- Safety Standards To Be Observed During Repair Or Maintenance Operations On Vehicles Equipped With Air-Bag System Provided By Supplier
- Preliminary Standards
- Repairs And Inspections Required After An Accident
- Accidents With Or Without Air-Bag Module Activation
- Accidents With Or Without Air-Bag Module Activation
- Painting
- Risks For Health
- Overexposure Effects
- Safety Standards To Observe When Handling Air-Bag Modules
- Air-Bag Module Scrapping
- Safety Standards To Observe When Handling Pretensioners
- Pretensioners Scrapping
- Operations On System Components
- Removing And Scrapping Activated Air-Bag Module And Pretensioner From Vehicle
- Removing And Scrapping Non-Activated Air-Bag Module From A Repairable Vehicle
- Air-Bag Module Deployment Remote Activation
- Activating Air-Bag Modules And Electronic Pretensioners Installed On Unrecoverable Vehicles
- Upper Steering Gear Shaft Removal
- For Vehicles Equipped With Air-Bag
- For All Vehicles
- Refitting
- Lower Steering Gear Shaft Removal
- Refitting
- Hydraulic Power Steering
- Hydraulic Power Steering Removal
- Refitting
- Steering Linkage Replacement
- Removal
- Refitting
- Rubber Bushing Replacement Procedure
- Power Steering Pump
- Power Steering Pump Overhaul Procedure

SECTION 11 - HYDRO-PNEUMATIC SYSTEM - BRAKES
- Hydro-pneumatic system - Brakes
- Graphic Symbols For Air/Hydraulic System Circuit Diagrams (Miscellaneo