4VCR Engine Repair Manual

Repair Manual
Common-rail In-line Engine
D0836LF20,D0836LF22
Page 1 of 200
INDEX Page
Special Instruction…………………………………………………………………………..004
Characteristic Data………………………………………………………………………....006
Engine Description……………………………………………………………….................007
Cooling System……………………………………………………………………………....012
 Fan……………………………………………………………………………………013
 Coolant Pipes………………………………………………………………………....015
 Thermostat with thermostat housing............................................................................019
 Coolant Pump ……………………………………………………………………..…021
Add – On Units……………………………………………………………………………...025
 Power Take-Off ………………………………………………………………….….026
 Air Compressor & Power Steering Pump …………………………………………...029
 Alternator ………………………………………………………………………….....033
 Starter Motor …………………………………………………………………………038
 Belt Drive …………………………………………………………………………….043
Common Rail System…………………………………………………………............…….045

 Injector ………………………………………………………………………….……048
 High pressure lines ……………………………………………………………...…....051
 High Pressure Pump ………………………………………………………………….066
 Fuel Service Centre …………………………………………………………..………077
Supercharging ……………………………………………………………………………....080
 Turbocharger …………………………………………………………………………081
Intake/Exhaust Manifold ……….…………………………………………………..………089

 Intake Manifold ………………………………………………………………………089
 Exhaust Manifold …………………………………………………………………….093
 Rocker ARM Mechanism ……………………………………………………………099
 Cylinder Head ………………………………………………………………………..104
 Valve Timing ………………………………………………………………………...122
Timing Gears …………………………………………………………………………….….130
Engine Lubrication ……………………………………………………………………..…..138
 Oil Cooler …………………………………………………………………………….139
 Oil Sump ………………………………………………………………………….….141
 Oil Pump ……………………………………………………………………..………144
Crankshaft Drive ……………………………………………………………………..…….148
 Vibration Damper ……………………………………………………………………149
 Flywheel ………………………………………………………………………..……151
 Piston and Connecting Rod………….………………………………………….……159
Engine Housing.......................................................................................................................175
 Cylinder Liner...............................................................................................................176
Flywheel Housing…….………………………………………………………………..….…179
Timing Case Cover/Timing Case……….………………………………………………….182
Crankcase Yoke.....…………………………………………....…………………….………194
Engine Control Unit….………………………………………………………………...……197
Page 2 of 200
PREFACE
This repair manual is intended to provide assistance in performing repairs correctly on vehicles
and units. The technical details were correct at the time of going to press.
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 or peripherals 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 relating to safety and accident prevention are specially highlighted in the
text as follows.
CAUTION
Type and source of danger
• 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
• 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.
Page 3 of 200
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:
Page 4 of 200
– 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:

– 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.
Model designation Explanation Example
D Fuel type Diesel
08 Bore + 100mm 108 mm bore
3 Stroke characteristic 130 mm stroke
(rounded) stroke =
(characteristic x 10) + 100
6 Number of cylinders 6-cylinder
L Supercharging With supercharging and intercooling
F Engine installation Engine/vertical/LHD forward-control vehicle
20/22 Type identification Power/speed/homologation
Page 5 of 200
Characteristic data
D 0836 LF20,22
Designation Unit Figures

No. of 6 cylinders/in-line/vertical
cylinders/arrangement
Valves per cylinder 4 Valves
Engine weight, dry Kg Approx.750
Injection system Common rail EDC17
Direction of rotation as Left
viewed onto flywheel
Net power to ISO 1585- kW/hp/rpm 221/300 at 2300 rpm
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 2300
Low idling speed rpm 600
Max. torque at engine speed Nm rpm 1150 at 1200 - 1800
Page 6 of 200
ENGINE DESCRIPTION
D0836 common-rail LF20,22
(1) Air compressor (8) Pressure pipe

(2) Coolant pipe (9) Oil module
(3) Cylinder head cover (10) High-pressure pump (lubricated by fuel)
(4) Turbocharger (11) Charge air pipe
(5) Heated fuel service centre (12) Refrigerant compressor
(6) Engine control unit (13) Fan
(7) Starter (14) Alternator
Page 7 of 200
Engine, general
The 6-cylinder diesel engines described here are liquid-cooled, 4-stroke diesel engines with
turbocharger and intercooler. The D 0836 LF20/ 22 engine, the engines operated using the
common-rail high-pressure injection system in conjunction with EDC 17 (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.
Page 8 of 200
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. An automatic, non-permanently engaged
viscous fan clutch, driven by the water pump, is installed in these engines. The viscous fan
clutch is engaged according to the coolant temperature. The fan is driven by the viscous fan
clutch.
Cylinder head
The full-length cylinder head in the D 0836 LF20/22 engines is made from alloyed grey cast-
iron. Exchangeable valve seat rings and valve guides are shrink-fitted in the cylinder head. The
valve guides have valve stem seals at all four valves. Because of the high ignition pressures
and the downsized valves, the cylinder head has vertically cast-in nozzle pipes in the middle of
the combustion chamber. Due to the necessary high bolt preload force, high-strength rounded
external hexagon bolts are used as cylinder head bolts. A single-layer bead seal with elastomer
elements over pairs of cylinders is used as the liquid seal between the cylinder head and the
crankcase. The cylinder head cover is made from plastic and acoustically decoupled with an
elastomer seal.
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, with a cast-on counter-holder for the EVB
mechanism, 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. The EVB mechanism is
integrated in the exhaust valve bridge. The EVB counter-holder is part of the rocker arm
mechanism.
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.
Page 9 of 200
High-pressure system
The high-pressure system consists of the flow-rate-controlled high-pressure pump with flange-
mounted fuel pre-supply 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 vertically in the cylinder head and clamped with a pressure flange.
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

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 pressurised 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 crack 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.
Page 10 of 200
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 V-belt pulleys on the vibration damper. These add-on/auxiliary units are generally
engine-mounted.
Page 11 of 200
COOLING SYSTEM
(1) Fan clutch (4) Intermediate flange

(2) Fan (5) Adapter flange mounting bolt
(3) Fan locknut (6) Fan clutch mounting bolt
Technical data
Fan clutch mounting bolt (6) ...................................M8x20-8.8 .........................................22 Nm
Adapter flange mounting bolts (5) ..........................M8x20-8.8 .........................................22 Nm
Fan locknut (3) ........................................................M8-8.8................................................22 Nm
Important information
WARNING
Malfunction due to incorrect storage of fan clutch
• Always store the fan clutch in its installation position.
Page 12 of 200
Removing the fan
Removing the fan with fan clutch
• Unscrew the mounting bolts (5)

• Remove the fan (1) with fan clutch
• 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)
Page 13 of 200
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 22Nm
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)
Page 14 of 200
COOLANT PIPES
Removing and installing coolant pipes
(1) Coolant pipe (5) Coolant outlet pipe

(2) Coolant manifold mounting bolt (6) O-ring
(3) Coolant manifold (7) Air compressor coolant supply line
(4) Coolant outlet pipe mounting bolt (8) Air compressor coolant return line
Technical data
Coolant pipe mounting bolt (1)...................................M8x55-10.9.....................................30 Nm
Coolant outlet pipe mounting bolt (2) ........................M8X65-10.9....................................30 Nm
Hollow screw, air compressor coolant lines (8), …...M14x1.5 ..........................................30 Nm
Union nut, air compressor coolant lines (8), …...................................................................30 Nm
Coolant manifold mounting bolt (2) ..........................M8x60-8.8 ......................................22 Nm
Coolant manifold mounting bolt (2) ..........................M8x80-8.8.......................................22 Nm
Coolant manifold mounting bolt (2) ..........................M8x85-8.8 ......................................22 Nm
Service products
Renolit Si 704 silicone grease
Page 15 of 200
Removing the coolant pipe
Removing the coolant outlet pipe

• 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 hollow screws (3)

• Remove the seals
• Remove the coolant lines (1) and (2)
Page 16 of 200
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

• Remove the coolant pipe (2) with gaskets (4)
• Remove the plug-in pipe (3)
Page 17 of 200
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 22 Nm
Fitting the air compressor coolant lines
• Fit the coolant lines (1) and (2) and position them
• Screw on the union nuts for the coolant lines (1) and (2) and tighten them by hand
• Screw in the hollow screws (3) with new seals and tighten to 30 Nm
• Tighten the union nuts for the coolant lines (1) and (2) to 30 Nm
Page 18 of 200
Installing the thermostat

• Insert the thermostat (2) into the thermostat housing (1) with the TOP mark facing upwards
• Renew the O-ring (3)
WARNING
Component damage due to installation of incorrect thermostats!
• Use a thermostat with the specified opening temperature of 83 °C.
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
Page 19 of 200
Installing the coolant pipe
• Apply a light coat of Renolit Si 704 silicone grease on the contact surfaces for the new plug-
in pipe (3)
• Insert the plug-in pipe (3) into the thermostat housing
• Fit the coolant pipe (2) with new seals (4) and position it
Page 20 of 200
COOLANT PUMP
Removing and installing coolant pump
(1) Coolant pump mounting bolt (2) Swiveling 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
Swiveling 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
Page 21 of 200
Removing the coolant pump
• Unscrew the union nut (3)

Removing the swiveling screw connection
• Unscrew the hollow screw (3)

• Remove the swiveling screw connection (1) with seals (2)
Page 22 of 200
Removing the coolant pump
• Mark the installation positions of the mounting bolts (1)

• Remove the coolant pump (2) with gasket (3)
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
Page 23 of 200
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
Page 24 of 200
ADD – ON UNITS
(1) Air compressor (2) Power steering pump

(3) Alternator (4) Starter
(5) Refrigerant compressor (6) Power take-off, alternator/coolant pump
Page 25 of 200
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) V-belt pulley mounting bolt
(5) V-belt pulley (6) Power take-off mounting bolt
(7) Timing case cover
Power take-off mounting bolt (6)...................M10x35-8.8 ................................................45 Nm

V-belt pulley mounting bolt (4) ....................M16x1.5x45-8.8...................initial torque 100 Nm
V-belt pulley mounting bolt (4) ....................M16x1.5x45-8.8 ...........................Final torque 90°
Page 26 of 200
Removing the power take-off
Removing the V-belt pulley.
Note
The mounting bolt for the V-belt pulley has a left-hand thread.
• Hold the 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 V-belt pulley (2)
Removing the power take-off

• Remove the power take-off (2), driver/carrier plate (4) and O-ring (3)
Page 27 of 200
Installing the power take-off
Mounting the power take-off
• Place the thick 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)
Mounting the V-belt pulley
• Place the V-belt pulley (2) on the power take-off (3)

• Screw in the mounting bolt (1)
• Hold the 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°
Page 28 of 200
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
Page 29 of 200
Removing the air compressor / power steering pump
• Unscrew the union nuts (3) from T-shaped connector

Removing the power steering pump
• Remove the steering oil lines

• Pull the power steering pump (4) off the air compressor (1)
• Remove the driver plate (2) and the O-ring (3)
Page 30 of 200
Removing the air compressor
• Removing the air compressor line

• Unscrew the mounting bolts (2) from the support block (7)
• 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 thick side of driver plate (3) at gear side of the air compressor
• Insert the air compressor (6) into the timing case
• Position the support block (7)
• Screw in the support block mounting bolt for support on the crankcase and tighten it to 22
Nm
• Mount the air compressor line
Page 31 of 200
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
• Fit the power steering pump oil lines
Page 32 of 200
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
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
Page 33 of 200
[1]
[2]
[2]
[1]
Page 34 of 200
Removing the alternator
Removing the V-belt pulley
• Disconnect the alternator electrical connection

• Unscrew the terminal B+ mounting nut
• Undo the collar nut on the V-belt pulley (2)
• Unscrew the collar nut (1)

• Pull the 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)
Page 35 of 200
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
• Place the V-belt pulley (2) on the alternator shaft (3)

• Screw on the new collar nut (1) and tighten it by hand
Page 36 of 200
Tightening the V-belt pulley
• Tighten the collar nut on the 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
Page 37 of 200
STARTER MOTOR Starter Motor - Removing
Starter motor – Removing and installing
• Disconnect the electrical connections from the

(1) Flywheel housing starter motor (1)
(2) Starter motor • Remove the starter motor (1)
(3) Mounting bolt

Starter motor – Installing
(4) Mounting nut
Technical data
Mounting bolt (3) M10x35-8.8 45 Nm
Mounting nut (4) M10 45 Nm
Relay mounting bolt M5x12 5 Nm
Terminal 30 mounting
nut M10 45 Nm
nut on relay M6 2.6 Nm
nut on relay M6 2.6 Nm
Terminal 31 and 50
mounting nut M4 1.2 Nm Note
Starter pinion tooth Before installing the starter motor, crank

number 11 the motor once and check the flywheel
ring gear for damage
Starter power 24 V / 4.0 kW
• Align the starter motor (1) with the flywheel housing

and insert it
• Screw on the mounting nut and tighten to 45 Nm
• Screw in the mounting bolt and tighten to 45 Nm
• Connect the electrical connections to the starter
motor (1)
Page 38 of 200
BELT DRIVE
Removing and installing the belt drive
(1) Coolant pump V-belt pulley (2) Vibration damper V-belt pulley
(3) Refrigerant compressor V-belt (4) Refrigerant compressor V-belt tensioner
(5) Refrigerant compressor (6) Power take-off V-belt pulley
(7) Alternator V-belt tensioner (8) Alternator V-belt
Technical data
Mounting bolt, vibration damper V-belt pulley (2)…………….………...M8x18-8.8.......22 Nm

Mounting bolt with collar, coolant pump V-belt pulley (1).......................M8x16-10.9.....30 Nm
V-belt tensioner mounting bolt (4), (7) .....................................................M10x65-8.8.....45 Nm
Page 39 of 200
Removing the belt drive
Removing the refrigerant compressor V-belt
WARNING
Danger of injury due to unintentional rebound of the V-belt tensioner.
• Secure the V-belt tensioner after tensioning in order to prevent unintentional rebound
• Relieve the V-belt tensioner carefully when the V-belts are removed
• Relieve the V-belt (1) by turning the tensioning pulley (2) in downward direction
• Hold the V-belt tensioner (2) and remove the V-belt
• Carefully relieve the V-belt tensioner (2)
Page 40 of 200
Removing the alternator V-belt
WARNING
• Relieve the V-belt tensioner carefully when the V-belts are removed
• Relieve the V-belt (1) by turning the tensioning pulley (2) clockwise
• Hold the V-belt tensioner (2) and remove the V-belt (1)
Removing the V-belt tensioner
• Unscrew the V-belt tensioner mounting bolt (2)

• Remove the V-belt tensioner (1)
Page 41 of 200
Removing the V-belt pulleys
• Mark the installed position of the V-belt pulley (2) relative to the vibration damper
• Remove V-belt pulley (2)
• Unscrew the mounting bolts with collar (3)
Installing the belt drive

Mounting the V-belt pulleys
• Fit the V-belt pulley (2) as marked.

• Fit the V-belt pulley (4)
• Screw in the mounting bolt (3) and tighten it to 30 Nm
Page 42 of 200
Installing the V-belt tensioner
• Screw in the mounting bolts for the V-belt tensioner (1) and tighten them to 45Nm
Fitting the alternator V-belt
WARNING
• Tension the V-belt tensioner (2) clockwise and hold it

• Fit the V-belt (1)
Page 43 of 200
Fitting the refrigerant compressor V-belt
• Tension the V-belt tensioner (2) by moving it in upward direction on a slot provided on AC
compressor bracket
• Fit the V-belt (1)
Page 44 of 200
COMMON RAIL SYSTEM
Protective sleeves, injectors and rail
(1) Protective sleeve, injector nozzle (9) End plug

(2) Mounting bolt (10) End plug
(3) Cap, injector feed bore (11) End plug
(4) Protective sleeve Z 14 x 15 (12) End plug
(5) End plug (13) End plug
(6) Protective sleeve Z 14 x 15 (14) End plug
(7) Cap (15) Storage sleeve, injector
(8) Protective sleeve Z 18 x 15
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: In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x
15) is imprinted in the protective sleeves. This is integrated in the special tool
designation (e.g. protective sleeve, high-pressure line connection Z 14 x 15).
Page 45 of 200
[3]
[4]
[5]
[6]
[7]
[8]
[9]
Page 46 of 200
[10]
[11]
[12]
[13]
Page 47 of 200
Removing and installing the injectors and rail
(1) Sealing washer (6) High-pressure line

(2) Injector (7) Rail-pressure sensor
(3) Mounting bolt (8) Rail
(4) Pressure flange (9) Pressure screw
(5) Return line
Technical data
Mounting bolt (3) ........................................ M8x45 ......................... Initial torque 2 Nm
Mounting bolt (3) ........................................ M8x45 ......................... Final torque 30 Nm
Pressure screw (9) ....................................... M22x1.5 ...................... Initial torque 10 Nm
Pressure screw (9) ....................................... M22x1.5 ...................... Final torque 55 Nm
Injector cable mounting nuts.......... Cable lug nut M4........................1.5 Nm
High-pressure line (6) .................................. M14x1.5 ...................... Initial torque 10 Nm
High-pressure line (6) (initial use) .............. M14x1.5 .......................Final torque 60°
High-pressure line (6) (re-use)..................... M14x1.5 .......................Final torque 30°
High-pressure line (6) ................................. M18x1.5 ....................... Initial torque 10 Nm
High-pressure line (6) (initial use) ............. M18x1.5 ........................Final torque 60°
High-pressure line (6) (reuse)..................... M18x1.5 ........................Final torque 30°
Rail-pressure sensor (7)............................. M18x1.5..........................70 Nm
Pressure limiting valve .............................. M18x1.5 .........................100 Nm
Page 48 of 200
WARNING
Damage in the common-rail system
• 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 rail, or depressurization must be checked by means of MAN-
cats® (desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Always replace rail connections once they have been undone
• Do not reuse plugs for the high-pressure lines, the rail or injectors, even if they have only
been used once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
WARNING
• Always remove only one fuel line
• Plug the component connections immediately using new, clean protective sleeves
WARNING
• If impact wrenches are used, these may only be used for pre tightening to max. 50% of the
• Final tightening must always be performed manually using a torque wrench
[14]
[15]
[14]
[16]
Page 49 of 200
[17]
[18]
[19]
[20]
[21]
[22]
[23]
[24]
Page 50 of 200
[25]
[26]
[27]
[28]
[29]
[30]
[31]
[32]
Page 51 of 200
Detaching the fuel lines
• Unscrew the hollow screw (2) and remove it with the sealing rings (1)
• Detach the fuel line (3)
Detaching the fuel return line on the

High-pressure pump side
WARNING
Component damage due to fuel in the combustion chamber
• Allow the return duct in the air distributor pipe to empty before extracting the injectors
WARNING
Danger of environmental pollution
• Collect emerging fuel in a permissible container
Page 52 of 200
Detaching the fuel return line on the fuel filter side
WARNING
WARNING
• Unscrew the hollow screw (5) and remove with the sealing rings (6) and (7)
• Pull off the fuel line (4) using the Release tool, size 2 [32] and the Release handle [30]
• Unscrew the hollow screw (2) and remove with the sealing rings (1) and the fuel line (3)
• Allowing the return duct to empty
Page 53 of 200
Removing the injectors and rail
Detaching the high-pressure line
WARNING
• Detach the high-pressure line (2) from the rail (1) and the high-pressure pump (3) using the
Socket, size 17 [27], the Socket, size 22 [28] if necessary and the Extension [29]
Disconnecting the rail-pressure sensor

Electrical connection
• Disconnect the electrical connection (2) for the rail-pressure sensor (1)
Page 54 of 200
Detaching the high-pressure lines
• Mark the installation position of the clamping pieces (1)

• Remove the clamping pieces (1)
• Mark the installation position of the high-pressure lines (2)
• Detach the high-pressure lines (2) using the Socket, size 17 [27], the Socket, size 22 [28] if
necessary and the Extension [29]
Removing the rail

• Remove the rail (1) from the air distributor pipe
Page 55 of 200
Unscrewing the pressure screw
• Unscrew the pressure screw (2) for the rail connection (1)
Removing the rail connection
• Extract the rail connection (2) from the bore (1) Using the Extractor device [15] (3) and the
Adapter [14]
Page 56 of 200
Removing the cylinder head cover
• Open the plug bracket bayonet fittings

• Remove the cylinder head cover (2) from the cylinder head (1)
Disconnecting the injector electrical connection
• Unscrew the mounting nuts (2)

• Remove the injector cable from the injector (1)
• Remove the plug bracket (3)
Page 57 of 200
Unscrewing the pressure flange mounting bolt
• Unscrew the mounting bolt (1)

• Remove the spherical washer (2)
Page 58 of 200
Assembling the special tool
• Mount the Support [20] (2) and the Support [19] (5) with the Hexagon nut [21] (7) on the
Plate [18] (6)
• Insert the Support [22] (4) into the Support [19] (5)
• Insert the Extractor device [16] (3) into the Plate [18] (6) and screw on the Knurled nut [17]
(1)
Page 59 of 200
Removing the injector
WARNING
Component damage due to incorrect removal of the injector
• Always remove the relevant rail connection before removing the injector
• Always remove one injector only
• Fitting the special tool

• Insert the Extractor device [16] into the groove for the pressure flange
• Clamp the clamping sleeve with the Knurled nut [17] (1)
• Extract the injector (3) from the cylinder head by turning the Knurled nut [17] (2)
• Remove the special tool
Removing the injector
• Remove the injector (1) with the pressure flange (4) and the sealing washer (2)
• Pull off the O-ring (3)
• Carefully clean the injector bore
Page 60 of 200
Installing the injectors and the rail
Installing the injector
Note
Always install injectors together with pressure flange.
It is not possible to install the pressure flange afterwards.
• Check to ensure that the hole in the cylinder head is clean

• Do not remove the injector (1) from the Injector storage sleeve [27] until immediately before
installation
• Remove the protective sleeves
• Push the pressure flange (4) onto the injector (1), ensuring that the fuel inlet opening is
turned towards the rail connection mounting hole
• Insert the injector (1) into the cylinder head with a new O-ring (3) and a new sealing washer
(2)
• Press the injector (1) fully into the cylinder head using Thrust piece [26]
Injector initial torque
• Screw in the new mounting bolt (1) for the pressure flange with the spherical washer (2)
• Tighten the mounting bolt (1) to Initial torque 2 Nm
Page 61 of 200
Installing the rail connection
WARNING
Rail connections are pressed together on the cone during installation
• Do not re-use rail connections if they have already been installed
• Thinly apply clean diesel fuel on a new O-ring (4) and fit it on the new rail connection (2)
• Slide the rail connection (2) into the bore (3) so that the balls on the rail connection (2) are
located in the grooves in the cylinder head
• Screw in the pressure screw (1) and tighten to Initial torque 10 Nm
Injector final torque
• Tighten the mounting bolt (1) to Final torque 30 Nm
Page 62 of 200
Rail connection final torque
• Tighten the pressure screw (1) to Final torque 55 Nm
Connecting the injector electrical connection
WARNING
Component damage due to possible short-circuit
• When tightening the mounting nuts, make sure that the cable plugs do not touch each other
• Fit the plug bracket (3)
• Position the injector cable on the injector (1)
• Place the Socket, size 7 [23] with Adapter [25] on the Torque screwdriver [24]
• Tighten the mounting nuts (2) to 1.5 Nm
Page 63 of 200
Mounting the cylinder head cover
• Check the gasket in the cylinder head cover (2) and the plug bracket; replace as necessary
• Fit the cylinder head cover (2) over the plug bracket and onto the cylinder head (1)
• Screw in and tighten the mounting bolts (3)
• Plug the bayonet fittings on the plug bracket
Mounting the rail
• Position the rail (1) on the air distributor pipe

• Screw in and tighten the new mounting bolts (2)
Page 64 of 200
Fitting a new rail-pressure sensor and pressure limiting valve
Note This work step only applies to D0836 Euro4 engines.

WARNING
Component damage due to lack of lubricant
• Do not wash off the pressure limiting valve and rail-pressure sensor as the thread and biting
edge are coated with lubricant
Attaching the high-pressure lines
WARNING
Component damage due to non-aligned high-pressure lines
• After initial tightening, check the alignment of the high-pressure lines and, if necessary, re-
align them
• Attach the high-pressure lines (2) to the rail and rail connection as marked
• Tighten the high-pressure lines (2) to Initial torque 10 Nm using the Socket, size 17 [27] (3),
the Socket, size 22 [28] if necessary and the Extension [29]
• If reusing, tighten the high-pressure lines (2) to Final torque 30° using the Socket, size 17
[27] (3), the Socket, size 22 [28] if necessary and the Extension [29]
• Tighten new high-pressure lines (2) to Final torque 60° using the Socket, size 17 [27] (3),
the Socket, size 22 [28] if necessary and the Extension [29]
• Mount the clamping pieces (1) as marked
Page 65 of 200
Removing and installing the high-pressure pump
(1) High-pressure line (4) High-pressure pump

(2) Mounting nut (5) O-ring
(3) Mounting bolt
Technical data
Fuel fill quantity, high-pressure pump (4).................................................... 60 ml
Mounting bolt (3) .................................................. M8x40...........................30 Nm
Mounting nut (2) ................................................... M8-8 .............................30 Nm
High-pressure line (1) ........................................... M14x1.5 ....................... Initial torque 10 Nm
High-pressure line (initial use) (1) ....................... M14x1.5 ……….............Final torque 60°
High-pressure line (re-use) (1)............................... M14x1.5 ........................Final torque 30°
Mounting nut, drive gear, high-pressure pump (4)... M18x1.5-8.8................105 Nm
Filler plug, high-pressure pump (4) ...............................................................18 Nm
Page 66 of 200
WARNING
Damage in the common-rail system
• 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 rail, or depressurization must be checked by means of MAN-
cats® (desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Do not reuse plugs for the high-pressure lines, the rail or the injectors, even if they have only
been used once
WARNING
WARNING
• If impact wrenches are used, these may only be used for pre tightening to max. 50% of the
Note : Mark the installation position of the fuel lines and the holders before removal. Route
and position the fuel lines and holders as marked when installing.
[33]
[34]
[35]
[36]
Page 67 of 200
[37]
[38]
Page 68 of 200
Removing the high-pressure pump
Disconnecting the metering unit electrical connection
• Disconnect the electrical connection (1)
Detaching the fuel return line on the high-pressure pump side
WARNING
WARNING
• Unscrew the hollow screw (1) with sealing rings (2) and allow the return duct to empty
Page 69 of 200
Detaching the HDP-fuel service center fuel line
Detaching the HDP-fuel service center fuel lines
• Unscrew the hollow screw (3) and remove it with the sealing rings (2)
Page 70 of 200
Detaching the high-pressure line
WARNING
• Detach the high-pressure line (2) from the rail (1) and the high-pressure pump (3) using the
Socket, size 17 [34], the Socket, size 22 [33] and the Extension [35]
Removing the high-pressure pump
Note
When fitting a new high-pressure pump, refit the high-pressure pump drive gear; see Refitting
the high-pressure pump drive gear.

• Unscrew the mounting nut (2)
• Remove the high-pressure pump (3) from the timing case
Page 71 of 200
Refitting the high-pressure pump drive gear
Unscrewing the mounting nut from the high-pressure pump drive gear
• Clean the high-pressure pump (3) and blow it dry using compressed air
• Brace the drive gear for the high-pressure pump (3)
• Unscrew the mounting nut (1)
• Remove the washer (2)
Removing the high-pressure pump drive gear
• Extract the drive gear (2) using the Three-arm puller [38] (1)
Page 72 of 200
Mounting the high-pressure pump drive gear
WARNING
Component damage due to incorrect cleaning agent
• Only use white spirit, spirit, glycol alcohol or isopropanol to clean the cone
• Degrease the cone in the drive gear and on the high-pressure pump (3)
• Put the drive gear on the cone of the high-pressure pump (3)
• Put a new washer (2) on the high-pressure pump (3)
• Screw on the new mounting nut (1)
• Brace the drive gear for the high-pressure pump (3)
• Tighten the mounting nut (1) to 105 Nm
Installing the high-pressure pump
• Insert the high-pressure pump (3) into the timing case by turning slightly to the right/left
• Screw on a new mounting nut (2) and tighten to 30 Nm
• Screw in new mounting bolts (1) and tighten to 30 Nm
Page 73 of 200
Installing the high-pressure line
WARNING
Component damage due to non-aligned high-pressure line
• After initial tightening, check the alignment of the high-pressure line and, if necessary, re-
align
• Attach the high-pressure line (2) at the rail (1) and high-pressure pump (3)
• Tighten the high-pressure line (2) to Initial torque 10 Nm using the Socket, size 17 [34], the
Socket, size 22 [33] and the Extension [35]
• If reusing the high-pressure line (2), tighten to Final torque 30° using the Socket, size 17
[34], the Socket, size 22 [33] and the Extension [35]
• Tighten a new high-pressure line (2) to Final torque 60° using the Socket, size 17 [34], the
Socket, size 22 [33] and the Extension [35]
Attaching the HDP-fuel service center fuel lines
• Put the fuel line (1) on the fitting on the high-pressure pump and fuel service center
• Check the fuel line (1) is seated firmly; if necessary, detach and attach again using the
Release tool, size 1 [37] and the Release handle [36]
• Put the fuel line (4) on the fitting on the high-pressure pump
• Check for firm seating of the fuel line (4), if necessary detach and attach again using the
• Fit the hollow screw (3) with new sealing rings (2), screw in and tighten
Page 74 of 200
Attaching the HDP-fuel service center fuel line
• Put the fuel line (1) on the fitting on the high-pressure pump and fuel service center
• Check the fuel line (1) is seated firmly; if necessary, detach and attach again using the
Attaching the fuel return line on the

High-pressure pump side
•Position the fuel line (3) with new sealing rings (2)
•Screw in the hollow screw (1) and tighten by hand
•Put the fuel line (3) on the fitting on the high-pressure pump
•Check the fuel line (3) is seated firmly; if necessary, detach and attach again using the
•Tighten the hollow screw (1)
Page 75 of 200
Connecting the metering unit electrical connection
•Connect the electrical connection (1)
Page 76 of 200
Removing and installing the fuel service center
(1) Air distributor pipe (4) Mounting bolt

(2) Hand pump (5) Pressure sensor
(3) Fuel service center
WARNING
• If impact wrenches are used, these may only be used for pre tightening to max. 50 % of the
WARNING
WARNING
• Collect any remaining fuel that emerges in a suitable container
Page 77 of 200
Removing the fuel service center
•Detach all fuel lines

•Unscrew the mounting bolts (2)
•Remove the fuel service center (1)
Removing the holder
• Unscrew the mounting bolt (2)

• Remove the holder (1)
Page 78 of 200
Installing the fuel service center
Mounting the holder
• Position the holder (1)

• Screw in and tighten the new mounting bolt (2)
Mounting the fuel service center
• Position the fuel service center (1)

• Attach all fuel lines
Page 79 of 200
SUPERCHARGING
(1) Turbocharger (9) Oil return line

(2) Turbocharger gasket (10) Oil return line retaining clip
(3) Oil pressure line (11) Oil return line seal
(4) Oil pressure line seal (12) Exhaust manifold
(5) Elbow joint (13) Heat shield mounting bolt
(6) Screw-in connection (14) Heat shield
(7) Screw-in connection seal (15) Turbocharger mounting nut
(8) Oil return line seal
Page 80 of 200
TURBOCHARGER
Removing and installing the turbocharger
(1) Turbocharger (9) Oil return line

(2) Turbocharger gasket (10) Oil return line retaining clip
(3) Oil pressure line (11) Oil return line seal
(4) Oil pressure line seal (12) Exhaust manifold
(5) Elbow joint (13) Heat shield mounting bolt
(6) Screw-in connection (14) Heat shield
(7) Screw-in connection seal (15) Turbocharger mounting nut
(8) Oil return line seal
Technical data
Oil pressure line mounting bolt (3) .........................M8x20-10.9...............................30 Nm
Oil return line mounting bolt (9) .............................M8x20-10.9...............................30 Nm
Clamping piece mounting bolt (10) ........................M8x28-10.9 ...............................30 Nm
Turbocharger mounting nut (15) .................................M10........................................45 Nm
Exhaust manifold mounting bolt (12)......................M10x45-SD ...............................45 Nm
Heat shield mounting bolt (13)...............................M10x106-SD...............................45 Nm
Heat shield mounting bolt (14)...............................M8x16-8.8 ..................................22 Nm
Intake hose clamp ....................................................................................................... 5 Nm
Charge air hose clamp................................................................................................. 5 Nm
Charge air manifold clamp .......................................................................................... 9 Nm
Intake hose mounting bolt ..........................................................................................22 Nm
Page 81 of 200
Removing the turbocharger
Removing the charge-air pipe
• Unscrew the mounting bolt (1) & (4)

• Undo the hose clamp (3)
• Pull off the charge-air pipe (2)
Removing the charge-air manifold
• Detach the hose (1)

• Undo the clamp (4)
• Remove the charge-air manifold (2) with O-ring (3)
Page 82 of 200
Removing the exhaust manifold heat shield

• Remove the heat shield (1)
Removing the exhaust manifold

• Remove the exhaust manifold (1)
Removing the intake fitting
• Undo the clamp (1)

• Pull off the intake fitting (2)
Page 83 of 200
Detaching the oil pressure line

• Remove the oil pressure line (1) with the gasket (3)
• Unscrew the threaded connection (4) and remove it with the sealing ring (5)
• Clean the mating faces
Detaching the oil return line
• Unscrew the mounting bolts (3) and (4)

• Remove the oil return line (2) with the gasket (1), holder (5) and O-Ring (6)
Page 84 of 200
Removing the turbocharger
• Unscrew the mounting nuts (1)

• Remove the turbocharger (2) with gasket (3)
Installing the turbocharger
Mounting the turbocharger
• Fit the turbocharger (2) with a new gasket (3)

• Screw on and tighten the new mounting nuts (1)
Attaching the oil return line
• Thinly apply clean engine oil on a new O-ring (6) and fit it on the oil return line (2)
• Insert the oil return line (2) with holder (5) into the crankcase yoke
• Fit the oil return line (2) with a new gasket (1) and position it on the turbocharger
• Screw in and tighten the mounting bolts (3) and (4)
Page 85 of 200
Attaching the oil pressure line
• Screw in the threaded connection (4) with a new sealing ring (5) and tighten
• Fit the oil pressure line (1) with a new gasket (3) and position it
• Screw in the new mounting bolts (2) and tighten them by hand
• Screw on and tighten the elbow fitting for the oil pressure line (1)
• Tighten the mounting bolts (2)
Mounting the exhaust manifold
• Position the exhaust manifold (1)

Page 86 of 200
Mounting the exhaust manifold heat shield
• Position the heat shield (1)

Mounting the charge-air manifold
• Thinly apply Technical Vaseline on a new O-ring (3) and insert it into the charge-air
manifold (2)
• Position the charge-air manifold (2) with the clamp (4)
• Tighten the clamp (4)
• Attach the hose (1)
Page 87 of 200
Installing the charge-air pipe
• Insert the charge-air pipe (2) with the hose clamp (3)
• Tighten the hose clamp (3)
• Screw in and tighten the new mounting bolt (1)
Page 88 of 200
AIR DISTRIBUTOR PIPE
Removing and installing the air distributor pipe
(1) Gasket (3) Air intake manifold

(2) Charge air pipe
Technical data
Air intake manifold bolt ..........................................M8x45-10.9...............................30 Nm
Air intake manifold bolt………. .............................M8x100-10.9.............................30 Nm
Air intake manifold bolt…………...........................M8x120-10.9 ............................30 Nm
Charge air manifold bolt………..............................M8x35-8.8……….....................22 Nm
Page 89 of 200
Removing the charge-pressure sensor
• Disconnect the electrical connection (1)

• Unscrew the mounting bolts (3) and remove the charge-pressure sensor (2)
Removing the charge-air manifold

• Remove the charge-air manifold (3) with gasket (2)
Page 90 of 200
Detaching the air distributor pipe
• Mark the installation position of the mounting bolts (3), (4) and (5)
• Unscrew the mounting bolts (3), (4) and (5)
• Remove the air distributor pipe (2) with gaskets (1)
Installing the air distributor pipe
Attaching the air distributor pipe
• Position the air distributor pipe (2) with new gaskets (1)
• Screw in the new mounting bolts (3), (4) and (5) as marked and tighten by hand
• Tighten the mounting bolts (3), (4) and (5)
Page 91 of 200
Mounting the charge-air manifold
• Fit the charge-air manifold (3) with a new gasket (2) and position it
Mounting the charge-pressure sensor
• Insert the charge-pressure sensor (2) with a new O-ring

• Connect the electrical connection (1)
Page 92 of 200
EXHAUST MANIFOLD
Removing and installing the exhaust manifold
(1) Exhaust manifold bolt (5) Gasket

(2) Exhaust manifold bolt (6) Exhaust manifold front
(3) Exhaust manifold bolt (7) Exhaust manifold center
(4) Exhaust manifold rear
Technical data
Mounting bolt (1) .................................................. M8x40-GA ......... Initial torque 25 Nm
Mounting bolt (1) .................................................. M8x40-GA …..... 2nd torque 45°
Mounting bolt (1) .................................................. M8x40-GA ...........Final torque 45°
Mounting bolt (2) .................................................. M8x40-GA .......... Initial torque 25 Nm
Mounting bolt (2) .................................................. M8x40-GA ......... 2nd torque 45°
Mounting bolt (2) .................................................. M8x40-GA ...........Final torque 45°
Mounting bolt (3) .................................................. M8x80-GA ......... Initial torque 25 Nm
Mounting bolt (3) .................................................. M8x80-GA ......... 2nd torque 45°
Mounting bolt (3) .................................................. M8x80-GA ..........Final torque 45°
Page 93 of 200
Removing the exhaust manifold

• Remove the exhaust manifold (3) with gaskets (4)
Disassembling the exhaust manifold
• Remove the exhaust manifold sections (1) and (3) from exhaust manifold section (2)
• Remove the multi-piece rings (4) from exhaust manifold sections (1) and (2)
Page 94 of 200
Installing the exhaust manifold
Assembling the exhaust manifold
• Insert new multi-piece rings (4) into exhaust manifold sections (1) and (2)
• Insert exhaust manifold sections (1) and (3) into exhaust manifold section (2)
Page 95 of 200
Mounting the exhaust manifold
WARNING
Component damage due to leaking exhaust manifold
• Do not reuse exhaust manifold mounting bolts that have already been used
• Fit the exhaust manifold (3) with new gaskets (4) and position it
• Screw in the new mounting bolts (1) and (2) and tighten by hand
• Tighten the mounting bolts (1) to Initial torque ……………………………………25 Nm
• Tighten the mounting bolts (2) to Initial torque ……………………………………25 Nm
• Tighten the mounting bolts (1) to 2nd torque ………………………………………45°
• Tighten the mounting bolts (2) to 2nd torque ………………………………………45°
• Tighten the mounting bolts (1) to Final torque ……………………………………..45°
• Tighten the mounting bolts (2) to Final torque ……………………………………..45°
Page 96 of 200
CRANKCASE VENTILATION
Removing and installing the crankcase ventilation
(1) Hose (8) Sealing ring

(2) Jubilee clip (9) Mounting bolt
(3) Vent line -pipe clamp (to intake) (10) Oil return line
(4) Oil return line (11) Holder
(5) O-ring (12) Mounting bolt
(6) Vent line (13) Oil separator with pressure control valve
(7) O-ring (14) Jubilee clip
Technical data
Oil return line (4)................................................... M24x1.5 .................................... 4 Nm
WARNING
• If impact wrenches are used, these may only be used for pre tightening to max. 50% of
the specified tightening torque
Note
Unlock and pull off the vent line (6) and the oil return line (10) by pressing together the
spring shackles (arrow). New mounting bolts (9) and (11) must be fitted.
New O-rings (5) and (7) and a new sealing ring (8) must be fitted. Apply Loctite 242
sealing compound on the thread of the oil return line (4) and tighten to 4 Nm.
Page 97 of 200
INTAKE / EXHAUST SYSTEM
(1) Cylinder head (5) Cylinder head cover

(2) Push rod (6) Rocker arm mechanism
(3) Exhaust Valve Bridge (7) Intake valve bridge
(4) Mounting bolt
Page 98 of 200
ROCKER ARM MECHANISM
Removing and installing the rocker arm mechanism

(3) Valve bridge, exhaust valve (7) Valve bridge, intake valve
(4) Mounting bolt
WARNING
• If impact wrenches are used, these may only be used for pre tightening to max. 50 % of
the specified tightening torque
Page 99 of 200
Removing the rocker arm mechanism
• Open the bayonet fittings on the plug bracket


• Remove the rocker arm mechanism (1)
Page 100 of 200

Installing the rocker arm mechanism
Fitting the rocker arm mechanism
• Oil the ball cups of the push rods

• Fit the rocker arm mechanism (1) onto the cylinder head and align it whilst inserting the
adjusting screw balls for the rocker arms into the push rod
Installing the cylinder head cover
• Check the condition of the cylinder head cover gasket and the plug console seals and, if
necessary, renew them
• Close the bayonet fittings on the plug bracket
Page 101 of 200

Dismantling and assembling the rocker arm mechanism
(1) Exhaust valve rocker arm (9) Thrust washer

(2) Exhaust valve adjusting screw (10) Pressure spring
(3) Thrust washer (11) Thrust washer
(4) Pressure spring (12) Intake valve rocker arm
(5) Thrust washer (13) Rocker arm shaft
(6) Intake valve adjusting screw (14) Rocker arm bracket
(7) Intake valve rocker arm (15) EVB adjusting screw
(8) Exhaust valve rocker arm (16) Rocker arm shaft fastening screw
Technical data
Rocker arm shaft fastening screw (16)...................M8x50-10.9................................30 Nm
Page 102 of 200

Dismantling the rocker arm mechanism
• Unscrew the fastening screw (8)

• Knock the rocker arm shaft (6) out of the rocker arm bracket (7)
• Slowly extract the puller to first remove the rocker arm (1), thrust washer (2), and
pressure spring (3) And thrust washer (4) and then remove the rocker arm (5)
Assembling the rocker arm mechanism
• Insert the rocker arms (1) and (5) into the rocker arm bracket (7)
• Insert the thrust washers (2) and (4) with pressure spring (3) into the rocker arm bracket
(7), ensuring they are fitted in the correct order and position
• Align the rocker arm shaft (6) with the bore for the fastening screw (8)
• Insert the rocker arm shaft (6) into the rocker arm bracket (7)
• Screw in the fastening screw (8) and tighten to 30Nm
Page 103 of 200

CYLINDER HEAD
Removing and installing the cylinder head

(3) Valve bridge, exhaust valve (7) Valve bridge, intake valve
(4) Mounting bolt
Page 104 of 200

Technical data
Cylinder head cover mounting bolts (5) ..................M6x30-8.8 ....................................9 Nm
Rocker arm mechanism mounting bolt (4) ..............M8x85-8.8 ..................................22 Nm
Cylinder head bolts...................................................14x2 (E18).............Initial torque 80 Nm
Cylinder head bolts...................................................14x2 (E18)...............2nd torque 150 Nm
Cylinder head bolts...................................................14x2 (E18).......................3rd torque 90°
Cylinder head bolts...................................................14x2 (E18)………...........4th torque 90°
Cylinder head bolts...................................................14x2 (E18)....................Final torque 90°
Cylinder head dimensions

Machining dimension.................................................................................................. 0.5 mm
Cylinder head height........................................................................ 109.85 mm - 110.15 mm
Cylinder head height after machining...............................................109.35 mm - 109.65 mm
Page 105 of 200

Removing the cylinder head

Note
Do not unscrew the fastening screw for the rocker arm shaft in order to remove the rocker
arm mechanism.

• Remove the rocker arm mechanism (1)
Page 106 of 200

Removing the valve bridges and push rods
• Mark the installation position of the valve bridges for the intake valve (3) and exhaust
valve (2)
• Remove the valve bridges
• Pull out the push rods (1)
Undoing the cylinder head bolts
• Place the special tool (1) onto the cylinder head bolt that is going to be undone
• Undo the cylinder head bolts using 2 x Socket
Page 107 of 200

Removing the cylinder head
• Remove the cylinder head bolts (2)

• Lift off the cylinder head (1) using the Lifting device
Removing the cylinder head gasket
• Remove the cylinder head gasket (2)

• Check the dowel pin (1) for completeness
• Clean the face of the crankcase
• Clean the tapped holes for the cylinder head bolts
Page 108 of 200

Checking the cylinder head
Checking the cylinder liner protrusion
• Place the Measuring plate (1) onto the cylinder liner

• Screw in the Cylinder head bolt (5) in conjunction with the Spacer sleeve (4) and tighten
to 80 Nm
• Place the Dial gauge holder with the Dial gauge (3) onto the Measuring plate (1)
• Locate the dial gauge tip (2) on the crankcase and zero the Dial gauge (3)
• Locate the dial gauge tip (2) on the cylinder liner and note the difference on the dial
gauge
• The cylinder liner protrusion must be 0.01 - 0.06 mm. Renew the cylinder liner if
necessary
• Remove the Measuring plate (1)
Checking the cylinder head sideways distortion
• Clean the cylinder head face

• Check the cylinder head (2) for sideways distortion using the Straightedge (1) and the
Feeler gauge (3)
• Repeat the measurement at various points
Page 109 of 200

Checking the cylinder head lengthways distortion
• Check the cylinder head (2) for lengthways distortion using the Straightedge (1) and the
Feeler gauge (3)
• Repeat the measurement at various points
Page 110 of 200

Installing the cylinder head
Fitting the cylinder head gasket
WARNING
Cylinder head gaskets that have already been used are no longer capable of ensuring
a reliable leak-tight connection.
• Previously installed cylinder head gaskets must not be re-used
• Place the new cylinder head gasket (2) over the dowel pins (1) and onto the crankcase
Fitting the cylinder head
• Place the cylinder head (1) onto the crankcase using the Lifting device
• Lightly oil the supporting surfaces of the cylinder head bolts (2)
• Screw in the cylinder head bolts (2) and tighten them by hand
Page 111 of 200

Fitting the special tool
• Fit
the special tool (1) in conjunction with 2 x Socket onto the cylinder head bolt that is
going to be tightened
Tightening the cylinder head
• Tighten the cylinder head to Initial torque 80 Nm in accordance with the tightening
diagram
• Tighten the cylinder head to 2nd torque 150 Nm in accordance with the tightening
diagram
• Tighten the cylinder head to 3rd torque 90° in accordance with the tightening diagram
• Tighten the cylinder head to 4th torque 90° in accordance with the tightening diagram
• Tighten the cylinder head to Final torque 90° in accordance with the tightening diagram
Page 112 of 200

Installing the valve bridges and push rods
• Oil the ball cups of the push rods (1)

• Insert the push rods (1) through the openings in the cylinder head
• Insert the push rods (1) into the ball cups of the tappets
• Fit the valve bridges for the exhaust valve (2) as marked
• Fit the valve bridges for the intake valve (3) as marked
Installing the rocker arm mechanism
• Oil the ball cups of the push rods

• Fit the rocker arm mechanism (1) onto the cylinder head and align it whilst inserting the
adjusting screw balls for the rocker arms into the push rod
Page 113 of 200

Page 114 of 200

Checking and setting the valve clearance
(1) Intake valve bridge (4) Exhaust valve adjusting screw

(2) Exhaust valve bridge (5) Intake valve adjusting screw
(3) EVB adjusting screw
Technical data
Cylinder head cover mounting bolts.......................M6x30-8.8 ..................................... 9 Nm
Valve adjusting screw locknut................................M10x1-8.8 ....................................40 Nm
Intake valve clearance .............................................................................................. 0.50 mm
Exhaust valve clearance ........................................................................................... 0.50 mm
EVB piston play........................................................................................................ 0.35 mm
Page 115 of 200

Checking the valve clearance

• Unscrew the mounting bolts (3) from the cylinder head (1)
• Remove the cylinder head cover (2)
Fitting the engine barring gear
• Remove the cover from the flywheel housing

• Fit the Engine barring gear (1) onto the flywheel housing
Page 116 of 200

Cranking to engine to the setting position
A= Rocker arms in overlap

B= Rocker arms free for valve clearance setting
• Crank the engine with Engine barring gear and Gear ratchet until the rocker arms are in
overlap
• Adjust the free rocker arms as indicated in the table above
Checking the intake valve clearance
• Insert the Feeler gauge (2) (0.50 mm leaf) between the rocker arm (1) and the valve
bridge (3) If the valve clearance between the rocker arm (1) and the valve bridge (3) is
not 0.50 mm, the valve clearance must be adjusted.
Page 117 of 200

Checking the exhaust valve clearance
• Push down the valve bridge (3) several times in order to force the oil out of the EVB
piston
• Insert the Feeler gauge [49] (2) (0.50 mm leaf) between the rocker arm (1) and the valve
bridge (3) If the valve clearance between the rocker arm (1) and the valve bridge (3) is not
0.50 mm, the valve clearance must be adjusted.
Checking the adjustment dimension for the EVB piston
• Lightly push down the valve bridge (3)

• Insert the Feeler gauge [49] (2) (0.35 mm leaf) between the adjusting screw (1) and the
valve bridge (3) If the adjustment dimension between the adjusting screw (1) and the
valve bridge (3) is not 0.35 mm, the valve clearance must be adjusted.
Page 118 of 200

Adjusting the valve clearance
Adjusting the intake valve clearance
• Crank the engine to the setting position

• Undo the locknut (1)
• Turn the adjusting screw (2) back until the Feeler gauge (4) (0.50 mm leaf) can be
inserted between the rocker arm (3) and the valve bridge (5)
• Screw in the adjusting screw (2) until the feeler gauge (4) can be moved between the
rocker arm (3) and the valve bridge (5) with little resistance
• Hold the adjusting screw (2) steady and tighten the locknut (1) to 40 Nm
• Check the setting once more
Forcing the engine oil out of the valve bridge
WARNING
Danger of incorrect valve clearance
• It must be possible to fully push the EVB piston into the valve bridge (1)
• Undo the locknut (2) and turn it back a long way
• Screw in the adjusting screw (3) for the valve bridge (1) as far as the stop several times in
order to force the engine oil out of the EVB piston
Page 119 of 200

Setting the exhaust valve clearance
• Screw down the adjusting screw (1) for the valve bridge (3) until the point of resistance is
reached
• Block the valve bridge (3) in this position with the EVB counter-holder adjusting screw
(4)
• Turn back the adjusting screw (1) with ball cup until the Feeler gauge (2) with 0.50 mm
can be inserted between the rocker arm and the valve bridge (3)
• Screw in the adjusting screw (1) until the Feeler gauge [49] (2) can be moved between the
rocker arm and the valve bridge (3) with little resistance
Adjusting the EVB piston clearance
Note
The valve bridge must not move the exhaust valve when the adjusting screw
is screwed in.
• Turn the adjuster screw (2) in the EVB counter-holder back until the Feeler gauge (3)
(0.35 mm leaf) can be inserted
• Screw in the adjusting screw (2) with the Feeler gauge (3) inserted until the valve bridge
reaches the stop – this can be felt by a noticeable increase in force
Page 120 of 200
Removing the engine barring gear
• Remove the Engine barring gear (1) from the flywheel housing
• Fit the cover on the flywheel housing
Page 121 of 200

VALVE TIMING
CAMSHAFT / CAMSHAFT BEARING Turbocharger – Removing and installing,

– Exhaust manifold – Removing and installing,
Camshaft / camshaft bearing – Removing and – Cylinder head – Removing and installing,
installing – Timing gears – Removing and installing,
Comprises – Air compressor / steering booster pump –
– Oil sump – Removing and installing, Removing and installing,
– Induction manifold – Removing and installing, – Flywheel housing – Removing and installing,
– Coolant pipes – Removing and installing, – Crankcase yoke – Removing and installing,
– Coolant pump – Removing and installing, – Piston and connecting rod – Removing,
– Thermostat / thermostat housing – Removing and – Crankshaft – Removing and installing,

installing,
–
(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
Page 122 of 200

Special tool
Camshaft guide tool

[39] 64.99617-0012
• Camshaft – Removing and installing
[40] Assembly set 64.99606-0013

• Camshaft bearing – Removing and
installing in conjunction with:
• Guide sword [41]
• Impact weight [42]
[41] Guide sword 80.99606-6102

• Assembly set [40]
• Impact weight [42]
[42] Impact weight 80.99606-0546

• Assembly set [40]
• Guide sword [41]
[43] Impact puller 80.99602-0016

• Front and rear camshaft bearing –
Removing in conjunction with:
• Extractor plate [44]
[44] Extractor plate 80.99602-6012

• Front and rear camshaft bearing –
Removing in conjunction with:
• Impact puller [43]
Page 123 of 200

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 [39] onto the camshaft (4) Camshaft bearing special tool
• Screw the guide pin (1) into the adapter (3)
Camshaft – Removing
• Push the Impact puller [43] (1) with Extractor plate

[44] (2) through the camshaft bearing 1 (3)
• Hinge the Extractor plate [44] (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
Page 124 of 200

Camshaft bearing 1 – Removing Camshaft bearings 2 –6 –Removing
• Pull out the camshaft bearing 1 (2) with the Impact Note
puller [43] (1) and Extractor plate [44] (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 [41] into camshaft bearing 2 (2)
• Insert the short end of the Guide sword [42] (3) (B)
into the press-out plate (1) (F)
• Push the double-sided guide bush (4) (G) onto the
Guide sword [42] (3)
• Insert the guide bush as marked with the balls in the
oil bores of the crankcase
• Use the tools from the Assembly set [26] 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
Page 125 of 200

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 [41] 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 [41] (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 [41] (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 [41] • 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 [41] (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 [41] (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
Page 126 of 200

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 [43] (1) and Extractor plate [44] (3)
• Push the short end of the Guide sword [42] (2) (B)
into the press-in plate (E) (3) and guide (D), making Camshaft bearing 7 – Installing
sure the Guide sword [42] (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 [43] (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 [41] (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 [41] (B) (4) together with the
press-in plate (2) (C) into the press-in plate (D) as
• Push the Impact puller [43] (2) with Extractor plate marked
[44] (1) through the camshaft bearing 7 (3) • Drive the camshaft bearing (1) into bearing point 7
• Hinge the Extractor plate [44] (1) behind the cam-
shaft bearing 7 (3) and center it in the
camshaft bearing
Page 127 of 200

Oil bores – Checking Camshaft – Installing
• Check the oil bores (2) of the camshaft bearings WARNING

(1) 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 [40] as a guide
Tappets – Installing
• Push the camshaft (1) with the mounted Camshaft
guide tool [39] into the crankcase (2)
• Remove the Camshaft guide tool [39]
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
Page 128 of 200

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
Page 129 of 200

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
WARNING
Defective timing gears can cause high-pressure pump damage
• Remove and check the high-pressure pump
NoteFollow the instructions for work on the common-rail system,see Fuel system
Page 130 of 200

[45]
[46]
[46]
[45]
Page 131 of 200

Removing the camshaft gear
Fixing the crankshaft 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 [45] using a locking pin
Unscrewing the mounting bolts
• Unscrew the mounting bolts (1) from the camshaft gear (2)
Page 132 of 200

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
Page 133 of 200

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

• 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
Page 134 of 200

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)
Page 135 of 200

• 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) & washer

• Pull off the oil pump drive gear (4)
• Remove the intermediate gear pin (2) and intermediate gear 2 (3)
Page 136 of 200

Removing intermediate gear 1
• Mark the mounting bolts (1) and (2) to indicate their installed position
• Remove the intermediate gear pin (3) and intermediate gear 1 (4)
Installing the intermediate gears

Installing intermediate gear 1
• Position the intermediate gear pin (3) with intermediate gear 1 (4)
Installing intermediate gear 2
• Position the intermediate gear pin (2) with intermediate gear 2 (3)
• Mount the oil pump drive gear (4)
• Screw on a new mounting nuts (5), washer and tighten to 30 Nm
Page 137 of 200
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
Page 138 of 200

OIL MODULE
Oil module – Removing and installing Comprises

– Coolant – Drain
(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
Screw plug in oil filter 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
Page 139 of 200

ENGINE LUBRICATION
ENGINE LUBRICATION Oil module – Installing
Oil module – Removing Oil cooler – Installing

• 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
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
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
• 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
Page 140 of 200

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
Page 141 of 200

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

• 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)
Page 142 of 200

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
Page 143 of 200

ENGINE LUBRICATION
OIL PUMP
Oil pump – Removing and installing

Comprises
– Coolant – Draining and topping up
– Fan (mounting on vibration damper) – Removing and installing
– Fan (mounting on coolant pump) – Removing and installing,
– Belt drive – Removing and installing,
– Vibration damper – Removing and installing,
– Alternator – Removing and installing,
– Coolant pump – Removing and installing,
– Thermostat / thermostat housing – Removing and installing,
– Timing gears – Removing and installing,
– Air compressor / steering booster pump – Removing and installing,
– Timing chain housing – Removing and installing,
(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
……..
Page 144 of 200

Special tool
Dial gauge
[47] 08.71000-3217
• Radial play of oil pump gears –
Checking in con-junction with:
• Dial gauge holder [48]
Dial gauge holder

08.71082-0005
[48] • Radial play of oil pump gears –
Checking in con-junction with:
• Dial gauge [47]
[49] Feeler gauge

64.99607-0002
• 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
Page 145 of 200

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 [49] (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
Page 146 of 200

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,
– Crankcase yoke - Removing and installing, WARNING
– Positive crankcase ventilation - Removing and Danger of engine damage

installing Line up the ball mark on the oil injector
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
Page 147 of 200

CRANKSHAFT DRIVE
(1)Vibration damper (5) Crankshaft

(2) Connecting rod (6) Connecting rod bearing shell
(3) Piston (7) Crankshaft main bearing shell
(4) Flywheel
Page 148 of 200

VIBRATION DAMPER
Removing and installing the vibration damper
(1) Vibration damper mounting bolt (2) Disc

(3) V-belt pulley mounting bolt (4) V-belt pulley
(5) Vibration damper
Technical data
Mounting bolt (1) ...............................M14x1.5-10.9...............................Initial torque 150 Nm
Mounting bolt (1) ...............................M14x1.5-10.9.........................................Final torque 90°
V-belt pulley mounting bolt (3) .........M8x22-8.8 …………….......................................22 Nm
Removing the vibration damper
• Unscrew the mounting bolts for the vibration damper (1)

• Remove the vibration damper (1) with disc
Page 149 of 200

Dismantling the vibration damper
• Mark the installed position of the V-belt pulley (2) relative to the vibration damper (3)
Assembling the vibration damper

• Fit the V-belt pulley (2) for the vibration damper (3) as marked
Installing the vibration damper
• Mount the vibration damper (1) on the crankshaft

• Screw in the new mounting bolts and tighten them to Initial torque 150 Nm
• Tighten the mounting bolts to Final torque 90°
Page 150 of 200

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
Page 151 of 200

Special tool
Internal extractor
[50] 08.99615-1410
• Clutch pilot bearing – Pulling out in
conjunction with:
• Counter support [51]
Counter support
08.99615-0015
[51] • Clutch pilot bearing – Pulling out in
conjunction with:
• Internal extractor [50]
Dial gauge 08.71000-3217

[52] • Flywheel lateral run-out – Checking i
conjunction with:
[53] Dial gauge holder 08.71082-0005

• Flywheel lateral run-out – Checking in
conjunction with:
• Dial gauge [52]
[54] Clutch pilot bearing press-in pin 64.99617-0011

• Clutch pilot bearing – Pressing in
[55] Guide pins 80.99617-0163

• Flywheel – Removing and fitting
[56] Socket 22 mm 80.99612-0024

• Flywheel bolts – Tightening in
conjunction with:
• Support [58]
• Force multiplier spanner i =
1 : 3.3 [57]
• Angle measuring disc [59]
• Holding fixture [60]
• Hexagon socket head cap screw [61]
• Connecting pin [62]
• Rubber ring 42 mm [63]
• Washer [64]
Page 152 of 200

Special tool
Force multiplier spanner i = 1 : 3.3

[57] • Flywheel bolts – Tightening in 80.99619-0006
conjunction with:
• Support [58]
• Washer [64]
• Socket 22 mm [56]
Support
64.99606-0002
[58] • Flywheel bolts – Tightening in
conjunction with:
1 : 3.3 [57]
• Washer [64]
Angle measuring disc
80.99607-0172
conjunction with:
• Support [58]
1 : 3.3 [57]
• Washer [64]
•
Holding fixture
conjunction with:
• Support [58]
1 : 3.3 [57]
• Washer [64]
Page 153 of 200

Special tool
Hexagon socket head cap screw

conjunction with:
• Support [58]
1 : 3.3 [57]
• Washer [64]
Connecting pin
[62] 06.22729-0006
• Flywheel bolts – Tightening in
conjunction with:
• Support [58]
1 : 3.3 [57]
• Washer [64]
Rubber ring 42 mm
08.06142-9006
conjunction with:
• Support [58]
1 : 3.3 [58]
• Washer [64]
Washer
80.99609-0033
conjunction with:
• Support [58]
1 : 3.3 [57]
Page 154 of 200

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 [60] (5) with Hexagon socket

head cap screw [61] (4) and Washer [64] (3) on the
Support [58] (2)
• Place the Angle measuring disc [59] (9) onto the • Screw the Guide pins [55] (1) through the flywheel
Force multiplier spanner i = 1 : 3.3 [57] (1) into the crankshaft
• Place the Socket 22 mm [56] (7) onto the Force • Unscrew the remaining mounting bolts
multiplier spanner i = 1 : 3.3 [57] (1) and secure
with the Connecting pin [62] (8) and Rubber ring
42 mm [63] (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 [55] (2)
Flywheel mounting bolts – Removing
Page 155 of 200

Flywheel – Installing Guide pins – Removing
Flywheel lateral run-out – Checking
• Unscrew the Guide pins [55] (1)

• Screw in the mounting bolts for the flywheel
• Clamp the flywheel (1) onto the fixture
• Fit the Dial gauge [52] (2) with Dial gauge holder Special tool – Assembling
[53]
• Place the measuring tip of the Dial gauge [52] (2)
against the flywheel with a preload
• Zero the Dial gauge [52] (2)
• Turn the flywheel (1) a few turns and, at the same
time, read off the deflection of the Dial gauge [52]
The permitted lateral run-out is max. 0.5 mm
Flywheel – Putting on

Support [58] (2)
• Place the Angle measuring disc [59] (9) onto the
Force multiplier spanner i = 1 : 3.3 [57] (1)
• Place the Socket 22 mm [56] (7) onto the Force
42 mm [63] (6)
WARNING
Flywheel bolts are expansion bolts
• Expansion bolts must not be re-used
after being unscrewed
• Screw in the Guide pins [55] (2)
• Line up the flywheel (1) with the crankshaft guide
pin
• Push the flywheel (1) over the Guide pins [55] onto
the crankshaft
• Screw in new mounting bolts for the flywheel and
tighten until finger-tight
Page 156 of 200

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 [50] (2) into the clutch pilot
bearing and expand it
Attach the Counter support [51] (1) and clamp it
Page 157 of 200

CRANKSHAFT DRIVE
Clutch pilot bearing – Pulling out Clutch pilot bearing – Installing
• Use the Internal extractor [50] (2) and Counter • Use the Clutch pilot bearing press-in pin [54] (1) to
support [51] (1) to pull the clutch pilot bearing drive the clutch pilot bearing (2) into the flywheel
(3) out of the flywheel (3)up to the stop
• Install the internal circlip
Page 158 of 200

CRANKSHAFT DRIVE
PISTON AND CONNECTING ROD
Piston and connecting rod – Removing and

installing
Comprises
– Coolant – Draining and topping up – Exhaust manifold – Removing and installing,
– Engine oil – Draining and topping up – Cylinder head – Removing and installing,
– Induction manifold – Removing and installing, – Oil sump – Removing and installing,
– Coolant pipes – Removing and installing, – Crankcase yoke – Removing and installing,
– Turbocharger – Removing and installing,
(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
Page 159 of 200

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

D1 measured 17 mm above lower edge of piston 107.791 – 107.800 mm
D3 measured 91.4 mm above lower edge of piston 107.541 – 107.500 mm
Piston heights Ø 108 mm WSK piston (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
Total height undersize II 102.60 mm
Piston diameter Ø 108 mm WSK piston (bevelled ring height 4 mm)

D3 measured 91.4 mm above lower edge of piston 107.541 – 107.500 mm
Page 160 of 200

CRANKSHAFT DRIVE
Piston heights Ø 108 mm WSK piston

Overall 103.00 mm
Total height undersize I 102.80 mm
Total height undersize II 102.60 mm
Taper-face ring all pistons

Piston ring height 2.478 – 2.49 mm
Piston ring width 4.25 – 4.60 mm
Ring gap 0.35 – 0.50 mm
Axial play in piston ring groove 0.15 mm
Gudgeon pin
Gudgeon pin 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
Page 161 of 200

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
Piston ring compressor pliers

[65] 64.09144-6001
• Piston rings – Removing and
installing
Feeler gauge
64.99607-0002
[66] • Piston ring gap –Checking
Dial gauge holder

64.99605-0003
[67] • Piston lag – Checking in
conjunction with:
• Dial gauge [68]
Dial gauge
08.71000-3217
[68]
• Piston lag – Checking in
conjunction with:
Piston ring scuff band 64.90613-0001

[69]
• Piston – Installing
Page 162 of 200

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
Piston – Removing using the micrometer gauge (3) to check the
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 [66] (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
Page 163 of 200

Piston rings – Removing Piston rings – Installing
• Set the Piston ring compressor pliers [65] (1) to the WARNING
piston diameter Piston rings can break during
• Use the Piston ring compressor pliers [65] (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 [66] (2)to check the ring gap. • Use the internal calliper (2) and Dial gauge [68] (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
Page 164 of 200

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 [69] (1) over
• Use the internal calliper (1) and Dial gauge [68] (4) the piston and let it sit on the crankcase (4)
to check the connecting rod bearing • Tighten the Piston ring scuff band [69] (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 [69] (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
Page 165 of 200

• 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 [68] (3) and Dial gauge holder
[67] (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
Page 166 of 200

Crankshaft – Removing and installing – Thermostat / thermostat housing – Removing and
installing
Comprises
– Turbocharger – Removing and installing,
– Oil sump – Removing and installing
– Exhaust manifold – Removing and installing,
– Fan (mounting on vibration damper) – Removing
and installing – Cylinder head – Removing and installing,
– Fan (mounting on coolant pump) – Removing and – Timing gears – Removing and installing,
installing, – Air compressor / steering booster pump –
– Belt drive – Removing and installing Removing and installing,
– Vibration damper – Removing and installing, – Timing chain housing – Removing and installing,
– Induction manifold – Removing and installing, – Crankcase yoke – Removing and installing,
– Coolant pipes – Removing and installing, – Piston and connecting rod – Removing,
– Coolant pump – Removing and installing,

–
(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°
Page 167 of 200

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
Dial gauge
[70] 08.71000-3217
• Crankshaft end play – Checking in
conjunction with:
Dial gauge holder

08.71082-0005
[71] • Crankshaft end play – Checking in
conjunction with:
• Dial gauge [70]
[72] Socket 22 mm
80.99612-0024
• Crankshaft bolts – Tightening in
conjunction with:
• Support [74]
• Force multiplier spanner i = 1 : 3.3 [73]
• Washer [80]
Page 168 of 200

Special tool
Force multiplier spanner i = 1 : 3.3

[73] • Crankshaft bolts – Tightening in 80.99619-0006
conjunction with:
• Support [74]
• Washer [80]
Support
conjunction with:
• Washer [80]
Angle measuring disc
conjunction with:
• Support [74]
• Washer [80]
Holding fixture
• Crankshaft bolts – Tightening in 80.99606-0585
[76]
conjunction with:
• Support [74]
• Washer [80]
[77] Hexagon socket head cap screw
• Crankshaft bolts – Tightening in 06.02191-0407
conjunction with:
• Support [74]
• Washer [80]
Page 169 of 200

Special tool
Connecting pin
conjunction with:
• Support [74]
• Washer [80]
Rubber ring 42 mm
conjunction with:
• Support [74]
• Washer [80]
Washer
conjunction with:
• Support [74]
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
Page 170 of 200

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

• Support [74] (2)
• Place the Angle measuring disc [76] (9) onto the
Force multiplier spanner i = 1 : 3.3 [74] (1)
WARNING
with the The crankshaft can be damaged
• Connecting pin [78] (8) and Rubber ring 42 mm [79] • 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
Page 171 of 200

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 [71] (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
journal with the oil grooves pointing towards the crankshaft
(1)
• Repeat the measurement for each journal
• Screw the axial shims (2) into the bearing seat by
• Dimensions, see Technical data, 10-190 pressing slightly
Page 172 of 200

CRANKSHAFT DRIVE
Lower axial shims – Installing Special tool – Assembling
• Insert the axial shims (1) and (4) into the crank- • Fit the Holding fixture [77] (5) with Hexagon socket
shaft main bearing cap (2) with the oil grooves head cap screw [78] (4) and Washer [81] (3) on the
pointing towards the crankshaft Support [75] (2)
• Place the crankshaft main bearing cap (2) onto the • Insert the Force multiplier spanner i = 1 : 3.3 [74] (1)
bearing seat and fix it into the Support [75] (2)
• Screw in the crankshaft main bearing bolts (3) until • Place the Angle measuring disc [76] (9) onto the
finger-tight Force multiplier spanner i = 1 : 3.3 [74] (1)
Crankshaft end play – Checking multiplier spanner i = 1 : 3.3 [73] (1) and secure
42 mm [80] (6)
Crankshaft main bearing bolts – Tightening
[72] (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 [70] (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 [70] (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°
Page 173 of 200

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°
Page 174 of 200

ENGINE HOUSING
(1) Cylinder liner (6) Positive crankcase ventilation filter

(2) Crankcase (7) Positive crankcase ventilation line
(3) Flywheel housing
(4) Timing chain housing cover
(5) Timing chain housing
Page 175 of 200

ENGINE HOUSING
CYLINDER LINER
Cylinder liner – Removing and installing

Comprises
– Oil sump – Removing and installing, – Coolant pipes – Removing and installing,
– Low-pressure system – Removing and installing, – Turbocharger – Removing and installing,
– Induction manifold – Removing and installing, – Exhaust manifold – Removing and installing
– Flame start system – Removing and installing, – Cylinder head – Removing and installing
– Crankcase yoke – Removing and installing,
– Piston and connecting rod – Removing,
(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….…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
Page 176 of 200

Special tool
[81] Dial gauge holder

64.99605-0003
• Cylinder liner protrusion – Checking in
conjunction with:
• Dial gauge [82]
[82] Dial gauge 08.71000-3217

• Cylinder liner protrusion – Checking in
conjunction with:
[83] Extractor device 64.99602-0004

• Cylinder liner – Removing in conjunction
with:
• Extractor plate [84]
[84] Extractor plate Included in [83]

• Cylinder liner – Removing in
conjunction with:
• Extractor device [83]
Cylinder liner – Checking • Zero the Dial gauge [82] (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
[81] (5) onto the crankcase (4)
• Place the dial gauge probe (1) onto the crankcase
(4)
Page 177 of 200

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
the stop
WARNING
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 [83] (2) and Extractor
device [84]
• Carefully insert the Extractor device [84] with
hinged Extractor plate [83] (2) into the cylinder liner
(1)
Cylinder liner – Pulling out
• Clamp the spindle (2) of the Extractor device [83]

(4) with the tool (3)
• Pull the cylinder liner (1) out of the crankcase
Page 178 of 200

FLYWHEEL HOUSING
Removing and installing the flywheel housing
(1) Crankcase (2) Flywheel housing mounting bolt

(3) Flywheel housing (4) Flywheel housing gasket
(5) RPM Sensor location
Technical data
Flywheel housing mounting bolts (2)......................M12x30-8.8 ............................75 Nm
Flywheel housing mounting bolts............................M12x90-8.8 ............................75 Nm
Page 179 of 200

Special tool
[85] Crankshaft oil seal special tool kit

64.99604-0027
• Crankshaft oil seal front and rear –
Removing
[86] Crankshaft oil seal press-in tool 64.99614-0015

• 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)
• Screw the mounting bolts (3) of the flywheel

housing (2) into the crankcase (1)
• Tighten the mounting bolts (3) to 75 Nm
Page 180 of 200

ENGINE HOUSING
Crankshaft oil seal – Removing Pull-out Crankshaft oil seal – Installing
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 [85] 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 [85]
• 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 Push the press-in sleeve (2) from the Crankshaft oil
housing by screwing in the threaded spindle (2) seal press-in tool [86] 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)
Page 181 of 200

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
Page 182 of 200

[87]
[88]
[89]
[90]
[91]
Page 183 of 200

[92]
[93]
[94]
[95]
Page 184 of 200

[96]
[97]
Page 185 of 200

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
• Remove the timing case cover (2)
Removing the timing case cover gasket
• Remove the timing case gasket (1) from the timing case (2)
Page 186 of 200

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
Page 187 of 200

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)
Page 188 of 200

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
Page 189 of 200

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
Page 190 of 200

Removing the timing case
Unscrewing the bottom mounting bolts
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)
Page 191 of 200

Removing the timing case gasket
• Remove the gasket (1) from the crankcase (2)

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
Page 192 of 200

Timing case attachment
• Tighten the mounting bolt (3)……………………. M8x18-10.9……………………30 Nm

• Tighten the mounting bolts (4)…………………….M8x25-10.9……………………30 Nm
• Tighten the mounting bolt (6)……………………...M8x45-10.9…………………...30 Nm
• Tighten the mounting bolt (2)……………………...M10x50-10.9………………….65 Nm
Screwing in the bottom mounting bolts
Page 193 of 200

CRANKCASE YOKE
Crankcase yoke – Removing and installing

Comprises
– Oil sump – Removing and installing,
– Positive crankcase ventilation – Removing and installing,
(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
Page 194 of 200

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)
Crankcase yoke – Installing
(1) Induction manifold

(2) Hose port
(3) Positive crankcase ventilation filter
(4) Positive crankcase ventilation line
• Apply a coat of Sealing agent to the contact

surfaces of the crankcase (3)
• Position the crankcase yoke (2) on the crankcase
(3)
• Screw in the mounting bolts (1) and tighten to 22
Nm
Page 195 of 200

Special tool
[98] Hose clamp pliers for spring-loaded band-

80.99625-0073
type clamps
• Spring-loaded band-type clamps –
Removing and installing
Positive crankcase ventilation – Removing
Positive crankcase ventilation filter – Removing
• Use the Hose clamp pliers for spring-loaded band-

type clamps [98] to remove the spring-loaded
band- type clamp (3) from the filter (2)
• Pull the filter (2) off the positive crankcase
ventilation line (4) and hose port (1)
Positive crankcase ventilation – Installing
Positive crankcase ventilation filter – Installing
Put the filter (2) onto the positive crankcase

ventilation line (4) and hose port (1)
Use the Hose clamp pliers for spring-loaded
band- type clamps [98] to fit the spring-loaded
band-type clamps (3)
Page 196 of 200

ENGINE CONTROL UNIT
Removing and installing the engine control unit
(1) Rubber mount (4) Mounting bolt

(2) Bracket (5) Engine control unit
(3) Rubber mount (6) Mounting bolt
Technical data
Mounting bolt (6) .................................................. M6x35-10.9 ...............................11 Nm
Mounting bolt (4) .................................................. M8x40-10.9 ...............................13 Nm
Note
After the engine is installed, the engine control unit must have its parameters reset and the fault
memory must be deleted.
Page 197 of 200

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

• Remove the engine control unit (5)
• Remove the bracket with rubber mounts (1) and (2)
Page 198 of 200

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 (3) into the bracket
• Thinly apply Loctite 270 sealing compound on the thread of the new mounting bolts (4)
• Position the bracket
• Position the engine control unit (5)
• Screw in the new mounting bolts (6) and tighten in the specified sequence to 11 Nm
Page 199 of 200

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
Page 200 of 200

4VCR Engine Repair Manual

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Repair Manual

Common-rail In-line Engine

Common Rail System…………………………………………………………............…….045

Intake/Exhaust Manifold ……….…………………………………………………..………089

MAN Trucks India Pvt. Ltd.

Danger of damage due to dirt ingress

Danger of damage due to dirt ingress

Designation Unit Figures

(1) Air compressor (8) Pressure pipe

Connecting rods (cracked connecting rods)

Rocker arm mechanism

Intake and exhaust system

Fuel system, general

Flame start system

Engine brake system

(1) Fan clutch (4) Intermediate flange

• Unscrew the mounting bolts (5)

Removing the fan clutch

• Unscrew the locknuts (3)

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

Fitting the fan with fan clutch

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

(1) Coolant pipe (5) Coolant outlet pipe

Removing the coolant outlet pipe

• Unscrew the mounting bolts (1)

Removing the air compressor coolant lines

• Unscrew the hollow screws (3)

Removing the coolant pipe

• Unscrew the mounting bolts (1)

Mounting the coolant manifold

Fitting the air compressor coolant lines

• Clean the sealing surfaces

Installing the coolant outlet pipe

Removing and installing coolant pump

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

• Unscrew the union nut (3)

Removing the swiveling screw connection

• Unscrew the hollow screw (3)

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

Installing the coolant pump

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

Fitting the air compressor coolant lines

• Fit the coolant lines (1) and (2)

(1) Air compressor (2) Power steering pump

Removing and installing the power take-off

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

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

Removing the power take-off

• Unscrew the mounting bolts (1)

Mounting the V-belt pulley

• Place the V-belt pulley (2) on the power take-off (3)

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

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

Removing the power steering pump

• Remove the steering oil lines

• Removing the air compressor line

Installing the air compressor / power steering pump

Installing the air compressor

Mounting the power steering pump

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

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

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

Removing the V-belt pulley