1992–1997 IVECO Daily Workshop Manual for TURBODAILY 4x4 (P/N 603.42.951)

• Document identity and revision coverage: 598-page PDF containing the IVECO-edited workshop publication P/N 603.42.951, 2nd Edition 1997, together with P/N 603.42.951A, 1st Revision 04/1998 and its six-digit repair-operation coding system.
• Vehicle and configuration identification: P.I.C. charts for 4x2 vehicles, 40.10 W 4x4 models, and motor-bus builds, covering body version, wheelbase, left- or right-hand drive, market code, engine installation, and rear-suspension configuration.
• 8140-series engine repair: Covers the 8140.67.F37, 8140.23.37, 8140.23.38, 8140.43.37, 8140.47R.2790, and revised 8140.63.37 engines, with removal/refitting, internal inspection, cylinder-head work, belt- and chain-driven timing, injection-pump timing, system bleeding, lubrication, and turbocharger service.
• Clutch, transmission, and 4x4 driveline: Includes clutch fault diagnosis and replacement, 2826.5 five-speed gearbox disassembly and reassembly, synchronizer and bearing work, shaft-end-play adjustment, power take-off coverage, Borg-Warner 1356 transfer/reduction-unit overhaul, and propeller-shaft checks.
• Axles, steering, suspension, and brakes: Details RO407/RO417/RO427/RO437 rear axles, 5811/5812/5811/2 front axles, the 5912 driving axle, wheel geometry, differential and hub repair, torsion-bar and leaf-spring suspension, TRW and ZF power steering, disc/drum brakes, ABS, bleeding, and load-proportioning systems.
• Drawings, tools, and 1998 additions: Provides component sections, exploded views, configuration-specific brake circuits, powered-door controls, 993-series special-tool references, torque and inspection tables, and New Daily K electric PTO and hydraulic body-dumping material.

Model and Build Identification

Coverage is organized by IVECO P.I.C. code and installed component build rather than by a blanket model-year statement. The 4x2 charts distinguish 30.8/30.10, 35.8/35.10/35.12, 49.10/49.12, and 59.12 families across Combi, dual-purpose, van, cab, and shielded versions. The 4x4 chart identifies 40.10 W van, cab, shielded, Combi, and dual-purpose configurations with their wheelbase and steering-side codes. Motor-bus tables cover A40.10/A40.12, A45.10/A45.12, and A49.10 school, public-transport, and hire-bus versions. These tables help identify the correct engine, axle, suspension, and market configuration when the badge description is not enough.

Mechanical and Engine Systems

The engine section separates the 2.5-liter and 2.8-liter 8140 builds by combustion and fuel-system design: naturally aspirated prechamber engines, direct-injection turbo engines, intercooled variants, and applications equipped with OXICAT, EGR, or EDC. It covers engine removal on 4x2 and 4x4 chassis, bench disassembly, cylinder-block and liner inspection, crankshaft measurement, piston and connecting-rod work, cylinder-head pressure testing, valve-guide and seat repair, precombustion chambers, glow plugs, oil-pump and heat-exchanger service, cooling-system testing, and turbocharger pressure-relief-valve checking. Separate procedures address toothed-belt and chain-driven timing, the hydraulic chain tensioner, injection-pump installation and timing, KSB cold-advance equipment, injector testing, and rotary-pump bench-test sheets.

The clutch chapter supplies symptom-based diagnostic charts, driven-disc and release-bearing checks, flywheel service, pedal-bush replacement, and pedal-height adjustment. The 2826.5 transmission section covers shafts, gears, synchronizers, forks, bearings, case work, assembly, and transmission-shaft bearing backlash adjustment. For 4x4 vehicles, the Borg-Warner 1356 unit has dedicated operating-control, transfer-case removal, inspection, disassembly, and reassembly material. Propeller shafts, rear differentials, free-wheel units, constant-velocity half-shafts, wheel hubs, and bearing end play are handled in separate repair sections.

Brakes, Steering, Suspension, and Body Systems

The brake chapter contains air/hydraulic circuit symbols and configuration-specific layouts for rear drum or rear disc brakes, mechanical or pneumatic suspension, and ABS. Repair content covers pipe fabrication, hose replacement, vacuum-servo checks, hydraulic bleeding, load-proportioning valves, ABS electronic control and modulation, wheel-speed sensors, caliper overhaul, disc machining criteria, rear drum inspection, and lining replacement. Steering material separates mechanical steering from TRW- and ZF-type hydraulic systems and includes pressure testing, steering-center checks, bleeding, control-support repair, and pump overhaul.

Suspension and body sections cover independent front suspension with longitudinal torsion bars, rear semi-elliptic and parabolic leaf springs, shock absorbers, stabilizers, door alignment, and motor-bus swing/sliding door gearmotors, limit switches, electrical checks, and crush-inhibition controls. The 1998 revision adds the 8140.63.37 engine and New Daily K material for the cab-controlled electric PTO, linear actuator, hydraulic distributor, gear pump, telescopic dumping cylinder, warning sensor, and revised rear spring data.

Technical Specifications, Diagrams, and Scope

Representative illustrations include 8140 engine longitudinal and cross sections, the lubrication-system diagram, the 2826.5 transmission longitudinal section, the Borg-Warner reduction-unit section, brake/ABS circuit layouts, and New Daily K electrical and hydraulic diagrams. Tool tables identify factory equipment such as 99360306 for flywheel retention, 99360333 for the 8140.23.38 hydraulic chain tensioner, 99360608 for timing-gear positioning, and 99395214 for flywheel positioning.

Tables cover torques, clearances, wear limits, fluid capacities, alignment data, pressure checks, and electrical test values. The maintenance section provides M1, M2, MFP, and M12 schedules for on-road and heavy-duty service, with separate 4x4 and bus notes.

The manual flags assembly traps that matter during major repair work. Reversing the hydraulic chain-tensioner non-return ring can leave the chain drive without reliable tension. Main-bearing shells and connecting-rod caps must stay in their assigned positions; mixing or reversing them can produce incorrect oil clearances and bearing damage. Belt-driven and chain-driven engines use different timing references, so the procedure must match the exact engine code.

Electrical coverage is system-specific rather than a complete vehicle-wide wiring chapter. Full body repair and painting are referred to separate IVECO publications 603.42.733 and 603.42.076. The P.I.C. chart identifies an electric vehicle code, but the powertrain repair chapters center on the listed 8140 diesel engines.

Engine, axle, brake, and 4x4 driveline repairs involve heavy assemblies, stored spring loads, and pressurized hydraulic circuits. Use the specified supports, locking tools, lifting equipment, and safety precautions before disassembly.