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WORKSHOP MANUAL C GB

Workshop Manual

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Astra Truck Workshop Manual

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WORKSHOP MANUAL

C

GB

II

The Company ASTRA VEICOLI INDUSTRIALI reserves the right to make any modifications to vehicles for technical or commercial reasons at any time; the information, descriptions and illustrations contained in this publication are therefore updated at the time of approval for printing. This Workshop Manual deals with optional equipment which cannot be present on your vehicle, and alternative equipment as well (e.g. mechanical and automatic gearbox). Moreover, the regulations in force in certain countries affect the standard equipment of the vehicle. This publication could therefore contain information and illustrations not corresponding to the vehicle version provided on a particular market.

ASTRA Veicoli Industriali Product Logistics Via Caorsana, 79 - 29100 PIACENZA (Italy) Tel. 0523/5431 - Fax 0523/543459

Publication A3500940 First edition - APRIL 2006 Prepared by SIPAL S.p.A. - TORINO (Italy)

Reproduction, even partial, of this text and illustrations contained therein is prohibited.

ASTRA HD8Ec

INDEX OF SECTIONS

1

INDEX OF SECTIONSSection Pages

Introduction

1 2 3 4 5 6

from 1 to 6

General Specifications

from 1 to 10

Engine F3B

from 1 to 134

Clutch

from 1 to 20

Power takeoff

from 1 to 18

Manual gearbox ZF 16S 1620 TD ZF 16S 2320 TD

from 1 to 64

Reduction gear unit TC 1800

9.1 9.2 10 11 12.1 12.3 12.4

from 1 to 22

Reduction gear unit TC 2200

from 1 to 22

Propeller shafts

from 1 to 10

Axle

from 1 to 16

Front drive axle

from 1 to 42

Single Rear axle

from 1 to 36

Intermediate axle (in tandem)

from 1 to 42

2

INDEX OF SECTIONS

ASTRA HD8Ec

Section

Pages

Rear axle (in tandem)

12.5 13.1 13.2 14.1 14.2 15 16 17 18

from 1 to 36

Brakes

from 1 to 16

Wheels and tyres

from 1 to 6

Front suspensions

from 1 to 14

Rear suspensions

from 1 to 18

Steering system

from 1 to 38

Pneumatic system - brakes

from 1 to 44

Electrical system

from 1 to 134

Cab and chassis

from 1 to 14

INTRODUCTION

SECTION I

ASTRA HD8Ec

SECTION I

INTRODUCTION

1

SECTION I

IntroductionPREFACE Page 3 3 3 4 5 5 6 6

- Definitions adopted in the current Manual - Introduction - Graphs and symbolsMEASURES (INTERNATIONAL SYSTEM)

- Conversion values for British unitsSTANDARD TIGHTENING TORQUES

- Screws and nuts with metric thread

2

INTRODUCTION

SECTION I

ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec

SECTION I

INTRODUCTION

3

PREFACE Definitions adopted in the current ManualThe Company ASTRA VEICOLI INDUSTRIALI, Via Caorsana, 79 - 29100 PIACENZA (Italy) is hereinafter called Manufacturer. The current WORKSHOP MANUAL is hereinafter called Manual. The equipment dealt with in the current Manual is hereinafter called vehicle. The operator directly or indirectly involved in vehicle repair is hereinafter called operator.

IntroductionThe current Manual applies essentially to authorised workshop technical staff. This Manual provides technical information but cannot replace a thorough professional experience. This Manual contains all data and information required to perform correct checking and setting up operations as well as repair and overhaul operations. Read this Manual right through before performing any operation on the vehicle. Compliance with the provided information and the use of the recommended tools guarantee correct repair and avoid damages to operators. You will frequently see that parts of the text are highlighted as shown below: Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause injury.

Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause damage to the vehicle.

Procedures, technical information and precautions which must be highlighted.

Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause environmental damages.

This Manual has been divided into Sections, each of which has a number and its relevant contents are indicated in the Index of Sections. Each section features a main Unit (e.g.: engine, gears, etc.) Where possible, the same sequence of procedures has been followed for easy reference. Diagram 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:

1 = Housing for connecting rod small end bush

2 = Housing for connecting rod bearings

Tighten to torque Tighten to torque + angular value

4

INTRODUCTION

SECTION I

ASTRA HD8Ec

Graphs and symbolsRemoval Disconnection Re-fitting in place Connection Removal Dis-assembly Fitting in place Assembly Driving torque

Intake

Exhaust

Operation

Compression ratio Tolerance Weight difference Rolling torque

Driving torque + angular valueASTRA

Press or Caulk Regulation Adjustment Caution Note Visual check Fitting position check Measurement Value to find Check Equipment Face for machining Machine finish Interference Strained assembly Thickness Clearance Lubrication Damp Grease Sealant Adhesive Air bleeding

Replacement Original spare parts Rotation Angle Angular value Preload

Number of revolutions

Temperature

bar

Pressure Oversized Greater than .. Maximum, peak Undersized Less than... Minimum Selection Classes Oversizing Temperature < 0o C Cold Winter Temperature >0o C Hot Summer

ASTRA HD8Ec

SECTION I

INTRODUCTION

5

MEASURES (INTERNATIONAL SYSTEM) Force in N (Newton) Conversion:IN = 0,1019 kg 9,81 N

Pressure in kPa (kilopascal)Other units in use: kg/cm2 (kilograms per square centimeter) Atm (metric atmosphere) psi (pounds per square inch)

1 kg =

Conversion: Power in kW (kilowatt)I kg/cm2 Other units in use: HP (Horsepower) I I I 1,36 CV 1,34 HP 0,736 kW 0,986 HP 0,746 kW 1,014 CV kg/cm2 kg/cm2 kg/cm2 = = = = = = = = = = = = = = 1 Atm 98,1 kPa 0,981 bar 1 bar * 14,22 psi 100 kPa 1,02 kg/cm2 14,51 psi 6,9 kPa 0,069 bar 0,0703 kg/cm2 0,145 psi 0,0102 kg/cm2 0,01 bar

Conversion:1 kW = 1 kW = 1 CV = 1 CV = 1 HP = 1 HP =

I kg/cm2 I bar I bar I bar I psi I psi I psi I kPa I kPa I kPa

Torque in Nm (Newton/metre) Conversion:1 Nm = 1 kgm = 1 kgm = 0,1019 kgm 9,81 Nm 10 Nm *

Conversion values for British units0,1 mm I mm Im I km I cm3 Il I bar Ig I kg = = = = = = = = = 3,937 mils 0,039 inch 3,281 ft. 0,621 miles 0,06 I cu. in. I ,759 pts (0,88 imp.qts) 14,5038 psi 0,035 oz. (0,564 dr.) 2,205 Ibs.

Specific consumption in g/kWh (grams per kilowatthour)Other unit in use: g/CVh (grams per horsepower-hour)

Conversion:I g/kWh 1 g/CVh = = 0,736 g/CVh 1,36 g/kWh

(in case of differences in temperature 1 C = 1.8 F) (*) Nm and bar are converted according to the ratios 10:1 and 1:1.

6

INTRODUCTION

SECTION I

ASTRA HD8Ec

STANDARD TIGHTENING TORQUES Screws and nuts with metric thread

Diameter x Pitch dxp (mm)

SCREW CLASS 8.8

SCREW CLASS 10.9

SCREW CLASS 12.9

UNCOATE D

DACROMET GALVANISED

CADMIUM PLATED

PHOSPHATE COATED

UNCOATE D

DACROMET GALVANISED

CADMIUM PLATED

PHOSPHATE COATED

UNCOATE D

DACROMET GALVANISED

CADMIUM PLATED

PHOSPHATE COATED

3 x 0,5 4 x 0,7 5 x 0,8 6x1 8 x 1,25 8x1 10 x 1,5 10 x 1,25 12 x 1,75 12 x 1,25 14 x 2 14 x 1,5 16 x 2 16 x 1,5 18 x 2,5 18 x 1,5 20 x 2,5 20 x 1,5 22 x 2,5 22 x 1,5 24 x 3 24 x 2 27 x 3 27 x 2 30 x 3,5 30 x 2

0,12 0,28 0,56 1,0 2,3 2,5 4,7 5,0 8,0 9,0 12,8 14,1 19,8 21,5 27,2 31,4 38,4 43,9 53,9 59,0 66,7 74,2 98,7 108,4 133,7 151,6

0,12 0,26 0,52 0,9 2,2 2,4 4,4 4,7 7,5 8,4 12,0 13,1 18,5 20,0 25,4 29,2 36,1 40,9 49,0 54,8 62,4 69,1 92,2 100,8 124,9 141,0

0,11 0,24 0,48 0,8 2,0 2,1 4,0 4,2 6,8 7,5 10,9 11,9 16,8 18,0 23,1 26,2 32,7 36,5 44,6 48,9 56,4 61,9 83,1 90,1 112,7 125,8

0,09 0,20 0,40 0,7 1,7 1,8 3,3 3,5 5,7 6,2 9,1 9,7 13,9 14,6 19,2 21,1 27,0 29,4 36,2 39,1 46,6 50,0 68,2 72,4 92,8 100,6

0,17 0,39 0,79 1,3 3,3 3,5 6,5 7,0 11,3 12,6 18,0 19,8 27,9 30,2 38,2 44,1 54,3 61,7 75,9 82,9 93,8 104,4 138,8 152,4 188,0 213,2

0,16 0,37 0,74 1,3 3,1 3,3 6,1 6,5 10,6 11,8 16,9 18,5 26,1 28,2 35,8 41,1 50,8 57,5 68,8 77,1 87,7 97,2 129,6 141,8 175,6 198,2

0,15 0,34 0,67 1,2 2,8 3,0 5,6 5,9 9,6 10,6 15,3 16,7 23,6 25,3 32,4 36,8 46,0 51,4 62,8 68,8 79,3 87,1 116,9 126,7 158,5 176,9

0,13 0,29 0,57 1,0 2,3 2,5 4,7 4,9 8,0 8,7 12,8 13,6 19,5 20,6 27,0 29,7 38,0 41,3 51,0 55,0 65,5 70,3 95,9 101,8 130,5 141,5

0,21 0,47 0,94 1,6 3,9 4,3 7,9 8,4 13,6 15,1 21,6 23,8 33,5 36,3 45,8 53,0 65,2 74,1 91,0 99,5 112,5 125,3 166,5 182,9 225,6 255,9

0,19 0,44 0,88 1,5 3,7 4,0 7,4 7,9 12,7 14,1 20,2 22,2 31,3 33,8 42,9 49,3 61,0 68,9 82,6 92,5 105,2 116,7 155,5 170,2 210,7 237,9

0,18 0,41 0,80 1,4 3,3 3,6 6,7 7,1 11,5 12,7 18,4 20,0 28,3 30,4 38,9 44,2 55,2 61,6 75,3 82,6 95,2 104,5 140,2 152,1 190,2 212,2

0,15 0,35 0,68 1,2 2,8 3,0 5,6 5,9 9,6 10,4 15,3 16,4 23,4 24,7 32,4 35,7 45,6 49,5 61,1 66,1 78,6 84,4 115,0 122,2 156,5 169,8

Maximum tightening torques for metric threads in daNm

GENERAL SPECIFICATIONS

SECTION 2

ASTRA HD8Ec

SECTION 2

GENERAL SPECIFICATIONS

1

SECTION 2

General specificationsCOMPOSITION OF THE MODEL POSITION OF VEHICLE IDENTIFICATION DATA - Model identification plate - Chassis - Manufacturers plate POSITION OF ASSEMBLY IDENTIFICATION DATA6 - Engine - Engine dependent power take-off - Gearbox 16 S 1620 TD - Gearbox 16 S 2320 TD - Distributor-reducer (transfer) - Front and rear drive axles - Power steering boxes - Cab LUBRICANT AND HYDRAULIC FLUID TABLES 6 6 6 6 7 7 8 8 9 Page 3 4 4 4 4

2

GENERAL SPECIFICATIONS

SECTION 2

ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec

SECTION 2

GENERAL SPECIFICATIONS

3

COMPOSITION OF THE MODELSMODELS 4x4 HD8 44.36 HD8 44.42 6x4 HD8 64.38 HD8 64.42 6x6 HD8 66.38 HD8 66.42 o o o o o o o o o o o o o o o o o o o 8x4 HD8 84.38 o o o o HD8 84.42 o o o o o

UNITS E N G I N E M A N. G E A R B O X MECHANICAL ZF 16 S 2320TD F3B WG (380 CV)

o

o

o

F3B

VG

(420 CV) Single disc 17 o

o o o

o o

CLUTCH

ZF 16 S 1620TD

o

o

o

o

o

TRANSFER AXLE F R O N T D R I V E A X L E TANDEM REAR 1st FRONT

TC 1800 TC 2200 ASTRA 9820 D 1385 AE 032/5985 R 8284 B027 (451391/1) INTERMEDIATE R 9189 BB033 (453291) REAR R 8298 B052 (453291) ZF 8098.955 ZF 8099.955

o o

o

SINGLE REAR

o

o

o

o

o

o o o o

o o

o o

HYDRAULIC POWER STEERING

4x4 = Two axle vehicles with front axle and rear driving axle. 6x4 = Three axle vehicles with two rear driving axles. 6x6 = Three axle vehicles with front axle and two rear driving axles. 8x4 = Four axle vehicles: first and second steering axles, third and fourth driving axles

4

GENERAL SPECIFICATIONS

SECTION 2

ASTRA HD8Ec

POSITION OF VEHICLE IDENTIFICATION DATAFigure 1

Figure 3

Manufacturers plateData for vehicle identification according to EEC regulations, on the lefthand side of the engine cover. (see following page)

Model identification plateLocated on the side walls of the cab.

Figure 2

ChassisPunch marked at the front end of the righthand side member. (see following page)

ASTRA HD8Ec

SECTION 2

GENERAL SPECIFICATIONS

5

Chassis punching1) right side member front end 2) rear axle front leaf spring Figure 4

ba

Vehicle registration number1) Worldwide identification of manufacturers (Astra Veicoli Industriali S.p.A.) 2) Type of vehicle 3) Vehicle features 4) Year of construction: (Y=2000; 1=2001; 2=2002; 3=2003; g 9=2009; A=2919; ecc.) 5) Production facility (P=Piacenza) 6) Chassis number

Vehicle identification plate1) Type approval number markings 2) Vehicle chassis punch markings 3) Overall vehicle weight 4) Overall tractor + trailer/semitrailer weight 5) Maximum admissible weight 1st axle 6) Maximum admissible weight 2nd axle 7) Maximum admissible weight 3rd axle 8) Maximum admissible weight 4th axle 9) Maximum admissible weight on fifth wheel (tractor versions only) 10) Vehicle commercial denomination 11) Axle spacing 12) Engine type 13) Engine power 14) Number of axles 15) Grade of smoke Figure 6

Figure 5

6

GENERAL SPECIFICATIONS

SECTION 2

ASTRA HD8Ec

POSITION OF ASSEMBLY IDENTIFICATION DATAMain assemblies mounted on vehicle are identified by a serial number which can be found on the concerned assembly in the positions shown on drawings. Assembly identification data must always be indicated when ordering spare parts.

Figure 9

Figure 7

Gearbox 16S 1620 TDGearbox type and serial number are shown on gearbox plate.

Figure 10

EngineEngine type and serial number are shown on engine plate. - engine F3BWG

Figure 8

Gearbox 16S 2320 TDGearbox type and serial number are shown on gearbox plate.

Engine dependent power take-offPower take-off type and serial number are shown on power take-off box plate.

ASTRA HD8Ec

SECTION 2

GENERAL SPECIFICATIONS

7

Figure 11

Figure 15

D

Distributor-reducer (transfer)Transfer type and serial number are shown on transfer case plate

Front and rear drive axlesAxle type and serial number are shown on axle casing. - axles (A) - front axle (B) - single rear axle (C)

Figure 12

A

- tandem rear axles

Figure 13

B

Figure 14

C

8

GENERAL SPECIFICATIONS

SECTION 2

ASTRA HD8Ec

Figure 16

Figure 18

A

Cab- Two-seater cab

Figure 17

B

Power steering boxesPower steering type and serial number are shown on power steering box plate. - 2-axle and 3-axle vehicles (A) - 4-axle vehicles (B)

ASTRA HD8Ec

SECTION 2

GENERAL SPECIFICATIONS

9

LUBRICANT AND HYDRAULIC FLUID TABLES

10

GENERAL SPECIFICATIONS

SECTION 2

ASTRA HD8Ec

Page left intentionally blank

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

1

SECTION 3

Engine - F3BVIEWS OF THE ENGINE TECHNICAL SPECIFICATION GENERAL CHARACTERISTICS ASSEMBLY CLEARANCE DATA DIAGNOSIS - Blink Code - Fault checking/identification procedure - Fault memory cancellation procedure from drivers seat - MS 6.2 EDC electronic control unit blink code table DIAGNOSIS TOOLS IT2000 - Upper level diagnosis CONTROL UNIT DIAGNOSIS ENGINE DIAGNOSIS (ENGINE TEST) AUXILIARY FUNCTIONS TROUBLESHOOTING - Introduction TROUBLESHOOTING (BLINK CODE) TROUBLESHOOTING BY SYMPTOMS TIGHTENING TORQUES TIGHTENING ORDER OF GEARBOX TO ENGINE BLOCK FASTENING SCREWS TOOLS ENGINE REMOVAL - REPLACEMENT - Removal - Replacement - Bleeding air from supply system - Checks and controls DISMANTLING THE ENGINE ON THE BENCH REPAIR OPERATIONS Page 5 10 11 14 20 20 20 20 21 22 22 22 23 23 23 24 24 25 33 40 43 47 57 57 62 63 63 64 72

2

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

CYLINDER BLOCK - Check and measurements CYLINDER LINERS - Replacing cylinder liners - Removal - Fitting and checking protrusion - CRANKSHAFT - Measuring main journals and crank pins - Choice of big end and main bearing half-shells DETERMINATION OF PRELIMINARY DATA FOR SELECTION - Replacing the timing control gear and the oil pump - Checking main journal installation clearance - Checking crankshaft end float - Piston-connecting rod assembly - Removal - Measuring the diameter of the pistons - Conditions for correct gudgeon pin-piston coupling - Piston rings CONNECTING ROD - Checking con rods - Fitting piston rings - Fitting connecting rod-piston assies in cylinder liners for checking fitting play CYLINDER HEAD - Valve removal

72 72 73 74 74 74 75 76 77 78 85 85 86 87 87 88 88 89 90 91 91 92 93 93

- Timing gear - Checking cam lift and pin alignment

98 98

- Fitting the connecting rod-piston assembly into the piston liners 99 - Bushes - Removal - Replacement - Valve springs - Fitting the valves and oil seal ring - Rocker shaft ROCKERS ASSEMBLY THE ENGINE ON THE BENCH - Fitting the connecting rod-piston assembly into the cylinder liners - Fitting the cylinder head - Replacing flywheel casing - Replacing engine flywheel - Replacing camshaft, valves and injectors - Replacing rocker shaft assembly - Timing the camshaft - Timing the phonic wheel - Adjusting the unload/intake rockers play and pump injector control rockers preload. COMPLETING ENGINE ASSEMBLY LUBRICATION - Lubrication system outline - Heat exchanger. - Engine oil filter. COOLING - Water pump - Thermostat operation view - Lubrication system outline - Lubrication system outline - Filling up the cooling system TURBOCHARGING 99 100 100 102 102 103 103 104 107 108 109 110 111 112 113 115 116 117 119 120 122 123 124 124 124 125 126 127 128

- Checking the planarity of the head on the cylinder block 93 - Removing deposits and checking the valves - Replacing of valve guides - Replacing - Reaming the valve seats REPLACING INJECTOR HOLDER CASED - Removal - Checking protrusion of injectors 93 95 95 95 95 97

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

3

HOLSET HX 50W (TURBINE WASTEGATE) PRESSURE LIMITER VALVE - Pressure limiter valve control and adjustment FUEL FEED - Pump-injector - Pumping element - Nozzle - Solenoid valve - Replacing pump-injectors - Injection phases - Filling phase - Injection phase - Pressure reduction phase

129 129 129 131 132 132 132 132 132 133 133 133 134

4

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

5

VIEWS OF THE ENGINEFigure 1

1780310

RIGHT SIDE 1. Engine control unit - 2. Oil sump - 3. Power steering pump on compressor - 4. Starting motor - 5. Air compressor 6. Fuel filter on engine - 7. Engine stop and start controls - 8. Air return line from intercooler - 9. Alternator 10. Water outlet to radiator

6

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Figure 2

1780311

LEFT SIDE 1. Oil-water heat exchanger. - 2. Engine oil filter. - 3. Water delivery from radiator.- 4. Fan. - 5. Air delivery pipe to intercooler. - 6. Water delivery pipe to cab heater. - 7. Intake. - 8. Exhaust gas turbocompressor. - 9. Exhaust. 10. Exhaust manifold. - 11. Power take-off (optional)

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

7

Figure 3

1780312

TOP VIEW 1. Fan - 2. Air delivery pipe to intercooler - 3. Exhaust gas turbocompressor - 4. Exhaust manifold - 5. Power take-off (optional) - 6. Fuel filter on engine - 7. Distributor cap - 8. Air return pipe from intercooler - 9. Alternator

8

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Figure 4

1780313

FRONT VIEW 1. Engine start-stop command - 2. Air return pipe from intercooler - 3. Fan - 4. Oil sump - 5. Engine oil filter 6. Air delivery pipe to intercooler - 7. Exhaust gas turbocompressor - 8. Distributor cap

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

9

Figure 5

1780314

REAR VIEW 1. Power take-off (optional) - 2. Exhaust gas turbocompressor - 3. Engine oil filter - 4. Flywheel - 5. Oil sump 6. Fuel pump - 7. Air return pipe from intercooler - 8. Engine start-stop command

10

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

TECHNICAL SPECIFICATION

TYPE F 3 B E 0 6 8 1 A * A 0 0 1 -

PART NUMBER

Progressive production number Version number within the B.o.M. Only for exhaust gas level with the same torque and power curves Engine power output or torque level Use (eg I = truck) Fuel feed + injection (TCA, direct injection diesel engine) Number of cylinders Number of strokes and cylinders position (eg 0 = 4 strokes, vertical) Engine (invariable) Engine family evolution (also irrespective of the displacement) Indicates the engine family

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

11

GENERAL CHARACTERISTICS

Type Cycle Feeding Injection N. of cylinders

F3B Diesel 4 strokes Turbocharged with aftercooler Direct 6 on-line mm mm 135 150 12880 16 0.8 kW (HP) rpm kW (HP) rpm kW (HP) rpm WG

j

Diameter Stroke

+

+

+.. = Total displacement cm3Compression ratio Max. power

Max. power

284 380

313 420

Max. power

1900 1800 184 900 1480

1900 1900 194 900 1500

Max. power

kW (HP) rpm

Engine idling speed, no load Maximum engine speed, no load

rpm

600 25 2400

rpm

12

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Type A VALVE TIMING opens before T.D.C. closes after B.D.C. B C opens before B.D.C. closes after T.D.C. D C A B

F3B

17 30

51 11

D For timing check X X Running X mm mm 0.35 to 0.45 0.35 to 0.45 DIRECT INJECTION With electronically regulated injectors PDE 31 pump injectors controlled by overhead camshaft 1-4-2-6-3-5 mm mm _ _

FEED Injection type Bosch Injection order

bar

Injection pressure

bar

1500

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

13

Type

F3B WG Holset Wastegate HX55W By centrifugal pump, regulating thermostat, viscostatic fan, radiator and heat exchanger By belt N. 1 ~85 C _ Forced by gear pump, pressure control valve, oil filter

SUPERCHARGING Turbocharger type COOLING COOLING Water pump control Thermostat: starts to open: fully open: LUBRICATION Oil pressure, engine hot (100 oC 5 oC): at idling speed bar at maximum speed bar OIL FILLING (*) Total capacity at 1st filling liters kg Capacity: - engine sump min level liters Urania Turbo LD (according to ACEA and/or E5 standard) Urania Turbo (according to ACEA E2-96) kg - engine sump max level liters kg - quantity in circulation that does not flow back to the engine sump liters kg - quantity contained in the cartridge filter (which has to be added to the cartridge filter fill) filt refill) liters kg

bar

1.5 5

35 25.5

20 18 28 24,5

7 6.3

3 2.7

(*) For the correct type of fluid, see section 2 - HYDRAULIC FLUID AND LUBRICANTS TABLE

14

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

ASSEMBLY CLEARANCE DATA

Type CYLINDER BLOCK AND CRANK MECHANISM COMPONENTS j1 Cylinder sleeve bore upper 1 lower Cylinder liners: outer diameter: upper 2 lower length Cylinder sleeve crankcase bore upper lower Outside diameter

F3B mm

153.500 153.525 152.000 152.025

L

153.461 153.486 L 151.890 151.915 _ 0.014 0.039 0.085 0.135 2 _

j2

ASTRA

j3X

Cylinder sleeve inner diameter inner diameter Protrusion 3A* 3B* X 135.000 135.013 135.011 135.024 0.045 0.075

* Available dia. class

X

j1 j2

Pistons: measuring dimension X outside diameter 1 A* outside diameter 1 B* pin bore 2 Piston - cylinder sleeve inner diameter 3A* 3B* 1 20 134.881 134.893 134.892 134.894 54.010 54.018 0.107 0.132 0.107 0.132 _

* available dia. class

* available dia. classASTRA

inner diameter Piston diameter

X Pistons protrusion X _

j3

Gudgeon pin

3

53.994 54.000

Gudgeon pin - pin housing

0.010 to 0.024

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

15

F3B Type X1* Piston ring grooves gg X2 X3 *measured on of 130 mm Piston rings: trapezoidal seal S1* p S1 S2 S3 lune seal S2 milled scraper ring ill d i with slits and internal spring S3 *measured on of 130 mm 1 Piston rings - grooves 2 Piston rings - grooves 3ASTRA

mm 3.445 3.475 3.05 3.07 5.02 5.04

X 1 X 2 X 3

3.296 3.364 2.970 2.990 4.970 4 970 4 990 4.990 0.081 0.179 0.060 0.100 0.030 0.070 _

Piston rings X1 X2 X3 Piston ring end gap in cylinder liners: X1 X2 X3 Small end bush housing 1 Big end bearing housing 2 1 2 3 Small end bush diameter outside 4 Selection classes 2

0.40 0.55 0.65 0.80 0.40 0.75 59.000 59.030 94.000 94.010 94.011 94.020 94.021 94.030 59.085 59.110 54.019 54.035 1.965 1.975 1.976 1.985 1.986 1.995 0.055 0.110 0.019 0.041 _

j1 j 2 j4 j3S

inside 3 Big end bearing shell S Red Green Yellow Small end bush - housing Piston pin - bush

ASTRA

Big end bearing shells Connecting rod weight A g Class B g C g

g. 4661 4694 g. g 4695 4728 g. 4729 4762

16

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Type

F3B mm

X Measuring dimension Max. connecting rod axis misalignment tolerance Main journals X 125

0.08 1 2 S1 99.970 100.000 89.970 90.000 3.110 3.120 3.121 3.130 3.131 3.140 1.965 1.975 1.976 1.985 1.986 1.995 106.300 106.330 0.060 0.100 0.050 0.090 -

j1

j2

Crankpins Main bearing shells Red Green Yellow Big end bearing shells Red Green Yellow

S1

S2

S2

j 3

Main bearing housings 3 Bearing shells - main journals Bearing shells - big ends

ASTRA

Main bearing shells Big end bearing shells Main journal, thrust bearing X1 Main bearing housing, thrust bearing X2

X1

47.95 48.00

X2 X3

40.94 40.99

Thrust washer halves Driving shaft shoulder 1 2 Alignment Ovality Taper

X3

3.38 3.43 0.10 0.30

1 2 1-2 1-2 0.025 0.010 0.010

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

17

Type

F3B mm

H

H1

H2

Valve outside spring height: free height H under a load of: 575 28 N H1 1095 54 N H2

72.40 58 45

Injector protrusion X

X

0.52 1.34

j

j j 2

j

Camshaft bush housing fitted in the cylinder head: 17

88.000 88.030

Camshaft journal diameter: 17

82.950 82.968

j 1

j 3 jCamshaft bushing outer diameter: Camshaft bushing inner diameter: Bushings and housings in engine block Bushings and journals Cam lift: 9.231 H 9.5607

88.153 88.183

j

83.018 83.085 0.123 0.183 0.050 0.135

11.216

1Rocker shaft 1 41.984 42.000

18

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Type CYLINDER HEADS - VALVE TRAIN

F3B mm

j 1Valve guide housings in cylinder head 1 15.980 15.997

j 2Valve guide 2 3 10.015 10.030 16.012 16.025

j 3Valve guides - housings in the cylinder headsASTRA

0.015 0.045 _

Valve guide

j 4

Valves: 4 9.960 9.975 60 30 7 30 9.960 9.975 45 30 + 7 30 0.040 0.070

a

4 Valve stem and its guide Housing in head for valve seat 1

49.185 49.220 46.985 47.020

j 1 j 2

1 Outside diameter of valve seat; angle of valve seat in cylinder head: 2

49.260 49.275 60 - 30 47.060 47.075 45 - 30 0.54 0.85 1.75 2.05

aRecessing of valve X Between valve seat and head

2

X

0.040 0.090

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

19

Type

F3B mm

Bushing housing in rocker arms 45.000 45.016 59.000 59.019

Bushing outer diameter for rocker arms:

46.000 46.016

45.090 45.130

j

59.100 59.140 46.066 46.091 Bushing inner diameter for rocker arms: 42.025 42.041

j

56.030 56.049 42.015 42.071 Between bushings and housings 0.074 0.130 0.081 0.140 0.050 0.091 Between rocker arms and shaft 0.025 0.057 0.025 0.057 0.015 0.087

20

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

DIAGNOSISElectrical faults and certain mechanical faults detected by the electronic control unit can be diagnosed by means of the Blink Code and diagnostic instruments.

Figure 7

Blink CodeThe EDC is designed to provide information on engine faults. The warning light comes on while the engine is running, to indicate a fault has occurred, which could be:

Warning light on

Serious fault Degraded system function Warning light blin- Very serious fault king Degraded system function Loss of one or more safety functions and possible engine stopInformation on the type of fault is given in the form of a code by the EDC warning light consisting of a series of long or short blinks (the blink code). To check the fault, use the diagnosis button located under the UCI compartment hatch, which has another EDC warning light operating in parallel with the one on the dashboard.

6679

EDC DIAGNOSIS BUTTON The fault code is explained in the following pages. For example: code 1.4 means that the warning light has given one long blink and four short ones. The procedure should be repeated until the code of the first indicated fault is repeated again.

Fault memory cancellation procedure from drivers seat- Press the Blink Code button (with key to stop); - turn key to RUN holding down the button; - Wait 5 seconds; - Turn key to stop; - Check cancellation by reading number by means of test button.

Figure 6

1780308

DASHBOARD WARNING LIGHTS

Fault checking/identification procedure- Stop vehicle and switch off engine (STOP); - Turn key to RUN (warning lights on and engine off); - Press diagnosis button and check that the EDC warning light blinks once; - After a short interval during which the warning light remains off, it begins to blink initially at long intervals and then shorter.

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

21

MS 6.2 EDC electronic control unit blink code table

Blink Code 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.1 2.2 2.3 2.4 2.5 2.6 3.5 4.1 4.2 4.3 4.4 4.5 4.6 5.1 5.4 5.2 5.6 5.3 5.5 6.1 6.2 6.4 7.1 7.2 7.3 7.4 9.1 9.2 9.3 9.4 9.5 9.6 *

EDC warning light * ON ON OFF ON OFF ON OFF

Fault

VEHICLE AREA Vehicle speed sensor Torque selector Cruise control Accelerator pedal Clutch pressure switch Brake pedal switch signal plausibility Plausibility between brake / accelerator pedal ENGINE AREA OFF Water temperature sensor OFF Air temperature sensor OFF Fuel temperature sensor ON Turbo pressure sensor OFF (Control unit) ambient temperature sensor ON Engine braking switch signal OFF Battery voltage TURBO AREA OFF Turbo actuator pressure sensor ON Turbine revs sensor ON Turbine overspeed ON Turbo management (mechanical fault) ON VGT solenoid valve BLINKING Engine braking solenoid valve INJECTORS ON Cylinder 1 injector fault ON Cylinder 4 injector fault ON Cylinder 2 injector fault ON Cylinder 6 injector fault ON Cylinder 3 injector fault ON Cylinder 5 injector fault ENGINE REVS SENSOR ON Flywheel sensor ON Valve train sensor OFF Engine overspeed INTERFACE WITH OTHER CONTROL UNITS OFF P .W.M. ABS/ASR interface OFF CAN line OFF CAN line (ASR management) OFF CAN line (gearbox data management) ENGINE CONTROL UNIT BLINKING Faulty control unit ON EEPROM data incorrect BLINKING Immobilizer ON Main relay ON Engine stop procedure error ON Control unit data recording error Slight fault Serious fault Very serious fault

Blink code warning light off Blink code warning light on Blink code warning light blinking

22

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

DIAGNOSIS TOOLS IT2000 Upper level diagnosisCommunicating with the control unit, this is able to carry out the following functions in detail: 1 2 3 G G G G G 4 G G 5 6 G 7 G 8 G 9 G G G G SYSTEM DESCRIPTION Explanation of MS 6.2 EDC system function, CONTROL UNIT PIN-OUT CONTROL UNIT DATA READ-OUT FAULT MEMORY READ-OUT Intermittent/permanent fault discrimination Details of fault, fault frequency, environmental conditions in which fault occurs Repair guide Diagram of circuit in question Details on use of UNITESTER on system in question PARAMETER READING Measurable parameters Status parameters FAULT MEMORY CANCELLATION ACTIVE DIAGNOSIS Memorised data read-out OTHER FAULTS Information is provided as to how to identify faults not directly recognised by the control unit PROGRAM GUIDE Explanation about how to use the program ENGINE TEST Compression Turbocompressor efficiency Engine braking efficiency Cylinder performance

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

23

CONTROL UNIT DIAGNOSIS1 2 G G G G G G 3 G G 4 G 5 CONTROL UNIT DATA FAULTS Selection: fault area Characteristics: design of component in question with photograph and electrical features Circuit diagram: cable/pin-out/connector coding Description: fault details, fault frequency, ambient conditions in which fault occurred Intervention: repair guide with access to multimeter/oscilloscope function, integrated with use of system dedicated adapters Cancellation: cancelling fault memory PARAMETERS Status parameters Measurable parameters ACTIVE DIAGNOSIS Memorised data read-out SYSTEM (description of function / PIN OUT / other faults not directly diagnosed by control unit)

ENGINE DIAGNOSIS (ENGINE TEST)These tests are carried out directly and automatically by the tester, including engine start/stop cycles (except for vehicles undergoing first phase Field Test) G G G G Compression Turbocompressor efficiency Engine braking efficiency Cylinder performance

AUXILIARY FUNCTIONSG G G TRADITIONAL ELECTRICAL SYSTEM DIAGNOSIS LOCATION OF CABLE BREAK / SHORT CIRCUIT COMPONENT TEST (RELAYS / DIODES / FUSES)

24

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

TROUBLESHOOTING IntroductionAn effective diagnosis can be made above all using the electronic diagnosis tools (IT2000) developed by Iveco. When the vehicle arrives at the workshop, the information provided by the driver should be given due consideration, although the first thing to do is to connect the IT2000 and carry out a complete diagnosis: G G G G Fault memory reading Parameter reading Engine test Etc.

It is useful to print out the results, especially if Help Desk assistance is required. In this case, note that the Help Desk may not accept requests for assistance based only on Blink Code. The Blink Code is a tool that can be useful in certain cases (vehicle broken down on the road, no Modus/IWT/IT2000), but must not substitute diagnosis with the Iveco tools because the code only offers general indications. Another factor important in troubleshooting is experience. To get around a possible lack of experience of the repair mechanic with respect to this new electronic system (there being no previous systems of the kind to use as reference, the following pages offer a TROUBLESHOOTING GUIDE developed by Training in collaboration with the experts who designed and developed the MS 6.2 EDC control unit. However, it has to be stressed that not even Troubleshooting can replace the IT2000, although it is an extra help in that it concentrates the experience of the people who have a profound knowledge of the system. The Troubleshooting guide consists of two distinct sections: G G The first looks for mechanical faults with Blink Code and regards faults that can be directly identified by the MS6.3 control unit. These faults are mainly of an electrical electronic nature; The second looks for mechanical faults by symptoms, and describes possible faults that cannot be recognised by the electronic control unit. These faults are mainly of a mechanical hydraulic nature.

Troubleshooting does not substitute diagnosis with Iveco electronic diagnosis tools, but is intended as a supplement to the same.

ASTRA HD8

BLINK CODE NOTES

EDC WARNING LIGHT POSSIBLE ANOMALIES ADVISED TESTS OR INTERVENTIONS

POSSIBLE CAUSE

1.1

On

Defective vehicle speed sensor.

Tachigraph not functioning.

Faulty tachigraph needle behaviour Juddering in high gears Check wiring, component connections, connections,

Vehicle speed longer limited, can surpassed in case poor resistance advancement.

no Flight recorder detects long time at Control unit replacement value: 5 kph be low speed. of Check wiring, connections, to component

1.2

On

Defective multi-state switch.

No reduction in Economy mode

TROUBLESHOOTING (BLINK CODE)

(1.2)

(On)

Multi-state switch blocked in one Remains in last selected Check wiring, position mode component

No switching between normal and economy operation Cruise Control / PTO Check wiring, not functioning component connections, Switch signals not plausible (pressed together)

SECTION 3

1.3

Off

Defective cruise control.

No reaction after turning CC/PTO switches

1.4

On

Accelerator pedal: defective powering or signal not plausible. Idle at 1000 rpm and faulty engine reaction to accelerator pedal

Can be varied with warm engine by CC switch (Set + / Set -)

1.4

On

Accelerator pedal: defective powering or signal not plausible. Idle at 1000 rpm and faulty engine reaction to accelerator pedal

Can be varied with warm engine by CC switch (Set + / Set -)

ENGINE F3B

25

26

BLINK CODE NOTESJuddering change Cruise control / PTO Check wiring, not functioning component connections, on gear Check wiring, component connections,

EDC WARNING LIGHT POSSIBLE ANOMALIES ADVISED TESTS OR INTERVENTIONS

POSSIBLE CAUSE

ENGINE F3B

1.5

Off

Defective clutch switch .

CC/PTO not functioning

1.6

On

Brake switch plausibility.

No reaction after turning CC/PTO switch

1.7

Off

Accelerator pedal sensor / brake switch plausibility

No reaction from system

2.1

Off

Defective sensor.

coolant

Excessive starting conditions temperature

temperature Greater combustion Active diagnosis of pre-heating Absence of overheating protection, noise due to high element. replacement value = 0C injection advance time in cold Parameter reading. Check wiring, connections, component Replacement value = 20C connections, sensor If sensor indicates Parameter reading. lower temperature Check wiring, than real, error not component memorised and engine achieves better performance but with black smoke Parameter reading. Check wiring, component connections,

SECTION 3

2.2

Off

Turbo air defective

2.3

Off

Defective fuel temperature sensor

No injection flow-rate correction, but driver does not notice. Replacement value = 970 mbar

2.4

On

Defective turbo pressure sensor.

Reduced power

Temporary black Modus parameter reading: if smoke in significant replacement value appears at idle, fault quantities is confirmedASTRA HD8

ASTRA HD8

BLINK CODE NOTESContact Help Desk for control unit Less accurate VGT function at high replacement because sensor built-in altitude, but driver does not notice. to the same Replacement value = 970 mbar Modus parameter reading. Check wiring, component connections,

EDC WARNING LIGHT POSSIBLE ANOMALIES ADVISED TESTS OR INTERVENTIONS

POSSIBLE CAUSE

2.5

Off

Defective ambient pressure sensor

(2.6)

(On)

Engine braking command switches or selector switch.

Engine brake not functioning in all three selected modes

(2.6)

(On)

Engine braking switch blocked closed.

Engine braking enabled only above 900 rpm Engine test on engine braking.

Active diagnosis of engine braking Fuel injection interrupted by ECU, solenoid valve engine speed drops to 800 rpm, fuel injection again interrupted by ECU Engine braking functions when activated by Modus or by other two Active diagnosis of engine braking selection modes (accelerator brake) solenoid valve

(2.6)

(On)

Engine braking switch blocked open

SECTION 3

3.5

Off

Battery voltage too low or fault in Possible pre-heating Test batteries voltage recognition and starting problems Possible reduction in Engine test: Check engine braking power connections, component.

EDC operates with replacement value of 28V

4.1

Off

Faulty VGT pressure sensor capsule.

Poor performance at low speeds and on acceleration

wiring, If capsule pressure increases during VGT test but , visually, the actuator does not move, it is seized. Check arrival of compressed air to capsule. Check function of shut-off valve on chassis.ENGINE F3B

27

28

BLINK CODE NOTESCapsule memorises turbine revs sensor error, even if it functions correctly

EDC WARNING LIGHT POSSIBLE ANOMALIES ADVISED TESTS OR INTERVENTIONS

POSSIBLE CAUSE

ENGINE F3B

4.1

Off

Rotating parts of turbo-compressor Reduced engine Engine test: engine check-up totally seized. braking power

Poor performance at low speeds and on acceleration vehicle Engine test: VGT. Turbine actuator active diagnosis

(4.1)

(Off)

VGT command solenoid blocked or Poor seized closed. acceleration

Noise indicates faulty turbo behaviour (speed does not follow accelerator pedal)

(4.2)

(Off)

VGT mechanism blocked closed. Black smoke with Engine test: engine brake and VGT. Power reduced by control unit due to Reduced power with engine speed normal function, after Turbine actuator active diagnosis excessive turbine speed below 1200 rpm. acceleration.SECTION 3

Engine brake disengaged by control unit in braking mode with high engine speeds Engine test: check wiring, connections, component brake Engine test Fuel flow reduction during turbine over-revving

4.2

On

Faulty turbo speed sensor.

Reduced power and speed

4.3

On

Turbine overspeed or excessive turbo Poor engine pressure. efficiency

Reduced power Engine test Deviation of VGT variable geometry beyond set thresholds

4.4

On

VGT monitoring of control unit.

Reduced power

ASTRA HD8

ASTRA HD8

BLINK CODE NOTESEngine test: active diagnosis: turbine actuator. Check compressed air delivery to capsule. Check function of shut-off valve on chassis If not functioning check connections, wiring, component and passage. If shut-off valve functions, check air line from shut-off to capsule and line connection to capsule. Check mechanical efficiency of VGT command solenoid valve.

EDC WARNING LIGHT POSSIBLE ANOMALIES ADVISED TESTS OR INTERVENTIONS

POSSIBLE CAUSE

(4.1)

(Off)

(4.4)

(On)

No compressed air delivery to VGT Possible reduction in valve or insufficient pressure. engine braking efficiency Poor performance at low speeds and in acceleration

(4.1)

(Off)

SECTION 3

(4.4)

(On)

VGT mechanism in turbine blocked Possible reduction in Engine test: VGT, engine brake. half open. Poor performance at low engine braking Turbine actuator active diagnosis and medium speeds and in efficiency acceleration

If external VGT command mechanisms function but VGT test indicates fault, fault should be sought in turbo internal mechanisms.

4.5

On

Electrical problem with VGT solenoid Reduction in engine Engine test: Check wiring, connections valve. braking efficiency and component

Significant power reduction at low speed and in acceleration

4.6

Blinking

Engine brake solenoid valve.

Engine brake not functioning

Engine test: check wiring, connections If engine brake does not function with and component engine test, solenoid valve is not powered by vehicle wiring Engine test (if fault is present): Check wiring, connections and component (header cable as well)ENGINE F3B

5.x

On

29

30

BLINK CODE NOTES

EDC WARNING LIGHT POSSIBLE ANOMALIES ADVISED TESTS OR INTERVENTIONS

POSSIBLE CAUSE

ENGINE F3B

6.1 and

On

Faulty flywheel sensor.

Reduced engine speed and power

Engine start may take Modus fault memory reading. longer than usual Check wiring, connections component

6.2 and

On

Camshaft sensor.

Reduced engine power and speed

Engine start may take Modus fault memory reading longer than usual Check wiring, connections component

(6.1 6.2)

(On)

Camshaft phonic wheel offset due to Reduced power with Disconnect camshaft sensor. loose screws. motor running (after If engine starts, taking longer that recommended Engine does not start or stops. Restart usual, phonic wheel is offset. intervention) impossible. rpm Fault memory reading. Read flight recorder to confirm engine overspeed. Check vehicle wiringSECTION 3

6.4

Blinking

Engine has reached 3800 (motoring) for any reason ABS/ASR interface

7.1

Off

Two cable problems

ASR not functioning

7.4

Off

CAN gearbox command interruption.

Gearbox command does not function via CAN

(9.1)

(Blinking)

Faulty EDC control unit

Engine stops or does not start

Contact Help Desk for control unit No diagnosis possible. replacement This error may not be memorised, depends on control unit condition.

ASTRA HD8

ASTRA HD8

BLINK CODE NOTESunit

EDC WARNING LIGHT POSSIBLE ANOMALIES ADVISED TESTS OR INTERVENTIONS

POSSIBLE CAUSE

9.2

On

Faulty control memory).

(EEPROM Fault memory Contact Help Desk for possible cancelled, diagnosis replacement of control unit possible only for Reduced engine speed and power current faults connections and Fault is memorised subsequent starting only after

9.4

On

Main relay faulty or blocked closed.

EDC power remains on Check wiring, after turning key to off, component EDC lamp stays on when key turned danger of flattening to OFF but engine stops. battery

9.5

On

ECU power frequently interrupted (5 times): Main relay faulty or engine stop by battery cut-off switch.

Check main relay, wiring and Problem solves only with subsequent component. Investigate possible driver switch-off procedure and correct data habits regarding stopping engine memorising. without turning key

9.6

On

ECU stop test fail.

SECTION 3

Reduced engine speed and power

Internal control unit Contact Help Desk for possible test procedure to replacement of control unit check power stages. Could memorise other errors related to various actuator power stages.

ENGINE F3B

31

32

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

33

TROUBLESHOOTING BY SYMPTOMSMain engine operating anomalies: 12345The engine does not start; The engine is excessively heated; The engine lacks efficiency; The engine has grey smokes (tending to white); The engine has blue smokes; 6789Poor engine braking efficiency; The engine stops; Excessive fuel consumption; Excessive or insufficient oil pressure.

1

ENGINE DOES NOT START

Battery efficientNO

Pre-heating element always on Check alternator efficiency Check battery terminal connections

YES

Starter motor efficientNO

Carry out checks / replace

YES

Air heater efficientNO

Check power supply and earth connection Check heater relay by active diagnosis

YES

Main relay efficientNO

Check fuses Check relay by active diagnosis

YES

Fuel pump efficientNO

Check efficiency checking pressure at filter

YES

Fuel prefilter - filter efficientNO

Check for clogging / replace

(continued)

34

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

0.8 bar valve on fuel return efficientNO

Check efficiency, replace if blocked open

YES

Fuel circuit efficientNO

Check circuit seal and bleed

2

ENGINE OVERHEATS

Coolant level correctNO

Check for leaks and top-up

YES

Water pump and fan belts efficientNO

Check, adjust tension and if necessary replace components

YES

Water pump efficientNO

Overhaul or replace group

YES

Thermostat efficientNO

Check whether remains closed or partially open. Replace

YES

Radiator efficientNO

Thoroughly clean, check for leaks, replace if necessary

YES

Air filter and circuit piping efficientNO

Check that hoses and pipes are clear Check filter clog indicator, replace filter.

(continued)

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

35

Cylinder head gasket efficientNO

Check water pressure and replace head gasket

YES

Fan efficientNO

Replace

3

ENGINE LACKS POWER

Fuel circuit efficientNO

Check whether tank filter, prefilter and fuel filter are clogged. Replace. Check whether 0.8 bar valve on fuel return from head is blocked open (low pressure) or closed (high temperature). Replace Check for circuit leaks and fuel pump efficiency

YES

Injectors efficientNO

Injector pump may seize or fuel leak from O-ring. Carry out engine test and proceed as per instructions given

YES

Engine air intake circuit efficientNO

Remove obstruction on circuit and replace air filter if clogged. Check clogged cartridge indicator

YES

Exhaust gas circuit efficientNO

Eliminate leaks on exhaust manifold

YES

Correct running temperatureNO

Check cooling system

(continued)

36

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

VGT actuator efficientNO

Carry out Engine Test following instructions displayed by diagnosis tool

YES

Turbocompressor efficientNO

YES

Carry out Engine Test on turbine and check integrity of following turbo components - turbine blades - bearings - modulator valve - Clogged VGT filter - turbine actuator Replace faulty components

Mechanical injection system efficientNO

Check injector rocker wear, check rollers, rocker bushes and camshaft cams

YES

Valve play correctNO

Adjust valve play

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

37

4

ENGINE EMITS GREY/WHITE SMOKE

Head gasket efficientNO

Grind head and replace gasket

YES

Injector sheathes efficientNO

Replace sheathes

YES

Turbocompressor cooling circuit seal efficientNO

Overhaul turbo

YES

Good quality fuelNO

Check for water in tank and eliminate

5

ENGINE EMITS BLUE SMOKE

Piston rings efficientNO

Overhaul pistons - cylinder

YES

Turbo lubrication circuit efficientNO

Overhaul turbo

YES

Valve oil seals efficientNO

Replace valve guide gaskets

38

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

6

POOR ENGINE BRAKING EFFICIENCY

Engine braking components efficientNO

Check correct function of engine brake actuator cylinders and command solenoid Check cylinder command oil piping seal Check exhaust valve play

YES

Turbocompressor efficientNO

VGT blocked open Faulty VGT actuator (seepage from tie rod) Faulty modulator valve Incorrect air supply to modulator valve Replace faulty components

7

ENGINE STOPS

Fuel in tankNO

Bleed group after filling tank

YES

Tank filter, pre-filter and engine fuel filter efficientNO

Clean tank filter and replace filter and prefilter

YES

Tank fuel lines correctly connectedNO

Inverting the pipes may cause vehicle to stop after 200 - 300 km even if tank has fuel because piping that feeds engine has less scavenge. Invert pipes.

ASTRA HD8EcENGINE

SECTION 3

ENGINE - F3B

39

8

EXCESSIVE FUEL CONSUMPTION

Air filter efficientNO

Replace

YES

Tank and fuel lines efficient.NO

Eliminate any leaks and replace worn parts

9

OIL PRESSURE INSUFFICIENT OR EXCESSIVE

Pressure regulator valve operates correctlyNO

Check and if necessary replace

YES

Oil pump and delivery piping efficientNO

Check and if necessary replace.

YES

Main bearings and big ends efficientNO

Replace bearings and if necessary grind crankshaft

YES

Engine oil SAE viscosity correctNO

Change engine oil with suitable viscosity oil

40

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

TIGHTENING TORQUESPART Nm Capscrews, undercrankcase to crankcase Outside screws M12x1.75 First phase: preliminary tightening Inner screws M 18x2 Second phase: preliminary tightening Inner screws Third phase: angle locking Inner screws Fourth phase: angle locking Outer screws Fifth phase: angle locking Piston cooling nozzle union Heat exchanger fixing screws to the block preliminary tightening tightening Spacer oil sump fixing screws to undercrankcase Fixing screws to oil sump preliminary tightening tightening Gearbox fixing screws to the block M 12x1.75 Control unit fastening screws on engine block Cylinder head fixing screws First phase preliminary tightening Second phase preliminary tightening Third phase angle locking Fourth phase angle locking - screws 4 - 5 - 12 - 20 - 21 Fourth phase angle locking - screws 1- 2 - 3 - 6 - 7 - 8 - 9 - 10 - 11 14 - 15 - 16 - 17 - 18 - 19 - 22 23 - 24 - 25 -26 Rocker shaft fixing screws First phase preliminary tightening Second phase angle locking Lock nut for rocker adjustment screw Injector blocking brackets screws Plastic cover fastening screws Shoulder plate fixing bolts to head Engine mounting bracket screws on head First phase pre-torque Second phase tightening to angle Lubricate with UTD oil before installation Lubricate with graphitized oil before installation 30 120 60 55 60 352 11.53.5 193 24,52,5 38 45 637 242.5 60 120 90 45 65 (3.5) (1.150.35) (1.90.3) (2.40.25) (3.8) (4.5) (6.3) (2.40.25) (6) (12) TORQUE kgm (3) (12)

100 60 395 26 8.51.5 193 120 45

(10) (3.90.5) (2.6) (0.850.15) (1.90.3) (12)

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

41

PART Nm Engine mounting bracket fastening screws on flywheel casing First phase pre-torque Second phase tightening to angle Camshaft cog fastening screws: First phase pre-torque Second phase tightening to angle Phonic wheel fastening screws to camshaft cog Exhaust manifold fastening screws: pre-torque full torque Big end cap fastening screws Viti fissaggio cappello di biella : Prima fase preserraggio Seconda fase chiusura ad angolo Big end cap fastening screws: First phase pre-torque Second phase tightening to angle Third phase tightening to angle Flywheel damper: First phase pre-torque Second phase tightening to angle Intermediate gear pin fastening screws: First phase pre-torque Second phase tightening to angle Link rod fastening screws for pulley wheel adjustment Oil pump fastening screws Crankshaft front gasket casing fastening screws Fuel pump / filter bracket fastening screws Control unit mounting screws Turbocompressor screws and nuts pre-torque full torque Vite fissaggio gruppo termostato Viti fissaggio pompa acqua Thermostat group fastening screws Water pump fastening screws Fan hub spacer fastening screws Fan bracket engine block fastening screws Air conditioner automatic belt tensioner fastening screws Auxiliary organs fixed pulley engine block fastening screws Starter motor fastening screws Air heater fastening screws Air compressor fastening screws Lubricate with UTD oil before installation Lubricate with graphitized oil before installation 100

TORQUE (kgm) (10) 60 60 60 8,51,5 32,5 45 19 60 60 120 60 30 70 50 30 90 24,52,5 24,52,5 24,52,5 19 193 35 46 193 25 30 30 100 263 505 1055 744 303 744 (2,450,25) (2,450,25) (2,450,25) (1,9) (1,90,3) (3,5) (4,6) (1,90,3) (2,5) (3) (3) (10) (2,60,3) (50,5) (10,50,5) (7,40,4) (30,3) (7,40,4) (3) (7) (12) (0,850,15) (3,2) (4,5) (1,9) (6) (6)

42

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

PART Air compressor command cog fastening nut Alternator fastening screws: M 10x1,5 l = 35 mm M 10x1,5 l = 60 mm Servosteering pump fastening screws Air conditioning compressor support fastening screws Cover fastening screws Clogged filter sensor fastening Fuel / water temperature sensor fastening Thermometric transmitter / switch fastening Air temperature transmitter fastening Pulse transmitter fastening Injector connector fastening Engine brake solenoid valve fastening Lubricate with UTD oil before installation Lubricate with graphitized oil before installation

TORQUE Nm 17010 303 444 46,54,5 24,52,5 24,52,5 555 35 25 35 82 1,361,92 32 (kgm) (171) (30,3) (4,40,4) (4,650,45) (2,50,25) (2,50,25) (5,50,5) (3,5) (2,5) (3,5) (0,80,2) (0,130,19) (3,2)

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

43

TIGHTENING ORDER OF GEARBOX TO ENGINE BLOCK FASTENING SCREWSFigure 8

FRONT SIDE

stage 1: pretightening, outer screws 30 Nm

60592

FRONT SIDE

stage 2: pretightenig, inner screws 120 Nm

60593

FRONT SIDE

stage 3: angle, inner screws 60

60593

FRONT SIDE

stage 4: angle, inner screws 55

60593

FRONT SIDE

stage 5: angle, outer screws 60

60594

44

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Figure 9

60580

DIAGRAM OF CYLINDER HEAD FIXING SCREWS TIGHTENING SEQUENCEFigure 10

60581

DIAGRAM OF EXHAUST MANIFOLD FIXING SCREWS TIGHTENING SEQUENCEFigure 11

60582

DIAGRAM OF TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING SEQUENCE

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

45

Figure 12

60666

DIAGRAM OF TIGHTENING SEQUENCE FOR HEAT EXCHANGER SCREWS

Figure 13

60583

DIAGRAM OF TIGHTENING SEQUENCE FOR ENGINE OIL SUMP SCREWS

46

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Figure 14

60633

Tightening order no. 10 M12 x 1.75 x 100 no. 2 M12 x 1.75 x 70 no. 4 M12 x 1.75 x 35 no. 1 M12 x 1.75 x 120

:

no. 2 M12 x 1.75 x 193

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

47

TOOLSTOOL NO. DESCRIPTION

99305019

Full-optional tool-kit to rectify valve seat

99305047

Rotary telescopic stand (range 2000 daN, torque 375 daNm)

99309002

Tool for bench calibration of L.D.A device

99322230

Rotary telescopic stand (range 2000 daN, torque 375 daN/m)

99340053

Extractor for crankshaft front gasket

99340054

Extractor for crankshaft rear gasket

48

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

TOOLSTOOL NO. DESCRIPTION

99340205

Percussion extractor

99342149

Extractor for injector-holder

99346250

Tool to install the crankshaft front gasket

99346251

Tool to install the crankshaft rear gasket

99348004

Universal extractor for 5 to 70 mm internal components

99350072

Box wrench for block junction bolts to the underblock

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

49

TOOLSTOOL NO. DESCRIPTION

99360143

Box wrench for block junction bolts to the underblock

99360144

Tools (12+6) for holding sliding blocks for rockers adjusting screws during disassembly reassembly rockers shaft

99360180

Injector housing protecting plugs (6)

99360184

Pliers for assembling and disassembling piston split rings (105-106 mm)

99360261

Tool to take down-fit engine valves (to be used with special plates)

99360263

Plate for take down-fit engine valves (to be used with 99360261)

50

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

TOOLSTOOL NO. DESCRIPTION

99360296

Tool to fit back valve guide (to be used with 99360143)

99360314

Tool to remove oil filter (engine)

99360321

Tool to rotate engine flywheel (to be used with 99360325)

99360325

Spacer (to be used with 99360321)

99360329

Tool to install gasket on valve guide

99360334

Compression tool for checking the protrusion of cylinder liners (to be used with 99370415-99395603 and special plates)

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

51

TOOLSTOOL NO. DESCRIPTION

99360336

Spacer (to be used with 99360334)

99360338

Cylinder liner compression plate (to be used with 99360334-99360336)

99360351

Tool to stop engine flywheel

99360499

Tool to take down and fit back camshaft bushes

99360500

Tool to lift crankshaft

99360551

Bracket to take down and fit engine flywheel

52

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

TOOLSTOOL NO. DESCRIPTION

99360553

Tool for assembling and installing rocker arm shaft

99360585

Swing hoist for engine disassembly assembly

99360605

Belt to insert piston in cylinder liner (60 - 125 mm)

99360612

Tool for positioning engine P .M.S.

99360613

Tool for timing of phonic wheel on timing gear

99360703

Tool to stop cylinder liners

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

53

TOOLSTOOL NO. DESCRIPTION

99360706

Tool to extract cylinder liners (to be used with specific rings)

99360728

Ring (125 mm) (to be used with 99360706)

99361036

Brackets fixing the engine to rotary stand 99322230

99365056

Tool for injector holder heading

99370415

Base supporting the dial gauge for checking cylinder liner protrusion (to be used with 99395603)

99378100

Tool for printing engine identification plates (to be used with special punches)

54

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

TOOLSTOOL NO. DESCRIPTION

99378101 99378102 99378103 99378104 99378105 99378106

Punches (A,B,C,D,E,F) for printing engine identification plates (to be used with 99378100)

99389834

Torque screwdriver for calibrating the injector solenoid valve connector check nut

99390330

Valve guide sleeker

99390772

Tool for removing injector holding case deposits

99390804

Tool for threading injector holding cases to be extracted (to be used with 99390805)

99390805

Guide bush (to be used with 99390804)

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

55

TOOLSTOOL NO. DESCRIPTION

99394015

Guide bush (to be used with 99394041 or 99394043)

99394041

Cutter to rectify injector holder housing (to be used with 99394015)

99394043

Reamer to rectify injector holder lower side (to be used with 99394015)

99395216

Measuring pair for angular tightening with 1/2 and 3/4 square couplings

99395219

Gauge for defining the distance between the centres of camshaft and transmission gear

99395363

Complete square to check connecting rod squaring

56

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

TOOLSTOOL NO. DESCRIPTION

99395603

Dial gauge (0 - 5 mm)

99395687

Reaming gauge (50 - 178 mm)

99396035

Centering ring of crankshaft front gasket cap

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

57

ENGINE REMOVAL - REPLACEMENT RemovalTo remove the engine group, proceed as follows: - Position the vehicle over a pit or on a vehicle lift; - Open the battery casing and disconnect cables to eliminate any risk of short circuit. - Proceed to drain the conditioning system For these operations refer to the procedures provided by the system manufacturer.

In case of special vehicle equipment, remove part or all of the fittings to permit access to elements for disconnection and the extraction of mechanical groups to be removed. For these operations refer to the procedures provided by the manufacturer of the equipment.

Figure 15

Do not discharge R134 fluid into the atmosphere. Even if its ozone impoverishment potential is zero, it is nevertheless a greenhouse gas. Recovery and recycling of this substance is governed by legislation. Always use approved refrigerant recovery and recharging equipment. Do not mix different refrigerant fluids in the same equipment.

Figure 16

178NM04

1780301

Place a suitable container under the engine and drain off the engine coolant by disconnecting the radiator hose from the pump (4). It is forbidden to dispose of exhausted fluid incorrectly or via the public drainage system.

178NM03

(a) single-seat cab, (b) two-seat cab - Open the filler cap (1) on the expansion chamber - It is forbidden to dispose of exhausted fluid incorrectly or via the public drainage system. - Tip the cab. - Disconnect all power take off electrical and pneumatic connections as indicated in SECTION 5 (only for versions with built-in power take off). - Unscrew the propeller shaft flange screws and remove it as indicated in SECTION 10.

58

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Figure 17

1780302A

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

59

Figure 18

1780303

60

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

- Place a suitable container and drain the servo steering hydraulic fluid as indicated in SECTION 15;

Figure 20

It is forbidden to dispose of exhausted fluid incorrectly or via the public drainage system.

Figure 19

1780305

All versions: - Remove the stay (40) and mounting bracket (41) complete with exhaust silencer - Disconnect all transmission electrical, pneumatic and hydraulic connections and proceed to remove the transmission group as indicated respectively in SECTION 6 (manual gearbox) - Disconnect / remove engine coolant piping: - from thermostat to radiator (2); - from thermostat to cab heater (3); - from expansion chamber to intake pump (5); - vent pipe from engine to expansion chamber (8);

1780304

- Remove the exhaust pipe (18) from the turbogroup; Two/three-axle versions - Disconnect all hydraulic lines: - from the servo steering reservoir (29); - servo steering pump intake on compressor (23); - servo steering pump delivery on engine (24). Four-axle versions - Disconnect all hydraulic lines: - from the servo steering reservoir (29); - servo steering pump intake on engine (21); - servo steering pump delivery on engine (22); - servo steering pump intake on compressor (23); - servo steering pump delivery on engine (24); - servo steering pump intake (25) and delivery (26) on gearbox. During this operation some residual coolant may leak from engine.

- Disconnect air conditioning system refrigerant fluid piping (9) from compressor; - Remove air piping: - from air filter to turbogroup (10) - from turbogroup to intercooler (11) - from intercooler to intake manifold (12) - compressor intake (13); - compressor delivery (14); - tank - compressor connector (15); - engine breather (16); - waste-gate pilot (17) (VGT versions only);

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

61

Figure 21

1780306A

- Disconnect electrical connections: - from starter motor (31); - from alternator (32); - from servosteering oil level indicator (33); - from air conditioner compressor (34); - from diagnostics cable (35); - Remove the start/stop button mounting (36) unscrewing fastenings; - Disconnect the lower connector (39) of the engine control unit (36) proceeding as follows: A. Lift the safety catch B. Turn the connector to remove it from the control unit C. lift the connector to free it from the attachment tooth. The upper connector (38) cannot be disconnected, except in the event of works on engine side wiring.

- Disconnect the following pipes: - fuel return (27); - Fuel supply (28); - Remove the gearshift command lever (43) and associated mechanisms, fastening the rod to the cab; - Remove the engine oil dipstick (not illustrated) from the radiator mounting; - Attach suitable chains or cables to the engine mounting brackets, then bring them into tension using appropriate lifting gear; - Check with extreme care that all elements have been disconnected and that all cable/piping and wiring clamps have been freed; - Remove the front and rear elastic engine supports from both sides; - Carefully lift the engine group extracting it from above, and place it on a suitable bench.

- Disconnect the fastening clamps and tip the vehicle side harness so that it does not obstruct operations;

62

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

ReplacementTo replace the engine group, follow the removal instructions in reverse order. Pay special attention to the manoeuvres necessary for installing the group into the engine compartment and take the following precautions: - Check the elastic engine group and gearbox supports. Replace them with new ones if any wear is evident; - Check all exhaust piping components. Replace with new in case of wear. - Tighten all fastenings to the specified torque. - Fill the sump with the specified lubricant and check the level. - Fill the cooling system with the specified coolant. - Fill the servosteering hydraulic system with the specified fluid and subsequently start the engine and bleed the system as indicated in section 1.5. - Connect the engine control unit lower connector (39) as follows: A. Insert the attachment tooth into its seat. B. Turn the connector to connect it to the control unit C. Lower the safety catch

Figure 22

1780307A

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

63

Bleeding air from supply systemFigure 23

178NM117

178NM118

178NM119

Before starting the engine bleed any air from the fuel supply system, applying the dedicated pipes to the bleed points to allow the fuel to bleed into a recipient placed below: - Bleed screw (1) located on pre-filter. - Bleed screw (2), located on filter support. - Bleed screw (3), located on front of cylinder head. - Operate the pump (4) situated on the prefilter support until bubble-free fuel flows from the screw (1). Close the screw (1). - Repeat the operation for screw 2. - Repeat the operation for screw 3. In all cases prevent fuel from soiling water pump/alternator drive belts.

Checks and controlsStart the engine and allow it to run at a speed slightly above idling and wait for the engine coolant to reach thermostat opening value, then check that: - The absence of coolant leaks from the engine cooling circuit and cab heater hoses, tighten the respective collars if necessary. - The absence of oil leaks from the cylinder head or rocker cover, between engine block and sump or from the various lubricant circuit pipes. - The absence of air leaks from any disconnected compressed air system connections. - Check that the dashboard warning lights function correctly along with any other equipment disconnected when engine was removed.

64

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

DISMANTLING THE ENGINE ON THE BENCH

Before fixing the engine on the rotary stand 99322230 remove the following components:

Figure 26

On the engine right-hand side diesel cartridge filter (1); power steering system tank (2); electric connections;

Figure 24

60484

-

remove the air conditioner control belt (1) using a fit tool (3) and acting in the direction shown by the arrow; disassemble the air conditioner (2) fitted with the engine support; engine support (1) Figure 27

On the engine left-hand side -

60482

-

soundproofing shield (1); all the pipes connecting the compressor;

Figure 25

60485

Figure 28

60483

-

compressor (1) fitted with power steering pump (2);

60486

-

oil pressure controlling valve (1);

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

65

Figure 29

71700

Fix the engine to the rotary stand 99322230, by means of brackets 99361036 (1), remove the fan.

66

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Remove all electrical wiring from the sensors and electric activators. Figure 30

Figure 32

71703

71701

Remove the fan (1) from the flange (2). Figure 31

Remove the flywheel pulley (1) by removing the six Allen screws. Figure 33

71704

Turning the specific tool (1) clockwise, remove the auxiliaries drive belt (2).71702

Lock the engine flywheel using tool 99360351 (1).

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

67

Figure 34

Figure 36

60490

71705

Apply extractor 99340053 (2) and remove the crankshaft oil seal. Remove the flange (3). Figure 37

Remove the following parts: - alternator (1) - fan flange (2) - automatic tensioner (3) - crankshaft pulley (4) - water pump (6) - air conditioner drive belt tensioner (5) Figure 35

Remove the following parts: - Water delivery pipe (5) - water return pipe (1) - actuator command air piping (2) - oil delivery pipe (3) - oil return pipe (4) - turbocompressor group (6) - exhaust manifold (7).71706

71707

Figure 38

Disconnect the pipes (3 and 6) from the V.G.T. command solenoid valve. Remove the thermostat group (1) complete with V.G.T command solenoid (2) Remove the pulley (5) using the Allen key (4).

60492

Unscrew the oil filter (1) using tool 99360314.

68

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Figure 39

-

PWN valve air filter (5); suction manifold (6) fitted with resistance for engine preheating; control unit (7). Figure 42

60493

-

Unscrew the screws (1) and remove the heat exchanger (4); unscrew the screws (2) and remove the water line (3).60495

Figure 40

-

Remove the rocker cover (1) and the timing gear cover (2) Figure 43

70708

-

Unscrew the screws (1) and remove the heat exchanger (4); unscrew the screws (2) and remove the water line (3). Figure 41

60575

-

Unscrew the screws (2) and remove the gear (1) fitted with phonic wheel. Figure 44

Remove the following components: - fuel filter support (1); - fuel pump (2) and lines; - starter (3); - engine starting button support (4);

60494 60497

-

Unscrew the screws (1); tighten one screw in a reaction hole and remove the shoulder plate (2), remove the sheet gasket.

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

69

Figure 45

Figure 48

60498

Unscrew the screws (1) and remove the transmission gear (2). Figure 49 Figure 46

60501

Unscrew the screws (1) and take down the gearbox (2).

60499

Stop the engine flywheel (3) rotation by means of tool 99360351 (1), unscrew the fixing screws (2) and remove the engine flywheel. Figure 47

Remove in the following order: - The P.T.O. drive cog (1); - The transmission cog (2); - The oil pump cog (3). Figure 50

71709

60511

60500

Apply the extractor 99340054 (2) and pull out the seal gasket (1).

- Remove the engine brake lever retaining springs (3). - Unscrew screws (3) to remove injector electrical connections. - Unscrew screws (6) fastening injector wiring to the head. - Electrically disconnect the engine brake solenoid valve (8). - Remove the engine brake cylinder (4) feeder pipes (5 and 7). - Remove the rocker shaft fastening screws (2). - Unscrew screws (6) to remove injector wiring from the head. The wiring must be removed from the front.

70

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Figure 51

Figure 54

60512

60515

Apply tool 99360553 (1) and remove the rocker arm shaft assembly.

- By means of metal ropes, lift the cylinder head (1). - Remove the seal (2) Figure 55

Figure 52

60513

60516

- Unscrew the screws (2) fixing the brackets (3) and remove the injectors (1). - Unscrew the screws (4) and remove the exhaust brake pins (5). - Unscrew the screws and remove the slave cylinder (6). Figure 53

Unscrew the screws (2) and remove the engine oil sump (1) fitted with spacer (3) and seal.

Figure 56

60514

60517

- Fit the plugs 99360180 (1) instead of injectors. - Remove the camshaft (2). - Unscrew the fixing screws on the cylinder head (3).

Unscrew the screws and remove suction rose (1).

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

71

Figure 57

Figure 60

47574

47570

Rotate the block (1) to the vertical position.

Remove the crankshaft (2) by means of tool 99360500 (1).

Figure 58

Figure 61

60518

47571

Untighten screws (2) fixing the connecting rod cap (3) and remove it. Remove the connecting rod-piston assembly from the upper side. Repeat these operations for the other pistons. Figure 59

Remove the crankshaft half-bearings (1), untighten the screws and remove oil spray nozzles (2). Take down cylinder liners as specified in the relative paragraph.

60519

After disassembling the engine, thoroughly clean disassembled parts and check their integrity. Instructions for main checks and measures are given in the following pages, in order to determine whether the parts can be re-used.

By means of proper and splined wrenches, untighten the screws (1) and (2) and remove the under-block.

72

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

REPAIR OPERATIONS CYLINDER BLOCK Checks and measurementsFigure 62 (Demonstration) Figure 64

34994

60595

Internal diameter of the cylinder liners is checked for ovalization, taper and wear, using a bore dial (1) centesimal gauge 99395687 (2) previously reset to ring gauge (3), diameter 135 mm.

A = Selection class 135.000 to 135.013 mm B = Selection class 135.011 to 135.024 mm In case of maximum wear >0.150 mm or maximum ovalization >0.100 mm compared to the values indicated in the figure, the liners must be replaced as they cannot be ground, lapped or trued.

If a 125 mm ring gauge is not available use a micrometer caliper.ASTRA

Cylinder liners are equipped with spare parts with A selection class.

Figure 63 Figure 65

60596

60597

1 = 1st measuring 2 = 2nd measuring 3 = 3rd measuring Carry out measurings on each cylinder liner at three different levels and on two (A-B) surfaces, to one another perpendicular, as shown in NO TAG.

A = 153.500 to 153.525 mm B = 152.000 to 152.025 mm C = 153.461 to 153.486 mm D = 151.890 to 151.915 mm The figure shows the outer diameters of the cylinder liners and the relative seat inner diameters. The cylinder liners can be extracted and installed several times in different seats, if necessary.

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

73

CYLINDER LINERSFigure 66

60598

BLOCK WITH CYLINDER LINERS Figure 67

Selection class

A mm 135.000 to 135.013 B mm 135.011 to 135.024 CYLINDER LINERS MAIN DATA

71710

Figure 68

DETAIL X Y - Selection class marking area

71711

74

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Replacing cylinder liners RemovalFigure 69 Figure 71

ASTRA

47577

Place details 99360706 (2) and plate 99360728 (4) as shown in the figure, by making sure that the plate (4) is properly placed on the cylinder liners. Tighten the screw nut (1) and remove the cylinder liner (3) from the block.

60520

Fitting and checking protrusionFigure 70ASTRA

Check the protrusion of the cylinder liners, using tool 99260472 (2) and tightening screw (1) to 225 Nm torque. Using comparator 99395603 provided with comparator base 99370415 (3) that the cylinder lining protrusion from the cylinder head surface is 0.045 - 0.075 mm (Figure 71). If not, replace the adjuster shim (1) (Figure 70) supplied in various thickness. 0,045 0,075

Figure 72

CYLINDER LINER PROTRUSION Figure 7316798

49017

Always replace water sealing rings (3, 4 and 5). Install the adjustment ring (1) on the cylinder liner (2); lubricate lower part of liner and install it in the cylinder unit using the proper tool.

ASTRA

The adjustment ring (1) is supplied as spare parts in the following thicknesses: 0.08 mm - 0.10 mm - 0.12 - 0.14 mm.60521

When the installation is completed, block the cylinder liners (1) to the block (2) with studs 99360703 (3).

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

75

CRANKSHAFTFigure 74

Upper main journal half bearing

Lower main journal half bearings

71712

MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear. The data given refer to the normal diameter of the pins. Figure 75 Figure 76

60603

71713

X. Detail of main journals connections

Y. Detail of crank pins connections

76

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Measuring main journals and crank pinsBefore grinding the crank pins using a micrometer (1), measure the main journals and the crank pins (2) and decide, on the basis of the undersizing of the bearings, the final diameter to which the pins are to be ground. Figure 77 Figure 78

47536

MEASURING CRANK PINS47535

During grinding, pay attention to journal and crank pins values specified.

MEASURING THE MAIN JOURNALS It is advisable to enter the values found in a table. All journals and crank pins must also be ground to the same undersizing class, in order to avoid any alteration to shaft balance.

Figure 79 Fill in this table with the measurements of the main journals and the crank pins.

MAIN JOURNALS

MIN. MAX.

MIN. MAX.

CRANK PINS

36061

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

77

Choice of big end and main bearing half-shellsIn order to obtain the clearance required, main half-bearings and big end half-bearings must be selected as specified below.

This operation makes it possible to identify the most suitable half-bearings for each journal (half-bearings can belong to different classes for the individual journals). Depending on half-bearing thickness, tolerance classes are selected by colors (red-green-red/black-green/black). Figure 80 shows the characteristics of main half-bearings and big end half-bearings supplied as spare parts in standard measures (STD) and admissible oversizing (+0.127, +0.254, +0.508).

Figure 80 Big end half-bearings red red/black green green/black 1.976 to 1.985 2.039 to 2.048 STD 1.965 to 1.975 2.028 to 2.038 2.103 to 2.112 2.230 to 2.239 +0.127 +0.254 2.092 to 2.102 +0.508 2.219 to 2.229

Main half-bearings red red/black green green/black

STD 3.110 to 3.120

+0.127

+0.254 3.237 to 3.247

+0.508 3.364 to 3.374

3.173 to 3.183 3.121 to 3.130 3.184 to 3.193

78

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

DETERMINATION OF PRELIMINARY DATA FOR SELECTIONFor each journal and crankpin, the following operations must be carried out: JOURNALS: - determine the diameter class of the block housing; - determine the diameter class of the main journal; - select half-bearing class to be installed. KRANKPINS: - determine the diameter class of the connecting rod housing; - determine the diameter class of the big end pin; - select half-bearing class to be installed.

Two series of numbers are marked on the front side of the block, in the position specified (top). - a four-digit number, representing the coupling number of block to the relevant underblock; - each of the following seven digits represents the diameter class of the housing they refer to (bottom); - each digit can be 1, 2 or 3.

Figure 81

47535

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

79

Definition of main journal and big end diameter class (journals with nominal diameter) Three series of numbers are specified on the driving shaft, in the position specified. - a five-digit number, representing the shaft serial number; - under this number, on the left, a six-digit number refers to big end pins and is preceded by a single digit, which indicates pin status (I = STD =-0.127); each of the following six digits represents the diameter class of each big end pin it refers to (bottom); - the seven-digit series, on the right, refers to the journals and is preceded by a single digit, which indicates journal status (I = STD =-0.127); each of the following seven digits represents the diameter class of the journal it refers to (bottom);

Figure 82

CRANKPINS BASEMENT

80

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Selection of main half-bearings After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to be used, in compliance with the following table:

Figure 83

STD.

1

2

3

green

green

green

1green green green

red

green

green

2red green green

red

red

red

3red red red

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

81

Selection of main half-bearings (rectified) If the journals have been rectified, the procedure described cannot be applied. In this case, make sure that the new diameter of the journals is as specified on the table and install the only half-bearing type required for this undersizing. Figure 84

red/black = mm 3.063 to 3.073 green/black = mm 3.074 to 3.083

-0.1271 2green/black green/black

3green/black green/black

82.783 1 82.792 82.793 2 82.802 82.803 3 82.813

green/black green/black

red/black red/black

green/black green/black

green/black green/black

red/black red/black

red/black red/black

green/black green/black

-0.254red = mm 3.127 to 3.137

1

2red red

3red red

82.666 82.686

red red

-0.508red = mm 3.254 to 3.264

1

2red red

3red red

82.412 82.432

red red

82

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Choice of big-end half-shells (standard diameter) Three indications are marked on the connecting rod, in position A Figure 85

1 Letter indicating the weight class A B C = = = 4661 to 4694 g. 4695 to 4728 g. 4729 to 4762 g. VIEW FROM A

2 Number indicating the diameter selected for the housing of the big end bearing: 1 2 3 = = = 94.000 to 94.010 mm 94.011 to 94.020 mm 94.021 to 94.030 mm

3 Numbers identifying the cap-connecting road coupling.

47557

The number specifying the diameter class of the half-bearing housing can be 1, 2 or 3. Determine the type of big end half-bearings to be installed on each pin by following the indications given in the table (Figure 86).

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

83

Figure 86

STD.

1

2

3

green

green

green

1green green green

red

green

green

2red green green

red

red

red

3red red red

84

ENGINE - F3B

SECTION 3

ASTRA HD8Ec

Choice of big-end half-shells (rectified) If pins have been rectified, the procedure described must be applied. In this case, (for each undersizing) determine the tolerance field the new big end pins belong to, and install the half-bearings identified according to the relative table. Figure 87red/black = mm 2.028 to 2.038 green/black = mm 2.039 to 2.048

-0.1271 2green/black green/black

3green/black green/black

72.788 1 72.797 72.798 2 72.807 72.808 3 72.818

green/black green/black

red/black red/black

green/black green/black

green/black green/black

red/black red/black

red/black red/black

green/black green/black

-0.254red mm 2.092 to 2.102 green = mm 2.103 to 2.112

1red red

2green green

3green green

72.671 72.680 72.681 72.691

red red

red red

green green

-0.508red = mm 2.219 to 2.229 green = mm 2.230 to 2.239

1red red

2green green

3green green

72.417 72.426 72.427 72.437

red red

red red

green green

ASTRA HD8Ec

SECTION 3

ENGINE - F3B

85

Replacing the timing control gear and the oil pumpCheck that the teeth of the gears are not damaged or worn, otherwise remove them using the appropriate extractor. Figure 88 Figure 90

1

ASTRA

2

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Using pulley system and hook 99360500 (1), mount the crankshaft (2).49020

When fitting the new gears (1) on the crankshaft (2), heat them for about 15 minutes in an oven at 180C. Let them cool down after the installation.

Checking main journal installation clearanceFigure 89 Figure 91

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Install the oil spray nozzles (2) and