2006–2013 Iveco Stralis AS 190/260/440 S 42–56 Euro 4-5 Service & Repair Manual (P/N 603.93.531)

• 1,916-page PDF set: Stralis AS Euro 4/5 repair manual, Iveco Print 603.93.531 (1,614 pages); EBS 2/ESP/EBL manual, Print 603.93.321 (128 pages); and BC2 circuit diagrams, Print 603.93.746 (174 pages).
• Factory repair coverage centers on Stralis AS Euro 4/5 Active Space tractors and cab-equipped vehicles in 4x2, 6x2C, 6x2P, and 6x4 configurations, with model-composition charts tying the installed engine, gearbox, axle, and suspension to the vehicle code.
• Engine procedures cover F3AE3681D, F3AE3681A, F3BE3681B, and F3BE3681A removal, bench disassembly, liner and crankshaft inspection, bearing selection, cylinder-head service, camshaft and phonic-wheel timing, pump-injector setup, VGT checks, cooling-system filling, and fuel-system bleeding.
• Drivetrain sections address ZF 16S manual and EuroTronic 12AS gearboxes, clutch removal and adjustment, clutch-circuit bleeding, EuroTronic DTC-FMI diagnosis, and ZF Intarder removal, overhaul, refilling, and stator end-float adjustment.
• Axle and chassis work includes Meritor MS 13-175/D, Iveco 451391, MT 23-155/D tandem, 5876-series front/steering axles, and 55080/56082/57080 added axles, with differential and wheel-end repair, geometry checks, and hydraulic steering-axle bleeding.
• Brake, suspension, and electrical coverage includes EBS/ABS/EBL/ASR and ESP pneumatic diagrams, KNORR SN7 caliper and brake repair, ECAS diagnosis and calibration, CAN network architecture, ECU/connector data, DTC-FMI troubleshooting, and BC2 circuit and block diagrams.

The main volume is the factory mechanical and electric/electronic repair manual for Stralis AS Euro 4/5, backed by separate EBS 2/ESP/EBL and BC2 electrical publications. Iveco expressly addresses this material to qualified and specialized personnel equipped with the required workshop, lifting, testing, and diagnostic equipment.

Configuration and Powertrain Depth

The model-composition tables cover AS 440 tractors and AS 190/260 cab-equipped vehicles. Their codes distinguish rear- or all-air suspension, liftable or steering added axles, low-chassis, rough-road, hub-reduction, high-cube, and other factory layouts. This matters because the listed gearbox, axle, brake, and suspension procedures are configuration-specific.

F3A and F3B chapters go well beyond routine service. They provide assembly-clearance data, inspection and wear limits, component-specific torque tables, tightening sequences, lubrication and cooling capacities, and illustrated overhaul procedures from cylinder liners and crankshafts through the valvetrain, timing drive, pump injectors, and variable-geometry turbocharger. Dedicated Iveco tools are identified by number, including 99360612 for engine TDC positioning and 99360613 for phonic-wheel timing. The engine section also documents the optional Hydrocar timing-drive PTO and the DENOX 2/SCR dosing system.

Chassis, Cab, and Scheduled Work

Beyond the major assemblies above, the manual covers propeller-shaft and universal-joint service, ZF 8098 power-steering removal, bleeding and pressure testing, steering-angle/ESP calibration, pneumatic suspension fault diagnosis, and axle-load display calibration. Cab and chassis procedures include cab-tilt hydraulics, windshield and door work, HVAC diagnosis and refrigerant-service equipment, chassis measurement, straightening and welding guidance, plus M1/M2, Extra Plan, and time-based maintenance schedules.

Diagrams and Diagnostic Material

Useful drawings include the F3A/F3B cylinder-head tightening-sequence diagrams, configuration-specific EBS and ABS-EBL pneumatic schemes, 6x2 air-suspension working diagrams with and without an added-axle lifter, the CAN-line assembly drawing, OBD diagnosis connector views, and the BC2 system block diagram. Diagnostic coverage names MODUS, IT 2000, and E.A.SY., with cluster access, DTC/FMI tables, fault reactions, checks, and repair actions for EDC, EuroTronic, ECAS, braking, SCR, HVAC, and multiplex systems.

The manual warns that over-travel of the KNORR SN7 caliper threaded tubes can put the adjusters out of synchronization and require caliper replacement. It also cautions that forcing the VGT turbine housing during assembly can damage the variable-geometry mechanism and cause control faults.

Scope note: Full mechanical repair coverage is for Stralis AS Euro 4/5. AT/AD material in this set is limited to the separate EBS 2/ESP/EBL publication and AS-versus-AT/AD instrument-panel content in the BC2 electrical volume; this is not a complete AT/AD mechanical repair manual. Brake pneumatics, cab-tilt hydraulics, heavy component handling, refrigerant systems, and ECU work require the stated isolation procedures and appropriate shop equipment.