Man Engine Shop Manual - D0834 Loh 40

Common-rail In-line Engines
D0834 LOH40
Copy deadline: 01.2016
Repair Manual
81.99185-2462 2st edition A89 Stage 2
MAN Nutzfahrzeuge Aktiengesellschaft Reparaturanleitung A89 Stufe 2, 2. Ausgabe
Dachauer Str. 667 Reihenmotor Common Rail
80995 MÜNCHEN D0834 LOH40
oder - Englisch -
Postfach 50 06 20 Printed in Germany
80995 MÜNCHEN
Repair Manual A89 Stage 2
2st edition
Common-rail In-line Engines

D0834 LOH40
81.99185-2462
1
PREFACE / PRINTER’S IMPRINT
PREFACE
This manual provides assistance in performing repairs correctly on vehicles and units and reects the known
technical situation appertaining at the copy deadline.
This publication assumes that persons who use it possess the requisite technical knowledge in repairing
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always
correspond to the unit to be repaired or its peripherals.
The repair jobs are divided up into sections and subsections. Each subsection starts with a page of jobs to do
in advance. The jobs to do in advance contain a summary of the main prerequisites for the repair section in
question. The detailed description of work can follow the jobs to do in advance. Only the tightening torques
for screw/bolt connections which deviate from the standard are indicated in the repair sections.
Important instructions concerning technical safety and the safety of personnel are specically highlighted, as
indicated below.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in order to avoid
exposing people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in order to avoid
serious or irreparable damage to property.
Note
An explanatory note which is useful for understanding the working or operating procedure to be
performed.
Comply with general safety regulations when performing any repair work.
We reserve the right to make modications in the course of further development.
Best wishes from
MAN Nutzfahrzeuge AG
PRINTER’S IMPRINT
© 2010 MAN Nutzfahrzeuge AG
Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN. All
rights under the copyright law are strictly reserved by MAN Nutzfahrzeuge AG. If any changes or modications
are made without the written approval of MAN Nutzfahrzeuge AG then MAN Nutzfahrzeuge AG shall not be
liable for any material defects attributable to the unauthorised changes or modications. MAN Nutzfahrzeuge
AG is not liable for any damage attributable to unauthorised changes or modications.
Redaktion: SAWDT, 2W Technische Informations GmbH, 10.2009
Satz: SAWDT, 2W Technische Informations GmbH
Druck: MAN-Werksdruckerei
2 A89 Stage 2 2st edition

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

The engine ................................................................................................................ 16
Model plate/model designation .................................................................................... 16
Characteristic data .................................................................................................. 18
Engine description ................................................................................................... 19
Engine electrics
Engine electrics .......................................................................................................... 25

Removing and installing the engine electrics ................................................................... 25
Cooling system
Coolant pipes ............................................................................................................. 29

Removing and installing the coolant pipes ...................................................................... 29
Thermostat with thermostat housing ................................................................................. 33
Removing and installing the thermostat with thermostat housing .......................................... 33
Coolant pump ............................................................................................................ 35
Removing and installing the coolant pump ..................................................................... 35
Dismantling and assembling the coolant pump ................................................................ 37
Mounted components
Power take-off ............................................................................................................ 45

Removing and installing the power take-off .................................................................... 45
Air compressor ........................................................................................................... 49
Removing and installing the air compressor .................................................................... 49
Dismantling and assembling the air compressor .............................................................. 53
Starter ..................................................................................................................... 57
Removing and installing the starter .............................................................................. 57
Belt drive .................................................................................................................. 61
Removing and installing the belt drive (2 alternators) ......................................................... 61
Removing and installing the belt drive (1 alternator) .......................................................... 64
Removing and installing the hydraulic pump belt drive ....................................................... 66
Alternator .................................................................................................................. 69
Removing and installing the alternators (2 alternators) ....................................................... 69
Removing and installing the alternator (1 alternator) ......................................................... 77
Hydraulic pump .......................................................................................................... 81
Removing and installing the hydraulic pump ................................................................... 81
Common-rail system
Injectors and rail ......................................................................................................... 91

Protective sleeves for injectors and rail ......................................................................... 91
Removing and installing the injectors and rail .................................................................. 94
High-pressure pump .................................................................................................. 105
Protective sleeves for high-pressure pump .................................................................. 105
Removing and installing the high-pressure pump ........................................................... 107
Fuel service centre .................................................................................................... 115
Protective sleeves for fuel service centre ..................................................................... 115
Removing and installing the fuel service centre ............................................................. 117
Dismantling and assembling the fuel service centre ........................................................ 119
Flame start system .................................................................................................... 125
Protective sleeves for ame start system ..................................................................... 125
A89 Stage 2 2st edition 3

TABLE OF CONTENTS
Removing and installing the ame start system ............................................................. 127

Engine control unit .................................................................................................... 129
Removing and installing the engine control unit ............................................................. 129
Turbocharging
Charge-air manifold ................................................................................................... 135

Removing and installing the charge-air manifold ............................................................ 135
Turbocharger ........................................................................................................... 137
Removing and installing the turbocharger .................................................................... 137
Intake/exhaust system
Intake pipe .............................................................................................................. 145

Removing and installing the intake pipe ....................................................................... 145
Exhaust manifold ...................................................................................................... 149
Removing and installing the exhaust manifold ............................................................... 149
Cylinder head
Rocker arm mechanism .............................................................................................. 155

Removing and installing the rocker arm mechanism ........................................................ 155
Dismantling and assembling the rocker arm mechanism .................................................. 157
Cylinder head .......................................................................................................... 161
Removing and installing the cylinder head .................................................................... 161
Checking and setting the valve clearance (variant without EVB) ......................................... 168
Removing and installing the valve stem seals ............................................................... 172
Valve timing
Timing gears ............................................................................................................ 185

Removing and installing the timing gears ..................................................................... 185
Camshaft with camshaft bearings .................................................................................. 193
Removing and installing the camshaft with camshaft bearings ........................................... 193
Engine lubrication
Oil module .............................................................................................................. 203

Removing and installing the oil module (hanging oil lter) ................................................. 203
Oil sump ................................................................................................................. 207
Removing and installing the oil sump .......................................................................... 207
Oil pump ................................................................................................................. 213
Removing and installing the oil pump .......................................................................... 213
Oil injector nozzles .................................................................................................... 219
Removing and installing the oil injector nozzles ............................................................. 219
Crank mechanism
Vibration damper ...................................................................................................... 223

Removing and installing the vibration damper ............................................................... 223
Flywheel ................................................................................................................. 227
Removing and installing the ywheel (variant with clutch) ................................................. 227
Removing and installing the ywheel (variant with Allison gearbox) ..................................... 234
Pistons and connecting rods ........................................................................................ 241
Removing and installing the pistons and connecting rods ................................................. 241
Mass compensation gear ............................................................................................ 249
Removing and installing the mass compensation gear ..................................................... 249
Crankshaft .............................................................................................................. 253
Removing and installing the crankshaft ....................................................................... 253

TABLE OF CONTENTS
Crankshaft oil seals
Crankshaft oil seals ................................................................................................... 265

Removing and installing the front crankshaft oil seal ....................................................... 265
Removing and installing the rear crankshaft oil seal ........................................................ 269
Engine housing
Crankcase ventilation ................................................................................................. 275

Removing and installing the crankcase ventilation .......................................................... 275
Flywheel housing ...................................................................................................... 277
Removing and installing the ywheel housing ............................................................... 277
Timing case cover/timing case ...................................................................................... 281
Removing and installing the timing case cover .............................................................. 281
Removing and installing the timing case ...................................................................... 285
Technical Data
Technical Data 289

INDEX
Catchword Page
A
Air compressor, 1-cylinder
Drive gear mounting bolt .......................................................................................................................... 55
C
Characteristic data......................................................................................................................................... 18
Common rail
Fuel lines ................................................................................................................................................ 110
Fuel pump O-rings.................................................................................................................................. 112
High-pressure pump drive gear.............................................................................................................. 110
Crank mechanism
Bearing cap thrust washers.................................................................................................................... 258
Connecting rod bearing shells................................................................................................................ 244
Crankcase thrust washers...................................................................................................................... 258
Flywheel lateral runout ........................................................................................................................... 231
Lower connecting rod bearing ................................................................................................................ 246
Piston pin................................................................................................................................................ 244
Piston rings............................................................................................................................................. 245
Crankcase
Front crankshaft oil seal ......................................................................................................................... 268
Oil ller neck........................................................................................................................................... 283
Crankshaft oil seals
Rear crankshaft oil seal.......................................................................................................................... 272
E
Engine description ......................................................................................................................................... 19
Engine lubrication
Oil cooler ................................................................................................................................................ 205
Oil lter ................................................................................................................................................... 204
Oil injector nozzles ................................................................................................................................. 220
Oil pump drive gear ................................................................................................................................ 215
F
Flame start system
Flame glow plug ..................................................................................................................................... 128
Solenoid valve ........................................................................................................................................ 128
Fuel service centre
Hand pump............................................................................................................................................. 122
Heating element ..................................................................................................................................... 121
Pressure switch ...................................................................................................................................... 121
H
Hydraulic pump
Hydraulic connections .............................................................................................................................. 84
Hydraulic pump holder ............................................................................................................................. 84
Poly-V-belt pulley...................................................................................................................................... 83
Poly-V-belt tensioning bolt........................................................................................................................ 83
Slider ........................................................................................................................................................ 84
Tensioning pulley...................................................................................................................................... 84
M
Model designation ......................................................................................................................................... 16
Model plate .................................................................................................................................................... 16
Mounted components
Air compressor ......................................................................................................................................... 51
Alternator.................................................................................................................................................. 79
Belt drive .................................................................................................................................................. 65
Power steering pump ............................................................................................................................... 51
Power take-off .......................................................................................................................................... 46
Starter....................................................................................................................................................... 59

INDEX
S
Safety instructions ........................................................................................................................................... 9
General....................................................................................................................................................... 9
V
Valve timing
Axial shim ............................................................................................................................................... 196
Camshaft ................................................................................................................................................ 196
Camshaft bearing 1 ................................................................................................................................ 197
Camshaft bearings 2 - 3 ......................................................................................................................... 197
Tappet..................................................................................................................................................... 196

INTRODUCTION
INTRODUCTION
SAFETY INSTRUCTIONS
General
Only trained personnel are allowed to perform operating, maintenance and repair work on trucks, buses and
coaches.
The following sections include summaries of important regulations, listed according to major topics, which
must be complied with. The intention is to provide the knowledge needed to avoid accidents which could
lead to injury, damage and environmental pollution. 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 in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin
contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes,
crushing of 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 pneumatic or spring suspension system.
– Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.
– Only use tools that are in perfect condition.
– Only authorised technical personnel are entitled to perform checking, setting and repair work.
Working on the brake system

– A dust extractor must be used if dust is released when working on the brake system.
– Perform visual, function and effectiveness checks on the brake system after carrying out any work on it
whatsoever. These checks must be made in accordance with the safety inspection (SP).
– Check the function of ABS/ASR systems using a suitable test system (e.g. MAN-cats).
– Collect any brake uid that leaks out.
– Brake uid is poisonous! Do not allow brake uid to come into contact with food or open wounds.
– Treat hydraulic uid/brake uid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
Working on vehicles with 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 whose engine 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 controller. 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 work, the compressed gas tanks must be removed and the gas-carrying lines
must be ushed with inert gas.
– Compressed-gas tanks are only allowed to be exposed to temperatures up to 60° C in paint-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 ushed 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 specically
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 exchanging standard-t components of the compressed natural gas system using the prescribed
procedures, check the assembly points for leaks. Perform these checks using leak indicator spray or a gas
warning device.

INTRODUCTION
Operating the engine

– Only authorised personnel are permitted to start and operate an engine.
– Do not approach moving parts of a running engine too closely and do not wear baggy clothing. Use an
extractor system if working in enclosed spaces.
– Danger of burns when working on engines at operating temperature.
– Danger of scalding when opening the hot cooling circuit.
Suspended loads
– People are not allowed to stand below suspended loads.
– Only use suitable lifting and gear that is in perfect working order. Use lifting devices with sufcient
load-carrying capacity.
Attachments and special bodies

– Comply with the safety instructions and regulations issued by the body builder in question if attachments or
special bodies have been tted.
Working on high-pressure lines

– Do not attempt to tighten or loosen pipe lines and hoses when they are under pressure (e.g. lubrication
circuit, coolant circuit and hydraulic oil circuit):
Risk of injury due to pressurised uids emerging!
Checking injector nozzles

– Wear suitable protective equipment.
– Do not hold any part of your body under the jet of fuel when checking the injector nozzles.
– Do not inhale fuel vapours. Ensure that there is adequate ventilation.
Working on the vehicle electrical system

– Do not disconnect batteries whilst the engine is running!
– Always disconnect batteries when working on the vehicle electronic system, central electrical system,
alternator and starter! When disconnecting batteries, remove the negative terminals rst. When connecting
batteries, t the positive terminals rst.
– Always use suitable test lines and test adapters when measuring at plug connections!
– If temperatures of over 80°C are to be expected (e.g. in a drying oven after painting), switch the battery
master switch to "OFF" and then remove the control units.
– The chassis is not intended for use as an earth return! If attachments are to be tted to the vehicle (e.g.
a wheelchair lift), additional earth (ground) lines with an adequate cross-section must be tted as well.
Otherwise the earth connection may be created along wire cables, wiring harnesses, gearbox shafts, gears
etc. Severe damage could result.
Be careful as battery gases are explosive!

– Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after long journeys or after
charging the batteries with a battery charger.
– When the batteries are disconnected this gas may be ignited by sparks produced by other continuously
operating consumers, the tachograph etc. that cannot be shut down. Blow compressed air through the
battery box before disconnecting the batteries!
– Always leave the batteries connected when towing the vehicle! Only tow the vehicle if the check lamps are
still dimly lit but the battery starting power is not reached.
Do not use a rapid-charger to jump-start the vehicle!
– Always disconnect the positive and negative leads before charging and rapid-charging batteries!
– Do not rapid-charge lead-gel and maintenance-free batteries! (not in the case of "maintenance-free acc. to
DIN") The maximum charging capacity is 10% of the indicated capacity per battery. In parallel circuits, the
capacity is increased, in accordance with the total number of batteries connected in parallel.
– Risk of short-circuits due to incorrect battery polarity!
– Do not put metal objects (spanners, mole grips, etc.) on the batteries, since they may connect the terminals
together. Risk of short-circuit!
– Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in use for prolonged periods.
Caution! Battery acid is poisonous and corrosive!

– Wear appropriate protective clothing (gloves) when handling batteries.
Do not tilt batteries, acid may leak out. Similarly, do not tilt gel batteries.
– Measure voltage only using suitable testers! The input resistance of the measurement device must be at
least 10 MΩ.

INTRODUCTION
– Only disconnect and connect plug connections for electronic control unit when the ignition is switched off!
Electric welding
– Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number 80.78010.0002) as
described in the instructions accompanying the device.
– If this device is not available, disconnect the batteries and connect the positive cable to the negative cable
in order to make a rm conductive connection.
– If the battery master switch is manually operated, move it to the driving position. If an electronic battery
master switch is tted, bridge “Negative” at the load-disconnecting relay contacts (jumper cable > 1mm2)
and “Positive” at the load-disconnecting relay load contacts. In addition, switch on many loads such as:
starter switch (ignition) in driving position, hazard warning lights switch “on”, lighting switch in “driving lights
on”position, ventilation blower in “maximum” position. The greater number of consumers that are switched
on, the greater the protection.
After completing welding work, rst switch off all the consumers and remove all jumpers (re-create original
state), then connect the batteries.
– Always earth the welding equipment as close as possible to the welding area. Do not lay the cables to the
welding equipment in parallel to electrical cables in the vehicle.
Working on plastic tubes – Danger of damage and re!

– Mechanical or thermal loading of plastic tubes is not permitted.
Painting
– If paint spraying is to be carried out, do not expose the electronic components to high temperatures (max.
95 °C) for more than brief periods; a time of up to 2 hours is permissible at a maximum of 85 °C. Disconnect
the batteries.
Painting of screw connections in the high-pressure section of the injection system is not permitted. Risk of
dirt ingress in the event of repairs.
Working with the cab tilted

– Keep the tilting area in front of the cab clear.
– Keep out of the area between the cab and the chassis during the tilting process. This is a danger area!
– Always tilt the cab past the tilting point and secure the cab using a support rod.
Working on the air-conditioning system

– Refrigerant uids and vapours represent a health hazard; avoid contact with them and protect your eyes
and hands.
– Do not drain gaseous refrigerants in enclosed rooms.
– Do not mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant.
– Dispose of refrigerant in accordance with regulations.
Working on airbag or belt tensioner units

– Work on airbag or belt tensioner units may only be carried out by staff who have veriably completed a
competence course at the MAN Service Academy.
– Mechanical loads, vibrations, heating to over 140° C and electrical pulses, including electrostatic discharge,
can cause unintentional ring of the airbag or belt tensioner units.
– Hot gases are released explosively when the airbag or belt tensioner unit is red. The non-mounted airbag
or belt tensioner unit can be tossed around uncontrollably. This poses an injury risk to people in or near the
cab.
– Risk of burns when touching the hot surfaces after the airbag has red.
– Do not open a red airbag.
– Do not touch a red, destroyed airbag with your bare hands. Wear nitrile rubber gloves.
– Before all work and testing on airbag or belt tensioner units or work on the vehicle that can cause vibrations,
switch off the ignition, remove the ignition key, disconnect the ground line from the battery and disconnect
the power supply plug connection for the airbag and belt tensioner.
– Mount the driver airbag restraint system, MAN part number 81.66900-6035, on the airbag steering wheel
in accordance with the operating instructions.
– Only use specially designated devices for testing airbag and belt tensioner units. Do not use test lamps,
voltmeters or ohmmeters.
– After all work and tests, rst switch off the ignition, then connect the plug connection(s) for airbag and belt
tensioner. Then connect the battery. There must be no-one in the cab whilst this work is going on.
– Always deposit the airbags individually and with the impact cushion upwards.
– Do not treat airbags or belt tensioners with grease or cleaners.

INTRODUCTION
– Always store and transport airbag and belt tensioner units in their original packaging. Transport in the
passenger compartment is not permitted.
– Always store airbag and belt tensioner units in lockable storage areas, up to a maximum of 200 kg.
Working on the independent heater

– Before commencing work, switch off the heater and allow all hot components to cool down.
– Ensure that suitable collecting containers are available and no sources of ignition are present when working
on the fuel system.
– Keep suitable re extinguishing equipment nearby and within easy reach!
– The heater may not be operated in enclosed areas such as garages or workshops unless an extractor
system is used.
2. Notes on preventing damage and premature wear on units
General
– Units are only designed for their specied purpose - dened by the manufacturer (designated use): Any
other use is classied as not in accordance with the designated 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.
– Designated use also includes compliance with the operating, maintenance and repair conditions specied
by the manufacturer.
– The unit may only be used, maintained and repaired by persons who are familiar with it and are fully aware
of the risks.
– Arbitrary changes to the engine mean that the manufacturer is no longer responsible for any damage
incurred as a result of such changes.
– Similarly, tampering with the injection and control system can affect the unit's performance and exhaust-gas
characteristics. This means that compliance with the statutory environmental requirements is no longer
assured.
– If malfunctions occur, determine the cause and remedy the problem immediately.
– Clean units thoroughly before repairs, ensuring that all openings where dirt is not allowed to enter for safety
or functioning reasons are plugged.
– Never run a unit dry, in other words always make sure that it has been lled with oil before running it.
– Never run engines without coolant.
– Apply a suitable information sign to units that are not ready to be operated.
– Only use service products as per the MAN Recommended Service Products booklet, otherwise the
manufacturer warranty will be invalidated.
Details of approved products can be found online at: http://www.man-mn.com/ > Products & Solutions >
E-Business.
– Comply with the specied maintenance intervals.
– Do not ll engine/gear 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 or trucks
are to be withdrawn from service or stored for longer than 3 months.
3. Limited liability for parts and accessories
General
Only use accessories and genuine MAN parts that have been expressly approved by MAN Nutzfahrzeuge
AG 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 prolonged, excessive or repeated skin contact with service products, excipients, thinners or solvents.
Protect your skin using a suitable skin protection agent or protective gloves. Do not use service products,
excipients, thinners or solvents to clean the skin. Apply a greasy skin cream after cleaning your skin.
Service products and excipients

Do not use food or drink containers for draining and storing service products or excipients. Comply with
local-authority regulations when disposing of service products and excipients.
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).

INTRODUCTION
Cleaning the cooling circuit

Do not pour cleaning uids and rinsing water down the drain if this practice is restricted by specic local
regulations. However, the cleaning uid and rinsing water must, in all cases, be passed through an oil
separator with a sludge trap.
Cleaning the lter insert

When blowing compressed air through the lter insert, make sure the lter dust is collected by a vacuum
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 insert, because cleaning agents have aggressive
grease-dissolving characteristics.
Engine/gear oil, lter cartridges, inserts and box-type lters, desiccant cartridges
Filter inserts, cartridges and box-type lters (oil and fuel lters, desiccant cartridges for the air dryer) are
classied as hazardous waste. Comply with local-authority regulations when disposing of the above parts.
Used engine/gear oil

Lengthy or repeated skin contact with any type of engine/gear oil removes grease from the skin. This can
cause dry skin, irritation or skin inammation. In addition to these hazards, used engine oil contains dangerous
materials which can trigger dangerous skin diseases. Wear gloves, especially when changing the oil.
Handling AdBlue®
AdBlue® is a synthetically produced 32.5 % urea/water solution which is used as an NOx reduction additive
for diesel engines with 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 classied 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 workplace 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 nishing 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® gets into your eyes, rinse your eyes with water or an eye-rinsing
products for at least 10 minutes, keeping your eyelids open. Remove any contact lenses beforehand. If
symptoms persist, consult a doctor. If AdBlue® is swallowed, consult a doctor immediately. Store AdBlue®
containers closed in liquid-tight storage areas. 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
– A jet of fuel can cut through the skin. Risk of re due to fuel atomisation.
– Never undo the screwed connections on the fuel high-pressure side of the common-rail system whilst the
engine is running (high-pressure line from the high-pressure pump to/on the rail and on the cylinder head
to the injector). Whilst the engine is running, the lines are constantly carrying fuel under a 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.
– Avoid standing near the running engine.
– Do not touch the live parts at the injector electrical connection whilst the engine is running.
– Any changes to the original wiring can lead to the limit values specied in pacemaker regulations being
exceeded. Examples of such changes include non-twisted injector wiring or the addition of the test box
(contact box).
– There is no danger to operators and persons wearing a pacemaker if units with MAN common-rail engines
are used for their intended, i.e. approved, purpose.
– A jet of fuel can cut through the skin. Risk of re due to fuel atomisation.
– Never undo the screwed connections on the fuel high-pressure side of the common rail system whilst the
engine is running (injection line from the high-pressure pump to/on the rail and on the cylinder head to the
injector).
– Avoid standing near the running engine.
– Whilst the engine is running, the lines are constantly carrying fuel under a pressure of 1800 bar or more.
– Before opening the screwed connections, wait for at least one minute so that the system can be
depressurised.
– If necessary, use MAN-cats to check that the pressure in the rail has dissipated.
– Do not touch the live parts at the injector electrical connection whilst the engine is running.

INTRODUCTION
Information for people with pacemakers

– Any changes made to the original engine cabling can result in the limit values specied in pacemaker safety
regulations being exceeded, e.g. non-twisted injector cables or installing the test box (terminal tester).
– There is no risk for the driver and all passengers with pacemakers in authorised use.
– There is no danger to operators wearing a pacemaker if units with MAN common rail engines are used for
their intended, i.e. approved, purpose.
– In its original state, the product does not violate any of the currently known pacemaker limit values.
Danger of damage due to dirt ingress

– Diesel-injection systems consist of precision engineered components that are subject to extreme loads.
Due to this high-precision technology, it is necessary to ensure the greatest possible cleanliness during
all work on the fuel system.
– Even dirt particles over 0.002 mm can cause component failure.
Before commencing work on the clean side

– Clean the engine and engine compartment with the fuel system closed. Do not use a powerful jet when
cleaning electrical components.
– Drive the vehicle into a clean area of the workshop where none of the work causes dust to be swirled up
(sanding, welding, brake repairs, brake checks, performance tests etc.).
– Avoid air movements (possible swirling up of dust due to starting of engines, the workshop
heating/ventilation system, due to draughts etc.).
– Clean and dry the area of the still closed fuel system using compressed air.
– Use a suitable extractor unit (industrial extractor unit) to remove loose dirt particles such as paint chippings
and insulating material.
– Areas of the engine compartment from which dirt particles could become detached, e.g. tilted cab, engine
compartment in bus motors, must be covered with a new, clean covering foil.
– Wash your hands before starting to strip down the system and wear a clean set of overalls.
After opening the clean side

– The use of compressed air for cleaning is not permitted.
– During assembly, remove loose dirt using a suitable extractor unit (industrial extractor unit).
– Only lint-free cleaning cloths are allowed to be used on the fuel system.
– Clean tools and equipment before commencing work.
– Only use tools that show no signs of damage (cracked chrome coatings).
– Do not use any materials such as cloths, cardboard or wood when removing and installing components,
because these can give off particles and bres.
– If any paint akes off when connections are loosened (e.g. if they have been painted over), these paint
akes must be removed carefully before completing the unfastening of the screw connection.
– All parts removed from the clean side of the fuel system must immediately have their apertures sealed
with suitable plugs.
– This sealing material must be packed to protect it from dust before it is used, and must be disposed of after
one use.
– Following this, the components must be carefully stored in a clean, sealed container.
– Never apply used cleaning or test uids to these components.
– New parts must not be removed from their original packaging until immediately before use.
– Work on removed components may only be carried out in a suitably equipped workplace.
– If removed parts are shipped, always use the new parts original packaging.
It is mandatory to comply with the following additional instructions during work on bus engines:
Danger of damage due to dirt ingress

– Before opening the clean-side fuel system:
Clean the parts of the engine around the pressure/rail connections, injection lines, rail and valve cover with
compressed air.
– Remove the valve cover and then clean the part of the engine around the pressure/rail connections, injection
lines and rail again.
– Only loosen rail connections at rst:
Release the union nuts of the rail connections and unscrew by 4 turns.
Raise the rail connections using a special tool.
Reason: only remove the rail connections completely once the injectors have been removed so that no dirt
can fall into the injectors from above.
– Remove the injectors.

INTRODUCTION
– After removal, rinse out the injectors with a cleaning uid, making sure that the high-pressure connection
hole is facing downwards.
– Remove the rail connections by unscrewing their union nuts.
– Clean the injector hole in the cylinder head.
6. Limp-home program for units with electronic control units
General information
The units have an electronic control system that monitors the unit as well as itself (self-diagnosis).
As soon as a malfunction occurs, the malfunction is evaluated and one of the following measures is
implemented automatically:
– Output of a fault message with fault code.

– Switchover to suitable default function for further operation, albeit with restrictions. Have malfunctions
remedied by MAN after-sales immediately.
– If MAN-cats is used, the fault code is output directly.
7. Installation instructions
Installation of piping
– Mechanical deformation of piping is not permitted when performing installation work - risk of fracture!
Installation of gaskets
– Only use genuine MAN gaskets
– Make sure the mating faces are undamaged and clean.
– Do not use adhesives or sealing compounds. If necessary, to facilitate installation, use a little grease to
stick the gasket to the part to be mounted.
– Tighten the bolts evenly to the specied tightening torque.
Installation of O-rings
– Only use genuine MAN O-rings.
– Make sure the mating faces are undamaged and clean.
Engine overhaul
– A range of very different factors affect the engine service life. It is therefore not possible to indicate the
exact number of operating hours or miles before a major overhaul is due.
– In our judgement, it is not advisable to open an engine or perform a major overhaul if the engine has good
compression values and the following operating values have not changed signicantly since they were
measured and taken during the initial start-up:
– Charge pressure
– Exhaust temperature
– Coolant and lubricating oil temperature
– Oil pressure and oil consumption
– Smoke characteristics
The following criteria have a major inuence on the engine service life:
– Correct power setting for the application type
– Correct installation
– Approval of the installation by authorised personnel
– Regular maintenance as per the maintenance schedule

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

(2) NI/NII rework levels
Explanation of rework levels

There are reworking levels for crankshaft bearings, main bearings and connecting rod bearings as well as for
pistons and cylinder liners. The reworked assemblies are indicated on the model plate, e.g.: P = Crankshaft
– connecting rod bearing NI or NII H = Crankshaft – main bearing NI or NII.
Explanation of the engine no. (Engine identication number)
Motor-Nr. / engine no. Classication terms (assignment)
074 Type number according to type code

1938 Assembly day
533 Assembly sequence (progression number on assembly day)
1937 The last four digits of the engine no. (Motor-Nr.) are production and
equipment-specic data.
Explanation of the model designation
Model Meaning Example

designation
D Fuel type Diesel
08 Bore + 100 mm 108 mm bore
3 Stroke characteristic (rounded) stroke = 130 mm stroke
(Characteristic x 10) + 100
4 Number of cylinders 4 cylinders

INTRODUCTION
Model Meaning Example

designation
L Turbocharging with turbocharging and
intercooling
O Engine installation Bus or coach
H Engine installation Engine/vertical/rear installation
40 Type identication Output/rpm/approval

INTRODUCTION
Characteristic data
D 0834 LOH40
Designation Unit of measurement Data

Emissions category Euro3
Number of cylinders 4 cylinders/in-line/vertical
/arrangement
Valves per cylinder 4 valves
Engine weight, dry kg 475
Injection system Common rail / EDC 7
Direction of rotation as viewed Left
onto ywheel
Rated output to ISO 1585-88 kW/hp/rpm 132/180 at 2400 rpm
/195 EEC at engine speed
Bore mm 108
Stroke mm 125
Swept volume cc 4580
Firing sequence 1-3-4-2
Rated speed rpm 2400 rpm
Low idling speed rpm 700 rpm
Max. torque at engine speed Nm rpm 700 Nm at 1400 rpm

INTRODUCTION
Engine description
(1) Coolant outlet pipe (11) High-pressure pump

(2) Thermostat housing (12) Oil module
(3) Heat shield, turbocharger (13) Coolant manifold
(4) Crankcase ventilation (14) Oil ller pipe
(5) Coolant pipe (15) Pulley, hydraulic pump
(6) Distributor pipe (16) Charge-air manifold
(7) Rail (17) Pulley, power take-off
(8) Engine control unit (18) Charge-air manifold
(9) Fuel service centre (19) Alternator
(10) Starter
Engine, general
The engine described here is a liquid-cooled, turbocharged 4-cylinder, 4-stroke diesel engine with an
exhaust-gas turbocharger, compliant with the Euro 3 emissions standard.
The engine operates 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 speed and temperature sensors, for example, which
send information about the various engine operating conditions and states to the engine control unit.
The engine control unit operates according to the IPO principle:
I = Input
P = Processing

INTRODUCTION
O = Output
The engine 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 proportioning unit on the high-pressure pump.
Crankcase
The crankcase and the cylinder block are a monoblock casting made from special cast iron. The pistons run
directly in the crankcase. Ceramic honing of the cylinder liner surfaces achieves optimal results with respect
to wear resistance and oil consumption. At the rear of the crankcase, there is a ywheel housing. At the
front of the crankcase, there is a timing case cover. The ywheel housing and timing case cover are made
of aluminium. The crankshaft oil seals are installed in the timing case cover and the ywheel 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 turbocharger.
Crankshaft
The crankshaft is forged in a die using high-quality, micro-alloyed steel. It has cast counterweights to balance
the masses. The crankshaft is mounted in 5 bearings in the crankcase. The crankshaft journals and crank
pins are mounted in ready-to-install three-component bearings. 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 cap. The surface structure
resulting from cracking results in a tooth engagement effect between the connecting rod bearing cap and the
connecting rod with a precise, non-interchangeable t and high lateral stability.
Pistons
3-ring pistons made of special die-cast aluminium are used. They feature a cast ring carrier for the uppermost
piston ring. The pistons have a cast-in cooling duct for reducing the thermal load when the output is high.
They are cooled by an oil jet from the oil injector nozzles. The ring set comprises one taper-face ring and
one full keystone ring, each as compression rings, as well as one double-bevelled slotted oil control ring with
spiral-type expander as an oil scraper ring.
Cylinder head
D08 series engines are equipped with a single-section cylinder head. The cylinder head is made from special
cast iron and is tted with shrink-tted valve seat rings and pressed-in, exchangeable valve guides. The valve
guides on all valves are equipped with valve stem seals. The valves are actuated by individually exchangeable
rocker arms on rocker 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 has 5 bearing points in the crankcase. The
camshaft drive onto the camshaft gear comes from the spur-toothed crankshaft gear.
Engine lubrication
The engine is lubricated by forced-feed lubrication for all bearing points. The engine oil lter and the oil cooler
are grouped together as an oil module. The oil level in the oil sump is measured by means of a dipstick and
using an oil level sensor.
Cooling system
The cooling circuit is a thermostat-controlled, forced-circulation cooling system with a maintenance-free
coolant pump that is driven by a poly-V-belt. The thermostat is an exchangeable insert with wax elements as
expansion elements. The connection for the heater feed is located on the thermostat housing.
Intake/exhaust system
The three-section exhaust manifold is made of high temperature-resistant nodular cast iron and secured to
the cylinder head using heat-resistant bolts. The maintenance-free turbocharger is mounted on the middle
exhaust manifold. The exhaust manifold is installed downstream of the turbocharger. The turbocharger 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 (KSC). The fuel service centre comprises
a pre-lter and a special microlter 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 ame start system.
The interface to the high-pressure system is the fuel pump.
High-pressure system
The high-pressure system consists of the ow-rate-controlled high-pressure pump with ange-mounted fuel
pump and the rail with rail-pressure sensor and pressure-limiting valve. Solenoid valve-controlled injectors
with rail connections 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 rail for injection via the injectors. The high-pressure pump
delivery quantity is controlled by a proportional valve. The injection point and the injection quantity are
calculated in the engine control unit and implemented by the solenoid valve-controlled injectors.
The solenoid valve-controlled injectors allow multiple injections:
1 Pilot injection to improve combustion, reduce combustion noise and reduce peak combustion pressures.
2 Main injection to introduce the energy for the required engine power output.
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 valve. They are arranged vertically in the cylinder head and clamped
with a pressure ange in the cylinder head.
Flame start system

The ame start system consists of a solenoid valve and a rapid ame glow plug built into the charge-air
manifold. After various parameter enquiries (via sensors), the ame 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
(KSC).
Starter
The starter is a reduction-gear starter with a free-engaging pinion construction. The starter shaft is guided
without a thrust bearing on the housing in the starter. A mechanical relay is mounted in the starter for starter
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 4 times the engine speed.
Air compressor
The air compressor is driven by the straight-cut camshaft gear.
Front power take-off

The power take-off serves as an alternator drive and consists of the housing, the power take-off shaft mounted
in ball bearings and the poly-V-belt pulley. The power take-off is driven indirectly by the air compressor gear.
There are two opposite-facing lugs cast onto both the power take-off shaft and the air compressor gear. The
cross-slotted driver plate engages in these lugs to create a non-rigid connection and ensures a driving effect.
The poly-V-belt pulley used for driving the alternator by means of poly-V-belt is mounted on the power take-off
shaft.
Power steering pump

The power steering pump is mounted at the rear of the air compressor, in accordance with its design.

ENGINE ELECTRICS
ENGINE ELECTRICS
(1) Camshaft sensor (8) Charge-air temperature sensor

(2) Charge-air pressure sensor (9) Rail-pressure sensor
(3) Flame glow plug (10) Fuel service centre pressure sensor
(4) Fuel service centre lter heater (11) Oil pressure switch
(5) Coolant temperature sensor (12) Oil level sensor
(6) Coolant temperature sensor (13) Metering unit
(7) Speed sensor (14) Flame start system solenoid valve

ENGINE ELECTRICS
ENGINE ELECTRICS
Removing and installing the engine electrics
(1) Camshaft sensor (8) Charge-air temperature sensor

(2) Charge-air pressure sensor (9) Rail-pressure sensor
(3) Flame glow plug (10) Fuel service centre pressure sensor
(4) Fuel service centre lter heater (11) Oil pressure switch
(5) Coolant temperature sensor (12) Oil level sensor
(6) Coolant temperature sensor (13) Metering unit
(7) Speed sensor (14) Flame start system solenoid valve
Technical data
Flame glow plug (3) .............................................. M20x1.5 ............................................................25 Nm
Coolant temperature sensor (5) ............................. M16x1.5 ............................................................45 Nm
Charge-air temperature sensor (9)......................... M16x1.5 ............................................................45 Nm
Rail-pressure sensor (10)...................................... M18x1.5 ............................................................70 Nm
Fuel service centre pressure sensor (11)................ M14x1.5 ............................................................25 Nm
Oil pressure switch (12) ........................................ M18x1.5 ............................................................50 Nm
Oil level sensor (13).............................................. M22x1.5 ............................................................25 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

ENGINE ELECTRICS
Note
Before removing switches or sensors, read out and document the fault memory.
Always install switches and sensors with new O-rings or sealing rings.
After installing switches or sensors, read out the fault memory and, if necessary, delete it.

COOLING SYSTEM
COOLING SYSTEM
(1) Air compressor coolant feed line (4) Coolant outlet pipe
(2) Air compressor coolant return line (5) Coolant manifold
(3) Coolant pump (6) Thermostat housing

COOLING SYSTEM
COOLANT PIPES
Removing and installing the coolant pipes
Additional jobs
– Removing and installing the belt drive (2 alternators), see 61
– Removing and installing the belt drive (1 alternator), see 64
(1) Air compressor coolant supply line (4) Coolant outlet pipe
(2) Air compressor coolant return line (5) Coolant manifold
(3) Coolant pump (6) Thermostat housing
Technical data
Hollow screw, coolant lines, air compressor (1) ...... M14x1.5 ............................................................35 Nm
WARNING

COOLING SYSTEM
Removing the coolant pipes Detaching the coolant outlet pipe
Removing the coolant manifold and thermostat
• Unscrew the mounting bolts (4) with washers (3)

• Remove the coolant manifold (1) with gasket (2)
• Unscrew the mounting bolts (1) • Clean the mating faces
• Remove the coolant manifold (2) from the
thermostat housing (5)
• Remove the thermostat (4) with O-ring (3) from the
thermostat housing (5)
• Clean the mating faces
Detaching the air compressor coolant lines
• Detach the coolant feed line (1) and coolant return

line (2)

COOLING SYSTEM
Installing the coolant pipes Installing the coolant manifold and thermostat
Attaching the coolant outlet pipe
WARNING
• Position the coolant manifold (1) with a new gasket Component damage due to installation
(2) of incorrect thermostats
• Screw in the mounting bolt (4) with washers (3) • Use a thermostat with the specied
and tighten it opening temperature of 83 °C
Attaching the air compressor coolant lines • Insert the thermostat (4) into the thermostat
housing (5) with the ball valve facing upwards
• Insert the new O-ring (3)
• Position the coolant manifold (2) on the thermostat
housing (5)
• Screw in and tighten the mounting bolts (1)
• Position the coolant feed line (1) and coolant return

line (2)
• Screw on the union nut for the coolant return line
(2) and tighten it by hand
• Tighten the union nut for the coolant feed line (2)
• Screw in the hollow screw for the coolant return
line (1) with new gaskets and tighten to 35 Nm

COOLING SYSTEM
THERMOSTAT WITH THERMOSTAT HOUSING

Removing and installing the thermostat with thermostat housing
Additional jobs
(1) Mounting bolt (5) Thermostat housing

(2) Coolant outlet pipe (6) Mounting bolt
(3) O-ring (7) Gasket
(4) Thermostat (8) Timing case
Technical data
Thermostat opening temperature...................................................................................................... 83 °C
WARNING

COOLING SYSTEM
Removing the thermostat with Installing the thermostat and thermostat

thermostat housing housing
Removing the coolant manifold and thermostat Installing the thermostat housing
• Unscrew the mounting bolts (1) • Position the thermostat housing (3) with a new
• Remove the coolant manifold (2) from the gasket (2) on the timing case (1)
thermostat housing (5) • Screw in the new mounting bolts (4) and (5) as
• Remove the thermostat (4) with O-ring (3) from the marked and then tighten them by hand
thermostat housing (5) • Tighten the mounting bolts (4) and (5)
Installing the coolant manifold and thermostat
Detaching the thermostat housing
WARNING
• Mark the installation position of the mounting bolts
Component damage due to installation
(4) and (5)
of incorrect thermostats
• Unscrew the mounting bolts (4) and (5)
• Use a thermostat with the specied
• Remove the thermostat housing (3) with gasket
opening temperature of 83 °C
(2) from the timing case (1)
• Insert the thermostat (4) into the thermostat
housing (5) with the ball valve facing upwards
• Insert the new O-ring (3)
• Position the coolant manifold (2) on the thermostat
housing (5)

COOLING SYSTEM
COOLANT PUMP
Removing and installing the coolant pump
Additional jobs
(1) Coolant pump (3) Mounting bolt

(2) Gasket
Technical data
Coolant line hollow screw...................................... M14x1.5 ............................................................35 Nm
WARNING

COOLING SYSTEM
Removing the coolant pump Installing the coolant pump

Detaching the air compressor coolant lines Mounting the coolant pump
• Detach the coolant feed line (1) and coolant return • Mount the coolant pump (2) with a new gasket (3)
line (2) • Screw in and tighten the mounting bolts (1)
Removing the coolant pump Attaching the air compressor coolant lines
• Unscrew the mounting bolts (1) • Attach the coolant feed line (1) and coolant return
• Remove the coolant pump (2) with gasket (3) line (2)
• Clean the mating faces • Screw on the union nut for the coolant return line
(2) and tighten it by hand
• Tighten the union nut for the coolant return line (2)
• Screw in the hollow screw for the coolant feed line
(1) with new gaskets and tighten to 35 Nm

COOLING SYSTEM
Dismantling and assembling the coolant pump

Additional jobs
– Removing and installing the coolant pump, see 35
(1) Coolant pump housing (4) Bearing

(2) Slide seal ring (5) Circlip
(3) Impeller (6) Hub
Technical data
Gap width between impeller (3) and coolant pump housing (1).......................................... 2.0 mm - 2.6 mm
Distance between impeller (3) and coolant pump housing (1)........................................ 33.1 mm - 33.3 mm
Projection, slide ring seal ............................................................................................ 10.0 mm - 10.2 mm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
WARNING

COOLING SYSTEM
Special tools
[1] Depth gauge (electronic) 08.71195-9003
• Measuring the slide ring seal press-in depth
[2] Splitter blades 08.99605-9003
• Pressing off the impeller
[3] Puller 83.09143-6060
• Removing the coolant pump hub
[4] Drift punch 80.99617-0029
• Pressing out the coolant pump slide seal ring
[5] Plug-on handle, short 80.99617-0187
• Pressing in the coolant pump slide seal ring in

conjunction with:
• Installer sleeve [7]
• Ring [6]
[6] Ring 80.99617-0144
• Pressing in the coolant pump slide seal ring
[7] Installer sleeve 80.99617-0191
• Pressing in the coolant pump slide seal ring

COOLING SYSTEM
Dismantling the coolant pump Removing the bearing
Removing the coolant pump hub
• Place the coolant pump (3) onto the remover (1)

• Use the Drift punch [4] to press out the bearing (2)
• Pull off the hub (3) using the Puller [3] against the remover (1)
• Detach the circlip (2) from the coolant pump (1)
Removing the slide seal ring
Removing the impeller
• Press the slide seal ring (2) out of the coolant

• Prevent the coolant pump (1) from falling down pump housing (1) using the Drift punch [4]
• Position the Splitter blades [2] (2) under the
impeller (3)
• Use a counter-support for the Splitter blades [2]
(2)
• Press the coolant pump (1) out of the impeller (3)
using the Drift punch [4]

COOLING SYSTEM
Assembling the coolant pump Mounting the coolant pump hub
Installing the bearing
• Press the hub (2) onto the bearing (1) until ush
Determining the impeller height

WARNING
Component damage due to incorrectly
carried out repairs
• Carefully press in the bearing until the
stop is reached
• Use a suitable sleeve as a brace
• Press the bearing (2) into the coolant pump

housing (1) at the outer race until the stop is
reached
• Attach the circlip (3) in the coolant pump housing
(1)
Installing the slide seal ring
• Coat the slide ring seal and the coolant pump

shaft with a mixture containing 50% water and • Determine the height of the impeller (1) using the
50% coolant to MAN Standard 324 Type N Depth gauge (electronic) [1] (2)
• Assemble the installer sleeve consisting of the • Note down the value
Plug-on handle, short [5] (3), the Ring [6] and the
Installer sleeve [7]
• Use the installer sleeve to press the slide seal ring
(2) into the coolant pump housing (1) until the stop
is reached

COOLING SYSTEM
Mounting the impeller
Note
Inset = desired value + noted-down value
• Check the inset between the upper edge of the

impeller (2) and the coolant pump housing (1)
using the Depth gauge (electronic) [1] (3)
• Press on the impeller until the inset is reached
• The desired value must be 33.1 mm - 33.3 mm
plus the noted-down value
• Adjust the impeller (2) as necessary
The inset is 33.1 mm - 33.3 mm.
If the inset is more than 33.1 mm - 33.3 mm, adjust

the impeller (2).
If the inset is less than 33.1 mm - 33.3 mm, pull off

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

MOUNTED COMPONENTS
MOUNTED COMPONENTS
(1) Air compressor (5) Starter

(2) Power steering pump (6) Hydraulic pump
(3) Alternator (7) Power take-off
(4) Holder

MOUNTED COMPONENTS
POWER TAKE-OFF
Removing and installing the power take-off
Additional jobs
(1) Driver plate (5) Poly-V-belt pulley

(2) O-ring (6) Mounting bolt
(3) Power take-off (7) Timing case cover
(4) Mounting bolt
Technical data
Mounting bolt (4) .................................................. M16x1.5x45-8.8 LH.......................Initial torque 100 Nm
Mounting bolt (4) .................................................. M16x1.5x45-8.8 LH..............................Final torque 90°
Service products
Technical Vaseline ............................................................................................................. 09.15014.0001
WARNING

MOUNTED COMPONENTS
Removing the power take-off Removing the power take-off
Removing the poly-V-belt pulley
Note
The mounting bolt for the poly-V-belt
pulley has a left-hand thread.
• Brace the poly-V-belt pulley (2) using a size-41

open-ended spanner
• Unscrew the mounting bolt (1) from the power
take-off (3)
• Remove the poly-V-belt pulley (2)
• Unscrew the mounting bolts (1)

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

MOUNTED COMPONENTS
Installing the power take-off Mounting the poly-V-belt pulley
Mounting the power take-off
• Place the poly-V-belt pulley (2) on the power

take-off (3)
• Screw in the mounting bolt (1)
• Brace the poly-V-belt pulley (2) using a size-41
open-ended spanner
• Tighten the mounting bolt (1) to Initial torque 100
Nm
• Tighten the mounting bolt (1) to Final torque 90°
• Place the thin side of the driver plate (2) on the air
compressor gear and align it correctly
• Apply Technical Vaseline on the new O-ring (3)
and then t the O-ring on the power take-off (4)
• Position the power take-off (4)

MOUNTED COMPONENTS
AIR COMPRESSOR
Removing and installing the air compressor
Additional jobs
– Removing and installing the power take-off, see 45
(1) Air compressor (7) Mounting bolt

(2) Driver plate (8) Mounting bolt
(3) O-ring (9) O-ring
(4) Power steering pump (10) Driver plate
(5) Mounting bolt (11) O-ring
(6) Support block
Technical data
Air compressor pressure-relief valve...................... M26x1.5 ............................................................90 Nm
Air compressor pressure-relief valve opening
pressure .............................................................. M26x1.5 ............................................................ 17 bar
Hollow screw, air compressor coolant lines ............ M14x1.5 ............................................................35 Nm
Service products
Technical Vaseline ............................................................................................................. 09.15014-0001

MOUNTED COMPONENTS
WARNING
WARNING
Danger of power steering pump malfunction
• Thoroughly clean the power steering pump, steering connections and surrounding area before
commencing work
• Immediately plug any open oil lines

MOUNTED COMPONENTS
Removing the air compressor/power Removing the power steering pump

steering pump
Detaching the air compressor coolant lines

• Pull the power steering pump (3) off the air
compressor (1)
• Detach the coolant feed line (1) and coolant return • Remove the driver plate (5) and the O-ring (4)
line (2)
Removing the air compressor
• Detach the air compressor line

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

MOUNTED COMPONENTS
Installing the air compressor/power Attaching the air compressor coolant lines
steering pump
Mounting the power steering pump
• Position the coolant feed line (1) and coolant return

line (2)
• Screw on the union nut for the coolant return line
• Insert a new O-ring (4) into the power steering (2) and tighten it by hand
pump (3) • Tighten the union nut for the coolant return line (2)
• Put the driver plate (5) on the power steering • Screw in the hollow screw for the coolant feed line
pump (3) (1) with new gaskets and tighten to 35 Nm
• Align the power steering pump (3) with the air
compressor (1) and then insert it
Installing the air compressor
• Thinly apply Technical Vaseline on the new O-rings

(4) and (5) and then position them on the air
compressor (6)
• Fit the driver plate (3) with the thin side facing the
the air compressor gear
• Insert the air compressor (6) into the timing case
• Position the support (7)
• Screw in and tighten the support block mounting
bolt for support on the crankcase
• Attach the air compressor line

MOUNTED COMPONENTS
Dismantling and assembling the air compressor

Additional jobs
– Removing and installing the air compressor, see 49
(1) Elbow union (6) Mounting bolt

(2) Pressure-relief valve (7) Drive gear
(3) Elbow union (8) Gasket
(4) Mounting bolt (9) Cylinder head
(5) Housing
Technical data
Pressure-relief valve (2) ........................................ M26x1.5 ............................................................90 Nm
Mounting bolt (6) .......................................................................................................Initial torque 100 Nm
Mounting bolt (6) ..............................................................................................................Final torque 90°
Elbow unions (1), (3)............................................. M26x1.5 ..........................................................100 Nm
Mounting bolt (4) .................................................. M8 x 80 ......................................... Initial torque 20 Nm
Mounting bolt (4) .................................................. M8 x 80 ...............................................Final torque 90°
WARNING

MOUNTED COMPONENTS
Special tools
[8] Removal device 80.99606-6118
• Locking the air compressor crankshaft

MOUNTED COMPONENTS
Dismantling the air compressor Removing the drive gear
Removing the air compressor connections
• Unscrew the mounting bolt (1)

• Remove the drive gear (2)
Removing the cylinder head
• Mark the installation position of the elbow unions

(1) and (3)
• Undo the lock nuts for the elbow unions (1) and (3)
• Unscrew the elbow unions (1) and (3) and then
remove the sealing rings
• Unscrew the pressure-relief valve (2) and remove
the sealing ring
Mounting the removal device on the air

compressor

• Mark the installation position of the cylinder head
(2) and gasket (3)
• Remove the cylinder head (2) with gasket (3) from
the housing (4)
• Mount the Removal device [8] (3) on the air

compressor (1) with the mounting bolts (2)

MOUNTED COMPONENTS
Assembling the air compressor Removing the removal device
Mounting the cylinder head

• Remove the Removal device [8] (3) from the air
compressor (1)
Installing the air compressor connections
• Fit the cylinder head (2) with a new gasket (3) and
place it on the housing (4) as marked
• Screw in the new mounting bolts (1)
• Tighten the mounting bolts (1) evenly to Initial
torque 20 Nm, working crosswise
• Tighten the mounting bolts (1) evenly to Final
torque 90°, working crosswise
Mounting the drive gear
• Screw in the angle union (1) with a new sealing

ring, as marked
• Tighten the lock nut for the angle union (1) to 100
Nm
• Screw in the angle union (3) with a new sealing
ring, as marked
• Position the drive gear (2) • Tighten the lock nut for the angle union (3) to 100
• Screw in the new mounting bolt (1) Nm
• Tighten the mounting bolt (1) to Initial torque 100 • Screw in the pressure-relief valve (2) with a new
Nm sealing ring
• Tighten the mounting bolt (1) to Final torque 90° • Tighten the pressure-relief valve (2) to 90 Nm

MOUNTED COMPONENTS
STARTER
Removing and installing the starter
Additional jobs
– Disconnecting and connecting the battery, see Operator's Manual
– Tilting the cab forwards and backwards, see Operator's Manual
(1) Flywheel housing (3) Mounting bolt

(2) Starter (4) Mounting nut
Technical data
Mounting bolt (3) .................................................. M10x35-10.9......................................................50 Nm
Mounting nut (4) ................................................... M10...................................................................50 Nm
Terminal 30 mounting nut on relay ......................... M10...................................................................24 Nm
Number of starter pinion teeth ...............................................................................................................12
Starter power .................................................................................................................... 5.0 kW at 24 V
WARNING

MOUNTED COMPONENTS
Special tools
[9] Engine barring gear 80.99626-6008
• Cranking the engine in conjunction with:

• Gear ratchet [10]
[10] Gear ratchet 80.99627-0001
• Cranking the engine

MOUNTED COMPONENTS
Removing the starter Installing the starter

Disconnecting the starter electrical connections Installing the starter
• Unscrew the mounting nut (1) • Crank the engine once in the engine's running
• Remove the earth cables (2) and (3) direction using the Engine barring gear [9] and
• Disconnect the electrical connection (4) the Gear ratchet [10] whilst checking the ywheel
ring gear for damage. Fit a new ywheel ring gear
Removing the starter if necessary
• Insert the starter (3) into the ywheel housing (2)
• Screw in the new mounting bolts (4)
• Screw on the new mounting nut (1)
• Tighten the mounting bolts (4) to 50 Nm
• Tighten the mounting nut (1) to 50 Nm
Connecting the starter electrical connections

• Unscrew the mounting nut (1)
• Remove the starter (3) from the ywheel housing
(2)
• Put on the earth cables (2) and (3) with washer

• Screw on the mounting nut (1) and tighten to 24
Nm
• Connect the electrical connection (4)

MOUNTED COMPONENTS
BELT DRIVE
Removing and installing the belt drive (2 alternators)
(1) Poly-V-belt (6) Hydraulic pump poly-V-belt pulley

(2) Guide roller (7) Hydraulic pump poly-V-belt
(3) Coolant pump poly-V-belt pulley (8) Power take-off
(4) Vibration damper poly-V-belt pulley (9) Poly-V-belt tensioner
(5) Tensioning pulley (10) Guide roller
WARNING

MOUNTED COMPONENTS
Removing the belt drive Removing the guide rollers
Removing the alternator poly-V-belt
• Remove the guide rollers (1) and (4) with sleeves

(2) and (3)
WARNING
Danger of injury due to unintentional
rebound of the poly-V-belt tensioner
• Secure the poly-V-belt tensioner
after tensioning in order to prevent
unintentional rebound
• Slacken the poly-V-belt (1) by turning the

poly-V-belt tensioner (2) anticlockwise
• Hold the poly-V-belt tensioner (2) and remove the
poly-V-belt (1)
• Carefully slacken the poly-V-belt tensioner (2)
Removing the poly-V-belt tensioner
• Remove the poly-V-belt tensioner (1)

MOUNTED COMPONENTS
Installing the belt drive Installing the alternator poly-V-belt
Mounting the guide rollers
WARNING
• Mount the guide rollers (1) and (4) with sleeves (2) Danger of injury due to the
and (3) and new mounting bolts poly-V-belt tensioner springing
• Tighten the mounting bolts back unintentionally
Mounting the poly-V-belt tensioner after tensioning in order to prevent
it springing back unintentionally
• Turn the poly-V-belt tensioner (2) anticlockwise

and hold it
• Fit the poly-V-belt (1)
• Mount the poly-V-belt tensioner (1) with a new

mounting bolt
• Tighten the mounting bolt

MOUNTED COMPONENTS
Removing and installing the belt drive (1 alternator)
(1) Alternator poly-V-belt (3) Power take-off

(2) Coolant pump poly-V-belt pulley (4) Alternator poly-V-belt tensioner
WARNING

MOUNTED COMPONENTS
Removing the belt drive Installing the belt drive

Removing the alternator poly-V-belt Installing the poly-V-belt tensioner
• Mount the poly-V-belt tensioner (1) with a new

WARNING
mounting bolt
• Tighten the mounting bolt
• Secure the poly-V-belt tensioner Mounting the alternator poly-V-belt
• Slacken the poly-V-belt tensioner
carefully when the poly-V-belts are
removed
• Slacken the poly-V-belt (1) by turning the

poly-V-belt tensioner (2) anticlockwise
• Hold the poly-V-belt tensioner (2) and remove the
poly-V-belt (1)
Removing the poly-V-belt tensioner
WARNING
• Carefully slacken the poly-V-belt
tensioner
• Turn the poly-V-belt tensioner (2) anticlockwise

and hold it
• Remove the poly-V-belt tensioner (1) • Carefully slacken the poly-V-belt tensioner (2)

MOUNTED COMPONENTS
Removing and installing the hydraulic pump belt drive
(1) Hydraulic pump (4) Holding plate

(2) Holder (5) Mounting nut
(3) Tensioning pulley (6) Poly-V-belt pulley
Technical data
Tensioning force for poly-V-belt when tted new ................................................................................950 N
Tensioning force for poly-V-belt after running for more than 10 minutes ..............................................650 N
WARNING
Special tools
[11] Tension tester 81.66814-6001
• Checking the poly-V-belt tension

MOUNTED COMPONENTS
Removing and mounting the poly-V-belt Mounting the poly-V-belt
Undoing the tensioning pulley mounting nut
• Put the poly-V-belt (1) on the poly-V-belt pulley for

the hydraulic pump and crankshaft
• Brace the mounting nut (2) and undo the mounting
nut (1) Checking the poly-V-belt tension
• Undo the mounting nut (2)
Slackening the poly-V-belt
Note
Do not continue to apply pressure after
the spring has unclipped; this falsies the
• Undo the lock nut (2) measuring result.
• Screw in the tensioning bolt (1) as far as the stop The measurement must be repeated.
Removing the poly-V-belt
• Place the Tension tester [11] (4) on the poly-V-belt
(3)
• Press the pressure pad (2) perpendicular to the
poly-V-belt until you can hear the spring unclip
• Read off the value for the tensioning force at the
point where the upper edge of the indicator arm
(1) intersects the scale
• Remove the poly-V-belt (1)

MOUNTED COMPONENTS
Tensioning the poly-V-belt
• Screw in the tensioning bolt (1) until the poly-V-belt

is pre-tensioned
• Check the poly-V-belt with the Tension tester [11]
• The tension for new poly-V-belts is 950 N, while the
tension for poly-V-belts that have been operated
for more than ten minutes is 650 N
• If the measured value deviates from these values,
adjust the poly-V-belt tension using the tensioning
bolt (1)
• Brace the tensioning bolt (1) and tighten the lock
nut (2)
Tightening the tensioning pulley mounting nut
• Tighten the mounting nut (2)

• Brace the mounting nut (2) and tighten the
mounting nut (1)

MOUNTED COMPONENTS
ALTERNATOR
Removing and installing the alternators (2 alternators)
Additional jobs
(1) Poly-V-belt (4) Poly-V-belt tensioner

(2) Alternator/belt tensioner carrier (5) Guide roller
(3) Alternator
Technical data
Poly-V-belt pulley collar nut ................................... M16x1.5 ............................................................80 Nm
Terminal B+.......................................................... M8 ....................................................................13 Nm
Alternator operating voltage ...............................................................................................................28 V
Charging current, alternator (3) ............................. LEB10 120 A .....................................50 A at 1800 rpm
Charging current, alternator (3) ............................. LEB10 120 A ................................... 120 A at 6000 rpm
WARNING

MOUNTED COMPONENTS
WARNING
Component damage due to short-circuit
• Switch off the current supply (switch off the battery master switch) before disconnecting the
positive lead from the alternator
Special tools
[12] Special spanner set, size 22 80.99603-6029
• Removing and mounting the poly-V-belt pulley in

conjunction with:
• Gripper [13]
[13] Gripper 08.06460-0002
• Removing and mounting the poly-V-belt pulley

MOUNTED COMPONENTS
Removing the alternators Removing the carrier
Disconnecting the alternator electrical

connections

(3) and (5)
• Disconnect the cable connections for terminals B+ • Remove the carrier (4)
(1) and (3) • Unscrew the mounting nut (2) and remove the
• Unlock and remove the compact connectors (2) carrier (1)
and (4)
• Free and secure the wiring harnesses

MOUNTED COMPONENTS
Removing the upper alternator Removing the lower alternator
• Mark the installation position of the mounting bolts • Mark the installation position of the mounting bolts
(1) and (3) (1) and (3)
• Unscrew the mounting bolts (1) and (3) • Unscrew the mounting bolts (1) and (3)
• Remove the alternator (2) from the holder • Remove the alternator (2) from the holder

MOUNTED COMPONENTS
Removing the holder Removing the poly-V-belt pulley

• Remove the poly-V-belt pulley (2) from the
alternator shaft (3)

(3), (4) and (5)
• Unscrew the mounting bolts (3), (4) and (5)
• Remove the holder (1) with sleeve (2)
• Mount the Special spanner set, size 22 [12] (2)

with the Gripper [13] (3) on the poly-V-belt pulley
mounting nut
• Insert the splined spanner (1) from Special
spanner set, size 22 [12] (2) into the alternator
shaft spline
• Brace the splined spanner (1) and undo the
mounting nut

MOUNTED COMPONENTS
Installing the alternators Installing the holder
Mounting the poly-V-belt pulley
• Slide the poly-V-belt pulley (2) onto the alternator

shaft (3)
• Screw on the new mounting nut (1) and tighten it
by hand
Tightening the poly-V-belt pulley mounting nut
• Position the holder (1) with sleeve (2)

• Screw in the new mounting bolts (3), (4) and (5)
as marked and then tighten them by hand
• Tighten the mounting bolts (3), (4) and (5)
• Put the Special spanner set, size 22 [12] (2)

with the Gripper [13] (3) on the poly-V-belt pulley
mounting nut
• Insert the splined spanner (1) from Special
spanner set, size 22 [12] (2) into the alternator
shaft spline
• Brace the splined spanner (1) and tighten the
mounting nut to 80 Nm

MOUNTED COMPONENTS
Installing the lower alternator Installing the upper alternator
• Insert the alternator (2) into the holder • Insert the alternator (2) into the holder
• Screw in the new mounting bolts (1) and (3) as • Screw in the new mounting bolts (1) and (3) as
marked and then tighten them by hand marked and then tighten them by hand
• Tighten the mounting bolts (1) and (3) • Tighten the mounting bolts (1) and (3)

MOUNTED COMPONENTS
Mounting the carrier Connecting the alternator electrical connections
• Position the carriers (1) and (4) • Connect the plug connections (2) and (4)
• Screw in the new mounting bolts (3) and (5) as • Connect the cable connections for terminals B +
marked and then tighten them by hand (1) and (3), then tighten the mounting nut to 13 Nm
by hand • Route the wiring harnesses and secure using
• Tighten the mounting bolts (3) and (5) cable ties

MOUNTED COMPONENTS
Removing and installing the alternator (1 alternator)

Additional jobs
(1) Alternator (4) Mounting bolt

(2) Carrier (5) Mounting bolt
(3) Mounting bolt
Technical data
Terminal B+ on alternator (1) ................................. M8 ....................................................................15 Nm
Operating voltage, alternator (1) .........................................................................................................28 V
WARNING

MOUNTED COMPONENTS
Special tools
[14] Special spanner set, size 22 80.99603-6029
• Removing and mounting the poly-V-belt pulley in

conjunction with:
• Gripper [15]
[15] Gripper 08.06460-0002
• Removing and mounting the poly-V-belt pulley

MOUNTED COMPONENTS
Removing the alternator Removing the alternator
• Undo the mounting bolts (4)

• Unscrew the mounting bolts (1) from the carrier (3)
• Disconnect the alternator electrical connection • Remove the alternator (2)
• Unscrew the terminal B + mounting nut
• Undo the collar nut on the poly-V-belt pulley (2)
using Special spanner set, size 22 [14] (1) in
conjunction with Gripper [15]
• Unscrew the collar nut (1)

• Pull the poly-V-belt pulley (2) off the alternator
shaft (3)

MOUNTED COMPONENTS
Installing the alternator Tightening the poly-V-belt pulley
Mounting the alternator
• Tighten the collar nut on the poly-V-belt pulley (2)

to 80 Nm using Special spanner set, size 22 [14]
• Insert the alternator (3) into the carrier (4) (1) in conjunction with Gripper [15]
• Screw in and tighten the mounting bolts (1), (2) • Connect the alternator electrical connection
and (5) • Screw on the terminal B+ mounting nut and tighten
it to 15 Nm
Mounting the poly-V-belt pulley
• Place the poly-V-belt pulley (2) on the alternator

shaft (3)
• Screw on the new collar nut (1) and tighten it by
hand

MOUNTED COMPONENTS
HYDRAULIC PUMP
Removing and installing the hydraulic pump
(1) Hydraulic pump (4) Holding plate

(2) Holder (5) Mounting nut
(3) Tensioning pulley (6) Poly-V-belt pulley
Technical data
Mounting nut (5) ................................................... M14x1.5 ............................................................70 Nm
Poly-V-belt tension
WARNING

MOUNTED COMPONENTS
Special tools
[16] Puller 08.99605-9014
• Pulling off the hydraulic pump poly-V-belt pulley
[17] Tension tester 81.66814-6001
• Checking the poly-V-belt tension

MOUNTED COMPONENTS
Removing the hydraulic pump Removing the poly-V-belt and poly-V-belt pulley
Undoing the tensioning pulley mounting nut
• Remove the poly-V-belt (3)

• Brace the poly-V-belt pulley (2) and unscrew the
• Brace the mounting nut (2) and undo the mounting mounting nut (1)
nut (1) • Pull off the poly-V-belt pulley (2) using the
• Undo the mounting nut (2) Puller [16]
• Remove the tted key from the drive shaft (4)
Slackening the poly-V-belt
Removing the hydraulic pump
• Undo the lock nut (2)

• Screw in the tensioning bolt (1) as far as the stop • Prevent the hydraulic pump (2) from falling down
• Undo the mounting nut (3) • Brace the mounting bolts (3) and unscrew the
mounting nuts (1)
• Pull the hydraulic pump (2) out of the holding plate

MOUNTED COMPONENTS
Removing the tensioning pulley Removing the slider
• Unscrew the mounting nuts (1) and (2) • Unscrew the mounting bolt (4)
• Remove the tensioning pulley (3) with spacer ring • Remove the mounting nut (3)
(4) • Pull the slider (2) out of the holding plate (1)
Removing the holding plate Removing the holder
• Prevent the holding plate (2) from falling down • Unscrew the mounting bolts (2)
• Mark the installation position of the mounting bolts • Remove the holder (1)
(1) and (5)
• Mark the installation position of the spacer bushes Removing the hydraulic pump elbow ttings
(3)
• Remove the spacer bushes (3)
• Brace the mounting bolts (5) and unscrew the
mounting nuts (4)
• Remove the holding plate (2)

• Remove the elbow tting (3) with O-ring (4)
• Remove the elbow tting (6) with O-ring (5)

MOUNTED COMPONENTS
Installing the hydraulic pump Installing the slider
Removing the hydraulic pump elbow ttings
• Insert the slider (2) into the holding plate (1)

• Position the mounting nut (3) on the holding plate
• Position the elbow tting (6) with a new O-ring (5) (1)
• Screw in and tighten the mounting bolts (7) and (8) • Screw the mounting bolt (4) through the mounting
• Position the elbow tting (3) with a new O-ring (4) nut (3) and slider (2) until the stop is reached and
• Screw in and tighten the mounting bolts (1) and (2) tighten it by hand
Mounting the holder Mounting the holding plate
• Mount the holder (1) using mounting bolts (2) • Position the holding plate (2) and insert the
• Tighten the mounting bolts (2) mounting bolts (5), then screw on the mounting
nuts (4) and tighten them by hand
• Insert the spacer bushes (3) as marked, then
screw in the mounting bolt (1) as marked and
tighten it by hand
• Tighten the mounting bolts (1)
• Brace the mounting bolts (5) and tighten the
mounting nuts (4)

MOUNTED COMPONENTS
Mounting the tensioning pulley Mounting the poly-V-belt and poly-V-belt pulley
• Put on the tensioning pulley (3) with the spacer • Insert the tted key into the drive shaft (4)
ring (4) • Fit the poly-V-belt pulley (2), ensuring that the tted
• Screw on the mounting nuts (1) and (2) and tighten key does not fall out
them by hand • Screw on the mounting nut (1) and tighten it by
hand
Installing the hydraulic pump • Brace the poly-V-belt pulley (2) and tighten the
mounting nut (1) to 70 Nm
Checking the poly-V-belt tension
• Install the hydraulic pump (2) using mounting bolts

(3) and mounting nuts (1)
• Brace the mounting bolts (3) and tighten the
mounting nuts (1)
• Attach the hydraulic lines Note
Do not continue to apply pressure after
the spring has unclipped; this falsies the
measuring result.
The measurement must be repeated.
• Place the Tension tester [17] (4) onto the V-belt (3)
• Press the pressure pad (2) perpendicular to the
poly-V-belt until you can hear the spring unclip
• Read off the value for the tensioning force at the
point where the upper edge of the indicator arm
(1) intersects the scale

MOUNTED COMPONENTS
Tensioning the poly-V-belt
• Screw in the tensioning bolt (1) until the poly-V-belt

is pre-tensioned
• Check the poly-V-belt with the Tension tester [17]
• The tension for new poly-V-belts is 950 N, while the
tension for poly-V-belts that have been operated
for more than ten minutes is 650 N
• If the measured value deviates from these values,
adjust the poly-V-belt tension using the tensioning
bolt (1)
• Brace the tensioning bolt (1) and tighten the lock
nut (2)
Tightening the tensioning pulley mounting nut
• Tighten the mounting nut (2)

• Brace the mounting nut (2) and tighten the
mounting nut (1)

COMMON-RAIL SYSTEM
COMMON-RAIL SYSTEM
(1) Injector (5) Rail

(2) Mounting bolt (6) Injection line
(3) Injector pressure ange (7) Rail-pressure sensor
(4) Injection line (8) Rail connection

COMMON-RAIL SYSTEM
INJECTORS AND RAIL

Protective sleeves for injectors and rail
(1) Injector feed hole cap 81.96002-0523 (8) End plug 81.96002-0521
(2) End plug 81.96002-0520 (9) End plug 81.96002-0521
(3) Protective sleeve Z 14 x 15 (10) Protective sleeve Z 30 x 22
81.96002-0512 81.96002-0515
(4) Protective sleeve A9 81.96002-0516 (11) End plug 81.96002-0519
(5) Protective sleeve Z 14 x 15 (12) End plug 81.96002-0519
81.96002-0512 (13) Storage sleeve, injector 09.81020-1000
(6) Protective sleeve Z 12 x 16 81.96002-0117 (14) Injector nozzle protective sleeve
(7) Cap 81.96002-0518 81.96002-0522
WARNING
The common-rail system can be damaged
• Do not reuse plugs for high-pressure lines, the rail and injectors, even if they have only been
used once
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 sleeve. 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
[18] Injector feed hole cap 81.96002-0523
• Plugging the injector feed bore
[19] Injector nozzle protective sleeve 81.96002-0522
• Plugging the injector nozzle
[20] Injector storage sleeve 09.81020-1000
• Storing the injectors
[21] End plug 81.96002-0520
• Plugging the cylinder head injector bore
[22] Protective sleeve Z 30 x 22 81.96002-0515
• Plugging the pressure-limiting valve

• Plugging the rail-pressure sensor
[23] End plug 81.96002-0521
• Plugging the high-pressure line
[24] End plug 81.96002-0519
• Plugging the rail-pressure sensor bore in the rail

• Plugging the bore for the pressure-limiting valve
in the rail
• Plugging the bore for the rail connection
• Plugging the return line
• Plugging the pump rail high-pressure line
• Plugging the cylinder head

COMMON-RAIL SYSTEM
• Plugging the pressure pipe (rail) high-pressure

line connection
• Plugging the high-pressure pump return line
connection
• Plugging the rail connection
[26] Protective sleeve A9 81.96002-0516
• Plugging the rail return bore
• Plugging the return line
[28] Cap 81.96002-0518
• Plugging the hollow screw connections

COMMON-RAIL SYSTEM
Removing and installing the injectors and rail
(1) Injector (5) Rail

(2) Mounting bolt (6) Injection line
(3) Injector pressure ange (7) Rail-pressure sensor
(4) Injection line (8) Rail connection
Technical data
Mounting bolt (2) .................................................. M8x45 ............................................. Initial torque 2 Nm
Mounting bolt (2) .................................................. M8x45 ............................................ Final torque 30 Nm
Rail connection (8)................................................ M22x1.5 ........................................ Initial torque 10 Nm
Rail connection (8)................................................ M22x1.5 ......................................... Final torque 55 Nm
Mounting nut, injector cable .................................. M4 ...................................................................1.5 Nm
High-pressure line ................................................ M14x1.5 ........................................ Initial torque 10 Nm
High-pressure line (initial use) ............................... M14x1.5 ..............................................Final torque 60°
High-pressure line (re-use).................................... M14x1.5 ..............................................Final torque 30°
Mounting bolt, rail (5) ............................................ M8x55-8.8 .................................... Initial torque 1.5 Nm
Mounting bolt, rail (5) ............................................ M8x55-8.8 ...................................... Final torque 22 Nm
Rail-pressure sensor............................................. M18x1.5 ...........................................................70 Nm
Pressure-limiting valve.......................................... M18x1.5 ..........................................................100 Nm
WARNING

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 enable
depressurisation in the rail, 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 t new rail connections once they have been undone
• Do not reuse plugs for the high-pressure lines, the rail or injectors, even if they have only been
used once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
WARNING
• Always detach only one fuel line and then immediately plug the fuel line connections and
component connections
Special tools
[29] Impact extractor 80.99602-0011
• Removing the rail connection in conjunction with:

• Adapter with joint [30]
[30] Adapter with joint 80.99602-0173
• Removing the rail connection
[31] Extractor device 80.99602-6015
• Extracting the injector in conjunction with:

• Support bridge [32]
• Support [33]
• Support [34]
• Hexagon nut [35]
• Support [36]
[32] Support bridge 80.99602-0176
• Extracting the injector
[33] Support 80.99602-0177

COMMON-RAIL SYSTEM
[34] Support 80.99602-0199
[35] Hexagon nut 06.11226-8306
[36] Support 80.99602-0198
[37] Torque screwdriver 08.06510-9026
• Installing the injector cable in conjunction with:

• Adapter [38]
• Socket, size 7 [39]
[38] Adapter 08.06139-9029
• Installing the injector cable
[39] Socket, size 7 08.06141-0700
• Installing the injector cable
[40] Thrust piece 80.99606-0609
• Installing the injectors
[41] Hexagon wrench, size 17 80.99603-0309
• Screwing on and unscrewing the high-pressure

line union nuts in conjunction with:
• Angle extension [43]

COMMON-RAIL SYSTEM

[43] Angle extension 08.06139-9025
• Unscrewing and screwing on the high-pressure

line union nuts

COMMON-RAIL SYSTEM
Removing the high-pressure lines and Detaching the rail

rail
Detaching the high-pressure pump-rail
high-pressure line
• Unscrew the mounting bolts from the rail (1)

• Remove the rail (1) from the intake pipe
Unscrewing the rail-pressure sensor and

• Detach the high-pressure line (1) using the pressure-limiting valve
Hexagon wrench, size 17 [41], the Hexagon
wrench, size 22 [42] and the Angle extension [43]
Detaching the cylinder 1 - 4 high-pressure lines
WARNING
Component damage due to lack of
lubricant
• Do not wash off the pressure-limiting
• Mark the installed position of the clamping pieces
valve and rail-pressure sensor as the
(3)
thread and lipped edge are coated with
• Remove the clamping pieces (3) from the
lubricant
high-pressure lines (1) for cylinder 1 - 2 and
cylinder 3 - 4 • Unscrew the pressure-limiting valve (1)
• Detach the high-pressure line (1) using the • Unscrew the rail-pressure sensor (2)
Hexagon wrench, size 17 [41] (2), the Hexagon
wrench, size 22 [42] (2) and the Angle
extension [43]
• Repeat the same procedure for all the
high-pressure lines

COMMON-RAIL SYSTEM
Removing the injector Removing the electrical connection
Removing the rail connection
• Unscrew the mounting nuts (2)

• Remove the injector cable from the injector (1)
• Unscrew the union nut (2) from the rail connection • Remove the plug bracket for the injector plug (3)
(1)
Removing the pressure ange mounting
Pulling off the rail connection

• Extract the rail connection (2) from the hole (1) • Remove the spherical washer (2)
with the Impact extractor [29] (3) and Adapter with
joint [30]
Removing the cylinder head cover
• Open the bayonet ttings for the plug bracket

• Remove the cylinder head cover (2)

COMMON-RAIL SYSTEM
Assembling the extractor tool for the injector Removing the injector
• Mount the Support [34] (1) on the Support • Remove the injector (4) with pressure ange (3)
bridge [32] (2)with the Hexagon nut [35] and sealing ring (1)
• Mount the Support [33] (5) with Hexagon nut [35] • Pull the O-Ring (2) ring off the injector (4) towards
(4) on the Support bridge [32] (2) the magnet
• Insert the Support [36] (6) into the Support [33] (5) • Store the injector (4) in the Injector storage
• Insert the Extractor device [31] (3) into the Support sleeve [20] immediately after removal
bridge [32] (2)
Extracting the injector
WARNING
Component damage due to incorrect
removal of the injector
• Always remove the relevant rail
connection rst before removing the
injector
• Always remove one injector only
• Place the Extractor device [31] (1) over the injector

(4)
• Clamp the Extractor device [31] (1) in the pressure
ange groove (3)
• Extract the injector (4) by turning the knurled nut
(2)
• Remove the Extractor device [31] (1)

COMMON-RAIL SYSTEM
Installing the injector Installing the rail connection
Inserting the injector
• Remove the protective sleeves

• Thinly apply clean diesel fuel on the O-ring (2) and
Note slide it onto the new rail connection (3)
Always install the injector together with • Insert the rail connection (3) into the hole (1) in the
the pressure ange. cylinder head until the guide balls engage in the
It is not possible to install the pressure recess
ange afterwards. • Screw on the union nut (4) and tighten it to Initial
torque 10 Nm
• Remove the protective sleeves Injector nal torque
• Align the hole for the rail connection in the injector
with the duct for the rail connection in the cylinder
head
• Fit a new O-ring (2) and new sealing ring (1) on
the injector
• Place the pressure ange (3) on the injector (4)
• Insert the injector (4) into the cylinder head
together with the sealing ring (1) and the pressure
ange (3)
• Remove the injector (4) from the Injector storage
sleeve [20]
• Press the injector (4) fully into the cylinder head
with the Thrust piece [40]
Injector initial torque
• Tighten the mounting bolt (1) to Final torque 30

Nm
Rail connection nal torque
• Screw in the mounting bolt (1) with spherical

washer (2)
• Tighten the mounting bolt (1) to Initial torque 2 Nm
• Tighten the union nut (1) to Final torque 55 Nm

COMMON-RAIL SYSTEM
Installing the electrical connection Installing the high-pressure lines and

rail
Screwing in the rail-pressure sensor and
pressure-limiting valve
WARNING
Component damage due to possible
short-circuit
• When tightening the mounting nut,
make sure that the cable plugs do not WARNING
touch each other Component damage due to lack of
lubricant
• Connect the injector cable to the injector (1) • Do not wash off the pressure-limiting
• Tighten the mounting nut (2) to 1.5 Nm using the valve and rail-pressure sensor as the
Torque screwdriver [37], the Adapter [38] and the thread and biting edge are coated with
Socket, size 7 [39] lubricant
• Mount the plug bracket (3)
• Tighten the plug bracket mounting bolt (3) • Screw in the rail-pressure sensor (2) and tighten it
to 70 Nm
Installing the cylinder head cover • Screw in the pressure-limiting valve (1) and tighten
it to 100 Nm
Attaching the rail
• Check the condition of the cylinder head cover

gasket and plug bracket gaskets; replace as
necessary
• Fit the cylinder head cover (2) over the plug • Position the rail (1) on the intake pipe
bracket on the cylinder head • Screw in the mounting bolts for the rail (1) and
• Screw in and tighten the mounting bolts (1) tighten them to Initial torque 1.5 Nm
• Plug the bayonet ttings for the plug bracket

COMMON-RAIL SYSTEM
Attaching the cylinder 1 - 4 high-pressure lines Attaching the high-pressure pump - rail
high-pressure line

• Attach the high-pressure line (1), ensuring that • Remove the protective sleeves
it is strain-free, using the Hexagon wrench, size • Attach the high-pressure line (1), ensuring that
17 [41] (2), Hexagon wrench, size 22 [42] (2) and it is strain-free, using the Hexagon wrench, size
Angle extension [43] 17 [41], Hexagon wrench, size 22 [42] and Angle
• Tighten the high-pressure line (1) to Initial torque extension [43]
10 Nm • Tighten the high-pressure line (1) to Initial torque
• If a high-pressure line (1) is being re-used, tighten 10 Nm
it to Final torque 30° • If a high-pressure line (1) is being re-used, tighten
• Tighten the new high-pressure line (1) to Final it to Final torque 30°
torque 60° • Tighten the new high-pressure line (1) to Final
• Repeat the same procedure for the other torque 60°
high-pressure lines • Tighten the rail mounting bolts to Final torque 22
• Mount the clamping pieces (3) as marked Nm
• Tighten the mounting bolts for the clamping pieces
(3)

COMMON-RAIL SYSTEM
HIGH-PRESSURE PUMP
Protective sleeves for high-pressure pump

81.96002-0512 (6) End plug 81.96002-0521
(2) End plug 81.96002-0521 (7) End plug 81.96002-0521
(3) End plug 81.96002-0521 (8) Protective sleeve Z 14 x 15
(4) End plug 81.96002-0521 81.96002-0512
WARNING
used once
Note
sleeve, high-pressure line connection Z 14 x 15)

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

• Plugging the pressure pipe (rail)
[45] End plug 81.96002-0521
• Plugging the high-pressure line

COMMON-RAIL SYSTEM
Removing and installing the high-pressure pump
(1) Rail (6) Mounting bolt

(2) Mounting bolt (7) High-pressure pump
(3) Fuel pump (8) O-ring
(4) Mounting nut (9) Mounting nut, drive gear
(5) O-rings
Technical data
Mounting nut, drive gear (9) .................................. M18x1.5 ..........................................................105 Nm
Mounting bolt (2) ............................................................................................................................. 8 Nm
Mounting bolt (6) .................................................. M8x40 ...............................................................30 Nm
Mounting nut (4) ................................................... M8 ...................................................................30 Nm
Charge-air manifold mounting bolt ......................... M8x35-8.8 .........................................................30 Nm
High-pressure line tightening torque ...................... M14x1.5 ........................................ Initial torque 10 Nm
High-pressure line tightening torque ...................... M14x1.5 ..............................................Final torque 60°
Spacer ...........................................................................................................................................55 Nm
Overow valve tightening torque............................ M14x1.5 ............................................................30 Nm
Hollow screw........................................................ M14x1.5 ............................................................30 Nm
Service products
Diesel fuel......................................................................................................................... 09.08020-0104

COMMON-RAIL SYSTEM
WARNING
WARNING
• All work on components of the common-rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, 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 t new rail connections once they have been undone
used once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
WARNING
Special tools

[47] Angle extension 08.06139-9025
• Unscrewing and screwing on the high-pressure

line union nuts:
[48] Three-arm puller 08.99605-9014
• Extracting the high-pressure pump drive gear
[49] Screwdriver bit TX25 08.06527-1007
• Removing and installing the metering unit in

conjunction with:
• Screwdriver [51]
• Bit holder [52]
• Ratchet [53]
• Torque wrench [54]

COMMON-RAIL SYSTEM
[50] Screwdriver bit TX 30 08.06527-1009
• Removing and installing the fuel pump in

conjunction with:
• Screwdriver [51]
• Bit holder [52]
• Ratchet [53]
• Torque wrench [54]
[51] Screwdriver 08.06510-9018
• Removing and installing the metering unit

• Removing and installing the fuel pump
[52] Bit holder 08.06564-9000

[53] Ratchet 08.06410-9072

[54] Torque wrench 08.06450-0006


COMMON-RAIL SYSTEM
Removing the high-pressure pump Removing the high-pressure pump
Detaching the fuel lines
• Remove the high-pressure pump (1) from between

the oil module and the timing case by tilting and
WARNING turning it
Danger of environmental pollution due
to emerging fuel Unscrewing the mounting nut from the
• Collect emerging fuel in a permissible high-pressure pump drive gear
container
• Disconnect the high-pressure pump electrical

connection
• Detach the high-pressure line (1) using the
Hexagon wrench, size 17 [46] in conjunction with
the Angle extension [47]
• Mark the fuel lines (2), (3), (4), (5) and (6) to
indicate their installed position
• Remove the fuel lines (2), (3), (4), (5) and (6)
Removing the high-pressure pump mounting
• Clamp the high-pressure pump at the drive gear

(3) using a vice with protective jaws
• Unscrew the mounting nut (1) and remove it with
the washer
• Remove the O-ring (2)
Extracting the high-pressure pump drive gear
• Unscrew the mounting bolts (1) for the

high-pressure pump (3)
• Extract the drive gear (2) using the Three-arm

puller [48] (1)

COMMON-RAIL SYSTEM
Removing the fuel pump Removing the overow valve
• Unscrew the mounting bolts (2) using the • Unscrew the overow valve (3) from the
Screwdriver bit TX 30 [50], Bit holder [52] and high-pressure pump (1)
Screwdriver [51] • Remove the O-ring (2) from the overow valve (3)
• Remove the fuel pump (1)
• Remove the O-rings (3) and (4)
Removing the metering unit
• Unscrew the mounting bolts using the Screwdriver

bit TX25 [49], Bit holder [52] and Screwdriver [51]
• Mark the installation position of the metering unit
(2)
• Extract the metering unit (2) from the
high-pressure pump (1) by turning slightly to the
right/left

COMMON-RAIL SYSTEM
Installing the high-pressure pump Mounting the fuel pump
Installing the overow valve
• Position new O-rings (3) and (4) on the fuel pump

(1)
• Screw the overow valve (3) with a new O-ring (2) • Align the driver for the fuel pump (1) with the driver
into the high-pressure pump (1) on the high-pressure pump
• Tighten the overow valve to 30 Nm • Position the fuel pump (1) on the high-pressure
pump
Installing the metering unit • Screw in the mounting bolts (2) and tighten them
to 30 Nm
Mounting the high-pressure pump drive gear
• Install the metering unit (2) in the high-pressure

pump (1)
• Unscrew the mounting bolts using the Screwdriver
bit TX25 [49], Bit holder [52] and Screwdriver [51]
• Note
Ensure that the cone in the drive gear
and on the high-pressure pump is free
from oil and grease before commencing
assembly.
• Position a new O-ring (2)

• Put on the high-pressure pump drive gear (3)
• Screw on the mounting nut (1) and tighten it to
105 Nm

COMMON-RAIL SYSTEM
Filling the high-pressure pump Tightening the high-pressure pump
WARNING • Screw on the mounting nut (2) for the

Damage in the common-rail system high-pressure pump (3) and tighten it to 8 Nm
• Ensure absolute cleanliness in all areas • Screw in the mounting bolts (1) and tighten them
when carrying out all work. Avoid any to 30 Nm
moisture whatsoever
Attaching the high-pressure pump fuel lines
• Remove the End plug [45] from the fuel return line
(2)
• Fill the high-pressure pump with clean Diesel fuel
through the fuel feed line (1) until Diesel fuel
emerges at the fuel return line (2)
• Fit the protective sleeves
Inserting the high-pressure pump

• Attach the high-pressure line (1), ensuring that
it is stress-free, using the Hexagon wrench, size
17 [46] in conjunction with the Angle extension [47]
• Tighten the high-pressure line (1) to Initial torque

10 Nm
• Tighten the high-pressure line (1) to Final torque
60°
• Insert the high-pressure pump (1) vertically • Position the fuel lines (2), (3), (4), (5) and (6) as
between the oil module and the timing case by marked
tilting and turning it • Tighten the fuel lines (2), (3), (4), (5) and (6)
• Turn the high-pressure pump (1) to align it with the • Connect the high-pressure pump electrical
timing case and then insert it connection

COMMON-RAIL SYSTEM
FUEL SERVICE CENTRE

Protective sleeves for fuel service centre

81.96002-0514 (10) Protective sleeve Z 14 x 15
(2) Protective sleeve Z 14 x 15 81.96002-0512
81.96002-0512 (11) Protective sleeve Z 14 x 15
(3) Protective sleeve Z 14 x 15 81.96002-0512
81.96002-0512 (12) End plug 81.96002-0521
(4) End plug 81.96002-0521 (13) End plug 81.96002-0521
(5) End plug 81.96002-0521 (14) Protective sleeve Z 14 x 15
(6) End plug 81.96002-0521 81.96002-0512
(7) End plug 81.96002-0521 (15) Protective sleeve A9 81.96002-0516
(8) End plug 81.96002-0521 (16) Protective sleeve A9 81.96002-0516
WARNING
• Do not reuse plugs for high-pressure lines, the rail or injectors, even if they have only been used
once
Note
sleeve, high-pressure line connection Z 14 x 15)

COMMON-RAIL SYSTEM
Special tools
[55] End plug 81.96002-0521
• Plugging the fuel lines
• Plugging the high-pressure line connection
• Plugging the ame start system fuel line
• Plugging the ame glow plug return line

COMMON-RAIL SYSTEM
Removing and installing the fuel service centre
(1) Fuel service centre (3) Pressure sensor

(2) Mounting bolts (4) Hand pump
WARNING
WARNING
• Always allow the fuel service centre to empty completely in order to remove dirt and impurities
before changing the fuel lter
WARNING

COMMON-RAIL SYSTEM
Removing the fuel service centre Installing the fuel service centre
Detaching the fuel lines Mounting the fuel service centre
• Position the fuel service centre (2) and bushes (1)

WARNING
and holder (4)
to emerging fuel
• Collect emerging fuel in a permissible Attaching the fuel lines
container
• Mark the fuel lines (1), (3), (4), (5), (6) and (7) to
indicate their installed position
• Unscrew the mounting bolt (2) from the fuel line
(1)
• Detach the fuel line (1)
• Remove the fuel lines (3), (4), (5), (6) and (7)
• Plug the detached fuel lines (1), (3), (4), (5), (6)
and (7) with protective sleeves
• Plug the freed connections with protective sleeves
Removing the fuel service centre

• Position the fuel lines (1), (3), (4), (5), (6) and (7)
as marked
• Tighten the fuel lines (1), (2), (3), (4), (5), (6) and
(7)
• Screw in the mounting bolt (2) at the holder for the
fuel line (1)

• Remove the fuel service centre (2) and bushes (1)
and holder (4)

COMMON-RAIL SYSTEM
Dismantling and assembling the fuel service centre

Additional jobs
– Removing and installing the fuel service centre, see 117
(1) Fuel lter (9) Heating element

(2) Cover (10) Hollow screw
(3) O-ring (11) Cover
(4) Housing (12) Fuel pre-lter
(5) Pressure sensor (13) O-ring
(6) Water drain plug (14) Housing
(7) Mounting bolts (15) Hand pump
(8) O-ring (16) Mounting bolts
Technical data
Pressure sensor ................................................... M18 x 1.5 ..........................................................45 Nm
Cover (2)........................................................................................................................................20 Nm
Cover (11) ......................................................................................................................................10 Nm
Water drain plug .............................................................................................................................. 2 Nm
WARNING

COMMON-RAIL SYSTEM
WARNING
• Always allow the fuel service centre to empty completely in order to remove dirt and impurities
before changing the fuel lter
• Only use fuel lters that are designated for common-rail systems and marked as such
• Do not re-use used lter elements
Special tools
[59] Hexagon socket wrench, size 36 80.99603-0325
• Removing and installing the fuel lter cover
[60] Socket, size 19 08.06141-9061
• Removing and installing the fuel pre-lter 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 O-ring (2)

from the fuel service centre
WARNING
Removing the lter elements
to emerging fuel
• Collect emerging fuel in a permissible
container
• Undo the cover (1) by approx. 2 - 3 turns using

the Hexagon socket wrench, size 36 [59]
• Open the water drain plug (2) and allow the fuel
service centre to empty
• Tighten the water drain plug (2) to 2 Nm
Removing the heating element
• Unscrew the mounting bolts (2) for the heating

element (3)
• Pull the heating element (3) with O-ring (4) out of
the fuel service centre (1) • Unscrew the cover (1)
• Pull the fuel lter (3) out of the fuel service centre
• Unscrew the fuel pre-lter cover (7)
• Pull the fuel pre-lter (6) off the housing (4)

COMMON-RAIL SYSTEM
Removing the hand pump Assembling the fuel service centre

Mounting the hand pump
• Unscrew the mounting bolts (2) from the fuel

service centre (3)
• Remove the hand pump (1) • Mount the hand pump (1) on the fuel service centre
(3) using mounting bolts (2)

COMMON-RAIL SYSTEM
Installing the lter elements Installing the pressure sensor
• Screw in the pressure sensor (1) with a new

sealing ring (2)
• Tighten the pressure sensor (1) to 45 Nm
Installing the heating element
WARNING
Damage on the common-rail system
• Dirt must not be allowed to reach the
clean side of the lter
• Do not re-use used lter elements
• Insert a new fuel pre-lter (6) • Insert the heating element (3) with a new O-ring
• Screw the cover (7) with a new O-ring (5) into the (4) into the fuel service centre (1)
housing (4) • Screw in and tighten the mounting bolts (2)
• Use Socket, size 19 [60] and a torque wrench to
tighten the cover (7) to 10 Nm
• Insert the new fuel lter (3) into the cover (1)
• Screw the cover (1) with a new O-ring (2) into the
fuel service centre
• Use Hexagon socket wrench, size 36 [59] and a
torque wrench to tighten the cover (1) to 20 Nm

COMMON-RAIL SYSTEM
FLAME START SYSTEM

Protective sleeves for ame start system
(1) Protective sleeve A9 81.96002-0516 (5) Protective sleeve A9 81.96002-0516

(2) Protective sleeve Z 10 x 10 81.96002-0511 (6) Protective sleeve Z 10 x 10 81.96002-0511
(3) Protective sleeve Z 10 x 10 81.96002-0511 (7) Protective sleeve Z 10 x 10 81.96002-0511
(4) Protective sleeve A9 81.96002-0516 (8) Protective sleeve A9 81.96002-0516
WARNING
• Do not reuse plugs for high-pressure lines, the rail or injectors, even if they have only been used
once
Note
sleeve, high-pressure line connection Z 14 x 15).

COMMON-RAIL SYSTEM
Special tools
• Plugging the ame glow plug return line
• Plugging the ame start system fuel line

COMMON-RAIL SYSTEM
Removing and installing the ame start system
(1) Fuel service centre (3) Flame glow plug

(2) Solenoid valve (4) Fuel line
Technical data
Flame glow plug ................................................... M20x1.5 ............................................................25 Nm
Fuel line union nut (4) ........................................... M10x1 ................................................................ 5 Nm
Service products
Curil T............................................................................................................................... 04.90300-9030
WARNING

COMMON-RAIL SYSTEM
Removing the ame start system Installing the ame start system
Removing the fuel line Installing the ame glow plug
• Disconnect the electrical connection (3) • Thinly apply Curil T on the thread of the ame glow
• Remove the fuel lines (1) and (2) plug (1)
• Screw in the ame glow plug (1) and tighten the
Removing the solenoid valve union nut to 25 Nm
Installing the solenoid valve

• Remove the solenoid valve (2)
• Position the solenoid valve (2)
Removing the ame glow plug • Screw in and tighten the mounting bolts (1)
Installing the fuel lines
• Remove the ame glow plug (1)

• Install the fuel lines (1) and (2)
• Connect the electrical connection (3)

COMMON-RAIL SYSTEM
ENGINE CONTROL UNIT

Removing and installing the engine control unit
(1) Rubber mount (4) Engine control unit

(2) Rubber mount (5) Mounting bolt
(3) Bracket mounting bolt
Technical data
Mounting bolt (5) .................................................. M6x35-10.9 ....................................................... 11 Nm
Bracket mounting bolt (3) ...................................... M8x40-10.9 .......................................................13 Nm
Service products
Loctite 270 ........................................................................................................................ 04.10160-9062
WARNING
Note
After exchanging the engine control unit, check the parameter settings and, if necessary, reset the
parameters.

COMMON-RAIL SYSTEM
Removing the engine control unit Installing the engine control unit
Disconnecting the engine control unit electrical Tightening sequence for engine control unit
connection
• Tighten the engine control unit in the sequence A,

• Unlock and pull off the connectors (1), (2) and (3) B, C, D, E, F, G, H, starting with A (1)
on the engine control unit
• Free the wiring harnesses Installing the engine control unit and bracket
Removing the engine control unit and bracket
• Insert the rubber mounts (1) and (2) into the

bracket
• Unscrew the mounting bolts (5) • Thinly apply Loctite 270 on the threads of the new
• Remove the engine control unit (4) mounting bolts for the bracket (3)
• Unscrew the mounting bolts for the bracket (3) • Position the bracket, then screw in the mounting
• Remove the bracket and pull out the rubber bolts for the bracket (3) and tighten them to 13 Nm
mounts (1) and (2)
• Position the engine control unit (4)
• Screw in the new mounting bolts (5) and tighten in
the specied sequence to 11 Nm

COMMON-RAIL SYSTEM
Connecting the engine control unit electrical

connection
• Insert and lock the connectors (1), (2) and (3) on

the engine control unit
• Route the wiring harnesses and secure using
cable ties

TURBOCHARGING
TURBOCHARGING
(1) Charge-air manifold (4) Gasket

(2) Gasket (5) Charge-air manifold
(3) Clamp

TURBOCHARGING
CHARGE-AIR MANIFOLD
Removing and installing the charge-air manifold
Additional jobs
– Removing and installing the ame start system, see 127
(1) Charge-air manifold (4) Gasket

(2) Gasket (5) Charge-air manifold
(3) Clamp
WARNING

TURBOCHARGING
Removing the charge-air manifold Installing the charge-air manifold

Removing the charge-air manifold Mounting the charge-air manifold
• Unscrew the mounting bolts (1) and (2) • Position the charge-air manifold (1) with a new
• Remove the charge-air manifold (3) with the gasket (2) and clamp (3)
gasket (4) • Tighten the clamp (3)
Mounting the charge-air manifold
Removing the charge-air manifold
• Position the charge-air manifold (3) with the gasket

• Undo the clamp (3) (4)
• Remove the charge-air manifold (1) with the clamp • Screw in and tighten the mounting bolts (1) and (2)
(3) and the gasket (2)

TURBOCHARGING
TURBOCHARGER
Removing and installing the turbocharger
Additional jobs
– Removing and installing the crankcase ventilation, see 275
– Removing and installing the charge-air manifold, see 135
(1) Oil pressure line (5) Exhaust manifold

(2) Turbocharger (6) Heat shield
(3) Oil return line (7) Holder
(4) Hollow screw, ring connector
Technical data
Hollow screw, ring connector (4)............................ M14x1.5 ............................................................30 Nm
Service products
Technical Vaseline ............................................................................................................. 09.15014-0001
WARNING

TURBOCHARGING
Removing the turbocharger Removing the heat shield
• Unscrew the mounting bolts (3) and (5) from the

holder (4)
• Undo the clamp (3) • Remove the holder (4)
• Remove the charge-air manifold (1) with the • Unscrew the mounting bolts (2)
gasket (2) and the clamp (3) • Remove the heat shield (1)
Removing the wastegate control pulse valve Removing the exhaust manifold heat shield
• Disconnect the electrical connection for the pulse • Unscrew the mounting bolts (3) and remove the
valve (4) holder (4)
• Mark the installation position of the control hoses • Unscrew the mounting bolts (2) and (5)
(1), (7) and (8) • Remove the heat shields (1)
• Remove the hose clamps (2), (6) and (9) • Unscrew the mounting bolts (6) and (7)
• Unscrew the mounting bolt (3) • Remove the heat shield (8)
• Pull off the control hoses (1), (7) and (8)
• Remove the pulse valve (4)

TURBOCHARGING
Removing the exhaust manifold Removing the holding bracket
• Mark and unscrew the mounting bolts (1) and (2) • Unscrew the mounting bolts (2) and (3)
• Remove the exhaust manifold (3) • Remove the holding bracket (1)
Detaching the oil pressure line Removing the turbocharger
• Unscrew the hollow screw at the oil pressure lines • Unscrew the mounting nuts (1)
(1) • Remove the turbocharger (2) with the gasket
• Undo and remove the oil pressure line (1) at the • Clean the mating faces
turbocharger
Detaching the return lines

• Remove the oil return lines (1) with gaskets

TURBOCHARGING
Mounting the turbocharger Filling the turbocharger
Mounting the turbocharger
WARNING
• Position the turbocharger (2) with a new gasket Component damage when the engine
• Screw on and tighten the new mounting nuts (1) is started for the rst time
• Fill the turbocharging module with clean
Mounting the holding bracket engine oil to MAN standard
• Pour oil through the oil feed neck (2) using the
funnel (1) until the oil duct is full
Attaching the oil pressure line
• Position the holding bracket (1)

Attaching the return lines

• Position the oil pressure lines (1)
• Screw in and tighten the hollow screw for the oil
pressure line (1) with new gaskets
• Tighten the oil pressure lines (1) on the
turbocharger
• Position the oil return lines (1) with new gaskets

• Screw in and tighten the mounting bolts (2) and (3)

TURBOCHARGING
Mounting the exhaust manifold Mounting the heat shield
• Position the exhaust manifold (3) • Position the heat shield (1)
• Screw in and tighten the mounting bolts (1) and • Screw in and tighten the mounting bolts (2)
(2) as marked • Position the holder (4) with the mounting bolts (3)
and (5)
Mounting the heat shield • Tighten the mounting bolts (3) and (5)
Mounting the charge-air manifold
• Position the heat shield (8)

• Screw in and tighten the mounting bolts (6) and (7)
• Position the heat shields (1) • Position the charge-air manifold (1) with the gasket
• Screw in and tighten the mounting bolts (2) and (5) (2) and the clamp (3)
• Position the holder (4) with the mounting bolts (3) • Tighten the clamp (3)

TURBOCHARGING
Mounting the wastegate control pulse valve
• Position the pulse valve (4)

• Fit the hose clamps (2), (6) and (9) over the control
hoses (1), (7) and (8)
• Attach the control hoses (1), (7) and (8) as marked
• Screw in and tighten the mounting bolt (3)
• Tighten the hose clamps (2), (6) and (9)
• Connect the electrical connection for the pulse
valve (4)

INTAKE/EXHAUST SYSTEM
(1) Mounting bolt (5) Intake pipe

(2) Exhaust manifold (6) Mounting bolt
(3) Mounting bolt (7) Charge-air manifold
(4) Coolant pipe (8) Exhaust manifold gasket

INTAKE PIPE
Removing and installing the intake pipe
Additional jobs
– Removing the high-pressure lines and rail, see 98
– Installing the high-pressure lines and rail, see 102
(1) Gasket, intake pipe (3) Intake pipe

(2) Mounting bolt (4) Charge-air manifold
Technical data
Charge-air temperature sensor.............................. M16x1.5 ............................................................45 Nm
WARNING

Removing the intake pipe Removing the wastegate control pulse valve
Removing the temperature sensor
• Disconnect the pulse valve electrical connection

• Mark the installation position of the control hoses
• Disconnect the electrical connection for the • Remove the hose clamps (2), (6) and (9)
temperature sensor (2) • Unscrew the mounting bolt (3)
• Unscrew the temperature sensor (2) with sealing • Pull off the control hoses (1), (7) and (8)
ring (1) • Unscrew the mounting bolts (5)
• Remove the pulse valve (4)
Removing the intake pipe
• Remove the charge-air sensor electrical

connection • Unscrew the mounting bolts (3)
• Unscrew the mounting bolts (1) and (2) • Remove the intake pipe (2) with gaskets (1)
• Remove the charge-air manifold (3) with the • Clean the mating faces
gasket (4)

Installing the intake pipe Mounting the charge-air manifold
Mounting the intake pipe
• Position the charge-air manifold (3) with a new

gasket (4)
• Position the intake pipe (2) with new gaskets (1) • Screw in and tighten the mounting bolts (1) and (2)
• Screw in and tighten the mounting bolts (3) • Connect the charge-pressure sensor electrical
connection
Mounting the wastegate control pulse valve
Installing the temperature sensor
• Position the pulse valve (4)

• Screw in and tighten the mounting bolts (5) • Screw in the temperature sensor (2) with a new
• Fit the hose clamps (2), (6) and (9) over the control sealing ring (1) and tighten to 45 Nm
hoses • Connect the electrical connection for the
• Attach the control hoses (1), (7) and (8) as marked temperature sensor (2)
• Tighten the hose clamps (2), (6) and (9)
• Connect the pulse valve electrical connection

EXHAUST MANIFOLD
Removing and installing the exhaust manifold
Additional jobs
– Removing and installing the turbocharger, see 137
– Removing and installing the alternators (2 alternators), see 69
– Removing and installing the alternator (1 alternator), see 77
(1) Gaskets (4) Mounting bolts

(2) Exhaust manifold (5) Heat shield
(3) Mounting bolts
Technical data
Mounting bolt (3) .................................................. M8x80-GA ..................................... Initial torque 25 Nm
Mounting bolt (3) .................................................. M8x80-GA ..................................... Final torque 2 x 45°
Mounting bolt, exhaust manifold ............................ M8x58-GA ..................................... Initial torque 25 Nm
Mounting bolt, exhaust manifold ............................ M8x58-GA ..................................... Final torque 2 x 45°
Mounting nut, exhaust manifold ............................. M8-GA ..............................................................27 Nm
Mounting bolt (4) .................................................. M8x55-8.8 .........................................................27 Nm
Mounting bolt, crane hook lug ............................... M10x25-GA .......................................................50 Nm

WARNING

Removing the exhaust manifold Installing the exhaust manifold

Removing the heat shield Mounting the exhaust manifold
• Unscrew the mounting bolts (1) • Position the exhaust manifold (4) with new gaskets
• Remove the crane hook lug (2) (1)
• Unscrew the mounting bolts (3) • Screw in the new mounting bolts (2) as marked
• Remove the heat shield (4) and tighten them to Initial torque 25 Nm
• Tighten the mounting bolts (2) to Final torque
Removing the exhaust manifold 2 x 45°
• Screw on the mounting nut (3) and tighten it to
27 Nm
Mounting the heat shield

(2) and then unscrew them
• Remove the exhaust manifold (4) with gaskets (1)
• Position the heat shield (4) at the exhaust manifold
• Position the crane hook lug (2)
• Screw in the mounting bolts (1) and tighten them
to 50 Nm

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

(2) Push rod (6) Rocker arm mechanism
(3) Exhaust valve bridge (7) Intake valve bridge
(4) Mounting bolt

CYLINDER HEAD
ROCKER ARM MECHANISM

Removing and installing the rocker arm mechanism
Additional jobs
– Checking and setting the valve clearance (variant without EVB), see 168

(4) Mounting bolt
WARNING

CYLINDER HEAD
Removing the rocker arm mechanism Installing the rocker arm mechanism
Removing the cylinder head cover Fitting the rocker arm mechanism
• Open the bayonet ttings on the plug bracket • Oil the ball cups of the push rods
• Unscrew the mounting bolts (3) • Fit the rocker arm mechanism (1) onto the cylinder
• Remove the cylinder head cover (2) from the head and align it whilst inserting the adjusting
cylinder head (1) screw balls for the rocker arms into the push rod
Removing the rocker arm mechanism
Installing the cylinder head cover

• Remove the rocker arm mechanism (1) • Check the condition of the cylinder head cover
gasket and plug bracket gaskets; replace as
necessary
• Fit the cylinder head cover (2) over the plug
bracket and onto the cylinder head (1)
• Plug the plug bracket bayonet ttings

CYLINDER HEAD
Dismantling and assembling the rocker arm mechanism

Additional jobs
– Removing and installing the rocker arm mechanism, see 155
(1) Exhaust valve rocker arm (9) Thrust washer

(2) Exhaust valve adjusting screw (10) Pressure spring
(3) Thrust washer (11) Thrust washer
(4) Pressure spring (12) Intake valve rocker arm
(5) Thrust washer (13) Rocker arm shaft
(6) Intake valve adjusting screw (14) Rocker arm bracket
(7) Intake valve rocker arm (15) EVB adjusting screw
(8) Exhaust valve rocker arm (16) Rocker arm shaft retaining bolt
WARNING

CYLINDER HEAD
Special tools
[63] Pressing tool 80.99617-0143
• Knocking out the rocker arm shaft

CYLINDER HEAD
Dismantling the rocker arm mechanism Assembling the rocker arm mechanism
• Unscrew the retaining bolt for the rocker arm shaft • Insert the exhaust valve rocker arm (1) and the
(8) intake valve rocker arm (5) into the rocker arm
• Knock the rocker arm shaft (6) out of the rocker bracket (7)
arm bracket (7) using the Pressing tool [63] • Insert the thrust washers (2) and (4) with pressure
• Slowly extract the Pressing tool [63] to rst remove spring (3) into the rocker arm bracket (7), ensuring
the exhaust valve rocker arm (1), thrust washer they are tted in the correct order and position
(2), pressure spring (3) and thrust washer (4) and • Align the rocker arm shaft (6) with the hole for the
then remove the intake valve rocker arm (5) rocker arm shaft retaining bolt (8)
• Insert the rocker arm shaft (6) into the rocker arm
bracket (7)
• Screw in and tighten the rocker arm shaft retaining
bolt (8)

CYLINDER HEAD
CYLINDER HEAD
Removing and installing the cylinder head
Additional jobs
– Removing and installing the exhaust manifold, see 149
– Removing and installing the injectors and rail, see 94
– Removing and installing the intake pipe, see 145

(4) Mounting bolt
Tightening sequence for cylinder head bolts

Cylinder head bolts............................................... 14x2 (E18)..................................... Initial torque 80 Nm
Cylinder head bolts............................................... 14x2 (E18)......................................2nd torque 150 Nm
Cylinder head bolts............................................... 14x2 (E18)............................................. 3rd torque 90°
Cylinder head bolts............................................... 14x2 (E18)............................................. 4th torque 90°
Cylinder head bolts............................................... 14x2 (E18)...........................................Final torque 90°
Cylinder head dimensions

Machining dimension .................................................................................................................... 0.5 mm

CYLINDER HEAD
Cylinder head height............................................................................................ 109.85 mm - 110.15 mm

Cylinder head height after machining .................................................................... 109.35 mm - 109.65 mm
WARNING
Special tools
[64] Cross beam 80.99629-6008
• Removing and installing the cylinder head
[65] Slinging chain (3 pcs.) 80.99629-6009
[66] Eye-bolt (4 pcs.) 80.99606-0660
[67] Socket, size 22 80.99612-0024
• Tightening the cylinder head bolts in conjunction

with:
• Socket E18105 [68]
• Torque multiplier i = 1 : 3.3 [69]
• Support [70]
• Angle measuring disc [71]
• Holding xture [72]
• Pan head screw [73]
• Connecting pin [74]
• Rubber ring 42 mm [75]
• Washer [76]
[68] Socket E18105 80.99612-0023
• Tightening the cylinder head bolts

CYLINDER HEAD
[69] Torque multiplier i = 1 : 3.3 80.99619-0006
[70] Support 80.99606-0551
[71] Angle measuring disc 80.99607-0172
[72] Holding xture 80.99606-0553
[73] Pan head screw 06.02191-0407
[74] Connecting pin 06.22729-0006
[75] Rubber ring 42 mm 08.06142-9006
[76] Washer 80.99609-0033

CYLINDER HEAD
Removing the cylinder head Removing the valve bridges and push rods
• Mark the installation position of the intake valve

bridge (3) and the exhaust valve bridge (2)
• Open the bayonet ttings on the plug bracket • Remove the valve bridges
• Unscrew the mounting bolts (3) • Pull the push rods (1) out of the cylinder head
• Remove the cylinder head cover (2) from the
cylinder head (1) Assembling the special tool
Removing the rocker arm mechanism
• Mount the Holding xture [72] (5) with Pan

head screw [73] (4) and Washer [76] (3) on the
Note Support [70] (2)
Do not unscrew the retaining bolt for the • Place the Angle measuring disc [71] (9) onto the
rocker arm shaft in order to remove the Torque multiplier i = 1 : 3.3 [69] (1)
rocker arm mechanism. • Place the Socket, size 22 [67] (7) on the Torque
multiplier i = 1 : 3.3 [69] (1) and secure with
• Unscrew the mounting bolts (2) Connecting pin [74] (8) and Rubber ring 42
• Remove the rocker arm mechanism (1) mm [75] (6)

CYLINDER HEAD
Undoing the cylinder head bolts Removing the cylinder head gasket
• Put the assembled special tool (1) on the cylinder • Remove the cylinder head gasket (2) over the
head bolt that is going to be undone alignment pins (1)
• Undo the cylinder head bolts using 2 x Socket • Clean the crankcase face
E18105 [68] • Clean the cylinder head bolt tapped holes
Removing the cylinder head
• Unscrew and remove the cylinder head bolts (2)

• Screw in and tighten the eye-bolts at the corners
of the cylinder head (1)
• Lift off the cylinder head (1) using the Cross
beam [64] and the Slinging chain (3 pcs.) [65]

CYLINDER HEAD
Installing the cylinder head Fitting the special tool
Fitting the cylinder head gasket
Note
Note the torque multiplier ratio, i = 1 : 3.3.
WARNING
Cylinder head gaskets that have
already been used are no longer
• Fit the special tool (1) in conjunction with 2 x
capable of ensuring a reliable
Socket E18105 [68] onto the cylinder head bolt
leak-tight connection
that is going to be tightened
• Previously installed cylinder head
gaskets must not be re-used Tightening the cylinder head
• Place the new cylinder head gasket (2) over the

dowel pins (1) and onto the crankcase
Fitting the cylinder head
• Tighten the cylinder head to Initial torque 80 Nm

in accordance with the tightening diagram
• Tighten the cylinder head to 2nd torque 150 Nm in
accordance with the tightening diagram
• Tighten the cylinder head to 3rd torque 90° in
• Lift the cylinder head (1) over the alignment pins
and onto the crankcase using the Cross beam [64]
• Tighten the cylinder head to 4th torque 90° in
• Unscrew the Eye-bolt (4 pcs.) [66]
• Tighten the cylinder head to Final torque 90° in
• Lightly oil the supporting surfaces of the cylinder
head bolts (2)
• Screw in the cylinder head bolts (2) and tighten
them by hand

CYLINDER HEAD
Installing the valve bridges and push rods Installing the cylinder head cover
• Oil the ball cups of the push rods (1) • Check the condition of the cylinder head cover
• Insert the push rods (1) through the openings in gasket and plug bracket gaskets; replace as
the cylinder head necessary
• Insert the push rods (1) into the ball cups of the • Fit the cylinder head cover (2) over the plug
tappets bracket and onto the cylinder head (1)
• Fit the exhaust valve bridge (2) as marked • Screw in and tighten the mounting bolts (3)
• Fit the intake valve bridge (3) as marked • Plug the bayonet ttings on the plug bracket
Installing the rocker arm mechanism
• Oil the ball sockets of the push rods

• Put the rocker arm mechanism (1) on the cylinder
head and align it whilst inserting the adjusting
screw balls for the rocker arms into the push rod

CYLINDER HEAD
Checking and setting the valve clearance (variant without EVB)
(1) Intake valve bridge (3) Exhaust valve adjusting screw

(2) Exhaust valve bridge (4) Intake valve adjusting screw
Technical data
Lock nut on valve adjusting screw (3), (4) .............. M10x1-8.8 .........................................................40 Nm
Intake valve clearance ................................................................................................................ 0.50 mm
Exhaust valve clearance ............................................................................................................. 0.50 mm
WARNING

CYLINDER HEAD
Special tools
[77] Holding xture 08.75300-0000
• Checking and adjusting the valve clearance in

conjunction with:
• Feeler gauge leaf 0.50 [78]
[78] Feeler gauge leaf 0.50 80.99607-0177
• Checking and setting the valve clearance
[79] Valve adjusting spanner, size 14 80.99603-6031
• Adjusting the valve clearance in conjunction with:

• Handle [80]
[80] Handle 08.06460-0003
• Setting the valve clearance

[82] Gear ratchet 80.99627-0001

CYLINDER HEAD
Checking and setting the valve Cranking the engine to the setting position
clearance
A = Rocker arms in overlap

B = Rocker arms free for valve clearance
setting
• Open the bayonet ttings on the plug bracket
• Unscrew the mounting bolts (3) for the cylinder • Turn the engine in the engine's running direction
head cover (2) until the setting position is reached using the
• Remove the cylinder head cover (2) from the Engine barring gear [81] and the Gear ratchet [82]
cylinder head (1)
• Adjust free rocker arms as per table
Attaching the engine barring gear
Checking the intake valve clearance
• Remove the cover from the ywheel housing

• Mount the Engine barring gear [81] (1) on the • Insert the Holding xture [77] (3) with Feeler gauge
ywheel housing leaf 0.50 [78] (2) between the rocker arm (1) and
the valve bridge (4)
If the valve clearance between the rocker arm (1)
and the valve bridge (4) is not 0.50 mm, the valve
clearance must be adjusted.

CYLINDER HEAD
Adjusting the intake valve clearance Adjusting the exhaust valve clearance
• Crank the engine to the setting position, see • Turn back the adjusting screw (1) with ball cup until
Cranking the engine to the setting position, 170 the Holding xture [77] (3) with Feeler gauge leaf
• Undo the lock nut (1) 0.50 [78] (2) can be inserted between the rocker
• Turn back the adjusting screw (2) with the Valve arm and the valve bridge (4)
adjusting spanner, size 14 [79] and the Handle [80] • Screw in the adjusting screw (1) until the Holding
until the Holding xture [77] (5) with the Feeler xture [77] (3) with Feeler gauge leaf 0.50 [78] (2)
gauge leaf 0.50 [78] (4) can be inserted between can be moved between the rocker arm and the
the rocker arm (3) and the valve bridge (6) valve bridge (4) with little resistance
• Screw in the adjusting screw (2) with the Valve • Brace the adjusting screw (1) and tighten the lock
adjusting spanner, size 14 [79] and the Handle [80] nut to 40 Nm
until the Holding xture [77] (5) with the Feeler • Check the setting once more
gauge leaf 0.50 [78] (4) can be moved between
the rocker arm (3) and the valve bridge (6) with Mounting the cylinder head cover
little resistance
• Brace the adjusting screw (2) and tighten the lock
nut (1) to 40 Nm
• Check the setting once more
Checking the exhaust valve clearance
• Check the condition of the cylinder head cover

gasket and the plug console seal and, if necessary,
t new ones
• Fit the cylinder head cover (2) over the plug
bracket and onto the cylinder head (1)
• Insert the Holding xture [77] (3) with Feeler gauge • Plug the bayonet ttings on the plug bracket
leaf 0.50 [78] (2) between the rocker arm (1) and
the valve bridge (4)
If the valve clearance between the rocker arm (1)
and the valve bridge (4) is not 0.50 mm, the valve
clearance must be adjusted.

CYLINDER HEAD
Removing and installing the valve stem seals

Additional jobs
– Removing and installing the rocker arm mechanism, see 155
(1) Valve (4) Valve spring

(2) Cylinder head (5) Valve collet
(3) Valve stem seal
Technical data
Radial play, valve stem (intake) ...................................................................................... 0.020 - 0.049 mm
Radial play, valve stem (exhaust) ................................................................................... 0.035 - 0.069 mm
Valve lag (intake)...................................................................................................................0.3 - 0.6 mm
Valve lag (exhaust) ................................................................................................................0.6 - 0.9 mm
WARNING

CYLINDER HEAD
Special tools

[84] Gear ratchet 80.99627-0001
[85] Adapter 80.99613-0042
• Removing and installing the valve springs in

conjunction with:
• Holder [89]
• Holder [90]
• Valve-spring compressor [88]
• Extension [87]
• Assembly device [86]
[86] Assembly device 80.99606-6092
• Removing and installing the valve springs
[87] Extension 80.99606-6094
[88] Valve-spring compressor 80.99613-6000
[89] Holder 80.99613-0052

CYLINDER HEAD
[90] Holder 80.99613-0053
[91] Magnetic pick-up tool 80.99639-0009
• Removing the valve cotters in conjunction with:

• Adapter [85]
• Holder [89]
• Holder [90]
• Valve-spring compressor [88]
• Extension [87]
• Assembly device [86]
[92] Assembly device 80.99606-6088
• Removing the valve stem seal

• Installing the valve stem seal in conjunction with:
• Mounting sleeve [93]
[93] Mounting sleeve 80.99606-0634
• Installing the valve stem seal

CYLINDER HEAD
Removing the valve stem seals Removal and installation position of valve stem
seals
Attaching the engine barring gear
A = Rocker arms in overlap

• Remove the cover from the ywheel housing B = Rocker arms free for valve clearance
• Mount the Engine barring gear [83] (1) on the setting
ywheel housing
WARNING
Turning the engine to the TDC mark Valves can fall into the cylinder
• Only remove valve stem seals when
corresponding pistons are at TDC
• Crank the engine in the engine's running direction

using the Engine barring gear [83] and the Gear
ratchet [84] until the rocker arms are in overlap (A)
• Remove and install the free valve stem seals (B)
as per the table
Removing the valve bridges and push rods
• Turn the engine in the engine's running direction

using the Engine barring gear [83] (1) and Gear
ratchet [84] until the 1st cylinder is at the TDC
mark (2)
• Mark the installation position of the exhaust valve

bridge (2) and the intake valve bridge (3)
• Remove the exhaust valve bridge (2) and the
intake valve bridge (3)
• Pull the push rods (1) out of the cylinder head

CYLINDER HEAD
Assembling the special tool Fitting the mounting device
• Screw the Adapter [85] (1) into the cylinder head

Note
• Screw the Assembly device [86] (2) into the
The retaining washer and Holder [90]
Adapter [85] (1)
have left-hand threads.
• Position the Holder [89] (5) and the Holder [90] (3)
on the Valve-spring compressor [88] (1) and then
screw on by turning the threaded spindle (4)
• Screw on the retaining washers (2) and (6)
• Position the lever (8) on the Valve-spring
compressor [88] (1) and secure using the
mounting bolt (7)

CYLINDER HEAD
Mounting the valve-spring compressor Removing the valve cotters
CAUTION
Risk of injury due to springing back of
the valve springs
• Ensure that the Holder [89] and
Holder [90] are seated correctly on
the spring cap
• Do not remove the valve cotters from
the valve spring with your bare hands
• Push down the Valve-spring compressor [88] (1)

with Extension [87]
• Remove the valve cotters (2) from the valve stem
(3) with Magnetic pick-up tool [91]
• Release the Valve-spring compressor [88] (1)
• Position the Holder [89] (4) and Holder [90] on the • Repeat the same procedure for all the valves
spring cap and tension by turning the threaded • Remove the special tool
spindle (5)
• Hook the Valve-spring compressor [88] (2) in the
Assembly device [86] (3)
• Place the Extension [87] (1) onto the Valve-spring
compressor [88] (2)

CYLINDER HEAD
Removing the valve springs Installing the valve stem seals

Installing the valve stem seals
• Remove the washer (3), valve spring (2) and

spring cap (1) over the valve stem
• Repeat the same procedure for all the valves • Thinly apply clean engine oil on the Mounting
sleeve [93] (2) and valve stem seal (3)
Removing the valve stem seals • Push the Mounting sleeve [93] (2) over the valve
stem (1)
• Insert the valve stem seal (3) into the Assembly
device [92] (4) and clamp
• Push the Assembly device [92] (4) over the
Mounting sleeve [93] (2)
• Knock the valve stem seal (3) onto the valve stem
(1) using impact weight (5)
• Remove the Assembly device [92] (4) and
Mounting sleeve [93] (2)
• Push the Assembly device [92] (2) over the valve

stem seal (1)
• Clamp the Assembly device [92] (2)
• Pull the valve stem seal (1) off the valve guide with
impact weight (3)

CYLINDER HEAD
Installing the valve springs Fitting the mounting device
• Insert the washer (3), valve spring (2) and spring • Screw the Adapter [85] (1) into the cylinder head
cap (1) over the valve stem • Screw the Assembly device [86] (2) into the
• Repeat the same procedure for all the valves Adapter [85] (1)

CYLINDER HEAD
Mounting the valve-spring compressor Installing the valve cotters
CAUTION
Risk of injury due to springing back of
the valve springs
• Ensure that the Holder [89] and
Holder [90] are seated correctly on
the spring cap
• Do not insert the valve cotters into the
valve spring with your bare hands
• Push down the Valve-spring compressor [88] (1)

with Extension [87]
• Use a suitable tool to insert the valve cotters (2) so
that the valve cotters (2) are seated in the grooves
of the valve stem (3)
• Position the Holder [89] (4) and Holder [90] on the • Release the Valve-spring compressor [88] (1)
spring cap and tension by turning the threaded • Remove the special tool
spindle (5)
• Hook the Valve-spring compressor [88] (2) in the Installing the valve bridges and push rods
Assembly device [86] (3)
• Place the Extension [87] (1) onto the Valve-spring
compressor [88] (2)
• Lightly apply clean engine oil on the balls of the

push rods (1)
• Insert the push rods (1) into the ball cups of the
tappets
• Fit the exhaust valve bridge (2) and the intake
valve bridge (3) as marked

CYLINDER HEAD
Removing the engine barring gear
• Remove the Engine barring gear [83] (1) from the

ywheel housing
• Mount the cover on the ywheel housing

VALVE TIMING
VALVE TIMING
(1) Intermediate gear 2 (8) Mounting bolt

(2) Mounting bolt (9) Camshaft gear
(3) Oil pump drive gear (10) Intermediate gear 1
(4) Mounting nut (11) Timing case
(5) Crankshaft gear (12) Camshaft
(6) Fixing bolt (13) Tappet
(7) Mounting bolt

VALVE TIMING
TIMING GEARS
Removing and installing the timing gears
Additional jobs
– Removing and installing the hydraulic pump, see 81
– Removing and installing the coolant pipes, see 29
– Removing and installing the thermostat with thermostat housing, see 33
– Removing and installing the vibration damper, see 223
– Removing and installing the timing case cover, see 281
– Removing and installing the hydraulic pump belt drive, see 66
(1) Intermediate gear 2 (4) Crankshaft gear

(2) Oil pump drive gear (5) Camshaft gear
(3) Intermediate gear 1
Technical data
Intermediate gear 1 Allen screw (3) ....................... M14x1.75x45-8.8 ............................................. 115 Nm
Camshaft gear mounting bolt (5) ........................... M10x38x1.25-10.9 .............................................65 Nm
Oil pump drive gear mounting nut (2) ..................... M12x1.5-6S .......................................................45 Nm

VALVE TIMING
Installation play values

Intermediate gear 1, radial play ...................................................................................... 0.060 - 0.109 mm
Intermediate gear 1, axial play........................................................................................ 0.200 - 0.280 mm
Timing gear backlash

Crankshaft gear - camshaft gear .................................................................................... 0.051 - 0.149 mm
Camshaft gear - air compressor gear.............................................................................. 0.051 - 0.185 mm
Crankshaft gear - intermediate gear 1............................................................................. 0.050 - 0.187 mm
Intermediate gear 1 - intermediate gear 2........................................................................ 0.051 - 0.175 mm
Intermediate gear 1 - oil pump gear ................................................................................ 0.053 - 0.190 mm
Service products
Loctite 573 ........................................................................................................................ 04.90300-9018
Loctite 648 ........................................................................................................................ 04.90300-9024
WARNING
Note
If the timing gears are defective, the high-pressure pump can be damaged and therefore has to be
removed and inspected.

VALVE TIMING
Removing the camshaft gear Removing the camshaft gear
Fixing the crankshaft gear
• Remove the camshaft gear (1) from the camshaft

(2)
• Lock the crankshaft gear (2) using the xing bolts
(1)
Setting the timing gears to the mark
• Crank the engine until the marks on the camshaft

gear (1) line up with the marks on the crankshaft
gear (2)
Unscrewing the camshaft gear mounting bolts
• Brace the crankshaft at the ywheel

• Unscrew the mounting bolts (1) for the camshaft
gear (2)

VALVE TIMING
Installing the camshaft gear Checking the overlap mark
Positioning the camshaft gear
• Crank the engine 720° until the marks on the

camshaft gear (1) line up with the marks on the
• Align the marks on the camshaft gear (1) and the crankshaft gear (2)
crankshaft gear • Check that the marks on the camshaft gear (1) and
• Line up the camshaft (2) with the hole pattern on crankshaft gear (2) match up
the camshaft gear (1), as necessary • Unscrew the xing bolts (3)
• Place the camshaft gear (1) over the guide pin and • Mount the ywheel housing cover
onto the camshaft (2)
Tightening the camshaft gear mounting bolts
• Brace the crankshaft at the ywheel

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

VALVE TIMING
Removing the crankshaft gear Removing the crankshaft gear
• Pull the crankshaft gear (1) off the crankshaft (2)

• Clean the contact faces and the guide pin (3)
• Fix the crankshaft gear (2) using the xing bolts
(1)
Setting the timing gears to the mark
• Crank the engine until the marks on the camshaft

gear (1) line up with the marks on the crankshaft
gear (2)
Releasing the crankshaft gear
• Unscrew the xing bolts (1) from the crankshaft

gear (2)

VALVE TIMING
Installing the crankshaft gear Checking the overlap mark
• Thinly apply Loctite 573 on the rear side of the • Crank the engine 720° until the marks on the
crankshaft gear (1) camshaft gear (1) line up with the marks on the
• Align the marks on the camshaft gear and crankshaft gear (2)
crankshaft gear (1) • Check that the marks on the camshaft gear (1) and
• Place the crankshaft gear (1) over the guide pin crankshaft gear (2) match up
(3) and onto the crankshaft (2) • Unscrew both xing bolts (3)
• Mount the ywheel housing cover
• Fix the crankshaft gear (1) using the xing bolts

(2)

VALVE TIMING
Removing the intermediate gears Installing the intermediate gears

Removing intermediate gear 2 Installing intermediate gear 1
• Unscrew the mounting nut (5) • Position the intermediate gear pin (4) with
• Pull off the oil pump drive gear (4) intermediate gear 1 (5)
• Unscrew the mounting bolts (1) • Screw in the mounting bolt (2) and tighten to 115
• Remove the intermediate gear pin (2) and Nm
intermediate gear 2 (3) • Screw in the mounting bolt (3) and tighten to 115
Nm
Removing intermediate gear 1 • Screw in and tighten the mounting bolt (1)
Installing intermediate gear 2

(2) and (3)
• Unscrew the mounting bolts (2) and (3) • Position the intermediate gear pin (2) with
• Unscrew the mounting bolt (1) intermediate gear 2 (3)
• Remove the intermediate gear pin (4) and • Screw in and tighten the mounting bolts (1)
intermediate gear 1 (5) • Fit the oil pump drive gear (4)
• Thinly apply Loctite 648 on the thread of the oil
pump drive gear
to 45 Nm

VALVE TIMING
CAMSHAFT WITH CAMSHAFT BEARINGS

Removing and installing the camshaft with camshaft bearings
Additional jobs
– Removing and installing the oil sump, see 207
– Removing and installing the cylinder head, see 161
– Removing and installing the timing gears, see 185
– Removing and installing the ywheel (variant with clutch), see 227
– Removing and installing the ywheel housing, see 277
– Removing and installing the pistons and connecting rods, see 241
– Removing and installing the crankshaft, see 253
(1) Camshaft (3) Push rod

(2) Tappet
Technical data
Inside diameter of camshaft bearings 1 - 4............................................................... Ø 54.910 - 54.940 mm
Outside diameter of camshaft bearing points............................................................ Ø 59.000 - 59.030 mm
Axial play ...................................................................................................................... 0.140 - 0.270 mm

VALVE TIMING
Valve timing
Intake valve opens............................................................................................6° crank angle before TDC
Intake valve closes ........................................................................................... 32° crank angle after BDC
Exhaust valve opens.......................................................................................63° crank angle before BDC
Exhaust valve closes .........................................................................................13° crank angle after TDC
WARNING
Special tools
[94] Insertion pin 80.99617-6008
• Removing and installing the camshaft
[95] Guide 80.99607-6102
• Removing and installing the camshaft bearings in

conjunction with:
• Impact weight [96]
• Installer sleeve for bearing 4 [97]
• Installer sleeve for bearings 2 - 3 [98]
• Remover sleeve for bearings 2 - 3 [100]
• Double-sided guide bush [101]
[96] Impact weight 80.99606-0546
• Removing and installing the camshaft bearings
[97] Installer sleeve for bearing 4 80.99606-6113
• Installing the camshaft bearings
[98] Installer sleeve for bearings 2 - 3 80.99606-6112

VALVE TIMING
[99] Installer sleeve for bearing 1 80.99606-6114
[100] Remover sleeve for bearings 2 - 3 80.99602-0162
• Removing the camshaft bearings in conjunction

with:
• Guide [95]
• Installer sleeve for bearings 2 - 3 [98]
• Double-sided guide bush [101]
[101] Double-sided guide bush 80.99606-6110
• Removing and installing the camshaft bearings
[102] Impact puller 80.99602-0016
• Removing the front and rear camshaft bearing in

conjunction with:
• Extractor device [103]
[103] Extractor device 80.99602-6012
• Removing the front and rear camshaft bearings

VALVE TIMING
Removing the camshaft/camshaft Removing the tappet

bearing
Removing the camshaft axial shim
• Use a magnet (1) to remove the tappet (2)
Camshaft bearing removal sequence

• Remove the axial shim (2) for the camshaft (3)
Mounting the camshaft guide tool
• Comply with the removal sequence (1)

Reference is made to the illustrated removal
sequence (1) in all the following steps.
• Use mounting bolts (2) to mount the adapter (3) Camshaft bearing special tool
on the camshaft (4)
• Screw the Insertion pin [94] (1) into the adapter (3)
Removing the camshaft
• Insert the Impact puller [102] (1) through camshaft

bearing 1 (3) with the Extractor device [103] (2)
folded up
• Fold out the Extractor device [103] (2) behind
• Pull the camshaft (1) out of the crankcase (2) camshaft bearing 1 (3) and centre it in the
towards the ywheel end camshaft bearing

VALVE TIMING
Removing camshaft bearing 1 Installing the camshaft/camshaft

bearings
Preparing to install the camshaft bearings
• Pull out the camshaft bearing 1 (2) with the Impact

puller [102] (1) and Extractor device [103] (3)
Removing camshaft bearings 2 - 3 • Place the camshaft bearing (1) onto the Installer
sleeve for bearings 2 - 3 [98] (2)
• The camshaft bearing notch (1) must be facing the
engine timing case end
• Engage the spring-loaded ball (3) in the oil bore
(4)
To check, make sure you can see the centring bore
in the press-in tool at the second oil bore.
Installation sequence
Note
Use camshaft bearing 4 as a guide when
removing camshaft bearings 2 - 3.
If camshaft bearing 4 is damaged to such
an extent that it can no longer be used
as a guide, remove and install camshaft
bearing 4 rst.
• Insert the Remover sleeve for bearings 2 - 3 [100] • Stick to the installation sequence for the camshaft
(4) into camshaft bearing 2 (5) bearings (1) in the following work steps
• Insert the short end of the Guide [95] (1) into the
Remover sleeve for bearings 2 - 3 [100] (4) until
the washer (3) is reached
• Slide the Double-sided guide bush [101] (2) onto
the Guide [95] (1)
• Engage the Double-sided guide bush [101] (2) with
the balls in the crankcase oil bores as marked
• Knock out camshaft bearing 2 (5)
• Remove camshaft bearing 2 (5) from the Remover
sleeve for bearings 2 - 3 [100] (4)
• Repeat the procedure for camshaft bearing 3

VALVE TIMING
Installing camshaft bearing 3 Installing camshaft bearing 2
• Insert the Remover sleeve for bearings 2 - 3 [100]

Note
into bearing seat 3 to function as a guide
To ensure rocker arm lubrication, only one
• Position the Installer sleeve for bearings 2 - 3 [98]
oil bore is free at camshaft bearing 2.
(4) at bearing seat 2 with the camshaft bearing (5)
pushed on
• Insert the Installer sleeve for bearing 4 [97] into • Insert the short end of the Guide [95] (1) and the
bearing seat 4 to function as a guide Remover sleeve for bearings 2 - 3 [100] used as
• Engage the spring-loaded ball in the oil bore for a guide into the Installer sleeve for bearings 2 -
camshaft bearing 4 3 [98] (4)
• Push the shorter side of the Guide [95] (1) into the • Push the Double-sided guide bush [101] (2) over
crankcase the Guide [95] (1) as marked and engage it in
• Push the Double-sided guide bush [101] (2) over camshaft bearing seat 1
the Guide [95] (1) as marked and engage it in • Knock the camshaft bearing (5) into the bearing
camshaft bearing seat 1 seat
• Position the Installer sleeve for bearings 2 - 3 [98] • Leave the Installer sleeve for bearings 2 - 3 [98]
(4) at bearing seat 3 with the camshaft bearing (4) inserted in camshaft bearing 2
connected
• Push the Guide [95] (1) into the Installer sleeve for Installing camshaft bearing 1
bearings 2 - 3 [98] (4)
• Knock in the camshaft bearing
• Place the Installer sleeve for bearing 1 [99] (3)

against bearing seat 1 with the camshaft bearing
(4) pushed on
• Insert the short end of the Guide [95] (2) into
the Installer sleeve for bearing 1 [99] (3) and the
Installer sleeve for bearings 2 - 3 [98], ensuring
that the Guide [95] (2) is guided by the pin in the
Installer sleeve for bearings 2 - 3 [98]
• Knock the Installer sleeve for bearing 1 [99] (3),
camshaft bearing (4) and Impact weight [96] (1)
into the crankcase until ush

VALVE TIMING
Mounting the camshaft bearing special tool Installing camshaft bearing 4
• Insert the Impact puller [102] (3) through camshaft • Insert the Installer sleeve for bearings 2 - 3 [98] into
bearing 4 (1) with the Extractor device [103] (2) camshaft bearing seat 3 to function as a guide
folded up • The Guide [95] (4) must be guided in the Installer
• Fold out and centre the Extractor device [103] (2) sleeve for bearings 2 - 3 [98] with the pin
behind camshaft bearing 4 (1) • Place the camshaft bearing (1) onto the Installer
sleeve for bearing 4 [97] (2)
Removing camshaft bearing 4 • Push the Guide [95] (4) together with the Installer
sleeve for bearing 4 [97] (2) into the Installer sleeve
for bearings 2 - 3 [98] as marked
• Knock the camshaft bearing (1) into bearing point
4 using the Impact weight [96] (3)
Checking the oil bores
• Extract the camshaft bearing (2) with Impact

puller [102] (3) and Extractor device [103] (1)
• Check that the oil bores (2) of the camshaft

bearings (1) are positioned correctly and that
there is sufcient overlap with the oil bores in the
crankcase (3). If necessary, remove the camshaft
bearings (1) and install the bearings correctly

VALVE TIMING
Installing the tappet
• Use a magnet (1) to insert the tappet (2) into the

crankcase
Installing the camshaft
• Insert the camshaft (1) with the mounted Insertion

pin [94] into the crankcase (2)
• Remove the Insertion pin [94]
Installing the camshaft axial shim
• Position the axial shim (2), screw the mounting

bolts (1) into the crankcase (3) and then tighten
them

ENGINE LUBRICATION
ENGINE LUBRICATION
(1) Gasket (7) Oil excess pressure valve

(2) Oil cooler (8) Oil sump
(3) Oil pressure sensor (9) Oil suction pipe
(4) Oil pressure transmitter (10) Gasket
(5) Oil module (11) Oil pump
(6) Gaskets (12) Coupling sleeve

ENGINE LUBRICATION
OIL MODULE
Removing and installing the oil module (hanging oil lter)
(1) Oil module (4) Gaskets

(2) Oil pressure sensor (5) Oil cooler
(3) Oil pressure transmitter (6) Gasket
Technical data
Oil pressure transmitter (3).................................... M18x1.5 ............................................................50 Nm
Oil pressure sensor (2) ......................................... M18x1.5 ............................................................45 Nm
Service products
Loctite 648 sealing compound ............................................................................................ 04.10160-9164
WARNING

ENGINE LUBRICATION
Removing the oil lter Installing the oil lter
• Unscrew the oil lter (1) • Thinly apply clean engine oil on the O-ring of the
new oil lter (1)
• Screw on and tighten the oil lter (1)

ENGINE LUBRICATION
Removing the oil module Installing the oil module

Detaching the oil module Installing the oil cooler
• Disconnect the electrical connection for the oil • Insert the oil cooler (4) with new gaskets (1) into
pressure sensor (1) and oil pressure transmitter the oil module (3)
(2) • Screw in and tighten the new mounting bolts (2)
• Remove the oil module (4) with gasket (5) Mounting the oil module
Removing the oil cooler
• Position the oil module (4) with a new gasket (5)

• Connect the electrical connection for the oil
• Put the oil module (3) aside so as not to damage pressure sensor (1) and oil pressure transmitter
the oil cooler (4) (2)
• Remove the oil cooler (4) with gaskets (1) from the
oil module (3)

ENGINE LUBRICATION
OIL SUMP
Removing and installing the oil sump
Additional jobs
– Draining and topping up the engine oil
(1) Gasket (3) Mounting bolt

(2) Oil sump (4) Oil level sensor
Technical data
Oil excess pressure valve screw plug .................... M24x1.5-5.8 ......................................................60 Nm
Oil level sensor (4)................................................ M22x1.5 ............................................................25 Nm
Verbrauchsmittel
Loctite 5970 ...................................................................................................................... 04.10394-9385
WARNING

ENGINE LUBRICATION
Special tools
[104] Hose clamp pliers for jubilee clips 80.99625-0073
• Removing and installing jubilee clips

ENGINE LUBRICATION
Removing the oil sump and oil suction Removing the oil sump
pipe
Detaching the oil return lines

• Remove the oil sump (2) with gasket (1) from the
crankcase (4)
• Undo the jubilee clips with the Hose clamp pliers • Clean the mating faces
for jubilee clips [104] and pull the oil return hoses
(1) and (2) off the oil return lines Removing the oil suction pipe
• Unscrew the mounting bolts and remove the oil
return line (5) together with the gasket
• Unscrew the union nut (4) and pull off the oil return
line (3)
Removing the oil level sensor

• Remove the oil suction pipe (1) with gasket (4)
• Unscrew the oil level sensor (2) and remove with

the sealing ring (1)

ENGINE LUBRICATION
Removing the oil excess pressure valve Installing the oil sump and oil suction
pipe
Installing the oil excess pressure valve
• Unscrew the screw plug (1) and remove with the

sealing ring (2)
• Remove the pressure spring (3) with piston (4)
from the crankcase • Thinly apply clean engine oil on the piston (4)
• Insert the piston (4) with pressure spring (3) into
the crankcase
• Screw in the screw plug (1) with a new sealing ring
(2) and tighten to 60 Nm
Installing the oil suction pipe
• Position the oil suction pipe (1) with a new gasket

(4)
• Screw in the mounting bolts (3)
• Screw in the mounting bolts (2)
• Tighten the mounting bolts (2) and (3)

ENGINE LUBRICATION
Attaching the upper part of the oil sump Installing the oil level sensor
• Screw in the oil level sensor (2) with a new sealing

ring (1) and tighten it to 25 Nm
Attaching the oil return lines
• Applying Loctite 5970 (1) thinly to the sealing

surface of the crankcase as shown
Mounting the oil sump
• Position the oil return line (3), screw on the union

nut (4) and then tighten
• Position the oil return hoses (1) and (2) with jubilee
clips at the oil return line
• Fit the jubilee clips with the Hose clamp pliers for
jubilee clips [104]
• Position the oil return line (5) together with a new
gasket and screw in the mounting bolts
• Tightening the mounting bolts
• Position the oil sump (2) with a new gasket (1) on

the crankcase (4)

ENGINE LUBRICATION
OIL PUMP
Removing and installing the oil pump
Additional jobs
– Removing and installing the high-pressure pump, see 107
– Removing and installing the timing case, see 285
(1) Drive gear, oil pump (4) O-rings

(2) Oil pump gear (5) Coupling sleeve
(3) Oil pump housing
Technical data
Mounting nut, oil pump gear (2) ............................. M12x1.5-6S .......................................................45 Nm
ENGINE LUBRICATION
Axial play, oil pump gears............................................................................................... 0.040 - 0.106 mm

Radial play, oil pump shaft ............................................................................................ 0.050 - 0.078 mm
Service products
Loctite 648 ........................................................................................................................ 04.90300-9024
WARNING
Special tools
[105] Dial gauge 08.71082-0005
• Checking the axial play of the oil pump gears in

conjunction with:
• Dial gauge holder [106]
[106] Dial gauge holder 08.71000-3217
• Checking the axial play of the oil pump gears

ENGINE LUBRICATION
Removing the oil pump Removing the oil pump mounting bolts
Removing the oil pump drive gear
• Unscrew the mounting nut (2) Removing the oil pump

• Pull off the drive gear (1)
Checking the oil pump gear axial play
• Pull the 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
• Mount the Dial gauge [105] (2) with the Dial gauge (1)
holder [106] (3)
• Position the tracer pin at the oil pump gear with a Dismantling the oil pump
preload
• Push the oil pump gear (1) into the end position,
towards the timing case
• Zero the Dial gauge [105] (2)
• Push the oil pump gear (1) into the end position,
towards the Dial gauge [105] (2), and read off the
difference
• Repeat the same procedure on the second oil
pump gear
The axial play must be 0.040 - 0.106 mm
• Mark the orientation and installation position of the

oil pump gears (1) and (3)
• Pull the oil pump gears (1) and (3) out of the oil
pump housing (2)

ENGINE LUBRICATION
Assembling the oil pump Installing the oil pump

Mounting the oil pump
Note
Each oil pump gear is identied by a dot • Lightly oil the new O-rings (2) and insert them into
on the end of the gear or by a chamfer on the designated grooves in the coupling sleeve (1)
the tooth of a gear. • Insert the coupling sleeve (1) into the oil pump (3)
until the stop is reached
• Lightly oil the oil pump gears (1) and (3) before • Insert the oil pump (3) through the designated
installing holes in the timing case
• Line up oil pump gears (1) and (3) with one another
as marked and insert them into the oil pump Screwing in the oil pump mounting bolts
housing (2)
Note
If the oil pump gears do not rotate
freely after nal tightening, repeat the
procedure

• Check the oil pump gears can turn freely

ENGINE LUBRICATION
Installing the oil pump drive gear
• Put on the drive gear (1)

• Brace the drive gear (1)
• Thinly apply Loctite 648 on the thread of the drive
gear (1)
• Tighten the new mounting nut (2) to 45 Nm

ENGINE LUBRICATION
OIL INJECTOR NOZZLES

Removing and installing the oil injector nozzles
Additional jobs
(1) Oil injector nozzle (3) Oil pressure valve

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

ENGINE LUBRICATION
Removing the oil injector nozzle Installing the oil injector nozzles
Inserting the oil injector nozzles
• Unscrew the oil pressure valve (2) and remove

with the spring washer
• Remove the oil injector nozzle (1) WARNING
Component damage caused by piston
overheating
• Align the oil injector nozzle correctly
• Insert the oil injector nozzle (2) with the injector

nozzle facing the piston in the liner
• Screw in the oil pressure valve with a new spring
washer and tighten by hand
• Align the oil injector nozzle (2) so that the xing
balls can be felt engaging into the recesses (1)
Tightening the oil pressure valve
• Check the oil injector nozzle (1) is correctly seated

and align it if necessary
• Tighten the oil pressure valve (2) to 40 Nm

CRANK MECHANISM
CRANK MECHANISM
(1) Connecting rod (5) Mass compensation gear

(2) Pistons (6) Crankshaft gear
(3) Flywheel (7) Vibration damper
(4) Crankshaft

CRANK MECHANISM
VIBRATION DAMPER
Removing and installing the vibration damper
Additional jobs
– Removing and installing the hydraulic pump belt drive, see 66
(1) Mounting bolt (4) Vibration damper poly-V-belt pulley

(2) Washer (5) Vibration damper
(3) Mounting bolt
Technical data
Mounting bolt (1) .................................................. M14x1.5-10.9................................Initial torque 150 Nm
Mounting bolt (1) .................................................. M14x1.5-10.9.......................................Final torque 90°
WARNING
WARNING
Component damage due to reused vibration damper bolts
• Fit new vibration damper bolts if the bolts have been undone

CRANK MECHANISM
Special tools
[107] Brace 80.99622-6002
• Bracing the vibration damper

CRANK MECHANISM
Removing the vibration damper Removing the vibration damper
• Remove the vibration damper (1)
• Mark the installed position of the poly-V-belt pulley

(2) relative to the vibration damper (3)
• Remove the poly-V-belt pulley (2)
Undoing the vibration damper
• Mount the Brace [107] (3) on the vibration damper

(4)
• Brace the vibration damper (4)
• Remove the washer (2)
• Remove the Brace [107] (3)

CRANK MECHANISM
Installing the vibration damper Mounting the poly-V-belt pulley
Positioning the vibration damper
• Position the poly-V-belt pulley (2) for the vibration

damper (3) as marked
• Position the vibration damper (1) • Screw in and tighten the mounting bolts (1)
• Remove the poly-V-belt pulley (2) from the
Tightening the vibration damper vibration damper (3)
• Insert the washer (2) into the vibration damper (4)

• Screw in the new mounting bolts (1) and tighten
them by hand
• Mount the Brace [107] (3) on the vibration damper
(4)
• Brace the vibration damper (4)
• Tighten the mounting bolts (1) to Initial torque
150 Nm
• Tighten the mounting bolts (1) to Final torque 90°

CRANK MECHANISM
FLYWHEEL
Removing and installing the ywheel (variant with clutch)
(1) Flywheel (3) Flywheel housing

(2) Mounting bolts
Technical data
Mounting bolts (2)................................................. M14x1.5x30-10.9 .........................Initial torque 100 Nm
Mounting bolts (2)................................................. M14x1.5x30-10.9 .................................Final torque 90°
Flywheel lateral runout..........................................................................................................max. 0.5 mm
Flywheel ring gear installation temperature .............................................................................. 200-230 °C
Land height ............................................................................................................................max. 5 mm
WARNING
WARNING
Component damage due to reused ywheel bolts
• Fit new ywheel bolts once they have been undone

CRANK MECHANISM
Special tools
[108] Internal extractor 08.99615-1410
• Extracting the clutch pilot bearing in conjunction

with:
• Support [109]
[109] Support 08.99615-0015
• Extracting the clutch pilot bearing
[110] Dial gauge 08.71082-0005
• Checking the ywheel lateral runout in

conjunction with:
• Checking the ywheel lateral runout
[112] Clutch pilot bearing installer sleeve 80.99617-0059
• Pressing in the clutch pilot bearing
[113] Aligning tool 80.99617-0163
• Removing and mounting the ywheel
[114] Socket, size 22 80.99612-0024
• Tightening the ywheel bolts in conjunction with:

• Support [116]
• Holding device [118]
• Rubber ring, 42 mm [121]
• Washer [122]

CRANK MECHANISM
• Tightening the ywheel bolts
[116] Support 80.99606-0551
• Flywheel bolts
[118] Holding device 80.99606-0585
[119] Pan head screw 06.02191-0407
[120] Connecting pin 06.22729-0006
[121] Rubber ring, 42 mm 08.06142-9006
[122] Washer 80.99609-0033

CRANK MECHANISM
Removing the ywheel Unscrewing the mounting bolts
Assembling the special tool
• Unscrew the mounting bolts (1) for the ywheel (2)

except for two bolts
• Mount the Holding device [118] (5) with Pan head
screw [119] (4) and Washer [122] (3) on the Installing the guide pins
Support [116] (2)
• Place the Angle measuring disc [117] (9) onto the
Torque multiplier i = 1 : 3.3 [115] (1)
• Place the Socket, size 22 [114] (7) on the
Torque multiplier i = 1 : 3.3 [115] (1) and secure
using Connecting pin [120] (8) and Rubber ring,
42 mm [121] (6)
Undoing the mounting bolts
• Screw the Aligning tool [113] (1) through the

ywheel and into the crankshaft
• Unscrew the remaining mounting bolts (2)
• Put the assembled special tool (1) on the ywheel

bolt that is going to be undone
• Undo all the ywheel bolts

CRANK MECHANISM
Pulling off the ywheel Installing the ywheel

Checking the ywheel lateral runout
CAUTION
Danger of injury due to heavy • Clamp the ywheel (1) onto the xture
components • Mount the Dial gauge [110] (2) with the Dial gauge
• Use lifting gear to install the ywheel holder [111]
• Place the measuring tip of the Dial gauge [110] (2)
• Screw in retaining bolts (1) and (2) to make it against the ywheel (1) with a preload
easier to pull off the ywheel • Zero the Dial gauge [110] (2)
• Pull off the ywheel (3) over the Aligning tool [113] • Turn the ywheel (1) a few turns and, at the same
(4) time, read off the deection of the Dial gauge [110]
(2)
The permissible lateral runout is max. 0.5 mm.
Fitting the ywheel
WARNING
Component damage due to reused
ywheel bolts
• Fit new ywheel bolts once they have
been undone
• Screw in the Aligning tool [113] (2)

• Line up the ywheel (3) with the crankshaft guide
pin
• Fit the ywheel (3) over the Aligning tool [113] (4)
and onto the crankshaft
• Unscrew the retaining bolts (1) and (2)
• Screw in new mounting bolts for the ywheel (3)
and tighten them by hand

CRANK MECHANISM
Removing the aligning tools Removing and installing the ywheel

ring gear
Spot-drilling the ywheel ring gear
• Unscrew the Aligning tool [113] (1)

• Screw in the remaining mounting bolts (2) and
tighten them by hand
WARNING
Tightening the ywheel mounting bolts Flywheel damage due to imbalance
• Take care not to damage the ywheel
when spot-drilling the ywheel ring gear
• Replace the spot-drilled ywheel
• Spot-drill the ywheel ring gear (1) and use a chisel

to break it off
• Remove the ywheel ring gear (1) from the
ywheel (2)
• Clean the contact surfaces of the ywheel ring
gear (1) on the ywheel (2) and check them for
damage
Installing the ywheel ring gear
Note
Note the torque multiplier ratio, i = 1 : 3.3
• Fit the assembled special tool (1)

• Tighten the mounting bolts to Initial torque 100 Nm
• Tighten the mounting bolts to Final torque 90°
Note
The chamfers on the teeth of the ywheel
ring gear must point away from the
ywheel.
• Heat the ywheel ring gear (1) to 200-230 °C

• Place the ywheel ring gear (1) on the ywheel (2)
and seat it as necessary

CRANK MECHANISM
Removing the clutch pilot bearing Installing the clutch pilot bearing
Removing the circlip
• Use the Clutch pilot bearing installer sleeve [112]

(1) to knock the clutch pilot bearing (2) into the
• Use internal circlip pliers (1) to remove the circlip ywheel (3) until the stop is reached
(2) from the ywheel
Installing the circlip
Mounting the extractor device
• Use internal circlip pliers (1) to install the circlip (2)

• Insert the Internal extractor [108] (2) into the clutch in the ywheel
pilot bearing and expand it
• Attach the Support [109] (1) and clamp it
Extracting the clutch pilot bearing
• Use the Internal extractor [108] (2) and

Support [109] (1) to pull the clutch pilot bearing
(4) out of the ywheel (3)

CRANK MECHANISM
Removing and installing the ywheel (variant with Allison gearbox)
(1) Flywheel (3) Flywheel housing

(2) Mounting bolt
Technical data
Lateral runout, ywheel (1)....................................................................................................max. 0.5 mm
Installation temperature, ywheel ring gear .............................................................................. 220-240 °C
WARNING
WARNING
Component damage due to reused ywheel bolts
• Replace the ywheel bolts with new ones once they have been undone

CRANK MECHANISM
Special tools
[123] Aligning tool 80.99617-0163
• Removing and mounting the ywheel
• Tightening the ywheel bolts in conjunction with:

• Socket, size 22 [125]
• Support [126]
• Washer [132]
[125] Socket, size 22 80.99612-0024
[126] Support 80.99606-0551
[128] Holding device 80.99606-0585
[129] Pan head screw 06.02191-0407

CRANK MECHANISM
[130] Connecting pin 06.22729-0006
[131] Rubber ring, 42 mm 08.06142-9006
[132] Washer 80.99609-0033

CRANK MECHANISM
Removing the ywheel Unscrewing the ywheel mounting bolts
• Unscrew the mounting bolts (1) for the ywheel (2)

except for two bolts
• Mount the Holding device [128] (5) with the Pan
head screw [129] (4) and the Washer [132] (3) on Installing the guide pins
the Support [126] (2)
• Put the Angle measuring disc [127] (9) on the
• Put the Socket, size 22 [125] (7) on the Torque
multiplier i = 1 : 3.5 [124] (1) and secure using
the Connecting pin [130] (8) and the Rubber ring,
42 mm [131] (6)
Undoing the ywheel mounting bolts
• Screw the Aligning tool [123] (1) through the

ywheel into the crankshaft
• Unscrew the remaining mounting bolts (2)
• Put the assembled special tool (1) on the ywheel

bolt that is going to be undone
• Undo all the ywheel bolts

CRANK MECHANISM
Pulling off the ywheel Removing and installing the ywheel

ring gear
Spot-drilling the ywheel ring gear
CAUTION
Danger of injury due to heavy
components
• Remove the ywheel with support WARNING
Flywheel damage due to imbalance
• Pull off the ywheel (1) over the Aligning tool [123] • Take care not to damage the ywheel
(2) when spot-drilling the ywheel ring gear
• Replace the spot-drilled ywheel
• Spot-drill the ywheel ring gear (1) and use a chisel

to prise it open
• Remove the ywheel ring gear (1) from the
ywheel (2)
• Clean the contact surfaces of the ywheel ring
gear (1) on the ywheel (2) and check them for
damage
Installing the ywheel ring gear
Note
The chamfers on the teeth of the ywheel
ring gear must point away from the
ywheel.
• Heat the ywheel ring gear (1) to 220-240 °C

• Put the ywheel ring gear (1) on the ywheel (2)
and seat it as necessary

CRANK MECHANISM
Installing the ywheel Screwing in the ywheel mounting bolts
Fitting the ywheel
• Screw all the mounting bolts (1) into the ywheel

(2)
WARNING
Tightening the ywheel mounting bolts
Component damage due to reused
ywheel bolts
• Replace the ywheel bolts with new
ones once they have been undone
• Screw in the Aligning tool [123] (2)

• Line up the ywheel (1) with the crankshaft guide
pin
• Position the ywheel (1) over the Aligning
tool [123] (2) on the crankshaft
• Screw in new mounting bolts for the ywheel (1)
and tighten them by hand
Removing the aligning tools
Note
Note the torque multiplier ratio, i = 1 : 3.3
• Fit the assembled special tool (1)

• Tighten the mounting bolts to Initial torque 100 Nm
• Tighten the mounting bolts to Final torque 90°
• Screw in two mounting bolts (2)

• Unscrew the Aligning tool [123] (1)

CRANK MECHANISM
PISTONS AND CONNECTING RODS

Removing and installing the pistons and connecting rods
Additional jobs
(1) Connecting rod bearing bolts (6) Piston

(2) Connecting rod bearing cap (7) Keystone ring
(3) Connecting rod (8) Taper-face ring
(4) Internal circlip (9) Double-bevelled ring
(5) Piston pin
Technical data
Connecting rod bearing bolts (1)............................ M11x1.5x60-11.9............................ Initial torque 50 Nm
Connecting rod bearing bolts (1)............................ M11x1.5x60-11.9..................................Final torque 90°
Connecting rods
Conrod length, middle of conrod eye to middle of conrod bearing......................................... 196 ± 0.02 mm
Inside diameter of conrod eye ................................................................................. Ø 44.050 - 44.066 mm
Crank pin width ............................................................................................................. 36.78 - 36.88 mm
Bore for bearing shells in connecting rod .....................................................................Ø 74.00 - 74.20 mm
Weight difference per set of connecting rods in an engine............................................................max. 50 g

CRANK MECHANISM
Connecting rod bearing

Connecting rod bearing normal dimension ............................................................... Ø 69.981 - 70.000 mm
Connecting rod bearing normal dimension I ............................................................. Ø 69.881 - 69.900 mm
Connecting rod bearing repair level 1 ...................................................................... Ø 69.731 - 69.750 mm
Wall thickness of connecting rod bearing

Connecting rod bearing thickness normal dimension ...................................................................1.975 mm
Connecting rod bearing thickness normal dimension I .................................................................2.025 mm
Connecting rod bearing thickness repair level I ...........................................................................2.100 mm
Piston diameter Ø 108 mm, Nüral pistons

D1 measured 17 mm above lower edge of piston .....................................................107.851 - 107.869 mm
Piston diameter Ø 108 mm, KS pistons

Piston heights Ø 108 mm

Overall height..........................................................................................................................103.00 mm
Piston height from middle of piston pin to piston crown / PH level 0 .................................. 63.85 - 63.90 mm
Keystone ring
Piston ring height..................................................................................................... 3 mm (nominal value)
Piston ring width ................................................................................................................ 4.25 - 4.60 mm
Ring gap ........................................................................................................................... 0.35 - 0.50 mm
Taper-face ring
Piston ring height............................................................................................................... 2.47 - 2.50 mm
Ring gap ........................................................................................................................... 0.50 - 0.65 mm
Double-bevelled ring
Ring gap ...............................................................................................................................0.3 - 0.6 mm
Piston pin
Piston pin diameter................................................................................................. Ø 43.994 - 44.000 mm
Piston standout
Piston standout from top edge of crankcase to piston crown ............................................ 0.093 - 0.391 mm
Piston weight
Piston weight difference per set in one engine.............................................................................max. 40 g
WARNING
WARNING
Crack surfaces are sensitive. The principle involved can cause chipping
• 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, always rinse them in clean cleaning agent
• After cleaning, use compressed air to blow-dry the crack surfaces
• Do not allow rinsed-out particles to enter the engine
Note
Measure the piston diameter perpendicular to the piston pin bore. Pistons are identied with A
or B.

CRANK MECHANISM
Special tools
[133] Piston ring compressor pliers 83.09144-6090
• Removing and installing piston rings
[134] Feeler gauge 80.99607-6019
• Checking the piston ring gap
• Checking the piston standout in conjunction with:

• Dial gauge [136]
[136] Dial gauge 08.71082-0005
• Checking the piston standout
[137] Piston ring compressor pliers 80.99613-0039
• Installing the pistons
[138] Setting tool 80.99622-0052
• Positioning the bearing shell – cracked

connecting rod
[139] Depth gauge (electronic) 08.71195-9003
• Piston ring insertion depth, checking ring gap

CRANK MECHANISM
Removing the pistons and connecting Removing the piston pin

rods
Removing the connecting rod bearing shells
• Mark the relative positions of the piston (3), piston

pin (2) and connecting rod (5)
• Remove the internal circlips (1) and (4) from the
• Mark the connecting rod bearing cap (2) and the piston (3)
connecting rod bearing shell (1) to indicate their • Press the piston pin (2) out of the piston (3)
installation position and pairing • Remove the piston (3)
• Unscrew the connecting rod bearing bolts
• Remove the connecting rod bearing cap (2) with Checking the piston pin
the connecting rod bearing shell (1)
• Push the piston and connecting rod out in the
direction of the cylinder head
Removing the piston
• Check the piston pin (1) using a micrometer (2)

The piston pin (1) is allowed to have an outside
diameter of Ø 43.994 - 44.000 mm.
• Mark the installation position and orientation of the

piston (2) relative to the crankcase (1)
• Pull the piston (2) with connecting rod upwards out
of the crankcase (1)

CRANK MECHANISM
Removing the piston rings Installing the piston rings
• Set the Piston ring compressor pliers [133] (1) to

WARNING
the piston diameter
Component damage due to incorrect
• Remove the piston rings (2) using the Piston ring
installation of the piston rings
compressor pliers [133] (1)
• Take care not to damage the jacket
• Carefully clean the piston ring grooves in the
surface of the piston when installing the
piston (3)
piston rings
Checking the piston ring gap
• Set the Piston ring compressor pliers [133] (1) to
the piston diameter
• Insert the new piston rings (2) into the correct
piston ring grooves in the piston (3) using the
Piston ring compressor pliers [133] (1), ensuring
that the gaps are 120° offset
Note
Determine the diameter of the cylinder
before measuring the ring gap.
• Insert the piston ring (3) into the cylinder (1)

• Use the Feeler gauge [134] (2) to check the ring
gap
The keystone ring gap is allowed to be 0.35 - 0.50
mm.
The permissible taper-face ring gap is 0.50 - 0.65

mm.
The permissible double-bevelled ring gap is 0.3 -

0.6 mm.
If the ring gap is too large, exchange the piston rings

(3).

CRANK MECHANISM
Checking the connecting rod bearing Checking the lower connecting rod bearing
Checking the piston pin bore
WARNING
Crack surfaces are sensitive. The
Note principle involved can cause chipping.
If there is too much bearing clearance in • Exchange the connecting rod if the
the upper connecting rod bearing, t a crack surfaces are damaged
new connecting rod with piston pin • Protect crack surfaces against damage
caused by hard and sharp objects
• Use the internal calliper (3) and the Dial • Only clean crack surfaces on the
gauge [136] (2) to check the piston pin bore connecting rods by washing in clean
in the connecting rod (1) cleaning agent
The inside diameter of the connecting rod eye is • Do not allow rinsed-out particles to
allowed to be Ø 44.050 - 44.066 mm. enter the engine
• Insert the connecting rod bearing into the

connecting rod (2) and connecting rod bearing
cap (3)
• Fit the connecting rod bearing cap (3) as marked
and tighten it using connecting rod bolts
• Use the internal calliper (1) and Dial gauge [136]
(4) to check the connecting rod bearing
The connecting rod bearing dimension must be
Ø 69.981 - 70.000 mm for the normal dimension

CRANK MECHANISM
Installing the piston and connecting rod Mounting the connecting rod bearing shell
Installing the piston pin
WARNING
• Attach the internal circlip (4) Crack surfaces are sensitive. The
• Put the piston (3) on the connecting rod (5) as principle involved can cause chipping.
marked • Exchange the connecting rod if the
• Press the piston pin (2) through the piston (3) crack surfaces are damaged
and connecting rod (5) as marked until the stop • Protect crack surfaces against damage
is reached caused by hard and sharp objects
• Attach the internal circlip (1) • Only clean crack surfaces on the
connecting rods by washing in clean
Installing the pistons cleaning agent
• Do not allow rinsed-out particles to
enter the engine
• Do not re-use used connecting rod bolts
• Insert the connecting rod bearing shell (1) into

the corresponding connecting rod bearing cap (2)
according to the marking and pairing; position
using the Setting tool [138] if necessary
• Put the connecting rod bearing cap (2) with
inserted connecting rod bearing shell (1) on the
connecting rod, taking care not to damage the
contact surfaces between the connecting rod
bearing cap (2) and the connecting rod
• Screw in the new connecting rod bearing bolts and
tighten them to Initial torque 50 Nm
• Tighten the connecting rod bearing bolts to Final
• Move the crankshaft for the cylinder concerned to
torque 90°
TDC
• Line up the gaps in the piston rings at 120° offset
to one another
• Thinly apply engine oil to MAN standard on the
piston (1)
• Insert the connecting rod bearing into the
connecting rod, positioning it using the Setting
tool [138] if necessary
• Open the Piston ring compressor pliers [137] (2)
and t over the piston (1)
• Clamp the Piston ring compressor pliers [137] (2)
• Insert the piston (1) through the Piston ring
compressor pliers [137] (2) and into the cylinder
liner as marked relative to the crankcase
• Carefully push through the piston (1) until the
connecting rod bearing is lying on the crankshaft

CRANK MECHANISM
Checking the piston standout
• Move the piston (2) to top dead centre

• Place the Dial gauge [136] (3) and Dial gauge
holder [135] (5) onto the crankcase (4)
• Position the dial gauge tip (1) on the crankcase (4)
and zero the Dial gauge [136] (3)
• Locate the dial gauge tip (1) on the piston (2) and
read off the difference
The piston standout is allowed to be 0.093 -
0.391 mm.

CRANK MECHANISM
MASS COMPENSATION GEAR

Removing and installing the mass compensation gear
Additional jobs
(1) Flywheel (3) Mass compensation gear

(2) Crankshaft (4) Crankshaft gear
Technical data
Axial play, shafts................................................................................................................ 0.08 - 0.25 mm
WARNING

CRANK MECHANISM
Special tools
[140] Feeler gauge 80.99607-6019
• Checking the shaft axial play
[141] Engine barring gear 80.99626.6008
• Cranking the engine in conjunction with

[142] Gear ratchet 80.99627.0001

CRANK MECHANISM
Removing the mass compensation gear Detaching the mass compensation gear
Do-it-yourself assembly pin
• Unscrew the mounting bolts (3) for the mass

compensation gear (2)
• Do-it-yourself assembly pin (1) • Remove the mass compensation gear (2) from the
crankcase (1)
Fixing the mass compensation gear • Remove the assembly pin
Checking the mass compensation gear axial

play
• Crank the engine using the Engine barring

gear [141] and the Gear ratchet [142] until the
marking (2) is aligned
• Fix the gear through the gap using the assembly • Check the axial play between the gears (1) and
pin (1) the bracket (3) using the Feeler gauge [140] (2)
• Mark the position of the mass compensation gears • Check the bearings and gears (1) for wear
relative to the crankshaft gear The permitted axial play is 0.08 - 0.25 mm.
If the axial play is out of tolerance, t a new mass

compensation gear.

CRANK MECHANISM
Installing the mass compensation gear

Fixing the mass compensation gear
• Align the mass compensation gears so that the

markings (2) line up
• Fix the gear through the gap using the assembly
pin (1)
Mounting the mass compensation gear
• Position the xed mass compensation gear (2) on

the crankcase (1)
• Screw in and tighten the new mounting bolts (3)
• Remove the assembly pin
• Release the Engine barring gear [141]

CRANK MECHANISM
CRANKSHAFT
Removing and installing the crankshaft
Additional jobs
– Removing and installing the mass compensation gear, see 249
– Removing and installing the timing case, see 285
– Removing and installing the ywheel housing, see 277
– Removing and installing the pistons and connecting rods, see 241

CRANK MECHANISM
(1) Crankshaft bearing shell, crankcase (5) Thrust washer, bearing cap
(2) Crankshaft bearing shell, bearing cap (6) Crankshaft
(3) Crankshaft bearing cap (7) Thrust washer, crankcase
(4) Mounting bolt (8) Crankcase
Technical data
Mounting bolt (4) .................................................. M14x118-10.9 ...............................Initial torque 115 Nm
Mounting bolt (4) .................................................. M14x118-10.9 ......................................Final torque 90°
Connecting rod bearing bolts................................. M11x1.5x60-11.9............................ Initial torque 50 Nm
Connecting rod bearing bolts................................. M11x1.5x60-11.9..................................Final torque 90°
Crankshaft
Crankshaft hardness............................................................................................................... 53 ± 3 HRC
Permitted curvature of journals...................................................................................................0.004 mm
Crankshaft axial play ..................................................................................................... 0.150 - 0.282 mm
Journal normal dimension ....................................................................................... Ø 86.978 - 87.000 mm
Journal normal dimension I ..................................................................................... Ø 86.878 - 86.900 mm
Journal repair level I ............................................................................................... Ø 86.738 - 86.750 mm
Journal repair level II .............................................................................................. Ø 86.238 - 86.250 mm
Journal repair level III ............................................................................................. Ø 85.738 - 85.750 mm
Journal repair level IV ............................................................................................. Ø 85.238 - 85.250 mm
Crankshaft bearing
Wall thickness, crankshaft bearing, normal dimension (1), (2) ......................................................2.468 mm
Wall thickness, crankshaft bearing, repair level I (1), (2)...............................................................2.593 mm
Wall thickness, crankshaft bearing, repair level II (1), (2)..............................................................2.718 mm
Wall thickness, crankshaft bearing, repair level III (1), (2).............................................................2.843 mm

CRANK MECHANISM
Wall thickness, crankshaft bearing, repair level IV (1), (2) ............................................................2.968 mm

Thrust washer, normal dimension (5), (7) ....................................................................................2.850 mm
Thrust washer, repair level I (5), (7) ............................................................................................3.100 mm
Spread......................................................................................................................................... 0.5 mm
WARNING
Special tools
[143] Dial gauge 08.71082-0005
• Checking the crankshaft axial play in conjunction

with:
• Checking the crankshaft axial play
[145] Socket, size 22 80.99612-0024
• Tightening the crankshaft bolts in conjunction

with:
• Support [147]
• Washer [153]
• Tightening the crankshaft bolts
[147] Support 80.99606-0551

CRANK MECHANISM
[149] Holding device 80.99606-0585
[150] Pan head screw 06.02191-0407
• Tightening the crankshaft bolts:
[151] Connecting pin 06.22729-0006
[152] Rubber ring, 42 mm 08.06142-9006
[153] Washer 80.99609-0033
[154] Setting tool 80.99622-0052
• Positioning the bearing shell – cracked

connecting rod

CRANK MECHANISM
Removing the crankshaft Unscrewing the crankshaft bearing bolts
Removing the connecting rod bearing shells
• Put the assembled special tool (1) on the

crankshaft bearing bolt
• Mark the connecting rod bearing cap (2) and • Unscrew all the crankshaft bearing bolts
connecting rod bearing shell (1) to indicate their
installation position and pairing Removing the crankshaft bearing shells
• Unscrew the connecting rod bearing bolts
• Remove the connecting rod bearing cap (2) with
the connecting rod bearing shell (1)
• Push the piston and connecting rod out in the
direction of the cylinder head
• Remove the mounting bolts (1)

• Mark the crankshaft bearing cap (2) and
crankshaft bearing shell (3) to indicate their
correct assignment and installation position
• Remove the crankshaft bearing cap (2) with the
crankshaft bearing shell (3)
• Repeat the work step for bearing caps 2, 3 and 5
• Mount the Holding device [149] (5) with Pan
head screw [150] (4) and Washer [153] (3) on the
Support [147] (2)
• Place the Angle measuring disc [148] (9) onto the
• Put the Socket, size 22 [145] (7) on the Torque
multiplier i = 1 : 3.3 [146] (1) and secure using
the Connecting pin [151] (8) and the Rubber ring,
42 mm [152] (6)

CRANK MECHANISM
Removing the bearing cap thrust washers Removing the crankshaft
• Remove the mounting bolts (3) WARNING

• Mark the crankshaft bearing cap (2) to indicate its Component damage due to incorrect
correct assignment and installation position lifting gear
• Remove the crankshaft bearing cap (2) with thrust • Do not use any lifting gear or steel
washers (1) and (4) cables with sharp edges to lift out the
• Mark the crankshaft bearings to indicate their crankshaft
correct installation position and assignment and
then remove them • Use lifting gear to lift the crankshaft (2) out of the
crankcase (1)
Removing the crankcase thrust washers
• Remove the thrust washers (2) from bearing seat

4 (1)

CRANK MECHANISM
Checking the crankshaft and crankshaft Checking the crankshaft

bearings
Checking the crankshaft bearing expansion
• Clean the journals of the crankshaft (2)

• Check the journals of the crankshaft (2) using a
micrometer (1)
Note • Repeat the measurement for each journal
The difference between dimension A and The dimensions of the journals must be within the
dimension B is the expansion of the specied tolerances, see Crankshaft, 254.
crankshaft bearings.
• Clean the bearing shells (2) and put them together

on a at surface as marked
• Measure dimension A using a micrometer (1)
• Measure dimension B using a micrometer (1)
• If the maximum permissible expansion of 0.5 mm
is exceeded, new crankshaft bearings (2) must be
tted
Checking the crankshaft bearing inside diameter
• Insert the crankshaft bearing into the crankcase

and crankcase bearing cap (3) as marked
• Put on the crankshaft bearing cap (3) as marked
• Screw in the crankshaft bearing mounting bolts
and tighten them to Initial torque 115 Nm
• Check the crankshaft bearing using the internal
calliper (2) in conjunction with the Dial gauge [143]
(1); for dimensions of crankshaft bearings, see
Crankshaft bearing, 254
• Repeat the same measuring procedure for all the
crankshaft bearings
• Remove the crankshaft bearing cap (3) after
measuring

CRANK MECHANISM
Installing the crankshaft Installing the bearing cap thrust washers
Installing the crankshaft
• Thinly apply clean engine oil on the crankshaft

bearing and thrust washers (1) and (4)
• Thinly apply clean engine oil on the crankshaft • Insert the thrust washers (1) and (4) into the
bearing shells crankshaft bearing cap (2) with the oil grooves
• Insert the crankshaft bearing shells into the pointing towards the crankshaft
crankcase (1) as marked • Put the crankshaft bearing cap (2) on the bearing
• Use lifting gear to insert the crankshaft (2) into the seat and x it
crankcase (1) • Screw in the new crankshaft bearing bolts (3) and
tighten by hand
Installing the crankcase thrust washers
Mounting the crankshaft bearing shells
Note
Make sure the installation orientation and • Thinly apply clean engine oil on the crankshaft
installation position are correct. bearing shell (3)
• Insert the crankshaft bearing shell (3) into the
crankshaft bearing cap (2) as marked
• Thinly apply clean engine oil on the thrust washers • Insert the crankshaft bearing cap (2) into the
(2) crankcase, down to the crankshaft bearing cap
• Insert the thrust washers (2) between the (2) for the fourth cylinder, as marked
crankcase and crankshaft at crankshaft bearing • Screw in the mounting bolts (1) and tighten them
4 (1) with the oil grooves pointing towards the by hand
crankshaft
• Insert the thrust washers (2) into the bearing seat
by pressing lightly

CRANK MECHANISM
Tightening the crankshaft bearing bolts Mounting the connecting rod bearing shell
Note WARNING
Note the torque multiplier ratio, i = 1 : 3.3. Crack surfaces are sensitive. The
principle involved can cause chipping.
• Exchange the connecting rod if the
• Put the assembled special tool (1) on the mounting crack surfaces are damaged
bolt • Protect crack surfaces against damage
• Tighten the mounting bolts to Initial torque 115 Nm caused by hard and sharp objects
• To clean the crack surfaces on the
• Tighten the mounting bolts to Final torque 90° connecting rods, always rinse them in
clean cleaning agent
Checking the crankshaft axial play • After cleaning, use compressed air to
blow-dry the crack surfaces
• Do not allow rinsed-out particles to
enter the engine
• Do not re-use used connecting rod bolts
• Install the pistons, see Removing and installing

the pistons and connecting rods, 241
• Insert the connecting rod bearing shell (1) into
the corresponding connecting rod bearing cap (2)
according to the marking and pairing; position
using the Setting tool [154] if necessary
• Put the connecting rod bearing cap (2) with
inserted connecting rod bearing shell (1) on the
connecting rod, taking care not to damage the
contact surfaces between the connecting rod
• Put the Dial gauge [143] (1) with the Dial gauge bearing cap (2) and the connecting rod
holder [144] (2) on the crankcase • Screw in the new connecting rod bearing bolts and
• Place the dial gauge tip onto the crankshaft (3), tighten them to Initial torque 50 Nm
push the crankshaft (3) into an end position and • Tighten the connecting rod bearing bolts to Final
zero the Dial gauge [143] (1) torque 90°
• Push the crankshaft (3) to the other end position
and read off the difference on the Dial gauge [143]
(1)
Thrust washer thickness, see Technical data, 254.
The maximum permissible axial play on the

crankshaft (3) is 0.150 - 0.282 mm.

CRANKSHAFT OIL SEALS
(1) Timing case cover (4) Rear crankshaft oil seal

(2) Timing case (5) Front crankshaft oil seal
(3) Flywheel housing


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

(2) Timing case
WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or grease before
installation.
• Clean the crankshaft and insertion tool before assembly

WARNING
Special tools
[155] Guide plate 80.99606-0568
• Removing the front crankshaft oil seal in

conjunction with:
• Threaded spindle [157]
• Crossmember [159]
• Pressure plate [160]
• Hook [161]
• Installing the front crankshaft oil seal in
conjunction with:
• Hexagon collar nut [162]
• Press-in plate [163]
[156] Pan head screw 06.02191-2713
• Removing and installing the front crankshaft oil

seal
[157] Threaded spindle 80.99606-0299

seal
[158] Hexagon nut 06.11065-2318

seal
[159] Crossmember 80.99606-0298
• Removing the front crankshaft oil seal

[160] Pressure plate 80.99609-0038
[161] Hook 80.99606-6013
[162] Hexagon collar nut 06.11222-0311
• Installing the front crankshaft oil seal
[163] Press-in plate 80.99606-0567
• Installing the front crankshaft oil seal

Removing the crankshaft oil seal Installing the crankshaft oil seal
Positioning the crankshaft oil seal
• Mount the Guide plate [155] (2) on the crankshaft

with the Pan head screw [156] (6)
• Screw the Pressure plate [160] into the Guide • Remove the Pressure plate [160]
plate [155] (2) • Position the new crankshaft oil seal (3) with
• Screw the Hexagon nut [158] (5) onto the transport sleeve (2) on the Guide plate [155] (1)
Threaded spindle [157] and secure with a second • Push the crankshaft oil seal (3) onto the Guide
Hexagon nut [158] (5) plate [155] (1)
• Screw the Threaded spindle [157] into the • Remove the transport sleeve (2)
Crossmember [159] (4)
• Insert the Hook [161] (3) through the Pressing in the crankshaft oil seal
Crossmember [159] (4) at between the
crankshaft oil seal (1) and the crankshaft
• Turn the Hook [161] (3) through 90° so that the
recess of the Hook [161] (3) is facing outwards
• Extract the crankshaft oil seal (1) by screwing in
the Threaded spindle [157]
• Push the Press-in plate [163] (2) onto the Guide

plate [155]
• Screw the Hexagon collar nut [162] onto the
Threaded spindle [157] (3)
• Screw the Threaded spindle [157] (3) into the
Guide plate [155]
• Press in the crankshaft oil seal (1) until the stop
is reached by screwing in the Hexagon collar
nut [162]

Removing and installing the rear crankshaft oil seal

Additional jobs
– Removing and installing the ywheel (variant with Allison gearbox), see 234
(1) Flywheel housing (2) Crankshaft oil seal
WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or grease before
installation
• Clean the crankshaft and insertion tool before assembly
WARNING

Special tools
[164] Guide plate 80.99606-0316
• Removing the rear crankshaft oil seal in

conjunction with:
• Crossmember [168]
• Hook [169]
• Pressure plate [170]
• Installing the rear crankshaft oil seal in
conjunction with:
• Hexagon collar nut [172]
• Press-in plate [171]
[165] Threaded spindle 80.99606-0299
• Removing and installing the rear crankshaft oil

seal
[166] Pan head screw 06.02191-2713

seal
[167] Hexagon nut 06.11065-2318

seal
[168] Crossmember 80.99606-0298
• Removing the rear crankshaft oil seal
[169] Hook 80.99606-6013

[170] Pressure plate 80.99609-0038
[171] Press-in plate 80.99606-0315
• Installing the rear crankshaft oil seal
[172] Hexagon collar nut 06.11222-0311
• Installing the rear crankshaft oil seal

Removing the crankshaft oil seal Installing the crankshaft oil seal
Mounting the special tool Positioning the crankshaft oil seal
• Mount the Guide plate [164] (4) on the crankshaft • Remove the Pressure plate [170]
with the Pan head screw [166] (6) • Position the new crankshaft oil seal (1) with
• Screw the Pressure plate [170] (5) into the Guide transport sleeve (2) on the Guide plate [164] (3)
plate [164] (4) • Push the crankshaft oil seal (1) onto the Guide
• Screw the Hexagon nut [167] onto the Threaded plate [164] (3)
spindle [165] and secure with a second Hexagon • Remove the transport sleeve (2)
nut [167]
• Screw the Threaded spindle [165] into the Pressing in the crankshaft oil seal
Crossmember [168] (2)
• Insert the Hook [169] (1) through the
Crossmember [168] (2) at between the
crankshaft oil seal (3) and the crankshaft
• Turn the Hook [169] (1) through 90° so that the
recess of the Hook [169] (1) is facing outwards
• Insert the Crossmember [168] (2) into the
Hook [169] (1)
Extracting the crankshaft oil seal
WARNING
Component damage caused by
incorrect installation
• Ensure that the special tool is tted with
the recess downwards, above the curve
on the ywheel housing
• Push the Press-in plate [171] (2) onto the Guide

plate [164]
• Screw the Hexagon collar nut [172] (1) onto the
• Extract the crankshaft oil seal (1) by screwing in
Threaded spindle [165]
the Threaded spindle [165] (2)
• Screw the Threaded spindle [165] into the Guide
plate [164]
• Press in the crankshaft oil seal (3) until the stop
is reached by screwing in the Hexagon collar
nut [172] (1)

ENGINE HOUSING
ENGINE HOUSING
(1) Crankcase ventilation (4) Timing case

(2) Flywheel housing (5) Timing case cover
(3) Crankcase

ENGINE HOUSING
CRANKCASE VENTILATION
Removing and installing the crankcase ventilation
(1) Oil separator (5) Oil return line

(2) Vent line (6) Vent line
(3) Hose (7) Jubilee clip
(4) Vent line (8) Hose
WARNING
Note
Fit new hoses, mounting bolts and O-rings when exchanging the crankcase ventilation.

ENGINE HOUSING
Special tools
• Removing and installing jubilee clips

ENGINE HOUSING
FLYWHEEL HOUSING
Removing and installing the ywheel housing
Additional jobs
– Removing and installing the starter, see 57
– Removing and installing the front crankshaft oil seal, see 265
– Removing and installing the rear crankshaft oil seal, see 269
(1) Crankcase (5) Crane hook lug

(2) Gasket (6) Mounting bolt
(3) Flywheel housing (7) Mounting bolt
(4) Spacer (8) Mounting bolt
Service products
Curil T............................................................................................................................... 04.90300-9030
WARNING
WARNING
Component damage due to contamination with oil or grease
• Do not allow the PTFE sealing ring to come into contact with oil or grease before installation

ENGINE HOUSING
WARNING
Component damage due to incorrect storage of the PTFE sealing ring
• Always store PTFE sealing rings with their transport sleeves tted
• PTFE sealing rings without transport sleeve are unusable

ENGINE HOUSING
Removing the ywheel housing Installing the ywheel housing

Removing the crane hook lug Positioning the ywheel housing
• Unscrew the mounting bolt (3) for the crane hook

Note
lug (2)
Insert the speed sensor with Curil T
applied when exchanging the ywheel
• Remove the crane hook lug (2) with spacer (1)
housing.
• Disconnect the speed sensor electrical connection
Removing the ywheel housing • Position the ywheel housing (3) with a new gasket
(2) over the alignment pins on the crankcase (1)
Mounting the crane hook lug
• Unscrew the mounting bolts (4) for the ywheel

housing (3)
• Remove the ywheel housing (3) with gasket (2)
from the crankcase (1)
• Position the crane hook lug (2) with spacer (1)
• Screw in the mounting bolts (3) and (4) and then
tighten them
• Connect the speed sensor electrical connection

ENGINE HOUSING
TIMING CASE COVER/TIMING CASE

Removing and installing the timing case cover
Additional jobs
– Removing and installing the front crankshaft oil seal, see 265
(1) Mounting bolt (4) Timing case

(2) Timing case cover (5) Gasket
(3) Gasket
Technical data
Oil ller neck ........................................................ M38x1.5 ............................................................35 Nm
Service products
Loctite 648 ........................................................................................................................ 04.10160-9164

ENGINE HOUSING
WARNING
WARNING
Component damage due to contamination with oil or grease
• Do not allow the PTFE sealing ring to come into contact with oil or grease before installation
WARNING
Component damage due to incorrect storage of the PTFE sealing ring
• Always store PTFE sealing rings with their transport sleeves tted
• PTFE sealing rings without transport sleeve are unusable
Special tools
• Removing and installing the jubilee clips
[175] Socket 27 mm 08.06556-9300
• Removing and installing the oil ller neck

ENGINE HOUSING
Removing the timing case cover Removing the timing case cover gasket
Removing the speed sensor
• Remove the gasket (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
• Remove the oil ller neck (4) with the Socket

27 mm [175]
(1), (2), (5) and (6)
• Unscrew the mounting bolts (1), (2), (5) and (6)
• Remove the timing case cover (3)

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

• Position the new gasket (1) over the alignment • Connect the electrical connection for the speed
pins on the timing case (2) sensor (1)
Mounting the timing case cover
WARNING
Component damage due to leaks
• Fit a new crankshaft oil seal after
mounting the timing case cover
• Position the timing case cover (3) over the

alignment pins
• Screw in the mounting bolts (1), (2), (5) and (6) as
marked and then tighten them
• Thinly apply Loctite 648 on the thread of the oil
ller neck (4)
• Screw in the oil ller neck (4) using the Socket
27 mm [175] and tighten to 35 Nm

ENGINE HOUSING
Removing and installing the timing case

Additional jobs
– Removing and installing the oil pump, see 213
(1) Timing case (2) Gasket
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292

ENGINE HOUSING
WARNING

ENGINE HOUSING
Removing the timing case Removing the timing case gasket
Unscrewing the mounting bolts at the bottom
• Remove the gasket (1) from the crankcase (2)

Removing the timing case

(1)
• Unscrew the mounting bolts (1) for the timing case
(2) from the crankcase (3)
• Remove the timing case (2), moving the oil pump
if necessary, see Removing and installing the oil
pump, 213

ENGINE HOUSING
Mounting the timing case Screwing in the mounting bolts at the bottom
Positioning the timing case gasket
• Position a new gasket (1) on the crankcase (2)
Mounting the timing case
• Fit new coupling sleeve O-rings and oil them, see

Mounting the oil pump, 216
• Thinly apply Loctite 5900 on the oil sump mating
face, see Removing and installing the oil sump,
207
• Position the timing case (2) over the alignment
pins on the crankcase (3)
• Screw in the mounting bolts (1) as marked and
tighten them

TECHNICAL DATA
TECHNICAL DATA
Removing and installing the engine electrics

Flame glow plug (3) .............................................. M20x1.5 ............................................................25 Nm
Coolant temperature sensor (5) ............................. M16x1.5 ............................................................45 Nm
Charge-air temperature sensor (9)......................... M16x1.5 ............................................................45 Nm
Rail-pressure sensor (10)...................................... M18x1.5 ............................................................70 Nm
Fuel service centre pressure sensor (11)................ M14x1.5 ............................................................25 Nm
Oil pressure switch (12) ........................................ M18x1.5 ............................................................50 Nm
Oil level sensor (13).............................................. M22x1.5 ............................................................25 Nm
Removing and installing the coolant pipes

Hollow screw, coolant lines, air compressor (1) ...... M14x1.5 ............................................................35 Nm
Removing and installing the thermostat with thermostat housing

Removing and installing the coolant pump

Coolant line hollow screw...................................... M14x1.5 ............................................................35 Nm
Dismantling and assembling the coolant pump

Gap width between impeller (3) and coolant pump housing (1).......................................... 2.0 mm - 2.6 mm
Distance between impeller (3) and coolant pump housing (1)........................................ 33.1 mm - 33.3 mm
Projection, slide ring seal ............................................................................................ 10.0 mm - 10.2 mm
Removing and installing the power take-off

Mounting bolt (4) .................................................. M16x1.5x45-8.8 LH.......................Initial torque 100 Nm
Mounting bolt (4) .................................................. M16x1.5x45-8.8 LH..............................Final torque 90°
Removing and installing the air compressor

Air compressor pressure-relief valve...................... M26x1.5 ............................................................90 Nm
Air compressor pressure-relief valve opening
pressure .............................................................. M26x1.5 ............................................................ 17 bar
Hollow screw, air compressor coolant lines ............ M14x1.5 ............................................................35 Nm
Dismantling and assembling the air compressor

Pressure-relief valve (2) ........................................ M26x1.5 ............................................................90 Nm
Mounting bolt (6) .......................................................................................................Initial torque 100 Nm
Mounting bolt (6) ..............................................................................................................Final torque 90°
Elbow unions (1), (3)............................................. M26x1.5 ..........................................................100 Nm
Mounting bolt (4) .................................................. M8 x 80 ......................................... Initial torque 20 Nm
Mounting bolt (4) .................................................. M8 x 80 ...............................................Final torque 90°
Removing and installing the starter

Mounting bolt (3) .................................................. M10x35-10.9......................................................50 Nm
Mounting nut (4) ................................................... M10...................................................................50 Nm
Terminal 30 mounting nut on relay ......................... M10...................................................................24 Nm
Number of starter pinion teeth ...............................................................................................................12
Starter power .................................................................................................................... 5.0 kW at 24 V
Removing and installing the hydraulic pump belt drive

Removing and installing the alternators (2 alternators)

Terminal B+.......................................................... M8 ....................................................................13 Nm
Alternator operating voltage ...............................................................................................................28 V

TECHNICAL DATA
Removing and installing the alternator (1 alternator)

Terminal B+ on alternator (1) ................................. M8 ....................................................................15 Nm
Operating voltage, alternator (1) .........................................................................................................28 V

Mounting nut (5) ................................................... M14x1.5 ............................................................70 Nm

Removing and installing the injectors and rail

Mounting bolt (2) .................................................. M8x45 ............................................. Initial torque 2 Nm
Mounting bolt (2) .................................................. M8x45 ............................................ Final torque 30 Nm
Rail connection (8)................................................ M22x1.5 ........................................ Initial torque 10 Nm
Rail connection (8)................................................ M22x1.5 ......................................... Final torque 55 Nm
Mounting nut, injector cable .................................. M4 ...................................................................1.5 Nm
High-pressure line ................................................ M14x1.5 ........................................ Initial torque 10 Nm
High-pressure line (initial use) ............................... M14x1.5 ..............................................Final torque 60°
High-pressure line (re-use).................................... M14x1.5 ..............................................Final torque 30°
Mounting bolt, rail (5) ............................................ M8x55-8.8 .................................... Initial torque 1.5 Nm
Mounting bolt, rail (5) ............................................ M8x55-8.8 ...................................... Final torque 22 Nm
Rail-pressure sensor............................................. M18x1.5 ...........................................................70 Nm
Pressure-limiting valve.......................................... M18x1.5 ..........................................................100 Nm
Removing and installing the high-pressure pump

Mounting nut, drive gear (9) .................................. M18x1.5 ..........................................................105 Nm
Mounting bolt (2) ............................................................................................................................. 8 Nm
Mounting bolt (6) .................................................. M8x40 ...............................................................30 Nm
Mounting nut (4) ................................................... M8 ...................................................................30 Nm
High-pressure line tightening torque ...................... M14x1.5 ........................................ Initial torque 10 Nm
High-pressure line tightening torque ...................... M14x1.5 ..............................................Final torque 60°
Spacer ...........................................................................................................................................55 Nm
Overow valve tightening torque............................ M14x1.5 ............................................................30 Nm
Hollow screw........................................................ M14x1.5 ............................................................30 Nm
Dismantling and assembling the fuel service centre

Pressure sensor ................................................... M18 x 1.5 ..........................................................45 Nm
Cover (2)........................................................................................................................................20 Nm
Cover (11) ......................................................................................................................................10 Nm
Water drain plug .............................................................................................................................. 2 Nm
Removing and installing the ame start system

Flame glow plug ................................................... M20x1.5 ............................................................25 Nm
Fuel line union nut (4) ........................................... M10x1 ................................................................ 5 Nm
Removing and installing the engine control unit

Mounting bolt (5) .................................................. M6x35-10.9 ....................................................... 11 Nm
Bracket mounting bolt (3) ...................................... M8x40-10.9 .......................................................13 Nm
Removing and installing the turbocharger

Hollow screw, ring connector (4)............................ M14x1.5 ............................................................30 Nm
Removing and installing the intake pipe

Charge-air temperature sensor.............................. M16x1.5 ............................................................45 Nm

TECHNICAL DATA
Removing and installing the exhaust manifold

Mounting bolt (3) .................................................. M8x80-GA ..................................... Initial torque 25 Nm
Mounting bolt (3) .................................................. M8x80-GA ..................................... Final torque 2 x 45°
Mounting bolt, exhaust manifold ............................ M8x58-GA ..................................... Initial torque 25 Nm
Mounting bolt, exhaust manifold ............................ M8x58-GA ..................................... Final torque 2 x 45°
Mounting nut, exhaust manifold ............................. M8-GA ..............................................................27 Nm
Mounting bolt (4) .................................................. M8x55-8.8 .........................................................27 Nm
Mounting bolt, crane hook lug ............................... M10x25-GA .......................................................50 Nm

Cylinder head bolts............................................... 14x2 (E18)..................................... Initial torque 80 Nm
Cylinder head bolts............................................... 14x2 (E18)......................................2nd torque 150 Nm
Cylinder head bolts............................................... 14x2 (E18)............................................. 3rd torque 90°
Cylinder head bolts............................................... 14x2 (E18)............................................. 4th torque 90°
Cylinder head bolts............................................... 14x2 (E18)...........................................Final torque 90°

Machining dimension .................................................................................................................... 0.5 mm
Cylinder head height............................................................................................ 109.85 mm - 110.15 mm
Cylinder head height after machining .................................................................... 109.35 mm - 109.65 mm
Checking and setting the valve clearance (variant without EVB)

Lock nut on valve adjusting screw (3), (4) .............. M10x1-8.8 .........................................................40 Nm
Intake valve clearance ................................................................................................................ 0.50 mm
Exhaust valve clearance ............................................................................................................. 0.50 mm
Removing and installing the valve stem seals

Radial play, valve stem (intake) ...................................................................................... 0.020 - 0.049 mm
Radial play, valve stem (exhaust) ................................................................................... 0.035 - 0.069 mm
Valve lag (intake)...................................................................................................................0.3 - 0.6 mm
Valve lag (exhaust) ................................................................................................................0.6 - 0.9 mm

Camshaft gear mounting bolt (5) ........................... M10x38x1.25-10.9 .............................................65 Nm
Oil pump drive gear mounting nut (2) ..................... M12x1.5-6S .......................................................45 Nm


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

Inside diameter of camshaft bearings 1 - 4............................................................... Ø 54.910 - 54.940 mm
Outside diameter of camshaft bearing points............................................................ Ø 59.000 - 59.030 mm
Axial play ...................................................................................................................... 0.140 - 0.270 mm

Intake valve opens............................................................................................6° crank angle before TDC
Intake valve closes ........................................................................................... 32° crank angle after BDC
Exhaust valve opens.......................................................................................63° crank angle before BDC
Exhaust valve closes .........................................................................................13° crank angle after TDC

TECHNICAL DATA
Removing and installing the oil module (hanging oil lter)

Oil pressure transmitter (3).................................... M18x1.5 ............................................................50 Nm
Oil pressure sensor (2) ......................................... M18x1.5 ............................................................45 Nm
Removing and installing the oil sump

Oil excess pressure valve screw plug .................... M24x1.5-5.8 ......................................................60 Nm
Oil level sensor (4)................................................ M22x1.5 ............................................................25 Nm
Removing and installing the oil pump

Mounting nut, oil pump gear (2) ............................. M12x1.5-6S .......................................................45 Nm
Axial play, oil pump gears............................................................................................... 0.040 - 0.106 mm
Radial play, oil pump shaft ............................................................................................ 0.050 - 0.078 mm
Removing and installing the oil injector nozzles

Oil pressure valve ................................................ M12...................................................................40 Nm
Removing and installing the vibration damper

Mounting bolt (1) .................................................. M14x1.5-10.9................................Initial torque 150 Nm
Mounting bolt (1) .................................................. M14x1.5-10.9.......................................Final torque 90°
Removing and installing the ywheel (variant with clutch)

Flywheel lateral runout..........................................................................................................max. 0.5 mm
Flywheel ring gear installation temperature .............................................................................. 200-230 °C
Land height ............................................................................................................................max. 5 mm
Removing and installing the ywheel (variant with Allison gearbox)

Lateral runout, ywheel (1)....................................................................................................max. 0.5 mm
Installation temperature, ywheel ring gear .............................................................................. 220-240 °C

Connecting rod bearing bolts (1)............................ M11x1.5x60-11.9............................ Initial torque 50 Nm
Connecting rod bearing bolts (1)............................ M11x1.5x60-11.9..................................Final torque 90°

Conrod length, middle of conrod eye to middle of conrod bearing......................................... 196 ± 0.02 mm
Inside diameter of conrod eye ................................................................................. Ø 44.050 - 44.066 mm
Crank pin width ............................................................................................................. 36.78 - 36.88 mm
Bore for bearing shells in connecting rod .....................................................................Ø 74.00 - 74.20 mm
Weight difference per set of connecting rods in an engine............................................................max. 50 g

Connecting rod bearing normal dimension ............................................................... Ø 69.981 - 70.000 mm
Connecting rod bearing normal dimension I ............................................................. Ø 69.881 - 69.900 mm
Connecting rod bearing repair level 1 ...................................................................... Ø 69.731 - 69.750 mm

Connecting rod bearing thickness normal dimension ...................................................................1.975 mm
Connecting rod bearing thickness normal dimension I .................................................................2.025 mm
Connecting rod bearing thickness repair level I ...........................................................................2.100 mm



Overall height..........................................................................................................................103.00 mm

TECHNICAL DATA
Piston height from middle of piston pin to piston crown / PH level 0 .................................. 63.85 - 63.90 mm

Ring gap ........................................................................................................................... 0.35 - 0.50 mm

Piston ring height............................................................................................................... 2.47 - 2.50 mm
Ring gap ........................................................................................................................... 0.50 - 0.65 mm

Ring gap ...............................................................................................................................0.3 - 0.6 mm

Piston pin diameter................................................................................................. Ø 43.994 - 44.000 mm

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

Piston weight difference per set in one engine.............................................................................max. 40 g
Removing and installing the mass compensation gear

Axial play, shafts................................................................................................................ 0.08 - 0.25 mm

Mounting bolt (4) .................................................. M14x118-10.9 ...............................Initial torque 115 Nm
Mounting bolt (4) .................................................. M14x118-10.9 ......................................Final torque 90°
Connecting rod bearing bolts................................. M11x1.5x60-11.9............................ Initial torque 50 Nm
Connecting rod bearing bolts................................. M11x1.5x60-11.9..................................Final torque 90°

Crankshaft hardness............................................................................................................... 53 ± 3 HRC
Permitted curvature of journals...................................................................................................0.004 mm
Crankshaft axial play ..................................................................................................... 0.150 - 0.282 mm
Journal normal dimension ....................................................................................... Ø 86.978 - 87.000 mm
Journal normal dimension I ..................................................................................... Ø 86.878 - 86.900 mm
Journal repair level I ............................................................................................... Ø 86.738 - 86.750 mm
Journal repair level II .............................................................................................. Ø 86.238 - 86.250 mm
Journal repair level III ............................................................................................. Ø 85.738 - 85.750 mm
Journal repair level IV ............................................................................................. Ø 85.238 - 85.250 mm

Wall thickness, crankshaft bearing, repair level I (1), (2)...............................................................2.593 mm
Wall thickness, crankshaft bearing, repair level II (1), (2)..............................................................2.718 mm
Wall thickness, crankshaft bearing, repair level III (1), (2).............................................................2.843 mm
Wall thickness, crankshaft bearing, repair level IV (1), (2) ............................................................2.968 mm
Thrust washer, normal dimension (5), (7) ....................................................................................2.850 mm
Thrust washer, repair level I (5), (7) ............................................................................................3.100 mm
Spread......................................................................................................................................... 0.5 mm
Removing and installing the timing case cover

Oil ller neck ........................................................ M38x1.5 ............................................................35 Nm

Man Engine Shop Manual - D0834 Loh 40

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Common-rail In-line Engines

Copy deadline: 01.2016

Common-rail In-line Engines

We reserve the right to make modications in the course of further development.

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© 2010 MAN Nutzfahrzeuge AG

Redaktion: SAWDT, 2W Technische Informations GmbH, 10.2009

Satz: SAWDT, 2W Technische Informations GmbH

2 A89 Stage 2 2st edition

Safety instructions ........................................................................................................ 9

Engine electrics .......................................................................................................... 25

Coolant pipes ............................................................................................................. 29

Power take-off ............................................................................................................ 45

Injectors and rail ......................................................................................................... 91

A89 Stage 2 2st edition 3

Removing and installing the ame start system ............................................................. 127

Charge-air manifold ................................................................................................... 135

Intake pipe .............................................................................................................. 145

Rocker arm mechanism .............................................................................................. 155

Timing gears ............................................................................................................ 185

Oil module .............................................................................................................. 203

Vibration damper ...................................................................................................... 223

4 A89 Stage 2 2st edition

Crankshaft oil seals

Crankshaft oil seals ................................................................................................... 265

Crankcase ventilation ................................................................................................. 275

Technical Data 289

A89 Stage 2 2st edition 5

A89 Stage 2 2st edition 7

8 A89 Stage 2 2st 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 compressed natural gas (CNG) system

Working on the compressed natural gas (CNG) system

A89 Stage 2 2st edition 9

Operating the engine

Attachments and special bodies

Working on high-pressure lines

Checking injector nozzles

Working on the vehicle electrical system

Be careful as battery gases are explosive!

Caution! Battery acid is poisonous and corrosive!

10 A89 Stage 2 2st edition

Working on plastic tubes – Danger of damage and re!

Working with the cab tilted

Working on the air-conditioning system

Working on airbag or belt tensioner units

A89 Stage 2 2st edition 11

Working on the independent heater

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

Service products and excipients

12 A89 Stage 2 2st edition

Cleaning the cooling circuit

Cleaning the lter insert

Used engine/gear oil

5. Special information for working on the common-rail system

A89 Stage 2 2st edition 13

Information for people with pacemakers

Danger of damage due to dirt ingress