Service Information

Document Title: Function Group: Information Type: Date:

Engine, dismantling 210 Service Information 2/7/2020
Profile:
D11M

Engine, dismantling
Valid for serial numbers
Model Production site Serial number start Serial number stop
D11M

Op nbr 210-077

Total procedure time (hr): 6.00

Tools:
88840300 Plate
88800502 Disassembly tool
9990114 Puller
9990262 Adapter
9993590 Gear wheel
9993717 Quick nut
9993722 Support
9993791 Puller bolt
9996400 Impact puller
9996876 Guide pin
11666013 Pump
11666054 Jack

1 pcs. lifting eye

NOTE!
O-rings, sealant and gaskets must always be replaced.

NOTE!
Since the images are reused for different engine versions, some parts may vary from the version in question. However, the
essential information in the images is always correct.

This operation also includes required tools and times for applicable parts of the following operations:

Power take-off, between engine and gearbox, reconditioning

Cylinder head, removing
Engine, mounting in work stand

1. Place the engine in a work stand, refer to Engine, mounting in work stand.

2. Remove the lifting eyes.

 Figure 1

1. Lifting eyes

3. Remove the alternator.

4. Remove the upper valve cover.

Figure 2

1. Upper valve cover

5. Disconnect the cables for the injectors, fuel rail pressure sensor SE2309, and engine brake (VCB) control MA2503.
Remove the bolts for the lower valve cover and remove the lower valve cover.
 Figure 3

1. Lower valve cover

2. Connector

6. Use 9993590 Gear wheel to turn the engine to TDC.

Figure 4

1. Flywheel housing
2. 9993590 Gear wheel
 Figure 5

7. Remove the oil lines.

Connect a lifting device and remove the oil filter housing and the oil filters.
Weight, filter housing and filters: approx. 11 kg (24 lb)

Figure 6

1. Oil lines (3 pcs.)

2. Oil filter housing and oil filters

8. Remove the oil filter housing bracket.

 9. Remove the cylinder head, refer to Cylinder head, removing.

10. Remove the oil lines, the fuel feed pump and the oil drain pump.

Figure 7

1. Oil lines
2. Pumps

11. Loosen the fuel lines and remove the aftertreatment fuel dosing unit.

Figure 8
Aftertreatment fuel dosing unit

12. Secure the start motor with a sling connected to a lifting device. Loosen the nuts and remove the starter motor.
Weight, start motor: approx. 13 kg (29 lb)
 Figure 9

1. Starter motor

13. Rotate the engine in the work stand and remove the oil sump. Mark the four differing bolts.
NOTE!
Position of the four bolts should not be changed.

Figure 10

1. Oil sump
2. Differing bolts

14. Rotate the engine in the work stand.

Lock the crankshaft with 9993590 Gear wheel and loosen the bolts for the flywheel.
Remove the bolts and the flywheel.
Weight, flywheel: approx. 16 kg (35 lb)
 Figure 11

1. Flywheel
2. Bolt

15. Remove the bolts and the cover with the sealing.
 Figure 12

1. Bolt
2. Cover

16. Clean the sealing area and lubricate with clean oil.

Figure 13

1. Sealing area

17. Remove two puller arms on 88800502 Disassembly tool, and place the lock pins in the midmost position on the
remaining arms.
Loosen the nut and bolt.

Figure 14

1. Puller arm
2. Lock pin
 3. Nut
4. Bolt

18. Install 88800502 Disassembly tool through the flywheel housing to the sealing. Install the two remaining puller arms
with the lock pins in the midmost position.
NOTE!
Make sure that the tool is correctly installed.

Tighten the nut until the tool is pressing against the sealing.
Remove the inner ring of the seal by tightening the bolt.
If needed, tap the outer ring of the seal inwards equally with hammer and wooden or plastic tool.

Figure 15

1. 88800502 Disassembly tool

2. Sealing

Figure 16

1. 88800502 Disassembly tool

 2. Lock pin
3. Puller arm

19. Loosen the nut and remove the sealing ring.

Remove two puller arms from 88800502 Disassembly tool to remove it from the flywheel housing.

20. Remove the outer ring of the seal in parallel with 9996400 Impact puller and 9990192 Puller.
NOTE!
Be careful not to damage the crankshaft surface.

Figure 17

21. Install 9996239 Lifting chain to the flywheel housing and connect it to a lifting device. Remove the bolts and lift away
the flywheel housing.
Weight, flywheel housing: approx 167 kg (368 lb)
Remove the lifting device.

Figure 18

22. Remove the timing gears.

NOTE!
On the double gear, only loosen the inner bolts.
 Figure 19
Timing gears

23. Remove the timing gear plate.

Figure 20
Timing gear plate

24. Rotate the engine in the work stand and remove the oil pump and the pipes connected to it.
Remove the pipe and the ladder frame.
 Figure 21

1. Oil pump and pipes

2. Pipe
3. Ladder frame

25. Rotate the engine in the work stand.

Loosen the lock nut and bolts holding the EGR cooler. Secure the EGR cooler with a sling connected to lifting device.
Weight, EGR cooler: approx 16 kg (37 lb)
Lift away the EGR cooler.
Disconnect the lifting device.

Figure 22

26. Loosen the bolts and remove the brackets.

Figure 23

27. Remove the brackets, oil line and coolant drain pipe.
 Figure 24

1. Oil line
2. Filter housing
3. Brackets
4. Coolant pipe

28. Loosen the bolts and remove the filter housing and the remaining oil lines.

29. Remove the coolant pipe and bracket. Loosen the bolts and remove the oil cooler cover.
NOTE!
Note the position of different types of bolts.

Figure 25

1. Bracket
2. Coolant pipe
3. Oil cooler cover

30. Remove the coolant pipe.

 Figure 26

1. Coolant pipe

31. Remove the belt pulleys, the belt tensioners together with the brackets.

Figure 27

32. Secure the engine mount with the sling connected to lifting device.
Loosen the bolts and remove the engine mount.
Weight, engine mount: approx. 24 kg (53 lb)
Disconnect the lifting device.
33. On the next step, if needed, lock the engine by installing two bolts on any side of the crankshaft and use a crowbar or
similar. If needed, ask for assistance from another person.

Figure 28

34. Loosen all the bolts holding the vibration damper and the belt pulley. Remove the two bolts and the crankshaft adapter.
Install 9996876 Guide pin to the crankshaft.

Figure 29
Crankshaft adapter

35. Remove the remaining bolts and remove the belt pulley.

36. Carefully pull out the vibration damper and install a lifting eye with a nut to it.
Connect a lifting device and remove the vibration damper.
Weight, vibration damper: approx. 22 kg (49 lb)
Disconnect the lifting device and remove the guide pins.
 Figure 30

1. Vibration damper
2. Lifting device
3. Lifting eye with a nut
4. 9996876 Guide pin

37. Remove the coolant pump and the housing.

Figure 31
Coolant pump and housing

38. Clean the sealing area and lubricate with clean oil.
 Figure 32

1. Sealing area

39. Place the lock pins on 88800502 Disassembly tool to the innermost position and loosen the nut and the bolt.
Install the tool to the sealing.
NOTE!
Make sure that the tool is correctly installed.

Tighten the nut until the tool is in contact with the seal. Remove the inner ring of the seal by tightening the bolt.

Figure 33
 Figure 34

1. 88800502 Disassembly tool

2. Puller arm
3. Lock pin
4. Bolt
5. Nut

40. Remove the outer ring of the seal in parallel with 9996400 Impact puller and 9990192 Puller.
NOTE!
Be careful not to damage the crankshaft surface.

Figure 35

41. Remove the crankshaft seal cover.

Remove the bracket.
 Figure 36
Crankshaft seal cover

42. Rotate the engine in the work stand. Loosen the bolts and remove the piston cooling nozzles.
NOTE!
The bolts must be replaced.

Use the bolts on the crankshaft to rotate the engine to get access to the piston cooling nozzles.

Figure 37

1. Piston cooling nozzle

2. Bolt

43. Rotate the engine in the work stand to vertical position. Remove the connecting rod bearing caps.
 Figure 38

1. Bolt
2. Connecting rod bearing cap

44. Press out the pistons so that the piston rings end up outside of the cylinder liners' edges. Use a hammer handle or
other tool made of plastic or wood. Remove the pistons and the connecting rods. Mark the connecting rods so that
they can be reinstalled in the same cylinder.
NOTE!
Avoid tapping on the connecting rods' assembly faces.

Figure 39

45. Rotate the engine to horizontal position. Loosen the bolts and remove the main bearing caps with 9996400 Impact
puller, 9990262 Adapter and 9990114 Puller.
 NOTE!
The main bearing cap no.4 contains thrust washers.

Figure 40

1. 9996400 Impact puller

2. 9998674 Adapter
3. 9990114 Puller

46. Connect two slings to the crankshaft, connect a lifting device and remove the crankshaft. Rotate the crankshaft if
needed.
NOTE!
Be careful not to damage the crankshaft.

Weight, crankshaft: approx. 105 kg (350 lb)

Figure 41

47. Remove the remaining main bearings and thrust washers.

 Figure 42

48. Install the tools 9993717 Quick nut, 11666054 Jack, 11666013 Pump, 9993722 Support, 9993791 Puller bolt and
88840300 Plate. Pull out the cylinder liners with tools as shown in the figure.

Figure 43

1. 9993717 Quick nut

2. 11666054 Jack
3. 88830175 Pump
4. 9993722 Support
5. 9993791 Puller bolt
6. 88840300 Plate

49. Clean the sealing areas on the engine block. Check the engine block and other parts for any damage and wear.
Thoroughly clean and replace any damaged or worn parts.
NOTE!
Work carefully to avoid damaging the block. Thoroughly clean the seal grooves and the cylinder liner's seal faces
against the cylinder block. Thoroughly clean the sealing face on the liner shelf from rust, grease, and deposits/coatings.
NOTE!
Do not use scraper tools made of metal.