🏷️ Basic Information

Make:

Iveco

Model:

Daily

Model Years Covered:

1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Platform Code General:

Iveco Daily (Second Generation)

👋 Introduction

Vehicle Segment:

Light Commercial Vehicle (LCV) / Van

Target Audience:

Fleet operators, independent garages, DIY mechanics, and enthusiasts seeking detailed repair and maintenance information for the Iveco Daily.

Manual Value Proposition:

Provides professional-level technical data and procedures, offering significant cost savings compared to dealership service or generic online information. Emphasis on completeness and accuracy for effective repairs.

Manual Features:

High-quality photos, illustrations, and diagrams; comprehensive A-Z coverage of repair procedures; instant digital download; printable format for workshop use; no missing or corrupt pages.

📋 Manual Details

Systems Covered:

Engine Mechanical, Engine Lubrication, Engine Cooling, Engine Control, Fuel System, Exhaust System, Clutch, Manual Transaxle, Automatic Transaxle, Front Axle, Rear Axle, Front Suspension, Rear Suspension, Road Wheels & Tyres, Brake System, Parking Brake, Brake Control System, Power Steering, Steering System, Seat Belts, Supplemental Restraint System (SRS), Body, Lock & Security System, Glasses, Window System & Mirrors, Roof, Exterior & Interior, Instrumental Panel, Seats, Air Conditioner, Wiring Diagrams, Starting & Charging System, Lighting System, Driver Information System, Wiper/Washer/Horn, Body Control System, LAN System, Audio Visual/Navigation/Telephone, Auto Cruise Control, Power Supply/Ground/Circuit Elements, General Maintenance

Procedures Included:

Repair, Maintenance, Rebuild, Refurbish, Restoration, Diagnostics, Troubleshooting

Estimated Page Count:

Extensive (Specific count not provided, but described as '100 percents COMPLETE and INTACT')

Manual Type:

Workshop Repair Service Manual

Language:

English (Implied by description and common industry practice)

Digital Format:

PDF

📖 Manual Coverage

Powertrain Systems:

Engine Mechanical, Lubrication, Cooling, Control Systems (ECU/ECM), Fuel Delivery (including injection), Exhaust Management, Clutch operation and repair, Manual and Automatic Transaxle overhaul and maintenance, Driveline and Axle component service.

Chassis Systems:

Front and Rear Suspension geometry, component replacement, and alignment specifications. Road Wheel and Tire service, including pressure and fitment guidance. Brake System hydraulics, friction components, ABS (if equipped), and parking brake mechanisms. Power Steering and manual Steering system diagnostics and repair.

Electrical Systems:

Comprehensive Wiring Diagrams for various circuits. Starting and Charging system diagnosis and repair. Lighting system service. Driver Information System components. Wiper, Washer, and Horn system functionality. Body Control Modules and associated circuits. LAN (Local Area Network) communication systems. Audio Visual, Navigation, and Telephone integration. Auto Cruise Control operation. Power Supply, Grounding points, and Circuit Protection elements.

Body And Interior Systems:

Body construction, panel repair, lock mechanisms, and security systems. Glass replacement, window regulator and mirror service. Roof panel and sealing. Exterior and Interior trim component removal and installation. Instrument Panel diagnostics and repair. Seat system service and restraint systems (Seat Belts, SRS airbags).

Diagnostic Procedures:

Detailed troubleshooting guides for common and uncommon issues, symptom-based diagnostics, electrical system fault tracing using wiring diagrams, engine performance analysis.

Repair Procedures:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major vehicle systems. Includes torque specifications and critical clearances.

Maintenance Procedures:

Scheduled maintenance tasks, fluid level checks and changes, filter replacements, lubrication points, belt tensioning, and general upkeep recommendations.

Technical Depth:

Comprehensive, covering basic maintenance to advanced engine rebuilds and electrical system diagnostics, mirroring professional technician-level information.

📊 Manual Specifications

File Type:

PDF

Compatibility:

All Versions of Windows, Mac, and Linux (requires PDF Reader)

Print Quality:

High Quality (supporting printability for workshop use)

Binding Type:

Digital Download (No physical binding)

Paper Type:

Not Applicable (Digital format)

⚙️ Engine Specifications

Engine Families Likely Covered:

Iveco 8140 series (e.g., 8140.07, 8140.27, 8140.43 variants), potentially including 2.5L, 2.8L, and 3.0L displacements. Diesel engines are primary.

Power Range Typical:

Approximately 75 HP to 125 HP (depending on specific engine variant and turbocharging).

Torque Range Typical:

Approximately 170 Nm to 280 Nm (depending on specific engine variant).

Fuel Type:

Diesel

Injection System Typical:

Indirect Injection (IDI) and Direct Injection (DI) systems, potentially including early common rail on later models, managed by Electronic Control Units (ECU).

🔧 Transmission

Standard Transmission Type:

Manual Transmission (typically 5-speed or 6-speed)

Optional Transmission Type:

Automatic Transmission (less common in earlier models, but potentially available on later variants)

Transmission Features:

Robust construction for commercial use, rear-wheel drive (RWD) configuration is standard.

📐 Dimensions

Body Styles Available:

Panel Van, Combi Van, Chassis Cab, Dropside, Tipper, Minibus. Multiple wheelbase options.

Typical Wheelbase Range:

Approximately 2,800 mm to 3,500 mm (varies significantly by configuration).

Gross Vehicle Weight Rating Gvw:

Ranges widely, typically from 3.5 to 6.5 tonnes, depending on configuration and market.

🛡️ Safety Features

Safety Ratings Era:

Pre-date modern stringent crash test rating systems like Euro NCAP's current standards. Focus was on occupant protection for the time.

Active Safety Features Typical:

Anti-lock Braking System (ABS) likely optional or standard on higher trims/later models. Power-assisted brakes.

Passive Safety Features Typical:

Seat belts (front), reinforced body structure, potentially airbags on later models as an option. Child seat anchor points (ISOFIX not standard in this era).

💡 Technology Features

Infotainment Features Typical:

Basic AM/FM radio with cassette player, optional CD player on later models. Limited connectivity features for this era.

Driver Assistance Features Typical:

Cruise Control (likely optional), power steering. Advanced driver-assistance systems (ADAS) were not prevalent in this generation.

Connectivity Features Typical:

Limited to basic wiring for optional radio/cassette systems. No Bluetooth or advanced telematics.

🔧 Maintenance

Oil Change Interval Typical Diesel:

Approximately 10,000 km to 15,000 km or annually, depending on operating conditions and oil type specified in the manual.

Air Filter Replacement Interval:

Typically every 20,000 km to 30,000 km, or more frequently in dusty conditions.

Fuel Filter Replacement Interval:

Usually every 30,000 km to 40,000 km, critical for diesel fuel system longevity.

Engine Oil Specification Typical:

API CG-4 or CH-4, ACEA E2/E3. Viscosity grade likely 10W-40 or 15W-40 (specific grade depends on ambient temperature and engine variant - check manual).

Coolant Specification:

Ethylene glycol based antifreeze, meeting Iveco's specific OAT (Organic Acid Technology) or HOAT (Hybrid OAT) requirements, often with a green or blue color. Dilution ratio of 50/50 with distilled water is standard.

Brake Fluid Specification:

DOT 3 or DOT 4 (check manual for precise specification for ABS equipped vehicles).

Common Wear Items:

Clutch wear, suspension bushings and ball joints, brake component wear (pads, discs), exhaust system corrosion, glow plug failure (diesel), starter motor and alternator reliability can be an issue in high mileage vehicles.

Electrical Gremlins:

As with many vehicles of this era, intermittent electrical issues can arise due to aging wiring harnesses, corrosion in connectors, and failing relays or switches. Wiper motors, lighting circuits, and dashboard warning lights are common areas.

Diesel Engine Specifics:

Injection pump and injector reliability, turbocharger seals, and diesel particulate build-up can be issues if maintenance is neglected or driving conditions are consistently short-trip focused.

📚 Vehicle History

Iveco Heritage:

Iveco (Industrial Vehicles Corporation) is an Italian company formed in 1975, a merger of FIAT's commercial vehicle divisions and other European manufacturers. Known for robust and durable commercial vehicles.

Iveco Daily Evolution:

The 1990-2003 period covers the second generation of the Iveco Daily, launched in 1990. This generation introduced significant updates in design, comfort, and engine technology over its predecessor. It was produced until 2006, when it was replaced by the third generation.

Production Locations:

Primarily manufactured in Italy (e.g., Suzzara plant), with potential assembly in other global locations for specific markets.

🏆 Awards & Recognition

Model Recognitions:

While specific awards for this generation might be scarce in public records, the Iveco Daily has a long-standing reputation in the commercial vehicle sector for durability, reliability, and versatility, often earning it high marks for total cost of ownership in fleet management contexts.