Iveco Turbodaily - Repair, Service and Maintenance Manual

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IVECO TURBODAILY - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual, to vehicles Iveco Turbodaily.

 
CONTENTS:

1-GENERAL
Composition of the models
Filling up
Vehicle identification data
2-ENGINE
General characteristics
Data on assembly clearances
Tightening torque
Tools
4x2 vehicles removing-refitting the engine
Oxicat - oxidizing catalyst
Dismantling the engine on the bench
Repair operations
- Cylinder block
- Crankshaft
- Engine fitting
- Flywheel
- Piston-connecting rod
- Flywheel timing
- Cylinder heads
- Valve tappet
- Valves
- Valve seats
- Precombustion chambers
- Glow plugs
- Valve springs
- Fitting cylinder heads
- Accessory equipments group
- Oil pressure control valve
- Oil pump
- Heat exchanger
- Lubrication
- Oil vapours full recirculadon system (blow-by)
- Cooling
- Belt-driven timing system
- Chain-drive timing system
- Hydraulic chain tightener
- Injection pump assembling and timing
- Adjustment of water pump and alternatordriving belt tension
- Supercharging
- Feeding
- Injection pump test values.
- (ksb)
- Feed pump
- Injectors
3-CLUTCH
Description
Diagnostics
Characteristics and data
Tightening torques
Removal and refitting ofclutch
Removal-refitting of col•lar bearing
Clutch release
Adjustment of clutch pedal height
4-TRANSMISION
General
Specifications and data
Diagnostics
Tightening torques
Tightening torques (4x4 vehicles)
Tools
Transmission removal and re-fitting
Gearbox disassembly
Speed control lever support
Power take-offs
Specificaton data
5-REDUCTION GEAR UNIT
Description
Characteristics and data
Diagnostics
Speed indicator control unit
Reduction gear unit external drive
Reduction gear unit tie-rod regulation
Transfer case removauinstallation
Tightening torques
Tools
Disassembly
Inspections and checks
Assembly
6-PROP SHAFTS
Characteristics and data
4x2 vehicles
4x4 vehicles
Diagnostics
Tightening torques
Tools
Removal and refitting of propeller shaft
Checking the propeller shafts onthe vehicle
7-REAR AXLES
Diagnostics
Removal-refitting of rearaxle
Rear axles:450211 (r0407)-45021111 (r0407) -450311 (r0417)
- Description
- Characteristics and data
- Tightening torques
- Special tools
- Complete overhaul of rear axle
- Differential repair 9perations
Rear axles:45021112 (r0407)-450311/1 (r0417)-450411/1 (r0427)
- Description
- Characteristics and data
- Tightening torques
- Special tools
- Complete overhaul of rearaxle
Rear axle:450212 (r0407)
- Description
- Characteristics and data
- Special tools
- Tightening torques
- Complete overhaul of rearaxle
Rear axle 450517 (r0437)
Description
Characteristics and data
Tightening torques
Special tools
Complete overhaul of rearaxle
8-FRONT AXLES
Axles driving axle
Diagnostics
Description
Axle 5811
- Specification and data
- Tightening torques
- Axle 5811 overhauling
Axle 5812
- Specifications and data
- Tightening torques
- Axle 5812 overhauling
Axle 5811/2
- Specification and data
- Tightening torques
- Axle 5811112 overhauling
Driving axle 5912
- Description
- Specifications and data
- Tightening torques
- Tools
- Driving axle removauinstallation
- Driving axle overhauling
Wheel geometry
- Description
- Specifications and data
- Tightening torques
- Tools
- Check of typical angles
9-SUSPENSION
Diagnostics
Front suspensions
- Description
- Specifications and data
- Tightening torques
- Suspensions overhaul
- Torsion bar pre-loading adjustment
- Front shock absorbers
Rear suspensions
- Description
- Specifications and data
- Tightening torques
- Rear leaf spring
- Repair operations
- Shock absorbers
10-WHEELS AND TYRES
Description
Fault diagnosis
Static balancing of the wheels
Tyre pressure
How' tyre behaviour depends onpressure
Specifications and data
11-STEERING
Steering geargeneral
Specifications and data
Specifications and data hydraulic power steering
Tightening torques
Diagnostics
Hydraulic power steering
Trw-type hydraulic power steering
Zf-type hydraulic power steering
Removing and re-fitting the steering control assembly
Removing and re-fitting the hydraulic power steering assembly
Checks and operations on. Thevehicle
Hydraulic power steering pump
12-HYDRAULIC SYSTEM (BRAKES)
Graphic symbols
Pipes and couplings
Braking system
- Wiring diagram
- Wiring diagram for vehicles fitted with rear drum brakes and mechanical or pneumatic suspension
- Wiring diagram for vehicles fitted w.ith rear drum brakes, mechanical suspension and abs
- Wiring diagram for vehicles fitted with rear drum brakes, pneumatic suspension and abs
- Wiring diagram for vehicles fitted with rear disc brakes and mechanical or pneumatic suspension
- Wiring diagram for vehicles fitted with rear disk brakes, mechanical suspension and abs
- Wiring diagram for vehicles fitted with rear disk brakes, pneumatic suspension and ass
- Main componets
- Abs system main components layout
- Braking proportioning valve layout for vehicles fitted with rear pneumatic suspension
- Description service brake
- Diagnostics
- Tightening torques
- Equipment
- Specifications and data - hydraulic system
- Specifications and data - brakes
- Checks
- Braking system main components
- Air bleed-off from hydraulic circuit
- Mechanical operated loadproportioning valve
- Pneumatic operated loadproportioning valve
- Control valve
- Abs wheel anti-lock device
- Brake repair operations
- Overhaul of brake calipers
- Overhaul of brake discs
- Rear disc brakes (2x44 brembo calipers)
- Rear drum brakes
13-BODY AND CHASSIS
Tightening torques
Door adjustment
- Cab doors
- Side sliding door
- Rear door
Swing-sliding door opening device semiglazed door
- Fault diagnosis
- Swing-sliding door removal i installation
- Adjusting door position
- Gearmotor removal i installation
- Adjusting gearmotor control devices
Swing-sliding door opening deviceswing-door
- Electrical checks
- Fault diagnosis
- Swing door removal i installation
- Adjusting lower tie bar
- Gearmotor removal i installation
- Adjusting door position
- Adjusting gearmotor control devicess
14-MAINTENANCE
Maintenance service table
Maintenance operationsservice mi
Service m 12 - end of warranty coupon
15-1ST REVISION
Engine 8140.63.37
- General characteristics
- Gaseous emissions
- Data on assembly clearances
- Tools
- Tightening torques
- Repair operations
- Assembling and tensioning the timing gear drive belt
Injection pumps:ve4/1 of 1900r808ve4/1 of 1900r808-1
- Injection pump test values
New daily k
- Description
- Electrical power take-off engagement control device
- Power take-off
- Characteristics and data
- Oil gear pump
- Characteristics and data
- Hydraulic distributor
- Characteristics and data
- Audible warning device sensor
- Telescopic oil-driven hydraulic cylinder
- Rear suspensionrear leaf spring