๐ท๏ธ Basic Information Identification Make: Iveco Model: Daily 2 Generation: Second Generation Product Name: Iveco Daily 2 Complete Workshop Service Repair Manual ๐ Introduction Market Position Target Audience: DIY mechanics, independent repair shops, fleet owners, and any owner seeking to maintain or repair their Iveco Daily 2. Competitive Analysis Value Proposition: Provides significant cost savings by enabling owners to perform their own repairs, reducing reliance on expensive dealership service. Key Features Ease Of Use: Features easy-to-follow, step-by-step instructions and pictures to simplify complex repair procedures. Accessibility: Downloadable and accessible on various devices including PCs, Macs, tablets, and smartphones. Permanence: Once downloaded, the manual is owned permanently by the user. ๐ Manual Details Coverage Areas Coverage Years: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998 Model Coverage Detail: All Models, Engines, Trim Levels, and Transmission Types within the specified production years. Page Count Page Count: Undisclosed (Implied Comprehensive) Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English (Implied by product description) Format Format: Downloadable Digital File (PDF) ๐ Manual Coverage Systems Covered Engine Systems: Engine mechanicals, fuel injection, ignition (where applicable), cooling, lubrication, exhaust, engine management systems. Drivetrain Systems: Clutch, transmission (manual and automatic), driveshafts, differentials, axle assemblies. Chassis Systems: Suspension (front and rear), steering system, braking system (hydraulic, pneumatic for heavier variants), wheels, tires. Electrical Systems: Wiring diagrams, lighting, instrumentation, charging system, starting system, body electronics, power windows/locks (if equipped). Body And Interior: Body panels, doors, windows, seats, trim, heating, ventilation, and air conditioning (HVAC) system. Procedures Included Maintenance Procedures: Routine checks, fluid changes (oil, coolant, brake fluid), filter replacements, lubrication points, belt adjustments. Repair Procedures: Engine overhaul, transmission repair, brake system overhauls, suspension component replacement, steering rack repair, electrical component diagnosis and replacement. Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, fault code interpretation (if applicable to the era), component testing procedures. Specification Data: Torque specifications for fasteners, fluid capacities and types, clearances, timing settings, electrical resistance values. Bodywork Repair: Repair of body panels, door mechanisms, tailgate/rear door operation, chassis frame inspection and repair (for chassis cab variants). Heating Ventilation Ac: Diagnosis and repair of HVAC systems, including blower motor, evaporator, condenser, refrigerant charging (where applicable). Troubleshooting Guides: Detailed symptom-based troubleshooting for common mechanical, electrical, and drivability issues. Technical Depth Depth Of Coverage: Comprehensive, A-Z coverage for all service and repair tasks. Includes step-by-step instructions with illustrations. Diagnostic Tools: Instructions for using basic diagnostic tools and techniques for electrical system testing (multimeter, test light). ๐ Manual Specifications File Format File Format: PDF Print Quality Print Quality: High Quality (Stated) Binding Type Binding Type: Digital Download (Printable) Paper Type Paper Type: N/A (Digital) Software Requirements Software Requirements: Adobe Reader or compatible PDF viewer. โ๏ธ Engine Specifications Primary Engine Engine Families: Iveco Sofim (various displacements, including 2.5L and 2.8L) and potentially Fiat/other derivative engines common in light commercial vehicles of this era. Diesel engines are primary. Performance Horsepower Range: Typically ranging from approximately 70 HP to 120 HP depending on engine variant and turbocharging. Torque Range: Varies by engine, with diesels offering strong low-end torque crucial for load carrying. Fuel System Fuel System Type: Indirect Injection (IDI) and Direct Injection (DI) diesel systems, often with mechanical injection pumps (e.g., Bosch VE). Engine Management Engine Control: Primarily mechanical engine control for earlier models, with some electronic controls for fuel injection and turbocharging on later versions within this range. ๐ง Transmission Standard Transmission Type Standard: 5-speed manual transmission. Optional Transmission Type Optional: Some heavier variants or specific market models may have featured heavier-duty manual transmissions or, less commonly, early forms of automated manual transmissions. Features Drive Layout: Rear-wheel drive (RWD) is standard, with some variants potentially offering all-wheel drive (AWD). ๐ Dimensions Exterior Body Styles: Panel Van, Chassis Cab, Dropside, Minibus, Crew Cab. Weights Gvw Range: Gross Vehicle Weight (GVW) varied significantly across the range, typically from 2.8 to 4.0 tonnes or higher for specialized variants. ๐ก๏ธ Safety Features Ratings Safety Standards: Compliance with European automotive safety standards applicable to light commercial vehicles of the period. Active Features Braking Features: Hydraulic disc brakes front, drum brakes rear. ABS may have been an option on later models or higher GVW variants. Some heavier variants might feature air-assisted braking systems. Passive Features Occupant Protection: Basic occupant protection typical of the era. Seat belts are standard. Some models may feature crumple zones in the chassis/body structure. ๐ก Technology Features Infotainment Infotainment Features: Basic radio/cassette player. Some later models might have offered CD players as an option. Limited by the era of production. Driver Assistance Driver Assistance Features: ABS was an optional feature, and not widespread. No advanced driver-assistance systems (ADAS) like lane keeping assist or adaptive cruise control were available. Connectivity Connectivity Features: No modern connectivity features like Bluetooth or USB ports. Analog gauges and basic warning lights for instrumentation. ๐ง Maintenance Service Intervals...
Engine overhaul, transmission repair, brake system overhauls, suspension component replacement, steering rack repair, electrical component diagnosis and replacement.
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, fault code interpretation (if applicable to the era), component testing procedures.
Specification Data:
Torque specifications for fasteners, fluid capacities and types, clearances, timing settings, electrical resistance values.
Bodywork Repair:
Repair of body panels, door mechanisms, tailgate/rear door operation, chassis frame inspection and repair (for chassis cab variants).
Heating Ventilation Ac:
Diagnosis and repair of HVAC systems, including blower motor, evaporator, condenser, refrigerant charging (where applicable).
Troubleshooting Guides:
Detailed symptom-based troubleshooting for common mechanical, electrical, and drivability issues.
Technical Depth
Depth Of Coverage:
Comprehensive, A-Z coverage for all service and repair tasks. Includes step-by-step instructions with illustrations.
Diagnostic Tools:
Instructions for using basic diagnostic tools and techniques for electrical system testing (multimeter, test light).
๐ Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High Quality (Stated)
Binding Type
Binding Type:
Digital Download (Printable)
Paper Type
Paper Type:
N/A (Digital)
Software Requirements
Software Requirements:
Adobe Reader or compatible PDF viewer.
โ๏ธ Engine Specifications
Primary Engine
Engine Families:
Iveco Sofim (various displacements, including 2.5L and 2.8L) and potentially Fiat/other derivative engines common in light commercial vehicles of this era. Diesel engines are primary.
Performance
Horsepower Range:
Typically ranging from approximately 70 HP to 120 HP depending on engine variant and turbocharging.
Torque Range:
Varies by engine, with diesels offering strong low-end torque crucial for load carrying.
Fuel System
Fuel System Type:
Indirect Injection (IDI) and Direct Injection (DI) diesel systems, often with mechanical injection pumps (e.g., Bosch VE).
Engine Management
Engine Control:
Primarily mechanical engine control for earlier models, with some electronic controls for fuel injection and turbocharging on later versions within this range.
๐ง Transmission
Standard
Transmission Type Standard:
5-speed manual transmission.
Optional
Transmission Type Optional:
Some heavier variants or specific market models may have featured heavier-duty manual transmissions or, less commonly, early forms of automated manual transmissions.
Features
Drive Layout:
Rear-wheel drive (RWD) is standard, with some variants potentially offering all-wheel drive (AWD).
๐ Dimensions
Exterior
Body Styles:
Panel Van, Chassis Cab, Dropside, Minibus, Crew Cab.
Weights
Gvw Range:
Gross Vehicle Weight (GVW) varied significantly across the range, typically from 2.8 to 4.0 tonnes or higher for specialized variants.
๐ก๏ธ Safety Features
Ratings
Safety Standards:
Compliance with European automotive safety standards applicable to light commercial vehicles of the period.
Active Features
Braking Features:
Hydraulic disc brakes front, drum brakes rear. ABS may have been an option on later models or higher GVW variants. Some heavier variants might feature air-assisted braking systems.
Passive Features
Occupant Protection:
Basic occupant protection typical of the era. Seat belts are standard. Some models may feature crumple zones in the chassis/body structure.
๐ก Technology Features
Infotainment
Infotainment Features:
Basic radio/cassette player. Some later models might have offered CD players as an option. Limited by the era of production.
Driver Assistance
Driver Assistance Features:
ABS was an optional feature, and not widespread. No advanced driver-assistance systems (ADAS) like lane keeping assist or adaptive cruise control were available.
Connectivity
Connectivity Features:
No modern connectivity features like Bluetooth or USB ports. Analog gauges and basic warning lights for instrumentation.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 to 15,000 km or annually, depending on operating conditions and oil type specified.
Air Filter Replacement:
Recommended every 20,000-30,000 km or more frequently in dusty conditions.
Fuel Filter Replacement:
Recommended every 20,000-40,000 km, critical for diesel engine longevity.
Fluid Specifications
Engine Oil Specification:
API CG-4 or ACEA E2/E3 rated diesel engine oil, typically SAE 15W-40 or 10W-40 depending on climate. Manual will specify exact grades.
Coolant Specification:
Ethylene glycol-based antifreeze with corrosion inhibitors, typically a green or blue type. Manual will specify the required type and concentration.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid is typically specified for hydraulic systems.
Known Issues
Common Wear Items:
Clutch wear, brake pad/shoe wear, suspension bushings and ball joints due to load carrying, injector pump seals, glow plug failure.
Common Electrical Issues:
Wiring harness degradation, alternator/starter motor issues, dashboard warning light malfunctions, especially in older, higher-mileage vehicles.
Preventative Maintenance
Turbocharger Care:
Importance of proper warm-up and cool-down cycles for turbocharged diesel engines to maximize turbocharger lifespan.
๐ Vehicle History
Brand Heritage
Iveco Focus:
Iveco (Industria Veicoli da Competizione) is an Italian manufacturer specializing in a wide array of commercial vehicles, buses, and special vehicles.
Model Evolution
Daily 2 Introduction:
The second generation Daily was introduced in 1996, succeeding the original Daily. It featured updated styling, improved ergonomics, and a wider range of engine and chassis options.
Production
Production Period:
1990-1998 covers the latter part of the first generation and the introduction and initial years of the second generation. The manual specifically covers the transition and the early second-generation models up to 1998.
๐ Awards & Recognition
Recognitions
Industry Acclaim:
The Iveco Daily range has historically been recognized for its robustness, load-carrying capacity, and versatility in various commercial applications.