Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Chassis Code:
Commonly referred to as the '3rd Generation Daily' or 'Iveco Daily 3'
Vehicle Class:
Light commercial vehicle (LCV), known for its versatility, durability, and payload capacity.
Key Competitors:
Ford Transit, Mercedes-Benz Sprinter, Fiat Ducato, Renault Master, Peugeot Boxer, Citroën Jumper.
Vehicle Strengths:
Robust chassis, wide range of body styles, efficient engines (for its class), excellent load-carrying capacity, and long service life. Popular for courier services, tradespeople, and specialized applications.
User Benefit:
Empowers owners and technicians to perform maintenance and repairs efficiently, saving time and money while ensuring the longevity and optimal performance of the Iveco Daily 3.
Systems Covered:
General Information, Engine Systems, Clutch, Transmission, Propeller Shafts, Rear Axles, Front/Rear Axles, Suspensions, Wheels and Tyres, Steering Gear, Hydro-pneumatic Systems, Brakes, Bodywork, Chassis Frame, Cab Interior, Air Conditioning, Scheduled Maintenance, Electrical/Electronic Systems
Estimated Page Count:
Estimated to be substantial, typical for a full factory service manual covering multiple aspects of the vehicle. Actual page count not explicitly stated, but implied to be comprehensive.
Type:
Service Repair Workshop Manual
Compatibility:
All Versions of Windows & Mac
Requirements:
Adobe PDF Reader & WinZip
Printability:
All pages are printable
Powertrain:
Detailed coverage of engine components, clutch operation and adjustment, manual and automatic transmission systems, propeller shafts, and rear axle assemblies.
Chassis And Suspension:
Comprehensive information on front and rear axle configurations, suspension components (springs, shock absorbers, linkages), wheel bearings, and tyre specifications.
Steering And Brakes:
In-depth details on steering gear mechanisms, hydraulic systems, brake system components (pads, discs, lines, master cylinder), and hydro-pneumatic system operation if applicable to specific models.
Body And Interior:
Coverage includes bodywork repairs, chassis frame integrity, cab interior trim, and air conditioning system maintenance and repair.
Electrical And Electronics:
Extensive documentation on the vehicle's electrical system, including wiring diagrams, component testing, diagnostic procedures, and electronic control unit (ECU) information.
Diagnostic Procedures:
Includes troubleshooting guides, symptom-based diagnostics, and procedures for identifying and rectifying common faults across all major systems.
Repair Procedures:
Step-by-step instructions for component removal, installation, overhaul, and adjustment, covering everything from minor repairs to major overhauls.
Maintenance Procedures:
Detailed guidance on routine maintenance tasks, including fluid changes, filter replacements, lubrication, and inspections, aligned with manufacturer's recommended intervals.
Depth Of Coverage:
This is a comprehensive factory-level service manual, offering in-depth technical data, specifications, and diagnostic procedures suitable for professional technicians and experienced DIY mechanics. It covers everything from basic checks to complete overhauls.
Format Details:
Digital document in PDF format, ensuring wide accessibility and easy navigation. Designed for both on-screen viewing and printing.
Print Quality Attributes:
High-quality diagrams and clear, readable text ensure accuracy and ease of use during repairs. Printable format allows for physical reference.
Binding Type Digital:
N/A (Digital PDF format)
Paper Type Digital:
N/A (Digital PDF format)
Engine Family:
Iveco's range of diesel engines. Common engines for this generation include the Sofim-derived engines (e.g., 2.8L, 2.3L) and potentially later common rail diesel variants.
Engine Displacement And Power:
Various diesel engines were offered, typically ranging from 2.3L to 2.8L, with power outputs varying from approximately 80 hp to 130 hp depending on the specific engine and turbocharging. (Specifics vary by market and exact model year).
Torque Output:
Torque figures would also vary by engine variant, generally providing strong low-end torque suitable for commercial applications.
Fuel Delivery:
Primarily direct injection diesel engines, with common rail technology becoming more prevalent in later models within this generation. Fuel pumps, injectors, and filtration are key components.
Key Maintenance Items:
Oil and filter changes, fuel filter replacement, air filter replacement, coolant checks, glow plug inspection/replacement, and belt inspections/replacements.
Gearbox Type:
Predominantly manual transmissions (5-speed or 6-speed) were standard across most variants. Heavy-duty versions might have featured more robust gearboxes.
Optional Gearbox:
Some models or specific configurations may have offered an automated manual transmission (AMT) or a torque converter automatic transmission, though less common than manual units.
Transmission Oil:
Specific gearbox oil specifications (e.g., API GL-4 or GL-5, viscosity grades like 75W-90) would be detailed in the manual. Gearbox fluid change intervals are critical.
Body Styles:
Van, Panel Van, Chassis Cab, Dropside, Tipper, Minibus, and specialized body conversions. Wheelbase and overall length varied significantly based on configuration.
Gross Vehicle Weight Rating:
GVWRs varied widely, typically ranging from 3.0 tonnes to 7.0 tonnes or more, depending on the chassis and axle ratings. (Specific figures require model year and variant details).
Payload Capacity:
Designed for significant payload capacity, often exceeding 1 tonne and reaching up to 3 tonnes or more for heavier variants.
Crash Test Ratings:
As a commercial vehicle, specific Euro NCAP or NHTSA ratings might not be as prominently published as for passenger cars. However, safety features were progressively improved during this generation.
Driver Assistance Features:
Depending on trim level and year, could include ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution). Traction control might have been available on some higher-spec models.
Restraint Systems:
Seatbelts, particularly for the driver and front passenger. Airbags were increasingly standard, especially for the driver, in later models.
Audio Systems:
Base models would feature simple AM/FM radios, possibly with CD players. Higher trims might offer upgraded audio systems, potentially with auxiliary inputs or basic digital displays.
Instrument Cluster:
Features a comprehensive instrument cluster with analog gauges for speed, RPM, fuel level, and engine temperature, along with warning lights and an odometer. Some might include basic trip computers.
Electrical Features:
Basic electrical features would include power windows (on some trims), central locking (optional or standard), and exterior lighting. The manual covers the diagnostic and repair of these systems.
Oil Change Interval:
Typically between 10,000 km and 20,000 km, or annually, depending on operating conditions. The manual will provide precise intervals for each engine variant and service type.
Other Intervals:
Includes intervals for timing belt/chain inspection/replacement (if applicable), coolant changes, brake fluid changes, and other fluid and filter replacements. Specific intervals are crucial.
Engine Oil Type:
Diesel engine oils meeting specific ACEA specifications (e.g., ACEA E3, E5, E7, B3, B4 depending on engine) and viscosity grades (e.g., 10W-40, 15W-40). The manual will specify the exact grade and API rating.
Coolant Type:
Ethylene glycol-based antifreeze coolant, typically meeting OAT (Organic Acid Technology) or HOAT (Hybrid Organic Acid Technology) specifications. Color and type are critical.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid, depending on the system's requirements. Hygroscopic nature necessitates regular replacement.
Common Wear Items:
Common wear items include suspension bushings, brake components (pads, discs), clutch wear, exhaust systems, and potentially turbocharger issues on higher-mileage vehicles. Electrical connectors can also be a point of concern.
Engine Specific Notes:
Early Sofim engines may require attention to timing components and fuel injection system reliability. Regular servicing is key to mitigating these.
Iveco History:
Iveco (Industrial Vehicles Corporation) is an Italian brand with a long history in commercial and industrial vehicles, known for robust engineering and practical designs.
Daily Evolution:
The Iveco Daily has been in continuous production since 1978, evolving through several generations. The 'Daily 3' represents a significant update, refining the platform and introducing newer technologies and powertrains compared to earlier models.
Manufacturing Locations:
Primarily manufactured by Iveco in Italy, with potential production or assembly plants in other global locations depending on market.
