🏷️ Basic Information

Make:

Iveco

Model:

Daily Turbodaily 4x4

Model Series:

G series (often identified by chassis codes related to its generation)

Generation:

First Generation Daily (Typ 35-10, 49-10, 59-10, 40-12 etc.)

Chassis Codes:

Various, depending on specific configuration and GVW (e.g., 35C, 59G, etc.)

👋 Introduction

Market Position:

The Iveco Daily Turbodaily 4x4 was positioned as a robust and versatile light commercial vehicle with exceptional off-road capability, targeting businesses and organizations requiring reliable transportation in demanding terrains and conditions. It served various sectors including construction, utility services, emergency response, and military applications.

Competitive Analysis:

Competed with other off-road capable light commercial vehicles and vans of its era, such as variants of the Mercedes-Benz Sprinter 4x4 (later generations), Land Rover Defender (as a utility vehicle), and specialized off-road trucks. Its key differentiators were its purpose-built 4x4 system and rugged construction.

Key Features:

Permanent or selectable 4x4 drivetrain, high ground clearance, robust chassis and suspension, durable engine options, excellent towing and payload capacity, ability to navigate challenging terrain.

Off Road Capability:

The '4x4' designation signifies a permanent or selectable all-wheel-drive system, likely including a low-range gear reduction for extreme off-road conditions and heavy loads.

📋 Manual Details

Coverage Areas:

All models within the 1988-1997 production range, all repair topics A-Z

Page Count:

Not specified, but described as 'full & complete' with 'great detail' on major topics.

Manual Type:

Service Repair Workshop Manual

Language:

English (implied by description, common for professional manuals of this era)

Format:

PDF

📖 Manual Coverage

Systems Covered:

Maintenance & Servicing, Engine, Clutch, Transmissions, Cooling Systems, Fuel System, Exhaust System, Ignition System, Electrical System, Brakes, Brake Assembly, Wheels, Tires, Steering System, Suspension System, Frame, Bodywork, Wiring Diagrams, Fault Finding, Troubleshooting

Engine Overhaul:

Detailed procedures for engine disassembly, inspection, repair, and reassembly, including piston rings, bearings, crankshaft, cylinder heads, valve train, timing components.

Transmission Repair:

Complete overhaul instructions for manual gearboxes, including gear sets, synchronizers, bearings, seals, and shift mechanisms, as well as transfer case repairs.

Brake System Service:

Procedures for brake pad/shoe replacement, caliper/wheel cylinder overhaul, brake line inspection and replacement, bleeding the brake system, and adjusting parking brake.

Suspension And Steering:

Repair and replacement of shock absorbers, springs, control arms, ball joints, tie rods, steering box/rack, and wheel bearings. Includes alignment specifications.

Fuel And Exhaust Systems:

Service procedures for fuel tank, fuel lines, filters, injection pump, injectors, and exhaust manifold/piping/muffler.

Cooling System Maintenance:

Radiator, fan, water pump, thermostat, and heater core service procedures.

Procedures Included:

Routine maintenance, diagnostic procedures, repair and overhaul of all major mechanical and electrical components, troubleshooting common issues, component replacement, adjustments, fluid changes, brake system service, steering and suspension alignment, bodywork repair.

Fault Finding Troubleshooting:

Systematic diagnostic approaches for various symptoms, covering engine performance, electrical faults, transmission issues, brake problems, and suspension noise.

Bodywork Repair:

Guidance on frame straightening, panel replacement, door repair, and trim component servicing.

Wheel And Tire Service:

Wheel bearing replacement, tire mounting/balancing, and lug nut torque specifications. Includes wheel bolt pattern (likely 5x130 or similar for commercial application).

Technical Depth:

Comprehensive, covering basic maintenance to advanced repair and diagnostic procedures. Designed for professional use.

Torque Specifications:

Detailed torque values for all critical fasteners and components during assembly and repair.

Diagnostic Procedures:

Step-by-step diagnostic flowcharts and testing methods for identifying the root cause of malfunctions.

Component Clearances:

Specified clearances and tolerances for engine and transmission internal components to ensure proper operation.

Wiring Diagrams:

Comprehensive wiring diagrams for all major electrical circuits, including lighting, starting, charging, ignition, instrumentation, and accessories.

📊 Manual Specifications

File Format:

PDF

Compatibility:

Compatible with all operating systems including Windows (95, 98, 2000, Me, Xp, Vista, 7, etc.) and MAC.

Print Quality:

High-quality pictures & diagrams

Binding Type:

Digital Download (N/A for physical binding)

Paper Type:

Digital (N/A for physical paper type)

⚙️ Engine Specifications

Engine Options:

Likely featured Iveco's range of naturally aspirated and turbocharged diesel engines. Common engines for this period and model would include the Iveco 8140 series, specifically the 2.5L (8140.61, 8140.21) and 2.8L (8140.41, 8140.43) variants, both naturally aspirated and turbocharged (Turbodaily). Specific power outputs varied but typically ranged from approximately 75-105 HP.

Horsepower Range:

Approx. 75-105 HP (varies by specific engine variant and turbocharging)

Torque Range:

Approx. 170-230 Nm (varies by specific engine variant and turbocharging)

Fuel System:

Direct injection diesel with rotary or inline injection pumps (Bosch, Lucas, or similar).

Common Engine Codes:

8140.61 (2.5 NA Diesel), 8140.21 (2.5 Turbo Diesel), 8140.41 (2.8 NA Diesel), 8140.43 (2.8 Turbo Diesel)

Cooling System Type:

Water-cooled, pressurized system with fan assistance (belt-driven).

Ignition Type:

Diesel (Compression Ignition)

🔧 Transmission

Transmission Type:

Manual transmission, typically 5-speed.

Transfer Case:

Integral part of the 4x4 system, often with selectable 2WD/4WD and low-range gearing.

Clutch Type:

Single dry plate, hydraulically operated diaphragm spring clutch.

Gear Ratios:

Specific ratios would vary by gearbox and model, detailed within the manual.

📐 Dimensions

Wheelbase:

Multiple wheelbase options were available depending on the specific model variant (e.g., short, medium, long).

Ground Clearance:

Significantly higher than standard 4x2 Daily models due to 4x4 conversion and suspension modifications. Specific figures vary by body style and configuration.

Gross Vehicle Weight Rating Gvwr:

Ranges from approximately 3.5 to 7.0 tonnes (3500 kg to 7000 kg) depending on the specific model designation (e.g., 35-10, 49-10, 59-10, 40-12).

🛡️ Safety Features

Safety Ratings:

No standardized crash test ratings (like Euro NCAP) were typically available for commercial vehicles of this era in the same way as passenger cars. Focus was on robust construction and passive safety for its class.

Active Safety Features:

Effective braking system (disc front, drum rear for most), power steering (often standard on 4x4 variants), good visibility.

Passive Safety Features:

Reinforced chassis, durable body structure, seatbelts, potentially head restraints on later models.

💡 Technology Features

Infotainment System:

Basic by modern standards. Likely an AM/FM radio with cassette player. Features would be minimal, focusing on functionality rather than advanced media integration.

Driver Assistance Features:

Limited. Primary focus was on the mechanical systems. Features like ABS were not common, and traction control systems were not present.

Connectivity:

None.

🔧 Maintenance

General Service Interval:

Typically every 10,000 to 15,000 km or annually, whichever comes first. Specific intervals for oil changes, filter replacements, and inspections are detailed in the manual.

Engine Oil Specification:

API CG-4 or ACEA E2 specification. Viscosity grades like 15W-40 or 10W-40 depending on climate. Exact grade and capacity are critical and found in the manual.

Coolant Specification:

Ethylene glycol based antifreeze with corrosion inhibitors. Typically a 50/50 mix with de-ionized water. Refer to manual for specific additive type (e.g., OAT or HOAT).

Transmission Fluid Specification:

API GL-4 or GL-5 gear oil. Viscosity grade such as 75W-90 or 80W-90. Specific type for transfer case and differentials also noted.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid. Always use new, sealed fluid.

Common Issues:

Rust and corrosion on chassis and body panels, wear in suspension components (bushings, ball joints), potential issues with older turbochargers, electrical gremlins in older wiring harnesses, clutch wear due to heavy-duty use, potential for fuel injector pump issues. The manual addresses these with diagnostic and repair procedures.

Oil Filter Part Numbers:

Part numbers vary by engine variant. Common suppliers like Mann-Filter, Bosch, or original Iveco parts would have specific OE numbers (e.g., Mann W930/21, Bosch 0451103010 are examples of similar period filters, exact part number needs verification from the manual).

📚 Vehicle History

Brand Heritage:

Iveco (Industrial Vehicles Corporation) has a long history in the commercial vehicle sector, formed in 1975 by Fiat. It is known for producing a wide range of trucks, vans, and buses, with a strong emphasis on durability and utility.

Model Evolution:

The Iveco Daily has been in production since 1978, evolving through several generations. The 1988-1997 models represent a significant update or continuation of the first generation (often referred to as the 'G' series), with the 'Turbodaily 4x4' being a specific ruggedized variant emphasizing off-road performance. Subsequent generations have seen significant redesigns and technological advancements.

Production Locations:

Iveco vehicles are manufactured globally, with key European production sites historically including Italy, France, and Germany.

🏆 Awards & Recognition

Industry Recognitions:

While specific 'awards' for this particular variant might not be widely documented, the Iveco Daily range has consistently been recognized for its durability, versatility, and ruggedness in the light commercial vehicle sector. Its 4x4 variants have often been favored in specialized applications for their off-road capabilities.