Iveco Daily. Manual - part 310

Check that the protection casings of the knuckle heads are in
perfect condition and that their pivots do not present play,
otherwise replace them as described below.
Loosen the nut (3) securing the knuckle head (2) to the tie rod
(4).
Remove the nut fixing the knuckle head to the steering gear
lever and using the extractor (1) 99347074 remove the
knuckle head.
Unscrew knuckle head from the tie rod of the steering box
noting down the number of turns needed to disassemble.
Remove the fixing brackets (5) and extract the protection
casing (6).
In order to re-fit the assembly, perform the above operation
in reversed order, sticking to the following instructions:
- carefully clean the steering gear tie rod knuckle;

- lubricate the protective boot seats on the power steering

box to facilitate assembly;

- screw up the knuckle head with the same number of turns

used to disassemble it;

- fit a new o-ring on the power steering box;

- tighten the nuts of the prescribed torque;

- Adjust toe-in as shown in the respective section.

Lift the front of the vehicle and put the wheels in the straight
ride position.
Start the engine and fully speed up; if the steering gear put itself
in steering position, the hydraulic steering centre is wrong and
the hydraulic power steering must be changed.

Checking hydraulic steering centre (for ”ZF”
power steering only)

Join a pressure gauge (2) on the oil delivery piping on the
power steering pump (1). Rotate the steering wheel up to the
limit stop, speed up the engine and read on the pressure gauge
the maximum pressure value, which mast be of 80 bar.

Check the oil level in the tank, if necessary top up.
Lift the front part of the vehicle, start the engine and make it
idle for a certain period.
Check that there is no oil leakage from the hydraulic circuit and
check the tank level.
Slowly rotate the steering wheel in the two steering directions
so that the air contained in the hydraulic system goes out.
Check again the oil level in the tank and, in case top up.

501430

Bleeding the air from the hydraulic
system

The only possible interventions on the power steering
and mechanical steering systems are: replacement of
ball joints, replacement of protective rubber boots,
linkages and rubber bushings. Follow the instructions
provided in the specific paragraphs.
Replace the power steering system if problems
referred to this system only are found.

19598

32875

Figure 11

Figure 12

CHECKS AND OPERATIONS ON THE
VEHICLE
Checking maximum pressure

520636

SWIVEL HEADS

501438

PROTECTION CASINGS

501410

STEERING GEAR CONTROL

Vehicles equipped with an Air-Bag

Before doing any work on steering gear control
components:

- steering wheel;

- steering control lever system;

- steering gear shaft
Strictly observe the safety standards described in the following
paragraphs for Air-Bag system components.

STEERING GEAR

AILY

Base - May 2004

System components are designed to operate just on vehicles
of the specified make and type. Air-Bags must therefore not be
adapted, reused or installed on other vehicles.
Mount and use them only on the vehicles for which they have
been designed and produced.

The following Standards shall be strictly observed
when performing any type of repair or maintenance
operations on vehicles equipped with Air-Bag safety
system.

Air-Bag modules shall be handled with the utmost care.
Use, transport and storage of these components are
governed by the handling procedures described in the
following paragraphs.

Component removal and refitting shall be performed
EXCLUSIVELY by skilled and authorised personnel.
Failure to comply with the following procedure can
result in unintentional activation of the system, severe
injury or repairs not required. IT IS ABSOLUTELY
FORBIDDEN TO DISASSEMBLE Air-Bag MODULE
COMPONENTS.

Any reuse, adaptation or installation on a different
type of vehicle can result in sever injury or death for
passengers in case of collision.

Repairs and inspections required after an
accident

Any safety system component damaged after an
accident must be replaced.
Do not attempt to repair the control unit, the coil
cable or the Air-Bag modules.

Accidents with or without Air-Bag module
activation

Certain system components must be inspected after any
crash, whether the Air-Bag deployed or not. These
components are the following:

- steering column;

- steering column support;

- electronic control unit anchoring area and modules;

- coil cable;

- dashboard (in the area of the passenger Air-Bag).

If any faulty condition is found, replace the faulty component.

Accidents with Air-Bag module activation

In case of front impact with total system activation, the
following components must be replaced:

- Air-Bag modules;

- pretensioners;

- electronic control unit;

- coil cable.

STEERING GEAR

AILY

Base - May 2004

SAFETY STANDARDS TO BE OBSERVED
DURING REPAIR OR MAINTENANCE OPE-
RATIONS ON VEHICLES EQUIPPED WITH
AIR-BAG SYSTEM PROVIDED BY SUPPLIER

Preliminary Standards

Before starting any bodywork repair operation, welding or
whatever work requiring to remove the Air-Bags or the control
unit, proceed as follows:

- set ignition key to ”STOP” and take it out;

- always disconnect the battery, i.e.: disconnect the two

terminals from the relevant pole and insulate them
properly by tape;

- wait for at least 10 minutes before proceeding;

- disconnect control unit connector.

Store modules with the cover set upwards, inside a metallic
key-locked cabinet that must be used just with this purpose and
that must not contain other type of materials, especially if
flammables.

Adopted connectors wired to Air-Bag modules are provided
with short-circuit clip. It is impossible to activate units
accidentally until Air-Bag modules are connected to a power
source with suitable properties.

A system component not activated in case of collision is to be
considered still ”live” (active).

Live components that shall be removed from vehicles (due to
defects, warranty expiry or other reasons) shall be returned to
the suitable Centre using the following procedure.

Inspect cables and connectors to find any burning, external
insulation melting or damages due to excessive heat.

If any faulty condition is found on coil cable, electronic control
unit anchoring area and modules, replace the faulty
component.

Painting

Since modules and pretensioners are designed to withstand
the temperatures developed during standard baking operation
on bodywork, no special safety requirement shall be observed
during painting or baking.
Do not use open flames when working near the modules.
Electronic control units (including the Air-Bag one) shall always
be removed when temperature in certain rooms is equal to or
exceeds 85

°C.

Risks for health

Precautions to be observed when handling live Air-Bag are the
following:

- wear protective polyethylene gloves and goggles;

- wash hands and any exposed body part with water and

soap after handling live modules.

Overexposure effects

Since system is completely sealed there is no potential danger
of exposure to propelling gas.
Propelling gas mixture is at solid state, it is therefore impossible
to inhale gas even in case of gas generator cartridge breakage.
There is no risk for health in case of gas leakage.
Avoid in any case contact with the skin and do not swallow the
propelling gas.
In case of:

- contact with the skin: rinse immediately with water and

soap;

- contact with eyes: rinse immediately with fresh water for

15 minutes at least;

- inhalation: bring immediately the injured person to open

air;

- swallow: make the injured person vomit if conscious.

Always call the doctor in any of the above cases.

Safety Standards to observe when handling
Air-Bag modules

Driver and passenger Air-Bags usually activate in case of
collision through the action of the electronic activation
control. Gas (mainly nitrogen) produced under these
conditions are not toxic.
Personnel operating on safety system shall strictly observe the
following safety standards.
Personnel operating on these devices shall be suitably trained
and must observe the following precautions:

- when removing or replacing activated Air-Bags, wear

protective polyethylene gloves and goggles and handle
just one module at a time;

- always place the Air-Bag module with the cover and

exhaust hole upwards. Never put something on Air-Bag
cover;

- once servicing is over rinse hands with water and neutral

soap, in case of eyes contact with residual powders rinse
immediately with fresh water;

- before starting servicing, disconnect both battery cables

(first the negative one), insulate terminals by tape and wait
at least 10 minutes before proceeding;

- metal components of the Air-Bag are hot after explosion,

avoid to touch these components for at least 20 minutes
from module activation;

- do not repair Air-Bags but send faulty modules to

supplier. Do not heat the Air-Bag module by welding,
percussion, drilling, mechanical machining, etc.;

- never install on vehicle a damaged or fall Air-Bag module;

- it is prohibited to store Air-Bag modules together with

flammable material or fuels;

- gas generators must not come into contact with acids,

greases or heavy metals since contact can result in
formation of poisonous, noxious gas or explosive
compounds;

- never use open flames when working near Air-Bag

modules or system components.

STEERING GEAR

AILY

Base - May 2004

Spare parts shall be stored in their original package and
temporary storing shall follow the same procedure as for live
modules disconnected from vehicle, i.e. storage into dedicated
metallic key-locked cabinet (resistant to shocks and provided
with grids to enable natural ventilation). Cabinet shall be
provided with proper warning plates (RISK OF EXPLOSION
-

OPEN

FLAMES

OPENING

UNAUTHORISED PEOPLE).

Air-Bag module scrapping

Air-Bag modules must not be scrapped together with the
vehicle, but must be previously removed and activated as
described in the following pages.
Air-Bag units must always be activated before scrapping.
An Air-Bag module not exploded during an accident is to be
considered still ”live”.
Live materials MUST NOT BE ACTIVATED but must be sent
to a specialised centre (in Italy to GECMA in Chivasso)
specifying on the freight note:

- Air-Bag DEVICE CONTAINING PYROTECHNIC

CHARGE TO BE DEACTIVATED.

Devices must be sent using their original packages only. Should
the original package be not available, a new one shall be
requested to SPARE PARTS.
In case of Air-Bag device replacement, the original package
shall obviously be kept in good conditions to send the
non-activated device.

FOREIGN MARKETS shall observe local current laws and
regulations.

Failure to observe these procedures can result in
unintentional Air-Bag module activation and severe
injury. Live Air-Bag units must NOT be disposed of
using the common disposal procedure. Live Air-Bag
units contain substances dangerous for health that can
cause severe injury if the sealed container is damaged
during disposal.

Safety Standards to observe when handling
pretensioners

In case of front impact, driver and passenger pretensioners
usually activate just a minute before Air-Bag modules
Personnel operating on these devices shall be suitably trained
and must observe the following precautions:

- when handling activated pretensioners, i.e. with activated

propelling gas, wear protective gloves and goggles;

- once servicing is over rinse hands with water and neutral

soap, in case of eyes contact with residual powders rinse
immediately with fresh water;

- disconnect both battery cables (first the negative one),

insulate terminals by tape and wait at least 10 minutes
before proceeding;

- pretensioner produce heat during activation, it is

therefore necessary to wait at least 10 minutes before
operating;

- protect pretensioners against fall or shock during handling

or transport; damaged or fallen pretensioners must not
be used and must be returned to supplier communicating
the reason for;

- never carry pretensioners by the seat belt;

- pretensioners must be protected against sparks and open

flames and must not stay in contact with surfaces with
temperatures exceeding 100

°C for more than 6 hours;

- propelling gas not burnt is flammable, therefore

generator components must never be disassembled,
damaged or tampered;

- it is prohibited to store pretensioners together with

flammable material or fuels;

- gas generators must not come into contact with acids,

greases or heavy metals since contact can result in
formation of poisonous, noxious gas or explosive
compounds;

- seat belts with pretensioners shall be stored in proper

key-locked compartments or cabinets, suitably aerated
and away from open flames and heat sources.

STEERING GEAR

AILY

Base - May 2004

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