Iveco Daily. Manual

62110

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

102313

62112

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

Revi - February 2005

STEERING GEAR

AILY

Base - May 2004

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

6
7

STEERING GEAR

AILY

Base - May 2004

86010

86011

86012

Use suitable pincers to loosen the retainer clamps (2 and 4),
remove the protective boot (3) from the power steering box
(1) and move it aside to access the steering linkage connection
(5) to the rack rod.

Tighten the rack rod (2) in a vice with lead covered jaws,
loosen the joint (3) and remove the steering linkage (4).
Remove the o-ring (1). Repeat the operations to remove the
opposite steering linkage. Follow the removal/refitting
operations described in the respective sections to reuse ball
joints.

Reassemble by reversing the disassembly sequence; observe
the following precautions:

- replace o-rings (1) and clamps (2 and 4) with new parts;

- lubricate (

→) protective boot (3) seats on power steering

unit (10) to facilitate assembly of the boots;

- tighten steering linkage joints (5) at 100

± 10 Nm (10 ±

1 kgm).

POWER STEERING SYSTEM SPARE PARTS

1. O-ring - 2. Clamp - 3. Protective boot - 4. Clamp -

5. Steering linkage - 6. Nut - 7. Head - 8. Tube - 9. Tube -

10. Power steering unit - 11. Rubber bushing.

Figure 23

Figure 24

Figure 25

Do not take the rack rod (2) to end of stroke after
removing the linkage (4) to avoid damaging the
power steering o-rings.

Refitting

Rubber bushing replacement procedure

Use a suitable ram to remove/refit rubber bushings (11).

STEERING GEAR

AILY

Base - May 2004

Steering linkage replacement

Removal

As soon as the hydraulic force (pressure difference multiplied
by the piston surface (4)) exceeds the spring force, the piston
moves leftward so that the exceeding oil returns in the suction
channel (11) of the pump, through the free hole. In this way
the steering gear is fed by a delivery of hydraulic oil almost
constant at any speed of the pump (and therefore of the
engine).
An overpressure valve (3) is fitted in the delivery relief piston (4).

When an overpressure occurs in the hydraulic circuit, the oil
pressing on the valve (3) increasing the pressure, overcomes
the spring resistance and through an hole, discharge in the
suction channel (11) of the pump.
In this way, the oil pressure adjustment is obtained.

19597

Figure 26

8140 ENGINE POWER STEERING PUMP OPERATION

Operation
Rotating the shaft (5) and the rotor (8) joined to it and the
blades (6) able of a radial motion, are pressed by their
centrifugal force and by the oil pressure against the guide track
of the stator (7).
Each couple of near blades forms a chamber, which has as side
limits thrust plates (9 and 10).
The suction and delivery chambers are arranged so that the
radial hydraulic stresses exerted on the rotor (8) balance one
another.
Four splines both made on the front plate cover side (10) and
in the internal plate (9), make the oil under pressure reach the
surfaces of the blades directed to the rotation centre, helping
in this way the centrifugal force.
The oil coming from pressure chambers comes to the delivery
relief valve through holes and then, through a choke (2) at the
delivery joint (1)
The oil under pressure downstream the choke is sent, through
suitable holes, to the side fitted with spring of the delivery relief
piston (4).
Increasing the number of turns, and therefore the pump
delivery, an increasingly higher difference in pressure between
the chambers upstream and downstream the choke is caused
on the side fitted with spring of the piston (4).

HIGH PRESSURE

LOW PRESSURE

8140 engine power steering pump

STEERING GEAR

AILY

Base - May 2004

POWER STEERING PUMP

Content .. 310 311 312 313 ..

Iveco Daily. Manual - part 312