Iveco Daily Euro 4. Manual — part 198
General instructions:
- follow all WARNINGS, PRECAUTIONS and safety
instructions reported in this manual;
- bring the vehicle outside in the provided area;
- remove from the area around the Air-Bag covering all
materials and slugs (glasses, tools, components etc.) and
make sure that no inflammable liquids are nearby;
- disconnect the two battery cables (first the negative
cable) and wait for at least 10 minutes before proceeding;
- use a connecting braid (L= about 1 m) with specific
terminal connector for the electric connection with the
module to activate;
- reach the electric module connection (Air-Bag or
electronic pretensioner), following the instructions of this
manual;
- disconnect connector C1 of the pretensioner or Air-Bag
module;
- check whether connector C2 is disconnected from
remote activation device;
- connect the electric connector C1 of the pretensioner or
Air-Bag module to the connecting braid of the remote
activation device;
- connect connector C2 to remote activation device;
- place people in a safe place;
- connect the remote control device to a 12 Volts circuit
or equivalent device;
- press the double activation push-button to activate all
pretensioners and Air-Bag modules at the same time;
- after activating the Air-Bag modules and pretensioners,
leave them cooling before touching them (about 20
minutes);
- after activating the Air-Bag modules and pretensioners,
the vehicle can be scrapped - by squashing or crushing -
and/or recycled, depending on the cases.
ABG= driver Air-Bag
ABP = passenger Air-Bag
C2 = remote activation device connector
C1 = specific pyrotechnic charge connector
L
= main cable, safety distance 10 m
Lb
= braid length
PTG = driver pretensioner
A.
Remote activation device
VEHICLE PYROTECHNIC CHARGES ACTIVATION DIAGRAM,
SINGLE ACTIVATION
8664
ABP
C1
Lb
ABG
PTG
C2
C1
Lb
Lb
C2
C2
C1
C2
L
+12V
A
Figure 14
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62107
62108
62108
62109
Disconnect the battery (2) cables (1-3) first the negative cable
(1) then the positive one (3) and insulate them taping the
terminals.
For vehicles without Air-Bag, remove the pressure-fit cover
(2) on the steering wheel.
For vehicles with Air-Bag, turn the steering wheel and position
it as shown in the figure, in order to easily reach the screws (1
and 3) and remove them.
- Lift the Air-Bag module (1) in order to disconnect
connector (2);
- Remove the Air-Bag module (1) from the steering wheel
(3).
Set front wheels in straight running and mark (
→) steering
wheel assembly position (1) on upper steering gear shaft (2)
Remove the steering wheel (1) from the shaft (2).
For vehicles with Air-Bag, make sure not to extract or damage
coil device cable (3).
!
After removal, non-activated Air-Bag modules must
be stored with plate laying on the surface in a suitable
key-locked cabinet.
For all vehicles
Remove fixing nut (4).
For vehicles equipped with Air-Bag
Follow the safety standards given in the relevant chapter and
wait for 10 minutes before proceeding.
Figure 15
Figure 16
Figure 17
Figure 18
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541415
Upper steering gear shaft removal
62110
102313
62112
Figure 19
Figure 20
Figure 21
Remove the two screws (2) and remove the upper protection (1).
Remove the three screws (4) and remove the lower
protection (3).
Cut electric cable fixing clamps and disconnect connectors
(9-10-13).
On vehicles equipped with ESP, take off connector (14) of
steering angle sensor (15) incorporated into the steering
column stalk. Loosen screw (3) locking indicator switch
retaining clamp to gear shaft (1).
Remove the indicator switch (2) from the gear shaft (1).
To remove steering angle sensor (15), you just need to take
off cover (16) and unscrew the three screws (17) that secure
it to the steering column stalk.Mark universal joint (6) assembly
position on lower shaft (8) and loosen the fixing screw (7).
Remove the screws (4-5) and disconnect the upper steering
gear shaft (1) from the lower steering gear shaft (8).
To replace or disassemble switch (12) it is necessary to
unscrew screws (11) using a proper punch or drill them in
order to eliminate the most of material to remove them. Make
sure not to damage switch thread in case of reuse.
At refitting, the new screws (11) must be tightened till the
hexagonal head is sheared from its rod.
Remove the upper steering gear shaft as described in the relevant
chapter (operation 541415). Lift cover (1) from floor. Unscrew
the three fixing screws (2) of lower shaft (3) support (4).
!
Make sure that steering wheel removal has lifted the
top cap of the coil device. If the top cap turns, it will
be necessary to block it by bringing it to the outside.
If you hear a ”click”, it means that the cap is blocked.
For any removals of the winding device, meticulously
observe what specified in “Electric System” section.
Refitting
For refitting reverse removal operations and observe the
following recommendations:
- reconnect shafts and refit steering wheel matching the
marks made during removal operations;
- at refitting, the self-braking nuts and the steering wheel
fixing nut must always be replaced;
- tighten nuts and screws to the prescribed torque;
- after tightening steering wheel fixing nut to upper shaft, it
is necessary to crimp the nut;
- when refitting is completed, carry out operation test on
indicator switch and horn.
541413
Lower steering gear shaft removal
On vehicles equipped with ESP, the steering angle
sensor is fitted inside the steering column stalk. In
this case, you will have to carry out the functional
checks as well as the calibration procedure
described in the relevant chapter of the “Brakes”
section (page 63).
NOTE
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62113
Figure 22
Mark universal joint (6) assembly position on hydraulic power
steering (3) shaft.
Loosen screw (7) and remove hydraulic power steering lower
shaft.
Refitting
For refitting reverse removal operations, complying with
upper steering gear shaft refitting operations.
5014
HYDRAULIC POWER STEERING
541413
Hydraulic power steering removal
Proceed as follows to remove the hydraulic power steering:
Loosen front wheel fixing screws or nuts.
Lift the front part of the vehicle, support it by proper stands
and brake rear wheels.
Position tool 99321024 near the wheels, remove wheel fixing
screws or nuts. Remove the wheels.
Remove cap (1) from hydraulic power steering oil tank.
Disconnect pipes (4-5) from hydraulic power steering (3) and
drain system oil into a suitable container.
Steer wheel hubs in both directions to drain out oil from the
system.
Remove nuts (8) fixing kingpins (10) to steering levers (9) and
remove the latter using extractor 99347074.
Loosen the screw (7) fixing the universal joint (6) to the
hydraulic power steering shaft (3).
Remove the fixing screws (2) and remove the hydraulic power
steering (3).
For refitting reverse removal operations and observe the
following recommendations:
- after refitting the hydraulic power steering to the front
cross member or to the driving axle, turn the pinion up
to bring the rack to the end of the stroke. Turn again the
pinion to the opposite direction for a number of turns
equal to half of the turns required to the rack to complete
the whole stroke (approx. 2 turns);
- in this position, set steering wheel in straight running
condition and connect the elastic joint to hydraulic power
steering pinion fork or the universal joint to the hydraulic
power steering.
- At refitting, the self-braking nuts must not be reused but
replaced with new ones.
- tighten screws and nuts to the prescribed torque;
- fill hydraulic power steering system tank in and carry out
the drainage as described in the relevant section;
- check and adjust toe-in as described in the relevant
section.
The only repair operations to carry out on hydraulic
power steering and mechanical steering are the
following: joint head replacement and rubber boots
replacement. In these cases, follow the operations
described in the relevant section.
If defects depending only on the hydraulic power
steering are found, replace it.
Refitting
!
STEERING GEAR
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