Iveco Daily Common Faults and Problems

The Iveco Daily has built a strong reputation across Europe as a rugged and capable commercial van. Designed on a truck-style chassis, it’s known for its durability and high load capacity. However, each generation comes with its own set of technical issues. This guide outlines the most common faults by generation, covering models from the first Daily in 1978 to the latest facelifted version.

Iveco Daily I Common Problems (1978 - 1989)

The first-generation Daily, originally introduced under the Fiat badge, marked the beginning of a long-lived platform. Despite its heavy-duty build, the early models were not free of faults.

Electrical System Faults

Frequent issues with electrical system — slow operation or complete failure.
General wiring unreliability due to aging components and poor moisture protection.
Requires replacement or re-wiring in problem areas.

Seals and Water Ingress

Loose or degraded door and window seals caused water leaks and cabin drafts.
Often led to interior damp and corrosion around door edges.
Fix involved resealing or replacing weatherstripping completely.

Brake Caliper Seizure

Front brake pistons were known to seize due to corrosion or lack of maintenance.
Results in uneven braking, overheating, and premature pad wear.
Solution: Regular brake servicing and caliper rebuild kits.

Chassis and Structural Rust

Rust on the chassis and cab floor was common, especially in high-mileage vehicles.
Areas around spring mounts and lower panels were particularly affected.
Prevention required underbody treatment and repair often involved welding.

Iveco Daily I Facelift (1989 - 1999)

The facelifted Daily improved on many of the previous generation’s weaknesses. While still based on a ladder frame, it introduced upgraded engines and better rustproofing.

Clutch Cable Wear

Manual clutch cables were prone to fraying and snapping without warning.
Often preceded by heavy clutch pedal feel.
Preventive maintenance involved early replacement and lubrication.

Drive Shaft and U-Joint Issues

Worn universal joints or center bearings caused driveline vibrations.
Ignoring symptoms could result in shaft imbalance or failure.
Routine inspection and timely bearing replacement helped prevent damage.

Brake System Maintenance

Brake sliders needed regular lubrication to avoid sticking calipers.
Long-term neglect could lead to brake imbalance and dragging.
Frequent servicing was key to reliability.

Brake pads front Iveco Daily 1999

Leaf spring Iveco Daily 2006-2014 single Trateo

Oil pan Iveco Daily 2006 3.0 HPI HPT Trateo

Propshaft centre bearing 45mm Iveco Daily 1989-2006 Trateo

Iveco Daily II Common Problems (1999 - 2006)

The second-generation Daily introduced common-rail diesel engines and better refinement. However, several reliability concerns became apparent with use.

Propeller Shaft Vibration

Driveshaft center bearings and U-joints frequently wore out.
Symptoms included knocking or high-speed vibration.
Recommended fix: Replacing support bearing and rebalancing the shaft.

Wiring Harness Water Ingress

Water infiltration into chassis wiring loom caused electrical shorts.
Resulted in blown fuses, no-start issues, and burnt wiring in extreme cases.
Fix involved sealing harnesses and re-routing exposed sections.

Front Brake Caliper Seizure

Brake pistons would seize due to poor pin lubrication.
Caused dragging brakes and premature disc wear.
Solution: Service calipers regularly and replace pins as needed.

Clutch Cable Failure

Like the facelifted Daily I, clutch cables continued to snap unexpectedly.
Heavier-duty aftermarket cables provided longer service life.
Early detection involved checking pedal feel and visible cable wear.

Iveco Daily II Facelift Common Problems (2006 - 2014)

This generation received Euro 4 and later Euro 5 engines, including the popular 2.3 HPI and 3.0 HPT diesels. While generally more refined, several issues began to emerge related to emissions and electronics.

EGR Valve Clogging (2.3 HPI / 3.0 HPT)

Common problem with stop-start urban driving and poor quality fuel.
Symptoms: rough idle, hesitation, and warning lights (P0401/P0402).
Cleaning the valve or full replacement often required every 60,000–90,000 km.

DPF Clogging and Regeneration Failure

Blocked diesel particulate filters were a common complaint on Euro 5 versions.
Warning messages and limp mode triggered by incomplete regeneration cycles.
DPF cleaning, sensor replacement, or ECU software update often needed.

Injector Seal Leaks (3.0 HPT)

Blow-by from injector seals leads to carbon buildup and fuel odors in the cabin.
Black deposits around injectors are an early sign.
Repair includes cleaning, re-sealing, and sometimes replacing injectors.

ABS Sensor Failures

Frequent on rear axle sensors—causing intermittent ABS/ESP warnings.
Wiring damage or corrosion at the hubs was usually the cause.
Cleaning or replacing sensors and securing wiring was the solution.

Iveco Daily III Common Faults (2014 - 2019)

This version brought a full redesign and improved fuel economy, as well as more advanced driver-assistance features. Nevertheless, issues persisted in engine components and electronic systems.

Turbocharger Actuator Failure (2.3 HPI)

Actuator motor failure led to underboost conditions or limp mode.
Often caused by heat and vibration or poor electrical contacts.
Replacement actuator or complete turbo may be necessary.

Crankcase Breather Leaks

Oil mist or residue around the intake system or intercooler pipes.
Caused by cracked breather hoses or faulty oil separator.
Fix: Replace separator assembly and hoses.

Battery Drain and BCM Errors

Battery drainage caused by faulty Body Control Module (BCM) keeping circuits alive.
Random electrical faults including interior lights, door locks, and warning lights.
Resetting the BCM or replacing it solved recurring problems.

Iveco Daily III Facelift Common Problems (2019 - )

The latest facelift brought Euro 6d diesel engines and updated infotainment. However, new problems emerged mainly tied to emissions systems and sensors.

NOx Sensor and AdBlue Failures

Frequent AdBlue-related warning messages like “Engine start not possible in x km.”
Common codes: P229F (NOx sensor), P20EE (SCR efficiency).
Solutions include sensor replacement, injector cleaning, and ECU resets.