Iveco Daily Air Suspension Issues Explained(+5 tips)

In this brief article, we are going to discuss the Iveco Daily air Suspension problems, what the causes are, and Troubleshooting Tips to help DIY enthusiasts save on repair costs.

Most common air suspension issues in the Iveco Daily

The most common air suspension issues seen in the Iveco Daily are:

  • Rear Suspension Sagging
  • Suspension stuck in the highest position

Iveco Daily Air Suspension

The Iveco Daily is a light-commercial van sold since 1978. It was sold as the Fiat Daily till 1983. The Daily is now into its 6th generation since 2014. IT is available in Van, Minibus and Pickup Truck configurations.

The Iveco Daily has 2 rear suspension variants :

  • Parabolic with Air suspension Ride height adjustment
  • Semi-Elliptic leafspring

The air suspension has the following layout

1 – Warning light.

2 – Right level sensor.

3 – Right air spring.

4 – Chassis lifting control push button.

5 – Chassis lowering control push button.

6 – ECU.

7 – Manual chassis levelling control push button.

8 – Left air spring.

9 – Pneumatic supply unit.

10 – Left level sensor.

11 – Centralised diagnostic socket.

Rear Suspension Sagging

Symptoms:

  • Rear Bump Stops hitting often during normal driving
  • Rear suspension sits low when parked
  • Compressor working noise can be heard when trying to lift the rear but no lift is achieved

Root Causes for Iveco Daily Rear Suspension Sagging

  • The system is not inflating the Air Springs and therefore causing the rear-side of the body to sag
  • The potential causes for this type of failure would be:
    • Leakage in the Air Springs
    • Ride height sensor malfunction
    • Compressor malfunction

Troubleshooting Rear Suspension Sagging: Leakage in the Air Springs

  • Within the Air suspension, the Air Springs are the most vulnerable to failure, as they are made of reinforced rubber and they undergo maximum wear and tear during vehicle operation
  • Over time, the Air springs develop cracks and form holes through which air escapes
  • A minor leak in the air spring causes the compressor to run for longer periods because of the frequent falling of ride height. If left unattended, this could cause the compressor to overheat and seize.
  • Apart from the air spring itself, the air spring air connector O-Rings could wear out, causing air leakages
  • All leakages must be located using the Soapy Bubble Test.

Soapy Bubble Leakage Test

  • This is the same procedure to detect and fix a Tire puncture
  • Fill a Spray can with Soapy water in a 50:50 proportion
  • Spray the soapy solution on all the air suspension points where the leakage is suspected
  • Observe for Bubbles that form persistently at a particular spot even after you try wiping the foam with a finger
  • These persistent bubble spots are the leakage locations
  • A leakage test must also be done for the ‘Brass  Connector’ on the side of the Air Spring. If there are bubbles detected here then the connector must be replaced.
  • While replacing the Air spring, it must be depressurized using the Diagnostic Scan tool Depressurization function

Troubleshooting Rear suspension sagging: Compressor malfunction

  • The compressor is responsible for developing the required pressure at the Air Springs.
  • If the compressor is not able to develop the required pressure, the rear suspension will sag
  • First, check if you hear the compressor noise when you start the vehicle
  • If the compressor noise cannot be heard then 
    • Check the connector on side of the compressor. If it happens to be corroded then try cleaning it or replacing it with a new one
    • Check the 40 A Fuse under the bonnet in the fuse box. If it is blown then replace it
  • In some cases, the fuse socket could be outside of the fuse box
  • If the noise is heard, then the compressor may not be able to generate the required pressure (~4 bar) at the air springs
  • This can be verified using a diagnostic tool and measuring live data while the vehicle and compressor are both running. Look for the Pressure sensor reading to see whether it is below 4 bar
  • If the pressure reads below the operating pressure, then it could be a fault with either the compressor, the desiccator
  • The compressor must be tested by separately powering it up with a battery and using a pressure gauge to measure the output pressure. If this is below acceptable, then the compressor must either be replaced or rebuilt.
  • If the compressor diagnosis is done, then the next thing is to check the desiccator
  • The desiccator contains desiccant pellets that should ideally be blue or white in color. The desiccant expands and turns brown when totally saturated. When the desiccant is saturated, it restricts the flow of air from the compressor to the valves. The desiccant can be replaced during compressor rebuild.

Replacing / Rebuilding the Air Compressor

  • Although there are rebuild kits available for the compressor, replacement would be the most ideal solution.
  • Rebuild kits would usually contain the Teflon Piston rings, Retainer Springs and O-rings required to restore the compressor’s capability to seal air.

Troubleshooting Rear suspension sagging: Ride height sensor malfunction

  • The Ride height sensor (1) provides a signal to the Suspension ECU as to the actual ride height
  • When chassis height changes, a cam and a lever linked to the axle makes the piston move inside the coil, thus modifying its inductance.
  • The system, ideally, would signal the compressor to pressurize the air springs in order to match the nominal ride height
  • When the sensor malfunctions, signals to the ECU get disrupted, causing a low ride height at the rear suspension
  • First, check for corrosion at the electrical connector (2), then check continuity at the sensor terminals to eliminate any possible wiring problem
  • If the wiring is found to be OK then the sensor would have an internal issue, needing it to be replaced

Suspension stuck in the highest position

  • The rear Ride height is stuck at its highest position 
  • When pressing the Lowering button the suspension does not go down. 

Troubleshooting Suspension stuck in the highest position

  • Such issues generally are due to issues in the Pneumatic supply unit (item #11 in the suspension diagram), also known as the solenoid valve. 
  • If the solenoid looks rusty, replacing is the best option

Conclusion

In this brief article, we are going to discuss the Iveco Daily air Suspension problems, what the causes are, and Troubleshooting Tips to help DIY enthusiasts save on repair costs.

For any questions or comments, please feel free to get in touch with us

References

https://zinref.ru/avtomobili/Iveco/007_Iveco%20Daily_%202004_english/298.htm

Leave a Comment