Iveco Daily 29L–65C 2004–2005 Repair Manual

The Iveco Daily factory repair manual, Print 603.93.281, covers the 29L–65C range, including chassis cabs, vans, and listed bus derivatives. This is the May 2004 first edition with integrated February 2005 revised pages marked 603.93.281/A.

Text Search, Bookmarks, and Wiring Detail

Search and diagram access: Main chapter text is searchable, and embedded bookmarks provide chapter and topic navigation. Search does not consistently locate labels within circuit drawings. Small wiring labels require zooming.

One printable PDF contains 1,898 pages, including the cover, publication page, and 12 preliminary pages. The revised pages are integrated into this file.

Diesel Overhaul, Gearbox Work, and Electrical Diagnosis

These selected workshop topics provide an overview of the coverage. Other subjects include oil/vacuum-pump assembly service and passenger-compartment heating and ventilation.

• Engine repair: Engine removal, cylinder-head work, timing-drive replacement, and full bench overhaul, with crankshaft, piston, and valve inspection.

• Clutch and transmission: Clutch repair, manual-gearbox overhaul, 6 AS 300 VD actuator and control-unit replacement and calibration, plus PTO service.

• Axles and driveline: Front axles 5817, 5818, 5819, and 5823; rear-axle and differential overhaul, hub repair, and propeller-shaft checks.

• Suspension and steering: Leaf-spring and torsion-bar suspensions, WABCO ECAS and VB-Techniek rear air suspension, wheel geometry, and ZF/TRW power-steering tests and service.

• Brakes and stability control: Brake circuit layouts, caliper, disc, and parking-brake repair, ABS/EBD/ABD and ABS 8/ESP 8 diagnosis, bleeding, programming, and calibration.

• Climate control: R134a recovery, evacuation, charging, leak detection, and pressure checks for Marelli and Denso equipment, plus Marelli electrical fault codes and mechanical troubleshooting charts.

• Electrical diagnosis: Harness layouts, connectors, pinouts, grounds, immobilizer and cruise-control circuits, PTO, Telma retarder, and fitted electrical options.

Written for qualified, specialized personnel, this manual assumes access to the specified Iveco tools and diagnostic equipment, including MODUS, IT 2000, and E.A.SY.

Match the Daily by Its Installed Assemblies

Model-composition and identification tables help a workshop select the applicable component data and repair procedures by matching the engine, transmission, axles, suspension, and electrical configuration. Check those assemblies before purchase: May 2004 and February 2005 identify the publication and revision dates.

Bodywork coverage: Bodywork and chassis-frame repairs are assigned to separate publication 603.43.606. This manual’s Section 12 covers cab air conditioning and related component procedures; airbag and pretensioner information appears in the steering and electrical material.

Engine Builds and Fuel-System Diagnosis

The 8140 material separates the 8140.43R/B/S/N electronic high-pressure injection engines from the 8140.43C and 8140.63 rotary mechanical-pump versions. The F1A and F1C chapters extend through complete engine overhaul, Common Rail component testing, ECU-controlled injection, and fixed- and variable-geometry turbocharging, with EGR coverage where fitted.

The engine chapters also cover turbocharger service, cooling and lubrication work, and injector and mechanical injection-pump replacement.

Troubleshooting uses stored codes and symptom charts. The MS6.3 blink-code tables identify the earlier button-operated diagnosis system, while the EDC 16 material calls for diagnostic instruments.

Common Rail repair cautions address single-use high-pressure pipes and prohibit dismantling injector nozzle bodies or electromagnets; contamination and disturbed fittings can damage calibrated components or compromise sealing.

Gearbox Repair and Final-Drive Setup

Step-by-step overhaul procedures cover the 5 S 200/270/300, 6 S 300, and 6 S 380 O.D. manual units, including shafts, gears, bearings, synchronizers, selectors, and end-float checks.

For the electro-mechanical 6 AS 300 VD, procedures cover the control unit, clutch actuator, gearbox actuator, and wiring, followed by the applicable diagnostic calibration. Internal gearbox overhaul is excluded: the repair section directs the complete assembly to a ZF service center.

Rear-axle sections cover 450210, 450311/1, 450511, 450517/2, and 450310, with differential-lock adjustment, pinion depth, bearing rolling torque, backlash, and tooth-contact checks. Ring gear and pinion are treated as matched replacement pairs; the section views illustrate correct and incorrect contact patterns.

Air Suspension, Steering, and Electronic Brakes

WABCO ECAS material is organized for 29L/35S vehicles, while VB-Techniek sections address the listed 35C–65C applications.

Steering scope: Rack-and-pinion service is limited to ball joints, protective boots, linkages, and bushings, with replacement of a faulty steering unit. The power-steering pump has a separate overhaul procedure.

ABS/ESP procedures distinguish steering-angle, yaw, and longitudinal-acceleration sensor calibration from modulator programming.

Circuit Charts, Tools, and Maintenance Data

The electrical index runs from Chart 1A through Chart 58. Examples include EDC 16 EGR/exhaust-gas control, WABCO ECAS and VB-Techniek suspension schematics, airbag and pretensioner wiring, ABS 8/ESP 8 charts, and the 6 AS 300 VD transmission circuit.

Factory tool lists identify timing tool 99360608, transmission support 99370629, brake/clutch bleeding equipment 99306010, and R134a recovery/refilling station 99305146.

Related chapters supply torque tables, assembly clearances, wear limits, fluid capacities, pressure-test values, sensor/actuator specifications, pin data, and fault-code tables. Separate maintenance schedules cover 8140-, F1A-, and F1C-powered vehicles.

Engine, transmission, axle, brake, refrigerant, and high-pressure fuel work requires suitable lifting and test equipment. Follow the manual’s isolation, cleanliness, support, and final-check procedures for the exact vehicle configuration.

A Preview of Rear-Axle Adjustment Data

For rear axle 450517/2, the pinion-to-crown-wheel backlash specification is 0.15–0.20 mm.

The same axle’s pinion-bearing rolling-torque specification is 2–3 Nm for new bearings, with bearings and seals lubricated. These values accompany the axle-specific adjustment-ring data and differential setup procedures.