BODYWORK AND TRIM

SECTION BT
CONTENTS
GENERAL SERVICING .................................................................................................................................... BT- 3
FRONT BUMPER ............................................................................................................................................ BT- 6
REAR BUMPER ................................................................................................................................................ BT- 7
CENTER AND SIDE PANELS .......................................................................................................................... BT- 8
FRONT GRILLE, STEP AND WING ................................................................................................................ BT-10
SOUNDPROOFING PANELS, MUDGUARDS AND SKIRTS.......................................................................... BT-12
HEAT INSULATORS ........................................................................................................................................ BT-16
REAR VIEW MIRRORS .................................................................................................................................... BT-20
CAB TILT MECHANISM .................................................................................................................................. BT-21
DOORS ............................................................................................................................................................ BT-28
INSTRUMENT PANEL...................................................................................................................................... BT-32
INTERIOR TRIM .............................................................................................................................................. BT-38
SEALING STRIPS ............................................................................................................................................ BT-52
SEATS .............................................................................................................................................................. BT-58
WINDOWS........................................................................................................................................................ BT-61
TOW HOOK, BATTERY BRACKET, CHOCK AND SPARE WHEEL ................................................................ BT-65
CAB AND FRAME ............................................................................................................................................ BT-67
ALIGNMENT OF CAB AND FRAME .............................................................................................................. BT-72
SEALING AND ANTI-RUST PROTECTION POINTS ...................................................................................... BT-81
BT
* See section MA for more about the seat belts.
* See section EL for the connection diagrams of electrical systems.
 GENERAL SERVICING

Precautions
• When removing or fitting several parts, place a cloth or other protective material on the bodywork to avoid scratching
the paint.
• Handle trims, mouldings, instruments, grille, etc. with great care during removal or fitting to avoid dirtying or damag-
ing them.
• When you refit removed parts, apply sealant paste on the required points.

• When you apply sealant, take care to prevent it from overflowing from the application parts.

• When replacing any metal part, make sure you take the required anti-rust measures.

Fasteners and latches

• The following numbers and symbols are used for the fasteners and latches shown in section BT.
• Replace any fasteners and latches that are damaged during removal or refitting.

No. Symbol Form Removal and Fitting

Removal:
Remove by bending upwards
with a flat end screwdriver.

Removal:
Remove by turning.

0442BF

BT-3
 GENERAL SERVICING

Fasteners and latches (Cont’d)

No. Symbol Form Removal and Fitting

Removal:
Remove with a flat end
screwdriver or with pliers.

Removal:
Flat end screwdriver
Trim

Snap
fastener
Bodywork panel

Removal:
Press the centre plug
Press to the clasping position.
(Do not remove the plug
by force).

Press

Fitting:

Removal:
Remove with a flat end
screwdriver or with pliers.

Snap fasterner-A Removal:

Flat end screwdriver

Trim

Snap fasterner-B

Sealing Snap fasterner-B

washers Bodywork
panel Snap fasterner-A
Sealing washers

0441BF

BT-4
 GENERAL SERVICING

Fasteners and latches (Cont’d)

No. Symbol Form Removal and Fitting

Removal: Fitting:

Turn 45°
to remove

Removal:

Removal:
1. Release the clasping piece.
2. Remove the rod.

Removal:
1. Use a Phillips type screwdriver.
2. Remove the socket piece with a flat end
screwdriver.

Removal:
Use a Phillips type screwdriver.

0440BF

BT-5
 FRONT BUMPER

• To remove fasterners and latches, see “Fasteners and latches” in the chapter “GENERAL SERVICING”.
• The bumper is made of plastic and should, therefore, not be submitted to excessive force or oil stains.
DISASSEMBLY
Remove the following components:
1. Front fog lamps. See chapter “EXTERIOR LIGHTS” in Section “EL”.
2. Bolt caps.
3. Centre bumper fixings.
4. Side bumper fixings.

55 (5.6; 40.6)

Q R 27 (2.8; 19.9)

E 44 (4.5; 32.5)

Nm (kgm; ft lb)
0417BF

BT-6
 REAR BUMPER

DISASSEMBLY
Remove the following components:
1. Side covers.
2. Screw caps (only type B).
3. Bolts fixing bumper to brackets

TYPE A

22 (2.2; 16.2)

52 (5.3; 38.4)

Nm (kgm; ft lb)
0367BF

TYPE B

E W

52 (5.3; 38.4)
Q

Nm (kgm; ft lb)
0416BF

BT-7
 CENTER AND SIDE PANELS

• To remove fasterners and latches, see “Fasteners and latches” in the chapter “GENERAL SERVICING”.
• Handle trims and mouldings with care, without employing excessive force, in order not to damage them.

Central panel

DISASSEMBLY
Remove the following components:
1. Windscreen wiper arms, along with their nuts, spacers and spray nozzles. See chapter “WINDSCREEN WIPER/WASH-
ER” in section “EL”.
2. Centre panel

C101

0608BF

BT-8
 CENTER AND SIDE PANELS

Side panels
DISASSEMBLY
Remove the following components:
1. Side panel. See the previous section.
2. Front flasher lights. See “Front side lights” in the chapter “EXTERIOR LIGHTS” of section “EL”.
3. Side panels.

EA

Fitting of rubber profiles on side panel

Adhesive area

0369BF

BT-9
 FRONT GRILLE, STEP AND WING

CABSTAR.E-95/120

U
A

O
A

I B
A A

A
U
A

Y
B
C106
CG101 E
C102
Q
W R T
C203
A

A : 5÷6 Nm (0.5÷0.6 kgm; 3.7÷4.4 ft lb)

B : 2÷3 Nm (0.2÷0.3 kgm; 1.5÷2.2 ft lb)
0408BF

COMPONENTS
1. Front grille 6. Wing
2. Bottom headlamp trim 7. Bottom wing trim
3. Headlamp 8. Wing bracket
4. Step * 9. Bottom wing trim bracket
5. Step anti-slip liner

*. Fit the step before fitting the front flasher.

BT-10
 FRONT GRILLE, STEP AND WING

CABSTAR.E-120DC

B
Y
C106
CG101
E
Q
C102
T
W R
C203
A
A : 5÷6 Nm (0.5÷0.6 kgm; 3.7÷4.4 ft lb)
B : 2÷3 Nm (0.2÷0.3 kgm; 1.5÷2.2 ft lb)
0409BF

COMPONENTS
1. Front grille 5. Step anti-slip liner
2. Bottom headlamp trim 6. Wing
3. Headlamp 7. Bottom wing trim
4. Step *

*. Fit the step before fitting the front flasher.

BT-11
 SOUNDPROOFING PANELS, MUDGUARDS AND SKIRTS

CABSTAR. E-120
I

C106 14 (1.4; 10.3)

C106
U
C106

E
14 (1.4; 10.3) Q
W
R
14 (1.4; 10.3)

14 (1.4; 10.3)

Nm (kgm; ft lb)
0422BF

COMPONENTS
1. Right side rubber 5. Right soundproofing panel
2. Left side rubber 6. Left soundproofing panel
3. Top skirt 7. Lower rear soundproofing panel *
4. Mudguard protection 8. Upper rear soundproofing panel *

*Only for FOCSA

BT-12
 SOUNDPROOFING PANELS, MUDGUARDS AND SKIRTS

CABSTAR. E-120 DC

13÷16 (1.3÷1.6: 9.6÷11.8)

5÷6 (0.5÷0.6; 3.7÷4.4)

C106
7
C106
6
3 13÷16 (1.3÷1.6:
9.6÷11.8)

1 8
2

5÷6 (0.5÷0.6;
3.7÷4.4)
4

5÷6 (0.5÷0.6; 3.7÷4.4)

5

Nm (kgm; ft-lb)
0607BF

COMPONENTS
1. Right side rubber 6. Step
2. Left side rubber 7. Lower skirt bracket
3. Top skirt 8. Stay anti-slip
4. Mudguard protection 9. Stay
5. Bottom skirt*

*. Fit the skirt so that the grained area is positioned towards the rear of the vehicle.

BT-13
 SOUNDPROOFING PANELS, MUDGUARDS AND SKIRTS

CHASSIS CAB MODELS (fixed cab)

1
13÷16 (1.3÷1.6; 9.6÷11.8)
13÷16 (1.3÷1.6; 9.6÷11.8)

13÷16 (1.3÷1.6; 9.6÷11.8)

7 Nm (kgm; ft-lb)
0602BF

COMPONENTS
1. Top mudguard bracket 5. Left bracket fixing cab
2. Mudguard 6. Front of vehicle
3. Bottom mudguard bracket 7. Rivet
4. Bottom skirt*

*. Fit the skirt so that the grained area is positioned towards the rear of the vehicle.

BT-14
 SOUNDPROOFING PANELS, MUDGUARDS AND SKIRTS

6
5
13÷16 (1.3÷1.6; 9.6÷11.8)
1 13÷16 (1.3÷1.6; 9.6÷11.8)

13÷16 (1.3÷1.6; 9.6÷11.8)

7 Nm (kgm; ft lb)

0603BF

COMPONENTS
1. Top mudguard bracket 5. Left bracket fixing cab
2. Mudguard 6. Front of vehicle
3. Bottom mudguard bracket 7. Rivet
4. Bottom skirt *

*. Fit the skirt so that the grained area is positioned towards the rear of the vehicle.

BT-15
 HEAT INSULATORS

CHASSIS CAB MODELS (Left hand drive)

Q Y
W

E
d

0411BF

COMPONENTS
1. Left engine bonnet hatch. 5. Heat insulation
2. Front cover gasket 6. Rear cover gasket
3. Front of vehicle 7. Clip fixing rear cover gasket
4. Sealing strip

Adhesive areas
Bending direction of the lugs holding the heat insulator.
:

BT-16
 HEAT INSULATORS

DOUBLE CAB MODELS (Left hand drive)

P O
Q

I
E

T
d Y

0412BF

COMPONENTS
1. Left engine bonnet hatch. 6. Heat insulation of bulkhead
2. Front cover gasket 7. Heat insulation of the rear cover
3. Engine bonnet heat insulation. 8. Rear cover
4. Sealing strip 9. Clip fixing rear cover gasket
5. Front of vehicle 10. Rear cover gasket

Adhesive areas

: Bending direction of the lugs holding the heat insulators.

BT-17
 HEAT INSULATORS

DOUBLE CAB MODELS (Right hand drive)

7
6

d
E

0587BF

COMPONENTS
1. Left engine bonnet hatch. 5. Heat insulation
2. Front cover gasket 6. Rear cover gasket
3. Front of vehicle 7. Clip fixing rear cover gasket
4. Sealing strip

Adhesive areas
Bending direction of the lugs holding the heat insulator.
:

BT-18
 HEAT INSULATORS

CHASIS CAB MODELS (Right hand drive)

9 0
1
2
8

5
6
0588BF
COMPONENTS
1. Left engine bonnet hatch. 6. Heat insulation of bulkhead
2. Front cover gasket 7. Heat insulation of the rear cover
3. Engine bonnet heat insulation. 8. Rear cover
4. Sealing strip 9. Clip fixing rear cover gasket
5. Front of vehicle 10. Rear cover gasket

Adhesive areas

: Bending direction of the lugs holding the heat insulators.

BT-19
 REAR VIEW MIRRORS

CAUTION
Take care to avoid scratching the rear view mirrors.

Exterior rear view mirror

• See the connection diagram in the chapter “HEATED REAR VIEW MIRRORS” in section “EL”.

DISASSEMBLY
Remove the following components:
1. Inner door trim. See “Door trim” in the chapter “INTERIOR TRIM”.
2. Disconnect the rear view mirror connector (only in vehicles with heated rear view mirrors).
3. Bolt fixing trim.
4. Bolts fixing rear view mirror.

Interior rear view mirror

DISASSEMBLY
Remove the following components:
1. Bolt fixing rear view mirror.
2. Rear view mirror spacer and fixing bolts.

Exterior rear view mirror Interior rear view mirror

Q W

0370BF 0371BF

BT-20
 CAB TILT MECHANISM

Cab tilting and closing

4
2

3
6

7
0592BF

TILTING
• Ensure there are no loose objects in the cab.
• Place the gear shift in neutral.
• Apply the parking brake
• Ensure that the doors are fully closed.
1. Release the lock (1) with the key.
2. Pull the lever (2) outward to release the cab catches. Hold the lever (2) in this position while moving the open and close
lever (3) outward.
3. Pull the lever (4) to free the safety catch.

 WARNING
• Ensure that the front of the vehicle is clear of people or objects.
4. Tilt the cab to its maximum position and apply the safety latch (5) on the support arm.
CLOSING
Remove the safety latch (5) leaving it in the fixture (6) and pull the lever (7) at the rear of the left mudguard.
Pull the cab down with sufficient force to ensure that it closes correctly.
Push the open and close lever (3) inward until it is heard to click into place.
Fit the lock (1).

BT-21
 CAB TILT MECHANISM

Cab tilting and closing (Cont’d)

DISASSEMBLY
NOTE:
• Tilt the cab and keep it fully tilted using some sort of hoist to prevent it from closing when the cab tilt bracket is removed.
• Make sure that the cab is firmly secured with the hoist employed.
Remove the following components (see the next page):
1. Blocking lock.
2. Coupling bolt of cab tilt bracket assembly.
3. Bolt pin.
4. Tilt bracket assembly.
5. Tilt cable.
6. Tilt cable bracket.
7. Retainer and pin.
When new seals and pins are fitted, fit the largest on the right hand side.
8. Cab catches assembly.
9. Opening and closing lever assembly.

INSTALLATION
To fit, proceed in the reverse order to that of disassembly, taking the following into account.
• Before fitting the cable to the tilt bracket assembly, take it through the holes in the left cab bracket (see detail A ).
• Loosen the nuts to adjust the length of the tilting cable so that the hammer (8) makes contact with the spring (9). Then
tighten the nuts (see detail B ).

Tilt cable fitting Tilt cable adjustment

A B





0437BF 0435BF

BT-22
 CAB TILT MECHANISM

Cab tilting and closing (Cont’d)

22 ÷ 28 (2.2 ÷ 2.9; 16.2 ÷ 20.7)

2 20 ÷ 29
17 ÷ 24
(1.7 ÷ 2.4;
(2 ÷ 3; 14.8 ÷ 21.4) 12.5 ÷ 17.7)

3 5

6
22 ÷ 28
(2.2 ÷ 2.9;
16.2 ÷ 20.7)
41 ÷ 61 (4.2 ÷ 6.2; 30.2; ÷ 45)
6
21 ÷ 31 (2.1 ÷ 3.2; 15.5 ÷ 22.9)

7
9
22 ÷ 28 (2.2 ÷ 2.9; 16.2 ÷ 20.7)

1
7÷9
(0.7 ÷ 0.9;
5.2 ÷ 6.6)
22 ÷ 28 (2.2 ÷ 2.9; 16.2 ÷ 20.7)

Apply grease

Nm (kgm; ft-lb)
* Replace when removed
0585BF

BT-23
 CAB TILT MECHANISM

Cab tilt force adjustment

5 6 7 6 5
9 7

9
8

10

10

88 (9; 64.9)

4
71 ÷ 90 2
(7.2 ÷ 9.2; 52.4 ÷ 66.4)

1 71 ÷ 90 (7.2 ÷ 9.2; 52.4 ÷ 66.4) Apply grease

: Nm (kgm; ft-lb)
88 (9; 64.9)
0565BF

COMPONENTS
1. Bolt fixing the anchoring arm 6. SilentBloc
2. Lock nut 7. Cab tilt bracket
3. Tilt foce adjustment bolt 8. Torsion bar
4. Anchoring arm 9. Front cab bracket
5. Bush 10. Front of vehicle

BT-24
 CAB TILT MECHANISM

Cab tilt force adjustment (Cont’d).

1. Remove the front grille. See the chapter “FRONT GRILLE, STEP AND WING”.
2. Tilt the cab. See “CAB TILT MECHANISM - Cab tilting and closing”.
NOTE:
To adjust the tilting force, the cab must be tilted. Otherwise, the force exerted by the
torsion bar will be aplied to the anchoring arm fixing bolt and lock nut.
3. Loosen the bolt (1) until it can be turned by hand. Do not remove it from its
housing.
3 4. Loosen the lock nut (2).
5. Use the adjustment bolt (3) to adjust the cab tilting force.
• Turn the bolt (3) clockwise to reduce the tilting force.
4 • Turn the bolt (3) anticlockwise to increase the tilting force.
2 • One complete turn of the bolt (3) changes the force by ±29N (±3kg; ±7lb).
6. Make sure the adjustment bolt (3) is in contact with the anchoring arm (4).
A 1 Projection “A” of the adjustment bolt:
15.5±0.5 mm (0.61±0.020 inches)
0566BF
7. Make sure the anchoring arm (4) is correctly inserted, and is in contact with
the left cab bracket (9).
8. Tighten the bolt (1) and the lock nut (2) to the specified torque.
Bolt fixing the anchoring arm:
71÷90Nm (7.2÷9.2kgm; 52.4÷66.4 ft lb).
Adjustment bolt lock nut:
71÷90Nm (7.2÷9.2kgm; 52.4÷66.4 ft lb).
9. Move the cab upwards and downwards and check the following:
4 • That the cab does not fall on its own when it is tilted at an angle of
40 to 45°.
9 • That the cab is balanced.
0374BF

BT-25
 CAB TILT MECHANISM

Cab tilt force adjustment (Cont’d).

NOTES:
5 • When fitting, apply grease on the points shown on the exploded view.
• When the bushes (5) are replaced with new ones, place them so that their groove is
positioned towards the front of the vehicle.

0567BF
• The clearance between the SilentBloc (6) and the cab tilt bracket assembly (7), must
6 7 be within the specificied value.
Clearance “B” for one side:
0 - 2.1 mm (0 - 0.083 inches)
• Apply the specified grease to the toothed areas of both the torsion bar (7) and the
bracket (7).
• When the torsion bar (8) is replaced, tilt the cab, insert the end of greatest diameter
B of the torsion bar in the cab tilt bracket (7) and make the areas without teeth of the
8 bar (8) and bracket (7) match.
Then fit the anchoring bar (4) making the areas without teeth of the bar (8) and
anchoring arm (4) match.

0428BF

• When the SilentBloc (6) is replaced, make its outer ridge (C) match the notch (D)
D C inside the cab bracket (9).

6
9
0568BF

BT-26
 CAB TILT MECHANISM

Tilt locking adjustment

1. Desbloquear la cerradura (1) con la llave.
2. Pull the lever (2) outward to release the cab catches. Hold the lever (2) in this
1 position while moving the open and close lever (3) outward.
NOTE:
Do not make the adjustments when the lever (3) is locked.

d
d
3
0583BF

3. Loosen the adjustment nuts (4) and (5).

4. Use nuts (5) and (4) to adjust the position of the rod (6) so that the locking
pin (7) makes contact with the right and left catches.
6 4 5. Tighten the nuts (4) and (5) fixing the lever (6).
Nuts fixing lever:
17 - 24 Nm ( 1.7 - 2.4 kgm ; 12.5 - 17.7 ft lb).

5
7
0376BF

6. Adjust the force of the lever (3) using the spacers (8) on the rubber stops (9).
9 Add or remove spacers so that force required to move the lever is within the
specified values.
Force required to move the lever:

8 196 - 245 N (20 - 25 kg; 46.7 - 58.5 lb)

Rubber stop nut torque:
25 - 32 Nm (2.5 - 3.3 kgm; 18.4 - 23.6 ft lb)

0377BF

BT-27
 DOORS

Front door

• To remove fasterners and latches, see “Fasteners and latches” in the chapter “GENERAL SERVICING”.
• Handle trims and mouldings with care, without employing excessive force, in order not to damage them.
• Apply sealant to the required points during assembly.
• When you apply sealant, take care to avoid it from overflowing from the application parts.
• Before removing the door, remove its trim. See section “Door trim” under “INTERIOR TRIM”.
• After adjusting the door or lock, check their operation.
• When fitting the CR103 clips that fix the internal door linkages, make sure they are positioned correctly.

DISASSEMBLY
Remove the following components:
1. Door trim. See section “Front door” under “INTERIOR TRIM”.
2. Door panel. See “Front door windows” in the chapter “Windows”.
NOTE:
During removal of the window winding mechanism or its guides, take care to avoid hitting the window with the removed part.

BT-28
 DOORS

Front door (Cont’d)

Adjustment of auxiliary
door window guide.
E
C

C
E
B
E
CR103
CR103

CR103
D
E

E
E CR103

Adjustment of exterior handle Door hinge adjustment Window guide fitting

1 ÷ 6 mm (0.039 ÷ 0.234 inches) B C
A
21÷26 Nm
(2.1÷2.7 Kgm
Bracket 15÷20 ft lb)

Linkage

Door hinge

Fitting of opening stop Lock striker plate adjustment

E : 5.1 ÷ 6.5 Nm (0.52 ÷ 0.66 kgm;
D 3.8 ÷ 4.8 ft lb)

16 ÷ 21 Nm : 21 ÷ 26 Nm (2.1 ÷ 2.7 kgm;

F
(1.6÷2.1 kgm; 15 ÷ 20 ft lb)
11.8÷15.5 ft lb)

0423BF

FL - Left side
FR - Right side

BT-29
 DOORS

Rear door

• To remove fasterners and latches, see “Fasteners and latches” in the chapter “GENERAL SERVICING”.
• Handle trims and mouldings with care, without employing excessive force, in order not to damage them.
• Apply sealant to the required points during assembly.
• When you apply sealant, take care to avoid it from overflowing from the application parts.
• Before removing the door, remove its trim. See section “Door trim” under “INTERIOR TRIM”.
• After adjusting the door or lock, check their operation.
• When fitting the CR103 clips that fix the internal door linkages, make sure they are positioned correctly.

DISASSEMBLY
Remove the following components:
1. Door trim. See section “Rear door (Double Cab)” under “INTERIOR TRIM”.
2. Door panel. See “Rear door windows” in the chapter “Windows”.
NOTE:
During removal of the window winding mechanism or its guides, take care to avoid hitting the window with the removed part.

BT-30
 DOORS

Rear door (Cont’d)

Adjustment of auxiliary
door window guide.

C
B D A

CR103
D
CR103

D CR103

CR103

Adjustment of exterior handle Door hinge adjustment Window guide fitting

1 ÷ 6 mm (0.039 ÷ 0.234 pul) B C
A Door
hinge 21÷26 Nm
Bracket (2.1÷2.7 kgm;
15 ÷20 ft lb)

Linkage

Lock striker plate adjustment

D : 5.1 ÷ 6.5 Nm (0.52 ÷ 0.66 kgm; 3.8 ÷ 4.8 ft lb)

E : 21 ÷ 26 Nm (2.1 ÷ 2.7 kgm; 15 ÷ 20 ft lb)

16 ÷ 21 Nm
(1.6÷2.1 kgm;
11.8÷15.5 ft lb)

0424BF

BT-31
 INSTRUMENT PANEL

CAUTION
Disconnect the battery earth terminal before starting work.
• These parts are made of plastic and must be treated with care, without employing excessive force, in order not to dam-
age them.
• To remove fasterners and latches, see “Fasteners and latches” in the chapter “GENERAL SERVICING”

DISASSEMBLY
Remove the following components:
1. Steering column cover and caps. See “STEERING CONTROLS” in section ST.
2. Brake and clutch fluid reservoir cap C .
3. Manual accelerator control.
4. Switches.
5. Instrument panel trim D .
6. Instrument panel stoppers and instrument panel.
7. Instrument panel trim.
8. Right heating duct. See chapter “DESCRIPTION” in Section HA.
9. Left heating duct. See chapter “DESCRIPTION” in Section HA.
10. Heating control trim E .
11. Heating and air conditioning controls. See chapter “DESCRIPTION” in Section HA.
12. Stowage space trim F .
13. Stowage space.
14. Glove compartment lid.
15. Top dashboard covers G .
16. Glass holder unit.
17. Glove compartment.
18. Ashtray and lighter.
19. Ashtray bracket
20. Instrument panel assembly.

C D Metal snap
Metal snap E
fastener Metal snap
Dog fastener fastener

Metal snap fastener

Dog

F G
Dog
Dog

0438BF

BT-32
 INSTRUMENT PANEL

MODELS SIN TACHOGRAPH (Left hand drive)

7 15 G
6
A

A
A
B
A

A A
5 D
*
4 A

3 A
9
A
16 *

A A

2
A
A 4 20
18
11 8
A A

10 E 17
A 19

A 14

A A
18
13

A 12 F
A : 3 ÷ 4 Nm (0.3 ÷ 0.4 kgm; 2.2 ÷ 3 ft-lb)

B : 5 ÷ 6 Nm (0.5 ÷ 0.6 kgm; 3.7 ÷ 4.4 lft-lb)

0605BF

*Fit the grid so that the word “UP” faces upward.

BT-33
 INSTRUMENT PANEL

CAUTION
Disconnect the battery earth terminal before starting work.
• These parts are made of plastic and must be treated with care, without employing excessive force, in order not to dam-
age them.
• To remove fasterners and latches, see “Fasteners and latches” in the chapter “GENERAL SERVICING”

DISASSEMBLY
Remove the following components:
1. Steering column cover and caps. See “STEERING CONTROLS” in section ST.
2. Brake and clutch fluid reservoir cap C .
3. Manual accelerator control.
4. Switches.
5. Instrument panel trim D .
6. Instrument panel covers, and instrument panel.
7. Instrument panel trim.
8. Right heating duct. See chapter “DESCRIPTION” in Section HA.
9. Left heating duct. See chapter “DESCRIPTION” in Section HA.
10. Heating control trim E .
11. Heating and air conditioning controls. See chapter “DESCRIPTION” in Section HA.
12. Stowage space trim F .
13. Stowage space.
14. Glove compartment lid.
15. Top dashboard covers G .
16. Cup holder assembly.
17. Glove compartment.
18. Ashtray and lighter.
19. Ashtray bracket
20. Instrument panel assembly.

C D Metal snap
Metal snap E
fastener Metal snap
Dog fastener fastener

Metal snap fastener

Dog

F G
Dog
Dog

0438BF

BT-34
 INSTRUMENT PANEL

MODELS WITH TACHOGRAPH (Left hand drive)

15 G
7

A A B
A

6 A A

A
* A
4
A
A
3
9 *
A 16
A

A
8
A
5 D

2 C 4 A
20 A
A 11
1 18
A A
17

19 10 E
A
A 14
A

A
A

18
13

12 F
A A : 3 ÷ 4 Nm (0.3 ÷ 0.4 kgm; 2.2 ÷ 3 ft-lb)

B : 5 ÷ 6 Nm (0.5 ÷ 0.6 kgm; 3.7 ÷ 4.4 ft-lb)

0606BF
*Fit the grid so that the word “UP” faces upward.

BT-35
 INSTRUMENT PANEL

CAUTION
Disconnect the battery earth terminal before starting work.
• These parts are made of plastic and must be treated with care, without employing excessive force, in order not to dam-
age them.
• To remove fasterners and latches, see “Fasteners and latches” in the chapter “GENERAL SERVICING”

DISASSEMBLY
Remove the following components:
1. Steering column cover and caps. See “STEERING CONTROLS” in section ST.
2. Brake and clutch fluid reservoir cap C .
3. Manual accelerator control.
4. Switches.
5. Instrument panel trim D .
6. Instrument panel covers, tachograph and instrument panel.
7. Instrument panel trim.
8. Right heating duct. See chapter “DESCRIPTION” in Section HA.
9. Left heating duct. See chapter “DESCRIPTION” in Section HA.
10. Heating control trim E .
11. Heating and air conditioning controls. See chapter “DESCRIPTION” in Section HA.
12. Stowage space trim F .
13. Stowage space.
14. Glove compartment lid.
15. Top dashboard covers G .
16. Glass holder unit.
17. Glove compartment.
18. Ashtray and lighter.
19. Ashtray bracket
20. Instrument panel assembly.

C D Metal snap
Metal snap E
fastener Metal snap
Dog fastener fastener

Metal snap fastener

Dog

F G
Dog
Dog

0438BF

BT-36
 INSTRUMENT PANEL

RIGHT HAND DRIVE MODELS

7
15 G

A
A
B A
A
A

A
6 D
A 5
A
A 4
A

A * A
*
16 A

8
A

A A 3

2 C
A
4 A
20
A
E
18 A
10
9 A
11
17
A
19
1
A
A
14
A 18
A

13
12 F

A A : 3 ÷ 4 Nm (0.3 ÷ 0.4 kgm; 2.2 ÷ 3 ft-lb)

B : 5 ÷ 6 Nm (0.5 ÷ 0.6 kgm; 3.7 ÷ 4.4 ft-lb)

0584BF

*Fit the grid so that the word “UP” faces upward.

BT-37
 INTERIOR TRIM

• To remove fasterners and latches, see “Fasteners and latches” in the chapter “GENERAL SERVICING”.
• Handle trims and mouldings with care, without employing excessive force, in order not to damage them.

Side and floor trim

DISASSEMBLY
Remove the following components:
1. Sun shades.
2. Interior rear view mirror. See the chapter “REAR VIEW MIRRORS”.
3. Interior light. See chapter “INTERIOR LIGHTS” in Section “EL”.
4. Trim above the windscreen.
5. Handle.
6. Side protection (see “Carpets”in the chapter “INTERIOR TRIM”.
7. Door sealing strip.
8. Top rear bracket of passenger seat. See “Front seat” under the chapter “SEATS”.
9. Trim above the door.
10. Rear cab trim. See “Carpets” in the chapter “INTERIOR TRIM”.
11. Rear cab panel.
12. Trim of the front pillar.
13. Seat belt anchoring
14. Trim of the rear pillar.

BT-38
 INTERIOR TRIM

Side and floor trim (Cont’d)

R A

Q wA
E
W

T U O A q
}A {A

I
Y
0378BF

Two-sided adhesive tape

Fitting of side trim

} O w

R {

} O w

0379BF

BT-39
 INTERIOR TRIM (Left hand drive)

• To remove fasterners and latches, see “Fasteners and latches” in the chapter “GENERAL SERVICING”.
• Handle trims and mouldings with care, without employing excessive force, in order not to damage them.

Carpets (chassis cab models)

DISASSEMBLY
Remove the following components:
1. Driver’s seat. See “Front seat” under “SEATS”.
2. Shift lever knob.
3. Protection of gear control turret
4. Side protector.
5. Front carpet.
6. Rear left carpet.
7. Rear right carpet.
8. Rear cab trim.

BT-40
 INTERIOR TRIM (Left hand drive)

Carpets (chassis cab models, cont’d)

W I
U

9 5b
a
T
Q
Y

0380BF

NOTE:
a. Push to fit.
b. Release to remove.
c. Insert the hitch in its housing.
d. Insert the plug fully to make the hitch stay in its housing.

BT-41
 INTERIOR TRIM (Left hand drive)

Carpets (double cab models)

DISASSEMBLY
Remove the following components:
1. Driver’s seat. See “Front seat” under “SEATS”.
2. Shift lever knob.
3. Protection of gear control turret
4. Side protector.
5. Front carpet.
6. Rear left carpet.
7. Rear right carpet.
8. Bulkhead carpet.
9. Rear floor carpet.

BT-42
 INTERIOR TRIM (Left hand drive)

Carpets (double cab models, cont’d)

W I
U
O
E

Y
Q

b
T

R a

0381BF

NOTE:
a. Insert the hitch in its housing.
b. Insert the plug fully to make the hitch stay in its housing.

BT-43
 INTERIOR TRIM (Right hand drive)

• To remove fasterners and latches, see “Fasteners and latches” in the chapter “GENERAL SERVICING”.
• Handle trims and mouldings with care, without employing excessive force, in order not to damage them.

Carpets (chassis cab models)

DISASSEMBLY
Remove the following components:
1. Driver’s seat. See “Front seat” under “SEATS”.
2. Shift lever knob.
3. Protection of gear control turret
4. Side protector.
5. Front carpet.
6. Rear left carpet.
7. Rear right carpet.
8. Rear cab trim.

BT-44
 INTERIOR TRIM (Right hand drive)

Carpets (chassis cab models, cont’d)

I Y
W
b
E

a 9
T
Q

d
R e

c
0590BF

NOTE:
a. Push to fit.
b. Release to remove.
c. Insert the hitch in its housing.
d. Insert the plug fully to make the hitch stay in its housing.

BT-45
 INTERIOR TRIM (Right hand drive)

Carpets (double cab models)

DISASSEMBLY
Remove the following components:
1. Driver’s seat. See “Front seat” under “SEATS”.
2. Shift lever knob.
3. Protection of gear control turret
4. Side protector.
5. Front carpet.
6. Rear left carpet.
7. Rear right carpet.
8. Bulkhead carpet.
9. Rear floor carpet.

BT-46
 INTERIOR TRIM (Right hand drive)

Carpets (chassis cab models, cont’d)

O I Y W

b T

R
a

0589BF

NOTE:
a. Insert the hitch in its housing.
b. Insert the plug fully to make the hitch stay in its housing.

BT-47
 INTERIOR TRIM

Door trim

FRONT DOOR
DISASSEMBLY
Remove the following components:
1. Latch knob.
2. Fixing screw of door opening handle.
3. Inside door handle.
4. Window winder handle (models with manual winder).
5. Interior moulding.
6. Door trim.

REAR DOOR (Double Cab)

DISASSEMBLY
Remove the following components:
1. Fixing screw of door opening handle and its cap.
2. Inside door handle.
3. Window winder handle.
4. Door trim.

BT-48
 INTERIOR TRIM

Door trim (Cont’d)

Front door Rear door (double cab)

TB Metal snap fasteners

Q
E (seven)

Q
C W
W R

Y EA Snap
fastener
*
C101 RA C101

Snap
fastener

*Only vehicles with power windows.

Removal and refitting of the window winder handle Fitting of the interior moulding

Window winder handle B

A

Removal

Remove the snap fastener in the direction shown by the arrow.

Refit the snap fastener as shown in the figure.

Fitting

Front side

Push the handle to insert it in its axle again.

Fit the handle as shown in the figure with the window com-
pletely closed.

Fitting the front end of the door

0420BF
trim.

BT-49
 INTERIOR TRIM

Roof trim

DISASSEMBLY
Remove the following components:
– Chassis cab
1. Roof trim. Start by unsticking the trim from a corner and then pull it off completely.
– Double cab
1. Roof reinforcement.
2. Roof trim. Start by unsticking the trim from a corner and then pull it off completely.

BT-50
 INTERIOR TRIM

Roof trim (Cont’d)

CHASSIS CAB MODELS

Q
Adhesive area

0382BF

DOUBLE CAB MODELS

Adhesive area
W

Q
W

0383BF

BT-51
 SEALING STRIPS

WINDSCREEN PROFILE

Chassis cab Double cab

Q Q

W Q

W
Q

0466BF

COMPONENTS

1. Windscreen profile 2. Windscreen

BT-52
 SEALING STRIPS

REAR WINDOW PROFILE

Chassis cab

0461BF

Double cab

W
E

Q
E

W
0427BF
COMPONENTS
1. Rear window 3. Weatherstrip
2. Rear window profile.

BT-53
 SEALING STRIPS

FRONT DOOR SEALING STRIP

Chassis cab Double cab

Q
Cross-section A-A

B
Q A
B

W
B

B
Cross-section B-B

W B
B
Cross-section C-C

0443BF

COMPONENTS
1. Top sealing strip 2. Door sealing strip

Adhesive area

BT-54
 SEALING STRIPS

REAR DOOR SEALING STRIP (Double Cab)

Cross-section A-A

A B

A B

Cross-section B-B

B
B

W W
Cross-section C-C

0467BF

COMPONENTS
1. Top sealing strip 2. Door sealing strip

Adhesive area

BT-55
 SEALING STRIPS

MOULDINGS AND FRONT WINDOW GUIDE

Chassis cab Double cab

A
Cross-section A-A

A W

W B Q
B
Cross-section B-B

0463BF

MOULDINGS AND REAR WINDOW GUIDE (Double cab)

Cross-section A-A
R A

R
B
Cross-section B-B
E E
B

0462BF

COMPONENTS

1. Front moulding 3. Rear moulding

2. Front window glass guide 4. Rear window glass guide

BT-56
 SEALING STRIPS

FRONT DRIP CHANNEL

Chassis cab Double cab

Q
Cross-section A-A A

0465BF

REAR DRIP CHANNEL (Double cab)

W
A
Cross-section A-A
A

0458BF

COMPONENTS
1. Front drip channel 2. Rear drip channel
Adhesive area

BT-57
 SEATS

• When removing or fitting the seat trim, take care to avoid it from getting diry or damaged.

• When removing the head rest, open the upholstery at the lower rear of the head rest and simultaneously press the ends
of the guide to release it.

Front seat
DRIVER (LEFT HAND DRIVE)

Headrest
guide

Tube guide

6
5

Press to release

3
2

1 4
4

0571BF
COMPONENTS

1. Cushion foam
2. Seat back foam
3. Seat upholstery
4. Control knob
5. Head rest guide with interlock
6. Plain headrest guide

BT-58
 SEATS

Front seat (Cont’d)

DRIVER (RIGHT HAND DRIVE)

Headrest
guide

Tube
guide

6
5
2 Press to release

4 4

21÷26 (2.1÷2.7; 15.5÷19.2)

: Nm (kgm, ft-lb)

0586BF

COMPONENTS

1. Cushion foam
2. Seat back foam
3. Seat upholstery
4. Control knob
5. Head rest guide with interlock
6. Plain headrest guide

BT-59
 SEATS

Passenger’s seat
Left hand drive

1
3

0572BF

Right hand drive

4 5

6
9
7

21 ÷ 26
(2.1 ÷ 2.7,
15.5 ÷ 19.2)

10 21 ÷ 26
(2.1 ÷ 2.7,
15.5 ÷ 19.2)

3
1 : Nm (kgm, ft-lb)
8
0591BF

COMPONENTS

1. Cushion foam 6. Document holder

2. Back foam 7. Tray
3. Seat upholstery 8. Mat
4. Head rest smooth guide 9. Draught excluder
5. Head rest guide with fixed positions 10. Thermal insulation

BT-60
 WINDOWS

Windscreen
Q DISASSEMBLY
1. Insert a screwdriver (a) between the rubber profile (1) and the frame (2), to
a wedge the profile (1) off to the outside of the cab .
NOTE:
• Perform this operation from inside the cab.
• Do not scratch the cab frame with the screwdriver.

W
0384BF

2. Keep the screw driver in this position while you tap the glass with a rubber
mallet around the perimeter.
d NOTE:
– Take care to avoid knocking the glass against the cab during removal; chips on the
edges could cause breakage later.
d
– Tap the windscreen with a rubber mallet at about 200 mm (7.87 inches) from the
border.
d (tapping distance): 200 mm (7.87 inches).

0385BF INSTALLATION
1. Fit the rubber profile (1) along all the perimeter of the windscreen (2).
NOTE:
Make sure that the draining holes of the rubber profile (1) are at the bottom of the
windscreen (2).

Q
W

0386BF

2. Fit a string (3) in the slot (4) of the rubber profile (1) all around the whole
perimeter.
E Leave about 40 mm (1.57 inches) of string (3) at each end, at the bottom of
the windscreen.

3. Clean the windscreen housing in the cab of all foreign objects that may dam-
age the rubber (1) or windscreen (2). Then apply soapy water to the contact
area between the rubber (1) and the frame.

R Q
0127BF

4. Once the rubber profile (1) is fitted, position the windscreen (2) on the cab
Q frame (5).

0387BF
W

BT-61
 WINDOWS

Windscreen (Cont’d)
5. Once the windscreen is positioned and adjusted (2) on the cab frame, slowly
d pull from the ends of the string inside the cab until point (b) is reached.
d NOTE:
– While one operator pulls from the ends of the string inside the cab, another should
b apply pressure on the outside of the windscreen.
– Do not pull the string at an angle from the windscreen, but rather in parallel to the
windscreen, so that the lip of the rubber profile overlaps the frame correctly.
d – This operation must be performed with two operators – one pulling on the rope
inside the cab and the other on the outside, lightly tapping the windscreen with a
mallet at about 200 mm (7.87 inches) from the border.
– Take care to avoid knocking the glass against the cab when fitting; chips on the
0388BF edges could cause breakage later.
d (tapping distance): 200 mm (7.87 inches).

Q 6. Press-fit the bottom ends of the rubber profile (1).

NOTE:
– Make sure that the bottom borders of the rubber profile are in place.


0389BF
Rear window

DISASSEMBLY

Chassis cab models

1. To remove the rear window glass, see the instructions under “Windscreen”.

Double cab models

Double cab 1. Remove the weatherstrip (1). Then remove the rear window glass as
Q described under “Windscreen”.

INSTALLATION
0427BF

To fit the rear window glass, follow points “1” to “5” under “Windscreen”.

Double cab models

Double cab
Q W 1. Once the rear window glass (1) with its rubber profile (2) are fitted, apply
soapy water to the contact area between the profile and the weatherstrip (3).
E 2. Fit the weatherstrip (3) with a special tool.

0427BF

BT-62
 WINDOWS

Front door window glass

Q
DISASSEMBLY
1. Remove the trim from the door. See section “Front door” under “INTERIOR
TRIM”.
2. Remove door panel (1).

0434BF

3. Lower the window down to the lowest position and remove the nuts (2)
fixing it.

W
0390BF

4. Set the window in the vertical position and remove it from the door.
k NOTE:
Take care to avoid hitting the window with the door during removal.

0391BF

INSTALLATION
1. Proceed in the reverse order to that of disassembly, taking the following into
account:
• Apply sealant paste on all the panel perimeter (1).
Window nut tightening torque:
5.1 ÷ 6.5 Nm (0.52÷0.66 kgm; 3.8 ÷ 4.8 ft lb)

NOTE:
Take care to avoid hitting the window glass with the door when fitting.

BT-63
 WINDOWS

Rear door window (Double cab)

DISASSEMBLY
1. Remove the trim from the door. See section “Rear door” under “INTERIOR
TRIM”.
2. Remove the door panel (1).

Q
0392BF

3. Lower the window down to the lowest position and remove the nuts (2)
fixing it.

0393BF

4. Remove the rear guide (3) of the window glass.

E
P

0394BF

5. Set the window in the vertical position and remove it from the door.
k NOTE:
Take care to avoid hitting the window glass with the door during removal.

0395BF

INSTALLATION
1. Proceed in the reverse order to that of disassembly, taking the following into
account:
• Apply sealant paste on the whole panel perimeter (1).
Window nut tightening torque:
5.1 ÷ 6.5 Nm (0.52÷0.66 kgm; 3.8 ÷ 4.8 ft lb)
Tightening torque for nut and bolt fixing the rear guide:
5.1 ÷ 6.5 Nm (0.52÷0.66 kgm; 3.8 ÷ 4.8 ft lb)
NOTE:
Take care to avoid hitting the window glass with the door when fitting.

BT-64
 TOW HOOK, BATTERY BRACKET, CHOCK AND SPARE WHEEL

Tow hook

118 ÷ 176 (12 ÷ 18; 87 ÷ 129.8)

: Nm (kgm, ft lb)
0396BF

Battery bracket

52 (5.3; 38.4)

: Nm (kgm, ft lb)
0414BF

BT-65
 TOW HOOK, BATTERY BRACKET, CHOCK AND SPARE WHEEL

Chock

52 (5.3; 38.4)

: Nm (kgm, ft lb)
0415BF

Spare wheel

52 (5.3; 38.4)

147 (15; 108.4)

26 (2.7; 19.2)
Nm (kgm; ft-lb)
0569BF

BT-66
 CAB AND FRAME

Cab

• Remove at least the following parts from the engine compartment:

1. Brake and clutch pipes
2. Steering column.
3. Brake servo vacuum pipe.
4. Parking brake and accelerator cables.
5. Odometer cable.
6. Main harness of electrical system.
7. Heater pipes.
8. Air conditioning pipes.
9. Fixed cab:
Cab brackets.
Tilt cab:
– Front cab brackets.
– Tilt bracket assembly.

NOTE: Make sure there is no electrical or mechanical component preventing the removal of the cab before starting to remove.

0397BF

BT-67
 CAB AND FRAME

Cab fixture (fixed cab)

Replace nuts and bolts with each assembly (the application of sealant paste to self locking nuts and bolts should be a stan-
dard procedure during assembly operations).

CHASSIS CAB MODELS

T
Y

81 (8.3; 59.7)
Q 52 (5.3; 38.4)

W
a
E
71 ÷ 108 (7.2 ÷ 11; 52.4 ÷ 79.7)

R
118 ÷ 137 (12 ÷ 14; 87 ÷ 101.1)

T
Y

: Nm (kgm, ft lb)
0398BF

COMPONENTS
1. Front of vehicle 4. Front cab bracket
2. Cab fixing bracket: 5. Rear SilentBloc
3. Front SilentBloc 6. Rear cab bracket

BT-68
 CAB AND FRAME

Cab fixture (fixed cab. Cont’d)

DOUBLE CAB MODELS

52 (5.3; 38.4)

Q 81 (8.3; 59.7)

a 118 ÷ 137
(12 ÷ 14; 87 ÷ 101.1)

W
75 ÷ 87
(7.7 ÷ 8.9; 55.3 ÷ 64.2)
E

TA
71 ÷ 108 (7.2 ÷ 11; 52.4 ÷ 79.7)

UB
I
: Nm (kgm, ft lb)
0399BF

COMPONENTS
1. Front of vehicle 5. Intemediate SilentBloc
2. Cab fixing bracket: 6. Intermediate cab bracket
3. Front SilentBloc 7. Rear SilentBloc
4. Front cab bracket 8. Rear cab bracket

BT-69
 CAB AND FRAME

Cab fixture (fixed cab. Cont’d)

Interior fixture of the intermediate cab bracket

0400BF

Interior fixture of the rear cab bracket

0401BF
COMPONENTS
5. Intemediate SilentBloc 7. Rear SilentBloc

BT-70
 CAB AND FRAME

Cab fixture (tilt cab)

Replace nuts and bolts with each assembly (the application of sealant paste to self locking nuts and bolts should be a stan-
dard procedure during assembly operations).

123 (12.5; 90.7)

71 ÷ 106 (7,2 ÷ 10.8;

52.4 ÷ 78.2)

W
Q
E a 88 (9; 64.9)

118 ÷ 137 (12 ÷ 14;

88 (9; 64.9) 87 ÷ 101)

25 ÷ 32 (2.5 ÷ 3.3; 18 ÷ 23.6)

: Nm (kgm, ft lb)
0402BF

COMPONENTS
1. Front of vehicle 4. Front cab bracket
2. Cab tilt bracket assembly 5. Rear SilentBloc
3. Front SilentBloc 6. Rear cab bracket

BT-71
 ALIGNMENT OF CAB AND FRAME

• When using the tram-tracking gauge, adjust both arms to equal lengths; check the arms and the gauge to ensure there
is no free play.
• When measuring with a tape, ensure that it is not twisted or folded.
• Measurements should be taken from the centre of the mounting holes and are given in mm.
• An asterisk (*) after the value, indicates that the matching point on the other side has the same value.

Cab

Chassis cab Double cab

Units: mm

Points A , a Points C , C Point of Dimension

D , d measurement (mm)
E , e A – a 1.400
G , g
H , h B – b 1.446
I , i
C – c 1.452
J , j Hole
centre D – d 1.468

E – e 1.474

F – f 1.645

G – g 1.474
Points B , b Points F , f H – h 1.584

I – i 1.474

J – j 1.584

0439BF

BT-72
 ALIGNMENT OF CAB AND FRAME

Frame
MODELS CABSTAR-E.95, E.120 (35, 35HD, 45)
Wheelbase 1 = 2400 mm
NOTE: The measurements are shown in mm only.

15

5
8.
36
.5
00 99
14

12 4
12 13

5
1.

3
73

98
17 (E-75, E-95)

11 REAR AXLE
.4

7
1
1
57
5.
46

0.
70
73
11

8 (E-120)

10
9
81

68 00
6
24 24
.4

-
21

B
11

W
4
63

7
5
2.
48
4
92

1
78

6
6
21

2
68

1 FRONT AXLE

EX
T. F
RA
3
752 ME
±1.
5 5
4

Units: mm
0446BF
COMPONENTS
1. Right side member wheelbase 2400 mm 10. Rear spring front bracket
2. Cross member 1 11. Cross member 3
3. Front of vehicle 12. Rear shock absorber bracket
4. Left side member wheelbase 2400 mm 13. Rear spring rear bracket
5. Front spring front bracket 14. Body to frame fixing bracket
6. Front shock absorber bracket 15. Cross member 4
7. Front spring rear bracket 17. Cross-member No. 2 (CABSTAR-E.95)
8. Cross member 2 (E-120)

BT-73
 ALIGNMENT OF CAB AND FRAME

Frame (Cont’d)
MODELS CABSTAR-E.95, E-120 (35, 35HD, 35HD DC, 45, 45DC and
FOCSA)
Wheelbase 2 = 2900 mm
NOTE: The measurements are shown in mm only.

8.
5 15
66 9
60

5
9.
49
16 (E-75, E-95)

5
12
1. 1 83
73 89 12 14

11 REAR AXLE
0
49 1 77
5. 0.1 10
71 74
46
.4 13
11
0
(E-120) 9
(E-75, E-95) 49
10
17 29
00
9 -
81 B
21
.4 W 8 (E-120)
11
68
29
4
6 63

7
5
4
92 81 2.
7 48
6
21 6
68

1 EX FRONT AXLE
FR T.
AM
75
2± E
1.5

5
2 3
4

Units: mm
0445BF
COMPONENTS
1. Right side member wheelbase 2900 mm 10. Rear spring front bracket
2. Cross member 1 11. Cross member 3
3. Front of vehicle 12. Rear shock absorber bracket
4. Left side member wheelbase 2900 mm 13. Rear spring rear bracket
5. Front spring front bracket 14. Body to frame fixing bracket
6. Front shock absorber bracket 15. Cross member 4
7. Front spring rear bracket 16. Intermediate cross member (CABSTAR-E.95)
8. Cross-member No. 2 (CABSTAR-E.120) 17. Cross-member No. 2 (CABSTAR-E.95)
9. Intermediate cross member (CABSTAR-E.120)

BT-74
 ALIGNMENT OF CAB AND FRAME

Frame (Cont’d)
MODELS CABSTAR-E-95, E-120 (35, 35HD, 35HD DC, 45, 45DC)
Wheelbase 3 = 3400 mm
NOTE: The measurements are shown in mm only.

8.5
96 09
9

9.5
49 15
16 (E-95)
1.5 91
73 8
83
1.5

11
46
.4
0.5 780 14
73
12
4.6
97
9.6 7 11
6 99 79
REAR AXLE
13

.4 81
9 10
21 0
11 40
- 3 3468
B
63
4 W
9
4
92 781

.1 2.5
21 48
1 11
21
6 8 (E-120)

E
68 7
FR XT.
75 AM
2 2±
1.
E
FRONT AXLE
6
5

3 5
4

Units: mm
0570BF

COMPONENTS
1. Right side member wheelbase 3400 mm 9. Intermediate cross member
2. Cross member 1 10. Rear spring front bracket
3. Front of vehicle 11. Cross member 3
4. Left side member wheelbase 3400 mm 12. Rear shock absorber bracket
5. Front spring front bracket 13. Rear spring rear bracket
6. Front shock absorber bracket 14. Body to frame fixing bracket
7. Front spring rear bracket 15. Cross member 4
8. Cross member 2 (E-120) 16. Cross member 2 (E-95)

BT-75
 ALIGNMENT OF CAB AND FRAME

Frame (Cont’d)

Notes:

BT-76
 ALIGNMENT OF CAB AND FRAME

Frame (Cont’d)
MODELS CABSTAR-E.95
2 Cross member 1
Fixed cab
81 (8.3; 59.7)

51.94 (5.3; 38.4)

0447BF 2
5 Front spring front bracket.
Tilting cab 88.2 (9: 64.9)

51.94 (5.3; 38.4) 5 2

0448BF

6 Front shock absorber bracket.

26 (2.65; 19.2)

0457BF
7 Front spring rear bracket.
26 (2.65; 19.2)
14 7
14 Body to frame fixing bracket.

14

7
88.2 (9; 64.9)
0449BF

8 Cross member 2
51.94 (5.3; 38.4)

0450BF Nm (kgm, ft-lb)

BT-77
 ALIGNMENT OF CAB AND FRAME

Frame (Cont’d)
MODELS CABSTAR-E.95 (Cont’d)
9 Intermediate cross member
(Wheelbase 3; 3400 mm) 51.94 (5.3; 38.4)

R
R 9
0451BF

(Wheelbase 2; 2900 mm)

51.94 (5.3; 38.4)

9
0452BF
10 Rear spring front bracket.
51.94 (5.3; 38.4)
11 Cross member No. 3

R 10 11
0453BF

12 Rear shock absorber bracket.

R
12

0454BF

13 Rear spring rear bracket.

51.94 (5.3; 38.4)
15 Cross member No. 4
13 15

R R
0455BF Nm (kgm, ft-lb)

R. Riveted joint

BT-78
 ALIGNMENT OF CAB AND FRAME

Frame (Cont’d)
MODELS CABSTAR-E.120
2 Cross member 1
Fixed cab (Std y DC)
81 (8.3; 59.7)

51.94 (5.3; 38.4)

0447BF
2
5 Front spring front bracket.
Tilting cab 88.2 (9: 64.9)

0448BF
51.94 (5.3; 38.4) 5 2
6 Front shock absorber bracket.

26 (2.65; 19.2)

0457BF
7 Front spring rear bracket.
26 (2.65; 19.2)
14
14 Body to frame fixing bracket. 7

14

7
88.2 (9; 64.9)
0449BF
8 Cross member 2
51.94 (5.3; 38.4)

0450BF Nm (kgm, ft-lb)

BT-79
 ALIGNMENT OF CAB AND FRAME

Frame (Cont’d)
MODELS CABSTAR-E.120 (Cont’d)
9 Intermediate cross member
(Wheelbase 3; 3400 mm) 51.94 (5.3; 38.4)

R
R 9
0451BF

(Wheelbase 2; 2900 mm)

51.94 (5.3; 38.4)

9
0452BF
10 Rear spring front bracket.
51.94 (5.3; 38.4)
11 Cross member No. 3

R 10 11
0453BF

12 Rear shock absorber bracket.

R
12

0454BF

13 Rear spring rear bracket.

51.94 (5.3; 38.4)
15 Cross member No. 4
13 15

R R
Nm (kgm, ft-lb)
0455BF

R - Riveted joint

BT-80
 SEALING AND ANTI-RUST PROTECTION POINTS

Sealing and anti-rust wax points

SEALING POINTS
The following figures show the areas where sealant is applied during the manufacturing process. During servicing opera-
tions, make sure you a apply a continuous and even thread of sealant.
Take care to avoid applying too much sealant or letting it reach non-applicable parts.

ANTIRUST WAX
To improve rust resistance, antirust wax is applied to certain areas of some cab components.
When any component is replaced, make sure that antirust wax is applied to the required areas of the new component as
shown in the following figures.
Use antirust wax of a high quality that penetrates in all parts of the component and has a long life.

BT-81
 SEALING AND ANTI-RUST PROTECTION POINTS

Sealing and anti-rust wax points (Cont’d)

Cross-section A-A Cross-section B-B

Sealing area
Wax application area
Anti-rust wax application area 0431BF

BT-82
 SEALING AND ANTI-RUST PROTECTION POINTS

Sealing and anti-rust wax points (Cont’d)

0413BF

Sealing area
Wax application area
Anti-rust wax application area

BT-83
 SEALING AND ANTI-RUST PROTECTION POINTS

Sealing and anti-rust wax points (Cont’d)

DOUBLE CAB MODELS

Cross-section A-A Cross-section B-B

0433BF

Sealing area
Wax application area
Anti-rust wax application area

BT-84
 SEALING AND ANTI-RUST PROTECTION POINTS

Sealing and anti-rust wax points (Cont’d)

DOUBLE CAB MODELS

0403BF

Sealing area

BT-85
 SEALING AND ANTI-RUST PROTECTION POINTS

Wax for undersides

• Before you apply wax, make sure that the application surface is completely dry.

0404BF

Application area of antirust wax DINOL 3650 (both sides of the frame).

NOTES
• Do not apply to the gear box, exhaust system, propeller shaft, license plate and tail lights, gearshift control parts, Brake Regulator Valve, parking brake
system, tyres, wheel drums, fuel pipes, wings, mudguards and battery cover.
• Make sure that the spring brackets are totally covered with wax.

BT-86
 SEALING AND ANTI-RUST PROTECTION POINTS

Wax for undersides (Cont’d)

CHASSIS CAB MODELS

• Before you apply wax, make sure that the application surface is completely dry.

0405BF

Application area of anti-rust wax DINOL 4941 M

NOTE:
• Do not apply to the engine, gearbox, exhaust system, parking brake system and dustguard of the steering box.

BT-87
 SEALING AND ANTI-RUST PROTECTION POINTS

Wax for undersides (Cont’d)

DOUBLE CAB MODELS

• Before you apply wax, make sure that the application surface is completely dry.

0406BF

Application area of anti-rust wax DINOL 4941 M

NOTE:
• Do not apply to the engine, gearbox, exhaust system, parking brake system and dustguard of the steering box.

BT-88