🏷️ Basic Information

Make:

Iveco

Model:

Daily

Generation:

Second Generation (1999-2006)

Model Years Covered:

2000, 2001, 2002, 2003, 2004

Chassis Codes:

Various chassis codes apply to the Daily platform, often denoted by Gross Vehicle Weight (GVW) ratings.

Manual Product Name:

Iveco Daily 2000-2004 Workshop Service Repair Manual

👋 Introduction

Vehicle Segment:

Light Commercial Vehicle (LCV) / Van

Target Audience:

Businesses and individuals relying on the Iveco Daily for transport, logistics, and specialized applications.

Key Competitors:

Ford Transit, Mercedes-Benz Sprinter, Fiat Ducato, Renault Master, Volkswagen Crafter.

Manual Value Proposition:

Cost-effective alternative to dealership servicing; empowers users with the knowledge for self-maintenance and repair.

Manual Usability:

Printable pages, clear indexing, detailed visuals, and straightforward instructions enhance user experience.

📋 Manual Details

General Information:

Included

Engine Mechanical System:

Included

Engine Electrical System:

Included

Emission Control System:

Included

Fuel System:

Included

Suspension System:

Included

Clutch System:

Included

Manual Transaxle System:

Included

Automatic Transaxle System:

Included

Driveshaft And Axle:

Included

Steering System:

Included

Brake System:

Included

Body Interior And Exterior:

Included

Body Electrical System:

Included

Restraint System:

Included

Estimated Page Count:

Comprehensive; exact page count varies based on specific engine and body configurations, typically hundreds of pages.

Type:

Workshop Service Repair Manual (Factory Equivalent)

Language:

English

File Format:

PDF

Delivery Method:

Instant Download

Print Quality:

Fully Printable

Zoom Functionality:

YES

Software Requirements:

Adobe PDF Reader, WinZip (or equivalent decompression software)

Operating System Compatibility:

All Versions of Windows & Mac

📖 Manual Coverage

Engine Systems:

Engine mechanical (overhaul, timing, valve train), engine electrical (ignition, starting, charging, ECU), fuel systems (injection, fuel pump, injectors), emission controls, cooling system, lubrication system.

Drivetrain:

Clutch (operation, replacement), manual transaxle (gearbox overhaul, shift mechanisms), automatic transaxle (if applicable, operation, fluid service), driveshaft, constant velocity (CV) joints, rear axle.

Suspension And Steering:

Front suspension (geometry, components, replacement), rear suspension (leaf springs, shock absorbers), steering system (rack and pinion, power steering pump, steering column), wheel alignment specifications.

Braking:

Front brakes (disc/drum, pads, rotors, calipers), rear brakes (disc/drum, pads, shoes, drums), parking brake, hydraulic system (master cylinder, brake lines, ABS if equipped).

Body And Chassis:

Body interior (trim, seats, dashboard), exterior (panels, doors, hinges, latches), body electrical (lighting, power windows, central locking), chassis maintenance and repair.

Safety Systems:

Restraint systems (airbags, seatbelts).

Maintenance:

Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, inspections.

Repair And Overhaul:

Step-by-step instructions for component removal, disassembly, inspection, repair, assembly, and installation for all covered systems.

Troubleshooting:

Diagnostic procedures for common issues, fault code interpretation (if applicable), systematic problem-solving guides.

Electrical Diagnostics:

Detailed wiring diagrams, electrical component testing, circuit diagnosis, connector identification.

Specifications:

Torque specifications for fasteners, clearances, fluid capacities, wear limits, diagnostic values.

Depth:

Comprehensive. Suitable for both DIY enthusiasts performing routine maintenance and professional mechanics undertaking major repairs and diagnostics.

Documentation Style:

Detailed illustrations, diagrams, wiring schematics, and step-by-step instructions.

📊 Manual Specifications

Format:

PDF

Printability:

Yes, all pages are printable for workshop use.

Image Resolution:

High-resolution illustrations and diagrams for clarity.

Binding Type:

Digital (PDF) - No physical binding

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Families:

Iveco Sofim (e.g., 2.8L), Iveco F1C diesel engines were common in this era. Specific engine codes (e.g., 8140.43, F1AE0481) would vary.

Power Output Range:

Typically ranging from approximately 80 HP to 145 HP depending on the specific engine variant and turbocharging.

Torque Output Range:

Torque figures varied significantly, generally from around 200 Nm to over 350 Nm for higher-output diesel engines.

Injection Type:

Commonly used direct injection diesel systems, often with mechanical or electronic fuel injection pumps and later common rail systems.

Fuel Type:

Diesel

Emission Standards:

Likely Euro III or early Euro IV compliant depending on the specific market and build date.

🔧 Transmission

Transmission Type Standard:

Manual transmission (5-speed and 6-speed options were common).

Transmission Type Optional:

Some variants may have offered automated manual transmissions (e.g., Agile gearbox) or basic automatic transmissions, though manual was prevalent.

Gear Ratios:

Specific gear ratios are detailed within the manual, varying by transmission and axle ratio.

Transmission Fluid Type:

Refer to the manual for specific OEM-approved manual transmission fluid (e.g., GL-4 or GL-5 rated) and automatic transmission fluid (ATF) specifications. Common examples include SAE 75W-90 for manuals.

📐 Dimensions

Body Styles:

Panel Van, Chassis Cab, Dropside, Tipper, Minibus, Passenger variants.

Wheelbase Options:

Multiple wheelbase options available to suit different load capacities and body types (e.g., short, medium, long wheelbases).

Gvw Range:

Gross Vehicle Weight (GVW) ratings varied significantly, from around 3.0 to 6.5 tons (or higher for specialized versions).

🛡️ Safety Features

Crash Test Data:

Specific crash test ratings from independent bodies like Euro NCAP for this generation may be limited, but generally reflect the safety standards of the era for LCVs.

Active Safety Features:

ABS (Anti-lock Braking System) was increasingly standard or optional on models during this period. Electronic Stability Program (ESP) might be present on later models within this range.

Passive Safety Features:

Seatbelts, reinforced chassis and body structure, driver and passenger airbags (depending on trim and optional fitment).

💡 Technology Features

Infotainment Systems:

Basic radio systems (AM/FM, CD player), potentially with auxiliary inputs. Navigation systems were not commonly integrated as standard in this period for LCVs.

Driver Assistance Features:

Limited by modern standards. ABS was the primary advanced driver assistance system. Cruise control might have been an option on higher trims.

Connectivity Features:

Basic connectivity might have included Bluetooth for hands-free calling on upgraded audio systems. No advanced smartphone integration (Apple CarPlay, Android Auto) expected.

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 to 30,000 km or annually, whichever comes first. Specific interval depends on engine, oil type, and operating conditions (refer to manual for precise details).

Other Intervals:

Fuel filter, air filter, cabin filter replacements usually at 30,000-60,000 km intervals. Timing belt/chain inspection/replacement as per manual specifications (often critical for diesel engines).

Engine Oil Specification:

API CI-4 or higher for diesel engines, ACEA E4/E6/E7 often recommended. Viscosity grades like 5W-30, 10W-40 depending on climate and engine variant. Consult manual for exact specification (e.g., CCMC D-4).

Coolant Type:

Ethylene glycol-based antifreeze coolant, often requiring specific OAT (Organic Acid Technology) or HOAT (Hybrid OAT) formulations as per Iveco specifications.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid, depending on ABS system presence and vehicle manufacturer recommendation.

Common Problems:

Potential issues can include wear on suspension components, DPF regeneration problems (if fitted), injector issues on high-mileage diesels, EGR valve malfunctions, and minor electrical gremlins common in vehicles of this age. Clutch wear on manual transmissions is also a common maintenance item.

📚 Vehicle History

Manufacturer:

Iveco (Industrial Vehicles Corporation), an Italian manufacturer of commercial vehicles.

Generation Context:

The second generation Daily was a significant update over its predecessor, offering improved styling, drivability, and a wider range of configurations.

Design Philosophy:

Designed for durability, versatility, and suitability for a wide array of commercial applications, from urban delivery to construction and passenger transport.

Production Period:

Second generation produced from 1999 to 2006.

🏆 Awards & Recognition

Industry Awards:

While specific awards for the 2000-2004 models are not prominently documented, the Iveco Daily platform has historically been recognized for its robustness and versatility in the commercial vehicle sector, often winning 'Van of the Year' awards in various European markets across different generations.