CORVUS TERRAIN DX4 CAB Workshop Manual Download Page 18

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Page

WORKSHOP

MANUAL

We reserve the right to modify the product and the design.

SPECIFIC TABLE OF TIGHTENING TORQUES

GROUP

ELEMENT

TIGHTENING TORQUE

SCREW THREAD

Filling plug
Draining plug
Filling plug
Draining plug
Driven belt pulley clamping screw
Driving belt pulley clamping screw

Engine-DC plate screw
Brake caliper bleed screw
Brake caliper clamping screws
Brake disc clamping screws

Cardan coupling clamping screw

Cardan clamping screws

Axle shaft nut
Wheel clamp nuts
Tilting ball -joint nut
Exhaust manifold clamping nuts

Rollbar screws
Central cross member screws
Seat cross member screws
Threshold plate screws
Light plate screws
Defence screws
Shock absorber clamping screws
Engine chassis clamping screws
D.C.-Front Diff. Chassis clamping screws

Steering column screws
Brake hub nut + loctite

Steering spider screws
Steering cardan screws

Steering ball joint nut

Steering rack and pinion screws

G3/4

M14x150
M14x150
M14x150

M10
M10

M8
M8
M8
M8
M8
M6

M8x1.5

M10x1.25

M14x1.5

M10

M8
M6
M8

M10
M10
M10
M10

M18x1.5

M8
M8

M10x1.25

M10

20 Nm
20 Nm
20 Nm
20 Nm
70 Nm
70 Nm
20 Nm

7-9 Nm

30 Nm
20 Nm
30 Nm
12 Nm

225 Nm

60 Nm
80 Nm
20 Nm
45 Nm
20 Nm
45 Nm
20 Nm
10 Nm
20 Nm
45 Nm
45 Nm
45 Nm
45 Nm

20 Nm
20 Nm
50 Nm
40 Nm

Transmission

Front Diff

CVT

Brakes

Transmission

Exhaust

Chassis

Engine
Front D.C. Diff

Steering

Summary of Contents for TERRAIN DX4 CAB

Page 1: ...WORKSHOP MANUAL DX4 PRO CAB Read this guide carefully It contains important safety information ...

Page 2: ......

Page 3: ...ityofitsutilityvehicles ongoingmodificationsmaytake place That is why the information in this catalogue may have changed since the time of printing CORVUS reserves the right to modify models colours and or technical specifications without notice and without incurring any obligation Drivers of CORVUS vehicles must comply with all requirements demanded by current legislation in relation to driving l...

Page 4: ... TABLE OF CONTENTS 6 9 10 10 11 11 12 12 14 15 17 18 19 21 37 38 38 39 40 40 41 41 42 43 44 45 Transmission oil check Transmission oil change Front differential oil check change 4WD locking oil check change Pre filter Water separator cleaning replacement Filter Water separator cleaning replacement CVT assembly Sliding pulley maintenance Driven pulley assembly Coolant check change Radiator pipes an...

Page 5: ...el and CVT ducts CVT ventilation ducts Engine intake ducts and air filter Silencer Exhaust manifold Engine assembly Transmission Suspension brakes and steering Suspensions disassembly regulation 91 92 92 93 93 94 95 95 96 96 97 98 98 99 99 100 102 103 104 105 106 107 108 109 113 114 Front brake callipers Rear brake callipers Brake discs Steering disassembly Steering column Steering cardan Steering...

Page 6: ...6 Page WORKSHOP MANUAL We reserve the right to modify the product and the design NOTES ...

Page 7: ...7 Page WORKSHOP MANUAL We reserve the right to modify the product and the design NOTES ...

Page 8: ...8 Page WORKSHOP MANUAL We reserve the right to modify the product and the design NOTES ...

Page 9: ...9 Page WORKSHOP MANUAL We reserve the right to modify the product and the design GENERAL INFORMATION ...

Page 10: ...n official CORVUS distributor or dealer Driving in the countryside is fascinating and we hope you will enjoy it to the full Although CORVUS vehicles are environmentally friendly environmental problems and conflict with other people may ensue in the countryside Handling the vehicle in a responsible way ensures that these problems and conflicts do not arise Be sure to use the vehicle within the boun...

Page 11: ...es that are produced contain CO Carbon Monoxide which can cause the loss of consciousness and their inhalation can be fatal The battery electrolyte contains sulphuric acid Protect your eyes clothingandskin Sulphuricacidishighlycorrosive incaseofcontact with eyes or skin wash with plenty of water and go to a doctor immediately If you have accidentally swallowed electrolyte drink largequantitiesofwa...

Page 12: ...y other foreign material prior to disassembly Use appropriate tools and cleaning equipment When dismantling parts always keep them paired up and together Thisincludesgears cylinders pistonsandotherpartssubjecttowear and tear in pairs Paired parts must always be replaced as an entire assembly As you disassemble the parts clean them and put them in trays in theorderyouremovethemin Thatwillspeedupthe...

Page 13: ...m During the installation always use new gaskets seals piston compression rings and latches After disassembly clean the components with non flammable solvent or one with a low flammability point Lubricate all working surfaces before installation excluding the conical couplings After assembly check that all components have been installed correctly and that they work perfectly For disassembly inspec...

Page 14: ...proval VIN mass of the vehicle maximum mass per axle A1 A2 and towable mass depending on type of braking and towing The vehicle identification number is also stamped on the rear right hand side of the chassis Your CORVUS TERRAIN DX4 has an engine identification plate which details manufacturer model displacement and serial number VEHICLE IDENTIFICATION CHASSIS ENGINE ...

Page 15: ...e design TOOLING TABLE GROUP Steering and suspension Chassis and protections CVT CODE 80990000000 80990000001 80990000002 03990000020 IMAGE DESCRIPTION Steering and suspension ball joint puller Spring hook Sealing rubber cutting scissors Belt pulley installation removal tool ...

Page 16: ...he right to modify the product and the design TOOLING TABLE GROUP CVT CODE 03990000021 03990000022 80990000000 03990000023 IMAGE DESCRIPTION Belt pulley plates separator tool Drive belt pulley removal tool Ball joint puller Retaining key ...

Page 17: ...ING TORQUES THREAD PITCH TIGHTENING TORQUE M 1 6 M 2 M 2 5 M 3 M 3 5 M 4 M 5 M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 0 35 0 4 0 45 0 5 0 6 0 7 0 8 1 1 25 1 5 1 75 2 2 2 5 2 5 2 5 3 0 15 Nm 0 301 Nm 0 63 Nm 1 1 Nm 1 7 Nm 2 5 Nm 4 9 Nm 8 5 Nm 20 Nm 41 Nm 70 Nm 110 Nm 170 Nm 245 Nm 345 Nm 465 Nm 595 Nm ...

Page 18: ...ember screws Seat cross member screws Threshold plate screws Light plate screws Defence screws Shock absorber clamping screws Engine chassis clamping screws D C Front Diff Chassis clamping screws Steering column screws Brake hub nut loctite Steering spider screws Steering cardan screws Steering ball joint nut Steering rack and pinion screws G3 4 M14x150 M14x150 M14x150 M10 M10 M8 M8 M8 M8 M8 M6 M8...

Page 19: ...ransmission Four stroke 3 cylinders in line Liquid 993 cc 74 mm x 77 mm 23 54 1 OHV 6 Valves Electric 12 V 1 2 KW 12 V 55 A 12 V 55 Ah 52 1 Nm at 2400 rpm 17 8 kw 23 87 hp 3600 rpm H 60 km h L 33 km h 1 973 mm 3 414 mm 1 656 mm 2 238 mm 309 mm 1 396 mm 1 370 mm 1 202 mm 1 340 mm 300 mm 0 48 m3 764 kg 785 kg With 10 L of fuel 630 kg 40 L 450 kg 907 kg Round tubular spine shaped steel chassis Indepe...

Page 20: ...SMISSION oil Differential oil 4WD actuator oil Type Emission of gases Fixed laminate Fixed tempered 2 separated Control unit 2 point Diesel B7 B10 50 ESPC G12 Quantity 7 L DOT 4 SAE 15W40 API CD CF CF 4 and CI 4 Quantity 1 7 L SAE 80W 90 GL5 EP Quantity 1 7 L SAE 80W 90 GL5 EP Quantity 0 5 L SAE 80W 90 GL5 EP Quantity 0 05 L EU T1B EC STAGE V 19 kW EPA FINAL TIER 4 19 kW CABIN LIQUIDS APPROVAL ...

Page 21: ...ant temperature Service warning indicator Fuel level Differential lock Gear indicator Clock WARNING The multifunction device is water resistant but not waterproof Do not wash it with water under pressure Do not leave the device in direct sunlight when the vehicle is not in use Avoid contact with petrol degreasers or other chemical cleaners as they may damage the device Remember to always pay atten...

Page 22: ...that The parking brake is activated The driver is not seated in the seat Orthereisamalfunctioninthebrakingsystemoralackofbrakefluid Ifthatisthecase parkthevehicleandcontactyournearest CORVUS technical service The warning indicator will illuminate for a few seconds when you switch on the vehicle using the ignition key More information in the maintenance section of this manual Engine coolant tempera...

Page 23: ...cator will illuminate when a change of direction is indicated by the indicator switch or the emergency button Diesel heaters Warning indicator to indicate that the combustion chamber is warming up to make it easier to start the engine Start the engine when the warning indicator has turned off The warning indicator will illuminate for a few seconds when you switch on the vehicle using the ignition ...

Page 24: ...of fuel left Operating Conditions Voltage supply From 10 to 16 V DC Minimum operating voltage supply without reset 6 5 V dc Operating temperature margin 20 C to 80 C Storage temperature margin 30 C to 90 C General specification Rated voltage 12 V dc Test voltage 13 5 0 1 V dc Maximum current consumption 300 mA 13 5 V Indicators and back lights active Current consumption at rest 300 μA without turn...

Page 25: ...ENGINE INDICATION BY LCD INDICATION BY INDICATOR PILOT From open manifold From open manifold Ground Positive Positive X X Hall Sensor Hall Sensor Odometer TRIP A TRIP B Service 20 bars SPEED PULSES RPM PULSES SPEED SENSOR POWER SUPPLY OIL PRESSURE SEAT BELT WARNING BATTERY CHARGE ALARM RIGHT TURN SIGNAL SUMMARY OF FEATURES Definition of each feature and its dependence at the architecture and progr...

Page 26: ...e Positive Positive Gauge R max 338 ohms 224 ohms Variable resistor Variable resistor 8 bars Icon Icon 8 bars 1 bar LEFT TURN SIGNAL LONG RANGE LIGHTS FUEL LEVEL DIESEL HEATER ENGINE WATER TEMPERATURE ENGINE WATER TEMPERATURE ALARM FUEL RESERVE INDICATOR COMBINED BRAKE AND HAND BRAKE FLUID LEVEL Positive Icon 4WD MODE ...

Page 27: ... H Common input for R L N H Common input for R L N H Common input for R L N H Icon Icon Icon Icon Icon NEUTRAL REAR DIFFERENTIAL LOCK REVERSE SHORT GEAR LONG GEAR N R L H DIGITAL INPUT VIA THE CONNECTOR ANALOGUE INPUT VIA THE CONNECTOR OUTPUT VIA THE CONNECTOR INDICATION BY STEP ENGINE INDICATION BY LCD INDICATION BY INDICATOR PILOT ...

Page 28: ...s from the sensor This input has an internal pull up resistor of 1 kOhm connected to Pin 6 Detection of low level of input 2 V Detection of high level of input 6 V Pin 8 Speed_sensor_GND to connect the sensor s ground Speedometer The speed will be indicated in analogue form using a needle backlit in red The dial of the speedometer has a linear scale of 0 to 80 km h Relationship pulses return 50 By...

Page 29: ...psed It also shows the letter h for the hours of operation The counter only increases in value when the engine is started using the ignition key The counter is displayed without zeros to the left When the counter reaches 9999 5 hours it will remain fixed at this value We can access the odometer from the hour meter by pressing TRIP 2 s We can access TRIP 1 from the hour meter by pressing MODE 2 s W...

Page 30: ...bol will flash on the screen When you have travelled 1500 km the service symbol will remain lit When there are 30 days left before the service is due the service sign will flash with the 1 Year symbol If 1 year goes by before you have travelled the kilometres at which maintenance is due the service symbol will activate with the text 1 YEAR Theoperatinghoursindicatorwillbeginat100andwilldecreaseunt...

Page 31: ...canloseupto29minutes Thiswillhappen as long as the vehicle s battery is switched off 24H clock The clock is displayed in the 24H format HH MM How to set the time SelectthefunctionodometerusingtheMODEbutton OrpresstheMODEbuttonformorethan2seconds untilthetwohourdigitsflash Repeatedly press the TRIP button to increase the hour digits or leave the TRIP button pressed to increase the hours Press the M...

Page 32: ...stently such as open circuit or short circuit the gear indication will disappear after 1 second In the event of a system reset the indication will reappear after 1 second Revolution counter RPM The instrument displays the engine revolutions via a bar indicator It has a total of 20 bars that will serve to indicate the range of 0 to 10000 rpm one bar is equivalent to 500 rpm Only 10 bars are used fo...

Page 33: ...e on when 1 8 of the tank remains When a short circuit is detected all the bars and the fuel LED will flash When an open circuit is detected bars 1 and 8 and the fuel LED will flash MULTIFUNCTION PANEL 8 7 6 5 4 3 2 1 0 FUEL LEVEL GAUGE RESISTANCE RANGE UPDATE TIME OPEN CIRCUIT DETECTION SHORT CIRCUIT DETECTION 48 78 109 139 154 174 195 276 338 Variable resistor 3 338 ohm 30 seconds 500 ohm 2 ohm ...

Page 34: ...e values fall below 2 OHM When an open circuit or a short circuit is detected bars 1 and 8 plus the LED alarm will flash Oil pressure The low oil pressure indicator will activate when the engine s internal pressure gauge detects a pressure lower than the alarm value Safety belt Seat When input 13 belt seat input goes from active 12 V to inactive open circuit and input 15 handbrake is inactive at t...

Page 35: ...ATORS NEXT CONDITION Short MODE Short TRIP Long MODE Long TRIP HOURS OF OPERATION INCREASE MINUTE TRIP 1 TRIP 2 INCREASE HOUR ODO X X X X X X X X X X X X X X X TRIP 1 Hours of operation Add time TRIP 1 ODO Add time TRIP 2 Reset TRIP 1 ODO Reset TRIP 2 Wheel size Add time Add minute Add minute Save time MODE TRIP buttons ...

Page 36: ...e push buttons seetableabove increasesordecreasesthesizeofthewheelinmm Keepingthebuttonpressedwillmakeitincreaseanddecrease rapidly To accept the selected value press MODE and TRIP at the same time until the screen returns to its normal appearance The X marked with an asterisk are special and are explained in the sections on the indicators PUSH BUTTONS INDICATORS NEXT CONDITION Short MODE Short TR...

Page 37: ...37 Page WORKSHOP MANUAL We reserve the right to modify the product and the design MAINTENANCE ...

Page 38: ...s in the work area Clean the brake pads in a ventilated place directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear and tear of the friction material Although such dust does not contain asbestos inhalation is nevertheless harmful DANGER Use original CORVUS spare parts and lubricants recommended by CORVUS Non original or non compliant spare parts...

Page 39: ...cooling sleeves Clean or replace air filter element General visual engine check CVT transmission belt 1 2 CVT pulleys CVT air ingress Check gearshift and front rear differential oil level Replace gearshift and front rear differential oil Check transmission joint boots Cardan gaskets Wheel bearings Nuts and studs of the wheel bolts Suspension ball joints and mounting points Tire pressure and wear A...

Page 40: ...n area at the front 1 and another at the rear 2 to facilitate its elevation WARNING BEFORE RAISING THE VEHICLE MAKE SURE THE BRAKE IS FULLY ON AND THAT THE SURFACE IS FLAT AND COMPLETELY HORIZONTAL 1 Place the base of the jack in the area indicated in the vehicle 2 Raise the vehicle slowly checking that it is stable MAINTENANCE 1 2 ...

Page 41: ...nderbody protector 4 Uncouple the protector 1 2 1 2 MOUNTING THE WHEEL 1 Put the vehicle in a horizontal position 2 Engage the parking brake 3 Raise the area of the vehicle front or rear where the wheel you are removing is located see page 40 4 Remove the four screws 1 holding the wheel rim 5 Remove the wheel INSTALLING THE WHEEL Perform the above process in reverse for the installation TECHNICAL ...

Page 42: ...eed is a factory setting If you need to adjust it proceed as follows 1 Warm the engine up to operating temperature 2 Stop the engine 3 Connect a tachometer see manufacturer s instructions 4 Start the engine and make the adjustment using the regulation screw 1 WARNING THE IDLE SPEED SHOULD NEVER BE GREATER THAN 1250 RPM MAINTENANCE 1 ...

Page 43: ...sed air from the inside toward the outside RECOMMENDATION Do not apply air at an excessive pressure to avoid tearing the air cleaner paper which could result in severe engine damage Recommended air pressure between 42 71 PSI 0 29 0 49 MPA 3 5 KGF cm2 DANGER THESE OPERATIONS MUST BE CARRIED OUT WITH THE APPROPRIATE PRECAUTION USING A MASK AND GOGGLES 4 Clean the inside of the air cleaner housing 3 ...

Page 44: ...l level should be between the maximum and minimum marks 2 of the plug dipstick 5 If the oil level is too high 5 1 Place a container under the engine to collect the used oil and avoid any spillage 5 2 Remove the excess using the drain plug screw 4 5 3 Tighten the plug screw 4 replacing its washer 6 If the oil level is too low 6 1 Fill it up with the required amount of oil removing either of the two...

Page 45: ...ing any tools 8 Tighten the plug screw 3 replacing its washer 9 Fill with new oil 10 Check the plug dipstick level 1 and the tightness of the filler plugs 2 with their O ring 11 Run the engine for a few minutes 12 Stoptheengineandafterabout5minutes checktheoillevelagain accordingtotheindicationsofthe oil level check WARNING FOR THE TRANSMISSION AND ENGINE TO FUNCTION PROPERLY KEEP THE OIL AT THE O...

Page 46: ...correct If on the contrary no liquid oozes from the hole you should continue to add more oil 5 If you need to add more oil you must do so through the filler cap 2 TRANSMISSION OIL CHANGE Changing the transmission oil 1 Put the vehicle in horizontal position and lift the load box 2 Remove the rear protector see page 41 3 Placeacontainerunderthetransmissiontocollecttheusedoiland avoid any spillage 4...

Page 47: ...ee page 75 3 Remove the front underbody protector before starting the operation see page 41 4 Placeacontainerunderthedifferentialtocollecttheusedoiland avoid any spillage 5 Remove the filler plug screw 1 to facilitate better oil drainage 6 Removethedrainplug screw 2 andwaituntilallthecontenthas drained out 7 Screw on the drain plug screw 2 and tighten the drain plug replacing the washer securing i...

Page 48: ...ehicle in the horizontal position and remove the front underbody protector see page 41 2 Place a container under the 4WD locking system to collect the used oil and avoid any spillage 3 Removethefillerplug 1 tofacilitateabetterdrainageofthe4WD oil 4 Remove the drain screw 2 the 4WD locking system oil 5 Once all the oil has drained out replace the washer and make sure the drain screw 2 is tightened ...

Page 49: ...AINTENANCE WATER PRE FILTER SEPARATOR CLEANING REPLACEMENT 1 Put the vehicle in a totally horizontal position and raise the cargo box 2 Remove the left hand side drawer 3 Close the fuel stopcock 1 to the C position 4 Placeacontainerunderthefilters 2 tocollectanyliquidthatmay spill out over the variator box CVT 2 1 ...

Page 50: ... into a container used to collect pollutants 7 Clean the inside of the socket with clean fuel 8 Inspectandcleanthemeshofthefilter 5 Ifitiswornout replace it with a new one 9 ChecktheconditionoftheO ring 4 andreplaceitifitiswornout 10 Reinstallthesocket introducingtheO ring 4 andtighteningthe fastening nut manually 3 11 Open the fuel stopcock 6 to the O position 12 Check the tightness of the instal...

Page 51: ...n MAINTENANCE WATER FILTER SEPARATOR CLEANING REPLACEMENT 1 Put the vehicle in horizontal position and lift the load box 2 Remove the left hand side drawer 3 Close the fuel stopcock 2 to the C position 4 Place a container under the filters 1 to collect any liquid that may spill out over the variator box CVT 1 2 ...

Page 52: ...pty its contents into a container used to collect pollutants 7 Clean the inside of the socket with clean fuel 8 Replace the fuel filter 5 if it is worn out 9 ChecktheconditionoftheO ring 4 andreplaceitifitiswornout 10 Reinstallthesocket introducingtheO ring 4 andtighteningthe fastening nut manually 3 11 Open the fuel stopcock 6 to the O position 12 Check the tightness of the installation 6 5 3 4 ...

Page 53: ...LETOCARRYOUTTHISPROCESSREGULARLY First of all you must remove the left hand side drawer 1 Removetheclamp 1 fromtheelbowconnection 2 betweenthe manifold and the CVT transmission cover 2 Pull the elbow 2 downwards to release it from the housing of the duct 3 Remove the four screws 3 from the left upper grid and remove it 4 Clean the intake duct WARNING PLUG THE AIR INTAKE TO THE TRANSMISSION WHILE C...

Page 54: ... Remove the eleven screws A B and C from the CVT cover 2 Uncouple the CVT cover WARNING PAY SPECIAL ATTENTION TO THE POSITION OF THE SCREWS OF THE CVT COVER DURING THE ASSEMBLY SEEPOSITIONSINDICATEDINTHEPHOTOGRAPHOFTHE DIFFERENT LENGTHS OF THE COVER SCREWS M6x25 screw M6x20 screw M6x16 screw A B C A B B B B B B B B C B ...

Page 55: ...ps of the pulley 3 Check the condition of the belt and change if it is worn out or needs to be replaced according to the service chart see page 39 4 Loosen the front screw and remove and its washer 2 5 Remove the driven belt pulley 3 together with the transmission belt 6 Remove the shaft key for later assembly MAINTENANCE TECHNICAL INFORMATION Plate spacer tool 03990000021 Transmission belt 031900...

Page 56: ...VT belt 4 see page 55 2 removetheboltandretainingwasher 5 usingthetooltolockthe pulley 6 3 Remove the CVT fan 7 4 Insert the tool 8 to remove the drive pulley until you have uncoupled it from the engine cone TECHNICAL INFORMATION Drive belt pulley removal tool 03990000022 Drive belt pulley locking tool 03990000023 Pulley retaining bolt torque 70 Nm 4 8 5 6 7 ...

Page 57: ...inspection General control Visual inspection Visual inspection Visual inspection Dimension Visual Dimension Visual Removing and cleaning Cleaning Cleaning Replacement recommended Replacement recommended Removing and cleaning Cleaning Cleaning Cleaning Replacement recommended Dimension Visual Drive pulley Fixed pulley Sliding pole Installation of centrifugal weights Friction bushing Driven pulley F...

Page 58: ...RANSMISSION BELT MUST BE INSPECTED TO AVOID THE RISK OF PERSONAL INJURY AND OR MECHANICAL BREAKAGE Thetransmissionbeltshouldbereplacedifcracksappearontherear of the belt Thedrivebeltshouldbereplacedwhenitsmaximumwidthdecreases by from 2 to 3 mm of its original width Be sure to measure the belt at its widest point MAINTENANCE ...

Page 59: ...3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Fixed pulley Adjustingwasher ifapplicable Floating bearing Adjusting shim Spring seat Adjusting washer if applicable Adjusting washer if applicable Opening limiter Spring Sliding pulley Assembly of centrifugal weights Housing Weight Cover Friction bushing Washer if applicable Nut Washer if applicable Removing the drive belt pulley 1 2 4 5 7 9 10 14 16 17 18...

Page 60: ...verthewearmarksdisplayedintheimageexceedthe wearlimit Theallowablewearlimitofthehousingislessthan14mm Friction bushing 15 Replace the cover bushings whenever there is too much noise at idlingspeedbetweentheseandtheslidingtowerofthepulley Usea gauge to measure wear as shown The maximum space of wear allowed is 1 mm WARNING ALWAYS CHANGE THE THREE RINGS 15 AT THE SAME TIME Floating bearing 3 Change ...

Page 61: ...ure that the pulley is balanced see images Tightening the pulley Use a torque wrench with a 30mm adapter to tighten the pulley WARNING MAKE SURE THAT THE ALIGNMENT OF THE HEXAGONAL SHAPE OF THE COVER 14 AND THE WASHER 16 ARE FULLY ENGAGED IN THE HEXAGONAL SHAPE OF THE SHAFT BEFORE APPLYING TORQUE TO THE NUT 17 Square notch Point Centring washer if applicable Hexagonal upper surface on the shaft of...

Page 62: ...t to modify the product and the design MAINTENANCE 1 2 3 4 5 6 7 8 9 Fixed pulley Washer if applicable Sliding pulley Friction bushing Friction bushing screw Spring Synchronizer block Cam Elastic ring Removing the driven pulley 2 1 3 6 7 8 9 4 5 ...

Page 63: ...TO THE FRICTION BUSHING WHENREINSTALLINGTHEPULLEY THEPOSITIONSMUST BETHESAMEASBEFOREREMOVAL THISENSURESTHAT THEPERFORMANCEOFTHEPULLEYISNOTAFFECTED DANGER USE THE REMOVAL TOOL TO REMOVE THE CAM FROM THE PULLEY THE PULLEY IS SPRING LOADED WITH A SIGNIFICANT AMOUNT OF FORCE USING THE REMOVAL TOOL WILL KEEP THE PULLEY COMPRESSED The correct installation of the driven pulley Position of the spring on t...

Page 64: ...revent the dismantling tool from turning Pressdownonthecam 3to4mmmaximum toreleasethecirclip by screwing the bar into the threaded rod Remove the circlip with suitable pliers Gently unscrew the bar from the threaded rod to slowly release the spring DANGER SLOWLY RAISE THE CAM TO RELEASE IT FROM THE SHAFT BY UNSCREWING THE REMOVAL TOOL Removing the cam Rotation lock ...

Page 65: ...ixed and sliding pulley Checkthewearofthebushingsoftheslidingpulley visualinspection only If there is excessive wear you must replace the entire pulley assembly Check the wear of the shaft both inside and out visual inspection only WARNING TO MAINTAIN THE PERFORMANCE OF THE PULLEY BE SURE TO CLEAN THE BUSHINGS OF THE PULLEY WITH A MICROFIBRE TOWEL OR A DRY CLOTH CAUTION DO NOT USE ACETONE TO CLEAN...

Page 66: ...imately 1 mm before making contact with the aluminium flange After you remove the screws with a Torx No 20 screwdriver the cam shoes can be removed with a flat ended screwdriver Assemblethefrictionbushing with the help of a hammer WARNING TAP THE FRICTION BUSHINGS GENTLY 4 SO AS NOT TO DAMAGE THEM ALWAYSCHANGETHETHREEFRICTIONBUSHINGS 4 AT THE SAME TIME APPLY A FASTENING TORQUE OF 2 5 TO 4 5 NM 4 ...

Page 67: ...am Install the pulley on the removal tool Place the spring on the orifice of the cam 8 in the same position as before removal Press the cam 8 down onto the fixed shaft of the pulley 1 using the removaltool Placethesynchronizerblock 7 onthegrooveonthefixed pulley 1 Makesurethatthefixedpulley 1 islocked rotatetheslidingpulley 3 totheleftortotherighttoplacethefrictionbushingonthecorrectside of the sl...

Page 68: ...ne overheats and can be severely damaged Check the fluid level every day TECHNICAL INFORMATION Recommended fluid 50 Long time 35 C Checking the coolant level 1 Place the vehicle in a completely horizontal position 2 Remove the three screws 1 from the cover 3 Unscrewthecapfromthereservoir 2 inananticlockwisedirection and wait a few seconds until the vapours disperse 4 Checkthecoolantlevel Theliquid...

Page 69: ...he radiator 3 Unscrew the radiator cap 2 anticlockwise and drain the coolant 4 Place a container underneath the connecting 3 and release it to drain the fluid 7 Tighten the radiator cap 2 and the sleeve 3 8 Add coolant up to 50 mm below the mouth of the cap closure 1 9 Close the reservoir cap 1 and start the engine 10 Check that the coolant level is correct 11 If the fluid level is low add the req...

Page 70: ...ORRECT LIQUID SOLUTIONS MAY CAUSE DAMAGE TO THE ENGINE AND THE COOLING SYSTEM USE COOLANT WITH A SPECIFIC CORROSION INHIBITOR FOR ALUMINIUM ENGINES AND RADIATORS IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS RADIATOR PIPES AND CONNECTIONS CHECK Radiator hosepipes Check that the radiator hosepipes do not have cuts or are damaged and that the connections do not have leaks Radiator Check that th...

Page 71: ...FFERENTTYPESOFBRAKEFLUID THE FLUIDUSEDTOFILLORRENEWYOURCIRCUITMUST RESPONDTOTHESPECIFIEDSTANDARDINTHEFLUID RESERVOIROFEACHCIRCUIT YOUMUSTUSEDOT 4 YOU SHOULD NEVER CHANGE THE SPECIFICATION ALWAYSRESPECTTHEDOT 4SPECIFICATION WHATIS IMPORTANTISNOTTHATTHEBRAKEFLUIDSHOULDBE THESAMEBRAND RATHERTHATITMUSTHAVETHESAME SPECIFICATION NEVERUSEFLUIDFROMACONTAINER THATISNOTSEALED UNOPENED ATSOURCE NEVER UNDERAN...

Page 72: ...tacharubbertubetocollectthe liquid 5 Keeping your foot on the brake pedal loosen the bleed screw 3 so that the air in the installation can get out 6 Repeattheoperationuntilonlynewbrakefluidoozesfromtherubbertube beforehand gradually fill the brake fluid reservoir with new fluid 7 Tighten the bleed screw 8 Restore the brake fluid level in the reservoir 9 Perform this operation for the four brake ca...

Page 73: ... the pads 4 Remove the pads 5 Install the new brake pads 6 For installation follow these steps in reverse order DANGER TO PREVENT DAMAGE TO THE CANOPY DO NOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH IT DURING BLEED OPERATIONS INADDITION WHENBLEEDINGTHEBRAKECALLIPERS DO NOT ALLOW THE FLUID TO COME INTO CONTACT WITH THE BRAKE DISCS OR WITH THE BRAKE PADS FAILURETOCOMPLYWITHTHISRULEISDETRIMENTAL T...

Page 74: ... THICKNESS IS AT LEAST 3 5 MM IN THE FRONT AXLE AND 3 5 MM IN THE REAR AXLE WARNING WE RECOMMEND THAT YOU GO TO YOUR CORVUS DEALER TO CHANGE THE BRAKE PADS THEY WILL ALSO CHECK FOR ANY POSSIBLE WEAR OF THE BRAKE DISCS WARNING ONCE YOU HAVE INSTALLED THE NEW PADS IT IS PROBABLE THAT THE BRAKE FLUID LEVEL WILL HAVE RISEN CHECK THE LEVEL TECHNICAL INFORMATION Wear limit 1 5 mm Wheel nuts tightening t...

Page 75: ...t Replacethebatterywithanewoneandfollowthestepsinreverseorder to reassemble it Maintenance is limited to checking the charge status and if necessary to recharging it Theseoperationsshouldbecarriedoutevery6monthswheninstorage withthecircuitopen Therefore itisnecessarytocontrolthechargeand ifnecessary torechargeitpriortostorageofthevehicleandthenevery 6 months Charging current of 1 10th of the rated...

Page 76: ...OTHING AND GOGGLES MAINTENANCE WARNING BATTERYISFULLYCHARGEDTOENSUREITSMAXIMUM PERFORMANCE IFTHEBATTERYISNOTCHARGEDPROPERLYPRIORTO OPERATION IT MAY SUFFER PREMATURE DAMAGE TIRES CHECK Checkthatthetiresarenotworn crackedordamaged Alsocheck that they are at the correct pressure TECHNICAL INFORMATION Recommended front rear pressure 1 0 bar empty vehicle 1 5 bar vehicle at full load BOLTS NUTS AND FAS...

Page 77: ...to modify the product and the design MAINTENANCE STEERING ALIGNMENT To align the vehicle properly the measurements indicated in the graph must be respected WARNING MEASUREMENTS AND ADJUSTMENTS MUST BE MADE WHEN THE VEHICLE IS EMPTY 0 0 1 0 0 1 X X ...

Page 78: ...ALLEL BETWEEN THE TWO POINTS ON THE REAR WHEEL RIM This process will project the ideal point for the front of the steering wheel 2 Check if the steering respects the indications in the chart If not you must perform the corresponding alignment TECHNICAL INFORMATION If you have the necessary machinery to do this do it mechanically and adjust 0 0 1 The steering wheels should have a divergence of 0 0 ...

Page 79: ...HEELS 1 TO ENSURE MINIMUM SLIPPAGE BEFORE YOU DO THIS YOU MUST PERFORM STEPS 1 AND 2 OF THE PREVIOUS PARAGRAPH CHECKING ALIGNMENT Then 1 Centre the steering wheel 2 Fixthepositionofthesteeringwheeltopreventmovementduring the alignment process 3 Use a wrench to loosen the nut 1 of the two steering braces 4 From point 2 adjust both sides until they are correctly aligned 5 Then fix the position by us...

Page 80: ... product and the design DANGER ALWAYS USE A WRENCH TO HOLD THE ENDS OF THE BRACE WHEN LOOSENING OR TIGHTENING THE COUNTER NUTS OR YOU MAY DAMAGE THEM TECHNICAL INFORMATION The front measurement should be 0 0 1 greater than the rear measurement MAINTENANCE 1 2 ...

Page 81: ...ain the volume required to clean the windshield properly The reservoir is located under the front hood 1 Loosen the 4 screws holding the cover 1 and remove it 2 Remove the cap 2 and check the level 3 If there isn t enough liquid fill it up to the top of the tank TECHNICAL INFORMATION The standard volume is 1 L Recommended fluid standard windshield wiper fluid 1 2 ...

Page 82: ...el spindle two in each cardan jointandoneinthetransmissioncardan output coupling joint Daubing the cardan To perform this process and to access the cardan it is necessary to disassemble the underbody protector see page 41 To daub the cardan follow the procedure 1 Use the three grease nipples 1a 1b 1c 2 Check the play of the crossarms If there is play replace the full bar Daubing the stub shafts 1 ...

Page 83: ...ble To adjust the play of the accelerator cable follow this procedure 1 Remove the cable sheath 1 2 Use a wrench to loosen the nut 2 3 Adjust from point 3 until the required play value is reached 4 Then put the sheath back on TECHNICAL INFORMATION Recommended play 2 3 mm on the accelerator pedal Nut tightening torque 12 Nm 2 3 1 ...

Page 84: ...lied to its maximum extent the angle of the cam with reference to the cable has to be 85 0 5 Hand brake cable To adjust the tension of the handbrake cable follow this procedure 1 Loosen the nut 1 2 Adjust by tensing the nut clockwise 2 3 Check to see if the hand brake has a correct tension 4 Follow this process for the two brake callipers the left hand one and the rear right hand one 2 1 ...

Page 85: ...ble To adjust the play in the gear cable follow this procedure 1 Use a wrench to loosen the nut 1 2 Use a wrench to loosen the nut 2 3 Adjust from point 3 by turning right or left until you reach the required play value 4 Then tighten the nuts TECHNICAL INFORMATION Nut tightening torque 12 15 Nm 2 1 3 ...

Page 86: ... the parking brake to immobilize it 2 Open the front hood 3 Unscrew the eleven screws from the base of the hood and remove it see page 94 4 Use the screws to adjust the headlights 1 3 Thelightbeammustbe30cmbelowthehorizontallineprojected onto the wall from the centre of the lamp 30 cm below the centrallineofthe lamp Central line of the lamp 10 meters from vehicle to wall 1 ...

Page 87: ... high beam lamps 1 Unplug the electrical connector 1 of the lamp you are replacing 2 Turn the bulb counterclockwise to remove it from its housing Replacing the indicator lamps 1 To replace the indicator lamps turn the bulb holder bushing 2 counterclockwise to disconnect it from its housing 2 Turn the lamp and separate it from the bushing TECHNICAL INFORMATION Low and high beam headlamps HB3 12V 60...

Page 88: ...EPLACEMENT 1 To access the rear lamps you will have to remove the light cover that is anchored with the two screws indicated in the image 1 2 You will then be able to see the two lamps Indicator 2 Brake and sidelight 3 TECHNICAL INFORMATION Indicator lamp 12V 21W Ref 09180040001 Brake and sidelight lamp 12V 21W 5W Ref 09180040002 1 2 3 ...

Page 89: ...89 Page WORKSHOP MANUAL We reserve the right to modify the product and the design CANOPY ...

Page 90: ... holding the fender and remove it REAR FENDER REMOVAL Before you do this you must lift out the cargo box 1 Loosen the six screws 1 holding the fender and remove it To remove the left fender you will need to remove the cap from the fuel tank WARNING COVER THE ORIFICE OF THE FUEL TANK TO PREVENT ANY OBJECT FROM FALLING INTO IT 1 1 1 1 1 1 1 ...

Page 91: ...y the product and the design CROSS MEMBER ROLLBAR COVER REMOVAL 1 Remove the rear side fenders see page 90 2 Loosen the two screws 1 located on the sides of the vehicle 3 Loosen the four screws 2 and remove the cover of the cross member rollbar CANOPY 1 2 ...

Page 92: ...he door of the side drawer 2 Remove the two screws 1 located on the inside of the compartment 3 Remove the two top screws 2 4 Remove the drawer TECHNICAL INFORMATION Screw tightening torque 24 Nm INNER DRAWERS REMOVAL 1 Open the door to the interior drawer you want to remove 2 Remove the screws 1 from the drawer you want to remove located inside at the top of each drawer TECHNICAL INFORMATION Scre...

Page 93: ...with the corresponding key 2 Slightly raise the hood 3 Loosen the screws 2 of the hinges 1 while holding the nuts on the inside THRESHOLD PLATES REMOVAL Before you remove the threshold plates you must previously withdraw the front and rear fenders see page 90 1 Remove the five screws 1 and remove the part CANOPY 1 1 2 ...

Page 94: ... REMOVAL Previously you need to remove the front hood 1 Loosen the eleven screws 1 holding the hood base and remove it 2 Remove the hood safety lock 2 3 Remove the cylinder from the lock 3 TECHNICAL INFORMATION Lock screws tightening torque 12 Nm Locking screws tightening torque 12 Nm CANOPY 2 3 1 ...

Page 95: ...emove the luggage compartment you must previously remove the front hood base see page 94 1 Loosenthesixscrews 1 thatholdthefrontluggagecompartment and remove it FRONT LIP REMOVAL To remove the front lip you must previously remove the front fenders see page 90 1 Loosen the four screws 1 that hold the front lip and remove it 1 1 ...

Page 96: ...gage compartment you must previously remove the front fenders see page 90 and the wheel arches 1 Loosen the ten screws 1 holding the mask and remove it WHEEL ARCH REMOVAL To remove the wheel arch you must previously remove the front fenders see page 90 1 Loosen the five screws 1 holding the wheel arch and remove it 1 1 1 1 1 ...

Page 97: ...REMOVAL 1 Raise the cargo box 2 Secure the cargo box by means of load slings 3 Loosen the upper clips 1 of the shock absorbers 4 Disconnect the wiring of the rear lights 2 5 Remove the screws from the latches 3 of the cargo box 6 Remove the latches 7 Raise the cargo box with the help of a crane 2 3 1 ...

Page 98: ...sign CANOPY SEATS REMOVAL 1 Remove the two screws 1 located in each of the two brackets underneath the seat 2 Remove the seat TECHNICAL INFORMATION Screw tightening torque 24 Nm ROOF REMOVAL 1 Remove the plugs on the inside 2 Remove the six screws 1 3 Remove the roof upwards 1 1 ...

Page 99: ...REMOVAL 1 Remove the seats see page 98 2 Remove the six top screws 1 3 Remove the five bottom screws 2 4 Remove the engine frame cover FRAME UNDER SEAT REMOVAL 1 Remove the seats see page 98 2 Remove the engine frame cover 3 Remove the eight top screws of the frame 1 4 Remove the seven bottom screws 2 1 1 2 2 ...

Page 100: ... screws 3 from the windshield wiper cover 4 Disable the windshield wiper button 4 5 Remove the windshield wiper cover 6 Lift up the cover of the windshield wiper arm 5 7 Remove the nut 6 8 Remove the plug 7 from the engine retaining screw 9 Remove the plastic nut 8 10 Remove the nuts 9 11 Remove the four screws 10 of the interior rear view mirror bracket holding the four nuts from the inside This ...

Page 101: ...101 Page WORKSHOP MANUAL We reserve the right to modify the product and the design 6 CANOPY 1 4 2 3 10 7 9 5 8 ...

Page 102: ... 2 Release the peripheral 2 rubber from the inside WARNING IT IS ADVISABLE THAT SOMEONE ELSE SHOULD HOLD THE WINDSHIELD LIGHTLY FROM THE OUTSIDE TO PREVENT IT FROM BEING EJECTED WHILE YOU ARE PUSHING THE RUBBER FROM THE INSIDE CANOPY Rear 1 Remove the two outer screws 1 2 Release the peripheral 2 rubber from the inside TECHNICAL INFORMATION Flange screws tightening torque 12 Nm 1 1 2 2 ...

Page 103: ...103 Page WORKSHOP MANUAL We reserve the right to modify the product and the design ENGINE ...

Page 104: ...t and the design 1 2 3 4 5 SNORKEL DUCTS AND CVT DUCTS REMOVAL 1 Remove the four screws 1 securing the snorkel grid and remove it 2 Remove the two inner screws 2 3 Remove the plastic plug 3 and the screw inside 4 4 Remove the two screws 5 and loosen the snorkel ENGINE ...

Page 105: ...CTS REMOVAL 1 Loosen the metal flange 1 and remove the joint boot 2 2 Remove the clamp 3 from the elbow connection 2 between the manifold DUCT and the CVT transmission cover 3 Pull the elbow 4 downwards to release it from the housing of the duct 4 Loosen the screw 5 and remove the CVT duct 6 ENGINE 3 4 5 6 ...

Page 106: ...ign ENGINE ENGINE INLET DUCTS AND AIR FILTER REMOVAL 1 Loosen the metal flange 1 and remove the joint boot 2 Remove the two screws 2 securing the air inlet duct 3 Loosen the four metal flanges 3 4 Remove the two screws 4 securing the air filter 5 Remove the entire assembly 1 3 4 2 ...

Page 107: ...lift up the cargo box WARNING MAKE SURE THAT THE SILENCER IS COMPLETELY COLD BEFORE YOU REMOVE IT 1 Releasethetwonuts 1 fromtheclampbetweenthesilencerandthe exhaust manifold 2 Liftthesilencerwiththetwosilentblocks 2 ofthebracketsontothe chassis WARNING CHECK THE CONDITION OF THE SILENTBLOCKS AND REPLACE THEM WITH NEW ONES IF THEY ARE FAULTY 2 1 ...

Page 108: ...e cargo box and remove the right side drawer WARNING MAKE SURE THAT THE EXHAUST IS COMPLETELY COLD BEFORE YOU REMOVE IT 1 Release the exhaust silencer see page 107 2 Release the four nuts 1 of the engine outlet to the exhaust 3 Removethesilentblock 2 fromthebrackettothechassis andthen the exhaust manifold WARNING CHECK THE CONDITION OF THE SILENTBLOCK AND REPLACE IT WITH A NEW ONE IF IT IS FAULTY ...

Page 109: ...91 5 Remove the side snorkels see page 104 the CVT ventilation system see page 105 and the inlet connections see page 106 6 Remove the rear windshield see page 102 7 Loosen the four screws 1 and remove the lower cross member rollbar 8 Remove the seats see page 98 9 Remove the lower inner drawers see page 92 10 Remove the engine frame cover see page 99 and the interior frame under the seats see pag...

Page 110: ... DRIVES ELECTRICAL SYSTEMS COOLING POWER SUPPLY AND IGNITION ARE SWITCHED OFF DANGER BEFORE PERFORMING ANY OPERATION MAKE SURE THE VEHICLE S BRAKE IS ON AND APPLY CHOCKS TO THE WHEELS THE ENGINE AND TRANSMISSION ARE REMOVED UPWARDS AND GIVEN THAT THIS IS A COMPLEX MANOEUVRE INVOLVING THE REMOVAL OF THE UPPER PARTS OF THE VEHICLE AND YOU MUST HAVE ELEMENTS TO CHOCK IT AND TO HANDLE IT ...

Page 111: ...nnections 5 5 Loosen the metal flanges 6 and remove the pipes of the cooling system 6 Remove the chassis reinforcement brace by removing the two screws 7 attaching it Engine removal operations 1 Remove the gear shift cable by loosening the nut and the counternut 1 and the ball joint nut 2 2 Removetheacceleratorcablebyremoving the elastic ring 3 and the fastening nut 4 ENGINE 7 3 4 5 6 1 2 ...

Page 112: ...ep them suspended 9 Remove the three retaining screws 9 of the chassis assembly 10 Remove the engine transmission upwards at a slight angle WARNING CHECK THE CONDITION OF THE SILENTBLOCKS AND CHANGE THEM IF THEY ARE FAULTY THEECCENTRICSILENTBLOCKHAS TOBEMOUNTEDBYMAKINGITS SYMMETRICALCENTRECOINCIDE ATITSHIGHPOSITION WITHTHE MARK ON THE BRACKET TECHNICAL INFORMATION Engine screws tightening torque 4...

Page 113: ...113 Page WORKSHOP MANUAL We reserve the right to modify the product and the design SUSPENSION BRAKES AND STEERING ...

Page 114: ...oosen the screw and nut 1 on the bottom 3 Loosen the screw and nut 2 at the top 4 Remove the shock absorber WARNING PAY SPECIAL ATTENTION TO THE POSITION OF THE SCREWS WASHERS AND BUSHING FOR REASSEMBLY For regulation follow this procedure WARNING FIRST OF ALL LOOSEN THE LOCKING SCREW 3 WHICH IS LOCATED ON THE ACTUAL PRE LOAD NUT 4 To regulate the preload manipulate the nut 4 Turning it clockwise ...

Page 115: ... the four nuts 1 of the corresponding wheel 3 Place a container underneath to collect the brake fluid 4 Remove the banjo screw 2 5 Drain the brake system 6 Remove the two screws 3 securing the clamp WARNING DO NOT ALLOW THE BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PLASTIC OR RUBBER PARTS REPLACETHEWASHERSOFTHEBANJOSCREWDURING THE ASSEMBLY PROCESS TECHNICAL INFORMATION Wheel nuts tightening to...

Page 116: ... the four nuts of the corresponding wheel 3 Place a container underneath to collect the brake fluid 4 Remove the banjo screw 3 5 Drain the brake system 6 Remove the two screws 4 securing the clamp WARNING DO NOT ALLOW THE BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PLASTIC OR RUBBER PARTS REPLACE THE WASHERS OF THE BANJO SCREW DURING THE ASSEMBLY PROCESS Parking brake clamp 1 Remove the two nuts...

Page 117: ...plines 1 Measure the disc thickness The disks must have a minimum thickness of 3 5mm Iftheyneedtobereplaced youshouldpreviouslyremovethefournuts of the corresponding wheel and the brake clamp s see page 73 1 Remove the four nuts of the disc together with the screws 1 2 Gently rotate the disk to release it from the orifices in the bushing 3 Remove the worn or defective disc TECHNICAL INFORMATION We...

Page 118: ...ts and indicators trim 3 5 Remove the two screws 4 from the control retainer clamp 6 Removethescrews 5 anddisconnectthespeedometerbypullingit downwards 7 Disconnect the electrical connector from the speedometer 6 8 Disconnect the electrical connector 7 from the lights control 9 Loosen the upper screw 8 of the cardan gasket of the lower anchorage of the steering rod 10 Loosen and remove the four sc...

Page 119: ...119 Page WORKSHOP MANUAL We reserve the right to modify the product and the design 7 SUSPENSION BRAKES AND STEERING 8 4 9 6 ...

Page 120: ...TEERING Steering cardan To access the steering cardan you must previously remove the dashboard Then follow these steps 1 Loosentheupperscrew 1 holdingthesteeringcardantotheEPS engine or to the steering column 2 Loosen the lower screw 2 holding the steering cardan to the steering box 3 Remove the cardan 1 2 ...

Page 121: ... 1 2 Using the tool 2 release the ball joint from the wheel spindle 3 Loosen the three screws 3 securing the steering rack to the chassis 4 Remove the steering arms and box assembly WARNING CHECK FOR ANY POSSIBLE PLAY IN THE STEERING BALL JOINTS OR BAR CROSSHEADS IF THERE IS ANY PLAY OR A MALFUNCTION REPLACE THEM AND THEN READJUST THE STEERING ALIGNMENT TECHNICAL INFORMATION Ball joint extractor t...

Page 122: ...t and the design SUSPENSION BRAKES AND STEERING EPS engine To access the EPS engine you must previously remove the dashboard Then follow these steps 1 Disconnect the ECU from the general wiring 1 2 Loosen the lower screw 2 of the cardan gasket 3 Loosen the upper screw of the steering cardan 3 2 1 3 ...

Page 123: ... the design 4 Loosenthethreescrews 4 thatholdtheEPSenginetothespider 5 Remove the EPS engine from its housing WARNING CHECK FOR ANY POSSIBLE PLAY IN THE STEERING BALL JOINTS OR BAR CROSSHEADS IFTHEREISANYPLAYORAMALFUNCTION REPLACE THEMANDTHENREADJUSTTHESTEERINGALIGNMENT SUSPENSION BRAKES AND STEERING 4 ...

Page 124: ...124 Page WORKSHOP MANUAL We reserve the right to modify the product and the design TRANSMISSION ...

Page 125: ...e of thechassisbyremovingthesixnutsandscrews 1 securingeachof them 2 Loosen and remove the six nuts and screws 2 on either end of the cardan 3 Loosen the nut 3 of the coupling and remove it WARNING CHECK ANY POSSIBLE PLAY OF THE CARDAN CROSS MEMBERS AND REPLACE THEM IF NECESSARY TECHNICAL INFORMATION Central screw tightening torque 30 Nm Coupling nuts tightening torque 12 Nm 1 2 3 ...

Page 126: ...wheel 5 Remove the cover of the bushing 2 6 Loosenandremovethenut 3 fromthebushing to the axle shaft 7 Loosen the two screws of the front brake caliper 4 and remove it 8 Inordertoaccesstheaxleshaft youwillneed to remove the three screws 5 and the guard 9 Removethelowernut 6 fromtheswingarm 10 Use the tool 7 to remove the stub shaft from the swingarm 11 Then release the stub shaft from the swingarm...

Page 127: ...HAFT TAKE CARE NOT TO DAMAGE THE SPLINES OF THE AXLE SHAFT THENUT 3 MUSTBEREPLACEDIN THE ASSEMBLY DO NOT PRESS ON THE BRAKE OTHERWISE YOU WILL NEED TO BLEED THE CIRCUIT YOUAREADVISEDTOPUTAPIECE OFPLASTICINPLACE THESAME THICKNESSASTHEDISC TOAVOID THEBRAKEPADSFROMCLOSING TECHNICAL INFORMATION Ball joint extractor tool 80990000000 Axel shaft nut tightening torque 225 Nm Calliper screws tightening tor...

Page 128: ...therearwheel 4 Remove the front wheel 5 Remove the cover of the bushing 2 6 Loosenandremovethenut 3 fromthebushing to the axle shaft 7 Remove the screw and nut 4 holding the stub shaft to the swingarm 8 Thenreleasethestubshaftfromtheswingarm by pulling it up 9 Extract the stub shaft from the axle shaft 10 Removetheaxleshaftfromthetransmission 11 Check for any possible bearing play the condition of...

Page 129: ...E NUT 3 MUST BE REPLACED IN THE ASSEMBLY WHENREMOVINGTHESTUBSHAFT TAKECARENOTTODAMAGETHESPLINESOF THE AXLE SHAFT TECHNICAL INFORMATION Axel shaft nut tightening torque 225 Nm Screw tightening torque axle stub shaft to swingarm 47 Nm Calliper screws tightening torque 30 Nm Wheel nuts tightening torque 60 Nm ...

Page 130: ...nterfere with the removal To remove it follow this procedure 1 Disconnect the electrical connector of the 4WD locking actuator 1 2 Loosen the six screws 2 of the cardan 3 Loosen the coupling screw 3 4 Loosen the six screws from each of the differential brackets 4 5 Remove the differential downwards TECHNICAL INFORMATION Differential cardan locking screws nuts tightening torque 12 Nm Differential b...

Page 131: ...131 Page WORKSHOP MANUAL We reserve the right to modify the product and the design ELECTRICAL SYSTEM ...

Page 132: ...F1 Heaters F2 GPS supply F3 Radiator blower F4 Key Low beam Horn F5 Starter relay F6 Fuel pump High beam Windshield wipers F7 EPS F8 KL30 power control F9 Heating AC F10 Trailer power supply F11 Stop coil F12 KL15 power control F13 4WD Differential lock F14 12V Accessory socket R2 Heaters R3 Safety start up R4 Radiator blower R5 R6 R7 R8 General power Element F1 Glow Plug F2 EPS F3 Radiator fan Ho...

Page 133: ...ensor R N H L VJ09 HCN14 1 2 3 4 VCN14 1 2 3 4 HF07 30A HF08 30A VCN59 1 HCN59 1 Timer 4s HC0107 VJ29 4 sec HCN50 2 1 4 3 VCN50 R W Y R B Coolant sensor VCN58 1 t C VJ36 HCN58 1 1 5 1 5 1 1 5 2 5 2 5 25 16 1 5 1 5 0 5 1 2 5 2 5 2 5 1 1 5 1 1 5 2 5 HF02 30A HK03 35A VJ31 1 1 HOLD PULL VJ52 0 5 0 5 0 5 0 75 0 75 BLACK WHITE 0 5 1 0 75 0 75 0 75 0 75 0 75 0 5 0 5 0 5 1 1 1 1 1 1 1 VCN83 HCN83 VCN82 1...

Page 134: ...rasero Diodo protección solenoide paro Relé paro Llave contacto HVAC Rueda selectora Temporizador 1s Alternador Actuador A C Interruptor A C Control potencia solenoide Relé seguridad Unidad control potencia Starter Batería Conector equipamiento 12 V Bomba de combustible Luz matrícula Sensor nivel combustible Compresor A C Detector asiento Zumbador Luz de techo Selector temperatura clima Electrovál...

Page 135: ......

Page 136: ...DQUARTERS C Paraje la Loma parcela 1 Polígono Industrial Cabecicos Blancos 30892 Librilla Murcia Spain T 34 968 785 201 CENTRO DE INGENIERÍA Y DESARROLLO C Energía 50 Polígono Industrial Pla dels Vinyats II 08250 St Joan de Vilatorrada Barcelona Spain T 34 938 726 703 www corvus utv com ...

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CORVUS TERRAIN DX4 CAB, Workshop Manual

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Summary of Contents for TERRAIN DX4 CAB

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