Engines

Repair Manual
INTRODUCTION

Welcome to the world of MAN Trucks India Pvt. Ltd. We are

pleased to present the first edition of the MAN Trucks Workshop
Manual. It will serve you as a reference to assist in vehicle
maintenance.
For the convenience of the user the Workshop Manual has been
divided into groups and are listed in a logical manner starting from
engine through rear box, transmission, axle and finally the cabin.

For the best results and continued operational reliability of the MAN
Trucks it is absolutely necessary to follow the instructions
given in this Workshop Manual.

In view of improvements being made on a continuous basis the

details given in this Workshop Manual may under go change.

Such changes will be intimated to out dealers through circulars

issued by our Service Department. The circulars may be used to
make necessary amendments in your original copy of Workshop
Manual.

Considerable efforts have been taken to ensure that the repair

manual is error free and easy to understand. We are confident that
you will find it very useful in carrying out repair operations.

(Pravin Matey)

Head - After Sales

PREFACE

This manual is intended to provide assistance in performing repairs correctly on vehicles and units and
reflects the known technical situation appertaining at the copy deadline.
This publication assumes that persons who use it possess the requisite technical knowledge in handling
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always
correspond to the unit in question, but this does not necessarily mean they are incorrect. In such cases,
plan and carry out the repair work in accordance with the sense of the instructions.
Repair work on complex add-on units should be entrusted to our customer service or to the customer
service of the manufacturing company. Special reference is made to these units in the text.
The repair jobs are divided up into sections and subsections. Each subsection starts with a page of jobs
to do in advance. The jobs to do in advance contain a summary of the main prerequisites for the repair
section in question. The detailed description of work can follow the jobs to do in advance.
Important instructions concerning technical safety and the safety of personnel are specifically
highlighted, as indicated below.

CAUTION
Type and source of danger
CAUTION refers to working and operating procedures which must be followed exactly in
order to avoid exposing people to risk.

WARNING
Type and source of danger
IMPORTANT refers to working and operating procedures which must be followed exactly
in order to avoid serious or irreparable damage to property.

Note
An explanatory note which is useful for understanding the working or operating procedure
to be performed.

Comply with general safety regulations when performing any repair work. We reserve the right to make
modifications in the course of further development.

Best wishes from

MAN Trucks India Pvt. Ltd.

PRINTER'S IMPRINT
Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN
Trucks India Pvt. Ltd. All rights under the copyright law are strictly reserved by MAN Trucks India
Pvt. Ltd. If any changes are made without the written approval of MAN Trucks then MAN Trucks India
Pvt. Ltd. shall not be liable for any warranty or guarantee claims arising from damage and defects
attributable to the unauthorized modification. Furthermore, MAN Trucks India Pvt. Ltd. shall not be liable
for any damage resulting from the unapproved modification
 TABLE OF CONTENT

Content Chapter/Page
Index
Introduction
Safety regulations
Presentation of the engine
Type plate / type designation
Characteristic data
Engine description
Cooling system
Fan
Fan (mounting on coolant pump) Removing and installing
Fan (mounting on vibration damper) Removing and installing
Coolant pipes
Coolant pipes Removing and installing
Thermostat / thermostat housing
Thermostat / thermostat housing Removing and installing
Coolant pump
Coolant pump – Removing and installing
Coolant pump – Dismantling and assembling
Add-on units
Air compressor / steering booster pump
Air compressor / steering booster pump Removing and installing
Alternator
Alternator Removing and installing
Starter motor
Starter motor Removing and installing
Belt drive
Belt drive Removing and installing
Fuel system
Injector nozzle
Injector nozzle – Removing and installing
Injector nozzle – Dismantling and assembling
Fuel injection pump
Fuel injection pump – Removing and installing
Start of pumping of the fuel injection pump Checking and setting
Low-pressure system
Low-pressure system Removing and installing
Flame start system
Flame start system Removing and installing
Supercharging
Turbocharger
Turbocharger Removing and installing
CONTENT
Repair Manual
Common-rail In-line Engine

D 0836 LFL13
 TABLE OF CONTENT

Induction / exhaust system

Exhaust manifold
Exhaust manifold Removing and installing
Induction manifold
Induction manifold Removing and installing

Cylinder head
Rocker arm mechanism
Rocker arm mechanism Dismantling and assembling
Cylinder head
Cylinder head – Removing and installing
Cylinder head – Dismantling and assembling
Valve clearance – Checking and setting

Valve timing
Camshaft / camshaft bearing
Camshaft / camshaft bearing Removing and installing
Timing gears
Timing gears Removing and installing

Engine lubrication
Oil module
Oil module Removing and installing
Oil sump
Oil sump Removing and installing
Oil pump
Oil pump Removing and installing
Oil injector nozzles
Oil injector nozzles Removing and installing

Crankshaft drive
Vibration damper
Vibration damper Removing and installing
Flywheel
Flywheel Removing and installing
Piston and connecting rod
Piston and connecting rod Removing and installing
Crankshaft
Crankshaft Removing and installing

Engine housing
Cylinder liner
Cylinder liner Removing and installing
Flywheel housing
Flywheel housing – Removing and installing
Timing chain housing
Timing chain housing – Removing and installing
Crankcase yoke
Crankcase yoke – Removing and installing
Positive crankcase ventilation
Positive crankcase ventilation – Removing and installing
 INDEX

Catchword Page

A
Add-on units
Alternator – Removing
Starter motor
Steering booster pump – Installing
Steering booster pump – Removing
V-belt
V-belt – Slackening
V-belt – Tightening
V-belt tension – Checking

C
Characteristic data
Cooling system
Coolant distributor pipe
Coolant pipes
Coolant pump – Assembling
Coolant pump – Dismantling
Coolant pump – Installing
Coolant pump – Removing
Fan clutch
Thermostat – In
Thermostat – Removing
Thermostat housing
Crankshaft drive
Big end bearing
Connecting rod bearing shells
Crankshaft main bearing
Flywheel lateral run-out Gudgeon pin
Lower axial shims
Piston ring axial play
Piston ring gap
Piston standout
Upper axial shims
Cylinder head
Cylinder head – Measuring
Cylinder head gasketSpecial tool
Valve cover

E
Engine description
Engine housing
Crankshaft oil seal
Crankshaft oil seal front
Cylinder liner protrusion
Positive crankcase ventilation filter
PTFE sealing rings
Timing chain housing cover
Engine lubrication
Oil cooler
Oil excess pressure valve
Oil injector nozzles
Oil pressure switch
Oil pump drive gear
Oil suction pipe
INDEX

Catchword Page

F
Fuel system
Flame glow plug
Fuel filter
Fuel injection pump Blocking
Fuel injection pump drive
Fuel lines
Fuel pump – Installing
Fuel pump – Removing
Hand fuel pump
Injection lines
Injection timing device cover
Injector nozzle Assembling
Injector nozzle – Checking
Injector nozzle – Dismantling
Leakage oil line
Parallel fuel filter box
Primary fuel filter
Start of pumping
Start of pumping on the fuel injection pump –Setting

I
Induction / exhaust system
Charge air pressure sensor
Heat shield

S
Safety regulations
General

T
Timing gears
Camshaft gear
Crankshaft gear
Idler gear 1
Idler gear 2
Turbocharger
Charge air pipe
Exhaust manifold
Induction port
Type designation
Type plate

V
Valve timing
Axial shim
Camshaft
Camshaft bearing 1
Camshaft bearings 2 - 6
Tappet
 INTRODUCTION

SAFETY REGULATIONS
General
Working with trucks, buses and the necessary service products does not pose any problems provided the people
entrusted with operation, maintenance and repair have been trained accordingly and actively keep their minds on
the job.
These surveys present a summary of the important regulations listed according to major topics. The intention is to
provide the knowledge needed to avoid accidents, which could lead to injury, damage and environmental pollution.
They represent only a small excerpt from the wide range of accident prevention regulations and cannot replace
these. It goes without saying that all other safety regulations must be followed and that the corresponding action
must be taken.
Additional direct references to danger are contained in the instructions at points where there is a potential danger.
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality, obtain
immediate medical assistance from a doctor. This is particularly important if the accident involves skin contact with
corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes, etc.

1. Regulations for preventing accidents leading to injury to personnel

– Secure units during their removal.
– Support the frame when working on the pneumatic or spring suspension system.
– Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.
Accidents caused by slipping can have very serious consequences.
Only authorised technical personnel are entitled to perform inspection, adjustment
and repair work

Working on the brake system

– Perform visual, function and effectiveness checks on the brake system after
carrying out any work on it whatsoever. These checks must be made in accordance
with the safety inspection (SP).
– Check the function of ABS/ASR systems using a suitable test system (e.g.MAN-
cats).
– Collect hydraulic oil and brake fluid as it drains out.
– Hydraulic oil/brake fluid is poisonous!
Do not allow brake fluid to come into contact with food or open wounds.
– Treat hydraulic oil/brake fluid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.

Operating the engine

– Only authorised personnel are permitted to start and operate an engine.
– Do not approach moving parts of a running engine too closely.
Do not wear baggy clothing.
Ensure adequate ventilation if you are working in enclosed spaces.
– Do not touch units with your bare hands when they are at operating temperature.
Danger of burns!
Do not work with bare hands, especially when changing the oil (units at operating
temperature).
– Do not open the coolant circuit unless the engine is cool.
Suspended loads
– No-one is allowed to stand under a unit suspended from a crane hook. - Keep all
lifting tackle in good condition –
INTRODUCTION

Working on high-pressure lines

– Do not attempt to tighten or loosen pipe lines and hoses when they are under
pressure (e.g. lubrication circuit, coolant circuit and hydraulic oil circuit).
Fluid spraying out represents an injury hazard!
– Do not hold your hands under the jet of fuel when Checking the injector nozzles. Do
not inhale fuel Vapors.

Working on the vehicle electrical system

– Always disconnect the batteries before working on the electrical system. Disconnect
the earth cable first and connect it last when reconnecting.

Important! Battery gases are explosive!

– Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after
long journeys and after charging the batteries with a battery charger.
– When the batteries are disconnected this gas may be ignited by sparks produced by
other continuously operating consumers, the tachograph etc. that cannot be shut
down. Blow compressed air through the battery box before disconnecting the
batteries!
– Tow-start the vehicle only with the batteries connected (minimum charge 40 %)!
Do not use a boost-charger to jump-start the vehicle! Disconnect the positive and
negative leads before boost-charging batteries!
– Avoid short circuits caused by polarity reversal or by placing metal objects
(spanners, mole grips, etc.) on the battery terminals.
– Disconnect the batteries or recharge them every 4 weeks if the vehicle is not in use.

Caution! Battery acid is poisonous and corrosive!

– Wear appropriate protective clothing (gloves) when handling batteries.
Do not tilt batteries, acid may leak out.
– Measure voltage only using suitable measurement devices! The input resistance of
a measuring device should be at least 10 Mohm.
– The ignition must be switched off before the wiring harness plugs of the electronic
control

Electric welding
– Connect the “ANTIZAP SERVICE SENTRY” Protection device (MTIPL item
number _______)as described in the instructions accompanying the device.
– If this device is not available, disconnect the batteries and connect the positive cable
to the negative cable in order to make a conductive connection.
– Always earth the welding equipment as close as possible to the welding area. Do not
lay the cables to the welding equipment in parallel to electrical cables in the vehicle.
– The chassis is not intended for use as an earth return. If attachments are to be fitted
to the vehicle (e.g. a wheelchair lift), additional earth (ground) lines with an adequate
cross-section must be fitted as well. Otherwise the earth connection may be created
along wire cables, wiring harnesses, gearbox shafts, gears etc. Severe damage
could result.

Working on plastic tubes – Danger of damage and fire!

– This warning sign is attached to the inside of the diesel fuel or heating oil tank flap.
It warns you against welding or drilling near to plastic tubes.
 INTRODUCTION

Painting
– If paint spraying is to be carried out, do not expose the electronic components to high
temperatures (max. 95 °C) for more than brief periods; a time of up to 2 hours is
permissible at a maximum of 85 °C. Disconnect the batteries.

Working with the cab tilted

– Keep the tilting area in front of the cab clear.
– Keep out of the area between the cab and the chassis during the tilting process. This
is a danger area!
– Always tilt the cab past the tilting point to its final position.

Working on the air-conditioning system

– Coolant fluids and vapours represent a health hazard, avoid contact with them and
protect your eyes and hands.
– Do not drain gaseous coolants in enclosed rooms.
– Do not mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant.

2. Notes on preventing damage and premature wear on units

– Only subject units to the load which they have been designed to cope with in accordance with their
designated use. Do not overload them.
– If a fault occurs during operation, determine its cause immediately and correct the problem before the fault
can get any worse – “A stitch in time saves nine”!
– Clean the units thoroughly before repairs. Make sure no dirt, sand or foreign bodies get into the units during
repair.
– Only use genuine spare parts. Fitting equivalent parts made by other companies can lead to severe damage
and the workshop that did the work will be responsible for it. Read the section entitled “Limited liability for
accessories and parts”.
– Never run a unit dry, in other words always make sure that it has been filled with oil before running it.
– Never run engines without coolant.
– Apply a suitable information sign to units that are not ready to be operated.
– Only use fuels and lubricants (engine oil and transmission Fluid as well as antifreeze and anti-corrosion
protection) that have been approved by MAN. Keep your workplace clean.
– Comply with the specified maintenance intervals.
– Do not fill engine/gear oil above the maximum level mark. Do not exceed the maximum permitted operational
tilt.
– Severe damage to the unit could result from failure to Follow these regulations.

3. Limited liability for accessories and parts

In your own interests, you are recommended to use only accessories expressly approved by MTIPL and
genuine MTIPL parts. The reliability, safety and suitability of these parts and accessories have been determined
specifically for MTIPL vehicles. Despite constant market observation, we cannot judge the aspects of other
Products, nor can we accept responsibility for them – even if they have been officially approved by the Indian
TÜV technical inspection authorities or some other official body.
Attachments and special bodies
Comply with the safety instructions and regulations issued by the body builder in question if attachments or special
bodies have been fitted.
Taking out of operation and storing
The special measures described in MTIPL Works Standard M 3069 Part 3 are necessary if buses or trucks are to
be withdrawn from service or stored for longer than 3 months.
 INTRODUCTION

4. Handling brake pads and similar components

– Toxic dust may be released when brake pads are machined, and in particular during turning and grinding as
well as when wheel brakes are blown out.
– Please take the necessary precautionary measures and observe the following safety advice to avoid
possible damage to your health:
– If possible, carry out the work in question in the open or in a room equipped with an efficient ventilation
system.
– If possible, use hand-operated or slow-running tools equipped with a dust-collector if required.
– Fast-running tools should always be fitted with such a device.
– If possible, wet the workpiece prior to cutting or drilling.
– Dispose of brake pads as hazardous waste in an environmentally sound manner.

5. Regulations for avoiding injury and environmental contamination

Coolant
Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority when
disposing of used coolant (mixture of antifreeze and water).
Cleaning the cooling circuit
Do not pour cleaning fluids and rinsing water down the drain if this practice is restricted by specific local regulations.
However, the cleaning fluid and rinsing water must in all cases have been passed through an oil trap with a sludge
trap.
Cleaning the filter insert
When blowing compressed air through the filter insert, make sure the filter dust is collected by a vacuum or is blown
into a dust collection bag. Otherwise, use a respiratory protection mask. Wear rubber gloves or use a skin barrier
hand cream when washing out the inserts, because cleaning agents have aggressive grease-dissolving
characteristics.
Engine/gear oil, filter cartridges, inserts and box-type filters, desiccant cartridges
Only dispose of used oil at an approved collection point or depot. It is extremely important that oil is not poured down
the drain or onto the ground since it can pollute drinking water. Filter inserts, cartridges and box-type filters (oil and
fuel filters, desiccant cartridges for the air dryer) are classified as hazardous waste materials and must be disposed
of properly. Please follow the instructions of your relevant local authority.
Used engine/gear oil
Lengthy or repeated skin contact with any type of engine/gear oil removes grease from the skin. This can cause dry
skin, irritation or skin inflammation. In addition to these hazards, used engine oil contains danger-ous materials,
which have been shown to have a carcinogenic effect in animal skin tests.

6. Health protection precautions

– Avoid lengthy, excessive or repeated skin contact with used oils.
– Protect your skin using a suitable skin protection agent or protective gloves.
– Clean areas of skin which have come into contact with engine oil.
– Wash the areas thoroughly with soap and water.
– Use a nail brush to increase the cleaning effectiveness.
– Special cleaning agents make it easier to clean dirty hands.
– Do not use petrol, diesel oil, gas oil, thinners or solvents.
– Apply a greasy skin cream after cleaning your skin.
– Change out of clothing or shoes which have become soaked with oil.
– Never put oil-soaked rags into your clothing pockets.
Take care to dispose of used engine/gear oil properly.
- Oils can damage groundwater quality –
Therefore, never pour used oil onto the ground, into water or down the drains or sewers. Failure to comply with these
instructions can lead to prosecution.
Collect and dispose of used oil carefully. Contact the point of sale, supplier or your local authority for information
about collection depots. Extract from “Information on dealing with used engine oil”
Special instructions for work on the common-rail system
Accident protection

A jet of fuel can cut through the skin. Risk of fire due to fuel atomisation.
– Never undo the screwed connections on the fuel high-pressure side of the common-rail system
whilst the engine is running (injection line from the high-pressure pump to/on the rail and on the
cylinder head to the injector).
– Avoid standing near the running engine.
When the engine is running, the lines are constantly under a fuel pressure of up to 1600
bar.
– Before opening the screwed connections, wait for at least one minute so that the system can be
depressurized.
– Check depressurization of the rail using MAN-cats, if necessary.
Danger of injury!
– Do not touch the live parts at the injector electrical connection whilst the engine is running.
Special instructions for people with pacemakers
– Any changes to the original engine wiring can lead to the limit values specified in pacemaker
regulations being exceeded. Examples of such changes include non-twisted injector wiring or the
addition of the test box (contact box).
– There is no danger to drivers and co-drivers wearing a pacemaker if the vehicle is used for its
intended, i.e. approved, purpose.
– There is no danger to operators wearing a pacemaker if units with MAN common-rail engines
are used for their intended, i.e. approved, purpose.
– In its original state, the product does not violate any of the currently known pacemaker limit
values.

Cleanliness
Diesel-injection systems consist of precision engineered components that are subject to extreme
loads. Due to the highly precise nature of this technology, all work on the fuel system requires
the utmost cleanliness.
Even dirt particles over 0.2 mm can cause component failure.
Before commencing work, you must therefore ensure that the following measures are taken
without fail:

Danger of damage due to dirt ingress

– Before commencing work on the clean side of the fuel system, clean the engine and the engine
compartment (using a steam cleaner), ensuring that the fuel system is closed.
– Visually inspect the fuel system for leaks or damage.
– Do not direct the steam cleaner jet directly at electrical components. Cover them if necessary.
– Drive the vehicle into a clean area of the workshop where none of the work causes dust to be
swirled up (sanding, welding, brake repairs, brake checks, performance tests etc.).
– Avoid air movements (possible swirling up of dust due to starting of engines, the workshop
heating/ventilation system, due to draughts etc.).
– Clean and dry the area of the still closed fuel system using compressed air.
– Use a suitable extractor unit (industrial extractor unit) to remove loose dirt particles such as
paint chippings and insulating material.
– Use a new and clean cover in areas of the engine compartment where dirt particles can become
loose, e.g. tilted cab, bus engine compartment.
– Before removing any components, wash your hands and put on clean working clothes.
When working, follow the instructions below without fail:

Danger of damage due to dirt ingress

– The use of compressed air for cleaning is not permitted after opening the clean side of the fuel
system.
– During assembly, remove loose dirt using a suitable extractor unit (industrial extractor unit).
– Only lint-free cleaning cloths are allowed to be used on the fuel system.
– Clean tools and equipment before commencing work.
– Only use tools that show no signs of damage (cracked chrome coatings).
– Do not use materials such as cloths, cardboard or wood when removing and installing
components as these materials can produce particles and fibers.
– If the undoing of connections causes the paint to chip (due to possible excess paint), carefully
remove these paint chippings before fully undoing the connection.
– All removed components on the clean side of the fuel system must be plugged immediately at
their connection openings using suitable caps.
– These caps must be stored in dustproof packaging until they are used and disposed of after they
have been used once.
– Then store the components in a clean, sealed container.
– Never use used cleaning or test fluids for these components.
– New parts must not be removed from their original packaging until immediately before use.
– Work on removed components may only be carried out in a suitably equipped workplace.
– If removed parts are shipped, always use the new part's original packaging.
When carrying out work on bus engines, the instructions below must also be followed without
fail:

Danger of damage due to dirt ingress

– Before opening the clean side of the fuel system:
Clean the areas of the engine around pressure line fittings, injection lines, the rail and valve
cover using compressed air.
– Remove the valve cover and then re-clean the areas of the engine around the pressure line
fittings, injection lines and rail.
– Only loosen pressure pipe connections at first:
Undo the union nuts on the pressure pipe connections and unscrew by 4 turns.
Raise the pressure pipe connections using a special tool.
Reason: only remove the pressure pipe connections completely once the injectors have been
removed so that no dirt can fall into the injectors from above.
– Remove the injectors.
– After removal, rinse out the injectors with a cleaning fluid, making sure that the high-pressure
connection hole is facing downwards.
– Remove the pressure pipe connections by unscrewing their union nuts.
– Clean the injector hole in the cylinder head.
– Then install the components. Installation is a reversal of the removal procedure.

What the model designation means

Model designation Explanation Example

D Fuel type Diesel
08 Bore + 100mm 108 mm bore
Stroke characteristic 130 mm stroke
3 (rounded) stroke =
(characteristic x 10) + 100
6 Number of cylinders 6-cylinder
Supercharging With supercharging and
L
intercooling
Engine installation Engine/vertical/LHD
F
forward-control vehicle
13 Type identification Power/speed/homologation

Characteristic data

D 0836 LFL13

Designation Unit Figures

No. of 6 cylinders/in-line/vertical
cylinders/arrangement
Valves per cylinder 2 Valves
Engine weight, dry Kg 650
Injection system Common rail
Direction of rotation as CCW
viewed onto flywheel
Net power to ISO 1585- kW/hp/rpm 206/280 / 2400
88/195 EEC at engine speed
Bore mm 108
Stroke mm 125
Swept volume cc 6871
Firing sequence 1-5-3-6-2-4
Rated speed rpm 2400
Low idling speed rpm 600
Max. torque at engine speed Nm rpm 1100 at 1300 - 1700
Engine description

D 0836 common-rail LFL13

(1) Air compressor

(2) Coolant pipe
(3) Cylinder head cover
(4) Turbocharger
(5) Heated fuel service centre
(6) Engine control unit
(7) Starter
(8) Pressure pipe
(9) Oil module
(10) High-pressure pump (lubricated by fuel)
(11) Charge air pipe
(12) Refrigerant compressor
(13) Fan
(14) Alternator
Engine, general
The 6-cylinder diesel engines described here are liquid-cooled, 4-stroke diesel engines with
turbocharger and intercooler. The D 0836 LFL13 engine, the engines operated using the
common-rail high-pressure injection system in conjunction with EDC 7 (Electronic Diesel
Control).

Crankcase
The engine housing comprises the crankcase and cylinder block. It is alloyed grey cast-iron
casting. Dry cylinder liners made from wear-resistant lamellar graphite cast iron are used as
sliding surfaces for the pistons. The crankcase is bolted onto a crankcase yoke underneath for
extra rigidity. Seven bearing seats each are integrated for the camshaft and crankshaft. The
timing case is mounted on the front of the engine housing while the flywheel housing is mounted
on the back. The crankshaft is sealed using radial shaft seals. The positive crankcase ventilation
system is designed as an enclosed system. The crankcase blow-by gases are returned for
recombustion in the engine through a valve with an integrated oil mist trap.

Crankshaft
The crankshaft is forged as a single piece in the die. It has 7 bearing points in the crankcase. The
fitted bearing with thrust washers for axial support is between the third and fourth cylinder. The
crankshaft journals and crank pins are mounted in ready-to-install three-component bearings. Oil
is supplied to the connecting rod bearings via oil channel connections for crankshaft main
bearing lubrication. The crankshaft gear for driving the timing gears and the rubber-bonded
metal torsional vibration damper are fitted at the front end of the crankshaft.

Connecting rods (cracked connecting rods)

The connecting rods are made from heat-treated steel and are precision-forged in a die. The large
connecting rod eye is split straight by cracking the bearing cap. The surface structure resulting
from cracking results in a tooth engagement effect between the bearing cap and the connecting
rod with a precise, non-interchangeable fit and high lateral stability.

Pistons
Three-ring pistons made of special die-cast aluminium are used. They feature a cast ring carrier
for the uppermost piston ring. The pistons have a cast cooling duct for relieving the thermal load.
They are cooled by an oil jet from the oil injection nozzles. The ring set comprises one half
keystone ring and taper-face ring each as compression rings as well as a double-bevelled ring as
oil scraper ring. The pistons can be removed from above together with the connecting rods.

Camshaft
The camshaft is forged from steel and is induction hardened. It has 7 bearing points in the
crankcase with lead-bronze bushes. The camshaft drive onto the camshaft gear comes from the
spur-toothed crankshaft gear.

Engine lubrication
The engine is lubricated by a force-feed lubrication system. The engine oil pressure is generated
by an external-gear pump. The oil pump is driven by the timing gears. The engine oil filter and
the oil cooler are grouped together in one component as an oil module. The oil level in the
engine oil sump is measured either manually using the dipstick or electronically by means of the
oil level sensor in the crankcase yoke. Oil can be filled through the timing case cover and at the
crankcase yoke.

Cooling system
The cooling circuit is a thermostatically controlled forced circulation cooling system with a zero-
maintenance coolant pump that is driven by the belt drive. The coolant pump is mounted on the
timing case. The thermostat housing with thermostat is mounted on the timing case. The
thermostat consists of an exchangeable insert with expansion element. The heating supply
connection is located on the thermostat housing. A non-permanently engaged viscous fan clutch,
driven by the crankshaft, is installed in these engines. The viscous fan clutch is engaged
according to the Cooling air temperature flowing through cooling module. The fan is driven by
the viscous fan clutch.

Cylinder head
The modular cylinder head in the D 0836 LFL13 engines is made from alloyed grey cast-iron.
Exchangeable valve seat rings and valve guides are shrink-fitted in the cylinder head. A single-
layer bead sealing gasket with elastomer elements over pairs of cylinders is used as the liquid
seal between the cylinder head and the crankcase.

Rocker arm mechanism

The rocker arm mechanism is made from grey cast-iron and is bolted to the cylinder head. It
consists of the rocker arm mechanism carrier, the rocker arms and valve bridges for the intake
and exhaust valves, the rocker-arm shaft, the adjusting screws and the pressure springs with
washers.

Intake and exhaust system

The 2-section exhaust manifold is cast from high temperature-resistant nodular cast iron and
secured to the cylinder head using heat-resistant bolts. The zero-maintenance turbocharger is
mounted on the exhaust manifold. The turbocharger is controlled by the wastegate valve. The
wastegate valve is directly controlled by the charge air pressure. The turbocharger is lubricated
by the bypass oil circuit of the engine, which supplies oil to the oil pressure port on the
turbocharger.

Fuel system, general

The fuel system consists of a low-pressure system and a high-pressure system. The low-pressure
system includes the fuel lines, the hand pump and the fuel service centre. The fuel service centre
comprises a pre-filter and a special microfilter with water separation to ensure the degree of fuel
purity required by the common-rail system. The interface to the high-pressure system is provided
by the fuel pre-supply pump which is flange-mounted on the flow-rate-controlled high-pressure
pump.

High-pressure system
The high-pressure system consists of the flow-rate-controlled high-pressure pump with flange-
mounted fuel feed pump, the pressure pipe with rail pressure sensor and pressure limiting valve,
solenoid valve-controlled injectors with pressure pipe connections and the necessary high-
pressure lines. Injection pressure generation and fuel injection are separate in the high-pressure
system. The injection pressure is generated by the high-pressure pump, irrespective of the engine
speed and the required injection quantity. This is available in the pressure pipe for injection via
the injectors. The high-pressure pump delivery quantity is controlled by a proportional valve.
The injection point and the injection quantity are calculated in the electronic control unit and
implemented by the solenoid valve-controlled injectors. Solenoid valve-controlled injectors
allow multiple injections.
1. Pilot injection to improve combustion, reduce combustion noise and reduce peak combustion
pressures.
2. Main injection to introduce the energy for the required engine power output.
The injectors are arranged inclined in the cylinder head and clamped with a pressure flange /
claws. Sensors monitor and control the entire system. Always ensure absolute cleanliness both in
and around the working area whenever carrying out work on the highly sensitive high-pressure
system.

Flame start system (optional)

Special equipment includes a flame start system which can be installed to serve as a cold starting
aid. The flame start system comprises a rapid flame glow plug installed in the suction pipe and a
solenoid valve. The air and fuel mixture ignites at the heating element in the front section of the
flame glow plug. Combustion heats the intake air. The flame glow plug is supplied with fuel
from the fuel filter clean side. The fuel flow to the flame glow plug is controlled by a solenoid
pulse valve based on the engine temperature and the corresponding engine load condition.

Engine brake system

The engine is equipped with an EVB in order to boost the engine braking power. This means that
the exhaust valve bridge contains a hydraulic piston which is pressurized by the engine oil
pressure. The engine oil pressure is released again via a balance hole. There is a counter-holder
above the valve bridge. The thrust piece of the counter-holder closes the balance hole when the
exhaust valve is closed. The balance hole is opened when the valve opens and the engine oil
pressure ahead of the hydraulic piston can dissipate.
Operation of the EVB is triggered when the exhaust brake flap is actuated. Pressure waves build
up in the exhaust manifold when the exhaust brake flap closes. The pressure waves cause a brief
post-opening of the exhaust valves. This means the exhaust valve is opened briefly again after
each closing. The hydraulic piston that is subject to engine oil pressure pushes itself behind the
exhaust valve as it springs up. The hydraulic piston can no longer return to its starting position
because the counter-holder, the balance hole and the non-return valve close the oil feeder hole.
As a result, the exhaust valve remains open by a slit during the compression stroke and the
subsequent expansion cycle. The braking power of the engine increases. The hydraulic piston
does not return to its initial position until the oil feeder hole has opened, since this allows the oil
pressure to dissipate.

Starter
The starter is a pre-engaged starter. When the starter is operated, the pre-engaged starter guides
the pinion into the ring gear by means of a starter solenoid controlled by ECU. A mechanical
relay is mounted in the starter for starter control.
Alternator
A low-noise, zero-maintenance alternator is mounted for generating the voltage. Its design
permits a higher maximum speed and, therefore, a higher rate of utilization. The smaller fan
diameter means there is less aerodynamic noise from the alternator. Reduced slip-ring diameters
not only increase the carbon brush service life but also reduce the magnetic noise considerably.
The voltage is regulated by an alternator regulator according to the temperature, battery charge
level and current level of power being consumed.

Air compressor
A 1-cylinder coolant-cooled air compressor is fitted. The air compressor is attached to the right-
hand side of the engine and is driven by the spur-toothed camshaft gear. The air compressor is
designed for a useful pressure of 12.5 bar.

Power take-off
Various add-on/auxiliary units such as a refrigerant compressor can be driven by means of
auxiliary poly-V-belt pulleys on the vibration damper. These add-on/auxiliary units are generally
engine-mounted.
COOLING SYSTEM

Cooling system, D0836 LFL13

(1) Coolant outlet pipe mounting bolt

(2) Coolant outlet pipe
(3) Fan
(4) Air compressor coolant supply line
(5) Air compressor coolant return line
(6) Thermostat housing
(7) Thermostat
(8) Coolant pipe
(9) Coolant pump
(10) Coolant manifold
(12) Coolant manifold mounting bolt
FAN
Removing and installing the fan (mounting on vibration damper)

(1) Fan clutch (4) Intermediate flange

(2) Fan (5) Adapter flange mounting bolt
(3) Locknut (6) Fan clutch mounting bolt
Technical data
Fan clutch mounting bolt (6) ..................................M8x20-8.8 .................................22 Nm
Locknut (6).....................................................M8x1.25-8...........................................22 Nm
Adapter flange mounting bolts (4) ............M8x20-8.8 ..............................................22 Nm

Important information

WARNING

Malfunction due to incorrect storage of fan clutch.

• Always store the fan clutch in its installation position.
Removing the fan

Removing the fan with clutch

• Unscrew the mounting bolts (5)

• Remove the fan (1) with fan clutch
• Unscrew the mounting bolts (3)
• Remove the adapter flange (4) from the vibration damper (2)

Removing the fan clutch

• Unscrew the locknuts (3)

• Pull the fan clutch (1) out of the fan (2)
Installing the fan

Fitting the fan clutch

• Insert the fan clutch (1) into the fan (2)

• Screw on the new locknuts (3) and tighten to 22 Nm

Fitting the fan with fan clutch

• Place the adapter flange (4) on the vibration damper (2)

• Screw in the mounting bolts (3) and tighten them to 22 Nm
• Place the fan (1) with fan clutch on the adapter flange (4)
• Screw in the mounting bolts (5) and tighten them to 22 Nm
COOLANT PIPES

Removing and installing coolant pipes, D0836 LFL13

(1) Coolant pipe (2) Timing gear case

(3) Coolant manifold mounting bolt (4) Coolant manifold
(5) Coolant outlet pipe mounting bolt (6) Coolant outlet pipe
(7) O-ring (8) Air compressor coolant supply line
(9) Air compressor coolant return line

Technical data
Coolant outlet pipe mounting bolt (2) ………….…...….M8x60-10.9…………….30Nm
Coolant manifold mounting bolt (4) …………….…M8x80-10.9…………………30Nm
Coolant manifold mounting bolt (3) ……………/…M8x95-10.9…………………30Nm
Hex screw, air compressor (3) ……………………/..M12x75-10.9………………105Nm
Air compressor, HHB (1) ………………….M8x60-8.8…………………………..22Nm
Air compressor, head screw (1) ………………..M8x45-8.8………………………22Nm
Coolant Pipe (water manifold) mounting bolt (12) ……..M8x50-10.9…………….30Nm
Injector clamp Screw (6)……………………M8x50-12.9…………………………35Nm
Removing the coolant pipes
Removing the coolant outlet pipe

• Unscrew the mounting bolts (1)

• Pull the wiring harness fastening upwards
• Remove the coolant outlet pipe (2) from the thermostat housing (3)

Removing the air compressor coolant lines

• Unscrew the projection nut from T-shaped connector (3)

• Unscrew the projection nut (4) from thermostat housing.
• Remove the seals
• Remove the coolant lines (1) and (2)
Removing the coolant manifold

• Mark the installation position of the mounting bolts (2) and (3) and then unscrew them
• Remove the coolant manifold (4) with gasket (1)
• Clean the sealing surfaces

Removing the coolant pipe (Water manifold)

• Unscrew the mounting bolts (5)

• Remove the coolant pipe (2) with gaskets (4)
• Remove the Elastomer tube (3)
• Loose the injector clamp screw and remove the reaction pad mounted on water manifold
• Clean the sealing surfaces
Installing the coolant pipes
Mounting the coolant manifold

• Fit the coolant manifold (4) with a new gasket (1) and position it
• Screw in the mounting bolt (2) and tighten to 30Nm
• Screw in the mounting bolt (3) and tighten to 30Nm

Fitting the air compressor coolant lines

• Fit the coolant lines (1) and (2) and position them
• Screw on the projection nuts on T-shaped connector for the coolant lines (1) and (2) and tighten
them by hand
• Screw in the projection nut (4) with new seals and tighten to 22 Nm
• Tighten the projection nuts for the coolant lines (1) and (2) to 22 Nm
Installing the thermostat

WARNING
Component damage due to installation of incorrect thermostats!
• Use a thermostat with the specified opening temperature of 83 °C.

• Clean the sealing surfaces

• Insert the thermostat (2) into the thermostat housing (1) with the TOP mark facing upwards
• Renew the O-ring (3)

Installing the coolant outlet pipe

• Fit the coolant outlet pipe (2) on the thermostat housing (3) and position it
• Align the wiring harness fastening with the coolant outlet pipe (2)
• Screw the mounting bolts (1) into the thermostat housing (3) and tighten to 30 Nm
Installing the coolant pipe (Water manifold)

• Clean the sealing surfaces

• Screw in the mounting bolts (5) and tighten them to 35Nm
• Fit the coolant pipe (2) with new gaskets (4)
• Apply a light coat of Renolit Si 704 silicone grease on the contact surfaces for new Elastomer
tube (3)
• Screw the injector clamp screw and mount properly the reaction pad on water manifold and
tighten the injector clamp screw to 35Nm
THERMOSTAT WITH THERMOSTAT HOUSING

Removing and installing the thermostat with thermostat housing, D0836 LFL13

(1) Coolant outlet pipe mounting bolt (2) Coolant outlet pipe
(3) Thermostat O-ring (4) Thermostat
(5) Screw-in connection sealing ring (6) Screw-in connection
(7) Thermostat housing (8) Thermostat housing mounting bolt
(9) Plug-in pipe (10) Thermostat housing gasket
(11) Timing case

Technical data

Thermostat mounting bolt H.S (2) ………….M8x65-10.9…………………30Nm

Thermostat mounting bolt H.S (1) ………….M8x90-10.9………………….30Nm
Closing plug (1) …………………………………M22x1.5
Thermostat cover (1) …………………………….M8x60-10.9…………………30Nm
Removing the thermostat with Thermostat housing
Removing the coolant outlet pipe

• Unscrew the mounting bolts (1)

• Remove the coolant outlet pipe (2) from the thermostat housing (3)

Removing the thermostat

• Remove the thermostat (2) with O-ring (3) from the thermostat housing (1)
• Clean the sealing surfaces
Removing the thermostat housing

• Unscrew the mounting bolts (3) and (4)

• Remove the thermostat housing (5) with gasket (2) from the timing case (1)
• Clean the sealing surfaces

Removing the plug-in pipe and screw-in connection

• Unscrew the screw-in connection (1)

• Remove the sealing ring (2)
• Pull the plug-in pipe (3) out of the thermostat housing (4)

Installing the thermostat and thermostat housing

Installing the plug-in pipe and screw-in connection

• Screw in the screw-in connection (1) with a new sealing ring (2) and tighten to 30 Nm
• Apply a light coat of Renolit Si 704 silicone grease on the contact faces of the plug-in pipe (3)
• Insert the plug-in pipe (3) into the thermostat housing (4)
Mounting the thermostat housing

• Fit the thermostat housing (5) with a new gasket (2) and position it on the timing case (1)
• Screw in the mounting bolts (3) and tighten them to 30 Nm
• Screw in the mounting bolts (4) and tighten them to 30 Nm

Installing the thermostat

WARNING
Component damage due to installation of incorrect thermostats!
• Use a thermostat with the specified opening temperature of 83 °C.

• Clean the sealing surfaces

• Insert the thermostat (2) into the thermostat housing (1) with the TOP mark facing upwards
• Renew the O-ring (3)
Installing the coolant outlet pipe

• Fit the coolant outlet pipe (2) on the thermostat housing (3) and position it
• Align the wiring harness fastening with the coolant outlet pipe (2)
• Screw the mounting bolts (1) into the thermostat housing (3) and tighten to 30 Nm
Coolant pump

Removing and installing coolant pump

(1) Coolant pump mounting bolt (2) Swivelling screw connection

(3) Coolant pump (4) Air compressor coolant supply line
(5) Coolant supply line hollow screw (6) Coolant pump gasket

Technical data
Coolant pump mounting bolt (1) ..................M8x70-10.9.........................................30 Nm
Coolant pump mounting bolt.......................M8x100-10.9 .......................................30 Nm
Swivelling screw connection (2)..................M14x1.5-8.8 ......................................30 Nm
Hexagonal head screw (5)......................M8x20-8.8 ...........................................22 Nm
Union nut, air compressor coolant lines .................................................................30 Nm
Removing the coolant pump

• Unscrew the union nut (3)

• Remove the seals
• Remove the coolant lines (1) and (2)
Removing the swiveling screw connection

• Unscrew the hollow screw (3)

• Remove the swiveling screw connection (1) with seals (2)
Removing the coolant pump

• Mark the installation positions of the mounting bolts (1)

• Unscrew the mounting bolts (1)
• Remove the coolant pump (2) with gasket (3)
• Clean the sealing surfaces
Installing the coolant pump
Mounting the coolant pump

• Mount the coolant pump (2) with a new gasket (3)

• Screw the first mounting bolts into the bores (4) as marked and tighten to 30 Nm
• Screw in the remaining mounting bolts (1) and tighten to 30 Nm

Installing the swiveling screw connection

• Insert new seals (2) into the swiveling screw connection (1)
• Screw in the hollow screw (3) and tighten to 30 Nm
Fitting the air compressor coolant lines

• Fit the coolant lines (1) and (2)

• Screw on the union nuts and tighten them by hand
• Tighten the union nuts (3) to 30 Nm
Dismantling and assembling the coolant pump

(1) Coolant pump housing (2) Slide seal ring

(3) Impeller (4) Coolant pump bearing
(5) Circlip (6) Coolant pump hub

Technical data
Projection of slide ring seal (2) ................................................................... 10.0 - 10.4 mm
Dimension, impeller (plastic) (3) - coolant pump housing (1) ............... 33.10 - 33.30 mm

Dismantling the coolant pump

Removing the coolant pump hub

• Brace the impeller for the coolant pump (1)

• Pull off the hub (3) using the Three-armed puller [1]
• Detach the circlip (2) from the coolant pump (1)
Removing the impeller

• Lay the coolant pump housing (3) on the opposing sleeve (1)
• Press out the bearing (2) using the Installer sleeve [2]
• Remove the impeller (4)

Removing the slide seal ring

• Press the slide seal ring (2) out of the coolant pump housing (1) using the Drift punch
Assembling the coolant pump
Installing the bearing

WARNING
Component damage due to incorrectly carried out repairs!
• Carefully press in the new bearing at the bearing outer race until the stop is reached
• Use a suitable sleeve as a brace

• Press the bearing (2) into the coolant pump housing (1) until the stop is reached
• Attach the circlip (3) in the coolant pump housing (1)

Installing the slide seal ring

• Slightly apply a mixture of 50 % water and 50 % Radiator antifreeze on the slide ring seal (2)
and coolant pump shaft
• Assemble the special tool consisting of the Plug-on handle, Washer and Installer
• Use the special tool to press the slide ring seal (2) into the coolant pump housing (1) until the
stop is reached
Checking the projection

• Check the projection between the slide ring seal and the coolant pump housing (1) using the
Depth gauge (electronic) [6] (2)
The permitted projection is 10.0 - 10.4 mm.
If the projection is more than 10.0 - 10.4 mm, adjust the slide ring seal.

Mounting the coolant pump hub

• Press the hub (2) onto the bearing (1) until flush

Pressing on the impeller (plastic)

• Press on the impeller (2) until dimension A 33.10 - 33.30 mm is reached

The permitted dimension A between the impeller (2) and the coolant pump housing (1) is 33.10 -
33.30 mm.
If the dimension A is more than 33.10 - 33.30 mm, adjust the impeller (2).
If the dimension A is less than 33.10 - 33.30 mm, pull off the impeller (2) and press on a new
impeller (2).
ADD – ON UNITS

(1) Air compressor (2) Power steering pump

(3) Alternator (4) Starter
(5) Refrigerant compressor (6) Power take-off, alternator/coolant pump
POWER TAKE-OFF

Removing and installing the power take-off

(1) Driver/Carrier plate (2) Power take-off O-ring

(3) Power take-off (4) Poly-V-belt pulley mounting bolt
(5) Poly-V-belt pulley (6) Power take-off mounting bolt
(7) Timing case cover

Power take-off mounting bolt (6)...................M10x35-8.8 .................................45 Nm

Poly-V-belt pulley mounting bolt (4) ...........M16x1.5x45-8.8.....initial torque 100 Nm
Poly-V-belt pulley mounting bolt (4) ............M16x1.5x45-8.8 .............................Final torque 90°
Removing the power take-off
Removing the poly-V-belt pulley.

Note
The mounting bolt for the poly-V-belt pulley has a left-hand thread.

• Hold the poly-V-belt pulley (2) steady using a size-41 open-ended spanner
• Unscrew the mounting bolt (1) from the power take-off (3)
• Remove the poly-V-belt pulley (2)

Removing the power take-off

• Unscrew the mounting bolts (1)

• Remove the power take-off (2), driver/carrier plate (3) and O-ring (4)
Installing the power take-off
Mounting the power take-off

• Place the thin side of the driver/carrier plate (3) on the air compressor gear and align it
correctly
• Apply Technical vaseline on the new O-ring and then fit the O-ring on the power take-off (2)
• Fit the power take-off (2)
• Screw in the mounting bolts (1) and tighten them to 45 Nm

Mounting the poly-V-belt pulley

• Place the poly-V-belt

pulley (2) on the power
take-off (3)
• Screw in the mounting
bolt (1)
• Hold the poly-V-belt
pulley (2) steady using a
size-41 open-ended spanner
• Tighten the mounting bolt (1) to Initial torque 100 Nm
• Tighten the mounting bolt (1) to Final torque 90°
AIR COMPRESSOR / POWER STEERING PUMP
Removing and installing the air compressor / power steering pump

(1) Air compressor (2) Power steering pump driver plate

(3) Power steering pump O-ring (4) Power steering pump
(5) Power steering pump mounting bolts (6) Air compressor support block
(7) Air compressor mounting bolt (8) Support block mounting bolt
(9) Air compressor housing O-ring (10) Power take-off driver plate
(11) Air compressor oil bore O-ring

Technical data
Air compressor mounting bolt (7)....................M12x75-10.9 .................................105 Nm
Support block mounting bolt (8) .....................M8x60-8.8 .....................................22 Nm
Support block mounting bolt ...........................M8x45-8.8 .....................................22 Nm
Power steering pump mounting bolt (5)...........M10x30-12.9 .................................75 Nm
Union nut, air compressor coolant lines .................................................................30 Nm
Removing the air compressor / power steering pump
Removing the air compressor coolant lines

• Unscrew the union nuts (3) from T-shaped connector

• Remove the seals
• Remove the coolant lines (1) and (2)

Removing the power steering pump

• Remove the steering oil lines

• Unscrew the mounting bolts (5)
• Pull the power steering pump (4) off the air compressor (1)
• Remove the driver plate (2) and the O-ring (3)
Removing the air compressor

• Removing the air compressor line

• Unscrew the mounting bolts (2) from the support block (7)
• Unscrew the mounting bolts (1)
• Pull the air compressor (6) out of the timing case rearwards
• Remove the O-rings (4) and (5) with driver plate (3)

Installing the air compressor / power steering pump

Installing the air compressor

• Apply a light coat of Technical vaseline on the new O-rings (4) and (5) and then position them
on the compressor (6)
• Fit the driver plate (3) with the thin side facing the air compressor gear
• Insert the air compressor (6) into the timing case
• Screw in the mounting bolts (1) and tighten them to 105 Nm
• Position the support block (7)
• Screw in the mounting bolts (2) and tighten them to 22 Nm
• Screw in the support block mounting bolt for support on the crankcase and tighten it to 22 Nm
• Mount the air compressor line
Installing the power steering pump

Mounting the power steering pump

• Insert a new O-ring (3) into the power steering pump

• Place the driver plate (2) onto the power steering pump (4)
• Align the power steering pump (4) with the air compressor (1) and then insert it
• Screw in the mounting bolts (5) and tighten them to 75 Nm
• Fit the power steering pump oil lines
ALTERNATOR
Removing and installing the alternator

(1) Alternator (2) Alternator/belt tensioner support

(3) Alternator bracket (4) Alternator mounting bolt
(5) Alternator mounting bolt

Alternator mounting bolt.....................M10x65-10.9 .................................................65 Nm

Alternator mounting bolt (4) ..............M10x110-10.9................................................65 Nm
Alternator mounting bolt (5) ..............M12x40-10.9 ..............................................105 Nm
Poly-V-belt pulley collar nut ..............M10x25-10.9 .............................................65 Nm
Countersunk bolt ..................................M10x70 ...................................................45 Nm
Terminal B+ on alternator ..................M8 ..............................................................15 Nm
Alternator operating voltage ......................................................................................28 V
Removing the alternator

Removing the poly-V-belt pulley

• Disconnect the alternator electrical connection

• Unscrew the terminal B+ mounting nut
• Undo the collar nut on the poly-V-belt pulley (2)

Removing the poly-V-belt pulley

• Unscrew the collar nut (1)

• Pull the poly-V-belt pulley (2) off the alternator
Removing the alternator

• Undo the mounting bolts (4)

• Unscrew the mounting bolts (1) from the holding block (3)
• Remove the alternator (2)
Installing the alternator

Fitting the alternator

• Insert the alternator (3)

• Screw in the mounting bolts (1) and (2) and tighten them by hand
• Tighten the mounting bolt (1) to 65 Nm
• Tighten the mounting bolt (2) to 105 Nm
• Screw in the mounting bolts (5) and tighten them to 65 Nm
Mounting the poly-V-belt pulley

• Place the poly-V-belt pulley (2) on the alternator shaft (3)

• Screw on the new collar nut (1) and tighten it by hand

Tightening the poly-V-belt pulley

• Tighten the collar nut on the poly-V-belt pulley (2) to 65 Nm

• Connect the alternator electrical connection
• Screw on the terminal B+ mounting nut and tighten it to 15 Nm
BELT DRIVE
Removing and installing the belt drive

(1) Coolant pump poly-V-belt pulley (2) Vibration damper poly-V-belt pulley
(3) Refrigerant compressor poly-V-belt (4) Refrigerant compressor poly-V-belt tensioner
(5) Refrigerant compressor (6) Power take-off poly-V-belt pulley
(7) Alternator poly-V-belt tensioner (8) Alternator poly-V-belt

Technical data

Mounting bolt, vibration damper poly-V-belt pulley

(2).................................................M8x18-8.8 .........................................................22 Nm
Mounting bolt with collar, coolant pump poly-V-belt pulley (1)....................................M8x16-
10.9 .......................................................30 Nm
Poly-V-belt tensioner mounting bolt (4), (7) ............M10x65-8.8 ...................45 Nm
Removing the belt drive

Removing the refrigerant compressor poly-V-belt

WARNING
Danger of injury due to unintentional rebound of the poly-V-belt tensioner.
• Secure the poly-V-belt tensioner after tensioning in order to prevent unintentional
rebound
• Relieve the poly-V-belt tensioner carefully when the poly-V-belts are removed

• Relieve the poly-V-belt (1) by turning the tensioning pulley (2) in downward direction
• Hold the poly-V-belt tensioner (2) and remove the poly-V-belt
• Carefully relieve the poly-V-belt tensioner (2)
Removing the alternator poly-V-belt

WARNING
Danger of injury due to unintentional rebound of the poly-V-belt tensioner.
• Secure the poly-V-belt tensioner after tensioning in order to prevent unintentional
rebound
• Relieve the poly-V-belt tensioner carefully when the poly-V-belts are removed
• Relieve the poly-V-belt (1) by turning the tensioning pulley (2) clockwise
• Hold the poly-V-belt tensioner (2) and remove the poly-V-belt (1)
• Carefully relieve the poly-V-belt tensioner (2)

Removing the poly-V-belt tensioner

• Unscrew the poly-V-belt tensioner mounting bolt (2)

• Remove the poly-V-belt tensioner (1)
Removing the poly-V-belt pulleys

• Mark the installed position of the poly-V-belt pulley (2) relative to the vibration damper
• Unscrew the mounting bolts (1)
• Remove the poly-V-belt pulley (2)
• Unscrew the mounting bolts with collar (3)
• Remove the poly-V-belt pulley (4)

Installing the belt drive

Mounting the poly-V-belt pulleys

• Fit the poly-V-belt pulley (2) as marked

• Screw in the mounting bolts (1) and tighten them to 22 Nm
• Fit the poly-V-belt pulley (4)
• Screw in the mounting bolt (3) and tighten it to 30 Nm
Installing the poly-V-belt tensioner

• Screw in the mounting bolts for the poly-V-belt tensioner (1) and tighten them to 45Nm

Fitting the alternator poly-V-belt

WARNING
Danger of injury due to unintentional rebound of the poly-V-belt tensioner.
• Secure the poly-V-belt tensioner after tensioning in order to prevent unintentional
rebound

• Tension the poly-V-belt tensioner (2) clockwise and hold it

• Fit the poly-V-belt (1)
• Carefully relieve the poly-V-belt tensioner (2)
Fitting the refrigerant compressor poly-V-belt

• Tension the poly-V-belt tensioner (2) by moving it in upward direction on a slot provided on
AC compressor bracket
• Fit the poly-V-belt (1)
• Carefully relieve the poly-V-belt tensioner (2)
Common Rail System

(1) Injector (2) Hand pump with fuel pre-filter

(3) Fuel service centre (4) Rail
(5) Rail pressure sensor (6) High-pressure lines
(7) High-pressure pump CP3.3
Technical data

Screw for injector clamp…………..M8x50-12.9………….……………………. 35Nm

High Pressure Pipe from High Pressure Pump to Rail ….. M10x25-
8.8………….……………………..45Nm
Pressure pipe mounting bolt………M8x55-8.8………….………………………22Nm
Removing the high pressure lines and Rail

Removing the return line

• Remove the return line (1)

• Remove the rail pressure sensor electrical connection (2)
• Remove the pressure line between CP3.3 and Rail (3)

Removing the high-pressure line, cylinder 1-6

• Mark the installed position of the clamping pieces (2)

• Remove the clamping pieces (1) from the high-pressure lines for cylinder 1 - 3 and cylinder 4 -
6
• Remove the high-pressure line (3)
• Repeat the same procedure for all the high-pressure lines
Removing rail

• Unscrew the mounting bolts (2) from the rail (1)

• Remove the rail (1) from the intake manifold

Removing the injector

Removing pressure pipe, Injector return line and injector clamp connection.

• Unscrew the union nut (2) on the pressure pipe connection (1)
• Unscrew the injector return line (3) from injector
• Unscrew the injector clamp screw (4)
Removing the electric connection

• Unscrew the mounting nuts from injector (1)

• Remove the injector cable from the injector

Removing the injector

• Remove the injector (4) with injector clamp (3) and sealing ring (1) - Clamp location is
incorrect
• Pull the O-Ring (2) ring off the injector towards the magnet
• Store the injector in the Storage sleeve immediately after removal – with cap
Installing the injector

Inserting the injector

Note
Always install the injector together with the injector clamp.
It is not possible to install the pressure flange afterwards. – Picture shown is not correct
• Remove the protective sleeves
• Align the bore for the pressure pipe connection in the injector with the high pressure pipe end.
• Fit a new O-ring (2) and new sealing ring (1) on the injector
• Place the injector clamp (3) on the injector (4)
• Insert the injector (4) into the cylinder head together with the sealing ring (1) and injector
clamp (3)
• Press the injector fully into the cylinder head

Injector initial torque

• Screw in the mounting bolt (1) with spherical washer

• Tighten the mounting bolt (1) to torque 35 Nm
Installing the Injector return line and injector clamp connection.

• Tighten the union nut (2) on the pressure pipe connection (1)
• Tighten the injector clamp screw (4)
• Tighten the injector return line (3) from injector
Installing the electric connection

WARNING
Component damage due to possible short-circuit
• When tightening the mounting nut, make sure that the cable plugs do not touch
each other

• Tighten the mounting nut to 1.25 - 1.75 Nm

• Fit the plug bracket (2)

Mounting pressure pipe

• Fit the rail (1) onto the intake manifold

• Screw in the mounting bolts for the rail (1) and tighten to Initial torque 1.5 ± 0.5 Nm
Mounting the high-pressure line, cylinder 1-6

• Remove the protective sleeves

• Mount the high-pressure line (3), ensuring that it is strain-free. Tighten the high-pressure line
(3) to Initial torque 10 Nm
• Repeat the same procedure for all the high-pressure lines
• Mount the clamping pieces (2) as marked
• Tighten the mounting bolts for the clamping pieces
(1) to 9 Nm
• Tighten the pressure pipe mounting bolts to Final torque 22 Nm

Installing the return line

• Install the return line (1)

• Install the rail pressure sensor (2)
• Install the pressure line (3)
• Tighten the pressure pipe mounting bolts to Final torque 22 Nm
HIGH-PRESSURE PUMP

High-pressure pump (lubricated by fuel)

Removing and installing high pressure pump

(1) Rail (2) High-pressure pump mounting nut

(3) Fuel pump O-rings (4) Fuel pump mounting bolt
(5) Fuel pump (6) High-pressure pump mounting bolt
(7) High-pressure pump (8) High-pressure pump O-ring
(9) High-pressure pump drive gear mounting nut

Technical data
High-pressure pump drive gear mounting nut (9) ....M18x1.5 ...................... 100 - 110 Nm
High-pressure pump mounting nut (2)....................M8...................................... 30 Nm
High-pressure pump mounting bolt (6) ...................M8x40……....................... 30 Nm
Spacer………………………………………………………………………..55Nm
Important information

WARNING
The common-rail system can be damaged.
• All work on components of the common-rail system must be performed by specially trained
personnel only.
• The engine must be stationary for at least 5 minutes before commencing work in order to
enable de-pressurization in the pressure pipe, or de-pressurization must be checked by means of
MAN-cats (desired value 0).
• Ensure absolute cleanliness in all areas when carrying out all work. Avoid moisture and
humidity at all times.
• Always renew pressure pipe connections once they have been undone.
• Do not reuse plugs for high-pressure lines, the pressure pipe or injectors, even if they have only
been used once.
• Follow the sequence described when tightening injectors, high-pressure lines, the pressure pipe
and pressure pipe connections.

WARNING
The common-rail system can be damaged
• Always detach only one fuel line and then immediately plug the fuel line connections and
component connections
Removing the high-pressure pump

Removing the high-pressure pump fuel lines

• Disconnect the electrical connection from the high-pressure pump (6)

• Detach the high-pressure line (1).
• Unscrew the hollow screw (2)
• Remove the connections from the fuel lines (3) and with the seals (4)
• Unscrew the spacer (5) with seal
• Unscrew the overflow valve (7).
• Remove the fuel line (8) with seals.

Removing the fuel pump fuel lines

• Mark the fuel lines (2), (3) and (4) to indicate their installed position
• Detach the fuel lines (2), (3) and (4)
Removing the high-pressure pump mounting

• Unscrew the mounting bolts (1) for the high-pressure pump (3)
• Unscrew the mounting nut (2)

Unscrewing the mounting nut from the

High-pressure pump drive gear

• Clamp the high-pressure pump drive gear (3) in a vice using protective jaws
• Unscrew the mounting nut (1)
• Remove the O-ring (2)
Removing the fuel pump

• Unscrew the mounting bolts (2)

• Remove the fuel pump (1)
• Remove the O-rings (3) and (4)

Installing the high-pressure pump

Mounting the fuel pump

• Fit new O-rings (3) and (4) on the fuel pump (1)
• Align the driver for the fuel pump (1) with the driver on the high-pressure pump
• Fit the fuel pump (1) on the high-pressure pump
• Screw in the mounting bolts (2) and tighten them.
Mounting the high-pressure pump drive gear

Note
Ensure that the cone in the drive gear and on the high-pressure pump is free from oil and grease
before commencing assembly.

• Fit a new O-ring (2)

• Position the high-pressure pump drive gear (3)
• Screw on the mounting nut (1) and tighten to 100-110 Nm

Filling the high-pressure pump

• Remove the protective sleeves

• Fill the high-pressure pump with clean Diesel fuel through the fuel feed line (1) until Diesel
fuel emerges at the fuel return line (2)
• Fit the protective sleeves
Tightening the high-pressure pump

• Screw on the mounting nut (2) for the high-pressure pump (3) and tighten to 30Nm
• Screw in the mounting bolts (1) and tighten them to 30Nm

Fitting the fuel pump fuel lines

• Remove the protective sleeves

• Fit the fuel line (2)
• Repeat the same procedure for the fuel lines (3) and (4)
• Check the fuel lines (2), (3) and (4) for firm seating.
Fitting the high-pressure pump fuel lines

• Fit the high-pressure line (1), ensuring that it is strain-free, and tighten to Initial torque 10 Nm
• Screw in the spacer (5) and tighten to 55Nm
• Fit the fuel line (8) on pump
• Screw in the overflow valve (7) with new seals (4) and tighten to 30Nm
• Fit the fuel lines (3) and (8) with new seals (4) and position them
• Screw in the hollow screw (2) and tighten to 30 Nm
• Connect the electrical connection for the high-pressure pump (6)
Fuel Service Sentre

Removing and installing the fuel service centre.

(1) Intake manifold (2) Hand pump

(3) Fuel service centre (4) Fuel service centre mounting bolts
(5) Groove for Pressure sensor
Technical data
Fuel service centre mounting bolts (4) ...................M8x40-10.9..............................30 Nm
Removing the fuel service centre

Removing the fuel lines

• Mark the position of the fuel lines (2) relative to the fuel service centre (1)

Removing the fuel service centre

• Unscrew the mounting bolts (4)

• Remove the fuel service centre (3) from the intake manifold (1)
Installing the fuel service centre

Mounting the fuel service centre

• Position the fuel service centre (3) on the intake manifold (1)
• Screw in the mounting bolts (4) and tighten them to 30 Nm

Fitting the fuel lines

• Remove the protective sleeves

• Fit the fuel lines (2) as marked
• Check the fuel line (2) for firm seating.
 SUPERCHARGING

(1) Charge air pipe (9) Turbocharger mounting nut

(2) Positive crankcase ventilation filter (10) Turbocharger
(3) Turbocharger seal (11) Oil return line O-ring
(4) Positive crankcase ventilation line (12) Oil return line
(5) Exhaust manifold seal (13) Induction port profile clip
(6) Exhaust manifold mounting nut (14) Induction port seal
(7) Exhaust manifold (15) Induction port
(8) Exhaust manifold cylinders 4 – 6 (16) Oil pressure line
 SUPERCHARGING

TURBOCHARGER

Turbocharger – Removing and installing

(1) Charge air pipe (9) Turbocharger mounting nut

(2) Positive crankcase ventilation filter (10) Turbocharger
(3) Turbocharger seal (11) Oil return line O-ring
(4) Positive crankcase ventilation line (12) Oil return line
(5) Exhaust manifold seal (13) Induction port profile clip
(6) Exhaust manifold mounting nut (14) Induction port seal
(7) Exhaust manifold (15) Induction port
(8) Exhaust manifold cylinders 4 – 6 (16) Oil pressure line

Technical data
Turbocharger mounting nut (9) AM10 45 Nm
Exhaust manifold mounting nut (6) AM10 45 Nm
Induction port profile clip mounting bolt (13) M8x40 22 Nm
Turbocharger oil return line mounting bolt (12) M8x20 22 Nm
Turbocharger oil pressure line mounting bolt (16) M8x20 22 Nm
Retaining plate mounting bolt 8x16-8.8 22 Nm
Wastegate valve start of opening 1.65 bar
Max. opening pressure 1.75 bar
Wastegate valve opening stroke 1.2 – 2.2 mm

Important information
Note
The actual charge air pressure and opening pressure of the wastegate valve can only be interro-gated
using the EDC electronic control unit. The turbocharger must be replaced if the specified values are
not reached. Replace the entire turbocharger if the wastegate valve is defective
 SUPERCHARGING

Turbocharger – Removing Note

Charge air pipe – Removing Use a suitable container to collect any
engine oil which emerges
! Remove the oil return line (1) with
seal
! Remove the oil pressure line (2) with
seal
! Clean the sealing surfaces
! Seal the oil bores

Exhaust manifold – Removing

! Unscrew the upper hose clamp from the charge air

hose (3)
! Unscrew the mounting bolts for the retaining plate
(2)
! Remove the retaining plate (2) with charge air pipe
(1)

Induction port – Removing

!
! Unscrew the mounting nuts (3) from the exhaust
manifold (2)
! Remove the exhaust manifold (2) with seal (1)

Turbocharger – Removing

! Remove the induction hose from the air

compressor at the induction port (1)
! Remove the positive crankcase ventilation line (2)
with positive crankcase ventilation filter
! Unscrew the profile clip (3) for the induction port (1)
! Remove the induction port (1) with seal (4)

Turbocharger oil lines – Removing ! Remove the turbocharger (1) with seal (2) from the
exhaust manifold (3)
 SUPERCHARGING

Turbocharger – Installing ! Fit the oil return line (2) with a new seal (1) and O-
Ring (3) and install it

Turbocharger – Fitting ! Tighten the mounting bolts to 22 Nm

! Install the clamping piece (4) for the oil return line
! Tighten the mounting bolt for the clamping piece (4)
to 22 Nm

Turbocharger – Filling

! Fit the turbocharger (1) with a new seal (2) and

position it on the exhaust manifold (3)
! Screw new mounting nuts on the turbocharger (1)
and tighten to 45 Nm

Exhaust manifold – Fitting WARNING

The turbocharger does not have any
lubrication, the turbocharger
bearings are damaged when first
started
! The turbocharger must be filled with clean engine
oil according to MAN standard
! Fill clean engine oil through the oil supply port (1)
using a funnel (2) until the oil duct is full

Turbocharger oil pressure line – Installing

! Fit the exhaust manifold (2) with a new seal (1) and
position it on the turbocharger
! Screw on the mounting nuts (3) for the exhaust
manifold (2) and tighten to 45 Nm

Turbocharger oil return line – Fitting

Screw in the oil pressure line (1) for the turbo-charger

(2) and tighten the mounting bolts to 22 Nm
 SUPERCHARGING

Intake Elbow – Fitting

! Fit the induction port (1) with seal (4) and clamping
ring
! Position the profile clip (3) for the induction port (1)
and tighten to 22 Nm
! Fit the positive crankcase ventilation line (2) with
positive crankcase ventilation filter
! Fit the induction hose from the air compressor at
the induction port (1)

Charge air pipe – Fitting

! Position the retaining plate (2) with charge air pipe

(1)
! Screw the mounting bolts for retaining plate (2) into
the exhaust manifold and tighten to 22 Nm
! Fit the upper hose clamp for the charge air hose (3)
INTAKE / EXHAUST SYSTEM

(1) Exhaust manifold (4) Charge air manifold

(2) Coolant pipe (5) Exhaust manifold seal
(3) Intake manifold (6) Heat shield
 INTAKE / EXHAUST SYSTEM

EXHAUST MANIFOLD

Exhaust manifold – Removing and installing

Comprises
– Turbocharger – Removing and installing, see 5-95

(1) Heat shield (4) Exhaust manifold 4 –6

(2) Exhaust manifold mounting bolts (5) Exhaust manifold seal
(3) Sealing ring (6) Exhaust manifold 1 –3

Technical data
Exhaust manifold mounting bolts (2) M10x48 Preliminary tightening 55 Nm
Exhaust manifold mounting bolts (2) M10x48 Final tightening 90 +10°
Exhaust manifold mounting bolt (2) M10x57 Preliminary tightening 55 Nm
Exhaust manifold mounting bolt (2) M10x57 Final tightening 90 +10°
Heat shield mounting bolts (1) M8x16-8.8 22 Nm
 INTAKE / EXHAUST SYSTEM

Exhaust manifold – Removing Note

Check the installation position of the
Heat shield – Removing seal for the exhaust manifold when
installing.
The projection on the seal must point
towards the cylinder head.

! Fit the exhaust manifolds (2) and (4) with new seals
(3) and (5) and position them
! Screw in new mounting bolts (1) and tighten to
Preliminary tightening 55 Nm
! Tighten the mounting bolts to Final tightening 90
+10°

Heat shield – Fitting

! Remove the heat shield (1) from the exhaust
manifold (2)

Exhaust manifold – Removing

! Fit the heat shield (1) to the exhaust manifold (2)

using new mounting bolts
! Tighten the heat shield mounting bolts to 22 Nm

! Mark the mounting bolts (1) for subsequent

installation and unscrew them from the exhaust
manifold (2) and (4)
! Remove the exhaust manifold (2) and (4) with seals
(3) and (5)
! Clean the sealing surfaces

Exhaust manifold – Installing

Exhaust manifold – Fitting

INTAKE MANIFOLD

Removing and installing the intake manifold

(1) Charge air manifold (2) Intake manifold

(3) Intake manifold mounting bolt

Technical data

Intake manifold mounting bolt (3).................M8x75-8.8 .......................................22 Nm

Intake manifold mounting bolt.......................M8x70-8.8 ....................................22 Nm
Intake manifold mounting bolt.......................M8x25-8.8 ....................................22 Nm
Charge air manifold mounting bolts .............M8x30-8.8........................................22 Nm
Charge air manifold mounting bolt ..............M8x40-8.8 .......................................22 Nm
Removing the intake manifold
Removing the charge air manifold

• Unscrew the mounting bolts (2)

• Remove the charge air manifold (1) with gasket (3)
• Clean the sealing surfaces
Removing the intake manifold

• Unscrew the mounting bolts (3)

• Remove the intake manifold (2) with gaskets (1)
• Clean the sealing surfaces

Fitting the intake manifold

• Fit the intake manifold (2) with new seals (1) and position it
• Screw in the mounting bolts (3) and tighten them to 22 Nm
Mounting the charge air manifold

• Fit the charge air manifold (1) with a new gasket (3) and position it
• Screw in the mounting bolts (2) and tighten them to 22 Nm
CYLINDER HEAD

(1) Push rod (4) Induction valve rocker arm

(2) Cylinder head (5) Valve cover
(3) Exhaust valve rocker arm (6) Cylinder head bolts

ROCKER ARM MECHANISM

Rocker arm mechanism – Dismantling and assembling
Comprises
– Positive crankcase ventilation – Removing and installing, see 11-221

Rocker arm mechanism variant without EVB

CYLINDER HEAD

(1) Circlip (2) Washer

(3) Compression spring (4) Washer
(5) Exhaust valve clearance adjuster screw (6) Exhaust valve rocker arm
(7) Bearing block (8) Rocker arm mechanism mounting bolt
(9) Washer (10)Compression spring
(11) Rocker arm shaft

Rocker arm mechanism variant with EVB

(1) Circlip (8) Rocker arm mechanism mounting bolt

(2) Washer (9) Induction valve rocker arm
(3) Compression spring (10)Washer
(4) Washer (11) Compression spring
(5) Exhaust valve clearance adjuster screw (12)Rocker arm shaft
(6) Exhaust valve rocker arm (13)EVB adjuster screw
(7) Bearing block

Technical data of rocker arm mechanism, equipment variant without EVB

Rocker arm mechanism mounting bolts (8) E12x10x65-8.8 65 Nm
Valve cover mounting bolts BM6x35-10.9 13 Nm

Technical data of rocker arm mechanism, equipment variant with EVB

Rocker arm mechanism mounting bolt (8) E12x10x65-8.8 65 Nm
Rocker arm mechanism mounting bolt (8) E12x10x75-8.8 65 Nm
Valve cover mounting bolt BM6x35-10.9 13 Nm

Service products
Assembly paste 09.16012-0117

Note
A rocker arm mechanism with or without EVB is installed, depending on the equipment variant. The
procedures for removal and installation as well as dismantling and assembly are the same. The
equipment variant with EVB is described here.
 CYLINDER HEAD

Rocker arm mechanism – Dismantling Rocker arm mechanism – Dismantling

Valve cover – Removing

! Mark the exhaust valve rocker arm (2), induction

valve rocker arm (3) and bearing block (1) for
subsequent installation
! Unscrew the mounting bolts (3)
! Remove the exhaust valve rocker arm
! Remove the valve cover (4) with seal (2) from
thecylinder head (1) ! Remove the washer (4) with compression spring
(5)
! Pull out the rocker arm shaft (6)
Rocker arm mechanism – Removing

Rocker arm mechanism – Assembling

! Unscrew the mounting bolts (2)

! Remove the rocker arm mechanism (1)
! Position the washers (4) on both sides of the
compression spring (5) and place on the rocker arm
Circlip – Removing shaft (6)
! ApplyAssembly paste to the contact surfaces of the
rocker arms on the rocker arm shaft (6)
! Place the exhaust valve rocker arm (2), induction
valve rocker arm (3) and bearing block (1) onto the
rocker arm shaft (6) as marked
! Use external circlip pliers to insert the circlip (1)
! Check that the circlip (1) has clipped into the groove
provided. If not, repeat the working step

! Mark the washers (2) and (4) with compression

spring (3) for subsequent installation
! Use external circlip pliers to remove the circlip (1)
! Remove the washers (2) and (4) with compression
spring (3)
 CYLINDER HEAD

Rocker arm mechanism – Fitting Valve cover–Fitting

! Align the rocker arm mechanism (1) with the push

rods and put it on
! Screw in the mounting bolts (2) for the rocker arm ! Fit the valve cover (4) with a new seal (2) and place
mechanism (1) and tighten to 65 Nm it on the cylinder head (1)
! Screw in the mounting bolts (3) and tighten to 13
Nm
 CYLINDER HEAD

Cylinder head – Removing and installing

Comprises
– Coolant – Draining and topping up
– Positive crankcase ventilation – Removing and installing, see 11-221
– Turbocharger – Removing and installing, see 5-95
– Exhaust manifold – Removing and installing, see 6-103
– Flame start system – Removing and installing, see 4-89
– Induction manifold – Removing and installing, see 6-105
– Coolant pipes – Removing and installing, see 2-21
– Low-pressure system – Removing and installing, see 4-81
– Injector nozzle – Removing and installing, see 4-57
– Valve clearance – Checking and setting, see 7-126

(1) Push rod (4) Induction valve rocker arm

(2) Cylinder head (5) Valve cover
(3) Exhaust valve rocker arm (6) Cylinder head bolts

Technical data
Cylinder head bolts (6) M14x2x140 1st preliminary tightening 80 Nm
Cylinder head bolts (6) M14x2x140 2nd preliminary tightening 150 Nm
Cylinder head bolts (6) M14x2x140 3rd preliminary tightening 2 x 90°
Cylinder head bolts (6) M14x2x140 Final tightening 90°
Rocker arm mechanism mounting bolt E12x10x65-8.8 65 Nm
Rocker arm mechanism mounting bolt E12x10x75-8.8 65 Nm
Valve cover mounting bolt (5) BM6x35-10.9 13 Nm
Maximum permitted cylinder head distortion 0.2 mm

Service products
Optimoly White T 09.16012-0122
CYLINDER HEAD

Special tool

[28] Feeler gauge

! Cylinder head distortion – Checking

[29] Measuring rail

! Cylinder heads – Aligning

[30] Socket 22 mm
? Cylinder head bolts – Tightening in
conjunction with:
? Socket E18105 [32]
? Support [33]
? Angle measuring disc [34]
? Holding fixture [35]
? Hexagon socket head cap screw [36]
? Connecting pin [37]
? Rubber ring 42 mm [38]
? Washer [39]
? Socket E18105 [31]
[31] Socket E18105
! Cylinder head bolts – Tightening in
conjunction with:
! Socket 22 mm [30]
! Support [33]
! Angle measuring disc [34]
! Holding fixture [35]
! Hexagon socket head cap screw [36]
! Connecting pin [37]
! Rubber ring 42 mm [38]
! Washer [39]
! Socket E18105 [31]
[32] Force multiplier spanner i = 1 : 3.3
! Cylinder head bolts – Tightening in
conjunction with:
! Support [33]
! Angle measuring disc [34]
! Holding fixture [35]
! Hexagon socket head cap screw [36]
! Connecting pin [37]
! Rubber ring 42 mm [38]
! Washer [39]
! Socket E18105 [31]
! Socket 22 mm [30]
CYLINDER HEAD

Special tool

[33] Support
! Cylinder head bolts – Tightening in
conjunction with:
! Force multiplier spanner i =
1 : 3.3 [33]
! Angle measuring disc [34]
! Holding fixture [35]
! Hexagon socket head cap screw [36]
! Connecting pin [37]
! Rubber ring 42 mm [38]
! Washer [39]
! Socket E18105 [31]
! Socket 22 mm [30]
[34] Angle measuring disc
! Cylinder head bolts – Tightening in
conjunction with:
! Support [33]
! Force multiplier spanner i =
1 : 3.3 [32]
! Holding fixture [35]
! Hexagon socket head cap
screw [36]
! Connecting pin [37]
! Rubber ring 42 mm [38]
! Washer [39]
! Socket E18105 [31]
! Socket 22 mm [30]
[35] Holding fixture
! Cylinder head bolts – Tightening in
conjunction with:
! Support [33]
! Angle measuring disc [34]
! Force multiplier spanner i =
1 : 3.3 [32]
! Hexagon socket head cap
screw [36]
! Connecting pin [37]
! Rubber ring 42 mm [38]
! Washer [39]
! Socket E18105 [31]
! Socket 22 mm [30]
[36] Hexagon socket head cap screw
! Cylinder head bolts – Tightening in
conjunction with:
! Support [33]
! Angle measuring disc [34]
! Holding fixture [35]
! Force multiplier spanner i =
1 : 3.3 [32]
! Connecting pin [37]
! Rubber ring 42 mm [38]
! Washer [39]
! Socket E18105 [31]
! Socket 22 mm [30]
CYLINDER HEAD

Special tool

[37] Connecting pin

! Cylinder head bolts – Tightening in
conjunction with:
! Support [33]
! Angle measuring disc [34]
! Holding fixture [35]
! Hexagon socket head cap
screw [36]
! Force multiplier spanner i =
1 : 3.3 [32]
! Rubber ring 42 mm [38]
! Washer [39]
! Socket E18105 [31]
! Socket 22 mm [30]
[38] Rubber ring 42 mm
! Cylinder head bolts – Tightening in
conjunction with:
! Support [33]
! Angle measuring disc [34]
! Holding fixture [35]
! Hexagon socket head cap
screw [36]
! Connecting pin [37]
! Force multiplier spanner i =
1 : 3.3 [32]
! Washer [39]
! Socket E18105 [31]
! Socket 22 mm [30]
[39] Washer
! Cylinder head bolts – Tightening in
conjunction with:
! Support [33]
! Angle measuring disc [34]
! Holding fixture [35]
! Hexagon socket head cap
screw [36]
! Connecting pin [37]
! Rubber ring 42 mm [38]
! Force multiplier spanner i =
1 : 3.3 [32]
! Socket E18105 [31]
! Socket 22 mm [30]
 CYLINDER HEAD

Cylinder head – Removing Cylinder head – Removing

Valve cover – Removing

! Unscrew the cylinder head bolts (3)

! Unscrew the mounting bolts (3) ! Remove the cylinder head (2) from the crankcase
! Remove the valve cover (4) with seal (2) from the (1)
cylinder head (1) ! Clean the sealing surfaces on the cylinder head (2)
! Clean the tapped holes for the cylinder head bolts
Rocker arm mechanism – Removing
Cylinder head gasket – Removing

! Unscrew the mounting bolts (2)

! Remove the rocker arm mechanism (1) ! Remove the cylinder head gasket (2) from the
crankcase (1)

Push rod – Removing ! Clean the sealing surfaces of the crankcase (1)

! Remove the push rod (1)

 CYLINDER HEAD

Cylinder head – Measuring Cylinder head – Installing

Cylinder head lengthways distortion – Checking Cylinder head gasket – Putting on

! Clean the cylinder head flat surface WARNING

! Use a bevelled steel edge (1) and Feeler gauge [28] Danger of engine damage
(2) to check the cylinder head (3) for length-ways ! Put on the cylinder head gasket as
distortion marked
! Repeat the measurement at various points ! Place the new cylinder head gasket (2) over the
! Maximum permitted distortion 0.2 mm guide pins (1) onto the crankcase

Cylinder head sideways distortion – Checking Cylinder head – Fitting

! Clean the cylinder head flat surface ! Place the cylinder head (2) over the guide pins onto
! Use a bevelled steel edge (1) and Feeler gauge [28] the crankcase (1)
(3) to check the cylinder head (2) for sideways ! Apply Optimoly White T to the bearing surfaces of
distortion the cylinder head bolt heads, screw in all cylinder
! Repeat the measurement at various points head bolts and tighten until finger-tight

! Maximum permitted distortion 0.2 mm ! Use Measuring rail [30] to align the cylinder head
 CYLINDER HEAD

Cylinder head tightening diagram Cylinder head bolts – Tightening

WARNING
Danger of cylinder head distortion Note
! It is essential to comply with the Note the multiplication ratio of the force
tightening diagram multiplier spanner i = 1 : 3.3
! Tighten the cylinder head bolts according to the
tightening diagram ! Place the assembled special tool (1) onto the
cylinder head bolt that is going to be tightened
Special tool – Assembling ! Screw in the cylinder head bolts and tighten to 1st
preliminary tightening 80 Nm
! Tighten the cylinder head bolts to 2nd preliminary
tightening 150 Nm
! Tighten the cylinder head bolts to 3rd preliminary
tightening 2 x 90°
! Tighten the cylinder head bolts to Final tightening
90°

Push rod – Installing

! Fit the Holding fixture [35] (5) with Hexagon socket

head cap screw [36] (4) and Washer [40] (3) on the
Support [33] (2)
! Insert the Force multiplier spanner i = 1 : 3.3 [32] (1)
into the Support [33] (2)
! Place the Angle measuring disc [35] (11) onto the
Force multiplier spanner i = 1 : 3.3 [32] (1)
! Place the Socket 22 mm [30] (8) onto the Force
multiplier spanner i = 1 : 3.3 [32] (1) and secure with
the Connecting pin [37] (9) and Rubber ring 42 mm
[38] (7) ! Insert the push rods (1) into the ball cups of the
tappets
! Insert the Socket E18105 [31] (6) into the Holding
fixture [35] ! Oil the ball cups of the push rods (1)

! Insert the Socket E18105 [31] (7) into the Socket 22

mm [30] (8)
 CYLINDER HEAD

Rocker arm mechanism – Fitting Cylinder head – Dismantling and assembling

Comprises
– Cylinder head – Removing and installing, see 7-113

! Align the rocker arm mechanism (1) with the push

rods and put it on
! Screw in the mounting bolts (2) for the rocker arm
mechanism (1) and tighten to 65 Nm

Valve cover – Fitting

(1) Induction valve

(2) Exhaust valve
(3) Cylinder head
! Fit the valve cover (4) with a new seal (2) and put it
on (4) Washer

! Screw in the mounting bolts (3) and tighten to 13 (5) Valve stem seal
Nm (6) Valve spring
(7) Valve key
 CYLINDER HEAD

Special tool

[40] Mounting fixture

! Valves – Removing and installing

[41] Locating plate

! Cylinder head – Dismantling and
assembling when removed

[42] Drive-up tool

! Valve stem seal – Removing and
installing in con-junction with:
! Mounting sleeve [44]

[43] Mounting sleeve

! Valve stem seal – Removing and
installing in con-junction with:
! Drive-up tool [43]

Cylinder head – Dismantling

Cylinder head – Clamping on Special tool – Fitting

! Clamp the Locating plate [41] (1)in a vice

! Fit the cylinder head (2) onto the Locating plate [41] ! Fit the base plate(1)from the Mounting fixture [40]
(1) using two mounting bolts (3) from the Mounting ! Fit the retaining fork from the Mounting fixture [40]
fixture [40] onto the base plate (1)
! Place the guide sleeve (2) over the valve spring and
screw it into the base plate (1)
 CYLINDER HEAD

Mounting cartridge – Inserting ! Remove the valve spring (2)with valve head
(3)from the cylinder head (1)

Valve stem seal – Removing

! Insert the mounting cartridge (2) into the guide

sleeve (1) ! Pull off the valve stem seal (2)
! Remove the washer (1) for the valve spring
Valve keys – Removing
Valve – Removing

! Insert the pressure fork (3) into the detents in the

retaining fork (1) ! Unscrew the mounting bolts (4)
! Press down the pressure fork (3) and apply a ! Lift the cylinder head (3) from the Locating plate
preload to the valve spring [41] (1)
! Press in the knurled screw of the mounting car- ! Remove the valve (2)
tridge (2) and press the valve keys off the valve
stem
! The valve keys remain in the mounting cartridge (2) Cylinder head – Assembling
after being pressed off, and are therefore lifted off
the valve stem
! Remove the Mounting fixture [40]

Valve springs – Removing

! Insert the valve (2) into the cylinder head (3)

! Fit the cylinder head (3) onto the Locating plate [41]
(1) using two mounting bolts (4) from the Mounting
fixture [40]
 CYLINDER HEAD

Valve stem seal – Fitting Special tool – Fitting

! Put on the washer (1) for the valve spring ! Fit the base plate(1)from the Mounting fixture [40]
! Place the Mounting sleeve [43] (2) onto the valve ! Fit the retaining fork from the Mounting fixture [40]
onto the base plate (1)
! Apply engine oil to the valve stem seal (3) and place
! Place the guide sleeve (2) over the valve spring and
it onto the Mounting sleeve [43] (2)
screw it into the base plate (1)

Valve stem seal – Pressing on Mounting cartridge – Inserting

! Use the Drive-up tool [42] (2) to press the valve ! Place the valve keys into the mounting cartridge (2)
stem seal (1) on up to the stop and insert it into the guide sleeve (1)

Valve keys – Installing

Valve springs – Putting on

! Insert the pressure fork (3) into the detents in the

! Put the valve spring (2) with valve head (3) onto the retaining fork (1)
cylinder head (1) ! Place the pressure fork (3) onto the mounting
cartridge (2) and press it down fully
! Pull up the knurled screw of the mounting
cartridge(2) until the valve keys drop into the spring
cap
! Slowly release the pressure fork (3) and remove the
mounting cartridge (2) from the guide sleeve
! Remove the Mounting fixture [40]
 CYLINDER HEAD

Valve clearance – Checking and setting

(1) Exhaust valve rocker arm (4) EVB adjuster screw

(2) Exhaust valve rocker arm adjuster screw (5) Induction valve rocker arm
(3) Induction valve rocker arm adjuster screw

Technical data
Lock nut on valve adjuster screw (2) M10x1-8.8 40 Nm
Lock nut on valve adjuster screw (3) M10x1-8.8 40 Nm
Lock nut on EVB adjuster screw (4) M10x1-8.8 40 Nm
Induction valve clearance 0.50 mm
Exhaust valve clearance 0.50 mm
EVB piston play 0.35 mm
Valve cover mounting bolts BM6x35-10.9 13 Nm

Special tool

[44] Engine barring gear

! Engine – Cranking in conjunction
with:
! Gear ratchet [46]

[45] Gear ratchet

! Engine – Cranking in conjunction
with:
! Engine barring gear [45]

[46] Feeler gauge

! Valve clearance – Checking
 CYLINDER HEAD

Valve clearance – Checking and setting Intake valve clearance – Checking

Valve cover – Removing

! Push the Feeler gauge [46] (2) with 0.50 mm

! Unscrew the mounting bolts (3) from the cylinder between the induction valve rocker arm (1) and
head (1) valve

! Remove the valve cover (4) with seal (2) ! Set the valve clearance if the valve clearance is not
0.50 mm

Engine – Cranking to setting position

EVB piston play – Checking

! A = Rocker arm in overlap

! B = Rocker arm free for valve clearance setting
! Fit the Engine barring gear [44] onto the flywheel
housing
! Crank the engine with Engine barring gear [44] and
Gear ratchet [45] until the rocker arms are in
overlap
! Check and set the free rocker arms according to the ! Press the exhaust valve rocker arm (1) down lightly
table
! Push the feeler gauge (3) 0.35 mm between the
counter holder adjuster screw (2) and exhaust
Exhaust valve clearance – Checking valve rocker arm (1) Set the EVB play if the play is
not 0.35 mm

! Push the Feeler gauge [46] (2) with 0.50 mm

between the exhaust valve rocker arm (1) and
valve (3)
! Set the valve clearance if the valve clearance is not
0.50 mm
 CYLINDER HEAD

Exhaust valve clearance – Setting Intake valve clearance – Setting

! Press the rocker arm (3) for the exhaust valve down ! Unscrew the lock nut (1) of the valve adjuster screw
several times to press the oil out of the EVB piston (2)
! Unscrew the lock nut (1) of the valve adjuster screw ! Press the valve adjuster screw (2) with ball cup
(2) back until you can push the Feeler gauge [46] 0.50
! Press the valve adjuster screw (2) with ball cup mm (4) between the induction valve rocker arm (3)
back until you can push the Feeler gauge [46] 0.50 and valve with slight resistance
mm (4) between the rocker arm(3) and valve (5) ! Tighten the lock nut (1) to 40 Nm
with slight resistance ! Check the setting again
! Tighten the lock nut (1) to 40 Nm
! Check the setting again Valve cover – Fitting

EVB piston play – Setting

! Fit the valve cover (4) with a new seal (2) and put it
on
! Unscrew the lock nut (3) of the adjuster screw (4) ! Screw the mounting bolts (3) into the cylinder head
! Turn the adjuster screw (4) in the EVB counter- (1) and tighten to 13 Nm
holder (2) back until you can push in the Feeler
gauge [46] 0.35 mm (5)
! Screw in the adjuster screw (4) with the feeler
gauge (5) still inserted until the exhaust valve
rocker arm (1)is in Contact with the stop (can be felt
by a slight increase in force)
! Tighten the lock nut (3) to 40 Nm
! Check the setting again
 VALVE TIMING

VALVE TIMING

(1) Camshaft
(2) Tappet
(3) Push rod
 VALVE TIMING

CAMSHAFT / CAMSHAFT BEARING – Turbocharger – Removing and installing, see 5-95

– Exhaust manifold – Removing and installing, see 6-
Camshaft / camshaft bearing – Removing and 103
installing – Cylinder head – Removing and installing, see 7-113
Comprises – Timing gears – Removing and installing, see 8-141
– Oil sump – Removing and installing, see 9-155 – Air compressor / steering booster pump –
– Induction manifold – Removing and installing, see Removing and installing, see 3-43
6-105 – Flywheel housing – Removing and installing, see
– Coolant pipes – Removing and installing, see 2-21 11-205

– Coolant pump – Removing and installing, see 2-33 – Crankcase yoke – Removing and installing, see 11-
219
– Thermostat / thermostat housing – Removing and
installing, see 2-27 – Piston and connecting rod – Removing, see 10-183
– Crankshaft – Removing and installing, see 10-189

(1) Camshaft
(2) Tappet
(3) Push rod

Technical data
Camshaft axial shim mounting bolts M8x16-8.8 22 Nm
Inside diameter of camshaft bearings 1 – 7 Diameter 54.910 – 54.940 mm
Outside diameter of camshaft bearing points Diameter 59.000 – 59.030 mm
End play 0.140 – 0.270 mm
Valve tappet stem diameter Diameter 20 mm
Height of valve tappet 54.50 mm

Valve timings (external exhaust gas recirculation)

Induction valve opens 18° crank angle before TDC
Induction valve closes 32° crank angle after BDC
Exhaust valve opens 63° crank angle before BDC
Exhaust valve closes 29° crank angle after TDC

Valve timings (internal exhaust gas recirculation)

Induction opens 18° crank angle before TDC
Induction valve closes 32° crank angle after BDC
Exhaust valve opens 63° crank angle before BDC
Exhaust closes 1° crank angle before TDC
VALVE TIMING

Special tool

[47] Camshaft guide tool

! Camshaft – Removing and installing

[48] Assembly set

! Camshaft bearing – Removing and
installing in conjunction with:
! Guide sword [49]
! Impact weight [50]

[49] Guide sword

! Camshaft bearing – Removing and
installing in conjunction with:
! Assembly set [48]
! Impact weight [50]

[50] Impact weight

! Camshaft bearing – Removing and
installing in conjunction with:
! Assembly set [48]
! Guide sword [49]

[51] Impact puller

! Front and rear camshaft bearing –
Removing in conjunction with:
! Extractor plate [52]

[52] Extractor plate

! Front and rear camshaft bearing –
Removing in conjunction with:
! Impact puller [51]
 VALVE TIMING

Camshaft / camshaft bearing – Removing Tappet – Removing

Camshaft axial shim – Removing

! Use a magnet (1) to remove the tappet (2)

! Unscrew the mounting bolts (1) Camshaft bearing removal sequence

! Remove the axial shim (2) from the camshaft (3)

Camshaft guide tool – Fitting

! Comply with the removal sequence (1) Reference

is made to the illustrated removal sequence in all
the following steps

! Use mounting bolts (2) to fit the adapter (3) from the
Camshaft guide tool [47] onto the camshaft (4) Camshaft bearing special tool

! Screw the guide pin (1) into the adapter (3)

Camshaft – Removing

! Push the Impact puller [51] (1) with Extractor plate

[52] (2) through the camshaft bearing 1 (3)
! Hinge the Extractor plate [52] (2) behind the cam-
shaft bearing 1 (3) and center it in the camshaft
! Pull the camshaft (1) out of the crankcase (2) bearing
towards the flywheel end
 VALVE TIMING

Camshaft bearing 1 – Removing Camshaft bearings 2 –6 –Removing

! Pull out the camshaft bearing 1 (2) with the Impact Note
puller [51] (1) and Extractor plate [52] (3) Use camshaft bearing 7 as a guide
when removing camshaft bearings 2 –
Camshaft bearing press-out tool 6.If camshaft bearing 7 is damaged to
such an extent that it can no longer be
used as a guide then remove and install
camshaft bearing 7 first

! Insert the press-out plate (1) (F) from the Assembly

set [49] into camshaft bearing 2 (2)
! Insert the short end of the Guide sword [50] (3) (B)
into the press-out plate (1) (F)
! Push the double-sided guide bush (4) (G) onto the
Guide sword [50] (3)
! Insert the guide bush as marked with the balls in the
oil bores of the crankcase
! Use the tools from the Assembly set [48] to remove ! Drive out camshaft bearing 2 (2)
and install the camshaft bearings 2, 3, 4, 5 and 6 ! Repeat the procedure for camshaft bearings 3, 4
and 5
Camshaft assembly set ! In addition, the press-in plate (D) must be inserted
behind the press-out plate (F) as a spacer for
pressing out camshaft bearing 6
A = Impact weight 80.99606-0546
B = Guide sword 80.99606-6102
C = Press-in plate bearing 7 80.99609-6113
D = Press-in plate bearings 2–6 80.99606-6112
E = Press-in plate bearing 1 80.99606-6114
F = Press-out plate bearings 2 –6 80.99602-0162
G= Double-sided guide bush 80.99606-6110
 VALVE TIMING

Camshaft / camshaft bearing – Installing Note

Camshaft bearing – Preparing to install Only one oil bore is free on each of cam-
shaft bearings 2, 4 and 6 in order to
guarantee rocker arm lubrication
! Take the press-in plate (2) (C) from the Assembly
set [49] and insert it as marked in bearing seat 7 to
function as a guide
! Engage the spring-loaded ball into the oil bore of
camshaft bearing 7
! Connect the press-out plate (F) (3) to the short end
of the Guide sword [49] (4) (B) and push it into the
crankcase
! Push the double-sided guide bush (G) as marked
! Take the camshaft bearing (1) of the correct over the Guide sword [49] (4) (B) and engage it in
installation sequence and place it on the press-in camshaft bearing seat 1
plate (2) from the Assembly set [49] ! Place the press-in plate (1) (D) against bearing seat
! The notch in the camshaft bearing must point to- 6 with the camshaft bearing connected
wards the timing chain housing end of the engine ! Push the Guide sword [49] (4) into the press-in
! Engage the spring loaded ball (3) into the oil bore plate (1)
(4) ! Drive in the camshaft bearing
! To check, make sure you can see the centring bore
in the press-in tool at the second oil bore
Camshaft bearings 5 –2 –Installing

Installation sequence

! Insert the press-out plate (F) into bearing seat 6 to

function as a guide
! Comply with the installation sequence (1) ! Place the press-in plate (4) (D) against bearing seat
Reference is made to the illustrated installation 5 with the camshaft bearing (5) pushed on
sequence in all the following steps
! Push the short end of the Guide sword 49] (1) (B)
into the press-in plate (4) (D) and guide (F)
Camshaft bearing 6 – Installing ! Push the double-sided guide bush (2) (G) as
marked over the Guide sword [49] (1) (B) and en-
gage it in bearing seat 1
! Drive the camshaft bearing (5) into the bearing seat
! Repeat the procedure for camshaft bearings 4, 3,
and 2, moving along the press-out device (F) as a
guide according to which bearing is to be pressed in
! Leave the press-in plate (4) (D) in the camshaft
bearing 2
 VALVE TIMING

Camshaft bearing 1 – Installing Camshaft bearing 7 – Removing

! Place the press-in plate (3) (E) against bearing seat ! Pull out the camshaft bearing (2) with the Impact
1 with the camshaft bearing (4) pushed on puller [51] (1) and Extractor plate [52] (3)
! Push the short end of the Guide sword [50] (2) (B)
into the press-in plate (E) (3) and guide (D), making Camshaft bearing 7 – Installing
sure the Guide sword [50] (2) (B) is guided by the
pin in the press-in tool (D)
! Knock the press-in plate (3) (C), camshaft bearing
(4) and Impact weight [51] (1) (A) into the crank-
case until flush

Camshaft bearing special tool – Fitting

! Insert the press-in plate (D) into camshaft bearing

seat 6 to function as a guide
! The Guide sword [49] (4) (B) must be guided by the
pin in the press-in plate (D)
! Place the camshaft bearing (1) onto the press-in
plate (2) (C)
! Push the Guide sword [49] (B) (4) together with the
press-in plate (2) (C) into the press-in plate (D) as
! Push the Impact puller [51] (2) with Extractor plate marked
[52] (1) through the camshaft bearing 7 (3) ! Drive the camshaft bearing (1) into bearing point 7
! Hinge the Extractor plate [52] (1) behind the cam-
shaft bearing 7 (3)and center it in the camshaft
bearing
 VALVE TIMING

Oil bores – Checking Camshaft – Installing

! Check the oil bores (2) of the camshaft bearings (1) WARNING
are positioned correctly and there is sufficient Camshaft bearings can be damaged
overlap with the oil bores in the crankcase (3), if during installation
necessary remove the camshaft bearings and
install the bearings correctly ! Always install the camshaft with the
Camshaft guide tool [48] as a guide

Tappets – Installing
! Push the camshaft (1) with the mounted Camshaft
guide tool [47] into the crankcase (2)
! Remove the Camshaft guide tool [47]

Camshaft axial shim – Installing

! Use a magnet (1) to insert the tappet (2) into the

crankcase

! Position the axial shim (2) and screw the mounting

bolts (1) into the crankcase (3)
! Tighten the mounting bolts (1) to 22 Nm
VALVE TIMING

(1) Intermediate gear 2 (2) Oil pump drive gear

(3) Oil pump drive gear mounting nut (4) Intermediate gear 2 mounting bolt
(5) Crankshaft gear (6) Crankshaft gear fixing bolt
(7) Intermediate gear 1 mounting bolt (8) Camshaft gear mounting bolt
(9) Camshaft gear (10) Intermediate gear 1
(11) Timing case (12) Camshaft
(13) Tappet
TIMING GEARS
Removing and installing the timing gears

(1) Intermediate gear 2 (2) Oil pump drive gear

(3) Intermediate gear 1 (4) Crankshaft gear
(5) Camshaft gear

Technical data
Intermediate gear 1 mounting bolt (3) ..........M14x1.75x45-8.8 .............................115 Nm
Intermediate gear 1 mounting bolt (3) ..........M14x1.75x60-8.8 .............................115 Nm
Intermediate gear 2 mounting bolt (1) ...........M8x40-8.8 ........................................22 Nm
Camshaft gear mounting bolt (5) ...................M10x38x1.25-10.9 ...........................65 Nm
Oil pump drive gear mounting nut (2)............M12x1.5-6S......................................30 Nm

Installation play values

Intermediate gear 1, radial play.............................................................. 0.060 - 0.109 mm
Intermediate gear 1, axial play............................................................... 0.200 - 0.280 mm
Intermediate gear 2, radial play ............................................................. 0.035 - 0.076 mm
Intermediate gear 2, axial play............................................................... 0.100 - 0.200 mm

Timing gear tooth backlash

Crankshaft gear - camshaft gear.............................................................. 0.051 - 0.149 mm
Camshaft gear - air compressor gear........................................................ 0.051 - 0.185 mm
Crankshaft gear - intermediate gear 1...................................................... 0.050 - 0.187 mm
Intermediate gear 1 - intermediate gear 2................................................. 0.051 - 0.175 mm
Intermediate gear 1 - oil pump gear ....................................................... 0.053 - 0.190 mm
Important information

WARNING
Defective timing gears can cause high-pressure pump damage
• Remove and check the high-pressure pump

Note
Follow the instructions for work on the common-rail system, see Fuel system, general, 22
Removing the camshaft gear
Fixing the camshaft gear

• Fix the crankshaft gear (2) using two fixing bolts (1)

Setting the timing gears to the mark

• Crank the engine with the Engine barring gear and Gear ratchet until the marks on the camshaft
gear (1) and on the crankshaft gear (2) line up
• Lock the Engine barring gear [107] using a locking pin

Unscrewing the mounting bolts

• Unscrew the mounting bolts (1) from the camshaft gear (2)
Removing the camshaft gear

• Pull the camshaft gear (1) off the camshaft (2)

Installing the camshaft gear

Positioning the camshaft gear

• Line up the marks on the camshaft gear and crankshaft gear

• Line up the camshaft (2) with the hole pattern in the camshaft gear (1) if necessary
• Place the camshaft gear (1) over the guide pin and onto the camshaft (2)

Tightening the camshaft gear mounting bolts

• Screw in new mounting bolts (1) for the camshaft gear (2) and, working crosswise, tighten
them to 65 Nm
Checking the overlap marking

• Release the Engine barring gear and turn the crankshaft through 720°
• Check that the marks on the camshaft gear (1) and crankshaft gear (2) match up
• Unscrew both fixing bolts (3)
• Remove the Engine barring gear
• Mount the flywheel housing cover

Removing the crankshaft gear

Fixing the crankshaft gear

• Lock the crankshaft gear (2) using two fixing bolts (1)

Setting the timing gears to the mark

• Crank the engine with the Engine barring gear and Gear ratchet until the marks on the camshaft
gear (1) and on the crankshaft gear (2) line up
• Lock the Engine barring gear using a locking pin
Releasing the crankshaft gear

• Unscrew both fixing bolts (1) from the crankshaft gear (2)

Removing the crankshaft gear

• Pull the crankshaft gear (1) off the crankshaft (2)

• Clean the contact faces and the guide pin (3)

Installing the crankshaft gear

• Apply a light coat of Loctite 573 sealing compound on the rear side of the crankshaft gear (1)
• Align the marks on the camshaft gear and crankshaft gear (1)
• Place the crankshaft gear (1) over the guide pin (3) and onto the crankshaft (2)
Fixing the crankshaft gear

• Fix the crankshaft gear (2) using two fixing bolts (1)

Checking the overlap marking

• Release the Engine barring gear and turn the crankshaft through 720°
• Check that the marks on the camshaft gear (1) and crankshaft gear (2) match up
• Unscrew both fixing bolts (3)
• Remove the Engine barring gear
• Mount the flywheel housing cover

Removing the intermediate gears

Removing intermediate gear 2

• Unscrew the mounting nut (5)

• Pull off the oil pump drive gear (4)
• Unscrew the mounting bolts (1)
• Remove the intermediate gear pin (2) and intermediate gear 2 (3)
Removing intermediate gear 1

• Mark the mounting bolts (2) and (3) to indicate their installed position
• Unscrew the mounting bolts (2) and (3)
• Unscrew the mounting bolt (1)
• Remove the intermediate gear pin (4) and intermediate gear 1 (5)

Installing the intermediate gears

Installing intermediate gear 1

• Position the intermediate gear pin (4) with intermediate gear 1 (5)
• Screw in the mounting bolt (2) and tighten to 115 Nm
• Screw in the mounting bolt (3) and tighten to 115 Nm
• Screw in the mounting bolt (1) and tighten to 22 Nm
Installing intermediate gear 2

• Position the intermediate gear pin (2) with intermediate gear 2 (3)
• Screw in the mounting bolts (1) and tighten them to 22 Nm
• Mount the oil pump drive gear (4)
• Screw on a new mounting nut (5) and tighten to 30 Nm
 ENGINE LUBRICATION

(1) Oil module (7) Oil suction pipe

(2) Oil cooler seal (8) Coupling sleeve
(3) Oil cooler (9) Coupling sleeve O-ring
(4) Oil module gasket (10) Oil pump
(5) Oil pressure valve (11) Oil sump with oil sump cover
(6) Oil suction pipe O-ring

OIL MODULE

Oil module – Removing and installing

Comprises
– Coolant – Draining
 ENGINE LUBRICATION

(1) Oil module housing (7) Oil cooler mounting bolt

(2) Oil pressure switch (8) Temperature sensor, flame start system
(3) Oil pressure switch seal (9) Oil cooler seal
(4) Screw-in port (10)Oil cooler
(5) Oil module screw plug (11) Oil filter mount gasket
(6) Oil module mounting bolt

Oil module technical data (standard version)

Oil module mounting bolts (6) M8x65-8.8 22 Nm
Oil module mounting bolts (6) M8x95-8.8 22 Nm
Oil cooler mounting bolts (7) M8x45-8.8 22 Nm
Oil cooler mounting bolts (7) M8x55-8.8 22 Nm
Screw-in port (4) M30x1.5-5.8 40 Nm
Screwplug in oilfilter mount M24x1.5-5.8 30 Nm
Screwplug in oilfilter mount M18x1.5-5.8 30 Nm
Screwplug in oilfilter mount M10x1.5-8.8 20 Nm
Oil pressure switch (2) M18x1.5 50 Nm
Temperature sensor, flame start system (8) M10x1 15 Nm

Oil module technical data (if Grosskopf alternator is fitted)

Oil module mounting bolts M8x115-8.8 22 Nm
Oil module mounting bolts M8x130-8.8 22 Nm
Oil cooler mounting bolts M8x38-8.8 22 Nm
Screwplug in oilfilter mount M18x1.5 30 Nm
Oil pressure switch onoilfilter mount M18x1.5 50 Nm
Temperature sensor for flame start system M10x1 15 Nm

Service products
LOCTITE 648 04.10160-9164
 ENGINE LUBRICATION

ENGINE LUBRICATION Oil module – Installing

Oil module – Removing Oil cooler – Installing

! Unscrew the mounting bolts (6)

! Remove the oil module (7) with gasket (8)
! Remove the oil pressure switch (2) with seal (1) ! Fit the oil cooler (3) with new seals (1) and position it
! Unscrew the screw-in port (3) ! Screw in the mounting bolts (2)
! Unscrew the screw plug (4) ! Tighten the mounting bolts (2) to 22 Nm
! Unscrew the temperature sensor, flame start sys-
tem (5) Oil module – Fitting
! Clean the sealing surfaces

Oil cooler – Removing

! Apply LOCTITE 648 to the screw plug (4), screw it

in and tighten it to 30 Nm
! Apply LOCTITE 648 to the screw-in port (3), screw
! Unscrew the mounting bolts (2) it in and tighten it to 40 Nm

! Remove the oil cooler (3) with seal (1) ! Fit the oil pressure switch (2) with a new seal (1),
screw it in and tighten it to 50 Nm
! Clean the sealing surfaces
! Fit the oil module (7) with a new gasket (8) and
position it
! Screw in the mounting bolts (6) and tighten to 22
Nm
! Fit the temperature sensor, flame start system (5),
with a new seal, screw it in and tighten it to 15 Nm
 ENGINE LUBRICATION

OIL SUMP

Oil sump – Removing and installing

Comprises
– Engine oil – Draining and topping up

(1) Oil sump cover (6) Oil sump

(2) Oil sump cover mounting bolt (7) Absorber mat
(3) Spacer sleeve (8) Oil sump holding block
(4) Crankcase yoke (9) Oil sump mounting bolt
(5) Oil sump seal

Technical data
Oil suction pipe mounting bolts M8x20-8.8 22 Nm
Oil sump cover mounting bolts (2) M8x50-8.8 22 Nm
Oil sump mounting bolts (8) M8x40-8.8 22 Nm
Oil drain plug M22x1.5 25 Nm
Oil excess pressure valve screw plug M24x1.5-5.8 60 Nm
 ENGINE LUBRICATION

Oil sump – Removing ! Unscrew the mounting bolts (4) of the oil sump (1)
! Remove the mounting bolts (4) with holding blocks
Oil sump cover – Removing (3)
! Remove the oil sump (1) with seal (2)

Oil suction pipe – Removing

! Unscrew the mounting bolts (4)

! Pull the oil suction pipe (3) out of the crankcase
yoke (1)
! Remove the O-ring (2) from the crankcase yoke (1)

Oil excess pressure valve – Removing

! Unscrew the mounting bolts (4) of the oil sump
cover (3)
! Remove the oil sump cover (3) with spacers and
absorber mat (2) from the oil sump (1)

Oil sump – Removing

! Unscrew the screw plug (1) with seal (3) and

washer (2)
! Pull out the oil excess pressure valve (4) and (5)
 ENGINE LUBRICATION

Oil sump – Installing Oil sump – Fitting

Oil excess pressure valve – Installing

! Insert the piston (5) with compression spring (4)

into the crankcase yoke
! Fit the screw plug (1) with the washer (2) and a new
seal (3) and screw it into the crankcase yoke
! Fit a new seal (2) onto the oil sump (1)
! Tighten the screw plug (1) to 60 Nm
! Position the oil sump (1)
! Screw in the mounting bolts (4) with holding blocks
Oil suction pipe – Installing (3) and tighten to 22 Nm

Oil sump cover – Fitting

! Fit the oil suction pipe (3)with a new O-ring(2) and

insert it into the crankcase yoke (1)
! Screw in the mounting bolts (3) for the oil suction
pipe (3) and tighten to 22 Nm

! Insert the absorber mat (2) into the oil sump cover
(3)
! Push the oil sump cover (3) over the oil sump (1)
! Fit the mounting bolts (4) with spacer sleeves,
screw them in and tighten to 22 Nm
 ENGINE LUBRICATION

OIL PUMP

Oil pump – Removing and installing

Comprises
– Coolant – Draining and topping up
– Engine oil – Draining and topping up
– Fan (mounting on vibration damper) – Removing and installing, see 2-19
– Fan (mounting on coolant pump) – Removing and installing, see 2-17
– Belt drive – Removing and installing, see 3-51
– Vibration damper – Removing and installing, see 10-169
– Alternator – Removing and installing, see 3-45
– Coolant pump – Removing and installing, see 2-33
– Thermostat / thermostat housing – Removing and installing, see 2-27
– Timing gears – Removing and installing, see 8-141
– Air compressor / steering booster pump – Removing and installing, see 3-43
– Timing chain housing – Removing and installing, see 11-209

(1) Oil pump drive gear (4) Sealing ring

(2) Oil pump gear (5) Coupling sleeve
(3) Oil pump housing

Technical data
Oil pump gear mounting nut M12x1.5-6S 30 Nm
Oil pump mounting bolt M8x20-10.9 Preliminary tightening 10 Nm
Oil pump mounting bolt M8x20-10.9 Final tightening 30 Nm
Oil excess pressure valve screw plug M24x1.5-5.8 60 Nm
End play on oil pump delivery gears (b=25) 0.040 – 0.106 mm
End play on oil pump delivery gears (b=32) 0.050 – 0.128 mm
Radial play on oil pump shaft 0.050 – 0.078 mm
 ENGINE LUBRICATION

Special tool

[55] Dial gauge

! Radial play of oil pump gears –
Checking in con-junction with:
! Dial gauge holder [56]

[56] Dial gauge holder

! Radial play of oil pump gears –
Checking in con-junction with:
! Dial gauge [55]

[57] Feeler gauge

! End play of oil pump gears –
Checking

Oil pump – Removing ! Remove mounting bolts (1) and (2) from the oil
pump

Oil pump drive gear – Removing ! Remove the idler gear 2

Oil pump – Removing

! Unscrew the mounting nut (1) for the oil pump drive
gear (2)
! Pull off the oil pump drive gear (2) ! Pull the oil pump (3) out of the timing chain housing
! Pull the coupling sleeve (1) out of the oil pump
Oil pump mounting bolts – Removing ! Remove the sealing rings (2) from the coupling
sleeve
 ENGINE LUBRICATION

End play of oil pump gears – Checking ! Lightly oil the oil pump gears (1) and (3) before
installing
! Line up oil pump gears (1) and (3) with one another
as marked and insert them in the oil pump housing
(2)

Oil pump – Installing

Oil pump – Fitting

! Please the measuring edge of a bevelled steel

edge (2) against the oil pump housing (4)
! Check the dimensions between both oil pump de-
livery gears (3) and the bevelled steel edge using
the Feeler gauge [58] (1)
! The end play must be 0.040 – 0.106 mm

Oil pump – Dismantling ! Lightly oil the new O-rings (2) and insert them into
the grooves provided in the coupling sleeve (1)
! Insert the coupling sleeve (1) into the oil pump up to
the stop
! Insert the oil pump (3) through the holes provided in
the timing chain housing

Oil pump mounting bolts – Screwing in

! Mark the orientation and installation position of the

oil pump gears (4) and (5)
! Pull the oil pump gears (4) and (5) out of the oil
pump housing (3)

Oil pump – Assembling

! Position the idler gear 2

! Screw in the mounting bolts (1) and (2) of the oil
pump and tighten them to Preliminary tightening 10
Nm
! Check the oil pump gears can turn freely
! Tighten the mounting bolts of the oil pump to Final
tightening 30 Nm
Note ! Repeat this working step until the oil pump gears
turn freely
Each oil pump gear is identified by a dot
on the end of the gear or by a chamfer on
the tooth of a gear
 ENGINE LUBRICATION

Oil pump drive gear – Installing Piston cooling nozzle – Removing

Note ! Unscrew the oil pressure valve

The mounting nut (1) of the oil pump ! Remove the Piston cooling nozzle (1)
drive gear (2) cannot be tightened until
all the timing gears have been installed Piston cooling nozzles – Installing
! Place the drive gear (2) of the oil pump onto the Piston cooling nozzles – Inserting
drive shaft
! Tighten the mounting nut (1) of the oil pump to 30
Nm

PISTON COOLING NOZZLES

Piston cooling nozzles – Removing and installing
Comprises
– Battery - Disconnecting and connecting
– Engine oil - Draining and topping up
– Oil sump - Removing and installing, see 9-155
– Crankcase yoke - Removing and installing, see 11- WARNING
219 Danger of engine damage
– Positive crankcase ventilation - Removing and Line up the ball mark on the oil injector
installing, see 11-221 nozzle exactly with the mark in the
crankcase
! Place the oil injector nozzle (2) aligned with the
mark (1) in the crankcase
! Place the corrugated washer on the oil pressure
valve and screw in until finger-tight

Oil pressure valve – Tightening

(1) Crankcase yoke (2) Piston cooling nozzle

(3) Corrugated disc (4) Oil pressure valve
Technical data
Oil pressure valve for start of opening 1.5 ±0.1 bar Check the oil injector nozzle is correctly seated and
Oil pressure valve fully open 2.0 ±0.1 bar align it if necessary
Oil pressure valve (4) 40 Nm
Tighten the oil pressure valve to 40 Nm
CRANKSHAFT DRIVE

(1) Vibration damper (5) Crankshaft

(2) Connecting rod (6) Connecting rod bearing shell
(3) Piston (7) Crankshaft main bearing shell
(4) Flywheel
 CRANKSHAFT DRIVE

VIBRATION DAMPER

Vibration damper – Removing and installing

Comprises
– Fan (mounting on vibration damper) – Removing and installing, see 2-19
– Fan (mounting on coolant pump) – Removing and installing, see 2-17
– Belt drive – Removing and installing, see 3-51

(1) Vibration damper mounting bolts (2) Vibration damper washer

(3) Vibration damper

Technical data
Vibration damper mounting bolts (1) M14x1.5x95-10.9 Preliminary tightening 150 Nm
Vibration damper mounting bolts (1) M14x1.5x95-10.9 Final tightening 90° +10°

Special tool

[58] Engine barring gear

! Engine – cranking
 CRANKSHAFT DRIVE

Vibration damper – Removing Vibration damper – Installing

! Place the vibration damper (3) on the crankshaft

! Fit the Engine barring gear [59] ! Insert the washer (2) into the vibration damper (3)
! Remove the vibration damper (2) with washer (1) ! Screw in new mounting bolts (1) for the vibration
damper (3) and tighten them to Preliminary tight-
ening 150 Nm
! Tighten the mounting bolts (1) of the vibration
damper (3) to Final tightening 90° +10°
! Remove the Engine barring gear [58]
Flywheel

Removing and installing the flywheel

1) Flywheel (2) Flywheel mounting bolt

(3) Flywheel housing (4) Flywheel Ring gear
Technical data
Flywheel mounting bolts (2) ...................M14x1.5x30-10.9 .............Initial torque 100 Nm
Flywheel mounting bolts (2) ...................M14x1.5x30-10.9............ Final torque 90° +10°
Mounting bolts (2) for Allison MD 3060 ...M14x1.5x66-10.9 ..........Initial torque 100 Nm
Flywheel mounting bolts (2) for Allison MD 3060...M14x1.5x66-10.9.... Final torque 90° +10°
Flywheel mounting bolts (2) ZF HP500/Ø 380...M14x1.5x45-10.9...Initial torque 100 Nm
Flywheel mounting bolts (2) ZF HP500/Ø 380...M14x1.5x45-10.9 Final torque 90° + 10°
Flywheel mounting bolts (2) automatic gearbox ......M14x1.5x50-10.9......................... Initial
torque 100 Nm
Flywheel mounting bolts (2) automatic gearbox ......M14x1.5x50-10.9....................... Final torque
90° + 10°
Flywheel lateral run-out...........................................................................max. 0.5 mm
Installation temperature of flywheel ring gear ............................................200 - 230 °C
CRANKSHAFT DRIVE

Special tool

[59] Internal extractor

! Clutch pilot bearing – Pulling out in
conjunction with:
! Counter support [60]

[60] Counter support

! Clutch pilot bearing – Pulling out in
conjunction with:
! Internal extractor [59]

[61] Dial gauge

! Flywheel lateral run-out – Checking in
conjunction with:
! Dial gauge holder [62]

[62] Dial gauge holder

! Flywheel lateral run-out – Checking in
conjunction with:
! Dial gauge [61]

[63] Clutch pilot bearing press-in pin

! Clutch pilot bearing – Pressing in

[64] Guide pins

! Flywheel – Removing and fitting

[65] Socket 22 mm
! Flywheel bolts – Tightening in
conjunction with:
! Support [67]
! Force multiplier spanner i =
1 : 3.3 [66]
! Angle measuring disc [68]
! Holding fixture [69]
! Hexagon socket head cap screw [70]
! Connecting pin [71]
! Rubber ring 42 mm [72]
! Washer [73]
CRANKSHAFT DRIVE

Special tool

[66] Force multiplier spanner i = 1 : 3.3

! Flywheel bolts – Tightening in
conjunction with:
! Support [67]
! Angle measuring disc [68]
! Holding fixture [69]
! Hexagon socket head cap screw [70]
! Connecting pin [71]
! Rubber ring 42 mm [72]
! Washer [73]
! Socket 22 mm [65]
[67] Support
! Flywheel bolts – Tightening in
conjunction with:
! Force multiplier spanner i =
1 : 3.3 [66]
! Angle measuring disc [68]
! Holding fixture [69]
! Hexagon socket head cap screw [70]
! Connecting pin [71]
! Rubber ring 42 mm [72]
! Washer [73]
! Socket 22 mm [65]
[68] Angle measuring disc
! Flywheel bolts – Tightening in
conjunction with:
! Support [67]
! Force multiplier spanner i =
1 : 3.3 [66]
! Holding fixture [69]
! Hexagon socket head cap screw [70]
! Connecting pin [71]
! Rubber ring 42 mm [72]
! Washer [73]
! Socket 22 mm [65]
[69] Holding fixture
! Flywheel bolts – Tightening in
conjunction with:
! Support [67]
! Angle measuring disc [68]
! Force multiplier spanner i =
1 : 3.3 [66]
! Hexagon socket head cap screw [70]
! Connecting pin [71]
! Rubber ring 42 mm [72]
! Washer [73]
! Socket 22 mm [65]
CRANKSHAFT DRIVE

Special tool

[70] Hexagon socket head cap screw

! Flywheel bolts – Tightening in
conjunction with:
! Support [67]
! Angle measuring disc [68]
! Holding fixture [69]
! Force multiplier spanner i =
1 : 3.3 [66]
! Connecting pin [71]
! Rubber ring 42 mm [72]
! Washer [73]
! Socket 22 mm [65]
[71] Connecting pin
! Flywheel bolts – Tightening in
conjunction with:
! Support [67]
! Angle measuring disc [68]
! Holding fixture [69]
! Hexagon socket head cap screw [70]
! Force multiplier spanner i =
1 : 3.3 [66]
! Rubber ring 42 mm [72]
! Washer [73]
! Socket 22 mm [65]
[72] Rubber ring 42 mm
! Flywheel bolts – Tightening in
conjunction with:
! Support [67]
! Angle measuring disc [68]
! Holding fixture [69]
! Hexagon socket head cap screw [70]
! Connecting pin [71]
! Force multiplier spanner i =
1 : 3.3 [67]
! Washer [73]
! Socket 22 mm [65]
[73] Washer
! Flywheel bolts – Tightening in
conjunction with:
! Support [67]
! Angle measuring disc [68]
! Holding fixture [69]
! Hexagon socket head cap screw [70]
! Connecting pin [71]
! Rubber ring 42 mm [72]
! Force multiplier spanner i =
1 : 3.3 [66]
! Socket 22 mm [65]
 CRANKSHAFT DRIVE

Flywheel – Removing ! Unscrew the mounting bolts (1) of the flywheel (2)
Special tool – Assembling except for two bolts

Guide pins – Installing

! Fit the Holding fixture [69] (5) with Hexagon socket

head cap screw [70] (4) and Washer [73] (3) on the
Support [67] (2)
! Place the Angle measuring disc [68] (9) onto the ! Screw the Guide pins [64] (1) through the flywheel
Force multiplier spanner i = 1 : 3.3 [66] (1) into the crankshaft
! Place the Socket 22 mm [65] (7) onto the Force ! Unscrew the remaining mounting bolts
multiplier spanner i = 1 : 3.3 [66] (1) and secure with
the Connecting pin [71] (8) and Rubber ring 42 mm
[72] (6) Flywheel – Pulling off

Flywheel mounting bolts – Unscrewing

CAUTION
The flywheel is heavy
! Place the assembled special tool (1) onto the fly- ! Use lifting gear
wheel bolt that is going to be unscrewed
! Unscrew all mounting bolts from the flywheel
! Pull off the flywheel (1) over the Guide pins [64] (2)

Flywheel mounting bolts – Removing

 CRANKSHAFT DRIVE

Flywheel – Installing Guide pins – Removing

Flywheel lateral run-out – Checking

! Unscrew the Guide pins [64] (1)

! Screw in the mounting bolts for the flywheel
! Clamp the flywheel (1) onto the fixture
! Fit the Dial gauge [61] (2) with Dial gauge holder Special tool – Assembling
[62]
! Place the measuring tip of the Dial gauge [61] (2)
against the flywheel with a preload
! Zero the Dial gauge [61] (2)
! Turn the flywheel (1) a few turns and, at the same
time, read off the deflection of the Dial gauge [61]
The permitted lateral run-out is max. 0.5 mm

Flywheel – Putting on

! Fit the Holding fixture [69] (5) with Hexagon socket

head cap screw [70] (4) and Washer [73] (3) on the
Support [67] (2)
! Place the Angle measuring disc [68] (9) onto the
Force multiplier spanner i = 1 : 3.3 [66] (1)
! Place the Socket 22 mm [65] (7) onto the Force
multiplier spanner i = 1 : 3.3 [66] (1) and secure with
the Connecting pin [71] (8) and Rubber ring 42 mm
[72] (6)

WARNING
Flywheel bolts are expansion bolts
! Expansion bolts must not be re-used
after being unscrewed
! Screw in the Guide pins [64] (2)
! Line up the flywheel (1) with the crankshaft guide
pin
! Push the flywheel (1) over the Guide pins [64] onto
the crankshaft
! Screw in new mounting bolts for the flywheel and
tighten until finger-tight
 CRANKSHAFT DRIVE

Flywheel mounting bolts – Tightening Flywheel ring gear – Installing

Note
The chamfers on the teeth of the
Note flywheel ring gear must point away from
the fly-wheel
Note the multiplication ratio of the force
multiplier spanner i = 1 : 3.3 ! Heat the flywheel ring gear (1) to 200 –230 °C

! Place the assembled special tool (1) onto the fly- ! Place the flywheel ring gear (1) on the flywheel (2)
wheel bolt that is going to be tightened and seat it if necessary

! Tighten the mounting bolts to Preliminary

tightening 100 Nm Clutch pilot bearing – Removing
! Tighten the mounting bolts to Final tightening 90° Internal circlip – Removing
+10°

Flywheel ring gear – Removing and installing

Flywheel ring gear – Spot-drilling

! Use internal circlip pliers (1) to remove the internal

circlip (2) from the flywheel

Extractor device – Fitting

WARNING
The flywheel can be destroyed
! Do not damage the flywheel when
spot-drilling the flywheel ring gear
! Spot-drill the flywheel ring gear (1) and use a chisel
to break it off
! Remove the flywheel ring gear (1) from the fly-
wheel (2)
! Clean the contact surfaces of the flywheel ring gear
(1) on the flywheel (2) and check them for damage Insert the Internal extractor [59] (2) into the clutch pilot
bearing and expand it
Attach the Counter support [60] (1) and clamp it
 CRANKSHAFT DRIVE

Clutch pilot bearing – Pulling out Clutch pilot bearing – Installing

! Use the Internal extractor [59] (2) and Counter ! Use the Clutch pilot bearing press-in pin [63] (1) to
support [60] (1) to pull the clutch pilot bearing (3) drive the clutch pilot bearing (2) into the flywheel
out of the flywheel (3)up to the stop
! Install the internal circlip
 CRANKSHAFT DRIVE

PISTON AND CONNECTING ROD

Piston and connecting rod – Removing and

installing
Comprises
– Coolant – Draining and topping up – Exhaust manifold – Removing and installing, see 6-
– Engine oil – Draining and topping up 103
– Induction manifold – Removing and installing, see – Cylinder head – Removing and installing, see 7-113
6-105 – Oil sump – Removing and installing, see 9-155
– Coolant pipes – Removing and installing, see 2-21 – Crankcase yoke – Removing and installing, see 11-
– Turbocharger – Removing and installing, see 5-95 219

(1) Connecting rod bearing bolts (4) Internal circlip

(2) Connecting rod bearing shell (5) Gudgeon pin
(3) Connecting rod (6) Piston

Technical data
Connecting rod bearing bolts M11x1.5x60-11.9 Preliminary tightening 50 +10 Nm
Connecting rod bearing bolts M11x1.5x60-11.9 Final tightening 90° +10°

Connecting rod
Conrod length, middle of conrod eye to middle of conrod bearing 196 ±0.02 mm
Inside diameter of connecting rod eye Diameter 42 +0.005 mm
Crank pin width 32.78 – 33.00 mm
Bore for connecting rod bearing shells Diameter 74.000 – 74.019 mm
CRANKSHAFT DRIVE

Connecting rod bearing

Connecting rod bearing normal dimension Diameter 69.981 – 70.00 mm
Connecting rod bearing normal dimension I Diameter 69.881 – 69.90 mm
Connecting rod bearing repair level 1 Diameter 69.731 – 69.75 mm
Connecting rod bearing repair level 2 Diameter 69.481 – 69.50 mm
Connecting rod bearing repair level 3 Diameter 69.231 – 69.25 mm
Connecting rod bearing repair level 4 Diameter 68.981 – 69.00 mm
Weight difference per set of connecting rods in an engine max. 50 g

Wall thickness of connecting rod bearing

Connecting rod bearing thickness normal dimension 1.975 mm
Connecting rod bearing thickness normal dimension I 2.025 mm
Connecting rod bearing thickness repair level I 2.100 mm
Connecting rod bearing thickness repair level II 2.225 mm
Connecting rod bearing thickness repair level III 2.350 mm
Connecting rod bearing thickness repair level IIII 2.475 mm

Piston diameter Ø 108 mm WSK piston (double-bevelled ring height 3 mm)

D1 measured 17 mm above lower edge of piston 107.791 – 107.800 mm
D2 measured 54 mm above lower edge of piston 107.686 – 107.695 mm
D3 measured 91.4 mm above lower edge of piston 107.541 – 107.500 mm

Piston diameter Ø 108.50 mm WSK piston oversize I (double-bevelled ring height 3 mm)
D1 measured 17 mm above lower edge of piston 108.291 – 108.300 mm
D2 measured 54 mm above lower edge of piston 108.186 – 108.195 mm
D3 measured 91.4 mm above lower edge of piston 108.041 – 108.000 mm

Piston heights Ø 108 mm WSK piston (double-bevelled ring height 3 mm)

Overall 103.00 mm
Piston height from middle of gudgeon pin to piston crown / PH level 0 63.90 mm
Total height undersize I 102.80 mm
Piston height from middle of gudgeon pin to piston crown / PH level 1 63.70 mm
Total height undersize II 102.60 mm
Piston height from middle of gudgeon pin to piston crown / PH level 2 63.50 mm

Piston heights Ø 108.50 mm WSK piston (double-bevelled ring height 3 mm)

Overall 103.00 mm
Piston height from middle of gudgeon pin to piston crown / PH level 0 63.90 mm
Total height undersize I 102.80 mm
Piston height from middle of gudgeon pin to piston crown / PH level 1 63.70 mm

Piston diameter Ø 108 mm WSK piston (double-bevelled ring height 4 mm)

D1 measured 17 mm above lower edge of piston 107.791 – 107.800 mm
D2 measured 54 mm above lower edge of piston 107.686 – 107.695 mm
D3 measured 91.4 mm above lower edge of piston 107.541 – 107.500 mm

Piston diameter Ø 108.50 mm WSK piston oversize I (double-bevelled ring height 4 mm)
D1 measured 17 mm above lower edge of piston 108.291 – 108.300 mm
D2 measured 54 mm above lower edge of piston 108.186 – 108.195 mm
D3 measured 91.4 mm above lower edge of piston 108.041 – 108.000 mm
 CRANKSHAFT DRIVE

Piston heights Ø 108 mm WSK piston (double-bevelled ring height 4 mm)

Overall 103.00 mm
Piston height from middle of gudgeon pin to piston crown / PH level 0 63.90 mm
Total height undersize I 102.80 mm
Piston height from middle of gudgeon pin to piston crown / PH level 1 63.70 mm
Total height undersize II 102.60 mm
Piston height from middle of gudgeon pin to piston crown / PH level 2 63.50 mm

Piston heights Ø 108.50 mm WSK piston (double-bevelled ring height 4 mm)

Overall 103.00 mm
Piston height from middle of gudgeon pin to piston crown / PH level 0 63.90 mm
Total height undersize I 102.80 mm
Piston height from middle of gudgeon pin to piston crown / PH level 1 63.70 mm

Piston heights Nüral piston (double-bevelled ring height 4 mm)

Overall 103.00 mm
Piston height from middle of gudgeon pin to piston crown / PH level 0 63.90 mm

Piston diameter Ø 108 mm Nüral piston (double-bevelled ring height 4 mm)

D2 measured 54 mm above lower edge of piston 107.686 – 107.695 mm
D3 measured 91.4 mm above lower edge of piston 107.541 – 107.500 mm

Double trapezoidal ring all pistons

Piston ring width 4.5 – 4.7 mm
Ring gap 0.3 – 0.55 mm

Taper-face ring all pistons

Piston ring height 2.478 – 2.50 mm
Piston ring width 4.25 – 4.60 mm
Ring g 0.3 – 0.5 mm
Axial play in piston ring groove 0.15 mm

Double-bevelled ring 3 mm
Piston ring height 3 mm (nominal value)
Piston ring width 3.40 – 3.65 mm
Ring g 0.3 – 0.6 mm
Axial play in piston ring groove 0.15 mm

Double-bevelled ring 4 mm
Piston ring height 3.975 –3.990mm
Piston ring width 3.05 – 3.40 mm
Ring g 0.3 – 0.6 mm
Axial play in piston ring groove 0.15 mm

Gudgeon pin
Gudgeon pin diameter Diameter 41.994 – 42.00 mm
Gudgeon pin play (radial) in connecting rod 0.05 – 0.066 mm
Gudgeon pin play (radial) in piston 0.003 – 0.015 mm

Piston standout
Piston standout from top edge of crankcase to piston crown 0.093 – 0.391 mm

Piston weight
Piston weight difference per set in one engine max. 40 g
CRANKSHAFT DRIVE

Important information Note

WARNING Conventional precision connecting rods
Crack surfaces are sensitive, pitting and cracked connecting rods can be
corrosion may occur as a result of intermixed.
the principle involved Only use cracked connecting rods when
Replace the connecting rod if the crack repairing.
surfaces on the connecting rod are
damaged Note
Protect crack surfaces against damage The piston diameter is always
by hard and sharp objects measured at right angles to the gudgeon
Only clean crack surfaces on the pin bore. Pistons are identified with A or
connecting rods by washing in clean B
cleaning agent
Dry crack surfaces with compressed air
after cleaning
Make sure washed-out particles do not
get into the engine

Special tool

[74] Piston ring compressor pliers

! Piston rings – Removing and
installing

[75] Feeler gauge

! Piston ring gap –Checking

[76] Dial gauge holder

! Piston lag – Checking in
conjunction with:
! Dial gauge [77]

[77] Dial gauge

! Piston lag – Checking in
conjunction with:
! Dial gauge holder [76]

[78] Piston ring scuff band

! Piston – Installing
 CRANKSHAFT DRIVE

Piston and connecting rod – Removing ! Mark the piston position in relation to the
Connecting rod bearing shells – Removing connecting rod
! Remove the internal circlips (1) and (4) from the
piston (3)
! Press the gudgeon pin (2) out of the piston (3)
! Remove the piston (3) from the connecting rod (5)

Piston, piston rings and connecting rod –

Checking
Gudgeon pin – Checking

! Mark the connecting rod bearing shell (2) and

connecting rod bearing (1) to indicate their
installation position and pairing
! Unscrew the connecting rod bearing bolts
! Remove the connecting rod bearing shell (2) with
connecting rod bearing (1)
! Push the piston and connecting rod out in the
direction of the cylinder head ! Remove the gudgeon pin (2) from the piston (1)
! Measure the gudgeon pin (2) at various points
using the micrometer gauge (3) to check the
Piston – Removing
gudgeon pin dimension Diameter 41.994 – 42.00
mm

Piston ring axial play – Checking

! Mark the piston (2) in relation to the crankcase (1)

! Pull the piston (2) with connecting rod upwards out
of the crankcase (1)
Note

Gudgeon pin – Removing It is not possible to check the ring gap of

a double trapezoidal ring
! Use the Feeler gauge [75] (4) to check the axial play
between the oil scraper ring (2) and the piston (3) at
various points
! The maximum permitted axial play of the oil scraper
ring (2) in the piston ring groove is0.15 mm
! Repeat the measurement on the compression ring
(1)
! The maximum permitted axial play of the
compression ring (1) in the piston ring groove is
0.15 mm
 CRANKSHAFT DRIVE

Piston rings – Removing Piston rings – Installing

! Set the Piston ring compressor pliers [74] (1) to the WARNING
piston diameter Piston rings can break during
! Use the Piston ring compressor pliers [74] (1) to installation
remove the piston rings (2) from the piston (3) ! Only install piston rings using
! Clean the piston ring grooves correctly set piston ring compressor
pliers

Piston ring gap – Checking ! Use the piston ring compressor pliers (1) to install
the piston rings (2) into the piston (3)

Connecting rod bearing – Checking

Gudgeon pin bore – Checking

Note
Repeat the measurement with a new
pis-ton ring if the ring gap is too large
If the play is still too large, measure the
cylinder liner and fit a new one if Note
necessary Fit a new connecting rod (1) if the
! Insert the piston ring (3) into the installed cylinder bearing play in the small end bearing is
liner (1) too large
! Use the Feeler gauge [75] (2)to check the ring gap. ! Use the internal calliper (2) and Dial gauge [77] (3)
! The permitted ring gap of a double trapezoidal ring to check the gudgeon pin bore
is 0.3 –0.55 mm ! The inside diameter of the connecting rod eye must
! The permitted ring gap of a taper-face ring is 0.3 be Diameter 42 +0.005 mm
–0.5mm.
! The permitted ring gap of a double-bevelled ring
with 3 mm height is 0.3 – 0.6 mm
! The permitted ring gap of a double-bevelled ring
with 4 mm height is 0.3 – 0.6 mm
 CRANKSHAFT DRIVE

Big end bearing – Checking Piston installation with piston ring scuff band

! Insert the connecting rod bearing into the ! Line up the gaps in the piston rings at 120° offset to
connecting rod (2) and connecting rod bearing one another
shell (3) ! Set the crankshaft to bottom dead centre of the
! Put on the connecting rod bearing shell as marked cylinder where the piston (2) is being installed
and tighten it using connecting rod bolts ! Slide the opened Piston ring scuff band [78] (1) over
! Use the internal calliper (1) and Dial gauge [77] (4) the piston and let it sit on the crankcase (4)
to check the connecting rod bearing ! Tighten the Piston ring scuff band [78] (1) with the
! The connecting rod bearing dimension must be key (3), but not too tight
Diameter 69.981 – 70.00 mm for the normal ! Slide the piston (2) through the Piston ring scuff
dimension band [78] (1) into the cylinder liner
! Carefully push the piston through until the small
Piston and connecting rod – Installing end bearing contacts the crankshaft
Gudgeon pin – Installing
Connecting rod bearing shell – Fitting

! Place the piston (3) on the connecting rod (5)

according to the marking WARNING
! Line up the connecting rod eye and gudgeon pin Crack surfaces are sensitive, pitting
bore with one another corrosion may occur as a result of
the principle involved
! Insert the gudgeon pin (2) through the piston (3)
and the connecting rod eye ! Replace the connecting rod if the crack surfaces on
the connecting rod are damaged
! Insert the internal circlips (1) and (4)
! Protect crack surfaces against damage by hard and
sharp objects
! Only clean crack surfaces on the connecting rods
by washing in clean cleaning agent
! Dry crack surfaces with compressed air after
cleaning
! Make sure washed-out particles do not get into the
engine
 CRANKSHAFT DRIVE

! Insert the connecting rod bearing (1) into the Piston standout – Checking
corresponding connecting rod bearing shell (2)ac-
cording to the marking and pairing
! Line up the connecting rod bearing shell (2) exactly
on the connecting rod and bring it into con-tact,
taking care not to damage the contact surfaces
between the connecting rod bearing shell and
connecting rod
! Screw in new connecting rod bearing bolts by hand
! Tighten the connecting rod bearing bolts to
Preliminary tightening 50 +10 Nm
! Tighten the connecting rod bearing bolts to Final
tightening 90° +10°
! Clean the contact surfaces of the cylinder head
gasket
! Set the piston (2)to top dead center
! Place the Dial gauge [61] (3) and Dial gauge holder
[62] (5) onto the crankcase (4)
! Place the dial gauge probe (1) on the crankcase (4)
and zero the gauge
! Place the dial gauge probe (1) on the piston (2) and
read off the difference
! The maximum permitted piston standout is 0.093
–0.391mm
CRANKSHAFT DRIVE

Crankshaft – Removing and installing – Thermostat / thermostat housing – Removing and

Comprises installing, see 2-27

– Oil sump – Removing and installing, see 9-155 – Turbocharger – Removing and installing, see 5-95

– Fan (mounting on vibration damper) – Removing – Exhaust manifold – Removing and installing, see 6-
and installing, see 2-19 103

– Fan (mounting on coolant pump) – Removing and – Cylinder head – Removing and installing, see 7-113
installing, see 2-17 – Timing gears – Removing and installing, see 8-141
– Belt drive – Removing and installing, see 3-51 – Air compressor / steering booster pump –
– Vibration damper – Removing and installing, see Removing and installing, see 3-43
10-169 – Timing chain housing – Removing and installing,
– Induction manifold – Removing and installing, see see 11-209
6-105 – Crankcase yoke – Removing and installing, see 11-
– Coolant pipes – Removing and installing, see 2-21 219

– Coolant pump – Removing and installing, see 2-33 – Piston and connecting rod – Removing, see 10-183

(1) Crankshaft main bearing top (5) Axial shim bottom

(2) Crankshaft main bearing bottom (6) Crankshaft
(3) Crankshaft main bearing cap (7) Axial shim top
(4) Crankshaft main bearing bolt (8) Crankcase

Technical data
Crankshaft main bearing bolts (4) M14x118-10.9 Preliminary tightening 115 Nm
Crankshaft main bearing bolts (4) M14x118-10.9 Final tightening 90° +10°
Connecting rod bearing bolts M11x1.5x60-11.9 Preliminary tightening 50 +10 Nm
Connecting rod bearing bolts M11x1.5x60-11.9 Final tightening 90° +10°
 CRANKSHAFT DRIVE

Crankshaft
Crankshaft hardness 53 ±3 HRC
Permitted curvature of journals 0.004 mm
Crankshaft end play 0.150 – 0.282 mm
Journal normal dimension Diameter 76.981 – 77.000 mm
Journal normal dimension I Diameter 76.781 – 76.800 mm
Journal repair level I Diameter 76.481 – 76.500 mm
Journal repair level II Diameter 75.981 – 76.000 mm
Journal repair level III Diameter 75.481 – 75.500 mm
Journal repair level IV Diameter 74.981 – 75.000 mm

Crankshaft main bearing

Crankshaft main bearing wall thickness normal dimension (1) (2) 2.468 mm
Crankshaft main bearing wall thickness normal dimension (1) (2) 2.518 mm
Crankshaft main bearing wall thickness repair level I (1) (2) 2.593 mm
Crankshaft main bearing wall thickness repair level II (1) (2) 2.718 mm
Crankshaft main bearing wall thickness repair level III (1) (2) 2.843 mm
Crankshaft main bearing wall thickness repair level IV (1) (2) 2.968 mm
Axial shim normal dimension (5) (7) 2.850 mm
Axial shim repair level I (5) (7) 3.100 mm
Expansion 0.5 mm

Special tool

[79] Dial gauge

! Crankshaft end play – Checking in
conjunction with:
! Dial gauge holder [81

[80] Dial gauge holder

! Crankshaft end play – Checking in
conjunction with:
! Dial gauge [79]

[81] Socket 22 mm
! Crankshaft bolts – Tightening in
conjunction with:
! Support [83]
! Force multiplier spanner i = 1 : 3.3 [82]
! Angle measuring disc [84]
! Holding fixture [85]
! Hexagon socket head cap screw [86]
! Connecting pin [87]
! Rubber ring 42 mm [88]
! Washer [89]
CRANKSHAFT DRIVE

Special tool

[82] Force multiplier spanner i = 1 : 3.3

! Crankshaft bolts – Tightening in
conjunction with:
! Support [83]
! Angle measuring disc [84]
! Holding fixture [85]
! Hexagon socket head cap screw [86]
! Connecting pin [87]
! Rubber ring 42 mm [88]
! Washer [89]
! Socket 22 mm [81]
[83] Support
! Crankshaft bolts – Tightening in
conjunction with:
! Force multiplier spanner i = 1 : 3.3 [82]
! Angle measuring disc [84]
! Holding fixture [85]
! Hexagon socket head cap screw [86]
! Connecting pin [87]
! Rubber ring 42 mm [88]
! Washer [89]
! Socket 22 mm [81]
[84] Angle measuring disc
! Crankshaft bolts – Tightening in
conjunction with:
! Support [83]
! Force multiplier spanner i = 1 : 3.3 [82]
! Holding fixture [85]
! Hexagon socket head cap screw [86]
! Connecting pin [87]
! Rubber ring 42 mm [88]
! Washer [89]
! Socket 22 mm [81]
[85] Holding fixture
! Crankshaft bolts – Tightening in
conjunction with:
! Support [83]
! Angle measuring disc [84]
! Force multiplier spanner i = 1 : 3.3 [82]
! Hexagon socket head cap screw [86]
! Connecting pin [87]
! Rubber ring 42 mm [88]
! Washer [89]
! Socket 22 mm [81]
[86] Hexagon socket head cap screw
! Crankshaft bolts – Tightening in
conjunction with:
! Support [83]
! Angle measuring disc [84]
! Holding fixture [85]
! Force multiplier spanner i = 1 : 3.3 [82]
! Connecting pin [87]
! Rubber ring 42 mm [88]
! Washer [89]
! Socket 22 mm [81]
 CRANKSHAFT DRIVE

Special tool

[87] Connecting pin

! Crankshaft bolts – Tightening in
conjunction with:
! Support [83]
! Angle measuring disc [84]
! Holding fixture [85]
! Hexagon socket head cap screw [86]
! Force multiplier spanner i = 1 : 3.3 [82]
! Rubber ring 42 mm [88]
! Washer [89]
! Socket 22 mm [81]
[88] Rubber ring 42 mm
! Crankshaft bolts – Tightening in
conjunction with:
! Support [83]
! Angle measuring disc [84]
! Holding fixture [85]
! Hexagon socket head cap screw [86]
! Connecting pin [87]
! Force multiplier spanner i = 1 : 3.3 [82]
! Washer [89]
! Socket 22 mm [81]
[89] Washer
! Crankshaft bolts – Tightening in
conjunction with:
! Support [83]
! Angle measuring disc [84]
! Holding fixture [85]
! Hexagon socket head cap screw [86]
! Connecting pin [87]
! Rubber ring 42 mm [88]
! Force multiplier spanner i = 1 : 3.3 [82]
! Socket 22 mm [81]

Crankshaft – Removing ! Remove the connecting rod bearing shell (2) with
Connecting rod bearing shells – Removing connecting rod bearing (1)
! Push the piston and connecting rod out in the
direction of the cylinder head

! Mark the connecting rod bearing shell (2) and

connecting rod bearing (1) to indicate their
installation position and pairing
! Unscrew the connecting rod bearing bolts
 CRANKSHAFT DRIVE

Special tool – Assembling ! Remove the crankshaft main bearing bolts (1)
! Remove the crankshaft main bearing shell (2) with
crankshaft main bearing (3)

Crankshaft – Lifting out

! Fit the Holding fixture [85] (5) with Hexagon socket

head cap screw [86] (4) and Washer [90] (3) on the
! Support [83] (2)
! Place the Angle measuring disc [85] (9) onto the
Force multiplier spanner i = 1 : 3.3 [83] (1)
! Place the Socket 22 mm [82] (7) onto the Force WARNING
multiplier spanner i = 1 : 3.3 [82] (1) and secure with
the The crankshaft can be damaged

! Connecting pin [87] (8) and Rubber ring 42 mm [88] ! Do not use any lifting gear with sharp
(6) edges to lift out the crankshaft
! Use lifting gear to lift the crankshaft
(2) out of the crankcase (1)
Crankshaft main bearing bolts – Unscrewing

Crankshaft main bearings – Checking

Crankshaft main bearings – Checking for

expansion

! Place the assembled special tool (1) onto the bolt

that is going to be unscrewed
! Crankshaft main bearing bolts – Unscrewing all

Crankshaft main bearing – Removing

! Clean the crankshaft main bearings (2) and put
them together on a flat surface as marked
! Use a micrometer gauge to check dimension A
! Use a micrometer gauge to check dimension B
! The difference between dimension A and
dimension B is the expansion of the crankshaft
main bearings
! The maximum permitted expansion is 0.5 mm
 CRANKSHAFT DRIVE

Crankshaft main bearing inside diameter – Crankshaft – Installing

Checking

Crankshaft – Inserting

! Insert the crankshaft main bearing into the crank-

shaft main bearing seat and crankshaft main
bearing cap (3) as marked ! Insert the crankshaft main bearing shells into the
crankcase (1) as marked
! Insert the crankshaft main bearing cap (3) into the
crankcase as marked ! Use lifting gear to lift the crankshaft (2) into the
crankcase (1)
! Tighten the crankshaft main bearing bolts
! Use the internal calliper (2) and Dial gauge [80] (1)
to measure the inside diameter of the crankshaft Upper axial shims – Installing
main bearing
! Repeat the measurement at various points,
dimensions see Technical data, 10-190
! Remove the crankshaft main bearing cap (3) after
the measurement

Crankshaft – Checking

Note
The axial shims of the crankshaft main
bearings are installed in the fourth
bearing seat.
Make sure the installation orientation
and installation position are correct.

! Clean the journals of the crankshaft (2) Use a ! Push the upper axial shims (2) between the crank-
micrometer gauge (1) to measure the crank-shaft case and crankshaft at crankcase bearing 4 with
journal the oil grooves pointing towards the crankshaft (1)

! Repeat the measurement for each journal ! Screw the axial shims (2) into the bearing seat by
pressing slightly
! Dimensions, see Technical data, 10-190
 CRANKSHAFT DRIVE

Lower axial shims – Installing Special tool – Assembling

! Insert the axial shims (1) and (4) into the crank- ! Fit the Holding fixture [86] (5) with Hexagon socket
shaft main bearing cap (2) with the oil grooves head cap screw [87] (4) and Washer [90] (3) on the
pointing towards the crankshaft Support [84] (2)
! Place the crankshaft main bearing cap (2) onto the ! Insert the Force multiplier spanner i = 1 : 3.3 [83] (1)
bearing seat and fix it into the Support [84] (2)
! Screw in the crankshaft main bearing bolts (3) until ! Place the Angle measuring disc [85] (9) onto the
finger-tight Force multiplier spanner i = 1 : 3.3 [83] (1)
! Place the Socket 22 mm [82] (7) onto the Force
Crankshaft end play – Checking multiplier spanner i = 1 : 3.3 [82] (1) and secure with
the Connecting pin [86] (8) and Rubber ring 42 mm
[89] (6)

Crankshaft main bearing bolts – Tightening

! Place the Dial gauge [79] (1) and Dial gauge holder
[81] (2) onto the crankcase
! Place the dial gauge probe onto the crankshaft (3),
push the crankshaft (3) into an end position and
zero the Dial gauge [79] (1) Note
! Push the crankshaft (3) to the other end position Note the multiplication ratio of the force
and read off the difference on the Dial gauge [79] (1) multiplier spanner i = 1 : 3.3
! Thickness of axial shims see Technical data, 10-
190 ! Place the assembled special tool (1) onto the fly-
wheel bolt that is going to be tightened
! Tighten the mounting bolts to Preliminary
tightening 115 Nm
! Tighten the mounting bolts to Final tightening 90°
+10°
 CRANKSHAFT DRIVE

Connecting rod bearing shell – Fitting

WARNING
Crack surfaces are sensitive, pitting
corrosion may occur as a result of
the principle involved
! Replace the connecting rod if the
crack surfaces on the connecting
rod are damaged
! Protect crack surfaces against
damage by hard and sharp objects
! Only clean crack surfaces on the
connecting rods by washing in clean
cleaning agent
! Dry crack surfaces with compressed
air after cleaning
! Make sure washed-out particles do
not get into the engine
! Insert the connecting rod bearing (1) into the
corresponding connecting rod bearing shell (2)ac-
cording to the marking and pairing
! Line up the connecting rod bearing shell (2) exactly
on the connecting rod and bring it into con-tact,
taking care not to damage the contact surfaces
between the connecting rod bearing shell and
connecting rod
! Screw in new connecting rod bearing bolts by hand
! Tighten the connecting rod bearing bolts to
Preliminary tightening 50 +10 Nm
! Tighten the connecting rod bearing bolts to Final
tightening 90° +10°
 ENGINE HOUSING

(1) Cylinder liner (6) Timing chain housing cover

(2) Positive crankcase ventilation tube (7) Timing chain housing
(3) Crankcase (8) Positive crankcase ventilation filter
(4) Flywheel housing (9) Positive crankcase ventilation line
(5) Crankcase yoke
 ENGINE HOUSING

CYLINDER LINER – Coolant pipes – Removing and installing, see 2-21

– Turbocharger – Removing and installing, see 5-95
Cylinder liner – Removing and installing – Exhaust manifold – Removing and installing, see 6-
Comprises 103

– Oil sump – Removing and installing, see 9-155 – Cylinder head – Removing and installing, see 7-113

– Low-pressure system – Removing and installing, – Crankcase yoke – Removing and installing, see 11-
see 4-81 219

– Induction manifold – Removing and installing, see – Piston and connecting rod – Removing, see 10-183
6-105
– Flame start system – Removing and installing, see
4-89

(1) Crankcase (2) Cylinder liner

Technical data
Cylinder liner outside diameter standard Diameter 111.475 – 111.490 mm
Cylinder liner outside diameter oversize Diameter 111.975 – 111.999 mm
Reworking higher liner height standard outside diameter Diameter 111.475 – 111.490 mm
Liner height standard 4.04 –4.06mm
Liner height oversize 4.04 –4.06mm
Reworking higher liner height standard outside diameter 4.24 – 4.26 mm
Cylinder liner protrusion 0.01 –0.06mm
 ENGINE HOUSING

Special tool

[90] Dial gauge holder

! Cylinder liner protrusion – Checking in
conjunction with:
! Dial gauge [62]

[91] Dial gauge

! Cylinder liner protrusion – Checking in
conjunction with:
! Dial gauge holder [63]

[92] Extractor device

! Cylinder liner – Removing in conjunction
with:
! Extractor plate [94]

[93] Extractor plate

! Cylinder liner – Removing in
conjunction with:
! Extractor device [93]

Cylinder liner – Checking ! Zero the Dial gauge [92] (3)

Cylinder liner protrusion – Checking ! Place the dial gauge probe (1) onto the cylinder
liner collar and read off the difference Use a cylinder
liner with a different collar height if the cylinder liner
protrusion is outside tolerance.

Note
Renew the cylinder liner if the honing
pattern on the cylinder liner is damaged
or incomplete.
Always renew a damaged cylinder liner
and the corresponding piston as a pair.
! Clean the contact surfaces of the cylinder head
gasket
! Place the Dial gauge [91] (3) and Dial gauge holder
[91] (5) onto the crankcase (4)
! Place the dial gauge probe (1) onto the crankcase
(4)
 ENGINE HOUSING

Cylinder liner – Removing Cylinder liner – Installing

Extractor device – Fitting

! Lightly oil the cylinder liner (1) before installing

! Push the cylinder liner (1) into the crankcase up to
WARNING the stop

Damaged and bent oil injector ! Check the protrusion of the cylinder liner (1) again
nozzles lead to engine damage
Insert the cylinder liner extractor device
so the oil injector nozzle cannot be bent
! Mark the installation orientation and installation
position of the cylinder liner (1) if it is to be reused
! Assemble Extractor plate [94] (2) and Extractor
device [93]
! Carefully insert the Extractor device [93] with
hinged Extractor plate [94] (2) into the cylinder liner
(1)

Cylinder liner – Pulling out

! Clamp the spindle (2) of the Extractor device [92]

(4) with the tool (3)
! Pull the cylinder liner (1) out of the crankcase
ENGINE HOUSING

FLYWHEEL HOUSING

Flywheel housing – Removing and installing

Comprises
– Flywheel – Removing and installing, see 10-171
– Starter motor – Removing and installing, see 3-49

(1) Crankcase (3) Flywheel housing

(2) Flywheel housing mounting bolt (4) Flywheel housing gasket

Technical data
Flywheel housing mounting bolts (2) M12x30-8.8 75 Nm
Flywheel housing mounting bolts (2) M12x90-8.8 75 Nm

Service products
Curil T sealing compound 04.90300-9030

Important information
WARNING
The PTFE sealing ring must not come into contact with oil or grease
! Clean oil and grease off the bearing surface on the crankshaft and the drawing-in tool before
mounting
! Do not remove PTFE sealing rings from the transport sleeve until immediately before they are
installed
 ENGINE HOUSING

Special tool

[95] Crankshaft oil seal special tool kit

! Crankshaft oil seal front and rear –
Removing

[96] Crankshaft oil seal press-in tool

! Crankshaft oil seal rear – Installing

Flywheel housing – Removing Flywheel housing – Installing

Mounting bolts – Unscrewing Flywheel housing – Positioning

! Unscrew the mounting bolts (3) of the flywheel Note

housing (2) from the crankcase (1) Insert the engine speed sensor with
Curil T sealing compound when
Flywheel housing – Removing exchanging the flywheel housing
! Fit the flywheel housing (3) with a new gasket (2)
and position it on the crankcase (3)

Mounting bolts – Screwing in

! Remove the flywheel housing (3) with gasket (2)

from the crankcase (1)
! Clean the sealing surfaces

! Screw the mounting bolts (3) of the flywheel

housing (2) into the crankcase (1)
! Tighten the mounting bolts (3) to 75 Nm
 ENGINE HOUSING

Crankshaft oil seal – Removing Crankshaft oil seal – Installing

Pull-out tool – Fitting Crankshaft oil seal – Pre-assembling

! Use hexagon socket head screws (5) to fit the WARNING

adapter (4) from the Crankshaft oil seal special tool The crankshaft oil seal can be dam-
kit [95] onto the camshaft aged
! Push the extractor hook (1) flat between the crank- The crankshaft oil seal remains in the
shaft oil seal (3) and crankshaft transport sleeve until being installed
! Turn the extractor hook (1) through 90° so the open ! Place the new crankshaft oil seal (1) onto the
side of the extractor hook (1) points towards the adapter (3) from the Crankshaft oil seal special tool
flywheel housing kit [95]
! Screw the pressure button onto the adapter (4) and ! Push the crankshaft oil seal (1) onto the adapter (3)
fit the extractor plate (2)
! Remove the transport sleeve (2)

Crankshaft oil seal – Pulling out

Crankshaft oil seal – Pressing in

! Pull the crankshaft oil seal (1) out of the flywheel

housing by screwing in the threaded spindle (2) ! Push the press-in sleeve (2) from the Crankshaft oil
seal press-in tool [96] over the adapter
! Screw in the threaded spindle
! Press the crankshaft oil seal (3) into the flywheel
housing up to the stop by screwing in the pull-in nut
(1)
TIMING CASE COVER/TIMING CASE

Removing and installing the timing case cover

(1) Timing case cover mounting bolt (2) Timing case cover
(3) Timing case cover gasket (4) Timing case
(5) Timing case gasket

Technical data
Oil filler neck ..........................................................M38x1.5 ...................................35 Nm
Timing case cover mounting bolts (1).....................M8x25-10.9............................22 Nm
Timing case cover mounting bolts (1).....................M8x35-10.9..............................22 Nm
Removing the timing case cover

• Remove the oil filler neck using the Socket, 27 mm (3)

• Mark the mounting bolts (1) for the timing case cover (2) to indicate their installed position
• Unscrew the mounting bolts (1)
• Remove the timing case cover (2)

Removing the timing case cover gasket

• Remove the timing case gasket (1) from the timing case (2)
• Clean the sealing surfaces
Installing the timing case cover

Fitting the timing case cover gasket

• Fit the new timing case cover gasket (1) over the dowel pins and onto the timing case (2)

Fitting the timing case cover

WARNING
Component damage due to leaks
• Renew the crankshaft oil seal after fitting the timing case cover

• Position the timing case cover (2) on the timing case

• Screw in the mounting bolts (1) as marked and tighten to 22 Nm
• Apply a light coat of Loctite 648 adhesive on the thread of the oil filler neck
• Screw in the oil filler neck using the Socket, 27 mm (3) and tighten to 35 Nm
Removing the crankshaft oil seal

• Fit the Thrust disc on the Guide plate (2)

• Mount the Guide plate (2) on the crankshaft using Cheese-head screw (6)
• Insert the Hook (3) flat between the crankshaft oil seal (1) and the crankshaft
• Turn the Hook (3) through 90° so the open side points towards the timing case
• Mount the Crossmember (4)
• Screw the Hexagon nut (5) onto the Threaded spindle
• Screw the second Hexagon nut (5) onto the Threaded spindle and secure using the other
Hexagon nut
• Screw the Threaded spindle into the Crossmember (4) and extract the crankshaft oil seal (1)
from the timing case

Installing the crankshaft oil seal

Pre-assembling the crankshaft oil seal

• Place the new crankshaft oil seal (3) with transport sleeve (2) onto the Guide plate (1)
• Push the crankshaft oil seal (3) onto the Guide plate (1)
• Remove the transport sleeve (2)
Pressing in the crankshaft oil seal

• Screw the Hexagon collar nut onto the Threaded spindle (3) with the collar facing the Installer
sleeve (2)
• Push the Installer sleeve (2) over the Guide plate
• Screw in the Threaded spindle (3)
• Press the crankshaft oil seal (1) into the timing case cover as far as the stop by screwing in the
Hexagon collar nut
Removing and installing the timing case

(1) Timing case (2) Timing case gasket

Technical data
Three timing case mounting bolts (1) .........M8x20-10.9........................................30 Nm
One timing case mounting bolt (2) .............M10x50-10.9.....................................65 Nm
One timing case mounting bolt (3) .............M8x18-10.9........................................30 Nm
Four timing case mounting bolts (4) ...........M8x25-10.9........................................30 Nm
Four timing case mounting bolts with collar (5) .......M8x35-10.9.............................30 Nm
One timing case mounting bolt (6) ...........M8x45-10.9.................................30 Nm
Crankcase yoke mounting bolts....................M8x40-8.8 .......................................22 Nm
Removing the timing case

Unscrewing the bottom mounting bolts

• Unscrew the mounting bolts (1)

Removing the timing case

• Mark the mounting bolts (1) for subsequent installation

• Unscrew the mounting bolts (1) for the timing case (2) from the crankcase
• Remove the timing case (2)

Removing the timing case gasket

• Remove the gasket (1) from the crankcase (2)

• Clean the sealing surfaces
Fitting the timing case
Fitting the timing case gasket

• Fit a new gasket (1) on the crankcase (2)

Fitting the timing case

• Renew and oil the coupling sleeve O-rings, see Fitting the oil pump, 224
• Apply a thin coat of Loctite 5900 sealing compound on the crankcase yoke sealing surface
• Line up the timing case (1) and the oil pump coupling sleeve with the crankcase (2)
• Fit the timing case over the dowel pins
• Screw in the mounting bolts as marked and tighten them by hand

Timing case attachment

• Tighten the mounting bolt (3) M8x18-10.9 to 30 Nm

• Tighten the mounting bolts (4) M8x25-10.9 to 30 Nm
• Tighten the mounting bolts (5) M8x35-10.9 to 30 Nm
• Tighten the mounting bolts (1) M8x20-10.9 to 30 Nm
• Tighten the mounting bolt (6) M8x45-10.9 to 30 Nm
• Tighten the mounting bolt (2) M10x50-10.9 to 65 Nm
Screwing in the bottom mounting bolts

• Screw in the mounting bolts (1) and tighten them to 22 Nm

 ENGINE HOUSING

CRANKCASE YOKE

Crankcase yoke – Removing and installing

Comprises
– Engine oil – Draining and topping up
– Oil sump – Removing and installing, see 9-155
– Positive crankcase ventilation – Removing and installing, see 11-221

(1) Crankcase yoke (2) Crankcase

(3) Crankcase yoke mounting bolts

Technical data
Crankcase yoke mounting bolts (3) M8x40-8.8 22 Nm
Turbocharger oil return line mounting bolt M8x20 22 Nm

Service products
Sealing agent 04.10394-9292
 ENGINE HOUSING

Crankcase yoke –Removing Turbocharger oil return line – Fitting

Turbocharger oil return line – Removing

! Fit the oil return line (2) with a new seal (1) and O-
Ring (3) and install it

! Remove the turbocharger oil return line (1) ! Tighten the mounting bolts to 22 Nm
! Install the clamping piece (4) for the oil return line

Crankcase yoke –Removing ! Tighten the mounting bolt for the clamping piece (4)
to 22 Nm

POSITIVE CRANKCASE VENTILATION

Positive crankcase ventilation – Removing and

installing

! Unscrew the mounting bolts (1) of the crankcase

yoke (2) from the crankcase (3)
! Clean the sealing surfaces

Crankcase yoke – Installing

(1) Induction manifold

(2) Hose port
(3) Positive crankcase ventilation filter
(4) Positive crankcase ventilation line
(5) Mounting nuts

! Apply a coat of Sealing agent to the contact

surfaces of the crankcase (3) Technical data

! Position the crankcase yoke (2) on the crankcase Mounting nuts (5) M6 9 Nm
(3)
! Screw in the mounting bolts (1) and tighten to 22
Nm
 ENGINE HOUSING

Special tool

[100] Hose clamp pliers for spring-loaded band-

type clamps
! Spring-loaded band-type clamps –
Removing and installing

Positive crankcase ventilation – Removing Positive crankcase ventilation – Installing

Positive crankcase ventilation filter – Removing Positive crankcase ventilation tube – Fitting

! Use the Hose clamp pliers for spring-loaded band- ! Fit the positive crankcase ventilation tube (2)with
type clamps [101] to remove the spring-loaded new seals (3) and position it
band- type clamp (3) from the filter (2) ! Screw on the mounting nuts (4) and tighten to 9 Nm
! Pull the filter (2) off the positive crankcase ! Fit the positive crankcase ventilation line (1)
ventilation line (4) and hose port (1)

Positive crankcase ventilation filter – Installing

Positive crankcase ventilation tube – Removing

! Put the filter (2) onto the positive crankcase

! Remove the positive crankcase ventilation line (1) ventilation line (4) and hose port (1)
! Unscrew the mounting nuts (4) for the positive ! Use the Hose clamp pliers for spring-loaded band-
crankcase ventilation tube (2) type clamps [101] to fit the spring-loaded band-type
! Remove the positive crankcase ventilation tube (2) clamps (3)
with seals (3)
ENGINE CONTROL UNIT

Removing and installing the engine control unit (Mounted on Engine)

(1) Rubber mount (2) Bracket

(3) Rubber mount (4) Mounting bolt
(5) Engine control unit (6) Mounting bolt

Technical data
Mounting bolt (6)........................ M6x30-10.9 .......................................................11 Nm
Mounting bolt (4)........................ M8x40-10.9 .......................................................13 Nm

Important information

WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of
the specified tightening torque
• Final tightening must always be performed manually using a torque wrench

Note
After the engine is installed, the engine control unit must have its parameters reset and the fault
memory must be deleted.
Removing the engine control unit

Disconnecting the engine control unit electrical connections

• Release and pull off the connectors (1), (2) and (3)
• Free the wiring harnesses

Removing the engine control unit and bracket

• Unscrew the mounting bolts (5)

• Remove the engine control unit (4)
• Unscrew the mounting bolts (3)
• Remove the bracket with rubber mounts (1) and (2)

Installing the engine control unit

Tightening sequence for engine control unit
• Follow the illustrated tightening sequence A to H for the mounting bolts (1) in the following
work step

Mounting the engine control unit and bracket

• Insert the rubber mounts (1) and (2) into the bracket
• Thinly apply Loctite 270 sealing compound on the thread of the new mounting bolts (3)
• Position the bracket
• Screw in the mounting bolts (3) and tighten them to 13 Nm
• Position the engine control unit (4)
• Screw in the new mounting bolts (5) and tighten in the specified sequence to 11 Nm

Connecting the engine control unit electrical connections

WARNING
Danger of irreparable engine control unit damage
• When installing the connectors, first fully open the lock and then insert and lock the
connectors

• Insert and lock the connectors (1), (2) and (3) in the engine control unit
• Route the wiring harnesses and secure using cable ties