Daily 4×4: Useful information

Below is some useful Iveco Daily 4×4 technical data that I have found out either from experience, or in various sources other than the vehicle handbook:

Tyre Pressures for Michelin 255/100 R 16: on-road, up to the vehicle rear axle limit

Load per axle kg               3400                       3550                       3700

Pressure PSI/Bar              65/4.5                   69/4.75                 73/5.0

Note: These tyres have two load/speed ratings:-

126 K (max axle weight 3400 kg at 110 kph) listed in the vehicle handbook.

134 J (max axle weight 4240 kg at 100 kph) not listed in the vehicle handbook!

Tyre Pressures for Michelin 255/100 R 16 on different surfaces                                                

Surface     Max speed       Front 2150 kg     Rear 3400 kg       Rear 3700 kg

.                   mph/kph         PSI          Bar         PSI          Bar         PSI          Bar

Road            62/100            40           2.6          65           4.5          73           5.0

Track            40/65              25           1.8          40           2.9          46           3.2

Sand             12/20              16           1.0          25           1.7          25           1.7

Differential Locks

Permitted Speeds and order to engage the Differential Locks

  1. Central Differential Lock: 0 Km/h to 40 Km/h
  2. Rear Differential Lock: 0 Km/h to 20 Km/h
  3. Front Differential Lock: 0 Km/h to 15 Km/h

Differential Lock automatically disengagement speeds

  1. Front Differential Lock: >30 Km/h
  2. Rear Differential Lock: >40 Km/h
  3. Central Differential Lock: >70 Km/h

Differential Lock ‘Check’ warning light

Steady light: Diff Lock ECU failure (you can get this if you stall and restart the engine too quickly).

Flashing: low hydraulic pressure in the diff lock system.

Code Flashing: 2 flashes alternated with 3 second pauses – failure in the speed signal.

ABS warning lights

The dash board ABS light is not connected on the Daily 4×4 model; it is replaced by the big ABS light on the Differential lock panel. The little ABS light on the Differential Lock panel, lights to tell you when the Differential Lock system has disabled the ABS. So if you have the Differential Lock off (i.e. the small ABS light off) and the big ABS light on, you probably have an ABS fault.  If you have the Differential Lock on (i.e. the small ABS light on) and the big ABS light on, you do not have an ABS fault.

The working of the Diesel Particulate Filter (DPF)

I have learnt the following information from internet research , so it comes with a ‘health warning’ to be used at your own risk:-

The DPF will self-regenerate when there is for at least 10 minutes, both: a) 8% oxygen in the exhaust gas; and b) an exhaust gas temperature above 230°C. These conditions are normally achieved with normal driving, but operating the vehicle at a higher weight will help, as the engine is working harder and the exhaust gases will be hotter.  Short start/stop journeys (e.g.  a delivery van in a town) should be avoided.

If for whatever reason, the DPF starts to block (e.g. due to start/stop journeys or high sulphur fuel), the ECU will attempt a commanded regeneration. In this situation “Start of pollution filter regeneration” will be displayed on the dash board display and extra fuel will be injected into the exhaust stroke to raise the exhaust gas temperature, which should regenerate the DPF.  While this process is taking place, the engine should not be turned off, in fact it would help to get the engine up to a higher rpm by driving on a clear road.

If the self-regeneration and the commanded regeneration fail, then a forced regeneration will be required.  This process is carried out by Iveco.  Due to the high thermal stress inflicted on the DPF, this process will shorten the life of the DPF and should therefore be avoided if possible.  The DPF has been designed for a normal service life of 400,000 km.

So what can be done to help avoid a visit to Iveco for a forced regeneration and keep the DPF clear? I haven’t found any advice on this in any of the Iveco documentation that I  received with the vehicle!  However, some internet research has uncovered the following advice:-

  • Avoid short distance start/stop journeys.
  • Operate mostly at higher weights.
  • When you have to do short distance, start/stop journeys, try once a week driving whilst  maintaining 3000 rpm for at least 15 minutes.
  • If the DPF is clogged, an on-road forced regeneration could be attempted by driving to maintain a more or less constant 3500 to 4000 rpm for at least 30 minutes.

Update to the above based on my experience: drive and maintain 80 kph (6th gear), approximatly 2000 rpm, is optimum for DPF regeneration.

Those lucky enough to have access to an Iveco EASY or other diagnostic tool, may be able to read the parameters of the ECU and the particulate quantity in the DPF. But what do the values mean?  From what I have seen, the DPF is considered ‘full’ when the soot level reaches 52 g and this will initiate the commanded regeneration.  If an ‘over- full’ level of 78 g is achieved (probably due to failed commanded regenerations), then the DPF warning light will be turned on, commanded regenerations are disabled, and engine power could be reduced;  you now almost certainly need a forced regeneration!

Regenerating the DPF on demand:

  1. Stop the vehicle on flat ground, away from traffic and pedestrians, ideally into wind. Be sure not to park over or near any flammable material such as long grass.
  2. Put the gearbox into neutral and apply the parking brake.
  3. Switch off the engine.
  4. Switch the ignition on.
  5. Press the brake pedal and the accelerator pedal at the same time. Wait for the DPF warning light to blink and the cluster to display the message “Cleaning DPF start the engine and keep the vehicle stationary”.
  6. Release the pedals.
  7. Start the engine without pressing any pedal (throttle, brake, or clutch). The DPF warning light will start flashing.  If the engine fails to start, repeat the procedure from the beginning.
      1. Regeneration on demand could stop automatically if there are system failures.
      2. Regeneration is complete when the DPF warning light is no longer flashing:
        1. If it goes out, it means that the procedure has been successfully completed.
        2. If the warning light remains lit, it means that the procedure has not been successfully completed and must be repeated by eliminating the causes that have caused it to stop.

    8. After the regeneration is complete, reset the engine oil counter.

    One final warning: during commanded and forced regenerations, the exhaust temperature can exceed 630°C! When doing this, DO NOT  park over a flammable surface e.g. dry grass!

    Engine oil counter reset

    It is important to have the ECU reset after an oil change. This is because the DPF commanded regeneration process can dilute the oil with diesel. The engine monitors this and decides when the oil needs changing.  The ‘oil can’ symbol for low oil pressure flashes when an oil change is required.  If the ECU is not told when the oil is changed, you are likely to be prompted to change the oil again and if you don’t do this, the engine will eventually go into ‘reduced power’ mode.

    Resetting the engine oil change counter:

        1. Switch the ignition on.
        2. Wait a few seconds until the cluster does its check.
        3. Press the accelerator pedal and start a timer.
        4. After 15 seconds, press the brake pedal 10 times, without releasing the throttle pedal.
        5. Switch the ignition off.
        6. Release the accelerator pedal.
        7. After 30-40 seconds, start the engine and the warning light (flashing oil can symbol) should be off.

    Why the engine cooling fan sometimes goes on and off repeatedly

    The cooling fan is not a simple on/off function; it is controlled by the ECU and is dependent on water temperature and air-conditioning (AC) gas pressure. The fan is connected to the fan belt via two electric clutches, which allows two coupling speeds and is switched as follows:-

    By water temperature as follows:-

        • At 100°C first speed is activated.
        • At 101.5°C second speed is activated.

    When water temp goes down to 90°C the fan turns off.

    By the AC gas pressure as follows:-

        • 19 bar first speed is activated.
        • 21 bar the first speed turns off.
        • 22 bar both speeds activated.

    As soon as the gas pressure decreases and reaches:-

        • 19 bar the second speed turns off.
        • 17 bar the first speed turns off.

    Some Specialist Tools and their Part Numbers

    Part No.               Tool Description

    99360186             Auxiliary belt fitting tool

    99342156             Fuel injector puller

    99358026             Alternator free wheel spanner

    99352115             Wrench for injector pipes

    99360076             Oil Filter spanner

    99370205             Clutch centring pin

    99355172             Wrench for wheel hub bearing adjustment ring nut

    99370498             Tool for installing wheel hub bearing

    99355047             Wrench for transfer box output flanges

    Some Iveco accessories for the Daily 4×4 that we have fitted

    Part No.               Description

    500025967           Tow Ball with gate for tow rings, 4 bolt mounting, D-value 31 kN

    16236731             High tensile HEXAGON BOLT (for tow bar) M10X1,25X40 MM

    17153021             High tensile HEXAGON NUT (for tow bar) M10X1,25

    17495034             SPRING WASHER (for tow bar) M12X1,75X25

    2994745                Window air deflector (long)

    2994939                Headlight guard

    2994995                Daily bulb kit

    2994264                Windscreen insulated blanket set (internal)

    2994512                Hot shot screen washer heater

    2994472                External Sun visor

    500025712           Anti-Theft wheel nuts

    Iveco Options we have on our Daily 4×4

    Option                  Description

    190                         CRANKCASE SUMP GUARD

    219                         WHEEL CHOCKS

    599                         DIN STD RADIO PRESET

    1131                       DIFFERENTIAL LOCK FRONT

    2211                       BREAKDOWN WARNING SIGN

    2714                       HEATED/ADJUSTABLE MIRRORS

    4544                       FIRE EXTINGUISHER PRE EQUIP (bracket for fire extinguisher between seats)

    5108                       BREAKDOWN WARNING LIGHT

    5133                       WITHOUT TACHOGRAPH

    5534                       FIRST AID KIT

    5864                       Central door locking

    5925                       Adjustable speed limiter

    6310                       HEATED DIESEL PREFILTER WITH WATER & SEDIMENT TRAP

    6358                       SPEED LIMITER 100 KMH

    6520                       13 PIN DIN ELECTRICAL SOCKET

    6628                       PVC ADJ DRI/PASS.SEAT HEATED

    6644                       PVC ADJ PASSEN.SEAT HEATED

    6650                       AIR CONDITIONER

    6654                       ENGINE HEATING SYSTEM

    7195                       ALTERNATOR 140A (12V)

    7196                       170 CC AIR CONDITIONING

    8628                       INCREASED STORAGE COMPARTMENT (above windscreen)

    8632                       3RD KEY

    8647                       HEATED BLOW BY FILTER (heater on crank case vent)

    8681                       COMFORT INSTRUMENT PANEL MPH + SERVICE

    8656                       BODYBUILDER CONNECTION

    20911                    Tyres 255/100 R 16 OFF ROAD

    Transfer Gearbox RPM Limit

    There has been a lot of talk on the Australian forums about transfer gearbox overheating and failures, so I decided to look at the specifications of the transfer gearbox.  Unfortunately, Iveco does not publish any information, specifications or limitations; however the SCAM website does provide a data-sheet for the 24 speed transfer gearbox.

    The limitations of interest are the inlet maximum RPMs.  There are two limits: one for high-range of 4000 rpm, and one for low-range of 1500 rpm.

    Assuming Michelin XZL 255/100 R 16 tyres, these rpm limits equate to a maximum theoretical speed in high-range of 138 kph, and with the half-gear selected, 111 kph.  Both of these are above the XZL tyre limit (and Cuthbert’s speed limiter) of 100 kph – no problem.  However with low-range selected, the maximum speed drops to 16.6 kph, and with the half gear selected, 13.4 kph!  Obviously these low-range speeds are quite easy to exceed.

    I have found that 3rd gear low-range, is about the same as 1st gear high-range with half-gear.  I have been changing back up to high-range if I find myself reaching 3rd in low-range; fortunately this has been keeping me within limits for my transfer gearbox.  If you have different tyres to the Michelin XZL’s, an engine rpm limit for gear selection can be calculated to ensure you don’t over-speed the transfer gearbox.

    Here are the limits I have calculated (if the gear is not listed, its rpm limit is above 4000 rpm):

    High-range (with or without half-gear):-

    5th gear = 4000 rpm

    6th gear = 3164 rpm

    Low-range (with or without half-gear):-

    3rd gear = 3061 rpm

    4th gear = 2047 rpm

    5th gear = 1500 rpm

    6th gear = 1186 rpm

    Engine Temperature Gauge

    I have seen the engine temperature rise just above ½ , and the cooling fan cut-in, many times while driving up hills.  However, on one occasion the engine temperature went as high as ¾ which is not normal.  That evening I downloaded the ECU stored data.  Analysis of the data revealed that the engine coolant temperature had not risen above the normal limits, but the fuel temperature had exceeded the normal levels.

    On this occasion I had been driving up a very steep off-road track and had very low fuel quantity in the main fuel tank.  Therefore my conclusions are:-

        1. The engine temperature gauge shows a combination of the coolant and fuel temperature. If either is high, the gauge goes up.
        2. With a low fuel quantity whilst working the engine at high power, the return fuel heats up the remaining fuel in the tank to unacceptable levels.

    I am now considering installing a fuel cooler in the return-to-tank fuel line.  Many vehicles have this fitted as standard to prevent this issue.  Until I have carried out this modification I will try to avoid a combination of high power and low fuel quantity.

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