Content

General information

• Vehicle identification
• Models complete set
• Decryption
• Lubricants
• F2B engine
• F3A engine
• Switch boxes (volume filled during the first filling)
• Hub (one)
• Rear axle

F2B Engines

• Engine identification
• Specifications
• Options
• Specifications
• Cylinder block and crank mechanism
• Crankshaft
• Valve actuator
• Cylinder head
• Tightening torques for screw connections
• Powertrain
• Removing and installing engine
• Withdrawal
• Installation
• Filling the cooling system
• Preliminary operations
• Filling the system
• Removing air from the cooling system
• Removing air from the power supply system
• Replacing the magnetic fan clutch
• Withdrawal
• Installation
• Dismantling the engine at the stand
• Cylinder block
• Checks and measurements
• Replacing the cylinder liner
• Withdrawal
• Install and check protrusion
• Crankshaft
• Crankshaft journal measurements
• Preliminary determination of the size group of the liners of the main and connecting rod bearings of the crankshaft
• Selection of main and connecting rod bearing shells
• Determination of the size group of the diameter of the main and connecting rod journals (journals of nominal diameter)
• Selection of main bearing shells (ground journals)
• Selection of main bearing shells (nominal diameter journals)
• Selection of bearing shells of the lower connecting rod head (journal of nominal diameter)
• Selection of the bearing shells of the lower end of the connecting rod (ground journals)
• Replacing the timing gear and oil pump
• Checking the crankshaft end play
• Checking installation clearances
• Piston
• Disassembly
• Piston rings
• Connecting rod
• Crankset marking scheme
• Alignment check
• Curl check
• Bending test
• Installing piston rings
• Installing the piston and connecting rod assembly into the sleeve
• Checking the connecting rod journal clearance
• Cylinder head
• Removing valves
• Checking the bottom plane of the cylinder head
• Valves
• Removing carbon deposits and checking valves
• Valve guides and seats
• Replacing the valve guides
• Replacing valve seats
• Replacing the injector sleeves
• Gas distribution mechanism
• Replacing bushings
• Camshaft
• Camshaft bushings
• Valve Springs
• Installing valves and valve stem seals
• Bal rocker arms
• Assembling the engine at the stand
• Adjusting the timing
• Valve clearance adjustment
• Adjusting the preload of the injector rocker arms
• Lubrication system
• Oil pump
• Heat exchanger
• Oil filter
• Valve in the piston coolant sprayer
• Cooling system
• Pressurization system
• Functional principle of the VGT turbocharger
• Actuator (drive)
• Power system
• Fuel pump
• Injector
• Replacing injectors
• Phases of injector operation

F3A Engines

• Engine designation
• Specifications
• Parameters, F3A engine
• Specifications
• Cylinder block and crank mechanism
• Crankshaft
• Valve actuator
• Cylinder head
• Tightening torques for screw connections
• Removing and installing engine
• Withdrawal
• Installation
• Filling the cooling system
• Removing air from the power supply system
• Replacing the magnetic fan clutch
• Withdrawal
• Installation
• Dismantling the engine at the stand
• Cylinder block
• Checks and measurements
• Replacing cylinder liners
• Crankshaft
• Crankshaft journal measurements
• Selection of main and connecting rod bearing shells
• Replacing the timing gear and oil pump
• Checking installation clearances
• Checking the crankshaft end play
• Piston
• Piston rings
• Connecting rod
• Crankset marking scheme
• Connecting rod bush
• Valves
• Valve guides and seats
• Replacing the injector sleeves
• Gas distribution mechanism
• Camshaft
• Camshaft bushings
• Valve springs
• Rocker shaft
• Assembling the engine at the stand
• Lubrication system
• Cooling system
• Electromagnetic fan clutch
• Pressurization system
• Power System

HIDROCAR power take-off on the gas distribution mechanism (option)

• Removal / Installation

DENOX emission control system

• Repair

Diagnostics

• Diagnostic devices
• Description of fault codes

Clutch

• Specifications, 17 "clutch for E2B / FZA engines
• Specifications, clutch 17 "for F2B engines with gearbox 9S 1310 TO / 9S 1311 TO 129
• Troubleshooting
• Tightening torques for screw connections
• Clutch removal and installation
• Replacing the clutch release bearing
• Replacing the clutch shaft support bearing
• Removing and installing SATA pedal unit
• Checking and adjusting the clutch pedal travel stops (vehicles with ABS)
• WABCO pedal (vehicles with EBS)
• Clutch pedal travel stop bolt
• Clutch pedal free play
• Pedal Control Valve Stroke
• Hydraulic steering (vehicles with ABS)
• Clutch Actuator (without friction lining wear indicator)
• Specifications (manual transmission)
• Pusher (rod) length adjustment
• Bleeding the clutch system
• Specifications (automatic transmission)
• Adjusting the length of the slave cylinder pusher (new clutch)
• Installing the slave cylinder
• Replacing the slave cylinder

Gearboxes

• Gearbox ZF 9 S 1310 TO
• Specifications
• Gearbox ZF 16 S 1620Т.D .; ZF 16 S 1920 T.D ;; ZF 16 S 2220 T.D. / T.O.
• Specifications
• Tightening torques for screw connections
• Removal and installation
• Gearbox ZF 16 S1621TD; ZF 16 S1921TD; ZF 16 S 2221 TO. / TO
• Removing the intarder
• Removing the rear case of the planetary gear unit
• Removing the planetary gear assembly
• Installing the planetary gear unit
• gearbox EUROTRONIC 12 AS 1420 TD.
• Specifications
• Gearbox EUROTRONIC AUTOMATED 12 AS 1930 TD. 12 AS 2330 TD. / TO
• Specifications
• Gearbox removal and installation
• Gearbox EUROTRONIC AUTOMATED 12 AS 1931 TD. 12 AS 2331 TD. / TO
• Removing and installing intarder
• Determining the thickness of the bearing shim
• Determining the thickness of the stator adjusting ring
• Removing the rear of the gearbox housing
• Disassembly of the planetary gear
• Planetary gear assembly
• ALLISON 3200 gearbox
• Specifications
• Tightening torques for screw connections
• Troubleshooting
• Removal and installation
• Diagnostics of the ELECTRONIC gearbox
• Fault codes

Hydraulic retarder (intarder)

• General information
• How it works
• Removing and installing retarder, gearbox ZF 16 S 1920/2220
• Withdrawal
• Installation
• Oil filling
• Specifications
• Tightening torques for screw connections
• Troubleshooting
• Retarder repair
• Removing the accumulator
• Installing the accumulator
• Dismantling the retarder
• Checking the technical condition of the retarder parts
• Retarder assembly

Cardan shafts

• Specifications
• Troubleshooting
• Removing and installing propeller shaft
• Checking the propeller shaft on the vehicle
• Disassembly and assembly of universal joints
• Disassembly and assembly of the support

Rear axle

• Troubleshooting
• faults
• Removing and installing rear axle
• Removing and installing differential from the rear axle (without removing the axle from the car)
• Rear axle ARVIN MERITOR MS 13-175 205 Specifications
• Wheel hub repair
• Differential removal and installation
• Differential repair
• Dismantling the differential box
• Removing the drive bevel gear from the support
• Checking differential components
• Determining the thickness of the stator shim
• Differential box assembly
• Installing the pinion pinion support
• Differential housing assembly
• Adjusting the distance between the covers
• Correction of the contact patch of the final drive gears
• Replacing the pinion support oil seal
• Rear axle 451391/1
• Specifications
• Repair
• Differential removal and installation
• Differential repair
• Tandem rear axle ARVIN MERITOR MT23-155 / D
• Specifications
• Wheel hub repair
• Center differential
• Removing and installing axle differential
• Output shaft removal and installation
• Rear axle ARVIN MERITOR MR11-155 / D
• Specifications

Front axle

• Front axles 5876/4; 5876/5; 5886/5 and and steered additional front axle 5876/4
• Specifications
• Troubleshooting
• Front axle removal and installation
• Additional steering axle (6x2 vehicles)
• Filling and bleeding hydraulic circuits
• Loop 1
• Loop 2
• Additional lifting steerable axle, 6x2 vehicles
• Checking the ball joint play of the steering link
• Front axle repair
• Removing and installing hubs
• Tie rod removal and installation
• Replacing the tie rod ball joints
• Removing and installing steering knuckle pivot
• Additional rear axle 55080 / D1
• Specifications
• Removal and installation
• Repair
• Optional lift rear axle 56082 / D1 with hydraulic raise / lower
• Specifications
• Removal and installation
• Repair
• Wheel alignment angles
• Optional steered rear axle 57080 / D 1 with pneumatic lift / lower
• Specifications
• Repair
• Hydraulic steering axle steering
• Checking nitrogen pressure and charging the hydraulic accumulator
• Slave cylinder
• Centering cylinder
• Bleeding hydraulic system
• Air suspension and pneumatic axle lift system
• Troubleshooting
• Tightening torques of threaded joints of parts of the steering mechanism and the device for raising and lowering
• Removal and installation of raising and lowering an additional steering axle
• Wheel alignment angles

Steering

• Specifications
• Removing and installing power steering
• Steering arm removal and installation
• Removing and installing steering column assembly
• Replacing the pneumatic cylinder
• Bleeding the power steering circuit
• Measuring steering play with the steering wheel
• Checking the maximum pressure in the power steering
• Troubleshooting

Wheels and tires

• Troubleshooting
• Static wheel balancing
• Tire pressure

Cab and frame

• Specifications
• Repair

Maintenance

• Cars with CURSOR 8 (F2B) engine
• Maintenance Descriptions
• Cars with CURSOR 10 (F3A) engine
• Maintenance Descriptions

Abbreviations