Iveco vector 8 diesel engine workshop manual

VECTOR SERIES
Industrial application
VECTOR 8
Technical and Repair manual

Publication edited by
Iveco Motors
Iveco SpA
PowerTrain
Mkt. Advertising & Promotion
Viale dell’Industria, 15/17
20010 Pregnana Milanese
Milano (Italy)
Print P2D32V001E - 1st Ed. 04.2006
This publication describes the characteristics, data and correct
methods for repair operations on each component of the ve-
hicle.
If the instructions provided are followed and the specified
equipment is used, correct repair operations in the pro-
grammed time will be ensured, safeguarding against possible
accidents.
Before starting to perform whatever type of repair, ensure that
all 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 time
of 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.
B.U. TECHNICAL PUBLISHING
Iveco Technical Publications
Lungo Stura Lazio, 15/19
10156 Turin - Italy
Produced by:

Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s
electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the
control units peculiar to the electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
PRELIMINARY REMARKS
General danger
It includes the dangers of above described signals.
Danger of serious damage for the assembly
Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may
sometimes cause the warranty to become null and void.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
Danger for persons
Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
SYMBOLS - WARNINGS
It indicates an additional explanation for a piece of information.
!
NOTE
3VECTOR ENGINES
Print P2D32V001E Base - April 2006

GENERAL WARNINGS
Warnings shown cannot be representative of all dangersituations possiblyoccurring. Therefore,it issuggested tocontact
immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained onharmful
materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by IVECO Motors original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
!
4 VECTOR ENGINES
Base - April 2006 Print P2D32V001E

GENERAL WARNINGS
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO Motors commercial and assistance
network is available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
5VECTOR ENGINES

GENERAL WARNINGS ON THE ELECTRIC SYSTEM
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with IVECO Motors system and are carefully recovered after repair or maintenance
interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
Connectors present must be seen from cable side. Connectors views contained in the manual arerepresentative ofcable
side.
!
NOTE
6 VECTOR ENGINES

7VECTOR ENGINES
Bonding and screening
Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying
then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR
d. DISTANCE ! 0
88039
Figure 1
Figure 2

8 VECTOR ENGINES
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling
directives issued by IVECO Motors.
It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in
order to simplify and normalise the electrical intervention that is care of preparation personnel.
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE
INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0° C = 32° F
1° C = (1 x 1.8 + 32) ° F

Section
General specifications 1
Fuel 2
Industrial application 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the VECTOR engine illustrating its featu-
res and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty andis dividedin foursepa-
rate parts:
1. Mechanical part, related to the engine overhaul,
limited to those components with different characteristics
based on the relating specific duty.
2. Electrical part, concerning wiring harness, electrical
and electronic equipment with different characteristics
based on the relating specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who,
being entitled to provide technical assistance, shall have simple
and direct instructions to identify the cause of the major incon-
veniences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
VECTOR 8 ENGINES
1VECTOR 8 ENGINES

2 VECTOR 8 ENGINES

Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see
next page) instead of giving descriptions of some operations or procedures.
Example
Ø 1 = housing for connecting rod small end bush
Ø 2 = housing for connecting rod bearings
α
Tighten to torque
Tighten to torque + angular value
1∅
∅ 2
3VECTOR 8 ENGINES
SPECIAL REMARKS

4 VECTOR 8 ENGINES
SYMBOLS - ASSISTANCE OPERATIONS
Removal
Disconnection
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fitting in place
Assembly
ρ Compression ratio
Tighten to torque
Tolerance
Weight difference
α
Tighten to torque + angle value Rolling torque
Press or caulk Rotation
Regulation
Adjustment
Angle
Angular value
Visual inspection
Fitting position check
Preload
Measurement
Value to find
Check
Number of revolutions
Equipment Temperature
Surface for machining
Machine finish bar
Pressure
Interference
Strained assembly
Oversized
Higher than….
Maximum, peak
Thickness
Clearance
Undersized
Less than….
Minimum
Lubrication
Damp
Grease
Selection
Classes
Oversizing
Sealant
Adhesive
Temperature < 0 °C
Cold
Winter
Air bleeding
Temperature > 0 °C
Hot
Summer
Replacement
Original spare parts

5VECTOR 8 ENGINES
UPDATING
Section Description Page Date of revision

6 VECTOR 8 ENGINES

SECTION 1 - GENERAL SPECIFICATIONS 1VECTOR 8 ENGINES
SECTION 1
General specifications
Page
CORRESPONDENCE BETWEEN TECHNICAL
CODE AND COMMERCIAL CODE 3. . . . . . .
LUBRICATION 5. . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING PRINCIPLE 5. . . . . . . . . . . . . . . . . .
- Oil vapour recirculation - blow-by filter 7. . . . . .
ENGINE COOLING 8. . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM ASSEMBLY 9. . . . . . . . . . . . .
VARIANT FOR APPLICATIONS WITH
BRAKE AIR COMPRESSOR 10. . . . . . . . . . . . . .
AIR/AIR INTERCOOLER SYSTEM
(DRAGON, G-DRIVE AND
GRIFFON APPLICATIONS) 11. . . . . . . . . . . . . .
AIR / WATER INTERCOOLER SYSTEM
(SPRINKLER APPLICATIONS) 12. . . . . . . . . . . .
SUPERCHARGING 13. . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 1 - GENERAL SPECIFICATIONS VECTOR 8 ENGINES

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code
Open
Commercial Code
FVAE2885X*F100 VECTOR 8 TE2
FVAE2884A*B201 -
FVAE2884A*B200 -
FVKE2887A*A200 -

LUBRICATION
The forced feed lubrication is produced by the following components:
- oil pump with rotors, housed in the rear part of the crankcase inside the sump.
It is driven by a helical toothed gear fitted on the crankshaft.The pump casing contains an oil pressure regulation valve.
- water/oil heat exchanger.
- oil filter mounting equipped with:
- oil pressure regulation valve;
- by-pass valve for excluding blocked oil filter;
- cartridge oil filter.
OPERATING PRINCIPLE
The (forced type) lubrication of the engine is produced by means of an oil pump fastened to the rear part of the crankcase and
driven by the crankshaft through an intermediate gear.
This pump draws in oil from the sump and sends it to the water/oil heat exchanger, to the filter assembly and, later on, to the oil
distribution ducts in the crankcase; the pressure of the oil is controlled by the pressure valve at the filter inlet.
The oil heat exchanger is the type with flat pipes that comes into contact with the coolant.
The oil is directed, from the two oil distribution ducts, positioned lengthwise in the crankcase, to lubricate the crankshaft bearings
and the camshaft and to cool the piston through calibrated jets.
Other ducts direct the oil to each of the heads to lubricate the timing components.
The oil flow rate is managed by two pressure relief valves (4) (one per bank) which close when the oil pressure reaches minimum
values (engine idling) in order to protect the bearings and other engine components.
The components fitted in the front and rear sections of the engine are lubricated by oil sprayed by special jets .
The crankshafts for the turbines are suitably lubricated by two pipes coming from the crankcase and the drainage goes directly to
the sump.
The return oil from the various components is collected in the oil sump.
The oil is filtered by means of two cartridge filters with a paper filter element operating in series.
The opening pressure of the oil filter safety valve is 3.4 ± 0.3 bar.
The theoretical starting temperature pressure for the engine lubrication pressure regulation valve (5) is around 5 bar.
The opening pressure for the piston lubrication pressure regulation valves (4) is around 2.65 bar.

Figure 3
1. Oil pump - 2. Water/oil heat exchange - 3. Oil filter support - 4. Relief pressure valve (piston cooler) -
5. Relief pressure valve (Engine oil pressure system).
103278

Oil vapour recirculation - blow-by filter
The oil vapours produced by the lubrication of the moving parts are directed via the pipe (3) and then are collected and filtered
in the blow - by (1).
In the blow-by, some of the vapours condense and return to the oil sump via the pipe (2), whilst the remaining vapours are
recirculated in the intake.
1. Blow-by filter - 2. Sump drainage pipe - 3. Oil vapour inlet - 4. Gas outlet
Figure 4
Figure 5
1. Blow-by filter casing - 2. Filter - 3. Gasket - 4. Cover - 5. Cover fixing bolts
The blow-by comprises two filtering layers (2), a casing (1) and two gaskets (3) which ensure the seal between the casing and the
two covers (4).
103275
81366

ENGINE COOLING
The cooling system is reponsible for cooling the engine casing and the engine lubrication oil inside the heat exchanger (2).
From the circulation pump (1), the coolant is sent to the heat exchanger (2) where the engine lubrication oil is cooled.
From here the coolant reaches the engine block and, after having cooled the cylinders, is sent to the thermostat casing.
Depending on the temperature, the coolant is either recirculated by the water pump (1) or sent to the radiator.
Figure 6
103273
1. Circulation pump - 2. Engine lubrication water/oil heat exchanger - 3. Thermostat casing

COOLING SYSTEM ASSEMBLY
Figure 7
Coolant coming from the cooling radiator being drawn into the pump.
Coolant coming from the engine block passing through the thermostat casing (temperature < 70˚C) sent to the
circulation pump.
Coolant coming from the engine block passing through the thermostat casing (thermostat valve opening
temperature around 70˚C, complete travel 85˚C) to the cooling radiator.
112492
1. Thermostat casing - 2. Radiator - 3. Coolant circulation pump - 4. Cooling fan.
A
B
C

VARIANT FOR APPLICATIONS WITH BRAKE AIR COMPRESSOR
Figure 8
103509
Rif. Description
1 Circulation pump
2 Engine lubrication water/oil heat exchanger
3 Air system compressor (for DRAGON applications)

AIR/AIR INTERCOOLER SYSTEM (DRAGON, G-DRIVE AND GRIFFON APPLICATIONS)
Figure 9
Air drawn in by the filters and sent to the turbochargers.
Air drawn in from the heat exchanger (air/air intercooler) to the main intake manifold and from there to the bank
intake manifolds.
Hot supercharing air coming from the two turbines to the heat exchanger (air/air intercooler).
112484
1. Air filter - 2. Turbochargers - 3. Heat exchanger (air/air intercooler)
A
B
The system has been designed to lower the temperature of the supercharing air before it is sent to the cylinders.
The air is drawn in and filtered by means of two dry filters and introduced inside the turbochargers.
The air is compressed, with a consequent increase in temperature and, after having been collected in a single pipe, it is sent to the
intercooler.
This heat exchanger, which the flow of air produced by the fan fastened axially and driven by the crankshaft comes into contact
with, cools the compressed air and sends it, via the pipe, to the main manifold and from there to the two intake manifolds, located
on each bank.
On versions for cold climates, there are two pre-heating heaters on the main manifold designed to assist engine starting at low
temperatures (ambient temperature up to - 25˚C).
Heater voltage: 24V DC
Peak current: 240 ± 50˚
Stabilization current: 83 ± 12A.
Together with the above mentioned heaters, these versions also have a resistance for heating the engine lubrication oil and a fuel
heater on the diesel pre-filter.
C

AIR / WATER INTERCOOLER SYSTEM (SPRINKLER APPLICATIONS)
Figure 10
112488
1. Heat exchanger (air/water intercooler) - 2. Turbochargers
Intake air and hot compressed air
Cold compressed air
Exhaust

SUPERCHARGING
The exhaust fumes are directed to the turbocharger (1) which rotates the section which draws in the air from the filters and
compresses it (with a consequent increase in temperature).
The hot compressed air is directed to the inside of the heat exchanger (air/air intercooler) in which it is cooled and sent to the
intake manifolds and to the inlet valves.
Figure 11
103512
FROM THE AIR/AIR
HEAT EXCHANGER
TO THE AIR/AIR
HEAT EXCHANGER

SECTION 2 - FUEL 1VECTOR 8 ENGINES
SECTION 2
Fuel
Page
HIGH—PRESSURE ELECTRONIC INJECTION
FUEL SYSTEM (COMMON RAIL) 3. . . . . . . . .
- General Information 3. . . . . . . . . . . . . . . . . . . .
- Description of the system 3. . . . . . . . . . . . . . . .
- Electrical system 3. . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fuel system diagram 8. . . . . . . . . . . . . . . . . . . . .
- Main mechanical components of the fuel system 9
- Fuel pre-filter for G-DRIVE and
SPRINKLER applications 9. . . . . . . . . . . . . . . . . .
- Fuel pre-filter for DRAGON and GRIFFON
applications 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fuel filter for G-DRIVE and
SPRINKLER applications 11. . . . . . . . . . . . . . . . . .
- Fuel filters for DRAGON and
GRIFFON applications 12. . . . . . . . . . . . . . . . . . .
- Low pressure pump for G-DRIVE, and SPRINKLER
applications 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Low pressure pump for DRAGON applications 14
- High—pressure pump 15. . . . . . . . . . . . . . . . . . . .
- High pressure pump operating principle 16. . . . .
- Rail 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electro—injector 24. . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 2 - FUEL VECTOR 8 ENGINES

Figure 1
HIGH—PRESSURE ELECTRONIC INJECTION FUEL SYSTEM (COMMON RAIL)
General Information
Reducing emissions and fuel consumption requires a high level of precision and high injection pressures.
The common rail system makes it possible to inject fuel at pressures of up to 1600 bar, while the injection precision, obtained
with an electronic control module (ECM), (also called electronic control unit, ECU) optimises the operation of the engine, limiting
emissions and consumption.
Description of the system
The system is composed of the electrical system and the fuel system.
Electrical system
The control unit governs the engine via the sensors on the engine.
1. Engine coolant temperature sensor — 2. Engine oil temperature sensor — 3. Oil filter clogging sensor — 4. ADEM III engine
control module — 5. Atmospheric pressure sensor — 6. Fuel temperature sensor — 7. Electro—injectors —
8. Engine speed/timing sensor on crankshaft — 9. Engine speed/timing sensor on camshaft — 10. Common rail fuel pressure
sensor — 11. Common rail high pressure control solenoid valve, also called pulse wide modulation (PWM) or M—Promp
valve — 12. Intake air temperature sensor after intercooler — 13. Intake air pressure sensor —
14. Engine oil pressure sensor — 15. Alternator
103265

Pressure sensors
The pressure sensors are used to notify the electronic control unit of the oil pressure values (reference 3, Figure 1), the
atmospheric pressure (reference 5, Figure 1) and the turbo outlet air pressure (reference 13, Figure 1).
Temperature sensors
These are NTC type sensors and are used to notify the electronic control unit of the operating temperatures of the enginecoolant
(reference 1, Figure 1), the engine oil (reference 2, Figure 1), the fuel (reference 6, Figure 1) and the heat exchanger outlet air
(reference 12, Figure 1).
Rpm sensors (timing sensor)
This is an inductive type sensor and is located on the camshaft (reference 9, Figure 1).
It produces signals obtained by means of the magnetic flow lines which close through the ports in the gear fitted on the camshaft.
The signal produced and sent to the electronic control unit allows the latter to calculate the moment of injection. The sensor
should be fitted by tightening it to a torque of 28 ± 7 Nm
Engine rpm sensors
This is an inductive type sensor and is located on the engine flywheel (reference 8, Figure 1).
It produces signals obtained through the magnetic flow lines which close via the ports in the actual flywheel. The electronic control
unit uses these signals to detect the various engine speeds.
Engine oil level sensors
This is a sensor used to signal a low oil level in the sump.

Figure 2
The fuel system consists of a low pressure part and a high pressure part.
The low pressure pump (LPP) (no.7) is located on the left side of the engine and it sucks the fuel from the fuel tank.
The fuel drawn in by the low pressure pump enters the pre-filter (5) where the water and the larger particles of impurities, that
may be present, are separated out.
This filter is equipped with a heater element (on certain applications) used to increase the temperature of the fuel in low
temperature conditions. There is also a mechanical pump on the pre-filter that is used to prime the circuit. On reaching the low
pressure pump, the fuel is sent for filtering to the filter or filters depending on the applications (8). The pump pressure is maintained
at 5 bar.
The high pressure system is a common rail system consisting of a high pressure pump and 8 injectors, which is electrically
controlled by an ECM.
1. Electro—injector — 2. Common rail — 3. Pressure sensor — 4. Common rail pressure relief valve —
5. Fuel pre-filter — 6. High—pressure pump — 7. Low—pressure pump — 8. Fuel filter.
103271
OPERATION

Figure 3
The fuel system is composed of a low—pressure circuit and a high—pressure circuit.
The high—pressure circuit is composed of the following pipes:
- pipe connecting the high—pressure pump outlet to the common rail;
- pipes connecting the electro—injectors to the common rail.
The low—pressure circuit is composed of the following pipes:
- fuel suction pipe from the tank to the pre—filter equipped with a priming pump, fuel pre—heating element and clogging sensor;
- pipes supplying the mechanical low—pressure fuel pump;
- pipe from the low pressure pump to the fuel filter/filters;
- pipes which supply the high pressure pump from the filter/filters;
The fuel system is completed by the fuel return circuit from the common rail, injectors and high—pressure pump.
103270
DIAGRAM SHOWING PIPES FOR G-DRIVE / SPRINKLER APPLICATIONS

Figure 4
103513
DIAGRAM SHOWING PIPES FOR DRAGON / GRIFFON APPLICATIONS
Rif. Description
1 Injector
2 Common rail pressure relief valve
3 Pressure sensor
4 Common rail
5 Diesel pre-filter
6 High pressure pump
7 Low pressure pump
8 Fuel filters (depending on the application)

Figure 5
Fuel system diagram
1. High—pressure pump — 2. Rail pressure valve — 3. Pressure sensor — 4. Common rail — 5. Clogging sensor on fine fuel
filters — 6. Fuel filter/s (*) — 7. Low—pressure pump — 8. Pre—filter with pre—heating element and priming pump —
9. Fuel tank.
* The number of fuel filters depends on the application.
The fuel drawn from the tank (9) is sent to the pre—filter (8) and from here to the low—pressure pump (7).
From the pump (7), the fuel reaches the fuel filter/s (6) and from there it goes to the high pressure pump (1).
The pressure relief valve fitted on the high—pressure pumps inlet side, keeps the inlet pressure at a constant level of 5 bar, so
the M—Promp (high—pressure regulator) receives a constant flow of fuel in order to work properly.
The M—Promp valve located upstream from the high—pressure pump, governs the necessary flow to the high pressure pump
allowing only the fuel necessary to maintain the pressure in the rail, improving energy efficiency and limiting system heating.
The high—pressure pump (1) takes the fuel up to a pressure of 1600 bar, depending on the engine conditions.
From the high—pressure pump the fuel is directed through the rails (4) to the electro—injectors.
The excess flow from the injectors and from the over pressure valve is collected and sent through pipes to the fuel tank.
The high—pressure pump drainage (excess fuel) is re—circulated by a pipe going directly to the low—pressure pump.
103269

Figure 6
Main mechanical components of the fuel system
Fuel pre-filter for G-DRIVE and SPRINKLER applications
The fuel pre—filter, a water separation type, has the water sensor (4) at the base of the cartridge (3) to indicate if there is water
in the fuel.
The manual priming pump (2) is located on the filter mounting (1).
1. Filter support — 2. Manual priming pump and system bleed — 3. Fuel pre—filter cartridge — 4. Water sensor
103268

Figure 7
Fuel pre-filter for DRAGON and GRIFFON applications
The high water separation type fuel pre-filter has a sensor (5) at the base of the cartridge (4) that signals the presence of water
to be drained.
There is a manual priming pump (2) and an air breather jet (7) on the filter mounting (1).
There is a heater (3) on the mounting for heating the diesel, an intake with a rapid connector (6) for the return pipe from the
tank and a temperature sensor (8).
1. Filter mounting — 2. Manual priming pump and system bleed — 3. Heater —
4. Fuel pre-filter cartridge — 5. Water in fuel presence sensor — 6. Attachment with rapid pipe connector —
7. System breather jet — 8. Temperature sensor
89669

Figure 8
The fuel filter (1) is fitted in the circuit between the high pressure pump and the low pressure pump behind the enginemanagement
control unit.
The bleed screw (2), the diesel pressure sensor (3) and the diesel temperature sensor (4) are located on the mounting.
1. Fuel filter — 2. System bleed screw — 3. Diesel pressure sensor — 4. Diesel temperature sensor —
5. Filter diesel inlet — 6. Diesel outlet from the filter to the high pressure pump.
103477
Fuel filter for G-DRIVE and SPRINKLER applications

Figure 9
The fuel filters (1) are located in the circuit between the low pressure pump and the high pressure pump.
The bleed screws and the filter blockage sensor (2) are located on the mounting.
1. Filter cartridges — 2. Filter blockage sensor
83422
Fuel filters for DRAGON and GRIFFON applications

Figure 10
The low pressure pump (1) (LPP) is fitted on the rear of the gear casing through the flange (3).
It receives power through the coupling (2) which meshes with the front teeth of the pump gear for the engine cooling circuit.
It has the task of pumping the fuel at low pressure to the high pressure pump.
1. Mechanical low pressure pump — 2. Pump control coupling (LPP) — 3. Flange — 4. Safety valve —
5. By-pass valve (Components 4 and 5 are housed inside the pump).
Main specifications
Safety valve (4):
- Valve opening pressure: 9,5 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Maximum pressure: 12 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
By-pass valve (5):
103266
Low pressure pump for G-DRIVE, and SPRINKLER applications

Figure 11
The mechanical low pressure pump (1) is fitted axially behind the braking system air compressor (2), if fitted. Otherwise, it is fitted
directly on the rear part of the gear casing.
It has the task of pumping fuel at low pressure to the high pressure pump.
1. Mechanical low pressure pump — 2. Braking system air compressor — 3. Safety valve —
4. By-pass valve (Components 3 and 4 are housed inside the pump).
Main specifications
Safety valve (4):
- Maximum pressure: 12 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
By-pass valve (5):
89701
Low pressure pump for DRAGON applications

Figure 12
High—pressure pump
The high—pressure pump (1) is located in the centre of the V—block and is secured to the rear gear housing of the engine.
Drive is provided by gears directly from the camshaft.
It receives the supply to the inlet (3) and, after compressing it, delivers it to the rails via outlets (4) and (9).
At the top there is an outlet (8) for draining off excess fuel to go to thelow—pressure pumpto bere—circulated tothe high pressure
pump.
The pump’s gear (5) is attached onto the pump’s shaft directly and secured by the nut (6). (350 torque; 300 Nm with the
screwdriver with final take off at 350 Nm with dynamometric wrench).
1. High—pressure pump — 2. Fixing screws — 3. Fuel inlet — 4. and 9. Outlet to Common Rail — 5. Pump gear — 6. Fixing nut —
7. Seal — 8. Outlet for draining off excess fuel.
81383

Figure 13
1. Outlet for supply to the rail — 2. Rail supply valve — 3. Pumping element — 4. Pump shaft — 5. Pumping supply duct —
6. Pressure regulator supply duct — 7. Pressure regulator (M-promp) — 8. Lubrication oil inlet — 9. Fuel return to the low
pressure pump — 10. Relief valve regulated to 5 bar
103245
103246
High pressure pump operating principle

Figure 14
The pumping element (5) is oriented on the cam on the pump shaft.
In the suction phase, the pumping element is fed through the supply line (3). The amount of fuel to send to the pumping element
is decided by the pressure regulator (7).
Depending on the command received from the control unit, the pressure regulator will control the flow of fuel to the pumping
element. During the compression phase of the pumping element, the fuel pressure opens the common rail delivery valve (2),
before going out the outlet (1).
The pump shaft supports are lubricated through the ducts (oil channels) (8).
The pressure regulator (7) decides the amount of fuel with which to supply the pumping elements; any excess fuel flows out
through the duct (9).
The pressure relief valve (10), has the function of keeping a constant inlet pressure at 5 bar for the pressure regulator.
High pressure regulator
Located at the high—pressure pump inlet, on the low—pressure system, it controls the flow of fuel to the high—pressure pump
according to the commands received from the electronic control unit (ECU).
If there is no command signal, the pressure regulator is normally open, so the high—pressure pump is in the condition of maximum
delivery.
The control unit sends the regulator a command signal to control the fuel flow to the high—pressure pump.
1. Electrical connector — 2. Fuel outlet — 3. Fuel inlet

Figure 15
Pressure relief valve 5 bar
Mounted in parallel with the pressure regulator, its function is to keep the pressure at the regulator inlet constant, which is
necessary for the system to work properly.
When the pressure at the inlet of the regulator exceeds 5 bar, the relief cylinder (8, Figure 16), will begin to open in order to
lead the additional fuel to the outlet.
Depending on the fuel flow required, with the pressure regulator partially closed, the cylinder moves into a dynamically balanced
position such as to ensure a constant pressure of 5 bar at the regulator inlet.

Figure 16
Pressure regulator and 5 bar pressure relief valve at max. fuel delivery
1. Coil — 2. Core — 3. Pre—loading spring — 4. Shutter — 5. High—pressure pump supply — 6. Fuel inlet (from the filter) — 7. Fuel
return from the high—pressure pump — 8. Cylinder for opening outlet line — 9. Fuel outlet — 10. Fuel delivery
When the coil (1) of the regulator is not energised, the core (2) is in the rest position due to the pre—loading spring (3). The
shutter (4) is in the position of maximum delivery and the HPP will provide the rail with max. pressure.
The clearance between the internal parts in the high pressure pump permits fuel leakage, which is used to lubricate the pump.
This excess fuel is sent towards the pressure relief valve.
The cylinder (8) in the pressure relief valve will then move into a balanced position and there it will maintain the pressure in the
low pressure line at 5 bar.
81386

Figure 17
Pressure regulator and 5 bar pressure relief valve in regulation mode
1. Coil — 2. Core — 3. Pre—loading spring — 4. Shutter — 5. High—pressure pump supply — 6. Fuel inlet (from the filter) — 7. Fuel
return from the high—pressure pump — 8. Cylinder for opening outlet line — 9. Fuel outlet — 10. Fuel delivery
When the PWM is in regulation mode the coil (1) is energised (between 0—1600mA depending on the pressure required by
the ECM) and the core (2) is moving the shutter (4) towards the closing position in order to limit the fuel flow to the HPP and
thereby reducing the fuel pressure in the rail.
The cylinder (8) in the pressure relief valve will move into a balance position and there it will maintain the pressure in the low
pressure line at 5 bar.
81387

Figure 18
Rail (pressure accumulator)
1. Common rail (one for each row) — 2. Flow limiters — 3. Fuel inlet from the high—pressure pump (one for each common
rail) — 4. Pressure sensor — 5. Pressure relief valve (one on the right—hand rail)
112490
81388
RAIL FOR G-DRIVE / DRAGON / SPRINKLER APPLICATIONS
RAIL FOR GRIFFON APPLICATION

Single—stage pressure relief valve (item 4, Figure 18)
Fitted at one end of the rail, its function is to protect the system’s components if any malfunctioning of the rail pressure sensor
or of the pump pressure regulator causes an excessive increase in the pressure of the high—pressure system.
The valve is a mechanical type and when the pressure in the high—pressure system reaches 1850 bar the valve opens to run fuel
off into the outlet line and accordingly reduce the pressure to acceptable values.
Flow limiters (item 2, Figure 18)
Located on the fuel outlet unions from the common rail, they protect the engine and vehicle in the event of larger fuel leakage
after the flow limiter (e.g. a jammed open nozzle) or external leakage (e.g. damage in high—pressure pipes).
Under this circumstance, cut off the fuel to the cylinder in question.
!
To reset the flow limiter it is necessary to stop the engine in order to zero the rail pressure.
However, if the cause of it switching on is not removed, the same fault will occur the next time the engine is started.
If the leakage is considerable, it will be impossible to restart the engine due to the lack of pressure in the rail.
Figure 19
Single—stage pressure relief valve (item 5, Figure 18)
Fitted at one end of the rail, its function is to protect the system’s components if any malfunctioning of the rail pressure sensor
or of the pump pressure regulator causes an excessive increase in the pressure of the high—pressure system.
The valve is a mechanical type and when the pressure in the high—pressure system reaches 1850 bar the valve opens to run fuel
off into the outlet line and accordingly reduce the pressure to acceptable values.
or lower for the single—stage
valves

Figure 20
The flow of fuel from the common rail to the injectors takes place via the ports in the small diameter of the piston.
In normal conditions, the pressure of the fuel is exerted on both sides of the piston, maintained by the spring in
the opening position
If there is a substantial loss in pressure downstream of the limiter, the inlet pressure becomes predominant and
moves the piston to the opposite side, obstructing the outlet of the fuel.
Limiter with piston in outlet closed position.
89672
1. Body - 2. Piston - 3. Fuel inlet - 4. Spring - 5. Part bolted onto the common rail
A
B
C

Figure 21
Electro—injector
The high—pressure pump keeps the delivery fuel pressure constantly high, irrespective of the phase and the cylinder that must
receive the injection and it accumulates the fuel in the common rail and piping to all the electro—injectors.
At the electro—injector inlet there is therefore always fuel available at the injection pressure calculated by the engine’s electronic
control unit (ADEM III).
When the solenoid valve of an electro—injector is energized by the electronic control unit, fuel taken directly from the rail is
injected into the relevant cylinder.
1. Nozzle — 2. Electro—injector — 3. Seals
103478

SECTION 3 - INDUSTRIAL APPLICATION 1VECTOR 8 ENGINES
SECTION 3
Industrial application
Page
GENERAL SPECIFICATIONS 3. . . . . . . . . . . . . . .
- Clearance data - 8 cyl. 7. . . . . . . . . . . . . . . . . . .
PART ONE -
MECHANICAL COMPONENTS 9. . . . . . . . .
ENGINE OVERHAUL 11. . . . . . . . . . . . . . . . . . . . .
- Preface 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Dismantling 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Installation of components for the application 22
- Fitting the flywheel cover housing 22. . . . . . . . . .
- Fitting the rear oil seal 23. . . . . . . . . . . . . . . . . . .
ENGINE FLYWHEEL 23. . . . . . . . . . . . . . . . . . . . .
- Fitting the engine flywheel 23. . . . . . . . . . . . . . . .
- Fitting the gearbox 25. . . . . . . . . . . . . . . . . . . . .
RODS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARM ASSEMBLY 27. . . . . . . . . . . . . . . . .
ROCKER ARMS 27. . . . . . . . . . . . . . . . . . . . . . . . .
JUMPERS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARM SUPPORT ROCKERS 27. . . . . . . .
- Adjusting operating clearance between valves and
rockers 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting the cylinder head tappet covers 30. . . . . .
- Fitting the injectors 30. . . . . . . . . . . . . . . . . . . . .
LUBRICATION 31. . . . . . . . . . . . . . . . . . . . . . . . . .
- Oil pump 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETING THE ENGINE 33. . . . . . . . . . . . . .
COMMON RAIL ASSEMBLY PROCEDURE 38. . .
- Preparing for assembly 38. . . . . . . . . . . . . . . . . .
- Cleaning and preparation 38. . . . . . . . . . . . . . . .
- Assembly procedure 38. . . . . . . . . . . . . . . . . . . .
- Test procedure for checking for diesel leaks
from the Common Rail system. 39. . . . . . . . . . . .
- Checks and inspections 41. . . . . . . . . . . . . . . . . .

2 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES
Page
SECOND PART -
ELECTRICAL EQUIPMENT 43. . . . . . . . . . . . . .
LOCATION OF COMPONENTS ON THE ENGINE 45.
- Circuit diagram of engine cable 46. . . . . . . . . . . .
- Engine components 47. . . . . . . . . . . . . . . . . . . . .
- ADEM III engine control unit 50. . . . . . . . . . . . . .
- Electronic control of the engine control unit 53. .
THIRD PART - DIAGNOSTICS 55. . . . . . . . . . . .
TROUBLESHOOTING 57. . . . . . . . . . . . . . . . . . . .
- General information 57. . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING WITH TOOL 99368550 58
- Connection procedures 58. . . . . . . . . . . . . . . . . .
- Diagnosis procedures for Vector 8V engines 59. .
- Diagnosis Environment 60. . . . . . . . . . . . . . . . . .
ENGINE PARAMETER READING 63. . . . . . . . . . .
READING PARAMETER FOR SAVE CODE 64. . . .
EVENTS TABLE 65. . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTS TABLE 67. . . . . . . . . . . . . . . . . . . . . . . . .
ILC SIMULATOR 99368543 TOOL 70. . . . . . . . . .
FOURTH PART -
PLANNED MAINTENANCE 77. . . . . . . . . . . . .
VECTOR 8 DRAGON FVAE2884A*B200
MAINTENANCE PLAN 79. . . . . . . . . . . . . . . . .
VECTOR 8 GENSET FVAE2885X*A100
MAINTENANCE PLAN 81. . . . . . . . . . . . . . . . .
DESCRIPTION OF PREVENTIVE AND
ROUTINE MAINTENANCE WORK 83. . . . . . .
CHECKING/REFILLING ENGINE OIL FILTERS 84.
CHANGING ENGINE OIL FILTERS 84. . . . . . . . . .
CHANGING THE ENGINE OIL 86. . . . . . . . . . . . .
CHANGING FUEL PREFILTER AND
WATER SEPARATOR FILTER 87. . . . . . . . . . . .
ADJUSTING ROCKER ARM ASSEMBLY 88. . . . . .
CHANGING FUEL FILTERS 91. . . . . . . . . . . . . . . .
Page
CHANGING AN INJECTOR 93. . . . . . . . . . . . . . .
CHANGING BLOW-BY FILTER 95. . . . . . . . . . . . .
CHANGING PRIMARY SYSTEM PUMP 96. . . . . . .
- Removal 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING/REFITTING STARTER MOTOR 98. . .
- Removal 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1
GENERAL SPECIFICATIONS
G-DRIVE application
103260

103503
DRAGON application
Figure 2

Figure 3
SPRINKLER application
112503

Figure 4
VECTOR engines feature a 4 stroke diesel cycle with
supercharging with 8 cylinders in two banks at 90˚.
They have high pressure injection fuelling (common rail) and
are entirely electronically driven in order to optimise the
working process in accordance to the operation, limiting as
much as possible the pollution emissions and consumption.
The section herein described is composed or four sections:
- Section of mechanical overhaul prescribed in accordance
to the engine’s specific duty, illustrating all necessary
operation to remove and assembly the external
components of the engine, including cylinder heads,
gearbox of the timing system and of the front part cover;
- Electrical section, describing the connections to the
different components of the engine control module and
of the sensors assembled to the engine;
- Diagnosis section;
- Section of preventive maintenance operations, providing
instructions for the execution of the main operations.
Data, features and performances are valid only if the
setter fully complies with all the installation
prescriptions provided by Iveco Motors.
Furthermore, the users assembled by the setter
shall always be in conformance to couple, power
and number of turns based on which the engine has
been designed.
112310
NOTE
GRIFFON application

Data, features and performances are valid only if the technician fully complies with all the installation requirements
provided by Iveco Motors.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.
NOTE
Clearance data - 8 cyl.
VECTOR 8
Type FVAE2885
X*F100
FVAE2884
A*B201
FVAE2884
A*B200
FVKE2887
A*A200
ρ Compression ratio 16 : 1
Max. output kW
(HP)
rpm
560
(760)
2100
-
-
-
745
(1000)
2200
680
(920)
2100
Max. torque Nm
(kgm)
rpm
3200
(320)
1400÷1700
-
-
-
3960
(396)
1400÷1700
3200
(320)
1500
Loadless engine
idling rpm
> 800 - 600 ± 25 -
Loadless engine
peak rpm
< 2300 - 2350 ± 25 -
Bore x stroke
Displacement cm3
145 x 152
20080
TURBOCHARGING with intercooler
Turbocharger type HOLSET HX55 KKK-K31
HOLSET
HX55
bar
LUBRICATION
Oil pressure (warm engine)
- idling bar
Forced by gear pump, relief valve single action
oil filter
4.0
- peak rpm bar Up to 6.5
COOLING
Water pump control
Thermostat
- start of opening ºC
By coolant
Through an idler gear
70 ± 2
15W40 ACEA E3
ACEA E5
FILLING
engine sump liters 80

PART ONE -
MECHANICAL COMPONENTS

Figure 1
Figure 2
Dismantling
- Remove the protective grilles from the exhaust
manifolds and from the turbochargers from the engine.
- Remove the dipstick complete with guide pipe from the
sump.Also remove the oil filler.
Seal appropriately to prevent particles of dirt from
entering.
- Secure the engine to the rotary stand 99322230 (1) with
the brackets 99361011 (2); drain off the lubrication oil
from the engine sump through the plug (3).
- Remove the oil filters (1) using the special
tool 99368501 (2).
Before disassembling, place under the filter a basin
of suitable capacity.
Improper waste disposal is a threat for the
environment. Potentially hazardous waste includes
lubricants, fuels, coolants, filters and batteries.
— Use watertight containers when draining off
fluids. Never use containers for foodstuffs or
beverages that can lead people to drink from
them.
— Never throw waste on the ground, on tips or
in water courses.
— Obtain information on the appropriate ways
of recycling or disposing of waste from the
local authorities or collection centres.
103226
82196
Handle all components very carefully. Do not put
your fingers between different components. Always
wear recommended protective clothing such as
goggles, gloves, safety shoes and protective
headgear.
The following information relates to the engine overhaul
operations only for what concerns the different components
customising the engine, according to its specific duties.
In section ”General overhaul”, all the operations of engine
block overhaul have been contemplated. Therefore the
above mentioned section is to be considered as following the
part hereby described.
All operations of Engine disassembly operations as
well as overhaul operations must be executed by
qualified technicians provided with the specific
tooling and equipment required.
Preface
NOTE
NOTE
ENGINE OVERHAUL

- Remove the engine wiring: disconnect the wiring from
coolant temperature sensor (1), sensors (2 and 14), XJ2
connector from ADEM III (4), atmospheric pressure
sensor (5), fuel temperature sensor (6), electro injector
(7), engine speed sensor (8), timing system speed sensor
(9), common rail fuel pressure sensor (10), common rail
high pressure control solenoid valve (11), turbo—blower
air temperature sensor (12) and air pressure sensor in
the intercooler (13).
Figure 3
Figure 4
- Remove the ADEM III engine management control unit
(2) from its mounting undoing the bolts for the flexible
mountings (3).
- Remove the atmospheric pressure sensor (4) from the
support.
- If present on the application, remove the flexible belt (16)
and the air conditioning compressor (17).
- Completely undo the screw (5) and release the belt (6).
- Remove the alternator complete with bracket.
- Remove the control unit support complete with diesel
filter mounting.
112865
The oil filter blockage sensor (3) and the alternator
(15) are not connected to the engine lead.
NOTE
On the DRAGON and GRIFFON applications, the
fuel filters are fitted in a remote position.
NOTE
103227
5
6
3
4
1
2
- Remove the diesel filter (1) using tool 99360091.

Figure 5
103479
- Remove the pipes (1) to the blow-by filter (2) from the
flywheel side.
- Undo the 4 bolts fixing the filter casing to the air intake
manifolds from the turbocharger body to the heat
exchanger (air/air intercooler) removed previously
together with the air filters.
- Loosen the bands (3) on both sides of the hoses near
the turbochargers.
- Undo the bolts from underneath the bracket above the
flywheel to release the manifold (4). Remove the
manifold securing it appropriately.
After having checked the cleanliness inside the
manifold, seal the three ends to preserve it.
Check the wear of the hoses in the case of obvious
signs of cracks or if there is a loss in the normal
flexibility replace them.
NOTE
Figure 6
- Remove the lubrication pipes from both turbines:
disconnect the oil intake pipe (1) from the crankcase at
the top flange on the body of the turbo—blower and the
exhaust pipe (2) from the bottom of the body of the
turbo—blower and from the seat on the sump.
- Also remove the oil pipes at the sump from the blow-by
filter removed previously.
- Remove the band fastening the pipe on the flywheel
casing and then undo it from the flange on the engine
sump.
103228
Figure 7
- Loosen the rail check u-bolt (4) fixing screws.
- Disassemble the assembly of the delivery pipes (1) from
the high pressure pump (2) and the ones on the
electro-injectors;
unscrew the washers (3) with a 99368506 wrench.
- Remove the rail assembly
- Disassemble the diesel fuel exhaust pipes from the
overpressure valve rail (5).
Plug all the pipes in order to prevent possible
contamination. Unscrew the fittings seeing to
protect the seal surfaces.
89790
Figure 8
RAIL ASSEMBLY FOR G-DRIVE / DRAGON /
SPRINKLER APPLICATIONS
Common rail (1), flow limiting device (2), delivery pipes to
the rail from the high pressure pump (3), pressure sensor
(4), overpressure valve (5).
If it is hard to disassemble, loosen the washers of the
electro-injector supply pipes on the rail side, of the
compensation pipes between the rail and the rail
side supply.
- Remove all the diesel return pipes: those of the injectors
and the one from the high—pressure pump.
89791
If there is a malfunction with components (2), (4)
or (5), replace the rail assembly (1).
NOTE
The RAIL assembly for GRIFFON applications is
shown on page 21 of the section 2.
NOTE
NOTE
NOTE
On the bench separate the pipes that are between the rail and
the support. Check the conditions of the thread seal conic
surfaces. Plug all pipes in order to prevent contamination

- Remove the pipe (1) which connects the pump to the
water/oil heat exchanger fitted between the two banks
and remove the hose (2) between the thermostat body
and the elbow connector on the pump.
!
Fully drain off the coolant contained in the cooling
pump.
Figure 9
103229
- Support the cooling pump (1) and undo the four fixing
nuts.
Thoroughly release the pump assembly for the inlet
pipes.
- Disconnect the pipes (2) from the rear of the gear casing.
Figure 10
103230
Seal the pipes and the connectors on the pump.NOTE
- Inspect the hydraulic pump and especially the state of
wear of the teeth of the driving gear (1) (both those
receiving motion from the gearbox and the front teeth
transmitting motion to the pump of the primary cooling
circuit).
- Replace if there is excessive gear wear: lock gear (1)
rotation properly and loosen screw (2). Disassemble the
gear and set the screw aside.
Figure 11
The gear has a left-hand locking screw.
The hydraulic sealing of the pump is assured by a
gasket (3). If the same pump is used again replace the
above mentioned seal before reassembly.
89792
NOTE
NOTE

Figure 12
Figure 13
Figure 14
Figure 15
- Unscrew the three screws (1) fixing the support to the
gearbox and remove the the low—pressure supply pump
(2).
- On the bench, go ahead and remove the support (3) and
separate the low—pressure supply pump (2); in addition,
remove the coupling drive (4).
103475
For G-DRIVE, GRIFFON and SPRINKLER applications
For DRAGON applications
- Disconnect the coolant connecting pipes (1).
89698
It is advisable to plug both the pipes and the ports on
the compressor that has to be shipped for overhaul.
- Unscrew the fixing screws of brakets (13, Figure 15)
- Unscrew the screws (2, Figure 13) fixing the compressor
on the spacer.
NOTE
- Take the compressor to the workbench and separate
the low-pressure pump (if not previously removed ).
Recover the universal joint (1), checking its state of
wear.
- After firmly securing the compressor in a vice, remove
the gear (2) by unscrewing the nut (3) andusing aspecific
extractor. In addition, remove the fittings (4) and (5).
- Unscrew the screw (13) that fixing the LPP (8) to air
compressor.
- Divide the LPP (8) from air compressor and recover
coupling drive (9) and O-ring (10).
For all applications
81969
NOTE
89697
- Check the state of wear of the coupling drive and its
coupling with the low—pressure pump spindle.
Figure 16
83490
- Remove the starter motor by unscrewing the three nuts
(1).
82205
Figure 17

Figure 18
- Remove the bracket (1) for the flywheel and intercooler
casing (2).
- Undo the nuts fixing the turbocharger (3) to the exhaust
manifold.
- Then repeat this procedure for the second
turbo—blower.
103231
For G-DRIVE, DRAGON and GRIFFON applications
Figure 19
- Remove the manifold (1) between the turbo—blower (2)
and the intercooler (3), loosening the clamp (4) on the
manifold and on the turbo—blower .
- Remove the exhaust pipe (5) between the waste gate
valve (7) and the pipe of the turbo—blower.
- Remove the air pipe (6) between the turbo—blower and
the waste gate valve (7).
- Lastly, unscrew the nuts fixing the turbo—blower to the
exhaust manifold.
- Then remove the cooling pipes of the waste gate valve
(7) and detach it from the exhaust manifold.
- Then repeat this procedure for the second
turbo—blower.
Figure 20
- Disassemble the junction plate (3) of the cooling pipes
(1) and the three way fitting on the exchanger.
- Then disassemble the cooling pipes (1), the three way
fittings by loosening the screws (2) and the fitting on the
inlet of the main bearings.
89793
83499
For SPRINKLER applications

Figure 21
- Proceed as follows:
Undo the screws of the collars (1) securing the pipes (2)
to the intake ducts.
Undo bolts (3) securing fastening collars (9) that join
pipes (2) to fittings (4) on the engine blocks by means
of gaiters (10).
Undo the screws (5) fixing the couplings (4) on the main
bearings and at the top unscrew the screws (6) fixing the
three—way coupling (7) on the oil/water cooler(8) ofthe
engine oil.
Figure 22
- Unscrew the 10 screws (1) fastening the intercooler to
the air intake manifolds.
114242
82212

Figure 23
- Unscrew the fixing screws and remove the water outlet
pipes (1) from the heads.
- Remove the thermostat casing (5).
Figure 24
- Remove the driving gear with the aid of tools 99368516
(1), 99368517 (2) that permit unscrewing the M24 x 1.5
nut (3).
- Then remove the engine water/oil cooler (2),
unscrewing the M10 x 40 mm screws (three on both
sides).
- Remove the diesel supply pipe from the high—pressure
pump (the coupling has been removed together with the
ADEM III control unit support).
- Remove the diesel recovery piping.
- Remove the intake manifolds (3), remove the gaskets
and remove the high pressure pump (4) from the
flywheel casing complete with gear. Figure 25
- Unscrew the screws (1) and remove the exhaust
manifolds (2) on both sides comprehensive of seals.
103190
82214
NOTE Separate the screws appropriately, marking their
placement to facilitate assembly.
NOTE Separate the screws appropriately, marking their
placement to facilitate assembly.
82215

Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
- From the front side disassemble the engine oil filter
supports (1) including the oil temperature transmitters
(2), the pressure sensor (5), the seal (4) and the filter clog
sensor (3).
- Remove the remaining diesel pipe from the LPP to the
filter mounting (the two components have already been
removed previously)
- Remove the electro—injectors. Using the wrench (2),
unscrew the screw (1) of the fixing bracket.
- Fit the tool 99368505 (1) and the wrench for extracting
the electro—injector.
- Unscrew the fixing screws (1) and remove the tappet
cover (2). Repeat this operation for all the covers.
- Remove the rocker arms (2) from the support (1), taking
out the circlips and seals on both sides of the support.
Extract the rods (3) from their seat on the heads and the
jumpers (4).
- Unscrew the fixing screws (7) and remove the head (6).
Remove the cases (5) protecting the valves.
Always change the O—ring in the assembly phase.
Lubricate the O-rings with vaseline before
installating
82216
82220
82218
82217
82219
NOTE If necessary, replace the worn parts. Always change
the seals in the assembly phase.
NOTE
NOTE
Note down the position of the tappet covers in
relation to the heads so as to fit them in the
positions they had with the first assembly.
The screws (7) fixing the head on the crankcase
have different sizes:
M15x170
M15x185
Mark them so as to facilitate the assembly phase.
NOTE

- Undo the M8 bolts (1) and remove the cover (2) for the
gear casing. Remove the gasket (3).
- Remove the duct (12).
- Unscrew the screw (4), remove the shaft (5) and the
gear (6) with the bearing (7).
- Remove the oil seal (1) using the tool 99368514 (2).
- Rotate the engine and remove the oil sump.
- Remove the engine lubricating oil pump with the suction
cup.
- Undo the bolt (10) securing the gear casing (11) to the
cylinder block/crankcase; after having removed the gear
casing, undo the bolt (9) and remove the spacers (8) and
(13) complete with O-rings.
- Fit tool 99368502 (1) and place the fixed spanner (2) as
shown in the diagram to prevent the rotation of the
flywheel during the dismantling of the pulley and the
damper flywheel on one side and the actual flywheel on
the other.
Figure 31
Figure 32
Figure 33
- At the front, undo the 8 botls (1) and remove the pulley
(2), the damper flywheel (3) and the counter-weight (4).
Figure 34
103191
82223
103192
2
1
1
2
4
3
1031931
1
2
3
4
6
7 8
5
12
13
9
10
11

Figure 35
Figure 36
Figure 37
Figure 38
- From the inside of the flywheel box prevent flywheel
rotation by using rotation tool 99368502 (1) and fixed
wrench (2). Then loosen screws (3).
- Fit the supporting tool 99368533 (1) for disassembling
and assembling the flywheel. Go ahead and unscrew the
flywheel fixing screws. Remove washer and engine
flywheel assembly.
- Fit the tool 99368513 (1) and extract the rear oil seal (2).
- Unscrew the screws (1), (2) and (3) after suitably slinging
the flywheel cover casing (4). Detach the flywheel cover
casing from the crankcase.
103194
103219
82228
103195
NOTE Mark the position of the screws (1), (2)
Screws (1): M12x35 mm 6 bolts tot.
Screws (2): M14x90 mm 12 bolts tot.

- Form a bead of IVECO 2992692 sealant as shown in the
figure.
Figure 39
Installation of components for the application
Fitting the flywheel cover housing
- Carefully clean the contact sides between the crankcase
and the flywheel cover housing, removing any remains
of sealant with a scraper.
!
A perfect seal is only obtained by carefully cleaning
the surface to seal.
Smear the case with IVECO SEAL 2992692 to
obtain a bead of a few mm diameter.
It shall be uniform (no clots), without air bubbles,thin
areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid using excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10—20 minutes).
103197
Figure 40
DIAGRAM SHOWING TIGHTENING ORDER FOR
BOLTS FIXING FLYWHEEL COVER CASING ON
G-DRIVE APPLICATION
103198
NOTE Make sure you put the screws in the seats from
where they were taken. There are screws of
different lengths as well as different sizes.
Figure 41
DIAGRAM SHOWING TIGHTENING ORDER FOR
BOLTS FIXING FLYWHEEL CASING COVER FOR
GRIFFON, DRAGON and SPRINKLER APPLICATIONS
- Refit the housing (1) to the engine block and screw the
fastening screws in the same position found at removal
and tighten them to the following torque values in the
sequence shown in the figure:
M12x1.75x45 torque 89 to 105 Nm
M14x2x90 torque 135 to 165 Nm
M12x1.75x45 torque 89 to 105 Nm
83507
G-DRIVE
Application
GRIFFON,
DRAGON and
SPRINKLER
Applications

Figure 42
Figure 43
- Apply tool 99368511 part (6) to the rear output shaft
tang (5), secure it with screws (4) and fit the new sealing
ring (3).
Position part (1) on part (5), screw nut (2) until
completing sealing ring (3) fitting into flywheel housing
(7).
ENGINE FLYWHEEL
00901t
75696
NOTE Check the important measurements depending on
the application.
- Check the condition of the teeth for the ring gear (2).
If the teeth are broken or very worn, remove it from the
engine flywheel (1) using an ordinary drift andfit thenew
ring gear, heated previously to a temperature of 150˚C
for 15’ P 20’; the bevel on the inner diameter of the ring
gear should be facing the engine flywheel.
Figure 44
- Screw the pins 99367019 (3) onto the crankshaft and fit
the flywheel (2) with tool 99368533 (1) and a suitable
lift.
Fitting the engine flywheel
83436
Figure 45
- Stop engine shaft rotation with tool 99368502: the fixed
wrench (5) keeps the flywheel in position preventing its
rotation. Assemble tool 99368546 (1) and tighten the
fixing screws that were previously lubricated with
”UTDM” oil up to the prescribed torque by using torque
multiplier 99389816 (2), dynamometric wrench
99389818 (3) and bush wrench 99367016 (4); for
angular closure use tool 99395216 (2).
103216
Fitting the rear oil seal

Figure 46
Tightening: pre—torque + angle
Pre—torque = 350 Nm
Angle 120°
Torque 910 to 1600 Nm
82246
NOTE If the screws turn out to have been removed
previously, check the stated diameter: if the
diameter ”d” turns out to be < 23.5 mm.

Figure 47
1031931
1
2
3
4
6
7 8
5
12
13
9
10
11
- Check the dimensions of the parts removed, examining
their state of wear.
Replace all the seals and O-rings.NOTE
- Check the spacer (8, Figure 47): check the state of wear
of the zones of contact with the shaft (5) and the
dimensions as shown in the figure.
- Insert the new O—rings in their seats on the spacer (1)
and, with the aid of a drift, go ahead with assembly on the
crankcase.
- Tighten the spacer fixing screws to the prescribed torque:
M10x1.5x25 mm cheese—headed screws: 45 to 50 Nm.
Lubricate the screws with ”UTDM” oil or alternatively
with engine oil.
Figure 48
82248
Figure 49
82250
- In addition, check the state of wear of both the bearings
and the gears. If there is noisiness or clear seizure of the
gears, replace them.
- Check the state of wear of the teeth of the gears and the
contact surface between the inside of the bearing and
the shaft.
NOTE The conical roller bearings and the gear are supplied
as spares already fitted.
The gear has the following dimensions:
-outer diameter 180, 700 P 180,900 mm;
-No. of teeth 34.
Fitting the gearbox

Figure 50
Figure 51
- Check the state of the contact surface of the shaft and
its dimensions. Blow compressed air into the bearing
lubrication passage to remove any debris.
- After applying a bead of IVECO 45500318 sealant onto
the contact surface of the crankcase with the gearbox,
position the box.
Tighten the fixing screws to the prescribed torque:
M8x1.25: 22—27 Nm
- Then fit the gear complete with conical roller bearings
on the shaft and fit the assembly in place on the spacer
fitted previously on the engine block. Tighten the bolt
fixing the shaft to the spacer to the recommended
torque: hexagonal head bolts M12x1.75x80 mm: 73 P 80
Nm.Before tightening, lubricate the bolt with UTDM oil
or, alternatively, with engine oil.
- Fit the seal (1) in its seat on the gearbox with the aid of
tool 99368512.
82251
- On the opposite side, fit the shaft illustrated in the
diagram. The idler gear should not be present.
- Take the new flat gasket out of the package and put it
in its seat on the gearbox cover.
- Fit the cover together with the gasket on the gearbox.
Tighten the screws to the prescribed tightening torque.
M8x1.25x30mm hexagonal—head screw: 22—27 Nm.
Replace all the seals.NOTE
Figure 52
103471
NOTE If the studs fitting the cooling pump and the sump
have been removed from the cover and from the
gear casing, proceed with fitting them.
82252

Figure 53
Figure 54
The valve pushrods must be free from distortion; the cup
seatings for the adjustment screws and the ball ends locating
in the tappets (arrowed) must not show any signs of seizing
or wear; if they do, replace the rods.
Pushrods for inlet and exhaust valves are identical and
therefore interchangeable.
ROCKER ARM ASSEMBLY
ROCKER ARMS
JUMPERS
ROCKER ARM SUPPORT ROCKERS
- Check that the rocker arms (2), jumpers (3) and support
(1) show no sign of wear, scoring or seizure.
Riscontrando anomalie, sostituire i particolari interessati.
- Check that the plug is assembled on the end of each
rocker—arm holding shaft.
RODS
- Install rods (1), rocker arm supports (2) with rocker arms
and bridges (3).
Figure 56
Make sure that the bevelled side of the fall plate is
turned towards the inside of the engine.
Figure 55
- Make sure that cylinder 1 is in the firing order and that
cylinder 6 is balanced, then assemble rocker—arm units
1-2-4-5 and 6.
- Check that the contact between the register and the
plate is centred and that the rods can turn freely.
82261
82721
82262
89828
NOTE

Figure 57 Adjusting operating clearance between valves
and rockers
- Undo the three nuts fixing the flywheel cover casing
cover (side opposite the starter motor). Fit tool
99368502 (6) with pinion 99368547 to rotate the engine
flywheel and secure it using the nuts for the cover
removed.
- After fitting the 24 mm ratchet wrench on the back of
tool 99368502, turn the engine flywheel until we obtain
the required cylinder balancing (the 4 valves are at the
same height).
Figure 58
- Unscrew the three fixing nuts of the cover of the box
that covers the flywheel (on the opposite side of the
starting motor). Insert tool 99368502 in order to turn
the engine flywheel and fix it with the nuts of the cover
that has been removed.
- Turn the engine clockwise for 360˚, then assemble
rocker—arm units 3-7 e 8.
- Check that the contact between the register and the
plate is centred and that the rods can turn freely.
Figure 59
- Apply the 20 ÷ 120 Nm torque wrench with the 1/2”
square connection to the wrench 99389813 to lock
bolts M12x1,75 to a torque of 80 ÷ 89 Nm.
- After the rocker—arm control rods (1) have been
assembled check that they are properly inserted in the
tappet seats and then lubricate then with engine oil in the
area in which the rod slides.
89827
81603
89829

- Using the wrench 99368503 (4), loosen the check nut
(1) of the adjuster screw (2).
- Insert the tappet feeler gauge (0,50 mm) 99368545 (3).
- With wrench, screw or unscrew the adjuster screw (2).
- Check that the tappet feeler gauge (3) can slide with a
slight amount of friction.
- Keeping the adjuster screw still (2), use wrench
99368503 (4) to lock the check nut (1) of the adjuster
screw.
Figure 60
Figure 61
Figure 62
Figure 63
- To obtain cylinder no.1 or no.6 in T.D.C. conditions it is
necessary to position the damping flywheel as indicated
in the picture. For the following balancing/adjustments it
is recommended to trace some marks on the flywheel
(1), placed at 90° one from the other (see picture).
- After obtaining this condition of balancing we move on
to adjust the valves in the following order:
- To make the adjustment, proceed as illustrated here:
BALANCING
ADJUST
FIRST STEP
BALANCING
ADJUST
SECOND STEP
- Apply the 10 — 60 Nm torque wrench with the 3/8”
square connection 99389831 (1) to the wrench
99368503 to lock the nut (1, Figure 63) to a torque of
34 to 44 Nm.
- Adjust the clearance between all valves and all rockers.
- Extract the tool for turning the flywheel and close the
flywheel cover.
Figure 64
83505
82722
81605
82723
81606

Figure 65 Figure 66
- Position a new gasket.
- Fit the tappet cover (2) on the head.
- Insert the cover fixing screws (1) and tighten them to a
torque of 20—24Nm.
Fitting the cylinder head tappet covers Fitting the injectors
- If the side inspection covers have been removed, fit on
both sides of the tappet cover together with the gasket.
- Tighten the screws of the inspection covers to a torque
of 7—10 Nm.
82219
82256
NOTENOTE
NOTE
The cover fixing screws have different lengths:
M8x1.25x40 front screws (three per cover)
M8x1.25x25 rear screws (two per cover)
Always change the seal.
Lubricate the O-rings with vaseline before fitting.
- Clean the injector seat (1) thoroughly and fit the injector
complete with mounting bracket (2) in its seat pressing
it until it clicks and is correctly inserted.
- Screw down the M10x1.5x70mm injector fixing screw
to a torque of 32÷36 Nm.
- Fit all the electro—injectors.

Figure 67
LUBRICATION
The engine is lubricated by a gear pump driven by the
crankshaft.
There is a safety valve located on the oil filter mounting which
starts opening at 3.4 ± 0.3 bar.
Lubricating pressure with oil at 110 °C:
- max pressure up to 6.5 bar
- min pressure 4.0 bar
- Remove the covers (1) and (2) by unscrewing thescrews
(3).
- Change the filtering parts (4) and the gaskets (5).
- Carefully clean the blow—by filter body (6) and the
covers.
The oil vapours that form inside the engine during operation
are directed into a condenser (blow-by filter) where some
of them are condensed and recirculated again and some of
them are directed via two pipes to the intake.
The oil vapour condenser needs a periodical overhaul.
engine oil is a pollutant. Protect your skin suitably
against contact with engine oil.
82716

Figure 68
- Check the pump casing and the external gears. If there
are any visible signs of deterioration (cracks in the casing
or gear teeth worn too much), change the whole part.
- Overhaul by unscrewing the screws (1) and removing
the gear (2) together with the ball bearing and pin (3).
- Check the bearing and the sliding surfaces of the internal
cage of the bearing and of the pin (3) work properly.
- Then separate the pump cover (4) from the casing (5).
Unscrew the two screws (6) M8x30mm from the top of
the cover and the two screws (7) M8x80mm from the
casing side.
- Check the state of wear of the internal gears (8) and (9).
In addition, check the gear (9) fitted stably on the cover
(4) turns freely.
Always change the seals (12) and O-rings.Wear or poor rotation of the gear (9) require
changing the cover assembly (4) + (9) + (2) +(3)
supplied as spare parts already fitted.
The cover assembly also includes the bushing in
which the gear spindle (8) turns.
- Fit the gear (8) on the cover assembly (4) and check its
rotation.
- Fit the cover together with the gears on the pump casing
(5).
- Fit the suction strainer on the pump with a new seal:
M8x1.25 screws (tightening torque 22—27 Nm).
- Fit the pump together with the suction strainer to the
crankcase.
The oil pump is secured with three M10x25mm
hexagonal—head screws with a tightening torque of
38—45 Nm, tightening the M8 screws to a torque of
22—27 Nm.
The suction strainer is secured to the cap for the central
support with two M8x25mm hexagonal—head screws
with a torque of 22—27 Nm.
- Fit the oil pipe (10) securing it with the screws (11)
M8x45mm to a tightening torque of 22—27 Nm.
- Lastly, fit the oil sump with a new seal.
Tighten the M10 nuts on the stud bolts of the gearbox
to a torque of 38—45 Nm. The remaining M10x1.5x35
mm screws (24 in all) must be tightened to a torque of
38÷45 Nm.
82254
Oil pump
NOTE NOTE

Figure 69
Figure 70
Figure 71
- From the front, fit the engine oil filter support (1)
together with the temperature transmitter (2), pressure
sensor (5), the gasket (4) and the filter clog sensor (3).
- Tighten the M8x1.25 fixing screws to a torque of 22—27
Nm.
- Fit the exhaust manifolds (2) tightening the screws (1)
M10x1.5 in two phases:
A: torque 47÷53Nm
B: pre—torque 47÷53 Nm
torque 64÷70 Nm
- Assemble gear (1) with tool 99368517; tighten the fixing
nut to 350 torque (300 Nm with the screwdriver with
final take off at 350 Nm with dynamometric wrench).
- Fit the high—pressure fuel pump together with its driving
gear and seals.
- Tighten the M10x1.5 fixing screws to a torque of 49—60
Nm.
Before tightening the screws (see order in
Figure 71), lubricate them with graphitized oil.
Always fit new gaskets.
Before tightening, lubricate the screws with UTDM
oil or alternatively with engine oil.
- Fit the intake manifolds together with new gaskets on the
heads.
- Tighten the M10x1.25 screws to a torque of 38—45 Nm.
- Fit the diesel supply pipe to the high—pressure pump.
Piping M18x1.5 tighten on the coupling to a torque of
50 Nm.
- Fit the water—oil cooler after changing the two O—rings.
- Tighten the 6 M10x1.5x40 mm screws to a torque of
25—30 Nm.
Figure 72
Wash and grease the shaft of the pump before
mounting the gear.
82216
COMPLETING THE ENGINE
82258
82215
89802
NOTE
NOTE
NOTE
NOTE

Figure 73
- Fit the head water outlet pipes (1).
- Fit the seals (2), fit the elbow (3), the connecting pipes
(4) and O-rings and the thermostat casing (5).
The new head—side gaskets have already been fitted
together with the air intake manifolds.
- Tighten all the screws to a torque of 22—27 Nm.
To facilitate assembly, here we describe how to use
the water pipe fixing screws correctly.
6. M8x1.25x75 mm
7. M8x65 mm
8. M8x1.25x60 mm
9. M8x20 mm
10. M8x30 mm
103472
NOTE
NOTE

Figure 74
Figure 75
- Fit the three—way coupling (7) on the water/oil cooler
(8) with the gasket.
- Tighten the M8x40mm and M8x100 mm screws (6) to
a torque of 22—27 Nm.
- Fit the couplings (4) on the main bearings with the
gaskets, tightening the screws to a torque of 22—27 Nm.
- Fit pipes (2) on three-way fitting (7). Connect pipes (2)
and fittings (4) to the engine blocks by means of gaiters
(10). Secure the pipes with collars (1) and (9).
- Fit the turbocharger (1) on the exhaust manifold
tightening the M12x1.75 mm
nuts:Torque 85-95 Nm
Repeat the operation on the opposite side.
- Fit the air supply manifold to the air/air heat exchanger
on the bracket tightening the 4 bolts from underneath
- Fit the blow-by filter on the manifold and the inlet and
outlet pipes from the filter.
Always change the gaskets with new spare parts.
Do not reuse gaskets even if they look sound.
114242
103474
NOTE
For G-DRIVE / GRIFFON and DRAGON applications
For SRINKLER applications
Figure 76
83499
- Fit the turbo—blower (2) on the exhaust manifold
tightening the M12x1.75mm nuts in two successive
phases:
Torque 85—95 Nm
- Then fit the waste—gate valve (7) on the exhaust
manifold.
- Fit the waste—gate cooling pipes and the air pipe (6)
between turbo—blower and waste—gate.
- Fit the exhaust pipe (4) between the waste—gate valve
and the turbo—blower exhaust pipes.
- Fit the manifold (1) between the turbo—blower and the
intercooler with the clamp (4).
Always change the gaskets with new spare parts.
Do not reuse gaskets even if they look sound.
NOTE

Figure 77
- On the bench, fit the previously removed fittings onto
the compressor (1): suction (2) and compression (3)
fittings: thread M26 = 100 Nm.
Change the gasket (4) at the fitting mounted on the
compression port.
- Insert the gear (5), flat washer (6) and screw down the
nut (7), tightening to a torque of from 160 ÷ 180 Nm.
- Fit the low-pressure pump (8), inserting the universal
joint (9) and O-ring (10).
Change the gaskets (10), (11) and (12).
Should compressor have been dismounted jointly
with spacer, tighten (M12x1.75) screws securing it
to gears box at 42 ÷ 51 Nm tightening torque.
- Put compressor into its seat by tightening (M12x1.75) at
74 ÷ 90 Nm Nm torque.
- Secure bracket (13, Figure 77) to engine block.
- During assembly, check that the coupling drive (9) and
the teeth on the front of the secondary circuit cooling
pump gear show no signs of wear or cracks. Change any
damaged parts.
- Fit support bracket (13) and tighten the screws securing
the low—pressure pump support to the air compressor
to the prescribed torque: 42÷51 Nm.
For DRAGON applications
89697
NOTE
NOTE
89698
Figure 78
NOTE

- Fit the low—pressure pump (2) together with the
coupling drive (4), O—ring and spacer (3) on the back of
the gearbox: tighten the screws (1) to the prescribed
torque.
Figure 79
Figure 80
Figure 81
- Fit the cooling pump.
- If the same pump is used replace seal (3).
- If necessary, replace the pump gear (1) tightening the
bolt (2) to the recommended torque.
- During assembly, check that the coupling drive and the
teeth on the front of the secondary circuit cooling pump
gear show no signs of wear or cracks. Change any
damaged parts.
- Tighten the screws securing the low—pressure pump
support to the gearbox to the prescribed torque.
Having to tighten screw (2), it is necessary to
prevent the gear (1) from turning in an appropriate
manner without damaging the parts. Before
tightening, lubricate the screws with UTDM oil or
alternatively with engine oil. (The gear has a
left-hand locking screw).
- At the front of the gearbox, fit the secondary system
cooling circuit pump together with the gears.
- Supporting the pump place it in its seat. Tighten the
M10x1.5 nuts securing the water pump to the front gear
cover 33 ÷ 40 Nm.
- Then fit the pipe (1) securing it to the actual pump and
the hose (2) using the two bolts (1).
Whilst fitting the drive coupling, check that thefront
drive teeth on the pump gear are properly housed
inside the splining.
89792
103475
103229
NOTE
For G-DRIVE / SPRINKLER and GRIFFON applications
NOTE

Figure 82
COMMON RAIL ASSEMBLY PROCEDURE
Preparing for assembly
- This procedure allows to have the best assembling,
reducing the stress on the CR components due to
tolerances and misalignments and will avoid the risk to
have dangerous fuel leakage under pressure, during all
typical condition of the Vector engines operative duty.
- This procedure will apply during first CR assembling in
manufacturing plant as well as during maintenance and
replacement of one or more CR components
Cleaning and preparation
- Before mounting, assure that each pipe is protected with
appropriate plastic cap supplied by Bosch. Remove by
hands the protective caps just before the installation. Do
not use sharp tooling that might cause damage on the
sealing surface. All pipes have to be cleaned up and to
be particulate free, and the sealing surface have to be
without any defect.
- All sealing surfaces, nuts and threads have to be
lubricated with clean engine oil (for example: 15W40).
Assembly procedure
- The high pressure pump (HPP) and the injector’s are
mounted firmly in average position of bolt clearance,
with the defined tightening torque.
- All the pipes are fitted by only tightening the areas
connected to the HPP, the rails and the injectors
manually (J1.1 - J8.2, V1.1 - V3.2: see Figure Figure 84).
Fit the centre support plate (1) closing the fastenings for
the pipes from the HPP to the rails, from the rails to the
injectors and on the intermediate pipe checking that the
centre pipes are kept in a horizontal position and are flat.
Apply a pre-tightening torque of 20 Nm and then a
pre-tightening torque of 50 Nm to all the connectors.
Figure 83
112491
It is vital to use a special torque wrench for the
fitting procedure described here.
NOTE
- The rails are installed on their supports, previously fixed
on the cylinder heads by the related screws tightened
with proper tightening torque of 25 Nm (screws 1). The
rails have to be in horizontal position and aligned and the
fixing caps have to be positioned with the related screws
loose on the support (screws 2).
82259
- lubricate all the connectors with clean oil.

Figure 84
103480
- Tighten the connectors for the pipes from the HPP to
the rails (V1.1 and V2.1) to the interface with the HPP
to torque checking that the pipes are kept in a horizontal
position and are flat. Apply a tightening torque of 140
+ 5 Nm.
- Tighten the connectors (V1.2 and V2.2) to the interface
with the rails checking that the pipes are kept in a
horizontal position and are flat in order to ensure the
seal between the contact surfaces. Apply a tightening
torque of 130 + 5 Nm.
- Tighten the connectors for the V3 pipe to a torque of
130 + 5 Nm in total for both parts.Check the horizontal
alignment of the pipe.
- Tighten the injector/rail connecting pipes to the
interface with the common rails in the following order:
J 8.2 - J 7.2 - J 6.2 - J 5.2 - J 4.2 - J 3.2 - J2.2 - J1.2. During
this fitting procedure the flow limiters should be kept
against the tightening direction.Apply a torque of 115 +
5 Nm.
- Tighten the connectors for the injector/rail connecting
pipes to the interface with the injectors in the following
order: J 8.1 - J 7.1 - J 6.1 - J 5.1 - J 4.1 - J 3.1 - J 2.1 - J
1.1.During this fitting procedure the injectors should be
kept against the tightening direction.Apply a torque of
95 + 5Nm.
- Tighten all the bolts for the common rail supports to the
caps (bolts (B)) to the recommended torque of 25 Nm.
- Any leaks are checked when the engine is switched on.
Test procedure for checking for diesel leaks
from the Common Rail system.
The following procedure is carried out on the engine to
check that there are no diesel leaks from the Common Rail
system after repair operations.
The aim of this test is to let the rail pressure reach maximum
values with the engine running in no load idling conditions.
Equipment to be used: IST or ELTRAC tool
Order of operations:
1) Switch on the engine and let it reach idle speed.
2) Key in the DIAGNOSTICS window on the IST
3) Select DIAGNOSTIC TESTS
4) Select FUEL RAIL PRESSURE TEST
5) Key in START at the bottom
6) Key in STEP UP several time up to 150-160 Mpa with the
engine idling.
7) Check that there are no leaks from all the connectors.
If a leak is detected, switch off the engine and carry out the
procedures describe previously.
8) Return to the nominal pressure using the STEP DOWN
button.
9) When running in the engine, check the tightening
torques of all fittings at least once and adjust. The aim of this
operation is to tighten any fittings that have become loose
due to settlement. Do not unscrew any fittings but simply
tighten to the specified installation torque. After running in
the engine, tighten all the fittings to the specified torques
using a torque wrench. Check the remaining torques as
indicated in the installation procedure.

Figure 85 Figure 86
- Fit the oil pipes (1) and (2) for lubricating the turbines.
Tightening torques:
screw fixing bottom pipes draining oil from the
turbo—blower to the oil sump — M8x1.25 = 22—27 Nm.
Screw fixing pipes delivering oil to the turbo—blower —
M8x1.25 = 22—27 Nm.
- Fit the engine support.
Screw fixing rear engine support (M16x2)
1st step Torque: 95÷105 Nm
2nd step Angle: 85˚-90˚
Guard torque: 310÷420 Nm
Screw fixing front engine support (M14x2)
1st step Torque: 65÷75 Nm
2nd step Angle: 60˚-65˚
Guard torque: 190÷270 Nm
- Fit the control unit support (3) on the engine (M8x1.25
bolts to be tightened to a torque of 22-27Nm) complete
with atmospheric pressure sensor (5) and diesel filter
mounting.
- If present on the application, fit the air conditioning
compressor (17, Figure 3) and the flexible belt (16, Figure
3).
- Fit the alternator complete with mounting bracket and
tension the bolt (6) tightening the bolt (5).
- Fit the ADEM III control unit (2) on the support with the
flexible mounts (3) (M8x1.25 screws to tighten to a
torque of 22 — 27 Nm).
- Fit the engine electric cable connecting the control unit
to the various sensors and services.
Suitably secure the electric cable on the engine with the
clamps.
- Fit the oil filters and the diesel filter (if present).
- Fit the protective grilles (if present).
- Affix the plate warning the engine has no lubricating oil.
103228
103227
5
6
3
4
1
2
NOTE The filters must be tightened by hand after lightly
lubricating the seals.
Tighten for another 3/4 turn with 99368539 tool.

- that there are no water leaks from the connecting
sleeves of engine cooling circuit pipes and cab internal
heating pipes, tighten the clamping collars if required;
- the connection between the low pressure fuel pipes and
the relevant connectors;
- that there are no oil leaks between the cover and the
cylinder head, between oil sump and engine block,
between heat exchanger oil filter and the relevant
housings and between the different pipes in the
lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes (if
fitted);
Carefully check and bleed the engine cooling equipment by
repeated draining operations.
Checks and inspections
Start the engine and leave it running just above the
idling speed, wait until the coolant reaches the
temperature necessary to open the thermostat and
then check:
The following checking inspections must be carried
out after the engine assembly on the vehicle .
NOTE

SECOND PART -
ELECTRICAL EQUIPMENT

Figure 1
control module — 5. Atmospheric pressure sensor — 6. Fuel temperature sensor — 7. Electro—injectors — 8. Engine
speed/timing sensor on crankshaft — 9. Engine speed/timing sensor on camshaft — 10. Common rail fuel pressure sensor —
11. Common rail high pressure control solenoid valve, also called pulse wide modulation (PWM) or M—Promp valve —
12. Intake air temperature sensor after intercooler — 13. Intake air pressure sensor —
14. Engine oil pressure sensor — 15. Alternator
103265
LOCATION OF COMPONENTS ON THE ENGINE

Figure 2
control module — 5. Atmospheric pressure sensor — 6. Fuel temperature sensor — 7. Electro—injectors — 8. Engine
speed/timing sensor on crankshaft — 9. Engine speed/timing sensor on camshaft — 10. Common rail fuel pressure sensor —
11. Common rail high pressure control solenoid valve, also called pulse wide modulation (PWM) or M—Promp valve —
12. Intake air temperature sensor after intercooler — 13. Intake air pressure sensor — 14. Engine oil pressure sensor
Circuit diagram of engine cable
89782
14

Tecnical view
1. electrical signal - 2. Ground
Pressure sensors
The pressure sensors are used to indicate the oil pressure (reference 3, Figure 1), atmospheric pressure (reference 5, Figure 1)
and turbo outlet air pressure (reference 13, Figure 1) values to the electronic unit.
Features:
Air pressure sensor
- max pressure : 472 kPa (absolut). . . . . .
- voltage 5 ± 0.25 Vdc. . . . . . . . . . . .
- energy absorption 20 mA Max. . . .
- Tightening torque 10 ± 2 Nm. . . .
Engine oil pressure sensor
- max pressure 1135 kPa (absolut). . . . . . .
- voltage 5 ± 0,25 Vdc. . . . . . . . . . . .
Atmosferic pressure sensor
- max pressure 116 kPa (assoluta). . . . . . .
- voltage 5 ± 0,25 Vdc. . . . . . . . . . . .
Figure 3
Figure 4
Engine components
Temperature sensors
These are NTC type sensors and are used to indicate the operating temperatures of the engine coolant (reference 1, Figure 1),
engine oil (reference 2, Figure 1), fuel (reference 6, Figure 1) and exchanger outlet air (reference 12, Figure 1) to the electronic
unit
A. feed - B. ground - C. Electrical signal
89783
89784

Tecnical view
Engine speed/timing sensor on crankshaft
This is an inductive type sensor and it is positioned on the engine flywheel (reference 8, Figure 1).
It generates signals obtained by means of the magnetic flow lines that close up through the holes that are made in the flywheel.
The electronic unit uses this signal in order to detect different engine r.p.m. states.
Figure 5
Figure 6
Engine speed/timing sensor on camshaft
This is an inductive type sensor and is positioned on the distribution shaft (reference 9, Figure 1).
It generates signals that are obtained by means of the magnetic flow lines that close up through the holes on the gears that are
keyed on the distribution shaft.. The signal that is generated and sent to the electronic unit that can calculate the injection moment.
The sensor must be assembled by tightening it to torque 28 ± 7 Nm.
Tecnical view

Figure 7
Engine oil level sensor
This sensor is used to indicate that the sump oil level is too low.
Features:
- max pressure : 5 - 28 Vdc. . . . . .
- resistance 130 mA a 28 Vdc Max. . . . . . . . . .
- work temperature -40˚C / + 125˚C. . .
A. Electrical contact in open position — B. Electrical contact in close position - low level in the oil sump

Figure 8
A
Figure 9
A: Ground wire
XJ1: connector on utilities
XJ2: connector on engine side.
It is fitted directly on the engine using flexible plugs that dampen the vibration transmitted by the engine.
Connector on engine side.
ADEM III engine control unit
81391
89788

Pinout of engine side connector XJ2
Pin Function Cable code
1 Potential +5V supplying atmospheric pressure sensor 0905
2 Potential +5V supplying rail fuel pressure sensor 1004
3 Reference potential 0V for the rail fuel pressure sensor 1005
4 Not used —
5 Not used —
6 Not used —
7 Not used —
8 Not used —
9 Not used —
10 Not used —
11 Not used —
12 Not used —
13 Not used —
14 Indicator signal of atmospheric pressure 0907
15 Not used —
16 Not used —
17 Not used —
18 Reference potential 0V for the atmospheric pressure sensor 0906
19 Not used —
20 Cylinder 2 injector (pin 2) 0915
22 Not used —
23 Not used —
24 Indicator signal of rail fuel pressure 1006
25 Indicator signal of engine oil pressure 0910
26 Not used —
27 Not used —
30 Not used —
31 Not used —
32 Indicator signal of engine oil temperature 0911
33 Indicator signal of engine coolant temperature 1002
34 Indicator signal of fuel temperature 1003
35 Indicator signal of turbo—blower air temperature 0912
36 Common to pins 1 of cylinder 1 and 2 injectors 0913
40 Indicator signal of turbine air outlet pressure 1001
41 Potential +5V supplying turbine air outlet and engine oil pressure sensors 0908
42 Reference potential 0V for the sensors on the engine 0909
43 Not used —
48 Positive of the engine speed sensor 1009
49 Negative of the engine speed sensor 1010
50 Not used —

Pin Function Cable code
51 Not used —
52 Not used —
53 Not used —
54 Not used —
55 Not used —
56 Not used —
57 Not used —
58 Positive of the timing system speed sensor 1007
59 Negative of the timing system speed sensor 1008
60 Not used —
61 To the rail pressure control valve (pin 1) 1014
62 To the rail pressure control valve (pin 2) 1015
63 Not used —
64 Not used —
65 Not used —
66 Not used —
67 Not used —
68 Not used —
69 Not used —
70 Not used —

Electronic control of the engine control unit
ENGINE PRE—HEATING ELEMENT CONTROL
Pre/post—heating is turned on even if just one of the water, air or fuel temperature sensors signals a temperature ≤ 5 °C.
PHASE RECOGNITION
The cylinder in which fuel must be injected is identified upon starting via the signals of the sensor on the camshaft and/or on the
crankshaft.
INJECTION CONTROL
The control unit, according to the information from the sensors, governs the pressure regulator and varies the injection modes.
INJECTION PRESSURE CLOSED CYCLE CONTROL
Depending on the engine load, determined by processing the signals from the various sensors, the control unit governs the
regulator to have the optimum pressure at all times.
PILOT AND MAIN INJECTION ADVANCE CONTROL
Depending on the signals from the various sensors, the control unit determines the optimal injection point according to internal
mapping.
PEAK SPEED LIMITATION
Appropriate engine speed thresholds are stored in the control unit according to the application. When the engine speed exceeds
these thresholds the control unit actuates suitable reductions in power by controlling the electro—injector energising time.
SMOKE CONTROL
With load requirements, depending on the signals received from both the engine speed sensor, air temperature and the pressure
sensors the control unit adjusts the air fuel ratio in order to avoid black smoke.

THIRD PART -
DIAGNOSTICS

TROUBLESHOOTING
General information
This Troubleshooting guide has been written for first level
service engineers.
The initial part of this Section describes the procedure for
connection and diagnosis by means of equipment 99368550.
By jointly using the troubleshooting ”clues” and the
summarizing tables with the event and error codes, you will
get an exhaustive picture of the situation as well as the specific
instructions to remedy the main faults.
The connection of the two tools is different so that
they cannot be mixed up. The tags of tool
99368550 tool have DIAGNOSE written on them
and the ones for of tool 99368543 have LOCAL
CONTROL written on them.
Troubleshooting carried out with the 99368550 equipment
can be performed by using simulation tool ILC 99368543 with
which it is possible to pilot the power pack that is to be
monitored locally.
The description of the ILC simulator tool follow the diagnosis
procedure.
NOTE

Connection procedures
- Unscrew plug (1) on switch box diagnosis connector.
- Connect the 25-pole connection of cable (2) on switch
box diagnosis connector.
- Connect signal transcoding adapter (3) (Compact
Communication Adapter) to the other side of cable (2).
- Connect cable (4) to the opposite side of part (3).
- Connect the USB connection of PC (5) to the other end
of cable (4).
Figure 1
Diagnosis interface kit for Vector motors
1. Cable connecting part 2 to diagnosis connector on
switch box - 2. Signal transcoding adapter (Compact
Communication Adapter) - 3. USB cable for PC -
4. Installation CD
The CD must be installed on a personal computer (not
included in the kit) having following minimum characteristics:
- Processor Intel Centrino I.IULV
- 512 MB Ram
- 40 GByte HD
- Internal modem 56 kbps V90
- Card LAN 100 BASE-TX/10-BASE-T
- 88 character keyboard
- Standard PC external interfaces
- Operating system Windows 2000 Professional.
Program installation must be performed following the
procedures that are contained on the CD in the kit.
Figure 2
LOCAL CONTROL
- ILC 99368543
connection
DIAGNOSE -
Troubleshooting
tool n. 99368550
connection
TROUBLESHOOTING WITH
TOOL 99368550
89757
89756
* The diagnostic connection (1) and the connector (2) vary depending on the application.
*
*

Diagnosis procedures for Vector 8V engines
SW IVECO MOTORS user interface for VECTOR diagnosis.
The graphic interface of the Vector diagnosis software has
been designed to ensure easier utilization of the equipment
available to the user, as well as make the available functions
visible, and make the diagnosis procedures understandableand
adjustable to many different requirements.
The graphic interface is divided into three sections:
- a blue section, referred to as ”Title Area”, providing the
information for the selected product and specifying the
point where you are within the exploration route of the
diagnosis process.
- A left-hand section, referred to as ”Button Area”, which
allows you to select the functions.
- A central area, referred to as ”Operative Area”, which
makes it possible to display the available lists and functions,
thus allowing you to access the various operations.
Main screen with function selecting options
Description of buttons
STOP
- It allows you to exit the VECTOR application at any
time.
TOOLS
- This button is selected to access the ”Select
language” function.
- If you do not wish to use the function shown, select
the ”Tools” button again.
NAVIGATION
- These buttons allow you to shift between different
environments.
SCROLL
- It allows you to scroll long lists which cannot be
displayed by means of one single screen.
ON-OFF
- When ON is selected, the parameters are
continuously updated.
- When OFF is selected, the parameters will be
”frozen” upon selecting.
SAVE ON FILE
- It allows you to save the parameter registration data
on a file.
PRINT

Diagnosis Environment
ECM electronic control unit identification code
The diagnosis instrument consults a storage area of the
electronic control unit, where the identification data are listed.
Then it displays, if available, the identification code, the control
unit and software versions, the date of manufacture and the
ECU configuration data.
In the event that communication with the control unit is
interrupted, you can print the ”Identification code” screen
(where enabled) by selecting the PRINT button.
Consulting the ”Identification code” card is essential in the
event that information is requested from the Service
Department.
Control unit identification code reading
Fault code reading
Faults (memorized by the control unit) are automatically
identified by the diagnosis instrument after actuating
communication with the electronic control unit.
This screen lists the faults or malfunctioning relative to the
components directly connected and managed by the
electronic control unit.
Reading the FAULT CODES (available in the control unit)
Stored fault code reading
Some of the stored and listed faults might be intermittent.
More precisely, some of them might, when being diagnosed,
not be present, yet previously memorized by the control unit
itself (intermittent faults).
This screen also allows you to clear the faults found in the
memory after the repair work has been carried out.
Reading the FAULT CODES (present and intermittent)
Event code reading
This screen lists anomalous faults or malfunctioning of
components not closely related to the engine management
electronic control unit, but which could in any case affect
correct operation of the engine.
Reading the EVENT CODES (out-of-range sensors)
The screen is saved automatically in the ELTRAC
folder. It is advisable to rename the identification file
because it will be overwritten if there is a
connection to the diagnostic socket of another
power unit.
Note — Save key use: pressing the save key the file
of the screen is saved in the ELTRAC folder and a
name will be automatically given to it. The name of
the file includes the hours, minutes and seconds of
when it was saved. The name is univocal and
cannot be overwritten.
NOTE
NOTE

Fault parameter registration
The ”Stored SnapShot” screen provides a picture of the
conditions at the time when a fault or event occurred. The
diagnosis software makes it possible to store up to 50 faults
or events. This screen also allows you to perform clearing.
Reading and recording fault parameters
Fault parameter reading - Environment conditions
By selecting a fault or event from the previous screen, the
related environment conditions are provided.
Displaying the related environment conditions
Work parameter reading
Work parameters include all the parameters available in the
control unit.
It is important that work parameters are read when the system
is active (engine running).
The ON/OFF button allows you to have, according to the
choice made, the parameters updated (button set to ON) or
frozen upon selection (button set to OFF).
Work parameter reading
Diagnostic Test
The ”Utilities” screen allows you display the Engine Test
options available.
The diagnosis software provides for the following tests:
Displaying the Engine Test options available
Note — In order to ”freeze” the parameters
displays, position the ON/OFF pushbutton on OFF.
Then save by pressing the specific pushbutton.
NOTE

- Electric test of injector solenoid valves with engine OFF.
- Injector efficiency test with engine started (cut-out test).
- High pressure system efficiency test with engine started
(rail pressure step test).
The initial conditions are:
- Engine on idle
- Initial pressure in kPa
Press START; three other pushbuttons will be displayed:
- STOP
- STEP UP
- STEP DOWN
Press on STEP UP making the rail operation pressure rise up
to 160.000 kPa.
Let the engine run in these conditions for 5 minutes and see
if there is any leakage from the rail and from the pipes.
Then press STEP DOWN in order to bring the pressure back
to the initial level.
Press STOP to finish the test.
During the injector operation inspection, the
VARIATION OF THE FUEL DELIVERY is to be
observed while a cylinder is excluded. (the value
must increase). If the value remains the same the
injector will be locked.
NOTE

ENGINE PARAMETER READING
Parameter Units of measurement
Engine speed rpm
Desired Engine speed rpm
Throttle Position %
Boost pressure kPa
Engine Oil Pressure kPa
Engine Coolant Temperature Deg C
Fuel Position
Rated Fuel Limit
FRC Fuel Limit
Atmospheric Pressure kPa
Fuel Temperature Deg C
Engine Load Factor %
Diagnostic Clock hours
Engine Oil Pressure (abs) kPa
Turbo Outlet Pressure (abs) kPa
Battery Voltage Volt
Hydraulic Oil Temperature Deg C
Injection Actuation Pressure kPa
Fuel Consumption Rate 1/h
Engine Oil Temperature Deg C
Inlet Air Temperature Deg C
Fan Pump Pressure kPa
Injector Actuation Current %
Number of Engine Cylinders
Active Diagnostic Codes Present
Delivered Fuel Volume mm3
Desired Fuel Rail Pressure (absolute) kPa
Fuel Rail Pressure (absolute) kPa
Fuel Rail Pressure Control Valve Sol Current %

READING PARAMETER FOR SAVE CODE
Parameter Units of measurement
Desired Engine speed rpm
Boost pressure kPa
Engine Oil Pressure kPa
Engine Coolant Temperature Deg C
Fuel Position
Atmospheric Pressure kPa
Fuel Temperature Deg C
Engine Oil Temperature Deg C
Inlet Air Temperature Deg C
Desired Fuel Rail Pressure (absolute) kPa
Fuel Rail Pressure (absolute) kPa

EVENTS TABLE
Low Engine Oil temperature Warning 492-1
Low Fuel Rail Pressure - Pressure Derate 398-2
Low Fuel Rail Pressure - Pressure Shutdown 398-3
Low Fuel Rail Pressure - Pressure Warning 398-1
Low Oil Level 171-1
Very Low Oil Level 171-2
Water In Fuel Derate 2093-2
Water In Fuel Shutdown 2093-3
Water In Fuel Warning 2093-1
Engine Oil Filter Restriction Derate 1-2
Engine Oil Filter Restriction Shutdown 2-3
Engine Oil Filter Restriction Warning 99-1
Engine Overspeed Derate 3-2
Engine Overspeed Shutdown 4-3
Engine Overspeed Warning 190-1
Fuel Filter Restriction Derate 5-1
Fuel Filter Restriction Shutdown 6-3
Fuel Filter Restriction Warning 95-1
Fuel Repair Pressure Leak Derate 499-2
Fuel Repair Pressure Leak Shutdown 499-3
Fuel Repair Pressure Leak Warning 499-1
High Boost Pressure Derate 162-2
High Boost Pressure Shutdown 162-3
High Boost Pressure Warning 162-1
High Engine Coolant Temperature Derate 15-2
High Engine Coolant Temperature Shutdown 16-3
High Engine Coolant Temperature Warning 17-1
High Engine Oil Temperature Derate 18-2
High Engine Oil Temperature Shutdown 19-3
High Engine Oil Temperature Warning 20-1

EVENTS TABLE
High Fuel Rail Pressure - Pressure Derate 396-2
High Fuel Rail Pressure - Pressure Shutdown 396-3
High Fuel Rail Pressure - Pressure Warning 396-1
High Fuel Temperature Derate 54-2
High Fuel Temperature Shutdown 55-3
High Fuel Temperature Warning 56-1
High Hydraulic Oil Temperature Derate 23-2
High Hydraulic Oil Temperature Shutdown 24-3
High Hydraulic Oil Temperature Warning 600-1
High Inlet Air Temperature Derate 25-2
High Inlet Air Temperature Shutdown 26-3
High Inlet Air Temperature Warning 27-1
Low Boost Pressure Derate 93-2
Low Boost Pressure Shutdown 93-3
Low Boost Pressure Warning 93-1
Low Coolant Level Derate 57-2
Low Coolant Level Shutdown 58-3
Low Coolant Level Warning 59-1
Low Engine Oil Pressure Derate 39-2
Low Engine Oil Pressure Shutdown 40-3
Low Engine Oil Pressure Warning 100-1
Low Engine Oil Temperature Derate 492-2
Low Engine Oil Temperature Shutdown 492-3

FAULTS TABLE
5 Volt Supply Above Normal 262-3
5 Volt Supply Below Normal 262-4
8 Volt Supply Above Normal 41-3
8 Volt Supply Below Normal 41-4
Alternator Disable Relay Open Circuit 1002-5
Alternator Disable Relay Short Circuit 1002-6
Alternator Pump Pressure Sensor Open / Short To Battery + 1003-3
Atmospheric Pressure Sensor Open / Short To Battery + 274-3
Atmospheric Pressure Sensor Open - Short to Ground 274-4
Battery Voltage Above Normal 168-3
Battery Voltage Below Normal 168-4
Diagnostic Lamp Open Circuit 1266-5
Diagnostic Lamp Short Circuit 1266-6
Engine Coolant Temperature Sensor Open / Short To Battery + 110-3
Engine Coolant Temperature Sensor Short to Ground 110-4
Engine Coolant Fan Pump Pressure Sensor Short to Ground 290-4
Engine Oil Pressure Sensor Open / Short To Battery + 100-3
Engine Oil Pressure Sensor Short to Ground 100-4
Engine Oil Refill Relay Open Circuit 1000-5
Engine Oil Refill Relay Short Circuit 1000-6
Engine Oil Temperature Sensor Open / Short To Battery + 175-3
Engine Oil Temperature Sensor Short to Ground 175-4
Engine Starter Relay Open Circuit 444-5
Engine Starter Relay Short Circuit 444-6
Fuel Filter Heater Relay Open Circuit 1001-5
Fuel Filter Heater Relay Short Circuit 1001-6
Fuel Rail Pressure Control Valve # 1 Machanical System 1779-7
Fuel Rail Pressure Control Valve # 1 Open Circuit 1779-5
Fuel Rail Pressure Control Valve # 1 Short Circuit 1779-6
Fuel Rail Pressure Sensor # 1 Open / Short To Battery + 1797-3

FAULTS TABLE
Fuel Rail Pressure Sensor # 1 Short To Ground 1797-4
Fuel Temperature Sensor Open / Short To Battery + 174-3
Fuel Temperature Sensor Short To Ground 174-4
Hydraulic Oil Temperature Sensor Open / Short To Battery + 600-3
Hydraulic Oil Temperature Sensor Short To Ground 600-4
Injector Cylinder 1 Open Circuit 1-5
Injector Cylinder 1 Short Circuit 1-6
Inlet Air Heater Relay Open Circuit 617-5
Inlet Air Heater Relay Short Circuit 617-6
Intake Air Temperature Sensor #1 Open / Short to Battery + 172-3
Intake Air Temperature Sensor #1 Short To Ground 172-4
J1939 Data Link CCVS Timeout 247-28
J1939 Data Link ENG CNTRL Timeout 247-27
J1939 Data Link ETC2 Timeout 247-29
J1939 Data Link TSC1 Timeout 247-30
Loss of Primary Engine Speed Signal 190-2

FAULTS TABLE
Loss of Secondary Engine Speed Signal 342-2
Engine flywheel speed irregular signal 605-8
Personality Module Interlock Mismatch 253-2
Primary Engine Speed Signal Abnormal 190-8
Remote Operator’s Lamp Open Circuit 823-5
Remote Operator’s Lamp Short Circuit 823-6
Remote Throttle Position Sensor 1923-8
Secondary Engine Speed Signal abnormal 342-8
Secondary Engine Speed Signal Machanical Failure 342-11
TGC Relay Open Circuit 477-5
TGC Relay Short Circuit 477-6
Turbo Outlet Pressure Sensor # 1 Open / Short To Battery + 273-3
Turbo Outlet Pressure Sensor # 1 Short To Ground 273-4
Warning Lamp Open Circuit 324-5
Warning Lamp Short Circuit 324-6

ILC SIMULATOR 99368543 TOOL
1. Switch - 2. Engine oil fill up pushbutton (prearranged
only for a few Vector versions) - 3. Connection to
electronic control unit - 4. Potentiometer for remote
intervention on engine rpm.
The ILC simulation tool is used to start the power unit
remotely and in order to be able to monitor operation via the
diagnostic equipment.
ILC simulator tool use:
- Connect connector (3) to the electrical shunt box on
which the unit is inserted.
- Press switch (1) (+15).
- Press START (5).
- If required use potentiometer (4) in order to increase
engine rpm.
- Pushbutton (2) used to fill up the sump with oil is not used
in this Vector version.
Figure 3
The connection (3) varies depending on the
application.
NOTE

Symptom
Visible
trouble
PossiblecauseRepairNotes
Attributabletoelectricalmalfunctioning:
Startingmotorcablesconnected
improperlyornotconnectedatall
Connectelectricalcablesproperly
Startermotordefective.Replacestartermotor.
(Changingthemotormustbethelastactivity
todoifalltheprecedingcheckshaveproved
negative).
Therelayforstartermotorshortedor
circuitopen.
Checkcableintegritybeforerequestingrelay
replacement
Inthiscasethediagnosisisavailableinthe
unit
Unitdiagnosisinhibitedatstartup
Checkdiagnosiscodespresentinorderto
verifythecause.
Theenginewillnot
start.
Nosignofstarting.
TroubleintheADEMIIIelectroniccontrol
unit.
(Shortcircuit)
Checkunitcablingintegritybeforereplacing
it
Noenableddiagnosisisavailable(theunitis
damaged)
Crankshaftsensor:nosignalorsignalnot
plausible.
Checkthesensoriscleanandcorrectly
secured.
Checkthephonicwheeliscleanandintegral.
Checktheintegrityofthesensor(R~920
Ω).
Ifthesensorisintegral,checkthewiring
betweenthesensorconnector(wiringside)
pin1andtheXJ2EDCconnectorpin49,
betweenthesensorconnector(wiringside)
pin2andtheXJ2EDCconnectorpin48.
Theenginefailstostartbecauseafterafew
turnsthecontrolunitturnsoffthestarter
motor.
Thischeckcannotbemadewiththemotor
fitted:itisnecessarytoremovetheflywheel
housing.
Totalabsenceof
pressureintherail
Pressuresensordamaged
Checkthetroublelevelofsensorandwiring
andchangethedefectivecomponents.

Symptom
Visible
trouble
Attributabletomalfunctioninginthefuelsupply:
Indicatorson-NoNofuelinthetankordefectascribableto
Fillupthetankandcheckwhythereisnofuel.
Chktididht
Inordertoascribeorexcludelevelsensor,
suctiondeviceorfuellevelindicatordefectIndicatorsonNo
startupsign
Nofuelinthetankordefectascribableto
asuctiondefectChecksuctiondeviceandremovewhatever
causedclogging.
suctiondeviceorfuellevelindicatordefect
checkfuellevelinthetankbyrelevantlevel
indicator.
IndicatorsonExcessivewaterintheprefilter
Aftercheckingisthereisanycondensate
exhaustasdescribedontheordinary
maintenancemanualorduringsensor
inspection.
Thereforefirstcheckthesensorconnection
andreplacethesensoriftroubleisduetoit.
Theenginewillnot
start.
IndicatorsonFiltersclogged
Aftercheckingtheconditionsofcartridge
cloggingreplacethemorcheckthesensor.
Afterwardschecktheconnectionandifthe
troubleisduetothesensorreplaceit.
Fuelleakingfrom
thepipes.
RuptureofthesupplycircuitpipesCheckandreplacethedamagedpart.
Totalabsenceof
pressureintherail
Airinthefuelcircuit
Checkthefuelsupplycircuitonlowpressure
side.
Checkthefuelsupplycircuitonhighpressure
side.
Checkthatthereisnoairintheprefiltersand
inthefinefilters.
Checkthatthereisnoairintherailandinthe
highpressurepumpbleed.
Ifthetroublepersistswithsuitablepressure
gaugecheckthehighandlowpressurepump
inletandoutletpressures.
Flowregulatingvalve(M-promp)locked
closed.
ReplaceM-promp

Symptom
Visible
trouble
Attributabletoelectricmalfunctioningorinefficientsensors:
StartupdifficultinMpropvalvelockedopen
Ifdiagnosisispresentintheunitchecksensor
andcablingintegrityIfthechecksturnouttoStartupdifficultin
everycase
M-propvalvelockedopenandcablingintegrity.Ifthechecksturnoutto
benegativereplacetheM-prompvalve
a)Heateralways
on.Thebatteryruns
down.
Defectiveremotecontrolforduelfilter
heater.
Checkvehiclecable.Fuelheatsuptoomuch
Sttidiffilt
b)Heaternever
turnson.Possible
filtercloggingdueto
fuelparaffiningwith
verylowoutside
temperatures(<
—15°C).
Remotecontrolforthefuelfilterheateris
defective.
Checkvehiclecableand/orreplacethe
filter.Thecloggedfilterindicatorturnson.
Startingdifficult.a)The
pre/post—heating
elementsarenot
powered,cold
startingmaybe
difficltand
gy
difficultand
smokinesson
starting.
b)The
pre/post—heating
elementsarealways
Theairheatercontrolrelaysassembledon
thevehiclearefaulty.
Checkthattheconnectionsofthetwo
remotecontrolsarenotcutoff.
Checkthatthewiringoftheenginecableand
theresistancesforairheatingarenotcutoff.
Resistanceenablingand/orlowbattery
chargeindications.
elementsarealways
powered:early
deteriorationofthe
heatingelements,
thebatteriesquickly
rundown.

Symptom
Visible
trouble
Attributabletomechanicalmalfunctioning:
Nostartingsign
Lowpressurepumpoperatingdefect
Checkthedegreeofthetroubleandreplace
thedamageorinefficientpartscheckingwith
apressuregaugethatthepressuresexceed
4.5bar
HighpressurepumpdamagedChangethehigh—pressurepump
NovisiblesignInefficienthighpressionpump
Aftercheckingandexcludinganyother
possibilityreplacethepump
Startingdifficult.
Startuprequiresat
least20seconds,
largeamountof
whilesmokefrom
exhaust,fuelsmell.
Injectorjammedopen(irreversibly).
Withoutanydiagnosisinstrument,the
injectorthatdoesnotworkcanbefound
becausetherelevanthighpressurepipesare
notheated
CAUTIONhotenginepartsmaycause
severeinjuries
Normallywiththesesymptomsitisnatural
toabandontheattemptofstartingthe
engine.Becauseinsistingtheenginestarts
withonecylinderlessandslowlythesmoke
diminishesanddisappears
exhaust,fuelsmell.
Checkthattherelevantengine-injector
cablecylindernumbermatch
Checkcablepositioningandifrequired
connecttheenginecableproperly
Difficultstartupand
poorperformance
inallconditions
Inefficientloworhighpressurepump
Aftercheckingandexcludinganyother
possibilityandcheckingrailpressuretrend,
replacethehighorlowpressurepump
accordingtowhichcomponentisdamaged
Difficultstartup,
poorperformances
andengineruns
withonecylinder
missing
Injectorwithshutterorsolenoidcore
(mechanicalpart)lockedopen.
Withoutanydiagnosisinstrument,the
injectorthatdoesnotworkcanbefoundby
feelingifthereisnopulsationonthehigh
pressurepiping
Withslightblow-bythatjeopardisesthe
mechanicaloperationoftheinjectorbut
doesnotenabletheflowlimiter

Symptom
Visible
trouble
Attributabletomalfunctioninginthefuelsupply:
InsufficientfuellevelduringoperationCheckfuellevel
Thelackoffuelcausestroubletonormal
systemoperationmostlywhenthereisa
remarkablerequestoffuel.
Scarceloading
Fuelsystemcloggedbeforetheprefilter
Checkiftheprefilterprimingpumpworks
properly.Iftheknobofthepumpremains
aspirateddownwardsbythedepression,
disassembleandcheckprefilterintegrity.If
thetroublepersistshavethemanufacturer
checkthesystembetweenthetankandthe
prefilter.
Checkaccuratelyandcleanfuelsystem
Scarceloading
request
performances.
Possiblesmokeand
rocking
Fuelleaksfromfittingsorpipesafterthe
lowpressurepump.
Checktheconditionsofthepipesand
relevantseals.
Abnormal
performance
rocking
Dieselfuelfilterclogged
Checkthepresenceoferrors(detectable
data)withthediagnosisinstrument,then
replacethefilters
Airblow-bybeforethelowpressurepump
Checktheconditionsofthepipesand
relevantsealsbetweentheprefilterandthe
lowpressurepump.Checkthatthebleed
screwsonthefilteraretightened.
Withfullload
performancedecay
occurs
Oneormoreinjectorsblocked.
Theinjectorthatdoesnotworkcanbe
foundevenwithoutdiagnosisinstruments
evenifitiscompletelyclosedbecausethe
relevanthighpressurepipeswouldbecold.
CAUTION:hotenginepartsmaycause
severeinjuries.
occurs.
Airfilterscloggedasindicatedbythe
sensors.
Requestcleaning/replacementofthefilters
andcleantheintakeductsbeforethefilters

Symptom
Visible
trouble
Attributabletoelectricalmalfunctioning.
Enginedoesnot
accelerate
PWMsignalnotplausibleormalfunctionof
theacceleratorpotentiometer.
Checkactivediagnosisandanycabling
control.Replace,ifrequired
Therailpressuredoesnotcorrespondto
theonewanted
Checkactivediagnosisandanyadjustable
flowcontrolvalvereplacement.
Ifreplacementdoesnotresolvethetrouble,
withamultimetercheckthatcablingworks
properly
Powerreduction
Railpressuresensordoesnotwork
properly
Checkactivediagnosisandanysensor
replacement
properly
Abnormal
performanceThepressureregulatordoesnotwork
properly
Checkactivediagnosis,checkthatthe
connectorisproperlyconnectedtothe
pressureregulatorandanysensor
replacement
properly
Theengine
suddenlystops
(withoutprevious
Thefuelfilterisclogged
Checkdiagnosisandthenfuelfilter
replacement
Checkwhycloggingoccurs
(p
hesitations)and
doesnotrestart
Ruptureormalfunctionoftherailpressure
sensororoftheoverpressurevalve
Checkactivediagnosisandanysensor
replacement
properly
sensororoftheoverpressurevalve
Checkand/orreplacetheoverpressurevalve
Coolanthigh
temperature
detectedbythe
enginesensor
None
InsufficientenginewaterlevelRequesttanklevelreset

FOURTH PART -
PLANNED MAINTENANCE

VECTOR 8 DRAGON FVAE2884A*B200 MAINTENANCE PLAN
Hourly intervals
h
Time intervals
First level service 500 1 year
Second level service 2500 5 years
General overhaul 5000 10 years
Engine replacement 25000 25 years
DAILY CHECKS
Check fumes
Check for faults during start-up
Check for clogged air/oil/diesel filter warning light activation
Check for abnormal noises
WEEKLY CHECKS
Check oil level manually - top up if necessary
Check coolant level - top up if necessary
Check for fluid leaks
Inspect the engine for lost or missing bolts/damaged parts
Inspect belt wear
Remove any dirt built up on the engine (leaves, dust, etc)
Take note of oil/diesel consumption per service hours/km and report and unexplained increases.
Check coolant overheating or excessive heating time
FIRST LEVEL MAINTENANCE
Carry out every 500 hours or at least once per year
Change oil filters
Change fuel filters
Change fuel prefilter
Change engine oil
Adjust valve clearance
Change alternator belt
Change blow-by filter
SECOND LEVEL MAINTENANCE
Carry out every 2500 hours or at least once every 5 years
Operations from the previous level
Change water pump
Change injectors
Change starter motor
Change alternator

GENERAL OVERHAUL
In addition to the operations at the previous level, change the following:
Cylinder liners
Cylinder heads
Damper
Pistons
Camshaft
High pressure fuel pump
Low pressure fuel pump
Wiring
Turbochargers
Turbocharger oil delivery/return pipes
Starter motor
Seals and gaskets
Oil pump
Oil pressure regulation valve
Gears
Oil exchanger
Oil level sensor
Oiljet pressure regulation valves
Air/oil/water heaters
Taper roller bearings on front casing
Crankshaft and camshaft bearings
Rockers and mounts
Roller tappets
Rocker shafts
Connecting rods
ENGINE REPLACEMENT

VECTOR 8 GENSET FVAE2885X*A100 MAINTENANCE PLAN
PRIME POWER
Prime Power is the maximum power available at variable loads for an unlimited number of hours. The average power available
during a 24 hour operating period should not exceed 80% of the prime power between the recommended servicing intervals in
standard environmental conditions.
An overload of 10% for 1 hour for every 12 hours of operation.
STAND-BY POWER
This is the maximum power available for a period of 500 hours/year with an average load factor of 90% of the stand-by power.
No type of overload is permitted for this usage.
CONTINUOUS POWER
Contact the Iveco Motors sales organization.
Continuous / Prime Stand-By
Periodic Checks 100 h 1 month
Hourly intervals
h
Time intervals
Hourly intervals
h
Time intervals
First level service 1000 1 year 500 1 year
Second level service 5000 2 years 1000 2 years
General overhaul 25000 10 years 2000 10 years
For special applications (heavy operating conditions, Tambient>40°C) the following reduction in these intervals is required:
Periodic checks 0%
First level service 0%
Second level service - 40%
General overhaul - 40%
LIST OF OPERATIONS
PERIODIC CHECKS
Check oil level/top up (Urania Turbo LD)
Check coolant level/top up
Check whether air/oil/diesel filter blocked warning lights are on (if wired)
Check water in diesel prefilter warning light

FIRST LEVEL SERVICE
Oil filter replacement
Fuel filter replacement1)
Fuel pre-filter replacement1)
Blow-by filter replacement
Engine oil change
Check density and pH of coolant
Valve clearance adjustment1)
Check on cooling assembly cleanliness
Replace supercharging hoses
1) only at the end of the service interval expressed in hours of operation
SECOND LEVEL SERVICE
Alternator drive belt replacement
Water pump replacement
Injector replacement
Coolant replacement
GENERAL OVERHAUL
Oil Jet pressure relief valves adjustment
Clean oil heat exchanger
Gear inspection
Oil pressure relief valve replacements
Valve control rods replacement
Connecting rod replacement
Oil pump replacement
Gasket replacement
Starter motor replacement
Oil return hoses replacement
Oil intake hoses replacement
Turbine replacement
Engine lead assembly replacement
Low pressure pump replacement
High pressure pump replacement
Conical roller bearing replacement
Camshaft replacement (including gear)
Rocker arms and supports replacement
Bearing kit replacement
Piston assembly replacement
Cylinder liner/bore replacement
Cylinder head replacement
Additional earth replacement
Tappet roller replacement
Torsion damper replacement
Common rail replacement
Alternator replacement
Overhaul thermostat
General engine overhaul

DESCRIPTION OF PREVENTIVE AND ROUTINE MAINTENANCE WORK
Philosophy of Preventive and Routine Maintenance Work
To make sure the working conditions are always perfect, the following pages specify the controls, checks and adjustments that
must be carried out on the various parts of the engine at the scheduled times.
Regular maintenance is the best guarantee for safe operation and keeping running costs at optimal levels.
These operations are to be carried out at the set mileages.
User recommendations
The frequency of engine lubrication is in relation to a percentage of sulphur in the diesel of less than 0.5%.
!
If using diesel with a percentage of sulphur higher than 0.5%, the mileage must be halved.

!
Handle all parts extremely carefully.
Never get your hands or fingers between pieces.
Wear the required safety clothing such as goggles,
gloves, safety shoes and helmet.
Every 25,000 km check the level of oil in the sump with the
dipstick.
The level must be between the max and min marks on the
dipstick.
If necessary, top up with oil of the same type contained in the
sump via the filler (Urania Turbo type of oil)
When filling, it is recommended to take out the
dipstick to help the oil flow into the sump.
!
Before touching the filters, make sure the engine
temperature is not such as to cause burns.
Engine lubricating oil is harmful: avoid contact with
skin and eyes. In the event of contact, wash with
plenty of running water.
To change the engine oil filters, proceed as illustrated here.
Before removing the filters, place a tray of
sufficient capacity in a suitable position: each filter
contains approximately 1 kg of engine oil.
Figure 1
To remove the engine oil filters (2) use tool 99368538 (1).
NOTE
CHECKING/REFILLING ENGINE OIL
FILTERS
CHANGING ENGINE OIL FILTERS
83512
NOTE

Replace the filters with new parts, lubricate the seals slightly
with engine oil, hand screw and tighten for another 3/4 turn
(tighten whit tool 99368539).
environment. Potentially hazardous waste used on
IVECO vehicles includes lubricants, fuels, coolants,
filters and batteries.
them.
in water courses.
Use only genuine products, capable of extending
the efficiency and life of the engine.
After fitting the filters, check the sump oil level and turn the
engine for a little while.
Stop the engine, wait for roughly ten minutes and check the
oil level again.
Top up as necessary.
Figure 2
NOTE
103184

- If not done beforehand, change the oil filters.
- Start up the engine, checking there is no leakage or
seepage.
The engine lubricating oil must be changed every 100000 km
according to the directions illustrated here.
Before draining off the oil, place a tray of sufficient
capacity under the oil sump in correspondence
with the drain plug. Quantity of oil contained in
sump approximately 40 litres.
- Unscrew the plug on the filler and extract the dipstick.
- Unscrew the oil drain plug and insert the drain tool
99368537.
- Drain the oil from the sump.
- Extract the drain tool 99368537 and screw on the plug.
- Add clean oil, checking the level from time to time by
inserting the dipstick. Quantity of oil approximately 40
litres.
- Put the plug on the filler.
them.
in water courses.
!
Handle all parts extremely carefully. Never get your
hands or fingers between pieces. Wear the required
safety clothing such as goggles, gloves, safety shoes
and helmet.
Before touching the sump plug, check that the
temperature of the oil in the engine is not such as
to cause burns.
Engine lubricating oil is harmful: avoid contact with
skin and eyes. In the event of contact, wash with
plenty of running water.
CHANGING THE ENGINE OIL
NOTE

Figure 3
Figure 4
Figure 5
- Remove the connector (3) for indicating water in the
fuel filter by acting on the locking piston (4).
- Turn the screw (1) and separate the connecting head (2)
from the filter casing (3).
- If the condensate drain operation is carried out,retighten
the screw plug as soon as the fuel begins to emerge.
- If you need to change the filter, fully drain the diesel in
the filter cartridge and separate component (2) from
filter cartridge (3).
- After positioning the tool 99360076 under the filter,
unscrew and remove the filter (1) with the aid of a 27
mm wrench (2).
CHANGING FUEL PREFILTER AND
WATER SEPARATOR FILTER
!
To change the fuel pre—filter and water separator filter,
proceed as illustrated here.
them.
in water courses.
Hand screw and tighten for another 3/4 turn.
83486
NOTE
83488
83487

Figure 6
Figure 7
Figure 8
Figure 9
- Unscrewing the relevant screws (3), remove the 16
covers of the tappet housings (4).
- Fit the tool 99368502 (6) in correspondence with the
inside of the flywheel housing (opposite side to the
starter motor).
!
Handle all parts extremely carefully. Never get
your hands or fingers between pieces. Wear the
required safety clothing such as goggles, gloves,
safety shoes and helmet.
To adjust the rocker arm assembly, proceed as illustrated
here:
In maintenance conditions with the engine on the
stand to obtain greater precision in positioning
cylinder 1 at T.D.C. it is also possible to removethe
tappet cover.
- Fitting the 24 mm ratchet wrench on the back of tool
99368502 (see preceding page), turn the engine flywheel
until we obtain the required cylinder balancing (the 4
valves are at the same height).
- To obtain cylinder no.1 or no.6 in T.D.C. conditions it is
necessary to position the damping flywheel as indicated
in the picture.
For the following balancing/adjustments it is
recommended to trace some marks on the elastic joint
drive wheel, placed at 90° one from theother.
- After obtaining this condition of balancing we move on
to adjust the valves in the following order.
BALANCING
ADJUST
FIRST STEP
83505
81601
ADJUSTING ROCKER ARM ASSEMBLY
NOTE
81605
81603

Figure 10
Figure 11
- Using the wrench kit 99368503, loosen the lock nut (1)
of the adjuster screw (2).
- Insert the tappet feeler gauge (0.50) 99368545 (3).
BALANCING
ADJUST
SECOND STEP
- To make the adjustment, proceed as illustrated here:
Figure 12
Figure 13
- With kit wrench 99368503, screw or unscrew the
adjuster screw (2).
- Check that the tappet feeler gauge (3) can slide with a
slight amount of friction.
Keeping the adjuster screw (2) still use wrench
99368503 to lock the check nut of the adjuster screw
(1).
81606
82184
82183
82185

Figure 14 - Adjust the other valves in the order shown on previous
page.
- Now close all 16 covers, extract the tool for turning the
flywheel and close the flywheel cover.
Tightening torque 7 ÷ 10 Nm.
Figure 15
1. Adjuster screw lock nut — 2. Adjuster screw.
- Apply the 10 — 60 Nm torque wrench with the 3/8”
square connection 99389831 (4) to the wrench
99368503 to lock the lock nut to a torque of 40 Nm.
0,5 mm
0,5 mm
82186
81611

After positioning the tool (1) 99360091 under the filter,
unscrew and remove the filters (3) and (4) with the aid of a
27 mm wrench (2). Hand screw and tighten for another 3/4
turn. Unscrew the air jets nozzle on filters support and pump
on the manual priming pump. Tighten the air jets nozzle
when the fuel go out.
CHANGING FUEL FILTERS
!
them.
in water courses.
Figure 16
Figure 17
NOTE

After positioning the tool (1) 99360091 under the filter,
unscrew and remove the filters (3 and 4) with the aid of a 27
mm wrench.
!
Handle all parts extremely carefully. Never get your
hands or fingers between pieces. Wear the required
safety clothing such as goggles, gloves, safety shoes
and helmet.
To change the fuel filters, proceed as illustrated here.
them.
in water courses.
Replace the filters with new parts, hand screw and tighten for
another 3/4 turn.
Figure 18
1
2
REPLACING DIESEL FILTER(S)
For applications DRAGON and GRIFFON
NOTE
103181

Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
- Disconnect the power supply cables (1).
- Unscrew the cheese-headed screw M10x70 (3)
fastening the fixing bracket (4).
- Now fit on tool 99368505 (5) and, using the specific
wrench, completely remove the injector from its casing.
- Clean the injector seat.
- On completing these operations, fit the injector (7) back
on together with the fixing bracket (6).
!
gloves, safety shoes and helmet
CHANGING AN INJECTOR
To change an injector, proceed as illustrated here:
- Disassemble the pipes (2) on the injector side and on the
flow limiting device side by means of wrench 99368506.

Figure 24
Figure 25
- Tight with a pre-torque of 20 Nm the fitting on both side,
flow-limiter and injector side. During the tightening
procedure the injector and the flow-limiter have to be
hold against the tighten direction.
- Tight with a final torque of 80±5 Nm the fitting on both
side, flow-limiter and injector side. During the tightening
procedure the injector and the flow-limiter have to be
hold against the tighten direction.
- Test engine for leak detection.
- Using the specific wrench, screw the cheese—headed
screw M10x70 back on to a tightening torque of 32 ÷ 36
Nm.
!
Lubricate the O—ring before installation (use
vaseline).
- Check the sealing surface of the leaking pipe and the
surface on the injector and flow limiter. Cleaning the
surfaces and remove dirt if necessary. In case the sealing
surface are damaged , replace the part.
- Lubricate with clean engine oil the fitting and the sealing
surface.
- Tight by hand the fitting on both side , flow-limiter and
injector side. !
During positioning please clean well the spherical
surfaces and the Threaded part of pipe by dipping it
in a clean container filled with clean motor oil.

CHANGING BLOW-BY FILTER
Figure 26
The blow-by filter is positioned, by means of a support, to
the gearbox supporting bracket in front of the passenger cab
water/heating water heat exchanger.
The blow-by filters can only be replaced by taking the unit
apart completely and disassembling the same at the bench.
- Disconnect the inlet pipe (3) to the filter and the
condensed oil drain pipe (2) to the sump.
- Loosen the straps that retain the sleeves (4) for vapour
escape towards the outlets.
- Unscrew the screws (5) securing the filter on its bracket.
them.
in water courses.
Support the blow-by filter to prevent sudden
disconnection.
- Loosen screws (5) on both sides, then separate the two
covers (4) from the filter (1) body.
- Take out the two filters (2), then replace them.
- Re-assemble the various parts after washing the body and
covers with a suitable detergent.
- After the filter has been fitted, place it into its own
housing on the support secured to the gearbox
supporting bracket.
Figure 27
Replace the gasket (3).NOTE
NOTE

CHANGING PRIMARY SYSTEM PUMP
Removal
The centrifugal pump of the primary cooling system can be
changed as follows:
- Place a big enough container to collect the motor’s
coolant contained in the sections of piping that have to
be removed and in the pump itself.
- Unscrew the retaining ring nut and after loosening the
clamp (1), remove the pipe (2) feeding the tank’s pump.
- Undo the screws fixing the pipe (3) returning to the
pump from the radiator.
Figure 28
- On the top side, undo the screws (1) to free the pipe (2)
from the flange (3) fitted on the pump
- Unscrew the nuts (4) securing the pump to the cover of
the gearbox.
- Use a crowbar to separate the pump from the gearbox
cover.
Figure 29
!
Support the pump to prevent sudden disconnection.

Figure 30
Figure 31
Figure 32
Figure 33
- After removing the pump, separate the components
from (1) to (7).
- Put the pump on the bench and, using the right pliers,
remove the snap ring (1).
- Remove the drive disc (2).
- Put in a vice and undo the central screw so as to be able
to remove the disc (1).
- Turn the pump and undo the three screws (7, Figure 30)
fixing the cover (6, Figure 30), complete with seal (1).
Fitting
- At the assembly stage, after changing the damaged parts,
assemble all the parts on the bench to complete the
pump.
Change the seal on the cover. If the pump is not
changed, wash to remove any incrustation.
Figure 34
- Fitting the complete pump on the gearbox must include
engaging the teeth (1) on the gear (2) on the drive disc.
- then screw the nuts onto the stud bolts on the gearbox.
- tightening torque 33 ÷ 40 Nm.
- then connect the water pipes.
NOTE

- Restore the electrical connections.
Tightening torque should be as follow:
Terminal 30: 20 ÷ 30 Nm
Terminal G: 20 ÷ 30 Nm
Terminal 50: 2 ÷ 3 Nm
Apply a light layer of Vaseline onto the terminals
to protect them from rusting.
- Check the engine starting.
Figure 35
The starter motor is located on the left-hand side of the
flywheel housing in an area fairly easy to access from the
bottom. Its disassembly requires no special tools and is not
particularly difficult. Proceed as follows:
- Unscrew the nuts (1). Disconnect the electrical
connections of cables (2), (3), (4), (5) and (6).
- Remove the starter motor by unscrewing the nuts (1).
Fitting
- Change the motor with a new one and position it in its
seat after changing the gasket between the flywheel
housing and the motor. Tighten the fixing nut (M12 x
1.75) to a torque of 105 ÷ 86 Nm.
!
Before proceeding to work on an electric or
electronic component, make sure the system is not
powered.
It is recommended to mark the cables in order to
make a secure connection in the assembly phase.
Figure 36REMOVING/REFITTING STARTER MOTOR
Removal
NOTE
NOTE
NOTE Always change the gasket with a new one. Do not
reuse the one removed.

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1VECTOR 8 ENGINES
SECTION 4
Overhaul and technical specifications
Page
GENERAL SPECIFICATIONS 3. . . . . . . . . . . . . . .
ASSEMBLY CLEARANCE DATA 4. . . . . . . . . . . .
ENGINE OVERHAUL 10. . . . . . . . . . . . . . . . . . . . .
- Dismantling the engine at the bench 10. . . . . . . .
REPAIR OPERATIONS
CYLINDER UNIT 11. . . . . . . . . . . . . . . . . . . . . .
- Checks and measurements 11. . . . . . . . . . . . . . .
- Replacing Cylinder Liners 12. . . . . . . . . . . . . . . .
TIMING SYSTEM 14. . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking cam lift and
pin alignment 14. . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing the camshaft
idle gear 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Changing the bushings 16. . . . . . . . . . . . . . . . . . .
- Changing the tappets 16. . . . . . . . . . . . . . . . . . .
- Fitting tappets and camshaft 16. . . . . . . . . . . . . .
OUTPUT SHAFT 16. . . . . . . . . . . . . . . . . . . . . . . .
- Measuring journals and crankpins 16. . . . . . . . . .
- Checking main journal alignment 18. . . . . . . . . . .
- Crankshaft balancing instructions 19. . . . . . . . . .
- Replacing water pump drive gear 19. . . . . . . . . .
- Changing the oil pump and
timing system gear 20. . . . . . . . . . . . . . . . . . . . . .
- Fitting the main bearings 20. . . . . . . . . . . . . . . . .
- Finding journal clearance 21. . . . . . . . . . . . . . . . .
- Tightening sequence 21. . . . . . . . . . . . . . . . . . . .
- Checking crankshaft thrust clearance 22. . . . . . .
- Camshaft timing 23. . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES
Page
PISTON ROD ASSEMBLY 28. . . . . . . . . . . . . . . . .
- Pistons 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring the piston diameter 28. . . . . . . . . . . .
- Gudgeon pins 28. . . . . . . . . . . . . . . . . . . . . . . . . .
- Conditions for correct mating of gudgeon
pin and piston 29. . . . . . . . . . . . . . . . . . . . . . . . .
- Piston rings 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connecting rods 30. . . . . . . . . . . . . . . . . . . . . . .
- Check of connecting rod alignment 31. . . . . . . . .
- Fitting the connecting rod—piston assembly 31. . .
- Connecting rod—piston mating 31. . . . . . . . . . . .
- Fitting the piston rings 31. . . . . . . . . . . . . . . . . . .
- Check of rod/piston alignment 32. . . . . . . . . . . . .
- Fitting the rod—piston assemblies
into the cylinder liners 32. . . . . . . . . . . . . . . . . . .
- Measuring the mounting clearance of big end pins 33
- Fitting the connecting rod caps 33. . . . . . . . . . . .
- Check of piston protrusion 33. . . . . . . . . . . . . . .
CYLINDER HEAD 34. . . . . . . . . . . . . . . . . . . . . . . .
- Hydraulic leak test 34. . . . . . . . . . . . . . . . . . . . . .
- Dismantling valves 34. . . . . . . . . . . . . . . . . . . . . .
- Checking the cylinder head support surface 34. .
VALVE 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing carbon deposits, and checking the valves 34
- Refacing the valves 35. . . . . . . . . . . . . . . . . . . . . .
- Checking valve centering 35. . . . . . . . . . . . . . . . .
- Checking clearance between valve stem 35. . . . .
VALVE GUIDES 35. . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing the valve guides 36. . . . . . . . . . . . . . . .
- Reaming the valve guides 36. . . . . . . . . . . . . . . . .
- Replacing and regrinding the valve seats 36. . . . .
Page
REPLACING THE INJECTOR—HOLDER CASES 37
- Fitting the valves 38. . . . . . . . . . . . . . . . . . . . . . .
- Installing the cylinder head 38. . . . . . . . . . . . . . . .
TIGHTENING TORQUE 39. . . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS
Type VECTOR 8
Cycle Four-stroke diesel engine
Power Supercharged with intercooler
Injection Direct
Number of cylinders 8 in two banks at 90˚
∅
Bore mm 145
Stroke mm 152
+ + +.. = Total displacement cm3 20.080
TIMING
start before T.D.C. A
end after B.D.C. B
16º
25º
start before B.D.C. D
end after T.D.C. C
66º
15º
X
Checking timing
mm
X
mm
Checking operation
mm
X
mm
-
-
0.5
0.5
FUEL FEED
Injection
Type: Bosch
high pressure common rail
Control unit ADEM III
Nozzle type Injectors
Injection sequence 1 - 3 - 7 - 2 - 6 - 5 - 4 - 8
bar
Injection pressure bar
Variable up to 1600 bar, controlled by the ECU.
The safety valve cuts in at 1850 bar.

ASSEMBLY CLEARANCE DATA
Type VECTOR 8
CYLINDER BLOCK AND CRANK
MECHANISM COMPONENTS
mm
∅1
Cylinder liners ∅ 1 164 000 ÷ 164 025Cylinder liners ∅ 1 164.000 ÷ 164.025
Cylinder liners:
L
outside diameter ∅
length L
164.003 ÷ 164.028
266.5 ÷ 267.5
∅2
Cylinder sleeve —
crankcase seats
(interference) 0.028 ÷ 0.022
Outside diameter ∅2 —
Cylinder liners
∅3
X
Cylinder liner position
X
on crankcase X 0.025 ÷ 0.095
inside diameter ∅ 3 145.00 ÷ 145.03
∅1
Pistons:
∅1
X measuring dimension X 25
∅2 outside diameter ∅ 1 144.825 ÷ 144.870
outside diameter ∅ 2 62.000 ÷ 62.008
Piston — cylinder liners 0.261 ÷ 0.309
Piston diameter ∅ 1 _
X
Pistons position from
crankcase X
0.19 ÷ 0.59
3∅ Gudgeon pin ∅ 3 61.982 ÷ 61.990
Gudgeon pin — pin housing 0.010 ÷ 0.026

VECTOR 8
Type
VECTOR 8
Type
mm
1X
Type of piston X1* 3.440 ÷ 3.470
X
1
2
X
Piston ring slots X 2 3.060 ÷ 3.080
X
3
2
X
X3 6.030 ÷ 6.050
3X
*measured on ∅ of 140 mm
1S S1* 3 330 ÷ 3 2961
2
S
S
S1*
Piston rings S2
3.330 ÷ 3.296
2.975 ÷ 2.990
3S
Piston rings S2
S3
2.975 ÷ 2.990
5.975 ÷ 5.990
*measured on ∅ of 140 mm
1 0.110 ÷ 0.174
Piston rings — slots 2 0.070 ÷ 0.105
3 0.040 ÷ 0.075
Piston rings _
X1
2X
Piston ring end opening in
cylinder liners:
3
2X
X
X1 0.50 ÷ 0.65
3X
X2 0.90 ÷ 1.15
X3 0.40 ÷ 0.70
1∅ Small end bushing seat
∅ 1 67.994 ÷ 67.963
∅ 2
Big end bearing
seat ∅2 110.000 ÷ 110.022
∅
∅4
Small end bushing diameter
∅3 outside ∅4 68.080 ÷ 68.120
inside ∅ 3 62.015 ÷ 62.030
S Big end bearing shell
supplied as spares S 2.466 ÷ 2.478
Small end bush — seat 0.086 ÷ 0.157
Gudgeon pin — bushing 0,056 ÷ 0.080
Big end bearing shells —

Type
VECTOR 8
Type
mm
X
Measuring dimension X 125
Max. error on alignment of
connecting rod axes 0.08
1 2∅∅ Main journals ∅1 121 995 ÷ 121 9751 2∅∅ Main journals ∅1 121.995 ÷ 121.9751 2∅∅
Crankpins ∅2 105 000 ÷ 104 980Crankpins ∅2 105.000 ÷ 104.980
Main bearing
shells S1* 2.958 ÷ 2.970
S 1 S 2
Big end bearing shells
S2*
*supplied as spares
2.466 ÷ 2.478
3∅ Main bearing housings
128.000 ÷ 130.025
Bearing shells — main
journals:
no. 1 — 5
no. 2 — 3 — 4
0.065 ÷ 0.134
0.065 ÷ 0.134
Bearing shells —
crankpins
0.044 ÷ 0.110
Main bearing shells —
Big end bearing shells —
X1
Main journal,
for shoulder X1 56.00 ÷ 56.40
X2
Main bearing housing,
for shoulder;
middle
front/rear X2
43.184 ÷ 43.232
—
X 3 Half thrust washer
X3 —
Crankshaft shoulder —

Type VECTOR 8
CYLINDER HEAD — VALVE TRAIN mm
∅ 1
Valve guide seats
in cylinder head
∅1 16.980 ÷ 16.997
2∅
∅ 3
Valve guide ∅2
∅3
10.015 ÷ 10.030
17.012 ÷ 17.015
Valve guides and seats
on the head
0.015 ÷ 0.035
Valve guide 17.212 ÷ 17.225
∅ 4 Valves:∅ 4 Valves:
∅4
α
9.960 ÷ 9.975
60° 30′ ± 7′ 30
α
∅4
α
9.960 ÷ 9.975
45° 30’ ± 7′ 30″
Valve stem and its guide 0.052 ÷ 0.092
Valve seat in
h dhead
∅
52.985 ÷ 53.020
∅ 1
∅1
∅1 50,985 ÷ 51.020
Outside diameter of valve
seat; angle of valve seat
2∅
seat; angle of valve seat
in cylinder head:
53.000 ÷ 52.500
∅2
α
60°
α
α
∅2 51.000 ÷ 50.500α
α 45°
X
Recessing of valve
0.50 ÷ 0.80
X
Recessing of valve
X 0.50 ÷ 0.80

Type
VECTOR 8
Type
mm
Between valve
0.050 ÷ 0.100
Between valve
seat and head
0.050 ÷ 0.100
Valve seat
54.270 ÷ 54.285
51.270 ÷ 51.285
Valve spring height:
free height H 74
H H 1
2
under a load of:H 1
H2 N 450 ±25 H1 57.5
N 800 ±40 H2 46.5
X
Injector protrusion X not adjustable
∅∅∅
Seats for camshaft bushing
no. 1 — 5:
Camshaft seats
no. 2 — 3 — 4
86.000 ÷ 86.030
—
∅
∅
∅1
2
3
Camshaft supporting
pins:
1 ⇒ 5 Ø 79.950 ÷ 79.968
∅
Outer diameter of
camshaft bushings: ∅ 86.133 ÷ 86.163
∅
Inner diameter of
camshaft bushings: ∅ 80.018 ÷ 80.087
Bushings and housings
in the cylinder head
0.163 ÷ 0.130
Bushings and bearing
journals —

Type
VECTOR 8
Type
mm
Cam lift:
H 6.9360
7.4066
∅1
Tappet cap seat
in the crankcase: ∅1 34.025 ÷ 34.000
Tappet cap outside
diameter: ∅2
Measurement from axis
tappet at end of fixing
pin X
33.600 ÷ 33.800
18.80 ÷ 19.00
∅ 1
Rocker arm shaft ∅1 31.984 ÷ 32.000
Rocker arms ∅1 32 025 ÷ 32 050Rocker arms ∅1 32.025 ÷ 32.050
∅ 1
Between rocker arms and
shaft
0.025 ÷ 0.066

Figure 1
- Remove the gear fitted on the camshaft: unscrew the
screw (1) and remove the spacer (2); extract the gear (3)
from the camshaft.
During disassembly, the components (5) and (6) are
fastened by the screws (7) on the gear (3). If
necessary, separate the various parts and replace the
worn ones.
Figure 2
Check the protrusion of the pistons (6) from the crankcase
and note it down.
Set the cylinder assembly upright. Extract the pistons as
follows:
- Loosen the nuts (1) of the bolts fixing the connecting rod
caps to the connecting rods.
- Turn the crankshaft until the piston is exactly at the TDC;
in any other position it would not be possible to extract
the piston because the connecting would interfere with
the cylinder liner.
- Remove the connecting rod cap (2) and extract the
piston from the cylinder liner.
Set the crankcase horizontally. Remove the top (4) and side
(3) bolts fixing the main bearing caps to the crankcase and ex-
tract them.
On the central main bearing housings (5) and on the
cap there are the thrust half—rings for adjusting the
crankshaft end float.
82230
ENGINE OVERHAUL
Dismantling the engine at the bench
The instructions below assume that the engine has been fitted on an overhaul stand and all the specific components for Iveco Motors
application components have been removed (see Section 3 of this manual).The section therefore includes all the most important
overhaul procedures for the engine block.
103196
NOTE
NOTE

Figure 3
Figure 4
- Once engine is disassembled, clean accurately the
cylinder—block assembly. Use the proper rings to handle
the cylinder unit. The engine block shall not show cracks.
- Check operating plug conditions and replace them in case
of uncertain seal or if rusted.
- Inspect cylinder barrel surfaces; they shall be free from
seizing, scores, ovalisation, taper or excessive wear.
Inspection of cylinder barrel bore to check ovalisation,
taper and wear shall be performed using the bore dial
gauge 99395687 (1) fitted with the dial gauge previously
set to zero on the ring gauge (2) of the cylinder barrel
diameter.
Figure 5
REPAIR OPERATIONS
CYLINDER UNIT
Checks and measurements
Should the ring gauge be not available, use a
micrometer for zero—setting.
- Measurements shall be performed on each cylinder, at
three different heights in the barrel and on two planes
perpendicular with each other: one parallel to the
longitudinal axis of the engine (A), and the other
perpendicular (B). Maximum wearis usuallyfound onplane
(B) in correspondence with the first measurement.
- Using a hoist (1) and tool 99360500 (2), appropriately
fitted on the crankpins, extract the crankshaft (3) from the
cylinder assembly.
- Extract the camshaft from the cylinder assembly, taking
care not to damage the supporting bushings. Extract the
roller tappets.
1
2
3
16788
16792
NOTE
2284

Figure 6
Figure 7
Figure 8
Figure 9
The diagram gives the diameters: the outside diameter of the
cylinder liner and the inside diameter of its seat.
If necessary, the cylinder liners can be extracted and fitted
several times in different seats.
Replacing Cylinder Liners
!
The crankcase can be levelled off only after making
sure that, after machining, the piston protrudes from
the cylinder liner from 0.19 to 0.59 mm.
If the measurements are higher than as shown in the figure, it
is necessary to change the cylinder liners. Their internal surface
is treated with liquid nitriding, so grinding, lapping or facing are
not permissible.
- Check the flatness of the cylinder head mating surface with
a calibrated rule and feeler gauge.
After finding the areas of deformation, level off the
supporting surface, after taking out the centring pins (2),
with tool (1), and the cylinder liners (3) according to the
procedures given under the heading REPLACING
CYLINDER LINERS.
- Remove the cylinder liners (2) from the cylinder assembly
with tool 99360799 (1) fitted as illustrated in the figure.
Carefully check the seats of the cylinder liners and the side
surfaces of the crankcase.
Check the state of the plugs fitted in the cylinder assembly
machining holes and replace them if they are rusty or there
is any doubt about their seal
1
2
3
164.003
164.028
164.000
164.025
162.000
162040
161.961
161.986
82231
16796
16797
2290

Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
- Always change the coolant seals (3, 4 and 5).
Fit the top brass ring (2) onto the cylinder liner (1).
Lubricate its bottom portion and fit it in the cylinder
assembly with the plate (5) of tool 99360799 (6).
- Using a dial gauge (1), check that the protrusion of the
cylinder liner (2) from the mating surface of the cylinder
head is from 0.025 to 0.095 mm.
- Change the seals (5) of the bushing (3) for the left—hand
main oilway. The bushing (3) is removedfrom thecylinder
assembly with a percussion extractor (1) and a suitable
part (2). Use an appropriate drift to fit the bushing.
- Change the seals (5) of the bushing (3) for the right—hand
main oilway. The bushing (3) is removed from the cylinder
assembly with a percussion extractor 99340205 (1) and a
suitable part (2). Use an appropriate drift to fit the bushing.
- If changing the bushing (1) for the coolant duct, use general
tools for removal; use an appropriate drift (2) for assembly.
82720
16804
16805
16799
16803

Figure 15
Figure 16
MAIN DATA ABOUT CAMSHAFT PINS
Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the camshaft
and the bushes.
* Data concerning the distribution shaft assembled on the engines with serial numbers starting from 01/01/2005
- Check the alignment of the supporting pins, setting the
camshaft as illustrated.
By means of a magnetic based comparator (1) read the
alignment error that must not exceed the one indicated on
the figure; otherwise replace the distribution shaft.
Check the useful cam lift that must be the same for both
the inlet and exhaust; if it is not, change the camshaft.
- Using a feeler gauge (1), check that the clearance between
the plate (3) retaining the camshaft (2) to the cylinder
assembly and the driving gear (4) is from 0.070 to 0.175
mm.
Check that the teeth of the driving gear (4) are neither
broken nor excessively worn.
The driving gear (4) of the camshaft is removed with an
extractor.
For assembly, heat the gear (4) to reach a temperature
difference of 250°C between it and the camshaft.
Checking cam lift and pin alignment Replacing the camshaft idle gear
Figure 17
89794
TIMING SYSTEM
Camshaft
16806
16808

MAIN DATA OF THE BUSHINGS SUPPORTING THE CAMSHAFT AND SEATS IN THE CRANKCASE.
The bushings must have been forced into their seats. The internal surfaces must be smooth with no sign of seizure or wear.
SEAT Ø 86.000 ÷ 86.030
PIN Ø 79.950 ÷ 79.968
Thickness variation
max 0.025 mm
Heigth to be
obteined after
driving the bushes
Heigth to be
obteined after
driving the bushes
Thickness variation
max 0.025 mm
SEAT Ø 86.000 ÷ 86.030
PIN Ø 79.950 ÷ 79.968
82233
Figure 18

Lubricate the tappets and fit them in their seats.
Lubricate the camshaft bushings and fit the shaft, taking care
not to damage the supporting bushings. Fit the nozzles, check-
ing that the centring pins are correctly positioned in the cylin-
der assembly.
Having to change the bushings, use one drift for removal and
assembly. The camshaft assembly clearance must be from
0.070 to 0.150 mm.
OUTPUT SHAFT
Measuring journals and crankpins
- Measure the pins of the bench and of the connecting rod
with the micrometric calliper and establish if the engine
shaft and/or the connecting rod and bench bearings need
to be replaced.
It is recommended to insert the found values in the
proper table.
During assembly, the bushings must be facing so that
the lubrication holes match those in the seats.
On completing assembly, bore the bushings to the diameter
shown in Figure 18.
Changing the tappets
- The surface of the tappets in contact with the cams of the
camshaft must be perfectly smooth with no dents.
Slight dents can be removed with an extremely fine
abrasive stone.
Changing the tappets, due to excessive clearance in the
seats, involves fitting oversized tappets after boring the
seats with an appropriate reamer.
Fitting tappets and camshaft
Werecommend tolubricate thetappets carefullyby
keeping them immersed for 30’.
82233
Changing the bushings
Figure 19
Figure 20
NOTE
NOTE
NOTE
89801

Figure 21
Figure 22
1 2 3 4 5
MIN. DIA.
MAX. DIA.
MIN. DIA.
MAX. DIA.
1 2 3 4
MAIN JOURNALS
Table for entering
main journal and
crankpin
measurements
CRANKPINS
The engine shaft is nitrided and its grinding is not
foreseen
105.000
104.980
121.995
121.975
CRANKSHAFT JOURNAL DATA
Check the state of the main journals and crankpins of the crankshaft. They must show no sign of scoring, ovality or excessive
wear. The data given refer to the nominal pin diameter.
8821
37710
NOTE

The tolerances allowed on the engine shaft pins are:
- ovality = 0.007 mm
- taper 0.012 mm
- main journal misalignment 0.10 mm
- crankpin misalignment ± 0.025 mm
- tolerance on the distances between the axis of the
crankshaft and the outside of each crankpin ± 0.10 mm
Figure 23
Figure 24
Figure 25
Detail of couplings of central main journal.
Detail of couplings of crankpin.
Detail of couplings of rear — thrust main journal.
Checking main journal alignment
LIMIT POSITION LIMIT POSITION
NORMAL POSITION
MAIN JOURNAL
CRANKPIN
Diagram for checking the flywheel mating surface is orthogonal
and coaxial with the axis of rotation and main journals.
Turn the shaft:
- with the dial gauge at B no change greater than 0.04 mm
must be measured on the dial gauge;
- with the dial gauge at A no change greater than 0.03 mm
must be measured.
Figure 26
Figure 27
Figure 28
B
A
0.025 0.025
83496
8296
83495
83494
8297
83493

Figure 29
Figure 30
Replacing water pump drive gear
Check that with a pressure of 15 bar (15 kg/cm2) there is no leakage from the plugs (1).
The counterweights (2) must be fitted with the crankshaft fitted in the cylinder assembly. The numbering marked on the counter-
weights must correspond to that marked on the cranks of the crankshaft.
The bolts fixing the counterweights to the crankshaft must be lubricated with ”UTDM” oil and tightened to the prescribed torque
(pre—torque 40 Nm, torque 90° check window 110—170 Nm) when the counterweights are parallel to the main bearing housings.
Crankshaft balancing instructions
The crankshaft must be dynamically balanced.
Maximum permissible unbalance for each of the two planes
of balancing: 1000 g mm.
- Check that the toothing of the gear (2) is neither damaged
nor worn; if it is, then extract it with an appropriate
extractor. The gear (2) must be mounted on the
crankshaft (1) when there is a difference in temperature
between them of 200°C.
- Check that under a load of 32000 N the gear (2) does not
shift in relation to the shaft.
82236
82237

Figure 31
Changing the oil pump and timing system gear
Figure 32
- Check that the gear toothing (2) is neither damaged nor
worn. If it is, remove the gear by unscrewing the screw (3)
and using an extractor.
Take out the split pin (4).
The gear (2) must be fitted on the crankshaft (1) by
bringing the gear into alignment with the threaded seat
and with the housing of the split pin on the crankshaft.
Using the right drift, bring the gear flush onto the
crankshaft and screw down the M8x1.25x80 mm screw,
tightening it to a torque of 22 to 27 Nm.
Fitting the main bearings
The crankshaft must be dynamically balanced.
Arrange the main bearing shells with the lubrication hole in
their respective seats and fit the crankshaft (3) with the tool
99360500 (2) and suitable hoist (1).
82270
NOTE

Figure 33
Figure 34
α
Finding journal clearance
Check the clearance betweenthe crankshaftmain journalsand
their respective bearings as follows:
- thoroughly clean the pins;
- apply a calibrated wire (2) on the main journals (1);
- fit the caps (1) of the main bearing housings with the half
bearings so that the stamped numbers face the same side
as the corresponding ones on the cylinder assembly;
- Lubricate under the bottom side of the heads of screws
(2 and 3) that fix the bench caps with engine oil and
tighten to the fixing torque prescribed;
When tightening to an angle, use tool 99395216.
Figure 35
Tightening sequence
Figure 36
M20x1.5 bolts
Type of tightening: pre-torque + angle
Pre-torque 160Nm
Angle 240˚
Guard-torque 600 ÷ 1000 Nm
M16x1.5 bolts
Type of tightening: pre-torque + angle
Pre-torque ~70Nm
Angle 120˚
Guard-torque 240 ÷ 460 Nm
16813
89797
89796
16886
NOTE

Figure 37
Figure 38
α
α
Checking crankshaft thrust clearance
The thrust clearance of the crankshaft (2) is checked by placing
a dial gauge (1) with a magnetic base and proceeding as shown
in the figure. The normal assembly clearance is from 0.070 to
0.270 mm.
If a greater clearance is measured, replace the thrust washers
with new ones of the normal thickness or oversized, if
necessary.
The housing washers are not interchangeable with those of the
cap.
Remove again:
- main bearing housing caps;
- lubricate the main journals, main bearings and thrust
washers with engine oil;
- refit the main bearing caps and tighten the screws (2 and
3, Figure 34) to the prescribed torque.
- Arrange the thrust rings (2) on the central main bearing
housing (1) with the grooves facing the crankshaft shim
adjustment.
Fit the caps (1, Figure 34) back on and tighten the screws
(2, Figure 34) to the prescribed tightening torque.
1
2
When tightening to an angle, use tool 99395216.
- Remove caps from supports.
The backlash between the main bearings and the pins is found
by comparing the width of the calibrated wire (2) at the
narrowest point with the scale on the envelope (1) containing
the calibrated wire.
The numbers on the scale indicate the backlash in mm.
!
Once the screws securing (vertical and lateral) main
bearing caps have been screwed up, they must
compulsorily keep their position during caps
dismounting and remounting successive operations.
1
2
16855
16814
NOTE

Check that TDC coincides with the mark made:
- Rotate the crankshaft backwards.
- Rotate the crankshaft again, forwards, until the dial gauge
changes direction.
- Check that the point at which the dial gauge changes
direction (zero point on the dial gauge) coincides with the
reference marks made on the crankshaft andon the
cylinder block/crankcase.
Determine top dead centre (TDC) for cylinder 1 proceeding
as follows:
- Rotate the crankshaft so that the piston for cylinder 1 is
close to TDC.
- Fit the dial gauge as illustrated in the diagram.
- Carefully determine TDC (the point at which the dial
gauge pointer stops).
Figure 39
Figure 40
Figure 41
Figure 42
Trace two marks, one on the crankshaft key (1) and one
reference one on the cylinder block/crankcase:
- Rotate the crankshaft until a movement of the pointer is
detected on the dial gauge and then make a second mark
on the crankshaft (2).
- Measure the halfway point between the two reference
marks and make a third reference mark (3) on the
crankshaft.
- Fit the dial gauge on the exhaust tappet for cylinder no.
4.
- Search for the point at which the tappet on which the dial
gauge is fitted is fully lowered and zero the dial gauge.
113060
Camshaft timing
Method 1 (without equipment)
82240
113061 113062

Figure 43
Figure 44
- Rotate the crankshaft fowards until a lifting height of 5.48
mm is reached.
- The camshaft is timed if the reference mark made
previously on the crankshaft is aligned with the reference
on the cylinder block/crankcase.
If the above condition is not achieved, the camshaft should be
adjusted using the openings in the toothed wheel.
See timing diagrams overleaf.
82243
82244
Figure 45
113063
Fit the flywheel (2) taking care to ensure that the reference
markt (1) is aligned with the position of the camshaft rpm
sensor (see timing diagrams on the pages that follow).
Tighten the bolts (3) to the recommended torque.

Figure 46
112863
TIMING DIAGRAMS FOR THE FOLLOWING APPLICATIONS:G
DRIVE - GRIFFON - SPRINKLER
1. Camshaft - 2. Camshaft rpm sensor - 3. Camshaft flywheel - 4. Engine flywheel -
5. Crankshaft rpm sensor fitted on the flywheel casing

Figure 47
112864
TIMING DIAGRAMS FOR THE FOLLOWING APPLICATIONS:
DRAGON
1. Camshaft - 2. Camshaft rpm sensor - 3. Camshaft flywheel - 4. Engine flywheel -
5. Crankshaft rpm sensor fitted on the flywheel casing

Figure 48
Figure 49
Position cylinders 1 and 6 at TDC.
Fit tool 99368509 (3) on the front casing.Secure it using the
bolts (2, 5).
At TDC the pins (2) and (3) for the tool engage in the dowels
for the crankshaft and the camshaft respectively guaranteeing
the timing.
With tool 99368509 (3, Figure 48) fitted, fit the two timing
gears (6) and the spacer (5) and secure the assembly using the
bolts (4).
Fit the tool (1) 99368508 on the front casing as shown in the
diagram.
Fit the flywheel (2) so that the tool 99368508 is inserted, via
the seat for the timing sensor, on the tooth on the flywheel
(see arrow).
Proceed with tightening the bolts (3).
113064
113065
Method 2 (using equipment)
Flywheel timing

Figure 50
Figure 51
Figure 52
Figure 53
Figure 54
Figure 55
PISTON—GUDGEON PIN ASSEMBLY
1. Piston — 2. Trapezoidal grommet — 3. Washer — 4. Oil
scraper ring — 5. Gudgeon pin — 6. Split rings — 7. Half
baerings — 8. Connecting rod — 9. Bush
- Check pistons for any signs of seizure, cracks or excessive
wear; if there are, replace them.
- Use pincers 99360183 (1) to remove the rings (2) from
the piston.
- Remove the piston (1) from the rod (3) by removing the
ring (2) and extracting the gudgeon pin (4).
- Measure through the micrometer (1) the piston diameter
(2) to determine the assembly play. The diameter shall be
measured at 21 mm from the piston skirt.
- The clearance between the piston (1) and cylinder liner
can be checked using a feeler (2) as shown in the above
figure.
- Measure the diameter of the gudgeon pin (1) using a
micrometer (2).
Gudgeon pins
Pistons
Measuring the piston diameter
82253
PISTON ROD ASSEMBLY
16821
16822
16817
37715 32618

Figure 56
Figure 57
- Lubricate the gudgeon pin (1) and its seating on the piston
with engine oil; arrange the piston so that the gudgeon pin
can be inserted into the piston with a slight thumb pressure
and does not drop out by gravity.
Conditions for correct mating of gudgeon pin
and piston
PRINCIPAL PISTON, GUDGEON PIN AND PISTON RING DATA
Piston rings
Figure 58
- Check thickness of piston rings (2) by a micrometer (1).
Figure 59
- Check the clearance between the piston rings (2) and their
seats on the piston (1) using a feeler gauge (3).
113006
36131
36133
16522

Figure 60
Figure 61
Figure 62
PRINCIPAL ROD, BUSHING, GUDGEON PIN AND
BEARING HALF DATA
* internal diameter to check on the rod small end
- Using a feeler gauge (3) check the gap between the ends
of the piston rings (2) once they have been fitted into the
cylinder liners (1).
Connecting rods
CONROD BUSHING
ROD HALF (LOWER AND UPPER)
Figure 63
Figure 64
The ring (2) of the first slot has a V—shape.
The clearance ”X” between a ring and its seat is measured by
placing the piston (1), with its ring, in the cylinder liner (3) so
that the ring comes half—way out of the cylinder liner.
The upper bushing of the connecting rod cannot be
replaced.
*
3613
83434
16826
83420
82267
NOTE

Figure 65
Figure 66
Figure 67
Use apparatus 99395363 (1) to check parallelism of the rod
arms. The maximum permitted tollerance is ± 0.05 mm,
measured at 125 mm from the longitudinal axis of the rod. If
a misalignment exceeding the permitted tolerance is encoun-
tered, replace the rod.
- Position the piston (1) on the rod (3), insert the pin (4)
and secure it with the piston rings (2).
- Insert the piston rings (2) on the piston using pliers
99360183 (1).
The body and cap of every connecting rod is marked
with a number indicating the part with which is to be
mated. In addition, the number of the cylinder where
the rod should be installed may be stamped on it.
Therefore, when replacing the rod, it is necessary to
mark the new rod with the same number as the rod
whitch is being replaced.
!
Fitting the piston rings
1
Check of connecting rod alignment Fitting the connecting rod—piston assembly
Connecting rod—piston mating
The connecting rod — piston coupling must be made
taking account that,on fittingthe assemblyin thecylin-
der block, the wording ”TAPPET SIDE” (stamped on
the crown of the piston) must be facing the tappet
side of the engine and the numbering of the connect-
ing rods must be facing the corresponding numbering
stamped on the cylinder block.
16557
37715
16817
NOTE

The connecting rod — piston assemblies (1) are fitted in the
cylinder liners with the aid of the flexible band 99360603 (2)
observing the following requirements:
- lubricate the pistons, piston rings and cylinder liners with
engine oil;
- take the crankpin of the piston involved in assembly to
T.D.C.;
- the number of the connecting rod must correspond to
the number of the cylinder liner in which it is inserted and
must face the same side as that stamped on the cylinder
block; in addition, the wording ”TAPPET SIDE” on the
crown of the piston must face the camshaft;
- the gaps in the piston rings must be staggered 120° apart.
Refit the main bearings that have not been replaced,
in the same position found at removal.
Do not try to adapt the half bearings.
Figure 68
After assembling the rod—piston group (1) check the squaring
using apparatus 99395363 (3) and feeler gauge (2). Squaring
must be exact otherwise the cause should be found and faulty
part replaced.
DIAGRAM FOR INSERTING THE CONNECTING
ROD-PISTON ASSEMBLY IN CYLINDER
1. Tappet side — 2. Camshaft
Fitting the rod—piston assemblies into the
cylinder liners
1
2
3
If it is not necessary to replace the big end bearings,
they must be reassembled according to the same
order and position found upon disassembly.
- Fit half bearings (1) on connecting rod and cap.
Figure 69
Figure 70
Figure 71
37716
Check of rod/piston alignment
81350
16793
37717
NOTE
NOTE

Figure 72
Figure 73
Figure 74
To check the clearance proceed as follows:
- clean all the parts accurately and remove any traces of oil;
- arrange the bearings in their seats;
- place a length of calibrated wire (1) on the drive shaft pins
(2).
- connect the connecting rods to the journals of the
crankshaft and fit the connecting rod caps together with
the half bearings;
- tighten the screws, which have been previously lubricated
with UTDM oil, with a dynamometer spanner to a
prescribed torque;
- remove the cap.
Measure the existing play by comparing the width of the
calibrated wire with the graduated scale shown on the package
which contained the wire. If the measured play is not equal to
the prescribed value, replace the bearing halves and repeat the
check.
- When the rod—piston group have been assembled, check
for piston protrusion at T.D.C. from the upper engine
block level.
- The protrusion should be from — 0.21 to +0.59 mm.
α
!
Upon final reassembly, the big end cap fastening
screws must always be replaced.
- Manually check that the connecting rods can be moved
sideways on the drive shaft pins.
Check of piston protrusion
Fitting the connecting rod caps
- Thoroughly clean the journals of the crankshaft and the
big end bearing shells of the remains ofthe calibratedwire.
Lubricate them and refit the connecting rod caps
tightening the nuts as described for measuring the
assembly clearance.
16795
Measuring the mounting clearance of big end
pins
16800
16896

- Rest the cylinder head on the workbench and use tool
99368544 (1) to apply pressure to spring cups (3) so that
by compressing springs (4) valve collets (2) can be
removed.
Then take off upper cups (3), springs (4), caps (5) and
lower cups (6).
Turn the cylinder head upside down and withdraw valves
(7). Repeat the operation on all the cilinder heads.
Figure 75
CYLINDER HEAD
Hydraulic leak test
Before dismantling the cylinder head, carry out the hydraulic
leak test using the appropriate tool.
Pump water heated to approx. 90˚ C and at a pressure of
4 ÷ 5 bar into the cylinder head. Under these conditions, no
leaks should be found; if they are, replace the cylinder head.
Dismantling valves
Figure 76
Figure 77
Check the flatness of the support surface using a rule and a
feeler gauge.
- Remove carbon deposits from valve using a steel brush.
Check that valves do not show signs of binding or
cracking.
Use a micrometer to check that the valve rod diamter is
as specified (see Figure 79). If not, replace the valves.
Figure 78
Checking the cylinder head support surface
VALVE
Removing carbon deposits, and checking the
valves
82266
103214
16824
18625

Figure 79
VALVE GUIDES
These checks are carried out using a magnetic support dial
gauge which is positoned as shown in the figure above.
By rotating the valve check that the centering error does not
exceed 0.03 mm.
Figure 80
Checking valve centering
Figure 81
These checks are carried out using a magnetic support dial
gauge which is positoned as shown in the figure above.
The mounting clearance is from 0.045 to 0.070.
Checking clearance between valve stem
Figure 82
Refacing the valves
MAIN DATA OF THE VALVE SEATS AND VALVE GUIDE
SEATS ON THE CYLINDER HEADS
A = INLET — S = EXHAUST
A. Intake valve on the engines with serial numbers starting up
to 484 - B. Intake valve on the engines with serial numbers
starting from 485
- Check with a micrometer that the diameter of the valve
stems is as indicated; if necessary, rebore the seats on the
valves with the grinding machine, removing as little material
as possible.
After machining, check that the dimensions come within
the permissible tolerance.
AB
103185
89832
83492
89766

Figure 83
Figure 84
Figure 85
- Using the reamer (1), ream the valve guide bore to obtain
the indicated value.
Replacing and regrinding the valve seats
- Dismantle the valve guides (2) with beater 99360143 (1);
mount the new valve guides using a beater 99360143 (1)
fitted with part 99360291 (3).
Replacing the valve guides
Reaming the valve guides
Figure 86
Figure 87
Figure 88
Replace the valve seats as follows:
- place the cylinder head (5) on the pillar drill (1);
- fit tool (4) on the pillar drill;
- adjust the stop device (3) on the milling cutter (2);
- operate the milling cutter and remove the valve seat;
- thoroughly clean the cylinder head.
- cool the new valve seats to — 180°C in liquid nitrogen;
- drive the valve seats (3) into the cylinder head with a drift
(1) and suitable part (2).
Assembly interference:
- inlet: 0.015 to 0.035 mm
- exhaust: 0.015 to 0.035 mm
- Regrind the valve seats (2) with tool 99305019 (1).
After regrinding the valve seats, use a dial gauge (1) on tool
99370415 to check that:
- the valve recessing is from 0.50 to 0.80 mm.
16830
16833
16834
82263
16835
16832

Figure 89
Figure 90
- Fit the new case (2) in the cylinder head (1) and
cold—head its bottom seat, on the cylinder head, with the
cold—heading tool 99365063 (3).
Figure 91
Figure 92
- Restore the hole in the case (2) with the reamer
99394017 (3) and the bushing 99394019 (1).
Restoretheinjector recessing,in relationto theface ofthe
cylinder head, with the milling cutter 99394018 (4) and
bushing 99394019 (1) that must be from 0.47 to 1.16
mm.
Figure 93
Figure 94
PRINCIPAL DATA FOR CHECKING SPRINGS FOR
INTAKE AND EXHAUST VALVE
kg 45± 2,5
kg 80±4
- Before mounting, check the flexibility of the valve spring
using tool 99305047. Compare the loading and
deformation data with those of the new spring indicated
in the following diagrams.
REPLACING THE INJECTOR—HOLDER
CASES
Imperfect coupling between the injector and case, forced into
the cylinder head or between the case and the seat on the
cylinder head, causes a loss of compression or water leakage.
In the first case, the trouble is eliminated by regrinding the seat
of the case (2) with the milling cutter 99394011 (3) and the
bushing 99394019 (1) taking accountthat theelectro—injector
recessing from the cylinder head face must be from 0.47 to
1.16 mm.
In the second case, it is necessary toreplace thecase asfollows:
- thread the case with the set of screw taps 99390800 (1);
- extract the case from the cylinder head with tool
99342145 (2).
1
2
3
1 2
1
2
3
1
2
1
2
3
4
16690
37722
82718
16859
2280

Figure 95
Figure 96
Figure 97
Figure 98
Figure 99
Figure 100
Fitting the valves
- Lubricate the stems of the valves (7) and insert them in
their respective valve guides. Position the bottom plates
(6), springs (4) and top plates (3) on the cylinder head.
Using tool 99368544 (1), compress the springs and fit the
retaining cotters (2).
- Fit the rings (1 and 3) on the cases (2) and insert them in
the cylinder block.
Installing the cylinder head
To reuse the bolts (2) fixing the cylinder heads, check
with a micrometer (1) that the diameter of its thread
is no less than 14.5 mm.
4 7 8
1
3
5
62
3 5 6
2
4
7
8
1
α
Fit new cylinder head gaskets. Mount the cylinder heads (1).
Lubricate the fixing bolts with ”UTDM” oil. Align the cylinder
heads with the tool applied in the holes to fasten the exhaust
manifolds.
Tighten the cylinder head bolts, following the order shown in
the following figure, as follows:
- first phase: pre—torque 70 Nm;
DIAGRAM OF TIGHTENING SEQUENCE FOR
CYLINDER HEAD BOLTS
α
Apply tool 99395216 (1) to the wrench.
- second phase: angle 240°;
- guard torque: 220 — 390 Nm.
The screw can be used again as long as the external
diameter of the shank is 14.5 mm long in each point.
103214
37724
24546
82719
36618
37725
NOTE
NOTE

TIGHTENING TORQUE
COMPONENT TORQUE
Nm kgm
Cylinder head fixing bolt (*) pre—torque
angle
guard—torque
70
240°
220 ÷ 390
7
240°
22 ÷ 39
Crankcase cap fixing bolt (*) pre—torque
angle
guard—torque
160
240°
600 ÷ 1000
16
240°
60 ÷ 100
Crankcase cap side fixing bolt (*) pre—torque
angle
guard—torque
70
120°
260 ÷ 460
7
120°
26 ÷ 46
Connecting rod cap fixing bolt (*) pre—torque
angle
guard—torque
90
60°
170 ÷ 230
9
60°
17 ÷ 23
Engine flywheel fixing bolt (*) pre—torque
angle
guard—torque
350
120°
910 ÷ 1600
35
120°
91 ÷ 160
Damper fixing bolt (*) pre—torque
angle
guard—torque
160
120°
540 ÷ 960
16
120°
54 ÷ 96
Nut fixing front cover oil sump (M10x1.5) 38 ÷ 45 3.8 ÷ 4.5
Bolt fixing oil sump to front cover and crankcase (M10x1.5) 38 ÷ 45 3.8 ÷ 4.5
Bolt fixing crankcase front gearbox (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing front gearbox and cover to crankcase (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing front cover to front gearbox (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Nut fixing front cover to front gear casing 27 ÷ 33 2.2 ÷ 2.7
Bolt fixing flywheel housing to crankcase (M12x1.75) 86 ÷ 105 8.6 ÷ 10.5
Bolt fixing flywheel casing to crankcase (M14x2) 135 ÷ 165 13.5 ÷ 16.5
Bolt fixing flywheel casing to crankcase (M14x2) 135 ÷ 165 13.5 ÷ 16.5
Bolt fixing gear pin centring (M10x1.5) (*) 45 ÷ 50 4.5 ÷ 5.0
Bolt fixing centring pin (M12x1.75) (*) 100 ÷ 110 10.0 ÷ 11.0
Bolt fixing cylinder head cover (M8x1.25) 20 ÷ 24 2.0 ÷ 2.4
Bolt fixing clearance adjustment cover (M6x1) 7 ÷ 10 0.7 ÷ 1.0
Bolt fixing left and right intake manifold to cylinder head (M10x1.5) 38 ÷ 45 3.8 ÷ 4.5
Bolt fixing exhaust manifold (M10x1.5) (**)
N. 12 bolts from front side (on both side) torque
N. 4 bolts from rear side (on both side) pre—torque
torque
47 ÷ 53
47 ÷ 53
64 ÷ 70
4.7 ÷ 5.3
4.7 ÷ 5.3
6.4 ÷ 7.0
Bolt fixing thrust plate to crankcase (M8x1.25) (*) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing inlet pipe to the right and left intake manifolds (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing driving gear to driven gear governing camshaft (M10x1.5) (*) 49 ÷ 60 4.9 ÷ 6.0
Bolt fixing rocker—arm assembly to head (M12x1.75) (*) 80 ÷ 89 8.0 ÷ 8.9
Nut adjusting clearance (rocker arms) (M10x1.25) (*) 34 ÷ 44 3.4 ÷ 4.4
Bolt fixing crankshaft rear gear (M8x1.25) (*) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing gear to PTO (M12x1.75) (*) 86 ÷ 105 8.6 ÷ 10.5
Bolt fixing PTO to spacer (M12x1.75) 74 ÷ 90 7.4 ÷ 9.0
Bolt fixing PTO spacer to gearbox (M12x1.75) 74 ÷ 90 7.4 ÷ 9.0
Bolt fixing gear assembly to camshaft (M12x1.75) 86 ÷ 105 8.6 ÷ 10.5
Bolt fixing phonic wheel to gear (M8x1.25) 24 ÷ 30 2.4 ÷ 3.0
Bolt fixing injector bracket to cylinder head (M10x1.5) (*) 32 ÷ 36 3.2 ÷ 3.6
Nut fixing turbo to exaust manifold (M12x1,75) 55 ÷ 65 5,5 ÷ 6,5
Bolt fixing oil delivery pipe to turbo (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7

COMPONENT TORQUE
Nm kgm
Bolt fixing air conveyor to cooler body (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing air delivery elbows to conveyor (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing oil pump to crankcase (M10x1.5) 38 ÷ 45 3.8 ÷ 4.5
Bolt fixing conveyor to intake manifold (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing bottom pipes discharging oil from turbo—blowers to oil sump (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing suction rose to oil pump (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing suction rose to cap for central support (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing oil pressure adjuster valve (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing oil filter body to crankcase (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing oil filter body to crankcase (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing engine oil cooler body to crankcase (M10x1.5) 25 ÷ 30 2.5 ÷ 3.0
Bolt fixing piston cooling jet (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing oil pressure adjuster valve for piston cooling jet (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Nut fixing coolant pump to front gear cover (M10x1.5) 33 ÷ 40 3.3 ÷ 4.0
Bolt fixing right and left manifold for coolant outlet from cylinder heads (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing elbow to head coolant outlet right manifold (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing head coolant outlet manifold union body (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing coolant pump connecting pipe and cooler cover (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing pipe from main coolant pump to crankcase (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing spacer to front casing (M12x1.75) 74 ÷ 90 7.4 ÷ 9.0
Bolt fixing air compressor spacer 74 ÷ 90 7.4 ÷ 9.0
Bolt fixing high—pressure pump (HPP) to crankcase (M10x1.5) (*) 49 ÷ 60 4.9 ÷ 6.0
High pressure gear pump fixing nut (HPP) 350 35
High pressure gear pump fixing nut (HPP) 160 ÷ 180 35
Bolt fixing ECU to support (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Nut fixing compressor drive gear 160 ÷ 180 16 ÷ 18
Bolt fixing low pressure pump to air compressor (M10x1.5) 42 ÷ 51 4.2 ÷ 5.1
Bolt fixing front manoeuvring hook (M12x1.75) 86 ÷ 105 8.6 ÷ 10.5
Bolt fixing front adjustment hook (M14x2) 153 ÷ 187 15.3 ÷ 18.7
Bolt fixing rear manoeuvring hooks (M14x2) 153 ÷ 187 15.3 ÷ 18.7
Bolt fixing heater to conveyor (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing front engine supports (M14x2) torque
angle
guard-torque
65 ÷ 75
60˚ - 65˚
190 ÷ 270
6.5 ÷ 7.5
60˚ - 65˚
19.0 ÷ 27.0
Bolt fixing rear engine supports (M16x2) torque
angle
guard-torque
95 ÷ 105
85˚ - 90˚
310 ÷ 420
9.5 ÷ 10.5
85˚ - 90˚
31.0 ÷ 42.0
Bolt fixing air/water radiator support to flywheel casing (M10x1.5) 49 ÷ 60 4.9 ÷ 6.0
Bolt fixing air/water radiator support to radiator (M10x1.5) 49 ÷ 60 4.9 ÷ 6.0
Bolt fixing flywheel speed sensor (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
Bolt fixing phonic wheel speed sensor (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7
High pressure pump / delivery pipe nut (M27x2) (*) 115 ÷ 125 11.8 ÷ 13.2
Delivery / rail pipe nut (M27x2) (*) 85 ÷ 95 10.0 ÷ 11.0
Compensating pipe BETWEEN rail 1 and 2 (M27x2) (*) 85 ÷ 95 10.0 ÷ 11.0
Injector / fuel inlet pipe nut (M22x1.5) (*) 45 ÷ 55 8.0 ÷ 8.5
Rail / fuel inlet pipe nut (M20x1.5) (*) 70 ÷ 80 8.0 ÷ 8.5
Flow limiter (only for loss, disassembly or replacement) 20 + 30˚ 2.0 + 30˚
(*) Before tightening, lubricate the bolt with UTDM oil or, alternatively, with engine oil.
(**) Before tightening, lubricate the bolt with grafitato oil.

SECTION 5 - TOOLS 1VECTOR 8 ENGINES
SECTION 5
Tools
Page
TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 5 - TOOLS F4AE NEF ENGINES

TOOLS
TOOL NO. DESCRIPTION
99305019 Case with full set of valve seating regrinding tools
99305047 Spring loading control apparatus
99322230 Rotary telescopic stand (capapity 2000 daN, torque 375 daNm)
99342145 Puller to remove injector holder
99360091 Tool for dismantling fuel filter
99360184 Calipers for disassembling and reassembling engine piston rings
(105 — 160 mm)

TOOLS
99360329 Key for installing gasket on valve guides
99360500 Tool for lifting the output shaft
99360603 Band for inserting piston into cylinder barrel (90 — 175)
99360785 Ring (145 mm) (use with 99360799)
99360799 Tool for disassembling and reassembling cylinder liners (use with
special rings)
99361011 Brackets securing engine to rotating overhaul stand 99322230

TOOLS
99365063 Tool for heading electro—injector seat
99367016 Sleeve key (27 mm) for flywheel fixing bolts
99367019 Guides set (2) M24x2 to mount engine flywheel
99368501 Tool for rotating the engine flywheel
99368502 Tool for rotating engine flywheel (to be used with 99368547)
99368503 Key for adjusting tappet clearance screw (use with 99389831)

TOOLS
99368505 Puller for dismantling injectors
99368506 Key (27 mm) for dismantling fuel injector pipes (use with 99389813)
99368508 Tool for positioning fonic wheel during timing ignition
99368509 Tool for timing camshaft
99368511 Tool for fiitting output shaft rear gasket
99368512 Tool for fiitting output shaft front gasket

TOOLS
99368513 Tool to remove output shaft rear gasket
99368514 Tool to remove output shaft front gasket
99368515 Stud set (use with 99360799)
99368516 Puller to remove the control gear of hight pressure pump (use with
99368517)
99368517 Retainer tool control gear of hight pressure pump
99368533 Support for disassembling and assembling the engine flywheel

TOOLS
99368537 Tool for drain engine oil
99368539 Installer oil filter (engine)
99368540 Ring wrench with 14X18 insert (18mm) for turbine bolts
99368542 Set of 8 insert box wrenches 14X18 (13 - 17 - 18 - 19 - 21- 22 -
24 - 27 - 30 mm)
99368543 ILC simulator for Vector Engine
99368544 Tool for disassembling and reassembling engine valves

TOOLS
99368545 Thickness gauge (0.50 mm) for tappets
99368546
Torque overgear reaction for teeghtening fly wheel bolts (use with
99367016-99389816-99389818)
99368547 Dial gauge base to adjust transmission shaft bearings (use with
99395603)
99395603)
99368550 Diagnostic interface for Vector engine
99395603)

TOOLS
99395603)
99389813 Torque wrench (20 — 120 Nm) with 1/2” square attachment
99389816 Torque overgear x 4 with 3/4” square attachment
99389818 Torque wrench (150 — 800Nm) with 3/4” square attachment

TOOLS
99389832 Torque wrench with 14X18 attachment (60-320 Nm)
99389833 Torque wrench with 14X18 attachment (20-120 Nm)
99390425 Tap for to thread injector seat (disassembly) (M12x1.75)
99394004 End mill for to work the rocker side of injector seat
99394017 Reamer for to work the bottom side fo the injector seat (use with
99394019)
99394018 End mill for to work the rocker side of injector seat (use with
99394019)

TOOLS
99394019 Driver bushing
99395216 Pair of measuring devices for angular tightening with 1/2” and 3/4”
square attachments
99395363 Complete square for checking rod squaring
99395603 Dial gauge (0 — 10 mm)
99395687 Bore gauge (50 — 178 mm)

APPENDIX 1VECTOR 8 ENGINES
Appendix
Page
SAFETY PRESCRIPTIONS 3. . . . . . . . . . . . . . . . . .
- Standard safety prescriptions 3. . . . . . . . . . . . . .
- Prevention of injury 3. . . . . . . . . . . . . . . . . . . . .
- During maintenance 3. . . . . . . . . . . . . . . . . . . . .
- Respect of the Environment 4. . . . . . . . . . . . . .

2 APPENDIX F4AE NEF ENGINES

Particular attention shall be drawn on some precautions that
must be followed absolutely in a standard working area and
whose non fulfillment will make any other measure useless
or not sufficient to ensure safety to the personnel in-charge
of maintenance.
Be informed and inform personnel as well of the laws in force
regulating safety, providing information documentation
available for consultation.
- Keep working areas as clean as possible, ensuring
adequate aeration.
- Ensure that working areas are provided with emergency
boxes, that must be clearly visible and always provided
with adequate sanitary equipment.
- Provide for adequate fire extinguishing means, properly
indicated and always having free access. Their efficiency
must be checked on regular basis and the personnel
must be trained on intervention methods and priorities.
- Organize and displace specific exit points to evacuate
the areas in case of emergency, providing for adequate
indications of the emergency exit lines.
- Smoking in working areas subject to fire danger must be
strictly prohibited.
- Provide Warnings throughout adequate boards signaling
danger, prohibitions and indications to ensure easy
comprehension of the instructions even in case of
emergency.
- Do not execute any intervention if not provided with
necessary instructions.
- Do not use any tool or equipment for any different
operation from the ones they’ve been designed and
provided for: serious injury may occur.
- In case of test or calibration operations requiring engine
running, ensure that the area is sufficiently aerated or
utilize specific vacuum equipment to eliminate exhaust
gas. Danger: poisoning and death.
SAFETY PRESCRIPTIONS
Standard safety prescriptions
Prevention of injury
- Do not wear unsuitable cloths for work, with fluttering
ends, nor jewels such as rings and chains when working
close to engines and equipment in motion.
- Wear safety gloves and goggles when performing the
following operations:
- filling inhibitors or anti-frost
- lubrication oil topping or replacement
- utilization of compressed air or liquids under pressure
(pressure allowed: ≤ 2 bar)
- Wear safety helmet when working close to hanging
loads or equipment working at head height level.
- Always wear safety shoes when and cloths adhering to
the body, better if provided with elastics at the ends.
- Use protection cream for hands.
- Change wet cloths as soon as possible
- In presence of current tension exceeding 48-60 V verify
efficiency of earth and mass electrical connections.
Ensure that hands and feet are dry and execute working
operations utilizing isolating foot-boards. Do not carry
out working operations if not trained for.
- Do not smoke nor light up flames close to batteries and
to any fuel material.
- Put the dirty rags with oil, diesel fuel or solvents in
anti-fire specially provided containers.
During maintenance
- Never open filler cap of cooling circuit when the engine
is hot. Operating pressure would provoke high
temperature with serious danger and risk of burn. Wait
unit the temperature decreases under 50ºC.
- Never top up an overheated engine with cooler and
utilize only appropriate liquids.
- Always operate when the engine is turned off: whether
particular circumstances require maintenance
intervention on running engine, be aware of all risks
involved with such operation.
- Be equipped with adequate and safe containers for
drainage operation of engine liquids and exhaust oil.
- Keep the engine clean from oil tangles, diesel fuel and or
chemical solvents.
- Use of solvents or detergents during maintenance may
originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
- Do not leave rags impregnated with flammable
substances close to the engine.
- Upon engine start after maintenance, undertake proper
preventing actions to stop air suction in case of runaway
speed rate.
- Do not utilize fast screw-tightening tools.
- Never disconnect batteries when the engine is running.
- Disconnect batteries before any intervention on the
electrical system.
- Disconnect batteries from system aboard to load them
with the battery loader.
- After every intervention, verify that battery clamp
polarity is correct and that the clamps are tight and safe
from accidental short circuit and oxidation.
- Do not disconnect and connect electrical connections
in presence of electrical feed.
- Before proceeding with pipelines disassembly
(pneumatic, hydraulic, fuel pipes) verify presence ofliquid
or air under pressure. Take all necessary precautions
bleeding and draining residual pressure or closing dump
valves. Always wear adequate safety mask or goggles.
Non fulfillment of these prescriptions may cause serious
injury and poisoning.
APPENDIX 3VECTOR 8 ENGINES

- Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
personnel’s safety and health shall be adopted.
- Be informed and inform the personnel as well of laws in
force regulating use and exhaust of liquids and engine
exhaust oil. Provide for adequate board indications and
organize specific training courses to ensure that
personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Collect exhaust oils in adequate specially provided
containers with hermetic sealing ensuring that storage is
made in specific, properly identified areas that shall be
aerated, far from heat sources and not exposed to fire
danger.
- Handle the batteries with care, storing them in aerated
environment and within anti-acid containers. Warning:
battery exhalation represent serious danger of
intoxication and environment contamination.
Respect of the Environment- Avoid incorrect tightening or out of couple. Danger:
incorrect tightening may seriously damage engine’s
components, affecting engine’s duration.
- Avoid priming from fuel tanks made out of copper alloys
and/or with ducts not being provided with filters.
- Do not modify cable wires: their length shall not be
changed.
- Do not connect any user to the engine electrical
equipment unless specifically approved by Iveco Motors.
- Do not modify fuel systems or hydraulic system unless
Iveco specific approval has been released. Any
unauthorized modification will compromise warranty
assistance and furthermore may affect engine correct
working and duration.
For engines equipped with electronic gearbox:
- Do not execute electric arc welding without having
priory removed electronic gearbox.
- Remove electronic gearbox in case of any intervention
requiring heating over 80ºC temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.
4 APPENDIX F4AE NEF ENGINES

Iveco vector 8 diesel engine workshop manual

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Iveco vector 8 diesel engine workshop manual