Manual Motor Liebherr

Workshop Manual en
Diesel Engine
D 934 A6 / D 936 A6
upwards of serial number 2004-03-0000 / 2004-04-0000
Document identification
Order number: 10116428
Issued: 06.12.2006
Valid for: D 934 A6 / D 936 A6
Compiler: LMB - department BE-MD3
Version: 00C
Product identification
Manufacturer: Liebherr Machines Bulle SA
240001.fm
Type: D 934 A6 / D 936 A6

Serial number: 2004-03-0000 / 2004-04-0000
LMB/00C/Issued: 06.12.2006/en
Address
Address: Liebherr Machines Bulle SA
45, rue de l‘Industrie
CH - 1630 Bulle
D 934 A6 !! ! i-1
D 936 A6 Mjfcifss
Machine data
The following data must be supplemented upon obtaining your diesel engine.
This will also be helpful when ordering spare parts.
Details indicated with * are printed on the company nameplate of the diesel en-
gine.
Diesel engine identification number *:
. . . . . . . . . . . . . . . . . .
Diesel engine serial number *:
. . . . . . . . . . . . . . . . . .
Date of initial start-up:
. . / . . / . .
240001.fm
i-2 !! ! D 934 A6
Mjfcifss D 936 A6
Foreword
Target group
This workshop manual has been compiled specifically for the mechanics and the workshop personnel of the LIEB-
HERR dealers and LIEBHERR subsidiaries, whose task it is to ensure that the diesel engines are in perfect working
order.
Contents
This workshop manual provides you with technical documentation regarding the installation and removal, assembly
and disassembly, adjustment tasks and technical data for Liebherr diesel engines.
The operating instructions D934 / D936 are an integral part of this workshop manual, within which descriptions re-
garding maintenance of the diesel engine can be obtained.
Notes on safety
The accident-prevention guidelines and all generally recognised safety-technical and occupational-medicinal regu-
lations are to be observed before commencing any maintenance and repair tasks on Liebherr diesel engines. Fur-
thermore, the special notes on safety regarding diesel engines in the chapter "Notes on Safety" are to be observed.
Notes on operation
Prerequisite for professional repair is a complete basic tool in sound condition, as well as any necessary devices and
special tools.
Cleanliness and order contribute toward safety in the workplace.
Clean the diesel engine of oil, fuel or detergents, in particular connections and threaded unions, before commencing
maintenance/repair tasks. Do not use any aggressive cleaning agents. Use fibre-free cleaning rags. Do not use any
flammable liquids for cleaning the diesel engine.
Sealing components (e.g. O-rings, seals, etc.) should essentially be replaced.
Dismantled parts should be checked for reusability, and replaced as required.
If no specific torques and tightening specifications are prescribed, screw connections should be tightened to the stan-
dard torques, which can be obtained in the chapter "Technical Data".
240002.fm
Special torques, tightening specifications and mounting instructions can be obtained in the chapter "Technical Data"
and in the respective job specifications.
Spare parts
Only original LIEBHERR spare parts, or spare parts purchased by LIEBHERR should be used for repairing LIEB-
HERR diesel engines.
LIEBHERR will declare all possible undertakings carried out by LIEBHERR and/or their dealers, such as guarantees,
service orders, etc. null and void without advance notice, if spare parts other than original LIEBHERR spare parts or
spare parts purchased by LIEBHERR are used for maintenance or repair.
D 934 A6 !! ! i-3
D 936 A6 Mjfcifss
Workshop Manual
Fuels and lubricants

Only fuels approved by LIEBHERR may be used for the operation of LIEBHERR diesel engines.
LIEBHERR will declare all possible undertakings carried out by LIEBHERR and/or their dealers, such as guarantees,
service orders, etc. null and void without advance notice, if spare parts other than original LIEBHERR spare parts or
spare parts purchased by LIEBHERR are used for maintenance or repair.
Notes on utilisation
A summary of the structure of this manual can be obtained in chapter 1 "General Information".
Several types and construction levels are described in this manual. The information applies for the types specified
in the footer. Any details which deviate from this information are details specific to the type number or serial number
and are specified in the respective descriptions.
Some diagrams in this manual may feature particulars which differ from your diesel engine. The respective tasks
should be carried out in correspondence with the job specifications at hand.
Any improvements which are to be undertaken on the diesel engines may lead to changes which have possibly not
yet been mentioned in this manual.
Should you require further explanations or information, the After-Sales-Service and After-Sales-Service training cen-
tre departments of the LIEBHERR Company are available at all times to answer any queries.
The workshop manual is not subject to any updating services. The workshop manual will undergo revision in accor-
dance with the technical requirements, and then published in the actual version.
The service information released by Liebherr Machines Bulle will serve as a supplement following publication of one
edition of the workshop manual.
The workshop manual at hand is available in German, English and French.
Modifications, requirements and copyright

Modification of the technical details of the diesel engines, as regards details and illustrations of the manual at hand
remain reserved.
Conditions for warranty and liability of the general terms of trade for the LIEBHERR Company are not extended by
the aforementioned details.
Details and pictures within this manual may not be reproduced and distributed, nor used for the purposes of the com-
petition. All rights remain exclusively reserved in accordance with copyright laws.
240002.fm
i-4 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual Table of Contents
1 General information .............................................................................................................................. 1-11
1.1 Structure of this manual................................................................................................................. 1-14
1.2 Important notes within this manual ................................................................................................ 1-16
1.3 Symbols in this manual.................................................................................................................. 1-17
1.4 Notes on safety.............................................................................................................................. 1-18
1.4.1 General notes on safety .................................................................................................. 1-18

1.4.2 Modifications to the diesel engine ................................................................................... 1-19
1.4.3 Preventing injury to persons............................................................................................ 1-19
1.4.4 Preventing damage to property ....................................................................................... 1-20
1.5 Technical Data............................................................................................................................... 1-22
1.5.1 Engine in general ............................................................................................................ 1-22

1.5.2 Standard tightening torques for screw connections ........................................................ 1-27
1.5.3 Standard torques for locking screws and banjo bolts...................................................... 1-28
1.5.4 Special torques, tightening specifications and installation specifications........................ 1-29
General notes............................................................................................................ 1-29
Tightening specification main bearing ....................................................................... 1-29
Tightening specifications for piston cooling nozzle ................................................... 1-29
Tightening specification for final regulating valve...................................................... 1-30
Tightening specification oil drain valve...................................................................... 1-30
Tightening specification crankshafts accessories ..................................................... 1-31
Tightening specification connecting rod .................................................................... 1-32
Tightening specification cylinder head ...................................................................... 1-32
Installation and tightening specification counterbalancing shafts (D 934)................. 1-33
Tightening specification for camshaft sprocket on aggregate carrier and
D934_D936_10116428_06122006_00C_enIVZ.fm
flywheel side.............................................................................................................. 1-34

Tightening specification fitting in oil filter bracket ...................................................... 1-34
Tightening specification injection pump .................................................................... 1-35
Tightening specification cable harness on injection pump ........................................ 1-35
Installation and tightening specification injection nozzle and pressure pipe tube ..... 1-36
Tightening specification for nozzle retaining nut ....................................................... 1-37
Installation and tightening specification injection line ................................................ 1-38
Tightening specification for sensoric ......................................................................... 1-39
Installation and tightening specification speed sensor (camshaft sprocket) ............. 1-40
Tightening specification heater flange....................................................................... 1-40

Tightening specification idler ..................................................................................... 1-41
Tightening specification air compressor gear............................................................ 1-41
Tightening specification for coolant pump connector ................................................ 1-41
Tightening specification turbocharger and flange on turbocharger ........................... 1-42
Tightening specification generator belt pulley ........................................................... 1-43
Tightening specification flywheel housing ................................................................. 1-43
Tightening specification flywheel............................................................................... 1-44
Tightening specification torsional vibration damper .................................................. 1-45
D 934 A6 !! ! i-5
D 936 A6 Mjfcifss
Table of Contents Workshop Manual
Tightening specification for engine control unit plug ................................................. 1-45

Tightening specification control unit-mount ............................................................... 1-45
Tightening specification power take-off ..................................................................... 1-46
1.5.5 Cleaning agents, thread-locking adhesives and greases ................................................ 1-47
1.6 Representations of the engine and engine components ............................................................... 1-48
1.6.1 View of the engine (aggregate carrier side and turbocharger side)................................. 1-48
1.6.2 View of the engine (flywheel side and injection system side).......................................... 1-50
1.6.3 Engine cross-section ....................................................................................................... 1-52
1.6.4 Crankshaft drive .............................................................................................................. 1-53
1.6.5 Gear train (D 934)............................................................................................................ 1-55
1.6.6 Gear train (D 936)............................................................................................................ 1-56
1.7 Diagram of the fuel system ............................................................................................................ 1-57
1.8 Diagram of lube oil system ............................................................................................................ 1-59
1.9 Diagram of coolant system ............................................................................................................ 1-60
1.10 Allocation of ducts in the crankcase and in the cylinder head ....................................................... 1-62
1.11 Tools .............................................................................................................................................. 1-63
1.11.1 Special tools .................................................................................................................... 1-63

Fastening the engine onto the engine assembly stand ............................................. 1-63
Fastening of lifting eyes on the crankcase ................................................................ 1-66
Turning gears ............................................................................................................ 1-67
Angle of rotation devices ........................................................................................... 1-70
Torx tools................................................................................................................... 1-71
Installing and dismantling the aggregate carrier........................................................ 1-72
D934_D936_10116428_06122006_00C_enIVZ.fm
Installing and dismantling the final regulating valve .................................................. 1-72
Installing and dismantling the cylinder liner ............................................................... 1-73
Checking excess length of the cylinder liners ........................................................... 1-73
Installing and dismantling crankshaft accessories .................................................... 1-74
Installing and dismantling the front crankshaft seal................................................... 1-74
Installing and dismantling the crankshaft .................................................................. 1-74
Checking combustion pressure ................................................................................. 1-74
Installing and dismantling the piston with connecting rod and piston rings ............... 1-75
Installing and dismantling the piston rings................................................................. 1-75
Installing and dismantling the cylinder head.............................................................. 1-75
Installing and dismantling valve stem seals, valve springs and valves ..................... 1-75
Installing and dismantling the counterbalancing shafts ............................................. 1-77
Installing and dismantling the oil cooler housing with oil cooler ................................ 1-77
Installing and dismantling the injection lines ............................................................. 1-77
Installing and dismantling the pressure pipe tube and injection nozzle..................... 1-78
Checking, dismantling and reassembling the injection nozzle (step-type holder) ..... 1-78
Installing and dismantling the injection pump and roller tappet ................................. 1-78
Installing and dismantling the exhaust pipes ............................................................. 1-79
Installing and dismantling the flywheel ...................................................................... 1-79
i-6 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the rear crankshaft seal ................................................... 1-79

1.11.2 Commercially-approved tools.......................................................................................... 1-80
2 Cylinder head, engine control and valves .......................................................................................... 2-81
2.1 Installing and dismantling the rocker arm support and push rods ................................................. 2-82
2.2 Installing and dismantling the valve fitting (for engines with and without ZBS) ............................. 2-83
2.3 Installing and dismantling the cylinder head .................................................................................. 2-84
2.4 Installing and dismantling valve stem seals, valve springs and valves ......................................... 2-86
2.4.1 Removing ........................................................................................................................ 2-88

2.4.2 Installation ....................................................................................................................... 2-88
2.5 Installing and dismantling the roller tappet (valve control)............................................................. 2-90
2.6 Dismantling and installing the camshafts ...................................................................................... 2-91
2.6.1 Removing ........................................................................................................................ 2-92

2.6.2 Installation ....................................................................................................................... 2-93
3 Engine .................................................................................................................................................... 3-95
3.1 Checking combustion pressure ..................................................................................................... 3-97
3.2 Installing and dismantling the piston with connecting rod and piston rings ................................. 3-100
3.2.1 Summary ....................................................................................................................... 3-100

3.2.2 A: Installing and dismantling the piston with connecting rod from the engine ............... 3-101
Removing ................................................................................................................ 3-102
D934_D936_10116428_06122006_00C_enIVZ.fm
Installation ............................................................................................................... 3-105

3.2.3 B: installing and dismantling the piston rings ................................................................ 3-107
Removing ................................................................................................................ 3-108
Installation ............................................................................................................... 3-108
3.2.4 C: installing and dismantling the piston ......................................................................... 3-109
3.3 Installing and dismantling the cylinder liner ................................................................................. 3-110
3.4 Checking excess length of the cylinder liners.............................................................................. 3-112

3.5 Installing and dismantling the generator mount ........................................................................... 3-113
3.6 Installing and dismantling the air-conditioning compressor and generator mount....................... 3-115
3.7 Installing and dismantling crankshaft accessories....................................................................... 3-117
3.8 Installing and dismantling the front crankshaft seal ..................................................................... 3-119
3.8.1 General notes................................................................................................................ 3-120

3.8.2 Removing ...................................................................................................................... 3-120
D 934 A6 !! ! i-7
D 936 A6 Mjfcifss
3.8.3 Installation ..................................................................................................................... 3-121
3.9 Installing and dismantling the aggregate carrier .......................................................................... 3-125
3.10 Installing and dismantling the flywheel ........................................................................................ 3-127
3.10.1 Removing ...................................................................................................................... 3-130

3.10.2 Installation ..................................................................................................................... 3-130
3.11 Installing and dismantling the rear crankshaft seal ...................................................................... 3-133
3.11.1 General notes ................................................................................................................ 3-134

3.11.2 Removing ...................................................................................................................... 3-134
3.11.3 Installation ..................................................................................................................... 3-135
3.12 Dismantling and installing the flywheel housing .......................................................................... 3-138
3.13 Dismantling and installing the idler .............................................................................................. 3-140
3.14 Installing and dismantling the crankshaft ..................................................................................... 3-142
3.14.1 Removing ...................................................................................................................... 3-145

3.14.2 Installation ..................................................................................................................... 3-148
3.15 Installing and dismantling the crankshaft gear wheel .................................................................. 3-151
4 Fuel system and injection system ..................................................................................................... 4-153
4.1 Notes regarding working on the fuel system and injection system .............................................. 4-154
4.2 Installing and dismantling fuel lines ............................................................................................. 4-155
4.3 Installing and dismantling the fuel prefilter with bracket .............................................................. 4-162
4.4 Installing and dismantling the fuel fine filter with bracket ............................................................. 4-163
D934_D936_10116428_06122006_00C_enIVZ.fm
4.5 Installing and dismantling the fuel multiplier ................................................................................ 4-165
4.6 Installing and dismantling the fuel delivery pump ........................................................................ 4-166
4.7 Installing and dismantling the injection lines ................................................................................ 4-167
4.7.1 Removing ...................................................................................................................... 4-168

4.7.2 Installation ..................................................................................................................... 4-169
4.8 Installing and dismantling the pressure pipe tube and injection nozzle ....................................... 4-170
4.8.1 Removing ...................................................................................................................... 4-171

4.8.2 Installation ..................................................................................................................... 4-172
4.9 Checking, dismantling and reassembling the injection nozzle (step-type holder)........................ 4-174
4.9.1 Check the injection nozzle............................................................................................. 4-177

Check the opening pressure ................................................................................... 4-178
Adjusting the opening pressure ............................................................................... 4-178
Spray formation test and buzz test .......................................................................... 4-180
Checking for leaks ................................................................................................... 4-180
4.9.2 Dismantling and reassembling the injection nozzle....................................................... 4-181
i-8 !! ! D 934 A6
Mjfcifss D 936 A6
4.10 Draining the fuel ducts in the crankcase...................................................................................... 4-184
4.11 Installing and dismantling the injection pump and roller tappet ................................................... 4-189
4.11.1 Removing ...................................................................................................................... 4-191

4.11.2 Installation ..................................................................................................................... 4-191
5 Belt drive ............................................................................................................................................. 5-195
5.1 Installing and dismantling the ribbed V-belt tensioning device .................................................... 5-196
5.2 Installing and dismantling the ribbed V-belt deflection pulley ...................................................... 5-197
6 Charge air and exhaust system ......................................................................................................... 6-199
6.1 Installing and dismantling the air induction pipe .......................................................................... 6-200
6.2 Installing and dismantling the connecting line (turbocharger - intercooler) ................................. 6-201
6.3 Installing and dismantling the exhaust pipes ............................................................................... 6-205
6.4 Installing and dismantling the engine brake ................................................................................ 6-207
6.5 Installing and dismantling the intake manifold ............................................................................. 6-208
6.6 Installing and dismantling the adapter ......................................................................................... 6-209
6.7 Installing and dismantling the exhaust stack ............................................................................... 6-210
6.8 Installing and dismantling the flange ........................................................................................... 6-211
6.9 Installing and dismantling the thermal protection plate on the exhaust pipe ............................... 6-212
6.10 Installing and dismantling the thermal protection plate on the turbocharger ............................... 6-213
6.11 Installing and dismantling the turbocharger ................................................................................. 6-214
6.12 Checking axial clearance and radial clearance of the turbocharger ............................................ 6-216
D934_D936_10116428_06122006_00C_enIVZ.fm
7 Electrical system ................................................................................................................................ 7-217
7.1 Installing and dismantling the heater flange ................................................................................ 7-218
7.2 Installing and dismantling the generator ...................................................................................... 7-220
7.3 Installing and dismantling the generator belt pulley..................................................................... 7-221
7.4 Installing and dismantling the starter ........................................................................................... 7-223
7.5 Installing and dismantling the sensors......................................................................................... 7-224

7.6 Installing and dismantling the engine control unit ........................................................................ 7-226
7.7 Installing and dismantling the engine control unit-mount............................................................. 7-228
8 Lubrication system ............................................................................................................................. 8-233
8.1 Installing and dismantling the crankcase breather ...................................................................... 8-234
8.2 Installing and dismantling the oil return-flow line (crankcase breather) ....................................... 8-236
8.3 Installing and dismantling the oil dipstick and guide tube ............................................................ 8-237
D 934 A6 !! ! i-9
D 936 A6 Mjfcifss
8.4 Installing and dismantling the oil intake ....................................................................................... 8-238
8.5 Installing and dismantling the multi-part oil sump and ladder frame (D 936) ............................... 8-240
8.6 Installing and dismantling the single-unit oil sump....................................................................... 8-246
8.7 Installing and dismantling the connector (oil sump - crankcase) (D 934) .................................... 8-250
8.8 Installing and dismantling the oil suction pipe (D 936)................................................................. 8-251
8.9 Installing and dismantling the ladder frame ................................................................................. 8-252
8.10 Installing and dismantling the oil cooler housing with oil cooler................................................... 8-253
8.11 Dismantling and installing the oil pressure pump ........................................................................ 8-255
8.12 Installing and dismantling the oil suction pump (D 936) .............................................................. 8-257
8.13 Installing and dismantling the piston cooling nozzle .................................................................... 8-258
8.14 Dismantling and installing the sealing parts of the oil suction pump............................................ 8-260
8.15 Installing and dismantling the final regulating valve..................................................................... 8-261
8.16 Check the oil pressure, adjust as necessary ............................................................................... 8-264
9 Cooling system ................................................................................................................................... 9-267
9.1 Installing and dismantling the coolant vent line ........................................................................... 9-268
9.2 Installing and dismantling the coolant pump ................................................................................ 9-269
9.3 Installing and dismantling the coolant manifold (on the thermostat housing or
aggregate carrier) ........................................................................................................................ 9-271
9.4 Installing and dismantling the thermostat housing and thermostat .............................................. 9-273
9.5 Checking the thermostat .............................................................................................................. 9-274
D934_D936_10116428_06122006_00C_enIVZ.fm
10 Power take-off and air / air-conditioning compressor ................................................................... 10-277
10.1 Installing and dismantling the power take-off for fuel delivery pump ......................................... 10-278
10.2 Dismantling and removing power take-off 1 .............................................................................. 10-279
10.6 Installing and removing the power take-off on the flywheel housing ......................................... 10-285
10.6.1 Removing .................................................................................................................... 10-286

10.6.2 Installation ................................................................................................................... 10-287
10.7 Dismantling and installing the switchable power take-off on the flywheel housing .................... 10-289
10.7.1 Removing .................................................................................................................... 10-290

10.7.2 Installation ................................................................................................................... 10-291
10.8 Installing and dismantling the air-conditioning compressor ....................................................... 10-293
i - 10 !! ! D 934 A6
Mjfcifss D 936 A6
1 General information
1 General information .............................................................................................................................. 1-11
1.1 Structure of this manual................................................................................................................. 1-14
1.2 Important notes within this manual ................................................................................................ 1-16
1.3 Symbols in this manual.................................................................................................................. 1-17
1.4 Notes on safety.............................................................................................................................. 1-18
1.4.1 General notes on safety .................................................................................................. 1-18

1.4.2 Modifications to the diesel engine ................................................................................... 1-19
1.4.3 Preventing injury to persons............................................................................................ 1-19
1.4.4 Preventing damage to property ....................................................................................... 1-20
1.5 Technical Data............................................................................................................................... 1-22
1.5.1 Engine in general ............................................................................................................ 1-22

1.5.2 Standard tightening torques for screw connections ........................................................ 1-27
1.5.3 Standard torques for locking screws and banjo bolts...................................................... 1-28
1.5.4 Special torques, tightening specifications and installation specifications........................ 1-29
General notes............................................................................................................ 1-29
Tightening specification main bearing ....................................................................... 1-29
Tightening specifications for piston cooling nozzle ................................................... 1-29
Tightening specification for final regulating valve...................................................... 1-30
Tightening specification oil drain valve...................................................................... 1-30
Tightening specification crankshafts accessories ..................................................... 1-31
Tightening specification connecting rod .................................................................... 1-32
Tightening specification cylinder head ...................................................................... 1-32
Installation and tightening specification counterbalancing shafts (D 934)................. 1-33
Tightening specification for camshaft sprocket on aggregate carrier and
01. Kapitel_Allg_Information.fm
flywheel side.............................................................................................................. 1-34

Tightening specification fitting in oil filter bracket ...................................................... 1-34
Tightening specification injection pump .................................................................... 1-35
Tightening specification cable harness on injection pump ........................................ 1-35
Installation and tightening specification injection nozzle and pressure pipe tube ..... 1-36
Tightening specification for nozzle retaining nut ....................................................... 1-37
Installation and tightening specification injection line ................................................ 1-38
Tightening specification for sensoric ......................................................................... 1-39

Installation and tightening specification speed sensor (camshaft sprocket) ............. 1-40
Tightening specification heater flange....................................................................... 1-40
Tightening specification idler ..................................................................................... 1-41
Tightening specification air compressor gear............................................................ 1-41
Tightening specification for coolant pump connector ................................................ 1-41
Tightening specification turbocharger and flange on turbocharger ........................... 1-42
Tightening specification generator belt pulley ........................................................... 1-43
Tightening specification flywheel housing ................................................................. 1-43
D 934 A6 !! ! 1 - 11
D 936 A6 Mjfcifss
Tightening specification flywheel ............................................................................... 1-44

Tightening specification torsional vibration damper .................................................. 1-45
Tightening specification for engine control unit plug ................................................. 1-45
Tightening specification control unit-mount ............................................................... 1-45
Tightening specification power take-off ..................................................................... 1-46
1.5.5 Cleaning agents, thread-locking adhesives and greases ................................................ 1-47
1.6 Representations of the engine and engine components ............................................................... 1-48
1.6.1 View of the engine (aggregate carrier side and turbocharger side)................................. 1-48
1.6.2 View of the engine (flywheel side and injection system side).......................................... 1-50
1.6.3 Engine cross-section ....................................................................................................... 1-52
1.6.4 Crankshaft drive .............................................................................................................. 1-53
1.6.5 Gear train (D 934)............................................................................................................ 1-55
1.6.6 Gear train (D 936)............................................................................................................ 1-56
1.7 Diagram of the fuel system ............................................................................................................ 1-57
1.8 Diagram of lube oil system ............................................................................................................ 1-59
1.9 Diagram of coolant system ............................................................................................................ 1-60
1.10 Allocation of ducts in the crankcase and in the cylinder head ....................................................... 1-62
1.11 Tools .............................................................................................................................................. 1-63
1.11.1 Special tools .................................................................................................................... 1-63

Fastening the engine onto the engine assembly stand ............................................. 1-63
Fastening of lifting eyes on the crankcase ................................................................ 1-66
Turning gears ............................................................................................................ 1-67
Angle of rotation devices ........................................................................................... 1-70
Torx tools................................................................................................................... 1-71
Installing and dismantling the aggregate carrier........................................................ 1-72
Installing and dismantling the cylinder liner ............................................................... 1-73
Checking excess length of the cylinder liners ........................................................... 1-73
Installing and dismantling crankshaft accessories .................................................... 1-74
Installing and dismantling the front crankshaft seal................................................... 1-74
Installing and dismantling the crankshaft .................................................................. 1-74
Checking combustion pressure ................................................................................. 1-74
Installing and dismantling the piston with connecting rod and piston rings ............... 1-75
Installing and dismantling the piston rings................................................................. 1-75

Installing and dismantling the cylinder head.............................................................. 1-75
Installing and dismantling valve stem seals, valve springs and valves ..................... 1-75
Installing and dismantling the counterbalancing shafts ............................................. 1-77
Installing and dismantling the oil cooler housing with oil cooler ................................ 1-77
Installing and dismantling the injection lines ............................................................. 1-77
Installing and dismantling the pressure pipe tube and injection nozzle..................... 1-78
Installing and dismantling the injection pump and roller tappet ................................. 1-78
1 - 12 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the exhaust pipes............................................................. 1-79

Installing and dismantling the flywheel ...................................................................... 1-79
Installing and dismantling the rear crankshaft seal ................................................... 1-79
1.11.2 Commercially-approved tools.......................................................................................... 1-80
D 934 A6 !! ! 1 - 13
D 936 A6 Mjfcifss
General information Workshop Manual
Structure of this manual
1.1 Structure of this manual
The job specifications within this manual have been compiled around the following:
1 Chapter title
2 Tasks already carried out, with details regarding
the name of the chapter
3 General diagram displaying where the respecti-
ve subassemblies are located on the diesel en-
gine, as well as all components which make up
the respective subassemblies
4 Legend to the overview diagram with notes on
operation, notes on safety, special tools, tighte-
ning torques, lubricants, etc.
5 Table of special tools
6 Table of commercially-approved tools
7 Table of lubricants
8 Table of tightening specifications
9 Table featuring technical data
10 Detailed job specifications featuring text and di-
agrams
The job specifications are presented in two different variants:
1. Brief job specification (A)
Comprises the aforementioned elements (1) to (4) and, if required by the respective operational procedure, also ele-
ments (5) to (9).
This type can be readily identified as the legend (4) features a „Notes on operation“ column in the table (magnification
A).
The operational procedure is described in the overview diagram. If necessary, notes on operation are given. Different
symbols are featured to differentiate between notes on installation and removal, as well as dismantling and assem-
bly.
An explanation of these symbols can be obtained over the following pages.
2. Detailed job specification (A)
Also comprises the aforementioned elements (1) to (4) and, if required by the respective operational procedure, also
elements (5) to (9), as well as element (10) with text and pictures.
This type can be readily identified as the legend (4) does not feature a „Notes on operation“ column in the table (ma-
gnification B).
Please read the complete job specifications through to the end of the chapter in order that all necessary information
is acquired.
Various symbols are used in the diagrams and in the text within this manual.
An explanation of these symbols can be obtained over the following pages.
1 - 14 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual General information
Structure of this manual
140398
D 934 A6 !! ! 1 - 15
D 936 A6 Mjfcifss
Important notes within this manual
1.2 Important notes within this manual
Important notes within this manual are highlighted with borders and symbols.
There are three different kinds of notes:
Danger!
2 Warning against dangers which can be harmful to persons if no respective precautionary measures are
taken.
Caution!
3 Warning against dangers which could cause damage to property or be harmful to the environment if no
respective precautionary measures are taken.
4
Note!
Additional information and user tips.
1 - 16 !! ! D 934 A6
Mjfcifss D 936 A6
Symbols in this manual
1.3 Symbols in this manual
Symbol Explanation Symbol Explanation
Remove, disassemble Seal, fasten, grease

a
b t
Dismantle Special tool
Assemble Special tightening torque or tightening

c 0 specification
d
Install, mount
D 934 A6 !! ! 1 - 17
D 936 A6 Mjfcifss
Notes on safety
1.4 Notes on safety
Working on the diesel engine can be hazardous to mechanics and workshop personnel.
Dangerous predicaments and accidents can be avoided if the notes on safety are read and observed carefully.
The notes on safety featured in the workshop manual are highlighted by bordered boxes and are indicated via sym-
bols.
The notes on safety are presented in two different variants:
Danger!
2 Warning against dangers which can be harmful to persons if no respective precautionary measures are
taken.
Caution!
3 Warning against dangers which can lead to damage to property or can be harmful to the environment if no
respective precautionary measures are taken.
Adherence to these notes on safety does not relieve you of the responsibility of observing the additional
rules and regulations!
The accident-prevention guidelines and all generally recognised safety-technical and occupational-medicinal regu-
lations are to be observed before commencing any maintenance and repair tasks on Liebherr diesel engines.
Special notes on safety for the diesel engine are listed as follows. These notes must be strictly adhered to if the safety
of yourself and others is to be guaranteed, as well as preventing damage to the diesel engine.
The notes on safety in this chapter are structured in accordance with the subject. In the job specifications, the ne-
cessary notes on safety are repeated wherever there are scenarios of possible danger.
1.4.1 General notes on safety
• Repairs to the diesel engine may only be carried out by authorised, specialist personnel.
Observe the legal, permissible minimum age!
• Employ trained, or instructed personnel only, ensure that all personnel are fully aware of their responsibilities.
• Ensure that personnel are familiar with the workshop manual before commencing any repair tasks. It is of utmost 01. Kapitel_Allg_Information.fm
importance that the entire job specifications are read through to the end of each respective chapter, as only then
can all necessary information be acquired.
• Personnel which are undergoing training, instruction or are currently involved in a general apprenticeship, may
only be allowed to work on the diesel engine under constant supervision of an experienced person.
• Ensure at regular intervals that the personnel are conscientious of safety and dangers while carrying out their
duties, and are observing the accident-prevention guidelines, the generally recognised safety-technical and
occupational-medicinal regulations and the workshop manual.
• Ensure that personnel wear safe working clothes.

The wearing of rings, wrist watches, ties, scarves, open jackets, loose fitting clothes, etc. is not permitted. There
is risk of injury, for example, getting caught up in or dragged into machinery.
1 - 18 !! ! D 934 A6
Mjfcifss D 936 A6
Notes on safety
• Prerequisite for a reliable repair is a complete basic tool in sound condition, as well as any necessary devices
and special tools.
• Cleanliness and order contribute toward safety in the workplace.
• Ensure that all preparations have been made for any accidents which may occur.
Ensure that fire extinguisher and first-aid kit are on-hand.
Ensure that the phone numbers for emergency situations are on-hand.
• Ensure that the workplace has sufficient lighting.
• Repair tasks may only be carried out while the diesel engine is switched off.
Ensure that the diesel engine can not be inadvertently started by unauthorised personnel.
1.4.2 Modifications to the diesel engine
• The manufacturer does not bear responsibility for any material damage or injury to persons which occurs as a
result of unauthorised modifications to the diesel engine.
This applies in particular for manipulations of the injection and regulation systems, as this will influence the out-
put and exhaust characteristics of the diesel engine. Maintenance of the legal environmental regulations can no
longer be guaranteed if modifications are carried out arbitrarily by the customer.
1.4.3 Preventing injury to persons
Crushing
• Do not try to lift heavy parts.
Fasten and secure individual components and larger subassemblies carefully to lifting gear when carrying out
replacements.
• Remaining and working beneath suspended loads is prohibited.
• Do not use any damaged load-carrying equipment, or load-carrying equipment which does not feature the
required lifting capacity.
• Ensure that no objects come into contact with rotating parts while the diesel engine is running.
The objects could come hurtling back out again.
Burns and scalding

• The diesel engine is hot when running at operating temperature. Avoid direct contact with hot engine parts.
• When the diesel engine is at operating temperature the cooling system is hot and is highly pressurised.
Avoid any contact with parts carrying cooling water.
• Only check the level of the cooling water if the sealing cap of the expansion tank has cooled sufficiently that it
can be touched.
Open the cap carefully to relieve any excess pressure.
• The engine oil is hot when the diesel engine is at operating temperature.
Avoid skin contact with hot oil or parts carrying oil.
D 934 A6 !! ! 1 - 19
D 936 A6 Mjfcifss
Notes on safety
Fires and explosions

• Do not smoke and avoid fires, sparks and naked flames when handling fuels and flammable liquids.
• Only start up the diesel engine in accordance with the guidelines prescribed in the operating and maintenance
instructions.
• Remedy leaks and replace damaged components immediately.

Oil spraying out of points which are not properly sealed is highly flammable.
• Wear protective glasses and industrial gloves when working on the batteries.
Avoid sparks and naked flames and do not smoke.
• Do not keep any oil-soaked cleaning rags stored anywhere. These may ignite of their own accord.
Toxication
• Only allow the diesel engine to run in enclosed areas if sufficient ventilation has been provided.
If necessary, open doors and windows to ensure a sufficient supply of fresh air.
• When draining fuels, never use receptacles originally intended for food or drink as somebody may inadvertently
drink the liquid.
• Do open any pressurised lines or hoses.

Do not remove any pressurised lines or hoses.
Escaping liquids can penetrate the skin and cause blood poisoning.
• When searching for leakages in pressurised lines and hoses, protect the hands, face and body from escaping
liquids.
1.4.4 Preventing damage to property
• Sealing components (e.g. O-rings, seals, etc.) should essentially be replaced.
• Dismantled parts should be checked for reusability, and replaced as required.
• If no specific torques and tightening specifications are prescribed, screw connections should be tightened to the
standard torques, which can be obtained in the chapter "Technical Data".
• Special torques, tightening specifications and mounting instructions can be obtained in the chapter "Technical
Data" and in the respective job specifications.
• Clean the diesel engine thoroughly of oil, fuel or preservative agents, and in particular, connections and threa-
ded unions, before commencing repair tasks. Do not use any aggressive cleaning agents. Use fibre-free clea-
ning rags. Do not use any flammable liquids for cleaning the diesel engine.
• For reasons of safety and/or functionality, cover or seal all openings which may be penetrated by water, steam
or cleaning agents before cleaning the diesel engine with water, steam jet (high-pressure cleaner) or other clea-
ning agents.
Crankcase vents, engine control unit, starter and generator are at particular risk.
After cleaning: remove all covers and seals completely following the cleaning work.
Inspect all fuel lines, diesel engine oil lines and hydraulic oil lines for leaks, loose connections, points of wear
and damage upon completion of cleaning.
Determined faults must be remedied immediately.
1 - 20 !! ! D 934 A6
Mjfcifss D 936 A6
Notes on safety
• Only start up the diesel engine with the batteries securely connected.
• Do not disconnect batteries while the diesel engine is running.
• The diesel engine may only ever be started with the control unit connected.
• Do not use a fast charger to start the diesel engines. Only use jump leads with separate batteries.
• The battery terminals must be removed for fast charging of the batteries.
Observe the operating instructions of the fast charger.
• Disconnect the batteries while working on the electrical system.
• When carrying out electrical welding work, the batteries must be disconnected and both cables (+ and -) tied
securely with each other. Connection to the control unit can be cut via both interface plugs.
• The interface plugs of the engine control unit may only be removed with the batteries disconnected or removed.
• Incorrect polarity of the control units voltage or supply voltage (e.g. via incorrect polarity of the batteries) can
lead to ruination of the control units.
• Tighten the connections to the injection system with the prescribed tightening torque.
• If temperatures exceeding 80 °C (e.g. drying kiln) are expected, the control units must be removed.
• Only use suitable test leads for measurements at the plug connections.
• Sensors or actuators may not be connected individually, or between external voltage sources for test purposes
or inspection purposes, but rather only in connection with the engine control unit, otherwise there is a serious
risk of ruination, or possibly a ruination of the diesel engine.
• The engine control unit is only sufficiently protected against dust and water with the mating connector mounted
and connected. If the mating connectors are not connected, the engine control unit must be sufficiently protected
against dust and water.
• Telephones and radio equipment which are not connected to an exterior aerial could lead to functional failure of
the vehicle's electronics, and thus jeopardise operational safety of the diesel engine.
Preventing harm to the environment

• Ensure a safe and environmentally-friendly disposal of fuels, lubricants and auxiliary agents, as well as "old"
parts.
• When handling fuels, ensure that these fuels do not mix into the earth, sewer systems or bodies of water. Use
sealed containers for draining fuels and lubricants. Under no circumstances should receptacles originally inten-
ded for food or drink be used as somebody may inadvertently drink the liquid.
• Different fuels are to be collected and disposed of in separate receptacles.

• Before disposing of, or recycling waste materials, make enquiries at your local environmental centre or recycling
centre as to the correct methods for such procedures. Incorrect disposal of waste products can harm the envi-
ronment and the ecology.
D 934 A6 !! ! 1 - 21
D 936 A6 Mjfcifss
Technical Data
1.5 Technical Data
1.5.1 Engine in general
Engine type description
D 93 4 S A6 Engine type description

D Engine type: D = Diesel engine
93 Bore: 122 mm
4 Number of cylinders:
4 = 4 cylinders / 6 = 6 cylinders
S Stroke:
S = short, 136 mm / L = long, 150 mm
A6 Injection system:
A6 = pump-line-nozzle
Engine company nameplate
The engine company nameplate is mounted on the right-hand

side of the crankcase, as viewed looking at the flywheel. A se-
cond company nameplate is mounted on the air induction pi-
pe.
140001
Engine serial-number
The engine serial-number is stamped on the engine company
nameplate and in the crankcase.
2004 03 0001 Engine serial-number
2004 Year of manufacture
03 Number of cylinders:
03 = 4 cylinders / 04 = 6 cylinders
0001 Progressional manufacturing number
1 - 22 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
The engine serial-number is stamped on the engine company

nameplate in the field
„Engine Number“.
140002
The engine serial-number is stamped on the crankcase joint

face to the cylinder heads.
140003
Firing sequence, cylinder classification, rotational direc-

tion and TDC mark
The firing sequence and the cylinder numbers are cast on the
side of the crankcase.
140005
Cylinder 1 is located on the same side as the flywheel.
The rotational direction is to the left, as viewed when looking

at the flywheel.
1-4 Cylinder numbers D 934

1-6 Cylinder numbers D 936
A Exhaust valve
E Intake valve
140006
D 934 A6 !! ! 1 - 23
D 936 A6 Mjfcifss
Technical Data
The TDC mark is located in the flywheel housing.
The notch in the flywheel must be aligned (arrows) with the pin
or the notch in the flywheel housing.
140127
Crankcase number
The crankcase number is stamped in the crankcase joint face

to the oil sump (flywheel side).
001 C 1 Crankcase number
C Code letter for the year of manufacture
1 Bearing cap number of the main bearing
cap:
1 to 5 for the D 934 / 1 to 7 for the D 936
Affiliation of the crankcase and main bearing cap can be iden-

140004
tified via the crankcase number.
Connecting rod number (cracked connecting rod)
The connecting rod number is stamped on the connecting rod

and on the connecting rod bearing cap.
00001 C Connecting rod number
Connecting rod and connecting rod bearing cap can be iden-
tified as a match via the connecting rod number.
140009
Turbocharger company nameplate
The turbocharger company nameplate is mounted on the tur-

bocharger.
140010
1 - 24 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
Injection nozzle numbers
The injection nozzle numbers are featured on the injection

nozzle in the area indicated with the arrow.
140031
Injection pumps company nameplate
The injection pumps company nameplate is mounted on the

solenoid valve body for the injection pump.
140008
Engine control unit company nameplate
The engine control unit company nameplate is mounted on

the engine control unit.
140007
Piston number
The piston number and the indicators for the crankshaft (to in-
dicate the installation position) are located in the area on the

piston crown indicated with the arrow.
140237
D 934 A6 !! ! 1 - 25
D 936 A6 Mjfcifss
Technical Data
Thermostat beginning of opening
Beginning of opening for the thermostat is engraved in the

area indicated with the arrow.
140379
1 - 26 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
1.5.2 Standard tightening torques for screw connections
For screws which comply with DIN EN ISO 4762 (previously DIN 912), DIN EN 24014 (previously DIN 931), DIN EN
24017 (previously DIN 933), DIN EN 28765 (previously DIN 960) and DIN EN 28676 (previously DIN 961).
Permissible tolerance ±10%.
Surface finish: screw Mn or Zn phosphated, unlubricated or oiled μoverall = 0.14
Standard Nm Nm Nm Metric fine Nm Nm Nm

metric thread
thread
8.8 10.9 12.9 8.8 10.9 12.9
M6 10 15 18 M8x1 27 39 46
M8 25 36 43 M10x1.25 52 76 90
M10 49 72 84 M12x1.25 93 135 160
M12 85 125 145 M12x1.5 89 130 155
M14 135 200 235 M14x1.5 145 215 255
M16 210 310 365 M16x1.5 225 330 390
M18 300 430 500 M18x1.5 340 485 570
M20 425 610 710 M20x1.5 475 680 790
M22 580 820 960 M22x1.5 630 900 1050
M24 730 1050 1220 M24x2 800 1150 1350
Surface finish: screw zinc plated, unlubricated or oiled μoverall = 0.125
Standard Nm Nm Nm Metric fine Nm Nm Nm

metric thread
thread
8.8 10.9 12.9 8.8 10.9 12.9
M6 9,6 14 16 M8x1 25 37 43
M8 23 34 40 M10x1.25 49 71 83
M10 46 67 79 M12x1.25 87 130 150
M12 79 115 135 M12x1.5 83 120 145
M14 125 185 220 M14x1.5 135 200 235
M16 195 290 340 M16x1.5 210 310 360

M18 280 400 470 M18x1.5 315 450 530
M20 395 560 660 M20x1.5 440 630 730
M22 540 760 890 M22x1.5 590 840 980
M24 680 970 1150 M24x2 740 1050 1250
D 934 A6 !! ! 1 - 27
D 936 A6 Mjfcifss
Technical Data
1.5.3 Standard torques for locking screws and banjo bolts
For locking screws which comply with DIN 908 and DIN 910, banjo bolts which comply with DIN 7643, and sealing
rings which comply with DIN 7603.
Thread Nm Thread Nm
M6x1 7 M 33 x 2 120
M 8 x 1.5 7,5 M 36 x 1,5 155
M 10 x 1 10,4 M 36 x 2 155
M 12 x 1.5 20 M 38 x 1.5 171
M 14 x 1.5 27 M 39 x 2 215
M 16 x 1.5 37 M 42 x 1.5 240
M 18 x 1.5 40 M 42 x 2 240
M 20 x 1.5 47 M 45 x 1.5 270
M 22 x 1.5 57 M 45 x 2 270
M 24 x 1.5 68 M 48 x 1.5 300
M 26 x 1.5 75 M 48 x 2 300
M 27 x 2 87 M 52 x 1.5 380
M 30 x 1.5 115 M 52 x 2 380
M 30 x 2 115 M 56 x 2 430
M 60 x 2 510
M 64 x 2 570
M 65 x 2 620
1 - 28 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
1.5.4 Special torques, tightening specifications and

installation specifications
General notes
If screws need to be oiled, apply a coating of engine oil to the

screw thread and on the screw head.
Should a thread-locking adhesive be required, first clean, de-

grease and dry the respective screw thread and threaded bo-
re.
Particular notes regarding degreasing of the component con-

tact surfaces are indicated for certain tightening specificati-
ons, as this concerns connections with force transmission for
the respective screw connections.
Tightening specification main bearing
Hexagon head screw M18x2x170-10.9

Lubricant Engine oil
Thread-locking adhesive -
Stage Torque in Nm
1. 30
2. 110
Stage Angle of rotation in °
3. 45
140064
4. 45
5. 45
Overall 135 ± 5
Tightening specifications for piston cooling nozzle
Banjo bolt M12x1.5

Lubricant -
Stage Torque in Nm
1. 30
140065
D 934 A6 !! ! 1 - 29
D 936 A6 Mjfcifss
Technical Data
Tightening specification for final regulating valve
Sealing nut M12

Lubricant -
Stage Torque in Nm
1. 50
140325
Tightening specification oil drain valve
Oil drain valve M30x1.5

Lubricant -
Thread-locking adhesive Omnivisc 1050
Stage Torque in Nm
1. 110
140075
1 - 30 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
Tightening specification crankshafts accessories
Hexagon socket head screw M16x1.5x-10.9

Component contact sur- Degreased
faces
Stage Torque in Nm
1. 20
2. 80
140047
3. 30
4. 30
Overall 60 ± 5
Caution!
3 Torx anti-fatigue bolts may not be used more than
once.
Torx anti-fatigue bolt M16x1.5x-10.9

faces
Stage Torque in Nm
1. 30 140375
2. 90
3. 90
4. 90
Overall 180 ± 5
D 934 A6 !! ! 1 - 31
D 936 A6 Mjfcifss
Technical Data
Tightening specification connecting rod
Caution!
3 Hexagon head anti-fatigue bolts may not be used
more than once.
Hexagon head anti-fatigue bolt M14x1.5x65-10.9

Stage Torque in Nm
1. 30 140066
2. 110
3. 45
4. 45
Overall 90 ± 5
Tightening specification cylinder head
Caution!
more than once.
A Air induction pipe side

B Exhaust pipe side
Hexagon head anti-fatigue bolt M16x2x195-10.9

Stage Torque in Nm
1. 30
2. 120
3. 200
4. 45
5. 90
6. 90
Overall 225 ± 5
140057
1 - 32 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
Installation and tightening specification counterbalancing shafts (D 934)
140072
• t Insert pin (1) [9078118] (2x) through flange (4) into the counterbalancing shafts (3) and t insert pin (2)
[9078119] through main bearing cap (7) into the crankshaft (8).
• Degrease the contact surfaces of counterbalancing shafts (3) and gear wheels (5).
• Affix gear wheels (5), apply a coating of Loctite 243 to hexagon head screws M14x50-8.8 (6) and tighten with the
respective tightening specification.
• Remove pins (1) and (2), apply a coating of Loctite 648 to the hexagon socket head screws M8x10-8.8 (9) and
tighten with the respective tightening specification.
t Special tool
140073 140074
D 934 A6 !! ! 1 - 33
D 936 A6 Mjfcifss
Technical Data
Hexagon head screw M14x50-8.8

Lubricant -
Thread-locking adhesive Loctite 243
faces
Stage Torque in Nm
1. 130
Hexagon socket head screw M8x10-8.8

Lubricant -
Stage Torque in Nm
1. 20
Tightening specification for camshaft sprocket on aggre-

gate carrier and flywheel side

faces
Stage Torque in Nm
1. 20
2. 50 140047
3. 40
Overall 40 ± 5
Tightening specification fitting in oil filter bracket
Fitting M30x2
Lubricant -
Stage Torque in Nm
1. 60 ± 15
140067
1 - 34 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
Tightening specification injection pump

Lubricant -
Stage Torque in Nm
1. 60
140082
Tightening specification cable harness on injection pump
Hexagon head screw M3x9.1

Lubricant -
Stage Torque in Nm
1. 1.5 ± 0.2
140234
D 934 A6 !! ! 1 - 35
D 936 A6 Mjfcifss
Technical Data
Installation and tightening specification injection nozzle

and pressure pipe tube
• Mount new O-ring (5) to injection nozzle (4) and apply

coating of oil to O-ring (5).
Note!
4 Use a new sealing washer in compliance with the

spare-parts catalogue, see spare-parts catalogue
group „Injection nozzle“.
• Install the injection nozzle (4) with new sealing washer

(9). 140059
• Fit lug (1) and spherical washer (2), apply a coating of oil
to hexagon socket head screw M10x65 (3) and tighten,
see tightening specification, stage 1.
Caution!
3 The pressure pipe tubes must be replaced once
dismantled.
• Grease the new O-ring (7) of the pressure pipe tube (6).
• Install the pressure pipe tube (6) so that the ball in the
pressure pipe tube and the recess in the cylinder head
align (arrow).
3
Caution!
The cap nuts must be replaced once removed.
• Tighten new cap nut M22x1.5 (8), see tightening specifi-

cation, stage 1.
• Tighten hexagon socket head screw M10x65 (3), see tigh-

tening specification, stage 2.
• Tighten cap nut M22x1.5 (8), see tightening specification, 01. Kapitel_Allg_Information.fm
stage 2.
1 - 36 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
Hexagon socket head screw M10x65

Stage Torque in Nm
1. (A) 5
2. (C) 50
Cap nuts M22x1.5

Lubricant -
140135
Stage Torque in Nm
1. (B) 5
2. (D) 50
Tightening specification for nozzle retaining nut
Caution!
The nozzle retaining nut may only be tightened
3 when the definitive tightening torque is applied, if
the nozzle body has been depressed with a force
of 0.45 kN. Use the respective special tool.
Nozzle retaining nut

Lubricant -
140301
Stage Torque in Nm
1. 40 - 50
D 934 A6 !! ! 1 - 37
D 936 A6 Mjfcifss
Technical Data
Installation and tightening specification injection line
Danger!
Injection lines must be replaced after each third
2 time of removal.
Each time they are removed: mark the injection li-
nes on the cap nut (arrow).
Danger!
Injection lines can become plastically deformed
when removed, and as a result, burst when rein-
2 stalled.
When removing: first unscrew the cap nut from the 140060
pump side in order that the injection line can turn
freely when the cap nut on the nozzle side is un-
screwed.
Cap nut without engraving = nozzle side.

Cap nut with engraving „P“ = pump side.
Cap nut nozzle side and pump side M14x1.5

Lubricant -
Stage Torque in Nm
1. 25 to 30
1 - 38 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
Tightening specification for sensoric
140070
Pos. Description Notes on operation

1 Coolant temperature sensor M14x1.5.............. 20 +0 /-5 Nm.
2 Charge air temperature sensor M14x1.5 ......... 25 +0 /-5 Nm.
(sometimes mounted directly on the equipment)

3 Charge air pressure sensor M12x1.5 or
M18x1.5 ........................................................... 40 +0 /-5 Nm.
4 Fuel temperature sensor M14x1.5 ................... 20 +0 /-5 Nm.
5 Oil pressure sensor M14x1.5 ........................... 40 +0 /-5 Nm.
6 Speed sensor (camshaft sprocket) .................. See installation and tightening specification.
7 Speed sensor 1 (flywheel) ............................... Hexagon socket head screw, 10 Nm.
(installed in the upper flywheel housing)

8 Speed sensor 2 (flywheel)................................ Hexagon socket head screw, 10 Nm.
(installed in the left-hand or right-hand side of
the flywheel housing)
D 934 A6 !! ! 1 - 39
D 936 A6 Mjfcifss
Technical Data
Installation and tightening specification speed sensor

(camshaft sprocket)
Note!
Measuring of the clearance must only be carried
out if the flywheel housing has been dismantled.
4 When replacing the speed sensor:

If a distance plate (6) is featured, install the speed
sensor (4) again with distance plate (6).
If no distance plate (6) is featured, install the speed
sensor (4) again without distance plate (6).
• Measure the clearance (X) between the machined sur-

faces on the flywheel housing (1) and gear wheel cams-
haft (2).
If clearance (X) is < 35.35 mm, install distance plate (6).

If clearance (X) is ≥ 35.35 mm, do not install distance plate (6).
• Install speed sensor (4) with new O-ring (3).
• If necessary, install a distance plate (6).
Note!
4 Should a distance plate (6) be required, see spare-

parts catalogue category „Engine regulation sen- 140071
soric“.
• Tighten hexagon socket head screw (5), 10 Nm.
Tightening specification heater flange
Hexagon ribbed nut M6

Lubricant -
Stage Torque in Nm
1. 11
140077
1 - 40 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
Tightening specification idler

Lubricant -
Stage Torque in Nm
1. 83
Axial clearance (A) = 0.1 - 0.3 mm.
140083
Tightening specification air compressor gear
Hexagonal nut M20x1.5

faces
Stage Torque in Nm
1. 200+50
140076
Tightening specification for coolant pump connector
Connector
Lubricant -
Stage Torque in Nm
1. 8±1
140376
D 934 A6 !! ! 1 - 41
D 936 A6 Mjfcifss
Technical Data
Tightening specification turbocharger and flange on tur-

bocharger
Double hexagon head screw M8x25

Lubricant -
Stage Torque in Nm
1. 10
2. 23
Double hexagon head screw M10x25 140235
Lubricant -
Stage Torque in Nm
1. 10
2. 46
Hexagonal nut M8
Lubricant -
Stage Torque in Nm
1. 10
2. 23
Hexagonal nut M10

Lubricant -
Thread-locking adhesive - 140236
Stage Torque in Nm
1. 10
2. 46
1 - 42 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
Tightening specification generator belt pulley

Lubricant -
Stage Torque in Nm
1. 35+10

Lubricant -
140068
Stage Torque in Nm
1. 70
Hexagonal collar nut M16x1.5

Lubricant -
Stage Torque in Nm
1. 80 ± 5
Tightening specification flywheel housing
Hexagon socket head screw M12-10.9

Lubricant -
Stage Torque in Nm
1. 45
2. 110
140069
D 934 A6 !! ! 1 - 43
D 936 A6 Mjfcifss
Technical Data
Tightening specification flywheel
Caution!
3 Where necessary, existing hexagon socket head

screws or hexagon socket head anti-fatigue bolts
should be replaced with Torx anti-fatigue bolts.
Caution!
once.
Torx anti-fatigue bolt M16x1.5x72-10.9 or

Torx anti-fatigue bolt M16x1.5x88-10.9
140377
faces
Stage Torque in Nm
1. 30
2. 90
3. 90
4. 90
Overall 180 ± 5
Caution!
3 Where necessary, hexagon socket head anti-fa-

tigue bolts should be replaced with Torx anti-fa-
tigue bolts.
Caution!
once.

140377
faces
Stage Torque in Nm
1. 30
2. 90
3. 90
4. 90
5. 90
Overall 270 ± 5
1 - 44 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
Tightening specification torsional vibration damper

Stage Torque in Nm
1. 45
2. 117
140061
Tightening specification for engine control unit plug
Hexagon socket head screw M5

Lubricant -
Stage Torque in Nm
1. 2.8 -0.0 / +0.3
140378
Tightening specification control unit-mount
Hexagon head screw M8-8.8

Lubricant -
Stage Torque in Nm
1. 10
140062
D 934 A6 !! ! 1 - 45
D 936 A6 Mjfcifss
Technical Data
Tightening specification power take-off
Thrust ring M40x1.5

Lubricant -
Stage Torque in Nm
1. 30
2. 240
Thrust ring M52x1.5

140063
Lubricant -
Stage Torque in Nm
1. 30
2. 300
1 - 46 !! ! D 934 A6
Mjfcifss D 936 A6
Technical Data
1.5.5 Cleaning agents, thread-locking adhesives and greases
This list includes all thread-locking adhesives and greases required for repair and maintenance tasks on the engine.
The application is described in the respective job specifications.
Note!
4 Should a thread-locking adhesive be required, first clean, degrease and dry the respective screw thread
and threaded bore.
Cleaning agents and thread-locking adhesives
Designation Ident. no. Amount Designation

Omniclean 10007113 500 ml or Loctite 7063
Omnivisc 1050 8627609 090 g or Loctite 601, Reinzoplast, Hylomar SQ 32 / M
Loctite 222 8629969 250 ml or Omnifit 50 M
Loctite 243 8628192 250 ml
Loctite 577 8622905 250 ml
Loctite 638 8627590 250 ml
Greases
Designation Ident. no. Amount

Molykote Longterm 2 Plus 8100714 1.00 kg
Staburags NBU 12 8655030 1.00 kg
Staburags NBU 30 10285708 1.20 kg
Copper paste; Motorex 14 10002552 0.85 kg
D 934 A6 !! ! 1 - 47
D 936 A6 Mjfcifss
Representations of the engine and engine components
1.6 Representations of the engine and engine components
1.6.1 View of the engine (aggregate carrier side and turbocharger side)
140032
1 Heater flange (flange-mounted on the air induc- 11 Oil cooler
tion pipe)
2 Air induction pipe 12 Crankcase
3 Connecting line 13 Oil sump
4 Cylinder head with cylinder head cover 14 Aggregate carrier
5 Charge air manifold 15 Crankshaft accessories
6 Intake manifold 16 Coolant pump
7 Starter 17 Final regulating valve
8 Adapter
9 Exhaust turbocharger
10 Exhaust pipe
1 - 48 !! ! D 934 A6
Mjfcifss D 936 A6
140034
1 Front lifting lug

2 Oil filter
3 Heater flange (installed in the air induction pipe)
4 Air compressor
5 Rear engine mount

6 Engine brake flap
7 Thermostat housing
8 Coolant pre-heating
9 Front engine mount
10 Fan
D 934 A6 !! ! 1 - 49
D 936 A6 Mjfcifss
1.6.2 View of the engine (flywheel side and injection system side)
140033
1 Rear lifting lug 11 Fuel prefilter

2 Crankcase breather 12 Fuel delivery pump
3 Engine control unit, engine control unit mount 13 Power take-off 3
(on air induction pipe and cable harness retai-
ner), cable harness, sensoric
4 Air-conditioning compressor 14 Flywheel housing
5 Generator 15 Flywheel
6 Power take-off 4 16 Power take-off for fuel delivery pump
7 Fuel lines, oil leakage pipe 17 Power take-off 1
8 Oil intake 18 Power take-off 2
9 Fuel fine filter (on the crankcase)

10 Oil dipstick
1 - 50 !! ! D 934 A6
Mjfcifss D 936 A6
140035
1 Fuel multiplier
2 Fuel fine filter (on the air induction pipe)
3 Switchable power take-off on the flywheel hou-
sing
4 Power take-off on the flywheel housing

5 Engine control unit, engine control unit-mount
(on the flywheel housing), cable harness, sen-
soric
6 Engine control unit, engine control unit-mount
(on the air induction pipe), cable harness, sen-
soric
D 934 A6 !! ! 1 - 51
D 936 A6 Mjfcifss
1.6.3 Engine cross-section
140038
1 Piston
2 Cylinder liner
3 Piston cooling nozzle
4 Oil pump
5 Oil suction pipe LMB/00C/Issued: 06.12.2006/en
1 - 52 !! ! D 934 A6
Mjfcifss D 936 A6
1.6.4 Crankshaft drive
140036
1 Intake valves
2 Valve spring
3 Valve fitting
4 Exhaust valves
5 Valve fitting
6 Valve spring
7 Connecting rod, connecting rod bearing
8 Mass compensation
9 Crankshaft, crankshaft bearing, crankshaft
sealing
D 934 A6 !! ! 1 - 53
D 936 A6 Mjfcifss
140037
1 Roller tappet for valve train

2 Push rod
3 Rocker arm
4 Rocker arm bearing support
5 Injection nozzle
6 Pressure pipe tube
7 Injection line
8 Injection pump
9 Roller tappet for injection pump
10 Cam shaft
1 - 54 !! ! D 934 A6
Mjfcifss D 936 A6
1.6.5 Gear train (D 934)
140039
A Aggregate carrier side B Flywheel side

1 Gear wheel - power take-off 4 4 Gear wheel - power take-off 3
2 Gear wheel - cam shaft 5 Gear wheel - fuel delivery pump
3 Gear wheel - coolant pump 6 Gear wheel - power take-off 1

7 Gear wheel - cam shaft
8 Idler
9 Gear wheel - power take-off 2 or air compressor
10 Gear wheel - crankshaft
11 Idler
12 Gear wheel - oil pump
13 Gear wheel - balance shaft left

14 Idler
15 Gear wheel - balance shaft right
D 934 A6 !! ! 1 - 55
D 936 A6 Mjfcifss
1.6.6 Gear train (D 936)
140040

1 Gear wheel - power take-off 4 4 Gear wheel - power take-off 3
2 Gear wheel - cam shaft 5 Gear wheel - fuel delivery pump
3 Gear wheel - coolant pump 6 Gear wheel - power take-off 1
7 Gear wheel - cam shaft
8 Idler
9 Gear wheel - power take-off 2 or air compressor
10 Gear wheel - crankshaft
11 Idler
12 Gear wheel - oil pump
13 Idler
14 Gear wheel - oil suction pump
1 - 56 !! ! D 934 A6
Mjfcifss D 936 A6
Diagram of the fuel system
1.7 Diagram of the fuel system
Engines featuring fuel fine filter on the crankcase
140041
A Suction pressure 1 Fuel tank (equipment-side)

B Low pressure 2 Engine control unit cooler

C High pressure 3 Fuel prefilter
D Bypass 4 Fuel delivery pump
(for cooling and lubrication of the injection
pumps)
E Leakage and return flow 5 Fuel fine filter
6 Injection pump
8 Injection nozzle
9 Pressure regulating valve
10 Bypass throttle
11 Fuel cooler (equipment-side)
D 934 A6 !! ! 1 - 57
D 936 A6 Mjfcifss
Diagram of the fuel system
Engines featuring fuel fine filter on the air induction pipe
140042
A Suction pressure 1 Fuel tank (equipment-side)

B Low pressure 2 Engine control unit cooler
C High pressure 3 Fuel prefilter
D Bypass 4 Fuel delivery pump
(for cooling and lubrication of the injection
pumps)
E Continuous ventilation, leakage and return flow 5 Fuel fine filter
6 Fuel multiplier
7 Injection pump
9 Injection nozzle
10 Pressure regulating valve

11 Bypass throttle
12 Fuel cooler (equipment-side)
13 Throttle
1 - 58 !! ! D 934 A6
Mjfcifss D 936 A6
Diagram of lube oil system
1.8 Diagram of lube oil system
140043
1 Oil filter 18 Lubrication idler

2 Final regulating valve 19 Connection M14X1.5
3 Lubrication cam shaft thrust bearing 20 Lubrication oil suction pump (D 936)
4 Cam shaft journal bearing 21 Crankshaft thrust bearing
5 Roller tappet for valve train 22 Crankshaft journal bearing and connecting rod
bearing
6 Lubrication rocker arm bearing in the cylinder 23 Piston cooling nozzle
head
7 Oil pressure sensor 24 Lubrication exhaust turbocharger
8 Roller tappet for injection pump 25 Oil pump
9 Connection M14X1.5 26 Suction hose

10 Connection M14X1.5 27 Oil cooler housing
11 Power take-off for fuel delivery pump 28 Bypass valve-oil cooler
12 Power take-off 3 29 Oil cooler
13 Power take-off 1 30 Coolant pump
14 Connection M14X1.5
17 Power take-off 2 or air compressor
D 934 A6 !! ! 1 - 59
D 936 A6 Mjfcifss
Diagram of coolant system
1.9 Diagram of coolant system
140044
1 Coolant pump
3 Cylinder liner
4 Hose connection - expansion tank supply
6 Vent line cylinder head
7 Cylinder head
8 Coolant collector rail
9 Coolant distributor rail
10 Oil cooler
11 Hose connection - return flow heater
12 Coolant drainage
13 Hose connection - supply heater
1 - 60 !! ! D 934 A6
Mjfcifss D 936 A6
Diagram of coolant system
140045
1 Coolant pump
3 Cylinder liner
6 Vent line cylinder head

7 Cylinder head
8 Coolant collector rail
9 Coolant distributor rail
10 Oil cooler
11 Hose connection - return flow heater
12 Coolant drainage
13 Hose connection - supply heater

14 Coolant cooler (equipment-side)
D 934 A6 !! ! 1 - 61
D 936 A6 Mjfcifss
Allocation of ducts in the crankcase and in the cylinder head
1.10 Allocation of ducts in the crankcase and in the cylinder head
140058
A Air induction pipe side 1 Push rod

B Exhaust pipe side 2 Oil supply (pressure oil)
3 Cylinder head bolt
4 Combustion chamber
5 Coolant return flow
6 Cylinder head bolt with insertion sleeve
7 Coolant supply 1
8 Oil return flow
9 Coolant supply 2
1 - 62 !! ! D 934 A6
Mjfcifss D 936 A6
Tools
1.11 Tools
1.11.1 Special tools
Fastening the engine onto the engine assembly stand
The engine assembly stand features ID no. 0540938.
Danger!
2 Engine and crankcase are heavy!
Use suitable lifting gear.
t Special tool
140343 140344 140345 140346 140347 140348
D936
Fastening on the sides of the crankcase and flywheel hou-
sing.
1 Crankcase bracket
1.1 t Bracket [9079908] (1x right)
1.2 t Bracket [9079908] (1x left)
2 Flywheel housing bracket

2.2 t Bracket [10117630] (1x left)
140349
D 934 A6 !! ! 1 - 63
D 936 A6 Mjfcifss
Tools
D936
Fastening on the sides and underneath the crankcase; the oil
sump has been dismantled.
1 Crankcase bracket
1.2 t Bracket [9079908] (1x left)
3 Crankcase bracket (oil sump joint face)

3.2 t Bracket [10117629] (1x left)
140350
D934
Fastening on the sides of the crankcase and flywheel hou-
sing.
1 Crankcase bracket
1.2 t Bracket [9079908] (1x left)
2 Flywheel housing bracket
2.2 t Bracket [10117629] (1x left)
4 Intermediate bracket
4.1 t Bracket [10119640] (1x right, 1x left)
140351
1 - 64 !! ! D 934 A6
Mjfcifss D 936 A6
Tools
D934
Fastening on the sides and underneath the crankcase; the oil
sump has been dismantled.
1 Crankcase bracket
1.2 t Bracket [9079908] (1x left)
3 Crankcase bracket (oil sump joint face)

3.2 t Bracket [10117629] (1x left)
4 Intermediate bracket
140352
D 934 A6 !! ! 1 - 65
D 936 A6 Mjfcifss
Tools
Fastening of lifting eyes on the crankcase
Danger!
2 Engine and crankcase are heavy!
t Special tool
140353 140354
1 t Lifting eyes [9076633] (1x aggregate carrier side)

2 t Bracket [9076634] (1x flywheel side)
140355
1 - 66 !! ! D 934 A6
Mjfcifss D 936 A6
Tools
Turning gears
t Special tool
140051 140356 140357 140358
Turning gear on the flywheel housing

Turning gear can not be mounted to SAE 2-flywheel housings
(arrow).
180001
The turning gear can not be adapted via subsequent adjust-

ment (arrow).
180002
D 934 A6 !! ! 1 - 67
D 936 A6 Mjfcifss
Tools
Subsequent adjustment on the special tool

Turning gear [0524045]
Previously
180003
Now
180004
Turning gear on crankshaft pulley - V-belt (included in de-

livery for some engine variants)
Can only be mounted subsequently if the respective
crankshaft pulley is featured.
140360
1 - 68 !! ! D 934 A6
Mjfcifss D 936 A6
Tools
Turning gear on air compressor

Can only be mounted if the respective air compressor is fea-
tured.
140361
Turning gear on threaded connection for vibration dam-

per
Can only be used if the vibration damper is connected with he-
xagon socket head screws.
or
If the engine has been dismantled and hexagon socket head
screws M16x1.5 are being used.
140362
D 934 A6 !! ! 1 - 69
D 936 A6 Mjfcifss
Tools
Angle of rotation devices
t Special tool
140126 140411
Angle of rotation device 0524062 features a 1/2“ drive.

Angle of rotation device 10023839 features a 3/4“ drive.
1 - 70 !! ! D 934 A6
Mjfcifss D 936 A6
Tools
Torx tools
t Special tool
140364 140365 140366 140367 140368
t Special tool
140399 140400 140401 140402 140403 140404
t Special tool
140405 140406 140407 140408
Torx toolkit [7014716] includes:

Designation Size Drive Designation Size Drive
Socket E8 1/4“ Socket E 18 1/2“
Socket E10 1/4“ Double-ended ring spanner E6 - E8 -
Socket E10 3/8“ Double-ended ring spanner E10 - E12 -

Socket E12 3/8“
The Torx sockets are available in the following sizes:

Ident. no. Size Drive Ident. no. Size Drive
7019851 E14 1/2“ 10119716 E18 3/4“
7011668 E18 1/2“ 10119717 E20 3/4“

7019852 E20 1/2“ 10119718 E24 3/4“
10354009 E24 1/2“ 8008601 TX30 1/2“
10119713 E18 3/4“ 10014369 TX40 1/2“
10119714 E20 3/4“ 10014368 TX45 1/2“
10119715 E24 3/4“ 8041994 TX50 1/2“
D 934 A6 !! ! 1 - 71
D 936 A6 Mjfcifss
Tools
Installing and dismantling the aggregate carrier

.
t Special tool
140238
Installing and dismantling the final regulating valve
t Special tool
140324

Stamp [0523639]
Previously
140371 01. Kapitel_Allg_Information.fm
Now
A = 27 +0.0 / -0.2 mm (as previously)

A = 90 mm
140372
1 - 72 !! ! D 934 A6
Mjfcifss D 936 A6
Tools
Installing and dismantling the cylinder liner
t Special tool
140227 140228 140217
Notes regarding the special tools
Use the threaded rod (3.1), hexagonal nut (3.2) and the ex-
traction plate (3.4) from t extractor [0526855] and the bridge
(3.3) of the extractor [0528462] featuring a dimension of
A=170 mm for removal of the cylinder liners.
Fit the extraction plate (3.4) onto the threaded rod (3.1) so that
the side featuring a diameter of B = 119,9 mm is facing toward
the bridge (3.3).
140229
Checking excess length of the cylinder liners
t Special tool
140217 140230
D 934 A6 !! ! 1 - 73
D 936 A6 Mjfcifss
Tools
Installing and dismantling crankshaft accessories
t Special tool
140048
Installing and dismantling the front crankshaft seal

.
t Special tool
140147 140148
Installing and dismantling the crankshaft
t Special tool
140126 140411 140074
Checking combustion pressure
.
t Special tool
140162 140163 140164 140165

1 - 74 !! ! D 934 A6
Mjfcifss D 936 A6
Tools
Installing and dismantling the piston with connecting rod and piston rings
t Special tool
140051 140217 140218 140126 140411
Installing and dismantling the piston rings
t Special tool
140220
Installing and dismantling the cylinder head
t Special tool
140126 140411
Installing and dismantling valve stem seals, valve springs and valves
t Special tool
140330 140369 140339 140331

D 934 A6 !! ! 1 - 75
D 936 A6 Mjfcifss
Tools

Cylinder head stand 0524048
The lever features an extra borehole:
A = 111,5 mm
(B) = 26.5 mm
C = 12.5 mm (diameter)
D = 6.0 mm
140340
File down the edge of the lever slightly:

E = 3.0 mm
140341
Note!
When using the reworked t cylinder head stand
[0524048], all four valve springs must be changed
over once for actuation.
The injection nozzle must be dismantled.
4
When using the t cylinder head stand [10354008]
all four valve springs can be actuated in one set-
ting.
The injection nozzle can be dismantled or in-
stalled.
140370
1 - 76 !! ! D 934 A6
Mjfcifss D 936 A6
Tools
Note!
When using t mounting plate [964128608], all
four valve springs can be pressed down at the
4 same time.
This is also possible with cylinder head and injec-
tion nozzle installed. Set the respective cylinder to
TDC to support the valves on the piston.
140332
Installing and dismantling the counterbalancing shafts
t Special tool
140073 140074
Installing and dismantling the oil cooler housing with oil

cooler
.
t Special tool
140246
Installing and dismantling the injection lines
t Special tool
140128
D 934 A6 !! ! 1 - 77
D 936 A6 Mjfcifss
Tools
Installing and dismantling the pressure pipe tube and injection nozzle
.
t Special tool
140081 140085 140080
Checking, dismantling and reassembling the injection nozzle (step-type holder)
t Special tool
140302 140303 140304 140314 140321 140342
140318 140319 140317
Note!
Repair of the step-type holder may only be carried out in association with the nozzle tester, ID no.
4 10340104 and a suction device, ID no. 10337931. The suction is necessary to ensure that none of the oil
mist is allowed to escape into the ambient air.
The nozzle tester, ID no. 7361236 is no longer appropriate for the checking and setting of all nozzle hol-
ders, as regards measuring accuracy, extent of damage and quality of the pressure gauge.
Installing and dismantling the injection pump and roller tappet
t Special tool
140081 140080 140097 140098
1 - 78 !! ! D 934 A6
Mjfcifss D 936 A6
Tools
Installing and dismantling the exhaust pipes

.
t Special tool
140238
Installing and dismantling the flywheel

.
t Special tool
140048
Installing and dismantling the rear crankshaft seal

.
t Special tool
140147 140156
D 934 A6 !! ! 1 - 79
D 936 A6 Mjfcifss
Tools
1.11.2 Commercially-approved tools
Commercially-approved tools
Description
Interior extractor
for the following dimensions:

A = Ø 17 mm
B = 100 mm
140373
Description Manufacturer
Ultrasonic cleaning machine e.g. from the company Bandelin electronic
GmbH&Co.KG
Heinrichstrasse 3-4
D-12207 Berlin
Tel: +49 / 30 / 768 80 - 0
Tel: +49 / 30 / 773 46 99 -
Type: Sonorex Super RK 102 H
(including insert basket and cover)
140374
Cleaning agent e.g. from the company Chemische Fabrik Dr. Weigert
GmbH&Co.KG
Mühlenhagen 85
D-20539 Hamburg
Tel: +49 / 40 / 789 60 - 0
Tel: +49 / 40 / 789 60 - 120
Type: Neodischer LM10
1 - 80 !! ! D 934 A6
Mjfcifss D 936 A6
2 Cylinder head, engine control and valves
2 Cylinder head, engine control and valves .......................................................................................... 2-81
2.1 Installing and dismantling the rocker arm support and push rods ................................................. 2-82
2.2 Installing and dismantling the valve fitting (for engines with and without ZBS) ............................. 2-83
2.3 Installing and dismantling the cylinder head .................................................................................. 2-84
2.4 Installing and dismantling valve stem seals, valve springs and valves ......................................... 2-86
2.4.1 Removing ........................................................................................................................ 2-88

2.4.2 Installation ....................................................................................................................... 2-88
2.5 Installing and dismantling the roller tappet (valve control)............................................................. 2-90
2.6 Dismantling and installing the camshafts ...................................................................................... 2-91
2.6.1 Removing ........................................................................................................................ 2-92

2.6.2 Installation ....................................................................................................................... 2-93
02. Kapitel_Zk_Motorst_Ventile.fm
D 934 A6 !! ! 2 - 81
D 936 A6 Mjfcifss
Cylinder head, engine control and valves Workshop Manual
Installing and dismantling the rocker arm support and push rods
2.1 Installing and dismantling the rocker arm support and push rods
Prerequisite tasks:
Cylinder head cover has been removed.
The crankshaft has been turned to allow the respective
valve to be relieved of pressure.
140170

1 Hexagon socket head screw M10x80-10.9
2 Rocker arm support bearing............................. d Following installation set the valve clearance,
see operating instructions.
3 Push rod
2 - 82 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual Cylinder head, engine control and valves
Installing and dismantling the valve fitting (for engines with and without ZBS)
2.2 Installing and dismantling the valve fitting (for engines with and without ZBS)
Prerequisite tasks:
The rocker arm support has been removed.
140171

A Engines without ZBS
1 Valve fitting....................................................... d The side which has been milled (arrows) must
sit on the valve on the push rod side.
B Engines with ZBS
2 Retainer
3 Exhaust valve fitting ......................................... d The side which has been milled (arrows) must
4 Intake valve fitting ............................................ d The side which has been milled (arrows) must
D 934 A6 !! ! 2 - 83
D 936 A6 Mjfcifss
2.3 Installing and dismantling the cylinder head
Prerequisite tasks:
The coolant vent line has been removed. The fuel oil leakage pipe has been removed.
The exhaust pipe has been removed. The injection line has been removed.
The air induction pipe has been removed. The valve fitting has been removed.
140125

1 Replace the cylinder head bolt M16x2x195- d Apply a coating of oil, 0 see tightening specifi-
10.9, ................................................................. cation.
2 Cylinder head ................................................... a Do not lay the cylinder head on the joint face as
the injection nozzle protrudes.
Clean the joint face thoroughly and check level-
ness using a hairline gauge.
d Ensure that the cylinder head is sitting correctly
on the insertion sleeves (4).
3 Cylinder head gasket........................................ d Replace. Ensure that the cylinder head seal is
sitting correctly on the insertion sleeves (4).
2 - 84 !! ! D 934 A6
Mjfcifss D 936 A6

4 Insertion sleeve
5 Crankcase ........................................................ d Clean the joint face and the threaded bores tho-
roughly. Check excess length of the cylinder li-
ner.
t Special tool
140126 140411
0 Tightening specification for cylinder head
(A) = Air induction pipe side

(B) = Exhaust pipe side
Hexagon head anti-fatigue bolt M16x2x195-10.9

Stage Torque in Nm
1. 30
2. 120
3. 200
4. 45
5. 90
6. 90
Overall 225 ± 5
140057
D 934 A6 !! ! 2 - 85
D 936 A6 Mjfcifss
2.4 Installing and dismantling valve stem seals, valve springs and valves
Prerequisite tasks:
The injection nozzle has been removed.
The cylinder head has been removed.
140329
Pos. Description
1 Valve collet
2 Upper valve head
3 Valve spring
4 Lower valve head
5 Valve stem seal

6 Exhaust valve
7 Intake valve
Note!
4 There are different variants for which:
- the lower valve head is not featured.
2 - 86 !! ! D 934 A6
Mjfcifss D 936 A6
t Special tool
140330 140369 140339 140331

Cylinder head stand 0524048
The lever features an extra borehole:
A = 111,5 mm
(B) = 26.5 mm
C = 12.5 mm (diameter)
D = 6.0 mm
140340
File down the edge of the lever slightly:

E = 3.0 mm
140341
Note!
When using the reworked t cylinder head stand
[0524048], all four valve springs must be changed
over once for actuation.

The injection nozzle must be dismantled.
4 When using the t cylinder head stand [10354008]
all four valve springs can be actuated in one set-
ting.
The injection nozzle can be dismantled or in-
stalled.
140370
D 934 A6 !! ! 2 - 87
D 936 A6 Mjfcifss
Note!
When using t mounting plate [964128608], all
four valve springs can be pressed down at the
4 same time.
This is also possible with cylinder head and injec-
tion nozzle installed. Set the respective cylinder to
TDC to support the valves on the piston.
140332
2.4.1 Removing
• t Fit the valve slave [0524048] (8) on the valve head and
push down the valve spring.
• Remove both valve collets (1).
• t Relieve pressure from the valve slave [0524048] (8)

and remove.
140333
• Remove the upper valve head (2) and valve spring (3).
• Remove the valve stem seal (5).
• If necessary, remove the lower valve head.
140334
• Turn the cylinder head to the side and pull the intake
valve (7) or the exhaust valve (6) from the valve guide.
2.4.2 Installation
• Apply a coating of oil to the valve guide and push in the

intake valve (7) or exhaust valve (6).
140335
2 - 88 !! ! D 934 A6
Mjfcifss D 936 A6
• Carefully place the cylinder head onto the sealing face.
• If necessary, insert the lower valve head.
• t Plug the sleeve [10023909] (9) onto the valve shaft.
• Push on the new valve stem seal (5) so that it is sitting

correctly on the valve guide (arrow).
• t Remove the sleeve [10023909] (9).
140336
• Insert the valve spring (3) and upper valve head (2).
140337
• t Fit the valve slave [0524048] (8) on the valve head and
push down the valve spring.
Caution!
3 Ensure that the valve collets are sitting correctly in
the grooves of the valve.
• Insert both valve collets (1) so that they are sitting cor-
rectly in the grooves of the valve (arrow).
• t Relieve pressure from the valve slave [0524048] (8)

and remove.
140338
D 934 A6 !! ! 2 - 89
D 936 A6 Mjfcifss
Installing and dismantling the roller tappet (valve control)
2.5 Installing and dismantling the roller tappet (valve control)
Prerequisite tasks:
The cylinder head has been removed.
If necessary, the fuel fine filter has been unscrewed.
If necessary, the power take-off for the fuel delivery
pump has been removed.
140172

1 Roller tappet ..................................................... d Align so that the groove is aligned with the bo-
rehole in the crankcase (arrows).
Following installation: check freedom-of-move-
ment and rotary lock.

2 Hexagon socket locking screw M10x20 -8.8. ..
d Replace.
2 - 90 !! ! D 934 A6
Mjfcifss D 936 A6
Dismantling and installing the camshafts
2.6 Dismantling and installing the camshafts
Prerequisite tasks:
Cylinder 1 is set at OT. The multi-part oil sump and ladder frame (D 936) have
Injection pump and roller tappet have been removed. been removed where necessary.
The aggregate carrier has been removed.
The roller tappet (valve control) has been removed.
The flywheel housing has been removed.
The single-unit oil sump has been removed.
140290
Pos. Description Pos. Description

1 Hexagon socket head screw M14x45-10.9 8 Hexagon socket head screw M14x45-10.9
2 Camshaft gear wheel, aggregate carrier side 9 Camshaft gear wheel, flywheel side
3 Thrust ring 10 Straight pin
5 Flange
6 O-ring 7.00x1.50
7 Cam shaft
D 934 A6 !! ! 2 - 91
D 936 A6 Mjfcifss
0 Tightening specification for camshaft gear wheel,

aggregate carrier and flywheel side
faces
Stage Torque in Nm
1. 20
2. 50
Stage Angle of rotation in ° 140047
3. 40
Overall 40 ± 5
2.6.1 Removing
• Unscrew the hexagon socket head screws (8) and take

out the camshaft gear wheel (9).
• Remove the straight pin (10).
140292
• Unscrew the hexagon socket head screws (1) and take

out the camshaft gear wheel (2).
• Remove the thrust washer (3).
140294
2 - 92 !! ! D 934 A6
Mjfcifss D 936 A6
• Unscrew the hexagon socket head screws (4) and

remove the flange (5).
• Remove the thrust washer (3).
• Remove the O-ring (6) from the flange (5).
140295
• Remove the camshaft (7).
• Check the camshaft and the camshaft bearing.
2.6.2 Installation
• Apply a coating of oil to the camshaft (7) at the bearing

points.
• Carefully insert the camshaft (7).
140296
• Apply a light coating of oil to the new O-ring (6) and insert
so that it fits correctly into the groove of the flange (5).
• Apply a light coating of grease to the thrust washer (3)

and fit.
• Mount the flange (5) so that the lube oil bore aligns with
the lube oil bore in the crankcase (arrows).
• Tighten the hexagon socket head screws (4).
140298
• Apply a light coating of grease to the thrust washer (3)

and fit.
• Remove grease from the contact face camshaft gear

wheel to camshaft.
• Remove grease from the contact face camshaft to cams-

haft gear wheel.
• Mount the camshaft gear wheel (2), apply a light coating

of oil to the hexagon socket head screws (1) and tighten,
0 see tightening specification.
140294
D 934 A6 !! ! 2 - 93
D 936 A6 Mjfcifss
• Insert the straight pin (10).
• Remove grease from the contact face camshaft gear

wheel to camshaft.
• Remove grease from the contact face camshaft to cams-

haft gear wheel.
• Fit the camshaft gear wheel (9) so that the borehole aligns
with the straight pin (arrows A) and the marking (1 point)
corresponds with the marking (2 points) on the crankshaft
gear wheel (arrow B).
• Apply a light coating of oil to the hexagon socket head

screw (8) and tighten, 0 see tightening specification.
• Turn the crankshaft around another full turn and check for
freedom-of-movement.
• Check axial clearance of the crankshaft.
140299
2 - 94 !! ! D 934 A6
Mjfcifss D 936 A6
3 Engine
3 Engine .................................................................................................................................................... 3-95
3.1 Checking combustion pressure ..................................................................................................... 3-97
3.2 Installing and dismantling the piston with connecting rod and piston rings ................................. 3-100
3.2.1 Summary ....................................................................................................................... 3-100

3.2.2 A: Installing and dismantling the piston with connecting rod from the engine ............... 3-101
Removing ................................................................................................................ 3-102
Installation ............................................................................................................... 3-105
3.2.3 B: installing and dismantling the piston rings ................................................................ 3-107
Removing ................................................................................................................ 3-108
Installation ............................................................................................................... 3-108
3.2.4 C: installing and dismantling the piston ......................................................................... 3-109
3.3 Installing and dismantling the cylinder liner ................................................................................. 3-110
3.4 Checking excess length of the cylinder liners.............................................................................. 3-112
3.5 Installing and dismantling the generator mount ........................................................................... 3-113
3.6 Installing and dismantling the air-conditioning compressor and generator mount....................... 3-115
3.7 Installing and dismantling crankshaft accessories....................................................................... 3-117
3.8 Installing and dismantling the front crankshaft seal ..................................................................... 3-119
3.8.1 General notes................................................................................................................ 3-120

3.8.2 Removing ...................................................................................................................... 3-120
3.8.3 Installation ..................................................................................................................... 3-121
3.9 Installing and dismantling the aggregate carrier .......................................................................... 3-125
3.10 Installing and dismantling the flywheel ........................................................................................ 3-127
3.10.1 Removing ...................................................................................................................... 3-130

03. Kapitel_Triebwerk.fm
3.10.2 Installation ..................................................................................................................... 3-130
3.11 Installing and dismantling the rear crankshaft seal...................................................................... 3-133
3.11.1 General notes................................................................................................................ 3-134

3.11.2 Removing ...................................................................................................................... 3-134
3.11.3 Installation ..................................................................................................................... 3-135
3.12 Dismantling and installing the flywheel housing .......................................................................... 3-138
3.13 Dismantling and installing the idler .............................................................................................. 3-140
3.14 Installing and dismantling the crankshaft..................................................................................... 3-142
3.14.1 Removing ...................................................................................................................... 3-145

3.14.2 Installation ..................................................................................................................... 3-148
3.15 Installing and dismantling the crankshaft gear wheel .................................................................. 3-151
D 934 A6 !! ! 3 - 95
D 936 A6 Mjfcifss
3 - 96 !! ! D 934 A6
Mjfcifss D 936 A6
3.1 Checking combustion pressure
Prerequisite tasks:
Valves have been set, see operating instructions. The injection nozzles have been removed.
The engine has been run up to approx. 80 °C coolant If necessary, the engine brake flap has been opened
temperature. completely.
.
140161

1 Sealing washer 4 Spherical washer
2 t Adapter [10297211] 5 Hexagon socket head screws M10x65
t Lug [10117612] t Combustion pressure test equipment
3 6
[8008782]
t Special tool
140162 140163 140164 140165
D 934 A6 !! ! 3 - 97
D 936 A6 Mjfcifss
Engine Workshop Manual
Technical Data
Set value in bar Set value in bar

(D 934 S / D 936 S) (D 934 L / D 936 L)
Combustion pressu- 20 - 30 22-34

re
Permissible deviati- max. 4 max. 4

on between the indi-
vidual cylinders
• t Install the adapter (2) [10297211] with sealing washer

(1).
• t Fit the lug (3) [10117612] and spherical washer (4),

tighten the hexagon socket head screw (5) with 50 Nm.
• t Connect the combustion pressure test equipment (6)

[8008782] to the t adapter (2) [10297211].
Note!
4 See the operating instructions of the combustion

pressure test equipment for details regarding its
operation.
Caution!
Fuel may run out of the injection pumps.
2 Set the injection pumps to zero delivery via the
„Cylinder shutdown“ function in the „DCDesk
2000“ diagnosis program.
Note!
The „Cylinder shutdown“ function is included in the
engine control unit software upwards of version
40.2, if necessary, update the engine control unit
4 software.
140244 03. Kapitel_Triebwerk.fm
The „Cylinder shut-off“ function is included in the
„DCDesk 2000“ diagnosis program, upwards of
version 4.23, if necessary, update the diagnosis
program.
• Activate the „Cylinder shut-off“ function for all cylinders via

menu level „Solenoid valve“ in the „DCDesk 2000“ diag-

nosis program.
This will set all injection pumps to zero delivery.
• Allow the engine to run until the pointer of the combustion

pressure test equipment no longer moves.
3 - 98 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual Engine
Caution!
As soon as the ignition is switched off, the „Cylin-
2 der shut-off“ function is deactivated again.
Ensure that the ignition is not switched off or the
„Cylinder shut-off“ function is not reactivated.
• If necessary, after testing each cylinder, activate the

„Cylinder shut-off“ function for all cylinders again.
This will set all injection pumps to zero delivery.
• Check all cylinders of the engine one after the other.
• Refer to the page featuring the diagram and compare the

measured value with the set values, see technical data.
• t Remove the combustion pressure test equipment

[8008782] from the t adapter [10297211].
• t Remove the adapter [10297211].
• Remove the sealing washer.
4
Note!
Install injection nozzle with new sealing washer.
D 934 A6 !! ! 3 - 99
D 936 A6 Mjfcifss
3.2 Installing and dismantling the piston with connecting rod and piston rings
Prerequisite tasks:
The cylinder head has been removed. If necessary, the ladder frame has been removed.
The multi-part oil sump has been removed. If necessary, the piston cooling nozzle has been remo-
ved.
If necessary, the single-unit oil sump has been remo-
ved.
3.2.1 Summary
140231
Pos. Description
A Piston with connecting rod, connecting rod bea-
ring, connecting rod bearing cap
B Piston rings
C Piston, gudgeon pin, connecting rod
3 - 100 !! ! D 934 A6
Mjfcifss D 936 A6
3.2.2 A: Installing and dismantling the piston with connecting rod from the engine
140201
Pos. Description
1 Piston with connecting rod
1.1 Piston
1.2 Connecting rod
2 Upper bearing shell

3 Lower bearing shell
4 Connecting rod bearing cap
5 Hexagon head anti-fatigue bolt
6 Cylinder liner
t Special tool
140051 140217 140218 140126 140411
D 934 A6 !! ! 3 - 101
D 936 A6 Mjfcifss
0 Tightening specification for connecting rod

Caution!
more than once.
Hexagon head anti-fatigue bolt M14x1.5x65-10.9

Stage Torque in Nm
1. 30
2. 110 140066

3. 45
4. 45
Overall 90 ± 5
Removing
• t Tighten the holding fixture (7) [0528464].
140202
• t Install the engine turning gear (8) [0524045].
140203
3 - 102 !! ! D 934 A6
Mjfcifss D 936 A6
• Turn the crankshaft so that the piston is positioned just

before the TDC and the upper area of the cylinder liner (6)
can be cleaned.
• Remove any combustion residue.
140204
• Turn the crankshaft so that the hexagon head anti-fatigue

bolts (5) are accessible.
• Unscrew the hexagon head anti-fatigue bolts (5).
140205
Caution!
The connecting rod and connecting rod bearing
cap are manufactured by cracking (break separa-
tion).
3 Connecting rod and connecting rod bearing cap

may only be fitted as the pair intended when origi-
nally manufactured.
The connecting rod (1.2) and connecting rod bea-
ring cap (5) are indicated as a pair by the connec-
ting rod number.
140206
Note!
4 Piston with connecting rod and bearing shells must

be reinstalled in the original engine cylinder if ever

reused.
• Mark the piston with connecting rod and bearing shells in

accordance with their cylinder number or remove and
store in accordance with their cylinder number.
D 934 A6 !! ! 3 - 103
D 936 A6 Mjfcifss
Caution!
The joint faces of the connecting rod and connec-
ting rod bearing cap may not sustain any damage.
3 Wire brushes or other tools should never be used
to clean these surfaces.
Do not set down the connecting rod and connec-
ting rod bearing cap on the cracked surface.
• Remove the connecting rod bearing cap (4) and lower

bearing shell (3) and store in accordance with its respec-
tive cylinder number.
140207
Caution!
The upper bearing shell is still in the connecting
3 rod.
Ensure that this does not become damaged when
it is removed.
• Push the piston with connecting rod (1) out of the cylinder
liner from below (6) and store in accordance with the
cylinder number.
140208
• Remove the upper bearing shell (2) from the connecting

rod (1.2) and store in accordance with its respective cylin-
der number. 03. Kapitel_Triebwerk.fm
140209
3 - 104 !! ! D 934 A6
Mjfcifss D 936 A6
Installation
• Clean and apply a coating of oil to the running surface of

the cylinder liner (6).
140210
• Turn the piston rings (9, 10 and 11) in the piston (1.1) so
that the piston ring gaps are shifted around approx. 120°
(arrows).
• Apply tension to the piston rings (9, 10 and 11) using the
t piston ring tightener (12) [8000592].
140211
• Insert the upper bearing shell (2), in compliance with the

identification mark, into the connecting rod (1.2) so that
the lug of the bearing shell fits into the groove of the con-
necting rod (arrows A).
• Check that the oil hole in the upper bearing shell (2) is ali-
gned with the oil hole of the connecting rod (1.2) (arrows
B).
• Apply a coating of oil to the running surface of the upper

bearing shell (2).
140212
Caution!
3 The upper bearing shell is in the connecting rod.


it is installed.
• Align the piston with connecting rod (1) so that the mar-
king on the piston crown (arrow) is pointing to the fly-
wheel.
• Push the piston with connecting rod (1) carefully into the
cylinder liner (6) until the connecting rod bearing is resting
on the crankpin of the crankshaft.
140213
D 934 A6 !! ! 3 - 105
D 936 A6 Mjfcifss
• Insert the lower bearing shell (3), in compliance with the

identification mark, into the connecting rod bearing cap (4)
so that the lug of the bearing shell fits into the groove of
the connecting rod bearing cap (arrows).
• Apply a coating of oil to the running surface of the lower

bearing shell (3).
140214
Caution!
The lower bearing shell is in the connecting rod be-
3 aring cap.
it is installed.
Caution!
The fitting surface of the connecting rod bearing
3 cap and connecting rod is sitting correctly if the

edges are flush (arrows).
A connecting rod which has been cross-threaded
may not be used again.
140215
• Fit the connecting rod bearing cap (4), in compliance with

the identification mark, carefully onto the connecting rod.
Caution!
more than once.
Caution!
The oil hole in the connecting rod can close as a
result of the upper and lower bearing shells tur-
3 ning.
Do not turn the crankshaft until the connecting rod
bearing cap has been tightened to the tightening

specifications.
140216
• Apply a coating of oil to the new hexagon head anti-
fatigue bolt (5) and tighten, 0 see tightening specifica-
tion.
• Turn the crankshaft around another full turn and check the
connecting rod for freedom-of-movement.
• Remove the t engine turning gear [0524045].
• Remove the t holding fixture [0528464].
3 - 106 !! ! D 934 A6
Mjfcifss D 936 A6
3.2.3 B: installing and dismantling the piston rings
140219
Pos. Description
1 Piston
2 KB-piston ring (full keystone ring)
3 M-piston ring (tapered compression ring)
4 DSF-piston ring (
spring-loaded bevelled-edge oil control ring)
t Special tool
140220
D 934 A6 !! ! 3 - 107
D 936 A6 Mjfcifss
Removing
Note!
4 Piston rings must be fitted into their original ring
nut if ever reused.
• Mark the piston rings (2, 3 and 4) or store in accordance

with their affiliation.
Caution!
3 Piston rings could sustain damage when being re-
moved. 140221
• Remove the piston rings (2, 3 and 4) carefully using t

piston ring pliers (6) [7009319].
• Clean the piston ring grooves.
Installation
Checking the ring gap of used piston rings:

• Insert the piston rings (2, 3 and 4) one after another into a
cleaned cylinder liner (5) and check the ring gap using a
feeler gauge.
Permissible ring gap in mm
KB-ring (2) 0.35 + 0.25
M-ring (3) 0.80 + 0.20

140222
DSF-ring (4) 0.30 + 0.30
Caution!
3 Piston rings could sustain damage when being in-
stalled.
• Align the piston rings (2, 3 and 4), if necessary in compli-

ance with their identification markings, so that the descrip-
tion „TOP“ is pointing to the piston crown.
• Fit the piston rings (2, 3 and 4) carefully using t piston

ring pliers (6) [7009319] into the respective ring nut.
140223
3 - 108 !! ! D 934 A6
Mjfcifss D 936 A6
3.2.4 C: installing and dismantling the piston
140

1 Piston ............................................................... a Mark the piston with the connecting rod (4).
d Fit the piston onto the connecting rod (4) in
compliance with the identification markings.
2 Gudgeon pin..................................................... d Apply a coating of oil to the gudgeon pin.

3 Circlip .............................................................. d Ensure that the circlip is sitting correctly in the
groove of the piston (arrow).
4 Connecting rod................................................. a Mark the connecting rod with the piston (1).
d Apply a coating of oil to the small end bush.
D 934 A6 !! ! 3 - 109
D 936 A6 Mjfcifss
3.3 Installing and dismantling the cylinder liner
Prerequisite tasks:
The piston with connecting rod has been removed. The piston cooling nozzle has been removed.
140226
1 Cylinder liner .................................................... a 4 Note!
The cylinder liners must be installed in their ori-
ginal cylinder if they are to be reused, and may
only be mounted in an upright position.
Mark the installation point and installation posi-
tion.
t Extractor [0526855] and t extractor
[0528462], see notes regarding the special
tools.
To protect against damage, insert wooden tim-
bers between crankcase-separating face and
extraction device.
Check the upper (3) and lower (4) seating of the
cylinder liners in the crankcase for damage.
3 - 110 !! ! D 934 A6
Mjfcifss D 936 A6

d Insert the cylinder liners in compliance with the
identification mark and push into the crankcase
as far as the stop.
Check excess length of the cylinder liner.
4 Note!
If a repair task is interrupted following complete
installation of the cylinder liners, the cylinder li-
ners must be fixed securely in their position
using the t holding fixture [0528464].
2 O-ring ............................................................... d Replace the O-ring, apply a coating of grea-
se [STABURAGS NBU 30]. Ensure that the O-
ring is sitting correctly in the groove in the crank-
case (arrows).
t Special tool
140227 140228 140217
Notes regarding the special tools
Use the threaded rod (3.1), hexagonal nut (3.2) and the ex-
traction plate (3.4) from t extractor [0526855] and the bridge
(3.3) of the extractor [0528462] featuring a dimension of
A=170 mm for removal of the cylinder liners.
Fit the extraction plate (3.4) onto the threaded rod (3.1) so that
the side featuring a diameter of B = 119,9 mm is facing toward
the bridge (3.3).
140229
D 934 A6 !! ! 3 - 111
D 936 A6 Mjfcifss
Checking excess length of the cylinder liners
3.4 Checking excess length of the cylinder liners
140129

1 Insertion sleeve ................................................ Remove the insertion sleeve and fit the t hol-
ding fixture (6) [0528464] (2x) so that the cylin-
der liner is pushed downwards and tighten the
hexagon socket head screw (6.1) with 30 Nm.
2 Crankcase
3 Cylinder liner .................................................... Check the excess length with a dial gauge (4)
and t dial gauge holder (5) [10023885].
Set value for excess length of the cylinder liner
to the joint face of the crankcase: (A) =
0.07 +0.03 / -0.02 mm.
t Special tool
140217 140230
3 - 112 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the generator mount
3.5 Installing and dismantling the generator mount
Prerequisite tasks:
The generator has been removed.
If necessary, the V-belt deflection pulley has been re-
moved.
If necessary, the V-belt tensioning device has been re-
moved.
Generator mount on the injection system side

140142

1 Generator bracket
2 Hexagon collar bolt M10x80-8.8

D 934 A6 !! ! 3 - 113
D 936 A6 Mjfcifss
Installing and dismantling the generator mount
Generator mount on the turbocharger side
140143

1 Generator bracket
3 - 114 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the air-conditioning compressor and generator mount
3.6 Installing and dismantling the air-conditioning compressor and generator mount
Prerequisite tasks:
The air-conditioning compressor has been removed.

If necessary, the V-belt deflection pulley has been re-
moved.
Air-conditioning compressor and generator mount (1-piece)

140144

1 Air-conditioning compressor and generator bra-
cket
D 934 A6 !! ! 3 - 115
D 936 A6 Mjfcifss
Installing and dismantling the air-conditioning compressor and generator mount
Air-conditioning compressor and generator mount (2-piece)
140145

1 Generator bracket
3 Air-conditioning compressor bracket
3 - 116 !! ! D 934 A6
Mjfcifss D 936 A6
3.7 Installing and dismantling crankshaft accessories

.
Prerequisite tasks:
V-belt has been removed, see operating instructions.
140046

1 Fastening screws ............................................. a Unscrew hexagon socket head screws
(hexagon socket head screws M16x1.5-10.9 M16x1.5x60-10.9,t screw in mounting bolts
or [0528470].
Torx anti-fatigue bolt M16x1.5x-10.9)
d Apply a coating of oil to the fastening screws
and tighten, 0 see tightening specification.
2 Belt pulley d Remove grease on the contact surface to vibra-

tion damper.
3 Vibration damper.............................................. ad Swing the tensioning device for the ribbed V-
belt to the side.
d Remove grease from contact surface to V-belt
and crankshaft.
4 Crankshaft........................................................ d Remove grease on the contact surface to vibra-
tion damper.
D 934 A6 !! ! 3 - 117
D 936 A6 Mjfcifss
Note!
There are various mounting possibilities, for which:
- the belt pulley may be different,
4 - the diameter of the vibration damper may be different,

- no vibration damper is featured and an adapter is employed,
- different fastening screws are used.
The crankshaft accessories can be installed and dismantled accordingly for different mounting possibili-
ties.
t Special tool
140048
0 Tightening specification crankshaft accessories

Hexagon socket head screw M16x1.5x-10.9
faces
Stage Torque in Nm
1. 20
2. 80
140047
3. 30
4. 30
Overall 60 ± 5
Caution!
once. 03. Kapitel_Triebwerk.fm
Torx anti-fatigue bolt M16x1.5x-10.9


faces
Stage Torque in Nm
1. 30 140375
2. 90
3. 90
4. 90
Overall 180 ± 5
3 - 118 !! ! D 934 A6
Mjfcifss D 936 A6
3.8 Installing and dismantling the front crankshaft seal
Prerequisite tasks:
The crankshaft accessories have been removed.
140146
Pos. Description
1 Fastening screw M8x20-8.8
2 Guard ring
3 Rotary shaft seal 110x130x12.0
t Special tool
140147 140148
D 934 A6 !! ! 3 - 119
D 936 A6 Mjfcifss
3.8.1 General notes
The rotary shaft seal used here is a PTFE-sealing washer (po-

lytetrafluorethylene, commonly known as „Teflon“). These are
different from the elastomer sealing washers previously used,
whereby the considerably wider, flat sealing lip, is no longer
pretensioned by a spiral-type expander.
The sealing lip is extremely sensitive.

The slightest of damage will lead to leakages.
140393
3.8.2 Removing
• Unscrew the fastening screws (1) and take out the guard
ring (2).
140149
Caution!
3 Do not damage the running surface of the

crankshaft and the borehole in the aggregate car-
rier.
• Cut back the dust lip and the sealing lip of the rotary shaft
seal (3) until the reinforcing ring is exposed (arrow).
• t Hook on the hook (5) [7019858] behind the reinforcing

ring.
• Push out the rotary shaft seal (3) with t hook (5) and
lever (4) [7019858]. 140150
3 - 120 !! ! D 934 A6
Mjfcifss D 936 A6
3.8.3 Installation
Notes on installation
Only remove new rotary shaft seal from the original packaging
directly before installation.
Open the original packaging carefully to ensure that the rotary

shaft seal is not damaged.
Do not touch the sealing lip of the rotary shaft seal.

Hold the rotary shaft seal on the outer circumference.
If the original packaging is damaged:

Check whether the rotary shaft seal is of sound condition.
In case of doubt:
Use other, new rotary shaft seal.
Oil and grease around the sealing lip render the rotary shaft
seal unusable and leads to the onset of leaks.
Cleaning of the rotary shaft seal is prohibited.
140392
D 934 A6 !! ! 3 - 121
D 936 A6 Mjfcifss
Preassembling the rotary shaft seal
Caution!
Oil and grease around the sealing lip render the ro-
3 tary shaft seal unusable and leads to the onset of

leaks.
Preassembly of the rotary shaft seal may only be
undertaken on a clean work surface.
Caution!
3 t Clean the press-in device [10116249] and

check for damage, if necessary replace the press-
in device.
140389
• Place the clean inner part (6) of the t press-in device
[10116249] on a flat, clean underlay.
Caution!
3 The sealing lip may not sustain damage and may
not be folded down.
• Push a new rotary shaft seal (3) carefully over the inner
part (6) of the t press-in device [10116249] until it is sit-
ting on the underlay.
• Ensure that the sealing lip is sitting properly around the

entire circumference of the inner part (arrows).
140390
• Ensure that the dust lip is sitting properly around the

140391
3 - 122 !! ! D 934 A6
Mjfcifss D 936 A6
Installing the rotary shaft seal

Caution!
3 Oil and grease around the sealing lip render the ro-
tary shaft seal unusable and leads to the onset of
leaks.
• Remove grease from the running surface of the

crankshaft and the borehole in the aggregate carrier
(arrows).
140397
• Tighten the inner part (6) of the t press-in device

[10116249] with pre-assembled rotary shaft seal (3) onto
the crankshaft.
140151
• Fit the outer piece (7) and the washer (8) of the t press
tool [10116249].
• Screw on the hexagonal nut (9) until the outer part (7) is
sitting on the rotary shaft seal (3).
Caution!
leaks.
• Apply a light coating of clean engine oil (3) around the cir-
cumference of the rotary shaft seal. 140152
Caution!
3 The rotary shaft seal must fit evenly on the boreho-
le in the aggregate carrier.
• Press in the rotary shaft seal (3) evenly up to the stop in

the aggregate carrier.
• t Detach the press tool [10116249].
• Check the rotary shaft seal (3) for correct seating.
D 934 A6 !! ! 3 - 123
D 936 A6 Mjfcifss
• Insert the guard ring (2) and tighten the fastening screws
(1) evenly.
140154
3 - 124 !! ! D 934 A6
Mjfcifss D 936 A6
3.9 Installing and dismantling the aggregate carrier

.
Prerequisite tasks:
The single-unit oil sump has been removed. Lube oil line from power take-off 4 has been removed.
The multi-part oil sump and ladder frame (D 936) has Thermostat housing and thermostat have been remo-
been removed. ved.
The crankcase breather at the front has been removed. Coolant pump has been removed.
Oil filter has been removed.
The air-conditioning compressor and generator mount Coolant manifold (on the thermostat housing or
have been dismantled. on the aggregate carrier) has been dismantled.
Ribbed V-belt deflection pulley has been removed.
140247

1 Hexagon collar screw M10x60-8.8................... a Unscrew and t screw in mounting bolts
[0528472].
3 Aggregate carrier
4 Seal .................................................................. d Replace.
5 Insertion sleeve
D 934 A6 !! ! 3 - 125
D 936 A6 Mjfcifss

6 O-ring 26.00x3.00............................................. d Replace and apply a coating of grease [Sta-
burags NBU 12]. Ensure that the O-ring is sitting
correctly in the groove of the crankcase housing
(arrow A).
(arrows B).
(arrows C).
Note!
There are different mounting possibilities for which:
4 - the aggregate carrier and coolant manifold are designed as single units.
- hexagon socket head screws with washers are used instead of hexagon collar bolts.
The aggregate carrier can be installed and dismantled accordingly for different mounting possibilities.
t Special tool
140238
3 - 126 !! ! D 934 A6
Mjfcifss D 936 A6
3.10 Installing and dismantling the flywheel

.
140049
Pos. Description
1 Fastening screw
(Torx anti-fatigue bolt M16x1.5-10.9)
2 Flywheel
3 Ring gear sensor
4 Ring gear starter
5 Borehole in the flywheel
6 Roll pin
Note!
There are various mounting possibilities for which:
4 - the diameter of the flywheel may be different,

- different fastening screws may be employed.
The flywheel can be installed or removed accordingly for these mounting possibilities, in accordance with
the different tightening torques.
D 934 A6 !! ! 3 - 127
D 936 A6 Mjfcifss
t Special tool
140048
0 Tightening specification flywheel
Caution!

Caution!
once.
Torx anti-fatigue bolt M16x1.5x72-10.9 or

140377
faces
Stage Torque in Nm
1. 30
2. 90
3. 90
4. 90
Overall 180 ± 5
3 - 128 !! ! D 934 A6
Mjfcifss D 936 A6
Caution!
3 Where necessary, hexagon socket head anti-fa-

tigue bolts should be replaced with Torx anti-fa-
tigue bolts.
Caution!
once.

140377
faces
Stage Torque in Nm
1. 30
2. 90
3. 90
4. 90
5. 90
Overall 270 ± 5
D 934 A6 !! ! 3 - 129
D 936 A6 Mjfcifss
3.10.1 Removing
• Unscrew the eight fastening screws (1).
140380
• t Screw in the mounting bolts [0528470] (7).
• Unscrew the remaining fastening screws (1).
140381
Danger!
2 The flywheel is heavy!
• Remove the flywheel (2).
• t Unscrew the mounting bolts [0528470] (7).
3.10.2 Installation
• Install the new crankshaft seal.
140382
Caution!
3 Do not damage the sealing lip of the rotary shaft
seal when screwing in the mounting bolts.
• t Screw in the mounting bolts [0528470] (7).
3 - 130 !! ! D 934 A6
Mjfcifss D 936 A6
Caution!
3 leaks.
The running surface for the rotary shaft seal must
be free of oil and grease.
The contact surface flywheel to crankshaft gear
must be free of oil and grease.
• Remove grease from running surface for rotary shaft seal

and contact surface flywheel to crankshaft gear (arrows).
140383
Danger!
2 The flywheel is heavy!
Caution!
3 Do not damage the speed sensors in the flywheel
housing.
• Mount the flywheel (2) onto the t mounting bolts

[0528470] (7) so that the borehole (5) and roll pin (6)
align.
140384
• Carefully push in the flywheel (2).
Caution!

Caution!
once.
• Apply a coating of oil to the three new Torx anti-fatigue

bolts (1) and screw them all in evenly until the flywheel is
sitting on the crankshaft gear. 140181
• t Unscrew the mounting bolts [0528470] (7).

• Apply a coating of oil to the remaining new Torx anti-

fatigue bolts (1) and screw them in.
• Screw in all Torx anti-fatigue bolts (1) in accordance with

the respective tightening torque.
D 934 A6 !! ! 3 - 131
D 936 A6 Mjfcifss
3
Caution!
The ring gear sensor (3) must be free of grease.
• Apply a light coating of grease to the starter ring gear (4)

[Molykote Longterm 2 Plus] (distributed evenly at eight
points around the circumference).
140385
3 - 132 !! ! D 934 A6
Mjfcifss D 936 A6
3.11 Installing and dismantling the rear crankshaft seal
Prerequisite tasks:
The flywheel has been removed.
.
140155
Pos. Description
1 Rotary shaft seal 115x140x12.0
t Special tool
140147 140156
D 934 A6 !! ! 3 - 133
D 936 A6 Mjfcifss
3.11.1 General notes
The rotary shaft seal used here is a PTFE-sealing washer (po-

lytetrafluorethylene, commonly known as „Teflon“). These are
different from the elastomer sealing washers previously used,
whereby the considerably wider, flat sealing lip, is no longer
pretensioned by a spiral-type expander.
The sealing lip is extremely sensitive.

The slightest of damage will lead to leakages.
140393
3.11.2 Removing
Caution!
3 Do not damage the borehole in the flywheel hou-
sing.
• Push out the rotary shaft seal (1) with t hook (3) and
lever (2) [7019858].
140157
3 - 134 !! ! D 934 A6
Mjfcifss D 936 A6
3.11.3 Installation
Notes on installation
Only remove new rotary shaft seal from the original packaging
directly before installation.
Open the original packaging carefully to ensure that the rotary

shaft seal is not damaged.
Do not touch the sealing lip of the rotary shaft seal.

Hold the rotary shaft seal on the outer circumference.
If the original packaging is damaged:

Check whether the rotary shaft seal is in a sound condition.
In case of doubt:
Use other, new rotary shaft seal.
Oil and grease around the sealing lip render the rotary shaft
seal unusable and leads to the onset of leaks.
Cleaning of the rotary shaft seal is prohibited.
140392
D 934 A6 !! ! 3 - 135
D 936 A6 Mjfcifss
Preassembling the rotary shaft seal
Caution!

leaks.
Preassembly of the rotary shaft seal may only be
undertaken on a clean work surface.
Caution!
3 t Clean the press-in device [10116250] and

check for damage, if necessary replace the press-
in device.
140394
• Fit the new rotary shaft seal (1) onto an even, clean
underlay.
3
Caution!
The sealing lip may not sustain any damage.
• Push the cleaned inner part (4) of the t press-in device

[10116250] carefully into the rotary shaft seal (1) until it is
sitting on the underlay.
• Ensure that the sealing lip is sitting properly around the

140395 03. Kapitel_Triebwerk.fm

3 - 136 !! ! D 934 A6
Mjfcifss D 936 A6
Installing the rotary shaft seal
Preparatory to installation of the flywheel:

Caution!

leaks.
Only clean the contact surface crankshaft gear to
flywheel with the rotary shaft seal removed.
• Remove grease from the contact surface crankshaft gear

to flywheel and the borehole for the rotary shaft seal in the
140396
flywheel housing (arrows).
• Tighten the inner part (4) of the t press-in device

[10116250] with pre-assembled rotary shaft seal (1) onto
the crankshaft. Ensure that the borehole in the inner piece
and the roll pin in the crankshaft are aligned (arrows).
140158
• Fit the outer piece (5) and the washer (6) of the t press
tool [10116250].
• Screw on the hexagonal nut (7) until the outer part (5) is
sitting on the rotary shaft seal (1).
Caution!
leaks.
• Apply a light coating of clean engine oil (1) around the cir-
cumference of the rotary shaft seal. 140160
Caution!
3
The rotary shaft seal must fit evenly on the boreho-

le in the flywheel housing.
• Press in the rotary shaft seal (1) evenly up to the stop in

the flywheel housing.
• t Detach the press tool [10116250].
• Check the rotary shaft seal (1) for correct seating.
D 934 A6 !! ! 3 - 137
D 936 A6 Mjfcifss
Dismantling and installing the flywheel housing
3.12 Dismantling and installing the flywheel housing
Prerequisite tasks:
The crankcase breather has been removed. The crankshaft seal at the rear has been removed.
Power take-off 1 has been removed. The single-unit oil sump has been removed.
Power take-off 2 has been removed.
The sensors have been removed. The multi-part oil sump and ladder frame (D 936) has
The flywheel has been removed. been removed.
The starter has been removed.
140265

1 Hexagon socket head screw M12-10.9 ............ d Tighten, 0 see tightening specification.
4 Washer
5 Flywheel housing.............................................. ad 2 Danger!
The flywheel housing is heavy!
6 Seal .................................................................. d Replace.
3 - 138 !! ! D 934 A6
Mjfcifss D 936 A6
Dismantling and installing the flywheel housing

7 O-ring 34.59x2.62 ............................................ d Replace O-ring and apply a coating of oil. Ensu-
re that the O-ring is sitting correctly in the groo-
ve of the crankcase (arrow).
8 Insertion sleeve
Note!
4 - different connection diameters are featured,
- screws featuring varying lengths are used.
The flywheel housing can be installed and dismantled accordingly for different mounting possibilities.
0 Tightening specification for flywheel housing

Hexagon socket head screw M12-10.9
Lubricant -
Stage Torque in Nm
1. 45
2. 110
140069
D 934 A6 !! ! 3 - 139
D 936 A6 Mjfcifss
Dismantling and installing the idler
3.13 Dismantling and installing the idler
Prerequisite tasks:
140266
1 Hexagon head screw M12x65-8.8.................... d Apply a coating of Loctite 243 and tighten, 0
see tightening specification.
2 Washer ............................................................. d The bevelled side must be pointing to the hexa-
gonal bolt (arrow).
3 Idler
3 - 140 !! ! D 934 A6
Mjfcifss D 936 A6
Dismantling and installing the idler
0 Tightening specification of idler

Lubricant -
Stage Torque in Nm
1. 83
Axial clearance (A) = 0.1 - 0.3 mm.
140083
D 934 A6 !! ! 3 - 141
D 936 A6 Mjfcifss
3.14 Installing and dismantling the crankshaft
Prerequisite tasks:
Cylinder 1 is set at OT. If necessary, the multipart oil sump has been removed.
The cylinder liners have been removed. If necessary, the oil suction pump has been removed.
The aggregate carrier has been removed. The crankshaft gear wheel has been removed.
The flywheel housing has been removed. The oil pump has been removed.
The single-unit oil sump has been removed. If necessary, the counterbalancing shaft has been re-
moved.
140271

1 Hexagon head screw M18x2x170-10.9 8 Upper thrust washer
2 Main bearing cover/thrust bearing cover 9 Upper main bearing shell
3 Main bearing cover 10 Crankcase
4 Insertion sleeve
5 Lower thrust washer
6 Lower main bearing shell
7 Crankshaft
3 - 142 !! ! D 934 A6
Mjfcifss D 936 A6
Arrangement of crankshaft bearing (D 934)
140272
Pos. Description
A Flywheel side
B Aggregate carrier side
2 Main bearing cover/thrust bearing cover
3 Main bearing cover

7 Crankshaft
8 Upper thrust washer
9 Upper main bearing shell
Note!
4 Crankshaft bearings are installed from different bearing materials, depending on the respective engine
output.
The crankshaft can be installed and dismantled accordingly for these variants.
D 934 A6 !! ! 3 - 143
D 936 A6 Mjfcifss
Arrangement of crankshaft bearing (D 936)
14027
Pos. Description
A Flywheel side
B Aggregate carrier side
2 Main bearing cover/thrust bearing cover
3 Main bearing cover
7 Crankshaft
8 Upper thrust washer
9 Upper main bearing shell
Note!
4 Crankshaft bearings are installed from different bearing materials, depending on the respective engine
output.
The crankshaft can be installed and dismantled accordingly for these variants.
3 - 144 !! ! D 934 A6
Mjfcifss D 936 A6
t Special tool
140126 140411 140074
0 Tightening specification for main bearing

Hexagon head screw M18x2x170-10.9
Stage Torque in Nm
1. 30
2. 110
3. 45
4. 45
140064
5. 45
Overall 135 ± 5
3.14.1 Removing
• Unscrew the hexagonal bolt (1).

140274
D 934 A6 !! ! 3 - 145
D 936 A6 Mjfcifss
Caution!
The crankcase, main bearing cover and thrust be-
aring cover are processed together.
The crankcase, cover for both main cover and
thrust bearing and the main bearing cover may
3 only be installed in the pairs in which they were ori-
ginally manufactured.
The crankcase (10), the cover for both main cover
and thrust bearing (2) and the main cover bearing
(3) can be identified as pairs via the crankcase
number.
140275
The crankcase number is stamped in the crankcase joint face

to the oil sump (flywheel side), as well as in every bearing co-
ver.
Meaning of the crankcase number:

001 C 1 Crankcase number
1 Bearing cap number of the main bearing
cap:
1 to 5 for the D 934 / 1 to 7 for the D 936
• Remove the lower cover for both main bearing and thrust
bearing (2) with thrust washers (5) and lower main bea-
ring cover (6), retain the parts in their pairs in compliance
with the crankcase number and store in a safe place.
Note!
4 Thrust washers and lower main bearing shell must

be reinstalled in the original bearing position if they
are to be used again.
140276
• Remove the main bearing cover (3) with lower main bea-
ring shell (6), retain the parts in their pairs in accordance
with the crankcase number and store in a safe place.
Note!
4 The main bearing shell must be reinstalled in the
original bearing position if it is to be used again.
140277
3 - 146 !! ! D 934 A6
Mjfcifss D 936 A6
Caution!
3 Ensure that the crankshaft does not sustain dama-
ge from the lifting gear.
• Take out the crankshaft (7) from the crankcase using a

suitable lifting gear (10) and set aside.
140278
• Remove the upper thrust washers (8) and upper main

bearing shells (9) from the crankcase (10), retain in their
original pairs in compliance with the crankcase number
and store in a safe place.
Note!
4 Thrust washers and upper main bearing shell must

be reinstalled in the original bearing position if they
are to be used again.
• Check the crankshaft.
• Check the crankcase, main bearing and thrust bearing. 140279

D 934 A6 !! ! 3 - 147
D 936 A6 Mjfcifss
3.14.2 Installation
• Install the upper main bearing shells (9), in compliance

with the identification mark, into the crankcase (10) so
that the lug of the bearing shell fits into the groove of the
crankcase (arrow A).
• Ensure that the lube oil bore of the main bearing shells (9)
aligns with the lube oil bore in the crankcase (10) (arrow
B).
• Apply a coating of oil to the running surface of the upper

main bearing shells (9).
140280
• Apply a light coating of grease to the upper thrust washers

(8), in compliance with the identification mark, on the side
which does not feature lubricating grooves and mount
onto the crankcase (10). Ensure that the lubricating
grooves (arrows) are pointing towards the crankshaft.
140281
Caution!
3 Ensure that the crankshaft does not sustain dama-
ge from the lifting gear.
• Install the crankshaft (7) into the crankcase (10) using a

suitable lifting gear.
140282
• Insert the lower bearing shell (6), in compliance with the

identification mark, into the main bearing cover (3) so that
the lug of the bearing shell fits into the groove of the bea-
ring cover (arrows).

main bearing shell (6).
140283
3 - 148 !! ! D 934 A6
Mjfcifss D 936 A6
• Insert the main bearing cover (3) so that the insertion

sleeves (4) engage in the boreholes of the crankcase
(10).
140284
• Insert the lower main bearing shell (6), in compliance with

the identification mark, into the cover for both main bea-
ring and thrust bearing (2) so that the lug of the bearing
shell fits into the groove of the bearing cover (arrows).

main bearing shell (6).
140285
• Apply a light coating of grease to the lower thrust washers

(5), in compliance with the identification mark, on the side
which does not feature lubrication grooves, and mount.
The lugs of the lower thrust washers (5) must fit into the
grooves of the cover for both main bearing and thrust bea-
ring (2) (arrows A). Ensure that the lubricating grooves
(arrow B) are pointing towards the crankshaft.
140286
• Insert the cover for both main bearing and thrust bearing
(2) so that the side featuring the groove is pointing out-
wards and the insertion sleeves (4) engage in the boreho-
les of the crankcase (10).
140287
D 934 A6 !! ! 3 - 149
D 936 A6 Mjfcifss
• Apply a coating of oil to the hexagonal screws (1) and

tighten, 0 see tightening specification.
• Turn the crankshaft around another full turn and check for
freedom-of-movement.
• Check axial clearance of the crankshaft.
140288
Checking the TDC position of the crankshafts:

• Continue to turn the crankshaft (7) so that the t pin (11)
[9078119] can be inserted through the cover for both main
bearing and thrust bearing (2) into the crankshaft (7).
140289
3 - 150 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the crankshaft gear wheel
3.15 Installing and dismantling the crankshaft gear wheel
Prerequisite tasks:
Cylinder 1 is set at OT.
140270

1 Roll pin 8.0x40
2 Crankshaft gear wheel ..................................... d Position so that the marking (2 points) matches
the marking (1 point) on the camshaft gear
wheel (arrow).
D 934 A6 !! ! 3 - 151
D 936 A6 Mjfcifss
Installing and dismantling the crankshaft gear wheel
3 - 152 !! ! D 934 A6
Mjfcifss D 936 A6
4 Fuel system and injection system
4 Fuel system and injection system .................................................................................................... 4-153
4.1 Notes regarding working on the fuel system and injection system .............................................. 4-154
4.2 Installing and dismantling fuel lines ............................................................................................. 4-155
4.3 Installing and dismantling the fuel prefilter with bracket .............................................................. 4-162
4.4 Installing and dismantling the fuel fine filter with bracket............................................................. 4-163
4.5 Installing and dismantling the fuel multiplier ................................................................................ 4-165
4.6 Installing and dismantling the fuel delivery pump ........................................................................ 4-166
4.7 Installing and dismantling the injection lines................................................................................ 4-167
4.7.1 Removing ...................................................................................................................... 4-168

4.7.2 Installation ..................................................................................................................... 4-169
4.8 Installing and dismantling the pressure pipe tube and injection nozzle ....................................... 4-170
4.8.1 Removing ...................................................................................................................... 4-171

4.8.2 Installation ..................................................................................................................... 4-172
4.9 Checking, dismantling and reassembling the injection nozzle (step-type holder) ....................... 4-174
4.9.1 Check the injection nozzle............................................................................................. 4-177

Check the opening pressure ................................................................................... 4-178
Adjusting the opening pressure............................................................................... 4-178
Spray formation test and buzz test.......................................................................... 4-180
Checking for leaks................................................................................................... 4-180
4.9.2 Dismantling and reassembling the injection nozzle....................................................... 4-181
4.10 Draining the fuel ducts in the crankcase...................................................................................... 4-184
4.11 Installing and dismantling the injection pump and roller tappet ................................................... 4-189
04. Kapitel_K und E_System.fm
4.11.1 Removing ...................................................................................................................... 4-191

4.11.2 Installation ..................................................................................................................... 4-191
D 934 A6 !! ! 4 - 153
D 936 A6 Mjfcifss
Fuel system and injection system Workshop Manual
Notes regarding working on the fuel system and injection system
4.1 Notes regarding working on the fuel system and injection system
Only trained and authorised personnel may work on the fuel system and injection system.
Only work on the fuel system and injection system while the diesel engine is switched off.
Wear suitable protective equipment (e.g. protective gloves, protective glasses, etc.) when carrying out any
tasks on the fuel system and injection system.
Ensure environmentally compatible disposal of fuels and "old" parts removed while carrying out tasks on
the fuel system and injection system.
• Fuel may not be allowed to seep into the soil, sewers or bodies of water.
• Catch the fuel in suitable containers and dispose of as prescribed.
• Before disposing of, or recycling waste materials, make enquiries at your local environmental centre or recycling
centre as to the correct methods for such procedures. Incorrect disposal of waste products can harm the envi-
ronment and the ecology.
Utmost cleanliness is to be observed at all times when working on the fuel system and injection system.
The following should be observed before commencing work:
• Only carry out tasks on the fuel system and injection system in areas in which there is no possibility of dust being
raised (for example as a result of grinding or welding work) or where other dirt particles can infiltrate the working
area. Use the respective workshop or assembly hall.
• Before removing parts, clean the respective area of the engine thoroughly and then dry.
• If necessary, hang a clean cover sheet over the engine cover.
• Only use clean and undamaged tools.
• Do not wear work clothes which have been used beforehand to carry out dusty tasks (for example, as a result of
grinding or welding work). If necessary, change work clothes.
• Only use fibre-free cleaning rags.
The following must be observed when carrying out this work:

• Remove any dirt which may loosen and detach itself (e.g. flakes of dried paint) using an industrial vacuum clea-

ner for example.
• Seal open line connections (e.g. on engine control unit, fuel prefilter, fuel fine filter, fuel multiplier, fuel delivery
pump, injection pump element, pressure pipe tube, cylinder head, crankcase) so that no dust or moisture can
penetrate.
• Package removed parts (e.g. fuel line, injection line, engine control unit, fuel prefilter, fuel fine filter, fuel multip-
lier, fuel delivery pump, injection pump, pressure pipe tube, cylinder head, crankcase) so that they are protected
against dust and moisture, and store.

Alternatively, removed parts (e.g fuel line, injection line, fuel prefilter, fuel fine filter, fuel multiplier, fuel delivery
pump, injection pump, pressure pipe tube, cylinder head, crankcase) can also be stored in a receptacle filled
with clean diesel fuel (as protection against fine dust and corrosion).
• Used parts must be thoroughly cleaned before reinstalling (for example with benzene).
Do not use any used cleaning fluids!
• Only remove „new“ parts from the original packaging directly before installation.
4 - 154 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual Fuel system and injection system
Installing and dismantling fuel lines
4.2 Installing and dismantling fuel lines
Prerequisite tasks:
The notes regarding working on the fuel system and injection system have been read.
Fuel shut-off valve is closed.
If necessary, the crankcase breather has been removed.

140102

A Crankcase
B Fuel prefilter head
C Engine control unit
D Fuel fine filter head

E Fuel delivery pump
1 Line engine control unit outlet - fuel prefilter inlet
(supply)
3 Line upper fuel duct in the crankcase - fuel pre-
filter inlet (return flow)
5 Line fuel delivery pump outlet -
fuel fine filter inlet (supply)
7 Line fuel prefilter outlet - fuel predelivery pump
inlet (supply)
D 934 A6 !! ! 4 - 155
D 936 A6 Mjfcifss
140103

A Crankcase

F Pressure regulating valve
J Bypass throttle.................................................. d Replace.
2 Line
From tank - engine control units inlet (supply)
4 Line................................................................... d Replace the sealing rings
Upper fuel duct in the crankcase - fuel fine filter
inlet (return flow)
8 Line................................................................... d Replace the sealing rings
Fuel fine filter outlet - lower fuel duct in the

crankcase (bypass for cooling and lubrication of
the injection pumps)
9 Line
Pressure regulating valve outlet - to tank (return
flow)
4 - 156 !! ! D 934 A6
Mjfcifss D 936 A6
140106

A Crankcase
H Cylinder head
10 Oil leakage pipe .............................................. d Replace the sealing rings
12 Line .................................................................. d Replace the sealing rings
Lower fuel duct in the crankcase - pressure re-
gulating valve outlet
Note!
4
Following installation of the respective fuel line:

See the operating instructions for bleeding the fuel system.
D 934 A6 !! ! 4 - 157
D 936 A6 Mjfcifss
140104

A Crankcase
B Fuel prefilter head

E Fuel delivery pump
G Fuel multiplier
K Throttle ............................................................. d Replace.
Engine control unit outlet - fuel prefilter inlet
(supply)

Fuel delivery pump outlet -
fuel fine filter inlet (supply)
7 Line
Fuel prefilter outlet - fuel delivery pump inlet
(supply)
4 - 158 !! ! D 934 A6
Mjfcifss D 936 A6

10 Line ................................................................. d Replace the sealing rings
Fuel fine filter outlet -
fuel multiplier inlet (supply)
Fuel fine filter - lower fuel duct in the crankcase
(continuous ventilation)
D 934 A6 !! ! 4 - 159
D 936 A6 Mjfcifss
140105

A Crankcase

G Fuel multiplier
J Bypass throttle.................................................. d Replace.
from tank - engine control units inlet (supply)
Upper fuel duct in the crankcase - fuel multiplier
inlet (return flow)
Upper fuel duct in the crankcase - fuel multiplier

inlet (return flow)
Fuel multiplier outlet - lower fuel duct in the
crankcase (bypass for cooling and lubrication of
the injection pumps)
Pressure regulating valve outlet - to tank (return
flow)
4 - 160 !! ! D 934 A6
Mjfcifss D 936 A6
140107

A Crankcase
G Fuel multiplier
H Cylinder head
Lower fuel duct in the crankcase - pressure re-
gulating valve outlet
Note!
4
Following installation of the respective fuel line:

See the operating instructions for bleeding the fuel system.
D 934 A6 !! ! 4 - 161
D 936 A6 Mjfcifss
Installing and dismantling the fuel prefilter with bracket
4.3 Installing and dismantling the fuel prefilter with bracket
Prerequisite tasks:
Battery has been disconnected.
Cable is disconnected from the fuel prefilter.
The respective fuel lines have been removed.

140108

1 Fuel prefilter with bracket
2 Washer
3 Hexagonal screw M10-8.8
4 - 162 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the fuel fine filter with bracket
4.4 Installing and dismantling the fuel fine filter with bracket
Prerequisite tasks:
140109

1 Fuel fine filter with bracket
3 Hexagonal screw M8x50-8.8
4 O-ring ............................................................... d Replace O-ring and apply a coating of oil.
Ensure that the O-ring is sitting correctly in the

groove of the bracket (arrow).
D 934 A6 !! ! 4 - 163
D 936 A6 Mjfcifss
Installing and dismantling the fuel fine filter with bracket
140110

1 Fuel fine filter with bracket
2 Washer

4 - 164 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the fuel multiplier
4.5 Installing and dismantling the fuel multiplier
Prerequisite tasks:
140111

1 Fuel multiplier
2 Hexagon socket head screw M8x55-8.8 .......... d Apply a coating of Loctite 243.
groove of the fuel multiplier (arrow).
D 934 A6 !! ! 4 - 165
D 936 A6 Mjfcifss
Installing and dismantling the fuel delivery pump
4.6 Installing and dismantling the fuel delivery pump
Prerequisite tasks:
140112
Pos. Description Notes on operation 04. Kapitel_K und E_System.fm
1 Fuel delivery pump

groove of the fuel delivery pump (arrow).
4 Coupling ........................................................... d Fit the coupling so that the side featuring a dia-
meter of D = 20 mm is pointing toward the po-
wer take-off.
4 - 166 !! ! D 934 A6
Mjfcifss D 936 A6
4.7 Installing and dismantling the injection lines
Prerequisite tasks:
The notes regarding working on the fuel system and in- If necessary, the fuel prefilter has been removed.
jection system have been read.
If necessary, the crankcase breather has been remo- If necessary, the engine control unit has been remo-
ved. ved.
If necessary, the boost pressure sensor has been re- If necessary, the cable harness retainer has been re-
moved. moved.
140078
Pos. Description
1 Injection line
t Special tool
140128
D 934 A6 !! ! 4 - 167
D 936 A6 Mjfcifss
0 Tightening specification
Danger!
Injection lines must be replaced after each third
2 time of removal.
Each time they are removed: mark the injection li-
nes on the cap nut (arrow).
Danger!
Injection lines can become plastically deformed
2 stalled.
When removing: first unscrew the cap nut from the
140060
pump side in order that the injection line can turn
freely when the cap nut on the nozzle side is un-
screwed.

Cap nut nozzle side and pump side M14x1.5

Lubricant -
Stage Torque in Nm
1. 25 to 30
4.7.1 Removing
Danger!
2 Injection lines must be replaced after each third
time of removal.
• Mark the injection lines (1) on the cap nut (arrow).
140386
Danger!
2 Injection lines can become plastically deformed

stalled.
• First unscrew the cap nut on the pump side (arrow) with
t special spanner [10020852] so that the injection line
can turn freely when unscrewing the cap nut on the nozzle
side.
• Unscrew the cap nut on the nozzle side t special span-

ner [10020852].
140387
4 - 168 !! ! D 934 A6
Mjfcifss D 936 A6
4.7.2 Installation
Caution!
3 Respect the installation position of the injection
line.

Note!
Injection line
from cyl. 1 (D 934, D 936) on the nozzle side,
4 from cyl. 4 (D 934) on the pump side,
from cyl. 6 (D 936) on the nozzle side
140388
after bleeding the injection system. See the opera-

ting instructions for bleeding the fuel system.
• Attach the injection line (1) with the side marked „P“ to the
injection pump and screw on the cap nuts.
• Tighten the cap nuts with t special spanner [10020852],

0 see tightening specification.
D 934 A6 !! ! 4 - 169
D 936 A6 Mjfcifss
4.8 Installing and dismantling the pressure pipe tube and injection nozzle
Prerequisite tasks:
The injection line has been removed.
Cylinder head cover has been removed.
If necessary, the charge air temperature sensor has been removed.
.

140130
Pos. Description
1 Lug
2 Spherical washer
3 Hexagon socket head screw M10x65
4 Injection nozzle
5 O-ring
7 O-ring
8 Cap nut M22x1.5
9 Sealing washer
10 Cylinder head
11 Roll pin
4 - 170 !! ! D 934 A6
Mjfcifss D 936 A6
t Special tool
140081 140085 140080
0 Tightening specification
Hexagon socket head screw M10x65
Stage Torque in Nm
1. (A) 5
2. (C) 50
Cap nuts M22x1.5

Lubricant -
140135
Stage Torque in Nm
1. (B) 5
2. (D) 50
4.8.1 Removing
• Unscrew the cap nut (8).
• Pull out the pressure pipe tube (6) with t adapter

[0524029] and t slide hammer puller [0524072] from the
cylinder head (10).
140131
D 934 A6 !! ! 4 - 171
D 936 A6 Mjfcifss
• Unscrew the hexagon socket head screw (3) and remove

with spherical washer (2) and lug (1).
• Pull out the injection nozzle (4) with t adapter

[10220689] and t slide hammer puller [0524072] from
the cylinder head (10).
• Remove the O-ring (5) from the injection nozzle (4).
Caution!
3 Do not damage the nozzle dome when removing
the sealing washer.
• Remove the sealing washer (9) from the injection nozzle

(4).
Note!
4 Grip sealing washers which are stuck fast with a

pair of pliers and pull away applying a light turning
movement.
4.8.2 Installation
• Mount new O-ring (5) to injection nozzle (4) and apply

coating of oil to O-ring (5).
140132

4 - 172 !! ! D 934 A6
Mjfcifss D 936 A6
Note!
4 Use new sealing washers in accordance with the

spare-parts catalogue, see spare-parts catalogue
group „Injection nozzle“.
• Fit the new sealing washer (9) with countersunk side (A)
toward the injection nozzle (4). The flat side (B) must act
as a seal on the side of the cylinder head.
Note!
The centring nodules on the sealing washer pre-
4 vent one side abutting against the shaft of the
nozzle, and thus prevents the shaft of the nozzle
from being subjected to lateral forces.
• Install the injection nozzle (4) with new sealing washer (9)
so that the roll pin (11) is aligned with the groove in the lug
(1). The supply borehole of the injection nozzle is thus
aligned with the borehole of the pressure pipe tube
(arrows).
• Fit the lug (1) so that the groove in the lug is aligned with
the roll pin (11) (arrow).
• Fit spherical washer (2), apply a coating of oil to the hexa-

gon socket head screw M10x65 (3) and tighten, see tight-
140133
ening specification, stage 1.
Caution!
3 The pressure pipe tubes must be replaced once
dismantled.
• Grease the new O-ring (7) of the pressure pipe tube (6).
• Install the pressure pipe tube (6) so that the ball in the
pressure pipe tube and the recess in the cylinder head

align (arrow).
3
Caution!
The cap nuts must be replaced once removed.
140134
• Tighten new cap nut M22x1.5 (8), see tightening specifi-

cation, stage 1.
• Tighten hexagon socket head screw M10x65 (3), see

tightening specification, stage 2.
• Tighten cap nut M22x1.5 (8), see tightening specification,

stage 2.
D 934 A6 !! ! 4 - 173
D 936 A6 Mjfcifss
4.9 Checking, dismantling and reassembling the injection nozzle (step-type holder)
Prerequisite tasks:
The injection nozzle has been removed.
140313
Pos. Description 04. Kapitel_K und E_System.fm
1 Injection nozzle
2 Nozzle holder
3 Fuel supply borehole
4 Pressure adjusting washer
5 Compression spring
6 Locating pin
7 Thrust pin
8 Intermediate washer
9 Locating pin
10 Nozzle body
11 Nozzle needle
12 Nozzle retaining nut
4 - 174 !! ! D 934 A6
Mjfcifss D 936 A6
t Special tool
140302 140303 140304 140314 140321 140342
140318 140319 140317
Note!
Repair of the step-type holder may only be carried out in association with the nozzle tester, ID no.
4 10340104 and a suction device, ID no. 10337931. The suction is necessary to ensure that none of the oil
mist is allowed to escape into the ambient air.
The nozzle tester, ID no. 7361236 is no longer appropriate for the checking and setting of all nozzle hol-
ders, as regards measuring accuracy, extent of damage and quality of the pressure gauge.
Ultrasonic cleaning machine e.g. from the company Bandelin electronic
GmbH&Co.KG
Heinrichstrasse 3-4
D-12207 Berlin
Tel: +49 / 30 / 768 80 - 0
Tel: +49 / 30 / 773 46 99 -
Type: Sonorex Super RK 102 H
(including insert basket and cover)
140374
D 934 A6 !! ! 4 - 175
D 936 A6 Mjfcifss
Cleaning agent e.g. from the company Chemische Fabrik Dr. Weigert
GmbH&Co.KG
Mühlenhagen 85
D-20539 Hamburg
Tel: +49 / 40 / 789 60 - 0
Tel: +49 / 40 / 789 60 - 120
Type: Neodischer LM10
Technical Data
D 934 S / D 934 L D 934 S / D 936 L
Type, nozzle body Bosch Bosch

with nozzle needle DLLA 145 P 1645 DLLA 145 P 1503
Opening pressure 330 + 10 330 + 10

for „new injection
nozzle“ in bar
Opening pressure 315 + 15 315 + 15

for
„used injection
nozzle“ in bar
0 Tightening specification for nozzle retaining nut

Caution!
The nozzle retaining nut may only be tightened
3 when the definitive tightening torque is applied, if
the nozzle body has been depressed with a force
of 0.45 kN. Use the respective special tool.
Nozzle retaining nut

Lubricant -

Stage Torque in Nm
140301
1. 40 - 50 LMB/00C/Issued: 06.12.2006/en
4 - 176 !! ! D 934 A6
Mjfcifss D 936 A6
4.9.1 Check the injection nozzle
1 Injection nozzle
13 t Adapter [10340119]
14 t Nozzle tester [10340104]
15 t Suction device [10337931]
The nozzle tester is used to test the injection nozzle for:

– Opening pressure (injection pressure)
– Spray formation
– Impermeability
Caution!
3 When carrying out tests, use a test oil or pure die-
sel fuel.
140300
Caution!
3 To not use steel wire brushes to clean the injection

nozzle. Steel wire brushes will damage the injec-
tion holes.
• Clean the injection nozzle prior to the test and check for
wear.
• Insert the injection nozzle (1) in the adapter (13) and align
so that the fuel supply borehole of the injection nozzle
aligns with the borehole (engraved with identification mark
„1“) in the adapter.
• Tighten the injection nozzle (1) with the intake connection

(13.1) in the adapter (13).
140305
• Clamp the injection nozzle (1) with the adapter (13) in the
suction device (15) and connect the fuel pressure line
(14.1) of the nozzle tester.
Danger!
Wear protective glasses during the test, and under
2 no circumstances should hands be placed bene-

ath a streaming jet. The fuel can penetrate deeply
into the flesh and destroy the tissue. Fuel infiltra-
ting the blood can lead to blood poisoning.
140306
D 934 A6 !! ! 4 - 177
D 936 A6 Mjfcifss
Check the opening pressure
• Switch on the pressure gauge.
• Slowly push through the lever of the nozzle tester until the
injection nozzle begins injection.
• Read off the opening pressure on the pressure gauge and

compare with the values specified in the technical data, if
necessary adjust the opening pressure.
140312
Adjusting the opening pressure
Caution!
3 Ensure the highest possible degree of cleanliness
when dismantling or reassembling.
• Insert the injection nozzle into the t mounting plate

[10340126] (16).
• Unscrew the nozzle retaining nut (12).
• Remove the nozzle body (11) with nozzle needle (10) and
intermediate washer (8).
• Remove the thrust pin (7), compression spring (5) and

pressure adjusting discs (4) .
• If opening pressure is too low, insert thicker pressure

adjustment discs, if opening pressure is too high, insert
thinner pressure adjustment discs (4).
• Insert the compression spring (5).

• Insert the thrust pin (7) so that the bevelled side is poin-
ting towards the intermediate washer (8).
• Fit the intermediate washer (8) so that the locating pin 140310
engages in the respective fixing bores of the nozzle body
(2).
• Fit the nozzle body (11) with nozzle needle (10) so that
the locating pin engages in the respective fixing bores of

the nozzle body (11).
Caution!
3 The definitive tightening torque may only be ap-

plied to the nozzle retaining nut (12) when the
nozzle body is pushed down.
• Screw on the nozzle retaining nut (12) around a few turns

of thread.
4 - 178 !! ! D 934 A6
Mjfcifss D 936 A6
• A commercially-approved press or bench drilling machine

with t dynamometer [10340124] (17), t force sensor
[10340125] (18) and t press-in device [10340126] (19)
are to be provided.
• Insert the injection nozzle into t the mounting plate

[10340126] (16) and position beneath the prepared press.
3
Caution!
Do not push down on the nozzle dome.
• t Fit the press-in device [10340126] (19) and apply a 140315

force of 0.45 kN to the nozzle body (10).
• Tighten the nozzle retaining nut (12) with the nozzle body
pressed down, 0 see tightening specification.
• Remove the injection nozzle.
Caution!
3 A thorough concentric running test and wobble

measurement is to be undertaken every time the
nozzle retaining nut is opened.
Concentric running test and wobble measurement

• Insert the injection nozzle (1) in the t testing device
[10340121] (20) and clamp securely.
• t Insert the dial gauge [8004064] (21) for concentric run-

ning test into the dial gauge fixture and secure.
• t Insert and secure the dial gauge [8004064] (22) for

wobble measurement.
• Turn the reception ring (20.1).

• Measure concentricity of the nozzle using the dial gauge

(21).
Set value: max. concentricity deviation = 0.4 mm.
• Using the dial gauge (22), measure the wobble of the

nozzle on the face side of the nozzle retaining nut.
Set value: max. wobble deviation = 0.08 mm.
• Check the opening pressure again.

140316
D 934 A6 !! ! 4 - 179
D 936 A6 Mjfcifss
Spray formation test and buzz test
• Switch off the pressure gauge.
• Actuate the lever of the nozzle tester rapidly and fre-

quently while observing the spray formation.
Fine, evenly dispersed sprays should be formed, without
any noticeable plumes at the sides.
Note!
Due to the special design of the nozzle needle
(IRH-needle), a buzz test is not possible. The in-
4 jection nozzles belong to buzz identification group

4.
To ensure more accuracy, in this case assessment
of the spray formation, as well as the opening pres-
sure test and leak test, must be carried out.
Checking for leaks
• Switch on the pressure gauge.
• Slowly push through the lever of the nozzle tester.

When subjected to a value of 25-30 bar below the prescri-
bed opening pressure, the injection nozzle should not
indicate any dripping.
140312

4 - 180 !! ! D 934 A6
Mjfcifss D 936 A6
4.9.2 Dismantling and reassembling the injection

nozzle
Caution!
3 Do not use steel wire brushes to clean the injection

nozzle. Steel wire brushes will damage the injec-
tion holes.
• Clean the injection nozzle prior to dismantling and check

for wear.
Caution!
3 Ensure the highest possible degree of cleanliness
when dismantling or reassembling.
• Insert the injection nozzle into the t mounting plate

[10340126] (16).
• Unscrew the nozzle retaining nut (12).
Caution!
3 Nozzle body (11) and nozzle needle (10) should

not be swapped and should always be replaced in
pairs.
• Remove the nozzle body (11) with nozzle needle (10) and 140311
intermediate washer (8).
• Remove the thrust pin (7), compression spring (5) and

pressure adjusting discs (4) .
Caution!
3 Do not use a steel wire brush to clean the nozzle

body and nozzle needle. Steel wire brushes will
damage the injection holes.
• Clean the nozzle body (11) and nozzle needle (10) with
commercially-approved ultrasound cleaning equipment.
If necessary, t use a nozzle cleaning tool [10340120].
• Immerse the cleaned nozzle body (11) and cleaned

nozzle needle (10) in clean diesel fuel, connect them and
check them using a drop test.
If the nozzle needle does not slide slowly and smoothly

into the nozzle body under its own weight with the nozzle
body held vertically, replace the nozzle body (11) with
nozzle needle (10).
D 934 A6 !! ! 4 - 181
D 936 A6 Mjfcifss
• Insert pressure adjusting disc (4) and compression spring

(5).
• Insert the thrust pin (7) so that the bevelled side is poin-
ting towards the intermediate washer (8).
• Fit the intermediate washer (8) so that the locating pin

engages in the respective fixing bores of the nozzle body
(2).
• Fit the nozzle body (11) with nozzle needle (10) so that
the locating pin engages in the respective fixing bores of
the nozzle body (11).
Caution!
3 The definitive tightening torque may only be ap-

plied to the nozzle retaining nut (12) when the
nozzle body is pushed down.
• Screw on the nozzle retaining nut (12) around a few turns

of thread.
140311

4 - 182 !! ! D 934 A6
Mjfcifss D 936 A6
• A commercially-approved press or bench drilling machine

with t dynamometer [10340124] (17), t force sensor
[10340125] (18) and t press-in device [10340126] (19)
are to be provided.
• Insert the injection nozzle into t the mounting plate

[10340126] (16) and position beneath the prepared press.
3
Caution!
Do not push down on the nozzle dome.
• t Fit the press-in device [10340126] (19) and apply a 140315

force of 0.45 kN to the nozzle body (10).
• Tighten the nozzle retaining nut (12) with the nozzle body
pressed down, 0 see tightening specification.
• Remove the injection nozzle.
Caution!
3 A thorough concentric running test and wobble

measurement is to be undertaken every time the
nozzle retaining nut is opened.
Concentric running test and wobble measurement

• Insert the injection nozzle (1) in the t testing device
[10340121] (20) and clamp securely.
• t Insert the dial gauge [8004064] (21) for concentric run-

ning test into the dial gauge fixture and secure.
• t Insert and secure the dial gauge [8004064] (22) for

wobble measurement.
• Turn the reception ring (20.1).

• Measure concentricity of the nozzle using the dial gauge

(21).
Set value: max. concentricity deviation = 0.4 mm.
• Using the dial gauge (22), measure the wobble of the

nozzle on the face side of the nozzle retaining nut.
Set value: max. wobble deviation = 0.08 mm.
• Check the injection nozzle and, if necessary, adjust the

opening pressure. 140316
D 934 A6 !! ! 4 - 183
D 936 A6 Mjfcifss
Draining the fuel ducts in the crankcase
4.10 Draining the fuel ducts in the crankcase
Prerequisite tasks:
The crankcase breather has been removed.
140099
Pos. Description
1 Oil leakage pipe
2 Banjo bolt
3 Banjo bolt
4 Fuel fine filter
5 Banjo bolt
4 - 184 !! ! D 934 A6
Mjfcifss D 936 A6
140100
Pos. Description
1 Oil leakage pipe
2 Banjo bolt
3 -
4 Fuel fine filter
5 Banjo bolt
6 Banjo bolt
D 934 A6 !! ! 4 - 185
D 936 A6 Mjfcifss
Note!
Before removing the injection pumps, the upper
4 and lower fuel ducts in the crankcase must be drai-

ned.
This prevents the fuel flowing from the fuel ducts
into the oil sump via the roller tappet (oil dilution).

• Unscrew the fuel fine filter (4).
• Unscrew the banjo bolt (3) and remove with sealing rings.
Danger!
Put on appropriate protective equipment, such as
protective glasses and protective gloves.
2 Cover the tip of the compressed air gun, the bore-
hole of the banjo bolt and the fuel fine filter head
with rags.
140087
• Blow compressed air into the borehole of the banjo bolt
(3) in the fuel fine filter head. The upper fuel duct is thus
drained.
The fuel is exuded at the fuel fine filter head.
• Tighten the banjo belt (3) with new sealing rings.
• Install new fuel fine filter (4).

4 - 186 !! ! D 934 A6
Mjfcifss D 936 A6

• Unscrew the fuel fine filter (4).
Danger!
protective glasses and protective gloves.
2 Cover the tip of the compressed air gun, the bore-
hole of the banjo bolt and the fuel fine filter head
with rags.
140101
(6) in the bracket. The upper fuel duct is thus drained.
The fuel is exuded at the fuel fine filter head.
• Install new fuel fine filter (4).
140088
D 934 A6 !! ! 4 - 187
D 936 A6 Mjfcifss
• Remove the oil leakage pipe (1) and remove with sealing
rings.
Danger!
2 protective glasses and protective gloves.
Cover the tip of the compressed air gun and the

borehole of the banjo bolt with rags.
140089

(2) in the crankcase.
The lower fuel duct will thus be drained. The fuel is exu-
ded from the borehole of the banjo bolt (5).
• Install oil leakage pipe (1) with new sealing rings.
140088

4 - 188 !! ! D 934 A6
Mjfcifss D 936 A6
4.11 Installing and dismantling the injection pump and roller tappet
Prerequisite tasks:
The fuel ducts in the crankcase have been drained.
The injection line has been removed.
If necessary, the cable harness retainer has been removed.
.
140086
Pos. Description
1 Injection pump
3 Hexagonal screw M3x9.1

4 O-ring (47,00x2,50, black)
5 O-ring (45.00x2.50, brown)
6 O-ring (40.00x4.00, black)
7 Roller tappet
8 Locking screw M10x20-8.8
D 934 A6 !! ! 4 - 189
D 936 A6 Mjfcifss
t Special tool
140081 140080 140097 140098
0 Tightening specification for injection pump

Lubricant -
Stage Torque in Nm
1. 60
140082
0 Tightening specification cable harness to injection

pump
Hexagon head screw M3x9.1
Lubricant -
Stage Torque in Nm
1. 1.5 ± 0.2
140234

4 - 190 !! ! D 934 A6
Mjfcifss D 936 A6
4.11.1 Removing
• Disconnect the cable harness from the injection pump.
• Designate the injection pump (1) to the respective cylinder

(arrow).
2
Danger!
The injection pump is under spring tension.
• Unscrew the hexagon socket head screws (2).

140090
Caution!
3 If the injection pump is sitting tight, do not attempt
to lever against the flange / solenoid valve.
• Pull out the injection pump (1) with t adapter [0524029]

and t slide hammer puller [0524072].
• Remove the O-rings (4, 5, 6).
140091
Note!
The roller tappet (7) is fixed via the locking screw
4
(8). The locking screw (8) does not have to be un-

screwed to remove the roller tappet. The locking
screw (8) must be replaced whenever it is remo-
ved.
• Remove the roller tappet (7) with magnet.
4.11.2 Installation
• If necessary, tighten the new locking screw (8).

140092
• Fit the roller tappet (7) and align so that the groove is alig-
ned with the locking screw (8) (arrow).
• Ensure easy freedom-of-movement of the roller tappet

(7).
D 934 A6 !! ! 4 - 191
D 936 A6 Mjfcifss
• t Fit the mounting collar (10) [10289319] on the injection

pump (1) and set the clearance of the groove to the O-ring
(4) using the screw (9).
• Apply a coating of oil to the O-ring (4) and mounting collar

(10) and fit O-ring (4). Ensure that the O-ring (4) does not
become overexpanded and twisted.
140093
• Set the clearance from the groove to the O-ring (5) using
the screw (9).

140094
• t Fit the mounting collar (11) [10289320] to the injection

pump (1).

140095
Caution!
3 Do not damage the O-rings when installing the in-
jection pump.
• Install the injection pump (1) in accordance with the dra-

wing (arrow) and tighten the hexagon socket head screws
(2), 0 see tightening specification.
Note!
4 If necessary, turn the engine a little further in order

that tension in the injection pump can be eased by
the change in position of the cam shaft.
140090
4 - 192 !! ! D 934 A6
Mjfcifss D 936 A6
• Connect the cable harness to the injection pump, 0 see

tightening specification.
The injection pumps are divided into four different tolerance

classes during manufacture.
These tolerance classes are annotated in coded form (ex-

ample: GT39) on the injection pump company nameplate (ar-
row).
Following replacement of the injection pumps:

Record the tolerance class of the new injection pump in the
engine control unit (allocated to the respective engine cylin-
der), see the operating instructions of the „Classify“ program
or the diagnosis program „DcDesk 2000“, in the chapter „In-
jector identification“.
140096
D 934 A6 !! ! 4 - 193
D 936 A6 Mjfcifss

4 - 194 !! ! D 934 A6
Mjfcifss D 936 A6
5 Belt drive
5 Belt drive ............................................................................................................................................. 5-195
5.1 Installing and dismantling the ribbed V-belt tensioning device .................................................... 5-196
5.2 Installing and dismantling the ribbed V-belt deflection pulley ...................................................... 5-197
05. Kapitel_Riementrieb.fm
D 934 A6 !! ! 5 - 195
D 936 A6 Mjfcifss
Belt drive Workshop Manual
Installing and dismantling the ribbed V-belt tensioning device
5.1 Installing and dismantling the ribbed V-belt tensioning device
Prerequisite tasks:
The cover for the belt drive has been removed where
necessary.
Ribbed V-belt has been removed.
140140

2 Washer
3 Ribbed V-belt tensioning device....................... d Ensure that the pin is aligned with the borehole
in the aggregate carrier (arrows).
Note!
There are different mount variants for which:
4 - the installation point may differ,
- hexagon collar bolts are used instead of hexagonal screws with washer.
The tensioning device can be installed and dismantled accordingly for different mounting possibilities.
5 - 196 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual Belt drive
Installing and dismantling the ribbed V-belt deflection pulley
5.2 Installing and dismantling the ribbed V-belt deflection pulley
Prerequisite tasks:
The cover for the belt drive has been removed where
necessary.
Ribbed V-belt has been removed.
140141

1 Hexagon collar bolt M10x55-8.8 ...................... d Apply a coating of Loctite 243.
2 Deflection pulley............................................... d The collar of the insertion sleeve must be facing
the hexagon collar bolt (arrow).
Note!
There are different mount variants for which:
4 - the installation point may differ,
- the number of deflection pulleys may vary.
The deflection pulley can be installed and dismantled accordingly for different mounting possibilities.
D 934 A6 !! ! 5 - 197
D 936 A6 Mjfcifss
Belt drive Workshop Manual
Installing and dismantling the ribbed V-belt deflection pulley
5 - 198 !! ! D 934 A6
Mjfcifss D 936 A6
6 Charge air and exhaust system
6 Charge air and exhaust system ......................................................................................................... 6-199
6.1 Installing and dismantling the air induction pipe .......................................................................... 6-200
6.2 Installing and dismantling the connecting line (turbocharger - intercooler) ................................. 6-201
6.3 Installing and dismantling the exhaust pipes ............................................................................... 6-205
6.4 Installing and dismantling the engine brake ................................................................................ 6-207
6.5 Installing and dismantling the intake manifold ............................................................................. 6-208
6.6 Installing and dismantling the adapter ......................................................................................... 6-209
6.7 Installing and dismantling the exhaust stack ............................................................................... 6-210
6.8 Installing and dismantling the flange ........................................................................................... 6-211
6.9 Installing and dismantling the thermal protection plate on the exhaust pipe ............................... 6-212
6.10 Installing and dismantling the thermal protection plate on the turbocharger ............................... 6-213
6.11 Installing and dismantling the turbocharger ................................................................................. 6-214
6.12 Checking axial clearance and radial clearance of the turbocharger ............................................ 6-216
06. Kapitel_Ladeluft_AbgasSystem.fm
D 934 A6 !! ! 6 - 199
D 936 A6 Mjfcifss
Charge air and exhaust system Workshop Manual
Installing and dismantling the air induction pipe
6.1 Installing and dismantling the air induction pipe
Prerequisite tasks:
The engine control unit has been removed. The crankcase breather has been removed.
The fuel prefilter has been removed. The cable of the sensors at the air induction pipe has
been disconnected.
If necessary, the fuel fine filter has been removed. The cable of the heater flange has been disconnected.
The cable harness rail has been removed.
140173

1 Air induction pipe
4 Seal .................................................................. d Replace. Fit the seal so that the inside contour
is aligned with the intake port in the cylinder
head (arrows).
6 - 200 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual Charge air and exhaust system
Installing and dismantling the connecting line (turbocharger - intercooler)
6.2 Installing and dismantling the connecting line (turbocharger - intercooler)
Connecting line fastened to exhaust manifold (intercooler connection, aggregate carrier side)
140176

1 Hexagon collar bolt M8-8.8 or M10-8.8
2 Spacing sleeve
3 Retainer
4 Connecting flange
5 O-ring ............................................................... d Replace the O-ring and apply a light coating of
grease to the new O-ring. Ensure that the O-ring
is sitting correctly in the groove of the connec-
ting line (6) (arrow).
6 Connecting line
7 Charge air manifold
is sitting correctly in the groove of the charge air
manifold (7) (arrow).
9 Clamp
D 934 A6 !! ! 6 - 201
D 936 A6 Mjfcifss
Note!
4 - varying screw dimensions may be used,
- no spacing sleeves are featured.
The connecting line can be installed and dismantled accordingly for different mounting possibilities.
6 - 202 !! ! D 934 A6
Mjfcifss D 936 A6
Connecting line fastened to exhaust manifold (intercooler connection, flywheel side)

Prerequisite tasks:
Oil dipstick holder has been removed.
140177

1 Retainer
4 Spacing sleeve
5 Connecting line with connecting flange
is sitting correctly in the groove of the connector

(7) (arrows).
7 Connector
8 Connector
is sitting correctly in the groove of the connector
(8) (arrow).
10 Clamp
11 Hexagonal screw connection M6-8.8
D 934 A6 !! ! 6 - 203
D 936 A6 Mjfcifss
Connecting line fastened to thermostat housing (intercooler connection, aggregate carrier side)
140178

1 Connecting flange
is sitting correctly in the groove of the connec-
ting line (4) (arrow).
4 Connecting line
5 Charge air manifold
is sitting correctly in the groove of the charge air

manifold (5) (arrow).
7 Clamp
6 - 204 !! ! D 934 A6
Mjfcifss D 936 A6
6.3 Installing and dismantling the exhaust pipes

.
Prerequisite tasks:
The exhaust turbocharger has been removed. If necessary, the thermal protection plate has been re-
moved.
The line and thermal protection plate of the crankcase
breather has been removed.
140185

1 Exhaust pipe (side piece)................................. d t Mounting bolt [0528472].
2 Multi-piece oil ring ............................................ d Check multi-piece oil ring for freedom-of-move-
ment, replace as necessary.
3 Exhaust pipe (centre piece) ............................. d t Mounting bolt [0528472].

4 Seal .................................................................. d Replace. Fit the seal so that the side with the
metal plating is facing toward the cylinder head.
5 Spacing sleeve
Note!
4 For the D 934 only an exhaust pipe is featured in place of parts 1 to 3 indicated here.
The exhaust pipe can be installed or dismantled accordingly.
D 934 A6 !! ! 6 - 205
D 936 A6 Mjfcifss
t Special tool
140238
6 - 206 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the engine brake
6.4 Installing and dismantling the engine brake
Prerequisite tasks:
The exhaust stack has been removed.
140180

1 Engine brake .................................................... ad The engine brake is screwed to the exhaust
stack.
2 Ball socket........................................................ d Grease the ball socket with copper com-
pound [e.g. Motorex 14].
3 Locking bow
4 Pneumatic cylinder
5 Hexagonal nut M8-10

6 Washer
7 Bracket
8 Hexagon socket locking screw M8x16 ............. d Replace.
D 934 A6 !! ! 6 - 207
D 936 A6 Mjfcifss
Installing and dismantling the intake manifold
6.5 Installing and dismantling the intake manifold
Prerequisite tasks:
If necessary, the air compressor line has been remo-
ved.
140174

1 Intake manifold
2 Hose clip
6 - 208 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the adapter
6.6 Installing and dismantling the adapter
Prerequisite tasks:
The crankcase breather line has been removed. If necessary, the adapter has been removed.
If necessary, the air compressor line has been remo-

ved.
140175

1 Adapter
is sitting correctly in the groove of the adapter

(1) (arrow).
3 Hexagon collar bolt M8-8.8
D 934 A6 !! ! 6 - 209
D 936 A6 Mjfcifss
Installing and dismantling the exhaust stack
6.7 Installing and dismantling the exhaust stack
140179
2 Spacing sleeve
3 Pipe clamp
5 Spacing sleeve
6 Retainer
7 Exhaust stack
8 Hexagonal nut M12-10
6 - 210 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the flange
6.8 Installing and dismantling the flange
Prerequisite tasks:
The engine brake has been removed.
140181

1 Double hexagon head screw M10x25.............. d 46 Nm.
2 Flange
3 Stud bolt M12x95-10.9
D 934 A6 !! ! 6 - 211
D 936 A6 Mjfcifss
Installing and dismantling the thermal protection plate on the exhaust pipe
6.9 Installing and dismantling the thermal protection plate on the exhaust pipe
140183
1 Thermal protection plate
2 Spacing sleeve
6 - 212 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the thermal protection plate on the turbocharger
6.10 Installing and dismantling the thermal protection plate on the turbocharger
Prerequisite tasks:
The flange has been removed.
140182

1 Thermal protection plate .................................. ad The thermal protection plate is screwed to the
exhaust pipe.
D 934 A6 !! ! 6 - 213
D 936 A6 Mjfcifss
Installing and dismantling the turbocharger
6.11 Installing and dismantling the turbocharger
Prerequisite tasks:
The connecting line has been removed. If necessary, the flange has been removed.
The adapter has been removed.
140184

1 Lube oil........................................................line d Replace.
2 Seal .................................................................. d Replace.
3 Turbocharger.................................................... a Check axial clearance and radial clearance.
d 3 Caution!
If the engine oil which is filled in is not clean, the
bearing will sustain damage the first time the
engine is started.
Fill in clean engine oil in the oil feed hole (ar-
row).
Following installation:
Replace engine oil and engine oil filter.
Clean the air lines.
Replace the air filter.
6 - 214 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the turbocharger

4 Seal .................................................................. d Replace.
6 Oil return-flow..............................................line d Replace.
7 Sealing ring ...................................................... d Replace.
8 Double hexagon head screw............................ d Tighten, 0 see tightening specification.
9 Washer
10 Hexagonal nut ................................................. d Tighten, 0 see tightening specification.
Note!
4 - the turbocharger used may feature different designs,

- the installation position may vary and only double hexagon head screws may be used with no hexagonal
nuts.
The turbocharger can be installed and dismantled accordingly for different mounting possibilities.
0 Tightening specification for turbocharger and flange

on turbocharger
Lubricant -
Stage Torque in Nm
1. 10
2. 23

140235
Lubricant -
Stage Torque in Nm
1. 10
2. 46
Hexagonal nut M8
Lubricant -
Stage Torque in Nm
1. 10
2. 23
Hexagonal nut M10

Lubricant -
Thread-locking adhesive - 140236
Stage Torque in Nm
1. 10
2. 46
D 934 A6 !! ! 6 - 215
D 936 A6 Mjfcifss
Checking axial clearance and radial clearance of the turbocharger
6.12 Checking axial clearance and radial clea-

rance of the turbocharger
Checking axial clearance

• Set the measuring pin of the dial gauge onto the face side
of the turbine wheel hub, measuring point (A).
• Push the rotor downwards and set the dial gauge to „0“.
• Push the rotor against the dial gauge; make a note of the
measured value.
Permissible axial clearance for turbocharger K27 and K29 =

0.16 mm.
140239
Checking radial clearance

Note!
4 Checking of the radial clearance is only necessary
on the turbine side.
• Set the measuring pin of the dial gauge in the middle of

the locating taper of the turbine wheel, measuring point
(B).
• Pull down the turbine wheel hub using spring balance

(measuring force: 50 N), point (C) and set the dial gauge
to „0“.
• Pull up the turbine wheel hub using spring balance

(measuring force: 50 N), point (C); make a note of the
measured value.
• Repeat the measurement with the rotor turned around
90°.
Permissible radial clearance for turbocharger K27 and K29 =

0.43 mm.
140
6 - 216 !! ! D 934 A6
Mjfcifss D 936 A6
7 Electrical system
7 Electrical system ................................................................................................................................ 7-217
7.1 Installing and dismantling the heater flange ................................................................................ 7-218
7.2 Installing and dismantling the generator ...................................................................................... 7-220
7.3 Installing and dismantling the generator belt pulley..................................................................... 7-221
7.4 Installing and dismantling the starter ........................................................................................... 7-223
7.5 Installing and dismantling the sensors......................................................................................... 7-224
7.6 Installing and dismantling the engine control unit ........................................................................ 7-226
7.7 Installing and dismantling the engine control unit-mount............................................................. 7-228

07. Kapitel_ Elektro_System.fm
D 934 A6 !! ! 7 - 217
D 936 A6 Mjfcifss
Electrical system Workshop Manual
Installing and dismantling the heater flange
7.1 Installing and dismantling the heater flange
Prerequisite tasks:
Cable disconnected at the heater flange.
Heater flange flange-mounted on the air induction pipe
140123

1 Heater flange.................................................... a Check coiled filament for damage, if necessary
replace the heater flange.
2 Earth cable
3 Hexagon ribbed nut M6 .................................... d Tighten, 0 see tightening specification.
4 Seal .................................................................. d Replace.
7 - 218 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual Electrical system
Installing and dismantling the heater flange
Heater flange installed in the air induction pipe
140124

1 Hexagonal screw M6x20-10.9.......................... a Check coiled filament for damage, if necessary
replace the heater flange.
2 Heater flange
3 Earth connection plate

4 Hexagon ribbed nut M6.................................... d Tighten, 0 see tightening specification.
0 Tightening specification for heater flange

Hexagon ribbed nut M6
Lubricant -
Stage Torque in Nm
1. 11
140077
D 934 A6 !! ! 7 - 219
D 936 A6 Mjfcifss
Installing and dismantling the generator
7.2 Installing and dismantling the generator
Prerequisite tasks:
Battery has been disconnected. The cover for the belt drive has been removed where
necessary.
Cable disconnected from generator. Ribbed V-belt has been removed.

140136

1 Generator
2 Hexagonal nut M12
3 Hexagonal nut M10
4 Washer
6 Washer
Note!
There are several different variants of generators and generator mounts, for which:
4 - the installation location may vary,

- hexagon collar bolts used instead of the hexagonal screws with washers,
- the hexagonal screws are screwed directly into the bracket.
The generator can be installed and dismantled accordingly for different mounting possibilities.
7 - 220 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the generator belt pulley
7.3 Installing and dismantling the generator belt pulley
Prerequisite tasks:
140137

1 Hexagonal nut ................................................. d Tighten, 0 see tightening specification.
2 Belt pulley
3 Bearing disc
4 Fan
5 Generator
Note!
There are different variants of generator for which:
- hexagonal collar nuts may be used instead of hexagonal nuts,
4 - different fans are used or,
- the fans are integrated in the generator.
The generator belt pulley can be installed or dismantled accordingly for these generator variants, in accor-
dance with the different tightening torques.
D 934 A6 !! ! 7 - 221
D 936 A6 Mjfcifss
Installing and dismantling the generator belt pulley
0 Tightening specification generator belt pulley

Lubricant -
Stage Torque in Nm
1. 35+10

Lubricant -
140068
Stage Torque in Nm
1. 70
Hexagonal collar nut M16x1.5

Lubricant -
Stage Torque in Nm
1. 80 ± 5

7 - 222 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the starter
7.4 Installing and dismantling the starter
Prerequisite tasks:
Cable disconnected from the starter.
140139

1 Starter
2 Hexagonal nut M10
3 Spring washer
grease to the new O-ring.
Note!
There are different starter and mount variants, mounted on the left-hand or right-hand side of the flywheel
housing, for which:
4 -hexagonal collar nuts may be used instead of hexagonal nuts with spring washers,
- the control box is mounted in another position,
- no O-ring has been fitted as a seal between starter and flywheel housing.
The starter can be installed and dismantled accordingly for different starter and mount possibilities.
D 934 A6 !! ! 7 - 223
D 936 A6 Mjfcifss
Installing and dismantling the sensors
7.5 Installing and dismantling the sensors
Prerequisite tasks:
Cable harness disconnected from corresponding sensor.
140070
Pos. Description Notes on operation 07. Kapitel_ Elektro_System.fm
1 Coolant temperature sensor M14x1.5 .............. 20 +0 /-5 Nm.

2 Charge air temperature sensor M14x1.5.......... 25 +0 /-5 Nm.
(sometimes mounted directly on the equipment)
3 Charge air pressure sensor M12x1.5 or
M18x1.5............................................................ 40 +0 /-5 Nm.
4 Fuel temperature sensor M14x1.5 ................... 20 +0 /-5 Nm.

5 Oil pressure sensor M14x1.5 ........................... 40 +0 /-5 Nm.
6 Speed sensor (camshaft sprocket)................... see installation and tightening specification.
7 Speed sensor 1 (flywheel) ............................... Hexagon socket head screw, 10 Nm.
(installed in the upper flywheel housing)
8 Speed sensor 2 (flywheel)................................ Hexagon socket head screw, 10 Nm.
(installed in the left-hand or right-hand side of
the flywheel housing)
7 - 224 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the sensors
Installation and tightening specification speed sensor

(camshaft sprocket)
Note!
Measuring of the clearance must only be carried
out if the flywheel housing has been dismantled.
4 When replacing the speed sensor:

If a distance plate (6) is featured, install the speed
sensor (4) again with distance plate (6).
If no distance plate (6) is featured, install the speed
sensor (4) again without distance plate (6).
• Measure the clearance (X) between the machined sur-

faces on the flywheel housing (1) and gear wheel cams-
haft (2).
If clearance (X) is < 35.35 mm, install distance plate (6).

If clearance (X) is ≥ 35.35 mm, do not install distance plate (6).
• Install speed sensor (4) with new O-ring (3).
• If necessary, install a distance plate (6).
Note!
4 Should a distance plate (6) be required, see spare-

parts catalogue category „Engine regulation sen-
140071
soric“.
• Tighten hexagon socket head screw (5), 10 Nm.

D 934 A6 !! ! 7 - 225
D 936 A6 Mjfcifss
Installing and dismantling the engine control unit
7.6 Installing and dismantling the engine control unit
Prerequisite tasks:
The respective fuel lines have been dismantled.
140119
1 Engine control unit

2 Washer
3 Hexagon socket head screw M6-8.8
4 Seal .................................................................. d Ensure that the seal is sitting correctly on the
connector and does not shift when inserted.
5 Connector
6 Hexagon socket head screw M5 ...................... d Tighten, 0 see tightening specification.
7 - 226 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the engine control unit
0 Tightening specification for engine control unit plug

Hexagon socket head screw M5
Lubricant -
Stage Torque in Nm
1. 2.8 -0.0 / +0.3
140378
D 934 A6 !! ! 7 - 227
D 936 A6 Mjfcifss
Installing and dismantling the engine control unit-mount
7.7 Installing and dismantling the engine control unit-mount
Prerequisite tasks:
The engine control unit has been dismantled.
Engine control unit-mount on air induction pipe and cable harness retainer
140120

2 Washer
3 Spacing sleeve
4 Compression spring ......................................... a Check compression spring for hardening and
swelling, replace as necessary.
5 Retainer
7 Retainer
7 - 228 !! ! D 934 A6
Mjfcifss D 936 A6
Engine control unit-mount on the air induction pipe
140121

1 Spacing sleeve................................................. d Only featured on certain mount designs.
3 Retainer
4 Hexagonal screw M8-8.8 ................................. d Apply a coating of Loctite 243 and tighten, 0
D 934 A6 !! ! 7 - 229
D 936 A6 Mjfcifss
Engine control unit-mount on the flywheel housing
140122

2 Washer

3 Retainer
4 Hexagonal screw M8x45-8.8............................ d Apply a coating of Loctite 243 and tighten, 0
6 Retainer
7 Hexagonal nut M10
8 Retainer
9 Stud bolt M10-8.8
7 - 230 !! ! D 934 A6
Mjfcifss D 936 A6
0 Tightening specification for control unit mount

Hexagon head screw M8-8.8
Lubricant -
Stage Torque in Nm
1. 10
140062
D 934 A6 !! ! 7 - 231
D 936 A6 Mjfcifss

7 - 232 !! ! D 934 A6
Mjfcifss D 936 A6
8 Lubrication system
8 Lubrication system ............................................................................................................................. 8-233
8.1 Installing and dismantling the crankcase breather ...................................................................... 8-234
8.2 Installing and dismantling the oil return-flow line (crankcase breather) ....................................... 8-236
8.3 Installing and dismantling the oil dipstick and guide tube ............................................................ 8-237
8.4 Installing and dismantling the oil intake ....................................................................................... 8-238
8.5 Installing and dismantling the multi-part oil sump and ladder frame (D 936)............................... 8-240
8.6 Installing and dismantling the single-unit oil sump ...................................................................... 8-246
8.7 Installing and dismantling the connector (oil sump - crankcase) (D 934) .................................... 8-250
8.8 Installing and dismantling the oil suction pipe (D 936) ................................................................ 8-251
8.9 Installing and dismantling the ladder frame ................................................................................. 8-252
8.10 Installing and dismantling the oil cooler housing with oil cooler .................................................. 8-253
8.11 Dismantling and installing the oil pressure pump ........................................................................ 8-255
8.12 Installing and dismantling the oil suction pump (D 936) .............................................................. 8-257
8.13 Installing and dismantling the piston cooling nozzle .................................................................... 8-258
8.14 Dismantling and installing the sealing parts of the oil suction pump ........................................... 8-260
8.15 Installing and dismantling the final regulating valve .................................................................... 8-261
8.16 Check the oil pressure, adjust as necessary ............................................................................... 8-264

08. Kapitel_Schmier_System.fm
D 934 A6 !! ! 8 - 233
D 936 A6 Mjfcifss
Lubrication system Workshop Manual
Installing and dismantling the crankcase breather
8.1 Installing and dismantling the crankcase breather
140168

1 Crankcase breather.......................................... d If necessary, adjust alignment to the housing (4)
(arrow).
2 Hose clip
3 Hexagon collar bolt M8-8.8 .............................. d Apply a coating of Loctite 243.
4 Housing
5 Hose clip
6 Seal .................................................................. d Replace.
7 Washer

9 Hose line
11 Hexagonal nut M8
12 Thermal protection plate
14 Spacer washer
8 - 234 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual Lubrication system
Installing and dismantling the crankcase breather
Note!
4 - the thermal protection plate may differ,
- hexagon collar bolts may be used instead of the hexagonal screws with washer.
The crankcase breather can be installed and dismantled accordingly for different mounting possibilities.
D 934 A6 !! ! 8 - 235
D 936 A6 Mjfcifss
Installing and dismantling the oil return-flow line (crankcase breather)
8.2 Installing and dismantling the oil return-flow line (crankcase breather)
140189

1 Hose clip
2 Oil return-flow line
3 Clamp
5 Clamp
Note!
4 - the length of the line may differ,

- the screw dimensions may vary
- and for which no sealing rings are featured.
The oil return-flow line can be installed and dismantled accordingly for different mounting possibilities.
8 - 236 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the oil dipstick and guide tube
8.3 Installing and dismantling the oil dipstick and guide tube
140186

1 Oil dipstick

3 Spacer
4 Guide tube with clamp
5 Screw plug ....................................................... d Replace screw plug wherever necessary.
6 Sealing ring ..................................................... d Replace.
Note!
- the installation point may differ
4 - the length and retainer on the engine may vary

- and the screw plug with integrated Viton-sealing may be featured instead of the screw plug with separate
sealing rings.
The oil dipstick and guide tube can be installed and dismantled accordingly for different mounting possi-
bilities.
D 934 A6 !! ! 8 - 237
D 936 A6 Mjfcifss
Installing and dismantling the oil intake
8.4 Installing and dismantling the oil intake
Oil intake on the oil sump or flywheel housing
140187
1 Oil intake
4 Seal .................................................................. d Replace.
Note!
4 - the installation point may differ
- and the oil intake may not be fastened.

The oil intake can be installed and dismantled accordingly for different mounting possibilities.
8 - 238 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the oil intake
Oil intake on the aggregate carrier (connection for power take-off 4)
140188

2 Oil intake

is sitting correctly in the groove of the oil intake
(2) (arrow).
D 934 A6 !! ! 8 - 239
D 936 A6 Mjfcifss
Installing and dismantling the multi-part oil sump and ladder frame (D 936)
8.5 Installing and dismantling the multi-part oil sump and ladder frame (D 936)
Prerequisite tasks:
Oil has been drained. The oil dipstick has been removed.
The oil return-flow line (crankcase breather) has been If necessary, the oil intake has been removed.
removed.
Summary and general notes
140190
Pos. Description
A Plate (with / without camber for oil suction
pump)
B Oil sump
C Plate
D Oil suction pipe, sealing cap, perforated metal
plate
E Ladder frame
8 - 240 !! ! D 934 A6
Mjfcifss D 936 A6
Note!
- the oil sump may be mounted on the aggregate carrier side, in the centre or on the flywheel side,
4 - the oil sump may feature varying oil capacities,
- the plate( A) and the oil sump (B) are designed as single units,
- two plates (A) and an oil sump (B) are mounted
- and an oil suction pump is installed with closure parts and perforated metal plate.
Caution!
The installation position and installation point for individual parts can be swapped over.
3 Before removing the oil sump:

Mark the parts to indicate that they belong together, thus ensuring that the parts can be reinstalled in their
original installation point and in their original installation position.
0 Tightening specification for the oil drain valve

Lubricant -
Stage Torque in Nm
1. 110
140075
D 934 A6 !! ! 8 - 241
D 936 A6 Mjfcifss
A and C: installing and dismantling the plate (with / without camber for oil suction pump)
140191

1 Plate (with / without camber for oil suction
pump)
d
2 Seal .................................................................. Replace.
3 Hexagon collar bolt M8..................................... a Mark the installation point.
6 Screw plug M14x1.5
Note!
4 Depending on the installation point of the plate (1), hexagon collar bolts (3, 4 and 5) featuring the same or
varying lengths, as well as varying tensile strengths (8.8 or 10.9) are fitted.
8 - 242 !! ! D 934 A6
Mjfcifss D 936 A6
B: installing and dismantling the oil sump
140192

1 Seal .................................................................. d Replace.
2 Plate ................................................................. a Mark insertion.

4 Oil sump
5 Hexagon collar bolt M8-8.8 .............................. a Mark the installation point.
6 Hexagon collar bolt M8-8.8 .............................. a Mark the installation point.
7 Oil drain valve .................................................. d Apply a coating of Omnivisc 1050, 0 see tigh-
tening specification.
10 Oil return-flow pipe

12 Retainer
14 Washer
15 Clamp
Note!
4 Depending on the installation point of the oil sump (4) hexagon collar bolts (5 and 6) are fitted with the
same or varying lengths.
D 934 A6 !! ! 8 - 243
D 936 A6 Mjfcifss
D: installing and dismantling the oil suction pipe, sealing cap and perforated metal plate
140193

1 Perforated metal plate ...................................... a Mark the installation point.
3 Sealing cap....................................................... a Mark the installation point.
5 Seal .................................................................. d Replace.
7 Oil suction pipe................................................. a Mark the installation point.
8 Seal .................................................................. d Replace.
Note!
Depending on the installation point of the oil sump, the oil suction pipe may be installed in a number of
4 different locations.
Depending on whether an oil suction pump is featured or not, the sealing cap and the perforated metal
plate is installed in different locations.
8 - 244 !! ! D 934 A6
Mjfcifss D 936 A6
E: installing or dismantling the ladder frame
140194

1 Seal .................................................................. d Replace.
2 Sealing ring (for engines featuring oil suction d Replace O-ring and apply a coating of oil. Ensu-
pump) ............................................................... re that the sealing rings are sitting correctly in

the grooves of the oil suction pump (6) and the
ladder frame (3). The side of the sealing ring
featuring the double sealing lip (arrow A) must
be pointing towards the oil suction pump (6).
3 Ladder frame
4 Spring washer .................................................. d Replace.
6 Oil suction pump
D 934 A6 !! ! 8 - 245
D 936 A6 Mjfcifss
Installing and dismantling the single-unit oil sump
8.6 Installing and dismantling the single-unit oil sump
Prerequisite tasks:
Oil has been drained. The oil dipstick has been removed.
The oil return-flow line (crankcase breather) has been
removed.
D 934
140195

1 Seal .................................................................. d Replace.
3 Cover
4 Perforated metal plate
5 Oil sump
7 Drain valve ....................................................... d Apply a coating of Omnivisc 1050, 0 see tigh-
10 Oil return-flow pipe
8 - 246 !! ! D 934 A6
Mjfcifss D 936 A6
Note!
4 - the oil sump may feature different oil capacities,
- the oil return-flow pipe is not featured.
The oil sump can be installed and dismantled accordingly for different mounting possibilities.

Lubricant -
Stage Torque in Nm
1. 110
140075
D 934 A6 !! ! 8 - 247
D 936 A6 Mjfcifss
D 936
140196

1 Hexagon collar bolt M8x20-8.8......................... d Apply a coating of Omnivisc 1050.
2 Baffle
3 Seal .................................................................. d Replace.
4 Oil sump
5 Hexagon collar bolt M8x120-8.8....................... a Mark the installation point.
7 Oil drain valve................................................... d Apply a coating of Omnivisc 1050, 0 see tigh-
8 Hexagon collar bolt M8x70-8.8......................... a Mark the installation point.
Note!
4 - the oil sump may feature different oil capacities,

- the baffle is not available
- and the hexagon collar bolts are fitted with the same or varying lengths.
The oil sump can be installed and dismantled accordingly for different mounting possibilities.
8 - 248 !! ! D 934 A6
Mjfcifss D 936 A6

Lubricant -
Stage Torque in Nm
1. 110
140075
D 934 A6 !! ! 8 - 249
D 936 A6 Mjfcifss
Installing and dismantling the connector (oil sump - crankcase) (D 934)
8.7 Installing and dismantling the connector (oil sump - crankcase) (D 934)
Prerequisite tasks:
The single-unit oil sump (D 934) has been removed.
140197
1 O-ring 40.87 x 3.53........................................... d Apply a light coating of oil to the O-ring. Ensure
that the O-ring is sitting correctly in the groove
of the connector (2) (arrow).
2 Connector
3 O-ring 40.64 x 5.33........................................... d Apply a light coating of oil to the O-ring. Ensure

of the connector (2) (arrow).
8 - 250 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the oil suction pipe (D 936)
8.8 Installing and dismantling the oil suction pipe (D 936)
Prerequisite tasks:
The single-unit oil sump (D 936) has been removed.
140198

1 O-ring 40.64 x 5.33 .......................................... d Apply a light coating of oil to the O-ring. Ensure
in the oil sump (2) (arrow).
2 Oil suction pipe
3 Hexagon collar bolt M8x16-8.8 ........................ d Apply a coating of Loctite 243.
4 Pipe clamp
Note!
4 There are different mounting possibilities for which:

- the length of the oil suction pipe may differ,
The oil suction pipe can be installed and dismantled accordingly for different mounting possibilities.
D 934 A6 !! ! 8 - 251
D 936 A6 Mjfcifss
Installing and dismantling the ladder frame
8.9 Installing and dismantling the ladder frame
Prerequisite tasks:
The single-unit oil sump has been removed.
140199
1 Ladder frame
2 Washer
Note!

- the length of the hexagonal screws may differ.
The ladder frame can be installed and dismantled accordingly for different mounting possibilities.
8 - 252 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the oil cooler housing with oil cooler
8.10 Installing and dismantling the oil cooler housing with oil cooler
.
Prerequisite tasks:
The coolant has been drained, see operating instruc-
tions.
The oil has been drained, see operating instructions.
140245

3 Oil cooler housing with oil cooler a Do not unscrew the screws indicated by the ar-
rows, these screws are securing the oil cooler to
the oil cooler housing.

d t Mounting bolt [0524059].
5 Seal .................................................................. d Replace.
A D936
B D934
D 934 A6 !! ! 8 - 253
D 936 A6 Mjfcifss
Installing and dismantling the oil cooler housing with oil cooler
Note!
4 - no O-rings are featured,

- different oil coolers are featured with varying numbers of fins.
The oil cooler housing with oil cooler can be installed and dismantled accordingly for these mount possi-
bilities.
t Special tool
140246
8 - 254 !! ! D 934 A6
Mjfcifss D 936 A6
Dismantling and installing the oil pressure pump
8.11 Dismantling and installing the oil pressure pump
Prerequisite tasks:
140268

3 Oil pressure pump............................................ d The conveyor wheel width is stamped in the
housing (arrow A). Ensure that the dowel pin is
sitting correctly in the borehole of the crankcase
(arrow B).
Check the tooth backlash between idler and

crankshaft gear wheel.
Set value = 0.150 - 0.285 mm.
4 Replace O-ring 34.59x2.62 .............................. d Replace O-ring and apply a coating of oil.
groove of the oil pressure pump (arrow C).
5 Replace O-ring 39,34x2.62 .............................. d and apply a light coating of oil.
groove of the oil pressure pump (arrow D).
D 934 A6 !! ! 8 - 255
D 936 A6 Mjfcifss
Dismantling and installing the oil pressure pump
Note!

- the conveyer wheel width is different.
The oil pressure pump can be installed and dismantled accordingly for different mounting possibilities.
8 - 256 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the oil suction pump (D 936)
8.12 Installing and dismantling the oil suction pump (D 936)
Prerequisite tasks:
140269

2 Oil suction pump .............................................. d The conveyor wheel width is stamped in the
housing (arrow C). Ensure that the dowel pin is
sitting correctly in the borehole of the crankcase
(arrow B).
Check the tooth backlash between idler and
crankshaft gear wheel.

Set value = 0.150 - 0.285 mm.
3 O-ring 7.00x1.50 .............................................. d Replace O-ring and apply a coating of oil.
groove of the oil suction pump (arrow A).
Note!

- the conveyer wheel width is different.
The oil suction pump can be installed and dismantled accordingly for different mounting possibilities.
D 934 A6 !! ! 8 - 257
D 936 A6 Mjfcifss
Installing and dismantling the piston cooling nozzle
8.13 Installing and dismantling the piston cooling nozzle
Prerequisite tasks:
The multi-part oil sump has been removedp. If necessary, the ladder frame has been removed.
If necessary, the single-unit oil sump has been remo- The crankshaft has been turned to allow access to the
ved. cooling nozzle.
140200

1 Piston cooling nozzle........................................ a Ensure when unscrewing the banjo bolt that the
piston cooling nozzle does not shore up on the
piston skirt and bend.
2 Banjo bolt ......................................................... d Tighten, 0 see tightening specification.

A Steel piston (with cooling duct)
B Aluminium piston (without cooling duct)
8 - 258 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the piston cooling nozzle
0 Tightening specification for piston cooling nozzle

Banjo bolt M12x1.5
Lubricant -
Stage Torque in Nm
1. 30
140065
D 934 A6 !! ! 8 - 259
D 936 A6 Mjfcifss
Dismantling and installing the sealing parts of the oil suction pump
8.14 Dismantling and installing the sealing parts of the oil suction pump
Prerequisite tasks:
140267
1 Hexagonal screw M8x16-8.8............................ d Apply a coating of Loctite 243.
2 Sealing cap
3 O-ring 7.00x1.50............................................... d Replace O-ring and apply a coating of oil.
groove of the sealing cap (arrow).
4
Note!
The sealing parts of the oil suction pump are installed if no oil suction pump is installed in the engine.
8 - 260 !! ! D 934 A6
Mjfcifss D 936 A6
8.15 Installing and dismantling the final regulating valve
Prerequisite tasks:
If necessary, the generator has been removed.
If necessary, the air-conditioning compressor and generator mount have been dismantled.
140323
Pos. Description
1 Sealing nut M12 ............................................... d Replace, 0 see tightening specification.
2 Locking screw
4 Adjusting ................................................. screw d Continue to screw in until the basic adjusting di-
mension A = 17.2 +0.3 / -0.3 mm can be adhe-
red to.
Following assembly: check the oil pressure, ad-
just as necessary.
5 Compression spring
6 Piston
7 Valve seat ........................................................ a Pull out using a commercially-approved interior
extractor.
d Drive in valve seat featuring t stamp
[0523639] all the way to the stop in the aggrega-
te carrier (8).
8 Aggregate carrier
D 934 A6 !! ! 8 - 261
D 936 A6 Mjfcifss
t Special tool
140324

Stamp [0523639]
Previously
140371
Now
A = 27 +0.0 / -0.2 mm (as previously)

A = 90 mm
140372 08. Kapitel_Schmier_System.fm

8 - 262 !! ! D 934 A6
Mjfcifss D 936 A6
Description
Interior extractor
for the following dimensions:

A = Ø 17 mm
B = 100 mm
140373
0 Tightening specification for final regulating valve

Sealing nut M12
Lubricant -
Stage Torque in Nm
1. 50
140325
D 934 A6 !! ! 8 - 263
D 936 A6 Mjfcifss
Check the oil pressure, adjust as necessary
8.16 Check the oil pressure, adjust as necessary
Prerequisite tasks:
The engine has been run up to an oil temperature of 90-100 °C.
140326
Pos. Description
1 Final regulating valve
2 Screw plug
3 Sealing nut M12
4 Adjusting screw
Technical Data
Nominal speed
Speed 2100 2000 1900 1800 1000

in rpm
Oil pressure 4.9 - 6.2 4.8 - 6.2 4.7 - 6.2 4.6 - 6.2 ≥ 2.5
in bar
Oil temper 90 - 100 90 - 100 90 - 100 90 - 100 90 - 100

ature in °C
8 - 264 !! ! D 934 A6
Mjfcifss D 936 A6
0 Tightening specification for final regulating valve

Sealing nut M12
Lubricant -
Stage Torque in Nm
1. 50
140325
Note!
4 The oil pressure is set at the factory and normally
does not require any adjusting.
• Arrest the adjusting screw (4) and loosen the sealing nut
(3). Ensure that the screw plug (2) does not loosen.
• Screw in the adjusting screw (4):

Oil pressure increases.
• Unscrew the adjusting screw (4):

Oil pressure reduces.
140327
Following adjustment:
• Arrest the adjusting screw (4) and tighten the sealing nut
(3), 0 see tightening torque.
D 934 A6 !! ! 8 - 265
D 936 A6 Mjfcifss
8 - 266 !! ! D 934 A6
Mjfcifss D 936 A6
9 Cooling system
9 Cooling system ................................................................................................................................... 9-267
9.1 Installing and dismantling the coolant vent line ........................................................................... 9-268
9.2 Installing and dismantling the coolant pump................................................................................ 9-269
9.3 Installing and dismantling the coolant manifold (on the thermostat housing or
aggregate carrier) ........................................................................................................................ 9-271
9.4 Installing and dismantling the thermostat housing and thermostat.............................................. 9-273
9.5 Checking the thermostat.............................................................................................................. 9-274

09. Kapitel_Kühl_System.fm
D 934 A6 !! ! 9 - 267
D 936 A6 Mjfcifss
Cooling system Workshop Manual
Installing and dismantling the coolant vent line
9.1 Installing and dismantling the coolant vent line
Prerequisite tasks:
tions.
140169
1 Coolant vent line
3 Hose nipple M14x1.5
4 Banjo bolt M14x1.5
9 - 268 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual Cooling system
Installing and dismantling the coolant pump
9.2 Installing and dismantling the coolant pump
Prerequisite tasks:
tions.
140241

1 Coolant pump................................................... a If necessary, screw in two screws M8 in the
threaded bores (arrow A) and push out the
coolant pump evenly from the aggregate carrier
(8).
2 O-ring 68.26x3.53 ............................................ d Replace the O-ring, apply a coating of grea-

ring is sitting correctly in the groove of the
coolant pump (1) (arrow C).
3 O-ring 113.89x3.53 .......................................... d Replace the O-ring, apply a coating of grea-
coolant pump (1) (arrow B).
ring is sitting correctly in the groove of the ag-
gregate carrier (8) (arrow D).
D 934 A6 !! ! 9 - 269
D 936 A6 Mjfcifss
Installing and dismantling the coolant pump

6 Hose
9 - 270 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the coolant manifold (on the thermostat housing or aggregate carrier)
9.3 Installing and dismantling the coolant manifold (on the thermostat housing or ag-
gregate carrier)
Prerequisite tasks:
tions.
140242

1 Seal .................................................................. d Replace.
2 Cover

coolant manifold (5) (arrow).
5 Coolant manifold (straight)
coolant manifold (8) (arrow).
8 Coolant manifold (90°)
D 934 A6 !! ! 9 - 271
D 936 A6 Mjfcifss
Installing and dismantling the coolant manifold (on the thermostat housing or aggregate carrier)

12 Aggregate carrier
Note!
4 - only coolant manifolds (straight ) are featured,

- only coolant manifolds (90°) are featured,
- the coolant manifolds are mounted in varying combinations in the positions represented above.
The coolant manifolds can be installed and dismantled accordingly for different mounting possibilities.
9 - 272 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the thermostat housing and thermostat
9.4 Installing and dismantling the thermostat housing and thermostat
Prerequisite tasks:
tions.
If necessary, the connecting line (turbocharger - inter- If necessary, the coolant manifolds (on the thermostat
cooler) has been removed. housing or on the aggregate carrier) have been remo-
ved.
140243

2 Retainer
4 Seal
5 Support ring
6 Thermostat
Note!
4 - the thermostat housing and coolant manifolds are designed as single units.
The thermostat housing and thermostat can be installed and dismantled accordingly for different mount
possibilities.
D 934 A6 !! ! 9 - 273
D 936 A6 Mjfcifss
Checking the thermostat
9.5 Checking the thermostat
Prerequisite tasks:
The thermostat has been removed.
140328
Pos. Description
1 Thermostat
The opening begin has been engraved (arrow)
Technical Data
Thermostat 79 °C Thermostat 83 °C
Temperature at 79 83
opening begin
in °C
Temperature at full 92 98
opening
in °C
Stroke (A) at full min. 8 min. 8

opening in mm
9 - 274 !! ! D 934 A6
Mjfcifss D 936 A6
• Secure the thermostat to a wire and immerse in a water

bath.
• Measure the water temperature and warm the tempera-

ture.
• Observe opening begin of the thermostat.
• Compare the measured value with the technical data.

D 934 A6 !! ! 9 - 275
D 936 A6 Mjfcifss
9 - 276 !! ! D 934 A6
Mjfcifss D 936 A6
10 Power take-off and air / air-conditioning compressor
10 Power take-off and air / air-conditioning compressor ................................................................... 10-277
10.1 Installing and dismantling the power take-off for fuel delivery pump ......................................... 10-278
10.6 Installing and removing the power take-off on the flywheel housing ......................................... 10-285
10.6.1 Removing .................................................................................................................... 10-286

10.6.2 Installation ................................................................................................................... 10-287
10.7 Dismantling and installing the switchable power take-off on the flywheel housing.................... 10-289
10.7.1 Removing .................................................................................................................... 10-290

10.7.2 Installation ................................................................................................................... 10-291
10.8 Installing and dismantling the air-conditioning compressor ....................................................... 10-293

11. Kapitel_ NA_LP.fm
D 934 A6 !! ! 10 - 277
D 936 A6 Mjfcifss
Power take-off and air / air-conditioning compressor Workshop Manual
Installing and dismantling the power take-off for fuel delivery pump
10.1 Installing and dismantling the power take-off for fuel delivery pump
Prerequisite tasks:
The fuel delivery pump has been removed.
140118

1 Power take-off
groove of the power take-off (arrow).
10 - 278 !! ! D 934 A6
Mjfcifss D 936 A6
Workshop Manual Power take-off and air / air-conditioning compressor
Dismantling and removing power take-off 1
10.2 Dismantling and removing power take-off 1
Prerequisite tasks:
Hydraulic pump has been removed.
140261

1 Hexagonal nut M10 .......................................... d Apply a coating of Loctite 243.

2 O-ring 101.20x3.53 .......................................... d Replace O-ring and apply a coating of oil. Ensu-
ve of the power take-off (arrow A).
3 Hexagonal screw M10x35-8.8.......................... d Apply a coating of Loctite 243.
4 Power take-off 1
5 Lube oil line

ve of the power take-off (arrow B).
D 934 A6 !! ! 10 - 279
D 936 A6 Mjfcifss
Note!
4 - different connect flanges are featured,

- the power take-off is fastened with hexagonal screws only or with hexagonal nuts only,
- no O-ring (2) is featured.
Power take-off 1 can be installed and dismantled accordingly for different mounting possibilities.

10 - 280 !! ! D 934 A6
Mjfcifss D 936 A6
Prerequisite tasks:
140262

1 Hexagon socket head screw M10x35-10.9 ...... d Apply a coating of Loctite 243.
2 O-ring 82,22x2.62 ............................................ d Replace O-ring and apply a coating of oil. Ensu-
3 Power take-off 2
4 O-ring 91.67x3.53 ............................................ d Replace O-ring and apply a coating of oil. Ensu-

5 Lube oil line
D 934 A6 !! ! 10 - 281
D 936 A6 Mjfcifss
Prerequisite tasks:
140263

1 Hexagon socket head screw M10x25-8.8 ........ d Apply a coating of Loctite 577.
2 Power take-off 3
3 O-ring 85.32x3.53............................................. d Replace O-ring and apply a coating of oil. Ensu-
ve of the power take-off (arrow).
10 - 282 !! ! D 934 A6
Mjfcifss D 936 A6
Prerequisite tasks:
140264

1 Hexagon socket head screw M10x30-10.9 ...... d Apply a coating of Loctite 243.
3 Banjo bolt
4 Sealing ring d Replace.
5 Lube oil line

7 Power take-off 4
D 934 A6 !! ! 10 - 283
D 936 A6 Mjfcifss
Note!
4 - different connection flanges are featured,

- the lube oil line is used with cap nut and compression ring instead of banjo bolt and sealing ring,
- no O-ring (2) is featured.
Power take-off 4 can be installed and dismantled accordingly for different mounting possibilities.

10 - 284 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and removing the power take-off on the flywheel housing
10.6 Installing and removing the power take-off on the flywheel housing
Prerequisite tasks:
Hydraulic pumps have been removed.
140409
Pos. Description
1 Power take-off
D 934 A6 !! ! 10 - 285
D 936 A6 Mjfcifss
10.6.1 Removing
• Place a suitable collecting vessel beneath.
• Unscrew the oil drain plug from the flywheel housing

(arrow).
• Drain the oil and dispose of in the correct manner.
• Tighten the oil drain plug (arrow).
140248
• Disconnect the lube oil line.
140249
• Unscrew the hexagon nuts and remove the hexagon

socket head screws.
140250
• Remove the power take-off from the flywheel housing.

140251
10 - 286 !! ! D 934 A6
Mjfcifss D 936 A6
10.6.2 Installation
• Insert the new O-ring with grease in the groove of the lube
oil borehole in the flywheel housing (arrow).
140252
• Apply a light coating of grease to the new O-ring and

insert in the groove of the power take-off (arrow).
140252
• Install the power take-off in the flywheel housing (Ensure

that the teeth engage).
• Insert the hexagon socket head screws and tighten the

hexagonal screws.
140250
• Connecting the lube oil line.

140249
D 934 A6 !! ! 10 - 287
D 936 A6 Mjfcifss
• Fill in approx. 1 l engine oil.
• Start up the engine, shut down again and check the

engine oil level, rectify as required.
Note!
There are different mounting possibilities for
which:
4 - a cover plate is mounted in place of the power
take-off.
These mount variants can be dismantled and in-
stalled accordingly.

10 - 288 !! ! D 934 A6
Mjfcifss D 936 A6
Dismantling and installing the switchable power take-off on the flywheel housing
10.7 Dismantling and installing the switchable power take-off on the flywheel housing
Prerequisite tasks:
Propshaft has been dismantled.
140410
Pos. Description
1 Switchable power take-off
D 934 A6 !! ! 10 - 289
D 936 A6 Mjfcifss
10.7.1 Removing
• Place a suitable collecting vessel beneath.
• Unscrew the oil drain plug from the flywheel housing

(arrow).
• Drain the oil and dispose of in the correct manner.
• Tighten the oil drain plug (arrow).
140254
• Disconnect the compressed air lines.
• Disconnect the cable from the proximity switch.
• Loosen the lock nut and unscrew the proximity switch.
140255
• Unscrew the hexagon nuts and remove the hexagon head

screws.
140256
• Remove the power take-off from the flywheel housing.

140257
10 - 290 !! ! D 934 A6
Mjfcifss D 936 A6
10.7.2 Installation
• Insert the new O-ring with grease in the groove of the lube
oil borehole in the flywheel housing (arrow).
140258
• Apply a light coating of grease to the new O-ring and

insert in the groove of the power take-off (arrow).
140
• Install the power take-off in the flywheel housing (Ensure

that the teeth engage).
• Insert the hexagon socket head screws and tighten the

hexagonal screws.
140256
• Connect the compressed air lines.
• Screw in the proximity switch slightly.

• Apply compressed air until the power take-off is activated.
• Screw in the proximity switch all the way and unscrew

around half a turn again (180°). This corresponds with a
setting dimension of A = 0.5 mm.
140260
D 934 A6 !! ! 10 - 291
D 936 A6 Mjfcifss
• Tighten the lock nut.
• Connect the cable.
140255
• Fill in approx. 1 l engine oil.
• Start up the engine, shut down again and check the

engine oil level, rectify as required.

10 - 292 !! ! D 934 A6
Mjfcifss D 936 A6
Installing and dismantling the air-conditioning compressor
10.8 Installing and dismantling the air-conditioning compressor
Prerequisite tasks:
Battery has been disconnected. Lines on the air-conditioning compressor have been
dismantled.
The air-conditioning system has been drained. The cover for the belt drive has been removed where
necessary.
Cable disconnected from the air-conditioning compres- Ribbed V-belt has been removed.
sor.
140138

1 Air-conditioning compressor
D 934 A6 !! ! 10 - 293
D 936 A6 Mjfcifss
Installing and dismantling the air-conditioning compressor

10 - 294 !! ! D 934 A6
Mjfcifss D 936 A6
.

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Manual Motor Liebherr

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Workshop Manual en

upwards of serial number 2004-03-0000 / 2004-04-0000

Type: D 934 A6 / D 936 A6

Cleanliness and order contribute toward safety in the workplace.

Sealing components (e.g. O-rings, seals, etc.) should essentially be replaced.

Dismantled parts should be checked for reusability, and replaced as required.

HERR diesel engines.

Fuels and lubricants

The workshop manual at hand is available in German, English and French.

Modifications, requirements and copyright

1 General information .............................................................................................................................. 1-11

1.1 Structure of this manual................................................................................................................. 1-14

1.2 Important notes within this manual ................................................................................................ 1-16

1.3 Symbols in this manual.................................................................................................................. 1-17

1.4 Notes on safety.............................................................................................................................. 1-18

1.4.1 General notes on safety .................................................................................................. 1-18

1.5 Technical Data............................................................................................................................... 1-22

1.5.1 Engine in general ............................................................................................................ 1-22

flywheel side.............................................................................................................. 1-34

Tightening specification heater flange....................................................................... 1-40

Tightening specification for engine control unit plug ................................................. 1-45

1.6 Representations of the engine and engine components ............................................................... 1-48

1.7 Diagram of the fuel system ............................................................................................................ 1-57

1.8 Diagram of lube oil system ............................................................................................................ 1-59

1.9 Diagram of coolant system ............................................................................................................ 1-60

1.11 Tools .............................................................................................................................................. 1-63

1.11.1 Special tools .................................................................................................................... 1-63

Installing and dismantling the rear crankshaft seal ................................................... 1-79

2 Cylinder head, engine control and valves .......................................................................................... 2-81

2.3 Installing and dismantling the cylinder head .................................................................................. 2-84

2.4.1 Removing ........................................................................................................................ 2-88

2.6 Dismantling and installing the camshafts ...................................................................................... 2-91

2.6.1 Removing ........................................................................................................................ 2-92

3 Engine .................................................................................................................................................... 3-95

3.1 Checking combustion pressure ..................................................................................................... 3-97

3.2.1 Summary ....................................................................................................................... 3-100

Installation ............................................................................................................... 3-105

3.3 Installing and dismantling the cylinder liner ................................................................................. 3-110

3.4 Checking excess length of the cylinder liners.............................................................................. 3-112

3.5 Installing and dismantling the generator mount ........................................................................... 3-113

3.7 Installing and dismantling crankshaft accessories....................................................................... 3-117

3.8.1 General notes................................................................................................................ 3-120

3.8.3 Installation ..................................................................................................................... 3-121

3.9 Installing and dismantling the aggregate carrier .......................................................................... 3-125

3.10 Installing and dismantling the flywheel ........................................................................................ 3-127

3.10.1 Removing ...................................................................................................................... 3-130

3.11.1 General notes ................................................................................................................ 3-134

3.12 Dismantling and installing the flywheel housing .......................................................................... 3-138

3.13 Dismantling and installing the idler .............................................................................................. 3-140

3.14 Installing and dismantling the crankshaft ..................................................................................... 3-142

3.14.1 Removing ...................................................................................................................... 3-145

4 Fuel system and injection system ..................................................................................................... 4-153

4.2 Installing and dismantling fuel lines ............................................................................................. 4-155

4.7 Installing and dismantling the injection lines ................................................................................ 4-167

4.7.1 Removing ...................................................................................................................... 4-168

4.8.1 Removing ...................................................................................................................... 4-171

4.8.2 Installation ..................................................................................................................... 4-172

4.9.1 Check the injection nozzle............................................................................................. 4-177

4.10 Draining the fuel ducts in the crankcase...................................................................................... 4-184

4.11.1 Removing ...................................................................................................................... 4-191

5 Belt drive ............................................................................................................................................. 5-195

6 Charge air and exhaust system ......................................................................................................... 6-199

6.3 Installing and dismantling the exhaust pipes ............................................................................... 6-205

6.4 Installing and dismantling the engine brake ................................................................................ 6-207