Iveco Stralis 440 E 44 Cursor 13 Service Manual

Technical data on the vehicle

Technical item

Data

Make
Model
Year
Engine

Iveco LV
Stralis 440 E 44 Cursor 13
2002-2009
F3B E0681C

Variant

Engine

Engine ID code
Number of cylinders
Number of valves
Capacity/ (bore/ stroke)
Compression ratio
Max. output kW (din hp)/ rpm
Max. torque NM/ rpm
Engine code location
Vehicle Identification Number location
Vehicle identification plate location
Valve clearance, inlet (cold/ hot)
Valve clearance, exhaust (cold/ hot)
Valve angle/ seat angle
Valve height in cylinder head, mm
Oil pressure/ rpm, bar
Radiator cap, bar/ thermostat °C
Thermostat gap at test temperature
Clutch freeplay, mm
Timing gear:
Drive belt

Engine management

Engine management system
Pump/ pump type
Injector/ injector type
Crank position °/ engine piston, mm
Pump position, mm
Adjustment method
Injector opening pressure, new, bar
Injection order

Electrical system

Terminal definitions DIN 72 552

Wheel alignment

Load
Toe-in, mm
Camber°
Caster°
KPI/SAI°
Rear camber°
Rear toe-in °

Tightening torques

Tightening, NM
Cylinder head bolts, stage 1, Nm
Cylinder head bolts, stage 2, Nm
Cylinder head bolts, stage 3, Nm
Cylinder head bolts, stage 4, Nm
Cylinder head bolts, stage 5, Nm
Main bearings, Nm

Date:

06-07-2011
Owner
Registration No.
VIN

1. Reg. Date

F3B E0681C
R6
24, OHV
12880 cm³ (135,0/ 150,0)
16,5: 1
324 (440)/ 1450 - 1900
2100/ 1000 - 1470
Engine block left side
Right side rail by front wheel
Behind front grille

0.40 ± 0.05 cold i

0.60 ± 0.05 cold i
Intake 60° 30'/ 60° Exhaust 45° 30'/ 45°

Min. 1.5/ idle speed (5.0/ max. rpm)
/ 84° ± 2° C
Max. open/ 94° ± 2° C
(Hydraulic)

Bosch MS6.2 PDE
Bosch/ PDE 31
Bosch/
Electronic

1500
1 - 4 - 2 - 6 - 3 - 5

Unloaded
1,00 ± 0,75
1°
1° 24'
7°
1° i
Left wheel 0 ± 0.75/ Right wheel ÷ 2.00 ± 0.75 i

Torque standards
60 Nm oiled i
120 Nm
+ 90°
Bolts 4, 5, 12, 20, 21 = 45°
Others = 65°

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Technical item

Data

Tightening torques

Connection rod bearings, Nm
Flywheel, Nm
Crankshaft pulley/ vibration damp. Nm
Camshaft pulley/ bearings, Nm
Pump pulley/ idle wheel, Nm
Nozzle retainer/ Nozzle in cylinder head
Wheel nuts/ bolts, Nm
Wheel hub, front/ rear, Nm

Brakes

Front, min. thickness (new)
Rear, min. thickness (new)
Min. brake lining thickness, front, mm
Min. brake lining thickness, rear, mm

Capacities

Engine oil/ - incl. filter, litre
Manual transmission, litre
Final drive, litre
Power steering, litre
Cooling system, litre

Environmental parametres

Idle speed, rpm
Max rpm (exhaust test)

60 Nm + 60° oiled
120 Nm + 60° + 30° oiled
/ 70 Nm + 50°
60 Nm + 60° (Rocker arm assembly 100 Nm + 60°)
/ 30 Nm + 90°
26/
Front 665/ Rear 600
515/ 932 i

37,0/ 414,0 mm (45,0/ 410,0 mm)
37,0/ 414,0 mm (45,0/ 410,0 mm)
Pads 2.0 mm (Shoes 4.7 mm)
Pads 2.0 mm (Shoes 4.7 mm)

28,0/ 31,0 (Urania Turbo LD)

i

U177 = 18,5, RT160 centre/ rear = 18.5/ 16,5
2,7 (Tutela GI/A) i

44.0 (64.0 with retarder)

525 ± 25
2250 ± 25

Remarks

n

n
n n

Order No.:
Mechanic

nection is good. Check

Accelerator pedal sensor

Function

The spindle which is connected to the accelerator pedal operates the position sensor. The sensor comprises a carbon strip
and a stylus, the spindle operates the stylus. The stylus moves over the carbon strip, the voltage on the stylus depends on
the position at which the stylus touches the carbon strip. Based on the output voltage the control unit determines fuel
delivery.

Info

Quickcheck

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the con
supply voltage accelerator pedal position sensor: Turn off ignition. Remove connector from pedal position sensor. Turn
ignition on. Measure voltage between supply terminal and the negative terminal of the battery. It should equal specified
voltage. If not check wiring then check ECU. Check connection to ECU: Turn off ignition. Remove connector from pedal
position sensor and ECU. Measure the resistance between connectors terminal and the corresponding terminal in the ECU
connector. Should be < 1 ohm. If not check wiring. Check position sensor signal: Connect oscilloscope to the signal wire pin
of the ECU and ground. Turn ignition on and compare to the data

e of the air increases.

nection is good. Check

direct ground or to the

Air temperature sensor

Function

The air temperature sensor incorporates a NTC thermistor, the resistance decreases as the temperatur
As the temperature changes, the thermistor resistance changes, enabling the control unit to calculate the air temperature
from the level of voltage that is registered on the sensors' signal wire.

Quickcheck

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the con
resistance: Turn off ignition. Remove connector from sensor. Measure resistance between pins of the sensor. Compare with
specified resistance. Check supply voltage: Turn off ignition. Remove connector from sensor. Turn ignition on and measure
successively voltage between connector terminal and the negative terminal of the battery. One should be 5 V. If not check
wiring then check ECU. Check connection to ECU: Turn off ignition. Remove connectors from sensor and ECU. Measure the
resistance between supply voltage connector terminal and the corresponding terminal in the ECU connector. It should be <
1 ohm. If not check wiring. Check ground: Check in schematic if ground connection is connected to a
ECU. When it is connected directly to ground: Turn off ignition. Remove connector from sensor and measure resistance
between ground connector terminal and the negative terminal of the battery. It should be < 1 ohm. If not check wiring.
When it is connected to the ECU: Turn off ignition. Remove connector from sensor and ECU. Measure resistance between
ground connector terminal and the corresponding terminal in the ECU connector. It should be < 1 ohm. If not check wiring
then check ECU.

s passing through the

nection is good. Check

ery. Check the second

Boost pressure valve

Function

The solenoid controls a valve which opens or closes the air line between the waste gate valve and vacuum. When the valve
opens vacuum is applied to the waste gate valve, which in turn regulates the amount of exhaust gasse
exhaust gas turbine. In this way the turbo pressure is regulated.

Quickcheck

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the con
resistance: Turn off ignition. Remove connector from solenoid. Locate the two pins of the solenoid. Measure resistance
between the two pins of the solenoid. Compare with specified resistance. Alternatively you can check functioning of the
solenoid by applying battery voltage to the two pins of the solenoid, the solenoid should "click". Check supply voltage: Turn
off ignition. Remove connector from solenoid. Locate the two connector terminals of the solenoid. Start the engine and
measure voltage between one connector terminal of the solenoid and the negative terminal of the batt
terminal of the solenoid, one of the two should equal the battery voltage. If not check wiring and if present fuse and relay.
Check connection to ECU: Turn off ignition. Remove connectors from solenoid and ECU. Locate the two connector terminals
of the solenoid. Measure the resistance between one of the two connector terminals of the solenoid and the corresponding
terminal in the ECU connector. Check the other terminal of the solenoid, one of the two should be < 1 ohm. If not check
wiring.

ery. Both should equal

Brake pedal switch

Function

Engaging the brakes is detected by the brake pedal switch. There are single and double switches. Single switches send a
voltage signal to the control unit, thus signaling that the brakes are engaged. In a double switch the additional switch
actuates the brake lights.

Fault finding:
Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good.
Check supply voltage:
Turn off ignition. Remove connector from brake pedal switch.
Turn ignition on. Measure voltage between connector terminal + and the negative terminal of the batt
battery voltage. If not check wiring, relay and fuse(s).
Check connection to ECU:
Turn off ignition. Remove connector from brake pedal switch.
Measure the resistance between connector terminal + and - and the corresponding terminals in the ECU connector. Both
should be < 1 ohm. If not check wiring.
Check switch signal:
Connect oscilloscope or voltage meter to the pin of the ECU which corresponds to the brake pedal switch and ground. Turn
ignition on, output voltage should equal battery voltage. Press brake, output voltage should be 0 V. Connect oscilloscope or
voltage meter to the pin of the ECU which corresponds to the brake light switch and ground. Turn ignition on, output
voltage should be 0 V. Press brake, output voltage should equal battery voltage.

CAN BUS SAE J1708

Function

CAN bus connection SAE J1708 is a data chain used to send trouble code information etc. The voltage on the data chain
varies and depends on the number of ECUs and the traffic on the line.

CAN BUS SAE J1939

Function

CAN bus connection SAE J1939 is an electric control chain used to send data that the system uses for control functions. The
voltage on the control chain varies and depends on the number of ECUs and the traffic on the line.

Info

ECU lamp

Function

The control unit actuates the check engine light when it senses inadequate functioning of the motormanagement system.

specified resistance.

resistance between

ng. When it is connected

Coolant temperature sensor

Function

The coolant temperature sensor incorporates a NTC thermistor, the resistance decreases as the temperature of the coolant
increases. As the temperature changes, the thermistor resistance changes, enabling the control unit to calculate the coolant
temperature from the level of voltage that is registered on the sensors' signal wire.

Quickcheck

Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good. Check resistance: Turn off
ignition. Remove connector from sensor. Measure resistance between pins of the sensor. Compare with
Check supply voltage: Turn off ignition. Remove connector from sensor. Turn ignition on and measure successively voltage
between connector terminal and the negative terminal of the battery. One should be 5 V. If not check wiring then check
ECU. Check connection to ECU: Turn off ignition. Remove connectors from sensor and ECU. Measure the
supply voltage connector terminal and the corresponding terminal in the ECU connector. It should be < 1 ohm. If not check
wiring. Check ground: Check in schematic if ground connection is connected to a direct ground or to the ECU. When it is
connected directly to ground: Turn off ignition. Remove connector from sensor and measure resistance between ground
connector terminal and the negative terminal of the battery. It should be < 1 ohm. If not check wiri
to the ECU: Turn off ignition. Remove connector from sensor and ECU. Measure resistance between ground connector
terminal and the corresponding terminal in the ECU connector. It should be < 1 ohm. If not check wiring then check ECU.

Diagnostic connector

Function

The diagnostic connector is connected to the control unit. It facilitates communication with the control unit to get
information on stored error codes and/or operating states of sensors and actuators.

Fault finding:
"Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good.
Check in schematic which diagnostic connector terminal is (are) connected to the connector terminal(s) of the ECU
connector or ground. Measure the resistance between the ECU connector terminal(s) and each pin of the diagnostic
connector. The resistance between the ECU connector terminal(s) and the corresponding terminal in the diagnostic
connector should be < 1 ohm.
Measure the resistance between the negative terminal of the battery and each pin of the diagnostic connector. The
resistance between the negative battery terminal and the corresponding terminal in the diagnostic connector should be < 1
ohm.

nector terminal(s) and

ECU

Function

The control unit is the electronic processing unit for the motormanagement system. The control unit has to ensure that the
engine receives the right amount of fuel, the right injection timing and a proper idle control in every operating state. The
control unit uses sensors to determine engine operating conditions. Depending on the engine conditions, the control unit
activates actuators.

Quickcheck

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good. When
you suspect the control unit is faulty make sure all sensors, actuators and the communication with other control units
function properly. Furthermore check the supply voltage and ground connections of the control unit: Turn ignition off.
Remove ECU connector. Locate the supply voltage connections. Turn ignition on, measure voltage between corresponding
connector terminal(s) and the negative terminal of the battery, these should equal battery voltage. If not check wiring and
fuse. Turn ignition off. Locate the ground connections. Measure resistance between corresponding con
the negative terminal of the battery, these should be < 1 ohm.

nection is good. Check

Exhaust pressure sensor

Function

The pressure in the exhaust is measured using the exhaust pressure sensor. The sensor is a transducer, the sensor senses
the absolute pressure in the exhaust and transduces this to a DC voltage signal.

Quickcheck

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the con
supply voltage: Turn off ignition. Remove connector from sensor. Turn ignition on and measure voltage between the
supplyterminal and negative terminal of the battery. It should be 5 V. Check connection to ECU: Turn off ignition. Remove
connector from sensor and ECU. Measure the resistance between the terminals and the corresponding terminals in the ECU
connector. They all should be < 1 ohm. If not check wiring.

nection is good. Check

iesel pump and ECU.

Fuel temperature sensor

Function

The fuel temperature sensor incorporates a NTC thermistor, the resistance decreases as the temperature of the fuel
increases. As the temperature changes, the thermistor resistance changes, enabling the control unit to calculate the fuel
temperature from the level of voltage that is registered on the sensors' signal wire.

Quickcheck

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the con
resistance: Turn off ignition. Remove connector from diesel pump. Measure resistance between pin 1 and 2 of the
connector. Compare with specified resistance. Check supply voltage: Turn off ignition. Remove connector from diesel pump.
Turn ignition on and measure voltage between terminal 4 and the negative terminal of the battery. It should equal 5 V. If
not check wiring then check ECU. Check connection to ECU: Turn off ignition. Remove connector from d
Measure the resistance between terminal 1, 2 and the corresponding terminals in the ECU connector, each one should be <
1 ohm. If not check wiring.

Inductive position sensor 1

Function

Function:
The sensor contains three parts: a coil, a magnet and a soft iron core. The teeth of a gearwheel move past the magnetic
pickup which changes the magnetic field of the magnet, increasing when a tooth approaches and decreasing when a tooth
moves away. These changes result in an AC voltage produced in the coil. Engine rpm and/or TDC are determined in this
way.

Trouble shooting:
"Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good.
Check resistance:
Turn off ignition. Remove connector from pickup sensor.
Measure resistance between the two pins of the coil of the pickup sensor. Compare with specified resistance.
Check connection to ECU:
Turn off ignition. Remove connector from pickup sensor and ECU.
Measure the resistance between each coil connector terminal and the corresponding terminals in the ECU connector. Both
should be < 1 ohm.
If present check shield connection:
Check in schematic if the shield terminal is connected to a direct ground or to the ECU. When it is connected to a direct
ground: Turn off ignition. Remove connector from pickup sensor. Measure resistance between the shield connector terminal
and the negative terminal of the battery. It should be < 1 ohm. When it is connected to the ECU: Turn off ignition. Remove
connector from pickup sensor and ECU. Measure the resistance between the shield connector terminal and the
corresponding terminal in the ECU connector. It should be < 1 ohm. If not check wiring.
Check sensor signal:
Connect oscilloscope to signal wire pin of the ECU and ground. Start or crank the engine and compare to the scope image
shown."

Info

Inductive position sensor 2

Function

Function:
The sensor contains three parts: a coil, a magnet and a soft iron core. The teeth of a gearwheel move past the magnetic
pickup which changes the magnetic field of the magnet, increasing when a tooth approaches and decreasing when a tooth
moves away. These changes result in an AC voltage produced in the coil. Engine rpm and/or TDC are determined in this
way.

Trouble shooting:
"Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good.
Check resistance:
Turn off ignition. Remove connector from pickup sensor.
Measure resistance between the two pins of the coil of the pickup sensor. Compare with specified resistance.
Check connection to ECU:
Turn off ignition. Remove connector from pickup sensor and ECU.
Measure the resistance between each coil connector terminal and the corresponding terminals in the ECU connector. Both
should be < 1 ohm.
If present check shield connection:
Check in schematic if the shield terminal is connected to a direct ground or to the ECU. When it is connected to a direct
ground: Turn off ignition. Remove connector from pickup sensor. Measure resistance between the shield connector terminal
and the negative terminal of the battery. It should be < 1 ohm. When it is connected to the ECU: Turn off ignition. Remove
connector from pickup sensor and ECU. Measure the resistance between the shield connector terminal and the
corresponding terminal in the ECU connector. It should be < 1 ohm. If not check wiring.
Check sensor signal:
Connect oscilloscope to signal wire pin of the ECU and ground. Start or crank the engine and compare to the scope image
shown."

Info