Man Engine Shop Manual - D0836 LF - LFL 40-41-44

Common rail in-line engine
D0836 LF/LFL40
D0836 LF/LFL41
D0836 LF/LFL44
Copy deadline: 01/2016
Repair manual
81.99185-6212 5th edition A20 Stage 2
MAN Truck & Bus AG Repair Manual A20 Stage 2, 5th edition
Dachauer Str. 667 Common rail in-line engine
80995 MÜNCHEN D0836 LF/LFL40
Or D0836 LF/LFL41
Postfach 50 06 20 D0836 LF/LFL44
80976 MÜNCHEN - Englisch -
Printed in Germany
Repair manual A20 Stage 2
5th edition
Common rail in-line engine

D0836 LF/LFL40
D0836 LF/LFL41
D0836 LF/LFL44
81.99185-6212
1
PREFACE/PUBLICATION DATA
PREFACE
These instructions are intended as a guide to help perform repair work on vehicles and units correctly.
This publication assumes that persons who use it possess the requisite technical knowledge in handling
vehicles and mechanical units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always corre-
spond to the unit in question, but this does not necessarily mean they are incorrect. In such cases, plan and
carry out the repair work in accordance with the sense of the instructions.
Repair work on complex add-on units should be entrusted to our customer service or to the customer service
of the manufacturing company. These units are mentioned specifically in the text.
The repair work is broken down into chapters and sub-chapters. Each sub-chapter begins with a preliminary
page. The preliminary page contains a summary of the main prerequisites for the repair section in question.
This preliminary page may be followed by a detailed description of the work.
Important instructions concerning technical safety and the safety of personnel are specifically highlighted, as
indicated below.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed in order to avoid exposing
people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed in order to avoid material
damage or destruction.
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.
Yours faithfully,
MAN Truck & Bus AG
Munich plant
PUBLICATION DATA
© 2016 MAN Truck & Bus AG
Not to be reprinted, duplicated by any means whatsoever or translated – in whole or in part – without the
prior written approval of MAN Truck & Bus AG. All rights under the copyright law are strictly reserved by MAN
Truck & Bus AG. If any changes or modifications are made without the written approval of MAN Truck & Bus
AG then MAN Truck & Bus AG shall not be liable for any material defects attributable to the unauthorised
changes or modifications. MAN Truck & Bus AG is not liable for any damage attributable to unauthorised
changes or modifications.
Editorial Department: SAWDT, 2W Technische Informations GmbH & Co. KG, 10/2008
Typesetting: SAWDT, 2W Technische Informations GmbH & Co. KG
Printing: MAN-Werksdruckerei
2 A20 Stage 2 5th edition

TABLE OF CONTENTS
Content Chapter/Page
Index 7
Introduction
Safety instructions ........................................................................................................ 9

The engine ................................................................................................................ 16
Model plate/Model designation .................................................................................... 16
Characteristic data .................................................................................................. 18
Description of engine ............................................................................................... 20
Engine electronics
Cable harness ............................................................................................................ 27

Removing and installing the cable harness ..................................................................... 27
Engine electronics ....................................................................................................... 39
Removing and installing the engine electronics ................................................................ 39
Cooling system
Fan ......................................................................................................................... 43
Removing and installing the fan (attachment to coolant pump) ............................................. 43
Removing and installing the fan (variant without hydraulic pump) .......................................... 45
Removing and installing the fan (variant with hydraulic pump) .............................................. 47
Coolant manifold ......................................................................................................... 49
Removing and installing the coolant manifold .................................................................. 49
Thermostat with thermostat housing ................................................................................. 57
Removing and installing the thermostat with thermostat housing .......................................... 57
Coolant pump ............................................................................................................ 65
Removing and installing the coolant pump ..................................................................... 65
Dismantling and assembling the coolant pump (open impeller variant) ................................... 69
Dismantling and assembling the coolant pump (closed impeller variant) ................................. 77
Add-on units
Power take-off ............................................................................................................ 83

Removing and installing the PTO ................................................................................. 83
Air compressor ........................................................................................................... 87
Removing and installing 1-cylinder air compressor ........................................................... 87
Dismantling and assembling 1-cylinder air compressor ...................................................... 92
Belt drive .................................................................................................................. 97
Removing and installing the belt drive (variant without Frigoblock alternator) ........................... 97
Removing and installing the belt drive (variant with Frigoblock alternator) ............................. 102
Removing and installing the belt drive (variant with hydraulic pump) .................................... 106
Removing and installing the belt drive (variant with stretchy belt) ........................................ 109
Alternator ................................................................................................................ 115
Removing and installing the alternator ........................................................................ 115
Frigoblock alternator .................................................................................................. 123
Removing and installing Frigoblock alternator ............................................................... 123
Starter motor ........................................................................................................... 127
Removing and installing the starter motor .................................................................... 127
Refrigerant compressor .............................................................................................. 131
Removing and installing the refrigerant compressor ........................................................ 131
Hydraulic pump ........................................................................................................ 135
Removing and installing the hydraulic pump ................................................................. 135
Common Rail system
Injectors and pressure pipe .......................................................................................... 143
A20 Stage 2 5th edition 3

TABLE OF CONTENTS
Protective sleeves for injectors and pressure pipe .......................................................... 143

Removing and installing the injectors and pressure pipe .................................................. 146
High pressure pump .................................................................................................. 157
Protective sleeves for high pressure pump ................................................................... 157
Removing and installing the high pressure pump ........................................................... 159
Disassembling and assembling the high pressure pump .................................................. 167
Fuel service centre .................................................................................................... 171
Protective sleeves fuel service centre ......................................................................... 171
Removing and installing the fuel service centre ............................................................. 173
Dismantling and assembling the fuel service centre ........................................................ 179
Flame-start system .................................................................................................... 185
Flame-start system protective sleeves ........................................................................ 185
Removing and installing the flame-start system ............................................................. 187
Protective sleeve for the flame-start system (D0836 LFL44) .............................................. 190
Removing and installing the flame-start system (D0836 LFL44) ......................................... 192
EDC control unit ....................................................................................................... 195
Removing and installing the EDC control unit ................................................................ 195
Turbocharging
Charge-air pipes ....................................................................................................... 201

Removing and installing the charge-air pipes (D0836 LFL44) ............................................ 201
Turbo charger .......................................................................................................... 203
Removing and installing the turbo charger .................................................................... 203
Intake/exhaust system
Air distributor pipe ..................................................................................................... 211

Removing and installing the air distributor pipe .............................................................. 211
EGR module ............................................................................................................ 215
Removing and installing the EGR module .................................................................... 215
Exhaust manifold ...................................................................................................... 221
Removing and installing the exhaust manifold ............................................................... 221
Cylinder head
Rocker arm mechanism .............................................................................................. 227

Removing and installing the rocker arm mechanism ........................................................ 227
Assembling and disassembling the rocker arm mechanism ............................................... 230
Cylinder head .......................................................................................................... 233
Removing and installing the cylinder head .................................................................... 233
Checking and adjusting the valve clearance ................................................................. 239
Removing and installing the valve-stem seal ................................................................. 245
Camshaft/camshaft bearing
Camshaft/camshaft bearing ......................................................................................... 259

Removing and installing the camshaft ......................................................................... 259
Removing and installing the camshaft bearing ............................................................... 265
Timing gears
Timing gears ............................................................................................................ 277

Removing and installing the timing gears ..................................................................... 277
Engine lubrication
Oil module .............................................................................................................. 287

Removing and installing the oil module ....................................................................... 287
Oil sump and oil intake pipe ......................................................................................... 293

TABLE OF CONTENTS
Removing and installing the oil sump and oil intake pipe .................................................. 293
Oil pump ................................................................................................................. 299
Removing and installing the oil pump .......................................................................... 299
Oil nozzles .............................................................................................................. 303
Removing and installing the oil nozzles ....................................................................... 303
Crankshaft drive
Vibration damper ...................................................................................................... 309

Removing and installing the vibration damper ............................................................... 309
Flywheel manually operated gearbox .............................................................................. 313
Removing and installing the flywheel for the manually operated gearbox .............................. 313
Piston and connecting rod ........................................................................................... 323
Removing and installing the piston and the connecting rod ............................................... 323
Crankshaft .............................................................................................................. 333
Removing and installing the crankshaft ....................................................................... 333
Crankshaft seals
Crankshaft seals ....................................................................................................... 345

Removing and installing the front crankshaft seal ........................................................... 345
Removing and installing the rear crankshaft seal ............................................................ 349
Engine housing
Crankcase ventilation ................................................................................................. 355

Removing and installing the crankcase ventilation .......................................................... 355
Flywheel housing ...................................................................................................... 357
Removing and installing the flywheel housing (version without PTO) ................................... 357
Removing and installing the flywheel housing (version with PTO) ....................................... 360
Crankcase yoke ........................................................................................................ 365
Removing and installing the crankcase yoke ................................................................. 365
Timing case cover/timing case ...................................................................................... 369
Removing and installing the timing case cover .............................................................. 369
Removing and installing the timing case ...................................................................... 373
Cylinder liner ........................................................................................................... 377
Removing and installing the cylinder liner .................................................................... 377
Power take-off
Power take-off .......................................................................................................... 385

Removing and installing the PTO ............................................................................... 385
Technical Data
Technical Data 387

INDEX
Index Page
A
Add-on units
Starter motor .......................................................................................................................................... 129
Air compressor
Suction line and pressure line .................................................................................................................. 89
Air compressor, 1-cylinder
Mounting bolt, drive wheels...................................................................................................................... 94
Air distributor pipe
Charge-air manifold................................................................................................................................ 212
Temperature sensor ............................................................................................................................... 213
Alternator
Bracket ................................................................................................................................................... 117
Carrier .................................................................................................................................................... 118
Coolant lines........................................................................................................................................... 117
B
Belt drive
Guide roller for the Frigoblock alternator................................................................................................ 103
Ribbed V-belt tensioner alternator............................................................................................................ 99
Ribbed V-belt tensioner Frigoblock alternator ........................................................................................ 104
C
Characteristic data......................................................................................................................................... 18
Crankcase
Crankshaft seal, front ............................................................................................................................. 348
Oil filler neck........................................................................................................................................... 371
Crankshaft drive
Connecting-rod bearing cover ................................................................................................................ 327
Connecting-rod bearings ........................................................................................................................ 329
Contact washers..................................................................................................................................... 340
Piston pin bushing .................................................................................................................................. 329
Piston pins.............................................................................................................................................. 327
Piston ring gap ....................................................................................................................................... 328
Piston rings............................................................................................................................................. 328
Vibration damper .................................................................................................................................... 311
Crankshaft seals
Crankshaft seal, rear .............................................................................................................................. 352
D
Description of engine..................................................................................................................................... 20
E
Engine housing
Testing/measuring the cylinder liner protrusion ...................................................................................... 380
Engine lubrication
Oil cooler ................................................................................................................................................ 290
Oil filter ................................................................................................................................................... 289
Oil nozzles.............................................................................................................................................. 305
Oil pressure switch ................................................................................................................................. 290
F
Flywheel
Circlip ..................................................................................................................................................... 320
Clutch pilot bearing................................................................................................................................. 320
Starter ring gear ..................................................................................................................................... 318
Frigoblock alternator
Bracket ................................................................................................................................................... 124
FSC
Hand pump............................................................................................................................................. 182
Heating element ..................................................................................................................................... 181

INDEX
Pressure sensor ..................................................................................................................................... 181
H
Hydraulic pump
Carrier .................................................................................................................................................... 137
V-belt pulley............................................................................................................................................ 137
M
Model plate .................................................................................................................................................... 16
O
Oil module
Draining the coolant ............................................................................................................................... 290
P
Power take-off
Ribbed V-belt disc .................................................................................................................................... 84
R
Refrigerant compressor
Bracket ................................................................................................................................................... 133
Console .................................................................................................................................................. 133
S
Safety instructions ........................................................................................................................................... 9
General....................................................................................................................................................... 9
V
Valve control
Axial shim ............................................................................................................................................... 262
Camshaft ................................................................................................................................................ 262
Camshaft bearing 1 ................................................................................................................................ 272
Camshaft bearings in bearing seats 2, 3 and 5...................................................................................... 270
Tappet..................................................................................................................................................... 262

INTRODUCTION
INTRODUCTION
SAFETY INSTRUCTIONS
General
Only trained personnel are permitted to perform operating, maintenance or repair work on trucks and buses
/coaches.
The following sections include summaries of important regulations listed according to major topics. These
must be observed, in order to avoid accidents which could lead to injury, damage and environmental pollu-
tion. Please note that these are merely brief extracts taken from various accident prevention regulations. Of
course, all other safety regulations must be followed and the necessary measures must be taken.
Additional references to danger are contained in the instructions at points where there is a potential danger.
Accidents may happen despite all precautionary measures having been taken. In such an eventuality, obtain
immediate medical assistance from a doctor. This is particularly important if the accident involves skin contact
with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes, crushing
limbs, etc.
1. Regulations for preventing accidents leading to injury to personnel
Checking, setting and repair work

– Secure units during their removal.
– Support the frame when working on the air or spring suspension system.
– Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.
– Do not use any tools that are not in perfect condition.
– Only authorised technical personnel are entitled to perform inspection, adjustment and repair work.
Working on the brake system

– Please use a dust extraction device if dust is released during work on the brake system.
– Perform visual, functional and effectiveness checks on the brake system after carrying out any work on it
whatsoever in accordance with the safety inspection (SI).
– Use a suitable test system (e.g. MAN-cats) to check the function of the ABS/ASR systems.
– Collect any brake fluid that leaks out.
– Brake fluid is poisonous! Do not allow brake fluid to come into contact with food or open wounds.
– Treat hydraulic fluid/brake fluid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
Working on vehicles with a compressed natural gas (CNG) system

– Vehicles with a defective compressed natural gas system may not be brought into the workshop. This also
applies to vehicles with engines that cannot be switched off by automatic emptying of the removal lines.
– When working on vehicles with a compressed natural gas system, set up a gas warning device above the
vehicle roof and in the engine compartment above the pressure governor. Further gas warning devices
must be carried by the persons working on the vehicle.
– Smoking is not allowed in areas where work on vehicles with compressed natural gas systems is carried
out. All sources of ignition must be removed from these areas.
– Before carrying out welding, the gas tanks must be removed and the gas-carrying lines must be flushed
with inert gas.
– Gas tanks must not be subject to temperatures in excess of 60°C in painting and drying booths. If the
temperatures are any higher, the compressed gas tanks must be removed or degassed using an inert gas
such as nitrogen. The gas-carrying lines must also be flushed with inert gas.
Working on the compressed natural gas (CNG) system

– Work on the compressed natural gas system may only be carried out by persons who have been specifically
trained to do so.
– The working area for the compressed natural gas system must be equipped with an adequate ventilation
system. The ventilation system must replace the air in the room with new air at least three times per hour.
– After following the prescribed procedures to replace standard-fit components of the compressed natural
gas system, check the assembly points for leaks. Perform these checks using leak detection spray or a
gas warning device.

INTRODUCTION
Operating the engine

– Only authorised personnel are permitted to start and operate an engine.
– Do not get too close to the moving parts of a running engine and do not wear baggy clothing. Use an
extractor system if working in enclosed spaces.
– Risk of burning when working on engines at operating temperature.
– Danger of scalding when opening the hot cooling circuit.
Suspended loads
– Persons may not stand or walk underneath suspended loads.
– Only use suitable hoists that are in technically faultless condition. Please also make sure that the load
suspension devices used have sufficient load capacity.
Bodies and special bodies

– Comply with the safety instructions and regulations issued by the respective body manufacturer if bodies
or special bodies are fitted.
Working on high-pressure lines

– Do not attempt to tighten, loosen or open pipes and hoses (e.g. in the lubrication circuit, coolant circuit and
hydraulic oil circuit) whilst they are pressurised:
Risk of injury from liquids escaping under pressure.
Testing injection nozzles

– Please wear the relevant protective equipment.
– Keep all body parts away from the jet of fuel when checking the injection nozzles.
– Do not breathe in fuel vapour, ensure sufficient ventilation.
Work on the vehicle electrical system

– Do not disconnect the batteries whilst the engine is running!
– Always disconnect the batteries when working on vehicle electronics, central electrical system, alternators
and starters. Remove the negative terminals first when disconnecting batteries. Attach the positive termi-
nals first when connecting.
– Use only matching test lines or test adapters to measure at plug connectors.
– If you expect temperatures in excess of 80°C (e.g. in the dryer after painting), set the main battery switch
to "OFF" and then remove the control units.
– The frame is not intended for use as a ground return. If attachments are to be fitted to the vehicle (e.g. a
wheelchair lift), additional ground cables with an adequate cross-section must be fitted as well. Otherwise
the ground connection may be created along wire cables, cable harnesses, gearbox shafts, gears etc.
Severe damage could result.
Important: battery gases are explosive!

– Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after long journeys and after
charging the batteries with a battery charger.
– When the batteries are disconnected, the gas may be ignited by sparks produced by continuously operating
consumers, tachographs, etc. that cannot be switched off. Blow compressed air through the battery box
before disconnecting the batteries!
– Only tow-start a vehicle if the batteries are connected. Only tow-start if the check lamps are still brightly lit,
although the batteries do not have enough charge to start the engine.
Do not use a boost-charger to jump-start the vehicle!
– Always disconnect the positive cable and ground cable before boost-charging and charging batteries!
– Do not boost-charge lead gel and maintenance-free batteries. (Not for “zero-maintenance acc. to DIN”.)
Maximum charging power is 10% of the specified capacity of each battery. Parallel connection increases
the capacity, in accordance with the total number of batteries connected in parallel.
– Risk of short-circuit if batteries have been incorrectly connected.
– Do not place any metal objects (keys, pliers, etc.) on the batteries otherwise there may be a short-circuit
at the terminals. Risk of short circuit!
– Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in use over a prolonged
period of time.
Caution! Battery acid is toxic and corrosive!

– Wear suitable protective clothing (gloves) when handling batteries.
Do not tip or tilt batteries as acid may emerge. Do not tilt gel batteries either.

INTRODUCTION
– Only measure voltage with suitable measuring devices! The input resistance of the measurement device
must be at least 10 MΩ.
– Connect/disconnect the plug connectors of electrical control units only when the ignition is switched off.
Electric welding
– Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number 80.78010.0002) as de-
scribed in the instructions accompanying the device.
– If this device is not available, disconnect the batteries and firmly connect the positive cable to the ground
cable in order to make a conductive connection.
– Move the manually operated main battery switch to the driving mode position. If an electronic main battery
switch is fitted, crosshead “Negative” at the power relay contacts (jumper cable > 1mm2) and “Positive” at
the power relay load contacts. In addition, switch on many loads such as: Starter switch (ignition) in driving
position, hazard warning system switch “on”, lighting switch in position “driving lights on”, ventilation blower
in “maximum” position. The more consumers are switched on, the greater the protection.
After ending the welding work, first switch off all consumers, remove all bypass jumpers (restore the original
condition) and then connect the batteries.
– Always ground the welding equipment as close as possible to the welding area. Do not lay the cables to
the welding equipment in parallel to electrical cables in the vehicle.
Work on plastic tubes – risk of damage and fire

– Plastic tubes must not be subject to mechanical or thermal load.
Painting work
– During painting work, electronic components may only be exposed to high temperatures (max. 95°C) for
short periods; a period of up to approx. 2 hours is permissible at max. 85°C; disconnect the batteries.
Do not paint the bolt connections of the high-pressure section of the injection system. Risk of dirt ingress
in the event of repairs.
Working with a tilted cab

– Keep the tilting area in front of the cab clear.
– Stay out of the area between the cab and the chassis while the cab is being tilted! Danger zone!
– Always tilt the cab over the tipping point or secure the cab with a prop.
Work on the air-conditioning system

– Refrigerant fluids and vapours represent a health hazard, avoid contact and protect eyes and hands.
– Do not drain gaseous refrigerants in enclosed areas.
– Never mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant.
– Dispose of refrigerant according to instructions.
Work on the airbag or belt pre-tensioner units

– Work on airbags or belt pre-tensioner units must only be performed by personnel that can provide proof of
a specialist course at the MAN Service Academy.
– Mechanical loads, impacts, heating to over 140°C, electrical pulses and electrostatic discharge may trigger
unwanted ignition of the airbag or belt pre-tensioner units.
– Hot gases are released explosively when the airbag or belt pre-tensioner units are triggered. Airbag or belt
pre-tensioner units that are not fitted may be catapulted around uncontrollably. This poses an injury risk to
people in or near the cab.
– Risk of burning when touching the hot surfaces after the airbag has been triggered.
– Do not open a triggered airbag or air cushion.
– Do not touch a triggered airbag with a destroyed air cushion with your bare hands. Wear nitrile rubber
gloves.
– Before performing any work and inspections on the airbag or belt pre-tensioner units, or works on the vehicle
during which vibrations are likely to occur, it is necessary to switch off the ignition, remove the ignition key
from the ignition lock, disconnect the ground cable from the battery and disconnect the plug connector for
the airbag and belt pre-tensioner power supply.
– Fit the driver airbag restraint system, MAN item number 81.66900-6035, to the airbag steering wheel as
instructed in the Operator's Manual.
– Only perform inspections on airbag and belt pre-tensioner units with devices specifically intended for this
purpose. Do not use inspection lamps, voltmeters or resistance meters.
– After having finished all work and inspections, switch off the ignition first, then connect the plug connector(s)
for the airbag and belt pre-tensioner and lastly connect the battery. There must be no-one in the cab whilst
these works are being carried out.

INTRODUCTION
– Only place aside airbag units individually, with the impact cushion facing up.
– Do not apply grease or cleaning agents to airbags and belt pre-tensioners.
– Store and transport airbag and belt pre-tensioner units in their original packaging only. Transport in the
passenger area is not permitted.
– Airbag and belt pre-tensioner units may only be stored in storage areas that can be locked, and up to a
maximum of 200 kg.
Working on the independent heating

– It is necessary to switch off the heater unit and allow all hot components to cool down before beginning
work.
– Ensure that suitable collecting containers are available and that no sources of ignition are present when
working on the fuel system.
– Keep suitable fire extinguishing equipment nearby and within easy reach!
– The heater unit must not be operated in enclosed areas such as garages or workshops without an extractor
system.
2. Notes on preventing damage and premature wear on units
General
– Units are only built for the purpose designated in the scope of delivery (according to their intended use),
which is defined by the device manufacturer: Any other use is classified as not in accordance with the
intended use. The manufacturer is not liable for damage caused as a result of such other use. In the event
of such other use, the user alone bears the risk.
– The intended use also includes compliance with the operating, maintenance and repair conditions defined
by the manufacturer.
– The unit must only be used, maintained and repaired by personnel who are acquainted with it and have
been instructed about any potential danger.
– The manufacturer does not assume any liability for damage resulting from unauthorised modifications to
the engine.
– Manipulation of the injection and control system may also affect the performance and exhaust-gas values of
the unit. This means that compliance with the statutory environmental requirements is no longer assured.
– Should faults occur during operation, the cause must be determined and rectified immediately.
– Thoroughly clean the units prior to repair work and ensure that all openings where the ingress of dirt could
cause functional or safety issues, are sealed.
– Never run units dry, i.e. always make sure that they have been filled with lubricating oil before running them.
– Never run engines that have not been filled with coolant beforehand.
– Use a suitable information sign to clearly indicate units that are not ready to be operated.
– Use service products only in accordance with MAN service product recommendations; otherwise the man-
ufacturer's warranty is rendered void.
You can find approved products on the Internet at: http://www.man-mn.com/ > Products & Solutions >
E-business.
– Comply with the specified service intervals.
– Do not fill engine/gearbox oil above the maximum level mark. Do not exceed the maximum permitted
operational tilt.
– The special measures described in MAN Works Standard M 3069 Part 3 are necessary if buses/coaches
or trucks are to be withdrawn from service or held in storage for longer than 3 months.
3. Limited liability for parts and accessories
General
Use only accessories expressly approved by MAN Nutzfahrzeuge AG and MAN genuine parts for your MAN
vehicle. MAN Nutzfahrzeuge AG accepts no liability for any other products.
4. Regulations for avoiding injury and environmental contamination
Health protection precautions

Avoid extended, excessive or repeated skin contact with service products, process materials, thinners and
solvents. Protect your skin using a suitable skin protection agent or protective gloves. Do not use service
products, process materials, thinners or solvents to clean the skin. Apply a greasy skin cream after cleaning
your skin.

INTRODUCTION
Service products and process materials

Do not use any containers intended for food or drink to drain and store service products or process materials.
Comply with local-authority regulations when disposing of service products and process materials.
Coolant
Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority
when disposing of used coolant (mixture of antifreeze and water).
Cleaning the cooling circuit

Do not pour cleaning fluids and rinsing water down the drain if this practice is restricted by specific local reg-
ulations. However, the cleaning fluid and rinsing water must, in all cases, be passed through an oil separator
with a sludge trap.
Cleaning the filter insert

When blowing compressed air through the filter insert, make sure the filter dust is collected by an extractor
system, or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear suitable
rubber gloves or use a skin barrier cream when washing out the element, because cleaning agents have
aggressive grease-dissolving characteristics.
Engine/gearbox oil, filter cartridges, inserts and box-type filters, desiccant cartridges
Filter inserts, cartridges and box-type filters (oil and fuel filters, desiccant cartridges for the air dryer) are
classified as hazardous waste materials. Comply with local-authority regulations when disposing of the above
parts.
Used engine/gearbox oil

Prolonged or repeated skin contact with any type of engine/gearbox oil causes the loss of natural skin oils.
This can result in dry skin, irritation or skin inflammation. In addition to these hazards, used engine oil contains
dangerous materials which can trigger dangerous skin diseases. Wear gloves, especially when changing the
oil.
Dealing with AdBlue®

AdBlue® is a synthetically produced 32.5 % urea water solution used as an NOx reduction additive for diesel
engines with an SCR catalytic converter. AdBlue® is not a hazardous substance but does decompose into
ammonium hydroxide and carbon dioxide when stored for prolonged periods. For this reason, AdBlue® is
classified as a water hazard (water hazard class 1) in Germany and is not allowed to enter sewage or the
ground. Ensure good ventilation in the work place when working on the AdBlue® system. Do not eat, drink
or smoke in the workplace. Avoid skin and eye contact with AdBlue®, thoroughly wash your hands and
use a skin protection cream before taking breaks and before finishing work. If your skin comes into contact
with AdBlue®, wash the skin using water and a skin cleaner, change out of dirty clothes immediately. If
the skin is irritated, consult a doctor. If AdBlue® comes into contact with the eyes, rinse eyes with water
or eye bath solution for at least 10 minutes with the eyelids open, ensuring that contact lenses (if fitted)
are removed beforehand. If problems persist, seek medical assistance. If AdBlue® is swallowed, consult a
doctor immediately. AdBlue® containers should be stored closed in water-tight storage rooms. The storage
temperature must not exceed 25°C. Soak up leaked or spilt AdBlue® using binding agent and dispose of in
the correct manner.
5. Special information for working on the common-rail system
General
– Fuel jets can cut through the skin. Risk of fire due to fuel atomisation.
– Never undo the bolt connections on the high fuel pressure side of the common-rail-system when the engine
is running (high pressure line from the high pressure pump to the rail, at the rail and on the cylinder head to
the fuel injector). Whilst the engine is running, the lines are constantly bearing a fuel pressure of 1800 bar
or more. Before the screw connections are opened, wait at least one minute until depressurisation has
occurred, using MAN-cats to check the depressurisation on the rail as necessary.
– Do not remain in the vicinity of the engine when it is running.
– Do not touch the live parts at the electrical connection of the injectors whilst the engine is running.
– Any change to the original wiring may lead to the limit values of the heart pacemaker regulations being
exceeded, e.g. untwisted fuel injector wiring or insertion of a break box (bushing box).
– Vehicle operators and persons with heart pacemakers are not at risk from systems with MAN Common Rail
engines in approved operation.
– Fuel jets can cut through the skin. Risk of fire due to fuel atomisation.

INTRODUCTION
– Never undo bolt connections on the high fuel pressure side of the common-rail-system when the engine is
running (fuel injection line from the high pressure pump to the rail, at the rail and on the cylinder head to
the fuel injector).
– Do not remain in the vicinity of the engine when it is running.
– Whilst the engine is running, the lines are constantly bearing a fuel pressure of 1800 bar or more.
– Wait for at least one minute before undoing bolt connections to allow the pressure to drop.
– If necessary, check that the pressure has dropped in the rail with MAN-cats.
– Do not touch the live parts at the electrical connection of the injectors whilst the engine is running.
Information for people with pacemakers

– Any change in the original engine cabling may lead to the limit values of the heart pacemaker regulations
being exceeded, e.g. untwisted fuel injector cabling or insertion of a break box (bushing box).
– There is no danger to the driver or any passengers with pacemakers in approved operation.
– Vehicle operators with heart pacemakers are not at risk from systems with MAN Common Rail engines in
approved operation.
– The product in original condition complies with all the currently known limit values for heart pacemakers.
Risk of damage due to ingress of dirt

– The components of the diesel fuel-injection system consist of high-precision parts that are subjected to
extreme loads. Owing to this high level of precision engineering, strict rules of cleanliness must be
followed when working on the fuel system.
– Even particles of dirt as small as 0.002 mm can cause component failure.
Before starting work on the clean side

– Clean the engine and engine compartment while the fuel system is still closed off; when doing so, do not
use a powerful jet to clean the electrical components.
– Drive the vehicle into a clean area of the workshop in which no work is performed that could swirl up dust
(grinding or welding work, brake repairs, brake and power testing, etc.).
– Avoid air movements (possible swirling up of dust through starting of engines, workshop ventilation/heating,
draughts, etc.).
– The area of the fuel system that is still closed must be cleaned and dried by means of compressed air.
– Remove loose dirt particles such as paint flakes and insulating material with a suitable suction device
(industrial vacuum cleaner).
– Cover areas of the engine compartment from which dirt particles could become detached, e.g. tilted cab,
engine compartment of bus engines, with new and clean foil covering sheets.
– Before starting disassembly, wash your hands and put on a clean working overall.
After opening the clean side

– It is not permitted to use compressed air for cleaning.
– Loose dirt must be removed during assembly work using a suitable suction device (industrial vacuum
cleaner).
– Only lint-free cleaning cloths are allowed to be used on the fuel system.
– Clean tools and working equipment before starting work.
– Only tools that are not damaged (e.g. cracked chromium plating) must be used.
– Materials such as cloths, cardboard or wood must not be used when removing and fitting components, as
particles and fibres may become detached from such materials.
– If paint flakes should be produced when undoing connections (e.g. due to painting over the connections),
these must be carefully removed before the bolt connection is finally undone.
– All removed components on the clean side of the fuel system must be covered immediately at their con-
nection openings using suitable caps.
– These covers must remain packaged dust-tight until use and must be disposed of after being used once.
– The components must then be stored carefully in a clean, closed container.
– Never expose these components to used cleaning or testing fluids.
– New parts must only be taken out of the original packaging immediately before use.
– Work on removed components must be performed only at a work place equipped for this purpose.
– If removed parts are shipped, always use the original packaging of the new part.
When performing work on bus engines, the measures described as follows must be strictly followed:
Risk of damage due to ingress of dirt

– Before opening the clean-side fuel system:
Clean the engine areas around the pressure sockets, fuel-injection lines, rail and cylinder head cover with
compressed air.

INTRODUCTION
– Remove the cylinder head cover and then clean the engine areas around the pressure sockets, fuel-injection
lines and rail once again.
– First only undo the pressure pipe sockets:
Undo the pressure pipe socket union nuts and screw them out by four turns.
Lift the pressure pipe sockets with a special tool.
Reason: only remove the pressure pipe sockets completely once the injectors have been removed so that
no dirt can fall into the injectors from above.
– Remove the fuel injectors.
– After removal, rinse out the injectors (with the high-pressure connection bore pointing downwards) using a
cleaning fluid.
– Remove the pressure pipe sockets; to do this, unscrew the pressure pipe socket union nut.
– Clean the injector bore in the cylinder head.
6. Limp-home program for units with electronic control units
General notes
The units have an electronic control system that monitors itself (self-diagnostics) and the unit.
As soon as there is a malfunction, the malfunction is evaluated and one of the following measures is initiated:
– Output of a fault message with a diagnostic memory entry.

– Changeover to suitable substitute function for continuing but limited operation. Have malfunctions remedied
immediately by MAN Customer Service.
– The diagnostic memory entry is output directly in conjunction with MAN-cats.
7. Installation instructions
Assembling pipes
– Pipes must not be mechanically deformed during assembly work; risk of fracture.
Mounting flat seals

– Only use MAN genuine seals
– Make sure that the areas to be sealed are undamaged and clean.
– Do not use adhesive agents or sealing agents. If necessary, to facilitate installation, use a little grease to
stick the seal to the part to be mounted.
– Tighten the bolts evenly to the specified tightening torque.
Mounting O-rings
– Only use MAN genuine O-rings.
– Make sure that the areas to be sealed are undamaged and clean.
Engine overhaul
– The engine's service life is influenced by very different factors. It is therefore not possible to indicate the
exact number of operating hours or miles before a major overhaul is due.
– We are of the opinion that opening an engine or performing a general overhaul is not required, as long as
the engine has good compression values and the following operating values do not deviate considerably
from those determined at start-up.
– Charging pressure
– Exhaust gas temperature
– Coolant and lubricating oil temperatures
– Oil pressure and oil consumption
– Smoke behaviour
The following criteria have considerable influence on the engine's service life:
– Correct performance setting according to deployment
– Correct installation
– Approval of the installation by authorised personnel
– Regular maintenance according to the maintenance schedule

INTRODUCTION
THE ENGINE
Model plate/Model designation
Explanation of the model plate
(1) Engine type (3) Engine serial number

(2) NI/NII rework levels
Explanation of post-processing stages

Rework levels apply to crankshaft bearings, connecting-rod bearings, as well as pistons. The reworking
subassemblies are indicated on the model plate, e. g.:
P = crankshaft - connecting-rod bearing NI or NII
H = crankshaft - crankshaft bearing NI or NII
Explanation of the engine no. (Engine identification number)
Engine no. Classification terms (assignment)

208 Model number according to model code
0042 Day of assembly
501 Assembly order (sequential number on day of assembly)
52B1 The last four digits of the engine no. are production and equipment-spe-
cific data.
Explanation of model designation
Model designa- Explanation Example

tion
D Fuel type Diesel

08 Figure + 100 108 mm bore
3 (Figure x 10) +100 130 mm stroke (rounded)
6 Number of cylinders 6 cylinders
L Turbocharging with turbocharging and intercooler

INTRODUCTION
F Engine installation Engine/stationary/front left-hand drive

L Engine installation Light series
44 Model identifier Rating/speed/approval

INTRODUCTION
Characteristic data
D0836 LFL40
Designation Unit Figures

Emission category Euro 3
Number of cylinders/arrangement 6 cylinder/in-line/upright
Valves per cylinder 4
Engine weight dry kg 625
Injection system Common rail / EDC 7
Direction of rotation as viewed onto flywheel Left
Rated output to ISO 1585-89/491 EEC KW/h.p. 176/240
Bore mm 108
Stroke mm 125
Displacement cc 6871
Firing order 1-5-3-6-2-4
Nominal rpm rpm 2400
Lower idling speed rpm 570
Max. torque at engine speed Nm rpm 925 Nm at 1200 - 1800 rpm
D0836 LFL41

Bore mm 108
Stroke mm 125
D0836 LFL44


INTRODUCTION

Bore mm 108
Stroke mm 125

INTRODUCTION
Description of engine
(1) Charge-air manifold (12) Flywheel housing

(2) Coolant pump (13) Starter motor
(3) Coolant outlet pipe (14) Pressure pipe
(4) Alternator (15) Crankcase yoke
(5) Air compressor (16) High pressure pump
(6) Turbo charger (17) Oil module
(7) EGR adjusting cylinder (18) Charge-air manifold
(8) Fuel Service Centre (FSC) (19) Noise suppression housing
(9) EGR module (exhaust gas recirculation) (20) Vibration damper
(10) Air distributor pipe (21) Refrigerant compressor
(11) EDC control unit (electronic diesel control) (22) Ribbed V-belt disc PTO
Engine, general
The engines described here are liquid-cooled, supercharged, 6-cylinder, 4-stroke diesel engines with exhaust
turbocharging meeting emission standard Euro 3.
The engines operate using the Common Rail high-pressure injection system in conjunction with EDC 7
(Electronic Diesel Control).
Engine monitoring
Various sensors monitor the engine. The sensors are e. g. speed and temperature sensors, which send
information about the various engine operating conditions and states to the EDC control unit.
The EDC control unit operates according to the IPO principle:
I = Input

INTRODUCTION
P = Processing
O = Output
The EDC control unit processes the information received from the sensors and controls the output signals
which are sent to the actuators. The actuators convert the signals into mechanical variables. An actuator is,
for example, the proportional valve on the high pressure pump.
Crankcase
The crankcase and the cylinder block are cast in one piece from special cast iron. The flywheel housing
is located at the rear of the crankcase and the timing case cover is at the front of the crankcase. Both the
flywheel housing and the timing case cover are made of aluminium. The crankshaft seals are installed in the
timing case cover and in the flywheel housing. The crankcase blow-by gases are returned to the combustion
air via an oil separator with pressure relief valve on the suction side of the turbo charger.
Crankshaft
The crankshaft is forged in a die using high-quality, micro-alloyed steel. It has eight cast-on counterweights
for mass balancing. The crankshaft is mounted in seven bearings in the crankcase. The crankshaft journals
and connecting-rod bearing journals are mounted in ready-to-install three-component bearings. They are
axially mounted with contact washers inserted in the crankcase at the 4th bearing seat. The connecting-rod
bearings are supplied with oil via a bore in the crankshaft bearing.
Connecting rods (“cracked” connecting rods)

The “cracked” connecting rods are precision forged in a die using quenched and tempered steel. The large
connecting-rod eye is split diagonally by “cracking” the connecting-rod bearing cover. The surface structure
generated from this “cracking” results in a tooth engagement effect between the connecting-rod bearing cover
and the connecting rod with a precise, non-interchangeable fit and high lateral stability.
Piston
Three-ring pistons made of special die-cast aluminium are used; they feature a cast-in ring support for the
uppermost piston ring. The pistons have a cast-in cooling duct for reducing the thermal load when the output
is high. They are cooled by an oil jet from the oil nozzles. The ring set comprises one taper-face ring and one
full keystone ring as compression rings, as well as one double-bevelled slotted oil control ring with spiral-type
expander as an oil scraper ring.
Cylinder head
Series D08 engines are equipped with a single-piece cylinder head. The cylinder head is made from special
cast iron and is fitted with shrink-fitted valve seat rings and pressed-in, exchangeable valve guides. The
valve guides have valve stem seals at all four valves. The valves are actuated by individually exchangeable
rocker arms on rocker arm shafts. The cylinder head is secured with high-strength external hexagon round
screws (cylinder head bolts). The single-layer steel cylinder head gasket has a specially designed combustion
chamber seal. There is an elastomer seal between the cylinder head and cylinder head cover.
Camshaft
The camshaft is forged from steel and induction hardened. It is mounted in seven bearings in the crankcase.
The camshaft is driven by the straight-toothed crankshaft gear being engaged on the camshaft gear.
Engine lubrication
The engine is lubricated by pressure lubrication for all bearing points. The engine oil filter and the oil cooler
are grouped together as an oil module. The oil level is measured in the oil sump with the help of an oil dipstick
and via an oil level sensor.
Cooling system
The cooling circuit is a thermostat-controlled forced circulation cooling system with a maintenance-free coolant
pump driven by a ribbed V-belt. The thermostat is a exchangeable insert with wax expansion elements. Lo-
cated at the thermostat housing is a connection for heating flow.
Intake/exhaust system
The three-section exhaust manifold is cast from high temperature-resistant nodular cast iron and secured to
the cylinder head using heat-resistant bolts. The maintenance-free turbo charger is mounted on the middle
exhaust manifold. The exhaust manifold is installed after the turbo charger. The turbo charger is lubricated
by the engine oil circuit.

INTRODUCTION
Fuel system
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 (FSC). 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 low-pressure system also includes a heating element and the flame-start system.
The interface to the high-pressure system is the fuel supply pump.
High-pressure system
The high-pressure system consists of the flow-rate-controlled high pressure pump with flange-mounted fuel
supply pump and the pressure pipe with rail pressure sensor and pressure-limiting valve. Solenoid valve-con-
trolled injectors with pressure pipe sockets and high-pressure lines which meet the necessary requirements
are also installed.
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. The injection quantity is available in the pressure pipe for injection via the injectors. The high
pressure pump supply quantity is controlled by a proportional valve. The injection point and the injection
quantity are calculated in the EDC control unit and implemented by the solenoid valve-controlled injectors.
The solenoid valve-controlled injectors allow for multiple injections:
1 Pre-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.
3 Post-injection to reduce the pollutant emissions, main constituent NOX.
Always ensure absolute cleanliness both in and around the working area whenever carrying out work on the
highly sensitive high-pressure system.
Injectors
The injectors are controlled by solenoid valves. They are arranged vertically in the cylinder head and clamped
with a pressure flange in the cylinder head.
Flame-start system
Special equipment includes a flame-start system which serves as a cold starting aid. The flame-start system
consists of a solenoid valve and a rapid flame glow plug built into the charge-air manifold. After various
parameter enquiries (via sensors), the flame glow plug and the corresponding solenoid valve are activated
by the EDC in order to heat the intake air. The fuel is supplied by the fuel service centre (FSC).
Starter motor
The starter motor is a reduction-gear starter motor with a free-engaging pinion construction. Free-engaging
means that the starter motor pinion is mounted on the housing in the starter motor without a counter bearing.
A mechanical relay is mounted in the starter motor for starter motor control.
Alternator
A compact, powerful, low-noise alternator is mounted for power generation. The alternator is equipped with
a multifunction controller. The voltage is controlled depending on the temperature, the battery charge level
and the current power consumption. The alternator speed is four times the engine speed.
Air compressor
The air compressor is driven by a straight-geared camshaft gear.
Front PTO
The PTO serves as an alternator drive and consists of the housing, the PTO shaft with ball bearings and the
ribbed V-belt disc. The PTO is indirectly driven by the air compressor gear. Two cast lugs have been posi-
tioned at each power take-off shaft and at the air compressor gear. The clutch drive plate with its cross-slots
engages with these lugs as a flexible connection, thus ensuring a deadweight effect. Mounted on the PTO
shaft is the ribbed V-belt disc which drives the alternator via the ribbed V-belt.
Rear PTO
This PTO is mounted at the rear of the flywheel housing. In the flywheel housing there are helical intermediate
gears and intermediate gear bolts fitted between the flywheel housing and the retaining plate. The PTO is
driven at the rear indirectly by an additional crankshaft gear on the flywheel side of the crankshaft. The power

INTRODUCTION
is transferred from the crankshaft gear to the PTO via the intermediate gears. The rear PTO serves as the
permanent power source for e.g. the hydraulic pumps.
Steering pump
The steering pump is mounted at the rear of the air compressor, in accordance with its design.

ENGINE ELECTRONICS
ENGINE ELECTRONICS
(1) Speed sensor (8) Heating element

(2) Oil level sensor (9) Pressure sensor
(3) Flame glow plug (10) Rail pressure sensor
(4) Temperature sensor (11) Pressure sensor
(5) Temperature sensor (12) Proportional valve
(6) EGR adjusting cylinder (13) Charging pressure sensor
(7) Speed sensor

ENGINE ELECTRONICS
CABLE HARNESS
Removing and installing the cable harness
(1) Earth cable (3) Cable duct

(2) Cable duct cover (4) Engine cable harness
Technical data
Cable lug mounting nut ......................................... M5 ..................................................................... 5 Nm
Mounting nut, terminal B+ ..................................... M8 ....................................................................13 Nm
Important information
CAUTION
Danger of injury on sharp-edged projections on the cable ties
• Only tighten and cut off cable ties with Cable tie pliers [1]
WARNING
Electrical cable damage due to over-tightening
• Follow the operating instructions for the Cable tie pliers [1]
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50 %
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench

ENGINE ELECTRONICS
Note
Mark the installation position of the cable harness cable ties before disassembly.
Install the cable ties as marked after installing the cable harness.
Special tools
[1] Cable tie pliers 08.02960-0100
• Tightening and cutting the cable ties

ENGINE ELECTRONICS
Removing the cable harness Disconnecting the alternator electrical connec-

tion
Disconnecting the electrical connection from the
speed sensor
• Unlock and pull off the compact plug (3)

• Disconnect the cable tie (2)
• Unscrew the mounting bolt (1) • Unscrew the terminal B+ mounting nut (1)
• Disconnect the electrical connection (2) • Free the cable harnesses
Disconnecting the refrigerant compressor elec- Disconnecting the charging pressure sensor
trical connection electrical connection
• Disconnect the electrical connection (1) • Disconnect the electrical connection (1) of the
charging pressure sensor (2)
Disconnecting the oil level sensor electrical con-
nection Disconnecting the pressure sensor electrical
connection
• Disconnect the electrical connection (2)

• Free the oil level sensor cable harness (1) • Disconnect the electrical connection (1) and pres-
sure sensor (2)

ENGINE ELECTRONICS
Disconnecting the electrical connection to the Disconnecting the air distributor pipe tempera-
proportional valve ture sensor electrical connection
• Disconnect the proportional valve (2) electrical • Disconnect the temperature sensor (1) electrical
connection (1) connection (2)
Disconnecting the rail pressure sensor electrical Disconnecting the flame-start system electrical
connection connections
• Disconnect the rail pressure sensor (1) electrical • Unscrew the mounting nut (2)
connection (2) • Remove the cable lug (1) along with the mounting
nut (2)
Disconnecting the EGR module temperature • Disconnect the electrical connection (3) for the
sensor electrical connection solenoid valve (4)
• Free the cable harnesses
• Disconnect the temperature sensor (2) electrical

connection (1)

ENGINE ELECTRONICS
Disconnecting the fuel service centre electrical Removing the speed sensor
connections
• Remove the speed sensor (1) from the flywheel

housing (2)
Disconnecting the EDC control unit electrical

connections
• Disconnect the pressure sensor (1) electrical con-

nection
• Disconnect the heating element electrical connec-
tion (3)
• Disconnect the cable tie (2)
• Unlock and pull off plugs (1), (2) and (3)
Disconnecting the proportional valve electrical
connection Freeing the engine cable harness
• Disconnect the proportional valve (2) electrical • Free the engine cable harness (1)
connection (1)
• Free the proportional valve (2) cable harness (3)

ENGINE ELECTRONICS
Removing the cable duct cover Removing the cable duct
• Open the locking pin (1) a quarter turn • Unscrew the mounting bolts (1)
• Remove the cable duct cover (2) • Remove, set aside and secure the cable duct (2)
Disconnecting the electrical connections to the

plug consoles
• Disconnect the plug console electrical connections

(1)
Disconnecting the EGR adjusting cylinder elec-

trical connection
• Disconnect the EGR adjusting cylinder electrical

connections (1)

ENGINE ELECTRONICS
Installing the cable harness Attaching the cable duct cover
Attaching the cable duct
• Put on the cable duct cover (2)

• Close the locking pin (1) a quarter turn
• Position the cable duct (2) with the cable harness
• Screw in and tighten the mounting bolts (1) Routing the engine cable harness
Connecting the EGR adjusting cylinder electrical

connection
• Route the cable harness (1) so that it is free of

tension and kinks and does not chafe
• Secure the cable harness (1) with cable ties
• Connect the EGR adjusting cylinder electrical con-
nections (1)
Connecting the plug console electrical connec-

tions
• Connect the plug console electrical connections

(1)

ENGINE ELECTRONICS
Connecting the EDC control unit electrical con- Connecting the proportional valve electrical
nections connection
• Connect the proportional valve (2) electrical con-

WARNING
nection (1)
Risk of irreparable EDC control unit
• Route the cable harness (3) so that it is free of
damage
tension and kinks and does not chafe
• When installing the plugs, first fully
open the lock and then insert and lock Connecting the fuel service centre electrical
the plugs connections
• Insert and lock the plugs (1), (2) and (3) in the EDC
control unit
• Route the cable harnesses and secure using cable
ties
Installing the speed sensor
• Install the speed sensor (1) in the flywheel housing

(2)
• Connect the pressure sensor electrical connection

(1)
• Connect the heating element electrical connection
(3)
• Route the cable harness so that it is free of tension
and kinks and does not chafe
• Secure the cable harnesses with cable ties (2)

ENGINE ELECTRONICS
Connecting the flame-start system electrical Connecting the EGR module temperature sensor
connections electrical connection
• Route the cable harness so that it is free of tension • Connect the temperature sensor (2) electrical con-
and kinks and does not chafe nection (1)
• Position the cable lug (1) along with the mounting
nut (2) on the flame glow plug Connecting the rail pressure sensor electrical
• Screw on the mounting nut (2) and tighten with connection
5 Nm
• Connect the solenoid valve (4) electrical connec-
tion (3)
Connecting the air distributor pipe temperature

sensor electrical connection
• Connect the rail pressure sensor (1) electrical con-

nection (2)
Connecting the proportional valve electrical

connection
• Connect the temperature sensor (1) electrical con-

nection (2)

nection (1)

ENGINE ELECTRONICS
Connecting the pressure sensor electrical con- Connecting the alternator electrical connection
nection

• Connect the pressure sensor (2) electrical con- and kinks and does not chafe
nection (1) • Screw on the mounting nut (1) with terminal B+
and tighten with 13 Nm
Connecting the charging pressure sensor elec- • Insert and lock the compact plug (3)
trical connection • Secure the cable harnesses with cable ties (2)
Connecting the oil level sensor electrical con-

nection
• Connect the charging pressure sensor (2) electri-

cal connection (1)
• Route the oil level sensor cable harness (1) so that

it is free of tension and kinks and does not chafe
• Connect the electrical connection (2)

ENGINE ELECTRONICS
Connecting the refrigerant compressor electri-

cal connection
Connecting the speed sensor electrical connec-

tion

• Position the clamp, screw in the mounting bolt (1)
and tighten it

ENGINE ELECTRONICS
ENGINE ELECTRONICS
Removing and installing the engine electronics
Additional jobs
– Removing and installing the cable harness, see 27
– Read-out diagnostic memory using MAN-cats®
(1) Speed sensor (8) Heating element

(2) Oil level sensor (9) Pressure sensor
(3) Flame glow plug (10) Rail pressure sensor
(4) Temperature sensor (11) Pressure sensor
(5) Temperature sensor (12) Proportional valve
(6) EGR adjusting cylinder (13) Charging pressure sensor
(7) Speed sensor
Technical data
Oil level sensor (2)................................................ M22x1.5 ............................................................25 Nm
Flame glow plug (3) .............................................. M20x1.5 ............................................................25 Nm
Temperature sensor (4)......................................... M16x1.5 ............................................................45 Nm
Pressure sensor (9) .............................................. M18x1.5 ............................................................45 Nm
Rail pressure sensor (10)...................................... M18x1.5 ............................................................70 Nm
Pressure sensor (11) ............................................ M18x1.5 ............................................................45 Nm

ENGINE ELECTRONICS
CAUTION
WARNING
WARNING
WARNING
Restricted driving mode due to defective entries in the diagnostic memory
• Before removing switches or sensors, read out and document the diagnostic memory
• Always install switches and sensors with new O-rings or seals
• After installing switches or sensors, read out the diagnostic memory and delete it if necessary
Special tools

COOLING SYSTEM
COOLING SYSTEM
Cooling system (D0836 LFL40/41)
(1) Mounting bolt coolant outlet pipe

(2) Coolant outlet pipe
(3) Fan
(4) Air compressor coolant supply line
(5) Air compressor coolant return line
(6) Thermostat housing
(7) Thermostat
(8) Cooling water pipe
(9) Heating supply
(10) Coolant pump
(11) Coolant manifold
(12) Mounting bolt for coolant manifold

COOLING SYSTEM
Cooling system (D0836 LFL44)
(1) Fan (7) Thermostat housing

(2) Mounting bolt coolant outlet pipe (8) Heating supply
(3) Coolant outlet pipe (9) Coolant pump
(4) Thermostat (10) Coolant manifold
(5) Air compressor coolant supply line (11) Mounting bolt for coolant manifold
(6) Air compressor coolant return line

COOLING SYSTEM
FAN
Removing and installing the fan (attachment to coolant pump)
(1) Mounting bolt fan clutch (4) Fan lock nut

(2) Fan (5) Fan clutch
(3) Ribbed V-belt disc
WARNING
WARNING
Malfunction if the fan clutch is set aside incorrectly
• Always store fan clutch in installation position

COOLING SYSTEM
Removing the fan Installing the fan

Removing the fan together with the fan clutch Installing the fan clutch
• Unscrew the mounting bolts (3) from the ribbed • Insert the fan clutch (1) into the fan (2)
V-belt disc (4) • Screw on and tighten the new mounting nuts (3)
• Remove the fan (2) together with the fan clutch (1)
Attaching the fan together with the fan clutch
Removing the fan clutch
• Position the fan (2) together with the fan clutch (1)
• Unscrew lock nuts (3) on the ribbed V-belt disc (4)
• Remove the fan clutch (1) from the fan (2) • Screw in and tighten the mounting bolts (3)

COOLING SYSTEM
Removing and installing the fan (variant without hydraulic pump)
(1) Fan clutch (3) Mounting nut

(2) Fan (4) Intermediate flange
Technical data
Mounting nut (3) ................................................... M8 ....................................................................22 Nm
WARNING
WARNING

COOLING SYSTEM

Removing the fan and the intermediate flange Installing the fan clutch
• Unscrew the mounting bolts (1) • Insert the fan clutch (1) into the fan (2)
• Remove the fan (2) • Screw in new mounting nuts (3) and tighten with
• Unscrew the mounting bolts (4) 22 Nm
• Remove the intermediate flange (3)
Attaching the fan and the intermediate flange
• Position the intermediate flange (3) on the vibra-

• Unscrew the mounting nuts (3) tion damper
• Remove the fan clutch (1) from the fan (2) • Screw in and tighten the mounting bolts (4)
• Position the fan (2)
• Screw in and tighten the mounting bolts (1)

COOLING SYSTEM
Removing and installing the fan (variant with hydraulic pump)

Additional jobs
– Removing and installing the belt drive (variant with hydraulic pump), see 106
(1) Fan clutch (4) V-belt pulley

(2) Fan (5) Intermediate flange
(3) Mounting nut
Technical data
Mounting nut (3) ................................................... M8 ....................................................................22 Nm
WARNING
WARNING

COOLING SYSTEM

Removing the fan and the intermediate flange Installing the fan clutch
• Insert the fan clutch (1) into the fan (2)

• Screw in new mounting nuts (3) and tighten with
22 Nm
Attaching the fan and the intermediate flange
• Unscrew the mounting bolts (1)

• Remove the fan (2)
• Remove the V-belt pulley (4) and the intermediate
flange (3)
• Position the intermediate flange (3) and the V-belt

pulley (4) on the vibration damper
• Unscrew the mounting nuts (3) • Screw in and tighten the mounting bolts (5)
• Remove the fan clutch (1) from the fan (2) • Position the fan (2)

COOLING SYSTEM
COOLANT MANIFOLD
Removing and installing the coolant manifold
Additional jobs
– Removing and installing the fan (attachment to coolant pump), see 43
– Removing and installing the fan (variant with hydraulic pump), see 47
– Removing and installing the fan (variant without hydraulic pump), see 45
– Removing and installing the belt drive (variant without Frigoblock alternator), see 97
– Removing and installing the belt drive (variant with stretchy belt), see 109
– Flame-start system protective sleeves, see 185
– Removing and installing the flame-start system, see 187
(1) Coolant line heating supply line (4) Bracket

(2) Coolant pump (5) Coolant outlet pipe
(3) Coolant manifold (6) O-ring
Technical data
Coolant line hollow screw...................................... M14x1.5 ............................................................35 Nm
Coolant line union nut .....................................................................................................................35 Nm
Opening temperature of thermostat .................................................................................................. 83 °C
Service products
Radiator antifreeze .......................................................See Maintenance and Service Product Regulations

COOLING SYSTEM
WARNING
Thermostats with the incorrect opening temperature cause engine damage
• Always use thermostats with the specified opening temperature
WARNING
Note
Different coolant manifolds are installed.
Removal and installation are essentially the same.

COOLING SYSTEM
Removing the coolant manifold Removing the charge-air manifold
Removing the hose

• Remove the charge-air manifold (4) with the seal
• Unscrew the hollow screw (2) and remove it with (2)
the seals • Pull the coupling pipe (3) out of the non-return
• Set the hose (1) aside valve body
• Clean the area to be sealed
Removing the heating flow bracket
Removing the air compressor line
• Unscrew the mounting bolt (1)

Removing the charging pressure sensor • Remove the clamps (3)
• Remove the air compressor line (1)
Removing the coolant pump coolant line

• Unscrew the mounting bolts (3) and remove the
• Unlock and remove the plug connectors for the
coolant line (2) by pressing the spring clip (1)

COOLING SYSTEM
Removing the thermostat housing coolant line Removing the coolant outlet pipe
• Unlock and remove the plug connectors for the • Unscrew the mounting bolts (3)
coolant line (2) by pressing the spring clip (1) • Remove the bracket (1)
• Remove the coolant outlet pipe (2) from the ther-
Removing the coolant lines mostat housing
Removing the thermostat
• Remove the clamps (5)

• Unscrew hollow screw (6) and remove with seals
• Unscrew the union nut on the coolant line (3)
• Unlock plug connectors (1) and (7) by pressing the • Remove the thermostat (2) with O-ring (3) from the
spring clips (2) thermostat housing (1)
• Remove coolant lines (3) and (4) • Clean the area to be sealed

COOLING SYSTEM
Removing the heating flow coolant line Removing the coolant pipe (variant without EGR
module)

• Unscrew the hollow screw (1) and remove with • Unscrew the mounting bolts (1)
seals (2) • Remove the coolant pipe (2) with seals (4)
• Remove the coolant line (3) • Take out coupling pipe (3)
Removing the coolant manifold
• Mark the installation position of the mounting

bolts (2)
• Remove coolant manifold (3) with seal (1)

COOLING SYSTEM
Installing the coolant manifold Attaching the heating flow coolant line
Installing the coolant pipe (variant without EGR

module)
• Position the coolant line (3)

• Screw in the hollow screw (1) with new seals (2)
and then tighten it
• Thinly apply Radiator antifreeze on the contact • Screw in and tighten the mounting bolt (4)
surfaces of the new coupling pipe (3)
• Insert coupling pipe (3) into the thermostat housing Installing the thermostat
• Position the coolant pipe (2) with new seals (4)
Attaching the coolant manifold
• Insert the thermostat (2) in the thermostat housing

(1) with the TOP mark facing upwards
• Insert a new O-ring (3)
• Position the coolant manifold (3) with new seal (1) Attaching the coolant outlet pipe
• Screw in and tighten the new mounting bolts (2)
as marked
• Position the coolant outlet pipe (2) and bracket (1)

at the thermostat housing

COOLING SYSTEM
Attaching the thermostat housing coolant line Attaching the coolant lines
WARNING WARNING
Component damage due to loose plug Component damage due to loose plug
connector connector
• Check plug connector of the coolant line • Check the coolant line plug connectors
for secure fit after securing for secure fit after securing
• Attach the plug connector for the coolant line (2) • Attach the coolant lines (3) and (4)
• If required, undo the plug connector (2) by press- • Undo the plug connectors (1) and (7) if necessary
ing the spring clip (1), re-insert and secure by pressing the spring clips (2), then reinsert and
secure
Attaching the coolant pump coolant line • Screw in the hollow screw (6) with new seals and
then tighten it with 35 Nm
• Screw on the coolant line union nut (3) and tighten
with 35 Nm
• Attach the clamp (5).
Attaching the air compressor line
WARNING
Component damage due to loose plug
connector
• Check plug connector of the coolant line
for secure fit after securing
• Attach the air compressor line (1)
• Attach the plug connector for the coolant line (2)
• Position the clamps (3)
• If required, undo the plug connector (2) by press-
ing the spring clip (1), re-insert and secure

COOLING SYSTEM
Attaching the charge-air manifold Attaching the heating flow bracket
• Thinly apply Radiator antifreeze on the new cou- • Screw in and tighten the mounting bolt (1)
pling pipe (3)
• Insert the coupling pipe (3) into the non-return Attaching the hose
valve body
• Position the charge-air manifold (4) with a new
seal (2)
Attaching the charging pressure sensor
• Position the hose (1)

• Screw in the hollow screw (2) with new seals and
then tighten it
• Insert the charging pressure sensor (2) with a new

O-ring

COOLING SYSTEM
THERMOSTAT WITH THERMOSTAT HOUSING

Removing and installing the thermostat with thermostat housing
Additional jobs
(1) Bracket (5) Bulkhead fitting

(2) Coolant outlet pipe (6) Thermostat housing
(3) O-ring (7) Coupling pipe
(4) Thermostat (8) Seal
Technical data
Bulkhead fitting (5)................................................ M14x1.5 ............................................................35 Nm
Opening temperature of thermostat (4) ............................................................................................. 83 °C
Service products
Radiator antifreeze .......................................................See Maintenance and Service Product Regulations
Loctite 648 ........................................................................................................................ 04.10160-9164
WARNING
Thermostats with the incorrect opening temperature cause engine damage
• Always use thermostats with the specified opening temperature

COOLING SYSTEM
WARNING

COOLING SYSTEM
Removing the thermostat with thermo- Removing the charge-air manifold

stat housing
Removing the hose

(2)
• Unscrew the hollow screw (2) and remove it with • Pull the coupling pipe (3) out of the non-return
the seals valve body
• Set the hose (1) aside • Clean the area to be sealed
Removing the heating flow bracket Removing the air compressor line
• Unscrew the mounting bolt (1) • Unscrew the mounting bolts (2)
Removing the charging pressure sensor • Remove the air compressor line (1)
Removing the thermostat housing coolant line

charging pressure sensor (2) • Unlock and remove the plug connectors for the

COOLING SYSTEM
Removing the coolant outlet pipe Removing the heating flow coolant line
• Unscrew the mounting bolts (3) • Unscrew the mounting bolts (4)
• Remove the bracket (1) • Unscrew the hollow screw (1) and remove with
• Remove the coolant outlet pipe (2) from the ther- seals (2)
mostat housing • Remove the coolant line (3)
Removing the thermostat housing
Removing the thermostat
• Mark the installation position of the mounting bolts

• Remove the thermostat (2) with O-ring (3) from the (1) and (2)
thermostat housing (1) • Unscrew the mounting bolts (1) and (2)
• Clean the area to be sealed • Remove the thermostat housing (3) with seal (4)
from the timing case

COOLING SYSTEM
Dismantling the thermostat housing Installing the thermostat and thermostat

housing
Assembling the thermostat housing
• Unscrew the bulkhead fitting (1) and remove with

the seal (2)
• Pull the coupling pipe (3) out of the thermostat
housing (4) • Thinly apply Loctite 648 on the thread of the bulk-
head fitting
• Screw in the bulkhead fitting (1) with a new seal
(2) and tighten with 35 Nm
• Thinly apply Radiator antifreeze on the new cou-
pling pipe (3)
• Insert the coupling pipe (3) into the thermostat
housing (4)
Attaching the thermostat housing
• Position the thermostat housing (3) with a new

seal (4) on the timing case
• Screw in the new mounting bolts (1) and (2) as
marked
• Tighten the mounting bolts (1) and (2)

COOLING SYSTEM
Attaching the heating flow coolant line Attaching the thermostat housing coolant line
• Position the coolant line (3)

WARNING
and then tighten it
connector
• Screw in and tighten the mounting bolt (4)
• Check plug connector of the coolant line
Installing the thermostat for secure fit after securing

• If required, undo the plug connector (2) by press-
ing the spring clip (1), re-insert and secure
• Insert the thermostat (2) in the thermostat housing

(1) with the TOP mark facing upwards
• Insert a new O-ring (3)
Attaching the coolant outlet pipe

• Position the coolant outlet pipe (2) and bracket (1)

at the thermostat housing

COOLING SYSTEM
Attaching the charge-air manifold Attaching the heating flow bracket
• Thinly apply Radiator antifreeze on the new cou- • Screw in and tighten the mounting bolt (1)
pling pipe (3)
valve body
seal (2)

then tighten it

O-ring

COOLING SYSTEM
COOLANT PUMP
Removing and installing the coolant pump
Additional jobs
(1) Mounting bolt (4) Coolant pump

(2) Ribbed V-belt disc (5) Seal
(3) Mounting bolt (6) Bulkhead fitting
Technical data
Service products
Loctite 648 ........................................................................................................................ 04.10160-9164
WARNING

COOLING SYSTEM
Removing the coolant pump Removing the air compressor line
Removing the ribbed V-belt

CAUTION • Remove the air compressor line (1)
The ribbed V-belt tensioner is under
Removing the ribbed V-belt disc
spring tension
• Brace the ribbed V-belt tensioner to pre-
vent it from springing back unintention-
ally
• Undo the mounting bolts (3)

• Turn the ribbed V-belt tensioner (2) counter clock-
wise until the stop and hold it
• Remove the ribbed V-belt (1)
• Carefully slacken the ribbed V-belt tensioner (2)
Removing the coolant pump coolant line

• Pull off the ribbed V-belt disc (2)
Removing the coolant pump
• Unlock and remove the plug connectors for the


bolts (1)
• Remove the coolant pump (2) with the seal (3)

COOLING SYSTEM
Detaching the bulkhead fitting Installing the coolant pump

Installing the bulkhead fitting
• Unscrew the bulkhead fitting (1) and remove with

the O-ring (2)
• Thinly apply Loctite 648 on the thread of the bulk-
head fitting (1)
• Screw in the bulkhead fitting (1) with O-ring (2) and
tighten with 35 Nm
Attaching the coolant pump
• Position the coolant pump (2) with a new seal (3)

as marked

COOLING SYSTEM
Attaching the ribbed V-belt disc Attaching the air compressor line
• Position the ribbed V-belt disc (2) • Attach the air compressor line (1)
• Screw in the new mounting bolts (1) and tighten • Position the clamps (3)
them by hand • Screw in and tighten the new mounting bolts (2)
Attaching the coolant pump coolant line Attaching the ribbed V-belt
WARNING CAUTION
Component damage due to loose plug The ribbed V-belt tensioner is under
connector spring tension
• Check plug connector of the coolant line • Brace the ribbed V-belt tensioner to pre-
for secure fit after securing vent it from springing back unintention-
ally
• If required, undo the plug connector (2) by press- • Turn the ribbed V-belt tensioner (2) counter clock-
ing the spring clip (1), re-insert and secure wise until the stop and hold it
• Fit the ribbed V-belt (1)
• Tighten the mounting bolts (3)

COOLING SYSTEM
Dismantling and assembling the coolant pump (open impeller variant)

Additional jobs
– Removing and installing the coolant pump, see 65
(1) Housing coolant pump (4) Bearing

(2) Axial face seal (5) Circlip
(3) Impeller (6) Hub
Technical data
Impeller dimensions (3) - housing coolant pump (1)......................................................... 33.10 - 33.30 mm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
WARNING

COOLING SYSTEM
Special tools
[3] Depth gauge (electronic) 08.71195-9003
• Checking the dimensions from impeller to coolant

pump housing in conjunction with:
• Measuring fixture [4]
[4] Measuring fixture 08.71109-0000
• Checking the dimensions from impeller to coolant

pump housing
[5] Separator 08.99605-9003
• Pressing off the hub in conjunction with:

• Pressing pin [6]
[6] Pressing pin 80.99617-0029
• Pressing out the axial face seal

• Pressing out the bearing
• Pressing off the hub
[7] Press-in mandrel 80.99617-0191
• Pressing in the axial face seal in conjunction with:

• Washer [9]
• Plug-on handle [8]
• Washer [12]
[8] Plug-on handle 80.99604-0344
• Pressing in the axial face seal

• Pressing on the hub
• Pressing in the bearing
[9] Washer 80.99617-0144


COOLING SYSTEM
[10] Pressing sleeve 80.99604-0432

• Washer [9]
• Sleeve [11]
• Washer [12]
[11] Sleeve 80.99616-0133
• Pressing the bearing in and out

[12] Washer 80.99616-0134
• Pressing on the impeller

[13] Press tool 80.99604-0461
• Determining the installation dimensions of the

impeller

COOLING SYSTEM
Dismantling the coolant pump Removing the hub of the coolant pump
Determining the installation dimensions of the

impeller
• Put Separator [5] (1) below the hub (3) and tension
it
• Place Separator [5] (1) on the hydraulic press
Note counter supports
Press-on tool must be positioned on the • Press the coolant pump (4) with the Pressing
surface after adjusting the impeller pin [6] (2) out of the hub (3)
The internal hexagonal bolt must be posi-
Removing the circlip
tioned on the hub shaft after adjustment.
• Place the Press tool [13] (1) onto the impeller (4)
• Screw in internal hexagonal bolt (2) until it is
against the hub shaft (3); during this, Press
tool [13] (1) must not lift off the impeller (4)
Measuring the determined installation dimen-

sions
• Determine and make a note of dimension A be-

tween the upper edge of the internal hexagonal
bolt (1) and the press-on tool (2) using Depth
gauge (electronic) [3]
• Remove the circlip (1) from the coolant pump (2)

COOLING SYSTEM
Removing the impeller Assembling the coolant pump

Installing the bearing
CAUTION
Impeller splits when pressed out of the
bearing WARNING
• Wear protective goggles and protective Component damage due to excessive
gear, if needed cover the impeller pressing
• Carefully press bearing until the stop,
• Insert the coolant pump housing (2) in Sleeve [11] do not press more, since the coolant
(4) pump housing might deform or break
• Press the bearing (3) out of the coolant pump
housing (2) using Pressing pin [6] • Assemble the special tool consisting of the Press-
• Remove the impeller (1) ing sleeve [10] (3), Plug-on handle [8] (1) and
Washer [9] (2)
Removing the axial face seal • Put the coolant pump housing (5) on the
Sleeve [11] (6) and align centred to the bore
• Carefully press in the bearing (4) with the special
tool until the stop
• Press the axial face seal (1) out of the coolant

pump housing (2) using Pressing pin [6]

COOLING SYSTEM
Installing the circlip Pressing on the hub of the coolant pump
• Install the circlip (1) from the coolant pump (2)

Note
Verify correct seat of circlip (1), if needed, remove
Perform procedure with a second spe-
and install the circlip again.
cialised person
Bearing is supported by Washer [12].
• Assemble the special tool consisting of the Press-

ing sleeve [10] (3), the Plug-on handle [8] (1) and
the Washer [9] (2)
• Put the hub shaft with the impeller side on the
Washer [12] (5) and hold straight
• Use the special tool to press the hub (1) flush on
the bearing (2)

COOLING SYSTEM
Installing the axial face seal Verifying the determined installation dimensions
• Check dimension A between the upper edge of

the internal hexagonal bolt (1) and the press-on
tool (2) using Depth gauge (electronic) [3]
• If needed, adjust dimension A to the recorded
size, see Measuring the determined installation
dimensions, 72
Pressing on the impeller
• Thinly apply a mixture from 50 % water and

50 % Radiator antifreeze on the axial face seal (2)
and the coolant pump shaft
• Place the hub centrally on the Washer [12] (4)
• Assemble the special tool (1), consisting of
Plug-on handle [8], Washer [9] and Press-in
mandrel [7]
• Press axial face seal (2) into the coolant pump
housing (3) until the stop using the special tool
WARNING
Component damage if pressed-on too
far
• Do not press on the impeller too far,
because it cannot be pulled off without
being damaged otherwise
• Place the coolant pump housing (3) with the hub

side onto Washer [12] (4)
• Carefully press on the impeller (2) with the Press
tool [13] (1), until the internal hexagonal bolt is
against the hub shaft.

COOLING SYSTEM
Checking the dimension from the impeller to the

coolant pump housing
• Check dimension A with Depth gauge (elec-

tronic) [3] in conjunction with Measuring fixture [4]
The allowed dimension A between the im-
peller (2) and the coolant pump housing (1) is
33.10 - 33.30 mm
If dimension A exceeds 33.10 - 33.30 mm, carefully

press the impeller (2) further.
If dimension A is less than 33.10 - 33.30 mm, pull

off the impeller (2) and press on a new impeller (2).

COOLING SYSTEM
Dismantling and assembling the coolant pump (closed impeller variant)

Additional jobs
(1) Coolant pump housing (4) Bearing of coolant pump

(2) Glide ring (5) Circlip
(3) Impeller (6) Coolant pump hub
Technical data
Gap dimension of the impeller (3) .................................................................................................. 0.5 mm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002

COOLING SYSTEM
Special tools
[14] Separator 08.99605-9003
• Pressing off the impeller
[15] Three-arm extractor 08.99605-9014
• Removing the hub of the coolant pump
• Pressing out the axial face seal of the coolant

pump
• Pressing out the bearing
[17] Plug-on handle 80.99617-0187
• Pressing in the axial face seal of the coolant pump

in conjunction with:
• Press-in mandrel [19]
• Washer [18]
[18] Washer 80.99617-0144
[20] Feeler gauge 80.99607-6019

COOLING SYSTEM
Dismantling the coolant pump Removing the bearing
Removing the hub of the coolant pump
• Position the coolant pump (3) on the counter

sleeve (1)
• Brace the impeller of the coolant pump (1) • Press out the bearing (2) with Press-in man-
• Pull off the hub (3) with Three-arm extractor [15] drel [16]
• Detach the circlip (2) from the coolant pump (1)
Removing the axial face seal
Removing the impeller
• Press the axial face seal (2) out of the coolant

• Position the Separator [14] (2) underneath the pump housing (1) with Press-in mandrel [16]
impeller (3)
• Place Separator [14] (2) on counter supports
• Press the coolant pump (1) out of the impeller (3)
with Press-in mandrel [16]

COOLING SYSTEM
Assembling the coolant pump Attaching the hub of the coolant pump
Installing the bearing
• Press the hub (2) flush on the bearing (1)
• Press the bearing (2) into the coolant pump hous- Pressing on the impeller
ing (1) until the stop
• Attach the circlip (3)
Installing the axial face seal
• Position the coolant pump (2) on the counter

sleeve
• Insert the Feeler gauge [20] (1) with 0.5 mm mea-
surement sheet between the impeller (3) and the
• Thinly apply a mixture of 50 % water and 50 % Ra- coolant pump housing (2)
diator antifreeze on the axial face seal (2) and the • Press on the impeller (3) until you reach a gap
coolant pump shaft dimension of 0.5 mm between the coolant pump
• Assemble the special tool, consisting of Plug-on housing (2) and the impeller (3)
handle [17] (3), Washer [18] and Press-in man- • Turn the impeller and check the gap dimension at
drel [19] multiple locations
• Press axial face seal (2) into the coolant pump
housing (1) until the stop using the special tool

ADD-ON UNITS
ADD-ON UNITS
(1) 1-cylinder air compressor (7) Refrigerant compressor

(2) Steering pump (8) Guide roller
(3) Ribbed V-belt disc coolant pump (9) Ribbed V-belt disc PTO
(4) Starter motor (10) Ribbed V-belt tensioner alternator
(5) Ribbed V-belt coolant compressor (11) Ribbed V-belt alternator
(6) Ribbed V-belt tensioner coolant compres- (12) Alternator
sor

ADD-ON UNITS
POWER TAKE-OFF
Removing and installing the PTO
Additional jobs
(1) Drive plate (5) Ribbed V-belt disc

(2) O-ring (6) Mounting bolt
(3) Power take-off (7) Timing case cover
(4) Mounting bolt (left-handed thread)
Technical data
Mounting bolt (left-handed thread) (4) .................... M16x1.5x45-8.8 LH..................... 1st tightening 100 Nm
Mounting bolt (left-handed thread) (4) .................... M16x1.5x45-8.8 LH.........................Final tightening 90°
Service products
Technical Vaseline ............................................................................................................. 09.15014-0017
WARNING

ADD-ON UNITS
Removing the power take-off Removing the PTO
Removing the ribbed V-belt disc

• Remove the PTO (4) with clutch drive plate (2) and
Note O-ring (3)
The mounting bolt has a left-handed
thread.
• Brace the ribbed V-belt disc (2)

• Remove the ribbed V-belt disc (2) from the PTO
(3)

ADD-ON UNITS
Installing the power take-off Attaching the ribbed V-belt disc
Attaching the PTO
Note
• Put on the clutch drive plate (2) with its thin side The mounting bolt has a left-handed
onto the air compressor gear thread.
• Thinly apply Technical Vaseline on a new O-ring
(3) and place it on the PTO (4) • Put the ribbed V-belt disc (2) on the PTO (3)
• Position the PTO (4) • Screw in a new mounting bolt (1)
• Screw in and tighten the new mounting bolts (1) • Brace the ribbed V-belt disc (2)
• Tighten the mounting bolt (1) with 1st tighten-
ing 100 Nm
• Tighten the mounting bolt (1) with Final tighten-
ing 90°

ADD-ON UNITS
AIR COMPRESSOR
Removing and installing 1-cylinder air compressor
Additional jobs
– Removing and installing the PTO, see 83
– Removing and installing the alternator, see 115
– Removing and installing the crankcase ventilation, see 355
(1) O-ring (6) Driver

(2) O-ring (7) O-ring
(3) 1-cylinder air compressor (8) Steering pump
(4) Pressure relief valve (9) Mounting bolt
(5) Pressure connection (10) Support bracket
Technical data
Hollow screw for steering pump (8)........................ M26x1.5 ............................................................75 Nm
Service products

ADD-ON UNITS
WARNING

ADD-ON UNITS
Removing the air compressor Removing the air compressor
Removing the suction line and pressure line
• Remove clamps (3) and (4)

• Remove the suction line (5)
• Unscrew the hollow screw (1) and remove it with
the seals
• Remove the pressure line (2)
Removing the steering pump
• Unscrew the mounting bolts (5) and (6)

• Remove the support bracket (4).
• Pull the air compressor (3) out of the timing case
• Remove the O-rings (1) and (2)

• Remove the steering pump (4) with driver (2) and
O-ring (3) from the air compressor (1)
• Remove O-ring (3) from the steering pump (4)

ADD-ON UNITS
Installing the air compressor Attaching the steering pump
Installing the air compressor
• Check the driver (2) for wear and replace as

needed
• Thinly apply Technical Vaseline on a new O-ring • Insert the driver (2) into the air compressor (1)
(1) and fit it on the air compressor (3) • Fit a new O-ring (3) on the steering pump (4)
• Apply a thin layer of Technical Vaseline onto a new • Insert the steering pump (4) into the air compres-
O-ring (2) and insert it into the air compressor (3) sor (1)
• Thinly apply Technical Vaseline to the fitting bore • Screw in and tighten the new mounting bolts (5)
for the air compressor in the timing case
• Insert the air compressor (3) into the timing case
• Screw in the mounting bolts (7)
• Position the support bracket (4)
• Screw in the mounting bolts (5) and (6)

ADD-ON UNITS
Attaching the suction line and pressure line
• Position the suction line (5) and screw in the hollow

screw (6) with new seals
• Position the pressure line (2) and screw in the
hollow screw (1) with new seals
• Attach the clamps (3) and (4)
• Tighten the hollow screw (6) with 75 Nm
• Tighten the hollow screw (1) with 50 Nm

ADD-ON UNITS
Dismantling and assembling 1-cylinder air compressor

Additional jobs
– Removing and installing 1-cylinder air compressor, see 87
(1) Pressure relief valve (6) Air compressor housing

(2) Angled connector (7) Mounting bolt
(3) Angled connector (8) Drive wheel
(4) Mounting bolt (9) Seal
(5) GE union (10) Cylinder head
Technical data
Pressure relief valve (1) ........................................ M26x1.5 ............................................................90 Nm
Mounting bolt (7) ..................................................................................................... 1st tightening 100 Nm
Mounting bolt (7) .........................................................................................................Final tightening 90°
Angled connectors (2), (3)..................................... M26x1.5 ..........................................................100 Nm
Mounting bolt (4) .................................................. M8x80 ..........................................1st tightening 20 Nm
Mounting bolt (4) .................................................. M8x80 ............................................Final tightening 90°
GE union (5) ........................................................ M14x1.5 ............................................................35 Nm

ADD-ON UNITS
WARNING
Special tools
[21] Removal device 80.99606-6118
• Locking the air compressor crankshaft

ADD-ON UNITS
Dismantling the air compressor Removing the drive wheel
Removing the air compressor connections

• Remove the drive wheel (2)
Removing the cylinder head
• Mark the installation position of angled connectors

(2) and (3)
• Undo the lock nuts of the angled connectors (2)
and (3)
• Unscrew angled connectors (2) and (3) and re-
move the seals
• Unscrew the GE union (4) and remove the seal
• Unscrew the pressure relief valve (1) and remove
the seal
Attaching the removal device to air compressor

• Mark the installation position of the cylinder head
(2)
• Remove the cylinder head (2) with seal (3) from
the housing (4)
• Attach the Removal device [21] (3) on the air com-

pressor (1) using the mounting bolts (2)

ADD-ON UNITS
Assembling the air compressor Attaching the drive wheel
Attaching the cylinder head
• Position the drive wheel (2)

• Screw in a new mounting bolt (1)
ing 100 Nm
ing 90°
Removing the removal device
• Fit the cylinder head (2) with a new seal (3) onto
the housing (4) as marked
• Screw in the new mounting bolts (1)
• Tighten the mounting bolts (1) uniformly crosswise
with 1st tightening 20 Nm
• Tighten the mounting bolts (1) uniformly crosswise
with Final tightening 90°
• Remove Removal device [21] (3) from the air com-
pressor (1)

ADD-ON UNITS
Installing the air compressor connections
• Screw in the angled connector (2) with a new seal

as marked
• Tighten the lock nuts of the angled connectors (2)
with 100 Nm
• Screw in the angled connector (3) with a new seal
as marked
• Tighten the angled connector lock nut (3) with
100 Nm
• Screw on GE union (4) with new seal and tighten
with 35 Nm
• Screw in the pressure relief valve (1) with a new
seal
• Tighten the pressure relief valve (1) with 90 Nm

ADD-ON UNITS
BELT DRIVE
Removing and installing the belt drive (variant without Frigoblock alternator)
Additional jobs
(1) Ribbed V-belt disc coolant pump (6) Mounting bolt

(2) Ribbed V-belt disc vibration damper (7) Guide roller
(3) Ribbed V-belt coolant compressor (8) Ribbed V-belt disc PTO
(4) Ribbed V-belt tensioner coolant compres- (9) Ribbed V-belt tensioner alternator
sor (10) Ribbed V-belt alternator
(5) Refrigerant compressor
Technical data
Mounting bolt for ribbed V-belt tensioner for the
alternator (9) ........................................................ M10x70-10.9......................................................47 Nm
Mounting bolt (6) .................................................. M10x70-10.9......................................................47 Nm
WARNING

ADD-ON UNITS
Removing the belt drive Removing the ribbed V-belt tensioner for the
coolant compressor
Removing the ribbed V-belt for the coolant com-
pressor

• Remove the ribbed V-belt tensioner (4)
• Remove the guide roller (2) with spacer (3)
CAUTION
spring tension
ally


ADD-ON UNITS
Removing the ribbed V-belt of the alternator Removing the ribbed V-belt tensioner for the
alternator

• Remove the poly-V-belt tensioner (2)
CAUTION
spring tension
ally


ADD-ON UNITS
Installing the belt drive Attaching the ribbed V-belt of the alternator
Attaching the ribbed V-belt tensioner for the al-

ternator
• Position the ribbed V-belt tensioner (2)

• Screw in the new mounting bolt (1) and tighten
with 47 Nm
CAUTION
spring tension
ally


ADD-ON UNITS
Attaching the ribbed V-belt tensioner for the Attaching the ribbed V-belt for the coolant com-
coolant compressor pressor

with 47 Nm
• Position the guide roller (2) with spacer (3)
• Screw in and tighten the new mounting bolt (1)
CAUTION
spring tension
ally


ADD-ON UNITS
Removing and installing the belt drive (variant with Frigoblock alternator)
Additional jobs
(1) Ribbed V-belt Frigoblock alternator (6) Ribbed V-belt tensioner coolant compres-
(2) Pressure spring sor
(3) Ribbed V-belt tensioner Frigoblock alter- (7) Refrigerant compressor
nator (8) Mounting bolt
(4) Guide roller (9) Guide roller
(5) Ribbed V-belt coolant compressor
Technical data
WARNING

ADD-ON UNITS
Removing the belt drive Removing the ribbed V-belt for the Frigoblock
alternator
Removing the ribbed V-belt for the coolant com-
pressor
CAUTION
CAUTION spring tension
The ribbed V-belt tensioner is under • Brace the ribbed V-belt tensioner to pre-
spring tension vent it from springing back unintention-
• Brace the ribbed V-belt tensioner to pre- ally
ally • Turn the ribbed V-belt tensioner (2) counter clock-
• Turn the ribbed V-belt tensioner (2) counter clock- • Remove the ribbed V-belt (1)
wise until the stop and hold it • Carefully slacken the ribbed V-belt tensioner (2)
• Carefully slacken the ribbed V-belt tensioner (2) Removing the guide roller for the Frigoblock
alternator
Removing the ribbed V-belt tensioner for the
coolant compressor

• Unscrew the mounting bolt (5) • Remove the guide roller (2) with carrier (3)
• Remove the ribbed V-belt tensioner (4)
• Remove the guide roller (2) with spacer (3)

ADD-ON UNITS
Removing the ribbed V-belt tensioner for the Installing the belt drive
Attaching the ribbed V-belt tensioner for the

• Remove the pressure spring (4)
• Removing the ribbed V-belt tensioner (3) • Attach the ribbed V-belt tensioner (3)
• Position the pressure spring (4)
• Screw in the new mounting bolts (1) and (2)
Attaching the guide roller for the Frigoblock al-

ternator
• Position the guide roller (2) with carrier (3)


ADD-ON UNITS
Attaching the ribbed V-belt for the Frigoblock Attaching the ribbed V-belt for the coolant com-
alternator pressor
CAUTION CAUTION
The ribbed V-belt tensioner is under The ribbed V-belt tensioner is under
spring tension spring tension
• Brace the ribbed V-belt tensioner to pre- • Brace the ribbed V-belt tensioner to pre-
vent it from springing back unintention- vent it from springing back unintention-
ally ally
• Turn the ribbed V-belt tensioner (2) counter clock- • Turn the ribbed V-belt tensioner (2) counter clock-
wise until the stop and hold it wise until the stop and hold it
• Fit the ribbed V-belt (1) • Fit the ribbed V-belt (1)
• Carefully slacken the ribbed V-belt tensioner (2) • Carefully slacken the ribbed V-belt tensioner (2)
Attaching the ribbed V-belt tensioner for the

coolant compressor

with 47 Nm
• Position the guide roller (2) with spacer (3)

ADD-ON UNITS
Removing and installing the belt drive (variant with hydraulic pump)
Additional jobs
(1) Carrier (4) V-belts

(2) Hydraulic pump (5) V-belt pulley
(3) Tension pulley (6) Mounting nut
Technical data
Clamping force of the V-belt (4) for new assembly .................................................................... 500 - 550 N
Clamping force of the V-belt (4) after more than 10 min. of operation ........................................ 350 - 400 N
WARNING
Special tools
[22] Measurement device for the V-belt 81.66814-6001
• Checking the V-belt tension

ADD-ON UNITS
Removing the belt drive Installing the belt drive

Undoing the tension pulley mounting nut Tensioning the V-belt
• Undo the mounting nut (1) • Fit the the V-belt (2)
• Screw in the turnbuckle (1)
Removing the V-belt
Checking the V-belt tension
• Unscrew the tensioner bolt (1) until the V-belt is

completely slackened; where necessary, unscrew Note
the turnbuckle (1) further Additional pressing after disengaging the
• Remove the V-belt (2) spring will give a false measurement re-
sult.
The measurement process will have to be
repeated.
• Place the Measurement device for the V-belt [22]

(4) on the longest section between the points of
contact of the V-belts (3)
• Press the pressure pad (2) vertically to the V-belt
(3) until the spring Measurement device for the
V-belt [22] (4) disengages
• Read the value of the clamping force at the posi-
tion where the upper edge of the indicator arm (1)
intersects the scale
• V-belt clamping force (3), see Technical data, 106
• If the clamping force for the V-belt (3) is incorrect,
re-tighten the V-belt (3)

ADD-ON UNITS
Tightening the tension pulley mounting nut
• Tighten the mounting nut (1)

ADD-ON UNITS
Removing and installing the belt drive (variant with stretchy belt)
Additional jobs
(1) Guide roller (3) Poly-V-belt

(2) Ribbed V-belt disc (4) Ribbed V-belt disc
Technical data
Mounting bolt of the guide roller (1) ....................... M12x80-10.9......................................................60 Nm
WARNING

ADD-ON UNITS
Special tools
[23] Assembly tool 51.99603-0003
• Removing and attaching the ribbed V-belt
[24] Engine cranking unit 80.99626-6008
• Cranking the engine in conjunction with:

• Gear ratchet [25]
[25] Gear ratchet 80.99627-0001
• Cranking the engine

ADD-ON UNITS
Removing the belt drive Removing the ribbed V-belt
Attaching the engine cranking unit
CAUTION
• Remove the cap from the flywheel housing Risk of injury from crushing
• Attach the Engine cranking unit [24] (1) on the • Do not reach between the ribbed V-belt
flywheel housing disc and the ribbed V-belt while crank-
ing the engine
Removing the intermediate guide roller Note
This should be done with assistance.
• Place the Assembly tool [23] (2) on the ribbed

V-belt disc (1)
• Crank the engine in the running direction using
Engine cranking unit [24] and Gear ratchet [25]
while pulling the ribbed V-belt off the ribbed V-belt
disc (1)
• Unscrew the mounting bolt of the guide roller (1)

• Remove the guide roller (1)

ADD-ON UNITS
Installing the belt drive Attaching the ribbed V-belt
Positioning the assembly tool
• Crank the engine in the engine’s running direc-

tion using Engine cranking unit [24] and Gear
• Place the Assembly tool [23] (1) on the ribbed ratchet [25] until ribbed V-belt (1) lies completely
V-belt disc on the ribbed V-belt disc
Pre-tensioning the ribbed V-belt Removing the assembly tool
• Place a new ribbed V-belt (3) on the ribbed V-belt • Remove the Assembly tool [23]
disc of the refrigerant compressor (1) and engine
• Pre-tension the ribbed V-belt (3) using Assembly Attaching the guide roller
tool [23] (2)
• Press ribbed V-belt downwards

• Position the guide roller (1)
• Screw in and tighten the guide roller mounting bolt

ADD-ON UNITS
Removing the engine cranking unit
• Remove the Engine cranking unit [24] (1) from the

flywheel housing
• Attach the cap on the flywheel housing

ADD-ON UNITS
ALTERNATOR
Removing and installing the alternator
Additional jobs
(1) Carrier (3) Ribbed V-belt disc

(2) Bracket (4) Alternator
Technical data
Mounting nut for the ribbed V-belt disc (3) .............. M16x1.5 ............................................................80 Nm
Coolant line union nut ........................................... M14x1.5 ............................................................35 Nm
Service products
Loctite 270 ........................................................................................................................ 04.10160-9131
CAUTION

ADD-ON UNITS
WARNING
WARNING
Special tools
[27] Special spanner 80.99603-6029
• Removing and attaching the ribbed V-belt disc in

conjunction with:
• Gripper [28]
[28] Gripper 08.06460-0002
• Removing and attaching the ribbed V-belt disc

ADD-ON UNITS
Removing the alternator Removing the coolant lines

nection

• Unscrew the union nut on the coolant line (3)
• Disconnect the electrical connection (2) • Unlock plug connectors (1) and (7) by pressing the
• Free, set aside and secure the oil level sensor spring clips (2)
cable harness (1) • Remove coolant lines (3) and (4)
Disconnecting the alternator electrical connec- Removing the bracket
tion
• Unlock and pull off the compact plug (3) • Unscrew the mounting nut (3)
• Disconnect the cable tie (2) • Pull out the mounting bolt (2) and remove the
• Unscrew the terminal B+ mounting nut (1) bracket (1)
• Expose, set aside and secure the cable harnesses

ADD-ON UNITS
Removing the air compressor line Removing the bracket
• Unscrew the mounting bolts (2) • Unscrew the mounting bolts (1)
• Remove the clamps (3) • Remove the bracket (2)
• Remove the air compressor line (1)
Removing the carrier
Removing the alternator

• Remove the carrier (2)
Undoing the ribbed V-belt disc mounting nut

(1) and (3)
• Remove Alternator (2)
• Place the Special spanner [27] (2) with Grip-
per [28] (3) on the ribbed V-belt disc mounting nut
• Insert the multiple-tooth key (1) into the alternator
shaft teething
• Brace the multiple-tooth key (1) and undo the
mounting nut

ADD-ON UNITS
Removing the ribbed V-belt disc Installing the alternator

Attaching the ribbed V-belt disc
• Unscrew the mounting nut (1)

• Remove ribbed V-belt disc (2) from the alternator
shaft (3) • Thinly apply Loctite 270 on the thread and contact
area of the new mounting nut (1)
• Put the ribbed V-belt disc (2) onto the alternator
shaft (3)
• Screw on the new mounting nut (1)
Tightening the ribbed V-belt disc mounting nut
• Place the Special spanner [27] (2) with Grip-

per [28] (3) on the ribbed V-belt disc mounting nut
• Insert the multiple-tooth key (1) into the alternator
shaft teething
• Brace the multiple-tooth key (1) and tighten the
mounting nut with 80 Nm

ADD-ON UNITS
Attaching the carrier Attaching the alternator
• Position the carrier (2)

Attaching the bracket
• Insert the alternator (2)

and (3) as marked

• Position the bracket (2)


ADD-ON UNITS
Attaching the bracket Connecting the alternator electrical connection

• Position the bracket (1) and kinks and does not chafe
• Insert new mounting bolt (2) • Screw on the mounting nut (1) with terminal B+
• Screw on the mounting nut (3) and tighten with 13 Nm
• Brace the mounting bolt (2) and tighten the mount- • Insert and lock the compact plug (3)
ing nut (3) • Secure the cable harnesses with cable ties (2)
using Cable tie pliers [26]
Attaching the coolant lines
Connecting the oil level sensor electrical con-
nection
WARNING
connector • Route the oil level sensor cable harness (1) so that
• Check the coolant line plug connectors it is free of tension and kinks and does not chafe
for secure fit after securing • Connect the electrical connection (2)
• Attach the coolant lines (3) and (4)

• Undo the plug connectors (1) and (7) if necessary
by pressing the spring clips (2), then reinsert and
secure
then tighten it with 35 Nm
• Screw on the coolant line union nut (3) and tighten
with 35 Nm
• Attach the clamps (5)

ADD-ON UNITS
FRIGOBLOCK ALTERNATOR
Removing and installing Frigoblock alternator
Additional jobs
– Removing and installing the belt drive (variant with Frigoblock alternator), see 102
(1) Engine bracket (3) Bracket

(2) Frigoblock alternator (4) Bracket
WARNING

ADD-ON UNITS
Detach the Frigoblock alternator Removing the Frigoblock alternator
Removing the bracket

• Remove the Frigoblock alternator (2)
(1) and (3) Removing the bracket
• Remove the bracket (2)


ADD-ON UNITS
Removing the bracket Installing the Frigoblock alternator


(2) and (3)
• Unscrew the mounting bolts (2) and (3) • Position the bracket (1)
• Remove the bracket (1) • Screw in and tighten the new mounting bolts (3)
and (2) as marked


ADD-ON UNITS
Attaching the Frigoblock alternator Attaching the bracket
• Position the Frigoblock alternator (2) • Position the bracket (2)

• Screw in and tighten the new mounting bolts (1) • Screw in the new mounting bolts (1) and (3) as
marked

ADD-ON UNITS
STARTER MOTOR
Removing and installing the starter motor
(1) Flywheel housing (3) Mounting bolt

(2) Starter motor (4) Mounting nut
Technical data
Number of starter pinion teeth ............................................................................................................... 11
Starter power .................................................................................................................... 4.0 kW at 24 V
WARNING

ADD-ON UNITS
Special tools

[30] Gear ratchet 80.99627-0001

ADD-ON UNITS
Removing the starter motor Installing the starter motor
• Unscrew the mounting bolts (4) • Crank the engine using Engine cranking unit [29]
• Unscrew the mounting nut (1) and Gear ratchet [30] once in its natural direction
• Pull out starter motor (3) from flywheel housing (2) of rotation whilst checking the starter ring gear for
damage. Fit a new starter ring gear if necessary
• Insert the starter motor (3) into the flywheel hous-
ing (2)
• Screw on and tighten the new mounting nut (1)

ADD-ON UNITS
REFRIGERANT COMPRESSOR
Removing and installing the refrigerant compressor
Additional jobs
(1) Console (3) Refrigerant compressor

(2) Bracket
CAUTION
Refrigerant and coolant can cause damage to your health and the environment
• Do not let refrigerant and refrigerator oil come into contact with the skin
• Disposing of refrigerant and refrigerator oil in the correct manner
WARNING

ADD-ON UNITS
Special tools
[31] Tool insert 80.99606-0610
• Screwing on and unscrewing the plug on the pres-

sure port
[32] Tool insert 80.99606-0611
• Screwing on and unscrewing the plug on the in-

take connection

ADD-ON UNITS
Removing the refrigerant compressor Removing the bracket
Disconnecting the refrigerant compressor elec-

trical connection

• Disconnect the electrical connection (1) Removing the refrigerant compressor
Closing the refrigerant connections
• Unscrew the mounting nuts (3)

• Pull out the mounting bolts (1)
Note • Remove refrigerant compressor (2) from the con-
The suction port is marked with an S. sole
The pressure spigot is marked with a D.
Removing the console
• Screw the plug onto the refrigerant connections of
the refrigerant compressor (1) with Tool insert [31]
(2) or Tool insert [32] (3)
• Mark the installation position of the console (2)

• Remove the console (2)

ADD-ON UNITS
Installing the refrigerant compressor Removing the plug
Attaching the console
• Unscrew the plug from the refrigerant compressor

(1) with Tool insert [31] (2) or Tool insert [32] (3)
• Position the console (2) as marked
• Screw in and tighten the new mounting bolts (1) Connecting the refrigerant compressor electri-
cal connection
Attaching the refrigerant compressor

• Position the refrigerant compressor (2) on the con-
sole
• Insert the new mounting bolts (1)
• Screw on and tighten the new mounting nuts (3)

• Screw in and tighten the mounting bolts (1) and (2)

ADD-ON UNITS
HYDRAULIC PUMP
Removing and installing the hydraulic pump
Additional jobs
(1) Carrier (4) V-belts

(2) Hydraulic pump (5) V-belt pulley
(3) Tension pulley (6) Mounting nut
Technical data
Mounting nut (6) ................................................... M18x1.5 ............................................................70 Nm
Clamping force of the V-belt (4) for new assembly .............................................................................550 N
Clamping force of the V-belt (4) after more than 10 min. of operation .................................................350 N
WARNING

ADD-ON UNITS
Special tools
[33] Tension gauge 81.66814-6001
• Checking the V-belt tension

ADD-ON UNITS
Removing the hydraulic pump Removing the V-belt pulley
Undoing the ribbed V-belt pulley mounting nut

• Pull off the V-belt pulley (1)
• Undo the mounting nut (1) • Remove the disc spring from the hydraulic pump
Undoing the tension pulley mounting nut Removing the hydraulic pump
• Undo the mounting nut (1) • Unscrew the mounting bolts (1)
• Remove the hydraulic pump (2) with the interme-
Removing the V-belt diate union (3)
Removing the carrier
• Unscrew the tensioner bolt (1) until the V-belt is

completely slackened; where necessary, unscrew
the turnbuckle (1) further • Mark the installation position of the mounting bolts
• Remove the V-belt (2) (1), (2) and (4)
• Unscrew the mounting bolts (1), (2) and (4)
• Remove the carrier (3)

ADD-ON UNITS
Install hydraulic pump Attaching the V-belt pulley
Attaching the carrier
• Insert the disc spring into the hydraulic pump

• Position the V-belt pulley (1)
• Position the carrier (3) • Screw on new mounting nut (2) hand-tight
• Screw in new mounting bolts (1), (2) and (4) as
marked Tensioning the V-belt
• Tighten mounting bolts (1), (2) and (4)
Attaching the hydraulic pump
• Fit the V-belt (2)

• Screw in the turnbuckle (1)
• Position the hydraulic pump (2) with intermediate

union (3)

ADD-ON UNITS
Checking the V-belt tension Tightening the V-belt pulley mounting nut
Note • Tighten the mounting nuts (1) with 70 Nm

Additional pressing after disengaging the
spring will give a false measurement re-
sult.
The measurement process will have to be
repeated.
• Place the Tension gauge [33] (4) on the longest

section between the points of contact of the V-belts
(3)
• Press the pressure pad (2) vertically to the V-belt
(3) until the spring Tension gauge [33] (4) disen-
gages
• Read the value of the clamping force at the posi-
tion where the upper edge of the indicator arm (1)
intersects the scale
• V-belt clamping force (3), see Technical data, 135
• If the clamping force for the V-belt (3) is incorrect,
re-tighten the V-belt (3)
Tightening the tension pulley mounting nut

COMMON RAIL SYSTEM
COMMON RAIL SYSTEM
(1) Seal (5) High-pressure line

(2) Injector (6) Rail pressure sensor
(3) Mounting bolt (7) Pressure pipe
(4) Pressure flange (8) High pressure pump

COMMON RAIL SYSTEM
INJECTORS AND PRESSURE PIPE

Protective sleeves for injectors and pressure pipe
(1) Injector nozzle protective sleeve (8) Protective sleeve Z 18 x 15

81.96002-0522 81.96002-0555
(2) Mounting bolt (9) End plug 81.96002-0521
(3) Cap injector supply bore 81.96002-0523 (10) End plug 81.96002-0556
(4) Protective sleeve Z 14 x 15 (11) End plug 81.96002-0521
81.96002-0512 (12) End plug 81.96002-0521
(5) End plug 81.96002-0521 (13) End plug 81.96002-0519
81.96002-0512 (15) Injector storage sleeve 09.81020-1000
(7) Cap 81.96002-0518
WARNING
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).

COMMON RAIL SYSTEM
Special tools
[34] Injector supply bore cap 81.96002-0523
• Closing the injector supply bore
[35] Injector nozzle protective sleeve 81.96002-0522
• Closing the injector nozzle
[36] Injector storage sleeve 09.81020-1000
• Storing the injectors
[37] Plug 81.96002-0520
• Closing the cylinder head injector bore
[38] Protective sleeve Z 18 x 15 81.96002-0555
• Closing the pressure-limiting valve

• Closing the rail pressure sensor
[39] Plug 81.96002-0521
• Closing the high-pressure lines

• Closing the air distributor pipe
[40] Plug 81.96002-0519
• Closing the pressure pipe socket bore

COMMON RAIL SYSTEM
[41] Plug 81.96002-0556
• Closing the rail pressure sensor bore in the pres-

sure pipe
• Closing the pressure-limiting valve bore in the
pressure pipe
• Closing the high-pressure line connection to the

pressure pipe
• Closing the pressure pipe socket
• Closing the high pressure line connection on the
high pressure pump
[43] Cap 81.96002-0518
• Closing the hollow screw connections

COMMON RAIL SYSTEM
Removing and installing the injectors and pressure pipe

Additional jobs
– Protective sleeves fuel service centre, see 171
– Removing and installing the fuel service centre, see 173
– Protective sleeves for injectors and pressure pipe, see 143
(1) Gasket (6) High-pressure line

(2) Injector (7) Rail pressure sensor
(3) Mounting bolt (8) Pressure pipe
(4) Pressure flange (9) Pressure screw
(5) Return line
Technical data
Mounting bolt (3) .................................................. M8x45 ............................................1st tightening 2 Nm
Mounting bolt (3) .................................................. M8x45 ....................................... Final tightening 30 Nm
Pressure screw (9) ............................................... M22x1.5 .......................................1st tightening 10 Nm
Pressure screw (9) ............................................... M22x1.5 .................................... Final tightening 55 Nm
Injector cable mounting nuts.................................. Cable lug nut M4...............................................1.5 Nm
High-pressure line (6) ........................................... M14x1.5 .......................................1st tightening 10 Nm
High-pressure line (6) ........................................... M14x1.5 .........................................Final tightening 60°
Rail pressure sensor (7)........................................ M18x1.5 ............................................................70 Nm
Pressure-limiting valve.......................................... M18x1.5 ..........................................................100 Nm

COMMON RAIL SYSTEM
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 en-
able depressurisation in the pressure pipe, or depressurisation 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 fit new pressure pipe sockets once the existing ones have been undone
• Do not reuse plugs for the high-pressure lines, the pressure pipe or injectors, even if they have
only been used once
• Follow the sequence described when tightening injectors, high-pressure lines, the pressure pipe
and pressure pipe sockets
WARNING
Component damage from re-used high-pressure lines
• Do not reuse high-pressure lines
Always replace the high-pressure lines
WARNING
Danger of damage due to dirt ingress
• Always remove only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
Special tools
[44] Adapter 80.99602-0173
• Removing the pressure pipe socket in conjunction

with:
• Extractor tool [45]
[45] Extractor tool 80.99602-0011
• Removing the pressure pipe socket
[46] Extractor tool 80.99602-6015
• Extracting the injectors in conjunction with:

• Plate [47]
• Support [48]
• Support [49]
• Hex collar nut [50]
• Support [51]

COMMON RAIL SYSTEM
[47] Plate 80.99602-0176
• Extracting the injectors
[48] Support 80.99602-0177
[49] Support 80.99602-0199
[50] Hex collar nut 06.11226-8306
[51] Support 80.99602-0198
[52] Torque wrench 08.06510-9026
• Attaching the injector cable in conjunction with:

• Adapter [53]
• Socket wrench insert, size 7 [54]
[53] Adapter 08.06139-9029
• Attaching the injector cable
[54] Socket wrench insert, size 7 08.06141-0700
• Attaching the injector cable

COMMON RAIL SYSTEM
[55] Pressure shim 80.99606-0609
• Installing the injectors
• Removing and installing the high-pressure lines

in conjunction with:
• Extension [57]
[57] Extension 08.06139-9025
• Removing and installing the high-pressure lines

COMMON RAIL SYSTEM
Removing the injectors and the pressure Removing the high-pressure line
pipe
Allowing the return duct to empty
WARNING
Danger of environmental pollution
• Collect any fuel that emerges in a suit-
able container
• Remove the high pressure line (2) with the Socket

wrench insert, size 17 [56] and the Extension [57]
from the pressure pipe (1) and the high pressure
pump (3)
Removing the high-pressure lines
WARNING
Component damage through fuel in
the combustion chamber
• Allow the return duct in the air distrib-
utor pipe to empty before the injectors
are removed
WARNING
• Mark the installation position of the clamp
able container
pieces (1)
• Unscrew the hollow screw (2) with seals (1) and • Remove the clamp pieces (1)
allow return duct to empty • Mark the installation position of the high-pressure
• Remove the fuel return line lines (2)
• Remove the high-pressure lines (2) with Socket
wrench insert, size 17 [56] (3) and Extension [57]

COMMON RAIL SYSTEM
Removing the pressure pipe Removing the cylinder head cover

Note
• Remove the pressure pipe (1) from the air distrib-
The mounting bolts can only be removed
utor pipe
from the cylinder head cover with damp-
Unscrewing the pressure screw ing elements and spacers.
• Open the plug console bayonet catches

• Remove the cylinder head cover (2) with seal from
the cylinder head (1)
• Clean the cylinder head cover (2) and the seal
Check the seal for damage, remove it from the
cylinder head cover (2) and replace if required
• Set aside the cylinder head cover (2) on a clean
surface with the seal facing downwards
If this is not done, engine oil can enter the seal sec-
tion. When the cylinder head cover (2) is tightened,
this oil is then pressed out, causing supposed leak-
age
Disconnecting the electrical connection from the

• Unscrewing pressure screw (2) pressure pipe injector
socket (1)
Removing the pressure pipe socket
• Unscrew the mounting nuts (2)

• Remove the injector cable from the injector (1)
• Remove the fuel plug console (3)
• Extract the pressure pipe socket (2) from bore (1)
with Extractor tool [45] (3) and Adapter [44]

COMMON RAIL SYSTEM
Unscrewing the pressure flange mounting bolt Extracting the injector

WARNING
• Remove the spherical washer (2)
Component damage due to improper
Assembling the special tool removal of the injector
• Always first remove the relevant pres-
sure pipe socket before removing the
injector
• Always detach only one injector
• Put on the special tool

• Insert the Extractor tool [46] into the groove for the
pressure flange
• Clamp the clamping sleeve with the knurled nut
(1)
• Extract the injector (3) from the cylinder head by
turning the knurled nut (2)
• Remove the special tool
Removing the injector
• Attach the Support [49] (1) with Hex collar nut [50]
to Plate [47] (2)
• Attach the Support [48] (5) to the Plate [47] (2) with
the Hex collar nut [50] (4)
• Insert the Support [51] (6) into the Support [48] (5)
• Insert the Extractor tool [46] (3) into the Plate [47]
(2)
• Remove the injector (1) with pressure flange (4)

and gasket (2)
• Pull off the O-ring (3)
• Carefully clean the injector bore

COMMON RAIL SYSTEM
Installing the injectors and pressure Installing the pressure pipe socket
pipe
Installing the injector
WARNING
Pressure pipe sockets are com-
pressed at the cone during installation
Note • Do not reuse pressure pipe socket,
Always install injectors together with even if it has only been used once
pressure flange.
It is not possible to install the pressure • Thinly apply clean diesel fuel on a new O-ring (4)
flange afterwards. and fit it on the pressure pipe socket (2)
• Push the pressure pipe socket (2) into the bore (3)
• Check to ensure that the cylinder head bore is so that the balls on the pressure pipe socket (2)
clean are located in the grooves in the cylinder head
• Do not remove the injector (1) from Injector stor- • Screw in the pressure screw (1) and tighten with
age sleeve [36] until immediately before installa- 1st tightening 10 Nm
tion
• Remove the protective sleeves Injector final tightening
• Push the pressure flange (4) onto the injector (1),
ensuring that the fuel inlet opening is turned to the
pressure pipe socket bore
• Insert the injector (1) into the cylinder head with a
new O-ring (3) and a new gasket (2)
• Press the injector (1) fully into the cylinder head
with the Pressure shim [55]
Injector 1st tightening

ing 30 Nm
• Screw in the new mounting bolt (1) for the pressure

flange with the spherical washer (2)
ing 2 Nm

COMMON RAIL SYSTEM
Pressure pipe socket final tightening Attaching the cylinder head cover
• Tighten the pressure screw (1) with Final tighten- • Check the seals of the plug consoles, replace as
ing 55 Nm needed
• Place the cylinder head cover (2) onto the cylinder
Connecting the electrical connection to the in- head (1) over the plug console, with a new seal if
jector necessary
• Screw in the mounting bolts (3) and tighten cross-
wise
• Close the plug console bayonet fittings
Attaching the rail
WARNING
Component damage due to possible
short-circuit
• When tightening the mounting nuts,
ensure that the cable plugs are not
touching • Position the pressure pipe (1) on the air distributor
pipe
• Attach the plug console (3) • Screw in and tighten the new mounting bolts (2)
• Position the injector cable at the injector (1)
• Place the Socket wrench insert, size 7 [54] with
Adapter [53] onto the Torque wrench [52]
• Tighten the mounting nuts (2) with 1.5 Nm

COMMON RAIL SYSTEM
Replacing the rail pressure sensor and pres- Attaching the high-pressure lines
sure-limiting valve
WARNING
WARNING Component damage due to misaligned
Component damage due to lack of lu- high-pressure lines
bricant • Check the alignment of the high-pres-
• Do not wash the pressure-limiting valve sure lines after the 1st tightening, repo-
and rail pressure sensor as the thread sition if needed
and biting edge are coated with lubri-
cant. • Attach the high pressure lines (2) according to the
markings to the pressure pipe and pressure pipe
• Unscrew the rail pressure sensor (2) and pres- socket
sure-limiting valve (1) • Tighten the high-pressure lines (2) with Socket
• Screw in the new pressure-limiting valve (1) and wrench insert, size 17 [56] (3) and Extension [57]
tighten with 100 Nm with 1st tightening 10 Nm
• Screw in the new rail pressure sensor (2) and • Tighten the high-pressure lines (2) with Socket
tighten with 70 Nm wrench insert, size 17 [56] (3) and Extension [57]
with Final tightening 60°
• Attach the clamp pieces (1) as marked

COMMON RAIL SYSTEM
Installing the high pressure line Attaching the fuel return line
WARNING
Component damage due to incorrectly
aligned high-pressure line
• Check the alignment of the high-pres-
sure line after the 1st tightening, repo-
sition if needed
• Attach the high pressure line (2) to the pressure

pipe (1) and the high pressure pump (3)
• Tighten the high-pressure line (2) with Socket
wrench insert, size 17 [56] and Extension [57] with
1st tightening 10 Nm
Final tightening 60° • Position the fuel return line
and then tighten it

COMMON RAIL SYSTEM
HIGH PRESSURE PUMP

Protective sleeves for high pressure pump
(1) End plug 81.96002-0521 (7) Protective sleeve Z 14 x 15

(2) Protective sleeve Z 14 x 15 81.96002-0512
81.96002-0512 (8) Protective sleeve Z 14 x 15
(3) End plug 81.96002-0521 81.96002-0512
(4) High-pressure line (9) Mounting bolt
81.96002-0512 (11) High pressure pump
(6) Protective sleeve Z 14 x 15 (12) Cap 81.96002-0518
81.96002-0512 (13) End plug 81.96002-0521
WARNING
Note

COMMON RAIL SYSTEM
Special tools
• Closing the high-pressure line connection on the

pressure pipe
• Closing the high pressure line connection on the
high pressure pump
[59] Plug 81.96002-0521
• Closing the high pressure pump high pressure

line
• Closing the fuel lines
• Closing the high pressure pump bore
• Closing the air distributor pipe
[60] Cap 81.96002-0518

COMMON RAIL SYSTEM
Removing and installing the high pressure pump

Additional jobs
– Protective sleeves for high pressure pump, see 157
(1) High-pressure line (4) High pressure pump

(2) Mounting nut (5) O-ring
(3) Mounting bolt
Technical data
Fuel-fill level for high pressure pump (4) ........................................................................................... 60 ml
Filler plug for the high pressure pump (4) .........................................................................................18 Nm
Mounting bolt (3) .................................................. M8x40-8.8 .........................................................30 Nm
Mounting nut (2) ................................................... M8 ....................................................................30 Nm

COMMON RAIL SYSTEM
WARNING
personnel only
• The engine must be stationary for at least 5 minutes before commencing work in order to en-
able depressurisation in the pressure pipe, or depressurisation must be checked by means of
MAN-cats® (desired value 0)
• Do not reuse plugs for the high-pressure lines, the pressure pipe or injectors, even if they have
only been used once
WARNING
Component damage from re-used high-pressure lines
• Do not reuse high-pressure lines
Always replace the high-pressure lines
WARNING
WARNING
Special tools
• Removing and installing the high-pressure line in

conjunction with:
• Extension [62]
[62] Extension 08.06139-9025
• Removing and installing the high-pressure pump
[63] Removing device 80.99601-6021
• Removing the high pressure pump in conjunction

with:
• Impact tool [64]
[64] Impact tool 80.99606-6078
• Removing the high pressure pump

COMMON RAIL SYSTEM
Removing the high pressure pump Removing the fuel return line
Disconnecting the electrical connection to the

proportional valve
• Disconnect the proportional valve (2) electrical

connection (1)
Removing the fuel return lines
WARNING
able container

seals (1)
• Remove the fuel return line
WARNING
able container

seals (3)
• Remove the fuel return lines (2) and (5)
• Unscrew the transition joint (4) and remove it with
the seal

COMMON RAIL SYSTEM
Removing the high-pressure line Removing the high pressure pump if

seized
Disconnecting the electrical connection to the
proportional valve
WARNING
able container • Disconnect the proportional valve (2) electrical
connection (1)
wrench insert, size 17 [61] and the Extension [62] Removing the fuel return lines
pump (3)
Removing the high pressure pump
WARNING
able container
Note
When replacing the high pressure pump, • Unscrew the hollow screw (1) and remove it with
remove and attach the drive wheel of the seals (3)
high pressure pump, see Disassembling • Remove the fuel return lines (2) and (5)
and assembling the high pressure pump, • Unscrew the transition joint (4) and remove it with
167. the seal
• Remove the high pressure pump (3) from the tim-
ing case

COMMON RAIL SYSTEM
Removing the fuel return line Removing the high-pressure line
WARNING
able container

wrench insert, size 17 [61] and the Extension [62]
pump (3)
Unscrewing the mounting bolts for the high

pressure pump
WARNING
able container

seals (1)
• Remove the fuel return line
• Unscrew the mounting bolts (1) for the high pres-

sure pump (3)

COMMON RAIL SYSTEM
Attaching the special tool Installing the high pressure pump

Filling the high pressure pump with fuel
• Screw the threaded spindle (4) into the plate (3)

Removing device [63] (2) with the Impact tool [64]
(5) until flush WARNING
• Attach the Removing device [63] (2) on the high Danger of damage due to dirt ingress
pressure pump (1) using two bolts • Make sure that no dirt can get into the
pump when filling
Removing the high pressure pump
• Do not continue to tilt the high pressure
pump once filled
• Unscrew the filler plug (2) and remove it with the

seal
• Using a pipette (1) 60 ml, fill clean and filtered
diesel fuel into the high pressure pump (3)
• Screw in the filler plug (2) with a new seal and
tighten with 18 Nm
Installing the high pressure pump
Note
When replacing the high pressure pump,
remove and attach the drive wheel of the
high pressure pump, see Disassembling
and assembling the high pressure pump,
167.
• Remove the high pressure pump (2) with Remov-

ing device [63] (1) from the timing case
• Remove the Removing device [63] (1) from the
high pressure pump (2) • Insert the high pressure pump (3) into the timing
case
• Screw in new mounting bolts (1) and tighten with
30 Nm
• Screw in new mounting nut (2) and tighten with
30 Nm

COMMON RAIL SYSTEM
Installing the high pressure line Attaching the fuel return line
WARNING
Component damage due to incorrectly
aligned high-pressure line
• Check the alignment of the high-pres-
sure line after the 1st tightening, repo-
sition if needed
• Attach the high pressure line (2) to the pressure

pipe (1) and the high pressure pump (3)
Final tightening 60° • Position the fuel return line
and then tighten it
Connecting the electrical connection to the pro-

portional valve

nection (1)

COMMON RAIL SYSTEM
Attaching the fuel return lines
• Screw in the transition joint (4) with a new seal and

then tighten
• Position the fuel return lines (2) and (5)
and then tighten

COMMON RAIL SYSTEM
Disassembling and assembling the high pressure pump

Additional jobs
– Removing and installing the high pressure pump, see 159
(1) Mounting nut (5) Proportional valve

(2) O-ring (6) Mounting bolt
(3) Drive wheel (7) Fuel pump
(4) High pressure pump (8) Mounting bolt
Technical data
Mounting bolt (6) .................................................. M5x20 .........................................Final tightening 7 Nm
Mounting bolt (8) .................................................. M6x1.5x36.......................................................... 8 Nm
Mounting nut (1) ................................................... M18x1.5-8.8 ....................................................105 Nm
WARNING
personnel only

COMMON RAIL SYSTEM
WARNING
Special tools
[65] Three-arm extractor 08.99605-9014
• Removing the drive wheel high pressure pump

COMMON RAIL SYSTEM
Dismantling the high pressure pump Removing the fuel supply pump
Unscrewing the high pressure pump drive wheel

mounting nut

• Pull out the fuel supply pump (1)
• Remove O-rings (3) and (4) from the fuel supply
• Clean the high pressure pump (3) and blow it dry pump (1)
using compressed air
• Brace the high pressure pump drive wheel (3) Removing the proportional valve
• Remove the O-ring (2)
Removing the high pressure pump drive wheel
• Mark the installation position of the proportional

valve (2)
• Extract the proportional valve (2) by turning slightly
• Pull off the drive wheel (2) using the Three-arm to the right/left
extractor [65] (1)

COMMON RAIL SYSTEM
Assembling the high pressure pump Attaching the high pressure pump drive wheel
Installing the proportional valve
• Degrease the cone in the drive wheel and at the

high pressure pump (3)
Note • Seat the drive wheel onto the high pressure pump
When using micro-encapsulated bolts, cone (3)
the time between the tightening stages • Fit a new O-ring (2) on the high pressure pump (3)
must not be longer than 2 minutes. • Screw on the new mounting nut (1)
• Brace the high pressure pump drive wheel (3)
• Insert the new proportional valve (2) into the high • Tighten the mounting nut (1) with 105 Nm
pressure pump by turning slightly to the right/left
Filling the high pressure pump with fuel
• Align the proportional valve (2) as marked
• Tighten the new mounting bolts (1) with 1st tight-
ening 4 Nm
• Tighten the mounting bolts (1) with Final tighten-
ing 7 Nm
Installing the fuel supply pump
WARNING
• Make sure that no dirt can get into the
pump when filling
• Do not continue to tilt the high pressure
pump once filled
• Push the new O-rings (3) and (4) into the fuel
supply pump (1) • Unscrew the filler plug (2) and remove it with the
• Insert the fuel supply pump (1) seal
• Screw in the new mounting bolts (2) and tighten • Using a pipette (1) 60 ml, fill clean and filtered
with 8 Nm diesel fuel into the high pressure pump (3)
• Screw in the filler plug (2) with a new seal and
tighten with 18 Nm

COMMON RAIL SYSTEM
FUEL SERVICE CENTRE

Protective sleeves fuel service centre
(1) Cap 81.96002-0517 (8) Protective sleeve Z 28 x 20

(2) Plug 81.96002-0521 81.96002-0514
(3) Protective sleeve Z 12 x 16 81.96002-0117 (9) Cap 81.96002-0518
(4) Plug 81.96002-0521 (10) Protective sleeve Z 28 x 20
(5) Cap 81.96002-0518 81.96002-0514
(6) Protective sleeves Z 30 x 22 (11) Protective sleeve Z 28 x 20
81.96002-0515 81.96002-0514
(7) Cap 81.96002-0518 (12) Protective sleeve Z 12 x 16 81.96002-0117
WARNING
Note

COMMON RAIL SYSTEM
Special tools
• Closing the fitting for the quick coupling
• Closing the quick-release couplings
• Closing the quick-release couplings
[69] Cap 81.96002-0517
[70] Cap 81.96002-0518
[71] Plug 81.96002-0521
• Closing the hand pump

• Closing the FSC bores

COMMON RAIL SYSTEM
Removing and installing the fuel service centre

Additional jobs
(1) Air distributor pipe (4) Mounting bolt

(2) Hand pump (5) Pressure sensor
(3) Fuel Service Centre (FSC)
WARNING
WARNING
WARNING
• Collect any remaining fuel that emerges in a suitable container

COMMON RAIL SYSTEM
Special tools
[72] Release tool, size 1 80.99606-0625
• Opening the quick-release couplings in conjunc-

tion with:
• Unlocking handle [73]
[73] Unlocking handle 80.99606-0597
• Opening the quick-release couplings

COMMON RAIL SYSTEM
Removing the fuel service centre Removing the proportional valve
Disconnecting the fuel service centre electrical

connections
• Remove the air pipe (3)

• Remove the proportional valve (2)
Removing the fuel lines
• Disconnect the pressure sensor (1) electrical con-

nection
• Disconnect the heating element electrical connec-
tion (3) • Unscrew hollow screws (3) and (6) and remove
• Disconnect the cable tie (2) them with seals (2)
• Remove the fuel lines (1) and (7)
Disconnecting the proportional valve electrical
• Detach the fuel line (4) with Release tool, size
connection
1 [72] (5) and Unlocking handle [73]
• Disconnect the proportional valve (2) electrical

connection (1)
• Free the proportional valve (2) cable harness (3)

COMMON RAIL SYSTEM
Removing the fuel lines Removing the fuel service centre
• Unscrew the hollow screw (3) and remove with • Unscrew the mounting bolts (2)
seals (2) • Remove the FSC (1)
• Remove the fuel line (1)
• Detach the fuel line (5) with Release tool, size Removing the bracket
Removing the fuel lines

• Unscrew hollow screws (3) and (5) and remove

them with seals (4)
• Detach the fuel line (6) with Release tool, size

COMMON RAIL SYSTEM
Installing the fuel service centre Attaching the fuel lines
• Position the fuel lines (1) and (2)

• Screw in and tighten hollow screws (3) and (5) with
• Position the bracket (1) new seals (4)
• Screw in and tighten the new mounting bolt (2) • Attach the fuel line (6)
• Check the fuel line (6) for secure fit; if necessary
Attaching the fuel service centre pull off with Release tool, size 1 [72] (7) and Un-
locking handle [73] and then re-attach
Attaching the fuel lines
• Position the fuel service centre (1)

• Position the fuel line (1)

and then tighten it
• Attach the fuel line (5)
• Check the fuel line (5) for secure fit; if necessary
pull off with Release tool, size 1 [72] (4) and Un-
locking handle [73] and then re-attach

COMMON RAIL SYSTEM
Attaching the fuel lines Connecting the proportional valve electrical

connection
• Position the fuel lines (1) and (7)

• Screw in and tighten hollow screws (3) and (6) with • Connect the proportional valve (2) electrical con-
new seals (2) nection (1)
• Attach the fuel line (4) • Route the cable harness (3) so that it is free of
• Check the fuel line (4) for secure fit; if necessary tension and kinks and does not chafe
pull off with Release tool, size 1 [72] (5) and Un-
locking handle [73] and then re-attach Connecting the fuel service centre electrical
connections
Attaching the proportional valve
• Position the proportional valve (2)

• Attach the air pipe (3)
• Connect the pressure sensor electrical connection

(1)
• Connect the heating element electrical connection
(3)
and kinks and does not chafe
• Secure the cable harnesses with cable ties (2)

COMMON RAIL SYSTEM
Dismantling and assembling the fuel service centre

Additional jobs
(1) Fuel filter (9) Heating element

(2) Cover (10) Hollow screw
(3) Seal (11) Cover
(4) Housing (12) Fuel pre-filter
(5) Pressure sensor (13) Seal
(6) Water drain plug (14) Housing
(7) Mounting bolt (15) Hand pump
(8) Seal (16) Mounting bolts
Technical data
Cover (11) ......................................................................................................................................15 Nm
Cover (2)........................................................................................................................................25 Nm
Water drain plug (6) ......................................................................................................................... 4 Nm
WARNING
The common rail system would be destroyed by contamination
• Always allow the fuel service centre to empty before changing the fuel filter
• Only use fuel filters that are designated for common-rail systems and marked as such
• Do not re-use used filter elements

COMMON RAIL SYSTEM
WARNING
Special tools
• Removing and installing the fuel filter cover
• Removing and installing the fuel pre-filter cover

COMMON RAIL SYSTEM
Dismantling the fuel service centre Removing the pressure sensor
Allowing the fuel service centre to empty
• Unscrew the pressure sensor (1) with seal (2)
Removing the fuel filter

WARNING
• Collect any remaining fuel that emerges
in a suitable container
• Undo the cover (1) by approx. 2 to 3 turns with

Socket wrench insert, size 36 [74]
• Open the water drain plug (2) and allow the fuel
service centre to empty
• Tighten the water drain plug (2) again with 4 Nm
Removing the heating element

• Pull the heating element (3) with seal (4) out of the
fuel service centre (1)
• Unscrew the cover (1) with the Socket wrench
insert, size 36 [74]
• Pull the cover (1) with fuel filter (3) out of the FSC
housing
• Remove the seal (2)
• Unscrew the cover (7) with the Socket wrench
insert, size 19 [75]
• Pull the fuel pre-filter (6) out of the hand pump
housing (4)
• Remove the seal (5)

COMMON RAIL SYSTEM
Removing the hand pump housing Assembling the fuel service centre
Attaching the hand pump housing
• Unscrew the mounting bolts (2) from the FSC (3)

• Remove the hand pump housing (1)
• Position the hand pump housing (1) on the FSC
(3)
Installing the fuel filter
• Thinly apply clean diesel fuel on the new seal (5)

• Fit the seal (5) on the hand pump housing (4)
• Insert a new fuel pre-filter (6)
• Screw on the cover (7) and tighten by hand
• Insert the new fuel filter (3) into the cover (1)
• Thinly apply clean diesel fuel on the new seal (2)
• Screw in the cover (1) with the seal (2) and tighten
by hand

COMMON RAIL SYSTEM
Tightening the fuel pre-filter cover Installing the heating element
• Tighten the fuel pre-filter cover with Socket wrench • Insert the heating element (3) with new seal (4)
insert, size 19 [75] (1) with 15 Nm into the fuel service centre (1)
Tightening the fuel filter cover
• Tighten the fuel filter cover with Socket wrench

insert, size 36 [74] (1) with 25 Nm
Installing the pressure sensor
• Screw in the pressure sensor (1) with a new seal

(2)
• Tighten the pressure sensor (1) with 45 Nm

COMMON RAIL SYSTEM
FLAME-START SYSTEM
Flame-start system protective sleeves
(1) Plug 81.96002-0521 (4) Protective sleeve A9 81.96002-0516

(2) Cap 81.96002-0518 (5) Cap 81.96002-0517
(3) Protective sleeve Z 10 x 10 81.96002-0511
WARNING
Note

COMMON RAIL SYSTEM
Special tools
• Closing the flame glow plug connection
[77] Protective sleeve A9 81.96002-0516
• Closing the flame-start system fuel line
[78] Cap 81.96002-0517
• Closing the FSC fuel line hollow screw connection

flame-start system
• Closing the fuel line solenoid valve hollow screw
connection
[79] Cap 81.96002-0518
[80] Plug 81.96002-0521
• Closing the solenoid valve borehole

• Closing the FSC bore

COMMON RAIL SYSTEM
Removing and installing the flame-start system

Additional jobs
(1) Flame glow plug (3) Fuel line

(2) Solenoid valve
Technical data
Fuel line union nut (3) ........................................... M10x1 ...............................................................10 Nm
Service products
Curil T sealing agent.......................................................................................................... 04.90300-9030
WARNING

COMMON RAIL SYSTEM
Removing the flame-start system Removing the solenoid valve
Disconnecting the electrical connection

• Remove the solenoid valve (2)
• Unscrew the cable lug mounting nut
• Disconnect the electrical connection (1) Removing the flame glow plug
Removing the fuel lines of the flame-start system
• Undo the mounting nut (1)

• Unscrew the flame glow plug (2)


COMMON RAIL SYSTEM
Installing the flame-start system Attaching the fuel lines for the flame-start sys-
tem
Installing the flame glow plug
• Apply a thin layer of Curil T sealing agent to the

thread on the flame glow plug (2)
• Screw in the flame glow plug (2) and align to fuel
line for solenoid valve and flame glow plug (2)
• Brace the flame glow plug (2) and tighten the
mounting nut (1) with 25 Nm
Attaching the solenoid valve

• Position the fuel line (1)
• Screw in the hollow screw with new seals
• Tighten the union nut for the fuel line (1) with
10 Nm
• Tighten the hollow screw for the fuel line (1)
• Attach the fuel line (3) with new seals
Connecting the electrical connection
• Position the solenoid valve (2)

• Position the electrical connection (1) at the flame

glow plug
• Screw on the cable lug mounting nut and tighten
with 5 Nm

COMMON RAIL SYSTEM
Protective sleeve for the flame-start system (D0836 LFL44)
(1) End plug 81.96002-0521 (4) Cap 81.96002-0517

(2) Protective sleeve Z 10 x 10 8096002-0511 (5) End plug 81.96002-0521
(3) End plug 81.96002-0521 (6) Cap 81.96002-0517
WARNING
Note

COMMON RAIL SYSTEM
Special tools
• Closing the flame glow plug connection

• Closing the solenoid valve connection
[82] Protective sleeve A9 81.96002-0516
• Closing the flame-start system fuel line
[83] Cap 81.96002-0517

flame-start system
• Closing the fuel line solenoid valve hollow screw
connection
[84] Cap 81.96002-0518
[85] End plug 81.96002-0521
• Closing the solenoid valve borehole

• Closing the FSC bore

COMMON RAIL SYSTEM
Removing and installing the flame-start system (D0836 LFL44)

Additional jobs
– Protective sleeve for the flame-start system (D0836 LFL44), see 190
(1) Hand pump (4) Fuel line

(2) Fuel Service Centre (FSC) (5) Flame glow plug
(3) Solenoid valve
Technical data
Fuel line union nut (4) ........................................... M10x1 ................................................................ 5 Nm
Solenoid valve hollow screw (3)............................. M10x1-6S..........................................................12 Nm
Service products
Curil T............................................................................................................................... 04.90300-9030
WARNING

COMMON RAIL SYSTEM
Removing the flame-start system Installing the flame-start system

Removing the fuel line Installing the flame glow plug
• Disconnect the electrical connection (3) • Thinly apply Curil T on the flame glow plug (1)
• Remove the fuel line (1) • Screw in the flame glow plug (1) and tighten with
• Unscrew the fuel supply line hollow screw (2) and 25 Nm
remove the seals
• Remove the fuel supply line (2) Installing the solenoid valve
Removing the solenoid valve
• Position the solenoid valve (2)

• Remove the solenoid valve (2)
Removing the flame glow plug
• Remove the flame glow plug (1)

COMMON RAIL SYSTEM
Installing the fuel lines
• Install the fuel line (1) with new seals

• Tighten the hollow screw for the fuel line (1) with
12 Nm
• Tighten the union nut for the fuel line (1) with 5 Nm
• Install the fuel line (2) with new seals
• Tighten the hollow screw for the fuel line (2) with
12 Nm

COMMON RAIL SYSTEM
EDC CONTROL UNIT

Removing and installing the EDC control unit
(1) Rubber bearing (4) Mounting bolt

(2) Console (5) EDC control unit
(3) Rubber bearing (6) Mounting bolt
Technical data
Mounting bolt (6) .................................................. M6x35-10.9 ....................................................... 11 Nm
Mounting bolt (4) .................................................. M8x40-10.9 .......................................................13 Nm
Service products
Loctite 270 ........................................................................................................................ 04.10160-9131
WARNING
Note
After installation of the engine, the EDC control unit needs to be reconfigured and the diagnostic
memory cleared.

COMMON RAIL SYSTEM
Removing the EDC control unit Installing the EDC control unit
Disconnecting the EDC control unit electrical Tightening sequence for EDC control unit
connections
• Follow the illustrated tightening sequence A to H

• Unlock and pull off the plugs (1), (2) and (3) of the mounting bolts (1) in the following work step
• Free the cable harnesses
Attaching the EDC control unit and console
Removing the EDC control unit and console
• Insert the rubber bearings (1) and (2) into the

• Unscrew the mounting bolts (5) console
• Remove the EDC control unit (4) • Thinly apply Loctite 270 on the threads of the new
• Unscrew the mounting bolts (3) mounting bolts (3)
• Remove the console with rubber bearings (1) and • Position the console
(2) • Screw in the mounting bolts (3) and tighten with
13 Nm
• Position the EDC control unit (4)
• Screw in the new mounting bolts (5) and tighten
according to the tightening sequence with 11 Nm

COMMON RAIL SYSTEM
Connecting the EDC control unit electrical con-

nections
WARNING
Risk of irreparable EDC control unit
damage
• When installing the plugs, first fully
open the lock and then insert and lock
the plugs
• Insert and lock the plugs (1), (2) and (3) in the EDC
control unit
• Route the cable harnesses and secure using cable
ties

TURBOCHARGING
TURBOCHARGING
(1) Turbo charger (9) Oil return line

(2) Seal (10) Bracket
(3) Oil pressure line (11) O-ring
(4) Seal (12) Exhaust manifold
(5) Angle union (13) Mounting bolt
(6) GE union (14) Heat shield
(7) Seal (15) Mounting nut
(8) Seal

TURBOCHARGING
CHARGE-AIR PIPES
Removing and installing the charge-air pipes (D0836 LFL44)
Additional jobs
– Removing and installing the flame-start system (D0836 LFL44), see 192
(1) Charge-air pipe (5) Charge-air manifold seal

(2) Mounting bolt charge-air pipe (6) Charge-air manifold
(3) Hose clamp connecting hose (7) Charge-air manifold mounting bolt
(4) Connecting hose
WARNING
Note
Different charge-air pipes are installed.

TURBOCHARGING
Removing the charge-air pipe Installing the charge-air pipe

Removing the charge-air manifold Installing the charge-air pipe
• Disconnect the electrical connection (4) to the • Place the connecting hose (4) on the charge-air
charge-air sensor pipe (1)
• Unscrew the mounting bolts (1) and (2) • Place the hose clamps (3) onto the charge-air
• Remove the charge-air manifold (3) with the seal hose (4)
(5) • Position the charge-air pipe (1)
• Clean the area to be sealed • Insert the mounting bolt (2), screw on a new
mounting nut (5) and tighten
Removing the charge-air pipe • Move the hose clamps (3) into the installation
position
• Tighten the hose clamps (3)
Attaching the charge-air manifold
• Undo the hose clamps (3) on the charge-air hose

(4)
• Pull out the mounting bolt (2)
• Remove the charge-air pipe (1) • Position the charge-air manifold (3) with a new
seal (5)
• Connect the electrical connection of the charge-air
sensor (4)

TURBOCHARGING
TURBO CHARGER
Removing and installing the turbo charger
Additional jobs
– Removing and installing the charge-air pipes (D0836 LFL44), see 201
(1) Turbo charger (9) Oil return line

(2) Seal (10) Bracket
(3) Oil pressure line (11) O-ring
(5) Angle union (13) Mounting bolt
(6) GE union (14) Heat shield
(7) Seal (15) Mounting nut
(8) Seal
Service products
WARNING

TURBOCHARGING
Note
Different charge-air pipes are installed.

TURBOCHARGING
Removing the turbo charger Removing the exhaust manifold
Removing the charge-air pipe

• Remove the exhaust manifold (1)
• Undo the hose clamp (3) Removing the intake fitting
• Pull off the charge-air pipe (2)
Removing the charge-air manifold
• Undo the hose clamp (1)

• Pull off the intake fitting (2)
• Remove the hose (1) Removing the oil pressure line

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

• Remove the oil pressure line (1) with the seal (3)
• Unscrew the GE union (4) and remove it with the
seal (5)
• Unscrew the mounting bolts (2) • Clean the area to be sealed
• Remove the heat shield (1)

TURBOCHARGING
Removing the oil return line Installing the turbo charger

Attaching the turbo charger

• Remove the oil return line (2) with seal (1), bracket
(5) and O-ring (6) • Position the turbo charger (2) with a new seal (3)
• Clean the area to be sealed • Screw on and tighten the new mounting nuts (1)
Removing the turbo charger Attaching the oil return line
• Unscrew the mounting nuts (1) • Thinly apply clean engine oil to a new O-ring (6)
• Remove the turbo charger (2) with seal (3) and fit it onto the oil return line (2)
• Clean the area to be sealed • Insert the oil return line (2) with the bracket (5) into
the crankcase yoke
• Position the oil return line (2) with a new seal (1)
on the turbo charger

TURBOCHARGING
Filling the turbo charger with oil Attaching the intake fitting
• Push on the intake fitting (2) with hose clamp (1)

WARNING
• Tighten the hose clamp (1)
If it is not filled with oil, the turbo
charger will be damaged when started Attaching the exhaust manifold
for the first time
• Fill the turbo charger with clean en-
gine oil before the oil pressure line is
installed.
• Fill clean engine oil into the oil inlet nozzle of the
turbo charger (2) using a funnel (1) until the oil
duct in the turbo charger (2) is full
Attaching the oil pressure line
• Position the exhaust manifold (1)

Attaching the exhaust manifold heat shield
• Screw in the GE union (4) with a new seal (5) and

tighten
• Position the oil pressure line (1) with a new seal
(3)
them by hand
• Screw on the angle union of the oil pressure line
(1) and tighten
• Position the heat shield (1)


TURBOCHARGING
Attaching the charge-air manifold
• Apply a thin layer of Technical Vaseline onto a new

O-ring (3) and insert it into the charge-air manifold
(2)
• Position the charge-air manifold (2) with profiled
clamp (4)
• Tighten the profiled clamp (4)
• Attach the hose (1)
Installing the charge-air pipe
• Insert the charge-air pipe (2) with the hose clamp

(3)
• Tighten the hose clamp (3)

INTAKE/EXHAUST SYSTEM
(1) Exhaust manifold (4) Air distributor pipe

(2) EGR adjusting cylinder (5) Charge-air manifold
(3) EGR module (6) Seal

AIR DISTRIBUTOR PIPE

Removing and installing the air distributor pipe
Additional jobs
– Removing and installing the injectors and pressure pipe, see 146
(1) Seal (3) Charge-air manifold

(2) Temperature sensor
Technical data
Service products
Silicone grease Renolit Si 704............................................................................................ 09.15014-0102
WARNING

Removing the air distributor pipe Removing the charging pressure sensor
Removing the hose

the seals
• Set the hose (1) aside
Removing the heating flow bracket

Removing the charge-air manifold

(2)
• Pull the coupling pipe (3) out of the non-return
valve body

Remove the temperature sensor Installing air distributor pipe

Attaching the air distributor pipe
• Disconnect the electrical connection of the tem-

perature sensor (2)
• Unscrew the temperature sensor (2) and remove • Position the air distributor pipe (2) with new seals
it with the seal (1) (1)
• Screw in the new mounting bolts (3), (4) and (5)
Removing the air distributor pipe as marked and tighten them by hand
• Tighten the mounting bolts (3), (4) and (5)
Installing the temperature sensor

(3), (4) and (5)
• Remove the air distributor pipe (2) with seals (1) • Screw in the temperature sensor (2) with a new
• Clean the area to be sealed seal (1) and tighten with 45 Nm
• Connect the electrical connection of the tempera-
ture sensor (2)

Attaching the charge-air manifold Removing the heating flow bracket
• Thinly apply Silicone grease Renolit Si 704 on the • Screw in and tighten the mounting bolt (1)
new coupling pipe (3)
valve body
seal (2)

then tighten it

O-ring

EGR MODULE
Removing and installing the EGR module
Additional jobs
– Removing and installing the thermostat with thermostat housing, see 57
– Removing and installing the air distributor pipe, see 211

(2) Mounting bolt (6) EGR module
(3) Shut-off flap (7) Non-return valve body
(4) EGR adjusting cylinder
Technical data
EGR module (6) temperature sensor ..................... M16x1.5 ............................................................45 Nm
Mounting nut EGR adjusting cylinder (4) ................ M8 ....................................................................16 Nm
EGR adjusting cylinder (4) pre-load ................................................................................... 1.25 ± 0.25 mm
WARNING
Risk of engine damage from the ingress of water
• Do not open pipe bundles in the EGR module

WARNING
Special tools
[86] Calliper pin 80.99605-0197
• Setting the EGR adjusting cylinder pre-load in

conjunction with:
• Gauge holder [87]
• Dial gauge [88]
[87] Gauge holder 08.71082-0005
• Setting the EGR adjusting cylinder pre-load
[88] Dial gauge 08.71000-3217
• Setting the EGR adjusting cylinder pre-load

Removing the EGR module Removing non-return valves and temperature

sensor
Removing the EGR shut-off flap
• Disconnect the EGR adjusting cylinder electrical WARNING

connection Leaks in EGR modules may cause
• Unscrew the mounting bolts (4) ingress of water into the combustion
• Remove the EGR shut-off flap (3) with seal (2) chamber, resulting in engine damage
from the exhaust manifold (1) • Do not remove the connector with EGR
• Remove the EGR shut-off flap (3) with coupling shut-off flap
pipes from the EGR module (5)
• Pull the coupling pipe (3) out of the non-return
Dismantling the EGR shut-off flap
valve body (1)
• Remove the non-return valve body (1) with non-re-
turn valves (4) and seal (5) from the EGR pipe (6)
• Remove the temperature sensor (7) with seal (8)
Removing the EGR pipe

• Detach ball coupling (2)
• Remove the EGR adjusting cylinder (3)
• Remove the coupling pipes (5) from the EGR
shut-off flap (1)

• Remove the EGR pipe (3) with seals (1)
• Pull the coupling pipe (4) out of the thermostat
housing

Installing the EGR pipe Assembling the EGR shut-off flap
Positioning the EGR pipe
• Check the oil rings of the coupling pipes (5), re-

place as needed
• Insert the new coupling pipe (4) • Insert the coupling pipes (5) into the EGR shut-off
• Fit the EGR pipe (3) with new seals (1) on the flap (1)
coupling pipe (4) • Position the EGR adjusting cylinder (3) and attach
• Screw in and tighten the mounting bolts (2) a new ball coupling (2)
• Screw on the mounting nut (4) and tighten with
Installing non-return valves and temperature 16 Nm
sensor
Installing the EGR shut-off flap
Note • Insert the EGR shut-off flap (3) with coupling pipes
The non-return valves must always be into the connector of the EGR module (5)
installed in flow direction. • Position the EGR shut-off flap (3) with a new seal
(2) on the exhaust manifold (1)
• Insert the coupling pipe (3) into the non-return • Screw in the mounting bolts (4) and tighten with
valve body (1) 16 Nm
• Insert the non-return valves (4) into the EGR pipe • Connect the EGR adjusting cylinder electrical con-
(6) nection
• Position the non-return valve body (1) with a new
seal (5) on the EGR pipe (6)
• Screw in the temperature sensor (7) with a new
seal (8) and tighten with 45 Nm

Adjusting the EGR adjusting cylinder
• Position the Gauge holder [87] (1) with Dial

gauge [88] (2) and Calliper pin [86] on the shut-off
flap
• Position the Calliper pin [86] with pre-load on the
EGR adjusting cylinder
• Undo the mounting nut (3)
• Unscrew the cylinder rod by several turns
• Screw in cylinder rod, until the dial Dial gauge [88]
(2) does not move any longer
• Rotate the cylinder rod by one turn
The permitted pre-load for the EGR adjusting cylin-
der is 1.25 ± 0.25 mm.
If the pre-load is out of tolerance, repeat the process.

EXHAUST MANIFOLD
Removing and installing the exhaust manifold
Additional jobs
– Removing and installing the turbo charger, see 203
(1) Connecting pipe (6) Seal

(2) Mounting bolt (7) Exhaust manifold front
(3) Seal (8) Mounting bolt
(4) Mounting bolt (9) Mounting bolt
(5) Exhaust manifold rear (10) Exhaust manifold centre
Technical data
Mounting bolt (9) .................................................. M8x40-GA ....................................1st tightening 25 Nm
Mounting bolt (9) .................................................. M8x40-GA ....................................... 2nd tightening 45°
Mounting bolt (9) .................................................. M8x40-GA ......................................Final tightening 45°
Mounting bolt exhaust manifold ............................. M8x58-GA ....................................1st tightening 25 Nm
Mounting bolt exhaust manifold ............................. M8x58-GA ....................................... 2nd tightening 45°
Mounting bolt exhaust manifold ............................. M8x58-GA ......................................Final tightening 45°


Mounting bolts shut-off flap ................................... M8x50-GA .........................................................27 Nm
WARNING

Removing the exhaust manifold Dismantling the exhaust manifold
Removing the connecting tube
• Pull exhaust manifolds (1) and (3) out of exhaust

manifold (2)
• Unscrew the mounting bolts (2) • Remove the oil rings (4) from the exhaust mani-
• Remove the connecting tube (1) and seals (3) folds (1) and (2)
• Clean the area to be sealed • Clean the area to be sealed
Removing the exhaust manifold

• Remove the exhaust manifold (3) with seals (5)

Installing the exhaust manifold Attaching the exhaust manifold
Assembling the exhaust manifold
WARNING
• Insert new oil rings (4) into the exhaust manifolds Component damage due to leaking
(1) and (2) exhaust manifolds
• Insert exhaust manifolds (1) and (3) into exhaust • Do not reuse mounting bolts of the
manifold (2) exhaust manifold, even if it has only
been used once
• Position the exhaust manifold (3) with new seals

(5)
• Screw in the new mounting bolts (1) and (2) and
tighten them by hand
• Tighten the mounting bolts (1) with 1st tighten-
ing 25 Nm
• Tighten the mounting bolts (2) with 1st tighten-
ing 25 Nm
• Tighten the mounting bolts (1) with 2nd tighten-
ing 45°
• Tighten the mounting bolts (2) with 2nd tighten-
ing 45°
ing 45°
ing 45°
• Screw in new mounting bolts (4) and tighten with
27 Nm
Attaching the connecting tube
• Position the connecting tube (1) with new seals (3)


CYLINDER HEAD
CYLINDER HEAD
(1) Cylinder head (5) Cylinder head cover

(2) Push rod (6) Rocker arm mechanism
(3) Valve crosshead exhaust valve (7) Valve crosshead inlet valve
(4) Mounting bolt

CYLINDER HEAD
ROCKER ARM MECHANISM

Removing and installing the rocker arm mechanism
Additional jobs
– Checking and adjusting the valve clearance, see 239

(3) Valve crosshead, exhaust valve (7) Valve crosshead inlet valve
(4) Mounting bolt
WARNING

CYLINDER HEAD
Removing the rocker arm mechanism Removing the cylinder head cover
Removing the cable duct cover
Note
• Open the locking pin (1) a quarter turn The mounting bolts can only be removed
• Remove the cable duct cover (2) from the cylinder head cover with damp-
ing elements and spacers.
Disconnecting the electrical connections to the
plug consoles • Open the plug console bayonet catches
age
Removing the rocker arm mechanism
• Disconnect the plug console electrical connections

(1)
Note
Do not unscrew the mounting bolt for
the rocker arm shaft when removing the
rocker arm mechanism.

• Remove the rocker arm mechanism (1)

CYLINDER HEAD
Installing the rocker arm mechanism Connecting the plug console electrical connec-
tions
Installing the rocker arm mechanism
• Connect the plug console electrical connections

• Apply a thin layer of clean engine oil to the ball (1)
sockets of the push rods
• Fit the rocker arm mechanism (1) on the cylinder Attaching the cable duct cover
head and align while inserting the balls of the
rocker arm adjusting screws into the push rods
wise
Attaching the cylinder head cover
• Put on the cable duct cover (2)

• Close the locking pin (1) a quarter turn
• Check the seals of the plug consoles, replace as

needed
• Place the cylinder head cover (2) onto the cylinder
head (1) over the plug console, with a new seal if
necessary
wise

CYLINDER HEAD
Assembling and disassembling the rocker arm mechanism

Additional jobs
– Removing and installing the rocker arm mechanism, see 227
(1) Exhaust valve rocker arm (9) Contact washer

(2) Adjusting screw exhaust valve (10) Pressure spring
(3) Contact washer (11) Contact washer
(4) Pressure spring (12) Inlet valve rocker arm
(5) Contact washer (13) Rocker arm shaft
(6) Adjusting screw inlet valve (14) Rocker bracket
(7) Inlet valve rocker arm (15) Mounting bolt
(8) Exhaust valve rocker arm
Service products
White T assembly paste..................................................................................................... 09.16012-0117
WARNING

CYLINDER HEAD
Special tools
• Removing the rocker arm shaft

CYLINDER HEAD
Dismantling the rocker arm mechanism Assembling the rocker arm mechanism
• Mark the installation position of rocker arms (1) • Insert the rocker arms (1) and (5) into the rocker
and (5), contact washers (2) and (4) and pressure arm support (7) as marked
spring (3) • Insert the contact washers (2) and (4) with pres-
• Unscrew the mounting bolt (8) sure spring (3) into the rocker arm support (7) as
• Press rocker arm shaft (6) with Press-in man- marked
drel [89] out of the rocker arm support (7) and • Thinly apply White T assembly paste on the rocker
leave Press-in mandrel [89] in the rocker arm sup- arm shaft (6)
port (7) • Align the rocker arm shaft (6) with the bore for the
• Slowly pull Press-in mandrel [89] out of the rocker mounting bolt (8)
arm support (7) while removing the rocker arms • Insert rocker arm shaft (6) into the rocker arm
(1) and (5), contact washers (2) and (4) and the bracket (7)
pressure spring (3) • Screw in and tighten the mounting bolt (8)

CYLINDER HEAD
CYLINDER HEAD
Removing and installing the cylinder head
Additional jobs
– Removing and installing the EGR module, see 215
– Removing and installing the exhaust manifold, see 221

CYLINDER HEAD

(3) Valve crosshead exhaust valve (7) Valve crosshead inlet valve
(4) Mounting bolt
Technical data
Cylinder head bolts............................................... 14x2 (E18)....................................1st tightening 80 Nm
Cylinder head bolts............................................... 14x2 (E18).................................2nd tightening 150 Nm
Cylinder head bolts............................................... 14x2 (E18)........................................ 3rd tightening 90°
Cylinder head bolts............................................... 14x2 (E18)........................................ 4th tightening 90°
Cylinder head bolts............................................... 14x2 (E18)......................................Final tightening 90°
WARNING
Special tools
[90] Eye bolt M8 80.99606-0660
• Removing and attaching the cylinder head
[91] Socket wrench insert 80.99612-0023
• Undoing and tightening the cylinder head bolts in

conjunction with:
• Power amplifier wrench i = 1 : 3.5 [93]
• Support [94]
• Protractor [95]
• Stop bolts [96]
• Stud bolt [97]
• Connecting pin [98]
• Rubber ring [99]
• Adapter [100]
• Undoing and tightening the cylinder head bolts
[93] Power amplifier wrench i = 1 : 3.5 80.99619-0007

CYLINDER HEAD
[94] Support 80.99606-0551
[95] Protractor 80.99607-0172
[96] Stop bolts 80.99606-0585
[97] Stud bolt 06.02191-0407
[98] Connecting pin 06.22729-0006
[99] Rubber ring 06.56331-3274
[100] Adapter 80.99606-0552

CYLINDER HEAD
Removing the cylinder head Undoing the cylinder head bolts
Removing the valve crossheads and push rods
• Place the special tool (1) onto the cylinder head

bolt which needs to be undone with Socket wrench
• Mark the valve crosshead installation positions (2) insert [91] (2x)
and (3) • Undo all cylinder head bolts with the special tool
• Remove the valve crossheads (2) and (3) (1)
• Pull out the push rods (1)
Removing the cylinder head
Assembling the special tool
• Unscrew the cylinder head bolts (2)

• Insert the Power amplifier wrench i = 1 : 3.5 [93] • Screw in Eye bolt M8 [90] (4x) at the corners of
(1) into the Support [94] (9) the cylinder head (1) and tighten
• Attach the Stop bolts [96] (6) with the Stud bolt [97] • Lift off the cylinder head (1) with the lifting gear
(8) and the Adapter [100] (7) to the Support [94] • Clean the area to be sealed
(9) • Unscrew the Eye bolt M8 [90] (4x)
• Position the Protractor [95] (2) on the Power am-
plifier wrench i = 1 : 3.5 [93] (1)
• Put the Socket wrench insert, size 22 [92] (3) on
the Power amplifier wrench i = 1 : 3.5 [93] (1)
and secure with the Connecting pin [98] (5) and
the Rubber ring [99] (4)

CYLINDER HEAD
Removing the cylinder head gaskets Installing the cylinder head

Placing the cylinder head gaskets
• Remove the cylinder head gaskets (2) via the

alignment pins (1)
• Clean the area to be sealed • Place new cylinder head gaskets (2) via alignment
• Clean the threaded bores of the cylinder head pins (1)
bolts
Attaching the cylinder head
WARNING
Component damage due to leaky
cylinder head gasket
• Do not reuse old cylinder head bolts,
even if they have only been used once
• Screw in Eye bolt M8 [90] (4x) at the corners of

the cylinder head (1) and tighten
• Place the cylinder head (1) on the crankcase using
the lifting gear
• Unscrew the Eye bolt M8 [90] (4x)
• Thinly apply clean engine oil on the contact sur-
faces of the new cylinder head bolts (2)
• Screw in the cylinder head bolts (2) by hand

CYLINDER HEAD
Tightening sequence for cylinder head Installing the valve crossheads and push rods
• Observe the illustrated tightening sequence 1 to • Thinly apply clean engine oil on the balls of the
24 in the following work step push rods (1)
• Insert the push rods (1) into the ball cups of the
Tightening the cylinder head bolts rods
• Install the valve crossheads (2) and (3) as marked
Note
Observe the gear ratio: Power amplifier
wrench i = 1 : 3.5 [93].
• Place the special tool (1) onto the cylinder head

bolt which needs to be tightened using Socket
wrench insert [91] (2x)
• Tighten the cylinder head bolts with the special
tool (1) with 1st tightening 80 Nm in the sequence
indicated
• Tighten the cylinder head bolts with the special tool
(1) with 2nd tightening 150 Nm in the sequence
indicated
tool (1) with 3rd tightening 90° in the sequence
indicated
tool (1) with 4th tightening 90° in the sequence
indicated
tool (1) with Final tightening 90° in the sequence
indicated

CYLINDER HEAD
Checking and adjusting the valve clearance
(1) Valve crosshead inlet valve (4) Adjusting screw exhaust valve
(2) Valve crosshead exhaust valve (5) Adjusting screw inlet valve
(3) Adjusting screw EVB
Technical data
Lock nuts of the adjusting screws (3), (4), (5) ......... M10x1-8.8 .........................................................40 Nm
Inlet valve clearance ................................................................................................................... 0.50 mm
Exhaust valve clearance ............................................................................................................. 0.50 mm
EVB brace setting dimensions..................................................................................................... 0.35 mm
WARNING
Danger of reduced engine output or engine damage
• Do not perform any settings if the coolant temperature is above 50 °C
WARNING

CYLINDER HEAD
Special tools

[102] Gear ratchet 80.99627-0001
[103] Feeler gauge 08.75310-3309
• Checking and adjusting the valve clearance
[104] Valve adjustment spanner SW 14 80.99603-6031
• Adjusting the valve clearance in conjunction with:

• Handle [105]
[105] Handle 08.06460-0003
• Setting the valve clearance
[106] Torque wrench 08.06450-0006
• Tightening the lock nut of the adjusting screw

CYLINDER HEAD
Checking and adjusting the valve clear- Placing the engine in the setting position
ance
Removing the cylinder head cover
A Rocker arms in overlap

B Rocker arm free
• Crank the engine with Engine cranking unit [101]

Note and Gear ratchet [102] in the engine's running
The mounting bolts can only be removed direction until the rocker arms are in overlap
from the cylinder head cover with damp- • Adjust the free rocker arms as per table
ing elements and spacers.
Checking the inlet valve clearance
• Open the plug console bayonet catches
age
• Crank the engine to the setting position see Plac-

ing the engine in the setting position, 241
• Insert the Feeler gauge [103] (2) with feeler gauge
leaf 0.50 mm between the rocker arm (1) and the
valve crosshead (3)
The valve clearance must be adjusted if the valve
clearance is not 0.50 mm.
• Remove the cap from the flywheel housing

• Attach the Engine cranking unit [101] (1) on the
flywheel housing

CYLINDER HEAD
Adjusting the inlet valve clearance Placing the EVB piston in the setting position
• Undo the lock nut (1) and adjusting screw (2)

WARNING
with Valve adjustment spanner SW 14 [104] in
Risk of incorrect valve clearance
conjunction with Handle [105]
• It must be possible to fully push the EVB
• Turn back the adjusting screw (2) with Valve ad-
piston into the valve crosshead
justment spanner SW 14 [104] and Handle [105]
until the Feeler gauge [103] (4) with feeler gauge
• Undo the lock nut (2) and unscrew it several turns
leaf 0.50 mm fits between the rocker arm (3) and
• Screw in the adjusting screw (3) to press the valve
the valve crosshead (5)
crosshead downwards several times until the stop
• Turn back the adjusting screw (2) with Valve ad-
All the engine oil must fully escape from the EVB
justment spanner SW 14 [104] and Handle [105]
piston (1)
until the Feeler gauge [103] (4) with feeler gauge
leaf 0.50 mm fits between the rocker arm (3) and
the valve crosshead (5)
• Brace the adjusting screw (2) and tighten the lock
nut (1) with Torque wrench [106] and Valve adjust-
ment spanner SW 14 [104] with 40 Nm
• Check the setting again and repeat the setting
procedure if necessary
Checking the exhaust valve clearance
• Insert the Feeler gauge [103] (2) with feeler gauge

leaf 0.50 mm between the rocker arm (1) and the
valve crosshead (3)
The valve clearance must be adjusted if the valve
clearance is not 0.50 mm.

CYLINDER HEAD
Adjusting the exhaust valve clearance Adjusting the EVB clearance
• Undo the lock nut (5) Note

• Screw in the adjusting screw (1) to press the valve The valve crosshead must not move the
crosshead (3) downwards several times until the exhaust valve when the adjusting screw
stop is screwed in.
• Block the valve crosshead (3) in this position with
the adjusting screw (4) • Undo the lock nut (1)
• Insert the Feeler gauge [103] (2) with feeler gauge • Screw out the adjusting screw (2) until the Feeler
leaf 0.50 mm between the rocker arm and the gauge [103] (3) with feeler gauge leaf 0.35 mm
valve crosshead (3) can be inserted
• Unscrew the adjusting screw (1) until the Feeler • Screw in the adjusting screw (2) with inserted
gauge [103] (2) with feeler gauge leaf can be Feeler gauge [103] (3) until the valve crosshead
moved with little resistance between the rocker reaches the stop – this can be felt by a noticeable
arm and the valve crosshead (3) increase in force
• Brace the adjusting screw (1) and tighten the lock • Brace the adjusting screw (2) and tighten the lock
nut (5) with Torque wrench [106] and Valve adjust- nut (1) with Torque wrench [106] and Valve adjust-
ment spanner SW 14 [104] with 40 Nm ment spanner SW 14 [104] with 40 Nm
• Check the setting again and repeat the setting • Check the setting again and repeat the setting
procedure if necessary procedure if necessary
Checking the setting dimensions for the EVB Attaching the cylinder head cover
piston
• Check the seals of the plug consoles, replace as

• Lightly push down valve crosshead (3) needed
• Insert the Feeler gauge [103] (2) with feeler gauge • Place the cylinder head cover (2) onto the cylinder
leaf 0.35 mm between the adjusting screw (1) and head (1) over the plug console, with a new seal if
the valve crosshead (3) necessary
The EVB clearance must be adjusted if setting di- • Screw in the mounting bolts (3) and tighten cross-
mension is not 0.35 mm. wise

CYLINDER HEAD
• Remove the Engine cranking unit [101] (1) from

the flywheel housing

CYLINDER HEAD
Removing and installing the valve-stem seal

Additional jobs
(1) Valve (4) Valve spring

(2) Cylinder head (5) Valve cotter
(3) Valve-stem seal
WARNING

CYLINDER HEAD
Special tools

[108] Gear ratchet 80.99627-0001
[109] Valve spring tensioner 80.99613-6000
• Removing and installing the valve spring in con-

junction with:
• Intermediate piece [110]
• Bracket [113]
• Bracket [114]
• Extension [112]
• Assembly device [111]
[110] Intermediate piece 80.99613-0041
• Removing and installing the valve springs
[111] Assembly device 80.99606-6092
[112] Extension 80.99606-6094
[113] Bracket 80.99613-0052

CYLINDER HEAD
[114] Bracket 80.99613-0053
[115] Magnetic lifter 80.99639-0009
• Removing the valve separators
[116] Assembly device 80.99606-6088
• Removing the valve-stem seal

• Installing the valve-stem seal in conjunction with:
• Assembling sleeve [117]
[117] Assembling sleeve 80.99606-0634
• Installing the valve-stem seal

CYLINDER HEAD
Removing the valve stem seals Removal and installation position for valve-stem
seals
• Remove and install the free valve stem seals ac-

• Remove the cap from the flywheel housing cording to the table
flywheel housing Removing the rocker arm mechanism
Turning the engine to the TDC mark
Note
Do not unscrew the mounting bolt for
• Turn the engine with Engine cranking unit [107]
the rocker arm shaft when removing the
(1) and Gear ratchet [108] in the engine's running
rocker arm mechanism.
direction until the 1st cylinder is at the TDC mark
(2) • Unscrew the mounting bolts (2)
• Remove the rocker arm mechanism (1)

CYLINDER HEAD
Removing the valve crossheads and push rods Assembling the special tool
• Mark the valve crosshead installation positions (2)

and (3)
• Remove the valve crossheads (2) and (3)
• Pull out the push rods (1)
Note
The lock washer and Bracket [114] have
left-handed threads.
• Position Bracket [113] (5) and Bracket [114] (3) at

Valve spring tensioner [109] (1) and screw on by
turning the threaded spindle (4)
• Screw on the lock washers (2) and (6)
• Position the lever (8) on the Valve spring ten-
sioner [109] (1) and secure using the mounting
bolt (7)

CYLINDER HEAD
Attaching the assembly device Attaching the valve-spring compressor
• Screw the Intermediate piece [110] (1) into the • Position the Bracket [113] (4) and the Bracket [114]
cylinder head at the spring disc and tension by turning the
• Screw the Assembly device [111] (2) into the Inter- threaded spindle (5)
mediate piece [110] (1) • Hook the Valve spring tensioner [109] (2) into the
Assembly device [111] (3)
• Put the Extension [112] (1) on the Valve spring
tensioner [109] (2)

CYLINDER HEAD
Removing the valve separators Removing the valve spring
CAUTION
Risk of injury due to the valve spring
snapping back
• Ensure that the Bracket [113] and the
Bracket [114] are seated correctly on
the spring disc
• Do not remove the valve separators
from the valve spring with your bare
hands
• Push down the Valve spring tensioner [109] (1)

with the Extension [112]
• Remove the valve separators (2) from the valve
stem (3) using the Magnetic lifter [115]
• Remove tension from Valve spring tensioner [109] • Remove the washer (3), valve spring (2) and
(1) spring disc (1) over the valve stem
• Repeat the same procedure for all the valves • Repeat the same procedure for all the valves
Removing the valve stem seals
• Slide the Assembly device [116] (2) over the

valve-stem seal (1)
• Tension the Assembly device [116] (2)
• Pull the valve stem seal (1) off the valve guide with
the impact weight (3)

CYLINDER HEAD
Installing the valve stem seals Installing the valve springs
Installing the valve stem seals
• Insert the washer (3), valve spring (2) and spring

disc (1) over the valve stem
• Thinly apply clean engine oil on the Assembling • Repeat the same procedure for all the valves
sleeve [117] (2) and the valve stem seal (3)
• Slide the Assembling sleeve [117] (2) over the
valve-stem (1)
• Insert the valve-stem seal (3) in the Assembly
device [116] (4) and tension it
• Slide the Assembly device [116] (4) over the As-
sembling sleeve [117] (2)
• Knock the valve stem seal (3) onto the valve stem
(1) using the impact weight (5)
• Remove the Assembly device [116] (4) and the
Assembling sleeve [117] (2)

CYLINDER HEAD
Attaching the assembly device Attaching the valve-spring compressor
• Screw the Intermediate piece [110] (1) into the • Position the Bracket [113] (4) and the Bracket [114]
cylinder head at the spring disc and tension by turning the
• Screw the Assembly device [111] (2) into the Inter- threaded spindle (5)
mediate piece [110] (1) • Hook the Valve spring tensioner [109] (2) into the
Assembly device [111] (3)
• Put the Extension [112] (1) on the Valve spring
tensioner [109] (2)

CYLINDER HEAD
Installing the valve separators Moving the engine into the removal and installa-
tion position
CAUTION
Risk of injury due to the valve spring Note
snapping back The following process must be repeated
• Ensure that the Bracket [113] and the for the remaining cylinders.
Bracket [114] are seated correctly on
the spring disc
• Crank the engine with the Engine cranking
• Do not insert the valve separators into
unit [107] and the Gear ratchet [108] in the direc-
the valve spring with your bare hands
tion of rotation of the engine by 120°
• Remove and install the free valve stem seals ac-
• Push down the Valve spring tensioner [109] (1)
cording to the table, see Removal and installation
with the Extension [112]
position for valve-stem seals, 248
• Use a suitable tool to insert the valve separators
(2) so that the valve separators (2) are seated in Installing the valve crossheads and push rods
the grooves of the valve stem (3)
• Remove tension from Valve spring tensioner [109]
(1)
• Thinly apply clean engine oil on the balls of the

push rods (1)
• Insert the push rods (1) into the ball cups of the
rods
• Install the valve crossheads (2) and (3) as marked

CYLINDER HEAD
Installing the rocker arm mechanism
• Apply a thin layer of clean engine oil to the ball

sockets of the push rods
• Fit the rocker arm mechanism (1) on the cylinder
head and align while inserting the balls of the
rocker arm adjusting screws into the push rods
wise
• Remove the Engine cranking unit [107] (1) from

the flywheel housing

CAMSHAFT/CAMSHAFT BEARING
(1) Camshaft (3) Tappet

(2) Flange

Removing and installing the camshaft
Additional jobs
– Draining and topping up the engine oil, see Maintenance Instructions
– Removing and installing Frigoblock alternator, see 123
– Removing and installing the refrigerant compressor, see 131
– Removing and installing the hydraulic pump, see 135
– Removing and installing the coolant manifold, see 49
– Removing and installing the vibration damper, see 309
– Removing and installing the starter motor, see 127
– Removing and installing the flywheel for the manually operated gearbox, see 313
– Removing and installing the timing case cover, see 369
– Removing and installing the cylinder head, see 233
– Removing and installing the oil sump and oil intake pipe, see 293
– Removing and installing the crankcase yoke, see 365
– Removing and installing the timing gears, see 277
– Removing and installing the timing case, see 373
– Removing and installing the front crankshaft seal, see 345
– Removing and installing the flywheel housing (version without PTO), see 357
– Removing and installing the rear crankshaft seal, see 349
– Removing and installing the flywheel housing (version with PTO), see 360
– Removing and installing the piston and the connecting rod, see 323
– Removing and installing the crankshaft, see 333

(1) Camshaft (3) Tappet

(2) Flange
Technical data
Axial play camshaft (1)................................................................................................... 0.140 - 0.270 mm
Radial play camshaft (1) ................................................................................................ 0.060 - 0.120 mm
WARNING

Special tools
[118] Insertion pin 80.99617-6008
• Removing and installing the camshaft in conjunc-

tion with:
• Stud bolt [119]
[119] Stud bolt 06.02099-0357
• Removing and installing the camshaft
[120] Dial gauge 08.71000-3217
• Checking the camshaft axial play in conjunction

with:
[121] Gauge holder 08.71082-0005
• Checking the camshaft axial play

Removing the camshaft Removing the tappet
Removing the axial shim from the camshaft

• Remove the axial shim (2) from the camshaft (3)
Attaching the guide tool
WARNING
Component damage due to residual
magnetism
• Do not remove the tappet with a mag-
net, as the residual magnetism causes
metallic wear debris to fix onto tappets
• Position the adapter (3) Insertion pin [118] (1) on and destroys the running surface
the camshaft (4)
• Screw in and tighten the Stud bolt [119] (2) • Remove the tappet (1)
• Screw the Insertion pin [118] (1) into adapter (3)
Removing the camshaft
• Pull the camshaft (2) out of the crankcase (1)

towards the flywheel side

Installing the camshaft Installing the camshaft
Installing the tappet
WARNING
Camshaft bearings may be damaged
during installation
• Always use the special tool to install the
camshaft
• Apply a thin layer of clean engine oil to the

camshaft (2) and the camshaft bearing surfaces
• Screw the Insertion pin [118] into the adapter
• Insert the camshaft (2) into the crankcase (1)
• Remove the Insertion pin [118]
Installing the axial shim on the camshaft
• Apply a thin layer of clean engine oil on the tappet

(1)
• Insert the tappet (1) into the crankcase
• Position the axial shim (2) on the camshaft (3)


Checking the camshaft axial play

Attaching the camshaft drive wheel
• Position the camshaft drive wheel (2) onto the

camshaft (3) via the guide pin (4)
• Secure the camshaft drive wheel (2) with two
screws (1)
Checking the camshaft axial play
• Fit the Dial gauge [120] (1) with the Gauge

holder [121] (2) on the crankcase
• Position the tracer pin of the dial gauge against
the camshaft drive wheel (3)
• Push the camshaft to one end position and zero
the Dial gauge [120] (1)
• Push the camshaft to the other end position and
read off the difference from the Dial gauge [120]
(1)
The permitted axial play of the camshaft is
0.140 - 0.270 mm.

Removing and installing the camshaft bearing

Additional jobs
– Removing and installing the camshaft, see 259

(1) Camshaft bearing 5 (4) Camshaft bearing 2

(2) Camshaft bearing 4 (5) Camshaft bearing 1
(3) Camshaft bearing 3
WARNING
WARNING
Component damage due to transposed camshaft bearing
• In the camshaft bearing for bearing seat 1 there is only one oil bore, which distinguishes it from
the other camshaft bearings
Note
For structural reasons, there are seven bearing seats located for the camshaft in the crankcase,
but only five camshaft bearings are installed.
The camshaft bearings are located in camshaft bearing seats 1, 2, 3, 5 and 7.

Special tools
[122] Guide mandrel 80.99606-0762
• Removing and installing the camshaft bearing in

conjunction with:
• Press-in bushing [129]
• Press-in bushing [128]
• Press-out bush [125]
• Stop [127]
• Yoke [123]
• Centring disc [124]
[123] Yoke 80.99606-0763
• Removing and installing the camshaft bearing
[124] Centring disc 80.99606-0765
• Removing and installing the camshaft bearing
[125] Press-out bush 80.99602-0768
• Removing the camshaft bearings
[126] Centring disc 80.99606-0767
• Removing the camshaft bearings
[127] Stop 80.99606-0766
• Installing the camshaft bearing
[128] Press-in bushing 80.99606-0769
• Installing the camshaft bearing 1

[129] Press-in bushing 80.99606-0764
• Installing the camshaft bearing
[130] Impact extractor 80.99602-0016
• Removing the bearing seat camshaft bearings 1

and 7 in conjunction with:
• Extractor tool [131]
[131] Extractor tool 80.99602-6012
• Removing the bearing seat camshaft bearings 1

and 7

Removing the camshaft bearings Removing the camshaft bearing 5 from bearing
seat 7
Removal order for camshaft bearings
• Remove the camshaft bearing (1) using Impact

extractor [130] (3) and Extractor tool [131] (2)
Note
All of the following steps refer to the re- Inserting the centring disk into bearing seat 4
moval order for the camshaft bearings il-
lustrated here.
• Adhere to the removal sequence (1) to (5)
Attaching the special tool for camshaft bearings
Note
Centring disc remains installed through-
out the entire removal and installation
process.
Insert centring disc so that the guide pin
• Insert the Impact extractor [130] (3) with folded in the centring disc points upwards to the
Extractor tool [131] (2) through camshaft bearing area of the oil sump to be sealed and
5 (1) snaps into the oil bore.
• Fold Extractor tool [131] (2) behind camshaft bear-
ing 5 (1) and centre it • Insert the Centring disc [124] (2) into the bearing
seat 4 (1)

Inserting the press-in bush in bearing seat 1 Note on removing camshaft bearings
Note Note
The press-in bush has Front top written The Yoke [123] must be attached in the
on the outside. appropriate position for the camshaft
Insert centring disc so that the marking bearing being removed.
points towards to the area of the oil sump
to be sealed and snaps into the oil bore. • Put the Yoke [123] on position (1) for the camshaft
bearing on bearing seat 5
• Insert the Press-in bushing [128] (2) into the bear- • Put the Yoke [123] onto the piston (2) for the
ing seat 1 (1) camshaft bearing on bearing seat 3
• Put the Yoke [123] onto the piston (3) for the
Inserting the centring disk into bearing seat 7 camshaft bearing on bearing seat 2
Removing the camshaft bearings from bearing

seats 2, 3 and 5
Note
The cantering disk has Rear top written
on the outside.
• Insert the Press-out bush [125] (2) into camshaft
Insert centring disc so that the marking
bearing 2
points towards to the area of the oil sump
• Insert Guide mandrel [122] (1) without Stop [127]
to be sealed and snaps into the oil bore.
with the long side through Press-out bush [125] (2)
into the centring disks in bearing seats 1, 4 and 7
• Insert the Centring disc [126] (2) into the bearing
• Fit the Yoke [123] (3)
seat 7 (1)
• Knock camshaft bearing 2 out
• Repeat the process for the camshaft bearings
on bearing seats 3 and 5, adjusting Press-out
bush [125] (2) with Yoke [123] (3) accordingly

Installing the camshaft/camshaft bear- Note on installing camshaft bearings

ing
Preparing to install the camshaft bearings
Note
The Yoke [123] must be attached in the
• Place the camshaft bearing (2) on the Press-in appropriate position for the camshaft
bushing [129] (4) bearing being removed.
• The notch (5) in the camshaft bearing must be No Yoke [123] is required for the camshaft
facing the timing case side of the engine bearing in bearing seat 1.
• Engage the spring loaded ball (3) in the oil bore
(1) • Put the Yoke [123] in position (1) for the camshaft
The centring bore of the press-in tool can be seen bearing seat on bearing seat 7
through the second oil bore. • Put the Yoke [123] onto the piston (2) for the bear-
ing seat on bearing seat 5
Installation order for camshaft bearings • Put the Yoke [123] onto the piston (3) for the bear-
• Put the Yoke [123] onto the piston (4) for the bear-
• Adhere to the installation sequence (1) to (5)

All of the following steps refer to the installation order
illustrated here.

Installing the camshaft bearings in bearing seats Inserting the special tool into camshaft bearing
2, 3, 5 and 7 1
• Push the Stop [127] with the side that is not re- • Insert the Impact extractor [130] (1) with folded
cessed onto Guide mandrel [122] (2) Extractor tool [131] (2) through camshaft bearing
• Position the Press-in bushing [129] (3) with 1 (3)
pushed-on camshaft bearing (4) on bearing seat 2 • Fold Extractor tool [131] (2) behind camshaft bear-
• Insert Guide mandrel [122] (2) with the long side ing 1 (3) and centre it
through Press-in bushing [129] (3) into the centring
disks in bearing seats 1, 4 and 7 Removing camshaft bearing 1
• Position Yoke [123] (1) accordingly, see Note on
installing camshaft bearings, 271
• Knock in the camshaft bearing (4) into bearing seat
2 until the Stop [127] on the crankcase is reached
• Repeat the procedure for the camshaft bearings
on bearing seats 3 and 5
• Remove the Centring disc [126] from bearing seat
7 and press the camshaft bearing in
Removing the press-in bush from bearing seat 1
• Remove the camshaft bearing 1 (3) using Impact

extractor [130] (1) and Extractor tool [131] (2)
• Remove the Press-in bushing [128] (2) from bear-

ing seat 1 (1)

Installing the camshaft bearing 1
• Insert the Press-in bushing [129] into bearing seat

2 and snap into the oil bore
• Push the Stop [127] (6) onto Guide mandrel [122]
(2) with the side that is not recessed
• Position Press-in bushing [128] (5) with pushed-on
camshaft bearing (4) on Guide mandrel [122] (2)
• Insert Guide mandrel [122] (2) with the long side
Press-in bushing [129] and Centring disc [124] (1),
ensuring that Guide mandrel [122] (2) is guided
into Centring disc [124] (1) by the rod
• Position the Press-in bushing [128] (5) with
pushed-on camshaft bearing (4) on bearing seat
1 (3)
• Knock in Press-in bushing [128] (5) with camshaft
bearing (4) into bearing seat 1 (3) until Stop [127]
on the crankcase is reached
Checking the oil bores
• Check that the oil bores (2) in the camshaft bearing

(1) are in the correct position or align sufficiently
with the oil bores in the crankcase (3)
If the oil bores are not aligned, remove the affected
camshaft bearing and install it correctly

TIMING GEARS
TIMING GEARS
(1) Intermediate gear 2 (4) Crankshaft gear wheel

(2) Drive gear oil pump (5) Camshaft gear wheel
(3) Intermediate gear bolt

TIMING GEARS
TIMING GEARS
Removing and installing the timing gears
Additional jobs
(1) Intermediate gear 2 (2) Drive gear oil pump

TIMING GEARS
(3) Intermediate gear bolt

(4) Crankshaft gear wheel
(5) Camshaft gear wheel
Technical data
Mounting bolts camshaft gear (5) .......................... M10x1.25x38-10.9 .............................................65 Nm
Mounting nut, drive wheel oil pump (2)................... M12x1.5-6S .......................................................45 Nm
Installation play of the timing wheels

Radial play, intermediate gear 1 ..................................................................................... 0.060 - 0.109 mm
Axial play, intermediate gear 1........................................................................................ 0.200 - 0.280 mm
Radial play intermediate gear 2 (1) ................................................................................. 0.035 - 0.076 mm
Axial play intermediate gear 2 (1) ................................................................................... 0.100 - 0.200 mm
Checking the tooth flank clearance of the timing gears

Crankshaft wheel (4) - camshaft gear (5) ........................................................................ 0.051 - 0.149 mm
Camshaft gear (5) - air compressor wheel....................................................................... 0.051 - 0.185 mm
Crankshaft gear (4) - intermediate gear 1........................................................................ 0.050 - 0.187 mm
Intermediate gear 1 - intermediate gear 2 (1) .................................................................. 0.051 - 0.175 mm
Intermediate gear 1 - oil pump gear (2) ........................................................................... 0.053 - 0.190 mm
Service products
Loctite 573 ........................................................................................................................ 04.10160-9249
Loctite 648 ........................................................................................................................ 04.10160-9164
WARNING
Special tools
• Locking the engine

[133] Gear ratchet 80.99627-0001

TIMING GEARS
Removing and installing the intermedi- Setting the timing gears as marked
ate gears
Fixing the crankshaft gear
• Crank the engine with Engine cranking unit [132]

and Gear ratchet [133] until the marks on the
camshaft gear (1) is lined up with the crankshaft
• Secure the crankshaft gear (2) using two mounting gear (2)
bolts (1) • Lock Engine cranking unit [132]
Attaching the engine cranking unit Undoing the oil pump mounting nut
• Remove the cap from the flywheel housing • Undo the mounting nut (1)
flywheel housing Removing intermediate gear 2

• Remove intermediate gear bolt (2) and intermedi-
ate gear (3)

TIMING GEARS
Removing intermediate gear 1 Attaching intermediate gear 1
• Mark the installation position of the mounting bolts • Thinly apply clean engine oil onto the intermediate
(1) and (2) gear bolt (3)
• Unscrew the mounting bolts (1) and (2) • Position the intermediate gear bolt (3) with the
• Remove intermediate gear bolt (3) and intermedi- intermediate gear (4)
ate gear (4) • Screw in and tighten the new mounting bolts (1)
and (2) as marked
Removing the oil pump drive gear
Attaching intermediate gear 2

• Pull off the oil pump drive gear (2) • Thinly apply clean engine oil on the intermediate
gear bolt (2)
Attaching the oil pump drive gear • Position the intermediate gear bolt (2) with the
intermediate gear (3)
• Thinly apply Loctite 648 to the cone in the oil pump

drive gear (2) and on the oil pump
• Fit the oil pump drive gear (2)
• Screw on the mounting nut (1)

TIMING GEARS
Tightening the oil pump mounting nut Removing and installing the camshaft
gear and camshaft gear
Unscrewing the camshaft gear mounting bolts
• Tighten the mounting nut (1) with 45 Nm
Removing the camshaft wheel
• Pull the camshaft gear (1) off camshaft (2)
Attaching the camshaft gear
• Align the marks on the camshaft gear (1) and the

crankshaft gear
• Align the camshaft (2), if needed to the hole pat-
tern of the camshaft gear (1)
• Place the camshaft gear (1) via the guide pin onto
the camshaft gear (2)

TIMING GEARS
Screwing in the camshaft gear mounting bolts Fitting the crankshaft gear
• Screw in new mounting bolts (1) and tighten with • Thinly apply Loctite 573 on the back of the crank-
65 Nm shaft gear (1)
• Align camshaft gear and crankshaft gear marks
Unscrewing the crankshaft gear mounting bolts (1) with each other
• Put the crankshaft gear (1) via the guide pin (3)
onto the crankshaft (2)
Fixing the crankshaft gear
• Unlock crankshaft gear (2) by screwing out the

mounting bolt (1)
Removing the crankshaft gear

• Secure the crankshaft gear (2) using two mounting
bolts (1)
• Pull the crankshaft gear (1) off the crankshaft (2)

• Clean the contact areas of the crankshaft gear (1),
crankshaft (2) and guide pin (3)

TIMING GEARS
Checking the marking overlap
• Unlock the Engine cranking unit [132] and crank

the crankshaft by 720°
• Check the marks for camshaft gear (1) and crank-
shaft gear (2) for consistency
If the marks are not in line, the camshaft gear (1)
must be removed and reinserted at the mark.
Unscrewing the crankshaft gear mounting bolts
• Unlock crankshaft gear (2) by screwing out the

mounting bolt (1)
• Remove the Engine cranking unit [132] from the

flywheel housing

ENGINE LUBRICATION
ENGINE LUBRICATION
(1) O-rings (8) Pressure relief valve

(2) Oil cooler (9) Oil intake pipe
(3) Seal (10) Noise suppression housing
(4) Pressure sensor (11) Mounting bolt
(5) Oil module (12) Oil pump
(6) Seal (13) Coupling sleeve
(7) Oil sump

ENGINE LUBRICATION
OIL MODULE
Removing and installing the oil module

(2) Oil module (6) Seal
(3) Pressure sensor (7) Oil cooler
(4) Screw plug
Technical data
Oil filter lid ......................................................................................................................................25 Nm
Mounting bolt (1) .................................................. M6x20 ...............................................................12 Nm
WARNING

ENGINE LUBRICATION
Special tools
[134] Oil filter wrench 80.99606-0581
• Removing and installing the oil filter lid

ENGINE LUBRICATION
Removing oil filter Installing oil filter

Removing oil filter
• Insert the new oil filter (3) into the oil filter lid (2)
• Screw the oil filter cover (2) into the oil module (4)
• Unscrew the oil filter cover (2) from the oil module using Oil filter wrench [134] (1) and tighten with
(4) using Oil filter wrench [134] (1) 25 Nm
• Pull the oil filter (3) out of the oil filter cover (2)
Renewing the seals
• Remove the O-ring (4) from the oil filter lid (3)
• Remove the O-rings (1) and (2)
• Fit the new O-ring (4) on the oil filter lid (3)
• Fit new O-rings (1) and (2)
• Thinly apply clean engine oil to O-rings (1), (2) and
(4)

ENGINE LUBRICATION
Removing the oil module Removing the oil module
Draining the coolant
• Disconnect the electrical connection of the pres-

sure sensor (2)
WARNING • Unscrew the pressure sensor (2) and remove it
Danger of engine damage due to oil with the seal (1)
emulsion • Unscrew the mounting bolts (3)
• Drain all the coolant before removing • Remove the oil module (4) with seal (5)
the oil module, otherwise coolant will • Clean the area to be sealed
enter the oil sump when the oil module
Removing the oil cooler
is removed from the crankcase
• Unscrew the screw plug (1) and remove it with the

seal
• Drain the coolant
Disconnecting the pressure sensor electrical

connection
• Put the oil module (3) aside so as not to damage

the oil cooler (4)
• Remove the oil cooler (4) with seal (2) from the oil
module (3)
• Disconnect the electrical connection (1) of the

pressure sensor (2)

ENGINE LUBRICATION
Installing the oil module Connecting the pressure sensor electrical con-
nection
Installing the oil cooler
• Connect the pressure sensor (2) electrical con-

• Insert the oil cooler (4) with new seal (2) into the nection (1)
oil module (3)
• Screw in new mounting bolts (1) and tighten with Screwing in the screw plug
12 Nm
Attaching the oil module
• Screw in the screw plug (1) with a new seal and

tighten
• Position the oil module (4) with a new seal (5)

• Apply a thin layer of clean engine oil to the thread
of the pressure sensor (2)
• Screw in the pressure sensor (2) with a new seal
• Connect the electrical connection of the pressure
sensor (2)

ENGINE LUBRICATION
OIL SUMP AND OIL INTAKE PIPE

Removing and installing the oil sump and oil intake pipe
Additional jobs
(1) Noise suppression housing (6) Oil sump

(2) Mounting bolt (7) Absorber mat
(3) Spacer (8) Holding piece
(4) Crankcase yoke (9) Mounting bolt
(5) Seal
Technical data
Oil level sensor..................................................... M22x1.5 ............................................................25 Nm
WARNING

ENGINE LUBRICATION
Removing the oil sump and the oil intake Removing the noise suppression housing
pipe
nection

• Free, set aside and secure the oil level sensor
cable harness (1)
Removing the oil level sensor

• Remove the noise suppression housing (2) with
absorber mat (1) and spacers (4)
• Unscrew the oil level sensor (1) and remove along

with the seal (2)

ENGINE LUBRICATION
Removing the oil sump Removing the oil-pressure relief valve
• Unscrew the screw plug (1) and remove with the

seal (2)
• Remove the pressure spring (3) with piston (4)
from the crankcase

• Remove the holding pieces (1)
• Remove the oil sump (3)
• Remove the seal (4) from the oil sump (3)
Removing the oil intake pipe

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

ENGINE LUBRICATION
Installing the oil sump and the oil intake Attaching the oil sump
pipe
Installing the oil-pressure relief valve
• Thinly apply clean engine oil on the piston (4)

• Insert the piston (4) with the pressure spring (3) in
the crankcase
• Screw in and tighten the screw plug (1) with a new
seal (2)
Installing the oil intake pipe
• Place a new seal (4) on the oil sump (3)

• Position the oil sump (3)
• Position the holding pieces (1)
them by hand
• Thinly apply clean engine oil to a new O-ring (2)

and insert it into the crankcase yoke (1)
• Insert the oil intake pipe (3) into the crankcase
yoke (1)

ENGINE LUBRICATION
Attaching the noise suppression housing Connecting the oil level sensor electrical con-
nection
• Route the oil level sensor cable harness (1) so that

it is free of tension and kinks and does not chafe
• Place the absorber mat (1) in the noise suppres-

sion housing (2)
• Position the noise suppression housing (2) with
spacers (4)
Installing the oil level sensor
• Thinly apply clean engine oil on the thread of the

oil level sensor (1)
• Screw in the oil level sensor (1) with a new seal

ENGINE LUBRICATION
OIL PUMP
Removing and installing the oil pump
Additional jobs

ENGINE LUBRICATION
(1) Oil pump gear (4) O-rings

(2) Oil pump gear (5) Coupling sleeve
(3) Oil pump housing
Technical data
Axial play, oil pump gears............................................................................................... 0.040 - 0.106 mm
WARNING
Special tools
[135] Straightedge 80.99605-0167
• Checking the axial play of the oil pump gears

ENGINE LUBRICATION
Removing the oil pump Checking the oil pump gear axial play
Unscrewing the oil pump mounting bolts
• Fit the Straightedge [135] (3) with the measuring

edge on the oil pump housing (4)
• Unscrew the mounting bolts (1) • Check the axial play between the oil pump gears
(2) and Straightedge [135] with the feeler gauge
Removing the oil pump (1)
The permitted axial play is 0.040 - 0.106 mm.
Disassembling the oil pump
• Pull coupling sleeve (1) out of the oil pump (3)

• Pull the oil pump (3) out of the timing case
• Remove the O-rings (2) from the coupling sleeve
(1) • Pull oil pump gears (1) and (3) out of oil pump
housing (2)

ENGINE LUBRICATION
Installing the oil pump Screw in the oil pump mounting bolts
Assembling the oil pump

• Check that the oil pump gears move freely, if nec-
Note essary, repeat the procedure
The oil pump gears are marked at the
front of the gears by a dotted mark at one
tooth.
• Thinly apply clean engine oil on the oil pump gears

(1) and (3)
• Insert oil pump gears (1) and (3) into the oil pump
housing (2), that the marks are lined up
Attaching the oil pump
• Thinly apply clean engine oil to new O-rings (2)

• Fit the O-rings (2) on the coupling sleeve (1)
• Insert the coupling sleeve (1) into the oil pump (3)
until the stop
• Insert the oil pump (3) into the timing case

ENGINE LUBRICATION
OIL NOZZLES
Removing and installing the oil nozzles
Additional jobs
(1) Oil nozzle (3) Oil pressure valve

(2) Spring washer
Technical data
Oil pressure valve (3)............................................ M12...................................................................40 Nm

ENGINE LUBRICATION
WARNING
Special tools
[136] Torque wrench 08.06450-0006
• Tightening the oil pressure valve hollow screw
[137] Setting gauge 80.99607-6055
• Aligning the oil nozzles

ENGINE LUBRICATION
Removing the oil nozzles Installing the oil nozzles

Inserting the oil nozzles
• Unscrew the oil pressure valve (2) and remove

with spring washer
• Remove oil nozzle (1) WARNING
Component damage due to piston
overheating
• Align the oil nozzle correctly
• Position the oil nozzle (2) to the crankcase (1)

• Screw the oil pressure valve in with a new corru-
gated washer and then tighten by hand
Aligning and tighten the oil pressure valve
Note
The setting gauge must be positioned
level on the bearing seat of the crankshaft
• Clean the flat faces of the bearing seats of the

crankshaft
• Insert the Setting gauge [137] (4) into the bores in
the bearing seats of the crankshaft, while making
sure that the oil nozzle (1) is arrested in the recess
(3)
• Check that the oil nozzle (1) is seated correctly,
realign if necessary
• Tighten oil pressure valve (2) with Torque
wrench [136] with 40 Nm
• Remove Setting gauge [137]

CRANKSHAFT DRIVE
CRANKSHAFT DRIVE
(1) Flywheel (4) Vibration damper

(2) Crankshaft (5) Connecting rod
(3) Bearing cover (6) Piston

CRANKSHAFT DRIVE
VIBRATION DAMPER
Removing and installing the vibration damper
Additional jobs
(1) Mounting bolt (4) Ribbed V-belt disc

(2) Washer (5) Vibration damper
(3) Mounting bolt
Technical data
Mounting bolt (1) .................................................. M14x1.5x95-10.9 ........................ 1st tightening 150 Nm
Mounting bolt (1) .................................................. M14x1.5x95-10.9 ............................Final tightening 90°
WARNING

CRANKSHAFT DRIVE
Special tools
• Barring the engine

CRANKSHAFT DRIVE
Removing the vibration damper Installing the vibration damper

Attaching the engine cranking unit Attaching the vibration damper
• Remove the cap from the flywheel housing • Position the vibration damper (3) with disc (2)
• Attach and lock the Engine cranking unit [138] (1) • Screw in new mounting bolts (1) and tighten with
Removing the ribbed V-belt disc • Tighten the mounting bolts (1) with Final tighten-
ing 90°
Attaching the ribbed V-belt disc
• Mark the installation position of ribbed V-belt disc

(2) in relation to the vibration damper (3)
• Remove the ribbed V-belt (2) • Position the ribbed V-belt disc (2) on at vibration
damper (3) as marked
Removing the vibration damper • Screw in and tighten the new mounting bolts (1)

• Remove the vibration damper (3) with disc (2)

CRANKSHAFT DRIVE
• Unlock and remove the Engine cranking unit [138]

(1)

CRANKSHAFT DRIVE
FLYWHEEL MANUALLY OPERATED GEARBOX

Removing and installing the flywheel for the manually operated gearbox
(1) Flywheel (3) Flywheel housing

(2) Mounting bolt
Technical data
Mounting bolt (2) .................................................. M14x1.5x30-10.9 ....................... 1st tightening 100 Nm
Flywheel axial run-out (1)...................................................................................................... max. 0.5 mm
Installation temperature starter ring gear.................................................................................220 - 240 °C
WARNING

CRANKSHAFT DRIVE
Special tools
[139] Counter support 08.99615-0015
• Pulling out the clutch pilot bearing
[140] Calliper pin 80.99605-0197
• Checking the flywheel axial runout in conjunction

with:
• Dial gauge [142]
[141] Internal extractor 08.99615-1410
• Pulling out the clutch pilot bearing in conjunction

with:
• Counter support [139]
[142] Dial gauge 08.71000-3217
• Checking the flywheel axial run-out
[143] Gauge holder 08.71082-0005
• Checking the flywheel axial run-out
[144] Pressing plate 80.99604-0302
• Pressing in the clutch pilot bearing in conjunction

with:
• Thrust washer [145]
[145] Thrust washer 80.99617-0144
• Pressing in the clutch pilot bearing
[146] Plug-on handle 80.99617-0187
• Pressing in the clutch pilot bearing

CRANKSHAFT DRIVE
[147] Guide mandrel 80.99617-0163
• Removing and installing the flywheel
• Undoing the flywheel mounting bolts and tighten-

ing them in conjunction with:
• Support [150]
• Protractor [151]
• Stop bolts [152]
• Stud bolt [153]
• Adapter [156]
• Undoing and tightening the flywheel mounting

bolts
[150] Support 80.99606-0551

bolts
[151] Protractor 80.99607-0172

bolts
[152] Stop bolts 80.99606-0585

bolts
[153] Stud bolt 06.02191-0407

bolts

CRANKSHAFT DRIVE
[154] Connecting pin 06.22729-0006

bolts
[155] Rubber ring 06.56331-3274

bolts
[156] Adapter 80.99606-0552

bolts

CRANKSHAFT DRIVE
Removing the flywheel Unscrewing the flywheel mounting bolts
• Unscrew two opposite-facing mounting bolts (1)
• Insert the Power amplifier wrench i = 1 : 3.5 [148] Screwing in the guide mandrels
(1) into the Support [150] (9)
• Attach the Stop bolts [152] (6) with Stud bolt [153]
(8) and Adapter [156] (7) at the Support [150] (9)
• Position the Protractor [151] (2) on the Power
amplifier wrench i = 1 : 3.5 [148] (1)
the Power amplifier wrench i = 1 : 3.5 [148] (1) and
secure with the Connecting pin [154] (5) and the
Rubber ring [155] (4)
Undoing the flywheel mounting bolts
• Screw in the Guide mandrel [147] (1) and (2)

• Unscrew the remaining mounting bolts
Pulling off the flywheel
• Place the special tool (1) onto the mounting bolt

that is going to be undone
• Undo all the mounting bolts
CAUTION
Risk of injury due to high component
weight
• Use hoist to remove the flywheel
• Pull off the flywheel (1) via Guide mandrel [147]

(2)

CRANKSHAFT DRIVE
Cleaning the flywheel Removing and installing the starter ring

gear
Removing the starter ring gear
• Clean the flywheel

• Check the flywheel for cracks, replace the flywheel
if required
• Check the friction surface (1) for burns and traces WARNING
of running-in, replace the flywheel if necessary Component damage due to
• Check the teeth (2) of the starter ring gear for wear, spot-drilling of the flywheel
replace the starter ring gear if necessary • Do not damage the flywheel when
spot-drilling the starter ring gear
• Replace the spot-drilled flywheel
• Spot-drill the starter ring gear (1) and force it open

• Remove the starter ring gear (1) from flywheel (2)
• Clean the contact areas of the flywheel (2) and
check for damage
Attaching the starter ring gear
CAUTION
Danger of injury due to hot compo-
nents
• Attach the starter ring gear with protec-
tive gloves
• Heat the starter ring gear (1) to 220 - 240 °C

• Place the starter ring gear (1) so that the chamfer
(3) at the toothing points away from the flywheel
(2) and that the starter ring (1) is aligned with the
flywheel (2)
• Adjust the starter ring gear (1) if necessary

CRANKSHAFT DRIVE
Installing the flywheel Unscrewing the guide mandrels
Checking the flywheel axial run-out
• Screw in the new flywheel mounting bolts

• Unscrew the Guide mandrel [147] (1) and (2)
• Clamp the flywheel (1)
• Attach the Gauge holder [143] (2) with the Dial Screwing in the flywheel mounting bolts
gauge [142] (3) and the Calliper pin [140]
• Position the Calliper pin [140] with pre-load on the
flywheel (1)
• Zero the Dial gauge [142] (3)
• Turn the flywheel (1) several rotations and read the
amplitude of the Dial gauge [142] (3) while doing
so
The permitted axial run-out of the flywheel (1) is
max. 0.5 mm.
If the axial run-out is out of tolerance, the flywheel

(1) must be replaced.
Positioning the flywheel
• Screw in the new mounting bolts (1)
CAUTION
weight
• Use the hoist to install the flywheel
• Line up the flywheel (1) with the crankshaft align-

ment pin
• Put on the flywheel (1) over the Guide man-
drel [147] (2)

CRANKSHAFT DRIVE
Tightening the mounting bolts Removing the clutch pilot bearing

Removing the circlip
Note
• Unclip the circlip (2) with internal circlip pliers (1)
wrench i = 1 : 3.5 [148].
Attaching the extractor tool
• Tighten the mounting bolts using the special tool
(1) with 1st tightening 100 Nm
(1) with Final tightening 90°
• Insert the Internal extractor [141] (2) in the clutch

pilot bearing and spread until it stops
• Attach the Counter support [139] (1) on the Internal
extractor [141] (2)
Pull out the clutch pilot bearing
• Pull out the clutch pilot bearing (2) with the special
tool (1)

CRANKSHAFT DRIVE
Installing the clutch pilot bearing

Pressing in the clutch pilot bearing
• Assemble the special tool (1), consisting of

Plug-on handle [146], Thrust washer [145] and
Pressing plate [144]
• Press the new clutch pilot bearing (2) into the
flywheel until the stop using the special tool (1)
Installing the circlip
• Attach circlip (2) with internal circlip pliers (1)

CRANKSHAFT DRIVE
PISTON AND CONNECTING ROD

Removing and installing the piston and the connecting rod
Additional jobs

CRANKSHAFT DRIVE
(1) Connecting-rod bearing bolt (6) Piston

(2) Connecting-rod bearing cover (7) Keystone compression ring
(3) Connecting rod (8) Taper-faced ring
(4) Circlip (9) Bevelled-edge ring
(5) Piston pins
Technical data
Connecting-rod bearing bolt (1) ............................. M11x1.5x60-11.9...........................1st tightening 55 Nm
Connecting-rod bearing bolt (1) ............................. M11x1.5x60-11.9.............................Final tightening 90°
Connecting rods
Connecting-rod length, centre (piston pin bushing - centre of connecting-rod bearing)........... 196 ± 0.02 mm
Inside diameter, piston pin bushing.......................................................................... Ø 41.995 - 42.005 mm
Crankpin width .............................................................................................................. 32.78 - 33.00 mm
Bore for the bearings shells in the connecting rod..................................................... Ø 74.000 - 74.019 mm
Weight difference per connecting rod set of an engine .................................................................max. 50 g
Connecting-rod bearings
Connecting-rod bearings......................................................................................... Ø 69.981 - 70.000 mm
Wall thickness of connecting-rod bearing shells

Thickness of connecting-rod bearing shells .................................................................................1.975 mm
Piston diameter
D1 measured 17 mm above lower edge of piston .....................................................107.885 - 107.894 mm
D3 measured 84.9 mm above lower edge of piston ..................................................107.579 - 107.588 mm

CRANKSHAFT DRIVE
Piston height
Overall height..........................................................................................................................103.00 mm
Piston height (centre piston pin - piston crown) ...........................................................................63.90 mm
Piston ring (keystone ring)

Piston ring width ....................................................................................................................4.5 - 4.7 mm
Ring gap ........................................................................................................................... 0.30 - 0.55 mm
Piston ring (taper-faced ring)

Piston ring height........................................................................................................... 2.478 - 2.500 mm
Piston ring width ................................................................................................................ 4.25 - 4.60 mm
Ring gap ........................................................................................................................... 0.30 - 0.50 mm
Axial play ................................................................................................................................... 0.15 mm
Piston ring (double-bevelled ring 3 mm)

Piston ring height..................................................................................................... 3 mm (nominal value)
Ring gap ........................................................................................................................... 0.30 - 0.60 mm
Axial play ................................................................................................................................... 0.15 mm
Piston ring (double-bevelled ring 4 mm)

Ring gap ........................................................................................................................... 0.30 - 0.60 mm
Axial play ................................................................................................................................... 0.15 mm
Piston pins
Piston pin diameter................................................................................................. Ø 41.994 - 42.000 mm
Radial play in connecting rod ......................................................................................... 0.050 - 0.066 mm
Radial play in piston ...................................................................................................... 0.003 - 0.015 mm
Piston protrusion
Piston protrusion (crankcase - piston) ............................................................................. 0.093 - 0.391 mm
Piston weight
Piston weight difference per set in one engine.............................................................................max. 40 g
WARNING
Crack surfaces are delicate, hence ruptures may occur
• Exchange the connecting rod if the crack surfaces are damaged
• Protect crack surfaces against damage caused by hard and sharp objects
• To clean the crack surfaces on the connecting rods, only rinse them in clean cleaning agent
• After cleaning, use compressed air to blow-dry the crack surfaces
• Do not allow flushed-out particles to enter the engine
WARNING
Note
The piston diameter is always measured across to the piston pin bore.
The pistons are marked with A or B.

CRANKSHAFT DRIVE
Special tools
[157] Piston ring pliers 83.09144-6090
• Removing and installing the piston rings
[158] Feeler gauge 08.75310-0806
• Checking the axial play and ring gap of the piston

rings
[159] Dial gauge 08.71000-3217
• Checking the piston pin bushing

• Checking the piston protrusion in conjunction
with:
[160] Gauge holder 80.99605-0172
• Checking the piston protrusion
[161] Piston ring band tool 80.99613-0039
• Installing the piston
[162] Settling tools 80.99622-0052
• Aligning the connecting-rod bearing shells
[163] Depth gauge (electronic) 08.71195-9003
• Checking the piston ring insertion depth

CRANKSHAFT DRIVE
Removing the piston and the connecting Removing and checking the piston
rod
Removing the piston pin
Removing the connecting-rod bearing cover
• Mark the relative positions of the piston (3), piston

WARNING pin (2) and connecting rod (5)
Crack surfaces are delicate, hence • Detach the circlips (1) and (4)
ruptures may occur • Press the piston pin (2) out of the piston (3)
• Exchange the connecting rod if the • Remove the piston (3) from the connecting rod (5)
crack surfaces are damaged
Checking the piston pin diameter
• Protect crack surfaces against damage
caused by hard and sharp objects
• Mark the connecting-rod bearing cover (2) and

connecting-rod bearing shells (1) to indicate cor-
rect assignment and installation position
• Unscrew the connecting-rod bearing bolts (3)
• Remove the connecting-rod bearing cover (2)
with the connecting-rod bearing shell (1) from the
crankshaft
• Push out the piston and the connecting rod to-
wards the cylinder head
Removing the piston
• Check the diameter of the piston pin (1) using a

micrometer (2)
The permitted diameter of the rocker arm support
(1) is Ø 41.994 - 42.000 mm.
If the diameter is out of tolerance, the piston must

be replaced together with the piston pin (1).
• Pull out the piston (2) with connecting rod from the
crankcase (1)
• Mark the connecting rod and the connecting-rod
bearing shell to indicate correct assignment and
installation position
• Remove the connecting-rod bearing shell from the
connecting rod

CRANKSHAFT DRIVE
Checking the piston ring axial play Checking the piston ring gap
Note Note
An axial play cannot be measured on the The ring gap is only allowed to be
keystone ring. checked if the piston bore has the correct
inside diameter, otherwise a false ring
• Check the axial play between piston rings (1) and gap reading would be obtained.
(2) and piston (3) with the Feeler gauge [158] (4) Check cylinder liner inside diameter
The permitted axial play of the bevelled-edge ring
(2) is 0.15 mm. • Insert the piston ring (3) evenly deep into the cylin-
der liner (1)
The permitted axial play on the taper-faced ring (1) • Check for even insertion depth of the piston ring
is 0.15 mm. (3) using the Depth gauge (electronic) [163]
• Check the ring gap with the Feeler gauge [158] (2)
If the axial plays are out of tolerance, the piston (3) The permitted ring gap of the keystone ring is
must be replaced together with piston rings (1), (2) 0.30 - 0.55 mm.
and the double-bevelled ring.
The permitted ring gap of the taper-faced ring is
Removing the piston rings 0.30 - 0.50 mm.
The permitted ring gap of the bevelled-edge ring is

0.30 - 0.60 mm.
If the ring gaps are out of tolerance, the piston rings

must be replaced.
• Set the Piston ring pliers [157] (1) to the piston

diameter
• Detach the piston rings (2) from the piston (3) with
the Piston ring pliers [157] (1)
• Carefully clean the piston ring grooves

CRANKSHAFT DRIVE
Checking the connecting rods and con- Installing the piston and the connecting
necting-rod bearings rod
Checking the piston pin bushing Installing the piston rings
• Check the piston pin bushing inner diameter with

WARNING
the internal calliper (3) and the Dial gauge [159]
Piston rings can break
(2)
• Install the piston rings with correctly set
The permitted inner diameter of the piston pin bush-
piston ring pliers
ing is Ø 41.995 - 42.005 mm.
If the inside diameter is out of tolerance, the con- • Set the Piston ring pliers [157] (1) to the piston
necting rod (1) must be replaced. diameter
• Insert the piston rings (2) with TOP mark facing
Checking the connecting-rod bearing inside di- the piston crown with the Piston ring pliers [157]
ameter (1) in the respective ring groove in the piston (3)
Installing the piston pin
• Insert the lower connecting-rod bearing shell into

the connecting rod (2)
• Insert the lower connecting-rod bearing shell into • Attach a new circlip (4) in the groove in the piston
the connecting-rod bearing cover (3) • Fit the piston (3) over the connecting rod (5) as
• Screw in the connecting-rod bolts and tighten with marked
1st tightening 55 Nm • Thinly apply clean engine oil on the piston pin (2)
• Use the Dial gauge [159] (4) and the internal cal- • Push the piston pin (2) through the piston (3) and
liper (1) to check the connecting-rod bearing inside the connecting rod (5) in accordance with its mark-
diameter ing until the stop
The permitted inner diameter of the connecting-rod • Attach a new circlip (1) into the groove in the piston
bearing is Ø 69.981 - 70.000 mm. (3)
• Check that the circlips (1) and (4) are seated cor-
If the inside diameter is out of tolerance, the con- rectly
necting-rod bearing shells must be replaced. If the circlips (1) and (4) have not engaged correctly,
remove and re-attach the circlips (1) and (4), ensur-
ing that they are seated correctly.

CRANKSHAFT DRIVE
Piston installation with piston ring band tool Attaching the connecting-rod bearing cover
Note WARNING
There is an installation arrow on the pis- Crack surfaces are delicate, hence
ton surface. This must point towards the ruptures may occur
coolant pump during installation. • Exchange the connecting rod if the
crack surfaces are damaged
• Move the crankshaft for the respective cylinder to • Protect crack surfaces against damage
BDC caused by hard and sharp objects
• Line up the gaps in the piston rings at 120° offset
to one another • Insert the lower connecting-rod bearing shell (1)
• Apply a thin layer of clean engine oil to the upper into the connecting-rod bearing cover (2)
connecting-rod bearing shell • Check the alignment of the lower connect-
• Insert the upper connecting-rod bearing shell into ing-rod bearing shell (1) and adjust using Settling
the connecting rod tools [162] if necessary
• Thinly apply clean engine oil on the piston (1) • Thinly apply clean engine oil on the lower connect-
• Put the Piston ring band tool [161] (2) on the piston ing-rod bearing shell (1)
(1) and tension it • Position the connecting-rod bearing cover (2) on
• Push the piston (1) with the connecting rod into the connecting rod as marked
the piston bore until the piston (1) is pushed out of • Screw in new connecting-rod bolts (3) and tighten
the Piston ring band tool [161] (2) with 1st tightening 55 Nm
• Push in the piston (1) until the connecting rod with • Tighten the connecting-rod bearing bolts (3) with
the connecting-rod bearing shell is lying on the Final tightening 90°
crankshaft

CRANKSHAFT DRIVE
Checking the piston protrusion
• Set piston (2) to OT

• Attach the Dial gauge [159] (3) with the Gauge
holder [160] (5)
• Put the dial gauge tip (1) onto the crankcase (4)
and zero the Dial gauge [159] (3)
• Put the dial gauge tip (1) onto the piston (2) and
read off the difference (piston protrusion)
The permitted piston protrusion is 0.093 - 0.391 mm.

CRANKSHAFT DRIVE
CRANKSHAFT
Removing and installing the crankshaft
Additional jobs

CRANKSHAFT DRIVE
(1) Crankshaft bearing shell (5) Contact washer

(2) Crankshaft bearing shell (6) Crankshaft
(3) Bearing cover (7) Contact washer
(4) Mounting bolt (8) Crankcase
Technical data
Mounting bolt (4) .................................................. M14x118-10.9 ............................. 1st tightening 115 Nm
Mounting bolt (4) .................................................. M14x118-10.9 .................................Final tightening 90°
Crankshaft
Hardness crankshaft (6).......................................................................................................... 53 ± 3 HRC
Permitted crowning of bearing journals .......................................................................................0.004 mm
Axial play of the crankshaft (6) ....................................................................................... 0.150 - 0.282 mm
Connecting-rod bearing journals.............................................................................. Ø 69.981 - 70.000 mm
Crankshaft bearing journal ...................................................................................... Ø 86.981 - 87.000 mm
Crankshaft bearing
Inner diameter crankshaft bearing ........................................................................... Ø 87.035 - 87.122 mm
Wall thickness crankshaft bearing shells (1), (2) .............................................................. 2.468 - 2.480 mm
Contact washers (5), (7).............................................................................................................2.850 mm
Spread of crankshaft bearing ................................................................................................ max. 1.5 mm
WARNING

CRANKSHAFT DRIVE
Special tools
[164] Calliper pin 80.99605-0197
• Checking the crankshaft axial play in conjunction

with:
[165] Dial gauge 08.71000-3217
• Checking the crankshaft axial play
[166] Gauge holder 08.71082-0005
• Checking the crankshaft axial play
• Undoing and tightening the bearing cover bolts in

conjunction with:
• Support [169]
• Power amplifier wrench i = 1 : 3.5 [168]
• Protractor [170]
• Stop bolts [171]
• Stud bolt [172]
• Adapter [175]
• Undoing and tightening the bearing cover mount-

ing bolts
[169] Support 80.99606-0551

ing bolts
[170] Protractor 80.99607-0172

ing bolts

CRANKSHAFT DRIVE
[171] Stop bolts 80.99606-0585

ing bolts
[172] Stud bolt 06.02191-0407

ing bolts
[173] Connecting pin 06.22729-0006

ing bolts
[174] Rubber ring 06.56331-3274

ing bolts
[175] Adapter 80.99606-0552

ing bolts
[176] Settling tools 80.99622-0052
• Aligning the crankshaft bearing shells

CRANKSHAFT DRIVE
Removing the crankshaft Undoing the bearing cover mounting bolts
Checking the crankshaft axial play
• Place the special tool (1) onto the mounting bolt

that is going to be undone
• Attach the Gauge holder [166] (2) with the Dial • Undo all the mounting bolts
gauge [165] (1) and the Calliper pin [164]
• Position the Calliper pin [164] with a pre-load at Removing the bearing covers
the crankshaft (3)
• Push the crankshaft (3) in the end position hori-
zontally in direction of the flywheel housing
• Zero the Dial gauge [165] (1)
• Pull the crankshaft (3) into the end position to-
wards Dial gauge [165] (1) and check the differ-
ence
The permitted axial play on the crankshaft (3) is
0.150 - 0.282 mm
If the axial play is out of tolerance, install new contact

washers.
• Mark the bearing cover (2) to indicate correct as-

signment and installation position
• Remove the bearing cover (2)
• Mark the crankshaft bearing cover (3) to indicate
correct assignment and installation position
• Repeat the procedure for bearing covers 2, 3, 5, 6
and 7
• Insert the Power amplifier wrench i = 1 : 3.5 [168]

(1) into the Support [169] (9)
• Attach the Stop bolts [171] (6) with the Stud
bolt [172] (8) and the Adapter [175] (7) at the
Support [169] (9)
• Position the Protractor [170] (2) on the Power
amplifier wrench i = 1 : 3.5 [168] (1)
the Power amplifier wrench i = 1 : 3.5 [168] (1)
and secure with the Connecting pin [173] (5) and
the Rubber ring [174] (4)

CRANKSHAFT DRIVE
Removing the bearing cover axial compensation Removing the crankshaft
CAUTION
weight
• Remove the crankshaft with support
WARNING
Component damage due to unsuitable
hoist
• Do not use steel wire or other
sharp-edged tools to lift the crankshaft
out
• Lift the crankshaft (2) from the crankcase (1)

• Mark the crankshaft bearing shells to indicate cor-
• Mark the bearing cover (2) to indicate correct as- rect assignment and installation position and re-
signment and installation position move from the crankcase (1)
• Remove the bearing cover (2) with the contact
washers (1) and (4)
• Mark the crankshaft bearing covers to indicate
Removing the upper contact washers
• Remove the contact washers (2) from bearing seat

4 (1)

CRANKSHAFT DRIVE
Checking the crankshaft and the crank- Checking the crankshaft bearing inner diameter
shaft bearing
Checking the crankshaft bearing spread
• Insert the upper and lower crankshaft bearing shell

as marked into the bearing seat
• Fit the bearing cover (3) as marked
Note • Screw in and tighten the bearing cover mounting
The difference between dimension A and bolts (3) and tighten with 1st tightening 115 Nm
dimension B gives the crankshaft bearing • Check the crankshaft bearing with internal calliper
spread. (2) and Dial gauge [165] (1)
• Repeat the test procedure several times at 120°
• Clean the crankshaft bearing shells (2) and place offset
them together on a flat surface as marked • Remove the bearing cover (3) again after test
• Check dimension A with a micrometer (1) procedure
• Check dimension B with a micrometer (1) The permitted inner diameter of the crankshaft bear-
The permitted spread of the crankshaft bearing is ing is Ø 87.035 - 87.122 mm
max. 1.5 mm.
If the inside diameter is out of tolerance, the crank-
If the spread is out of tolerance, the crankshaft bear- shaft bearing shells must be replaced.
ing shells (2) must be replaced.
Checking the connecting-rod bearing journals
outside diameter
• Clean the crankshaft connecting-rod bearing jour-

nal (2)
• Check the connecting-rod bearing journal using a
micrometer (1)
• Repeat the test procedure several times at 120°
offset
The permitted outside diameter of the connect-
ing-rod bearing journal is Ø 69.981 - 70.000 mm.
If the outside diameter is out of tolerance, the crank-

shaft (2) must be replaced.

CRANKSHAFT DRIVE
Installing the crankshaft Installing the bearing cover axial compensation
Installing the crankshaft
WARNING
Component damage due to unsuitable
hoist
• Do not use steel wire or other
sharp-edged tools to lift in the crank-
shaft.
• Thinly apply clean engine oil on the crankshaft

bearing shells
• Place the crankshaft bearing shells in the bearing
seats as marked, and align with Settling tools [176]
• Insert the crankshaft (2) in the crankcase (1)
Installing the upper contact washers bearing shell and the contact washers (1) and (4)
• Place the crankshaft bearing shells in the bear-
ing cover (2) as marked, and align with Settling
tools [176]
• Insert the contact washers (1) and (4) with oil
grooves to the crankshaft in the bearing cover (2)
• Place the bearing cover (2) with the contact wash-
ers (1) and (4) on bearing seat 4
them by hand
• Thinly apply clean engine oil on the contact wash-

ers (2)
• Insert the contact washers (2) on bearing seat 4
with oil grooves to the crankshaft (1)
• Screw in the contact washers (2) by pressing them
slightly into the bearing seat

CRANKSHAFT DRIVE
Attaching the bearing covers

bearing shell (3)
• Place the crankshaft bearing shell (3) in the bear-
ing cover (2) as marked and align with Settling
tools [176]
• Put on the bearing cover (2)
• Thinly apply clean engine oil on the screw head
contact area of the new mounting bolts (1)
• Tighten the mounting bolts (1) by hand
Tightening the bearing cover mounting bolts
Note
wrench i = 1 : 3.5 [168].

(1) with 1st tightening 115 Nm
(1) with Final tightening 90°
• Check the crankshaft for ease of movement
If the crankshaft does not turn at all or only with
difficulty, the crankshaft has to be removed together
with the crankshaft bearings.
Re-check the crankshaft bearing and crankshaft,

replace the crankshaft bearing or the crankshaft if
necessary.

CRANKSHAFT SEALS
CRANKSHAFT SEALS
(1) Timing case cover (4) Crankshaft seal, rear

(2) Timing case (5) Crankshaft seal, front
(3) Flywheel housing

CRANKSHAFT SEALS
CRANKSHAFT SEALS
Removing and installing the front crankshaft seal
Additional jobs
(1) Timing case cover (3) Crankshaft seal

(2) Timing case
WARNING
PTFE seals are rendered unusable if they come into contact with oil or grease before instal-
lation
• Clean the crankshaft and insertion tool before assembly
WARNING

CRANKSHAFT SEALS
Special tools
[177] Guide plate 80.99606-0568
• Removing the front crankshaft seal in conjunction

with:
• Spindle [179]
• Hex nut [180]
• Cross member [181]
• Pressure plate [182]
• Catch [183]
• Stud bolt [178]
• Installing the front crankshaft seal in conjunction
with:
• Spindle [179]
• Hex nut [180]
• Press plate [185]
• Stud bolt [178]
[178] Stud bolt 06.02191-2713
• Removing and installing the front crankshaft seal
[179] Spindle 80.99606-0299
[180] Hex nut 06.11065-2318
[181] Cross member 80.99606-0298
• Removing the front crankshaft seal
[182] Pressure plate 80.99609-0038

CRANKSHAFT SEALS
[183] Catch 80.99606-6013
[184] Hex collar nut 06.11222-0311
• Installing the front crankshaft seal
[185] Press plate 80.99606-0567
• Installing the front crankshaft seal

CRANKSHAFT SEALS
Removing the crankshaft seal Installing the crankshaft seal

Positioning the crankshaft seal
• Attach the Guide plate [177] (2) on the crankshaft

with the Stud bolt [178] (6)
• Screw the Pressure plate [182] into the Guide • Remove the Pressure plate [182]
plate [177] (2) • Position the new crankshaft seal (2) with transport
• Screw the Hex nut [180] (5) onto the Spindle [179] sleeve (3) on the Guide plate [177] (1)
and secure with the second Hex nut [180] (5) • Push the crankshaft seal (3) onto the Guide
• Screw the Spindle [179] into the Cross mem- plate [177] (1)
ber [181] (4) • Remove the transport sleeve (2)
• Insert the Catch [183] (3) into the Cross mem-
ber [181] (4) flat between the crankshaft seal (1) Pressing in the crankshaft seal
and the crankshaft
• Turn the Catch [183] (3) by 90° so that the recess
in the Catch [183] (3) is facing outwards
• Pull the crankshaft seal (1) out by screwing in the
Spindle [179]
• Push the Press plate [185] (2) onto the Guide

plate [177]
• Screw the Hex collar nut [184] onto the Spin-
dle [179] (3)
• Screw the Spindle [179] (3) into the Guide
plate [177]
• Press in the crankshaft seal (1) by pressing in the
Hex collar nut [184] until the stop

CRANKSHAFT SEALS
Removing and installing the rear crankshaft seal

Additional jobs
(1) Flywheel housing (2) Crankshaft seal
WARNING
PTFE seals are rendered unusable if they come into contact with oil or grease before instal-
lation
• Clean the crankshaft and insertion tool before assembly
WARNING

CRANKSHAFT SEALS
Special tools
[186] Guide plate 80.99606-0316
• Removing the rear crankshaft seal in connection

with:
• Cross member [190]
• Catch [191]
• Stud bolt [188]
• Spindle [187]
• Hex nut [189]
• Pressure plate [192]
• Installing the rear crankshaft seal in connection
with:
• Press plate [193]
• Stud bolt [188]
• Spindle [187]
• Hex nut [189]
[187] Spindle 80.99606-0299
• Removing and installing the rear crankshaft seal
[188] Stud bolt 06.02191-2713
[189] Hex nut 06.11065-2318
[190] Cross member 80.99606-0298
• Removing the rear crankshaft seal
[191] Catch 80.99606-6013

CRANKSHAFT SEALS
[192] Pressure plate 80.99609-0038
[193] Press plate 80.99606-0315
• Installing the rear crankshaft seal
[194] Hex collar nut 06.11222-0311
• Installing the rear crankshaft seal

CRANKSHAFT SEALS
Removing the crankshaft seal Installing the crankshaft seal

Attaching the special tool Positioning the crankshaft seal
• Attach the Guide plate [186] (4) on the crankshaft • Remove the Pressure plate [192]
with Stud bolt [188] (6) • Position the new crankshaft seal (2) with transport
• Screw the Pressure plate [192] (5) into the Guide sleeve (1) on the Guide plate [186] (3)
plate [186] (4) • Push the crankshaft seal (1) onto the Guide
• Screw the Hex nut [189] onto the Spindle [187] plate [186] (3)
and secure with the second Hex nut [189] • Remove the transport sleeve (2)
• Screw the Spindle [187] into the Cross mem-
ber [190] (2) Pressing in the crankshaft seal
• Insert the Catch [191] (1) into the Cross mem-
ber [190] (2) flat between the crankshaft seal (3)
and the crankshaft
• Turn the Catch [191] (1) by 90° so that the recess
Catch [191] (1) is facing outwards
• Insert the Cross member [190] (2) into the
Catch [191] (1)
Extracting the crankshaft seal
• Push the Press plate [193] (2) onto the Guide

plate [186]
• Screw Hex collar nut [194] (1) onto Spindle [187]
• Screw the Spindle [187] into the Guide plate [186]
• Press in the crankshaft seal (3) by pressing in the
Hex collar nut [194] (1) until the stop
• Extract the crankshaft seal (1) by screwing in the

Spindle [187] (2)

ENGINE HOUSING
ENGINE HOUSING
(1) Cylinder liner (6) Timing case cover

(2) Flywheel housing (7) O-ring
(3) Crankcase (8) O-ring
(4) Crankcase yoke (9) Crankcase ventilation line mounting bolt
(5) Timing case (10) Crankcase ventilation filter

ENGINE HOUSING
CRANKCASE VENTILATION
Removing and installing the crankcase ventilation
(1) Bleed line (10) Spring band clamp

(2) Spring band clamp (11) Hose
(3) Hose (12) Bleed line
(4) Oil return line (13) Bleed line
(5) Seal (14) Hose
(6) O-ring (15) Spring band clamp
(7) Seal (16) Oil separator
(8) Mounting bolt (17) Hose
(9) Clamp
WARNING
Note
Replace the hoses, mounting bolts and O-rings when replacing the crankcase ventilation.

ENGINE HOUSING
Special tools
[195] Hose clamp pliers for spring band clamps 80.99625-0073
• Removing and installing the spring band clamps

ENGINE HOUSING
FLYWHEEL HOUSING
Removing and installing the flywheel housing (version without PTO)
Additional jobs
(1) Crankcase (5) Mounting bolt

(2) Mounting bolt (6) Mounting bolt
(3) Cap (7) Seal
(4) Flywheel housing
Technical data
Mounting bolt (5) .................................................. M14x105-10.9..................................................170 Nm
Mounting bolt (6) .................................................. M12x30-10.9....................................................105 Nm
Service products
WARNING

ENGINE HOUSING
Removing the flywheel housing Installing the flywheel housing

Removing the speed sensor Positioning the flywheel housing
• Disconnect the electrical connection for the speed • Position the flywheel housing (3) with new seal (2)
sensor (1) on the crankcase (1) via alignment pins
• Remove the speed sensor (1) from the flywheel
housing (2) Screwing in the mounting bolts
Unscrewing the mounting bolts
• Screw in the new mounting bolts (1) and (2)

• Tighten the mounting bolts (2) with 105 Nm
• Unscrew the mounting bolts (1) and (2) • Tighten the mounting bolts (1) with 170 Nm
Removing the flywheel housing
• Remove the flywheel housing (3) with seal (2) from

the crankcase (1)

ENGINE HOUSING
• Lightly apply Curil T sealing agent on the contact

surface of the speed sensor (1)
(2)
• Connect the electrical connection for the speed
sensor (1)

ENGINE HOUSING
Removing and installing the flywheel housing (version with PTO)

Additional jobs
(1) Retaining plate (4) Intermediate gear bolt

(2) Flywheel housing (5) Intermediate gear
(3) Contact washers (6) Crankshaft gear
Service products
Loctite 573 sealing agent ................................................................................................... 04.90300-9018
WARNING

ENGINE HOUSING
Removing the flywheel housing Removing the flywheel housing
Removing the speed sensor
CAUTION
• Disconnect the electrical connection for the speed Risk of injury due to high component
sensor (1) weight
• Remove the speed sensor (1) from the flywheel • Use a hoist to remove the flywheel
housing (2) housing
Unscrewing the mounting bolts • Remove the flywheel housing (3) with seal (2) from
the crankcase (1)
Removing the crankshaft gear

bolts (1)
• Mark the installation position of the crankshaft
gear (1)
• Pull the crankshaft gear (1) off the crankshaft
• Clean the contact areas

ENGINE HOUSING
Disassembling the flywheel housing Assembling the flywheel housing

Removing the retaining plate Attaching the intermediate gears

(2) and (3)
• Remove the retaining plate (1)
Removing the intermediate gears
Note
The grooves of the contact washers have
to point to the intermediate gear bolts.
• Position the contact washers (4) as marked

• Thinly apply clean engine oil on the intermediate
gear bolt (2)
• Position the intermediate gear (1) and intermedi-
ate gear bolts (2) as marked
• Position the contact washers (3) as marked
• Mark the intermediate gears (1), intermediate gear

bolts (2), contact washers (3) and (4) to indicate
• Remove the contact washers (3)
• Remove the intermediate gear (1) and intermedi-
ate gear bolt (2)
• Remove the contact washers (4)

ENGINE HOUSING
Attaching the retaining plate Installing the flywheel housing

Attaching the crankshaft gear
• Position the retaining plate (1)

• Screw in the new mounting bolts (2) and (3) as
marked • Lightly apply Loctite 573 sealing agent on the con-
• Tighten the mounting bolts (2) and (3) tact surface of the crankshaft gear (1)
• Push the crankshaft gear (1) onto the crankshaft
as marked
Positioning the flywheel housing
CAUTION
weight
• Use a hoist to install the flywheel hous-
ing
• Position the flywheel housing (3) with new seal (2)

on the crankcase (1) via alignment pins

ENGINE HOUSING
Screwing in the mounting bolts
• Screw in the new mounting bolts (1) as marked

• Lightly apply Curil T sealing agent on the contact

surface of the speed sensor (1)
(2)
• Connect the electrical connection for the speed
sensor (1)

ENGINE HOUSING
CRANKCASE YOKE
Removing and installing the crankcase yoke
Additional jobs
(1) Crankcase yoke (3) Mounting bolt

(2) Crankcase
Technical data
Crankcase yoke mounting bolt (3) ......................... M8x45 ...............................................................30 Nm
Service products
Loctite 5900 sealing agent ................................................................................................. 04.10394-9292

ENGINE HOUSING
Removing the crankcase yoke Installing the crankcase yoke

Installation instruction for crankcase yoke

• Remove the crankcase yoke (2) from the
crankcase (3)
WARNING
Component damage caused by incor-
rect installation
• The mating surface must be free of
grease
• The bead of sealing agent must be
continuous and no wider than 2 mm
• Check that the bead of sealing agent is
continuous
• Thinly apply Loctite 5900 sealing agent to the

contact surfaces of the crankcase (1)

ENGINE HOUSING
Tightening sequence for the upper section of the

oil sump housing
• Tighten all mounting bolts in the tightening se-

quence from (1) to (21)
Installing the crankcase yoke
• Position the crankcase yoke (2) on crankcase (3)

• Screw in the mounting bolts (1) and tighten with
30 Nm

ENGINE HOUSING
TIMING CASE COVER/TIMING CASE

Removing and installing the timing case cover
Additional jobs
(1) Timing case (2) Mounting bolt

ENGINE HOUSING
(3) Oil filler neck (5) Timing case cover

Technical data
Oil filler neck (3) ................................................... M38x1.5 ............................................................35 Nm
Service products
WARNING
Special tools
[196] Socket wrench insert 27 mm 08.06556-9300
• Removing and installing the oil filler neck

ENGINE HOUSING
Removing the timing case cover Removing the timing case cover seal
Removing the speed sensor
• Remove the seal (1) from the timing case (2)

• Disconnect the electrical connection for the speed
sensor (1)
• Pull out the speed sensor (1)
• Remove the O-ring from the speed sensor (1)
Removing the timing case cover
• Unscrew the oil filler neck (4) using Socket wrench

insert 27 mm [196]
(1), (2) and (5)
• Remove the timing case cover (3)

ENGINE HOUSING
Installing the timing case cover Installing the speed sensor
Positioning the timing case cover seal
• Insert the speed sensor (1) with a new O-ring

• Screw in and tighten the mounting bolt (2)
• Position the new seal (1) on the timing case (2) via • Connect the electrical connection for the speed
alignment pins sensor (1)
Attaching the timing case cover
• Position the timing case cover (3) via alignment

pins
• Screw in mounting bolts (1), (2) and (5) as marked
and tighten
• Thinly apply Curil T sealing agent on the thread of
the oil filler neck (4)
• Screw in the oil filler neck (4) with Socket wrench
insert 27 mm [196] and tighten with 35 Nm

ENGINE HOUSING
Removing and installing the timing case

Additional jobs

ENGINE HOUSING
(1) Timing case (2) Seal
WARNING

ENGINE HOUSING
Removing the timing case Installing the timing case

Removing the timing case Positioning the timing case seal
• Position the new seal (1) on the crankcase (2) via

Note
alignment pins
For conversion of the timing case, remove
and install the oil pump as needed, see Attaching the timing case
Removing and installing the oil pump,
299.

bolts (1)
• Pull the timing case (2) off the crankcase (3)
Removing the timing case seal
• Replace the O-rings of the oil pump coupling

sleeve and thinly apply clean engine oil, see At-
taching the oil pump, 302
• Align the oil pump coupling sleeve with the
crankcase (3)
• Position the timing case (2) via alignment pins
• Screw in the new mounting bolts (1) by hand as
marked
• Remove the seal (1) from the crankcase (2) • Tighten the mounting bolts (1)

ENGINE HOUSING
CYLINDER LINER
Removing and installing the cylinder liner
Additional jobs
– Removing and installing the charge-air pipes (D0836 LFL44), see 201
(1) Crankcase (2) Cylinder liner
Technical data
Cylinder liner outside diameter standard (2) ........................................................... Ø111.475 - 111.490 mm

ENGINE HOUSING
Cylinder liner outside diameter above tolerance limit (2) ........................................ Ø 111.975 - 111.999 mm
Cylinder liner inside diameter standard (2) ................................................................ Ø108.00-108.022 mm
Reworking higher standard collar height outside diameter......................................... Ø111.475-111.490 mm
Standard collar height ........................................................................................................ 4.04 - 4.06 mm
Collar height above tolerance limit ........................................................................................4.04-4.06 mm
Reworking higher standard collar height outside diameter.................................................... 4.24 - 4.26 mm
Cylinder liner protrusion (2) ................................................................................................ 0.01 - 0.06 mm
Cylinder head bolt ................................................ 14x2 (E18).........................................................80 Nm
Special tools
[197] Gauge holder 80.99605-0172
• Checking the cylinder liner protrusion in conjunc-

tion with:
[198] Dial gauge 08.71082-0005
• Checking the cylinder liner protrusion
[199] Extractor tool 80.99602-6023
• Removing the cylinder liner in conjunction with:

• Extractor plate [200]
[200] Extractor plate 80.99602-0123
• Removing the cylinder liner
[201] Measuring plate 80.99605-0287
• Checking the cylinder liner protrusion in conjunc-

tion with:
• Spacer [202]
• Cylinder head bolt [203]

ENGINE HOUSING
[202] Spacer 80.99635-0053
[203] Cylinder head bolt 51.90020-0383

ENGINE HOUSING
Checking the cylinder liner Removing the cylinder liner

Checking the cylinder liner protrusion Attaching the extractor tool
• Place the Measuring plate [201] (1) on the cylinder WARNING

liner Damaged and bent oil nozzles lead to
• Screw in the Cylinder head bolt [203] (5) in con- engine damage.
junction with the Spacer [202] (4) and tighten with • Insert the cylinder liner extractor tool in
80 Nm such a way that the oil nozzle cannot
• Position the Gauge holder [197] with the Dial be bent
gauge [198] (3) on the Measuring plate [201] (1)
• Put the dial gauge tip (2) onto the crankcase and • If the cylinder liner (1) is to be reused, mark the
zero the Dial gauge [198] (3) installation location and position
• Place the dial gauge tip (2) on the cylinder liner • Assemble the Extractor plate [200] (2) and Extrac-
and read off the difference tor tool [199]
• The cylinder liner protrusion must be • Carefully insert the Extractor tool [199] with folded
0.01 - 0.06 mm, replace the cylinder liner if Extractor plate [200] (2) into the cylinder liner (1)
required
• Remove the Measuring plate [201] (1) Extracting the cylinder liner
• Tension the threaded spindle (2) Extractor

tool [199] (4) with removable nut (3)
• Extract the cylinder liner (1) from the crankcase

ENGINE HOUSING
Installing the cylinder liner
• Lightly oil the cylinder liner (1) before installation

• Insert the cylinder liner (1) into the crankcase until
the stop
• Recheck protrusion of the cylinder liner (1)

POWER TAKE-OFF
POWER TAKE-OFF
(1) Mounting bolt (2) Power take-off

POWER TAKE-OFF
POWER TAKE-OFF
(1) Mounting bolt (2) Power take-off
WARNING

POWER TAKE-OFF
Removing the power take-off Installing the power take-off
• Unscrew the mounting bolts (1) • Thinly apply clean engine oil on a new O-ring (3)
• Pull the PTO (2) with O-ring (3) out of the flywheel and fit it on the PTO (2)
housing • Insert the PTO (2) into the flywheel housing

TECHNICAL DATA
TECHNICAL DATA
Removing and installing the cable harness

Removing and installing the engine electronics

Oil level sensor (2)................................................ M22x1.5 ............................................................25 Nm
Rail pressure sensor (10)...................................... M18x1.5 ............................................................70 Nm
Pressure sensor (11) ............................................ M18x1.5 ............................................................45 Nm
Removing and installing the fan (variant without hydraulic pump)

Mounting nut (3) ................................................... M8 ....................................................................22 Nm
Removing and installing the fan (variant with hydraulic pump)

Mounting nut (3) ................................................... M8 ....................................................................22 Nm
Removing and installing the coolant manifold

Coolant line union nut .....................................................................................................................35 Nm
Opening temperature of thermostat .................................................................................................. 83 °C
Removing and installing the thermostat with thermostat housing

Opening temperature of thermostat (4) ............................................................................................. 83 °C
Removing and installing the coolant pump

Dismantling and assembling the coolant pump (open impeller variant)

Impeller dimensions (3) - housing coolant pump (1)......................................................... 33.10 - 33.30 mm
Dismantling and assembling the coolant pump (closed impeller variant)

Gap dimension of the impeller (3) .................................................................................................. 0.5 mm

Mounting bolt (left-handed thread) (4) .................... M16x1.5x45-8.8 LH..................... 1st tightening 100 Nm
Mounting bolt (left-handed thread) (4) .................... M16x1.5x45-8.8 LH.........................Final tightening 90°
Removing and installing 1-cylinder air compressor

Dismantling and assembling 1-cylinder air compressor

Pressure relief valve (1) ........................................ M26x1.5 ............................................................90 Nm
Mounting bolt (7) ..................................................................................................... 1st tightening 100 Nm
Mounting bolt (7) .........................................................................................................Final tightening 90°
Angled connectors (2), (3)..................................... M26x1.5 ..........................................................100 Nm
Mounting bolt (4) .................................................. M8x80 ..........................................1st tightening 20 Nm
Mounting bolt (4) .................................................. M8x80 ............................................Final tightening 90°
GE union (5) ........................................................ M14x1.5 ............................................................35 Nm
Removing and installing the belt drive (variant without Frigoblock alternator)
Mounting bolt for ribbed V-belt tensioner for the
alternator (9) ........................................................ M10x70-10.9......................................................47 Nm

TECHNICAL DATA
Removing and installing the belt drive (variant with Frigoblock alternator)
Removing and installing the belt drive (variant with hydraulic pump)
Clamping force of the V-belt (4) for new assembly .................................................................... 500 - 550 N
Clamping force of the V-belt (4) after more than 10 min. of operation ........................................ 350 - 400 N
Removing and installing the belt drive (variant with stretchy belt)
Mounting bolt of the guide roller (1) ....................... M12x80-10.9......................................................60 Nm
Removing and installing the alternator

Mounting nut for the ribbed V-belt disc (3) .............. M16x1.5 ............................................................80 Nm
Coolant line union nut ........................................... M14x1.5 ............................................................35 Nm
Removing and installing the starter motor

Number of starter pinion teeth ............................................................................................................... 11
Starter power .................................................................................................................... 4.0 kW at 24 V
Removing and installing the hydraulic pump

Mounting nut (6) ................................................... M18x1.5 ............................................................70 Nm
Clamping force of the V-belt (4) for new assembly .............................................................................550 N
Clamping force of the V-belt (4) after more than 10 min. of operation .................................................350 N
Removing and installing the injectors and pressure pipe

Mounting bolt (3) .................................................. M8x45 ....................................... Final tightening 30 Nm
Pressure screw (9) ............................................... M22x1.5 .......................................1st tightening 10 Nm
Pressure screw (9) ............................................... M22x1.5 .................................... Final tightening 55 Nm
Injector cable mounting nuts.................................. Cable lug nut M4...............................................1.5 Nm
Rail pressure sensor (7)........................................ M18x1.5 ............................................................70 Nm
Pressure-limiting valve.......................................... M18x1.5 ..........................................................100 Nm
Removing and installing the high pressure pump

Mounting bolt (3) .................................................. M8x40-8.8 .........................................................30 Nm
Mounting nut (2) ................................................... M8 ....................................................................30 Nm
Disassembling and assembling the high pressure pump

Mounting bolt (6) .................................................. M5x20 .........................................Final tightening 7 Nm
Mounting bolt (8) .................................................. M6x1.5x36.......................................................... 8 Nm
Mounting nut (1) ................................................... M18x1.5-8.8 ....................................................105 Nm
Dismantling and assembling the fuel service centre

Cover (11) ......................................................................................................................................15 Nm
Cover (2)........................................................................................................................................25 Nm
Water drain plug (6) ......................................................................................................................... 4 Nm
Removing and installing the flame-start system

Fuel line union nut (3) ........................................... M10x1 ...............................................................10 Nm

TECHNICAL DATA
Removing and installing the flame-start system (D0836 LFL44)

Fuel line union nut (4) ........................................... M10x1 ................................................................ 5 Nm
Solenoid valve hollow screw (3)............................. M10x1-6S..........................................................12 Nm
Removing and installing the EDC control unit

Mounting bolt (6) .................................................. M6x35-10.9 ....................................................... 11 Nm
Mounting bolt (4) .................................................. M8x40-10.9 .......................................................13 Nm
Removing and installing the air distributor pipe

Removing and installing the EGR module

EGR module (6) temperature sensor ..................... M16x1.5 ............................................................45 Nm
Mounting nut EGR adjusting cylinder (4) ................ M8 ....................................................................16 Nm
EGR adjusting cylinder (4) pre-load ................................................................................... 1.25 ± 0.25 mm
Removing and installing the exhaust manifold

Mounting bolt exhaust manifold ............................. M8x58-GA ....................................1st tightening 25 Nm
Mounting bolt exhaust manifold ............................. M8x58-GA ....................................... 2nd tightening 45°
Mounting bolt exhaust manifold ............................. M8x58-GA ......................................Final tightening 45°
Mounting bolts shut-off flap ................................... M8x50-GA .........................................................27 Nm
Removing and installing the cylinder head

Cylinder head bolts............................................... 14x2 (E18)....................................1st tightening 80 Nm
Cylinder head bolts............................................... 14x2 (E18).................................2nd tightening 150 Nm
Cylinder head bolts............................................... 14x2 (E18)........................................ 3rd tightening 90°
Cylinder head bolts............................................... 14x2 (E18)........................................ 4th tightening 90°
Cylinder head bolts............................................... 14x2 (E18)......................................Final tightening 90°
Checking and adjusting the valve clearance

Lock nuts of the adjusting screws (3), (4), (5) ......... M10x1-8.8 .........................................................40 Nm
Inlet valve clearance ................................................................................................................... 0.50 mm
Exhaust valve clearance ............................................................................................................. 0.50 mm
EVB brace setting dimensions..................................................................................................... 0.35 mm
Removing and installing the camshaft

Axial play camshaft (1)................................................................................................... 0.140 - 0.270 mm
Radial play camshaft (1) ................................................................................................ 0.060 - 0.120 mm

Mounting bolts camshaft gear (5) .......................... M10x1.25x38-10.9 .............................................65 Nm
Mounting nut, drive wheel oil pump (2)................... M12x1.5-6S .......................................................45 Nm

Radial play, intermediate gear 1 ..................................................................................... 0.060 - 0.109 mm
Axial play, intermediate gear 1........................................................................................ 0.200 - 0.280 mm
Radial play intermediate gear 2 (1) ................................................................................. 0.035 - 0.076 mm
Axial play intermediate gear 2 (1) ................................................................................... 0.100 - 0.200 mm

Crankshaft wheel (4) - camshaft gear (5) ........................................................................ 0.051 - 0.149 mm
Camshaft gear (5) - air compressor wheel....................................................................... 0.051 - 0.185 mm
Crankshaft gear (4) - intermediate gear 1........................................................................ 0.050 - 0.187 mm
Intermediate gear 1 - intermediate gear 2 (1) .................................................................. 0.051 - 0.175 mm
Intermediate gear 1 - oil pump gear (2) ........................................................................... 0.053 - 0.190 mm

TECHNICAL DATA
Removing and installing the oil module

Oil filter lid ......................................................................................................................................25 Nm
Mounting bolt (1) .................................................. M6x20 ...............................................................12 Nm
Removing and installing the oil sump and oil intake pipe
Oil level sensor..................................................... M22x1.5 ............................................................25 Nm
Removing and installing the oil pump

Axial play, oil pump gears............................................................................................... 0.040 - 0.106 mm
Removing and installing the oil nozzles

Oil pressure valve (3)............................................ M12...................................................................40 Nm
Removing and installing the vibration damper

Mounting bolt (1) .................................................. M14x1.5x95-10.9 ........................ 1st tightening 150 Nm
Removing and installing the flywheel for the manually operated gearbox
Mounting bolt (2) .................................................. M14x1.5x30-10.9 ....................... 1st tightening 100 Nm
Flywheel axial run-out (1)...................................................................................................... max. 0.5 mm
Installation temperature starter ring gear.................................................................................220 - 240 °C

Connecting-rod bearing bolt (1) ............................. M11x1.5x60-11.9...........................1st tightening 55 Nm
Connecting-rod bearing bolt (1) ............................. M11x1.5x60-11.9.............................Final tightening 90°

Connecting-rod length, centre (piston pin bushing - centre of connecting-rod bearing)........... 196 ± 0.02 mm
Inside diameter, piston pin bushing.......................................................................... Ø 41.995 - 42.005 mm
Crankpin width .............................................................................................................. 32.78 - 33.00 mm
Bore for the bearings shells in the connecting rod..................................................... Ø 74.000 - 74.019 mm
Weight difference per connecting rod set of an engine .................................................................max. 50 g

Connecting-rod bearings......................................................................................... Ø 69.981 - 70.000 mm

Thickness of connecting-rod bearing shells .................................................................................1.975 mm

D3 measured 84.9 mm above lower edge of piston ..................................................107.579 - 107.588 mm

Overall height..........................................................................................................................103.00 mm
Piston height (centre piston pin - piston crown) ...........................................................................63.90 mm

Piston ring width ....................................................................................................................4.5 - 4.7 mm
Ring gap ........................................................................................................................... 0.30 - 0.55 mm

Ring gap ........................................................................................................................... 0.30 - 0.50 mm
Axial play ................................................................................................................................... 0.15 mm

Piston ring height..................................................................................................... 3 mm (nominal value)

TECHNICAL DATA

Ring gap ........................................................................................................................... 0.30 - 0.60 mm
Axial play ................................................................................................................................... 0.15 mm

Ring gap ........................................................................................................................... 0.30 - 0.60 mm
Axial play ................................................................................................................................... 0.15 mm

Piston pin diameter................................................................................................. Ø 41.994 - 42.000 mm
Radial play in connecting rod ......................................................................................... 0.050 - 0.066 mm
Radial play in piston ...................................................................................................... 0.003 - 0.015 mm

Piston protrusion (crankcase - piston) ............................................................................. 0.093 - 0.391 mm

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

Mounting bolt (4) .................................................. M14x118-10.9 ............................. 1st tightening 115 Nm
Mounting bolt (4) .................................................. M14x118-10.9 .................................Final tightening 90°

Hardness crankshaft (6).......................................................................................................... 53 ± 3 HRC
Permitted crowning of bearing journals .......................................................................................0.004 mm
Axial play of the crankshaft (6) ....................................................................................... 0.150 - 0.282 mm
Connecting-rod bearing journals.............................................................................. Ø 69.981 - 70.000 mm
Crankshaft bearing journal ...................................................................................... Ø 86.981 - 87.000 mm

Inner diameter crankshaft bearing ........................................................................... Ø 87.035 - 87.122 mm
Wall thickness crankshaft bearing shells (1), (2) .............................................................. 2.468 - 2.480 mm
Contact washers (5), (7).............................................................................................................2.850 mm
Spread of crankshaft bearing ................................................................................................ max. 1.5 mm
Removing and installing the flywheel housing (version without PTO)

Mounting bolt (5) .................................................. M14x105-10.9..................................................170 Nm
Mounting bolt (6) .................................................. M12x30-10.9....................................................105 Nm
Removing and installing the crankcase yoke

Crankcase yoke mounting bolt (3) ......................... M8x45 ...............................................................30 Nm
Removing and installing the timing case cover

Oil filler neck (3) ................................................... M38x1.5 ............................................................35 Nm
Removing and installing the cylinder liner

Cylinder liner outside diameter standard (2) ........................................................... Ø111.475 - 111.490 mm
Cylinder liner outside diameter above tolerance limit (2) ........................................ Ø 111.975 - 111.999 mm
Cylinder liner inside diameter standard (2) ................................................................ Ø108.00-108.022 mm
Reworking higher standard collar height outside diameter......................................... Ø111.475-111.490 mm
Standard collar height ........................................................................................................ 4.04 - 4.06 mm
Collar height above tolerance limit ........................................................................................4.04-4.06 mm
Reworking higher standard collar height outside diameter.................................................... 4.24 - 4.26 mm
Cylinder liner protrusion (2) ................................................................................................ 0.01 - 0.06 mm
Cylinder head bolt ................................................ 14x2 (E18).........................................................80 Nm

Man Engine Shop Manual - D0836 LF - LFL 40-41-44

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Man Engine Shop Manual - D0836 LF - LFL 40-41-44

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Common rail in-line engine

Copy deadline: 01/2016

Common rail in-line engine

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MAN Truck & Bus AG

© 2016 MAN Truck & Bus AG

Typesetting: SAWDT, 2W Technische Informations GmbH & Co. KG

2 A20 Stage 2 5th edition

Safety instructions ........................................................................................................ 9

Cable harness ............................................................................................................ 27

Power take-off ............................................................................................................ 83

Common Rail system

Injectors and pressure pipe .......................................................................................... 143

A20 Stage 2 5th edition 3

Protective sleeves for injectors and pressure pipe .......................................................... 143

Charge-air pipes ....................................................................................................... 201

Air distributor pipe ..................................................................................................... 211

Rocker arm mechanism .............................................................................................. 227

Camshaft/camshaft bearing ......................................................................................... 259

Timing gears ............................................................................................................ 277

Oil module .............................................................................................................. 287

4 A20 Stage 2 5th edition

Vibration damper ...................................................................................................... 309

Crankshaft seals ....................................................................................................... 345

Crankcase ventilation ................................................................................................. 355

Power take-off .......................................................................................................... 385

Technical Data 387

A20 Stage 2 5th edition 5

A20 Stage 2 5th edition 7

Pressure sensor ..................................................................................................................................... 181

8 A20 Stage 2 5th edition

1. Regulations for preventing accidents leading to injury to personnel

Checking, setting and repair work

Working on the brake system

Working on vehicles with a compressed natural gas (CNG) system

Working on the compressed natural gas (CNG) system

A20 Stage 2 5th edition 9

Operating the engine

Bodies and special bodies

Working on high-pressure lines

Testing injection nozzles

Work on the vehicle electrical system

Important: battery gases are explosive!

Caution! Battery acid is toxic and corrosive!

10 A20 Stage 2 5th edition

Work on plastic tubes – risk of damage and fire

Working with a tilted cab

Work on the air-conditioning system

Work on the airbag or belt pre-tensioner units

A20 Stage 2 5th edition 11

Working on the independent heating

2. Notes on preventing damage and premature wear on units

3. Limited liability for parts and accessories

4. Regulations for avoiding injury and environmental contamination

Health protection precautions

12 A20 Stage 2 5th edition

Service products and process materials

Cleaning the cooling circuit

Cleaning the filter insert

Used engine/gearbox oil

Dealing with AdBlue®

5. Special information for working on the common-rail system

A20 Stage 2 5th edition 13