Iveco Daily Euro 4. Manual

Remove the straps (shown by arrows) that secure the cable
to the gearbox.

102194

102196

Figure 68

Disconnect wiring (1) from the gearbox control unit, taking
care that it is not hit or does not get caught.

After the re-attachment operation has been
completed, verify, by getting connected to the
vehicle by means of the diagnosis instrument, that no
error is found in the gearbox control unit fault
memory.

NOTE

Refitting

Re-attachment is carried out by reversing the order of
detachment operations. Also tighten the nuts or screws to the
specified torque.

769152104

GEARBOX WIRING -
GEARBOX

Removal

Place the vehicle in a pit, or on an auto lift or special supporting
stands.

Disconnect the battery cable in the engine compartment.

102195

Figure 69

Take full wiring (1) off the vehicle.

Figure 70

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Press connector springs (2) inwards (see arrows).

Remove the connector from clutch actuator (1).

102198

102199

Figure 71

Remove connector (1) from control unit (2), by releasing the
pull-back spring downwards, as shown by the arrow.

Figure 72

Re-attachment is carried out by reversing the order of
detachment operations. Also follow the advice below:

- Lay the wiring onto the gearbox by fitting the same with

brackets at the specified points, then place it on the engine,
taking care that it does not get pinched.

- Check for correct insertion of connectors, which can be felt

when the locking bracket has been closet.

Refitting

NOTE

Remove the connectors (1) from the gearbox actuator
electric motors by pressing the fastening springs, as shown by
the arrows.

102200

Figure 73

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Some modifications or repairs that affect the ESV1 system components, automatic transmission, require a calibration procedure.
The repairs that require this operation are detailed as follows:

Replacing the gearbox kit + control unit

Replacing the control unit only

Replacing the clutch actuator

Replacing the gearbox actuator

Replacing an electric motor of the gearbox actuator

Replacing the engaging fork

Replacing the gearbox wiring requires no calibration procedure.

NOTE

Calibration in case of replacement of the gearbox kit + control unit

The control unit must be programmed (no error in the memory) by providing the same with the vehicle data, e.g. axle ratio, rolling
radius, strength curve, etc.

Get connected to the vehicle by means of the diagnosis instrument, with the vehicle stationary, engine OFF and gearshift lever
in neutral.

Carry out the operations indicated by the instrument: key ON (engine ON), then the dedicated calibration procedure will be
started

→ ” Adaptation of touch Point.

Message “service” will appear on the display; the system in automatic mode will carry out the following operations:

- opening the clutch;

- engaging the 5

or 6

speed;

- he clutch closes three times searching for the point of initial slip (the vehicle will pick up three times);

- putting the lever in neutral;

- closing the clutch.

The procedure is interrupted when the engine is switched off.

Wait 10 seconds prior to the next KEY ON.

NOTE

When the procedure has been completed, check the control unit memory and verify that no error is found.

Calibration in case of replacement of the control unit

The control unit must be programmed by providing the same with the vehicle data, e.g. axle ratio, rolling radius, strength curve,
etc.

Get connected to the vehicle by means of the diagnosis instrument, with the vehicle stationary, engine OFF and gearshift lever
in neutral.

Carry out the operations indicated by the instrument: key ON (engine OFF), then the dedicated calibration procedures will be
started

→ Measurement of Maximum Clutch Travel

Transmission Self Adaptation

Message “service” will appear on the display; the system in automatic mode will carry out the aforesaid procedures. Upon
completion of this step, the engine will be started and the

→ Adaptation of touch Point calibration procedure will be started.

Message “service” will appear on the display; the system in automatic mode will carry out the following operations:
- opening the clutch;
- engaging the 5

or 6

speed;

- he clutch closes three times searching for the point of initial slip (the vehicle will pick up three times);
- putting the lever in neutral;
- closing the clutch.

The procedure is interrupted when the engine is switched off.

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NOTE

When the procedure has been completed, check the control unit memory and verify that no error is found.

Calibration in case of replacement of the clutch actuator

Clear the control unit error memory.

Get connected to the vehicle by means of the diagnosis instrument, with the vehicle stationary, engine OFF and gearshift lever
in neutral.

Carry out the operations indicated by the instrument: key ON (engine OFF), then the dedicated calibration procedure will be
started

→ Measurement of Maximum Clutch Travel.

Message “service” will appear on the display; the system in automatic mode will carry out the necessary operations. The procedure
will be interrupted when the engine is switched off.

Wait 10 seconds prior to the next KEY ON.

NOTE

When the procedure has been completed, check the control unit memory and verify that no error is found.

Calibration in case of replacement of the gearbox actuator or an electric motor of the gearbox
actuator

Clear the control unit error memory.

Get connected to the vehicle by means of the diagnosis instrument, with the vehicle stationary, engine OFF and gearshift lever
in neutral.

Carry out the operations indicated by the instrument: key ON (engine OFF), then the dedicated calibration procedure will be
started

→ Transmission Self Adaptation.

Message “service” will appear on the display; the system in automatic mode will carry out the necessary operations. The procedure
will be interrupted when the engine is switched off.

Wait 10 seconds prior to the next KEY ON.

NOTE

When the procedure has been completed, check the control unit memory and verify that no error is found.

Calibration in case of replacement of the clutch engaging/release fork

Clear the control unit error memory.

Get connected to the vehicle by means of the diagnosis instrument, with the vehicle stationary, engine OFF and gearshift lever
in neutral.

Carry out the operations indicated by the instrument: key ON (engine ON), then the dedicated calibration procedure will be
started

→ Adaptation of Touch Point.

Message “service” will appear on the display; the system in automatic mode will carry out the following operations:

- opening the clutch;
- engaging the 5

or 6

speed;

- the clutch closes three times searching for the point of initial slip (the vehicle will pick up three times);
- putting the lever in neutral;
- closing the clutch.

The procedure is interrupted when the engine is switched off.

Wait 10 seconds prior to the next KEY ON.

NOTE

When the procedure has been completed, check the control unit memory and verify that no error is found.

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Iveco Daily Euro 4. Manual - part 117