Iveco Daily (2000-2006) - Repair, Service and Maintenance Manual

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IVECO DAILY - REPAIR MANUAL - SERVICE MANUAL

- English Service Manual to vehicles Iveco Daily.
 

INDEX:


SECTION 1 - GENERAL
- General
- Identification Data
- Vehicle Identification Plate
- Composition Of Models
- Alphanumerical Coding For Vehicle Identification
- Alphanumerical Coding For Bus Identification
- Replenishing Fluids

SECTION 2 - ENGINES
- Engines
- engines 8140.xxx
- main servicing operations to be performed on vehicle engine
- engine removal-refitting
- removal (engine 8140.43b/r/s)
- removal (engine 8140.43c - 8140.63)
- refitting
- checks and tests
- bleending the fuel system
- power steering system air bleed
- oxicat - oxydizer catalyst (vehicles with 8140.43c - 8140.63 engines)
- description
- cylinder head removal and refitting
- removal
- refitting
- replacing belts
- replacing air-conditioning compres- sor drive belt
- disassembly
- assembly and adjusting belt tension
- replacing water pump - alternator drive belt
- disassembly
- assembly and adjusting belt tension
- changing the timing system driving belt
- disassembly
- removal
- refitting
- replacing water pump
- disassembly
- assembly
- replacing injectors (engine 8140.63 - 8140.43c)
- disassembly
- assembly
- replacing injection pump
- disassembly
- assembly and injection pump adjustment
- engine flywheel removal-refitting
- removal
- refitting
- removal
- refitting
- engines with electronic high-pressure injection system
- emissions values
- engine 8140.43r.43xx/44xx
- engine 8140.43b.43xx/44xx
- engine 8140.43s.41..
- engine 8140.43s.43xx/44xx
- engine 8140.43n.43xx/44xx
- general specifications
- assembly data - clearances
- tightening torques
- tools
- overhauling engine
- disassembling the engine at the bench
- repair operations
- cylinder block
- checks and measurements
- checking head mating surface on cylinder block
- spare cylinder barrel assembling
- crankshaft
- measuring main journals and connecting rods
- checking crankshaft
- replacing gearbox input shaft centering ring
- replacing timing control gear
- engine assembly
- assembling main bearings
- measuring main journals assembly clearances
- checking crankshaft end float
- checking alignment pulley crankshaft
- rear crankshaft cover
- front crankshaft cover
- engine flywheel
- replacing bearing supporting gearbox input shaft
- replacing engine flywheel ring gear
- connecting rod - pistonas- sembly
- pistons
- measuring the pistons diameter
- piston gudgeon pins
- conditions for correct pin-piston coupling
- piston rings
- connecting rods
- bushes
- checking connecting rod for distortion
- checking torsion
- checking bending

- assembling connecting rod - piston assembly
- coupling connecting rod - pistons
- checking for connecting rod - piston distortion
- assembling piston rings
- assembling connecting rod - piston assemblies in cylinder barrels
- measuring connecting rod assembly clearance
- checking piston protrusion
- flywheel adjustment
- cylinder heads
- disassembling camshaft
- checks
- checking cam lift and journal alignment
- valve tappet
- disassembling valves
- checking cylinder head seal
- checking cylinder head mating surface
- valves
- removing deposits, refacing and checking valves
- checking clearance between valve stem and valve guide and centring valves
- valve guides
- replacing valve guides
- reaming valve guides
- valve seats
- regrinding and replacing valve seats
- valve springs
- assembling cylinder heads
- assembling valves
- assembling tappets
- assembling camshaft
- adjusting tappet clearance
- refitting cylinder head
- auxiliary member assembly
- disassembling auxiliary member assembly
- oil pressure control valve
- oil pump
- assembling auxiliary member assembly
- 6-element heat exchanger
- lubrication
- general
- oil vapour recycling system
- cooling
- description
- operation
- electromagnetic pulley
- water pump
- thermostat
- timing and auxiliary member control
- setting the timing system
- checking and aligning electromagnetic coupling pulleys
- checking alternator pulley alignment
- checking compressor pulley alignment
- adjusting alternator - water pump drive belt tension
- adjusting compressor - air-conditioner drive belt tension
- timing system speed sensor
- engine speed sensor
- supercharging
- description
- turbocharger
- repairs
- pressure relief valve
- checking and adjusting the pressure relief valve
- changing the pressure relief valve
- garret gt 2256 t variable geometry turbosupercharger
- general
- operation at low engine rpm
- operation at high engine rpm
- proportional solenoid valve controlling turbocharger actuator
- actuator
- repairs
- checking the actuator
- fuel supply
- high-pressure electronic injection system (common rail ms 6.3 or edc.16)
- general
- system operation
- self-diagnosis - blink code
- immobilizer recognition
- checking fuel temperature
- checking engine coolant temperature
- checking quantity of fuel injected
- checking idling adjustment
- fuel cut-off in release phase
- checking cylinder balancing on idling
- checking regulator engine rotation (anti-sawing)
- checking smokiness at exhaust on acceleration
- checking exhaust gas recirculation (e.g.r. If present)
- checking top speed limit
- checking rotation regularity during acceleration
- checking thermostart
- checking activation of air-conditioning system
- checking fuel pump
- checking diesel warming
- checking cylinder position
- checking pilot and main injection timing
- checking injection pressure closed cycle
- fuel supply
- correcting flow rate according to water temperature
- correcting flow rate to avoid noise, smoke or overloading
- de-rating
- adjusting turbine speed (for variable geometry turbocharger - when present)
- injection timing electronic test
- speed governor
- engine starting
- cold starting
- warm starting
- run up
- after run
- cut-off
- cylinder balancing
- synchronization search
- operation
- hydraulic system
- fuel pump
- specifications
- fuel filter
- tightening torques
- fuel pipes
- high-pressure pump
- 3rd pumping element exclusion device
- pressure regulator
- hydraulic accumulator (rail)
- flow limiters
- pressure relief valve
- fuel recirculation and supply system
- electro-injectors
- operation
- electric/electronic components
- electronic control unit ms6.3 or edc 16
- sensors
- engine speed sensor
- camshaft timing sensor
- air temperature and pressure sensor
- fuel temperature sensor
- fuel pressure sensor
- atmospheric pressure sensor
- engine coolant temperature sensor
- throttle pedal position sensor
- clutch pedal position sensor
- brake pedal position sensor
- vehicle speed sensor
- actuators
- pwm (pulse width modulation) controls
- exhaust gas recirculation system e.g.r. (vehicles with homologation mi)
- guide to troubleshooting
- engines with rotary mechanical injection pump
- troubleshooting
- engine 8140.43c.43xx
- gas emissions
- smokiness
- noise emissions
- general specifications
- assembly data - clearances
- tightening torque
- tools
- engine overhaul
- dismantling engine on bench
- cylinder head
- engine assembling at the bench
- setting the timing system
- injection pump assembling and timing
- cooling
- feeding
- injection pump test values
- cold injection advance automatic device (ksb) [kalt start betriebseinrichtung]
- description
- operation
- engine 8140.63.40xx
- emissions values
- gas emissions
- smokiness
- noise emissions
- general specifications
- assembly data - clearances
- tightening torques
- tools
- 8140.63 engine overhaul
- disassembly engine on bench
- pistons - pins - snap rings
- assembling connecting rod-piston assembly
- fitting connecting rods-pistons
- cylinder heads
- camshaft
- checking cam lift and journal alignment
- checking cylinder head mating surface
- precombustion chambers
- disassembly
- assembly
- glow plugs
- disassembly
- checking glow plugs continuity
- assembly
- lubrication
- heat exchanger
- oil vapour full recirculation system (blow-by)
- cooling system
- thermostat
- exhaust gas recirculation system e.g.r.
- general information
- operation
- modulating solenoid valve
- potentiometer on injection pump lever
- engine rpm sensor
- engine coolant temperature sensor
- absolute pressure sensor
- vacuum sensor
- electronic control unit
- operation logics
- air conditioner interface operation logic
- pre-post heating operating logic
- engine cooling fan operating logic
- ksb operating logic
- feeding
- injection pump test values
- f1a engine
- main operations on engine mounted on vehicle
- engine removal-refitting
- removal
- refitting
- checks and tests
- power steering system air bleed
- replacing belts
- replacing air-conditioning compressor drive belt (version with belt tensioner)
- disassembly
- assembly and adjusting belt tension
- replacing air-conditioning compressor drive belt (version with elastic belt)
- disassembly
- assembly
- power steering pump-alternator belt replacement
- disassembly
- assembly
- replacing timing drive belt
- disassembly
- assembly
- replacing electro-injectors
- disassembly
- assembly
- cylinder head removal and refitting
- removal
- refitting
- replacing high-pressure pump cp3
- removal
- refitting
- replacingwater pump
- removal
- refitting
- emissions
- engine identification code
- characteristic curves
- general specifications
- assembly data - clearances
- tools
- experimental tools
- tightening torque
- overhauling engine f1a
- disassembling the engine at the bench
- repairs
- cylinder block
- checks and measurements
- checking head mating surface on cylinder block
- crankshaft
- measuring main journals and crank pins
- checking crankshaft
- replacing timing control gear
- engine assembly
- assembling main bearings
- measuring main journal assembly clearance
- checking crankshaft end float
- assembling rear seal
- engine flywheel
- replacing bearing supporting gear- box input shaft
- connecting rod - piston assembly
- pistons
- measuring piston diameter
- piston pins
- conditions for correct pin-piston coupling
- piston rings
- connecting rods
- bushes
- checking connecting rods
- checking torsion
- checking bending
- assembling connecting rod-piston assembly
- checking for connecting rod - piston distortion
- assembling piston rings
- assembling connecting rod - piston assemblies in cylinder barrels
- measuring crankpin assembly clearance
- checking piston protrusion
- cylinder head
- disassembly
- removing valves
- checking cylinder head seal
- checking cylinder head mating surface
- valves
- removing deposits, refacing and checking valves
- checking clearance between valve stem and valve guide and centring valves
- valve guides
- replacing valve guides
- boring valve guides
- valve seats
- regrinding - replacing valve seats
- valve springs
- rocker arms - tappets
- checks
- assembling cylinder heads
- overhead
- overhead removal
- timing system
- description
- camshaft
- checks
- checking cam lift and pin alignment
- assembling overhead
- assembling front seal ring
- refitting cylinder head
- adjusting air-conditioner - compressor drive belt tension
- timing speed sensor
- engine speed sensor
- lubrication
- general
- oil vacuum pump assembly (gpod)
- oil pump
- characteristic data
- vacuum pump
- oil pressure control valve
- oil filter
- modine heat exchanger
- oil vapour recirculation system
- description
- cooling
- description
- operation
- electromagnetic pulley
- water pump
- thermostat
- turbocharging
- description
- turbocharger
- repairs
- pressure relief valve
- checking and adjusting pressure relief valve
- replacing pressure relief valve
- exhaust gas recirculation (egr) system
- egr system operation
- operating principles
- air flow meter
- fuel supply
- high-pressure electronic injection system (ms 6.3 - edc 16)
- general
- system operation
- self-diagnosis - blink code
- immobilizer recognition
- checking fuel temperature
- checking engine coolant temperature
- checking quantity of fuel injected
- checking idling adjustment
- fuel cut-off in release phase
- checking cylinder balancing on idling
- checking regular engine rotation (anti-sawing)
- checking smokiness at exhaust on acceleration
- checking exhaust gas recirculation (e.g.r. If present)
- checking top speed limit
- checking regular rotation on acceleration
- checking glow plug control unit
- checking activation of air-conditioning system
- checking fuel pump
- checking diesel warming
- checking cylinder position
- checking pilot and main injection timing
- checking injection pressure closed cycle
- fuel supply
- correcting flow rate according to water temperature
- correcting flow rate to avoid noise, smoke or overloading
- de-rating
- injection timing electronic test
- speed governor
- engine starting
- cold starting
- warm starting
- run up
- after run
- cut-off
- cylinder balancing
- synchronization search
- operation
- hydraulic system
- fuel pump
- specifications
- fuel filter
- tightening torques
- fuel pipes
- high-pressure pump
- high-pressure pump internal structure
- working principle
- pressure control valve
- replacing pressure regulator
- mechanical supply pump
- hydraulic accumulator (rail)
- overpressure valve (for forged hydraulic accumulator)
- electro-injectors
- operation
- electric/electronic components
- electronic control unit ms6.3 or edc 16
- glow plug electronic control unit
- glow plugs
- sensors
- engine speed sensor
- camshaft timing sensor
- air temperature and pressure sensor
- fuel temperature sensor
- fuel pressure sensor
- atmospheric pressure sensor
- engine coolant temperature sensor
- throttle pedal position sensor
- clutch pedal position sensor
- brake pedal position sensor
- vehicle speed sensor
- actuators
- pwm (pulsewidth modulation) controls

- guide to troubleshooting
- f1c engine
- main operations on engine mounted on vehicle
- engine removal-refitting
- removal
- refitting
- checks and tests
- power steering system air bleed
- replacing air-conditioning compressor drive belt (version with belt tensioner)
- disassembly
- assembly
- power steering pump-alternator belt replacement
- disassembly
- assembly

AND MORE....