Iveco Van Parts UK - Quality Used & Genuine Parts

How to Replace Iveco Daily Headlights

Iveco Daily headlight replacement is straightforward and can be completed in 20-30 minutes per side. The 2024 model year Daily features updated lighting systems with improved visibility and safety compliance.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely. Locate the rear of the headlight assembly from within the engine bay. The Daily's commercial design provides good access to headlight mounting points. On diesel models, the 2.3L or 3.0L Cursor engine sits further back allowing clear access. On eDaily electric models, the motor placement provides even better clearance for headlight work.
2. Disconnect all electrical connectors. Iveco Daily headlights typically have 2-3 electrical connectors depending on specification. These include main beam, dipped beam, and side light connections. On models with DRL (daytime running lights), there may be additional connectors. Press the release tabs carefully and pull straight out to disconnect each connector. Note their positions for correct reconnection.
3. Remove the headlight mounting bolts. Most Iveco Daily models use T20 or T25 Torx screws to secure the headlight assembly. There are typically 3-4 mounting bolts along the top and side edges accessible from the engine bay. On 2024 model year Dailys with updated lighting systems, mounting may differ slightly but remains accessible. Remove all mounting bolts completely and keep them organized for refitting.
4. Release any additional clips or retainers. Some Daily headlights use supplementary plastic clips at the bottom or inner corner for additional security. These clips can become brittle with age, especially on vans operating in harsh commercial environments. Work carefully to avoid breaking clips. If clips are damaged, replacement clips are available from Iveco breakers.
5. Carefully remove the headlight assembly. With all bolts and clips released, gently pull the headlight straight forward out of its mounting position. Iveco Daily headlights are secured on locating pins that ensure correct alignment. Support the weight as you pull to prevent dropping. The headlight assembly is moderately heavy on Daily vans due to robust commercial-grade construction.
6. Transfer components to new headlight if needed. If your replacement headlight doesn't include bulbs, transfer these from the old unit. When handling bulbs, wear clean gloves to avoid touching glass surfaces with bare hands as oils cause premature bulb failure. H7 bulbs are commonly used in Daily headlights. Check bulb type before ordering replacements.
7. Install the new headlight assembly. Reverse the removal process by aligning the new headlight with mounting pins and push firmly into place ensuring all locating pins engage correctly. Refit all mounting bolts and tighten securely. Reconnect all electrical connections ensuring each clicks firmly into place. Test all lighting functions before closing the bonnet including dipped beam, main beam, side lights, and indicators to verify correct installation.

Important Notes: Iveco Daily headlight replacement is straightforward for most owners. The commercial vehicle design provides practical access for maintenance. When handling new headlights, never touch lens or reflector surfaces. On 2024 model year Dailys with advanced safety systems, headlight coding may be required to avoid warning lights appearing on the digital instrument cluster. Check headlight alignment after fitting using adjustment screws on the rear of the assembly for optimal visibility and safety compliance.

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How to Replace Iveco Daily Front Bumper

Replacing an Iveco Daily front bumper is achievable in 60-90 minutes depending on specification. The Daily's commercial construction and ladder-frame chassis means bumper mounting differs from unibody vans like Transit or Sprinter.

Step-by-Step Instructions:

1. Open the bonnet and secure it with the prop rod. Locate the upper bumper mounting fixings along the top edge just below the grille area. Iveco Daily models have 4-6 Torx screws or bolts securing the bumper to the front panel. These are typically T20 or T25 Torx screws on most Daily models. On 2024 model year vans with updated front styling, mounting may include additional fixings. Remove all upper fixings systematically and keep them organized.
2. Access the wheel arch areas on both sides. Turn the steering wheel fully to one side to maximize access to the wheel arch liner. Behind each front wheel, locate the plastic arch liner. Remove or release 3-5 plastic clips or screws securing the front section of the arch liner to expose side bumper mounting points. Iveco uses plastic push-in clips that release by pressing the center pin first, then pulling the entire clip out. Repeat on both driver and passenger sides.
3. Remove the side mounting screws from both wheel arches. Behind each wheel arch liner, you'll find 2-3 screws or bolts securing each side of the bumper to the chassis. These are usually T20 or T25 Torx screws on Daily models. The ladder-frame chassis construction means side mountings are robust and may be slightly different from unibody van designs. Remove all side fixings on both sides and keep track of them for refitting.
4. Remove undertray screws and lower bumper fixings. Get underneath the vehicle safely using ramps or jack stands. Locate and remove all screws and clips securing any engine undertray sections and the lower edge of the bumper. Iveco Daily typically uses 6-10 fixings along the bottom edge. These may be Torx screws or plastic push-in clips depending on model year and specification. You may need to remove sections of undertray for full access.
5. Disconnect fog lights, sensors, and electrical connections. Reach behind the bumper and disconnect all electrical connectors including fog lights if fitted, parking sensor connections if equipped with parking assist on higher specifications, and any additional connections for cameras or radar on 2024 models with advanced driver assistance systems. Press release tabs carefully and pull straight out. Count connections as you disconnect them to ensure correct reconnection during refitting.
6. Release the bumper from chassis mounting brackets. The Iveco Daily's bumper mounts to the ladder-frame chassis via metal brackets. With all fixings removed, the bumper should pull away from these brackets. You may need to wiggle the bumper slightly to release it from mounting tabs. The commercial-grade construction means Daily bumpers are heavier and more robust than typical van bumpers. A second person is helpful for supporting the bumper during removal.
7. Remove the bumper completely from the vehicle. With all fixings removed and brackets released, carefully pull the bumper straight forward away from the vehicle. Support the bumper properly as Daily bumpers are heavy commercial-duty components. Place the removed bumper on a protected surface to avoid scratching or damaging the painted surface if you plan to reuse or sell it.
8. Prepare and fit the replacement bumper assembly. Before installation, transfer any brackets, trim pieces, or components from the old bumper if not fitted to your replacement. Check that all fog light surrounds, grille sections, and mounting brackets are properly attached to the new bumper. Align the new bumper with chassis mounting brackets and push into place ensuring all mounting tabs engage correctly with the ladder-frame chassis. Reconnect all electrical connections including fog lights and parking sensors. Systematically secure with all screws, bolts, and clips in reverse order of removal. Test all electrical functions including fog lights, parking sensors, and DRLs before final assembly. Check all panel gaps are even on both sides.

Top Tips: Iveco Daily bumpers are built for commercial durability and are heavier than car-derived van bumpers. When refitting parking sensors, ensure each clicks firmly into its mounting hole and sits flush with the bumper surface for correct operation. On 2024 model year Dailys with radar systems for autonomous emergency braking or adaptive cruise control, sensor calibration may be required after bumper replacement at an Iveco specialist. The ladder-frame chassis construction means mounting is robust but requires proper alignment. Take photos before removal to aid refitting.

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Common Iveco Van Parts Problems & Solutions

Iveco vans are renowned for heavy-duty construction and commercial vehicle engineering. The Daily has been in production for over 30 years with more than 1,800,000 units built, and holds a very good reliability rating of 732 out of 999 according to VehicleScore. The brand offers an industry-leading 5-year or 100,000-mile warranty and service intervals up to 37,000 miles. However, certain components can experience specific issues particularly on higher-mileage examples. Here are the most commonly reported Iveco van parts problems based on verified data from UK operators, mechanics, and commercial vehicle specialists.

DPF (Diesel Particulate Filter) Blockages - Most Common Issue:

• Widespread Problem Affecting All Diesel Models: DPF blockages are the single most common issue affecting Iveco Daily vans, particularly models from 2010 onwards with Euro 5 and Euro 6 emission standards. The DPF works by trapping soot particles from exhaust gases but requires regular regeneration at high temperatures to burn off accumulated soot. When regeneration fails or is incomplete, the DPF becomes blocked causing severe performance issues and potentially expensive repairs.
• Symptoms and Warning Signs: White smoke billowing from exhaust during regeneration attempts making the van look like it's on fire, regeneration incomplete fault code appearing on dashboard, limp mode activation restricting engine to 1500 RPM, loss of power during acceleration, increased fuel consumption, DPF warning light illuminated, fault codes P2002 (resistance too high), P1205 (resistance too low), P1206 (resistance issue), and P2452 (differential pressure sensor out of range). In severe cases, the van may refuse to start or go into limp mode repeatedly requiring roadside assistance.
• Root Causes: Short urban journeys preventing DPF from reaching regeneration temperature of 600 degrees Celsius, using incorrect engine oil that is not low-SAPS ACEA C2 specification causing rapid DPF blocking, faulty injectors leaking excess diesel into the DPF, EGR valve blockages affecting exhaust flow, turbocharger issues preventing correct boost pressure, differential pressure sensor failures giving false readings, and induction system air leaks causing incorrect fuelling. One faulty injector can cause weekly DPF blockages according to Daily owners. Wrong oil is a major cause of rapid DPF failure.
• Repair Costs and Solutions: DPF cleaning costs £300-£800 depending on method used, with pressure washing and chemical cleaning providing temporary relief. New DPF replacement costs £800-£2,500 depending on model and supplier. However, if the underlying cause is not addressed, new DPFs will block again quickly. Proper solution requires diagnosing and fixing root cause such as faulty injectors, EGR cleaning, or turbo repair. Some operators opt for DPF removal and ECU remapping but this is illegal for road use in the UK and will cause MOT failure under current emissions testing regulations.
• Prevention: Use only low-SAPS ACEA C2 specification engine oil, never use standard oil. Perform regular longer motorway runs allowing DPF to reach full regeneration temperature. When regeneration starts indicated by increased fan noise and fuel consumption, continue driving for 15-20 minutes to allow completion. Maintain engine RPM at 3000 RPM during manual regeneration procedures. Address any injector, EGR, or turbo faults immediately before they cause DPF damage. Change engine oil at recommended intervals without extending service periods.

Injector Failures - Very Common and Expensive:

• Frequent Replacement Required: Iveco Daily vans commonly require multiple sets of replacement injectors during their service life. Fleet operators report needing injector replacements at £1,400 per complete set, with some vans requiring multiple sets even when relatively new. One reported case involved a Daily needing injectors after only a few months despite Iveco claiming poor fuel quality, though laboratory fuel analysis proved the diesel was perfectly fine. Injector problems are endemic on Daily models with 2.3L and 3.0L engines.
• Symptoms of Injector Problems: Decreased fuel efficiency with van using significantly more diesel than normal, decreased engine power and poor performance, slow or weak acceleration, rough idle and engine vibration, unusual engine noises including knocking or rattling sounds, engine misfires, check engine light illuminated, injector warning light flashing red on dashboard, and when injector light activates the engine won't rev beyond 1500 RPM even when stationary. Injector issues often contribute to DPF blockages by introducing excess unburned fuel into the exhaust system.
• Expected Lifespan and Failures: Injectors are typically designed to last up to 100,000 miles but many Iveco Daily injectors fail well before reaching this mileage. The causes include poor fuel quality, deposit buildup on injector tips, internal wear, electrical faults in injector control circuits, and ECU management issues. When one injector fails, it often causes imbalanced fuelling leading to DPF problems and potential damage to other injectors. Testing injector balance is essential for diagnosis.
• Repair Costs: Complete set of four injectors costs £1,400 or more depending on supplier and specification. Individual injector replacement is possible but when one fails others often follow soon after, making complete set replacement more economical long-term. Labour costs add £200-£500 depending on accessibility. Injector removal can be difficult on high-mileage engines with carbon buildup. Some specialists offer injector reconditioning services at lower cost but reliability varies.

Turbocharger Problems:

• Turbo Vane Sticking and Actuator Failures: Variable geometry turbochargers on Daily vans suffer from vanes sticking open or closed due to carbon buildup, causing underboost or overboost conditions. Symptoms include loss of power particularly at idle, EDC (Electronic Diesel Control) warning light, fault code 194 for boost pressure too low, and turbo not responding correctly to load demands. If vanes stay open when returning to idle, underboost results. Sticking can be caused by faulty vacuum solenoid allowing too much vacuum into the actuator or by the turbo vanes themselves being stuck with carbon deposits.
• Complete Turbo Replacement: Severe turbo failures require complete turbocharger replacement. Some operators report needing new turbo and actuator assemblies after DPF problems or injector failures have caused damage. Turbo replacement costs £800-£2,000 including labour depending on model and turbo specification. The 2.3L and 3.0L engines use different turbos with different price points.
• Vacuum System Issues: The turbo actuator operates via vacuum supplied through solenoid valves. Vacuum leaks, clogged vacuum lines, or faulty solenoid valves can prevent correct turbo operation. EGR solenoid and turbo actuator solenoid are located under the power steering reservoir with the EGR on top. Testing with a handheld vacuum pump helps diagnose vacuum system problems before expensive turbo replacement.

EGR Valve Blockages:

• Carbon Buildup Causing Restricted Flow: The EGR (Exhaust Gas Recirculation) valve recirculates exhaust gases to reduce emissions but becomes blocked with carbon deposits over time. Blocked EGR valves affect engine performance, contribute to DPF problems, and cause poor running. Symptoms include loss of power, rough idle, increased smoke, and check engine light. EGR valve cleaning or replacement costs £300-£800. Blanking the EGR is sometimes done but affects emissions compliance.

Electrical and Build Quality Issues:

• Frequent Light Bulb Failures: Multiple Daily owners report having to change light bulbs for both exterior and interior lights repeatedly due to circuit problems. Despite dealers claiming to fix electrical issues when vans are sold, the problems persist throughout ownership indicating underlying wiring or circuit design faults.
• Trim and Interior Wear: Plastic trim pieces on the exterior fall off requiring repair with tape. Keys and rubber gearknobs fall apart after approximately one year of use. This is disappointing given Iveco's commercial vehicle heritage, though it reflects the competitive pricing positioning of the Daily.

Payload Limitations (3.5 Tonne Models):

• Reduced Payload Capacity vs Competitors: The Daily's heavy-duty ladder-frame chassis and truck-derived construction provides exceptional strength and versatility but results in a heavier unladen weight. At 3.5 tonnes GVW, the maximum payload is only 1,362kg which is almost 300kg less than a Renault Master can carry. This limitation means operators choosing 3.5-tonne Daily models for car licence eligibility sacrifice significant cargo capacity compared to lighter-built competitors like Transit, Sprinter, or Master.
• High Loading Floor: The rear-wheel drive chassis layout results in a higher loading floor than front-wheel drive competitors, making loading and unloading more physically demanding for operators. This is a compromise of the robust construction that enables higher GVW variants up to 7.2 tonnes.

Dealer Network and Parts Availability:

• Limited Dealer Coverage: There are fewer Iveco dealers compared to mainstream van brands like Ford, Mercedes, or Vauxhall. While dealers are spread across the UK and servicing is thorough with good parts stock, finding nearby specialist support can be challenging in some regions. This can increase downtime if repairs require dealer attention. Fortunately Iveco's telematics and connected services offer remote diagnostics and predictive maintenance helping prevent breakdowns.

Iveco Daily Reliability Assessment:

Very Good Overall with Known Weaknesses: The Iveco Daily achieves a very good reliability rating of 732 out of 999 according to VehicleScore UK MOT analysis. The van is backed by an industry-leading 5-year or 100,000-mile warranty demonstrating Iveco's confidence in build quality. Service intervals can be extended up to 37,000 miles which is class-leading and reduces maintenance costs for fleet operators. With over 1,800,000 Daily vans built across 30+ years of production, the platform is proven and mature. The ladder-frame chassis construction provides exceptional durability and longevity with many Dailys reaching 200,000+ miles in commercial service.

DPF and Injector Issues Dominate: However, the Daily suffers from endemic DPF and injector problems that cause frustration and expense for operators. DPF blockages are the most common fault requiring frequent regeneration attempts, cleaning, or replacement. Using incorrect oil that is not low-SAPS ACEA C2 specification accelerates DPF failure. Injectors fail frequently costing £1,400 per set with some vans requiring multiple replacements. These issues are particularly problematic for urban delivery operations with short stop-start journeys that prevent proper DPF regeneration.

Prevention is Essential: To maximize Daily reliability, operators must use only low-SAPS ACEA C2 engine oil, perform regular longer runs to enable DPF regeneration, address injector and turbo faults immediately, keep EGR systems clean, and use quality fuel from major suppliers. The Daily rewards proper maintenance with long service life but punishes neglect with expensive emissions system failures. For operators needing heavy-duty capability, high GVW ratings, or maximum load volume, the Daily remains an excellent choice despite its known issues.

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