Iveco Daily Euro 4. Manual

109056

109134

109135

109132

Figure 58

Figure 59

Figure 60

Figure 61

Remove safety springs (2) from pins (3).
Unthread pins (3) from brake caliper (6) and recover springs
(4) checking braking gaskets (1).
Disconnect electrical connection (5) for gasket wear
signalling unit.
Unthread braking gaskets (1) from brake caliper (6).

Check the conditions of check springs (1) or (4, Figure 58)
of braking gaskets and sliding bushes (2); should they be
worn, replace them.
Visually check the conditions of dust cowlings (3 and 4).
Should they be deformed or cracked, they must be replaced.
Remove dirt from brake caliper using a metal brush and
avoiding to damage the dust cowlings.
Clean pads rest area using suitable materials and products
(e.g. a wet cloth); on the contrary, do not use a
nitro-perchlorate based diluent, petrol, etc., which might
damage the protection cowlings.
Check brake disk surfaces and make sure that the disk is not
corroded, scored or grooved.
Slight superficial cracks are acceptable; however, brake disk
must be ground as described in relating chapter; on the
contrary, if the disk is worn out, it must be replaced.

Insert new brake liners (1) in the brake calliper mount and
check that they slide in their seats.
Fit cable (4) into brake caliper (1), and connect the cable to
braking gasket (3).

For 2x60 brake calipers

Retracting the pistons will increase the level of brake
fluid in the reservoir. For this reason, check the fluid
does not spill out of the reservoir and damage
vehicle paintwork during the operation.

Withdraw pistons (1) by a retractor or other suitable tool (2),
paying attention not to damage piston surfaces and
protection cowlings.

Checks

We suggest that both brake discs be renewed also
in case one of them only needs to be replaced.
As regards brake lining

pairs, always replace a

complete series for each axle.

Always overhaul both brake calipers also in case one
of them only seems to be damaged.

For 2x48 calipers

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

URO

Figure 62

Figure 63

Figure 64

Figure 65

Move bush (1) inside brake caliper (2) and position the
caliper on caliper support (4).
Screw screw (3) and tighten it to prescribed torque.

Mount protection plug (1).
Connect cable (3) of wear sensor to support blade (2) and
cable connection to chassis cable connection.

Mount braking gaskets (1).
Position springs (4) and fit pins (3) into brake caliper (6).
Mount safety springs (2) into pins (3).
Connect electrical connection (5) of braking gasket wear
signalling unit.

109131

109137

527413

Removal/Re-fitting of brake calipers

Removal 2x48 calipers

For 2x84 brake calipers

Disconnect electrical connection (1) of wear sensor from
chassis cable and release the cable of the electrical
connection from support blade (2).
By suitable wrench, disconnect hose (3) of brake liquid from
pipe and drain brake liquid into special container.
If necessary, plug the pipe preventing piping complete
draining.

For 2x60 calipers

109122

109056

The hose has to be removed at the bench.

NOTE

Brake liquid is venomous and corrosive: in case of
accidental contact, immediately wash with water and
neutral soap.

Figure 66

109138

Remove rubber protection plug (1).
Unscrew screws (2), take off brake caliper (4) and disconnect
electrical cable (3) of braking gasket wear sensor.
Check braking gaskets conditions. If braking gaskets are found
to be worn out, replace them and follow checks as described
in relating chapter.

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

URO

Figure 67

Figure 68

Dismount braking gaskets as described in relating chapter.
By suitable wrench, disconnect hose (3) of brake liquid from
pipe and drain brake liquid into special container.
If necessary, plug the pipe preventing piping complete
draining.

Remove screws (4) and take brake caliper (2) off caliper
support (1).

Disconnect electrical connection (3) of wear sensor from
chassis cable and release the cable of the electrical
connection from support blade.
Remove rubber protection plug (1) and unscrew screw (2).

Move (

→-) bush (3) inside brake caliper (2) and tilt the brake

caliper.
Disconnect cable (1) from braking gasket (4) and unthread
the cable from brake caliper (2).
Dismount braking gaskets (4 and 5) from caliper support (6).
For 2x44 and 2x48 calipers, withdraw pistons (7) following
indications in Figure 57.

109139

Removal 2x60 brake caliper

The hose has to be removed at the bench.

NOTE

Brake liquid is venomous and corrosive: in case of
accidental contact, immediately wash with water and
neutral soap.

Check the pistons are fully retracted inside the
caliper body.

Refit by carrying out the operations described for
removal in reverse order, observing the required
tightening torques.

Drive slowly without prolonged, sudden brake
application during the first period of use of new
brake pads because braking efficiency is reduced.

Refitting

527440

REAR BRAKES

The following operations have been carried out on vehicles
with 2x48 Brembo rear calipers.
They should be considered similar also for 2x44 - 1x52C -
1x60C Brembo rear calipers unless stated otherwise.

Press the brake pedal repeatedly to restore pressure in the
system and correct brake pedal stroke.

527447

Removal/Refitting of brake calipers

Set the vehicle on level ground, loosen the nuts (1) securing
the wheels.
Lift the front of the vehicle with a hydraulic lift and rest it on
two stands (2).
Unscrew the nuts (1) and remove the wheels.

45045

Figure 69

109140

Figure 70

109141

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

URO

Using tool 99372236 (1) retract the piston (3) by pushing
constantly in line with the piston axis with a force of approx.
300

÷ 400 N while turning the tool clockwise until the piston

(3) is fully retracted.

During this operation, take care not to twist the
protective cap (2) or let it swell out.

Let the air out of the cap by moving it away from the
brake caliper.

For x52 - 1x60 calipers

Figure 71

51223

Figure 72

Figure 73

109140

For all brake callipers

Drive slowly without prolonged, sudden brake
application during the first period of use of new
brake pads because braking efficiency is reduced.

Press the brake pedal repeatedly to restore pressure in the
system and correct brake pedal stroke.

Checks

109142

Check the conditions of springs (4) and sliding bushes (2);
should they be worn out, replace them.
Visually check the conditions of dust cowlings (1) and (1,
Figure 78). Should they be deformed or cracked, they must
be replaced. Remove dirt from brake caliper using a metal
brush and avoiding to damage the dust cowlings.
Clean pads rest area using suitable materials and products
(e.g. a wet cloth); on the contrary, do not use a
nitro-perchlorate based diluent, petrol, etc., which might
damage the protection cowlings.
Check brake disk surfaces and make sure that the disk is not
corroded, scored or grooved.
Slight superficial cracks are acceptable; however, brake disk
must be ground as described in relating chapter; on the
contrary, if the disk is worn out, it must be replaced.

We suggest that both brake discs be renewed also
in case one of them only needs to be replaced.
As regards brake lining

pairs, always replace a

complete series for each axle.

Always overhaul both brake calipers also in case one
of them only seems to be damaged.

109143

Fit new gaskets (4 and 5) into caliper support and check for
their freely sliding in their seats.
Fit cable (1) into brake caliper (2) and connected the cable
to braking gasket (4).
Move (

→) bush (3) inside brake caliper (2) and position it on

caliper support (6).

Figure 74

Screw screw (2) and tighten it to prescribed torque.
Mount rubber protection plug (1).
Connect the cable of wear sensor (3) to support blade and
cable connection to chassis cable.

HYDRO-PNEUMATIC SYSTEM - BRAKES

AILY

URO

Content .. 214 215 216 217 ..

Iveco Daily Euro 4. Manual - part 216