Content

General information and car operation

Maintenance

• Scheduled maintenance
• Maintenance of cars with F1A engines
• Maintenance of cars with F1C engines
• Maintenance operations
• Maintenance M1
• Maintenance M2
• EP1 maintenance
• EP2 maintenance
• Maintenance of EPZ
• Maintenance T1 (annually - in the early spring)
• Maintenance T2 (annually - before the start of the cold season)
• Maintenance of technical specifications (every two years and, if possible, simultaneously with maintenance)
• Maintenance T4 (every three years and, if possible, simultaneously with maintenance)

F1A engine

• Specifications
• General data
• The main sizes of engine elements
• Engine repair
• General recommendations for repair and maintenance of the engine
• Removing and installing the engine
• A / C compressor drive belt
• Alternator and water pump drive belt
• Timing belt
• Bleeding the hydraulic drive of the power steering
• Replacing fuel injectors
• Cylinder head
• Fuel pump of a high pressure CPH1
• Water pump
• Throttle node
• Glow plugs
• EGR valve
• Heat exchanger
• OXICAT - oxidative catalytic converter
• Exhaust system
• Complete exhaust system
• Components exhaust system with catalytic converter with DPF
• Engine disassembly
• Cylinder block repair
• Crankshaft
• Engine assembly
• Installing the rear crankshaft oil seal
• Flywheel
• Pistons
• Cranks
• Assembly of the piston and connecting rod
• Dismantling and checking the cylinder head
• Valves
• Valve seats
• Valve springs
• Rocker arms and pushers
• Cylinder head assembly
• Upper cylinder head section
• Gas distribution mechanism
• Camshafts
• Assembly of the upper section of the cylinder head
• Cylinder head installation
• Lubrication system
• General information
• Oil and vacuum pump assembly (GPOD)
• Additional elements of the lubrication system
• Crankcase oil vapor separation system
• Cooling system
• General information
• Electromagnetic fan clutch
• Water pump
• Thermostat
• Turbocharged air
• General information
• Pressure control valve
• Turbocharger GARRETT GT 17 with variable geometry of the blades (engine F1А E0481 Н-136 HP)
• Exhaust gas recirculation (EGR) system
• General information
• EGR function
• Exhaust gas recirculation system components
• Air flow meter
• Throttle node
• Exhaust emission reduction system with DPF catalytic converter
• Catalytic converter microparticle filter (DPF)
• Microparticle filter regeneration system
• Heat exchanger
• Fuel injection system MS 6.3 and EDC16
• EDC 16 electronically controlled high pressure fuel injection system
• Fuel injection system
• Hydraulic part of the fuel system
• Fuel booster pump
• Fuel filter "UFI filters"
• Fuel filter "Filtrauto"
• Fuel lines
• Fuel pressure regulator
• Fuel pump of a high pressure CPH1
• Hydraulic accumulator (fuel rail)
• Fuel injectors
• EDC 16 electronic control unit
• Glow plug control unit
• Glow plugs
• Sensors
• Drives
• PWM drives

F1C engine

• Specifications
• General data
• The main sizes of engine elements
• Engine repair
• General recommendations for repair and maintenance of the engine
• Removing and installing the engine
• Bleeding the hydraulic drive of the power steering
• A / C compressor drive belt
• Alternator and power steering pump drive belt
• Water pump
• Vacuum and oil pump assembly
• Power steering pump
• High pressure fuel pump
• Replacing front crankshaft seal and front cover gasket
• Fuel injectors
• Cylinder head
• Replacing the rear crankshaft oil seal
• EGR heat exchanger
• Exhaust system
• Components exhaust system with catalytic converter with DPF
• Engine disassembly
• Cylinder block repair
• Crankshaft
• Engine assembly
• Installing the rear crankshaft oil seal
• Flywheel
• Pistons
• Cranks
• Assembly of the piston and connecting rod
• Dismantling the cylinder head
• Valves
• Valve seats
• Valve springs
• Rocker arms and pushers
• Cylinder head assembly
• Upper cylinder head section
• Gas distribution mechanism
• Camshafts
• Assembly of the upper section of the cylinder head
• Final engine assembly
• Lubrication system
• General Information
• Oil and vacuum pump assembly (GPOD)
• Pressure control valve
• Oil filter
• Heat exchanger
• Crankcase ventilation system
• Cooling system
• General information
• Electromagnetic fan clutch
• Thermostat
• Water pump
• Turbocharged air
• General information
• Turbocharger Mitsubishi TD 4 HL-13T-6
• Pressure control valve
• Turbocharger GARRET GT 2260 V with variable blade geometry
• Exhaust gas recirculation (EGR) system
• General information
• Exhaust gas recirculation system components
• Air flow meter
• Throttle node
• Heat exchanger
• Exhaust emission reduction system with DPE catalytic converter
• Catalytic converter microparticle filter (DPF)
• Microparticle filter regeneration system
• Fuel injection system MS 6.3 and EDC16
• EDC 16 fuel injection system
• Fuel injection system
• Fuel lines
• Hydraulic part of the fuel system
• Fuel booster pump
• Fuel filter "Filtrauto"
• Fuel filter "UFI filters"
• Fuel pump of a high pressure CP3.2
• Fuel pressure regulator
• Hydraulic accumulator (fuel rail)
• Fuel injectors
• Marking and replacing fuel injectors
• EDC 16 electronic control unit
• Glow plug control unit
• Glow plugs
• Sensors
• Drives
• PWM drives
• Clutch
• General information
• Specifications

Grip

• Inspections and repairs on the car
• Removing and installing clutch
• Removing and installing clutch release bearing
• Hydraulic clutch
• Pedal block
• Automatic wear compensation clutch used with 6 AS’300 VD gearbox
• Clutch Diagnostics

Gearboxes

• Gearboxes
• Removing and installing gearbox
• Gear shift mechanism
• Gear lever base
• Gearbox diagnostics
• Gearbox 5 S 300
• Specifications
• Description of the gearbox 5 S 300
• Gear selection and gearshift
• Safety devices
• Gearbox repair
• Gearbox control unit
• Gearbox disassembly
• Checking gearbox elements
• Intermediate shaft assembly
• Assembly of the main shaft
• Removing and installing rods, forks, selector and slide
• Gearbox assembly
• Gearbox 6 S 400 O.D
• Specifications
• Gearbox description
• Gear selection and gearshift
• Gearbox repair
• Gearbox control unit
• Gearbox disassembly
• Checking gearbox elements
• Intermediate shaft assembly
• Assembly of the main shaft
• Removing and installing rods, forks, selector and carrier
• Gearbox assembly
• Gearbox 6 S 400 A O.D
• Specifications
• Gearbox description 6 S 400 A O.D
• The main functions of the system
• Limp home mode (hard to get home)
• Gradient car hold system
• System Structure
• Gear selection and gearshift
• Diagnostics
• Removing and installing gearbox 6 S 400 A O.D
• Gearbox repair
• Gearbox control unit 6 S 400 A O.D
• Clutch gear 6 S 400 A 0.D
• Gearbox control drive 6 S 400 A O.D
• Wires connecting the gearbox 6 S 400 A O.D chassis
• Transmission harnesses 6 S 400 A O.D
• Calibration
• Power take-off
• Specifications
• Assembly instructions
• Electric power take-off drive

Cardan shafts

• General information
• Specifications
• Drive shaft
• Inspections and repairs on the car
• Removing and installing propeller shaft
• Checking propeller shafts mounted on a vehicle
• Diagnostics of malfunctions

Rear axles

• Rear axle NDA RS
• Specifications
• NDA RS rear axle description
• Removing and installing the rear axle NDA RS
• NDA RS rear axle repair
• NDA RS rear axle differential repair
• Rear axle NDA RG
• Specifications
• Description of the rear axle NDA RG
• Repair of the rear axle NDA RG
• Rear axle 450511
• Specifications
• Description of the rear axle 450511
• Removing and installing rear axle 450511
• Rear axle repair 450511
• Dismantling and assemblage of the mechanism of blocking of differential of the back bridge 450511
• Dismantling and assembly of the differential of the rear axle 450511
• Rear axle 450517/2
• Specifications
• Description of the rear axle 450517/2
• Removing and installing rear axle 450517/2
• Rear axle repair 450517/2
• Disassembly and assembly of wheel hubs
• Differential lock mechanism
• Dismantling and differential assembly
• Diagnostics of malfunctions of rear axles

Front axles

• Front axle 5817
• Specifications
• Front axle 5817
• Removing and installing front axle 5817
• Removing and installing front wheel axle 5817
• Removing and installing steering knuckle
• Front axle 5818
• Specifications
• Front axle 5818
• Removing and installing wheel hub
• Removing and installing steering knuckle
• Front axle 5819
• Specifications
• Front axle 5819
• Front axle repair
• Removing and installing steering knuckle
• Front axle 5823
• Specifications
• Front axle 5823
• Removing and installing front axle 5823
• Front axle repair 5823
• Removing and installing wheel hub
• Diagnostics of malfunctions of front axles

Wheel, wheel, and tire angles

• Wheel alignment
• Specifications
• Wheel alignment
• Checking the wheel alignment
• Checking rotation angles
• Checking the alignment of the wheels of the rear axle
• Calculation of thickness of compensating gaskets
• Wheels and tires
• Tires
• Static wheel balancing
• Dependence of tire performance on pressure
• Diagnostics of malfunctions

Front and rear pendants

• Front mechanical suspension
• Specifications front suspension
• Mechanical front suspension
• Checking the ball joint play
• Front suspension arms
• Car shock absorber 29 L - 35 S
• Leaf spring
• Torsion bar front suspension models 35C, 40C, 45C and 50C with 5819 axles
• Technical specifications of torsion bar suspension
• Torsion bar front suspension
• Checking the ball joint play
• Jet thrusts
• Torsion
• Anti-roll bar
• Shock absorber
• 60C and 65C torsion bar front suspension with 5823 axles
• Specifications
• Repair front torsion bar suspension
• Replacing ball joint for jet thrust
• Torsion
• Replacing rubber grommets
• Rear mechanical suspension
• Specifications
• Rear mechanical suspension
• Removing and installing the parabolic spring for models 29 L and 35 S
• Removing and installing a semi-elliptic spring for models 35 C, 40 C, 45 C, 50 C, 60 C and 65 C
• Dismantling, checking and assembling the spring
• Rear shock absorbers
• Anti-roll bar
• Suspension diagnostics
• Rear air suspension
• Technical specifications for VB-WABCO rear air suspension
• General information
• Rear air suspension type VB-WABCO
• Automatic leveling, raising and lowering the chassis
• Air supply unit
• Electronic control unit (ECU)
• Clearance sensor
• Air spring
• Pneumatic brake force control valve
• Leaf spring
• Rear shock absorbers
• Anti-roll bar
• PANHARD jet thrust
• Diagnostics of the rear air suspension

Steering

• General information
• Specifications
• Steering
• Power steering
• Power steering TRW
• Power steering ZF
• Inspections and repairs on the car
• Security precautions
• Checking the maximum pressure
• Checking the hydraulic center of the hydraulic cylinder (only for ZF amplifiers)
• Removing air from the hydraulic system
• Protective covers for ball joints and tie rods
• Steering shaft
• Steering gear
• Power steering pump
• Diagnostics

Brake system

• Service brake system
• Specifications
• Diagrams and general description of the brake system
• Brake tubes and their connections
• Tube expansion and bending
• Vacuum brake booster
• Vacuum pump
• Checks
• Removing air from hydraulic circuits (vehicles without ABS)
• Bleeding the hydraulic circuits of the brake system using the air removal kit
• Proportional pressure regulator models 35 S
• Mechanically controlled dual-circuit pressure regulator, model 29 L and 35 S
• Brake system repair
• Replacing the front brake pads
• Replacing the front caliper
• Replacing the rear brake pads
• Replacing the rear caliper
• Caliper repair brembo 2x44, 2x48 and 2x60
• Calipers brembo 1x52 and 1x60
• Brake disc
• Parking brake
• Parking brake mechanisms
• Parking brake adjustment
• Tightening sequence for wheel nuts
• Electronic stability control (ESP) and anti-lock brake system (ABS)
• Electronic systems
• ESP system features
• ABS sensor and sensor driving rotor
• ESP sensors
• Replacing ESP elements
• Diagnostics of malfunctions

Heating, ventilation and air conditioning system

• Heating and air conditioning systems
• Specifications
• General information
• Heating and air conditioning system
• The main elements of an air conditioning system
• Compressor
• Capacitor
• Filter drier
• Expansion valve
• Evaporator
• Control and protection devices
• Heater / air conditioning unit type M. MARELLI or DENSO
• Electrical equipment

Car electrical equipment

• General security measures
• Electrical power equipment
• Negative power connections to the ground
• Basic elements of electrical equipment
• Battery
• Generator BOSCH KCBI 14 V, 110 A
• Starter
• Electrical connectors
• Display
• Gearshift paddles
• Switch cluster for dashboard center console
• The switch box located under the instrument cluster
• Additional block
• Data channels of the CAN multiplex system
• On-board computer
• EDC16 electronically controlled fuel injection system
• Distinctive features of Euro 4 engines
• EDC16 electronic control unit
• Electronic fuel injection system
• Additional electronic systems
• ABS 8 / ESP 8 systems
• The functioning of the ESP (electronic stabilization system)
• Immobilizer
• Passive safety system (SRS)
• Additional passive safety system
• Security control module
• Spiral airbag wire
• Seat belt tensioners
• Replacing the electronic control unit for the security system
• Replacing the driver’s airbag
• Replacing the passenger airbag
• Replacing the spiral wire of the airbag
• Automatic transmission 6AS 400 O.D. YD
• Operation of the 6AS 400 O.D. gearbox YD
• Electronic control unit
• Gear shift drive
• Clutch drive
• Accelerator pedal
• Automatic transmission control lever (selector lever)
• Power take-off
• Diagnostic connector (EOBD)

Wiring diagrams