Contents

Operating instructions

• Electronically controlled air suspension ECAS
• Pneumatic suspension (can only be installed on 35C / 65C models)

Starting the engine and moving the car

• Immobilizer
• Car keys
• Code card
• Emergency start engine ignition switch position
• Enabling the immobilizer
• Disabling the immobilizer
• Starting the engine
• Engine shutdown
• Centralized door locking system (if installed)
• Cold weather starting
• Self-diagnosis of car systems
• Centralized door locking system with electronic alarm (if installed)
• AGILE gearbox (if fitted)
• Display vehicle operation with automatic transmission
• Speed ??programming
• Using the power take-off (if equipped)
• Fault signaling
• Starting the engine by towing the vehicle
• Engaging the rear axle differential lock
• Anti-lock braking system (ABSJ / pressure limiting valve (EBD) / tire adhesion monitor (ABD)
• ESP8 - electronic stability control system
• Grade hold system
• ABS8 (if installed)
• Cruise control (if installed)
• Power take-off (if included in the transmission)
• Works performed by the driver independently
• Precautions when working with electronic control units installed in the vehicle
• Mandatory instructions
• Car towing
• Driver checks
• Before every trip
• Scheduled maintenance

Specifications

• Engine

Maintenance

• Car maintenance schedule
• Inspection and maintenance checklist
• Maintenance operations
• M1 maintenance
• Maintenance M2
• Maintenance EP1
• Maintenance EP2
• EPZ maintenance
• Maintenance T1 (at the beginning of each spring)
• Maintenance T2 (at the beginning of each winter)
• Technical maintenance of technical specifications
• Maintenance T4
• Under-dash fuse and relay box
• Under-dash fuse and relay box (EURO 4, EURO 5, NATURAJ POWER)
• Fuse and relay box in the engine compartment (EURO 4, EURO 5. NATURAL POWER)
• Fuse and relay box in the engine compartment (EURO 4) (EURO 4, EURO 5, NATURAL POWER) outdoor unit
• Engine compartment fuse and relay box (EURO 5)
• Additional fuse box (engine compartment)
• Additional fuse box in the engine compartment (EURO 5)
• Engine compartment fuse and relay box (NATURAL POWER)
• Additional fuse box in the engine compartment (NATURAL POWER)

Menu control panel

• Display message
• BASE version display
• BASE version menu structure - engine start (ignition switch ON)
• Dashboard COMFORT version
• COMFORT version display
• Diesel particulate filter (particulate filter for diesel engines)
• F1A engine
• Engine removal / installation
• Replacing the timing belt
• Replacing electrically operated fuel injectors
• Exhaust toxicity, smoke and noise
• F1AE0 engine
• Diagnostics
• Basic operations with an engine not removed from the vehicle
• Tightening torques for threaded connections
• Longitudinal section of the engine with horn system
• Cross section of an engine with horn system
• Repair of the F1A engine
• Dismantling the engine at the stand
• Renovation work
• Cylinder block
• Crankshaft
• Engine assembly
• Installing the rear oil seal
• Flywheel
• Assembly of pistons with connecting rods
• Pistons
• Rods
• Cylinder head
• Valves
• Valve guides
• Valve seats
• Valve springs
• Swing levers (rockers) - pushers
• Installing the cylinder head
• Gas distribution system
• Camshaft
• Adjusting the tension of the air conditioning compressor drive belt
• Camshaft position sensor
• Crankshaft speed sensor
• Lubrication system
• Oil and vacuum pump assembly (GPOD)
• Oil pressure reducing valve
• Oil filter
• Heat exchanger modine
• Crankcase ventilation and oil separator
• Cooling system
• Fan clutch
• Water pump
• Thermostat
• Turbocharging
• Turbocharger
• Repair
• Pressure reducing valve
• Exhaust gas recirculation
• Power system
• Electronically controlled high pressure fuel injection (MS 6.3)
• System operation
• Hydraulic part of the fuel system
• Fuel pump
• Fuel lines
• High pressure fuel pump
• High pressure fuel pump device
• Pressure regulator valve
• Mechanical booster pump
• Hydraulic accumulator (RAMP)
• Pressure reducing valve
• Electrically operated injectors
• Electrical / electronic components
• Electronic control unit edc 16 for EUR04 engines
• Sensors
• Actuators
• Regulators with pulse width modulation (PWM)
• Differences of EURO4 motors
• Exhaust Gas Recirculation (EGR)
• Control solenoid valve
• Mass air flow sensor (DMRV)
• Throttle assembly (body)
• EGR heat exchanger
• Exhaust gas cleaning system (particulate filter)
• Particulate filter regeneration system
• Muffler with catalytic particulate filter
• Fuel system

F1C engine

• While the engine has not yet been removed from the vehicle
• Electrically operated injectors
• High pressure fuel pump SRZ
• High pressure fuel pipes
• Fuel rail components
• Removal and engine installation
• Withdrawal
• Installation
• Checks
• Removing air from the mains (pumping)
• Replacing the A / C compressor drive belt (tensioner option)
• Replacing the power steering belt and generator
• Replacing the water pump
• Replacing the high pressure fuel pump (injection pump)
• Replacing the power steering pump
• Replacing the front crankshaft oil seal and front engine cover gasket
• Replacing the vacuum and oil pump assembly
• Replacing the rear crankshaft oil seal
• Replacing fuel injectors
• Removing / installing cylinder head
• General view of the engine
• Sticker
• Cylinder block marking
• Characteristic curves
• Technical data
• Special tools
• Tightening torques of threaded connections, НМ
• F1C engine repair
• Dismantling the engine at the workbench
• Repair
• Cylinder block
• Table of measurements of the diameters of the main and connecting rod journals
• Crankshaft 188 Checking the crankshaft
• First main journal (timing side)
• Root necks No. 2, No. 4
• Root collar No. 3
• Rear neck (flywheel side)
• Connecting rod journals
• Installing the engine
• Flywheel
• Pistons with connecting rods
• Pistons
• 540830 connecting rods
• Bushings
• Dismantling the cylinder head
• Valves
• Valve guides
• Valve seats
• Valve springs
• Rockers and hydraulic supports
• Cylinder head assembly
• Gas distribution mechanism drive
• Crankshaft locking
• Gas distribution mechanism drive
• Lubrication system
• General information
• Oil system operation
• Oil / Vacuum pump assembly
• Oil filter
• Heat exchanger
• Crankcase ventilation system

Cooling system

• Description
• Electromagnetic clutch
• Water pump
• Thermostat
• Turbocharging
• Repair
• Bypass valve
• Turbocharger GARRET GT 2256 TC variable turbine geometry (F1C E0481 V engine - 166 hp)
• Repair

Fuel system

Electronically controlled high pressure battery power system (EDC 16)

• General information
• System operation
• Fuel system operation
• Fine fuel filter
• Booster fuel pump
• Fuel filter
• High pressure fuel pump (TNVD)
• Pressure regulator
• Mechanical booster pump
• Electro-controlled (electromechanical) fuel injectors
• Electrical and electronic components
• Electronic control unit (ECM) EDC 16
• Electronic control unit for glow plug power supply
• Glow plugs
• Sensors
• Actuators (executive devices)
• F1С EURO-4 engines
• Specifications
• Exhaust gas recirculation (EGR) heat exchanger removal / installation
• Exhaust system
• Removing the muffler
• Removing the catalyst and filter
• Installation

Clutch

• Description
• Diagnostics
• Technical data
• Removing and installing clutch
• Removing and installing release bearing
• Clutch actuator
• Hydraulic clutch actuator
• Removing-installing pedal board
• Pedal board
• Clutch with automatic wear compensation - complete with gearbox 6 AS'300 VD
• Removing and installing clutch with automatic wear compensation

Gearbox

• Diagnostics
• Removal-installation of the checkpoint
• Gearbox control
• Gearbox 5 S 300
• Mechanism of selection and inclusion of gears
• Safety devices
• Technical data (specifications)
• 5 S 300 gearbox repair
• Gearbox
• Disassembly of the main shaft
• Input shaft
• Disassembly of the transfer (intermediate) shaft
• Checks
• Main shaft assembly
• Stems - forks - selector - carrier
• Gearbox assembly
• Gearbox 6 S 400 O.D
• Technical data (specifications)
• Tightening torques
• 6 S 400 gearbox repair
• Gearbox
• Disassembly of the gearbox
• Removing the bearings from the rear cover
• Removing bearings from gearbox housing
• Disassembly of the main shaft
• Disassembly of the gearbox input shaft
• Dismantling the intermediate shaft
• Synchronizers
• Installing the intermediate (transfer) shaft
• Main shaft assembly
• Stems - forks - selector - carrier
• Gearbox assembly
• Automatic transmission 6 S 400 A O.D
• Main functions of the system
• Vehicle restraint system on a slope
• Management system structure
• Technical data
• Tightening torques for threaded connections
• Diagnostics
• MODUS connection - IT 2000 - E.A.SY
• Removal and installation of the checkpoint
• Gearbox repair
• Body-gearbox wiring harness
• Gearbox cable harness
• Calibration

Power take-off

• Technical data
• Assembly instructions
• Electric actuator for power take-off

Cardan shafts

• Technical data
• 4x2 models
• 4x2 models
• Removing and installing propeller shaft

Rear axle

• Troubleshooting
• Rear axle NDA RS
• Removing / installing rear axle
• Description
• Technical data
• Rear axle NDA RG
• Removing / installing rear axle
• Description
• Technical data
• Rear axle 450511
• Rear axle technical data 450511
• Removing / installing rear axle
• Description
• Technical data
• Rear axle repair
• Build
• Wheel hub repair
• Differential repair operations

Front axle

• Diagnostics
• 5817 front axle
• Description
• Technical data
• Removing and installing front axle
• 5817 front axle repair
• Removing and installing a wheel hub
• Removing / installing steering knuckle
• 5818 front axle
• Description
• Technical data
• 5818 Front axle repair
• Replacing the driving wheel of the ABS sensor
• Installation
• Removing and installing a wheel hub
• 5819 front axle
• Description
• Front suspension 5819
• Technical data
• 5819 front suspension repair
• 5823 Front axle
• Description
• Technical data
• Removal and installation of bridge 5823
• Repair of the front suspension 5823
• Removing and installing a wheel hub
• Replacing the driving wheel of the ABS sensor
• Installation
• Replacing the wheel stud

Camber and toe

• Description
• Camber angle
• Angle of lateral inclination of the axle of rotation of wheels
• Caster angle of the wheel axis
• Wheel alignment
• Wheel alignment angles
• Checking wheel alignment

Mechanical suspension

• Mechanical front suspension
• Description
• Cross leaf spring (models 29 L - 35 S - 35 С)
• Specifications
• Front single leaf spring
• Anti-roll bar
• Front shock absorbers
• Tools
• Tightening torques for threaded connections (NM)
• Renovation work
• Suspension repair
• Suspension arms
• Replacing the suspension arm bushings
• Anti-roll bar model 29 L - 35 S
• Front shocks 29 L - 35 S
• Leaf spring suspension
• Torsion bar suspension (front axles 5819 model 35 С - 40 С - 45 С - 50 С)
• Repair of jet suspension rods
• Replacing the swivel tips
• Torsion bars
• Replacing silent blocks and bumpers
• Replacing the swivel tips
• Adjusting the pre-tension bar
• Front anti-roll bar 35 C - 40 C - 45 C - 50 C
• Front shock absorbers 35 C - 40 C - 45 C - 50 C
• Suspension repair
• Replacing the swivel tips
• Torsion bars
• Replacing rubber grommets
• Rear suspension
• Technical data
• Tools
• Tightening torques for threaded connections (NM)
• Rear springs
• Renovation work
• Spring assembly
• Replacing bushings
• Rear shock absorbers
• Rear anti-roll bar

Pneumatic suspension

• Diagnostics
• Rear air suspension - VB-TECHNIEK model flashing code
• Rear air suspension - WABCO model
• Flashing code
• General part
• WABCO air suspension (for models 29 L - 35 S)
• Technical data
• WABCO Pneumatic System (ECAS)
• Electronic control
• How the air suspension works
• Models without ABS
• ABS models
• Automatic chassis trim, raise and lower
• Main components of the system
• Air supply unit
• Electronic control unit
• Clearance sensor
• Pneumatic element (air spring)
• Load sensing valve
• Rear suspension repair
• Leaf spring
• Rear shock absorbers
• Rear anti-roll bar
• Panhard's jet thrust