Document overview
Workshop Manual for LAMBORGHINI SPARK 160.4 → WSXJN00200LL10001 from the SPARK (STAGE 5) family. Digital PDF in English with 1,445 pages.
The corresponding English table of contents contains 47 sections and 554 individual topics.
Main sections included
- Introduction
- Safety
- Technical characteristics
- Calibrations and electronic diagnosis
- Method of intervention
- Wiring diagrams
- Service Info
Document details
- Brand: LAMBORGHINI
- Family: SPARK (STAGE 5)
- Model: SPARK 160.4
- Starting serial number: WSXJN00200LL10001
- Document type: Workshop Manual
- Language: English
- Pages: 1,445
- File size: 779.47 MiB
- Format: Digital PDF download
Compatibility
Before purchasing, verify that your machine model and reference code match LAMBORGHINI SPARK 160.4 → WSXJN00200LL10001.
Complete table of contents
Introduction
- Tightening torques
- Pump tightening torques
- Wheel nut/screw tightening torques
- Tightening torques for nuts and bolts of electrical connections
- Installation of solenoid valves and cartridge valves
- Installation of quick couplers
- Units of measurement and conversion factors
- Maintenance intervals
- Thread lock adhesives, sealants and lubricants
Safety
Preface
- Important notes concerning safety
Important safety information
- Recognising hazards
- Indications for persons in contact with the tractor
Safety rules
- Risks during tractor preparation
- Risks during maintenance
- Work on machine systems
- Special disassembly/assembly/inspection procedures
Safety pictograms
- Replacing safety pictograms
Environmental risks
- Hazards associated with the operating environment
Technical characteristics
- External views
- Viste interni cabina
- Dimensions and weights of the tractor
- Main technical data
Engine
- Pressure transducer (exhaust gas backpressure) – (B60)
- Pressure transducer (ahead of SCR catalytic converter) – (B88)
- Pressure transducer (ahead of SCR catalytic converter) – (B88)
- Differential pressure transducer (diesel particulate filter) – (B61)
- Differential pressure transducer (diesel particulate filter) – (B58)
- Pressure transducer (lubricant oil) – (B6) / (fuel) – (B51)
- Pressure transducer
- Pressure/temperature sender (engine intake air) – (B48)
- Temperature sender (cooling system) – (B43)
- Temperature sender (exhaust gas recirculation) – (B64)
- Temperature sender (intake air, ambient air) – (B74)
- Temperature sender (ahead of and after diesel oxidation catalyst) – (B65)
- Temperature sender (ahead of SCR catalytic converter) – (B78)
- Temperature sender (ahead of SCR catalytic converter) – (B66)
- Speed sensor (crankshaft) – (B40.2)
- Speed sensor (camshaft) – (B40.1)
- NOx sensor (SCR ahead of catalytic converter) – (B54)
- NOx sensor (SCR ahead of catalytic converter) – (B54)
Engine accessories
- Coolant reservoir
- Coolant radiator
- Air filter
- Intercooler
- Diesel radiator
- Diesel fuel tank
- Diesel pre-filter
- AdBlue tank
- AdBlue float sensor
- SCR exhaust pipe
- Fuel float sensor
- AdBlue pump
Transmission
- Design and function of transmission
- Layout of rear axle
- Main clutch
- Sensors
- Switches and valves
- Automatic range shift
- Connections
- Power flow
- PTO shaft
- Powershiftable front-wheel drive
- Hydraulic diagram
- Measuring points
- Transmission data
- Type plate
- Electronic transmission control unit EST-57A
- Electronic transmission control unit EC3
- Fault diagnosis of the electronic transmission control unit
- Operation modes of the transmission control unit
- Oil change
- Checking oil level
- Lubrication
Front axle
- Definition of views – 735 AXLES (SERIES M40)
- Definition of views 740 AXLES (SERIES M40)
- Definition of views 745 AXLES (SERIES M40)
- Maintenance points – 735 AXLES (SERIES M40)
- Maintenance points – 740 AXLES (SERIES M40)
- Maintenance points – 745 AXLES (SERIES M40)
Bodywork – Cab – Platform
- Front console and cab pillars
- Instrument panel
- Multifunction armrest – Configuration A
- Multifunction armrest – Configuration B
- Multifunction armrest – Configuration C
- Left hand console
- Right hand console – Configuration A
- Right hand console – Configuration B
- Right hand console – Configuration C
- Roof panel
- Right hand pillar for versions with light control panel
- Right hand pillar for versions without light control panel
- Provision for radio
- Air conditioning system
- Air conditioning system compressor
- Air conditioning condenser
Hydraulic system
- Base hydraulic circuit
- Optional hydraulic circuit
- Optional hydraulic circuit 1
- Optional hydraulic circuit 2
- Full house hydraulic circuit
- 45 cc variable displacement pump
- 60 cc variable displacement pump
- Delivery oil filter
- Air compressor
- Front axle suspension solenoid valve block
- Pulsation damper
- Priority valve
Front PTO
- Front PTO
Front lift
- Front lift
Rear lift
- Rear lift
- Rear 3-point linkage
Calibrations and electronic diagnosis
- ECUs NO PLA
- ECUs PLA
Diagnostic tools
- D-Tech and diagnostic ports
- D-TECH App
Commissioning and calibrating the tractor
- Commissioning procedure (EOL)
- Commissioning procedure (EOL)
- Electronic Control Unit (ECU) Reset
- Vehicle model selection
- ECUs initialization
- Transmission Control Unit (TCU) initialization
- Transmission Control Unit (TCU) initialization
- Distributors configuration
- Maximum vehicle speed
- Tyre type
- Language
- Measurement unit
- Front Power Take-Off (PTO)
- Radar
- Automatic Air Conditioning
- iMonitor
- WOLP
- ISO 11786
- Iso 11783
- MMI (man machine interface)
- Agrosky
- Font Suspension
- ASM (Automatic Steering Management)
- Ext cylinders
- Oil pump displacement
- Stoll
- Engine brake
- Front Brake
- Pneumatic trailer brake
- Hydraulic trailer brake MR
- PTO front ratio configuration
- GTECU init
- Distributors command calibration neutral
- eTCV parameters configuration
- Clutch pedal calibration
- Hand brake position calibration
- Throttle pedal calibration
- Hand gas calibration
- Water mix motor calibration
- Recirculation Motor calibration
- Draft sensor calibration
- Rear hitch position calibration
- Steering angle calibration
- Front suspension calibration
- Wheel angle sensor calibration
- PVED-CL Valve spool calibration
- Main clutch calibration
- Powershift calibration
- Rear Power Take-Off (PTO) calibration
ECU alarms
- SDF Severity of alarms
- ECU ALARMS
Software management
- Engine dataset upgrade
- Aggiornamento software iMonitor 4
Method of intervention
- Special tools
- Standard tools and fixtures
- Operating supplies and auxiliary materials
- Special tools
B0 – Engine
- Measure the pressure in the crankcase
- Disassembling and assembling crankcase breather
- Removing and fitting the fan mount (fastener elements)
- Removal and assembly of the fan support
- Removal and assembly of the fan support
- Removing and fitting the belt tensioner (ribbed V-belt, level 2)
- V-belt pulley
- Removing and fitting the V belt pulley/poly-V belt pulley
- Fitting and removing the rotation device
- Blanking tool (crankcase)
- Blanking tool (crankcase)
- Blanking tools (crankcase, electronic engine governor)
- Pipe (crankcase breather)
- Cover
- Mount (assembly foot, flywheel side)
- Mount (assembly foot, side opposite of the flywheel)
- Support (Assembly foot, opposite side to flywheel)
- Mount (fasteners)
- Blanking elements (crankcase, PTO-A)
- Blanking elements (PTO-B)
- Fastener elements (PTO-B power take off)
- Blanking elements (PTO-B)
- Replacing crankshaft seal ring (side opposite flywheel)
- Disassembling/assembling crankshaft wear sleeve (side opposite flywheel)
- Disassembling and assembling the front cover (fixing elements)
- Disassembling and assembling the flywheel (fixing elements)
- Replacing the starter motor ring gear of the flywheel
- Fitting and removing the crankshaft bearings
- Fitting and removing the crankshaft bearings
- Checking the crankshaft
- Check the endfloat of the crankshaft
- Checking the crankshaft bearings
- Replacing the crankshaft seal ring (flywheel side)
- Assembly and disassembly of piston cooling nozzles
- Assembly and disassembly of piston cooling nozzles
- Disassembling and assembling the sensor wheel
- Removing and fitting the connecting rod shank
- Checking the connecting rod shank
- Disassembling and assembling the piston
- Disassembling and assembling the piston rings
- Check the piston rings
- Check the piston rings
- Compression test
- Checking compression
- Measuring piston protrusion
- Fitting and removing the counterweight shaft
- Checking counterweight shafts
- Checking the camshaft bearing
- Assembly and disassembly of the counterweight drive shaft
- Disassembling and assembling the gearbox
- Assembly and disassembly of the camshaft
- Checking the camshaft
- Removing and fitting the valve timing system
- Assembly and disassembly of the distribution valve
- Removing and refitting the valve timing system
- Removing and refitting the valve timing system
- Disassembly and assembly of the control elements
- Removing and fitting the cylinder head cover
- Removing and fitting the cylinder head cover
- Removing and fitting the cylinder head cover
- Disassembling and assembling the cylinder head (fasteners)
- Disassembling and assembling the cylinder head (fasteners)
- Removing and fitting the valves
- Checking valves, valve guides, valve springs and valve recess
- Transport eye-bolt (cylinder head)
- Transport eye-bolt (cylinder head)
- Transport eye-bolt (cylinder head)
- Engine suspension (cylinder head)
- Checking and setting valve clearance (4 cylinder engine)
- Checking and setting valve clearance (6 cylinder)
- Removing and fitting lubricant oil sump (heavy version)
- Oil filler neck
- Removing and fitting lubricant oil cooler
- Removing and fitting the lubricant oil cooler housing
- Fastener elements (lubricant oil cooler housing)
- Coolant pipe (lubricant oil radiator housing – crankcase)
- Removing and fitting the oil suction pipe
- Replacing the injector bush
- Cleaning the injector bush
- Cleaning the injector bush seat
- Disassembly and assembly of the fuel control unit (fastening elements)
- Disassembly and completion of the fuel control unit
- Disassembling and assembling the high pressure pump (fastener elements)
- Removing and fitting the injector (1600 bar injection system)
- Removing and fitting the injector (1600 bar injection system)
- Disassembling and assembling the fuel delivery pump (fastener elements)
- Fuel filter
- Manual fuel pump
- Removing and fitting the fuel line (fuel control block – high pressure pumps)
- Disassembling and assembling the rail (1600 bar injection system)
- Fitting and removing the pressure limiting valve (Rail)
- Fitting and removing the rail pressure sensor
- Assembly of the pressure transducer (fuel pressure)
- Fuel pipe (fuel control unit)
- Fuel pipes (fuel delivery pump, fuel filter, fuel control block, rail, cylinder head)
- Fuel pipes (fuel delivery pump, fuel filter, fuel control block, rail, cylinder head)
- Removing and fitting the coolant pump
- Removing and fitting the coolant pump (fastening elements)
- Removing and refitting adapter (coolant pump – thermostat housing)
- Transmission components (coolant pump)
- Assembling and disassembling the thermostat
- Check the thermostat (after removing)
- Removal and installation of the thermostat housing
- Removal and installation of the thermostat housing
- Blanking elements (thermostat housing)
- Blanking elements (thermostat housing)
- Fastener elements (thermostat housing)
- Blanking elements (thermostat housing)
- Blanking elements (cylinder head)
- Flexible hose fastening (Thermostat housing)
- Breather pipe (thermostat box – cooler)
- Disassembling and assembling charge air pipe
- Pressure transducer (mixer pipe)
- Intake manifold (exhaust gas turbocharger)
- Disassembling and assembling the exhaust manifold
- Disassembling and assembling the butterfly valve
- Disassembling and assembling the radiator
- Disassembling and assembling the regulator
- Disassembling and assembling the Venturi pipe
- Removing and fitting the mount (radiator – exhaust gas recirculation)
- Disassembling and assembling the temperature sender
- Disassembling and assembling the pressure transducer (Venturi pipe)
- Disassembling and assembling the turbocharger
- Disassembling and assembling the lubricating oil pipe (exhaust gas turbocharger)
- Removing and refitting the lubricant oil return pipe (lower part) (turbocharger)
- Cover guard (Differential pressure transducer)
- Disassembling and assembling the heater
- Disassembling and assembling the heater
- Disassembling and assembling the heater
- Disassembling and assembling the mixer pipe
- Disassembling and assembling the butterfly valve
- Shield plate (starter)
- Disassembling and assembling alternator (poly-V-belt, level 1)
- Disassembling and assembling the console (ribbed V-belt, level 1)
- Disassembling and assembling the crankshaft speed sensor (fasteners)
- Crankshaft speed sensor
- SCR delivery pump (Selective Catalytic Reduction)
- AC compressor belt – Version without front PTO
- Complete engine
- Separating engine / transmission
C0 – Engine accessories
- Replacing the coolant
- Fastener elements (wiring bundle)
- Wiring harness (fasteners)
- Protective caps (relays – alternator)
- Heater (connector line)
- Check the seal of the cooling system
- Connection (Starter)
- Starter (fasteners)
- Threaded connector (drain line)
- Pipes (exhaust pipe – mixer pipe)
- Removing and refitting the diesel particulate filter (module size 8.5″)
- Removing and fitting the V-belt pulley (version with locking cone)
- Alternator
- Alternator
- Removing and fitting the rotational speed sensor (crankshaft)
- Disassembling and assembling the camshaft speed sensor (ancillaries)
- Disassembly and refitting of the intake air pressure/temperature sender
- Temperature sender (coolant)
- Fitting the pressure transducer (fuel pressure / lubricant oil pressure)
- Heater relay
- Relay (heater, thermo-starter, glow plugs)
- Disassembling and assembling the NOx sensor
- Assembling the SCR (Selective Catalytic Reduction) metering unit
- Flushing the SCR (Selective Catalytic Reduction) delivery pump
- Flushing/Checking SCR (Selective Catalytic Reduction) metering unit
- Flushing the SCR (Selective Catalytic Reduction) pipe (delivery pump – metering unit)
- Temperature sender (ahead of and after diesel oxidation catalytic converter)
- Temperature sender (inlet air and ambient air temperature)
- Connector cable (relay – alternator)
- Connector cable (relay – heater)
- Bleeding the fuel circuit
- Engine air intake fan
- Water radiator
- Removing the water radiator
- Expansion tank
- Complete cooling pack
- Diesel radiator
- Transmission oil radiator
- Intercooler and gearbox oil / fuel heat exchanger
- Air filter
- Engine air intake pipe
- Diesel pre-filter
- Fuel tank and carrier
- AdBlue tank
- AdBlue pump
- AdBlue pump filter
- AdBlue 2 way solenoid valve
- Air compressor
- Air compressor disassembly
- Starter motor
- Exhaust silencer – DOC (diesel oxidation catalyst) catalytic converter
- Disassembling the exhaust silencer – DOC (diesel oxidation catalyst) catalytic converter
- Exhaust pipe – SCR catalytic converter
D0 – Transmission
- Changing the transmission oil
- Torsionally flexible coupling and flywheel
- Connector housing
- Draining oil
- Removing the electronics and transmission control unit
- Removing the TPT cable (Variant 1)
- Removing the control unit (TCU) (Variant 1)
- Removing the TPT cable (Variant 2)
- Removing the control unit (TCU) (Variant 2)
- Removing the TPT cable (Variant 3)
- Removing the control unit (TCU) (Variant 3)
- Removing the TPT cable (Variant 4)
- Removing the control unit (TCU) (Variant 4)
- Separating rear axle from main transmission
- Removing input shaft
- Removing the clutch housing from the transmission housing
- Removing and dismantling bearing cover
- Removing the clutches from the clutch housing
- Dismantling clutch (K2/K1)
- Dismantling clutch (K4/K3)
- Dismantling clutch (K5/KR)
- Removing lubrication pressure relief valve
- Removing and dismantling hydraulic shift system
- Dismantling pump drive
- Removing and dismantling front wheel drive
- Removing and dismantling crawler gear shift and main clutch
- Removing the pressure regulator
- Removing and dismantling hydraulic shift system (IRS)
- Removing oil supply
- Removing shift system (IRS)
- Removing shift system (manual)
- Removing and dismantling main shaft
- Removing and dismantling countershaft
- Removing pump drive gear
- Assembling clutch (K2/K1)
- Assembling clutch (K4/K3)
- Assembling clutch (K5/KR)
- Installing clutches and mounting bearing cover
- Mounting and assembling hydraulic shift system
- Installing lubrication pressure relief valve
- Assembling the transmission housing
- Assembling and installing countershaft
- Installing main shaft
- Installing the shift system (IRS)
- Installing shift system (manual)
- Attaching the control unit (TUC)
- Assembling main clutch
- Installing main clutch and crawler gear shift system
- Assembling and installing front wheel drive
- Assembling and mounting pump drive
- Installing the pressure regulator and speed transmitter
- Assembling and installing hydraulic shift system (IRS)
- Mounting the clutch housing onto the transmission housing
- Installing input shaft
- Installing oil supply
- Adjusting crawler gear shift system
- Adjusting crawler gear shift system
- Closing components
- Mounting the electronics and the control unit
- Attaching the control unit (TUC) (variant 1)
- Installing the TPT cable (variant 1)
- Attaching the control unit (TUC) (variant 2)
- Installing the TPT cable (variant 2)
- Attaching the control unit (TUC) (variant 3)
- Installing the TPT cable (variant 3)
- Attaching the control unit (TUC) (variant 4)
- Installing the TPT cable (variant 4)
- Bleeding the braking system
F0 – Front axle
- Oscillating pin
- Planetary reduction gearbox
- Stub axle and steering sensor
- Double universal joint
- Steering cylinder
- Bevel pinion
- Limited slip differential assembly
- Hydrolock differential assembly
- 4WD shaft
- Carrier with front axle
- Front axle
- Front axle carrier
- Under-sump reinforcement
- Front axle carrier cylinders
G0 – Bodywork – Cab – Platform
- Cab – Configuration A
- Cab – Configuration B
- Cab access steps
- Engine hood
- Battery mount
- Front mudguards
- Mat
- Under-seat mat
- Right hand console – Configuration A
- Right hand console – Configuration B
- Left hand console
- Left hand pillar cover
- Right hand pillar cover
- Dashboard
- Instrument panel
- Roof panel
- Rear windscreen wiper motor
- Windscreen wiper electric motor
- Door handle
- Seat
- Passenger seat
- Empty and charge the air conditioning system
- A/C unit
- A.C. Electronic Control Unit replacement
- Air conditioner unit compressor
- Disassembling the A/C system compressor
- Air conditioning condenser
- Dehydrator filter
- Electronic throttle control
- Disassembling the electronic throttle control
- Clutch pedal
- Brake pedals
- Steering column
- Steering wheel
- Master cylinder
- Auxiliary utility distributor control levers
- Rear PTO control levers
- Main gear lever
H0 – Hydraulic system
- Hydrostatic steering (orbitrol)
- Front axle suspension solenoid valve block
- Brake system accumulator
- Disassembling the rear auxiliary utility distributors
- Brake control valve
- Steering system resonator
- Air braking system air filter
- Pneumatic trailer braking solenoid valves
- Right hand compressed air tank
- Left hand compressed air tank
L0 – Electrical system
- Battery
- Engine Control Unit (ECU)
- Alternator
- Instrument panel
- Ignition switch barrel
- iMonitor
- Wabco pneumatic trailer braking control unit
- Multifunction armrest
M0 – Front PTO
- Front PTO
- Front PTO shaft
N0 – Front lift
- Front lift
- Front lift arm carrier
- Front lift cylinders
- Front top link
R0 – Rear lift
- Lift draft sensor
- Lift cylinders
- 3-point linkage
S0 – Wheels
- Front Wheels
- Rear wheels
V0 – Ballast – towing hitches
- Tow hook
Wiring diagrams
- W-TECH – ELECTRICAL SECTION
- Wiring looms
Service Info
A0 – TRACTOR
- Diagnostics 2026 subscription
- SERVICE NEWS – TTV SERIES – CRUISE CONTROL BEHAVIOUR
- After-sales 2026 subscription
- SERVICE NEWS RESEARCH GUIDE
- Diagnostics 2025 subscription
- After-sales 2025 subscription
- Diagnostics 2023 subscription
- Diagnostics 2024 subscription
- After-sales 2024 subscription
- After-sales 2023 subscription
C0 – ENGINE ACCESSORIES
- SERVICE NEWS – DEF Unit – Wrong level indication
- Possible Dust entry at air duct sleeve
- Diagnostic protocol – AdBlue – Float level unit
- Filter and prefilter tool p/n 5.9035.865.0
- SCR AREA DAMAGED SENSORS
D0 – TRANSMISSION
- SERVICE NEWS – Series 6 PS – Bowden cable version – Damaged synchronizer gear 3
F0 – FRONT AXLE
- Bevel gear set loosing screws
G0 – BODYWORK – CAB
- SERVICE NEWS – Brake Fluid Reservoir vent missing
- MIRROR SUPPORT BREAKAGE
H0 – HYDRAULIC AND PNEUMATIC SYSTEM|
- SERVICE NEWS – HPT – Front axle suspension – Damaged 2.8l accumulator
- Hydraulic CUNA trailer braking kit (ITALY)
- Single connection hydraulic braking kit availability update – only for EUROPEAN market
L0 – ELECTRIC AL SYSTEM
- SERVICE NEWS – New fixation for LED driving lights
- SERVICE NEWS – Software package release 2026-02
- PRESSURE SWITCH ON TRAILER BRAKE VALVE “CUNA”
- SerDia4.0
- iMonitor x35 malfunctioning
- GO-ANYWHERE DIAGNOSTICS
- iMonitor SW upgrade & iMonitor UBOOT update instruction
- Lost connection diagnostic tools
- New Electrical cable P/N 0.037.0255.4/10
- PTO switch not working
- Precision Farming and iMonitor user manuals
R0 – REAR LIFT
- Series 6 TTV/TPT – Broken side stabilizer support screws
V0 – BALLAST, TOWING HITCHES
- SERVICE NEWS – Rear Hitch drawbar hole position
V1 – AFTERMARKET KITS
- Check correct installation of braking KIT
- Instructions for kit aftersales
