IVECO Daily & TURBODAILY 4x2/4x4 1992–1997 Workshop Manual Set

The revision builds on the base engine chapter, describing the differences from the 8140.67F engine rather than repeating the full overhaul instructions. Its New Daily K material covers the PTO, body-dumping equipment, and revised rear suspension.

Coverage limits: Detailed antipollution-system work and 8140.47R EDC component diagnosis are referred to separate IVECO publications 603.42.128 and 603.42.758. Further body/chassis repair and painting are referred to 603.42.733 and 603.42.076; these separate manuals are not included. The electric-vehicle P.I.C. entry is an identification reference; the engine repair chapters cover 8140 diesels.

PDF Text Search, Section Bookmarks, and Diagram Detail

Finding sections and reading diagrams: Technical-page text search is not available. Embedded PDF bookmarks provide navigation to the main workshop sections and the revision. Small labels and legends in the brake and PTO diagrams require zooming for comfortable reading.

One printable, English-language 598-page PDF combines the publications above, including their covers, introductory and blank pages, plus two additional notice pages. File size: 297.33 MB.

8140 Engine, Driveline, and Chassis Workshop Coverage

The following are selected workshop topics, not a complete table of contents. Other examples include wheel balancing and headlight aiming.

• Engine overhaul: Engine removal and installation, cylinder-block and liner inspection, crankshaft measurement, piston and connecting-rod work, and cylinder-head repair.

• Timing and fuel systems: Belt- and chain-drive procedures, hydraulic chain-tensioner assembly, injection-pump timing, KSB cold-advance checks, injector testing, and fuel-system bleeding.

• Clutch and transmission: Symptom-based diagnosis, clutch replacement, 2826.5 gearbox disassembly and reassembly, synchronizer inspection, bearing adjustment, and power take-off information.

• 4x4 driveline and axles: Borg-Warner 1356 transfer-unit overhaul, propeller-shaft checks, differential repair, free-wheel service, constant-velocity half-shafts, and wheel-hub work.

• Brakes and steering: Brake fault charts, caliper overhaul, hydraulic bleeding, load-proportioning checks, ABS layouts, and TRW/ZF steering-system tests.

• Suspension and body equipment: Torsion-bar and leaf-spring service, door adjustment, bus-door electrical checks, and New Daily K PTO and hydraulic body-dumping documentation.

This manual is suited to experienced vehicle mechanics equipped for engine bench work, precision measurement, and heavy-assembly handling.

Matching the Vehicle and Installed Components

P.I.C. charts distinguish body version, wheelbase, steering side, market, engine installation, and bus rear-suspension configuration. These tables help identify the correct engine, axle, suspension, and market configuration when the badge description is not enough.

The model-composition matrix includes both 35.10W and 40.10W 4x4 builds; the dedicated 4x4 P.I.C. chart identifies 40.10 W configurations. Bus entries include school, public-transport, and hire versions, with mechanical or pneumatic rear suspension.

Engine Inspection, Timing, and Fuel Equipment

Engine builds: Procedures distinguish naturally aspirated prechamber engines, direct-injection turbo engines, intercooled variants, and equipment using OXICAT, EGR, or EDC. The base chapter covers 8140.67F.37, 8140.23.37, 8140.23.38, 8140.43.37, and 8140.47R.2790 builds; the revision adds 8140.63.37 material.

Step-by-step procedures extend to cylinder-head pressure testing, valve guides and seats, precombustion chambers, glow plugs, the oil pump and heat exchanger, cooling-system checks, and turbocharger wastegate testing and replacement. The electromagnetic fan-drive assembly is treated as a replacement unit rather than an internally repairable assembly.

Timing differences: Belt-driven engines and the 8140.23.38 chain drive use different timing references. The chain-tensioner section explains the non-return ring and its internal positioning; the timing-case instructions warn that excessive crankshaft rotation during positioning can cause piston-to-valve contact. Engine assembly also addresses keeping reused bearing shells and matching connecting-rod caps in their assigned positions.

Pump-test scope: Rotary-pump sheets accompany KSB and injector material, but the manual labels pump test and adjustment figures as general guidance and directs calibration work to the applicable Service Information specifications.

Gearbox, Transfer Unit, and Axle Repair

Clutch coverage includes driven-disc and release-bearing checks, flywheel service, pedal-bushing replacement, and pedal-height adjustment. The gearbox chapter distinguishes 4x2 and 4x4 installation details and tightening data while covering shafts, gears, forks, synchronizers, cases, and transmission-shaft bearing end play.

The transfer-unit material adds operating controls, shift-linkage adjustment, internal chain and bearing inspection, and assembly checks. Rear-axle sections distinguish RO407, RO417, RO427, and 450517 assemblies; front-axle sections cover 5811, 5812, 5811/2, and the 5912 driving axle. Wheel geometry and variant-specific hub-bearing arrangements are included.

Brakes, Steering, Suspension, and Door Controls

Brake configurations: Air/hydraulic symbols and circuit layouts distinguish rear drums or discs, mechanical or pneumatic suspension, and ABS. Repair material extends to rigid-pipe fabrication, hose replacement, vacuum-servo checks, brake-disc machining criteria, drum inspection, and lining replacement. ABS material describes the control unit, electrohydraulic modulators, and wheel-speed sensors.

Steering and suspension: Steering material distinguishes mechanical steering from TRW/ZF hydraulic systems, with pressure and hydraulic-center checks, bleeding, and steering-control support repair. Pump coverage provides general overhaul notes and an exploded view. Steering-gear repairs are limited to tie-rod ends and protective boots; internal faults call for unit replacement.

Independent front suspension uses longitudinal torsion bars. Rear sections distinguish semi-elliptic and parabolic leaf springs, shock absorbers, and stabilizers, with configuration-specific inspection and adjustment data.

Powered doors and Daily K: Bus-door coverage includes gearmotor removal, limit-switch adjustment, electrical checks, emergency opening, and crush-inhibition controls. The revision adds the cab-controlled electric PTO, linear actuator, hydraulic distributor, gear pump, telescopic dumping cylinder, warning sensor, and revised rear-spring data.

Diagrams, Service Tools, and Maintenance Plans

Illustrations include 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-installation and hydraulic-distributor diagrams. Electrical material is organized around specific systems rather than a complete vehicle-wide wiring chapter.

Tool references include 99360306 for flywheel retention, 99360333 for the hydraulic chain tensioner, 99360608 for timing-gear positioning, and 99395214 for flywheel positioning. Six-digit operation codes connect repair headings with IVECO's repair-time and failure-code systems.

Torque, clearance, wear-limit, fluid, alignment, pressure, and electrical-test tables accompany the repair sections. M1, M2, MFP, and M12 maintenance information distinguishes on-road and heavy-duty use, with separate 4x4 and bus notes.

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.

Compression and Thermostat Specification Examples

For the base 8140 engine builds, the compression table lists 20–26 bar and a minimum permissible pressure of 16 bar. These figures apply with the engine turned by the starter, oil at 40–50°C, and the injection pump in the stop condition.

The same base-engine specifications list thermostat opening at 79 ± 2°C and full opening at 110°C.