Generation Code:
Second Generation (1990-1998)
Production Years Covered:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Target Audience:
Mechanical technicians, fleet maintenance managers, and owners of Iveco Daily 2 vehicles seeking in-depth repair knowledge.
Manual Advantage:
Provides detailed, dealer-level information for independent repair and maintenance, enabling quality service and cost savings.
Safety Emphasis:
Highlights safety precautions, including the use of safety equipment and torque wrenches, denoted by WARNING, CAUTION, and NOTE.
Tool Information:
Identifies and illustrates recommended or required special tools by their Iveco Daily 2 special tool numbers.
Completeness:
Aims to be a complete service manual covering all necessary instructions for any repair.
Engine Systems:
Engine mechanical, fuel system, ignition system, lubrication system, cooling system, emission control system, engine overhaul.
Drivetrain Systems:
Transmission (manual and automatic, if applicable), clutch, driveshafts, differentials, axles.
Chassis Systems:
Suspension (front and rear), steering system, braking system (hydraulic, ABS if equipped), wheels and tires.
Electrical Systems:
Wiring diagrams, lighting, starting and charging system, ignition system, instrument cluster, body electricals, power accessories.
Body And Interior:
Body panel removal and installation, interior trim, seats, doors, windows, HVAC system, body diagnostics.
Routine Maintenance:
Oil changes, filter replacements, fluid level checks and top-offs, tire pressure checks, belt inspections.
Diagnostics And Troubleshooting:
Identification of common issues, diagnostic flowcharts, symptom-based troubleshooting guides.
Repair And Overhaul:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Component Specific Instructions:
Instructions for proprietary components as supplied by their manufacturers.
Depth Of Coverage:
Comprehensive; suitable for professional technicians and experienced DIY mechanics.
Engine Variants:
Likely includes various diesel engines (e.g., Sofim engines) and possibly petrol variants, common for the era and model. Specifics depend on regional configurations.
Engine Power Output:
Varies significantly based on engine displacement and configuration. Horsepower typically ranged from approximately 70 HP to 120 HP for diesel variants.
Engine Torque:
Varies by engine, optimized for load-carrying capacity in commercial applications. Specific figures not provided in product info.
Fuel Delivery:
Typically direct injection diesel with mechanical injection pumps, or possibly common rail in later models within the range. Carbureted or injected petrol engines in some variants.
Tune Ups:
Covers procedures for engine tune-ups, including ignition timing, fuel system adjustments, and emissions control.
Transmission Types:
Likely manual transmissions with 5-speed configurations as standard, with potential for 6-speed or automatic options on specific models or as optional equipment.
Optional Transmissions:
Automatic transmissions or higher gear count manual transmissions may have been available as optional equipment.
Clutch System:
Details on clutch operation, adjustment, and replacement procedures for manual transmissions.
Body Styles:
Panel van, chassis cab, minibus, dropside truck, tipper. Various wheelbase options available.
Gross Vehicle Weight:
Gross Vehicle Weight (GVW) ratings varied widely, from light commercial use (e.g., 3.0 tons) to heavier duty applications (e.g., 4.5 tons or more).
Crash Safety:
Vehicle safety standards of the era were less stringent than modern standards. Specific crash test ratings for this generation are not detailed in the product information.
Braking System:
Hydraulic braking system, likely with front disc brakes and rear drum brakes. ABS may have been an option on higher-spec models.
Occupant Protection:
Basic occupant protection features typical of the early to mid-1990s commercial vehicle segment. Likely includes seatbelts.
Audio System:
Basic AM/FM radio, possibly with cassette player. CD players were rare options during this period.
ABS Availability:
Anti-lock Braking System (ABS) was likely an optional feature, not standard across all models.
Connectivity Features:
Minimal to non-existent by modern standards. No integrated Bluetooth, USB, or advanced telematics.
Oil Change Interval:
Typically every 5,000 to 10,000 km or 6 months, depending on operating conditions and engine type. Specific intervals detailed in the manual.
Transmission Fluid Change:
Intervals vary for manual and automatic transmissions, generally between 40,000 to 80,000 km.
Coolant Change Interval:
Typically every 2 to 4 years or a specified mileage, e.g., 50,000 to 100,000 km.
Engine Oil Type:
Likely API CD, CE, or CF specifications for diesel engines, with SAE viscosity grades like 15W-40 or 10W-40. Petrol variants would use different specifications.
Coolant Type:
Typically ethylene glycol-based antifreeze coolant. Specific Ivasco or industry standard may be required.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Points:
Potential for wear in suspension components (bushings, ball joints), exhaust systems, and early diesel injection system components.
Electrical Gremlins:
Age-related issues with wiring harnesses, connectors, and minor electrical components are not uncommon in vehicles of this vintage.
Torque Wrench Necessity:
Essential for ensuring fasteners are tightened to manufacturer specifications to prevent component damage or failure.
Iveco Legacy:
Iveco, an Italian manufacturer, has a long history in commercial vehicles, trucks, and buses, established in 1975 from a merger of FIAT's commercial vehicle divisions.
Daily Lineage:
The Iveco Daily is a long-standing light commercial vehicle platform, known for its robustness and versatility, with the second generation representing a significant update to the original Daily design.
Manufacturing Locations:
Iveco vehicles, including the Daily, have been produced in various plants across Europe and other global locations.
