Man D2066 - LOH01 - 12

Common rail In-line Engine
D2066 LOH01 - LOH08

D2066 LOH10 - LOH12
Copy deadline: 07.2015
Repair manual
81.99185-5342 4th edition A 41 Stage 2
MAN Truck & Bus AG Repair manual A 41 Stage 2, 4th edition
Dachauer Str. 667 Common rail In-line Engine
80995 MÜNCHEN D2066 LOH01 - LOH08
or D2066 LOH10 - LOH12
Postfach 50 06 20 - Englisch -
80976 MÜNCHEN Printed in Germany
Repair manual A 41 Stage 2
4th edition
Common rail In-line Engine

D2066 LOH01 - LOH08
D2066 LOH10 - LOH12
81.99185-5342
1
PREFACE/PUBLICATION DATA
PREFACE
These instructions are intended as a guide to help perform repair work on vehicles and units correctly.
This publication assumes that persons who use it possess the requisite technical knowledge in handling
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always corre-
spond to the unit in question, but this does not necessarily mean they are incorrect. In such cases, plan and
carry out the repair work in accordance with the sense of the instructions.
Repair work on complex add-on units should be entrusted to our customer service or to the customer service
of the manufacturing company. These units are mentioned specifically in the text.
The repair work is broken down into chapters and sub-chapters. Each subsection begins with a preliminary
page The preliminary page contains a summary of the main prerequisites for the repair section in question.
This preliminary page may be followed by a detailed description of the work.
Important instructions concerning technical safety and the safety of personnel are specifically highlighted, as
indicated below.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed in order to avoid exposing
people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed in order to avoid material
damage or destruction.
Note
An explanatory note which is useful for understanding the working or operating procedure to be
performed.
Comply with general safety regulations when performing any repair work.
We reserve the right to make modifications in the course of further development.
Yours faithfully,
MAN Truck & Bus AG
Munich plant
PUBLICATION DATA
© 2015 MAN Truck & Bus AG
Not to be reprinted, duplicated by any means whatsoever or translated – in whole or in part – without the
prior written approval of MAN Truck & Bus AG. All rights under the copyright law are strictly reserved by MAN
Truck & Bus AG. If any changes or modifications are made without the written approval of MAN Truck & Bus
AG, then MAN Truck & Bus AG shall not be liable for any material defects attributable to the unauthorised
changes or modifications. MAN Truck & Bus AG is not liable for any damage attributable to unauthorised
changes or modifications.
Editorial Department: SAWDS, 2W Technische Informations GmbH & Co. KG, 07.2015
Typesetting: SAWDS, 2W Technische Informations GmbH & Co. KG
Printing: MAN-Werksdruckerei
2 A 41 Stage 2 4th edition

TABLE OF CONTENTS
Content Chapter/Page
Index 7
Introduction
Safety instructions ....................................................................................................... 11

The engine ................................................................................................................ 18
Model plate/Model designation .................................................................................... 18
Characteristic data .................................................................................................. 20
Description of engine ............................................................................................... 25
Engine electronics
Engine electronics ....................................................................................................... 31

Removing and installing the engine electrical system ........................................................ 31
Cooling system
Coolant manifold ......................................................................................................... 35

Remove and install coolant manifold (version without retarder) ............................................ 35
Removing/installing the coolant manifold (version with retarder) ........................................... 40
Thermostats .............................................................................................................. 45
Removal and installation the thermostats ....................................................................... 45
Thermostat housing ..................................................................................................... 47
Removing and installing the thermostat housing .............................................................. 47
Coolant pump ............................................................................................................ 51
Removing and installing the coolant pump ..................................................................... 51
Distributor housing ...................................................................................................... 55
Removal and installation the distributor housing .............................................................. 55
Mounted components
Air compressor ........................................................................................................... 59

Removal and installation of the 1-cylinder air compressor ................................................... 59
Removing and installing the 1-cylinder air compressor with steering and hydraulic pump ............ 66
Removing and installing the 1-cylinder air compressor with two steering pumps ........................ 74
Removing and installing of 1-cylinder air compressor with power steering pump and two
hydraulic pumps ..................................................................................................... 82
Removing and installing 1-cylinder air compressor with two power-steering pumps and
hydraulic pump ....................................................................................................... 91
Removing and installing 2-cylinder air compressor with power steering pump .......................... 99
Removing and installing the 2-cylinder air compressor with steering and hydraulic pump .......... 105
Removing and installing 2-cylinder air compressor with two power-steering pumps and
hydraulic pump ..................................................................................................... 112
Removing and installing of 2-cylinder air compressor with power steering pump and two
hydraulic pumps ................................................................................................... 119
Dismantling and assembling 1-cylinder air compressor .................................................... 126
Dismantling and assembling 2-cylinder air compressor .................................................... 138
Starter ................................................................................................................... 151
Removal and installation of the starter ........................................................................ 151
Belt drive ................................................................................................................ 153
Removing and installing belt drive .............................................................................. 153
Alternators .............................................................................................................. 159
Removing and installing alternators 1 and 2 .................................................................. 159
Removing and installing alternator 3 ........................................................................... 167
Refrigerant compressor .............................................................................................. 173
Removal and installation of the coolant compressor ........................................................ 173
A 41 Stage 2 4th edition 3

TABLE OF CONTENTS
Common Rail system
Injectors and pressure pipe .......................................................................................... 181

Protective sleeves for injectors and pressure pipe .......................................................... 181
Removing and installing the injectors and pressure pipe .................................................. 184
High-pressure pump/high-pressure pump drive ................................................................. 197
Protective sleeves for high-pressure pump/high-pressure pump drive .................................. 197
Removing and installing the high pressure pump/high pressure pump drive (fuel-lubricated) ...... 199
Removing and installing the high pressure pump/high pressure pump drive (fuel-lubricated) ...... 207
High pressure pump/high pressure pump drive disassembly and assembly ........................... 215
Fuel service centre .................................................................................................... 223
Protective sleeves for fuel service centre ..................................................................... 223
Removal and installation of the fuel service centre ......................................................... 225
Dismantling and assembling the fuel service centre ........................................................ 229
Flame-start system .................................................................................................... 235
Flame-start system protective sleeves ........................................................................ 235
Removing and installing the flame-start system ............................................................. 237
Engine control unit .................................................................................................... 241
Removal and installation of the engine control unit ......................................................... 241
Turbocharging
Charge-air pipes ....................................................................................................... 247

Remove and install the charge air pipe ........................................................................ 247
Turbocharger ........................................................................................................... 253
Removal and installation of the turbocharger ................................................................ 253
Intake/exhaust system
EGR module ............................................................................................................ 263

Removing and installing the EGR module without an intermediate plate ............................... 263
Removing and installing the EGR module with intermediate plate ....................................... 270
Dismantling and assembling EGR module without intermediate plate ................................... 276
Dismantling and assembling the EGR module with intermediate plate .................................. 281
Exhaust manifold ...................................................................................................... 287
Removal and installation of the exhaust manifold ........................................................... 287
Cylinder head
Cylinder head .......................................................................................................... 293

Removal and installation of the cylinder head ................................................................ 293
Checking and adjusting valve clearance ...................................................................... 305
Removal and installation the valve-stem seal ................................................................ 312
Valve control
Camshaft/camshaft bearing ......................................................................................... 325

Remove and fit camshaft/camshaft bearing .................................................................. 325
Valve timing ............................................................................................................. 341
Checking the valve timing ........................................................................................ 341
Timing gears
Front drive gears ....................................................................................................... 349

Removal and installation of front drive gears ................................................................. 349
Rear timing gears ...................................................................................................... 357
Removing and installing rear timing gears (Version crankshaft seal flywheel) ......................... 357
Removing, installing the timing gear (crankshaft seal, crankshaft gear Version) ...................... 371

TABLE OF CONTENTS
Engine lubrication
Oil module .............................................................................................................. 387

Removal and installation of the oil module .................................................................... 387
Oil sump and oil intake pipe ......................................................................................... 395
Removing and installing the oil sump and oil intake pipe .................................................. 395
Disassembling and assembling the oil sump ................................................................. 400
Oil injector nozzles .................................................................................................... 401
Removing and installing the oil nozzle ......................................................................... 401
Oil pump ................................................................................................................. 403
Removal and installation the oil pump ......................................................................... 403
Crankshaft seals
Crankshaft seals ....................................................................................................... 417

Removal and installation of front crankshaft seal ............................................................ 417
Removal and installation of rear crankshaft seal (crankshaft seal version flywheel) .................. 423
Removing, installing the rear crankshaft seal for Crankshaft gear with stud ........................... 428
Crankshaft drive
Vibration damper ...................................................................................................... 435

Removal and installation of the vibration damper ........................................................... 435
Manually operated gearbox flywheel (Flywheel crankshaft seal version) ................................... 439
Removal and installation of the gearbox flywheel (Flywheel crankshaft seal) .......................... 439
Flywheel of automatic gearbox (crankshaft seal flywheel version) ........................................... 449
Removing and installing flywheel of automatic gearbox (crankshaft seal flywheel version) ......... 449
Gearbox flywheel (crankshaft seal crankshaft gear version) .................................................. 455
Removing and installing flywheel (crankshaft seal crankshaft gear version) for manually
operated gearboxes ............................................................................................... 455
Automatic gearbox flywheel (crankshaft seal crankshaft gear version) ..................................... 465
Removing and installing flywheel (with race) for the automatic gearbox ................................ 465
Dual-mass flywheel (crankshaft seal crankshaft gear version) ................................................ 471
Removing and installing dual-mass flywheel (crankshaft seal crankshaft gear version) ............. 471
Piston and connecting rod ........................................................................................... 477
Removal and installation of piston and connecting rod ..................................................... 477
Crankshaft .............................................................................................................. 491
Removal and installation of crankshaft ........................................................................ 491
Engine case
Flywheel housing/timing case ....................................................................................... 505

Removing and installing flywheel housing/timing case ..................................................... 505
Cover .................................................................................................................... 507
Removal and installation cover ................................................................................. 507
Cylinder liners .......................................................................................................... 509
Removal and installation the cylinder liner .................................................................... 509
Engine brake system
engine brake ............................................................................................................ 517

Removal and installation the engine brake ................................................................... 517
Technical Data
Technical Data 521

INDEX
Index Page
A
Air compressor, 1-cylinder
Connector................................................................................................................................................. 85
Cover...................................................................................................................................................... 128
Crankshaft .............................................................................................................................................. 132
Cylinder head ......................................................................................................................................... 129
Drive wheel mounting bolts .................................................................................................................... 129
Fins......................................................................................................................................................... 130
Hydraulic pump ........................................................................................................................................ 85
Installation advice..................................................................................................................................... 63
Moulded hose........................................................................................................................................... 37
Piston ..................................................................................................................................................... 131
Piston pins.............................................................................................................................................. 131
Piston rings............................................................................................................................................. 131
Power steering pump ............................................................................................................................... 61
Power steering pump 2 ............................................................................................................................ 85
Pressure relief valve................................................................................................................................. 62
PTO shaft ............................................................................................................................................... 132
Valve plate.............................................................................................................................................. 130
Air compressor, 2-cylinder
Cover...................................................................................................................................................... 140
Crankshaft .............................................................................................................................................. 144
Cylinder head ......................................................................................................................................... 142
Drive wheel mounting bolts .................................................................................................................... 141
Fins......................................................................................................................................................... 143
Hydraulic pump ...................................................................................................................................... 114
Piston ..................................................................................................................................................... 143
Piston pins.............................................................................................................................................. 144
Piston rings............................................................................................................................................. 144
Power steering pump 2 .......................................................................................................................... 114
PTO shaft ............................................................................................................................................... 144
Valve plate.............................................................................................................................................. 142
Alternator 2
Bracket for alternator.............................................................................................................................. 164
B
Belt drive
Ribbed V-belt tensioner .......................................................................................................................... 154
Ribbed V-belt tensioner bracket ............................................................................................................. 154
C
Camshaft
Axial play ................................................................................................................................................ 332
Camshaft bearing shells......................................................................................................................... 334
Camshaft gear wheel ............................................................................................................................. 334
Cover...................................................................................................................................................... 336
Intermediate gear wheel......................................................................................................................... 336
Radial play.............................................................................................................................................. 333
Coolant manifold
Temperature sensor ................................................................................................................................. 43
Crankshaft
Axial compensation ................................................................................................................................ 497
Axial play ................................................................................................................................................ 496
Bearing cover ......................................................................................................................................... 497
Connecting rod bearing journals ............................................................................................................ 499
crankshaft bearing pin ............................................................................................................................ 499
Crankshaft drive
Race ....................................................................................................................................................... 427
Cylinder head .............................................................................................................................................. 316

INDEX
Engine timing.......................................................................................................................................... 338

Rocker arm mechanism ......................................................................................................................... 299
Tightening sequence .............................................................................................................................. 302
Valve crossheads ................................................................................................................................... 303
Cylinder liners
Cylinder liner stand out........................................................................................................................... 513
O-rings.................................................................................................................................................... 512
D
Drive gears
Backlash on the crankshaft gear/intermediate gear for the high-pressure pump drive .......................... 351
Crankshaft gear wheel ........................................................................................................................... 352
E
EGR module
Check valves .......................................................................................................................................... 283
Connecting tube ..................................................................................................................................... 265
EGR adjusting cylinder........................................................................................................................... 266
Heat shield ............................................................................................................................................. 265
Shut-off flap ............................................................................................................................................ 284
Unscrewed conduit................................................................................................................................. 265
engine brake
Air pipes ................................................................................................................................................. 255
Positioning cylinder ................................................................................................................................ 519
Proportional valve................................................................................................................................... 519
Exhaust manifold
Heat shields............................................................................................................................................ 288
F
Flame-start system
Flame glow plug ..................................................................................................................................... 239
Solenoid valve ........................................................................................................................................ 239
Flywheel
starter ring gear ...................................................................................................................................... 460
Fuel service centre (KSC)
Bracket ................................................................................................................................................... 228
Fuel lines ................................................................................................................................................ 227
hand pump ............................................................................................................................................. 232
Heater element....................................................................................................................................... 231
Pressure sensor ..................................................................................................................................... 231
H
High-pressure pump
Fuel pump .............................................................................................................................................. 217
Installation instructions for high-pressure pump drive ............................................................................ 212
Metering unit........................................................................................................................................... 217
Radial shaft seal..................................................................................................................................... 220
High-pressure system
Extracting the injector............................................................................................................................. 191
High-pressure line high pressure pump-pressure pipe .......................................................................... 189
Injector cable harness ............................................................................................................................ 191
Pressure pipe ......................................................................................................................................... 189
Pressure pipe socket.............................................................................................................................. 190
Rail pressure sensor .............................................................................................................................. 190
O
Oil module
Drain the coolant .................................................................................................................................... 389
Oil cooler ................................................................................................................................................ 390
Pressure relief valve............................................................................................................................... 390
Oil pump
Axial play ................................................................................................................................................ 406

INDEX
Backlash on the crankshaft gear/ring gear............................................................................................. 406

Radial play.............................................................................................................................................. 406
Oil sump
Oil dipstick .............................................................................................................................................. 397
Oil drain pipe .......................................................................................................................................... 397
Oil filler tube ........................................................................................................................................... 397
Oil intake pipe......................................................................................................................................... 397
Oil return line .......................................................................................................................................... 397
P
Piston and connecting rod
Axial play ................................................................................................................................................ 482
Connecting rod bearing cap ................................................................................................................... 483
Piston pins.............................................................................................................................................. 483
Piston ring axial play .............................................................................................................................. 484
Piston rings............................................................................................................................................. 484
Radial play.............................................................................................................................................. 482
R
Refrigerant compressor
Bracket ................................................................................................................................................... 176
Ribbed V-belt
Guide rollers ........................................................................................................................................... 154
S
Safety instructions ......................................................................................................................................... 11
General..................................................................................................................................................... 11
T
Thermostat housing
Coupling pipes.......................................................................................................................................... 48
Timing gears
Air compressor intermediate gear .......................................................................................................... 367
Air compressor intermediate gear axial play .......................................................................................... 366
Air compressor intermediate gear radial play......................................................................................... 381
Axial play of small intermediate gear...................................................................................................... 378
Backlash on the crankshaft gear/large intermediate gear ...................................................................... 375
Camshaft intermediate gear ................................................................................................................... 378
Crankshaft gear wheel ........................................................................................................................... 380
Crankshaft intermediate gear ................................................................................................................. 376
Large intermediate gear axial play ......................................................................................................... 376
Large intermediate gear radial play........................................................................................................ 362
Radial play intermediate gear camshaft ................................................................................................. 364
Tooth backlash of the small intermediate gear/large intermediate gear ................................................. 361
Turbocharger
Oil pressure line ..................................................................................................................................... 255
Oil return line .......................................................................................................................................... 255
V
Valve clearance
Engine in the setting position ................................................................................................................. 307
Forcing the engine oil out of the valve crosshead .................................................................................. 308

INTRODUCTION
INTRODUCTION
SAFETY INSTRUCTIONS
General
Only trained personnel are permitted to perform operating, maintenance or repair work on trucks and buses
/coaches.
The following sections include summaries of important regulations listed according to major topics. These
must be observed, in order to avoid accidents which could lead to injury, damage and environmental pollu-
tion. Please note that these are merely brief extracts taken from various accident prevention regulations. Of
course, all other safety regulations must be followed and the necessary measures must be taken.
Additional references to danger are contained in the instructions at points where there is a potential danger.
Accidents may happen 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 limbs, etc.
1. Regulations to prevent accidents with personal injury
During inspection, adjustment and repair work

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

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

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

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

INTRODUCTION
Operating the engine

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

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

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

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

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

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

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

INTRODUCTION
– Only measure voltage with suitable measuring devices! The input resistance of the measurement device
must be at least 10 MΩ.
– Connect and/or disconnect the plug connectors of electrical control units only when the ignition is switched
off.
Electric welding
– Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number 80.78010.0002) as de-
scribed in the instructions accompanying the device.
– If this device is not available, disconnect the batteries and firmly connect the positive cable to the earth
cable in order to make a conductive connection.
– Move the manually operated main battery switch to the driving mode position. If an electronic battery
master switch is fitted, 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 load consumers
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.
When welding is complete, first switch off all consumers and remove all jumpered connections (reset to
original condition) before connecting the batteries.
– Always earth the welding equipment as close as possible to the welding area. Do not lay the cables of the
welding equipment parallel to electrical cables in the vehicle.
Work on plastic tubes – risk of damage and fire

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

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

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

– Work on airbags or belt pre-tensioner units must only be performed by personnel that can provide proof of
a specialist course at the MAN Service Academy.
– Mechanical loads, impacts, heating to over 140°C, electrical pulses and electrostatic discharge may trigger
unwanted ignition of the airbag or belt pre-tensioner units.
– Hot gases are released explosively when the airbag or belt pre-tensioner units are triggered. Airbag or belt
pre-tensioner units that are not fitted may be catapulted around uncontrollably. This poses an injury risk to
people in or near the cab.
– Risk of burning when touching the hot surfaces after the airbag has been triggered.
– Do not open a triggered airbag or air cushion.
– Do not touch a triggered airbag with a destroyed air cushion with your bare hands. Wear nitrile rubber
gloves.
– Before performing any work and inspections on the airbag or belt pre-tensioner units, or working on the
vehicle where impacts are likely, it is necessary to switch off the ignition, remove the key from the ignition
lock, disconnect the earth cable from the battery and disconnect the plug connector for the airbag and belt
pre-tensioner power supply.
– Fit the driver airbag restraint system, MAN item number 81.66900-6035, to the airbag steering wheel as
instructed in the Operator's Manual.
– Only perform inspections on airbag and belt pre-tensioner units with devices specifically intended for this
purpose. Do not use inspection lamps, voltmeters or resistance meters.

INTRODUCTION
– After having finished all work and inspections, switch off the ignition first, then connect the plug connector(s)
for the airbag and belt pre-tensioner and, as a last step, connect the battery. There must be no-one in the
cab whilst this work is going on.
– Only place airbag units individually, with the impact cushion facing up.
– Do not apply grease or cleaning agents to airbags and belt pre-tensioners.
– Only store and transport airbag and belt pre-tensioner units in their original packaging. Transport in the
passenger compartment is not permitted.
– Airbag and belt pretensioner units may only be stored in storage areas that can be locked, and up to a
maximum of 200 kg.
Working on the independent heating

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

Avoid extended, excessive or repeated skin contact with service products, process materials, diluting agents
and solvents. Protect your skin using a suitable skin protection agent or protective gloves. Do not use service

INTRODUCTION
products, excipients, thinners or solvents to clean the skin. Apply a greasy skin cream after cleaning your
skin.
Service products and process materials

Do not use any containers intended for food or beverages to drain and store service products or process
materials. 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).
Clean the cooling circuit

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

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

Lengthy or repeated skin contact with any type of engine/gearbox oil removes grease from the skin. This
can cause dry skin, irritation or skin inflammation. In addition to these hazards, used engine oil contains
dangerous materials which can trigger dangerous skin diseases. Wear gloves, especially when changing the
oil.
Dealing with AdBlue®

AdBlue® is a synthetically produced 32.5 % urea water solution used as an NOx reduction additive for diesel
engines with an SCR catalytic converter. AdBlue® is not a hazardous substance but does decompose into
ammonium hydroxide and carbon dioxide when stored for prolonged periods. For this reason, AdBlue® is
classified as a water hazard (water hazard class 1) in Germany and is not allowed to enter sewage or the
ground. Ensure good ventilation in the 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 finishing work. If your skin comes into contact with
AdBlue®, wash the skin using water and a skin cleaner, change out of dirty clothes immediately. If the skin
is irritated, consult a doctor. If AdBlue® 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. Information about working on the common rail system
General
– Fuel jets can cut through the skin. Risk of fire due to fuel atomisation.
– Never undo the bolt connections on the high fuel pressure side of the Common Rail system when the engine
is running (high-pressure line from the high-pressure pump to the rail, at the rail and on the cylinder head
to the fuel injector). Whilst the engine is running, the lines are constantly 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.
– Do not remain in the vicinity of the engine when it is running.
– Do not touch the live parts at the injector electrical connection whilst the engine is running.
– Any change to the original wiring may lead to the limit values of the heart pacemaker regulations being
exceeded, e.g. untwisted fuel injector wiring or insertion of a break box (terminal tester).
– Vehicle operators and persons with heart pacemakers are not at risk from systems with MAN Common Rail
engines in approved operation.

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

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

– The components of the diesel fuel-injection system consist of high-precision parts that are subjected to
extreme loads. Due to the highly precise nature of this technology, all work on the fuel system requires the
highest possible degree of cleanliness.
– Even dirt particles over 0.002 mm can cause component failure.
Before starting work on the clean side

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

– It is not permitted to use compressed air for cleaning.
– Loose dirt must be removed during assembly work using a suitable suction device (industrial vacuum
cleaner).
– Only lint-free cleaning cloths are allowed to be used on the fuel system.
– Clean tools and working equipment before starting work.
– Only tools that are not damaged (e.g. cracked chromium plating) must be used.
– Materials such as cloths, cardboard or wood must not be used when removing and fitting components, as
particles and fibres may become detached from such materials.
– If paint flakes should be produced when undoing connections (e.g. due to painting over the connections),
these must be carefully removed before the bolt connection is finally undone.
– All removed components on the clean side of the fuel system must be plugged immediately at their con-
nection openings using suitable caps.
– These sealing parts must remain packaged dust-tight until use and must be disposed of after being used
once.
– The components must then be stored carefully in a clean, closed container.
– Cleaning or test fluids that have already been used must not be used for these components.
– New parts must only be taken out of the original packaging immediately before use.
– Work on removed components must be performed only at a work place equipped for this purpose.
– If removed parts are shipped, always use the original packaging of the new part.
When performing the work on bus/coach engines, it is essential that the following measures are also ob-
served:

INTRODUCTION
Risk of damage due to ingress of dirt

– Before opening the clean-side fuel system:
Clean the engine areas around the pressure sockets, fuel-injection lines, rail and cylinder head cover with
compressed air.
– Remove the cylinder head cover and then clean the engine areas around the pressure sockets, fuel-injection
lines and rail once again.
– First only loosen the pressure pipe sockets:
Loosen the pressure pipe socket union nuts and unscrew four turns.
Lift the pressure pipe sockets with a special tool.
Reason: only fully remove the pressure pipe sockets when the fuel injectors have already been dismantled
so that no dirt can fall into the fuel injectors from above.
– Remove the fuel injectors.
– After removal, rinse out the injectors (with the high-pressure connection hole pointing downwards) using a
cleaning fluid.
– Remove the pressure pipe sockets; to do this, unscrew the pressure pipe socket union nut.
– Clean the injector bore in the cylinder head.
6. Emergency running program on assemblies with electronic control units
General information
The units have an electronic control system that monitors itself (self-diagnostics) and the unit.
As soon as there is a malfunction, the malfunction is evaluated and one of the following measures is initiated:
– Output of an SPN message with a diagnostic memory entry.

– Changeover to suitable, yet limited operation. Have malfunctions remedied by MAN after-sales immedi-
ately.
– The diagnostic memory entry is output directly in conjunction with MAN-cats.
7. Assembly information
Assembling pipes
– Pipes must not be mechanically deformed during assembly work; risk of fracture.
Mounting gaskets
– Only use MAN genuine gaskets
– Make sure that the areas to be sealed are undamaged and clean.
– Do not use adhesive agents or sealing agents. If necessary, to facilitate installation, use a little grease to
stick the seal to the part to be mounted.
– Tighten the bolts evenly to the specified tightening torque.
Mounting O-rings
– Only use MAN genuine O-rings.
– Make sure that the areas to be sealed are undamaged and clean.
Engine overhaul
– The engine's service life is influenced by very different factors. It is therefore not possible to indicate the
exact number of operating hours or miles before a major overhaul is due.
– We are of the opinion that opening an engine or performing a general overhaul is not required, as long as
the engine has good compression values and the following operating values do not deviate considerably
from those determined at start-up.
– Charging pressure
– Exhaust gas temperature
– Coolant and lubricating oil temperatures
– Oil pressure and oil consumption
– Smoke behaviour
The following criteria have considerable influence on the engine's service life:
– Correct performance setting according to deployment
– Correct installation
– Approval of the installation by authorised personnel
– Regular maintenance according to the maintenance schedule

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

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

Rework levels apply to crankshaft bearings, connecting rod bearings, pistons and cylinder liners. The rework-
ing subassemblies are indicated on the model plate, e. g.
P = crankshaft - connecting rod bearing NI or NII
H = crankshaft - crankshaft bearing NI or NII
Explanation of the engine no. (Engine identification number)
Motor-Nr./Engine-No. Classification terms (assignment)
504 Model number according to model code

1380 Day of assembly
315 Assembly order (sequential number on day of assembly)
1390 The last four digits of the engine no. are production and equipment-specific
data
Explanation of model designation
Model designa- Explanation Example

tion
D Fuel type Diesel

20 Figure + 100 120 mm bore
6 (Figure x 10) +100 160 mm stroke (rounded)
6 Number of cylinders 6 cylinders

INTRODUCTION
L Turbocharging with turbocharging and intercooler
OH Engine installation Engine/stationary/bus-rear mounting

02 Model identifier Rating/speed/approval

INTRODUCTION
Characteristic data
D2066 LOH01
Designation Unit Figures
Emission category Euro 4

Number of cylinders/arrangement 6 cylinder/in-line/upright
Valves per cylinder 4
engine weight dry kg 1043
Injection system Common Rail/EDC 7
Direction of rotation as viewed onto flywheel Left
Rated output to ISO 1585-88/195 EEC kW/hp 235/320
Bore mm 120
Stroke mm 160
Displacement cc 10518
Firing order 1-5-3-6-2-4
Nominal rpm rpm 1400-1900
Low idling speed rpm 550
Max. torque at engine speed Nm rpm 1600 Nm at 1000-1400 1/min
D2066 LOH02

Injection system Common rail / EDC 7
Bore mm 120
Stroke mm 160
D2066 LOH03


INTRODUCTION

Bore mm 120
Stroke mm 160
Nominal rpm rpm 1900
D2066 LOH04

Bore mm 120
Stroke mm 160
D2066 LOH05

Bore mm 120
Stroke mm 160

INTRODUCTION

D2066 LOH06

Bore mm 120
Stroke mm 160
D2066 LOH07

Bore mm 120
Stroke mm 160
D2066 LOH08


INTRODUCTION

Bore mm 120
Stroke mm 160
D2066 LOH10

Bore mm 120
Stroke mm 160
D2066 LOH11

Bore mm 120
Stroke mm 160

INTRODUCTION

D2066 LOH12

Bore mm 120
Stroke mm 160

INTRODUCTION
Description of engine
(1) Coolant manifold (15) 2-cylinder air compressor

(2) Flame glow plug (16) Power steering pump 1
(3) Oil module (17) Hydraulic pump
(4) EGR module (18) Fuel Service Centre (KSC)
(5) Turbocharger (19) Pressure pipe
(6) EGR adjusting cylinder (20) Power steering pump 2
(7) Coolant manifold (21) Fuel supply pump
(8) Cylinder head cover (22) High pressure pump
(9) Cable duct cover (23) Alternator 3
(10) EDC control unit (electronic diesel control) (24) Alternator 2
(11) Coolant manifold (Retarder version) (25) Cylinder head
(12) Flywheel housing/timing case (26) Charge-air manifold
(13) Moulded hose (27) Thermostat manifold
(14) Cylinder head air compressor (28) Alternator 1
Engine, general
The engines described here are liquid-cooled, turbocharged 6-cylinder, 4-stroke diesel engines with exhaust
turbocharging that meet the Euro 3 and 4 emission standards.
The engines operate using the Common Rail high-pressure injection system in conjunction with EDC 7
(Electronic Diesel Control).
OBD (On-board diagnosis)

OBD is an abbreviation for on-board diagnosis. The on-board diagnostics system is a diagnostic system for
emissions monitoring that is integrated in the vehicle. It has to be capable of displaying malfunctions and
their causes by means of error codes stored in its memory.

INTRODUCTION
Its functions include the monitoring of the exhaust gas recirculation and the NOx content in the exhaust system
using a NOx sensor.
Engine monitoring
Various sensors monitor the engine. The sensors are speed and temperature sensors, e. g., 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
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 mono block casting made from special cast iron. The wet cylinder
liners made from special, highly wear-resistant centrifugal casting are exchangeable. The cylinder liners are
sealed using elastomer sealing rings. At the rear of the crankcase, there is a flywheel housing/timing case.
At the front of the crankcase, there is a cover. The flywheel housing/timing case and cover are made of
aluminium. The crankshaft oil seals are installed in the cover and in the flywheel housing/timing case. 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 eight cast counterweights to
balance the masses. The crankshaft is mounted in 7 bearings in the crankcase. The crankshaft journals
and crank pins are mounted in ready-to-install three-component bearings. They are axially mounted in thrust
washers inserted in the crankcase at the 6th bearing seat. The connecting rod bearings are supplied with oil
via a bore in the crankshaft bearing.
Connecting rods (“cracked” connecting rods)

The “cracked” connecting rods are precision forged in a die using quenched and tempered steel. The large
connecting rod eye is split diagonally by “cracking” the connecting rod bearing 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 fit and high lateral stability.
Piston
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
Series D20 engines are equipped with a single-section cylinder head with overhead camshaft (OHC –
Over-Head Camshaft). The cylinder head is made from special cast iron and is fitted with shrink-fitted
valve seat rings and pressed-in, exchangeable valve guides. The valve guides have valve stem seals at
all four valves. The valves are actuated by individually exchangeable rocker arms on rocker shafts. The
EVB (Eexhaust Valve Brake) has individually exchangeable bridges. The cylinder head is secured with
high-strength external hexagon round screws (cylinder head bolts). The single-layer steel cylinder head seal
has a specially designed combustion chamber seal. There is an elastomer seal between the cylinder head
and cylinder head cover.
Camshaft
The camshaft is forged from steel and induction hardened. It is mounted 7x in the camshaft bearing shells in
the cylinder head. It is axially mounted in a centre bearing on the camshaft. It is driven by spur gears on the
flywheel side.

INTRODUCTION
Engine lubrication
The engine is lubricated by forced-feed lubrication for all bearing points. The engine oil filter and the oil cooler
are grouped together as an oil module. The oil in the oil sump is measured using a dipstick and an oil level
sensor installed in the crankcase.
Cooling system
The cooling circuit is a thermostat-controlled forced circulation cooling system with a maintenance-free coolant
pump driven by a ribbed V-belt. The distributor housing accommodates the coolant pump, the alternator and
the refrigerant compressor. The connection for the heater feed is also mounted on the distributor housing.
The thermostats are exchangeable inserts with wax expansion elements.
Intake/exhaust system
The 3-section exhaust manifold is cast from high temperature-resistant nodular cast iron and secured to
the cylinder head using heat-resistant bolts. The maintenance-free turbocharger is mounted on the middle
exhaust manifold. After the turbocharger, the exhaust manifold is built-in with permanently installed engine
brake flap. The turbocharger is lubricated by the engine oil circuit.
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-filter and a special microfilter with water separation to ensure the degree of fuel purity required by the
common-rail system. The low-pressure system also includes a heating element and the flame start system.
The interface to the high-pressure system is the fuel pump.
High-pressure system
The high-pressure system consists of the flow-rate-controlled high-pressure pump with flange-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 pres-
sure 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 calcu-
lated 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 flange in the cylinder head.
Flame start system

Special equipment includes a flame start system which serves as a cold starting aid. The flame-start system
consists of a solenoid valve and a rapid flame glow plug built into the charge-air manifold. After various
parameter enquiries (via sensors), the flame glow plug and the corresponding solenoid valve are activated
by the EDC in order to heat the intake air. The fuel is supplied by the fuel service centre (KSC).
Engine brake system

Series D20 engines are equipped with a non-controlled EVB as standard. The exhaust valve bridge has a
built-in hydraulic piston which is pressurised by the engine oil pressure and depressurised via a relief hole.
Above the valve bridge is a brace whose pressure shim plugs the relief hole when the exhaust valve is closed.
When the valve is opened, the relief hole is unplugged and the engine oil pressure can be reduced upstream
of the hydraulic piston. If the engine brake butterfly is closed against the torsion spring by the adjusting
cylinder, pressure waves build up in the exhaust manifold, causing the exhaust valves to open briefly once
again. In other words, the exhaust valve is opened briefly once again after each closure. The hydraulic
piston, which is held under the engine oil pressure, is pushed behind the briefly opening valve. However, the

INTRODUCTION
hydraulic piston can no longer move back as the brace plugs of the relief hole and the check valve closes the
oil feed bore. The exhaust valve therefore remains open with a gap during the compression stroke and the
following expansion stroke. The engine braking power increases.
Starter
The starter is a reduction-gear starter with a free-engaging pinion construction. Free-engaging means that
the starter pinion is mounted on the housing in the starter without a thrust bearing. 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 spur gears in the rear timing case. There may also be a hydraulic pump and
a further power steering pump mounted on the air compressor PTO, depending on the variant.
Power steering pump

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

ENGINE ELECTRONICS
ENGINE ELECTRONICS
(1) EGR adjusting cylinder (7) Pressure sensor

(2) Speed sensor (8) Charge pressure sensor
(3) Temperature sensor (9) Oil pressure switch
(4) Crankshaft sensor (10) Flame glow plug
(5) Heating element (KSC) (11) Rail pressure sensor
(6) Oil level sensor (12) Proportional valve

ENGINE ELECTRONICS
ENGINE ELECTRONICS
Removing and installing the engine electrical system
(1) EGR adjusting cylinder (7) Pressure sensor

(2) Speed sensor (8) Charge pressure sensor
(3) Temperature sensor (9) Oil pressure switch
(4) Crankshaft sensor (10) Flame glow plug
(5) Heating element (KSC) (11) Rail pressure sensor
(6) Oil level sensor (12) Metering unit
Technical data
Temperature sensor (3)......................................... M16x1.5 ............................................................45 Nm
Oil level sensor (6)................................................ M22x1.5 ............................................................25 Nm
Pressure sensor (7) .............................................. M18x1.5 ............................................................45 Nm
Pressure switch (9)............................................... M18x1.5 ............................................................50 Nm
Rail pressure sensor (11) ...................................... M18x1.5 ............................................................70 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench

ENGINE ELECTRONICS
WARNING
Restricted driving mode due to defective entries in the fault memory
• 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) Unscrewed conduit (7) Mounting bolt

(2) Coolant manifold (8) Unscrewed conduit
(3) Mounting bolt (9) Coolant manifold
(4) EGR module (10) Thermostat manifold
(5) O-ring (11) Distributor housing
(6) Coolant manifold (12) Coolant pump

COOLING SYSTEM
COOLANT MANIFOLD
Remove and install coolant manifold (version without retarder)
(1) Unscrewed conduit (8) Unscrewed conduit

(2) Coolant manifold (9) Coupling pipe
(3) Mounting bolt for coolant manifold (10) Coolant manifold
(7) Mounting bolt for coolant manifold
Technical data
Temperature sensor.............................................. M16x1.5 ............................................................45 Nm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
Technical Vaseline ............................................................................................................. 09.15014-0001
WARNING

COOLING SYSTEM
Special tools
[1] Hose clamp pliers for jubilee clips 80.99625-0073
• Attaching and detaching the air intake pipe from

the air compressor

COOLING SYSTEM
Removing the coolant manifold Removing the coolant manifold
Detaching the air intake pipe
• Unscrew the mounting bolts (3)

• Remove the coolant manifold (2) with O-ring (1)
• Unscrew the mounting bolts (1) • Clean the mating faces
• Undo the spring band clamp (3) using the Hose
clamp pliers for jubilee clips [1] Detach the coolant manifold to the EGR module
• Repeat the procedure for the jubilee clip at the
turbocharger intake pipe
• Remove the air intake pipe (2)
• Remove the mounting clamps for the moulded
hose (4) at the cable harness bracket
clamp pliers for jubilee clips [1]
• Pull the moulded hose (4) off the fitting (6)
Removing the coolant manifold

• Unscrew the mounting bolt (2) approx. 10 mm
• Pull the coolant manifold (4) with the unscrewed
conduit (3) out of the EGR module (6)
• Unscrew the mounting bolt (2)
• Remove the seal (1)
• Clean the sealing surfaces

• Pull off the coolant manifold (2)
• Remove the O-ring (5)
• Pull out the coupling pipes (3) and (4)

COOLING SYSTEM
Removing the temperature sensor Installing the coolant manifold

Install temperature sensor
Note
The temperature sensor can also be re- • Thinly apply clean engine oil on the thread of the
moved and installed with the coolant temperature sensor (1)
manifold mounted. • Screw in the temperature sensor (1) with a new
sealing ring (2) into the coolant manifold (3) and
• Unscrew the temperature sensor (1) with sealing
tighten to 45 Nm
ring (2) from the coolant manifold (3)
Install the coolant manifold to the EGR module
• Thinly apply Radiator antifreeze on the contact

surfaces of the new unscrewed conduit (3)
• Insert the unscrewed conduit (3) into the coolant
manifold (4)
• Put on a new seal (1)
• Screw in a new mounting bolt (2) approx. 10 mm
• Insert the coolant manifold (4) into the EGR mod-
ule (6)
• Screw in and tighten the new mounting bolts (5)
• Tighten the mounting bolt (2)

COOLING SYSTEM
Mounting the coolant manifold Attaching the air intake pipe
• Position the coolant manifold (2) with a new O-ring • Push the moulded hose (4) with jubilee clip (5) on
(1) the fitting (6)
• Screw in and tighten the new mounting bolts (3) • Install the mounting clamps for the moulded hose
(4) at the cable harness bracket
Mounting the coolant manifold • Install the spring band clamp (5) using the Hose
• Insert the air intake pipe (2) with jubilee clip (3)
• Install the spring band clamp (3) using the Hose

surfaces of the new unscrewed conduits (3) and
(4)
• Insert the unscrewed conduits (3) and (4) into the
coolant manifold (2)
• Thinly apply Technical Vaseline on a new O-ring
(5) and fit it on the coolant manifold (2)
• Attach the coolant manifold (2)

COOLING SYSTEM
Removing/installing the coolant manifold (version with retarder)
(1) Unscrewed conduit (7) Mounting bolt

(2) Coolant manifold (8) Unscrewed conduit
(3) Mounting bolt (9) Coolant manifold
Technical data
Service products
WARNING

COOLING SYSTEM
Special tools

the air compressor

COOLING SYSTEM
Removing the coolant manifold Removing the coolant manifold

• Pull out the coolant manifold (3) from the EGR
• Unscrew the mounting bolts (1) module
• Undo the spring band clamp (3) using the Hose • Pull off the O-ring (1)
• Repeat the procedure for the jubilee clip at the Detach the coolant manifold to the EGR module
Removing the coolant manifold

• Clean the sealing surfaces

• Pull off the coolant manifold (2) with O-ring (4) and
coupling pipe (1) from the cylinder head
• Pull out the coupling pipe (1)

COOLING SYSTEM
Removing the temperature sensor Installing the coolant manifold

Install temperature sensor
Note
The temperature sensor can also be re- • Thinly apply clean engine oil on the thread of the
moved and installed with the coolant temperature sensor (1)
manifold mounted. • Screw in the temperature sensor (1) with a new
sealing ring (2) into the coolant manifold (3) and
• Unscrew the temperature sensor (1) with sealing
tighten to 45 Nm
ring (2) from the coolant manifold (3)
Install the coolant manifold to the EGR module

manifold (4)
ule (6)

COOLING SYSTEM
Mounting the coolant manifold Attaching the air intake pipe
• Thinly apply Technical Vaseline on a new O-ring • Push the moulded hose (4) with jubilee clip (5) on
(1) and fit it on the coolant manifold (3) the fitting (6)
• Insert the coolant manifold (3) into the EGR mod- • Install the mounting clamps for the moulded hose
ule (4) at the cable harness bracket
• Screw in and tighten the new mounting bolts (2) • Install the spring band clamp (5) using the Hose
Mounting the coolant manifold • Insert the air intake pipe (2) with jubilee clip (3)

• Insert the coupling pipe (1) into the coolant mani-
fold (2)
• Position the coolant manifold (2) with a new O-ring
(4)

COOLING SYSTEM
THERMOSTATS
Removal and installation the thermostats
(1) Mounting bolt (3) O-rings

(2) Thermostat manifold (4) Thermostat
Technical data
Opening temperature of thermostat (4) ............................................................................................. 83 °C
WARNING
Thermostats with the incorrect opening temperature damage the engine
• Always use thermostats with the specified opening temperature
WARNING

COOLING SYSTEM
Removing the thermostats Installing the thermostats

Dismantling the thermostat manifold Installing the thermostats
• Unscrew the mounting bolts (4) • Insert new seals (1) into the thermostat housing
• Remove thermostat manifold (3) (3)
• Remove O-rings (2) from thermostats (1) • Insert the thermostats (2) with the ball valve or
• Clean the sealing surfaces TOP mark facing upwards
Removing the thermostats Installing thermostat manifold
• Remove the thermostats (2) with seals (1) from • Fit the new O-rings (2) onto the thermostats (1)
the thermostat housing (3) • Position the thermostat manifold (3) on the ther-
• Clean the mating faces mostat housing

COOLING SYSTEM
THERMOSTAT HOUSING
Removing and installing the thermostat housing
Additional jobs
– Remove and install the charge air pipe, see 247
– Removal and installation the thermostats, see 45
(1) Coupling pipe with cross-sectional restric- (3) Thermostat housing

tion (4) Coupling pipe without cross-sectional re-
(2) Gasket striction
Service products
WARNING

COOLING SYSTEM
Removing the thermostat housing Detaching the thermostat housing
Detach the coolant manifold to the EGR module

• Clean the mating faces
Unscrew the mounting bolt
• Dismantle thermostat housing (2) with the seal (1)

and coupling pipes
Replace coupling pipes
• Unscrew mounting bolt (1) from the thermostat

housing (2)
• Mark the installation position of the coupling pipes

(2) and (3)
• Remove the unscrewed conduits (2) and (3) from
the thermostat housing (1)
• Lightly apply Radiator antifreeze on the contact
surfaces of the new insert pipes (2) and (3)
• Insert coupling pipes (2) and (3) as marked into
the thermostat housing (1)

COOLING SYSTEM
Installing the thermostat housing Install the coolant manifold to the EGR module
Mounting the thermostat housing

manifold (4)
ule (6)
• Position the thermostat housing (2) with a new

seal (1) on the distributor housing
Screwing in the mounting bolt
• Screw in the new mounting bolts (1) through ther-

mostat housing (2) and tighten

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

(2) Poly-V-belt pulley (5) Gasket
(3) Mounting bolt (6) Distributor housing
WARNING

COOLING SYSTEM
Removing the coolant pump Removing the coolant pump
Undo the mounting bolts
• Mark the installation position of the mounting bolts

(1) and (2)
CAUTION • Unscrew the mounting bolts (1) and (2)
The poly-V-belt tensioner is under • Remove the coolant pump (3) with the gasket (4)
spring tension • Clean the mating faces
• Brace the poly-V-belt tensioner to pre-
vent it from springing back unintention-
ally
• Undo the mounting bolts (1)

• Turn the ribbed V-belt tensioner (2) clockwise as
far as the stop and hold it
• Removing the ribbed V-belt
• Carefully slacken the ribbed V-belt tensioner (2)
Removing the ribbed V-belt disc

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

COOLING SYSTEM
Installing the coolant pump Tightening the mounting bolts
Mounting the coolant pump
CAUTION
• Insert the coolant pump (3) with a new gasket (4) The poly-V-belt tensioner is under
• Screw in and tighten the new mounting bolts (1) spring tension
and (2) as marked • Brace the poly-V-belt tensioner to pre-
Mount the ribbed V-belt disc ally

• Fitting the ribbed V-belt
• Tighten the mounting bolts (1)
• Position the poly-V-belt pulley (2) on the hub (3)

• Screw in the new mounting bolts (1) and tighten
them by hand

COOLING SYSTEM
DISTRIBUTOR HOUSING
Removal and installation the distributor housing
Additional works
– Removing and installing belt drive, see 153
– Remove and install coolant manifold (version without retarder), see 35
– Removing/installing the coolant manifold (version with retarder), see 40
– Removing and installing the thermostat housing, see 47
– Removing and installing the coolant pump, see 51
(1) Distributor housing (3) Mounting bolt

(2) Mounting bolt
WARNING

COOLING SYSTEM
Removing the distributor housing Installing the distributor housing
• Dismantling alternator 1, see Removing and in- • Position distributor housing (1) with new seal
stalling alternators 1 and 2, 159 • Screw in and tighten the new mounting bolts (2)
• Mark the installation position of the mounting bolts and (3) as marked
(2) and (3) • Installing alternator 1, see Removing and installing
• Unscrew the mounting bolts (2) and (3) alternators 1 and 2, 159
• Remove distributor housing (1) with seal

MOUNTED COMPONENTS
MOUNTED COMPONENTS
(1) Starter (9) Alternator 3

(2) Air intake pipe (10) Ribbed V-belt disc, high pressure pump
(3) Moulded hose engine
(4) 2-cylinder air compressor (11) Ribbed V-belt disc, alternator 2
(5) Power steering pump 1 (12) Guide roller
(6) Hydraulic pump (13) Ribbed V-belt disc, alternator 1
(7) Power steering pump 2 (14) Ribbed V-belt disc, coolant pump
(8) Refrigerant compressor

MOUNTED COMPONENTS
AIR COMPRESSOR
Removal and installation of the 1-cylinder air compressor
(1) Air intake pipe (3) 1-cylinder air compressor

(2) Moulded hose (4) Power steering pump
Technical data
connecting union .................................................. M16x1.5 ............................................................30 Nm
GE union.............................................................. M26x1.5 ............................................................45 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

MOUNTED COMPONENTS
Special tools

the air compressor

MOUNTED COMPONENTS
Remove air compressor Detaching the coolant lines
• Unlock and remove the plug connectors for the

coolant line (1) by pressing the spring clip (2)
• Repeat the procedure for other coolant lines
Detaching the steering pump

• Undo the jubilee clip (3) using Hose clamp pliers
for jubilee clips [3] and push onto the air intake
pipe (2)
clamp pliers for jubilee clips [3] and push onto the
fitting (5)

• Remove the power steering pump (3) with driver
(2) from the air compressor (1)

MOUNTED COMPONENTS
Detaching the air compressor Removing pressure relief valve
• Mark the installation position of the mounting bolts • Unscrew the pressure relief valve (1) and remove
(1) and (2) it with the seal
• Unscrew the mounting bolts (1) and (2)
• Remove the air compressor (3)
Removing the connection fitting
• Unscrew the supply bulkhead fitting (2) and return

line (3) and remove them with the seals
• Unscrew the GE union (1) and remove with the
seal

MOUNTED COMPONENTS
Installing air compressor Installation instruction for air compressor
Install pressure relief valve
• Thinly apply sealing agent Loctite 5900 (1) on the

mating face as illustrated
• Screw in the excess pressure relief valve (1) with
a new seal Attaching the air compressor
• Tighten the pressure-relief valve (1) with 90 Nm
Installing the connection fitting
• Position the air compressor (3)

and (2) as marked
• Screw on supply (2) and return line (3) bulkhead

fitting with new seals and tighten to 30 Nm
• Screw on GE union (1) with new seal and tighten
with 45 Nm

MOUNTED COMPONENTS
Attaching the steering pump Tighten the coolant lines
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for firm seating after securing
• Loose plug-in connectors must be re-
leased by pressing the spring clip, repo-
sitioning them, then securing them
• Installing the plug connector for the coolant line (1)

• If required, undo the plug connector (1) by press-
ing the spring clip (2), re-insert and secure
• Check the driver (2) for wear and replace as nec-

essary
• Insert the driver (2) into the air compressor (1)
• Insert the power steering pump (3) with the new
O-ring into the air compressor (1)

MOUNTED COMPONENTS
Attaching the air intake pipe
• Push the moulded hose (6) with spring band clamp

(4) on the fitting (5)
• Install the mounting clamps for the moulded hose

MOUNTED COMPONENTS
Removing and installing the 1-cylinder air compressor with steering and hydraulic
pump

(2) 1-cylinder air compressor (4) Hydraulic pump
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
Mounting bolts for hydraulic pump (4) .................... M10x40-10.9......................................................55 Nm
Technical data air compressor

Axial play of PTO drive shaft .......................................................................................... 0.100 - 0.700 mm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

MOUNTED COMPONENTS
Special tools

the air compressor
[5] Dial gauge 08.71000-3217
• Checking the PTO drive shaft axial play in con-

junction with:
• gauge holder [6]
• Caliper pin [7]
[6] gauge holder 08.71082-0005
• Checking axial play of PTO drive shaft
[7] Caliper pin 80.99605-0197

MOUNTED COMPONENTS


pipe (2)
• Undo the jubilee clip (4) using the Hose clamp
pliers for jubilee clips [4] and push onto the fitting
(5)

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

MOUNTED COMPONENTS
Detaching the hydraulic pump Removing the connection fitting

• Remove the hydraulic pump (2) with driver (3) from
the air compressor (4)
Detaching the air compressor
• Unscrew the supply (2) and return line (3) bulk-

head fitting from the air compressor (4) and re-
move them with the seals
• Unscrew the GE unions (1) from the air compres-
sor (4) and remove it with the seal

(2) and (3)

MOUNTED COMPONENTS
Removing pressure relief valve Checking axial play of PTO drive shaft
• Unscrew the pressure relief valve (1) from the air • Install gauge holder [6] (2) with Dial gauge [5] (3)
compressor (2) and remove it with the seal and Caliper pin [7]
• Caliper pin [7] position with pre-load on the drive
shaft
• Push the drive shaft against the Dial gauge [5] (3)
into the end position
• Zero the Dial gauge [5] (3)
• Pull the drive shaft into the end position towards
Dial gauge [5] (3) and check the difference
The permitted axial play on the drive shaft is
0.100 - 0.700 mm.
If the axial play is out of tolerance, replace the air

compressor (1).

MOUNTED COMPONENTS
Installing air compressor Installing the connection fitting

fitting with new seals in air compressor (4)and
• Screw the pressure relief valve (1) with a new seal tighten to 30 Nm
into the air compressor (2) • Screw in the GE union (1) with a new seal in the
• Tighten the pressure-relief valve (1) with 90 Nm air compressor (4) and tighten to 45 Nm
Installation instruction for air compressor


MOUNTED COMPONENTS
Attaching the air compressor Attaching the steering pump

and (3) as marked
Attaching the hydraulic pump

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

• Insert the hydraulic pump (2) with a new O-ring
• Screw in new mounting bolts (1) and tighten to
55 Nm

MOUNTED COMPONENTS
Tighten the coolant lines Attaching the air intake pipe
WARNING
connection



MOUNTED COMPONENTS
Removing and installing the 1-cylinder air compressor with two steering pumps
(1) 1-cylinder air compressor (6) Mounting bolt

(2) Driver (7) Power steering pump 2
(3) O-ring (8) O-ring
(4) Power steering pump 1 (9) Driver
(5) Mounting bolt
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm

Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

MOUNTED COMPONENTS
CAUTION
Risk of accidents due to possible power steering failure
• The power steering pumps have different directions of rotation and must not be exchanged ac-
cording to their installation position
Special tools

the air compressor
[9] Dial gauge 08.71000-3217

junction with:
• Caliper pin [11]
[10] gauge holder 08.71082-0005
[11] Caliper pin 80.99605-0197

MOUNTED COMPONENTS

Removing power steering pump 1

pipe (2)
(5)

O-ring (3) from the air compressor (1)

MOUNTED COMPONENTS
Removing power steering pump 2 Removing the connection fitting

• Unscrew the supply (2) and return (3) bulkhead

fitting from the air compressor (4) and remove
them with the seals

(2) and (3)

MOUNTED COMPONENTS
• Unscrew the pressure relief valve (1) from the air • Install gauge holder [10] (2) with Dial gauge [9] (3)
compressor (2) and remove it with the seal and Caliper pin [11]
shaft
• Push the drive shaft against the Dial gauge [9] (3)
into the end position
0.100 - 0.700 mm.

compressor (1).

MOUNTED COMPONENTS
• Screw on supply (2) and return (3) bulkhead fitting

with new sealing rings in air compressor (4)and
into the air compressor (2) • Screw in the GE union (1) with a new sealing ring
• Tighten the pressure-relief valve (1) with 90 Nm in the air compressor (4) and tighten to 45 Nm


MOUNTED COMPONENTS
Attaching the air compressor Mounting power steering pump 1

and (3) as marked
Mounting power steering pump 2

O-ring (3)

O-ring (2)

MOUNTED COMPONENTS
WARNING
connection



MOUNTED COMPONENTS
Removing and installing of 1-cylinder air compressor with power steering pump and
two hydraulic pumps
(1) Moulded hose (4) Hydraulic pump 1

(2) 1-cylinder air compressor (5) Hydraulic pump 2
(3) Power steering pump
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
Mounting bolt for hydraulic pump 1 (4) ................... M10x150-10.9....................................................55 Nm
Mounting bolts for hydraulic pump 2 (5) ................. M10x205-10.9....................................................55 Nm

Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

MOUNTED COMPONENTS
Special tools

the air compressor
[13] Dial gauge 08.71000-3217

junction with:
[14] gauge holder 08.71082-0005
[15] Caliper pin 80.99605-0197

MOUNTED COMPONENTS


pipe (2)
(5)


MOUNTED COMPONENTS
Dismantle hydraulic pump 2 Detaching the air compressor

(2) and (3)

• Take out hydraulic pump (3) with coupling sleeve
(2) and O-Ring from hydraulic pump 1 (1)
Dismantle hydraulic pump 1

• Take out hydraulic pump (4) with driver (3) and
O-ring from air compressor (2) • Unscrew the supply (2) and return (3) bulkhead
them with the seals

MOUNTED COMPONENTS
• Unscrew the pressure relief valve (1) from the air • Install gauge holder [14] (2) with Dial gauge [13]
compressor (2) and remove it with the seal (3) and Caliper pin [15]
shaft
• Push the drive shaft against the Dial gauge [13]
(3) into the end position
0.100 - 0.700 mm.

compressor (1).

MOUNTED COMPONENTS



MOUNTED COMPONENTS
Attaching the air compressor Dismantle hydraulic pump 2

and (3) as marked
• Insert driver (2) into the hydraulic pump (1)

55 Nm
• Insert coupling sleeve (3) into the air compressor

(2)
• Screw in the new mounting bolt (1) and tighten to
55 Nm

MOUNTED COMPONENTS
WARNING
connection


O-ring

MOUNTED COMPONENTS


MOUNTED COMPONENTS
Removing and installing 1-cylinder air compressor with two power-steering pumps
and hydraulic pump
(1) Air intake pipe (4) Hydraulic pump

(2) 1-cylinder air compressor (5) Power steering pump 2
(3) Power steering pump 1
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
Mounting bolts for hydraulic pump (4) .................... M10x150-10.9....................................................65 Nm
Mounting bolts for power steering pump 2 (5)......... M10x175-10.9....................................................65 Nm

Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

MOUNTED COMPONENTS
Special tools

the air compressor
[17] Dial gauge 08.71000-3217

junction with:
[18] gauge holder 08.71082-0005
[19] Caliper pin 80.99605-0197

MOUNTED COMPONENTS

Removing power steering pump 1

pipe (2)
• Repeat the procedure for the jubilee clip at the • Unscrew the mounting bolts (4)
turbocharger intake pipe • Remove the steering pump (3) with driver (2) and
• Remove the air intake pipe (2) O-ring from the air compressor (1)
hose (6) at the cable harness bracket Removing power steering pump 2
(5)

• Take out power steering pump (4) with driver (3)
from hydraulic pump (1)

MOUNTED COMPONENTS
Detaching the hydraulic pump Removing the connection fitting

(3) and O-ring from the air compressor (2)

them with the seals

(2) and (3)

MOUNTED COMPONENTS
• Unscrew the pressure relief valve (1) from the air • Install gauge holder [18] (2) with Dial gauge [17]
compressor (2) and remove it with the seal (3) and Caliper pin [19]
shaft
0.100 - 0.700 mm.

compressor (1).

MOUNTED COMPONENTS



MOUNTED COMPONENTS
Attaching the air compressor Mounting power steering pump 2
• Position the air compressor (1) • Insert driver (3) into the hydraulic pump (1)
• Screw in and tighten the new mounting bolts (2) • Insert the power steering pump (4) with a new
and (3) as marked O-ring
Attaching the hydraulic pump 65 Nm
• Insert coupling sleeve (3) into the air compressor

(2)
• Insert the hydraulic pump (4) with a new O-ring • Insert the driver (2) into the air compressor (1)
• Screw in the new mounting bolt (1) and tighten to • Insert the power steering pump (3) with a new
65 Nm O-ring

MOUNTED COMPONENTS
WARNING
connection



MOUNTED COMPONENTS
Removing and installing 2-cylinder air compressor with power steering pump
(1) Air intake pipe (3) Power steering pump

(2) 2-cylinder air compressor (4) Moulded hose
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING
CAUTION

MOUNTED COMPONENTS
Special tools

the air compressor

MOUNTED COMPONENTS
Remove air compressor Detaching the steering pump
Detaching the coolant lines

• Unlock and remove the plug connectors for the O-ring (3) from the air compressor (1)
• Repeat the procedure for other coolant lines Detaching the air compressor
CAUTION
• Unscrew the mounting bolt (1) Danger of injury due to heavy compo-
• Undo the jubilee clip (3) using Hose clamp pliers nents
for jubilee clips [20] and push onto the air intake • Remove the air compressor with sup-
pipe (2) port
turbocharger intake pipe • Mark the installation position of the mounting bolts
• Remove the air intake pipe (2) (1) and (2)
• Remove the mounting clamps for the moulded • Unscrew the mounting bolts (1) and (2)
hose (4) at the cable harness bracket • Remove the air compressor (3)
• Undo the jubilee clip (4) using the Hose clamp • Clean the mating faces
(6)

MOUNTED COMPONENTS
Removing the connection fitting Installing air compressor


them with the seals • Screw the pressure relief valve (1) with a new seal
• Unscrew the GE unions (3) from the air compres- into the air compressor (2)
sor (1) and remove it with the seal • Tighten the pressure-relief valve (1) with 90 Nm
Removing pressure relief valve Installing the connection fitting
• Unscrew the pressure relief valve (1) from the air • Screw on supply (2) and return (4) bulkhead fitting
compressor (2) and remove it with the seal with new sealing rings in air compressor (1)and
tighten to 30 Nm
• Screw in the GE union (3) with a new sealing ring
in the air compressor (1) and tighten to 45 Nm

MOUNTED COMPONENTS
Installation instruction for air compressor Installing the steering pump
• Thinly apply sealing agent Loctite 5900 (1) on the • Insert the driver (2) into the air compressor (1)
mating face as illustrated • Insert the power steering pump (4) with a new
O-ring (3)
Attaching the air compressor • Screw in and tighten the new mounting bolts (5)
CAUTION
Danger of injury due to heavy compo-
• Push the moulded hose (4) with jubilee clip (5) on
nents
the fitting (6)
• Install the air compressor with support
and (2) as marked

MOUNTED COMPONENTS
Tighten the coolant lines
WARNING
connection

ing the spring clip (2), re-inserting and securing

MOUNTED COMPONENTS
Removing and installing the 2-cylinder air compressor with steering and hydraulic
pump

(2) 2-cylinder air compressor (4) Hydraulic pump
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm

Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

MOUNTED COMPONENTS
Special tools

the air compressor
[22] Dial gauge 08.71000-3217

junction with:
[23] gauge holder 08.71082-0005
[24] Caliper pin 80.99605-0197

MOUNTED COMPONENTS

pipe (2)
(6)
• Pull the moulded hose (4) off the fitting (6) • Unscrew the mounting bolts (4)
Detaching the hydraulic pump

• Repeat the procedure for other coolant lines • Unscrew the mounting bolts (1)
• Remove the hydraulic pump (2) with driver (3) from
the air compressor (4)

MOUNTED COMPONENTS
CAUTION • Unscrew the pressure relief valve (1) from the air
Danger of injury due to heavy compo- compressor and remove it with the seal
nents
• Remove the air compressor with sup-
port

(1) and (2)

them with the seals

MOUNTED COMPONENTS
Checking axial play of PTO drive shaft Installing air compressor

• Screw in the pressure-relief valve (1) with a new

sealing ring in the air compressor
• Install gauge holder [23] (2) with Dial gauge [22]

(3) and Caliper pin [24]
shaft
Dial gauge [22] (3) and check the difference • Screw on supply (2) and return (4) bulkhead fitting
The permitted axial play on the drive shaft is with new sealing rings in air compressor (1)and
0.100 - 0.700 mm. tighten to 30 Nm
If the axial play is out of tolerance, replace the air in the air compressor (1) and tighten to 45 Nm
compressor (1).

MOUNTED COMPONENTS
Installation instruction for air compressor Attaching the hydraulic pump
• Thinly apply sealing agent Loctite 5900 (1) on the • Insert the driver (3) into the air compressor (4)
mating face as illustrated • Insert the hydraulic pump (2) with a new O-ring
Attaching the air compressor 55 Nm
Attaching the steering pump
CAUTION
nents

and (2) as marked

O-ring

MOUNTED COMPONENTS
Tighten the coolant lines
WARNING
connection


the fitting (6)

MOUNTED COMPONENTS
Removing and installing 2-cylinder air compressor with two power-steering pumps
and hydraulic pump
(1) Air intake pipe (4) Hydraulic pump

(2) 2-cylinder air compressor (5) Power steering pump 2
(3) Power steering pump 1 (6) Moulded hose
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm

Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

MOUNTED COMPONENTS
CAUTION
Special tools

the air compressor
[26] Dial gauge 08.71000-3217

junction with:
[27] gauge holder 08.71082-0005
[28] Caliper pin 80.99605-0197

MOUNTED COMPONENTS
Remove air compressor Removing power steering pump 1

• Unlock and remove the plug connectors for the O-ring (3) from the air compressor (1)
• Repeat the procedure for other coolant lines Removing power steering pump 2

• Take out power steering pump (4) with driver (3)
• Unscrew the mounting bolt (1) from hydraulic pump (1)
for jubilee clips [25] and push onto the air intake Detaching the hydraulic pump
pipe (2)
(6)

(3) and O-ring from the air compressor (2)

MOUNTED COMPONENTS
CAUTION • Unscrew the pressure relief valve (1) from the air
Danger of injury due to heavy compo- compressor and remove it with the seal
nents
• Remove the air compressor with sup-
port

(1) and (2)

them with the seals

MOUNTED COMPONENTS

• Screw in the pressure-relief valve (1) with a new

sealing ring in the air compressor

shaft
Dial gauge [26] (3) and check the difference • Screw on supply (2) and return (4) bulkhead fitting
The permitted axial play on the drive shaft is with new sealing rings in air compressor (1)and
0.100 - 0.700 mm. tighten to 30 Nm
If the axial play is out of tolerance, replace the air in the air compressor (1) and tighten to 45 Nm
compressor (1).

MOUNTED COMPONENTS
Installation instruction for air compressor Attaching the hydraulic pump
• Thinly apply sealing agent Loctite 5900 (1) on the • Insert coupling sleeve (3) into the air compressor
mating face as illustrated (2)
Attaching the air compressor • Screw in the new mounting bolt (1) and tighten to
65 Nm
CAUTION
nents
O-ring
and (2) as marked

MOUNTED COMPONENTS
Mounting power steering pump 1 Attaching the air intake pipe
• Insert the driver (2) into the air compressor (1) • Push the moulded hose (4) with jubilee clip (5) on
• Insert the power steering pump (4) with a new the fitting (6)
O-ring (3) • Install the mounting clamps for the moulded hose
• Screw in and tighten the new mounting bolts (5) (4) at the cable harness bracket
Tighten the coolant lines clamp pliers for jubilee clips [25]
WARNING
connection


MOUNTED COMPONENTS
Removing and installing of 2-cylinder air compressor with power steering pump and
two hydraulic pumps
(1) Moulded hose (4) Hydraulic pump 1

(2) 2-cylinder air compressor (5) Hydraulic pump 2
(3) Power steering pump
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm

Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

MOUNTED COMPONENTS
Special tools

the air compressor
[30] Dial gauge 08.71000-3217

junction with:
[31] gauge holder 08.71082-0005
[32] Caliper pin 80.99605-0197

MOUNTED COMPONENTS

pipe (2)
(6)
• Pull the moulded hose (4) off the fitting (6) • Unscrew the mounting bolts (5)

• Repeat the procedure for other coolant lines • Unscrew the mounting bolts (2)
(3) and O-Ring from hydraulic pump 1 (1)

MOUNTED COMPONENTS
Dismantle hydraulic pump 1 Removing the connection fitting
• Unscrew the mounting bolt (1) • Unscrew the supply (2) and return (4) bulkhead
• Take out hydraulic pump (4) with driver (3) and fitting from the air compressor (1) and remove
O-ring from air compressor (2) them with the seals
Detaching the air compressor sor (1) and remove it with the seal
Removing pressure relief valve
CAUTION
nents • Unscrew the pressure relief valve (1) from the air
• Remove the air compressor with sup- compressor and remove it with the seal
port

(1) and (2)

MOUNTED COMPONENTS


• Caliper pin [32] position with pre-load on the drive • Screw the pressure relief valve (1) with a new seal
shaft into the air compressor (2)
• Push the drive shaft against the Dial gauge [30] • Tighten the pressure-relief valve (1) with 90 Nm
• Zero the Dial gauge [30] (3) Installing the connection fitting
0.100 - 0.700 mm.

compressor (1).

fitting with new seals into the air compressor and
tighten to 30 Nm
• Screw in the GE union (3) with a new seal in the
air compressor and tighten to 45 Nm

MOUNTED COMPONENTS
Installation instruction for air compressor Dismantle hydraulic pump 1
• Thinly apply sealing agent Loctite 5900 (1) on the • Insert coupling sleeve (3) into the air compressor
mating face as illustrated (2)
Attaching the air compressor • Screw in the new mounting bolt (1) and tighten to
65 Nm
CAUTION
nents
55 Nm
and (2) as marked

MOUNTED COMPONENTS
WARNING
connection

• Insert the driver (2) into the air compressor (1) Attaching the air intake pipe
O-ring (3)

the fitting (6)

MOUNTED COMPONENTS
Dismantling and assembling 1-cylinder air compressor

Additional jobs
– Removing and installing 1-cylinder air compressor with two power-steering pumps and hydraulic pump, see
91
– Removing and installing the 1-cylinder air compressor with steering and hydraulic pump, see 66
– Removing and installing the 1-cylinder air compressor with two steering pumps, see 74
– Removing and installing of 1-cylinder air compressor with power steering pump and two hydraulic pumps,
see 82
(1) Circlip (19) Mounting bolt

(2) Piston pins (20) Washer
(3) Piston (21) Cover
(4) Piston ring (22) Mounting bolt
(5) Air compressor drive wheel (23) Washer
(6) Gasket (24) PTO drive wheel
(7) Valve plate (25) Gasket
(8) Fin (26) Cover
(9) Mounting nut (27) Screw plug
(10) Pressure relief valve (28) Mounting bolt
(11) Sealing ring (29) Housing
(12) Mounting bolt (30) Mounting bolt
(13) Mounting bolt (31) Cover
(14) Air compressor cylinder head (32) O-ring
(15) Gasket (33) Crankshaft
(16) Intermediate plate (34) Connecting rods
(17) Gasket
(18) Cover

MOUNTED COMPONENTS
Technical data
Mounting bolt (19) ................................................ M10x1.5-LH .......................................................80 Nm
Mounting bolt (22) ................................................ M10x1.5 ............................................................80 Nm
Mounting bolt (13) ................................................ M8x85Z1-10.9-MAN 183-A2 C............................30 Nm
Connecting-rod bearing bolts ..........................................................................................................16 Nm
Mounting bolt (30) ..........................................................................................................................24 Nm
Mounting bolt (28) ..........................................................................................................................12 Nm
Screw plug (27) ..............................................................................................................................40 Nm
WARNING
Note
The dismantling and assembling of the air compressor with and without PTO is the same in prin-
ciple.
Special tool
[33] Removal device 80.99606-6118
• Locking air compressor crankshaft
[34] Piston ring pliers 83.09144-6090
• Installation and removal of piston rings
[35] Piston ring band tool 80.99613-0035
• Installing the piston
[36] Torque wrench 08.06450-0006
• Tightening connecting rod bearing bolts
[37] Torque wrench 08.06450-0002
• Tightening the cylinder head bolts of the air com-

pressor
• Tightening the drive wheel mounting bolts

MOUNTED COMPONENTS
Dismantling the air compressor Removing the cover
Attaching removal device to air compressor
• Unscrew the screw plug (1) and remove with the

seal
• Attach Removal device [33] (2) to air compressor • Unscrew the mounting bolts (4)
(1) • Remove the cover (2) with the seal (3)
Removing the cover
• Place Removal device [33] in a vice (4)

• Remove covers (1) and (2) from the air compres-
sor (3)

MOUNTED COMPONENTS
Unscrewing the drive wheel mounting bolts Remove air compressor drive wheel
• Remove the drive wheel (1) from the air compres-

sor (2)
• Clean the toothing on the drive wheel (1) and
crankshaft
Remove the cylinder head
Note
The drive wheel mounting bolt for the air
compressor has a left-handed thread.
• Secure PTO drive shaft from dropping

• Unscrew the mounting bolt (left-handed thread)
(1) and remove with the washer (2)
• Unscrew the mounting bolt (4) and remove with
washer (3)
Remove PTO shaft drive wheel
• Unclamp and Removal device [33] remove the air

compressor
• Remove cylinder head (2)
• Remove intermediate plate (4) with seal (3)
sor (1)
• Clean the toothing on the drive wheel (2) and PTO
shaft

MOUNTED COMPONENTS
Detach valve plate Detach oil ring
• Remove valve plate (2) with seal (1) • Mark installation position of fins (4) and supporting
• Clean the mating faces plates (3)
• Unscrew the mounting nuts (1)
Remove cylinder head gasket • Remove the mounting bolts (2)
• Remove fins (4) and supporting plates (3)
• Clean valve plate
• Mark the O-ring installation position (2)

• Remove cylinder head gasket (1) with O-ring (2)

MOUNTED COMPONENTS
Detach the connecting-rod shell Remove piston pin
• Turn the crankshaft to the removal position • Mark the relative positions of the piston (3), piston
• Mark the connecting rod bearing shell (2) installa- pin (2) and connecting rod (5)
tion position • Detach the circlips (1) and (4)
• Unscrew the mounting bolts (3) • Press the piston pin (2) out of the piston (3)
• Remove the connecting rod bearing shell (2) • Remove the piston (3) from the connecting rod (5)
• Push out the piston and the connecting rod (1)
towards the cylinder head Removing the piston rings
Removing the piston
• Mark the installation position of the piston rings (3)

• Set Piston ring pliers [34] (1) to the piston diameter
• Pull out the piston (2) with connecting rod from the • Remove the piston rings (3) with Piston ring pli-
cylinder liner (1) ers [34] (1)
• Carefully clean the piston ring grooves in the pis-
ton (2)

MOUNTED COMPONENTS
Remove PTO shaft Assembling the air compressor

Installing the crankshaft
• Remove PTO shaft (1) from the air compressor (2)
Removing the crankshaft • Thinly apply clean engine oil on the crankshaft
mounting
• Insert crankshaft (4) into housing (5)
• Position the cover (2) with a new O-ring (3)
24 Nm
Installing the piston rings

• Remove the cover (2) with the O-ring (3)
• Pull crankshaft (4) out of the housing (5)

• Insert the piston rings (3) into the piston (2) with
Piston ring pliers [34] (1), ensuring that the TOP
mark is facing the piston crown

MOUNTED COMPONENTS
Install piston pin Installing the piston
• Placing crankshaft on UT
• Line up the gaps in the piston rings at 120° offset
to one another
• Thinly apply clean engine oil to the piston (2) and
cylinder running surfaces
• Put Piston ring band tool [35] on the piston (2) and
clamp it
• Push the piston (2) with connecting rod into the
cylinder liner (1) until the piston (2) has been
pushed out of the Piston ring band tool [35] (2)
• Push in the piston (2) until the connecting rod is
lying on the crankshaft
Installing PTO shaft

• Attach a new locking ring (4) in the piston groove
(3)
• Fit the piston (3) over the connecting rod (5) as
marked
• Thinly apply clean engine oil on the piston pin (2)
• Push the piston pin (2) through the piston (3) and
the connecting rod (5) as marked until the stop is
reached
(3)
• Check that the circlips (1) and (4) are seated cor-
rectly
If the circlips (1) and (4) have not engaged correctly,
remove and re-attach the circlips (1) and (4), ensur-
ing that they are seated correctly.
• Thinly apply clean engine oil on the bearing points
of the PTO shaft (1)
• Insert PTO shaft (1) into the air compressor (2)

MOUNTED COMPONENTS
Attaching connecting rod bearing shell Installing the discs
• Turn the crankshaft to the installation position • Position fins (4) and supporting plates (3) on the
• Position the connecting rod bearing shell (2) onto valve plate as marked
the connecting rod (1) • Insert the new mounting bolts (2)
• Screw in the new mounting bolts (3) • Screw on and tighten the new mounting nuts (1)
• Tighten mounting bolts (3) with Torque wrench [36]
with 16 Nm Fit the cylinder head gasket
Note
A guide pin determines the installation
position of the cylinder head gasket.
• Fit the new cylinder head gasket (1)

• Insert new O-ring (2) as marked

MOUNTED COMPONENTS
Attach valve plate Mount the cylinder head
Note Note
Guide pins determine the installation po- Guide pins determine the installation po-
sition of the valve plate and seal. sition of the intermediate plate, seal and
cylinder head.
• Position the valve plate (2) with a new seal (1)
• Fit the intermediate plate (4)
• Fitting the cylinder head (2) with a new seal (3)
• Screw in mounting bolts (1) and tighten crosswise
by 30 Nm
Attaching removal device to air compressor
• Attach Removal device [33] (2) to air compressor

(1)

MOUNTED COMPONENTS
Insert air compressor drive wheel Tightening the drive wheel mounting bolts
• Insert the drive wheel (1) laterally into the air com-
pressor (2)
• Insert the drive wheel (1) into the toothing of the
crankshaft
Drive wheel PTO shaft
Note
• Screw in new mounting bolts (1) (left-handed

thread) and (4) with washers (2) and (3)
• Insert the drive wheel (2) into the air compressor • Tighten mounting bolt (1) (left-handed thread) with
(1) Torque wrench [37] with 80 Nm
• Insert drive wheel (2) into the toothing of the PTO • Tighten the mounting bolt (4) with Torque
shaft wrench [37] with 80 Nm

MOUNTED COMPONENTS
Mounting the cover
• Position the cover (2) with a new gasket (3)

12 Nm
• Screw in the screw plug (1) with a new seal and
tighten to 40 Nm
Installing the cover
• Install new covers (1) and (2) with a plastic ham-

mer into the air compressor (3)
• Unclamp Removal device [33] from vice (4) and
detach from air compressor (3)

MOUNTED COMPONENTS

Additional jobs
– Removing and installing 2-cylinder air compressor with power steering pump, see 99
(1) Piston ring (19) Gasket

(2) Piston (20) Intermediate plate
(3) Circlip (21) Gasket
(4) Mounting bolt (22) Cover
(5) Cover (23) Mounting bolt
(6) Gasket (24) Washer
(7) Air compressor drive wheel (25) PTO drive wheel
(8) Valve plate (26) Gasket
(9) Fin (27) Cover
(10) Mounting nut (28) Screw plug
(11) Gasket (29) Mounting bolt
(12) Washer (30) Housing
(13) Mounting bolt (31) Crankshaft
(14) Cover (32) O-ring
(15) Pressure relief valve (33) Mounting bolt
(16) Sealing ring (34) Connecting rods
(17) Mounting bolt (35) Piston pins
(18) Air compressor cylinder head
Technical data

MOUNTED COMPONENTS

Mounting bolt (33) ..........................................................................................................................24 Nm
Mounting bolt (29) ..........................................................................................................................12 Nm
Screw plug (28) ..............................................................................................................................40 Nm
WARNING
• If impact wrenches are used, these may only be used for pre-tightening to max. 50 % of the
Note
The dismantling and assembling of the air compressor with and without PTO is the same in prin-
ciple.
Special tool
[38] Removal device 80.99606-6118
• Locking air compressor crankshaft
[40] Piston ring band tool 80.99613-0035
[41] Torque wrench 08.06450-0006
• Tightening connecting rod bearing bolts
[42] Torque wrench 08.06450-0002
• Tightening the cylinder head bolts of the air com-

pressor
• Tightening the drive wheel mounting bolts

MOUNTED COMPONENTS
Dismantling the air compressor Removing the cover
Removing the cover
• Place Removal device [38] in a vice

• Remove covers (1) and (2) from the air compres-
sor (3)
Removing the cover

• Remove the cover (2) with the seal (3)
Attaching removal device to air compressor • Unscrew the screw plug (1) and remove with the
seal
• Remove the cover (3) with the seal (2)
• Attach Removal device [38] (2) to air compressor

(1)

MOUNTED COMPONENTS
Unscrewing the drive wheel mounting bolts Remove air compressor drive wheel

Note
sor (1)
• Clean the toothing on the drive wheel (2) and
crankshaft
• Secure PTO drive shaft from dropping

• Unscrew the mounting bolt (left-handed thread)
(1) and remove with the washer (2)
washer (3)
Remove PTO shaft drive wheel

sor (2)
• Clean the toothing on the drive wheel (1) and PTO
shaft

MOUNTED COMPONENTS
Removing the cylinder head Detach valve plate
• Unclamp and Removal device [38] remove the air • Remove valve plate (2) with seal (1)
compressor • Clean the mating faces
• Remove cylinder head (2) Remove cylinder head gasket
• Remove intermediate plate (4) with seal (3)
• Remove the cylinder head gasket (1)


MOUNTED COMPONENTS
Detach oil ring Detach the connecting-rod shell
• Mark installation position of fins (2) and supporting • Turn the crankshaft to the removal position
plates (1) • Mark the connecting rod bearing shell (2) installa-
• Unscrew the mounting nuts (3) tion position
• Remove fins (2) and supporting plates (1) • Unscrew the mounting bolts (3)
• Clean valve plate • Remove the connecting rod bearing shell (2)
• Push out the piston and the connecting rod (1)
towards the cylinder head
• Repeat the same procedure for the second con-
necting rod
Removing the piston
• Pull out the piston (1) with connecting rod from the
housing (2)
• Repeat the procedure on piston (3)

MOUNTED COMPONENTS
Remove piston pin Remove PTO shaft
• Remove PTO shaft (1) from the air compressor (2)
Removing the crankshaft
• Mark the relative positions of the piston (3), piston

pin (2) and connecting rod (5)
• Detach the circlips (1) and (4)
• Press the piston pin (2) out of the piston (3)
• Remove the piston (3) from the connecting rod (5) • Unscrew the mounting bolts (1)
• Repeat the procedure on the second piston • Remove the cover (2) with the O-ring (5)
• Pull crankshaft (4) out of the housing (3)
Removing the piston rings
• Mark the installation position of the piston rings (3)

• Remove the piston rings (3) with Piston ring pli-
ers [39] (1)
• Carefully clean the piston ring grooves in the pis-
ton (2)
• Repeat the procedure on the second piston

MOUNTED COMPONENTS
Assembling the air compressor Install piston pin
• Thinly apply clean engine oil on the crankshaft

mounting
• Insert crankshaft (4) into housing (3)
• Position the cover (2) with a new O-ring (5)
24 Nm

(3)
marked
reached
(3)
• Set Piston ring pliers [39] (1) to the piston diameter rectly
• Insert the piston rings (3) into the piston (2) with • Repeat the procedure on the second piston
Piston ring pliers [39] (1), ensuring that the TOP If the circlips (1) and (4) have not engaged correctly,
mark is facing the piston crown remove and re-attach the circlips (1) and (4), ensur-
• Repeat the procedure on the second piston ing that they are seated correctly.

MOUNTED COMPONENTS
Installing the piston Attaching connecting rod bearing shell

to one another
• Thinly apply clean engine oil to the piston (1) and
cylinder running surfaces
• Put Piston ring band tool [40] on the piston (1) and
clamp it
• Push the piston (1) with connecting rod into the
cylinder liner (2) until the piston (1) has been
pushed out of the Piston ring band tool [40]
• Push in the piston (1) until the connecting rod is
lying on the crankshaft
• Repeat the procedure on piston (3)
Installing PTO shaft

• Turn the crankshaft to the installation position
• Position the connecting rod bearing shell (2) onto
the connecting rod (1)
• Screw in the new mounting bolts (3)
• Tighten mounting bolts (3) with Torque wrench [41]
with 16 Nm
• Repeat the same procedure for the second con-
necting rod

of the PTO shaft (1)
• Insert PTO shaft (1) into the air compressor (2)

MOUNTED COMPONENTS
Installing the discs Attach valve plate
• Position fins (2) and supporting plates (1) on the • Position the valve plate (2) with a new seal (1)
valve plate as marked
• Screw on and tighten the new mounting nuts (3)
Fit the cylinder head gasket
• Fit the new cylinder head gasket (1)

MOUNTED COMPONENTS
Mount the cylinder head Insert air compressor drive wheel
• Fit the intermediate plate (4) • Insert the drive wheel (2) laterally into the air com-
• Fitting the cylinder head (2) with a new seal (3) pressor (1)
• Screw in nine new mounting bolts (1) and tighten • Insert the drive wheel (2) into the toothing of the
them crosswise to Torque wrench [42] with 30 Nm crankshaft
Attaching removal device to air compressor Drive wheel PTO shaft
• Attach Removal device [38] (2) to air compressor • Insert the drive wheel (1) into the air compressor
(1) (2)
• Insert drive wheel (1) into the toothing of the PTO
shaft

MOUNTED COMPONENTS
Tightening the drive wheel mounting bolts Mounting the cover

12 Nm
• Screw in the screw plug (1) with a new seal and
tighten to 40 Nm
Installing the cover
Note
• Screw in new mounting bolts (1) (left-handed

thread) and (4) with washers (2) and (3)
• Tighten mounting bolt (1) (left-handed thread) with
Torque wrench [42] with 80 Nm • Install new covers (1) and (2) with a plastic ham-
• Tighten the mounting bolt (2) with Torque mer into the air compressor (3)
wrench [42] with 80 Nm • Unclamp Removal device [38] from vice (4) and
detach from air compressor (3)

MOUNTED COMPONENTS
Mounting the cover


MOUNTED COMPONENTS
STARTER
Removal and installation of the starter
(1) Mounting bolt (4) Flywheel housing/timing case

(2) Guard plate (5) Mounting bolt
(3) Starter (6) Terminal 30 mounting nut
Technical data
Number of starter pinion teeth ...............................................................................................................12
Starter power .................................................................................................................... 5.5 kW at 24 V
Terminal mounting nut 30 (6)................................. M10...................................................................22 Nm
Mounting bolt (5) .................................................. M12x40-10.9......................................................70 Nm
WARNING
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
Note
Crank once before installing the engine starter and check the starter ring gear for damage, where
applicable, replace the starter ring gear

MOUNTED COMPONENTS
BELT DRIVE
Removing and installing belt drive
(1) Ribbed V-belt disc, coolant pump (7) Ribbed V-belt disc, high pressure pump
(2) Poly-V-belt (8) Vibration damper
(3) Ribbed V-belt disc, alternator 2 (9) Mounting bolt
(4) Mounting bolt (10) Ribbed V-belt tensioner
(5) Alternator 3 (11) Alternator 1
(6) Mounting bolt
Technical data
Mounting bolt for ribbed V-belt tensioner (10) ......... M10x70-10.9......................................................47 Nm
Mounting bolt (6) .................................................. M14x110-10.9 ..................................................150 Nm
WARNING

MOUNTED COMPONENTS
Removing ribbed V-belts for alternators Removing the ribbed V-belt tensioner
1 and 2
Removing the ribbed V-belt

• Remove the poly-V-belt tensioner (2)
Removing the ribbed V-belt tensioner bracket

CAUTION
The poly-V-belt tensioner is under
spring tension
ally

• Remove the ribbed V-belt (1)
Removing the guide rollers

• Remove the bracket (2)
• Mark the installation position of the guide rollers

(4) and (5) as well as the distance sleeve (3)
• Remove the washers (2)
• Remove guide rollers (4) and (5) with distance
sleeve (3)

MOUNTED COMPONENTS
Install the ribbed V-belts for alternators Mounting the guide rollers
1 and 2
Mounting the ribbed V-belt tensioner bracket
• Position guide rollers (4) and (5) with distance

sleeves (3) as marked
• Position the washers (2)
• Position the bracket (2) • Screw in new mounting bolts (1) and tighten to
• Screw in and tighten the new mounting bolts (1) 60 Nm
Mounting the ribbed V-belt tensioner Mounting the poly-V-belt
• Position the ribbed V-belt tensioner (2)

• Screw in the new mounting bolt (1) and tighten to CAUTION
47 Nm The poly-V-belt tensioner is under
spring tension
ally

• Fit the ribbed V-belt (1)

MOUNTED COMPONENTS
Remove the ribbed V-belt of the coolant Removing the ribbed V-belt tensioner
compressor

• Remove the ribbed V-belt tensioner (1)
Removing the ribbed V-belt tensioner bracket

CAUTION
spring tension
ally

Removing the guide rollers


• Remove guide rollers (1)

MOUNTED COMPONENTS
Removing the ribbed V-belt for alterna- Installing the ribbed V-belt for alternator
tor 3 3
Removing the ribbed V-belt Mounting the ribbed V-belt tensioner and guide
roller
CAUTION • Position the ribbed V-belt tensioner (1)

The poly-V-belt tensioner is under • Screw in the new mounting bolt (3) and tighten to
spring tension 47 Nm
• Brace the poly-V-belt tensioner to pre- • Position the guide roller
vent it from springing back unintention- • Screw in and tighten the new mounting bolt (2)
ally
Mounting the poly-V-belt
Remove ribbed V-belt tensioner and guide roller
CAUTION
spring tension
• Mark the installation position of the mounting bolts ally
(2) and (3)
• Unscrew the mounting bolts (2) and remove guide • Turn the ribbed V-belt tensioner (1) clockwise as
roller far as the stop and hold it
• Unscrew the mounting bolt (3) • Fit the ribbed V-belt (2)
• Remove the poly-V-belt tensioner (1) • Carefully slacken the ribbed V-belt tensioner (1)

MOUNTED COMPONENTS
Installing the ribbed V-belt for the Mounting the poly-V-belt

coolant compressor
Mounting the ribbed V-belt tensioner bracket
CAUTION
• Position the bracket (2) spring tension
• Screw in and tighten the new mounting bolts (1) • Brace the poly-V-belt tensioner to pre-
Mounting the ribbed V-belt tensioner ally

• Position the ribbed V-belt tensioner (1)

• Screw in the new mounting bolt (2) and tighten to
150 Nm
• Screw in and tighten the new mounting bolt (3)
Mounting the guide rollers
• Position guide rollers (1)


MOUNTED COMPONENTS
ALTERNATORS
Removing and installing alternators 1 and 2
(1) Holder (7) Mounting bolt

(3) Holder (9) Mounting nut
(4) Mounting bolt (10) Mounting nut
(5) Mounting bolt (11) Alternator 1
(6) Mounting nut
Technical data
Mounting nuts (6), (9) ........................................... M16x1.5 ............................................................95 Nm
Mounting nut, terminal B+ ..................................... M8 ....................................................................13 Nm
Service products
Loctite 270 ........................................................................................................................ 04.10160-9062
WARNING

MOUNTED COMPONENTS
Special tools
[43] Special spanner 80.99603-6029
• Removing/installing the ribbed V-belt disc in con-

junction with:
• Gripper [44]
[44] Gripper 08.06460-0002
• Removing and installing the ribbed V-belt disc

MOUNTED COMPONENTS
Removing alternator 1 Remove the alternator
Disconnecting the alternator electrical connec-

tion
• Release and pull off the compact connector (3)

• Disconnect the cable tie (2)
• Unscrew the terminal B+ mounting nut (1)
• Expose the alternator cable harness
• Unscrew the mounting nut (5)

• Unscrew mounting bolt (1) from bracket (3)
• Remove alternator (6)
Remove the holder
CAUTION
spring tension
ally


• Remove the holder (1)

MOUNTED COMPONENTS
Undo the ribbed V-belt disc mounting nut Installing alternator 1

Mounting the ribbed V-belt disc
• Place theSpecial spanner [43] (2) with Gripper [44]

(3) on the ribbed V-belt disc mounting nut
• Insert the multiple-tooth key (1) into the alternator • Put the ribbed V-belt disc (2) onto the alternator
shaft teething shaft (3)
• Brace the multiple-tooth key (1) and undo the • Thinly apply Loctite 270 on the threads of the
mounting nut contact surface of the new mounting nut (1)
• Screw on the new mounting nut (1)
Tightening the ribbed V-belt disc mounting nut

• Remove ribbed V-belt disc (2) off the alternator • Place theSpecial spanner [43] (2) with Gripper [44]
shaft (3) (3) on the ribbed V-belt disc mounting nut
• Insert the multiple-tooth key (1) into the alternator
shaft teething
• Brace the multiple-tooth key (1) and tighten the
mounting nut with 95 Nm

MOUNTED COMPONENTS
Mounting the holders Connecting the alternator electrical connection
• Position the holder (1) • Route the alternator cable harness

• Screw in and tighten the new mounting bolts (2) • Screw on the mounting nut (1) with terminal B+
and tighten to 13 Nm
Mount the alternator • Insert and lock the compact connector (3)
• Secure the alternator wiring harness using cable
ties (2)
CAUTION
spring tension
ally

• Position alternator (6) and bracket (2) • Carefully slacken the ribbed V-belt tensioner (2)
• Screw in the new mounting bolts (1) into the
bracket (3)
• Screw in the new mounting bolt (4)
• Tighten the mounting bolts (1) and (4)
• Tighten the mounting nut (5)

MOUNTED COMPONENTS
Removing alternator 2 Remove alternator bracket

tion

(1) and (3)
• Release and pull off the compact connector (3) • Remove the holder (2)
• Unscrew the terminal B+ mounting nut (1) Remove the alternator

• Unscrew the mounting bolt (4) and remove alter-
nator
CAUTION
spring tension
ally


MOUNTED COMPONENTS
Undo the ribbed V-belt disc mounting nut Installing alternator 2


• Insert the multiple-tooth key (1) into the alternator • Put the ribbed V-belt disc (2) onto the alternator
shaft teething shaft (3)
• Brace the multiple-tooth key (1) and undo the • Thinly apply Loctite 270 on the threads of the
mounting nut contact surface of the new mounting nut (1)

• Remove ribbed V-belt disc (2) off the alternator • Place theSpecial spanner [43] (2) with Gripper [44]
shaft (3) (3) on the ribbed V-belt disc mounting nut
shaft teething

MOUNTED COMPONENTS
Mount the alternator Connecting the alternator electrical connection
• Position the bracket (1) • Route the alternator cable harness

• Position the bracket (2) and tighten to 13 Nm
• Screw in the new mounting bolt (3) • Insert and lock the compact connector (3)
• Inserting the alternator • Secure the alternator wiring harness using cable
• Screw in the new mounting bolt (4) ties (2)
• Tighten mounting bolts (3) and (4) Mounting the poly-V-belt
Attach the alternator bracket
CAUTION
• Position the bracket (2) spring tension
• Screw in and tighten the new mounting bolts (1) • Brace the poly-V-belt tensioner to pre-
and (3) as marked vent it from springing back unintention-
ally


MOUNTED COMPONENTS
Removing and installing alternator 3

Additional jobs
– Remove the ribbed V-belt of the coolant compressor, see 156
– Installing the ribbed V-belt for the coolant compressor, see 158
(1) Alternator 3 (4) Mounting bolt

(2) Poly-V-belt pulley (5) Mounting bolt
(3) Mounting nut
Technical data
Mounting nut (3) ................................................... M16x1.5 ............................................................95 Nm
Service products
Loctite 270 ........................................................................................................................ 04.10160-9062
WARNING

MOUNTED COMPONENTS
Special tools
[45] Special spanner 80.99603-6029
• Removing/installing the ribbed V-belt disc in con-

junction with:
• Gripper [46]
[46] Gripper 08.06460-0002
• Removing and installing the ribbed V-belt disc

MOUNTED COMPONENTS
Removing alternator 3 Remove the alternator

tion

• Release and pull off the compact connector (3) Remove the holder

Undo the ribbed V-belt disc mounting nut
CAUTION
spring tension
ally


shaft teething
• Brace the multiple-tooth key (1) and undo the
mounting nut

MOUNTED COMPONENTS
Removing the ribbed V-belt disc Installing alternator 3


• Remove ribbed V-belt disc (2) off the alternator
shaft (3) • Put the ribbed V-belt disc (2) onto the alternator
shaft (3)
• Thinly apply Loctite 270 on the threads of the
contact surface of the new mounting nut (1)

shaft teething

MOUNTED COMPONENTS
Mounting the holders Mounting the poly-V-belt
• Position the holder (2)

CAUTION
Mount the alternator spring tension
ally

Connecting the alternator electrical connection
• Position alternator (1)

and (3)
• Route the alternator cable harness

• Screw on the mounting nut (1) with terminal B+
and tighten to 13 Nm
• Insert and lock the compact connector (3)
• Secure the alternator wiring harness using cable
ties (2)

MOUNTED COMPONENTS
REFRIGERANT COMPRESSOR
Removal and installation of the coolant compressor
Additional jobs
(1) Holder (6) Mounting bolt

(3) Mounting bolt (8) Carrier
(5) Refrigerant compressor (10) Mounting nut
Technical data
CAUTION
Refrigerant and refrigerator oil can harm your health and the environment
• Do not let refrigerant and refrigerator oil come into contact with the skin
• Disposing of refrigerant and refrigerator oil in the correct manner
WARNING

MOUNTED COMPONENTS
Removing the refrigerant compressor Remove the alternator

tion

• Release and pull off the compact connector (3) Remove the holder

CAUTION
spring tension
ally


MOUNTED COMPONENTS
Remove the refrigerant compressor Removing the coolant compressor

bracket
Remove the bracket
CAUTION
nents • Mark the installation position of the mounting bolts
• Lift the coolant compressor using lifting (2) and (4)
gear and the hoist • Unscrew the mounting bolts (4)
• Unscrew the mounting bolts (2) • Unscrew the mounting bolts (2)
• Lift out the coolant compressor (1) • Remove the holder (1)
Remove the bracket

(1) and (2)
• Unscrew the mounting bolts (1) and (2) and re-
move the bracket

MOUNTED COMPONENTS
Removing the console Installing the coolant compressor

bracket
Installing the console
CAUTION
nents
• Lift out bracket using lifting equipment CAUTION
and the hoist Danger of injury due to heavy compo-
nents
• Mark the installation position of the mounting bolts • Position the bracket with lifting equip-
(1), (2) and (4) ment and lifting gear
• Remove the holder (3) • Position the bracket (5)
• Unscrew the mounting bolts (4) • Screw in and tighten the new mounting bolts (4)
• Remove the bracket (5) as marked
• Position the bracket (3)
and (2) as marked
Mounting the bracket
• Position bracket
• Screw in mounting bolts (1) and (2) as marked and
tighten

MOUNTED COMPONENTS
Mounting the holders Installing the refrigerant compressor

Installing the refrigerant compressor

as marked CAUTION
• Position the bracket (3) Danger of injury due to heavy compo-
• Screw in and tighten the new mounting bolts (4) nents
as marked • Position coolant compressor with lifting
equipment and lifting gear
• Position the coolant compressor (1)

Mounting the holders


MOUNTED COMPONENTS
Mount the alternator Connecting the alternator electrical connection
• Position alternator (1) • Route the alternator cable harness

and (3) and tighten to 13 Nm
• Insert and lock the compact connector (3)
Mounting the poly-V-belt • Secure the alternator wiring harness using cable
ties (2)
CAUTION
spring tension
ally


COMMON RAIL SYSTEM
COMMON RAIL SYSTEM
(1) Mounting nut (9) Mounting bolt

(2) Injector wiring harness (10) Ribbed V-belt disc, high-pressure pump
(3) Rail connection (11) Mounting bolt
(4) Pressure screw (12) High-pressure line
(5) Bracket, fuel service centre (13) Cylinder head
(6) Fuel service centre (14) Pressure flange
(7) Fuel pump (15) Mounting bolt
(8) High-pressure pump (16) Injector

COMMON RAIL SYSTEM
INJECTORS AND PRESSURE PIPE

Protective sleeves for injectors and pressure pipe
(1) Protective sleeve Z 14 x 15 (8) Protective sleeve Z 18 x 15

81.96002-0512 81.96002-0555
(2) Plug 81.96002-0521 (9) Plug 81.96002-0556
(3) Cap 81.96002-0518 (10) Plug 81.96002-0521
(4) Plug 81.96002-0521 (11) Plug 81.96002-0541
(5) Cover lid 81.96002-0518 (12) Plug 81.96002-0520
(6) Plug 81.96002-0521 (13) Injector storage sleeve 09.81020-1000
(7) Protective sleeve Z 14 x 15 (14) Cap injector supply bore 81.96002-0523
81.96002-0512 (15) Injector nozzle protective sleeve
81.96002-0522
WARNING
Note
In order to ensure that the correct protective sleeve is used, the designation (e. g. Z 14 x 15) is
imprinted in the protective sleeves. This is integrated in the special tool designation (e. g. protective
sleeve, high-pressure line connection Z 14 x 15).

COMMON RAIL SYSTEM
Special tools
[47] Injector storage sleeve 09.81020-1000
• Storing the injectors
[48] plug 81.96002-0520
• Plugging the cylinder head injector bore
[49] Injector nozzle protective sleeve 81.96002-0522
• Plugging the injector nozzle
[50] Fit cap injector supply bore 81.96002-0523
• Plugging the injector feed bore
[51] plug 81.96002-0541
• Plug the bore for the pressure pipe fitting
[52] plug 81.96002-0521
• Plugging the high-pressure lines

• Plugging the fuel return line bore
• Plugging the high-pressure line high pressure
pump-pressure pipe
[53] Protective sleeve Z 14 x 15 81.96002-0512
• Plugging the high-pressure line connections

COMMON RAIL SYSTEM
[54] Cap 81.96002-0518
• Plugging the fuel line hollow screw connections
[55] plug 81.96002-0556
• Plug the rail-pressure sensor bore in the pressure

pipe
• Plugging the pressure-limiting valve bore in the
pressure pipe
• Close off rail pressure sensor

• Plugging the pressure-limiting valve

COMMON RAIL SYSTEM
Removing and installing the injectors and pressure pipe

Additional jobs
– Protective sleeves for injectors and pressure pipe, see 181
– Removal and installation of the engine control unit, see 241
– Removal and installation of the fuel service centre, see 225
(1) Pressure screw (6) Injector

(2) Pressure pipe socket (7) Mounting nut
(3) Cylinder head (8) Injector cable harness
(4) Pressure flange (9) Pressure pipe
Technical data
High-pressure line ..........................................................................................................1st torque 10 Nm
High-pressure line ............................................................................................................Final torque 60°
Mounting bolt (10) ................................................ M8x50-10.9 ......................................1st torque 1.5 Nm
Mounting bolt (10) ................................................ M8x50-10.9 .................................... Final torque 35 Nm
Mounting bolt (5) .................................................. M8x50-10.9 ......................................1st torque 1.5 Nm
Mounting bolt (5) .................................................. M8x50-10.9 ........................... Final torque 25 Nm + 90°
Pressure screw (1) ....................................................................................................... 1st torque 10 Nm
Pressure screw (1) ............................................................................................. Final torque 20 Nm + 60°
Mounting nut (7) .................................................. Cable lug nut M4...............................................1.5 Nm
Mounting bolt of the injector cable harness (8) ....... M6x16-10.9 .......................................................15 Nm
Pressurisation, drip test .......................................................................................................... 4 + 0.5 bar
Pressure drop .................................................................................................................0.1 bar in 10 min
Rail pressure sensor............................................. M18x1.5 ............................................................70 Nm
Pressure-limiting valve.......................................... M20x1.5 ..........................................................100 Nm

COMMON RAIL SYSTEM
Mounting bolts, cylinder head cover.................................................................................................10 Nm
Service products
WARNING
The common rail system may suffer damage
• 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 to enable de-pres-
surisation in the pressure pipe, or de-pressurisation must be checked by means of MAN-cats®
(specified value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Always fit new pressure pipe sockets once the existing ones have been undone
• Do not reuse plugs for the high-pressure lines, the pressure pipe or injectors
• Follow the sequence described when tightening injectors, high-pressure lines, the pressure pipe
and pressure pipe sockets
WARNING
Component damage from re-used high-pressure lines
• Do not reuse high-pressure lines
Always replace the high-pressure lines
WARNING
Danger of damage due to dirt ingress
• Always remove only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
Special tools
[57] extractor 80.99602-0011
• Removing the pressure pipe fitting in conjunction

with:
• Adapter [58]
[58] Adapter 80.99602-0173
• Removing the pressure pipe socket
[59] Extension 08.06139-9025
• Remove/install high-pressure lines in conjunction

with:
• Socket, size 17 [60]

COMMON RAIL SYSTEM
[60] Socket, size 17 80.99603-0309
• Removing and installing the high-pressure lines
[61] Socket, size 19 80.99603-0310
• Removal and installation of the high pressure

pump
[62] Extractor 80.99601-6022
• Extracting the injector in conjunction with:

• Plate [63]
• Column 66 mm [64]
• Column 70 mm [65]
• Hex nut [66]
[63] Plate 80.99602-0176
• Extracting the injector
[64] Column 66 mm 80.99602-0193
[65] Column 70 mm 80.99602-0194
[66] Hex nut 06.11226-8306
[67] Torque screwdriver 08.06510-9024
• Mount the injector cable in conjunction with:

• Adapter [68]

COMMON RAIL SYSTEM
[68] Adapter 08.06139-9029
• Attaching the injector cable
[69] Socket, size 7 08.06141-0700
• Attaching the injector cable
[70] Pressure shim 80.99606-0609
• Installing the injectors
[71] Pressure loss tester 80.99607-6027
• Checking the high-pressure system for leaks in

conjunction with:
• Adapter [72]
• GE union [73]
• Hollow screw [74]
• Ring union [75]
• Seal with elastomer sealing lip [76]
[72] Adapter 80.99620-0033
• Checking the high-pressure system for leaks
[73] GE union 81.98130-0614
[74] Hollow screw 51.98150-0175

COMMON RAIL SYSTEM
[75] Ring union 51.98103-0037
[76] Seal with elastomer sealing lip 06.56639-0017

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

pipe
Detaching fuel return line
WARNING
• Always detach only one high-pressure
WARNING line
Component damage through fuel in • Close the component connections im-
the combustion chamber mediately using new, clean protective
• Allow the fuel return duct in the cylinder sleeves
head to empty before the injectors are
removed • Mark the installation position of the high-pressure
lines (2)
WARNING
• Remove the high-pressure lines (2) with Socket,
Danger of environmental pollution
size 17 [60] (1) and Extension [59] (3)
• Collect any remaining fuel that emerges
in a suitable container Detaching the pressure pipe
• Unscrew the hollow screw (1) with seals and allow
return duct to run empty
• Unscrew the hollow screw (2) with seals from the
pressure pipe (3)
• Detaching fuel return line
Detaching the high-pressure line

• Remove the pressure pipe (1)

• Remove high pressure line (3) with Socket, size
19 [61] and Extension [59] from the high pressure
pump (4) and the pressure pipe (1)

COMMON RAIL SYSTEM
Unscrewing the rail pressure sensor and pres- Removing the cylinder head cover
sure-limiting valve
Note
WARNING The mounting bolts can only be removed
Component damage due to lack of lu- from the cylinder head cover with damp-
bricant ing elements and spacer sleeves.
• Do not clean the pressure-limiting valve
and rail pressure sensor as the thread • Unscrew the mounting bolts (4)
and biting edge are coated with lubri- • Remove the cylinder head cover (3) with gasket
cant (2) from the cylinder head (1)
• Clean the cylinder head cover (3) and the gasket
• Unscrew the rail pressure sensor (2) (2)
• Unscrew the pressure-limiting valve (1) Check the gasket (2) for damage. Remove from
the cylinder head cover (3) and replace if required
Removing the cable duct cover • Set aside the cylinder head cover (3) on a clean
surface with the gasket (2) facing downwards
If this is not done, engine oil can enter the gasket
section (2). When the cylinder head cover (3) is
tightened, this oil is then pressed out, causing sup-
posed leakage
Removing the pressure pipe socket
• Open the locking pin (2) a quarter turn

• Remove the cable duct cover (1)
• Unscrew the pressure screw (3)

• Extract the pressure pipe socket (2) from the cylin-
der head (1) with Adapter [58] and extractor [57]

COMMON RAIL SYSTEM
Removing the injector cable Assembling the special tool
• Loosing the mounting nuts (2) • Assemble Plate [63] (4) with Column 66 mm [64]
• Remove the injector cable harness (1) (1), Column 70 mm [65] (5) and Hex nut [66] (2)
• Insert the Extractor [62] (3) into the Plate [63] (4)
Removing injector cable harness
Extracting the injector
• Carefully take out the injector cable harness (4)

from the camshaft bearing cap (1)
WARNING
Component damage due to improper
• Carefully pull out the flange (2) from the cylinder
removal of the injector
head
• Always first remove the relevant pres-
• Carefully remove the injector cable harness (4)
sure pipe socket before removing the
through the borehole
injector
Unscrewing the pressure flange mounting bolt • Always detach only one injector
• Put on the special tool (1)

• Insert the Extractor [62] into the groove for the
pressure flange
• Clamp the clamping sleeve (5) with the knurled nut
(2)
• Extract the injector (4) from the cylinder head by
turning the knurled nut (3)

the spherical washer (1)

COMMON RAIL SYSTEM
Installing the injectors and pressure Installing the rail connection

pipe
Installing the injector
WARNING
Pressure pipe fittings are compressed
at the cone during installation
Note • Do not reuse pressure pipe fittings
Always install injectors together with
pressure flange. It is not possible to • Slide the new pressure pipe socket (2) into the
install the pressure flange afterwards. cylinder head (1) so that the balls on the pressure
pipe socket (2) are located in the groove in the
• Remove the old gaskets (5) cylinder head
• Check to ensure that the bore in the cylinder head • Screw in the pressure screw (3) and tighten to 1st
is clean torque 10 Nm
• Do not remove the injector (2) from the Injector
storage sleeve [47] until immediately before in- Injector final torque
stallation
• Remove the protective sleeves
• Slide the pressure flange (1) onto the injector (2),
ensuring that the fuel inlet opening (3) is turned
towards the mounting bore (4) of the pressure pipe
socket
• Insert the injector (2) into the cylinder head with a
new O-ring (6) and a new gasket (5)
• Press the injector (2) fully into the cylinder head
with the Pressure shim [70]
Injector 1. torque
• Tightening the pressure flange mounting bolt of

the injector (1) to Final torque 25 Nm + 90°
• Screw in the new mounting bolt (2) for the pressure

flange with the spherical washer (1)
• Tighten the mounting bolt (2) to 1st torque 1.5 Nm

COMMON RAIL SYSTEM
Rail connection final torque Attaching the injector cable
• Tighten the pressure screw (1) to Final

WARNING
torque 20 Nm + 60°
Component damage due to possible
Installing the injector cable harness short-circuit
• When tightening the mounting nuts,
ensure that the cable connectors are
not in contact
• Insert Socket, size 7 [69] (2) with Adapter [68] on

Torque screwdriver [67] (3)
• Tighten the mounting nuts (1) to 1.5 Nm
• Thinly apply Technical Vaseline to a new O-ring for

injector cable harness (4)
• Carefully insert the injector cable harness (4)
through the borehole
• Carefully insert the flange (2) into the cylinder head
• Screw in the mounting bolts (3) and tighten to
15 Nm
• Carefully insert the injector cable harness (4) into
the camshaft bearing shell (1)

COMMON RAIL SYSTEM
Tightening sequence for cylinder head cover Mounting the cable duct cover
• Put on the cable duct cover (1)

• Close the locking pin (2) a quarter turn
Screw in the rail pressure sensor and pres-

sure-limiting valve
A Intake side
B Exhaust side
• Stick to the illustrated mounting bolt tightening

sequence 1 to 18 in the following work step
Mounting the cylinder head cover

WARNING
Component damage due to lack of lu-
bricant
• Do not clean the pressure-limiting valve
and rail pressure sensor as the thread
and biting edge are coated with lubri-
cant
• Screw in the new rail pressure sensor (2) and

tighten to 70 Nm
• Screw in the new pressure-limiting valve (1) and
tighten to 100 Nm
• Put the cylinder head cover (3), if necessary with

a new gasket (2), on the cylinder head (1)
• Screw in the mounting bolts (4)
• Tighten the mounting bolts (4) to 10 Nm in the
sequence indicated

COMMON RAIL SYSTEM
Mounting the rail Pressure pipe final tightening
• Position the pressure pipe (1) on the cylinder head • Tighten the mounting bolts (1) to Final
• Screw in new mounting bolts (2) and tighten to torque 35 Nm
1st torque 1.5 Nm
High-pressure line final tightening
Attaching the high-pressure lines
• Tighten the high-pressure lines (2) to Final

torque 60° using Socket, size 17 [60] (1) and
WARNING
Extension [59] (3)
Component damage due to misaligned
high-pressure lines
• After the initial torque, check the align-
ment of the high-pressure line, reseat if
needed
• Attach the high pressure lines (2) according to the

markings on the pressure pipe (3) and pressure
pipe socket (1)
• Tighten the high-pressure lines (2) to
1st torque 10 Nm using Socket, size 17 [60] and
Extension [59]

COMMON RAIL SYSTEM
Attaching the high-pressure line Checking the pressure loss
• Attach the high-pressure line (3) to the high pres-

WARNING
sure pump (4) and the pressure pipe (1)
Injectors can be damaged
• Tighten the high-pressure line (3) to
• Pressurisation for the leak test must not
1st torque 10 Nm using Socket, size 19 [61] and
exceed 4 + 0.5 bar
Extension [59]
• Check that the high-pressure line (3) is seated free
• Pressurise the Pressure loss tester [71] using
of stress
4 + 0.5 bar
• Pull off the compressed-air connection (2)
• Tighten the high-pressure line (3) to Final
• Check the maximum permitted pressure loss on
torque 60° using Socket, size 19 [61] and Exten-
the pressure gauge (1)
sion [59]
Pressure loss setpoint value is max.
Mounting the pressure loss tester 0.1 bar in 10 min.
Attaching the fuel return line
• Mount the Ring union [75] with Hollow screw [74]

(2) and Seal with elastomer sealing lip [76] on the • Position the fuel return line
union (1) • Screw in the hollow screw (1) with new seals
• Mount the Adapter [72] with GE union [73] and • Screw in the hollow screw (2) with new seals into
Pressure loss tester [71] (3) on the Ring union [75] the pressure pipe (3)
• Tighten hollow screws (1) and (2)

COMMON RAIL SYSTEM
HIGH-PRESSURE PUMP/HIGH-PRESSURE PUMP DRIVE

Protective sleeves for high-pressure pump/high-pressure pump drive
(1) Cover lid 81.96002-0518 (10) Protective sleeve Z 14 x 15

(2) Cover lid 81.96002-0518 81.96002-0512
(3) Plug 81.96002-0521 (11) Plug 81.96002-0521
(4) Cover lid 81.96002-0518 (12) Plug 81.96002-0521
(5) Cover lid 81.96002-0518 (13) Plug 81.96002-0521
(7) Cover lid 81.96002-0518 81.96002-0512
(8) Plug 81.96002-0521 (15) Protective sleeve Z 14 x 15
(9) Protective sleeve Z 14 x 15 81.96002-0512
81.96002-0512 (16) Plug 81.96002-0521
WARNING
Note

COMMON RAIL SYSTEM
Special tools
• Plugging the high pressure pump connections

• Plugging the fuel return line
[78] Cap 81.96002-0518
[79] plug 81.96002-0521
• Plugging the high-pressure lines

• Seal the fuel lines
• Seal the KSC bores

COMMON RAIL SYSTEM
Removing and installing the high pressure pump/high pressure pump drive (fuel-lu-
bricated)
Additional jobs
– Removing alternator 2, see 164
– Installing alternator 2, see 165
– Protective sleeves for fuel service centre, see 223
– Protective sleeves for high-pressure pump/high-pressure pump drive, see 197
(1) Fuel service centre (6) Mounting bolt

(2) High-pressure pump (7) High pressure pump drive
(3) Mounting bolt (8) High-pressure line
(4) Ribbed V-belt disc, high pressure pump (9) KSC bracket
(5) Washer
Technical data
Mounting bolts for high pressure pump (2) ............. M10x50-10.9......................................................65 Nm
High pressure pump drive mounting bolts (7) ......... M12x90-10.9.................................................... 115 Nm
High-pressure line (8) .....................................................................................................1st torque 10 Nm
High-pressure line (8) .......................................................................................................Final torque 60°
Fuel-fill level for high pressure pump (2) ........................................................................................... 60 ml
Fuel-filling screw for high pressure pump (2) .......... M10x1 ...............................................................18 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292

COMMON RAIL SYSTEM
WARNING
personnel only
(specified value 0)
WARNING
WARNING
WARNING
WARNING
PTFE seals are rendered unusable if they come into contact with oil or grease before instal-
lation
• Clean the high pressure pump drive and press-in tool before assembly
Special tool
[80] Removing device 80.99601-6021
• Removing the high pressure pump in conjunction

with:
• impact tool [81]
[81] impact tool 80.99606-6078
• Removing the high pressure pump
[82] Impact extractor 80.99602-0016
• Extract the radial shaft seal in conjunction with:

• Hook [83]

COMMON RAIL SYSTEM
[83] Hook 80.99602-0137
• Removing the radial shaft seal
[84] Plug-on handle 80.99617-0187
• Press in the radial shaft seal in conjunction with:

• Washer [85]
• Press plate [86]
[85] Washer 80.99617-0144
• Pressing in the radial shaft seal
[86] Press plate 80.99604-0289
[87] Socket, size 19 80.99603-0310
• Remove/install high-pressure line in conjunction

with:
• Extension [88]
[88] Extension 08.06139-9025
• Removal and installation of the high-pressure

pump
[89] Engine barring gear 80.99626-6008
• Barring the engine

COMMON RAIL SYSTEM
Removing the high pressure pump Removing the high pressure pump if
firmly seated

• Remove high pressure line (3) with Socket, size • Unscrew the mounting bolt (2)
19 [87] and Extension [88] from the high pressure • Remove high pressure line (3) with Socket, size
pump (4) and the pressure pipe (1) 19 [87] and Extension [88] from the high pressure
Removing the high pressure pump
Fitting the special tool

• Remove the high pressure pump (3) from the high • Unscrew the mounting bolts for the high pressure
pressure pump drive (5) pump (5)
• Remove the O-ring (1) • Screw the threaded spindle (2) into the plate (3)
• Pull the driver (4) off the drive shaft for the Removing device [80] (4) using the impact
tool [81] (1) until flush
• Mount Removing device [80] (4) on the high-pres-
sure pump (5) using two bolts

COMMON RAIL SYSTEM
Removing the high pressure pump Removing the high pressure pump drive
Mount engine cranking unit
• Carefully remove the high pressure pump (3) with

light blows from the high pressure pump drive
by using impact tool [81] (1) and Removing de- • Remove the cover from the flywheel hous-
vice [80] (2) ing/timing case
• Mount the Engine barring gear [89] (1) on the
flywheel housing/timing case and lock

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

COMMON RAIL SYSTEM
Removing the hub Installing the high-pressure pump drive

Installation instructions for high-pressure pump
drive

• Remove the washer (2)
• Pull the hub (3) from the multi-tooth shaft (4)
• Thinly apply Loctite 5900 sealing agent (1) on the
Extracting the high-pressure pump drive radial area to be sealed of the high pressure pump drive
shaft seal as illustrated
Mount the high pressure pump drive
• Remove the radial shaft seal (3) using Impact

extractor [82] (2) and Hook [83] (1)
• Position the high pressure pump drive (2)
Remove the high pressure pump drive • Screw in new mounting bolts (1) and tighten to
115 Nm
• Unscrew the mounting bolts (1) and remove the

high pressure pump drive (2)

COMMON RAIL SYSTEM
Pressing in the radial shaft seal Mount the ribbed V-belt disc
• Press the new radial shaft seal (2) with Plug-on

handle [84] (3) and Washer [85] as well as Press
plate [86] (4) into the high pressure pump drive (1)
Position hub

• Screw in and tighten the mounting bolts (1)
Removing engine cranking device
• Position new hub (1)

• Thinly apply Loctite 5900 (2) as illustrated
Mounting the washer
• Remove the Engine barring gear [89] (1) from the

flywheel housing/timing case
• Mount the cap on the flywheel housing/timing case
• Position washer (2) on hub (3)

• Tighten mounting bolts (1) by hand
• Thinly apply Loctite 5900 on the threads of the new
mounting bolts (4)
• Screw in and tighten the mounting bolt (4)

COMMON RAIL SYSTEM
Installing the high pressure pump Attaching the high-pressure line
Fill high pressure pump with fuel

WARNING • Tighten the high-pressure line (3) to
Danger of damage due to dirt ingress 1st torque 10 Nm using Socket, size 19 [87] and
• Ensure that no dirt can contaminate the Extension [88]
pump when filling • Check that the high-pressure line (3) is seated free
• After filling, ensure the high pressure of stress
pump is no longer tilted • Screw in and tighten the new mounting bolt (2)
• Unscrew the filler plug (2) and remove with the torque 60°
seal
• Via pipette (1) 60 ml, fill with clean and filtered
diesel fuel
• Screw in the filler plug (2) with a new seal and
tighten to 18 Nm
Installing the high pressure pump
• Slide the driver (4) onto the drive shaft for the high
pressure pump (3)
• Thinly apply Technical Vaseline on a new O-ring
(1) and place it on the high pressure pump (3)
• Insert the high pressure pump (3) into the high
pressure pump drive (5)
65 Nm

COMMON RAIL SYSTEM
Removing and installing the high pressure pump/high pressure pump drive (fuel-lu-
bricated)
Additional jobs

(2) High-pressure pump (7) High pressure pump drive
(3) Mounting bolt (8) High-pressure line
(4) Ribbed V-belt disc, high pressure pump (9) KSC bracket
(5) Washer
Technical data
Oil fill amount for the high pressure pump (2) .................................................................................... 40 ml
Oil filler plug of high pressure pump (2).................. M10x1 ...............................................................18 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292

COMMON RAIL SYSTEM
WARNING
personnel only
(specified value 0)
WARNING
WARNING
WARNING
WARNING
lation
• Clean the high pressure pump drive and press-in tool before assembly
Special tool
• Removing the high pressure pump in conjunction

with:
• impact tool [91]
[91] impact tool 80.99606-6078
• Removing the high pressure pump

• Hook [93]

COMMON RAIL SYSTEM
[93] Hook 80.99602-0137
[94] Plug-on handle 80.99617-0187

• Washer [95]
[95] Washer 80.99617-0144
[96] Press plate 80.99604-0289
[97] Socket, size 19 80.99603-0310
• Remove/install high-pressure line in conjunction

with:
• Extension [98]
[98] Extension 08.06139-9025
• Removal and installation of the high-pressure

pump

COMMON RAIL SYSTEM
Removing the high pressure pump Removing the high pressure pump if
firmly seated

• Remove high pressure line (2) with Socket, size • Unscrew the mounting bolt (3)
19 [97] and Extension [98] from the high pressure • Remove high pressure line (2) with Socket, size
pump (4) and the pressure pipe (1) 19 [97] and Extension [98] from the high pressure
Removing the high pressure pump
Fitting the special tool

• Remove the high pressure pump (3) from the high • Unscrew the mounting bolts for the high pressure
pressure pump drive (1) pump (1)
• Remove the O-rings (2) and (5) • Screw the threaded spindle (4) into the plate (5)
• Pull the driver (6) off the drive shaft for the Removing device [90] (2) using the impact
tool [91] (3) until flush
• Mount Removing device [90] (2) on the high-pres-
sure pump (1) using two bolts

COMMON RAIL SYSTEM
Removing the high pressure pump Removing the high pressure pump drive
• Carefully remove the high pressure pump (1) with

light blows from the high pressure pump drive
by using impact tool [91] (2) and Removing de- • Remove the cover from the flywheel hous-
vice [90] (3) ing/timing case

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

COMMON RAIL SYSTEM
Removing the hub Installing the high-pressure pump drive

Installation instructions for high-pressure pump
drive

• Remove the washer (2)
• Pull the hub (3) from the multi-tooth shaft (4)
• Thinly apply Loctite 5900 sealing agent (1) on the
Extracting the high-pressure pump drive radial area to be sealed of the high pressure pump drive
shaft seal as illustrated
Mount the high pressure pump drive
• Remove the radial shaft seal (3) using Impact

• Position the high pressure pump drive (2)
Remove the high pressure pump drive • Screw in new mounting bolts (1) and tighten to
115 Nm

high pressure pump drive (2)

COMMON RAIL SYSTEM
Pressing in the radial shaft seal Mount the ribbed V-belt disc

plate [96] (4) into the high pressure pump drive (1)
Position hub

• Position new hub (1)

• Thinly apply Loctite 5900 (2) as illustrated
Mounting the washer

• Position washer (2) on hub (3)

• Tighten mounting bolts (1) by hand
• Thinly apply Loctite 5900 on the threads of the new
mounting bolts (4)

COMMON RAIL SYSTEM
Installing the high pressure pump Attaching the high-pressure line
Fill high pressure pump with fuel

WARNING • Tighten the high-pressure line (2) to
Danger of damage due to dirt ingress 1st torque 10 Nm using Socket, size 19 [97] and
• Ensure that no dirt can contaminate the Extension [98]
pump when filling • Check that the high-pressure line (2) is seated free
• After filling, ensure the high pressure of stress
pump is no longer tilted • Screw in and tighten the new mounting bolt (3)
• Unscrew the filler plug (2) and remove with the torque 60°
seal
• Using a pipette (1) 40 ml fill with clean engine oil
• Screw in the filler plug (2) with a new seal and
tighten to 18 Nm
Installing the high pressure pump
• Slide the driver (6) onto the drive shaft for the high
pressure pump (3)
• Thinly apply Technical Vaseline on new O-rings (2)
and (5) and apply to the high pressure pump (3)
• Insert the high pressure pump (3) into the high
pressure pump drive (1)
65 Nm

COMMON RAIL SYSTEM
High pressure pump/high pressure pump drive disassembly and assembly

Additional jobs
– Removing and installing the high pressure pump/high pressure pump drive (fuel-lubricated), see 199
(1) Drive housing (8) Mounting bolt

(2) Drive wheel (9) Metering unit
(3) Drive shaft (10) Mounting bolt
(4) Driver (11) Fuel pump
(5) High-pressure pump (12) Coupling element
(6) Flow regulator valve (13) Sleeve
(7) Overflow valve (14) Cylindrical pin
Technical data
Flow regulator valve (6) ..................................................................................................................34 Nm
Overflow valve (7) ..........................................................................................................................20 Nm
Mounting bolt (8) .................................................. M5x20 .................................................1st torque 4 Nm
Mounting bolt (8) .................................................. M5x20 ..............................................Final torque 7 Nm
Mounting bolt (10) ................................................ M6x20 ................................................................ 8 Nm

COMMON RAIL SYSTEM
WARNING
personnel only
WARNING
Special tools

• Hook [101]
[101] Hook 80.99602-0137
[102] Plug-on handle 80.99617-0187

• Washer [103]
[103] Washer 80.99617-0144
[104] Press plate 80.99604-0289

COMMON RAIL SYSTEM
Dismantling the high pressure pump Remove fuel supply pump (fuel-lubricated ver-
sion for high pressure pump)
Remove proportional valve (fuel-lubricated ver-

• Pull out the fuel pump (2)
• Clean the high-pressure pump and blow it dry • Remove the coupling element (4) and the O-ring
using compressed air (3) from the fuel pump (2)
• Mark the installation position of the metering
unit (2) Remove fuel supply pump (oil-lubricated version
• Unscrew the mounting bolts (1) for high pressure pump)
• Extract the metering unit (2) by turning slightly to
the right/left
Remove proportional valve (oil-lubricated ver-


• Pull out the fuel supply pump (3)
• Remove coupling piece (4) and O-ring from the
fuel supply pump (3)
• Clean the high-pressure pump and blow it dry

using compressed air
• Mark the installation position of the proportional
valve (1)
• Extract the proportional valve (1) by turning slightly
to the right/left

COMMON RAIL SYSTEM
Remove overflow and flow regulator valve Assembling the high pressure pump
(fuel-lubricated version for high pressure pump)
Install overflow and flow regulator valve (fuel-lu-
bricated version for high pressure pump)
• Unscrew the overflow valve (2) from the high pres-

sure pump and remove with O-ring (3)
• Unscrew the flow regulator valve (1) from the high • Screw in the overflow sensor (2) with a new O-ring
pressure pump and remove with O-ring (4) and (3) and tighten to 20 Nm
seal (5) • Screw in the flow control valve (1) with a new
O-ring (4) and new sealing ring (5) and tighten
to 34 Nm
Install fuel supply pump (fuel-lubricated version

for high pressure pump)
• Insert the coupling element (4) and a new O-ring

(3) into the fuel pump (2)
• Insert the fuel pump (2)
• Screw in the mounting bolts (1) and tighten to 8 Nm

COMMON RAIL SYSTEM
Install fuel supply pump (oil-lubricated version Install proportional valve (oil-lubricated version
for high pressure pump) for high pressure pump)
• Insert the coupling element (4) and a new O-ring

Note
into the fuel supply pump (3)
When using micro-encapsulated bolts,
• Insert the fuel supply pump (3)
the time between the tightening stages
• Screw in the mounting bolts (1) and (2) and tighten
must not exceed 2 minutes.
to 8 Nm
• Insert the new proportional valve (1) into the high
Install proportional valve (fuel-lubricated ver-
pressure pump by turning slightly to the right/left
• Align proportional valve (1) as marked
• Tighten the mounting bolts (2) to 1st torque 4 Nm
• Tighten the mounting bolts (2) to Final torque 7 Nm
Note
When using micro-encapsulated bolts,
the time between the tightening stages
must not exceed 2 minutes.
• Insert the new metering unit (2) into the high-pres-

sure pump by turning slightly to the right/left
• Align metering unit (2) as marked
• Tighten the mounting bolts (1) to Final torque 7 Nm

COMMON RAIL SYSTEM
Disassemble the high pressure pump Removing the drive gear

drive
Extracting the high-pressure pump drive radial
shaft seal
• Remove the drive gear (1) from the drive housing

(2)
• Check the components for wear
If components are worn, the high pressure pump
• Remove the radial shaft seal (2) using Impact drive must be replaced.
Removing the drive shaft
• Pull the centring pin (1) and sleeve (5) out of the
drive housing (2)
• Mark the installation position of the drive wheel
relative to the drive shaft (3)
• Brace drive shaft (3)
• Pull out the drive shaft (3)
• Check the drive shaft (3) for wear
If the drive shaft (3) is worn, the high-pressure pump
drive must be replaced.

COMMON RAIL SYSTEM
Assemble the high-pressure pump drive Pressing in the radial shaft seal
Installing the drive gear

• Insert the drive wheel (1) into the drive housing (2) plate [104] (2) into the high pressure pump drive
(3)
Installing the input shaft

of the input shaft (3)
• Insert the input shaft (3) through the drive gear into
the drive housing (2) as marked
• Brace drive shaft (3)
• Insert centring pin (1) and sleeve (5) into the drive
housing (2)

COMMON RAIL SYSTEM
FUEL SERVICE CENTRE

Protective sleeves for fuel service centre
(1) Cover lid 81.96002-0518 (6) Plug 81.96002-0521

(2) Plug 81.96002-0521 (7) Plug 81.96002-0521
(3) Plug 81.96002-0521 (8) Plug 81.96002-0521
(5) Plug 81.96002-0521 81.96002-0512
WARNING
Note

COMMON RAIL SYSTEM
Special tools
[105] plug 81.96002-0521
• Plugging the fuel line

• Seal the KSC bores
• Plugging the fuel line connections
[107] Cap 81.96002-0518

COMMON RAIL SYSTEM
Removal and installation of the fuel service centre

Additional jobs
(1) Hollow screw (7) Fuel line (KSC - solenoid valve)

(2) Fuel return line (8) Fuel line
(3) Hollow screw (9) Hollow screw
(4) Fuel return line (10) Hollow screw
(5) Fuel Service Centre (KSC) (11) Flame glow plug
(6) Heating element
Technical data
Hollow screw (10) ................................................. M10x1 ...............................................................15 Nm
WARNING
WARNING

COMMON RAIL SYSTEM
WARNING
• Collect any emerging fuel in a suitable container
Note
Mark all fuel lines before dismounting according to their function and installation position.

COMMON RAIL SYSTEM
Removing the fuel service centre Removing the fuel service centre
Remove KSC fuel lines

• Remove the KSC (1)
• Unscrew hollow screws (1) and (2) and remove
with the seals Remove the bracket
• Dismantle fuel lines (3) and (4)
• Dismantle fuel line (5) and remove with seals
Remove KSC fuel lines
• Mark the installation position of the mounting

bolts (1)
• Unscrew the hollow screw (1) and remove it with
seals and ring union
• Removing fuel line (2)
• Unscrew the hollow screw (4) and remove it with
the seals
• Remove the fuel line (3)

COMMON RAIL SYSTEM
Installing the fuel service centre Installing the fuel service centre fuel lines
Mounting the holders
• Fitting fuel line (2)

• Screw in the hollow screw (1) with ring union and
• Position the bracket (2) new seals and then tighten it
• Screw in and tighten the new mounting bolts (1) • Position fuel line (3) and screw in hollow screws
as marked (4) with new seals
• Tighten the hollow screw (4) at the solenoid valve
Mounting the fuel service centre to 15 Nm
• Tighten the hollow screw at the fuel service centre
to
Installing the fuel service centre fuel lines
• Position the fuel service centre (1)

• Install fuel lines (3) and (4)

• Screw in and tighten hollow screws (1) and (2) with
new seals
• Install fuel line (5) with new seals

COMMON RAIL SYSTEM
Dismantling and assembling the fuel service centre

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

(2) Cover (10) Hollow screw
(3) Sealing ring (11) Cover
(4) Housing (12) fuel pre-filter
(5) Pressure sensor (13) Sealing ring
(6) Water drain plug (14) Housing
(7) Mounting bolt (15) hand pump
(8) Sealing ring (16) Mounting bolts
Technical data
Cover (11) ......................................................................................................................................10 Nm
Cover (2)........................................................................................................................................20 Nm
Water drain plug (6) ......................................................................................................................... 3 Nm
WARNING
The common rail system would be damaged through contamination
• Always allow the fuel service centre to empty before changing the fuel filter
• Only use fuel filters that are designated for common-rail systems and marked as such
• Do not re-use used filter elements

COMMON RAIL SYSTEM
WARNING
Special tools
[108] Socket, size 36 80.99603-0325
• Removing and installing fuel filter cover
[109] Socket, size 19 08.06141-9061
• Removing and installing fuel pre-filter cover

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

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

Socket, size 36 [108]
• Open the water drain plug (2) and allow the fuel
service centre to empty
• Tighten the water drain plug (2) again to 3 Nm
Removing the heating element

• Pull the heating element (3) with sealing ring (4)
out of the fuel service centre (1)
• Unscrew the cover (1) with the Socket, size

36 [108]
• Pull the cover (1) with fuel filter (3) out of the KSC
housing
• Remove the sealing ring (2)
• Unscrew the cover (7) with the Socket, size
19 [109]
• Pull the fuel pre-filter (6) out of the hand pump
housing (4)
• Remove the sealing ring (5)

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

• Remove the hand pump housing (1)
• Position the hand pump housing (1) on the KSC
(3)

COMMON RAIL SYSTEM
Installing the fuel filter Tightening the fuel filter cover
• Tighten the fuel filter cover to Socket, size 36 [108]

(1) using 20 Nm
Installing the pressure sensor
• Thinly apply clean diesel fuel on the new sealing

ring (5)
• Fit the sealing ring (5) on the hand pump housing
(4)
• Insert a new fuel pre-filter (6)
• Screw on the cover (7) and tighten by hand • Screw in the pressure sensor (1) with a new seal-
• Insert the new fuel filter (3) into the cover (1) ing ring (2)
• Thinly apply clean diesel fuel on the new sealing • Tighten the pressure sensor (1) to 45 Nm
ring (2)
• Screw in the cover (1) with the sealing ring (2) and Installing the heater element
tighten by hand
Tightening the fuel pre-filter cover
• Insert the heating element (3) with new sealing

ring (4) into the fuel service centre (1)
• Tighten cap of fuel pre-filter with Socket, size
19 [109] (1) using 10 Nm

COMMON RAIL SYSTEM
FLAME-START SYSTEM
Flame-start system protective sleeves
(1) Protective sleeve Z 10 x 10 81.96002-0511 (5) Cover lid 81.96002-0517

(2) Protective sleeve A9 81.96002-0516 (6) Protective sleeve Z 10 x 10 81.96002-0511
(3) Plug 81.96002-0521 (7) Charge-air manifold
(4) Cover lid 81.96002-0518
WARNING
Note

COMMON RAIL SYSTEM
Special tools
[110] Protective sleeve A9 81.96002-0516
• Plugging the flame-start system fuel line
• Plugging solenoid valve

• Sealing the flame glow plug
[112] Cap 81.96002-0518
• Fuel line KSC – closing solenoid valve
[113] Cap 81.96002-0517
• Plugging the FSC solenoid valve hollow screw

connection
[114] plug 81.96002-0521
• Plugging the solenoid valve borehole

• Seal the KSC bore

COMMON RAIL SYSTEM
Removing and installing the flame-start system

Additional jobs
– Flame-start system protective sleeves, see 235
(1) Charge-air manifold (6) Fuel line

(2) Flame glow plug (7) Hollow screw
(3) Fuel line (8) Solenoid valve
(5) Hollow screw
Technical data
Hollow screw (7)................................................... M10x1 ...............................................................15 Nm
Flame glow plug (2) ............................................. M20x1.5 ............................................................25 Nm
Fuel line union nut (3) ...................................................................................................................10 Nm
Service products
Curil T sealing compound .................................................................................................. 04.90300-9030
WARNING

COMMON RAIL SYSTEM
WARNING

COMMON RAIL SYSTEM
Removing the flame-start system Removing the solenoid valve
Removing the fuel lines of the flame-start system
• Disconnect the electrical connection (2)

• Unscrew hollow screws (2) and (4) and remove solenoid valve (1)
with the seals
• Remove the fuel line (3)
• Remove fuel line (1)
Removing the flame glow plug

• Loosen the mounting nut (3)
• Unscrew the flame glow plug (1)

COMMON RAIL SYSTEM
Installing the flame-start system Attach the fuel lines for the flame-start system
Attaching the solenoid valve
• Position fuel line (3)

• Screw in hollow screws (2) and (4) with new seals
• Position the solenoid valve (1) • Tighten hollow screw (4) to 15 Nm
• Screw in and tighten the new mounting bolts (3) • Tighten the hollow screw (2)
• Connect the electrical connection (2) • Remove the fuel line (1) between the solenoid
valve and flame glow plug
Installing the flame glow plug • Tighten the union nuts for the fuel line (1) to 10 Nm
• Thinly apply Curil T sealing compound on the

flame glow plug (1)
• Screw in the flame glow plug (1) and align to fuel
line for solenoid valve and flame glow plug
• Brace the flame glow plug (1) and tighten the
mounting nut (3) with 25 Nm
• Connect the electrical connection (2)

COMMON RAIL SYSTEM
ENGINE CONTROL UNIT

Removal and installation of the engine control unit
(1) Bracket (3) Engine control unit electrical connections

(2) Mounting bolt (4) Engine control unit
Technical data
Mounting bolt (2) .................................................. M6x35-10.9 ....................................................... 11 Nm
Mounting bolts for bracket (1) ................................ M8x40-10.9 .......................................................13 Nm
Service products
Loctite 270 ........................................................................................................................ 04.10160-9062
WARNING
Note
After installation of the engine, the engine control unit needs to be reconfigured and the fault
memory cleared.

COMMON RAIL SYSTEM
Removing engine control unit Removing the engine control unit bracket
Disconnecting the engine control unit electrical

connections

• Remove the bracket (3) with rubber mounts (2)
• Fully unlock and pull off the connectors (1), (2)
and (5)
• Unscrew the mounting bolt (4) for the cable
bracket
• Free the wiring harnesses
Detaching the engine control unit

• Remove the engine control unit (1)

COMMON RAIL SYSTEM
Installing the engine control unit Mounting the engine control unit
Mounting the engine control unit bracket
• Position the engine control unit (1)

• Screw in new mounting bolts (2) and tighten ac-
• Thinly apply Loctite 270 on the threads of the new cording to the tightening sequence to 11 Nm
mounting bolts (1)
• Position the bracket (3) with rubber mounts (2) Connecting the engine control unit electrical
• Screw in the mounting bolts (1) and tighten to connections
13 Nm
Tightening sequence for engine control unit
WARNING
Risk of irreparable engine control unit
damage
• Tighten engine control unit (1) starting with A ac-
• When installing the plugs, first fully
cording to tightening sequence A, B, C, D, E, F, G,
open the lock and then insert and lock
H
the plugs
• Insert and lock the connectors (1), (2) and (5) in

the engine control unit
• Screw in and tighten the mounting bolt (4) for the
cable bracket
• Route the wiring harnesses and secure them using
cable ties (3)

TURBOCHARGING
TURBOCHARGING
(1) Turbocharger (6) Exhaust manifold

(2) Gasket (7) Mounting nut
(3) Oil return line (8) Mounting nut
(4) Mounting bolt (9) Oil pressure line
(5) Gasket

TURBOCHARGING
CHARGE-AIR PIPES
Remove and install the charge air pipe
Additional jobs
– Removing and installing the flame-start system, see 237
(1) Charge-air manifold (4) Solenoid valve

(2) O-ring (5) Charge-air manifold
(3) Clamp (6) Flame glow plug
Technical data
Profiled clamp (3) ................................................. M6 ....................................................................10 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

TURBOCHARGING
Note
A range of charge air pipes is installed.Removal and installation is intrinsically the same.

TURBOCHARGING
Removing the charge-air manifold Removing the charge-pressure sensor

CAUTION • Remove the charge-air pressure sensor (3) with
The poly-V-belt tensioner is under O-ring
spring tension
Removing the charge-air manifold
ally

Removing the bracket

• Remove the charge-air manifold (1)


TURBOCHARGING
Installing the charge-air manifold Mounting the charge-pressure sensor
Mounting the charge-air manifold
• Position the charge-air pressure sensor (3) with a

new O-ring
• Thinly apply Loctite 5900 on the sealing surfaces • Screw in and tighten the new mounting bolts (1)
• Position the charge-air manifold (1) • Connect the electrical connection (2)
Installing the bracket
• Position the bracket (3) CAUTION

• Screw in and tighten the new mounting bolts (1) The poly-V-belt tensioner is under
and (2) spring tension
ally


TURBOCHARGING
Removing the turbo charger charge-air Installing the turbo charger charge-air
manifold manifold
• Loosen the profiled clamp (1) • Thinly apply Technical Vaseline on a new O-ring
• Remove the charge-air manifold (3) with O-ring (2) (2)
• Remove the charge-air manifold (3) with an O-ring
(2) and profiled clamp (1)
• Tighten the profiled clamp (1) to 10 Nm

TURBOCHARGING
TURBOCHARGER
Removal and installation of the turbocharger
(1) Turbocharger (6) Exhaust manifold

(2) Gasket (7) Mounting nut
(3) Oil return line (8) Mounting nut
(4) Mounting bolt (9) Oil pressure line
(5) Gasket
Technical data
Mounting nut (8) ................................................... M10-10..............................................1st torque 10 Nm
Mounting nut (8) ................................................... M10-10................................................Final torque 90°
Profiled clamp ...................................................... M6 ....................................................................10 Nm
Screw-in coupling for adjusting cylinder ................. M16x1.5 ............................................................15 Nm
Mounting bolt for compressor housing ................... M8x20-10.9 .......................................................25 Nm
Service products
Multi-purpose grease MAN 285 Li-PF2 ............................................................................... 09.15001-0012
WARNING

TURBOCHARGING
Special tools
[115] Ring spanner SW15 i = 1 : 1.22 80.99603-0323
• Unscrewing and screwing on the turbocharger

mounting nuts
[116] Test tool 80.99606-0399
• Engage check of pressurised air connectors

TURBOCHARGING
Removing the turbo charger Detach the oil pressure line
Removing the turbo charger charge-air manifold
• Detach the oil pressure line (1)
• Loosen the profiled clamp (1) Detaching the oil return line
• Remove the charge-air manifold (2) with O-ring (2)
Detaching the air pipes

• Unscrew the oil return line (2) at the screw fitting
• Remove the seal (4) and sealing ring (1)
• Detach the compressed air pipe (1) • Clean the mating faces
• Detach the air pipe (2) from the adjusting cylinder
(3) Removing the turbo charger
Removing the exhaust manifold
• Unscrew the mounting nuts (1) using Ring spanner

SW15 i = 1 : 1.22 [115]
• Unscrew the mounting nuts (3) • Remove the turbocharger (2) with seal (3)
• Remove the exhaust manifold (2) with seal from • Clean the mating faces
the turbocharger (1)

TURBOCHARGING
Clean turbo charger Remove compressor housing
Release compressor housing
WARNING
• Mark the installation position of the mounting plate Risk of irreparable turbo charger dam-
(2) age
• Mark compressor housing (1) to the housing of • When removing the compressor hous-
shaft bearing (3) ing, do not expose the turbine blades to
• Unscrew the mounting bolts (4) any impact
• Remove mounting plate (2)
• Carefully remove the compressor housing (1)
• Take the O-ring (3) out of the groove (2)
• Clean compressor housing (1)
• Clean the shaft bearing (1) without damaging the

blades (2) of the turbine shaft

TURBOCHARGING
Position the compressor housing Installing the turbo charger

Mounting the turbocharger
WARNING
Risk of irreparable turbo charger dam-
age WARNING
• When positioning the compressor Component damage caused by incor-
housing, do not expose the blades of rect use of special tool
the turbine to any impact • Observe ratio Ring spanner SW15
i = 1 : 1.22 [115]
• Insert a new O-ring (3) into the groove (2)
• Carefully position the compressor housing (1) • Position the turbocharger (2) with a new seal (3)
• Screw in new mounting nuts (1) and tighten
Secure the compressor housing with Ring spanner SW15 i = 1 : 1.22 [115] to
1st torque 10 Nm
• Tighten the mounting nuts (1) to Final torque 90°
Bottom right mounting nut for turbo charger
• Align the compressor housing (1) to the marking

on the shaft bearing housing (3)
• Position mounting plate (2) as marked
• Tighten the mounting bolts (4) in a criss-cross WARNING
pattern with 25 Nm Component damage caused by incor-
rect use of special tool
• Gear ratio Ring spanner SW15
i = 1 : 1.22 [115]
• In the rotation direction, set a smaller
torque than the initial torque
• Tighten mounting nut using Ring spanner SW15

i = 1 : 1.22 [115] (1) and torque wrench (2) to
1st torque 10 Nm
• Tighten the mounting nut to Final torque 90°

TURBOCHARGING
Bottom left mounting nut for turbo charger Fill turbo charger with oil
WARNING WARNING
Component damage caused by incor- Unless it is filled with oil, the turbo
rect use of special tool charger will be damaged when started
• Observe ratio Ring spanner SW15 for the first time
i = 1 : 1.22 [115] • Fill the turbo charger with clean en-
• In the rotation direction, set a smaller gine oil before the oil pressure line is
torque than the initial torque installed
• Tighten mounting nut using Ring spanner SW15 • Fill clean engine oil into the oil inlet nozzle on the
i = 1 : 1.22 [115] (1) and torque wrench (2) to turbo charger (2) using the funnel (1) until the oil
1st torque 10 Nm duct in the turbo charger (2) is full
• Tighten the mounting nut to Final torque 90°
Attaching the oil pressure line
Attaching the oil return line
• Attach the oil pressure line (1)

• Screw the oil return line (2) with a new sealing ring • Tighten the union nuts for the oil pressure line (1)
(1) into the crankcase
• Position the oil return line (2) with a new seal (4)
• Tighten the oil return line union nut (2)

TURBOCHARGING
Mounting the exhaust manifold Attaching the air pipes
• Position the exhaust manifold (2) on the turbo • Attach the air pipe (1)
charger (1) • Screw the retaining screw into the adjusting cylin-
• Screw on and tighten the new mounting nuts (3) der (3) and tighten it to 15 Nm
• Check compressed air pipe (2) for a firm seat using
Repair the compressed-air connection of the ad- Test tool [116]
justing cylinder • If the connector comes out of the retaining screw,
repeat the procedure
Installing the turbo charger charge-air manifold
• Remove the retaining clip (2)

• Pull off the retaining screw (3) from the plug con-
nector (6)
• Fit new O-rings (4) and (5) • Thinly apply Technical Vaseline to the new O-ring
• Thinly apply Multi-purpose grease • Remove the charge-air manifold (2) with an O-ring
MAN 285 Li-PF2 on the O-rings (4) and (5) (2) and profiled clamp (1)
• Replace spring element (1) in the adjusting cylin- • Tighten the profiled clamp (1) to 10 Nm
der
• Insert a new retaining clip (2) into the adjusting
cylinder

INTAKE/EXHAUST SYSTEM
(1) Heat shields (6) Charge-air manifold

(2) Exhaust manifold rear (7) Connecting tube
(3) Coolant manifold (8) Coolant manifold
(4) Exhaust manifold, centre (9) Gasket
(5) EGR module (10) Exhaust manifold front

EGR MODULE
Removing and installing the EGR module without an intermediate plate
Additional jobs
(1) EGR module (3) Connecting tube

Technical data
EGR adjusting cylinder pre-load ........................................................................................ 1.25 ± 0.25 mm
Mounting nuts for EGR adjusting cylinder............... M8 ....................................................................10 Nm
Dimension of bracket from threaded bolts to limit stop Version 1 .................................................... 164 mm
Dimension of bracket from threaded bolts to limit stop Version 2 ..................................................161.5 mm
Service products
WARNING

Special tools
[117] Dial gauge 08.71000-3217
• Set the EGR adjusting cylinder pre-load in con-

junction with:
[118] gauge holder 08.71082-0005
• Set the EGR positioning cylinder preload
[119] Caliper pin 80.99605-0197
[120] Test tool 80.99606-0399

Removing the EGR module Removing the EGR module
Removing the heat shield

bolts (7)
• Remove the heat shield (1) • Unscrew the mounting bolts (5) and (7)
• Remove the EGR module (6)
Remove the air pipe • Remove the coupling pipe (3) and insert the cou-
pling pipe (2) from the EGR module (6)
• Remove the seal (4) from the connecting tube
• Remove the washers (1) from the EGR module (6)
and the exhaust manifold
Removing the multi-piece rings from the un-

screwed conduit

• Expose the cable harness
• Remove the compressed-air line (1)
Unscrewing the mounting bolts of the connect-

ing tube
• Remove the multi-piece rings (1) and (2) from

unscrewed conduit
• Clean the unscrewed conduit
• Unscrew the mounting bolts (2) of the connecting

tube (3) from the shut-off valve (1)

Removing the EGR positioning cylinder Check the recessed version bracket
• Unscrew the mounting nut (2) and remove with the • Check dimension A between limit stop (1) and stud
washer (3) bolt (2)
• Unscrew the mounting nut (4) and remove with the If dimension A is 164 mm, the bracket has to be
washer (5) replaced for a bracket with 161.5 mm.
• Remove the EGR adjusting cylinder (1) from the
EGR shut-off flap lever (6) Removing the console
Dismantle the EGR positioning cylinder

• Brace the cylinder rod of the EGR positioning cylin-
der (3) and undo the mounting nut (2)
• Unscrew the ball head (1) and mounting nut (2)

Installing the EGR module Mount the EGR positioning cylinder
Installing the console
• Slide EGR adjusting cylinder (1) onto the EGR

shut-off flap lever (6)
• Position the bracket (1) • Screw on new mounting nuts (2) and (4) with the
• Screw in and tighten the new mounting bolts (2) washers (3) and (5) and tighten with the special
tool 10 Nm
Assemble the EGR positioning cylinder
Adjusting the EGR adjusting cylinder
• Screw on the mounting nut (2) and ball head (1)

onto the piston rod of the EGR positioning cylinder • Position the gauge holder [118] (1) with Dial
(3) gauge [117] (4) and Caliper pin [119] on the
shut-off flap
• Position Caliper pin [119] with pre-load on the EGR
positioning cylinder
• Loosen the mounting nut (3)
• Unscrew the cylinder rod (2) by several turns
• Screw in cylinder rod (2), until the dial Dial
gauge [117] (4) does not move any longer
• Screw in the cylinder rod (2) by one turn
The pre-load for the EGR positioning cylinder is
1.25 ± 0.25 mm.
If the pre-load is out of tolerance, repeat the process.

Fit the multi-piece rings on the unscrewed con- Screw in connecting tube mounting bolts
duit
• Align the connecting tube (3) with the shut-off

• Fit new multi-piece rings (1) and (2) on the un- valve (1)
screwed conduit, ensuring that the gap is offset by • Screw in and tighten the new mounting bolts (2)
90° in each case
Repair the compressed-air connection of the ad-
Mounting the EGR module justing cylinder
• Apply Radiator antifreeze on the contact surfaces • Remove the retaining clip (2)
of the new unscrewed conduit (3) and insert into • Pull off the retaining screw (3) from the plug con-
the EGR module (6) nector (6)
• Insert the new washers (1) into the EGR module • Fit new O-rings (4) and (5)
(6) and exhaust manifold • Thinly apply Multi-purpose grease
• Insert the coupling pipe (2) into the EGR module MAN 285 Li-PF2 on the O-rings (4) and (5)
(6) • Insert the spring element (1) into the EGR adjust-
• Position the EGR module (6) with a new seal (4) ing cylinder
• Screw in and tighten the new mounting bolts (7) • Insert a new retaining clip (2) into the EGR adjust-
as marked ing cylinder

Install the compressed-air pipe
• Screw a new retaining screw into the EGR adjust-

ing cylinder and then tighten it
• Check compressed air pipe (1) for a firm seat using
Test tool [120]
• If the connector comes out of the retaining screw,
• Route the cable harness and secure using cable
ties
Install the heat shield
• Install the heat shield (1)

Removing and installing the EGR module with intermediate plate

Additional jobs
(1) Connecting tube (3) EGR module

Technical data
Service products
WARNING

Special tools
[121] Dial gauge 08.71000-3217
• Set the EGR adjusting cylinder pre-load in con-

junction with:
[122] gauge holder 08.71082-0005
[123] Caliper pin 80.99605-0197
[124] Test tool 80.99606-0399

Removing the EGR module Removing the EGR module

bolts (2)
• Remove the heat shield (1) • Unscrew the mounting bolts (2) and (7)
• Remove the EGR module (1)
Remove the air pipe • Remove the insert pipe (4) and insert the pipe (5)
from the EGR module (1)
• Remove the seal (6) from the connecting pipe (8)
• Remove the washers (3) from the EGR module (1)
and the exhaust manifold
Removing the multi-piece rings from the un-

screwed conduit

• Expose the wiring harness
• Remove the holding clips (2)
• Remove the compressed-air line (1)
Unscrewing the mounting bolts of the connect-

ing tube
• Remove the multi-piece rings (1) and (2) from

unscrewed conduit
• Clean the unscrewed conduit
• Unscrew the mounting bolts (3) of the connecting

tube (2) from the shut-off valve (1)

Removing the EGR positioning cylinder Installing the EGR module

Assemble the EGR positioning cylinder
• Unscrew the mounting nut (2) and remove with the

washer (3)
• Unscrew the mounting nut (4) and remove with the • Screw on the mounting nut (2) and ball head (1)
washer (5) onto the piston rod of the EGR positioning cylinder
• Remove the EGR adjusting cylinder (1) from the (3)
EGR shut-off flap lever (6)
Mount the EGR positioning cylinder
Dismantle the EGR positioning cylinder
• Slide EGR adjusting cylinder (1) onto the EGR

• Brace the cylinder rod of the EGR positioning cylin- shut-off flap lever (6)
der (3) and undo the mounting nut (2) • Screw on new mounting nuts (2) and (4) with the
• Unscrew the ball head (1) and mounting nut (2) washers (3) and (5) and tighten with the special
tool 10 Nm

Adjusting the EGR adjusting cylinder Mounting the EGR module
• Position the gauge holder [122] (1) with Dial • Apply Radiator antifreeze on the contact surfaces
gauge [121] (4) and Caliper pin [123] on the of the new unscrewed conduit (5) and insert into
shut-off flap the EGR module (1)
• Position Caliper pin [123] with pre-load on the EGR • Insert the new washers (3) into the EGR module
positioning cylinder (1) and exhaust manifold
• Loosen the mounting nut (3) • Insert the unscrewed conduit (4) into the EGR
• Unscrew the cylinder rod (2) by several turns module (1)
• Screw in cylinder rod (2), until the dial Dial • Position the EGR module (1) with a new seal (6)
gauge [121] (4) does not move any longer connecting tube (8)
• Screw in the cylinder rod (2) by one turn • Screw in and tighten the new mounting bolts (2)
• Tighten the mounting nut (3) as marked
The pre-load for the EGR positioning cylinder is • Screw in and tighten the new mounting bolts (7)
1.25 ± 0.25 mm.
Screw in connecting tube mounting bolts
Fit the multi-piece rings on the unscrewed con-

duit
• Align the connecting tube (2) with the shut-off

valve (1)
• Fit new multi-piece rings (1) and (2) on the un-
screwed conduit, ensuring that the gap is offset by
90° in each case

Repair the compressed-air connection of the ad- Install the heat shield
justing cylinder
• Install the heat shield (1)

nector (6)
• Fit new O-rings (4) and (5)
• Thinly apply Multi-purpose grease
MAN 285 Li-PF2 on the O-rings (4) and (5)
• Insert the spring element (1) into the EGR adjust-
ing cylinder
• Insert a new retaining clip (2) into the EGR adjust-
ing cylinder
Install the compressed-air pipe
• Screw a new retaining screw into the EGR adjust-

ing cylinder and then tighten it
• Install air pipe (1) and check for a firm seat using
Test tool [124]
• Mount the holding clips (2)
• If the connector comes out of the union screw,
• Route the cable harness and secure using cable
ties

Dismantling and assembling EGR module without intermediate plate

Additional jobs
– Removing and installing the EGR module without an intermediate plate, see 263
(1) Shut-off flap (8) Mounting bolt

(3) Mounting bolt (10) Check valve housing
(4) Connecting tube (11) Check valve
(5) Mounting bolts (12) EGR module housing
(6) Connecting tube (13) Gasket
(7) Mounting bolts
Technical data
Mounting bolt (3) .................................................. M8x105-HWF ......................................1st torque 3 Nm
Mounting bolt (3) .................................................. M8x105-HWF ...................................2nd torque 15 Nm
Mounting bolt (3) .................................................. M8x105-HWF ................................. Final torque 28 Nm
Mounting bolt (9) .................................................. M8x55-10.9 .........................................1st torque 3 Nm
Mounting bolt (9) .................................................. M8x55-10.9 ......................................2nd torque 15 Nm
Mounting bolt (9) .................................................. M8x55-10.9 .................................... Final torque 30 Nm

WARNING
Risk of engine damage from the ingress of water
• Do not open pipe bundles in the EGR module
• When removing the shut-off flap, the glued on seal between the pipe bundle and cooler housing
must not be removed
WARNING

Dismantling the EGR module Remove the non-return valve body
Detaching the connecting tube

• Remove the non-return valve body (2) from the
• Unscrew the mounting bolts (3) EGR module housing (1)
• Remove the connecting tube (2) from the non-re- • Clean the mating faces
turn valve body (1)
• Clean the mating faces Remove on-return valves
Note on removing check valve housing
• Remove the non-return valves (1) and (2) from the

non-return valve body (3)
• To remove the check valve housing (2), do not • Clean the mating faces
unscrew the mounting bolts (1) and (3)

Remove shut-off flap Assembling the EGR module

Tightening sequence shut-off flap

• Remove the shut-off flap (3) with seal (4) from the
EGR module housing (5) • Follow the illustrated mounting bolt (1) tightening
• Carefully clean the sealing surfaces sequence A to F in the following work step
If the pipe bundle in the EGR module housing (5)
has become undone after removing the shut-off flap Install shut-off flap
(3), the EGR module has to be completely replaced.
• Position the shut-off flap (3) with a new seal (4) at

the EGR module housing (5)
• Screw in the new mounting bolts (1) and (2)
• Tighten the mounting bolts (1) and (2) to
1st torque 3 Nm in the sequence indicated
• Tighten the mounting bolts (1) and (2) to
2nd torque 15 Nm in the sequence indicated
• Tighten the mounting bolts (1) and (2) to Final
torque 28 Nm in the sequence indicated

Install non-return valve Mount the non-return valve body
WARNING • Position the non-return valve body (2) from the

Danger of malfunctions of the ex- EGR module housing (1)
haust gas recirculation and damage • Screw in the new mounting bolts (3) and (4)
to non-return valves • Tighten the mounting bolts (3) and (4) to
• Do not damage rubber lining of non-re- 1st torque 3 Nm in the sequence indicated
turn valves when inserting them into the • Tighten the mounting bolts (3) and (4) to
body 2nd torque 15 Nm in the sequence indicated
• Carefully insert the non-return valves (1) and (2) torque 30 Nm in the sequence indicated
into the non-return valve body (3)
Attaching the connecting tube
Tightening sequence non-return valve body
• Position the connecting tube (2) on the non-return

• Follow the illustrated mounting bolt (1) tightening valve body (1)
sequence A to F in the following work step • Screw in and tighten the new mounting bolts (3)

Dismantling and assembling the EGR module with intermediate plate

Additional jobs
– Removing and installing the EGR module with intermediate plate, see 270
(1) Non-return valve body mounting bolt (9) Connecting tube mounting bolt
(2) Check valve housing (10) Connecting tube
(3) Check valves (11) Check valves
(4) Intermediate plate (12) Mounting bolt, console
(5) Seal of intermediate plate (13) Mounting bolt for intermediate plate
(6) EGR module housing (14) Connecting tube mounting bolt
(7) Seal of closing flap (15) Connecting tube
(8) Shut-off flap (16) Non-return valve body mounting bolt
Technical data
Mounting bolt for closing flap (8)............................ M8x105-HWF ......................................1st torque 3 Nm
Mounting bolt for closing flap (8)............................ M8x105-HWF ...................................2nd torque 15 Nm
Mounting bolt for closing flap (8)............................ M8x105-HWF ................................. Final torque 28 Nm
Mounting bolt for check valve housing (16) ............ M8x55-10.9 .........................................1st torque 3 Nm
Mounting bolt for check valve housing (16) ............ M8x55-10.9 ......................................2nd torque 15 Nm
Mounting bolt for check valve housing (16) ............ M8x55-10.9 .................................... Final torque 30 Nm
Mounting bolt for check valve housing (1) .............. M8x90-10.9 .........................................1st torque 3 Nm
Mounting bolt for check valve housing (1) .............. M8x90-10.9 ......................................2nd torque 15 Nm

Mounting bolt for check valve housing (1) .............. M8x90-10.9 .................................... Final torque 30 Nm
WARNING
Risk of engine damage from the ingress of water
• Pipe bundle in the EGR module must not be opened
• When removing the shut-off flap, the glued on seal between pipe bundle and cooler housing
must not be opened
WARNING

Dismantling the EGR module Remove the intermediate plate
Detaching the connecting tube

• Remove the intermediate plate (1) with seal (2)
• Unscrew the mounting bolts (1) from the EGR module housing (3)
• Remove the seal (2) from the non-return valve • Clean the mating faces
body (3)
• Clean the mating faces Remove on-return valves
Remove the non-return valve body
• Remove the non-return valves (2) and (3) from the

non-return valve body (1)
• Unscrew the mounting bolts (1) and (4) • Clean the mating faces
• Remove the non-return valve body (2) from the
EGR module housing (3)

Remove shut-off flap Assembling the EGR module

Tightening sequence shut-off flap

• Remove the shut-off flap (2) with seal (4) from the • Tighten shut-off flap starting with A (1) according
EGR module housing (1) to tightening sequence A, B, C, D, E, F, G, H
• Carefully clean the sealing surfaces
If the pipe bundle in the EGR module housing (1) Install shut-off flap
has become undone after removing the shut-off flap
(2), the EGR module has to be completely replaced.
• Position the shut-off flap (2) with a new seal (4) at

the EGR module housing (1)
• Screw in the new mounting bolts (3) and (5)
in the sequence indicated
• Tighten the mounting bolts (3) to 2nd torque 15 Nm
in the sequence indicated
• Tighten the mounting bolts (3) to Final
torque 28 Nm in the sequence indicated

Install the intermediate plate Tightening sequence non-return valve body
• Position the intermediate plate (1) with a new seal • Tighten non-return valve body starting with A (1)
(2) at the EGR module housing (3) according to tightening sequence A, B, C, D, E, F,
• Screw in and tighten the new mounting bolts (4) G, H
Install non-return valve Mount the non-return valve body
WARNING • Position the non-return valve body (2) from the

Danger of malfunctions of the ex- EGR module housing (3)
haust gas recirculation and damage • Screw in the new mounting bolts (1) and (4)
to non-return valves • Tighten the mounting bolts (1) and (4) to
• Do not damage rubber lining of non-re- 1st torque 3 Nm in the sequence indicated
turn valves when inserting them into the • Tighten the mounting bolts (1) and (4) to
body 2nd torque 15 Nm in the sequence indicated
• Carefully insert the non-return valves (2) and (3) torque 30 Nm in the sequence indicated
into the non-return valve body (1)

Attaching the connecting tube
• Position the connecting tube (2) on the non-return

valve body (3)

EXHAUST MANIFOLD
Removal and installation of the exhaust manifold
Additional jobs
– Removal and installation of the turbocharger, see 253

(2) Exhaust manifold (6) Heat shield
(3) Gasket (7) Mounting bolt
(4) Cylinder head (8) Heat shield
Technical data
Mounting bolt for exhaust manifold (5) ................... M10x50-HWF ................................ Initial torque 60 Nm
Mounting bolt for exhaust manifold (5) ................... M10x50-HWF ......................................Final torque 90°
Mounting bolt for exhaust manifold (1) ................... M10x95-HWF ....................................1st torque 60 Nm
WARNING

Removing the exhaust manifold Dismantling the exhaust manifold
Remove the heat shields
• Pull exhaust manifold sections (1) and (5) out of

exhaust manifold section (2)
• Unscrew the mounting bolts (2) • Unscrew the mounting bolts (3)
• Remove the heat shields (1) and (3) • Remove the connecting tube (4)
• Remove the multi-piece rings from exhaust mani-
Removing the exhaust manifold
fold sections (1) and (5)

(2) and (3)
• Remove the exhaust manifold (4) with seals (1)

Installing the exhaust manifold Mounting the exhaust manifold
Assembling the exhaust manifold
• Position gaskets (1) with the raised section facing

the exhaust manifold (4)
• Insert new multi-piece rings into exhaust manifold • Position the exhaust manifold (4)
sections (1) and (5) • Screw in the new mounting bolts (2) and (3) as
• Insert exhaust manifold sections (1) and (5) into marked
exhaust manifold section (2) • Tighten the mounting bolts (2) and (3) to
• Position the connecting tube (4) 1st torque 60 Nm in the sequence indicated
• Screw in and tighten the new mounting bolts (3) • Tighten the mounting bolts (2) and (3) to Final
torque 90° in the sequence indicated
Tightening sequence for exhaust manifold
Install the heat shields
• Follow the illustrated mounting bolt (1) tightening

sequence A to F in the following work step • Position the heat shields (1) and (3)

CYLINDER HEAD
CYLINDER HEAD
(1) Crankcase (4) Mounting bolt

(2) Cylinder head gasket (5) Cylinder head cover
(3) Cylinder head

CYLINDER HEAD
CYLINDER HEAD
Removal and installation of the cylinder head
Additional jobs
– Removal and installation of the oil module, see 387
– Removal and installation of the exhaust manifold, see 287
– Removing and installing the injectors and pressure pipe, see 184
– Checking and adjusting valve clearance, see 305
(1) Crankcase (4) Mounting bolt

(2) Cylinder head gasket (5) Cylinder head cover
(3) Cylinder head
Technical data
cylinder head bolt ................................................. M18x2x246-10.9 ................................1st torque 10 Nm
CYLINDER HEAD
cylinder head bolt ................................................. M18x2x246-10.9 .............................2nd torque 150 Nm

cylinder head bolt ................................................. M18x2x246-10.9 ..............................3rd torque 300 Nm
cylinder head bolt ................................................. M18x2x246-10.9 .................................... 4th torque 90°
cylinder head bolt ................................................. M18x2x246-10.9 ..................................Final torque 90°
Rocker arm mechanism mounting bolts ................. M12x60-10.9....................................................105 Nm
Mounting bolt (4) ............................................................................................................................10 Nm
Cylinder liner stand out .................................................................................................. 0.035 - 0.085 mm
Service products
White T assembly paste..................................................................................................... 09.16012-0117
WARNING
Component damage due to leaky cylinder head seal
• Do not reuse old cylinder head bolts, even if they have only been used once
WARNING
personnel only
(specified value 0)
• Always fit new pressure pipe sockets once the existing ones have been undone
• Follow the sequence described when tightening injectors, high-pressure lines, the pressure pipe
and pressure pipe sockets
WARNING
Special tools
[125] Torque multiplier i = 1 : 3.5 80.99619-0007
• Undo and tighten the cylinder head bolts in con-

junction with:
• Support [126]
• protractor [127]
• Holding device [128]
• Stud bolt [129]
• connecting pin [130]
• Rubber ring [131]
• Adapter [132]
• Socket [134]
[126] Support 80.99606-0551
• Undoing and tightening the cylinder head bolts

CYLINDER HEAD
[127] protractor 80.99607-0172
[128] Holding device 80.99606-0641
[129] Stud bolt 06.02191-0407
[130] connecting pin 06.22729-0006
[131] Rubber ring 06.56331-3274
[132] Adapter 80.99606-0552
[133] Socket, size 22 80.99612-0024
[134] Socket 80.99603-0327

CYLINDER HEAD
• Crank the engine in conjunction with:

• Gear ratchet [136]
[136] Gear ratchet 80.99627-0001
• Crank the engine
[137] Crossbeam 80.99629-6008
• Removal and installation of the cylinder head in

conjunction with:
• chain [138]
• Load hook [139]
[138] chain 80.99629-6009
• Removing and mounting the cylinder head
[139] Load hook 80.99629-0040
• Removing and mounting the cylinder head
[140] gauge holder 80.99605-0172
• Check the cylinder liner protrusion in conjunction

with:
• Dial gauge [142]
• measuring plate [141]
• hex shoulder stud [143]
• Washer [144]
[141] measuring plate 80.99605-0286

with:
• Dial gauge [142]
• Washer [144]
[142] Dial gauge 08.71000-3217
• Checking the cylinder liner stand out

CYLINDER HEAD
[143] hex shoulder stud 06.01499-0015
[144] Washer 06.15013-0417

CYLINDER HEAD
Removing the cylinder head Removing the cylinder head cover
Disconnecting the speed sensor electrical con-

nection
Note
The mounting bolts can only be removed
• Disconnect the electrical connection (1) from the cylinder head cover with damp-
ing elements and spacer sleeves.
Removing the cable duct cover
• Remove the cylinder head cover (3) with gasket
(2) from the cylinder head (1)
(2)
Check the gasket (2) for damage. Remove from
• Set aside the cylinder head cover (3) on a clean
posed leakage

Remove the cable duct bracket
• Remove the cover from the flywheel hous-

ing/timing case
• Set aside and secure the cable duct bracket (2)
and wiring harness

CYLINDER HEAD
Turning the engine to the TDC mark Removing the valve bridges
• Turn the engine with Engine barring gear [135] Note

(1) and Gear ratchet [136] in the engine's running The cylinder head can also be removed
direction until the 1st cylinder is at the TDC mark whilst the valve bridges are installed, de-
(2) pending on the type of repairs involved.
Removing the rocker arm mechanism
• Mark the installation position of the valve
crossheads (1) and (2)
• Remove the valve crossheads (1) and (2)
Assembling the special tool
Note
The cylinder head can also be removed
whilst the rocker arm mechanism is in-
stalled, depending on the type of repairs
involved. • Insert the Torque multiplier i = 1 : 3.5 [125] (1) into
the Support [126] (2)
• Unscrew the mounting bolts (5) • Install the Holding device [128] (5) with Stud
• Remove the EVB brace (6) bolt [129] (3) and Adapter [132] (4) at the Sup-
• Unscrew the mounting bolts (3) and (4) port [126] (2)
• Remove the rocker arm mechanism (2) with rocker • Put the protractor [127] (10) on the Torque multi-
arm bearing bracket (1) plier i = 1 : 3.5 [125] (1)
• Put Socket, size 22 [133] (8) on the Torque mul-
tiplier i = 1 : 3.5 [125] (1) and secure with the
connecting pin [130] (9) and the Rubber ring [131]
(7)
• Insert the Socket [134] (6) into the Socket, size
22 [133] (8)

CYLINDER HEAD
Undo the cylinder head bolts Removing the cylinder head
Note
Undo the cylinder head bolts from the
outside inwards.
• Place the special tool (1) onto the cylinder head

bolt which needs to be undone
• Loosen all cylinder head bolts using special tool
(1) and key (2)
Unscrewing the cylinder head bolts
• Hook the Load hook [139] (6) to the cylinder head

(4) and camshaft
• Hook the chain [138] (3) in Load hook [139] (6)
and Crossbeam [137] (5)
• Lift the cylinder head (4) down from the crankcase
(1) using the lifting gear
• Remove the cylinder head gasket (2)
• Clean the threaded bores of the cylinder head
bolts
• Remove the special tool
• Unscrew the cylinder head bolts (1)

CYLINDER HEAD
Installing the cylinder head Mounting the cylinder head
Turning the camshaft to the TDC mark
• Turn the camshaft (3) so that the TDC mark (1) is

aligned with the cylinder head face (2)
Checking the cylinder liner stand out
• Hook the Load hook [139] (6) to the cylinder head

(4) and camshaft
• Hook the chain [138] (3) in Load hook [139] (6)
and Crossbeam [137] (5)
• Place the new cylinder head gasket (2) on the
guide pins in the crankcase (1)
• Place the cylinder head (4) on the crankcase (1)
• Place the measuring plate [141] (2) on the cylinder • Remove the special tool
liner
• Screw in the hex shoulder stud [143] (4) with
Washer [144] (5) and tighten them
• Fit the gauge holder [140] (6) with Dial gauge [142]
(3) on measuring plate [141] (2)
• Place the dial gauge tip (1) on the crankcase
• Carefully place the dial gauge tip (1) on the cylin-
der liner and note the difference on the dial gauge
The permitted cylinder liner protrusion is
0.035 - 0.085 mm
If the cylinder liner stand out is out of tolerance, the

cylinder liner must be replaced, see Removal and
installation the cylinder liner, 509.

CYLINDER HEAD
Tightening sequence for cylinder head Screw in the cylinder head bolts
WARNING
Component damage due to leaky
cylinder head seal
• Do not reuse old cylinder head bolts,
even if they have only been used once
• Thinly apply White T assembly paste on the con-

tact surfaces of the new cylinder head bolts (1)
• Screw in the cylinder head bolts (1) and tighten
them by hand
• Tighten the cylinder head bolts (1) to
1st torque 10 Nm in the sequence indicated
• Tighten the cylinder head bolts (1) to
2nd torque 150 Nm in the sequence indicated
A Intake side • Tighten the cylinder head bolts (1) to
B Exhaust side 3rd torque 300 Nm in the sequence indicated
• Tighten the cylinder head bolts in the in the se- Cylinder head bolts final tightening
quence indicated, 1 to 26 clockwise
• Place the special tool (1) onto the cylinder head

bolt which needs to be tightened
• Tighten the cylinder head bolts with the special tool
(1) and key (2) to 4th torque 90° in the sequence
indicated
(1) and key (2) to 5th torque 90° in the sequence
indicated
(1) and key (2) to Final torque 90° in the sequence
indicated

CYLINDER HEAD
Checking the camshaft TDC mark Installing the rocker arm mechanism
• Check the TDC mark (1) on the camshaft (3) • Put the rocker arm bearing bracket (1) on the
The TDC mark (1) must be in line with the cylinder cylinder head
head face (2). • Put the rocker arm mechanism (2) on the rocker
arm bearing bracket (1)
If the marks are not in line, the camshaft (3) must be • Screw in the mounting bolts (3) and (4)
removed and reinserted at the mark. • Tighten the mounting bolt (4) to 105 Nm
• Tighten the mounting bolt (3) to 105 Nm
Fitting the valve crossheads • Place the EVB brace (6)
Tightening sequence for cylinder head cover
Note
The valve crosshead recesses must al-
ways face towards the camshaft.
• Install the valve crossheads (1) and (2) as marked
A Intake side
B Exhaust side


CYLINDER HEAD
Mounting the cylinder head cover Connecting the speed sensor electrical connec-
tion

a new gasket (2), on the cylinder head (1) • Connect the electrical connection (1)
sequence indicated
Mount the cable duct bracket

• Position the cable duct bracket (2) with wiring har-
ness without tension, kinks or chafing
Mounting the cable duct cover


CYLINDER HEAD
Checking and adjusting valve clearance
(1) Adjusting screw, exhaust valve (4) Lock nut

(2) Lock nut (5) Lock nut
(3) Adjusting screw, intake valve (6) Adjusting screw, EVB
Technical data
Intake valve clearance .................................................................................................................. 0.5 mm
Exhaust valve clearance ............................................................................................................... 0.8 mm
EVB brace setting dimensions....................................................................................................... 0.6 mm
Lock nuts (2), (4) .................................................. M10x1-8.8 .........................................................45 Nm
Lock nut, EVB brace (5) ........................................ M14x1-8.8 .........................................................45 Nm
WARNING
Danger of reduced engine output or engine damage
• Do not perform setting if the engine temperature is above 50 °C
WARNING

CYLINDER HEAD
Special tools

[146] Gear ratchet 80.99627-0001
[147] Feeler gauge 08.75310-3309
• Checking and adjusting the valve and EVB clear-

ance
[148] Valve setting tool AF 14 80.99603-6031
• set valve clearance
[149] Valve setting tool AF 21 80.99603-6032
• Adjusting the EVB clearance
[150] Ratchet 08.06410-9072
[151] Gripper 08.06460-0003
[152] Torque wrench 08.06450-0006
• Adjust the valve and EVB clearance

CYLINDER HEAD
Checking and adjusting valve clearance Mount engine cranking unit

ing/timing case
• Open the locking pin (2) a quarter turn • Mount the Engine barring gear [145] (1) on the
• Remove the cable duct cover (1) flywheel housing/timing case
Removing the cylinder head cover Cranking the engine to the setting position
Note • Crank the engine in the engine's running direction

The mounting bolts can only be removed (arrow) using Engine barring gear [145] and Gear
from the cylinder head cover with damp- ratchet [146] until cylinder 1 the 1st cylinder is
ing elements and spacer sleeves. at ignition TDC (note TDC mark on flywheel, 6th
cylinder rocker arms overlap)
• Unscrew the mounting bolts (4) • Black marked valves are set
• Remove the cylinder head cover (3) with gasket • Turn engine another 360° until the 6th cylinder is
(2) from the cylinder head (1) at ignition TDC (note TDC mark on flywheel, 1st
• Clean the cylinder head cover (3) and the gasket cylinder rocker arms overlap)
(2) • White marked valves are set
posed leakage

CYLINDER HEAD
Checking the intake valve clearance Forcing the engine oil out of the EVB piston
• Insert the Feeler gauge [147] (4) with leaf 0.5 mm

WARNING
(2) between the ball cup (1) and the valve
Risk of incorrect valve clearance
crosshead (3)
• It must be possible to fully push the EVB
The valve clearance must be adjusted if valve toler-
piston into the valve bridge
ance is not 0.5 mm.
Adjusting the inlet valve clearance • Undo the union nut (2) and unscrew it several turns
• Screw in the adjusting screw (1) to press the valve
bridge (3) downwards several times until the stop
is reached
All the engine oil must fully escape from the EVB
piston (4)
Checking the exhaust valve clearance
• Undo the lock nut (2) and adjusting screw (1)

crosshead (4)
• Screw in the adjusting screw (1) until the 0.5 mm
leaf (6) can be moved between the ball cup (3) and
the valve bridge (4) with little resistance
• Align adjusting screw (1) and brace with Valve
setting tool AF 14 [148], Ratchet [150] and Grip-
crosshead (2)
per [151]
If the valve clearance is not 0.8 mm, the valve clear-
• Tighten the lock nut (2) with Torque wrench [152]
ances for the exhaust valve and the EVB piston (5)
with 45 Nm
must be adjusted.
• Check the setting again and, if necessary, repeat
the setting procedure

CYLINDER HEAD
Checking the setting dimensions for the EVB Adjusting the exhaust valve clearance
piston
WARNING
• Push down the valve crosshead (1)
• Insert the Feeler gauge [147] (3) with 0.6 mm leaf
• Before setting the valve clearance,
(2) between the ball cup brace (4) and the valve
force all the engine oil out of the EVB
crosshead (1)
piston
If the setting is not 0.6 mm, the valve clearances
for the exhaust valve and the EVB piston must be
• Undo the lock nut for the adjusting screw (1)
adjusted
• Push the EVB piston into the valve bridge (6)
until the stop is reached. To do this, screw in the
adjusting screw (2) and push the valve bridge (6)
downwards up to the pressure point (the valve
bridge must not move the exhaust valve)
• Block the valve crosshead (6) in this position with
the adjusting screw (1)
• Insert the Feeler gauge [147] with leaf 0.8 mm (5)
between the ball cup (4) and the valve crosshead
(6)
• Unscrew the adjusting screw (2) until the Feeler
gauge [147] with the 0.8 mm leaf (5) can be moved
between the ball cup (4) and the valve crosshead
(6) with little resistance
• Align adjusting screw (2) and brace with Valve
per [151]
with 45 Nm

CYLINDER HEAD
Setting the clearance for the EVB piston Tightening sequence for cylinder head cover
WARNING
• Set the exhaust valve clearance before
setting
Note
The valve crosshead must not move the
exhaust valve when the adjusting screw
is screwed in.
• Unscrew the adjusting screw (1) until the Feeler

gauge [147] (3) with 0.6 mm leaf (4) can be in-
serted between the adjusting screw (1) and the
valve crosshead
• Screw in the adjusting screw (1) with the inserted A Intake side
Feeler gauge [147] (3) and 0.6 mm leaf (4) until B Exhaust side
the valve crosshead reaches the stop - this can be
felt by a noticeable increase in force • Observe the illustrated tightening sequence 1 to
• Align adjusting screw (1) and brace with Valve 18 in the following work step
per [151] Mounting the cylinder head cover
with 45 Nm

sequence indicated


CYLINDER HEAD


CYLINDER HEAD
Removal and installation the valve-stem seal

Additional jobs
(1) Cylinder head (3) Valve spring

(2) Valve-stem seal (4) Valve cotter
Technical data
Stud bolt bell crank support ................................... M12x60-10.9....................................................105 Nm
WARNING

CYLINDER HEAD
Special tools

[154] Gear ratchet 80.99627-0001
[155] valve spring tensioner 80.99613-6000
• Remove/install valve spring in conjunction with:

• intermediate piece [156]
• Assembly device [157]
• Extension [158]
• Holder [159]
• Holder [160]
[156] intermediate piece 80.99613-0042
• Remove and install valve springs
[157] Assembly device 80.99606-6092
[158] Extension 80.99606-6094
[159] Holder 80.99613-0052

CYLINDER HEAD
[160] Holder 80.99613-0053
[161] magnetic lifter 80.99639-0009
• Remove valve separator
[162] Assembly device 80.99606-6088
• Remove valve-stem seal

• Install the valve-stem seal in conjunction with:
• Assembling sleeve [163]
[163] Assembling sleeve 80.99606-0287
• Install the valve-stem seal

CYLINDER HEAD
Removing the valve stem seals Mount engine cranking unit

ing/timing case
Removing the cylinder head cover Placing the engine in the setting position
Note A Rocker arms in overlap

The mounting bolts can only be removed B Rocker arm free
from the cylinder head cover with damp-
• Crank the engine with Engine barring gear [153]
and Gear ratchet [154] in the engine's running
direction until the rocker arms are in overlap
• Removing and installing free valve stem seals
according to the table
(2)
posed leakage

CYLINDER HEAD
Removing the rocker arm mechanism Assembling the special tool

• Remove the EVB brace (6)
• Remove the rocker arm mechanism (2) with rocker
Removing the valve bridges
Note
The lock washer and Holder [160] have
left-hand threads.
• Position Holder [159] (5) and Holder [160] (3) at

valve spring tensioner [155] (1) by turning the
threaded spindle (4)
• Mark the installation position of the valve • Screw on the lock washers (2) and (6)
crossheads (1) and (2) • Position the lever (8) on the valve spring ten-
• Remove the valve crossheads (1) and (2) sioner [155] (1) and secure using the mounting
bolt (7)

CYLINDER HEAD
Mounting the assembly device Mounting the valve-spring compressor
• Screw in the intermediate piece [156] (2) into the • Position Holder [159] (4) and Holder [160] at the
bracket (1) spring disc and tension by turning the threaded
• Screw the Assembly device [157] (3) into the in- spindle (5)
termediate piece [156] (2) • Hook the valve spring tensioner [155] (2) into the
Assembly device [157] (3)
• Put the Extension [158] (1) on the valve spring
tensioner [155] (2)

CYLINDER HEAD
Remove valve separator Installing the valve stem seals

Installing the valve stem seals
CAUTION
Risk of injury from springing back of
the valve spring
• Ensure that the Holder [159] und
Holder [160] are seated correctly on
the spring disc
• Do not remove the valve separators
from the valve spring with your bare
hands
• Connect the valve spring tensioner [155] (1) with

the Extension [158]
• Remove the valve separators (2) from the valve
stem (3) using the magnetic lifter [161]
• Remove tension from valve spring tensioner [155]
(1)
• Remove the valve spring together with the washer Note
and spring disc The valve stem seals for the inlet and
• Repeat the same procedure for all the valves exhaust valves differ in colour.
• Remove the special tool Green valve stem seals are installed on
inlet valves.
Removing the valve stem seals Brown valve stem seals are installed on
exhaust valves.
• Thinly apply clean engine oil on the Assembling

sleeve [163] (2) and valve stem seal (3)
• Slide the Assembling sleeve [163] (2) over the
valve-stem (1)
• Insert the valve-stem seal (3) in Assembly de-
vice [162] (4) and tension it
• Slide the Assembly device [162] (4) over the As-
sembling sleeve [163] (2)
• Knock the valve stem seal (3) onto the valve stem
(1) using the impact weight (5)
• Remove the Assembly device [162] (4) and the
Assembling sleeve [163] (2)
• Slide the Assembly device [162] (2) over the

valve-stem seal (1)
• Tension the Assembly device [162] (2)
• Pull the valve stem seal (1) off the valve guide with
the impact weight (3)

CYLINDER HEAD
Mounting the assembly device Mounting the valve-spring compressor
• Screw in the intermediate piece [156] (2) into the • Position Holder [159] (4) and Holder [160] at the
bracket (1) spring disc and tension by turning the threaded
• Screw the Assembly device [157] (3) into the in- spindle (5)
termediate piece [156] (2) • Hook the valve spring tensioner [155] (2) into the
Assembly device [157] (3)
• Put the Extension [158] (1) on the valve spring
tensioner [155] (2)

CYLINDER HEAD
Installing the valve springs Install valve separators
CAUTION
Risk of injury from springing back of
the valve spring
• Ensure that the Holder [159] und
Holder [160] are seated correctly on
the spring disc
• Do not insert the valve separators into
the valve spring with your bare hands
• Connect the valve spring tensioner [155] (1) with

the Extension [158]
• Use a suitable tool to insert the valve keys (2) so
that the valve keys (2) are seated in the grooves
of the valve stem (3)
• Insert the washer (3), valve spring (2) and spring • Remove tension from valve spring tensioner [155]
disc (1) over the valve stem (1)
• Repeat the same procedure for all the valves • Remove the special tool
Fitting the valve crossheads
Note

CYLINDER HEAD
Installing the rocker arm mechanism Tightening sequence for cylinder head cover
• Put the rocker arm bearing bracket (1) on the

cylinder head
• Put the rocker arm mechanism (2) on the rocker
• Screw in the mounting bolts (3) and (4)
• Place the EVB brace (6)
A Intake side
B Exhaust side



sequence indicated

CYLINDER HEAD


VALVE CONTROL
VALVE CONTROL
(1) Camshaft gear wheel (4) Cylinder head

(2) Intermediate gear wheel (5) Camshaft bearing cover
(3) Camshaft

VALVE CONTROL
CAMSHAFT/CAMSHAFT BEARING
Remove and fit camshaft/camshaft bearing
Additional jobs
– Checking the valve timing, see 341
(1) Camshaft gear wheel (4) Cylinder head

(2) Intermediate gear wheel (5) Camshaft bearing cover
(3) Camshaft
Technical data
Mounting bolts camshaft gear (1) .......................... M8x30-10.9 .......................................1st torque 15 Nm
Mounting bolts camshaft gear (1) .......................... M8x30-10.9 .........................................Final torque 90°
Mounting bolts intermediate gear (2)...................... M8x30-10.9 .......................................................30 Nm
Technical data camshaft

Axial play, camshaft (3) .................................................................................................. 0.250 - 0.850 mm
Radial play, camshaft (3)................................................................................................ 0.034 - 0.091 mm
Camshaft bearing shells.......................................................................................... Ø 39.974 - 40.015 mm
Camshaft bearings ................................................................................................. Ø 39.925 - 39.950 mm
Depth of camshaft bearing ......................................................................................... 42.095 - 42.150 mm
Installation depth camshaft gear (1) ................................................................................ 9.000 - 9.010 mm
Width, camshaft bearing seat ..................................................................................... 32.300 - 32.700 mm
Spread, camshaft bearing shells.......................................................................................... max. 1.00 mm

VALVE CONTROL
Width, camshaft bearing shell .................................................................................... 25.700 - 26.000 mm
Technical data rocker arm

Rocker arm radial play ................................................................................................... 0.030 - 0.066 mm
Inside diameter, rocker arm bearing......................................................................... Ø 32.005 - 32.025 mm
Rocker arm shaft outside diameter .......................................................................... Ø 31.959 - 31.975 mm
Service products
Omnifit 200M..................................................................................................................... 04.10160-9301
WARNING
Special tools
[164] Dial gauge 08.71000-3217
• Checking the camshaft axial and radial play in

conjunction with:
• Check the rocker arm radial play in conjunction
with:
[165] gauge holder 08.71082-0005
• Checking the camshaft axial and radial play

• Checking the rocker arm radial play
[166] Caliper pin 80.99605-0197
• Checking the camshaft axial and radial play

• Checking the rocker arm radial play
[167] Depth gauge (electronic) 08.71195-9003
• Check camshaft bearing depth

• Check installation depth camshaft gear
[168] Plug-on handle 80.99617-0187
• hammer down the sealing cap in conjunction with:

• press plate [169]

VALVE CONTROL
[169] press plate 80.99604-0301
• Tap in the cover

[171] Gear ratchet 80.99627-0001

VALVE CONTROL
Checking the rocker arm Mount engine cranking unit

ing/timing case
Removing the cylinder head cover Moving the engine into the checking position
Note A Rocker arms in overlap

The mounting bolts can only be removed B Rocker arm free
• Crank the engine with Engine barring gear [170]
and Gear ratchet [171] in the engine's running
direction until the rocker arms are in overlap
• Check free rocker arms as per table
(2)
posed leakage

VALVE CONTROL
Checking the rocker arm radial play Removing the rocker arm mechanism
Removing the rocker arm mechanism

• Position the Caliper pin [166] with a pre-load at the • Unscrew the mounting bolts (5)
rocker arm (1) • Remove the EVB brace (6)
• Press the rocker arm (1) vertically downwards to • Unscrew the mounting bolts (3) and (4)
the end position • Remove the rocker arm mechanism (2) with rocker
• Zero the Dial gauge [164] (3) arm bearing bracket (1)
• Pull the rocker arm (1) upwards to the end position
and read off the difference Removing the valve bridges
• Repeat the procedure for the remaining rocker
arms
The permitted axial play of the rocker arm (1) is
0.030 - 0.066 mm.
If the radial play is out of tolerance, check the rocker

arm inside diameter (1) and the rocker arm shaft
outside diameter.
Check the inside diameter of the rocker arm (1), see

Checking the rocker arm bearing inside diameter,
330.
Check the rocker arm shaft outside diameter, see

Checking the rocker arm shaft outside diameter,
330. • Mark the installation position of the valve
crossheads (1) and (2)
• Remove the valve crossheads (1) and (2)

VALVE CONTROL
Dismantling the rocker arm mechanism Checking the rocker arm shaft outside diameter
Dismantling the rocker arm mechanism
• Clean the rocker arm shaft (2)

• Check the outside diameter of the rocker arm shaft
• Detach the circlip (4) (2) using a micrometer (1)
• Remove the washer (3) • Repeat the procedure for the remaining rocker arm
• Mark the installation position of the rocker arm (1) shafts (2)
• Pull the rocker arm (1) off the rocker arm shaft (2) The permitted outside diameter of the rocker arm
shaft (2) is Ø 31.959 - 31.975 mm.
Checking the rocker arm bearing inside diameter
If the outside diameter is out of tolerance, the rocker
arm shaft (2) must be replaced.
Unscrewing the adjusting screw
• Clean the rocker arm (1) with bearing

• Use the Dial gauge [164] (3) and internal calliper
(2) to check the rocker arm bearing inside diameter
• Repeat the procedure for the remaining rocker
arms • Unscrew the lock nut (1)
The permitted inner diameter of the rocker arm bear- • Unscrew the adjusting screw (3) from the rocker
ing is Ø 32.005 - 32.025 mm arm (2)
If the inside diameter is out of tolerance, the rocker

arm (1) must be replaced.

VALVE CONTROL
Unscrew the EVB adjusting screw Assembling the rocker arm mechanism
Screwing in the adjusting screw
• Unscrew the lock nut (3)

• Unscrew the adjusting screw (1) from the EVB
brace (2) • Screw the adjusting screw (3) into the rocker arm
(2)
• Screw on the lock nut (1)
Screw in the EVB adjusting screw
• Screw the adjusting screw (1) into the EVB brace

(2)
• Screw on the lock nut (3)

VALVE CONTROL
Assembling the rocker arm mechanism Checking the camshaft

Check camshaft axial play
• Thinly apply clean engine oil on the rocker arm

shaft (2)
• Push the rocker arm (1) onto the rocker arm shaft • Install gauge holder [165] (2) with Dial gauge [164]
(2) as marked (1) and Caliper pin [166]
• Fit the washer (3) • Position the Caliper pin [166] with a pre-load at the
• Attach the circlip (4) camshaft (3)
• Push the camshaft (3) horizontally into the end
position towards the flywheel housing/timing case
• Push the camshaft (3) into the end position to-
wards Dial gauge [164] (1) and check the differ-
ence
The permitted axial play of the camshaft (3) is
0.250 - 0.850 mm.
If the axial play is out of tolerance, the camshaft

bearing depth, installation depth of the camshaft
gear and width of the camshaft bearing seat 7 must
be checked.
Check camshaft bearing depth, see Check camshaft

bearing depth 7, 335.
Check installation depth camshaft gear, see Check

installation depth camshaft gear, 335.
Check the width of the camshaft bearing seat (7),

see Check the width of the camshaft bearing seat 7,
335.

VALVE CONTROL
Checking the camshaft radial play Removing the camshaft

Turning the engine to the TDC mark

• Position the Caliper pin [166] with a pre-load at the • Turn the engine with Engine barring gear [170]
camshaft (3) (1) and Gear ratchet [171] in the engine's running
• Press the camshaft (3) vertically downwards to the direction until the 1st cylinder is at the TDC mark
end position (2)
• Push the camshaft (3) into the end position to- Checking the camshaft TDC mark
wards Dial gauge [164] (2) and check the differ-
ence
The permitted radial play of the camshaft (3) is
0.034 - 0.091 mm.
If the radial play is out of tolerance, check the inside

diameter of the camshaft bearing shell and the out-
side diameter of the camshaft bearing.
Check inside diameter of the camshaft bearing

shells, see Check the camshaft bearing shells, 334.
Check outside diameter of the camshaft bearing,

see Check outside diameter of the camshaft bearing,
335.
• Check the TDC mark (1) on the camshaft (3)
The TDC mark (1) must be in line with the cylinder
head face (2).
If the marks are not in line, continue cranking the

engine by 360° in the engine's running direction until
the TDC mark on the flywheel is reached.
Lock Engine barring gear [170].

VALVE CONTROL
Removing the camshaft Check the camshaft bearing

Check the camshaft bearing shell spread
• Mark the installation position of the bearing cap (1)

• Mark the installation position of the camshaft bear- Note
ing shells The difference between dimension A and
• Remove the bearing cover (1) with the camshaft dimension B gives the camshaft bearing
bearing shells spread.
• Remove the camshaft (3) with the camshaft bear-
ing shells • Clean the camshaft bearing shells (2) and place
them together on a flat surface as marked
Removing camshaft wheel
• Check dimension A with a micrometer (1)
• Check dimension B using a micrometer (1)
The permitted spread of the camshaft bearing shells
(2) is max. 1.00 mm.
If the spread is out of tolerance, the camshaft bear-

ing shells (2) must be replaced.
Check the camshaft bearing shells

• Pull the pulse disc (3) and camshaft gear (2) off
the camshaft (1)
• Clean the bearing cover (1) with the camshaft

bearing shells
• Mount the bearing cover (1) with the camshaft
bearing shells on the cylinder head (4) as marked
(2) to check the inside diameter of the camshaft
bearing shells
The permitted inside diameter of the camshaft bear-
ing shells is Ø 39.974 - 40.015 mm.
If the inside diameter is out of tolerance, the

camshaft bearing shells must be replaced.

VALVE CONTROL
Check outside diameter of the camshaft bearing Check installation depth camshaft gear
• Clean the camshaft (3) • Clean the camshaft gear (2)

• Check the outside diameter of the camshaft bear- • Check the camshaft gear (2) with Depth gauge
ing (1) using a micrometer (2) (electronic) [167] (1)
• Repeat the procedure for the remaining camshaft The permitted installation depth of the camshaft gear
bearings (2) is 9.000 - 9.010 mm.
The permitted outside diameter of the camshaft
bearing (1) is Ø 39.925 - 39.950 mm. If the installation depth is out of tolerance, the
camshaft gear (2) must be replaced.
If the outside diameter is out of tolerance, the
camshaft (3) must be replaced. Check the width of the camshaft bearing seat 7
Check camshaft bearing depth 7
• Clean the camshaft bearing seat 7 (2)

• Check the width of the camshaft bearing seat 7 (2)
• Check the camshaft bearing 7 (2) with Depth using a micrometer (1)
gauge (electronic) [167] (1) The permitted width of the camshaft bearing seat 7
The permitted depth of the camshaft bearing 7 (2) is (2) is 32.300 - 32.700 mm.
42.095 - 42.150 mm.
If the width is out of tolerance, the intermediate
If the depth is out of tolerance, the camshaft (3) must cylinder head must be replaced.
be replaced.

VALVE CONTROL
Remove the camshaft intermediate gear Remove the camshaft intermediate gear
Removing the cover
• Remove the intermediate gear (1) with intermedi-

ate gear pin (2) upwards out of the cylinder head
• Hammer down sealing cap (2) with screwdriver (1) • Pull the intermediate gear (1) off the intermediate
at the lowest edge gear pin (2)
• Open the sealing cap (2)
Unscrewing the intermediate gear mounting

bolts
• Unscrew the mounting bolts (2) of the intermediate

gear (1)

VALVE CONTROL
Install the camshaft intermediate gear Installing the cover
Install the camshaft intermediate gear
• Thinly apply Omnifit 200M on the contact surfaces

of the new sealing cap (3)
• Thinly apply clean engine oil on the idler bolt (2) • Assemble the press plate [169] (1) and Plug-on
• Insert the intermediate gear pin (2) into the inter- handle [168] (2)
mediate gear (1) • Hammer down the sealing cap (3) with the special
• Insert the intermediate gear (1) with intermediate tool until the stop is reached
gear pin (2) into the cylinder head from above
Screwing in the intermediate gear mounting

bolts
• Align the intermediate gear (1) with the bores in

the cylinder head
30 Nm

VALVE CONTROL
Installing the camshaft Tighten the camshaft bearing mounting bolts
Mount the camshaft gear

• Align the camshaft gear (3) and the pulse wheel
(4) with the fixing pin (2) Releasing the engine barring gear
• Place the camshaft gear (3) and pulse disc (4) on
the camshaft (1)
1st torque 15 Nm
• Tighten the mounting bolts (5) to Final torque 90°
Installing the camshaft
• Unlock the Engine barring gear [170] (1)
Checking the engine timing
• Thinly apply clean engine oil on the camshaft bear-

ing shells
• Insert the lower camshaft bearing shells as
marked
• Place the camshaft (5) so that the TDC mark (1)
is aligned with the cylinder head face (2)
• Thinly apply clean engine oil on the camshaft bear-
ing shells
• Insert the upper camshaft bearing shells (3) into
the bearing cover as marked
• Put on the bearing cover (3)
• Screw in the new mounting bolts (4) evenly by
• Crank the engine with Gear ratchet [171] in the
hand without tensioning the camshaft (5)
engine's running direction 720° until the TDC mark
(2) is reached
• Block the Engine barring gear [135] (1)

VALVE CONTROL
Checking the camshaft TDC mark Installing the rocker arm mechanism
Fitting the valve crossheads
• Check the TDC mark (1) on the camshaft (3)

The TDC mark (1) must be in line with the cylinder
head face (2). Note
If the marks are not in line, the camshaft (3) must be
removed and reinserted at the mark.
Installing the rocker arm mechanism
• Put the rocker arm bearing bracket (1) on the

cylinder head
• Put the rocker arm mechanism (2) on the rocker
• Screw in the mounting bolts (3) and (4)
• Place the EVB brace (6)

VALVE CONTROL
Tightening sequence for cylinder head cover Mounting the cable duct cover

A Intake side
B Exhaust side

Mounting the cylinder head cover flywheel housing/timing case

sequence indicated

VALVE CONTROL
VALVE TIMING
Checking the valve timing
Additional jobs
(1) Camshaft (3) Crankcase

(2) Flywheel housing/timing case
Technical data
Valve lift during measurement ............................................................................................ 7.90 - 8.50 mm
WARNING
Note
The valve timing must be checked with the valve clearance set correctly.

VALVE CONTROL
Special tools
[172] Dial gauge 08.71000-3217
• Check the valve timing in conjunction with:

[173] gauge holder 08.71082-0005
• Checking the valve timing
[174] Caliper pin 80.99605-0197
• Checking the valve timing

[176] Gear ratchet 80.99627-0001

VALVE CONTROL
Checking the valve timing Removing the cable duct cover

ing/timing case Removing the cylinder head cover
Turning the engine to the TDC mark
Note
The mounting bolts can only be removed
• Crank the flywheel in the engine's running direc- ing elements and spacer sleeves.
tion with Engine barring gear [175] (1) and Gear
ratchet [176] until the TDC mark on the flywheel is • Unscrew the mounting bolts (4)
lined up with the TDC mark (2) • Remove the cylinder head cover (3) with gasket
Rocker arms of cylinder 6 Cylinders must be in over- (2) from the cylinder head (1)
lap. • Clean the cylinder head cover (3) and the gasket
(2)
Upright rocker arm 6. If the cylinder is not in overlap, Check the gasket (2) for damage. Remove from
turn the flywheel a further 360° to the TDC mark. the cylinder head cover (3) and replace if required
posed leakage

VALVE CONTROL
Checking the valve lift Tightening sequence for cylinder head cover
WARNING
Falsified measurement result by
cranking the engine against the en-
gine's running direction
• Only crank the engine in the running
direction
• Put Dial gauge [172] (4) with Caliper pin [174] (2)
and gauge holder [173] (3) on the 3rd cylinder inlet
valve disc
• Continue cranking the engine in the engine's run-
ning direction until the dial gauge pointer stops
moving
In this position, the correct valve lift must be A Intake side
7.90 - 8.50 mm. B Exhaust side


sequence indicated

VALVE CONTROL



TIMING GEARS
TIMING GEARS
(1) Small intermediate gear (7) Front crankshaft gear

(2) Intermediate gear wheel (8) Oil pump
(3) Large intermediate gear (9) High pressure pump drive intermediate
(4) Air compressor intermediate gear gear
(5) Rear crankshaft gear (10) Intermediate gear stud
(6) Mounting bolt

TIMING GEARS
FRONT DRIVE GEARS

Removal and installation of front drive gears
Additional jobs
– Removing and installing alternators 1 and 2, see 159
– Removal and installation the distributor housing, see 55
– Removal and installation of the vibration damper, see 435
– Removal and installation of the coolant compressor, see 173
– Removal and installation cover, see 507
– Removal and installation of front crankshaft seal, see 417
(1) High-pressure pump drive intermediate (3) Mounting bolt

gear (4) Crankshaft gear wheel
(2) Intermediate gear stud (5) Oil pump
Technical data
Mounting bolt (3) .................................................. M12x50-10.9....................................................105 Nm
TIMING GEARS
Backlash, crankshaft gear (4) - high-pressure pump drive intermediate gear (1)................ 0.057 - 0.183 mm
Axial play, high-pressure pump drive intermediate gear (1) .............................................. 0.100 - 0.290 mm
Radial play, high-pressure pump drive intermediate gear (1) ............................................ 0.060 - 0.109 mm
Height, high-pressure pump drive intermediate gear (1)............................................... 21.000 - 21.500 mm
Inside diameter, high-pressure pump drive intermediate gear (1)............................... Ø 60.000 - 60.030 mm
Outside diameter, intermediate gear pin (2).............................................................. Ø 59.921 - 59.940 mm
Height, intermediate gear pin (2) ................................................................................ 27.200 - 27.240 mm
WARNING
Note
The intermediate gear and pin do not have to be exchanged as a set.
They can also be replaced individually, depending on the degree of wear.
Special tools
[177] Centring mandrel 80.99617-0020
• Removal and installation of front crankshaft gear
[178] Dial gauge 08.71000-3217
• Check the backlash in conjunction with:

• Check the axial and radial play of the intermediate
gear in conjunction with:
[179] gauge holder 08.71082-0005
• Checking backlash
• Checking the ring gear axial and radial play of the
intermediate gear
[180] Caliper pin 80.99605-0197
• Checking the ring gear axial and radial play of the
intermediate gear
• Checking the intermediate gear pin height

TIMING GEARS
Checking the front drive gears Checking the axial play on the high pressure
pump drive intermediate gear
Fixing the crankshaft gear
• Mount the gauge holder [179] (2) with Dial

• Screw in the Centring mandrel [177] (1) and (3) gauge [178] (3) and Caliper pin [180]
• Screw in and tighten the mounting bolt (2) • Position Caliper pin [180] with a pre-load at the
intermediate gear (1)
Checking the tooth flank clearance on the crank- • Push the intermediate gear (1) into the end posi-
shaft gear/intermediate gear for the high-pres- tion
sure pump drive • Zero the Dial gauge [178] (3)
• Pull the intermediate gear (1) into the end position
and read off the difference
The permitted axial play of the intermediate gear (1)
is 0.100 - 0.290 mm.
If the axial play is out of tolerance, check the height

of the small intermediate gear (1) and intermediate
gear pin.
Check the high intermediate gear (1), see Checking

the height of the high pressure pump drive interme-
diate gear, 353.
Check the intermediate gear pin height, see Check-

ing the intermediate gear pin height, 353.
gauge [178] (3) and Caliper pin [180]
• Position Caliper pin [180] with a pre-load at the
intermediate gear (1)
• Check the backlash between the crankshaft gear
(2) and the intermediate gear (1)
The permitted backlash is 0.057 - 0.183 mm.
If the backlash is out of tolerance, fit a new crank-

shaft gear (2) and intermediate gear (1).

TIMING GEARS
Checking the radial play on the high-pressure Removing the crankshaft gear
pump drive intermediate gear
Unscrew the mounting bolt

gauge [178] (2) and Caliper pin [180] • Unscrew the mounting bolt (1)
intermediate gear (3) Removing the crankshaft gear
• Push the intermediate gear (3) into the end posi-
tion towards the crankshaft gear
• Pull the small intermediate gear (3) into the end po-
sition towards the Dial gauge [184] (2) and check
the difference
The permitted radial play of the intermediate gear
(3) is 0.060 - 0.109 mm.
If the radial play is out of tolerance, check the small

intermediate gear (3) and the intermediate gear pin.
Check the inside diameter of the intermediate gear

(3), see Checking the inside diameter of the high
pressure pump drive intermediate gear, 353.
• Pull off the crankshaft gear (2)
Check the outside diameter of the intermediate gear • Unscrew the Centring mandrel [177] (3) and (4)
pin, see Checking the outside diameter of the inter- • Clean the contact surfaces of the crankshaft gear
mediate gear pin, 354. (2) and crankshaft (1)

TIMING GEARS
Removing the high-pressure pump drive Checking the inside diameter of the high pres-
intermediate gear sure pump drive intermediate gear
Removing the intermediate gear
• Clean intermediate gear (3)

• Unscrew the mounting bolts (2) (1) to check the inside diameter of the big interme-
• Pull the intermediate gear (1) with the intermediate diate gear (3)
gear pin (3) The permitted inside diameter of the intermediate
gear (3) is Ø 60.000 - 60.030 mm.
Checking the height of the high pressure pump
drive intermediate gear If the inside diameter is out of tolerance, the inter-
mediate gear (3) must be replaced.
Checking the intermediate gear pin height
• Clean intermediate gear (1)

• Check dimension A of the intermediate gear (1)
The permitted dimension A is 21.000 - 21.500 mm.
• Clean the intermediate pin (1)
If dimension A is out of tolerance, the intermediate • Check the height of the intermediate gear pin (1)
gear (1) must be replaced. using Depth gauge (electronic) [181] (2)
The permitted height of the intermediate gear pin (1)
is 27.200 - 27.240 mm.
If the height is out of tolerance, the intermediate gear

pin (1) must be replaced.

TIMING GEARS
Checking the outside diameter of the intermedi- Installing the front drive gears
ate gear pin
Installing the intermediate gear
• Check the outside diameter of the intermediate

gear pin (1) using a micrometer (2) • Thinly apply clean engine oil on the idler bolt (3)
The permitted outside diameter of the intermediate • Insert the intermediate gear pin (3) into the inter-
gear bolt (1) is Ø 59.921 - 59.940 mm. mediate gear (1)
• Install the intermediate gear (1) in the crankcase
If the outside diameter is out of tolerance, the inter- with the intermediate gear pin (3)
mediate gear pin (1) must be replaced. • Screw in the new mounting bolts (2)
Tightening the intermediate gear pin mounting

bolts
• Tighten the mounting bolts (1) to 105 Nm

TIMING GEARS
Installing the crankshaft gear
• Screw in the Centring mandrel [177] (3) and (4)

• Put the crankshaft gear (2) on the crankshaft (1),
ensuring that the stop is reached
• Unscrew the Centring mandrel [177] (3) and (4)

TIMING GEARS
REAR TIMING GEARS

Removing and installing rear timing gears (Version crankshaft seal flywheel)
Additional jobs
– Removal and installation of the cylinder head, see 293
– Removal and installation of the starter, see 151
– Removal and installation of the gearbox flywheel (Flywheel crankshaft seal), see 439
– Removing and installing flywheel of automatic gearbox (crankshaft seal flywheel version), see 449
– Removing and installing dual-mass flywheel (crankshaft seal crankshaft gear version), see 471
– Removing and installing flywheel housing/timing case, see 505
– Removal and installation of rear crankshaft seal (crankshaft seal version flywheel), see 423

TIMING GEARS
(1) Rear crankshaft gear (4) Large intermediate gear

(2) Air compressor intermediate gear (5) Mounting bolt
(3) Mounting bolt (6) Small intermediate gear
Technical data
Mounting bolt (5) .................................................. M14x80-10.9.................................... 1st torque 105 Nm
Mounting bolt (5) .................................................. M14x80-10.9........................................Final torque 90°
Mounting bolt (3) .................................................. M12x55-10.9.................................................... 115 Nm
Mounting bolts for small intermediate gear (6) ........ M8x20-10.9 .......................................................30 Nm
Backlash
Tooth backlash, large intermediate gear (4) - rear crankshaft gear (1)............................... 0.052 - 0.176 mm
Backlash, large intermediate gear (4) - Small intermediate gear (6) ................................. 0.052 - 0.176 mm
Air compressor intermediate gear

Axial play, intermediate gear air compressor (2) .............................................................. 0.100 - 0.190 mm
Radial play intermediate gear air compressor (2)............................................................. 0.060 - 0.109 mm
Intermediate gear height, air compressor (2) ............................................................... 25.900 - 26.000 mm
Height contact washer intermediate gear air compressor (2) ............................................ 4.800 - 5.000 mm
Inside diameter, intermediate gear air compressor (2)...................................................Ø 60.00 - 60.03 mm
Outside diameter, air compressor intermediate gear pin............................................ Ø 59.921 - 59.940 mm
Height, air compressor intermediate gear pin .............................................................. 26.100 - 26.140 mm
Large intermediate gear

Axial play, large intermediate gear (4) ............................................................................. 0.100 - 0.290 mm
Radial play, large intermediate gear (4)........................................................................... 0.060 - 0.109 mm
Height of large intermediate gear (4)........................................................................... 52.950 - 53.000 mm
Inside diameter of large intermediate gear (4) .......................................................... Ø 80.000 - 80.035 mm
Outside diameter, large intermediate gear pins......................................................... Ø 79.921 - 79.940 mm

TIMING GEARS
Height, large intermediate gear pins ........................................................................... 56.200 - 56.240 mm
Small intermediate gear

Axial play of small intermediate gear (6).......................................................................... 0.100 - 0.290 mm
Radial play of small intermediate gear (6) ....................................................................... 0.060 - 0.109 mm
Height of small intermediate gear (6) .......................................................................... 17.000 - 17.500 mm
Inside diameter of small intermediate gear (6) .......................................................... Ø 60.000 - 60.030 mm
Outside diameter of intermediate gear pins .............................................................. Ø 59.921 - 59.940 mm
Height of small intermediate gear pins ........................................................................ 21.200 - 21.240 mm
WARNING
Note
Note
The intermediate gear to the air compressor is designed in two parts for noise reduction and
pre-stressed.
Backlash cannot be measured at this point.
Special tools
• Installing the rear crankshaft gear
[183] Guide mandrel 80.99617-0209
• Removing the air compressor intermediate gear
[184] Dial gauge 08.71000-3217
• Checking the inside diameter of intermediate

gears
• Check backlash of intermediate gears in conjunc-
tion with:
• Check axial and radial play of intermediate gears
in conjunction with:
[185] gauge holder 08.71082-0005
• Checking the axial and radial play of intermediate
gears

TIMING GEARS
[186] Caliper pin 80.99605-0197
gears

TIMING GEARS
Check the tooth flank clearance of the Setting the crankshaft gear to the marks
timing gears
Checking the crankshaft gear/large - intermedi-
ate gear backlash
• Fix the crankshaft gear (1) by screwing in mount-

ing bolts (2) and (3)
gauge [184] (2) and Caliper pin [186] Setting the crankshaft gear to the marks
large intermediate gear (1)
(4) and large intermediate gear (1)
If the backlash is out of tolerance, the crankshaft

gear (4) and the small intermediate gear (1) must be
replaced.
Checking the tooth backlash of the small inter-

mediate gear/large intermediate gear
• Crank the engine until the mark (1) is aligned with

the mark (2)
Mark (1) and mark (2) are aligned.
Unscrew the crankshaft gear mounting bolts

gauge [184] (1) and Caliper pin [186] (3)
• Position the Caliper pin [186] (3) against the small
intermediate gear (4) with pre-load
• Checking the backlash of the small intermediate
gear (4)
If the backlash is outside the tolerance, the small • Release the crankshaft gear (1) by unscrewing the
intermediate gear (4) and large intermediate gear mounting bolts (2) and (3)
must be replaced.

TIMING GEARS
Removing the large intermediate gear Checking the radial play on the large intermedi-
ate gear
Checking the axial play on the large intermediate
gear

• Mount the gauge holder [185] (3) with Dial • Position Caliper pin [186] with a pre-load at the
gauge [184] (2) and Caliper pin [186] large intermediate gear (1)
• Position Caliper pin [186] with a pre-load at the • Press the large intermediate gear (1) vertically
large intermediate gear (1) downwards to the end position
• Push the large intermediate gear (1) into the end • Zero the Dial gauge [184] (3)
position • Push the intermediate gear (1) upwards to the end
• Zero the Dial gauge [184] (2) position and read off the difference
• Pull the large intermediate gear (1) into the end The permitted radial play is 0.060 - 0.109 mm.
position and read off the difference
The permitted axial play is 0.100 - 0.290 mm. If the radial play is out of tolerance, check the large
intermediate gear (1) and the large intermediate
If the axial play is out of tolerance, check the height gear pin.
of the large intermediate gear (1) and large interme-
diate gear pin (4). Check inner diameter of large intermediate gear
(1), see Checking the inside diameter of the large
Check the height of the large intermediate gear (1), intermediate gear, 363.
see Checking the height of the large intermediate
gear, 363. Check the outside diameter of the big intermediate
gear pin, see Checking the outside diameter of large
Check the intermediate gear pin height (4), see intermediate gear pin, 363.
Checking the height of the large intermediate gear
pin, 363. Removing the large intermediate gear

• Remove large intermediate gear (3) with large
intermediate gear pin (2)

TIMING GEARS
Checking the height of the large intermediate Checking the height of the large intermediate
gear gear pin
• Clean large intermediate gear (1) • Clean large intermediate gear pin (1)
• Check dimension A of large intermediate gear with • Check the height of the large intermediate gear
a micrometre (1) pin (1) using Depth gauge (electronic) [187] (2)
The permitted dimension A is 52.950 - 53.000 mm. The permitted installation height is
56.200 - 56.240 mm.
If dimension A is out of tolerance, the large interme-
diate gear (1) must be replaced. If the height is out of tolerance, the large intermedi-
ate gear pin (1) must be replaced.
Checking the inside diameter of the large inter-
mediate gear Checking the outside diameter of large interme-
diate gear pin

(1) to check the inside diameter of the intermediate • Checking the outside diameter of large intermedi-
gear (3) ate gear pin (1) with outside micrometre (2)
The permitted outside diameter is The permitted outside diameter Ø 79.921 - 79.94
Ø 80.000 - 80.035 mm. 0 mm.
If the inside diameter is out of tolerance, the large If the outside diameter is out of tolerance, the large
intermediate gear (3) must be replaced. intermediate gear pin (1) must be replaced.

TIMING GEARS
Removing the small intermediate gear Checking the radial play on the small intermedi-
ate gear
Checking the axial play on the small intermediate
gear

• Mount the gauge holder [185] (2) with Dial • Position Caliper pin [186] against the small inter-
gauge [184] (1) and Caliper pin [186] mediate gear (1) with pre-load
• Position Caliper pin [186] against the small inter- • Press the small intermediate gear (1) vertically
mediate gear (3) with preload downwards to the end position
• Push the small intermediate gear (3) into the end • Zero the Dial gauge [184] (3)
position • Push the small intermediate gear (1) upwards to
• Zero the Dial gauge [184] (1) the end position and read off the difference
• Pull the small intermediate gear (3) into the end The permitted radial play is 0.060 - 0.109 mm.
position and check the difference
The permitted axial play is 0.100 - 0.290 mm. If the radial play is out of tolerance, check the small
intermediate gear (1) and the small intermediate
of the small intermediate gear (3) and small interme-
diate gear pin. Check the inside diameter of the small intermediate
gear (1), see Checking the inside diameter of the
Check the height of the small intermediate gear (3), small intermediate gear, 365.
see Check the height of the small intermediate gear,
365. Checking the outside diameter of the small interme-
diate gear pin see Checking the outside diameter of
Check height of small intermediate gear pin, see the small intermediate gear pin, 365.
Checking the height of the intermediate gear pin,
365. Removing the small intermediate gear

• Remove small intermediate gear (3) with small

TIMING GEARS
Check the height of the small intermediate gear Checking the height of the intermediate gear pin
• Clean the small intermediate gear (1) • Clean small intermediate gear pin (1)
• Check dimension A of small intermediate gear (1) • Check the height of the small intermediate gear
The permitted dimension A is 17.000 - 17.500 mm. pin (1) using Depth gauge (electronic) [187] (2)
The permitted height of the small intermediate gear
If dimension A is out of tolerance, the small interme- pin (1) is 21.200 - 21.240 mm.
diate gear (1) must be replaced.
If the height is out of tolerance, the small intermedi-
Checking the inside diameter of the small inter- ate gear pin (1) must be replaced.
mediate gear
Checking the outside diameter of the small in-
termediate gear pin

(1) to check the inside diameter of the small inter-
mediate gear (3) • Check the outside diameter of the small interme-
The permitted inside diameter of the small intermediate gear pin (1) using a micrometre (2)
diate gear (3) is Ø 60.000 - 60.030 mm. The permitted outside diameter of the intermediate
gear bolt (1) is Ø 59.921 - 59.940 mm.
If the inside diameter is out of tolerance, the small
intermediate gear (3) must be replaced. If the outside diameter is out of tolerance, the small
intermediate gear pin (1) must be replaced.

TIMING GEARS
Removing the crankshaft gear Removing the air compressor interme-

diate gear
Checking the axial play on the air compressor
intermediate gear
• Prise off the crankshaft gear (1) with a lever (3)

from the crankshaft (1)

• Position Caliper pin [186] against the air compres-
sor intermediate gear (2) with pre-load
• Push the air compressor intermediate gear (2) into
the end position
• Pull the air compressor intermediate gear (2) into
the end position and read off the difference
The permitted axial play is 0.100 - 0.190 mm.

of the intermediate gear air compressor (2) and in-
termediate gear pin.
Check the height between the air compressor and

the intermediate gear(2), see Checking the height of
the intermediate gear air compressor, 368.

ing the height of the air compressor intermediate
gear pin, 368.

TIMING GEARS
Checking the radial play on the air compressor Screwing in the guide mandrel
intermediate gear
• Unscrew a mounting bolt (1)

• Mount the gauge holder [185] (3) with Dial • Screw in the Guide mandrel [183] (2)
gauge [184] (1) and Caliper pin [186] • Unscrew remaining mounting bolts (1) from the
• Position Caliper pin [186] against the air compres- interim gear bolt air compressor (3)
sor intermediate gear (2) with preload
• Press the air compressor intermediate gear (2) Removing the air compressor intermediate gear
vertically downwards to the end position
• Push the intermediate gear air compressor (2) up-
wards to the end position and read off the differ-
ence
The permitted radial play is 0.060 - 0.109 mm.

diameter of the intermediate gear air compressor (2)
and the outside diameter of the intermediate gear
pin.

(2), see Checking the inside diameter of the air
compressor intermediate gear, 368.
Check the outside diameter of the intermediate gear WARNING

pin, see Checking the outside diameter of the air The contact washer may fall into the
compressor intermediate gear pin, 368. oil sump
• Before removing the intermediate gear,
secure the contact washer to prevent it
from falling
• Secure the contact washer (2) behind the interme-

diate gear air compressor (1)
• Unscrew the Guide mandrel [183]
• Remove the intermediate gear air compressor (1)
with contact washer (2) and intermediate gear pin
air compressor (3)

TIMING GEARS
Checking the height of the intermediate gear air Checking the height of the air compressor inter-
compressor mediate gear pin
• Clean the intermediate gear air compressor (1) • Clean the air compressor intermediate gear pin (1)
and contact washer (2) • Check the height of the intermediate gear pin of
• Check the height of the intermediate gear air the air compressor (1) using Depth gauge (elec-
compressor (1) and the thickness of the contact tronic) [187] (2)
washer (2) The permitted height of the intermediate gear pin (1)
The permitted dimension A is 25.900 - 26.000 mm. is 26.100 - 26.140 mm.
If dimension A is out of tolerance, the intermediate If the height is out of tolerance, the air compressor
gear air compressor (1) must be replaced. intermediate gear pin (1) must be replaced.
The permitted thickness of the contact washer (2) is Checking the outside diameter of the air com-
4.800 - 5.000 mm. pressor intermediate gear pin
If the thickness is out of tolerance, the contact

washer (2) must be replaced.
Checking the inside diameter of the air compres-

sor intermediate gear
• Clean the air compressor intermediate gear pin (1)

• Check the outside diameter of the air compressor
intermediate gear pin (1) by using an outside mi-
crometre (2)
The permitted outside diameter of the inter-
mediate gear pin of the air compressor (1) is
• Clean intermediate gear air compressor (3) Ø 59.921 - 59.940 mm.
(1) to check the inside diameter of the intermediate If the outside diameter is out of tolerance, the air
gear air compressor (3) compressor intermediate gear pin (1) must be re-
The permitted inside diameter of the intermediate placed.
gear of the air compressor (3) is Ø 60.00 - 60.03 mm.
If the inside diameter is out of tolerance, the air

compressor intermediate gear (3) must be replaced.

TIMING GEARS
Installing timing gear Installing the intermediate gear air compressor
Installation instructions for intermediate gear air

compressor
• Extract the intermediate gear air compressor with

the intermediate gear pin (3), position contact
washer in the crankcase and secure with Guide
• Mount the Intermediate gear air compressor mandrel [183] (2)
with the wider side (1) of the division facing the • Screw in the new mounting bolts (1)
crankcase • Unscrew the Guide mandrel [183] (2)
The rubber element of the intermediate gear air • Screw in remaining new mounting bolts (1)
compressor points to the crankcase. • Tighten the mounting bolts (1) to 115 Nm
Position the intermediate gear air compressor Installing small intermediate gear
• Thinly apply clean engine oil to the intermediate • Thinly apply clean engine oil to the small interme-
gear pin air compressor (3) diate gear pin (2)
• Place the intermediate gear pin air compressor (3) • Position the small intermediate gear (4) with a
into the intermediate gear air compressor (1) flat approach surface (3) to the small intermediate
• Position the contact washer (2) with the more gear pin (2)
chamfered side to the crankcase pointing towards • Install small intermediate gear (4) with small inter-
the intermediate gear pin air compressor (3) mediate gear pin (2) in crankcase
30 Nm

TIMING GEARS
Installing the crankshaft gear Checking the crankshaft gear mark
• Turn the crankshaft until the centring pin (4) is • Check that the mark (1) on the large intermediate
perpendicular to the oil sump gear and the mark (2) on the crankshaft gear are
• Screw in the Centring mandrel [182] (3) and (5) in line
• Align the crankshaft gear (1) with the centring pin If the marks (1) and (2) are not in line, remove the
(4) large intermediate gear and re-insert it at the mark.
• Push the crankshaft gear (1) onto the crankshaft
Installing the large intermediate gear
• Thinly apply clean engine oil to large intermediate

gear pin (2)
• Insert the large intermediate gear pin (2) into the
• Install the large intermediate gear (3) so that the
markings on the large intermediate gear (3) and
the crankshaft gear are lined up, see Checking
the crankshaft gear mark, 370
1st torque 105 Nm

TIMING GEARS
Removing, installing the timing gear (crankshaft seal, crankshaft gear Version)
Additional jobs
– Removing and installing flywheel (crankshaft seal crankshaft gear version) for manually operated gear-
boxes, see 455
– Removing and installing flywheel (with race) for the automatic gearbox, see 465
– Removing, installing the rear crankshaft seal for Crankshaft gear with stud, see 428

TIMING GEARS
(1) Rear crankshaft gear (4) Large intermediate gear

(2) Air compressor intermediate gear (5) Mounting bolt
(3) Mounting bolt (6) Small intermediate gear
Technical data
Backlash
Air compressor intermediate gear

Large intermediate gear


TIMING GEARS
Small intermediate gear

WARNING
Note
Note
The intermediate gear to the air compressor is designed in two parts for noise reduction and
pre-stressed.
Backlash cannot be measured at this point.
Special tools
• Installing the rear crankshaft gear
[189] Guide mandrel 80.99617-0209
• Removing the air compressor intermediate gear
[190] Dial gauge 08.71000-3217
• Checking the inside diameter of intermediate

gears
• Check backlash of intermediate gears in conjunc-
tion with:
• Check axial and radial play of intermediate gears
in conjunction with:
[191] gauge holder 08.71082-0005
• Checking backlash of interim gears

gears

TIMING GEARS
[192] Caliper pin 80.99605-0197
• Checking backlash of interim gears

gears

TIMING GEARS
Check the tooth flank clearance of the Setting the crankshaft gear to the marks
timing gears
Checking the crankshaft gear/large - intermedi-
ate gear backlash
• Fix the crankshaft gear (3) by screwing in mount-

ing bolts (1) and (2)
gauge [190] (3) and Caliper pin [192] Setting the crankshaft gear to the marks
(1) and large intermediate gear (4)
If the backlash is out of tolerance, the crankshaft

gear (1) and the small intermediate gear (4) must be
replaced.
Checking the tooth backlash of the small inter-

mediate gear/large intermediate gear
• Crank the engine until the mark (1) is aligned with

the mark (2)
Mark (1) and mark (2) are aligned.
Unscrew the crankshaft gear mounting bolts

gauge [190] (1) and Caliper pin [192] (3)
• Position the Caliper pin [192] (3) against the small
intermediate gear (4) with pre-load
• Checking the backlash of the small intermediate
gear (4)
If the backlash is outside the tolerance, the small • Release the crankshaft gear (3) by unscrewing the
intermediate gear (4) and large intermediate gear mounting bolts (1) and (2)
must be replaced.

TIMING GEARS
Removing the large intermediate gear Checking the radial play on the large intermedi-
ate gear
Checking the axial play on the large intermediate
gear

• Mount the gauge holder [191] (3) with Dial • Position Caliper pin [192] with a pre-load at the
gauge [190] (2) and Caliper pin [192] large intermediate gear (1)
• Position Caliper pin [192] with a pre-load at the • Press the large intermediate gear (1) vertically
large intermediate gear (1) downwards to the end position
• Push the large intermediate gear (1) into the end • Zero the Dial gauge [190] (3)
position • Push the intermediate gear (1) upwards to the end
• Zero the Dial gauge [190] (2) position and read off the difference
• Pull the large intermediate gear (1) into the end The permitted radial play is 0.060 - 0.109 mm.
position and read off the difference
The permitted axial play is 0.100 - 0.290 mm. If the radial play is out of tolerance, check the large
intermediate gear (1) and the large intermediate
of the large intermediate gear (1) and large interme-
diate gear pin (4). Check inner diameter of large intermediate gear
(1), see Checking the inside diameter of the large
Check the height of the large intermediate gear (1), intermediate gear, 377.
see Checking the height of the large intermediate
gear, 377. Check the outside diameter of the big intermediate
gear pin, see Checking the outside diameter of large
Checking the height of the large intermediate gear intermediate gear pin, 377.
pin (4), see Checking the height of the large inter-
mediate gear pin, 377. Removing the large intermediate gear

• Remove large intermediate gear (3) with large

TIMING GEARS
Checking the height of the large intermediate Checking the height of the large intermediate
gear gear pin
• Clean large intermediate gear (1) • Clean large intermediate gear pin (1)
• Check dimension A of large intermediate gear with • Check the height of the large intermediate gear
a micrometre (1) pin (1) using Depth gauge (electronic) [193] (2)
The permitted dimension A is 52.950 - 53.000 mm. The permitted installation height is
56.200 - 56.240 mm.
If dimension A is out of tolerance, the large interme-
diate gear (1) must be replaced. If the height is out of tolerance, the large intermedi-
ate gear pin (1) must be replaced.
Checking the inside diameter of the large inter-
mediate gear Checking the outside diameter of large interme-
diate gear pin

(1) to check the inside diameter of the intermediate • Checking the outside diameter of large intermedi-
gear (3) ate gear pin (1) with outside micrometre (2)
The permitted outside diameter is The permitted outside diameter Ø 79.921 - 79.94
Ø 80.000 - 80.035 mm. 0 mm.
If the inside diameter is out of tolerance, the large If the outside diameter is out of tolerance, the large
intermediate gear (3) must be replaced. intermediate gear pin (1) must be replaced.

TIMING GEARS
Removing the small intermediate gear Checking the radial play on the small intermedi-
ate gear
Checking the axial play on the small intermediate
gear

• Mount the gauge holder [191] (2) with Dial • Position Caliper pin [192] against the small inter-
gauge [190] (1) and Caliper pin [192] mediate gear (1) with preload
• Position Caliper pin [192] against the small inter- • Press the small intermediate gear (1) vertically
mediate gear (3) with preload downwards to the end position
• Push the small intermediate gear (3) into the end • Zero the Dial gauge [190] (3)
position • Push the small intermediate gear (1) upwards to
• Zero the Dial gauge [190] (1) the end position and read off the difference
• Pull the small intermediate gear (3) into the end The permitted radial play is 0.060 - 0.109 mm.
position and check the difference
The permitted axial play is 0.100 - 0.290 mm. If the radial play is out of tolerance, check the small
intermediate gear (1) and the small intermediate
of the small intermediate gear (3) and small interme-
diate gear pin. Check the inside diameter of the small intermediate
gear (1), see Checking the inside diameter of the
Check the height of the small intermediate gear (3), small intermediate gear, 379.
see Check the height of the small intermediate gear,
379. Checking the outside diameter of the small interme-
diate gear pin see Checking the outside diameter of
Check height of small intermediate gear pin, see the small intermediate gear pin, 379.
Checking the height of the intermediate gear pin,
379. Removing the small intermediate gear

• Remove small intermediate gear (3) with small

TIMING GEARS
Check the height of the small intermediate gear Checking the height of the intermediate gear pin
• Clean the small intermediate gear (1) • Clean small intermediate gear pin (1)
• Check dimension A of small intermediate gear (1) • Check the height of the small intermediate gear
The permitted dimension A is 17.000 - 17.500 mm. pin (1) using Depth gauge (electronic) [193] (2)
The permitted height of the small intermediate gear
If dimension A is out of tolerance, the small interme- pin (1) is 21.200 - 21.240 mm.
diate gear (1) must be replaced.
If the height is out of tolerance, the small intermedi-
Checking the inside diameter of the small inter- ate gear pin (1) must be replaced.
mediate gear
Checking the outside diameter of the small in-
termediate gear pin

(1) to check the inside diameter of the small inter-
mediate gear (3) • Check the outside diameter of the small interme-
The permitted inside diameter of the small intermediate gear pin (1) using a micrometre (2)
diate gear (3) is Ø 60.000 - 60.030 mm. The permitted outside diameter of the intermediate
gear bolt (1) is Ø 59.921 - 59.940 mm.
If the inside diameter is out of tolerance, the small
intermediate gear (3) must be replaced. If the outside diameter is out of tolerance, the small
intermediate gear pin (1) must be replaced.

TIMING GEARS
Removing the crankshaft gear Removing the air compressor interme-

diate gear
Checking the axial play on the air compressor
intermediate gear
• Remove the crankshaft gear (1) with a lever (2)

from the crankshaft

• Position Caliper pin [192] against the air compres-
• Push the air compressor intermediate gear (2) into
the end position
• Pull the air compressor intermediate gear (2) into
the end position and read off the difference
The permitted axial play is 0.100 - 0.190 mm.

of the intermediate gear air compressor (2) and in-
termediate gear pin.
Check the height between the air compressor and

the intermediate gear(2), see Checking the height of
the intermediate gear air compressor, 382.

ing the height of the air compressor intermediate
gear pin, 382.

TIMING GEARS
Checking the radial play on the air compressor Screwing in the guide mandrel
intermediate gear
• Unscrew a mounting bolt (1)

• Mount the gauge holder [191] (3) with Dial • Screw in the Guide mandrel [189] (2)
gauge [190] (1) and Caliper pin [192] • Unscrew remaining mounting bolts (1) from the
• Position Caliper pin [192] against the air compres- interim gear bolt air compressor (3)
• Press the air compressor intermediate gear (2) Removing the air compressor intermediate gear
vertically downwards to the end position
• Push the intermediate gear air compressor (2) up-
wards to the end position and read off the differ-
ence
The permitted radial play is 0.060 - 0.109 mm.

diameter of the intermediate gear air compressor (2)
and the outside diameter of the intermediate gear
pin.

(2), see Checking the inside diameter of the air
compressor intermediate gear, 382.
Check the outside diameter of the intermediate gear WARNING

pin, see Checking the outside diameter of the air The contact washer may fall into the
compressor intermediate gear pin, 382. oil sump
• Before removing the intermediate gear,
secure the contact washer to prevent it
from falling
• Secure the contact washer (2) behind the interme-

diate gear air compressor (1)
• Unscrew the Guide mandrel [189]
• Remove the intermediate gear air compressor (1)
with contact washer (2) and intermediate gear pin
air compressor (3)

TIMING GEARS
Checking the height of the intermediate gear air Checking the height of the air compressor inter-
compressor mediate gear pin
• Clean the intermediate gear air compressor (1) • Clean the air compressor intermediate gear pin (1)
and contact washer (2) • Check the height of the intermediate gear pin of
• Check the height of the intermediate gear air the air compressor (1) using Depth gauge (elec-
compressor (1) and the thickness of the contact tronic) [193] (2)
washer (2) The permitted height of the intermediate gear pin (1)
The permitted dimension A is 25.900 - 26.000 mm. is 26.100 - 26.140 mm.
If dimension A is out of tolerance, the intermediate If the height is out of tolerance, the air compressor
gear air compressor (1) must be replaced. intermediate gear pin (1) must be replaced.
The permitted thickness of the contact washer (2) is Checking the outside diameter of the air com-
4.800 - 5.000 mm. pressor intermediate gear pin
If the thickness is out of tolerance, the contact

washer (2) must be replaced.
Checking the inside diameter of the air compres-

sor intermediate gear
• Clean the air compressor intermediate gear pin (1)

• Check the outside diameter of the air compressor
intermediate gear pin (1) by using an outside mi-
crometre (2)
The permitted outside diameter of the inter-
mediate gear pin of the air compressor (1) is
• Clean intermediate gear air compressor (3) Ø 59.921 - 59.940 mm.
(1) to check the inside diameter of the intermediate If the outside diameter is out of tolerance, the air
gear air compressor (3) compressor intermediate gear pin (1) must be re-
The permitted inside diameter of the intermediate placed.
gear of the air compressor (3) is Ø 60.00 - 60.03 mm.
If the inside diameter is out of tolerance, the air

compressor intermediate gear (3) must be replaced.

TIMING GEARS
Installing timing gear Installing the intermediate gear air compressor
Installation instructions for intermediate gear air

compressor
• Extract the intermediate gear air compressor with

the intermediate gear pin (3), position contact
washer in the crankcase and secure with Guide
• Mount the Intermediate gear air compressor mandrel [189] (2)
with the wider side (1) of the division facing the • Screw in the new mounting bolts (1)
crankcase • Unscrew the Guide mandrel [189] (2)
The rubber element of the intermediate gear air • Screw in remaining new mounting bolts (1)
compressor points to the crankcase. • Tighten the mounting bolts (1) to 115 Nm
Position the intermediate gear air compressor Installing small intermediate gear
• Thinly apply clean engine oil to the intermediate • Thinly apply clean engine oil to the small interme-
gear pin air compressor (3) diate gear pin (2)
• Place the intermediate gear pin air compressor (3) • Position the small intermediate gear (4) with a
into the intermediate gear air compressor (1) flat approach surface (3) to the small intermediate
• Position the contact washer (2) with the more gear pin (2)
chamfered side to the crankcase pointing towards • Install small intermediate gear (4) with small inter-
the intermediate gear pin air compressor (3) mediate gear pin (2) in crankcase
30 Nm

TIMING GEARS
Installing the crankshaft gear Checking the crankshaft gear mark
• Turn the crankshaft until the centring pin (2) is • Check that the mark (1) on the large intermediate
perpendicular to the oil sump gear and the mark (2) on the crankshaft gear are
• Screw in the Centring mandrel [188] (3) and (4) in line
• Align the crankshaft gear (1) with the centring pin If the marks (1) and (2) are not in line, remove the
(2) large intermediate gear and re-insert it at the mark.
• Push the crankshaft gear (1) onto the crankshaft
Installing the large intermediate gear
• Thinly apply clean engine oil to large intermediate

gear pin (2)
• Insert the large intermediate gear pin (2) into the
• Install the large intermediate gear (3) so that the
markings on the large intermediate gear (3) and
the crankshaft gear are lined up, see Checking
the crankshaft gear mark, 384
1st torque 105 Nm

ENGINE LUBRICATION
ENGINE LUBRICATION
(1) Oil sump (4) Oil cooler

(2) Oil intake pipe (5) Oil module
(3) Oil pump

ENGINE LUBRICATION
OIL MODULE
Removal and installation of the oil module

(2) Oil cooler (7) Oil module
(3) Gasket (8) Screw-in union
(4) Union (9) Mounting bolt
(5) Vent line
Technical data
Oil cooler mounting bolts (2).................................. M8x55-8.8 .........................................................27 Nm
Sealing cap oil module (7)..................................... M38x1.5 ............................................................80 Nm
Screw-in fitting (4) ................................................ M24x1.5 ............................................................. 4 Nm
Oil filter lid ......................................................................................................................................45 Nm
Service products
Loctite 242 ........................................................................................................................ 04.90300-9025

ENGINE LUBRICATION
WARNING
Special tools
[194] Socket, size 32 80.99603-0326
• Removal and installation the oil filter cover
• Removing and mounting the oil module line

ENGINE LUBRICATION
Removing the oil module Detach the oil module line
• Remove the jubilee clips (2) using Hose clamp

pliers for jubilee clips [195]
• Remove the heat shield (1) • Pull off the vent line (1) of the oil separator
Detaching the vent line Drain the coolant
• Unscrew the mounting bolt (1) WARNING

• Pull the vent line (3) off the screw-in fittings (2) and Danger of engine damage due to oil
(4) emulsion
• Unscrew the screw-in fittings (2) and (4) • Drain all the coolant before removing
the oil module, otherwise coolant will
Unscrew the coolant pump mounting bolts
enter the oil sump when the oil module
is removed from the crankcase
• Unscrew the sealing cap (3) and remove with the

sealing ring (2) from the oil module (1)
• Drain the coolant
• Only unscrew the coolant pump mounting bolts (1)

and (2) of the coolant pump from the oil module

ENGINE LUBRICATION
Oil module removal instructions Dismantling the oil module

Removing the oil cooler
• To remove the oil module (1), do not unscrew the

oil cooler mounting bolts (2) and (3)
Removing the oil module WARNING

Component damage if the oil module
is set aside incorrectly
• Lay the oil module so that the oil cooler
does not get damaged

bolts (4)
• Remove the oil cooler (3) with seals (2) from the
oil module (1)
Unscrew the pressure-relief valve

(4) and (5)
• Remove the oil module (1) with seal (2) from the
crankcase (3)
• Unscrew the oil pressure-relief valve (2) from the

oil module (1)

ENGINE LUBRICATION
Removing the connecting manifold Removing oil filter
• Detach the unscrewed conduits (5) from the con-

necting manifold (3)
• Remove the connecting manifold (3) with seal (1)
from the oil module (2)
Removing the oil separator
• Unscrew the oil filter cover (1) from the oil module
(4) with the Socket, size 32 [194]
• Remove the O-ring (2) from the oil filter cover (1)
• Pull the oil filter (3) out of the oil filter cover (1)

• Pull the oil separator (2) out of the oil module

ENGINE LUBRICATION
Assembling the oil module Install the oil separator
Installing oil filter
• Insert the oil separator (2) into the oil module

• Fit the new O-ring (2) on the oil filter cover (1)
• Thinly apply clean engine oil on the O-ring (2) Mounting the connecting manifold
• Insert the new oil filter (3) into the oil filter cover (1)
• Screw the oil filter cover (1) into the oil module (4)
with the Socket, size 32 [194] and tighten to 45 Nm
• Position the connecting manifold (3) with a new

seal (1) on the oil module (2)
surfaces of the new unscrewed conduits (5) and
insert into the connecting manifold (3)

ENGINE LUBRICATION
Install pressure relief valve Installing the oil module

Installing the oil module
• Screw the pressure-relief valve (2) into the oil mod-

ule (1)
• Tighten the pressure-relief valve (2) with 45 Nm WARNING
Component damage caused by incor-
Installing the oil cooler
rect tightening sequence
• Follow the tightening sequence in the
next steps, otherwise the distributor
housing might break
• Position the oil module (1) on the crankcase (3)

with a new seal (2)
• Screw in the new mounting bolts (4) and (5) as
marked and tighten them by hand
Screwing in the coolant pump mounting bolts
• Insert the oil cooler (3) with new seals (2) into the
oil module (1)
• Screw in the new mounting bolts (4) by hand as
marked
Tightening the oil cooler mounting bolts

and (2)
• Tighten the oil module mounting bolts
• Lay the oil module (1) so that the oil cooler does
not get damaged

ENGINE LUBRICATION
Screwing in the screw plug Install the oil module line
• Screw in the sealing cap (3) with a new sealing ring • Push the vent line (1) completely on the oil sepa-
(2) into the oil module (1) and tighten to 80 Nm rator
• Place the jubilee clips (2) using Hose clamp pliers
Installing bleed line for jubilee clips [195]
Mounting the heat shield
• Thinly apply Loctite 242 on the thread of the

screw-in fitting (4)
• Screw the screw-in fitting (4) into the crankcase • Mount the heat shield (1)
and tighten it to 4 Nm
• Thinly apply Loctite 242 on the thread of the
screw-in fitting (2)
• Screw the screw-in fitting (2) into the oil module
and tighten it to 4 Nm
• Fit vent line (3)

ENGINE LUBRICATION
OIL SUMP AND OIL INTAKE PIPE

Removing and installing the oil sump and oil intake pipe
Additional jobs
– Draining and topping up engine oil
(1) Oil sump (4) Oil intake pipe

(2) Mounting bolt (5) Crankcase
(3) Gasket
Technical data
Dimension of connecting-rod bearing bolt - oil intake pipe............................................................... 5.0 mm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

ENGINE LUBRICATION
Note
Oil sumps are installed with an oil drain pipe or a blank flange.
The sealing for both versions varies.
The version fitted with an oil drain tube is sealed with Loctite 5900.
The version with a blank flange is sealed with a seal.
Special tools

[197] Gear ratchet 80.99627-0001

ENGINE LUBRICATION
Removing the oil sump and oil intake Remove the oil drain pipe
pipe
Removing the oil dipstick guide tube

(1) and (3)
• Pulling out the oil dipstick • Pull out the oil drain pipe (2)
• Removing the oil dipstick guide tube (1) • Clean the mating faces
Detaching the oil filler tube Removing the oil intake pipe
• Unscrew the mounting bolts (1) and (3) • Unscrew the mounting bolts (1)
• Remove the oil filler tube (2) with seal • Pull the oil intake pipe (2) out of the crankcase
• Clean the mating faces • Pull the O-ring (3) out of the crankcase
Detach the oil sump Removing the oil return line
• Unscrew the mounting bolts (2) • Undo the hose clamp (4)
• Remove the oil sump (1) with seal (3) • Unscrew the mounting bolt (2)
• Clean the mating faces • Remove oil return line (1) with hose (3)

ENGINE LUBRICATION
Install oil sump and oil intake pipe Mount engine cranking unit
Installing the oil return line

ing/timing case
• Position oil return line (1) with hose (3) • Mount the Engine barring gear [196] (1) on the
• Screw in and tighten the new mounting bolt (2) flywheel housing/timing case
• Tighten the hose clamp (4)
Checking the connecting rod for ease of move-
Installing the oil intake pipe ment
• Thinly apply Technical Vaseline on a new O-ring • Crank the engine with Engine barring gear [196]
(3) and insert it into the crankcase and Gear ratchet [197] in the direction of rotation
• Insert the oil intake pipe (2) into the crankcase of the engine
• Screw in and tighten the new mounting bolts (1) • Check distance between connecting-rod bearing
bolts and oil intake pipe
The allowed measure A between connecting-rod
bearing bolt and oil intake pipe is 5.0 mm.
If measure A is less than 5.0 mm, realign the oil

intake pipe.

ENGINE LUBRICATION
Removing engine cranking device Attaching the oil filler tube
• Remove the Engine barring gear [196] (1) from the • Position the oil filler tube (2) with a new seal
flywheel housing/timing case • Screw in and tighten the new mounting bolts (3)
• Mount the cap on the flywheel housing/timing case • Screw in and tighten the new mounting bolt (1)
Installing the oil drain pipe Installing the oil dipstick guide tube
• Thinly apply Loctite 5900 on the mating faces of • Installing the guide tube (1)
the oil drain pipe (2) • Pushing in the oil dipstick
• Insert the oil drain pipe (2)
and (3) as marked
Mount the oil sump
• Position the oil sump (1) with a new seal (3)

• Screw in mounting bolts (2) and tighten crosswise

ENGINE LUBRICATION
Disassembling and assembling the oil sump

Additional works
– Removing and installing the oil sump and oil intake pipe, see 395
(1) Screw plug (7) Sealing ring

(2) Blank flange (8) Oil level sensor
(4) Gasket (10) Blank flange
(5) Sealing ring (11) Gasket
(6) Screw plug (12) Oil sump
Technical data
Note
Oil sumps are installed with an oil drain pipe or a blank flange.
The sealing for both versions varies.
The version with a blank flange is sealed with a seal.
The version fitted with an oil drain tube is sealed with Loctite 5900.
Removing and installing the oil drain pipe, see Removing and installing the oil sump and oil intake
pipe, 395

ENGINE LUBRICATION
OIL INJECTOR NOZZLES

Removing and installing the oil nozzle
Additional works
(1) Oil nozzle (2) Mounting bolt
WARNING

ENGINE LUBRICATION
Removing the oil nozzles Install oil nozzles
• Unscrew the mounting bolt (2) • Insert the oil nozzle (1) into the crankcase (3)
• Pull out the oil nozzle (1) from the crankcase (3) • Screw in and tighten the new mounting bolt (2)

ENGINE LUBRICATION
OIL PUMP
Removal and installation the oil pump
Additional jobs
– Removal and installation of the coolant compressor, see 173
(1) Mounting bolt (5) O-ring

(2) Ring gear (6) Axle
(3) Oil pump pinion (7) Crankcase
(4) Mounting bolt (8) Bearing bush

ENGINE LUBRICATION
(9) O-ring (10) Oil pump cover
Technical data
Mounting bolt (1) .................................................. M6x20-10.9 .......................................................15 Nm
Technical data ring gear

Backlash, ring gear (2) - crankshaft gear......................................................................... 0.092 - 0.272 mm
Axial play, ring gear (2) .................................................................................................. 0.020 - 0.093 mm
Radial play, ring gear (2) ................................................................................................ 0.053 - 0.210 mm
Outside diameter, bearing, ring gear (2) ...................................................................... 96.893 - 96.928 mm
Height, ring gear (2)................................................................................................... 29.952 - 29.970 mm
Technical data axle

Outside diameter, axle (6) .......................................................................................... 36.965 - 36.980 mm
Technical data oil pump pinion

Height, oil pump pinion (3) ......................................................................................... 27.770 - 28.300 mm
Inside diameter, oil pump pinion (3) ............................................................................ 36.985 - 37.050 mm
WARNING
Component damage at oil pump and storage
• If repairing, always fit a new oil pump complete with the bearing
• Always ensure absolute cleanliness when installing the oil pump
WARNING
Special tools
[198] Dial gauge 08.71000-3217
• Check the backlash in conjunction with:

• Check the ring gear axial and radial play in con-
junction with:
[199] gauge holder 08.71082-0005
• Checking the ring gear axial and radial play
• Removal and installation of front crankshaft gear

ENGINE LUBRICATION
[201] Extractor 08.99605-9011
• Pull out bearing bush in conjunction with:

• extractor [202]
• Adapter [203]
[202] extractor 80.99602-0300
• Extracting the bearing bush
[203] Adapter 80.99602-0207
• Extracting the bearing bush
[204] Drive-up tool 80.99604-6038
• Press in the bearing bush with lubricating groove

• Press in the bearing bush with lubricating bore in
conjunction with:
• Pressure shim [205]
• Plate [206]
[205] Pressure shim 80.99604-0424
• Pressing in the bearing bush
[206] Plate 80.99604-0429
• Pressing in the bearing bush
[207] Torque wrench 08.06450-0006
• Tightening the oil pump cover mounting bolts
[208] Torque wrench 08.06450-0002
• Tightening the shaft mounting bolt

ENGINE LUBRICATION
Checking the oil pump Checking the ring gear axial play
Checking the ring gear-crankshaft gear backlash
• Install the gauge holder [199] (1) with Dial

gauge [198] (3)
• Install the gauge holder [199] (2) with Dial • Position the tracer pin of the Dial gauge [198] (3)
gauge [198] (1) against the ring gear (2) with a pre-load
• Position the tracer pin of the Dial gauge [198] • Push the ring gear (2) into the end position
against the ring gear (3) and zero the dial gauge • Zero the Dial gauge [198] (3)
(1) • Pull the ring gear (2) into the end position and
• Check the backlash between the crankshaft gear check the difference on the dial gauge
and the ring gear (3) The permitted axial play of the ring gear (2) is
The permitted backlash is 0.092 - 0.272 mm. 0.020 - 0.093 mm.
If the backlash is out of tolerance, fit a new crank- If the axial play is out of tolerance, the oil pump must
shaft gear and oil pump. be replaced.
Removing the crankshaft gear Checking the ring gear radial play
• Screw in the Centring mandrel [200] (3) and (4) • Install the gauge holder [199] (3) with Dial
• Pull off the crankshaft gear (2) gauge [198] (1)
• Unscrew the Centring mandrel [200] (3) and (4) • Position the tracer pin of the Dial gauge [198] (1)
• Clean the contact surfaces of the crankshaft gear against the ring gear (2) with a pre-load
(2) and crankshaft (1) • Push the ring gear (2) outwards into the end posi-
tion
• Push the ring gear (2) into the end position towards
The permitted radial play of the ring gear (2) is
0.053 - 0.210 mm.
If the radial play is out of tolerance, fit a new oil

pump.

ENGINE LUBRICATION
Removing the oil pump Checking the oil pump bearing

Removing the oil pump cover Checking the outside diameter of the ring gear
bearing

• Remove the oil pump cover (2) with O-ring (4) from
Note
the crankcase (3)
If there is scoring or pitting on the ring
Removing the oil pump gear bearing surface, the ring gear must
be replaced.
• Clean the ring gear (1)

• Check the outside diameter of the ring gear (1)
using a micrometer (2)
The permitted outside diameter 96.893 - 96.928 mm.
If the outside diameter is out of tolerance, the oil

pump with bearing must be replaced.
Checking the height of the ring gear
• Remove the ring gear (1) and the oil pump pinion
(2) from the crankcase (3)
Removing the oil pump pinion shaft
• Clean the ring gear (1)

• Check the height of the ring gear (1) using a mi-
crometer (2)
The permitted dimension is 29.952 - 29.970 mm.
If the dimension is out of tolerance, the oil pump with

bearing must be replaced.

• Remove the shaft (3) with O-ring (2) from the
crankcase (4)

ENGINE LUBRICATION
Checking the internal diameter of the oil pump Checking the height of the oil pump pinion
pinion
• Clean the oil pump pinion (1)

• Check the height of the oil pump pinion (1) using
a micrometer (2)
The permitted dimension is 27.770 - 28.300 mm.
If the dimension is out of tolerance, the oil pump with

bearing must be replaced.
Checking the outside diameter of the shaft
• Clean the oil pump pinion (2)

• Use the Dial gauge [198] (1) and internal calliper to
check the inside diameter of the oil pump pinion (2)
The permitted inside diameter of the oil pump pinion
(2) is 36.985 - 37.050 mm.
If the inside diameter is out of tolerance, the oil pump

with bearing must be replaced.
• Clean the shaft (1)

• Check the outside diameter of the shaft (1) using
a micrometer (2)
The permitted outside diameter 36.965 - 36.980 mm.
If the outside diameter is out of tolerance, the oil

pump with bearing must be replaced.

ENGINE LUBRICATION
Removing the bearing bush Extracting the bearing bush
Bearing bush with lubrication groove
WARNING
Component damage due to shavings
WARNING in the oil sump
Component damage due to use of in- • Cover the opening to the oil sump
correct bearing bush and incorrect
press-in tool WARNING
• Before stripping the equipment down, Component damage on bearing seat
determine which bearing bush is in- • Position the puller so that the bearing
stalled bush is pulled off straight rather than at
an angle
• For a bearing bush with a lubrication groove (1),
the Drive-up tool [204] must be used for pressing • Insert the extractor [202] (3) into the bearing bush
in (5) and expand it
• Fit the hose clamp (4) over the extractor [202] (3)
Bearing bush with lubricating hole and tighten it
• Mount the Adapter [203] (2)
• Screw the Extractor [201] (1) into the Adapter [203]
(2)
• Extract the bearing bush (4) using the Extrac-
tor [201]
• For a bearing bush with lubricating hole (1), the

special tool Drive-up tool [204] must be modified
with Pressure shim [205] and Plate [206] as com-
ponents

ENGINE LUBRICATION
Install bearing bush with lubrication Fitting the guide plate

groove
Screwing in the threaded spindle
• Thinly apply clean engine oil on the bearing bush

• Insert the guide plate (2) with bearing bush (1) so
that the brace (4) slides into the oil pump bore (3)
• Clean the threaded spindle (2) • Tighten the threaded spindle mounting bolt
• Clean the contact area of the threaded spindle (2)
in the crankcase Press in the bearing bush with lubricating
• Screw in the threaded spindle (2) of the Drive-up groove
tool [204] using the mounting bolt (1)
• Do not tighten the mounting bolt (1) as alignment
is subsequently necessary
Prepare press-in device for bearing bush with

lubrication groove
• Screw on the hex nut (1)

• Press in the bearing bush (3) with the hex nut (2)
until the stop is reached
• Remove the Drive-up tool [204] (2)
WARNING
Component damage due to use of
wrong press-in tool
• Use the correct press-in device for
bearing bushes with lubricating hole
• Align the recess on the bearing bush (2) with the

mark on the Drive-up tool [204] (1)
• Fit a new bearing bush (2)

ENGINE LUBRICATION
Install bearing bush with lubricating Prepare the press-in tool for bearing bush with
hole lubricating hole
Convert special tool
WARNING
Component damage due to use of
WARNING wrong press-in tool
Component damage due to use of • Use the refitted press for bearing
wrong press-in tool bushes with lubricating hole
• Convert the press-in tool for pressing
the bearing bush with lubricating hole • Align the recess on the bearing bush (2) with the
mark on the special tool (1)
• Put the Plate [206] (1) on Pressure shim [205] (2) • Fit a new bearing bush (2)
and secure using bolts (3)
• Unscrew the guide pins (4) from Drive-up tool [204] Fitting the guide plate
and attach to Plate [206] (1)
Screwing in the threaded spindle
• Thinly apply clean engine oil on the bearing bush

• Insert the guide plate (2) with bearing bush (1) so
that the brace (4) slides into the oil pump bore (3)
• Clean the threaded spindle (2) from Drive-up • Tighten the threaded spindle mounting bolt
tool [204]
• Clean the contact area of the threaded spindle (2)
in the crankcase
• Screw in the threaded spindle (2) of the Drive-up
tool [204] using the mounting bolt (1)
• Do not tighten the mounting bolt (1) as alignment
is subsequently necessary

ENGINE LUBRICATION
Pressing in the bearing bush with lubricating Installing the oil pump
hole
Installing the oil pump pinion shaft
• Screw on the hex nut (1)

• Press in the bearing bush (3) with the hex nut (2)
Note
until the stop is reached
A guide pin determines the shaft installa-
• Remove the special tool (2)
tion position.
• Thinly apply clean engine oil on the new O-ring (2)

• Fit the O-ring (2) on the shaft (3)
• Insert the shaft (3) into the crankcase (4)
• Screw in new mounting bolt (1) and tighten Torque
wrench [208] with 65 Nm
Installing the oil pump
• Thinly apply clean engine oil on the bearing sur-

faces of the ring gear (1) and oil pump pinion (2)
• Insert the ring gear (1) into the crankcase (3)
• Push the oil pump pinion (2) onto the shaft so that
the markings (4) are visible

ENGINE LUBRICATION
Mounting the oil pump cover
• Position the oil pump cover (2) with O-ring (4) on

the crankcase (3)
• Screw in new mounting bolts (1) and tighten them
with Torque wrench [207] with 15 Nm
• Check the ring gear concentricity
If the ring gear does not run truly or freely, repeat the
work step
Installing the crankshaft gear

• Put the crankshaft gear (2) on the crankshaft (1),
ensuring that the stop is reached

CRANKSHAFT SEALS
CRANKSHAFT SEALS
(1) Rear crankshaft seals (3) Cover

(2) Flywheel housing/timing case (4) Front crankshaft seal

CRANKSHAFT SEALS
CRANKSHAFT SEALS
Removal and installation of front crankshaft seal
Additional jobs
– Removing the ribbed V-belt for alternator 3, see 157
– Installing the ribbed V-belt for alternator 3, see 157
(1) Cover (2) Crankshaft seal
WARNING
lation
• Clean the crankshaft and insertion tool before assembly
WARNING

CRANKSHAFT SEALS
Special tools
[209] cross member 80.99606-0298
• Extract the crankshaft sealing ring in conjunction

with:
• Pressure plate [210]
• Hex nut [213]
• Hook [211]
• spindle [214]
• Stud bolt [215]
• Guide plate [216]
[210] Pressure plate 80.99609-0038
• Extracting the crankshaft oil seal
[211] Hook 80.99606-6013
[212] Press-in bushing 80.99606-0659
• Press in crankshaft seal in conjunction with:

• Hex nut [213]
• spindle [214]
• Stud bolt [215]
• Washer [217]
• hex collar nut [218]
• Washer 6 mm [219]
• Washer 3 mm [220]
[213] Hex nut 06.11069-0064

• Pressing in the crankshaft oil seal
[214] spindle 80.99606-0299

[215] Stud bolt 06.02191-2822


CRANKSHAFT SEALS
[216] Guide plate 80.99606-0658

[217] Washer 06.15230-0609
[218] hex collar nut 06.11222-0211
• Pressing in the crankshaft seal
[219] Washer 6 mm 81.90711-0195
[220] Washer 3 mm 81.90712-0984
• Determining the crankshaft oil seal press-in depth

CRANKSHAFT SEALS
Removing the front crankshaft oil seal Installing the front crankshaft oil seal
Determining the crankshaft oil seal repair level Positioning the crankshaft seal
• Determine the press-in depth for the crankshaft oil

WARNING
seal (1) using the Depth gauge (electronic) [221]
The crankshaft oil seal can be dam-
(2)
aged
– Press-in depth 0 mm, see Installing crankshaft
• Carefully separate the discs from the
seal 1. repair level, 421
transport sleeve using a suitable tool
• Separate two opposite-facing discs from the trans-
port sleeve (3) in each case
• Mount the Guide plate [216] (4) on the crankshaft
Extracting the crankshaft oil seal (1) with the Stud bolt [215]
• Position the crankshaft oil seal (2) with transport
sleeve (3) and push the crankshaft oil seal (2) onto
the Guide plate [216] (4)
• Remove the transport sleeve (3)
• Mount the Guide plate [216] (1) on the crankshaft

with Pressure plate [210] and Stud bolt [215] (5)
• Screw the spindle [214] into the cross mem-
ber [209] (3) with the Hex nut [213]
• Screw the second Hex nut [213] (4) onto the spin-
dle [214] and secure using Hex nut [213]
• Insert Hook [211] (2) into the cross member [209]
(3) flat between the crankshaft seal (6) and the
crankshaft
• Turn the Hook [211] (2) through 90° so that the
recess in the Hook [211] (2) is facing outwards
• Pull the crankshaft oil seal (6) out by screwing in
the spindle [214]

CRANKSHAFT SEALS
Installing crankshaft seal 1. repair level Installing crankshaft seal 2. repair level
• Push Press-in bushing [212] (2) with Washer • Place the Press-in bushing [212] (2) on the Guide
3 mm [220] to Guide plate [216] plate [216]
• Screw hex collar nut [218] (3) on to spindle [214] • Screw hex collar nut [218] (3) on to spindle [214]
(4) (4)
• Screw Hex nut [213] on to spindle [214] (4) • Screw Hex nut [213] on to spindle [214] (4)
• Screw the second Hex nut [213] onto spindle [214] • Screw the second Hex nut [213] onto spindle [214]
(4) and brace with Hex nut [213] (4) and brace with Hex nut [213]
• Screw the spindle [214] (4) into the Guide • Screw the spindle [214] (4) into the Guide
plate [216] with the Washer [217] plate [216] with the Washer [217]
• Brace Hex nut [213] against spindle [214] (4) • Brace Hex nut [213] against spindle [214] (4)
• Press in the crankshaft seal (1) by screwing on • Press in the crankshaft seal (1) by screwing on
the hex collar nut [218] (3) until the Press-in bush- the hex collar nut [218] (3) until the Press-in bush-
ing [212] (2) with Washer 3 mm [220] is at the ing [212] (2) is at the Guide plate [216]
Guide plate [216] • Remove the special tool

CRANKSHAFT SEALS
Installing crankshaft seal 3. repair level
WARNING
Risk of leaks in the engine
• When reaching the 3rd repair stage, the
crankshaft gear must be replaced
• Removing the crankshaft gear, see Removing the

crankshaft gear, 352
• Installing the crankshaft gear, see Installing the
crankshaft gear, 355
• Push Press-in bushing [212] (2) with Washer
6 mm [219] to Guide plate [216]
• Screw hex collar nut [218] (3) on to spindle [214]
(4)
• Screw Hex nut [213] on to spindle [214] (4)
• Screw the second Hex nut [213] onto spindle [214]
(4) and brace with Hex nut [213]
• Screw the spindle [214] (4) into the Guide
plate [216] with the Washer [217]
• Brace Hex nut [213] against spindle [214] (4)
• Press in the crankshaft seal (1) by screwing on
the hex collar nut [218] (3) until the Press-in bush-
ing [212] (2) with Washer 6 mm [219] is at the
Guide plate [216]

CRANKSHAFT SEALS
Removal and installation of rear crankshaft seal (crankshaft seal version flywheel)
Additional jobs
boxes, see 455
(1) Crankshaft seal (2) Flywheel housing/timing case
Technical data
Installation temperature for race ............................................................................................ about 120 °C
Service products
Loctite Antipor ................................................................................................................... 04.90300-9011
WARNING
lation
• Clean the crankshaft and insertion tool before assembly

CRANKSHAFT SEALS
WARNING
Special tools
• Extract the crankshaft seal in conjunction with:

• Extractor hook [223]
[223] Extractor hook 80.99602-0175
• Extracting the crankshaft seal
• Pull off race in conjunction with:

• spindle [225]
[225] spindle 80.99601-0156
• Pull off race
[226] Pressure plate 80.99601-0183
• Pull off race
[227] Plug-on handle 80.99617-0187
• Force on race in conjunction with:

• Install the crankshaft seal in conjunction with:
• Washer [229]
• Guide bushing [230]
[228] press plate 80.99617-0017
• Pressing on the race

CRANKSHAFT SEALS
[229] Washer 80.99617-0144
• Pressing on the race

• Install the crankshaft seal
[230] Guide bushing 80.99604-0286
[231] press plate 80.99604-0069

CRANKSHAFT SEALS
Removing the rear crankshaft oil seal Installing the rear crankshaft oil seal
• Pull the crankshaft oil seal (3) out of the flywheel • Push Guide bushing [230] (4) onto crankshaft
housing/timing case with Impact extractor [222] (1) • Assemble press plate [231] (6) with Plug-on han-
and Extractor hook [223] (2) dle [227] (1) and Washer [229] (2)
• Place crankshaft gear (3) with sealed side on the
special tool
• Push the special tool to Guide bushing [230] (4)
• Press in the crankshaft seal (3) by screwing on
the flywheel housing/timing case (5) until the press
plate [231] (6) is at the Guide bushing [230] (4)

CRANKSHAFT SEALS
Replace race Pressing on the race
Determine flywheel design
• Thinly apply Loctite Antipor on the contact area of

the race (4) on the flywheel (5)
Note • Heat race (4) to about 120 °C and attach it to the
If a race is installed on the flywheel, a flywheel (5)
race and the corresponding crankshaft • Assemble race (4) with press plate [228] (3),
seal will have to be installed. Plug-on handle [227] (1) and Washer [229] (2)
• For a flywheel without a race, measure the running

surface of the crankshaft seal (Dimension A)
• Dimension "A" = 120 mm, replace the flywheel
• Dimension "A" = 115 mm, pull off race
Removing the race
• Fit Pressure plate [226] (3) on flywheel (5)

• Slide the Removing device [224] (2) behind the
race (4)
• Screw in spindle [225] (1) into Removing de-
vice [224] (2) and pull off race (4)

CRANKSHAFT SEALS
Removing, installing the rear crankshaft seal for Crankshaft gear with stud
Additional jobs
(1) Crankshaft gear wheel (3) Flywheel housing/timing case

(2) Crankshaft seal
WARNING
Component damage due to leaks
• Do not allow the crankshaft seal (PTFE sealing ring) to come into contact with oil or grease before
installing it
• Clean the crankshaft and special tool before assembly
WARNING

CRANKSHAFT SEALS
Special tools
[232] cross member 80.99606-0298
• Extract the crankshaft sealing ring in conjunction

with:
• Hook [234]
• spindle [238]
• Hex nut [240]
• Stud bolt [242]
[233] Pressure plate 80.99609-0038
[234] Hook 80.99601-6045
• Removing and installing the flywheel

[236] Press-in bushing 80.99604-0327
• Install the crankshaft seal in conjunction with:

• Centring mandrel [235]
• Washer [237]
• spindle [238]
• hex collar nut [239]
• Hex nut [240]
• Stud bolt [242]
[237] Washer 06.15230-0609
[238] spindle 80.99606-0299


CRANKSHAFT SEALS
[239] hex collar nut 06.11222-0211
[240] Hex nut 06.11069-0064

[241] Guide plate 80.99606-0658

[242] Stud bolt 06.02099-0419

CRANKSHAFT SEALS
Removing the rear crankshaft oil seal Extracting the crankshaft oil seal
Mount the guide plate
WARNING
Component damage on crankshaft
• Install the Guide plate [216] (1) with Stud bolt [215]
gear
(3) (two opposite) on crankshaft gear
• If run-in grooves should be visible on
• Screw in the Pressure plate [233] (2)
the crankshaft gear, detach the fly-
wheel housing and replace the crank-
shaft gear, see Removing and installing
flywheel housing/timing case, 505
Replacing the crankshaft gear, see Re-
moving and installing rear timing gears
(Version crankshaft seal flywheel), 357
• Screw the spindle [238] (3) into the cross mem-

ber [232] (6)
• Screw the second Hex nut [240] (5) onto spin-
dle [238] (3) and brace with Hex nut [240] (4)
• Insert Hook [234] (1) into the cross member [232]
(6) flat between the crankshaft seal (2) and the
crankshaft gear
• Turn the Hook [234] (1) through 90° so that the
recess in the Hook [234] (1) is facing outwards
• Tighten the mounting nuts Hook [234] (1)
• Extract the crankshaft seal (2) by screwing in the
spindle [238] (3)
• Remove crankshaft seal (2)

CRANKSHAFT SEALS
Installing the rear crankshaft oil seal Pressing in the crankshaft oil seal
Preparing to install the crankshaft seal
• Put on the Press-in bushing [236] (2) over the

Guide plate [241]
WARNING • Screw hex collar nut [239] (3) onto spindle [238]
The crankshaft oil seal can be dam- (4)
aged • Screw the Hex nut [240] (5) onto the spindle [238]
• Carefully separate the discs from the (4) and secure with the second Hex nut [240] (6)
transport sleeve using a suitable tool • Screw the spindle [238] (4) into the Guide
plate [241] with the Washer [237]
• Screw the Centring mandrel [235] (3) into the • Press the crankshaft oil seal (1) into the flywheel
crankshaft gear housing/timing case until the stop is reached by
• Separate two opposite-facing discs from the trans- screwing in the hex collar nut [239] (3)
port sleeve (1) in each case • Remove the special tool
• Push the Guide plate [241] (4) over the Centring
mandrel [235] (3) and mount on the crankshaft
with the Stud bolt [242] (5)
• Position the crankshaft oil seal (2) with transport
sleeve (1) and push the crankshaft oil seal (2) onto
the Guide plate [241] (4)
• Remove the transport sleeve (1)

CRANKSHAFT DRIVE
CRANKSHAFT DRIVE
(1) Poly-V-belt pulley (5) Crankshaft

(2) Vibration damper (6) Connecting rod
(3) Piston (7) Bearing cover
(4) Flywheel

CRANKSHAFT DRIVE
VIBRATION DAMPER
Removal and installation of the vibration damper
Additional jobs
– Removing the ribbed V-belt for alternator 3, see 157
– Installing the ribbed V-belt for alternator 3, see 157
(1) Mounting bolt (3) Vibration damper

(2) Poly-V-belt pulley (4) Mounting bolt
Technical data
Mounting bolt (1) .................................................. M16x1.5x85-10.9 ............................. 1st torque 155 Nm
Mounting bolt (1) .................................................. M16x1.5x85-10.9 .................................Final torque 90°
WARNING
Component damage through incorrect position of the vibration damper
• Depending on version, the vibration damper is equipped with cooling fins for cooling
• Take care not to damage the vibration damper cooling fins
WARNING

CRANKSHAFT DRIVE
Special tools
[244] Socket wrench insert SW14 80.99603-0344
• Undoing and tightening the vibration damper

mounting bolts

CRANKSHAFT DRIVE
Removing vibration damper Removing the ribbed V-belt disc

• Take out ribbed V-belt disc (1) from the vibration
• Remove the cover from the flywheel hous- damper (3)
ing/timing case
Detaching the vibration damper
• Unscrew the mounting bolts (1) with Socket

wrench insert SW14 [244]
• Remove the vibration damper (3) with ribbed
V-belt disc (2)

CRANKSHAFT DRIVE
Installing vibration damper Removing engine cranking device
Mount the ribbed V-belt disc

• Inserting ribbed V-belt disc (1) into the vibration • Mount the cap on the flywheel housing/timing case
damper (3)
Mounting the vibration damper
• Positioning vibration damper (3) with ribbed V-belt

disc (2)
• Tighten mounting bolts (1) using Socket wrench
insert SW14 [244] to 1st torque 155 Nm
• Tighten mounting bolts (1) using Socket wrench
insert SW14 [244] to Final torque 90°

CRANKSHAFT DRIVE
MANUALLY OPERATED GEARBOX FLYWHEEL (FLYWHEEL CRANKSHAFT SEAL

VERSION)
Removal and installation of the gearbox flywheel (Flywheel crankshaft seal)
Additional jobs
(1) Flywheel housing/timing case (3) Mounting bolt

(2) Flywheel
Technical data
Mounting bolt (3) .................................................. M16x1.5x80-12.9 ..........................Initial torque 105 Nm
Mounting bolt (3) .................................................. M16x1.5x80-12.9 ............................... Final torque 180°
Installation temperature starting ring gear ...............................................................................200 - 230 °C
Flywheel axial run-out (2)...................................................................................................... max. 0.5 mm
Dimension of flywheel bridge to friction surface (maximum) .................................................... max. 7.0 mm
WARNING

CRANKSHAFT DRIVE
Special tools
[246] Dial gauge 08.71000-3217
• Checking the flywheel run-out in conjunction with:

[247] gauge holder 08.71082-0005
• Checking the flywheel axial run-out
[248] Caliper pin 80.99605-0197
• Checking the flywheel for wear in conjunction

with:
• measuring fixture [250]
[250] measuring fixture 08.71109-0000
• Flywheel, checking for wear
• Undo flywheel mounting bolts and tighten in con-

junction with:
• Support [252]
• Adapter [255]
• Stud bolt [256]

CRANKSHAFT DRIVE
[252] Support 80.99606-0551
• Undo and tighten flywheel mounting bolts
[253] protractor 80.99607-0172
[254] Holding device 80.99606-0553
[255] Adapter 80.99606-0552
[256] Stud bolt 06.02191-0407
[257] connecting pin 06.22729-0006
[258] Rubber ring 06.56331-3274
[259] Socket, size 19 80.99603-0311

CRANKSHAFT DRIVE
[260] Plug-on handle 80.99617-0187
• Press-in clutch pilot bearing in conjunction with:

• Thrust washer [262]
[261] Press plate 80.99604-0302
• Pressing in the clutch pilot bearing
[262] Thrust washer 80.99617-0144

CRANKSHAFT DRIVE
Removing the flywheel Unscrew the flywheel mounting bolts
• Unscrew two opposite-facing mounting bolts (1)
• Insert the Torque multiplier i = 1 : 3.5 [251] (1) into Screwing on centring mandrels
• Install the Holding device [254] (6) with Stud
bolt [256] (8) and Adapter [255] (7) at the Sup-
port [252] (9)
• Position protractor [253] (2) on Torque multiplier i
= 1 : 3.5 [251] (1)
• Put the Socket, size 19 [259] (3) on the Torque
multiplier i = 1 : 3.5 [251] (1) and secure with the
(4)
Undo flywheel mounting bolts

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

that is going to be undone
• Undo all the mounting bolts
CAUTION
nents
• Use lifting gear to remove the flywheel
• Pull off flywheel (1) via Centring mandrel [245] (2)

CRANKSHAFT DRIVE
Remove the clutch pilot bearing Mounting the starter ring gear
• Remove the clutch pilot bearing (2) from the fly- • Heat starting ring gear (1) to 200 - 230 °C
wheel (1) • Place the starting ring gear (1) so that the chamfer
(3) at the toothing points away from the flywheel
Detaching the starter ring gear (2) and that the starter ring (1) is aligned with the
flywheel (2)
• Adjust the starting ring gear (1) as necessary
WARNING
Component damage due to
spot-drilling of the flywheel
• Take care not to damage the flywheel
when spot-drilling the starting ring gear
• Fit a new spot-drilled flywheel
• Spot-drill the starting ring gear (2) with a drill (3)

and force it open
• Remove starting ring gear (3) from flywheel (1)
• Clean the contact area of the starter ring gear (3)
and the flywheel (1) and check for damage

CRANKSHAFT DRIVE
Checking the flywheel Checking the flywheel axial run-out
Flywheel, checking for wear
• Clamp the flywheel (1)

• Cleaning the flywheel gauge [246] (3) and Caliper pin [248]
• Check flywheel for cracks, replace flywheel if re- • Position Caliper pin [248] with pre-load on the
quired flywheel (1)
• Check the friction surface (1) of the flywheel for • Zero the Dial gauge [246] (3)
burns and traces of running-in, replace the fly- • Turn flywheel (1) several turns and read the kick
wheel if necessary of the Dial gauge [246] (3) while doing so
• Check the toothing (2) of the starter ring gear for The permitted axial run-out diameter of the flywheel
wear, and replace the starter ring gear if necessary (1) is max. 0.5 mm.
Check the friction surface of the flywheel stud If the axial run-out is out of tolerance, the flywheel
(only he flywheel with race) (1) must be replaced.
• Use the Depth gauge (electronic) [249] (2) and

measuring fixture [250] (3) to check the flywheel
stud of the friction surface (1)
The permitted ring gap of the fly wheel is
max. 7.0 mm.
If the ring gap is out of the tolerance, the flywheel

has to be replaced.

CRANKSHAFT DRIVE
Install the flywheel Place flywheel
Pressing in the clutch pilot bearing
CAUTION
nents
• Use lifting gear to install the flywheel
• Line up the flywheel (1) with the crankshaft gear

dowel pin
• Put on the flywheel (1) over the Centring man-
drel [245] (2)
Unscrewing the centring pins
• Assemble the special tool consisting of the

Plug-on handle [260] (1), Thrust washer [262] (2)
and Press plate [261] (3)
• Use the special tool to press the clutch pilot bear-
ing (4) into the flywheel (5) until the stop is reached
• Screw in the new flywheel mounting bolts


CRANKSHAFT DRIVE
Screwing in the flywheel mounting bolts
Tightening the mounting bolts
Note
Note the multiplication ratio of the power
amplifier wrench i = 1 : 3.5.
• Tighten the mounting bolts using the special tool

(1) to Initial torque 105 Nm
(1) to Final torque 180°

CRANKSHAFT DRIVE
FLYWHEEL OF AUTOMATIC GEARBOX (CRANKSHAFT SEAL FLYWHEEL VERSION)

Removing and installing flywheel of automatic gearbox (crankshaft seal flywheel
version)
Additional jobs
(1) Race (4) Diaphragm

(2) starter ring gear (5) Washer
(3) Flywheel (6) Mounting bolt
Technical data
Installation temperature for starter ring gear (2) .......................................................................200 - 230 °C
WARNING

CRANKSHAFT DRIVE
Special tools
• Remove and install flywheel

junction with:
• Support [266]
• Stud bolt [269]
• Adapter [272]
[265] Socket, size 19 80.99603-0311
[266] Support 80.99606-0551
[267] protractor 80.99607-0172
[268] Holding device 80.99606-0553
[269] Stud bolt 06.02191-0407

CRANKSHAFT DRIVE
[270] connecting pin 06.22729-0006
[271] Rubber ring 06.56331-3274
[272] Adapter 80.99606-0552

CRANKSHAFT DRIVE
port [266] (9)
= 1 : 3.5 [264] (1)
• Put the Socket, size 19 [265] (3) on Torque multi-
plier i = 1 : 3.5 [264] (1) and secure with connecting
pin [270] (5) and Rubber ring [271] (4)


• Undo the mounting bolts

CRANKSHAFT DRIVE
Pulling off the flywheel Mounting the starter ring gear
• Heat starting ring gear (1) to 200 - 230 °C

CAUTION
• Position the starter ring gear (1) so that the cham-
fer (3) points away from the flywheel (2) and that
nents
the starter ring gear (1) is aligned with the flywheel
(2)
• Mark the installation position of the membrane (3)
and washer (1) to the flywheel (2)
• Pull off the membrane (3) from the washer (1)
• Pull off flywheel (2) via Centring mandrel [263]
Detaching the starter ring gear
WARNING
• Spot-drill the starter ring (2) with a drill and force it

open

CRANKSHAFT DRIVE
Install the flywheel Screwing in the flywheel mounting bolts
Place flywheel

CAUTION
nents
• Line up the fitting hole in the flywheel (2) with the

fitting hole (4) of the crankshaft
drel [263] (3) and (5)
• Install the membrane (6) and washer (1) as
marked
Note

(1) to 1st torque 105 Nm
• Screw in the new mounting bolts


CRANKSHAFT DRIVE
GEARBOX FLYWHEEL (CRANKSHAFT SEAL CRANKSHAFT GEAR VERSION)

Removing and installing flywheel (crankshaft seal crankshaft gear version) for man-
ually operated gearboxes
Additional jobs

(2) starter ring gear (4) Flywheel housing/timing case
Technical data
WARNING

CRANKSHAFT DRIVE
Special tools
[274] Dial gauge 08.71000-3217
• Checking the flywheel run-out in conjunction with:

[275] gauge holder 08.71082-0005
[276] Caliper pin 80.99605-0197
[277] Plug-on handle 80.99617-0187

• Washer [278]
[278] Washer 80.99617-0144
[279] Press plate 80.99604-0302
• Checking the flywheel for wear in conjunction

with:
• measuring fixture [281]

CRANKSHAFT DRIVE
[281] measuring fixture 08.71109-0000
• Flywheel, checking for wear

junction with:
• Support [283]
• Adapter [286]
• Stud bolt [287]
[283] Support 80.99606-0551
[284] protractor 80.99607-0172
[285] Holding device 80.99606-0553
[286] Adapter 80.99606-0552
[287] Stud bolt 06.02191-0407

CRANKSHAFT DRIVE
[288] connecting pin 06.22729-0006
[289] Rubber ring 06.56331-3274
[290] Socket, size 19 80.99603-0311

CRANKSHAFT DRIVE
port [283] (9)
= 1 : 3.5 [282] (1)
(4)

Pulling off the flywheel

CAUTION
nents
• Pull off flywheel (1) via Centring mandrel [273] (2)

CRANKSHAFT DRIVE
Remove the clutch pilot bearing Mounting the starter ring gear
• Remove the clutch pilot bearing (2) from the fly-

wheel (1) • Heat starting ring gear (1) to 200 - 230 °C
• Place the starting ring gear (1) so that the chamfer
Detaching the starter ring gear (3) at the toothing points away from the flywheel
(2) and that the starter ring (1) is aligned with the
flywheel (2)
WARNING

and force it open

CRANKSHAFT DRIVE
Checking the flywheel Checking the flywheel axial run-out
Flywheel, checking for wear
• Clamp the flywheel (1)

• Cleaning the flywheel gauge [274] (3) and Caliper pin [276]
• Check flywheel for cracks, replace flywheel if re- • Position Caliper pin [276] with pre-load on the
quired flywheel (1)
• Check the friction surface (1) of the flywheel for • Zero the Dial gauge [274] (3)
burns and traces of running-in, replace the fly- • Turn flywheel (1) several turns and read the kick
wheel if necessary of the Dial gauge [274] (3) while doing so
• Check the toothing (2) of the starter ring gear for The permitted axial run-out diameter of the flywheel
wear, and replace the starter ring gear if necessary (1) is max. 0.5 mm.
Check the dimension of flywheel study to the If the axial run-out is out of tolerance, the flywheel
friction surface (1) must be replaced.
• Use the Depth gauge (electronic) [280] (2) and

measuring fixture [281] (3) to check the flywheel
stud of the friction surface (1)
The permitted ring gap of the fly wheel is
max. 9.5 mm.
If the ring gap is out of the tolerance, the flywheel

has to be replaced.

CRANKSHAFT DRIVE
Install the flywheel Place flywheel
CAUTION
nents
• Line up the flywheel (1) with the crankshaft gear

dowel pin
drel [273] (2)

Plug-on handle [277] (1), Washer [278] (2) and
Press plate [279] (3)
• Use the special tool to press the clutch pilot bear-
ing (4) into the flywheel (5) until the stop is reached
• Screw in the new flywheel mounting bolts


CRANKSHAFT DRIVE
Screwing in the flywheel mounting bolts
Note

(1) to Initial torque 105 Nm

CRANKSHAFT DRIVE
AUTOMATIC GEARBOX FLYWHEEL (CRANKSHAFT SEAL CRANKSHAFT GEAR

VERSION)
Removing and installing flywheel (with race) for the automatic gearbox
Additional jobs
(1) starter ring gear (4) Washer

(3) Diaphragm
Technical data
WARNING

CRANKSHAFT DRIVE
Special tools
• Remove and install flywheel

junction with:
• Support [293]
• Stud bolt [296]
• Adapter [299]
[293] Support 80.99606-0551
[294] protractor 80.99607-0172
[295] Holding device 80.99606-0553
[296] Stud bolt 06.02191-0407
[297] connecting pin 06.22729-0006

CRANKSHAFT DRIVE
[298] Rubber ring 06.56331-3274
[299] Adapter 80.99606-0552
[300] Socket, size 19 80.99603-0311

CRANKSHAFT DRIVE
port [293] (9)
= 1 : 3.5 [292] (1)
• Put the Socket, size 19 [300] (3) on Torque multi-
plier i = 1 : 3.5 [292] (1) and secure with connecting
pin [297] (5) and Rubber ring [298] (4)



CRANKSHAFT DRIVE
Pulling off the flywheel Mounting the starter ring gear
• Heat starting ring gear (1) to 200 - 230 °C

CAUTION
• Position the starter ring gear (1) so that the cham-
fer (3) points away from the flywheel (2) and that
nents
the starter ring gear (1) is aligned with the flywheel
(2)
• Mark the installation position of the membrane (3)
and washer (1) to the flywheel (2)
• Pull off the membrane (3) from the washer (1)
• Pull off flywheel (2) via Centring mandrel [291]
Detaching the starter ring gear
WARNING

and force it open

CRANKSHAFT DRIVE
Install the flywheel Screwing in the flywheel mounting bolts
Place flywheel

CAUTION
nents
• Line up the fitting hole in the flywheel (2) with the

fitting hole (4) of the crankshaft
drel [291] (3) and (5)
• Install the membrane (6) and washer (1) as
marked
Note

• Screw in the new mounting bolts


CRANKSHAFT DRIVE
DUAL-MASS FLYWHEEL (CRANKSHAFT SEAL CRANKSHAFT GEAR VERSION)

Removing and installing dual-mass flywheel (crankshaft seal crankshaft gear ver-
sion)
Additional jobs
(1) Dual-mass flywheel (3) Mounting bolt

(2) starter ring gear (4) Flywheel housing/timing case
Technical data
Mounting bolt (3) .................................................. M16x1.5x122-12.9 ........................... 1st torque 105 Nm
Mounting bolt (3) .................................................. M16x1.5x122-12.9 .........................2. Tightening by 90°
Mounting bolt (3) .................................................. M16x1.5x122-12.9 ...............................Final torque 90°
WARNING

CRANKSHAFT DRIVE
Special tools
• Removing and installing dual-mass flywheel
• Loosening and tightening mounting bolts for

dual-mass flywheel in conjunction with:
• Support [303]
• Adapter [306]
• Stud bolt [307]
[303] Support 80.99606-0551

dual-mass flywheel
[304] protractor 80.99607-0172

dual-mass flywheel
[305] Holding device 80.99606-0553

dual-mass flywheel
[306] Adapter 80.99606-0552

dual-mass flywheel
[307] Stud bolt 06.02191-0407

dual-mass flywheel

CRANKSHAFT DRIVE
[308] connecting pin 06.22729-0006

dual-mass flywheel
[309] Rubber ring 06.56331-3274

dual-mass flywheel
[310] Socket, size 19 80.99603-0311

dual-mass flywheel
[311] Plug-on handle 80.99617-0187

• Thrust washer [312]
[312] Thrust washer 80.99617-0144
[313] Press plate 80.99604-0302

CRANKSHAFT DRIVE
Removing dual-mass flywheel Unscrewing mounting bolts for dual-mass fly-

wheel

• Insert the Torque multiplier i = 1 : 3.5 [302] (1) into
the Support [303] (9) Screwing on centring mandrels
port [303] (9)
= 1 : 3.5 [302] (1)
(4)
Loosening mounting bolts for dual-mass fly-

wheel



CRANKSHAFT DRIVE
Pulling off dual-mass flywheel Install dual-mass flywheel

CAUTION
nents
• Remove dual-mass flywheel (1) through Centring

mandrel [301] (2)
Remove the clutch pilot bearing

Plug-on handle [311] (1), Thrust washer [312] (2)
and Press plate [313] (3)
• Press in clutch pilot bearing (4) with special tool
up to the limit stop in the dual-mass flywheel (5)
• Remove clutch pilot bearing (2) from the

dual-mass flywheel (1)

CRANKSHAFT DRIVE
Put on the dual-mass flywheel Screw in mounting bolts for dual-mass flywheel
CAUTION • Screw in the new mounting bolts (1)

nents
• Line up the dual-mass flywheel (1) with the crank-

shaft gear alignment pin
• Put on the dual-mass flywheel (1) over the Cen-
tring mandrel [301] (2)
Note

(1) to 2. Tightening by 90°
• Screw in new mounting bolts for dual-mass fly- • Tighten the mounting bolts using the special tool
wheel (1) to Final torque 90°

CRANKSHAFT DRIVE
PISTON AND CONNECTING ROD

Removal and installation of piston and connecting rod
Additional jobs
(1) Piston (7) Piston ring

(2) Connecting rod (8) Bottom connecting rod bearing shell
(3) Connecting-rod bearing bolt (9) Top connecting rod bearing shell
(4) Connecting rod bearing cap
(5) Piston pins
(6) Circlip

CRANKSHAFT DRIVE
Technical data
Connecting-rod bearing bolt (3) ............................. M12x1.5x64-11.9 ............................. 1st torque 100 Nm
Connecting-rod bearing bolt (3) ............................. M12x1.5x64-11.9 .................................Final torque 90°
Technical data connecting rod

Axial play, connecting rod............................................................................................... 0.130 - 0.330 mm
Radial play, connecting rod ............................................................................................ 0.060 - 0.122 mm
Inside diameter, piston pin bushing.......................................................................... Ø 52.055 - 52.065 mm
Width, connecting rod ................................................................................................ 43.170 - 43.270 mm
Bore connecting rod bearing shell in connecting rod ................................................. Ø 95.000 - 95.022 mm
Weight difference per set of connecting rods (2) for one engine....................................................max. 50 g
Spread of connecting rod bearing shells (8), (9) ..................................................................... max. 2.0 mm
Connecting rod bearing shell dimensions

Connecting rod bearing shells (8), (9), normal dimension.......................................... Ø 90.044 - 90.086 mm
Connecting rod bearing shells (8), (9), normal dimension I ........................................ Ø 90.144 - 90.186 mm
Connecting rod bearing shells (8), (9), repair level I .................................................. Ø 90.294 - 90.336 mm
Connecting rod bearing shells (8), (9), repair level II ................................................. Ø 90.544 - 90.586 mm
Wall thickness of connecting rod bearing shells

Wall thickness, connecting rod bearing shells (8), (9), normal dimension ......................... 2.468 ± 0.010 mm
Wall thickness, connecting rod bearing shells (8), (9), normal dimension I ....................... 2.518 ± 0.010 mm
Wall thickness, connecting rod bearing shells (8), (9), repair level I.................................. 2.593 ± 0.010 mm
Wall thickness, connecting rod bearing shells (8), (9), repair level II................................. 2.718 ± 0.010 mm
Piston diameter Nüral piston class A without/with cooling duct

D1 measured 16 mm above lower edge of piston ..................................................Ø 119.871 - 119.880 mm
D3 measured 100 mm above lower edge of piston ................................................Ø 119.564 - 119.597 mm
D4 measured 116.7 mm above lower edge of piston..............................................Ø 118.179 - 118.212 mm
Piston diameter Nüral piston class B without/with cooling duct

Piston diameter of Mahle pistons without cooling duct

D3 measured 100.5 mm above lower edge of piston .............................................Ø 119.581 - 119.599 mm
D4 measured 113 mm above lower edge of piston.................................................Ø 118.156 - 118.224 mm
Piston diameter Nüral piston cooling duct

D3 measured 95.5 mm above lower edge of piston ............................................... Ø 119.611 - 119.629 mm
Piston height Nüral piston

Overall piston height ..................................................................................................................123.3 mm
Piston height, centre of piston pin to piston crown ........................................................... 76.75 - 76.80 mm
Piston height Mahle piston

Piston ring (keystone ring)

Piston ring height............................................................................................. 3.5 mm (nominal measure)
Piston ring width ................................................................................................................ 4.70 - 5.10 mm
Ring gap ........................................................................................................................... 0.40 - 0.55 mm

CRANKSHAFT DRIVE
Piston ring (taper faced ring)

Piston ring height............................................................................................................... 2.97 - 3.00 mm
Ring gap ........................................................................................................................... 0.70 - 0.90 mm
Axial play .......................................................................................................................... 0.08 - 0.13 mm
Piston ring (double-bevelled ring)

Ring gap ........................................................................................................................... 0.25 - 0.55 mm
Axial play .......................................................................................................................... 0.03 - 0.07 mm
Piston weights
Piston weight Nüral piston...................................................................................................... 1940 ± 30 g
Piston weight Mahle piston............................................................................................................. 1906 g
Piston weight difference per set of an engine ..............................................................................max. 60 g
Piston pin hole

Piston bolt bore Nüral piston ................................................................................... Ø 52.010 - 52.016 mm
Piston bolt bore Mahle piston .................................................................................. Ø 52.005 - 52.012 mm
Piston pins
Piston pins ............................................................................................................. Ø 51.992 - 52.000 mm
Piston projection
Piston projection (crankcase - piston) .................................................................... 0.3 mm (nominal value)
WARNING
Cracked surfaces are weakened and may lead to material breaking off
• 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 flushed-out particles to enter the engine
WARNING
Note
The piston diameter is always measured across to the piston pin bore.

CRANKSHAFT DRIVE
Special tools
[315] Feeler gauge 08.75310-0806
• Check axial play and ring gap piston rings
[316] Dial gauge 08.71000-3217
• Checking the inside diameter of the connecting

rod bearing shells and piston pin bushing
• Checking the piston protrusion in conjunction
with:
• Check the connecting rod axial and radial play in
conjunction with:
[317] gauge holder 80.99605-0172
• Checking the piston protrusion
[318] gauge holder 08.71082-0005
• Checking the connecting rod axial and radial play
[319] Caliper pin 80.99605-0197
• Checking the connecting rod axial and radial play

• Checking the piston protrusion
• Checking the piston ring insertion depth

CRANKSHAFT DRIVE
[321] Piston ring clamping sleeve 80.99613-0038
[322] settling tools 80.99622-0052
• Aligning the connecting rod bearing shells

CRANKSHAFT DRIVE
Check the connecting rod Checking the connecting rod radial play
Checking the connecting rod axial play

gauge [316] (2) and Caliper pin [319] on the
• Mount the gauge holder [318] (2) with Dial crankcase (3)
gauge [316] (1) and Caliper pin [319] on the • Position the Caliper pin [319] with a pre-load at the
crankcase (3) connecting rod (4)
• Position the Caliper pin [319] with a pre-load at the • Press the connecting rod (4) vertically downwards
connecting rod (4) to the end position
• Push the connecting rod (4) horizontally into the • Zero the Dial gauge [316] (2)
end position towards the flywheel housing/timing • Push the connecting rod (4) into the end position
case towards Dial gauge [316] (2) and check the differ-
• Zero the Dial gauge [316] (1) ence
• Push the connecting rod (4) into the end position • Repeat the procedure for the remaining connect-
towards Dial gauge [316] (1) and check the differ- ing rods
ence The permitted radial play of the connecting rod (4)
• Repeat the procedure for the remaining connect- is 0.060 - 0.122 mm.
ing rods
The permitted axial play of the connecting rod (4) is If the radial play is out of tolerance, check the con-
0.130 - 0.330 mm. necting rod bearing shells and journals.
If the axial play is out of tolerance, check the width of Check the connecting rod inside diameter, see
the connecting rod (4), see Checking the connecting Checking the connecting rod bearing inside diame-
rod width, 486. ter, 485.
Check the connecting rod outside diameter, see

Checking the connecting rod bearing journals out-
side diameter, 499.

CRANKSHAFT DRIVE
Removing the piston and connecting Remove and check the piston
rod
Remove piston pin
Remove the connecting rod bearing cap
• Mark the relative positions of the piston (1), piston

WARNING pin (5) and connecting rod (3)
Cracked surfaces are weakened and • Detach the circlips (2) and (4)
may lead to material breaking off • Press the piston pin (5) out of the piston (1)
• Exchange the connecting rod if the • Remove the piston (1) from the connecting rod (3)
crack surfaces are damaged
Checking the piston pin diameter
• Protect crack surfaces against damage
caused by hard and sharp objects
• Mark the connecting rod bearing cap (3) and con-

necting rod bearing shell (2) to indicate correct
assignment and installation position
• Unscrew the connecting rod bearing bolts (4)
• Remove the connecting rod bearing cap (3) with
the connecting rod bearing shell (2)
• Push out the piston and connecting rod (1) towards
the cylinder head
Removing the piston
• Check the diameter of the piston pin (2) using a

micrometer (1)
The permitted diameter of the rocker arm support
(2) is Ø 51.992 - 52.000 mm.
If the diameter is out of tolerance, the piston with

piston pin (2) must be replaced.
• Extract the piston (1) with connecting rod (2) from

the cylinder liner (4)
• Mark the connecting rod (2) and connecting rod
bearing shell (3) to indicate correct assignment
and installation position
• Remove the connecting rod bearing shell (3) from

CRANKSHAFT DRIVE
Checking the piston ring axial play Checking the piston ring gap
Note Note
An axial play cannot be measured on the The ring gap is only allowed to be
keystone ring. checked if the cylinder liner has the cor-
rect inside diameter, otherwise a false
• Check axial play between piston rings (2) and (3) ring gap reading would be obtained.
and piston (4) with Feeler gauge [315] (1) Checking cylinder liner inside diameter,
The permitted axial play of the bevelled-edge ring see Removal and installation the cylinder
(3) is 0.03 - 0.07 mm. liner, 509.
The permitted axial play on the Taper-faced com- • Insert the piston ring (3) evenly deep into the cylin-
pression ring (2) is 0.08 - 0.13 mm. der liner (1)
• Check for even insertion depth of the piston ring
If the axial plays are out of tolerance, the piston (4) (3) using the Depth gauge (electronic) [320]
with piston rings (2), (3) and double-bevelled ring • Repeat the check with various insertion depths
must be replaced. • Check ring gap with Feeler gauge [315] (2)
The permitted ring gap of the keystone ring is
Removing the piston rings 0.40 - 0.55 mm.
The permitted ring gap of the taper-faced compres-

sion ring is 0.70 - 0.90 mm.
The permitted ring gap of the bevelled-edge ring is

0.25 - 0.55 mm.
If the ring gaps are out of tolerance, the piston rings

must be replaced.
• Set Piston ring pliers [314] (1) to the piston diam-

eter
• Detach the piston rings (2) from the piston (3) with
Piston ring pliers [314] (1)
• Carefully clean the piston ring grooves

CRANKSHAFT DRIVE
Checking the connecting rods and con- Checking the connecting rod bearing inside di-
necting rod bearings ameter
Correct matching of connecting rod and con-

necting rod bearing cap
• Insert the upper connecting rod bearing shell into

• Insert the lower connecting rod bearing shell into
WARNING the connecting rod bearing cap (1)
Incorrect matching of connecting rod • Screw in the connecting rod bolts and tighten to
and connecting rod bearing cap 1st torque 100 Nm
• Ensure that the connecting rod and • Use the Dial gauge [316] (2) and internal calliper
the connecting rod bearing cap are (3) to check the connecting rod bearing inside
matched correctly diameter
Connecting rod bearing inside diameter, see Con-
• Check the pairing numbers (1) and (2) on the necting rod bearing shell dimensions, 478.
connecting rod (3) and the connecting rod bearing
If the inside diameter is out of tolerance, the con-
cap (4)
necting rod bearing shells must be replaced.
Checking the piston pin bushing
• Use the internal calliper and the Dial gauge [316]

(2) to check the inside diameter of the piston pin
bushing (3)
The permitted inner diameter of the piston pin bush-
ing (3) is Ø 52.055 - 52.065 mm.
If the inside diameter is out of tolerance, the con-

necting rod (1) must be replaced

CRANKSHAFT DRIVE
Checking the connecting rod bearing shell Installing the piston and connecting rod
spread
Note • Set Piston ring pliers [314] (1) to the piston diam-
The difference between dimension A and eter
dimension B gives the connecting rod • Insert the piston rings (2) with TOP mark facing
bearing shell spread. the piston crown with Piston ring pliers [314] (1) in
the respective ring groove in the piston (3)
• Clean the connecting rod bearing shells (2) and
place them together on a flat surface as marked Install piston pin
• Check dimension A with a micrometer (1)
• Check dimension B using a micrometer (1)
The permitted spread of the connecting rod bearing
shells (2) is max. 2.0 mm.
If the spread is out of tolerance, the connecting rod

bearing shells (2) must be replaced.
Checking the connecting rod width
• Attach a new locking ring (2) in the groove in the

piston
marked
reached
• Attach a new circlip (4) in the groove in the piston
• Check the width of the connecting rod (1)
• Remove the connecting rod bearing cap
rectly
The permitted dimension A is 43.170 - 43.270 mm.
If the circlips (2) and (4) have not engaged correctly,
If dimension A is out of tolerance, the connecting remove and re-attach the circlips (2) and (4), ensur-
rod (1) must be replaced ing that they are seated correctly.

CRANKSHAFT DRIVE
Installation instructions for connecting rod bear- Piston installation with piston ring clamping
ing shells sleeve
WARNING Note
Cracked surfaces are weakened and There is an installation arrow on the pis-
may lead to material breaking off ton surface. This must point towards the
• Exchange the connecting rod if the coolant pump during installation.
crack surfaces are damaged
• Protect crack surfaces against damage • Move the crankshaft for the cylinder concerned to
caused by hard and sharp objects TDC
• Clean the contact surfaces of the connecting rod to one another
bearing shells in the connecting rod and connect- • Thinly apply clean engine oil on the upper con-
ing rod bearing cap necting rod bearing shell
• Place the lower connecting rod bearing shell into • Insert the upper connecting rod bearing shell into
the connecting rod bearing cap so that the lug (1) the connecting rod
engages in the recess (4) • Thinly apply clean engine oil on the piston (1) and
• Place the upper connecting rod bearing shell into cylinder liner (3)
the connecting rod so that the lug (2) engages in • Put the Piston ring clamping sleeve [321] (2) on
the recess (3) the piston (1) and clamp it
• Use the settling tools [322] to align the connecting • Push the piston (1) with connecting rod into the
rod bearing shells in the connecting rod and con- cylinder liner (3) until the piston has been pushed
necting rod bearing cap out of the Piston ring clamping sleeve [321] (2)
• Push in the piston (1) until the connecting rod
with connecting rod bearing shell is lying on the
crankshaft

CRANKSHAFT DRIVE
Checking the connecting rod alignment Installing the connecting rod bearing cap
WARNING WARNING
Cracked surfaces are weakened and Cracked surfaces are weakened and
may lead to material breaking off may lead to material breaking off
• Exchange the connecting rod if the • Exchange the connecting rod if the
crack surfaces are damaged crack surfaces are damaged
• Protect crack surfaces against damage • Protect crack surfaces against damage
caused by hard and sharp objects caused by hard and sharp objects
• Check the alignment of the connecting rod bearing • Insert the lower connecting rod bearing shell (2)
shell (2) in the connecting rod (1) and, if necessary, into the connecting rod cap (3)
adjust using the settling tools [322] (3) • Check the alignment of the lower connecting rod
bearing shell (2) and, if necessary, reseat using
settling tools [322]
• Thinly apply clean engine oil on the lower connect-
ing rod bearing shell (2)
• Position the connecting rod bearing cap (3) on the
connecting rod (1) as marked
• Screw in new connecting rod bolts (4) and tighten
to 1st torque 100 Nm
• Tighten the connecting rod bearing bolts (4) to
Final torque 90°

CRANKSHAFT DRIVE
Checking the connecting rod for ease of move- Checking the piston protrusion
ment
• Set piston (2) onto OT

• Check the connecting rod (1) for ease of move- • Mount the Dial gauge [316] (4) with gauge
ment by moving it in lengthwise direction of the holder [317] (1) and Caliper pin [319] (3)
engine • Fit the Caliper pin [319] (3) with pre-load on the
If the connecting rod (1) is not free, check connecting crankcase (5)
rod and correct arrangement of connecting rod and • Zero the Dial gauge [316] (4)
connecting-rod bearing cover, see Correct matching • Put the Dial gauge [316] (4) with gauge
of connecting rod and connecting rod bearing cap, holder [317] (1) and Caliper pin [319] (3) on the
485. piston (2) and check the difference (piston protru-
sion)
If the wrong connecting rod shells are installed, they
The permitted piston protrusion is 0.3 mm (nominal
must be replaced.
value).
Check the seat of the connecting rod shells in the
connecting rod and connecting rod cover, if needed,
realign connecting rod, see Checking the connecting
rod alignment, 488.

CRANKSHAFT DRIVE
CRANKSHAFT
Removal and installation of crankshaft
Additional jobs
– Removing and installing alternator 3, see 167
boxes, see 455
– Removing and installing rear timing gears (Version crankshaft seal flywheel), see 357
– Removing, installing the timing gear (crankshaft seal, crankshaft gear Version), see 371
– Removal and installation of front drive gears, see 349
– Removal and installation of piston and connecting rod, see 477

CRANKSHAFT DRIVE
(1) Flywheel (4) Crankshaft bearing cover

(2) Crankshaft (5) Piston
(3) Connecting rods
Technical data
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 .....................................1st torque 50 Nm
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 ..................................2nd torque 150 Nm
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 ...................................3rd torque 315 Nm
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 .......................................Final torque 90°
Crankshaft Technical Data

Axial play of the crankshaft (2) ....................................................................................... 0.200 - 0.401 mm
Radial play of crankshaft (2)........................................................................................... 0.060 - 0.126 mm
Crankshaft measurements
Centring of crankshaft bearing pin for front crankshaft gear.......................................... 99.975 - 99.995 mm
Standard measurements for crankshaft bearing journal ........................................ Ø 103.998 - 104.000 mm
Crankshaft bearing pin, normal dimension I.......................................................... Ø 103.898 - 103.900 mm
Crankshaft bearing pin, repair stage I .................................................................. Ø 103.748 - 103.750 mm
Crankshaft bearing pin, repair stage II ................................................................. Ø 103.448 - 103.500 mm
Crankshaft bearing shell dimensions

Crankshaft bearing cover, normal dimension ........................................................ Ø 104.044 - 104.090 mm
Crankshaft bearing cover, normal dimension I ...................................................... Ø 104.144 - 104.190 mm
Crankshaft bearing cover, repair stage I............................................................... Ø 104.294 - 104.340 mm
Crankshaft bearing cover, repair stage II.............................................................. Ø 104.544 - 104.590 mm
Crankshaft bearing shell wall strength

Wall thickness for crankshaft bearing cover, normal dimension ......................................... 3.466 ± 0.12 mm

CRANKSHAFT DRIVE
Wall thickness for crankshaft bearing cover, normal dimension I........................................ 3.516 ± 0.12 mm
Wall thickness for crankshaft bearing cover, repair level I.................................................. 3.591 ± 0.12 mm
Wall thickness for crankshaft bearing cover, normal dimension II....................................... 3.716 ± 0.12 mm
Spread, crankshaft bearing ................................................................................................... max. 1.2 mm
Connecting rod bearing journal dimensions

Connecting rod bearing journal, normal dimension ................................................... Ø 89.980 - 90.000 mm
Connecting rod bearing journal, normal dimension I ................................................. Ø 89.970 - 89.900 mm
Connecting rod bearing journal, repair level I ........................................................... Ø 89.730 - 89.750 mm
Connecting rod bearing journal, repair level II........................................................... Ø 89.480 - 89.500 mm
Dimensions of thrust washers

Contact washer thickness, normal dimension .................................................................. 3.350 - 3.400 mm
Contact washer thickness Repair stage I ........................................................................ 3.600 - 3.650 mm
Contact washer thickness Repair stage II........................................................................ 3.850 - 3.900 mm
WARNING
Cracked surfaces are weakened and may lead to material breaking off
• 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 flushed-out particles to enter the engine
WARNING
• If impact wrenches are used, these may only be used for pretightening to max. max. 50 % of
the specified tightening torque
Special tools
[323] Dial gauge 08.71000-3217
• Check the crankshaft bearing inner diameter

• Check crankshaft axial and radial play in connect-
ing tube with:
[324] gauge holder 08.71082-0005
• Checking the crankshaft axial and radial play
[325] Caliper pin 80.99605-0197
• Checking the crankshaft axial and radial play

CRANKSHAFT DRIVE
• Loosing and tightening the mounting bolts of the

crankshaft bearing cover in conjunction with:
• Support [327]
• Support [329]
• Adapter [330]
• Stud bolt [331]
[327] Support 80.99606-0551

crankshaft bearing cover
[328] protractor 80.99607-0172

[329] Support 80.99606-0584

[330] Adapter 80.99606-0552

[331] Stud bolt 06.02191-0407

[332] connecting pin 06.22729-0006


CRANKSHAFT DRIVE
[333] Rubber ring 06.56331-3274

[334] Socket, size 27 80.99603-0312

[335] settling tools 80.99622-0052
• Align the crankshaft bearing shells

CRANKSHAFT DRIVE
Checking the crankshaft Checking the crankshaft radial play
Check crankshaft axial play

gauge [323] (2) and Caliper pin [325] on the
• Install gauge holder [324] (3) with Dial gauge [323] crankcase (3)
(2) and Caliper pin [325] • Position the Caliper pin [325] with a pre-load at the
• Position the Caliper pin [325] with a pre-load at the crankshaft (4)
crankshaft (1) • Press the crankshaft (4) vertically downwards to
• Push the crankshaft (1) horizontally into the end the end position
position towards the flywheel housing/timing case • Zero the Dial gauge [323] (2)
• Zero the Dial gauge [323] (2) • Push the crankshaft (4) into the end position to-
• Push the crankshaft (1) into the end position towards Dial gauge [323] (2) and check the differ-
wards Dial gauge [323] (2) and check the difference
ence The permitted radial play on the crankshaft (4) is
The permitted axial play on the crankshaft (1) is 0.060 - 0.126 mm.
0.200 - 0.401 mm.
If the radial play is outside the tolerance, check the
If the axial play is outside the tolerance, fit corre- external diameter of the crankshaft bearing journal
sponding contact washers. and internal diameter of the crankshaft bearing.
Install corresponding contact washer, see Dimen- Checking the crankshaft bearing journals external
sions of thrust washers, 493. diameter, see Checking the outer diameter of the
crankshaft bearing journal, 499.
Check inner diameter of crankshaft bearings, see

Check the crankshaft bearing inner diameter, 499.

CRANKSHAFT DRIVE
Removing the crankshaft Remove the crankshaft bearing cover axial com-
pensation
• Insert the Torque multiplier i = 1 : 3.5 [326] (1) into WARNING

the Support [327] (9) Cracked surfaces are weakened and
• Install the Support [329] (6) with Stud bolt [331] (8) may lead to material breaking off
and Adapter [330] (7) at the Support [327] (9) • Crankcase must be replaced if cracked
• Position protractor [328] (2) on Torque multiplier i surfaces on the bearing cover or bear-
= 1 : 3.5 [326] (1) ing seats are damaged
• Put the Socket, size 27 [334] (3) on the Torque • Protect crack surfaces against damage
multiplier i = 1 : 3.5 [326] (1) and secure with the caused by hard and sharp objects
(4) • Mark the bearing cover (4) to indicate correct as-
signment and installation position
Loosening the mounting bolts of the crankshaft • Unscrew the mounting bolts (1)
bearing covers • Remove the bearing cover (4) with thrust washers
(2) and (3)
• Mark the crankshaft bearing covers to indicate
correct assignment and installation position
Removing the crankshaft bearing cover
• Loosen the bearing cover mounting bolts using the

special tool (1)
• Mark the bearing cover (2) to indicate correct as-

signment and installation position
• Remove the bearing cover (2)
• Mark the crankshaft bearing cover (1) to indicate
correct assignment and installation position
• Repeat the procedure for bearing covers 2, 3, 4, 5
and 7

CRANKSHAFT DRIVE
Removing the crankshaft Check crankshaft and crankshaft bear-

ing
Check the crankshaft bearing spread
CAUTION
nents
• Remove the crankshaft including sup- Note
port The difference between dimension A and
dimension B gives the crankshaft bearing
WARNING spread.
Component damage due to unsuitable
lifting device • Clean the crankshaft bearing shells (2) and place
• Do not use steel wire or other them together on a flat surface as marked
sharp-edged tools to lift the crankshaft • Check dimension A with a micrometer (1)
out • Check dimension B using a micrometer (1)
The permitted spread of the crankshaft bearing is
• Lift crankshaft (3) from crankcase (2)
max. 1.2 mm.
• Mark the crankshaft bearing shells (1) to indicate
correct assignment and installation position and If the spread is out of tolerance, fit new crankshaft
remove from crankcase (2) bearing shells.
Remove the upper thrust washers
• Remove the contact washers (2) and (3) from

bearing seat 6 (1)

CRANKSHAFT DRIVE
Check the crankshaft bearing inner diameter Checking the outer diameter of the crankshaft
bearing journal
• Insert the upper and lower crankshaft bearing shell

as marked in bearing seat • Clean crankshaft bearing pin of crankshaft (1)
• Fit the bearing cover (3) as marked • Check the crankshaft bearing pin with micrometre
• Screw in and tighten the bearing cover mounting (2)
bolts (3) and tighten with 1st torque 50 Nm • Repeat the test procedure several times at 120°
• Check the crankshaft bearing with internal caliper offset
(2) and Dial gauge [323] (1) Inner diameter of the crankshaft bearing pin, see
• Repeat the test procedure several times at 120° Crankshaft measurements, 492.
offset
• Remove the bearing cover (3) again after test If the outside diameter is out of tolerance, the crank-
procedure shaft (1) must be replaced.
Inner diameter of the crankshaft see Crankshaft
bearing shell dimensions, 492.
If the inside diameter is out of tolerance, the crank-

shaft bearing shells must be replaced.
Checking the connecting rod bearing journals

outside diameter
• Clean the crankshaft connecting rod journal (1)

• Check the connecting rod bearing journal using a
micrometer (2)
• Repeat the test procedure several times at 120°
offset
Connecting rod bearing journals outside diameter,
see Connecting rod bearing journal dimensions,
493.
If the outside diameter is out of tolerance, the crank-

shaft (1) must be replaced.

CRANKSHAFT DRIVE
Installing the crankshaft Install the upper thrust washers
Note
Only fit contact washers with the same
WARNING wall thickness for the upper and lower
Component damage due to unsuitable contact washers.
lifting device
• Do not use steel wire or other • Examine contact washers (2), see Check crank-
sharp-edged tools to lift the crankshaft shaft axial play, 496
in. • Thinly apply clean engine oil on the thrust washers
(2)
• Thinly apply clean engine oil on the crankshaft • Insert the thrust washers (2) on bearing seat 6 with
bearing shells (1) oil grooves to the crankshaft (1)
• Place the crankshaft bearing shells (1) in the • Screw in the thrust washers (2) by pressing them
bearing seats as marked, and align with settling slightly into the bearing seat
tools [335]
• Insert the crankshaft (3) in the crankcase (2)

CRANKSHAFT DRIVE
Installing axial compensator of crankshaft bear- Install crankshaft bearing cover

ing covers
WARNING
Cracked surfaces are weakened and
bearing shell and the thrust washers (2) and (3)
may lead to material breaking off
• Place the crankshaft bearing shells in the bear-
• Exchange the crankcase if the crack
ing cover (4) as marked, and align with settling
surfaces on the bearing cover or
tools [335]
crankcase are damaged
• Insert the thrust washers (2) and (3) with oil
• Protect crack surfaces against damage
grooves to the crankshaft in the bearing cover (4)
caused by hard and sharp objects
• Position bearing cover (4) with contact washers
(2) and (3)
• Screw in new mounting bolts (1) and, with
bearing shells (1)
1st torque 50 Nm
• Place the crankshaft bearing shells (1) in the bear-
• Check the crankshaft for ease of movement
ing cover (2) as marked, and align with settling
If the crankshaft turns not at all or only with difficulty,
tools [335]
the crankshaft has to be removed together with the
• Put on the bearing cover (2)
crankshaft bearings.
• Thinly apply clean engine oil on the screw head
Re-check the crankshaft bearing and crankshaft, if contact area of the new mounting bolts (3)
needed replace crankshaft bearing or crankshaft. • Screw in the mounting bolts (3) and tighten to
1st torque 50 Nm
• Tighten the mounting bolts (3) to
2nd torque 150 Nm

CRANKSHAFT DRIVE
Tightening the mounting bolts on the crankshaft

bearing cover
Note

(1) to 3rd torque 315 Nm

ENGINE CASE
ENGINE CASE
(1) O-rings (3) Flywheel housing/timing case

(2) Cylinder liner (4) Cover

ENGINE CASE
FLYWHEEL HOUSING/TIMING CASE

Removing and installing flywheel housing/timing case
Additional jobs
boxes, see 455
(1) Mounting bolt (4) Flywheel housing/timing case

(2) Mounting bolt (5) Crankcase
(3) Mounting bolt
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

ENGINE CASE
Removing flywheel housing/timing case Mounting flywheel housing/timing case

Note on installing flywheel housing/timing case
CAUTION
Danger of injury due to heavy compo- • Thinly apply sealing agent Loctite 5900 (1) on the
nents mating face as illustrated
• Removing flywheel housing/timing case
with support Mounting flywheel housing/timing case

bolts (1)
• Removing flywheel housing/timing case (2)
CAUTION
nents
• Mounting flywheel housing/timing case
with support
• Positioning flywheel housing/timing case (2)

• Screw in the new mounting bolts (1) by hand as
marked
• Tighten the mounting bolts (1) crosswise

ENGINE CASE
COVER
Removal and installation cover
Additional jobs
(1) Mounting bolt (4) Gasket

(2) Mounting bolt (5) Oil pump
(3) Cover
WARNING

ENGINE CASE
Removing the cover Mounting the cover
• Mark the installation position of the mounting bolts • Position the cover (1) with a new gasket (4)
(2) and (3) • Screw in the new mounting bolts (2) and (3) as
• Unscrew the mounting bolts (2) and (3) marked and tighten them by hand
• Remove the cover (1) with the seal (4) • Tighten the mounting bolts (2) and (3)

ENGINE CASE
CYLINDER LINERS
Removal and installation the cylinder liner
Additional jobs
– Removal and installation of piston and connecting rod, see 477
(1) Cylinder liner (3) Crankcase

(2) O-rings
Technical data on cylinder liner


ENGINE CASE
Technical data on crankcase

Installation depth of cylinder liner bundle in crankcase ........................................................ 8.0 ± 0.015mm
Bore lower O-ring area........................................................................................ Ø 139.500 - 139.540 mm
WARNING
Special tools
[336] extractor 80.99602-6023
• Extracting the cylinder liner in conjunction with:

• extractor plate [337]
[337] extractor plate 80.99601-0217
• Extracting the cylinder liner
[338] Dial gauge 08.71000-3217
• Checking the cylinder liner diameters

with:
• measuring plate [340]
• Washer [342]
[339] gauge holder 80.99605-0172
[340] measuring plate 80.99605-0286
[341] hex shoulder stud 06.01499-0015

ENGINE CASE
[342] Washer 06.15013-0417
• Check the cylinder liner seat

ENGINE CASE
Remove cylinder liner seat Extracting the cylinder liner
Checking the cylinder liner diameters
• Clamp the extractor [336] (3) with the nut (2)

• Extract the cylinder liners (1) with the extrac-
• Check the cylinder liner (3) using the Dial tor [336] (3)
gauge [338] (2) and the internal calliper (1) • Clean the cylinder liners (1)
• Repeat the measurement several times at 120°
offset Removing the O-rings
• Repeat the measurement at four different heights
If the cylinder liner (3) has become oval, it must be
replaced
Mounting the extractor tool
• Remove the O-rings (2) from the crankcase

• Clean the cylinder liner seats (1) and O-ring seats
WARNING
Risk of engine damage from damaged
oil nozzles
• Take care not to damage the oil nozzles
when inserting the extractor plate [337]
• Mark the cylinder liners (1) to indicate their correct

assignment and installation position
• Insert the extractor [336] (3) with folded extractor
plate [337] (2) into the cylinder liner (1)

ENGINE CASE
Install the cylinder liners Installing the cylinder liner
Check the cylinder liner seat
• Thinly apply clean engine oil on the new O-rings

(2) and insert them into the O-ring seats in the
• Check seat of cylinder liner with Depth gauge crankcase
(electronic) [343] (1) • Thinly apply clean engine oil in the outer lower
• Check the cylinder liner eat at four points situated area of the cylinder liner (1) on the outside
opposite each other • Insert cylinder line (1) into crankcase as marked
The permitted installation depth is 8.0 ± 0.015mm. and advance until it engages
If the installation depth is out of tolerance, the crank-
shaft must be replaced.
Checking the cylinder liner stand out
• Place the measuring plate [340] (2) on the cylinder

liner
• Screw in the hex shoulder stud [341] (4) with
Washer [342] (5) and tighten them
• Fit the gauge holder [339] (6) with Dial gauge [338]
(3) on measuring plate [340] (2)
• Place the dial gauge tip (1) on the crankcase
• Carefully place the dial gauge tip (1) on the cylin-
der liner and note the difference on the dial gauge
The permitted cylinder liner protrusion is
0.035 - 0.085 mm
If the cylinder liner stand out is out of tolerance, the

cylinder liner must be replaced

ENGINE BRAKE SYSTEM
ENGINE BRAKE SYSTEM
(1) Proportional valve (5) Mounting nut

(2) Adjusting cylinder (6) Holder
(3) Mounting nut (7) Compressed-air line
(4) Exhaust manifold (8) Mounting bolt

ENGINE BRAKE SYSTEM
ENGINE BRAKE
Removal and installation the engine brake
(1) Proportional valve (5) Mounting nut

(2) Positioning cylinder (6) Holder
(3) Mounting nut (7) Compressed-air line
(4) Exhaust manifold (8) Mounting bolt
Technical data
Adjusting cylinder pre-load (2) ................................................................................................1.0 - 1.5 mm
Screw-in coupling for adjusting cylinder (2) ............ M16x1.5 ............................................................15 Nm
Service products
WARNING

ENGINE BRAKE SYSTEM
Special tools
[344] Test tool 80.99606-0399

ENGINE BRAKE SYSTEM
Removing the engine brake Installing the engine brake

Detaching the air pipes Install the positioning cylinder
• Detach the compressed air pipe (1) • Fit the positioning cylinder (2)
• Detach the air pipe (2) from the adjusting cylinder • Screw on and tighten the new mounting nut (1)
(3) • Attach the ball coupling (3)
Remove the proportional valve Set the adjusting cylinder pre-load
• Unscrew the mounting bolts (1) • Loosen the lock nut (3) and unscrew piston rod for
• Remove proportional valve (2) from bracket (3) the adjusting cylinder (4) until the gap between the
lever (2) and limit stop (1) is min. 1 mm
Removing the positioning cylinder • Screw in the piston rod of the positioning cylinder
(4) until the lever (2) is at the stop (1)
• Screw in the piston rod of the positioning cylinder
(4) by approx. 1 to 1.5 turns
• Tighten the lock nut (3)
The permitted pre-load of the positioning cylinder (4)
is 1.0 - 1.5 mm.

• Detach ball coupling (3)
• Remove the adjusting cylinder (2)

ENGINE BRAKE SYSTEM
Mount the proportional valve Attaching the air pipes
• Position proportional valve (2) on the bracket (3) • Attach the air pipe (1)
• Screw in and tighten the new mounting bolts (1) • Screw the retaining screw into the adjusting cylin-
der (3) and tighten it to 15 Nm
Repair the compressed-air connection of the ad- • Check compressed air pipe (2) for a firm seat using
justing cylinder Test tool [344]
• If the connector comes out of the retaining screw,

nector (6)
• Fit new O-rings (4) and (5)
• Thinly apply Multi-purpose grease
MAN 285 Li-PF2 on the O-rings (4) and (5)
• Replace spring element (1) in the adjusting cylin-
der
• Insert a new retaining clip (2) into the adjusting
cylinder

TECHNICAL DATA
TECHNICAL DATA
Removing and installing the engine electrical system

Temperature sensor (3)......................................... M16x1.5 ............................................................45 Nm
Pressure switch (9)............................................... M18x1.5 ............................................................50 Nm
Rail pressure sensor (11) ...................................... M18x1.5 ............................................................70 Nm
Remove and install coolant manifold (version without retarder)

Removing/installing the coolant manifold (version with retarder)

Removal and installation the thermostats

Opening temperature of thermostat (4) ............................................................................................. 83 °C
Removal and installation of the 1-cylinder air compressor

GE union.............................................................. M26x1.5 ............................................................45 Nm
Removing and installing the 1-cylinder air compressor with steering and hydraulic pump
GE union.............................................................. M26x1.5 ............................................................45 Nm
GE union.............................................................. M26x1.5 ............................................................45 Nm
Removing and installing of 1-cylinder air compressor with power steering pump and two hydraulic
pumps
GE union.............................................................. M26x1.5 ............................................................45 Nm
pumps
Removing and installing 1-cylinder air compressor with two power-steering pumps and hydraulic
pump
GE union.............................................................. M26x1.5 ............................................................45 Nm
Mounting bolts for power steering pump 2 (5)......... M10x175-10.9....................................................65 Nm

TECHNICAL DATA
pump
Removing and installing 2-cylinder air compressor with power steering pump
GE union.............................................................. M26x1.5 ............................................................45 Nm
GE union.............................................................. M26x1.5 ............................................................45 Nm
pump
GE union.............................................................. M26x1.5 ............................................................45 Nm
pump
pumps
GE union.............................................................. M26x1.5 ............................................................45 Nm
pumps

Mounting bolt (30) ..........................................................................................................................24 Nm
Mounting bolt (28) ..........................................................................................................................12 Nm
Screw plug (27) ..............................................................................................................................40 Nm

Mounting bolt (33) ..........................................................................................................................24 Nm
Mounting bolt (29) ..........................................................................................................................12 Nm
Screw plug (28) ..............................................................................................................................40 Nm
Removal and installation of the starter

Number of starter pinion teeth ...............................................................................................................12
Starter power .................................................................................................................... 5.5 kW at 24 V

TECHNICAL DATA
Terminal mounting nut 30 (6)................................. M10...................................................................22 Nm

Removing and installing belt drive

Mounting bolt for ribbed V-belt tensioner (10) ......... M10x70-10.9......................................................47 Nm
Mounting bolt (6) .................................................. M14x110-10.9 ..................................................150 Nm
Removing and installing alternators 1 and 2

Mounting nuts (6), (9) ........................................... M16x1.5 ............................................................95 Nm
Removing and installing alternator 3

Mounting nut (3) ................................................... M16x1.5 ............................................................95 Nm
Removal and installation of the coolant compressor

Removing and installing the injectors and pressure pipe

High-pressure line ..........................................................................................................1st torque 10 Nm
High-pressure line ............................................................................................................Final torque 60°
Mounting bolt (10) ................................................ M8x50-10.9 ......................................1st torque 1.5 Nm
Mounting bolt (10) ................................................ M8x50-10.9 .................................... Final torque 35 Nm
Mounting bolt (5) .................................................. M8x50-10.9 ......................................1st torque 1.5 Nm
Mounting bolt (5) .................................................. M8x50-10.9 ........................... Final torque 25 Nm + 90°
Pressure screw (1) ....................................................................................................... 1st torque 10 Nm
Pressure screw (1) ............................................................................................. Final torque 20 Nm + 60°
Mounting nut (7) .................................................. Cable lug nut M4...............................................1.5 Nm
Mounting bolt of the injector cable harness (8) ....... M6x16-10.9 .......................................................15 Nm
Pressurisation, drip test .......................................................................................................... 4 + 0.5 bar
Pressure drop .................................................................................................................0.1 bar in 10 min
Rail pressure sensor............................................. M18x1.5 ............................................................70 Nm
Pressure-limiting valve.......................................... M20x1.5 ..........................................................100 Nm
Removing and installing the high pressure pump/high pressure pump drive (fuel-lubricated)
Fuel-fill level for high pressure pump (2) ........................................................................................... 60 ml
Fuel-filling screw for high pressure pump (2) .......... M10x1 ...............................................................18 Nm
Removing and installing the high pressure pump/high pressure pump drive (fuel-lubricated)
Oil fill amount for the high pressure pump (2) .................................................................................... 40 ml
Oil filler plug of high pressure pump (2).................. M10x1 ...............................................................18 Nm
High pressure pump/high pressure pump drive disassembly and assembly

Flow regulator valve (6) ..................................................................................................................34 Nm
Overflow valve (7) ..........................................................................................................................20 Nm
Mounting bolt (8) .................................................. M5x20 .................................................1st torque 4 Nm
Mounting bolt (8) .................................................. M5x20 ..............................................Final torque 7 Nm
Mounting bolt (10) ................................................ M6x20 ................................................................ 8 Nm
Removal and installation of the fuel service centre

Hollow screw (10) ................................................. M10x1 ...............................................................15 Nm

TECHNICAL DATA
Dismantling and assembling the fuel service centre

Cover (11) ......................................................................................................................................10 Nm
Cover (2)........................................................................................................................................20 Nm
Water drain plug (6) ......................................................................................................................... 3 Nm
Removing and installing the flame-start system

Hollow screw (7)................................................... M10x1 ...............................................................15 Nm
Flame glow plug (2) ............................................. M20x1.5 ............................................................25 Nm
Fuel line union nut (3) ...................................................................................................................10 Nm
Removal and installation of the engine control unit

Mounting bolt (2) .................................................. M6x35-10.9 ....................................................... 11 Nm
Mounting bolts for bracket (1) ................................ M8x40-10.9 .......................................................13 Nm
Remove and install the charge air pipe

Profiled clamp (3) ................................................. M6 ....................................................................10 Nm
Removal and installation of the turbocharger

Mounting nut (8) ................................................... M10-10..............................................1st torque 10 Nm
Mounting nut (8) ................................................... M10-10................................................Final torque 90°
Profiled clamp ...................................................... M6 ....................................................................10 Nm
Screw-in coupling for adjusting cylinder ................. M16x1.5 ............................................................15 Nm
Mounting bolt for compressor housing ................... M8x20-10.9 .......................................................25 Nm
Removing and installing the EGR module without an intermediate plate

Dimension of bracket from threaded bolts to limit stop Version 1 .................................................... 164 mm
Dimension of bracket from threaded bolts to limit stop Version 2 ..................................................161.5 mm
Removing and installing the EGR module with intermediate plate

Dismantling and assembling EGR module without intermediate plate

Dismantling and assembling the EGR module with intermediate plate

Mounting bolt for check valve housing (16) ............ M8x55-10.9 .........................................1st torque 3 Nm
Mounting bolt for check valve housing (16) ............ M8x55-10.9 ......................................2nd torque 15 Nm
Mounting bolt for check valve housing (16) ............ M8x55-10.9 .................................... Final torque 30 Nm
Mounting bolt for check valve housing (1) .............. M8x90-10.9 .........................................1st torque 3 Nm
Mounting bolt for check valve housing (1) .............. M8x90-10.9 ......................................2nd torque 15 Nm
Mounting bolt for check valve housing (1) .............. M8x90-10.9 .................................... Final torque 30 Nm

TECHNICAL DATA
Removal and installation of the exhaust manifold

Mounting bolt for exhaust manifold (5) ................... M10x50-HWF ................................ Initial torque 60 Nm
Mounting bolt for exhaust manifold (1) ................... M10x95-HWF ....................................1st torque 60 Nm
Removal and installation of the cylinder head

cylinder head bolt ................................................. M18x2x246-10.9 ................................1st torque 10 Nm
cylinder head bolt ................................................. M18x2x246-10.9 .............................2nd torque 150 Nm
cylinder head bolt ................................................. M18x2x246-10.9 ..............................3rd torque 300 Nm
cylinder head bolt ................................................. M18x2x246-10.9 ..................................Final torque 90°
Mounting bolt (4) ............................................................................................................................10 Nm
Checking and adjusting valve clearance

Intake valve clearance .................................................................................................................. 0.5 mm
Exhaust valve clearance ............................................................................................................... 0.8 mm
EVB brace setting dimensions....................................................................................................... 0.6 mm
Lock nuts (2), (4) .................................................. M10x1-8.8 .........................................................45 Nm
Lock nut, EVB brace (5) ........................................ M14x1-8.8 .........................................................45 Nm
Removal and installation the valve-stem seal

Stud bolt bell crank support ................................... M12x60-10.9....................................................105 Nm

Mounting bolts camshaft gear (1) .......................... M8x30-10.9 .......................................1st torque 15 Nm
Mounting bolts camshaft gear (1) .......................... M8x30-10.9 .........................................Final torque 90°
Mounting bolts intermediate gear (2)...................... M8x30-10.9 .......................................................30 Nm

Axial play, camshaft (3) .................................................................................................. 0.250 - 0.850 mm
Radial play, camshaft (3)................................................................................................ 0.034 - 0.091 mm
Camshaft bearing shells.......................................................................................... Ø 39.974 - 40.015 mm
Camshaft bearings ................................................................................................. Ø 39.925 - 39.950 mm
Depth of camshaft bearing ......................................................................................... 42.095 - 42.150 mm
Installation depth camshaft gear (1) ................................................................................ 9.000 - 9.010 mm
Width, camshaft bearing seat ..................................................................................... 32.300 - 32.700 mm
Spread, camshaft bearing shells.......................................................................................... max. 1.00 mm
Width, camshaft bearing shell .................................................................................... 25.700 - 26.000 mm

Rocker arm radial play ................................................................................................... 0.030 - 0.066 mm
Inside diameter, rocker arm bearing......................................................................... Ø 32.005 - 32.025 mm
Rocker arm shaft outside diameter .......................................................................... Ø 31.959 - 31.975 mm
Checking the valve timing

Valve lift during measurement ............................................................................................ 7.90 - 8.50 mm
Removal and installation of front drive gears

Mounting bolt (3) .................................................. M12x50-10.9....................................................105 Nm
Backlash, crankshaft gear (4) - high-pressure pump drive intermediate gear (1)................ 0.057 - 0.183 mm
Axial play, high-pressure pump drive intermediate gear (1) .............................................. 0.100 - 0.290 mm
Radial play, high-pressure pump drive intermediate gear (1) ............................................ 0.060 - 0.109 mm
Height, high-pressure pump drive intermediate gear (1)............................................... 21.000 - 21.500 mm

TECHNICAL DATA
Inside diameter, high-pressure pump drive intermediate gear (1)............................... Ø 60.000 - 60.030 mm
Outside diameter, intermediate gear pin (2).............................................................. Ø 59.921 - 59.940 mm
Height, intermediate gear pin (2) ................................................................................ 27.200 - 27.240 mm

TECHNICAL DATA

Removal and installation of the oil module

Sealing cap oil module (7)..................................... M38x1.5 ............................................................80 Nm
Oil filter lid ......................................................................................................................................45 Nm
Removing and installing the oil sump and oil intake pipe
Dimension of connecting-rod bearing bolt - oil intake pipe............................................................... 5.0 mm
Disassembling and assembling the oil sump


Mounting bolt (1) .................................................. M6x20-10.9 .......................................................15 Nm

Backlash, ring gear (2) - crankshaft gear......................................................................... 0.092 - 0.272 mm
Axial play, ring gear (2) .................................................................................................. 0.020 - 0.093 mm
Radial play, ring gear (2) ................................................................................................ 0.053 - 0.210 mm
Outside diameter, bearing, ring gear (2) ...................................................................... 96.893 - 96.928 mm
Height, ring gear (2)................................................................................................... 29.952 - 29.970 mm

Outside diameter, axle (6) .......................................................................................... 36.965 - 36.980 mm

Height, oil pump pinion (3) ......................................................................................... 27.770 - 28.300 mm
Inside diameter, oil pump pinion (3) ............................................................................ 36.985 - 37.050 mm
Removal and installation of rear crankshaft seal (crankshaft seal version flywheel)
Installation temperature for race ............................................................................................ about 120 °C
Removal and installation of the vibration damper

Mounting bolt (1) .................................................. M16x1.5x85-10.9 .................................Final torque 90°
Removal and installation of the gearbox flywheel (Flywheel crankshaft seal)

Installation temperature starting ring gear ...............................................................................200 - 230 °C
Removing and installing flywheel of automatic gearbox (crankshaft seal flywheel version)

TECHNICAL DATA
Removing and installing flywheel (crankshaft seal crankshaft gear version) for manually operated
gearboxes
Removing and installing flywheel (with race) for the automatic gearbox
Removing and installing dual-mass flywheel (crankshaft seal crankshaft gear version)
Mounting bolt (3) .................................................. M16x1.5x122-12.9 ........................... 1st torque 105 Nm
Mounting bolt (3) .................................................. M16x1.5x122-12.9 .........................2. Tightening by 90°
Mounting bolt (3) .................................................. M16x1.5x122-12.9 ...............................Final torque 90°

Connecting-rod bearing bolt (3) ............................. M12x1.5x64-11.9 ............................. 1st torque 100 Nm
Connecting-rod bearing bolt (3) ............................. M12x1.5x64-11.9 .................................Final torque 90°

Axial play, connecting rod............................................................................................... 0.130 - 0.330 mm
Radial play, connecting rod ............................................................................................ 0.060 - 0.122 mm
Inside diameter, piston pin bushing.......................................................................... Ø 52.055 - 52.065 mm
Width, connecting rod ................................................................................................ 43.170 - 43.270 mm
Bore connecting rod bearing shell in connecting rod ................................................. Ø 95.000 - 95.022 mm
Weight difference per set of connecting rods (2) for one engine....................................................max. 50 g
Spread of connecting rod bearing shells (8), (9) ..................................................................... max. 2.0 mm

Connecting rod bearing shells (8), (9), normal dimension.......................................... Ø 90.044 - 90.086 mm
Connecting rod bearing shells (8), (9), normal dimension I ........................................ Ø 90.144 - 90.186 mm
Connecting rod bearing shells (8), (9), repair level I .................................................. Ø 90.294 - 90.336 mm
Connecting rod bearing shells (8), (9), repair level II ................................................. Ø 90.544 - 90.586 mm

Wall thickness, connecting rod bearing shells (8), (9), normal dimension ......................... 2.468 ± 0.010 mm
Wall thickness, connecting rod bearing shells (8), (9), normal dimension I ....................... 2.518 ± 0.010 mm
Wall thickness, connecting rod bearing shells (8), (9), repair level I.................................. 2.593 ± 0.010 mm
Wall thickness, connecting rod bearing shells (8), (9), repair level II................................. 2.718 ± 0.010 mm



D3 measured 100.5 mm above lower edge of piston .............................................Ø 119.581 - 119.599 mm

TECHNICAL DATA

D3 measured 95.5 mm above lower edge of piston ............................................... Ø 119.611 - 119.629 mm



Piston ring height............................................................................................. 3.5 mm (nominal measure)
Ring gap ........................................................................................................................... 0.40 - 0.55 mm

Ring gap ........................................................................................................................... 0.70 - 0.90 mm
Axial play .......................................................................................................................... 0.08 - 0.13 mm

Ring gap ........................................................................................................................... 0.25 - 0.55 mm
Axial play .......................................................................................................................... 0.03 - 0.07 mm

Piston weight Nüral piston...................................................................................................... 1940 ± 30 g
Piston weight Mahle piston............................................................................................................. 1906 g
Piston weight difference per set of an engine ..............................................................................max. 60 g

Piston bolt bore Nüral piston ................................................................................... Ø 52.010 - 52.016 mm
Piston bolt bore Mahle piston .................................................................................. Ø 52.005 - 52.012 mm

Piston pins ............................................................................................................. Ø 51.992 - 52.000 mm

Piston projection (crankcase - piston) .................................................................... 0.3 mm (nominal value)

Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 .....................................1st torque 50 Nm
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 ..................................2nd torque 150 Nm
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 ...................................3rd torque 315 Nm
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 .......................................Final torque 90°

Axial play of the crankshaft (2) ....................................................................................... 0.200 - 0.401 mm
Radial play of crankshaft (2)........................................................................................... 0.060 - 0.126 mm

Centring of crankshaft bearing pin for front crankshaft gear.......................................... 99.975 - 99.995 mm
Standard measurements for crankshaft bearing journal ........................................ Ø 103.998 - 104.000 mm
Crankshaft bearing pin, normal dimension I.......................................................... Ø 103.898 - 103.900 mm
Crankshaft bearing pin, repair stage I .................................................................. Ø 103.748 - 103.750 mm
Crankshaft bearing pin, repair stage II ................................................................. Ø 103.448 - 103.500 mm

TECHNICAL DATA

Crankshaft bearing cover, normal dimension ........................................................ Ø 104.044 - 104.090 mm
Crankshaft bearing cover, normal dimension I ...................................................... Ø 104.144 - 104.190 mm
Crankshaft bearing cover, repair stage I............................................................... Ø 104.294 - 104.340 mm
Crankshaft bearing cover, repair stage II.............................................................. Ø 104.544 - 104.590 mm

Wall thickness for crankshaft bearing cover, normal dimension ......................................... 3.466 ± 0.12 mm
Wall thickness for crankshaft bearing cover, normal dimension I........................................ 3.516 ± 0.12 mm
Wall thickness for crankshaft bearing cover, repair level I.................................................. 3.591 ± 0.12 mm
Wall thickness for crankshaft bearing cover, normal dimension II....................................... 3.716 ± 0.12 mm
Spread, crankshaft bearing ................................................................................................... max. 1.2 mm

Connecting rod bearing journal, normal dimension ................................................... Ø 89.980 - 90.000 mm
Connecting rod bearing journal, normal dimension I ................................................. Ø 89.970 - 89.900 mm
Connecting rod bearing journal, repair level I ........................................................... Ø 89.730 - 89.750 mm
Connecting rod bearing journal, repair level II........................................................... Ø 89.480 - 89.500 mm

Contact washer thickness, normal dimension .................................................................. 3.350 - 3.400 mm
Contact washer thickness Repair stage I ........................................................................ 3.600 - 3.650 mm
Contact washer thickness Repair stage II........................................................................ 3.850 - 3.900 mm


Installation depth of cylinder liner bundle in crankcase ........................................................ 8.0 ± 0.015mm
Bore lower O-ring area........................................................................................ Ø 139.500 - 139.540 mm
Removal and installation the engine brake

Adjusting cylinder pre-load (2) ................................................................................................1.0 - 1.5 mm
Screw-in coupling for adjusting cylinder (2) ............ M16x1.5 ............................................................15 Nm

Man D2066 - LOH01 - 12

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Man D2066 - LOH01 - 12

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Common rail In-line Engine

D2066 LOH01 - LOH08

Copy deadline: 07.2015

Common rail In-line Engine

We reserve the right to make modifications in the course of further development.

MAN Truck & Bus AG

© 2015 MAN Truck & Bus AG

Typesetting: SAWDS, 2W Technische Informations GmbH & Co. KG

2 A 41 Stage 2 4th edition

Safety instructions ....................................................................................................... 11

Engine electronics ....................................................................................................... 31

Coolant manifold ......................................................................................................... 35

Air compressor ........................................................................................................... 59

A 41 Stage 2 4th edition 3

Common Rail system

Injectors and pressure pipe .......................................................................................... 181

Charge-air pipes ....................................................................................................... 247

EGR module ............................................................................................................ 263

Cylinder head .......................................................................................................... 293

Camshaft/camshaft bearing ......................................................................................... 325

Front drive gears ....................................................................................................... 349

4 A 41 Stage 2 4th edition

Oil module .............................................................................................................. 387

Crankshaft seals ....................................................................................................... 417

Vibration damper ...................................................................................................... 435

Flywheel housing/timing case ....................................................................................... 505

Engine brake system

engine brake ............................................................................................................ 517

Technical Data 521

A 41 Stage 2 4th edition 5

A 41 Stage 2 4th edition 7

Engine timing.......................................................................................................................................... 338

8 A 41 Stage 2 4th edition

Backlash on the crankshaft gear/ring gear............................................................................................. 406

A 41 Stage 2 4th edition 9

1. Regulations to prevent accidents with personal injury

During inspection, adjustment and repair work

Working on the brake system

Working on vehicles with a compressed natural gas (CNG) system

Working on the compressed natural gas (CNG) system

A 41 Stage 2 4th edition 11

Operating the engine

Bodies and special bodies

Working on high-pressure lines

Testing injection nozzles

Work on the vehicle electrical system

Important: battery gases are explosive!

Caution! Battery acid is poisonous and corrosive!

12 A 41 Stage 2 4th edition

Work on plastic tubes – risk of damage and fire

Working with a tilted cab

Work on the air-conditioning system

Work on the airbag or belt pre-tensioner units

A 41 Stage 2 4th edition 13

Working on the independent heating

2. Information on how to avoid damage and premature wear on assemblies

3. Liability limitations for replacement parts and accessories

4. Regulations to prevent damage to health and the environmental

Health protection precautions

14 A 41 Stage 2 4th edition

Service products and process materials

Clean the cooling circuit

Cleaning the filter insert