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Man D2066 - LOH01 - 12
Man D2066 - LOH01 - 12
Repair manual
81.99185-5342 4th edition A 41 Stage 2
MAN Truck & Bus AG Repair manual A 41 Stage 2, 4th edition
Dachauer Str. 667 Common rail In-line Engine
80995 MÜNCHEN D2066 LOH01 - LOH08
or D2066 LOH10 - LOH12
Postfach 50 06 20 - Englisch -
80976 MÜNCHEN Printed in Germany
Repair manual A 41 Stage 2
4th edition
81.99185-5342
1
PREFACE/PUBLICATION DATA
PREFACE
These instructions are intended as a guide to help perform repair work on vehicles and units correctly.
This publication assumes that persons who use it possess the requisite technical knowledge in handling
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always corre-
spond to the unit in question, but this does not necessarily mean they are incorrect. In such cases, plan and
carry out the repair work in accordance with the sense of the instructions.
Repair work on complex add-on units should be entrusted to our customer service or to the customer service
of the manufacturing company. These units are mentioned specifically in the text.
The repair work is broken down into chapters and sub-chapters. Each subsection begins with a preliminary
page The preliminary page contains a summary of the main prerequisites for the repair section in question.
This preliminary page may be followed by a detailed description of the work.
Important instructions concerning technical safety and the safety of personnel are specifically highlighted, as
indicated below.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed in order to avoid exposing
people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed in order to avoid material
damage or destruction.
Note
An explanatory note which is useful for understanding the working or operating procedure to be
performed.
Comply with general safety regulations when performing any repair work.
Yours faithfully,
Munich plant
PUBLICATION DATA
Not to be reprinted, duplicated by any means whatsoever or translated – in whole or in part – without the
prior written approval of MAN Truck & Bus AG. All rights under the copyright law are strictly reserved by MAN
Truck & Bus AG. If any changes or modifications are made without the written approval of MAN Truck & Bus
AG, then MAN Truck & Bus AG shall not be liable for any material defects attributable to the unauthorised
changes or modifications. MAN Truck & Bus AG is not liable for any damage attributable to unauthorised
changes or modifications.
Editorial Department: SAWDS, 2W Technische Informations GmbH & Co. KG, 07.2015
Printing: MAN-Werksdruckerei
Content Chapter/Page
Index 7
Introduction
Engine electronics
Cooling system
Mounted components
Turbocharging
Intake/exhaust system
Cylinder head
Valve control
Timing gears
Engine lubrication
Crankshaft seals
Crankshaft drive
Engine case
Technical Data
Index Page
A
Air compressor, 1-cylinder
Connector................................................................................................................................................. 85
Cover...................................................................................................................................................... 128
Crankshaft .............................................................................................................................................. 132
Cylinder head ......................................................................................................................................... 129
Drive wheel mounting bolts .................................................................................................................... 129
Fins......................................................................................................................................................... 130
Hydraulic pump ........................................................................................................................................ 85
Installation advice..................................................................................................................................... 63
Moulded hose........................................................................................................................................... 37
Piston ..................................................................................................................................................... 131
Piston pins.............................................................................................................................................. 131
Piston rings............................................................................................................................................. 131
Power steering pump ............................................................................................................................... 61
Power steering pump 2 ............................................................................................................................ 85
Pressure relief valve................................................................................................................................. 62
PTO shaft ............................................................................................................................................... 132
Valve plate.............................................................................................................................................. 130
Air compressor, 2-cylinder
Cover...................................................................................................................................................... 140
Crankshaft .............................................................................................................................................. 144
Cylinder head ......................................................................................................................................... 142
Drive wheel mounting bolts .................................................................................................................... 141
Fins......................................................................................................................................................... 143
Hydraulic pump ...................................................................................................................................... 114
Piston ..................................................................................................................................................... 143
Piston pins.............................................................................................................................................. 144
Piston rings............................................................................................................................................. 144
Power steering pump 2 .......................................................................................................................... 114
PTO shaft ............................................................................................................................................... 144
Valve plate.............................................................................................................................................. 142
Alternator 2
Bracket for alternator.............................................................................................................................. 164
B
Belt drive
Ribbed V-belt tensioner .......................................................................................................................... 154
Ribbed V-belt tensioner bracket ............................................................................................................. 154
C
Camshaft
Axial play ................................................................................................................................................ 332
Camshaft bearing shells......................................................................................................................... 334
Camshaft gear wheel ............................................................................................................................. 334
Cover...................................................................................................................................................... 336
Intermediate gear wheel......................................................................................................................... 336
Radial play.............................................................................................................................................. 333
Coolant manifold
Temperature sensor ................................................................................................................................. 43
Crankshaft
Axial compensation ................................................................................................................................ 497
Axial play ................................................................................................................................................ 496
Bearing cover ......................................................................................................................................... 497
Connecting rod bearing journals ............................................................................................................ 499
crankshaft bearing pin ............................................................................................................................ 499
Crankshaft drive
Race ....................................................................................................................................................... 427
Cylinder head .............................................................................................................................................. 316
D
Drive gears
Backlash on the crankshaft gear/intermediate gear for the high-pressure pump drive .......................... 351
Crankshaft gear wheel ........................................................................................................................... 352
E
EGR module
Check valves .......................................................................................................................................... 283
Connecting tube ..................................................................................................................................... 265
EGR adjusting cylinder........................................................................................................................... 266
Heat shield ............................................................................................................................................. 265
Shut-off flap ............................................................................................................................................ 284
Unscrewed conduit................................................................................................................................. 265
engine brake
Air pipes ................................................................................................................................................. 255
Positioning cylinder ................................................................................................................................ 519
Proportional valve................................................................................................................................... 519
Exhaust manifold
Heat shields............................................................................................................................................ 288
F
Flame-start system
Flame glow plug ..................................................................................................................................... 239
Solenoid valve ........................................................................................................................................ 239
Flywheel
starter ring gear ...................................................................................................................................... 460
Fuel service centre (KSC)
Bracket ................................................................................................................................................... 228
Fuel lines ................................................................................................................................................ 227
hand pump ............................................................................................................................................. 232
Heater element....................................................................................................................................... 231
Pressure sensor ..................................................................................................................................... 231
H
High-pressure pump
Fuel pump .............................................................................................................................................. 217
Installation instructions for high-pressure pump drive ............................................................................ 212
Metering unit........................................................................................................................................... 217
Radial shaft seal..................................................................................................................................... 220
High-pressure system
Extracting the injector............................................................................................................................. 191
High-pressure line high pressure pump-pressure pipe .......................................................................... 189
Injector cable harness ............................................................................................................................ 191
Pressure pipe ......................................................................................................................................... 189
Pressure pipe socket.............................................................................................................................. 190
Rail pressure sensor .............................................................................................................................. 190
O
Oil module
Drain the coolant .................................................................................................................................... 389
Oil cooler ................................................................................................................................................ 390
Pressure relief valve............................................................................................................................... 390
Oil pump
Axial play ................................................................................................................................................ 406
P
Piston and connecting rod
Axial play ................................................................................................................................................ 482
Connecting rod bearing cap ................................................................................................................... 483
Piston pins.............................................................................................................................................. 483
Piston ring axial play .............................................................................................................................. 484
Piston rings............................................................................................................................................. 484
Radial play.............................................................................................................................................. 482
R
Refrigerant compressor
Bracket ................................................................................................................................................... 176
Ribbed V-belt
Guide rollers ........................................................................................................................................... 154
S
Safety instructions ......................................................................................................................................... 11
General..................................................................................................................................................... 11
T
Thermostat housing
Coupling pipes.......................................................................................................................................... 48
Timing gears
Air compressor intermediate gear .......................................................................................................... 367
Air compressor intermediate gear axial play .......................................................................................... 366
Air compressor intermediate gear radial play......................................................................................... 381
Axial play of small intermediate gear...................................................................................................... 378
Backlash on the crankshaft gear/large intermediate gear ...................................................................... 375
Camshaft intermediate gear ................................................................................................................... 378
Crankshaft gear wheel ........................................................................................................................... 380
Crankshaft intermediate gear ................................................................................................................. 376
Large intermediate gear axial play ......................................................................................................... 376
Large intermediate gear radial play........................................................................................................ 362
Radial play intermediate gear camshaft ................................................................................................. 364
Tooth backlash of the small intermediate gear/large intermediate gear ................................................. 361
Turbocharger
Oil pressure line ..................................................................................................................................... 255
Oil return line .......................................................................................................................................... 255
V
Valve clearance
Engine in the setting position ................................................................................................................. 307
Forcing the engine oil out of the valve crosshead .................................................................................. 308
INTRODUCTION
SAFETY INSTRUCTIONS
General
Only trained personnel are permitted to perform operating, maintenance or repair work on trucks and buses
/coaches.
The following sections include summaries of important regulations listed according to major topics. These
must be observed, in order to avoid accidents which could lead to injury, damage and environmental pollu-
tion. Please note that these are merely brief extracts taken from various accident prevention regulations. Of
course, all other safety regulations must be followed and the necessary measures must be taken.
Additional references to danger are contained in the instructions at points where there is a potential danger.
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin
contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes,
crushing limbs, etc.
Suspended loads
– Persons may not stand or walk underneath suspended loads.
– Only use suitable hoists that are in top condition technically. Please also make sure that the load suspension
devices used have sufficient load capacity.
– Only measure voltage with suitable measuring devices! The input resistance of the measurement device
must be at least 10 MΩ.
– Connect and/or disconnect the plug connectors of electrical control units only when the ignition is switched
off.
Electric welding
– Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number 80.78010.0002) as de-
scribed in the instructions accompanying the device.
– If this device is not available, disconnect the batteries and firmly connect the positive cable to the earth
cable in order to make a conductive connection.
– Move the manually operated main battery switch to the driving mode position. If an electronic battery
master switch is fitted, bridge “Negative” at the load-disconnecting relay contacts (jumper cable > 1mm2)
and “Positive” at the load-disconnecting relay load contacts. In addition, switch on many load consumers
such as: starter switch (ignition) in driving position, hazard warning lights switch “on”, lighting switch in
“driving lights on” position, ventilation blower in “maximum” position. The greater number of consumers that
are switched on, the greater the protection.
When welding is complete, first switch off all consumers and remove all jumpered connections (reset to
original condition) before connecting the batteries.
– Always earth the welding equipment as close as possible to the welding area. Do not lay the cables of the
welding equipment parallel to electrical cables in the vehicle.
Painting work
– During painting work, electronic components may only be exposed to high temperatures (max. 95°C) for
short periods; a period of up to approx. 2 hours is permissible at max. 85°C; disconnect the batteries.
Do not paint the bolt connections of the high-pressure section of the injection system. Risk of dirt ingress
in the event of repairs.
– After having finished all work and inspections, switch off the ignition first, then connect the plug connector(s)
for the airbag and belt pre-tensioner and, as a last step, connect the battery. There must be no-one in the
cab whilst this work is going on.
– Only place airbag units individually, with the impact cushion facing up.
– Do not apply grease or cleaning agents to airbags and belt pre-tensioners.
– Only store and transport airbag and belt pre-tensioner units in their original packaging. Transport in the
passenger compartment is not permitted.
– Airbag and belt pretensioner units may only be stored in storage areas that can be locked, and up to a
maximum of 200 kg.
General
– Units are only built for the purpose designated in the scope of delivery (according to their intended use),
which is defined by the device manufacturer: Any other use is classified as not in accordance with the
designated use. The manufacturer is not liable for damage caused as a result of such other use. In the
event of such other use, the user alone bears the risk.
– The intended use also includes compliance with the operating, maintenance and repair conditions defined
by the manufacturer.
– The unit must only be used, maintained and repaired by personnel who are acquainted with it and have
been instructed about any potential danger.
– The manufacturer does not assume any liability for damage resulting from unauthorised modifications to
the engine.
– Manipulation of the injection and control system may also affect the performance and exhaust-gas values of
the unit. This means that compliance with the statutory environmental requirements is no longer assured.
– Should faults occur during operation, the cause must be determined and rectified immediately.
– Thoroughly clean the units prior to repair work and ensure that all openings where the ingress of dirt could
cause functional or safety issues, are sealed.
– Never run units dry, i.e. always make sure that they have been filled with lubricating oil before running them.
– Never run engines that have not been filled with coolant beforehand.
– Use a suitable information sign to clearly indicate units that are not ready to be operated.
– Use service products only in accordance with MAN service product recommendations; otherwise the man-
ufacturer's warranty is rendered void.
You can find approved products on the Internet at: http://www.man-mn.com/ > Products & Solutions >
E-Business.
– Comply with the specified service intervals.
– Do not fill engine/gear oil above the maximum level mark. Do not exceed the maximum permitted opera-
tional tilt.
– The special measures described in MAN Works Standard M 3069 Part 3 are necessary if buses/coaches
or HGVs are to be withdrawn from service or held in storage for longer than 3 months.
General
Use only accessories expressly approved by MAN Truck & Bus AG and MAN genuine parts for your MAN
vehicle. MAN Truck & Bus AG accepts no liability for any other products.
products, excipients, thinners or solvents to clean the skin. Apply a greasy skin cream after cleaning your
skin.
Coolant
Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority
when disposing of used coolant (mixture of antifreeze and water).
Engine/gearbox oil, filter cartridges, inserts and box-type filters, desiccant cartridges
Filter inserts, cartridges and box-type filters (oil and fuel filters, desiccant cartridges for the air dryer) are
classified as hazardous waste materials. Comply with local-authority regulations when disposing of the above
parts.
General
– Fuel jets can cut through the skin. Risk of fire due to fuel atomisation.
– Never undo the bolt connections on the high fuel pressure side of the Common Rail system when the engine
is running (high-pressure line from the high-pressure pump to the rail, at the rail and on the cylinder head
to the fuel injector). Whilst the engine is running, the lines are constantly carrying fuel under a pressure of
1800 bar or more. Before the screw connections are opened, wait at least one minute until depressurisation
has occurred, using MAN-cats to check the depressurisation on the rail as necessary.
– Do not remain in the vicinity of the engine when it is running.
– Do not touch the live parts at the injector electrical connection whilst the engine is running.
– Any change to the original wiring may lead to the limit values of the heart pacemaker regulations being
exceeded, e.g. untwisted fuel injector wiring or insertion of a break box (terminal tester).
– Vehicle operators and persons with heart pacemakers are not at risk from systems with MAN Common Rail
engines in approved operation.
– Fuel jets can cut through the skin. Risk of fire due to fuel atomisation.
– Never undo bolt connections on the high fuel pressure side of the Common Rail system when the engine
is running (fuel injection line from the high pressure pump to the rail, at the rail and on the cylinder head to
the fuel injector).
– Do not remain in the vicinity of the engine when it is running.
– Whilst the engine is running, the lines are constantly carrying fuel under a pressure of 1800 bar or more.
– Wait for at least one minute before undoing bolt connections to allow the pressure to drop.
– If necessary, check that the pressure has dropped in the rail with MAN-cats.
– Do not touch the live parts at the injector electrical connection whilst the engine is running.
General information
The units have an electronic control system that monitors itself (self-diagnostics) and the unit.
As soon as there is a malfunction, the malfunction is evaluated and one of the following measures is initiated:
7. Assembly information
Assembling pipes
– Pipes must not be mechanically deformed during assembly work; risk of fracture.
Mounting gaskets
– Only use MAN genuine gaskets
– Make sure that the areas to be sealed are undamaged and clean.
– Do not use adhesive agents or sealing agents. If necessary, to facilitate installation, use a little grease to
stick the seal to the part to be mounted.
– Tighten the bolts evenly to the specified tightening torque.
Mounting O-rings
– Only use MAN genuine O-rings.
– Make sure that the areas to be sealed are undamaged and clean.
Engine overhaul
– The engine's service life is influenced by very different factors. It is therefore not possible to indicate the
exact number of operating hours or miles before a major overhaul is due.
– We are of the opinion that opening an engine or performing a general overhaul is not required, as long as
the engine has good compression values and the following operating values do not deviate considerably
from those determined at start-up.
– Charging pressure
– Exhaust gas temperature
– Coolant and lubricating oil temperatures
– Oil pressure and oil consumption
– Smoke behaviour
The following criteria have considerable influence on the engine's service life:
– Correct performance setting according to deployment
– Correct installation
– Approval of the installation by authorised personnel
– Regular maintenance according to the maintenance schedule
THE ENGINE
Characteristic data
D2066 LOH01
D2066 LOH02
D2066 LOH03
D2066 LOH04
D2066 LOH05
D2066 LOH06
D2066 LOH07
D2066 LOH08
D2066 LOH10
D2066 LOH11
D2066 LOH12
Description of engine
Engine, general
The engines described here are liquid-cooled, turbocharged 6-cylinder, 4-stroke diesel engines with exhaust
turbocharging that meet the Euro 3 and 4 emission standards.
The engines operate using the Common Rail high-pressure injection system in conjunction with EDC 7
(Electronic Diesel Control).
Its functions include the monitoring of the exhaust gas recirculation and the NOx content in the exhaust system
using a NOx sensor.
Engine monitoring
Various sensors monitor the engine. The sensors are speed and temperature sensors, e. g., which send
information about the various engine operating conditions and states to the engine control unit.
I = Input
P = Processing
O = Output
The engine control unit processes the information received from the sensors and controls the output signals
which are sent to the actuators. The actuators convert the signals into mechanical variables. An actuator is,
for example, the proportioning unit on the high-pressure pump.
Crankcase
The crankcase and the cylinder block are a mono block casting made from special cast iron. The wet cylinder
liners made from special, highly wear-resistant centrifugal casting are exchangeable. The cylinder liners are
sealed using elastomer sealing rings. At the rear of the crankcase, there is a flywheel housing/timing case.
At the front of the crankcase, there is a cover. The flywheel housing/timing case and cover are made of
aluminium. The crankshaft oil seals are installed in the cover and in the flywheel housing/timing case. The
crankcase blow-by gases are returned to the combustion air via an oil separator with pressure-relief valve on
the suction side of the turbocharger.
Crankshaft
The crankshaft is forged in a die using high-quality, micro-alloyed steel. It has eight cast counterweights to
balance the masses. The crankshaft is mounted in 7 bearings in the crankcase. The crankshaft journals
and crank pins are mounted in ready-to-install three-component bearings. They are axially mounted in thrust
washers inserted in the crankcase at the 6th bearing seat. The connecting rod bearings are supplied with oil
via a bore in the crankshaft bearing.
Piston
3-ring pistons made of special die-cast aluminium are used. They feature a cast ring carrier for the uppermost
piston ring. The pistons have a cast-in cooling duct for reducing the thermal load when the output is high.
They are cooled by an oil jet from the oil injector nozzles. The ring set comprises one taper-face ring and
one full keystone ring, each as compression rings, as well as one double-bevelled slotted oil control ring with
spiral-type expander as an oil scraper ring.
Cylinder head
Series D20 engines are equipped with a single-section cylinder head with overhead camshaft (OHC –
Over-Head Camshaft). The cylinder head is made from special cast iron and is fitted with shrink-fitted
valve seat rings and pressed-in, exchangeable valve guides. The valve guides have valve stem seals at
all four valves. The valves are actuated by individually exchangeable rocker arms on rocker shafts. The
EVB (Eexhaust Valve Brake) has individually exchangeable bridges. The cylinder head is secured with
high-strength external hexagon round screws (cylinder head bolts). The single-layer steel cylinder head seal
has a specially designed combustion chamber seal. There is an elastomer seal between the cylinder head
and cylinder head cover.
Camshaft
The camshaft is forged from steel and induction hardened. It is mounted 7x in the camshaft bearing shells in
the cylinder head. It is axially mounted in a centre bearing on the camshaft. It is driven by spur gears on the
flywheel side.
Engine lubrication
The engine is lubricated by forced-feed lubrication for all bearing points. The engine oil filter and the oil cooler
are grouped together as an oil module. The oil in the oil sump is measured using a dipstick and an oil level
sensor installed in the crankcase.
Cooling system
The cooling circuit is a thermostat-controlled forced circulation cooling system with a maintenance-free coolant
pump driven by a ribbed V-belt. The distributor housing accommodates the coolant pump, the alternator and
the refrigerant compressor. The connection for the heater feed is also mounted on the distributor housing.
The thermostats are exchangeable inserts with wax expansion elements.
Intake/exhaust system
The 3-section exhaust manifold is cast from high temperature-resistant nodular cast iron and secured to
the cylinder head using heat-resistant bolts. The maintenance-free turbocharger is mounted on the middle
exhaust manifold. After the turbocharger, the exhaust manifold is built-in with permanently installed engine
brake flap. The turbocharger is lubricated by the engine oil circuit.
Fuel system
The fuel system consists of a low-pressure system and a high-pressure system. The low-pressure system
includes the fuel lines, the hand pump and the fuel service centre (KSC). The fuel service centre comprises
a pre-filter and a special microfilter with water separation to ensure the degree of fuel purity required by the
common-rail system. The low-pressure system also includes a heating element and the flame start system.
The interface to the high-pressure system is the fuel pump.
High-pressure system
The high-pressure system consists of the flow-rate-controlled high-pressure pump with flange-mounted fuel
pump and the rail with rail pressure sensor and pressure-limiting valve. Solenoid valve-controlled injectors
with rail connections and high-pressure lines which meet the necessary requirements are also installed.
Injection pressure generation and fuel injection are separate in the high-pressure system. The injection pres-
sure is generated by the high-pressure pump, irrespective of the engine speed and the required injection
quantity. The injection quantity is available in the rail for injection via the injectors. The high-pressure pump
delivery quantity is controlled by a proportional valve. The injection point and the injection quantity are calcu-
lated in the engine control unit and implemented by the solenoid valve-controlled injectors.
1 Pilot injection to improve combustion, reduce combustion noise and reduce peak combustion pressures.
2 Main injection to introduce the energy for the required engine power output.
3 Post injection to reduce the pollutant emissions, main constituent NOX.
Always ensure absolute cleanliness both in and around the working area whenever carrying out work on the
highly sensitive high-pressure system.
Injectors
The injectors are controlled by solenoid valve. They are arranged vertically in the cylinder head and clamped
with a pressure flange in the cylinder head.
hydraulic piston can no longer move back as the brace plugs of the relief hole and the check valve closes the
oil feed bore. The exhaust valve therefore remains open with a gap during the compression stroke and the
following expansion stroke. The engine braking power increases.
Starter
The starter is a reduction-gear starter with a free-engaging pinion construction. Free-engaging means that
the starter pinion is mounted on the housing in the starter without a thrust bearing. A mechanical relay is
mounted in the starter for starter control.
Alternator
A compact, powerful, low-noise alternator is mounted for power generation. The alternator is equipped with
a multifunction controller. The voltage is controlled depending on the temperature, the battery charge level
and the current power consumption. The alternator speed is 4 times the engine speed.
Air compressor
The air compressor is driven by spur gears in the rear timing case. There may also be a hydraulic pump and
a further power steering pump mounted on the air compressor PTO, depending on the variant.
ENGINE ELECTRONICS
ENGINE ELECTRONICS
Removing and installing the engine electrical system
Technical data
Temperature sensor (3)......................................... M16x1.5 ............................................................45 Nm
Oil level sensor (6)................................................ M22x1.5 ............................................................25 Nm
Pressure sensor (7) .............................................. M18x1.5 ............................................................45 Nm
Pressure switch (9)............................................... M18x1.5 ............................................................50 Nm
Rail pressure sensor (11) ...................................... M18x1.5 ............................................................70 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Restricted driving mode due to defective entries in the fault memory
• Before removing switches or sensors, read out and document the fault memory
• Always install switches and sensors with new O-rings or sealing rings
• After installing switches or sensors, read out the fault memory and, if necessary, delete it
COOLING SYSTEM
COOLANT MANIFOLD
Remove and install coolant manifold (version without retarder)
Technical data
Temperature sensor.............................................. M16x1.5 ............................................................45 Nm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
Technical Vaseline ............................................................................................................. 09.15014-0001
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Note
The temperature sensor can also be re- • Thinly apply clean engine oil on the thread of the
moved and installed with the coolant temperature sensor (1)
manifold mounted. • Screw in the temperature sensor (1) with a new
sealing ring (2) into the coolant manifold (3) and
• Unscrew the temperature sensor (1) with sealing
tighten to 45 Nm
ring (2) from the coolant manifold (3)
Install the coolant manifold to the EGR module
• Position the coolant manifold (2) with a new O-ring • Push the moulded hose (4) with jubilee clip (5) on
(1) the fitting (6)
• Screw in and tighten the new mounting bolts (3) • Install the mounting clamps for the moulded hose
(4) at the cable harness bracket
Mounting the coolant manifold • Install the spring band clamp (5) using the Hose
clamp pliers for jubilee clips [1]
• Insert the air intake pipe (2) with jubilee clip (3)
• Install the spring band clamp (3) using the Hose
clamp pliers for jubilee clips [1]
• Repeat the procedure for the jubilee clip at the
turbocharger intake pipe
• Screw in and tighten the new mounting bolts (1)
Technical data
Temperature sensor.............................................. M16x1.5 ............................................................45 Nm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
Technical Vaseline ............................................................................................................. 09.15014-0001
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Note
The temperature sensor can also be re- • Thinly apply clean engine oil on the thread of the
moved and installed with the coolant temperature sensor (1)
manifold mounted. • Screw in the temperature sensor (1) with a new
sealing ring (2) into the coolant manifold (3) and
• Unscrew the temperature sensor (1) with sealing
tighten to 45 Nm
ring (2) from the coolant manifold (3)
Install the coolant manifold to the EGR module
• Thinly apply Technical Vaseline on a new O-ring • Push the moulded hose (4) with jubilee clip (5) on
(1) and fit it on the coolant manifold (3) the fitting (6)
• Insert the coolant manifold (3) into the EGR mod- • Install the mounting clamps for the moulded hose
ule (4) at the cable harness bracket
• Screw in and tighten the new mounting bolts (2) • Install the spring band clamp (5) using the Hose
clamp pliers for jubilee clips [2]
Mounting the coolant manifold • Insert the air intake pipe (2) with jubilee clip (3)
• Install the spring band clamp (3) using the Hose
clamp pliers for jubilee clips [2]
• Repeat the procedure for the jubilee clip at the
turbocharger intake pipe
• Screw in and tighten the new mounting bolts (1)
THERMOSTATS
Removal and installation the thermostats
Technical data
Opening temperature of thermostat (4) ............................................................................................. 83 °C
Important information
WARNING
Thermostats with the incorrect opening temperature damage the engine
• Always use thermostats with the specified opening temperature
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
• Unscrew the mounting bolts (4) • Insert new seals (1) into the thermostat housing
• Remove thermostat manifold (3) (3)
• Remove O-rings (2) from thermostats (1) • Insert the thermostats (2) with the ball valve or
• Clean the sealing surfaces TOP mark facing upwards
• Remove the thermostats (2) with seals (1) from • Fit the new O-rings (2) onto the thermostats (1)
the thermostat housing (3) • Position the thermostat manifold (3) on the ther-
• Clean the mating faces mostat housing
• Screw in and tighten the new mounting bolts (4)
THERMOSTAT HOUSING
Removing and installing the thermostat housing
Additional jobs
– Remove and install the charge air pipe, see 247
– Removal and installation the thermostats, see 45
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Installing the thermostat housing Install the coolant manifold to the EGR module
COOLANT PUMP
Removing and installing the coolant pump
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
CAUTION
• Insert the coolant pump (3) with a new gasket (4) The poly-V-belt tensioner is under
• Screw in and tighten the new mounting bolts (1) spring tension
and (2) as marked • Brace the poly-V-belt tensioner to pre-
vent it from springing back unintention-
Mount the ribbed V-belt disc ally
DISTRIBUTOR HOUSING
Removal and installation the distributor housing
Additional works
– Removing and installing belt drive, see 153
– Remove and install coolant manifold (version without retarder), see 35
– Removing/installing the coolant manifold (version with retarder), see 40
– Remove and install the charge air pipe, see 247
– Removal and installation the thermostats, see 45
– Removing and installing the thermostat housing, see 47
– Removing and installing the coolant pump, see 51
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
• Dismantling alternator 1, see Removing and in- • Position distributor housing (1) with new seal
stalling alternators 1 and 2, 159 • Screw in and tighten the new mounting bolts (2)
• Mark the installation position of the mounting bolts and (3) as marked
(2) and (3) • Installing alternator 1, see Removing and installing
• Unscrew the mounting bolts (2) and (3) alternators 1 and 2, 159
• Remove distributor housing (1) with seal
• Clean the mating faces
MOUNTED COMPONENTS
AIR COMPRESSOR
Removal and installation of the 1-cylinder air compressor
Technical data
connecting union .................................................. M16x1.5 ............................................................30 Nm
GE union.............................................................. M26x1.5 ............................................................45 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Mark the installation position of the mounting bolts • Unscrew the pressure relief valve (1) and remove
(1) and (2) it with the seal
• Unscrew the mounting bolts (1) and (2)
• Remove the air compressor (3)
• Clean the mating faces
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for firm seating after securing
• Loose plug-in connectors must be re-
leased by pressing the spring clip, repo-
sitioning them, then securing them
Removing and installing the 1-cylinder air compressor with steering and hydraulic
pump
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolts for hydraulic pump (4) .................... M10x40-10.9......................................................55 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing pressure relief valve Checking axial play of PTO drive shaft
• Unscrew the pressure relief valve (1) from the air • Install gauge holder [6] (2) with Dial gauge [5] (3)
compressor (2) and remove it with the seal and Caliper pin [7]
• Caliper pin [7] position with pre-load on the drive
shaft
• Push the drive shaft against the Dial gauge [5] (3)
into the end position
• Zero the Dial gauge [5] (3)
• Pull the drive shaft into the end position towards
Dial gauge [5] (3) and check the difference
The permitted axial play on the drive shaft is
0.100 - 0.700 mm.
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for firm seating after securing
• Loose plug-in connectors must be re-
leased by pressing the spring clip, repo-
sitioning them, then securing them
Removing and installing the 1-cylinder air compressor with two steering pumps
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
CAUTION
Risk of accidents due to possible power steering failure
• The power steering pumps have different directions of rotation and must not be exchanged ac-
cording to their installation position
Special tools
Removing pressure relief valve Checking axial play of PTO drive shaft
• Unscrew the pressure relief valve (1) from the air • Install gauge holder [10] (2) with Dial gauge [9] (3)
compressor (2) and remove it with the seal and Caliper pin [11]
• Caliper pin [11] position with pre-load on the drive
shaft
• Push the drive shaft against the Dial gauge [9] (3)
into the end position
• Zero the Dial gauge [9] (3)
• Pull the drive shaft into the end position towards
Dial gauge [9] (3) and check the difference
The permitted axial play on the drive shaft is
0.100 - 0.700 mm.
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for firm seating after securing
• Loose plug-in connectors must be re-
leased by pressing the spring clip, repo-
sitioning them, then securing them
Removing and installing of 1-cylinder air compressor with power steering pump and
two hydraulic pumps
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolt for hydraulic pump 1 (4) ................... M10x150-10.9....................................................55 Nm
Mounting bolts for hydraulic pump 2 (5) ................. M10x205-10.9....................................................55 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing pressure relief valve Checking axial play of PTO drive shaft
• Unscrew the pressure relief valve (1) from the air • Install gauge holder [14] (2) with Dial gauge [13]
compressor (2) and remove it with the seal (3) and Caliper pin [15]
• Caliper pin [15] position with pre-load on the drive
shaft
• Push the drive shaft against the Dial gauge [13]
(3) into the end position
• Zero the Dial gauge [13] (3)
• Pull the drive shaft into the end position towards
Dial gauge [13] (3) and check the difference
The permitted axial play on the drive shaft is
0.100 - 0.700 mm.
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for firm seating after securing
• Loose plug-in connectors must be re-
leased by pressing the spring clip, repo-
sitioning them, then securing them
Removing and installing 1-cylinder air compressor with two power-steering pumps
and hydraulic pump
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolts for hydraulic pump (4) .................... M10x150-10.9....................................................65 Nm
Mounting bolts for power steering pump 2 (5)......... M10x175-10.9....................................................65 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing pressure relief valve Checking axial play of PTO drive shaft
• Unscrew the pressure relief valve (1) from the air • Install gauge holder [18] (2) with Dial gauge [17]
compressor (2) and remove it with the seal (3) and Caliper pin [19]
• Caliper pin [19] position with pre-load on the drive
shaft
• Push the drive shaft against the Dial gauge [17]
(3) into the end position
• Zero the Dial gauge [17] (3)
• Pull the drive shaft into the end position towards
Dial gauge [17] (3) and check the difference
The permitted axial play on the drive shaft is
0.100 - 0.700 mm.
• Position the air compressor (1) • Insert driver (3) into the hydraulic pump (1)
• Screw in and tighten the new mounting bolts (2) • Insert the power steering pump (4) with a new
and (3) as marked O-ring
• Screw in new mounting bolts (2) and tighten to
Attaching the hydraulic pump 65 Nm
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for firm seating after securing
• Loose plug-in connectors must be re-
leased by pressing the spring clip, repo-
sitioning them, then securing them
Removing and installing 2-cylinder air compressor with power steering pump
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
CAUTION
Risk of accidents due to possible power steering failure
• The power steering pumps have different directions of rotation and must not be exchanged ac-
cording to their installation position
Special tools
CAUTION
• Unscrew the mounting bolt (1) Danger of injury due to heavy compo-
• Undo the jubilee clip (3) using Hose clamp pliers nents
for jubilee clips [20] and push onto the air intake • Remove the air compressor with sup-
pipe (2) port
• Repeat the procedure for the jubilee clip at the
turbocharger intake pipe • Mark the installation position of the mounting bolts
• Remove the air intake pipe (2) (1) and (2)
• Remove the mounting clamps for the moulded • Unscrew the mounting bolts (1) and (2)
hose (4) at the cable harness bracket • Remove the air compressor (3)
• Undo the jubilee clip (4) using the Hose clamp • Clean the mating faces
pliers for jubilee clips [20] and push onto the fitting
(6)
• Pull the moulded hose (4) off the fitting (6)
• Unscrew the pressure relief valve (1) from the air • Screw on supply (2) and return (4) bulkhead fitting
compressor (2) and remove it with the seal with new sealing rings in air compressor (1)and
tighten to 30 Nm
• Screw in the GE union (3) with a new sealing ring
in the air compressor (1) and tighten to 45 Nm
• Thinly apply sealing agent Loctite 5900 (1) on the • Insert the driver (2) into the air compressor (1)
mating face as illustrated • Insert the power steering pump (4) with a new
O-ring (3)
Attaching the air compressor • Screw in and tighten the new mounting bolts (5)
CAUTION
Danger of injury due to heavy compo-
• Push the moulded hose (4) with jubilee clip (5) on
nents
the fitting (6)
• Install the air compressor with support
• Install the mounting clamps for the moulded hose
(4) at the cable harness bracket
• Position the air compressor (3)
• Install the spring band clamp (5) using the Hose
• Screw in and tighten the new mounting bolts (1)
clamp pliers for jubilee clips [20]
and (2) as marked
• Insert the air intake pipe (2) with jubilee clip (3)
• Screw in and tighten the new mounting bolts (1)
• Install the spring band clamp (3) using the Hose
clamp pliers for jubilee clips [20]
• Repeat the procedure for the jubilee clip at the
turbocharger intake pipe
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for firm seating after securing
• Loose plug-in connectors must be re-
leased by pressing the spring clip, repo-
sitioning them, then securing them
Removing and installing the 2-cylinder air compressor with steering and hydraulic
pump
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolts for hydraulic pump (4) .................... M10x40-10.9......................................................55 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
CAUTION • Unscrew the pressure relief valve (1) from the air
Danger of injury due to heavy compo- compressor and remove it with the seal
nents
• Remove the air compressor with sup-
port
• Thinly apply sealing agent Loctite 5900 (1) on the • Insert the driver (3) into the air compressor (4)
mating face as illustrated • Insert the hydraulic pump (2) with a new O-ring
• Screw in new mounting bolts (1) and tighten to
Attaching the air compressor 55 Nm
CAUTION
Danger of injury due to heavy compo-
nents
• Install the air compressor with support
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for firm seating after securing
• Loose plug-in connectors must be re-
leased by pressing the spring clip, repo-
sitioning them, then securing them
Removing and installing 2-cylinder air compressor with two power-steering pumps
and hydraulic pump
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolts for hydraulic pump (4) .................... M10x150-10.9....................................................65 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
CAUTION
Risk of accidents due to possible power steering failure
• The power steering pumps have different directions of rotation and must not be exchanged ac-
cording to their installation position
Special tools
CAUTION • Unscrew the pressure relief valve (1) from the air
Danger of injury due to heavy compo- compressor and remove it with the seal
nents
• Remove the air compressor with sup-
port
• Thinly apply sealing agent Loctite 5900 (1) on the • Insert coupling sleeve (3) into the air compressor
mating face as illustrated (2)
• Insert the hydraulic pump (4) with a new O-ring
Attaching the air compressor • Screw in the new mounting bolt (1) and tighten to
65 Nm
CAUTION
Danger of injury due to heavy compo-
nents
• Insert driver (3) into the hydraulic pump (1)
• Install the air compressor with support
• Insert the power steering pump (4) with a new
O-ring
• Position the air compressor (3)
• Screw in and tighten the new mounting bolts (2)
• Screw in and tighten the new mounting bolts (1)
and (2) as marked
• Insert the driver (2) into the air compressor (1) • Push the moulded hose (4) with jubilee clip (5) on
• Insert the power steering pump (4) with a new the fitting (6)
O-ring (3) • Install the mounting clamps for the moulded hose
• Screw in and tighten the new mounting bolts (5) (4) at the cable harness bracket
• Install the spring band clamp (5) using the Hose
Tighten the coolant lines clamp pliers for jubilee clips [25]
• Insert the air intake pipe (2) with jubilee clip (3)
• Screw in and tighten the new mounting bolts (1)
• Install the spring band clamp (3) using the Hose
clamp pliers for jubilee clips [25]
• Repeat the procedure for the jubilee clip at the
turbocharger intake pipe
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for firm seating after securing
• Loose plug-in connectors must be re-
leased by pressing the spring clip, repo-
sitioning them, then securing them
Removing and installing of 2-cylinder air compressor with power steering pump and
two hydraulic pumps
Technical data
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolt for hydraulic pump 1 (4) ................... M10x150-10.9....................................................65 Nm
Mounting bolts for hydraulic pump 2 (5) ................. M10x205-10.9....................................................55 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Unscrew the mounting bolt (1) • Unscrew the supply (2) and return (4) bulkhead
• Take out hydraulic pump (4) with driver (3) and fitting from the air compressor (1) and remove
O-ring from air compressor (2) them with the seals
• Unscrew the GE unions (3) from the air compres-
Detaching the air compressor sor (1) and remove it with the seal
CAUTION
Danger of injury due to heavy compo-
nents • Unscrew the pressure relief valve (1) from the air
• Remove the air compressor with sup- compressor and remove it with the seal
port
• Thinly apply sealing agent Loctite 5900 (1) on the • Insert coupling sleeve (3) into the air compressor
mating face as illustrated (2)
• Insert the hydraulic pump (4) with a new O-ring
Attaching the air compressor • Screw in the new mounting bolt (1) and tighten to
65 Nm
CAUTION
Danger of injury due to heavy compo-
nents
• Insert driver (3) into the hydraulic pump (1)
• Install the air compressor with support
• Insert the hydraulic pump (4) with a new O-ring
• Screw in new mounting bolts (2) and tighten to
• Position the air compressor (3)
55 Nm
• Screw in and tighten the new mounting bolts (1)
and (2) as marked
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for firm seating after securing
• Loose plug-in connectors must be re-
leased by pressing the spring clip, repo-
sitioning them, then securing them
• Insert the driver (2) into the air compressor (1) Attaching the air intake pipe
• Insert the power steering pump (4) with a new
O-ring (3)
• Screw in and tighten the new mounting bolts (5)
Technical data
Mounting bolt (19) ................................................ M10x1.5-LH .......................................................80 Nm
Mounting bolt (22) ................................................ M10x1.5 ............................................................80 Nm
Mounting bolt (13) ................................................ M8x85Z1-10.9-MAN 183-A2 C............................30 Nm
Connecting-rod bearing bolts ..........................................................................................................16 Nm
Mounting bolt (30) ..........................................................................................................................24 Nm
Mounting bolt (28) ..........................................................................................................................12 Nm
Screw plug (27) ..............................................................................................................................40 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
The dismantling and assembling of the air compressor with and without PTO is the same in prin-
ciple.
Special tool
Unscrewing the drive wheel mounting bolts Remove air compressor drive wheel
Note
The drive wheel mounting bolt for the air
compressor has a left-handed thread.
• Remove valve plate (2) with seal (1) • Mark installation position of fins (4) and supporting
• Clean the mating faces plates (3)
• Unscrew the mounting nuts (1)
Remove cylinder head gasket • Remove the mounting bolts (2)
• Remove fins (4) and supporting plates (3)
• Clean valve plate
• Turn the crankshaft to the removal position • Mark the relative positions of the piston (3), piston
• Mark the connecting rod bearing shell (2) installa- pin (2) and connecting rod (5)
tion position • Detach the circlips (1) and (4)
• Unscrew the mounting bolts (3) • Press the piston pin (2) out of the piston (3)
• Remove the connecting rod bearing shell (2) • Remove the piston (3) from the connecting rod (5)
• Push out the piston and the connecting rod (1)
towards the cylinder head Removing the piston rings
Removing the crankshaft • Thinly apply clean engine oil on the crankshaft
mounting
• Insert crankshaft (4) into housing (5)
• Position the cover (2) with a new O-ring (3)
• Screw in new mounting bolts (1) and tighten to
24 Nm
• Placing crankshaft on UT
• Line up the gaps in the piston rings at 120° offset
to one another
• Thinly apply clean engine oil to the piston (2) and
cylinder running surfaces
• Put Piston ring band tool [35] on the piston (2) and
clamp it
• Push the piston (2) with connecting rod into the
cylinder liner (1) until the piston (2) has been
pushed out of the Piston ring band tool [35] (2)
• Push in the piston (2) until the connecting rod is
lying on the crankshaft
• Turn the crankshaft to the installation position • Position fins (4) and supporting plates (3) on the
• Position the connecting rod bearing shell (2) onto valve plate as marked
the connecting rod (1) • Insert the new mounting bolts (2)
• Screw in the new mounting bolts (3) • Screw on and tighten the new mounting nuts (1)
• Tighten mounting bolts (3) with Torque wrench [36]
with 16 Nm Fit the cylinder head gasket
Note
A guide pin determines the installation
position of the cylinder head gasket.
Note Note
Guide pins determine the installation po- Guide pins determine the installation po-
sition of the valve plate and seal. sition of the intermediate plate, seal and
cylinder head.
• Position the valve plate (2) with a new seal (1)
• Fit the intermediate plate (4)
• Fitting the cylinder head (2) with a new seal (3)
• Screw in mounting bolts (1) and tighten crosswise
by 30 Nm
Insert air compressor drive wheel Tightening the drive wheel mounting bolts
• Insert the drive wheel (1) laterally into the air com-
pressor (2)
• Insert the drive wheel (1) into the toothing of the
crankshaft
Note
The drive wheel mounting bolt for the air
compressor has a left-handed thread.
Technical data
Mounting bolt (13) ................................................ M10x1.5-LH .......................................................80 Nm
Mounting bolt (23) ................................................ M10x1.5 ............................................................80 Nm
Mounting bolt (17) ................................................ M8x85Z1-10.9-MAN 183-A2 C............................30 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50 % of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
The dismantling and assembling of the air compressor with and without PTO is the same in prin-
ciple.
Special tool
Attaching removal device to air compressor • Unscrew the screw plug (1) and remove with the
seal
• Unscrew the mounting bolts (4)
• Remove the cover (3) with the seal (2)
• Clean the mating faces
Unscrewing the drive wheel mounting bolts Remove air compressor drive wheel
• Unclamp and Removal device [38] remove the air • Remove valve plate (2) with seal (1)
compressor • Clean the mating faces
• Unscrew the mounting bolts (1)
• Remove cylinder head (2) Remove cylinder head gasket
• Remove intermediate plate (4) with seal (3)
• Clean the mating faces
• Mark installation position of fins (2) and supporting • Turn the crankshaft to the removal position
plates (1) • Mark the connecting rod bearing shell (2) installa-
• Unscrew the mounting nuts (3) tion position
• Remove fins (2) and supporting plates (1) • Unscrew the mounting bolts (3)
• Clean valve plate • Remove the connecting rod bearing shell (2)
• Push out the piston and the connecting rod (1)
towards the cylinder head
• Repeat the same procedure for the second con-
necting rod
• Pull out the piston (1) with connecting rod from the
housing (2)
• Repeat the procedure on piston (3)
• Position fins (2) and supporting plates (1) on the • Position the valve plate (2) with a new seal (1)
valve plate as marked
• Screw on and tighten the new mounting nuts (3)
• Fit the intermediate plate (4) • Insert the drive wheel (2) laterally into the air com-
• Fitting the cylinder head (2) with a new seal (3) pressor (1)
• Screw in nine new mounting bolts (1) and tighten • Insert the drive wheel (2) into the toothing of the
them crosswise to Torque wrench [42] with 30 Nm crankshaft
• Attach Removal device [38] (2) to air compressor • Insert the drive wheel (1) into the air compressor
(1) (2)
• Insert drive wheel (1) into the toothing of the PTO
shaft
Note
The drive wheel mounting bolt for the air
compressor has a left-handed thread.
STARTER
Removal and installation of the starter
Technical data
Number of starter pinion teeth ...............................................................................................................12
Starter power .................................................................................................................... 5.5 kW at 24 V
Terminal mounting nut 30 (6)................................. M10...................................................................22 Nm
Mounting bolt (5) .................................................. M12x40-10.9......................................................70 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
Crank once before installing the engine starter and check the starter ring gear for damage, where
applicable, replace the starter ring gear
BELT DRIVE
Removing and installing belt drive
(1) Ribbed V-belt disc, coolant pump (7) Ribbed V-belt disc, high pressure pump
(2) Poly-V-belt (8) Vibration damper
(3) Ribbed V-belt disc, alternator 2 (9) Mounting bolt
(4) Mounting bolt (10) Ribbed V-belt tensioner
(5) Alternator 3 (11) Alternator 1
(6) Mounting bolt
Technical data
Mounting bolt for ribbed V-belt tensioner (10) ......... M10x70-10.9......................................................47 Nm
Mounting bolt (9) .................................................. M12x55-10.9......................................................60 Nm
Mounting bolt (6) .................................................. M14x110-10.9 ..................................................150 Nm
Mounting bolt (4) .................................................. M10x30-10.9......................................................47 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Removing ribbed V-belts for alternators Removing the ribbed V-belt tensioner
1 and 2
Removing the ribbed V-belt
Install the ribbed V-belts for alternators Mounting the guide rollers
1 and 2
Mounting the ribbed V-belt tensioner bracket
Remove the ribbed V-belt of the coolant Removing the ribbed V-belt tensioner
compressor
Removing the ribbed V-belt
Removing the ribbed V-belt for alterna- Installing the ribbed V-belt for alternator
tor 3 3
Removing the ribbed V-belt Mounting the ribbed V-belt tensioner and guide
roller
CAUTION
The poly-V-belt tensioner is under
spring tension
• Brace the poly-V-belt tensioner to pre-
vent it from springing back unintention-
• Mark the installation position of the mounting bolts ally
(2) and (3)
• Unscrew the mounting bolts (2) and remove guide • Turn the ribbed V-belt tensioner (1) clockwise as
roller far as the stop and hold it
• Unscrew the mounting bolt (3) • Fit the ribbed V-belt (2)
• Remove the poly-V-belt tensioner (1) • Carefully slacken the ribbed V-belt tensioner (1)
CAUTION
The poly-V-belt tensioner is under
• Position the bracket (2) spring tension
• Screw in and tighten the new mounting bolts (1) • Brace the poly-V-belt tensioner to pre-
vent it from springing back unintention-
Mounting the ribbed V-belt tensioner ally
ALTERNATORS
Removing and installing alternators 1 and 2
Technical data
Mounting nuts (6), (9) ........................................... M16x1.5 ............................................................95 Nm
Mounting nut, terminal B+ ..................................... M8 ....................................................................13 Nm
Service products
Loctite 270 ........................................................................................................................ 04.10160-9062
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
CAUTION
The poly-V-belt tensioner is under
spring tension
• Brace the poly-V-belt tensioner to pre-
vent it from springing back unintention-
ally
CAUTION
The poly-V-belt tensioner is under
spring tension
• Brace the poly-V-belt tensioner to pre-
vent it from springing back unintention-
ally
CAUTION
The poly-V-belt tensioner is under
• Position the bracket (2) spring tension
• Screw in and tighten the new mounting bolts (1) • Brace the poly-V-belt tensioner to pre-
and (3) as marked vent it from springing back unintention-
ally
Technical data
Mounting nut (3) ................................................... M16x1.5 ............................................................95 Nm
Mounting nut, terminal B+ ..................................... M8 ....................................................................13 Nm
Service products
Loctite 270 ........................................................................................................................ 04.10160-9062
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Release and pull off the compact connector (3) Remove the holder
• Disconnect the cable tie (2)
• Unscrew the terminal B+ mounting nut (1)
• Expose the alternator cable harness
CAUTION
The poly-V-belt tensioner is under
spring tension
• Brace the poly-V-belt tensioner to pre-
vent it from springing back unintention-
ally
REFRIGERANT COMPRESSOR
Removal and installation of the coolant compressor
Additional jobs
– Remove the ribbed V-belt of the coolant compressor, see 156
– Installing the ribbed V-belt for the coolant compressor, see 158
Technical data
Mounting nut, terminal B+ ..................................... M8 ....................................................................13 Nm
Important information
CAUTION
Refrigerant and refrigerator oil can harm your health and the environment
• Do not let refrigerant and refrigerator oil come into contact with the skin
• Disposing of refrigerant and refrigerator oil in the correct manner
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
• Release and pull off the compact connector (3) Remove the holder
• Disconnect the cable tie (2)
• Unscrew the terminal B+ mounting nut (1)
• Expose the alternator cable harness
CAUTION
The poly-V-belt tensioner is under
spring tension
• Brace the poly-V-belt tensioner to pre-
vent it from springing back unintention-
ally
CAUTION
Danger of injury due to heavy compo-
nents • Mark the installation position of the mounting bolts
• Lift the coolant compressor using lifting (2) and (4)
gear and the hoist • Unscrew the mounting bolts (4)
• Remove the holder (3)
• Unscrew the mounting bolts (2) • Unscrew the mounting bolts (2)
• Lift out the coolant compressor (1) • Remove the holder (1)
CAUTION
Danger of injury due to heavy compo-
nents
• Lift out bracket using lifting equipment CAUTION
and the hoist Danger of injury due to heavy compo-
nents
• Mark the installation position of the mounting bolts • Position the bracket with lifting equip-
(1), (2) and (4) ment and lifting gear
• Unscrew the mounting bolts (1) and (2)
• Remove the holder (3) • Position the bracket (5)
• Unscrew the mounting bolts (4) • Screw in and tighten the new mounting bolts (4)
• Remove the bracket (5) as marked
• Position the bracket (3)
• Screw in and tighten the new mounting bolts (1)
and (2) as marked
• Position bracket
• Screw in mounting bolts (1) and (2) as marked and
tighten
CAUTION
The poly-V-belt tensioner is under
spring tension
• Brace the poly-V-belt tensioner to pre-
vent it from springing back unintention-
ally
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
In order to ensure that the correct protective sleeve is used, the designation (e. g. Z 14 x 15) is
imprinted in the protective sleeves. This is integrated in the special tool designation (e. g. protective
sleeve, high-pressure line connection Z 14 x 15).
Special tools
Technical data
High-pressure line ..........................................................................................................1st torque 10 Nm
High-pressure line ............................................................................................................Final torque 60°
Mounting bolt (10) ................................................ M8x50-10.9 ......................................1st torque 1.5 Nm
Mounting bolt (10) ................................................ M8x50-10.9 .................................... Final torque 35 Nm
Mounting bolt (5) .................................................. M8x50-10.9 ......................................1st torque 1.5 Nm
Mounting bolt (5) .................................................. M8x50-10.9 ........................... Final torque 25 Nm + 90°
Pressure screw (1) ....................................................................................................... 1st torque 10 Nm
Pressure screw (1) ............................................................................................. Final torque 20 Nm + 60°
Mounting nut (7) .................................................. Cable lug nut M4...............................................1.5 Nm
Mounting bolt of the injector cable harness (8) ....... M6x16-10.9 .......................................................15 Nm
Pressurisation, drip test .......................................................................................................... 4 + 0.5 bar
Pressure drop .................................................................................................................0.1 bar in 10 min
Rail pressure sensor............................................. M18x1.5 ............................................................70 Nm
Pressure-limiting valve.......................................... M20x1.5 ..........................................................100 Nm
Service products
Technical Vaseline ............................................................................................................. 09.15014-0001
Important information
WARNING
The common rail system may suffer damage
• All work on components of the common rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work to enable de-pres-
surisation in the pressure pipe, or de-pressurisation must be checked by means of MAN-cats®
(specified value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Always fit new pressure pipe sockets once the existing ones have been undone
• Do not reuse plugs for the high-pressure lines, the pressure pipe or injectors
• Follow the sequence described when tightening injectors, high-pressure lines, the pressure pipe
and pressure pipe sockets
WARNING
Component damage from re-used high-pressure lines
• Do not reuse high-pressure lines
Always replace the high-pressure lines
WARNING
Danger of damage due to dirt ingress
• Always remove only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
WARNING
Danger of damage due to dirt ingress
• Always detach only one high-pressure
WARNING line
Component damage through fuel in • Close the component connections im-
the combustion chamber mediately using new, clean protective
• Allow the fuel return duct in the cylinder sleeves
head to empty before the injectors are
removed • Mark the installation position of the high-pressure
lines (2)
WARNING
• Remove the high-pressure lines (2) with Socket,
Danger of environmental pollution
size 17 [60] (1) and Extension [59] (3)
• Collect any remaining fuel that emerges
in a suitable container Detaching the pressure pipe
• Unscrew the hollow screw (1) with seals and allow
return duct to run empty
• Unscrew the hollow screw (2) with seals from the
pressure pipe (3)
• Detaching fuel return line
Unscrewing the rail pressure sensor and pres- Removing the cylinder head cover
sure-limiting valve
Note
WARNING The mounting bolts can only be removed
Component damage due to lack of lu- from the cylinder head cover with damp-
bricant ing elements and spacer sleeves.
• Do not clean the pressure-limiting valve
and rail pressure sensor as the thread • Unscrew the mounting bolts (4)
and biting edge are coated with lubri- • Remove the cylinder head cover (3) with gasket
cant (2) from the cylinder head (1)
• Clean the cylinder head cover (3) and the gasket
• Unscrew the rail pressure sensor (2) (2)
• Unscrew the pressure-limiting valve (1) Check the gasket (2) for damage. Remove from
the cylinder head cover (3) and replace if required
Removing the cable duct cover • Set aside the cylinder head cover (3) on a clean
surface with the gasket (2) facing downwards
If this is not done, engine oil can enter the gasket
section (2). When the cylinder head cover (3) is
tightened, this oil is then pressed out, causing sup-
posed leakage
• Loosing the mounting nuts (2) • Assemble Plate [63] (4) with Column 66 mm [64]
• Remove the injector cable harness (1) (1), Column 70 mm [65] (5) and Hex nut [66] (2)
• Insert the Extractor [62] (3) into the Plate [63] (4)
Removing injector cable harness
Extracting the injector
WARNING
Pressure pipe fittings are compressed
at the cone during installation
Note • Do not reuse pressure pipe fittings
Always install injectors together with
pressure flange. It is not possible to • Slide the new pressure pipe socket (2) into the
install the pressure flange afterwards. cylinder head (1) so that the balls on the pressure
pipe socket (2) are located in the groove in the
• Remove the old gaskets (5) cylinder head
• Check to ensure that the bore in the cylinder head • Screw in the pressure screw (3) and tighten to 1st
is clean torque 10 Nm
• Do not remove the injector (2) from the Injector
storage sleeve [47] until immediately before in- Injector final torque
stallation
• Remove the protective sleeves
• Slide the pressure flange (1) onto the injector (2),
ensuring that the fuel inlet opening (3) is turned
towards the mounting bore (4) of the pressure pipe
socket
• Insert the injector (2) into the cylinder head with a
new O-ring (6) and a new gasket (5)
• Press the injector (2) fully into the cylinder head
with the Pressure shim [70]
Injector 1. torque
Tightening sequence for cylinder head cover Mounting the cable duct cover
A Intake side
B Exhaust side
• Position the pressure pipe (1) on the cylinder head • Tighten the mounting bolts (1) to Final
• Screw in new mounting bolts (2) and tighten to torque 35 Nm
1st torque 1.5 Nm
High-pressure line final tightening
Attaching the high-pressure lines
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
In order to ensure that the correct protective sleeve is used, the designation (e. g. Z 14 x 15) is
imprinted in the protective sleeves. This is integrated in the special tool designation (e. g. protective
sleeve, high-pressure line connection Z 14 x 15).
Special tools
Removing and installing the high pressure pump/high pressure pump drive (fuel-lu-
bricated)
Additional jobs
– Remove the ribbed V-belt of the coolant compressor, see 156
– Installing the ribbed V-belt for the coolant compressor, see 158
– Removing alternator 2, see 164
– Installing alternator 2, see 165
– Protective sleeves for fuel service centre, see 223
– Removal and installation of the fuel service centre, see 225
– Protective sleeves for high-pressure pump/high-pressure pump drive, see 197
Technical data
Mounting bolts for high pressure pump (2) ............. M10x50-10.9......................................................65 Nm
High pressure pump drive mounting bolts (7) ......... M12x90-10.9.................................................... 115 Nm
High-pressure line (8) .....................................................................................................1st torque 10 Nm
High-pressure line (8) .......................................................................................................Final torque 60°
Fuel-fill level for high pressure pump (2) ........................................................................................... 60 ml
Fuel-filling screw for high pressure pump (2) .......... M10x1 ...............................................................18 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
The common rail system may suffer damage
• All work on components of the common rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work to enable de-pres-
surisation in the pressure pipe, or de-pressurisation must be checked by means of MAN-cats®
(specified value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Do not reuse plugs for the high-pressure lines, the pressure pipe or injectors
WARNING
Component damage from re-used high-pressure lines
• Do not reuse high-pressure lines
Always replace the high-pressure lines
WARNING
Danger of damage due to dirt ingress
• Always remove only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
PTFE seals are rendered unusable if they come into contact with oil or grease before instal-
lation
• Clean the high pressure pump drive and press-in tool before assembly
Special tool
Removing the high pressure pump Removing the high pressure pump if
firmly seated
Detaching the high-pressure line
Detaching the high-pressure line
Removing the high pressure pump Removing the high pressure pump drive
Mount engine cranking unit
Pressing in the radial shaft seal Mount the ribbed V-belt disc
Position hub
• Slide the driver (4) onto the drive shaft for the high
pressure pump (3)
• Thinly apply Technical Vaseline on a new O-ring
(1) and place it on the high pressure pump (3)
• Insert the high pressure pump (3) into the high
pressure pump drive (5)
• Screw in new mounting bolts (2) and tighten to
65 Nm
Removing and installing the high pressure pump/high pressure pump drive (fuel-lu-
bricated)
Additional jobs
– Remove the ribbed V-belt of the coolant compressor, see 156
– Installing the ribbed V-belt for the coolant compressor, see 158
– Removing alternator 2, see 164
– Installing alternator 2, see 165
– Protective sleeves for fuel service centre, see 223
– Removal and installation of the fuel service centre, see 225
– Protective sleeves for high-pressure pump/high-pressure pump drive, see 197
Technical data
Mounting bolts for high pressure pump (2) ............. M10x50-10.9......................................................65 Nm
High pressure pump drive mounting bolts (7) ......... M12x90-10.9.................................................... 115 Nm
High-pressure line (8) .....................................................................................................1st torque 10 Nm
High-pressure line (8) .......................................................................................................Final torque 60°
Oil fill amount for the high pressure pump (2) .................................................................................... 40 ml
Oil filler plug of high pressure pump (2).................. M10x1 ...............................................................18 Nm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
The common rail system may suffer damage
• All work on components of the common rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work to enable de-pres-
surisation in the pressure pipe, or de-pressurisation must be checked by means of MAN-cats®
(specified value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Do not reuse plugs for the high-pressure lines, the pressure pipe or injectors
WARNING
Component damage from re-used high-pressure lines
• Do not reuse high-pressure lines
Always replace the high-pressure lines
WARNING
Danger of damage due to dirt ingress
• Always remove only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
PTFE seals are rendered unusable if they come into contact with oil or grease before instal-
lation
• Clean the high pressure pump drive and press-in tool before assembly
Special tool
Removing the high pressure pump Removing the high pressure pump if
firmly seated
Detaching the high-pressure line
Detaching the high-pressure line
Removing the high pressure pump Removing the high pressure pump drive
Mount engine cranking unit
Pressing in the radial shaft seal Mount the ribbed V-belt disc
Position hub
• Slide the driver (6) onto the drive shaft for the high
pressure pump (3)
• Thinly apply Technical Vaseline on new O-rings (2)
and (5) and apply to the high pressure pump (3)
• Insert the high pressure pump (3) into the high
pressure pump drive (1)
• Screw in new mounting bolts (4) and tighten to
65 Nm
Technical data
Flow regulator valve (6) ..................................................................................................................34 Nm
Overflow valve (7) ..........................................................................................................................20 Nm
Mounting bolt (8) .................................................. M5x20 .................................................1st torque 4 Nm
Mounting bolt (8) .................................................. M5x20 ..............................................Final torque 7 Nm
Mounting bolt (10) ................................................ M6x20 ................................................................ 8 Nm
Important information
WARNING
The common rail system may suffer damage
• All work on components of the common rail system must be performed by specially trained
personnel only
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Dismantling the high pressure pump Remove fuel supply pump (fuel-lubricated ver-
sion for high pressure pump)
Remove proportional valve (fuel-lubricated ver-
sion for high pressure pump)
Remove overflow and flow regulator valve Assembling the high pressure pump
(fuel-lubricated version for high pressure pump)
Install overflow and flow regulator valve (fuel-lu-
bricated version for high pressure pump)
Install fuel supply pump (oil-lubricated version Install proportional valve (oil-lubricated version
for high pressure pump) for high pressure pump)
Note
When using micro-encapsulated bolts,
the time between the tightening stages
must not exceed 2 minutes.
• Pull the centring pin (1) and sleeve (5) out of the
drive housing (2)
• Mark the installation position of the drive wheel
relative to the drive shaft (3)
• Brace drive shaft (3)
• Unscrew the mounting bolts (4)
• Pull out the drive shaft (3)
• Check the drive shaft (3) for wear
If the drive shaft (3) is worn, the high-pressure pump
drive must be replaced.
Assemble the high-pressure pump drive Pressing in the radial shaft seal
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
In order to ensure that the correct protective sleeve is used, the designation (e. g. Z 14 x 15) is
imprinted in the protective sleeves. This is integrated in the special tool designation (e. g. protective
sleeve, high-pressure line connection Z 14 x 15).
Special tools
Technical data
Hollow screw (10) ................................................. M10x1 ...............................................................15 Nm
Important information
WARNING
Danger of damage due to dirt ingress
• Always remove only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Danger of environmental pollution
• Collect any emerging fuel in a suitable container
Note
Mark all fuel lines before dismounting according to their function and installation position.
Removing the fuel service centre Removing the fuel service centre
Installing the fuel service centre Installing the fuel service centre fuel lines
Technical data
Pressure sensor (5) .............................................. M18x1.5 ............................................................45 Nm
Cover (11) ......................................................................................................................................10 Nm
Cover (2)........................................................................................................................................20 Nm
Water drain plug (6) ......................................................................................................................... 3 Nm
Important information
WARNING
The common rail system would be damaged through contamination
• Always allow the fuel service centre to empty before changing the fuel filter
• Only use fuel filters that are designated for common-rail systems and marked as such
• Do not re-use used filter elements
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the hand pump housing Assembling the fuel service centre
Mounting the hand pump housing
FLAME-START SYSTEM
Flame-start system protective sleeves
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
In order to ensure that the correct protective sleeve is used, the designation (e. g. Z 14 x 15) is
imprinted in the protective sleeves. This is integrated in the special tool designation (e. g. protective
sleeve, high-pressure line connection Z 14 x 15).
Special tools
Technical data
Hollow screw (7)................................................... M10x1 ...............................................................15 Nm
Flame glow plug (2) ............................................. M20x1.5 ............................................................25 Nm
Fuel line union nut (3) ...................................................................................................................10 Nm
Service products
Curil T sealing compound .................................................................................................. 04.90300-9030
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Danger of damage due to dirt ingress
• Always remove only one fuel line
• Close the component connections immediately using new, clean protective sleeves
Installing the flame-start system Attach the fuel lines for the flame-start system
Technical data
Mounting bolt (2) .................................................. M6x35-10.9 ....................................................... 11 Nm
Mounting bolts for bracket (1) ................................ M8x40-10.9 .......................................................13 Nm
Service products
Loctite 270 ........................................................................................................................ 04.10160-9062
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
After installation of the engine, the engine control unit needs to be reconfigured and the fault
memory cleared.
Removing engine control unit Removing the engine control unit bracket
Installing the engine control unit Mounting the engine control unit
WARNING
Risk of irreparable engine control unit
damage
• Tighten engine control unit (1) starting with A ac-
• When installing the plugs, first fully
cording to tightening sequence A, B, C, D, E, F, G,
open the lock and then insert and lock
H
the plugs
TURBOCHARGING
CHARGE-AIR PIPES
Remove and install the charge air pipe
Additional jobs
– Flame-start system protective sleeves, see 235
– Removing and installing the flame-start system, see 237
Technical data
Profiled clamp (3) ................................................. M6 ....................................................................10 Nm
Service products
Technical Vaseline ............................................................................................................. 09.15014-0001
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
A range of charge air pipes is installed.Removal and installation is intrinsically the same.
Removing the turbo charger charge-air Installing the turbo charger charge-air
manifold manifold
• Loosen the profiled clamp (1) • Thinly apply Technical Vaseline on a new O-ring
• Remove the charge-air manifold (3) with O-ring (2) (2)
• Remove the charge-air manifold (3) with an O-ring
(2) and profiled clamp (1)
• Tighten the profiled clamp (1) to 10 Nm
TURBOCHARGER
Removal and installation of the turbocharger
Technical data
Mounting nut (8) ................................................... M10-10..............................................1st torque 10 Nm
Mounting nut (8) ................................................... M10-10................................................Final torque 90°
Profiled clamp ...................................................... M6 ....................................................................10 Nm
Screw-in coupling for adjusting cylinder ................. M16x1.5 ............................................................15 Nm
Mounting bolt for compressor housing ................... M8x20-10.9 .......................................................25 Nm
Service products
Technical Vaseline ............................................................................................................. 09.15014-0001
Multi-purpose grease MAN 285 Li-PF2 ............................................................................... 09.15001-0012
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Loosen the profiled clamp (1) Detaching the oil return line
• Remove the charge-air manifold (2) with O-ring (2)
WARNING
• Mark the installation position of the mounting plate Risk of irreparable turbo charger dam-
(2) age
• Mark compressor housing (1) to the housing of • When removing the compressor hous-
shaft bearing (3) ing, do not expose the turbine blades to
• Unscrew the mounting bolts (4) any impact
• Remove mounting plate (2)
• Carefully remove the compressor housing (1)
• Take the O-ring (3) out of the groove (2)
• Clean compressor housing (1)
WARNING
Risk of irreparable turbo charger dam-
age WARNING
• When positioning the compressor Component damage caused by incor-
housing, do not expose the blades of rect use of special tool
the turbine to any impact • Observe ratio Ring spanner SW15
i = 1 : 1.22 [115]
• Insert a new O-ring (3) into the groove (2)
• Carefully position the compressor housing (1) • Position the turbocharger (2) with a new seal (3)
• Screw in new mounting nuts (1) and tighten
Secure the compressor housing with Ring spanner SW15 i = 1 : 1.22 [115] to
1st torque 10 Nm
• Tighten the mounting nuts (1) to Final torque 90°
Bottom left mounting nut for turbo charger Fill turbo charger with oil
WARNING WARNING
Component damage caused by incor- Unless it is filled with oil, the turbo
rect use of special tool charger will be damaged when started
• Observe ratio Ring spanner SW15 for the first time
i = 1 : 1.22 [115] • Fill the turbo charger with clean en-
• In the rotation direction, set a smaller gine oil before the oil pressure line is
torque than the initial torque installed
• Tighten mounting nut using Ring spanner SW15 • Fill clean engine oil into the oil inlet nozzle on the
i = 1 : 1.22 [115] (1) and torque wrench (2) to turbo charger (2) using the funnel (1) until the oil
1st torque 10 Nm duct in the turbo charger (2) is full
• Tighten the mounting nut to Final torque 90°
Attaching the oil pressure line
Attaching the oil return line
• Position the exhaust manifold (2) on the turbo • Attach the air pipe (1)
charger (1) • Screw the retaining screw into the adjusting cylin-
• Screw on and tighten the new mounting nuts (3) der (3) and tighten it to 15 Nm
• Check compressed air pipe (2) for a firm seat using
Repair the compressed-air connection of the ad- Test tool [116]
justing cylinder • If the connector comes out of the retaining screw,
repeat the procedure
INTAKE/EXHAUST SYSTEM
EGR MODULE
Removing and installing the EGR module without an intermediate plate
Additional jobs
– Remove and install coolant manifold (version without retarder), see 35
– Removing/installing the coolant manifold (version with retarder), see 40
Technical data
EGR adjusting cylinder pre-load ........................................................................................ 1.25 ± 0.25 mm
Mounting nuts for EGR adjusting cylinder............... M8 ....................................................................10 Nm
Dimension of bracket from threaded bolts to limit stop Version 1 .................................................... 164 mm
Dimension of bracket from threaded bolts to limit stop Version 2 ..................................................161.5 mm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
Multi-purpose grease MAN 285 Li-PF2 ............................................................................... 09.15001-0012
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the EGR positioning cylinder Check the recessed version bracket
• Unscrew the mounting nut (2) and remove with the • Check dimension A between limit stop (1) and stud
washer (3) bolt (2)
• Unscrew the mounting nut (4) and remove with the If dimension A is 164 mm, the bracket has to be
washer (5) replaced for a bracket with 161.5 mm.
• Remove the EGR adjusting cylinder (1) from the
EGR shut-off flap lever (6) Removing the console
Fit the multi-piece rings on the unscrewed con- Screw in connecting tube mounting bolts
duit
• Apply Radiator antifreeze on the contact surfaces • Remove the retaining clip (2)
of the new unscrewed conduit (3) and insert into • Pull off the retaining screw (3) from the plug con-
the EGR module (6) nector (6)
• Insert the new washers (1) into the EGR module • Fit new O-rings (4) and (5)
(6) and exhaust manifold • Thinly apply Multi-purpose grease
• Insert the coupling pipe (2) into the EGR module MAN 285 Li-PF2 on the O-rings (4) and (5)
(6) • Insert the spring element (1) into the EGR adjust-
• Position the EGR module (6) with a new seal (4) ing cylinder
• Screw in and tighten the new mounting bolts (7) • Insert a new retaining clip (2) into the EGR adjust-
as marked ing cylinder
• Screw in and tighten the new mounting bolts (5)
Technical data
EGR adjusting cylinder pre-load ........................................................................................ 1.25 ± 0.25 mm
Mounting nuts for EGR adjusting cylinder............... M8 ....................................................................10 Nm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Position the gauge holder [122] (1) with Dial • Apply Radiator antifreeze on the contact surfaces
gauge [121] (4) and Caliper pin [123] on the of the new unscrewed conduit (5) and insert into
shut-off flap the EGR module (1)
• Position Caliper pin [123] with pre-load on the EGR • Insert the new washers (3) into the EGR module
positioning cylinder (1) and exhaust manifold
• Loosen the mounting nut (3) • Insert the unscrewed conduit (4) into the EGR
• Unscrew the cylinder rod (2) by several turns module (1)
• Screw in cylinder rod (2), until the dial Dial • Position the EGR module (1) with a new seal (6)
gauge [121] (4) does not move any longer connecting tube (8)
• Screw in the cylinder rod (2) by one turn • Screw in and tighten the new mounting bolts (2)
• Tighten the mounting nut (3) as marked
The pre-load for the EGR positioning cylinder is • Screw in and tighten the new mounting bolts (7)
1.25 ± 0.25 mm.
Screw in connecting tube mounting bolts
If the pre-load is out of tolerance, repeat the process.
Repair the compressed-air connection of the ad- Install the heat shield
justing cylinder
Technical data
Mounting bolt (3) .................................................. M8x105-HWF ......................................1st torque 3 Nm
Mounting bolt (3) .................................................. M8x105-HWF ...................................2nd torque 15 Nm
Mounting bolt (3) .................................................. M8x105-HWF ................................. Final torque 28 Nm
Mounting bolt (2) .................................................. M8x130-HWF ......................................1st torque 3 Nm
Mounting bolt (2) .................................................. M8x130-HWF ...................................2nd torque 15 Nm
Mounting bolt (2) .................................................. M8x130-HWF ................................. Final torque 28 Nm
Mounting bolt (9) .................................................. M8x55-10.9 .........................................1st torque 3 Nm
Mounting bolt (9) .................................................. M8x55-10.9 ......................................2nd torque 15 Nm
Mounting bolt (9) .................................................. M8x55-10.9 .................................... Final torque 30 Nm
Mounting bolt (8) .................................................. M8x90-10.9 .........................................1st torque 3 Nm
Mounting bolt (8) .................................................. M8x90-10.9 ......................................2nd torque 15 Nm
Mounting bolt (8) .................................................. M8x90-10.9 .................................... Final torque 30 Nm
Important information
WARNING
Risk of engine damage from the ingress of water
• Do not open pipe bundles in the EGR module
• When removing the shut-off flap, the glued on seal between the pipe bundle and cooler housing
must not be removed
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
(1) Non-return valve body mounting bolt (9) Connecting tube mounting bolt
(2) Check valve housing (10) Connecting tube
(3) Check valves (11) Check valves
(4) Intermediate plate (12) Mounting bolt, console
(5) Seal of intermediate plate (13) Mounting bolt for intermediate plate
(6) EGR module housing (14) Connecting tube mounting bolt
(7) Seal of closing flap (15) Connecting tube
(8) Shut-off flap (16) Non-return valve body mounting bolt
Technical data
Mounting bolt for closing flap (8)............................ M8x105-HWF ......................................1st torque 3 Nm
Mounting bolt for closing flap (8)............................ M8x105-HWF ...................................2nd torque 15 Nm
Mounting bolt for closing flap (8)............................ M8x105-HWF ................................. Final torque 28 Nm
Mounting bolt for closing flap (9)............................ M8x130-HWF ......................................1st torque 3 Nm
Mounting bolt for closing flap (9)............................ M8x130-HWF ...................................2nd torque 15 Nm
Mounting bolt for closing flap (9)............................ M8x130-HWF ................................. Final torque 28 Nm
Mounting bolt for check valve housing (16) ............ M8x55-10.9 .........................................1st torque 3 Nm
Mounting bolt for check valve housing (16) ............ M8x55-10.9 ......................................2nd torque 15 Nm
Mounting bolt for check valve housing (16) ............ M8x55-10.9 .................................... Final torque 30 Nm
Mounting bolt for check valve housing (1) .............. M8x90-10.9 .........................................1st torque 3 Nm
Mounting bolt for check valve housing (1) .............. M8x90-10.9 ......................................2nd torque 15 Nm
Mounting bolt for check valve housing (1) .............. M8x90-10.9 .................................... Final torque 30 Nm
Important information
WARNING
Risk of engine damage from the ingress of water
• Pipe bundle in the EGR module must not be opened
• When removing the shut-off flap, the glued on seal between pipe bundle and cooler housing
must not be opened
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
• Position the intermediate plate (1) with a new seal • Tighten non-return valve body starting with A (1)
(2) at the EGR module housing (3) according to tightening sequence A, B, C, D, E, F,
• Screw in and tighten the new mounting bolts (4) G, H
EXHAUST MANIFOLD
Removal and installation of the exhaust manifold
Additional jobs
– Remove and install coolant manifold (version without retarder), see 35
– Removing/installing the coolant manifold (version with retarder), see 40
– Removing and installing the EGR module without an intermediate plate, see 263
– Removal and installation of the turbocharger, see 253
Technical data
Mounting bolt for exhaust manifold (5) ................... M10x50-HWF ................................ Initial torque 60 Nm
Mounting bolt for exhaust manifold (5) ................... M10x50-HWF ......................................Final torque 90°
Mounting bolt for exhaust manifold (1) ................... M10x95-HWF ....................................1st torque 60 Nm
Mounting bolt for exhaust manifold (1) ................... M10x95-HWF ......................................Final torque 90°
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
CYLINDER HEAD
CYLINDER HEAD
Removal and installation of the cylinder head
Additional jobs
– Remove and install coolant manifold (version without retarder), see 35
– Removing/installing the coolant manifold (version with retarder), see 40
– Flame-start system protective sleeves, see 235
– Removing and installing the flame-start system, see 237
– Remove and install the charge air pipe, see 247
– Removal and installation the thermostats, see 45
– Removing and installing the thermostat housing, see 47
– Protective sleeves for fuel service centre, see 223
– Removal and installation of the fuel service centre, see 225
– Removal and installation of the turbocharger, see 253
– Removal and installation of the engine control unit, see 241
– Removing and installing the EGR module without an intermediate plate, see 263
– Removal and installation of the oil module, see 387
– Removal and installation of the exhaust manifold, see 287
– Protective sleeves for injectors and pressure pipe, see 181
– Removing and installing the injectors and pressure pipe, see 184
– Checking and adjusting valve clearance, see 305
Technical data
cylinder head bolt ................................................. M18x2x246-10.9 ................................1st torque 10 Nm
A 41 Stage 2 4th edition 293
CYLINDER HEAD
Service products
White T assembly paste..................................................................................................... 09.16012-0117
Important information
WARNING
Component damage due to leaky cylinder head seal
• Do not reuse old cylinder head bolts, even if they have only been used once
WARNING
The common rail system may suffer damage
• All work on components of the common rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work to enable de-pres-
surisation in the pressure pipe, or de-pressurisation must be checked by means of MAN-cats®
(specified value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Always fit new pressure pipe sockets once the existing ones have been undone
• Do not reuse plugs for the high-pressure lines, the pressure pipe or injectors
• Follow the sequence described when tightening injectors, high-pressure lines, the pressure pipe
and pressure pipe sockets
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Note
The mounting bolts can only be removed
• Disconnect the electrical connection (1) from the cylinder head cover with damp-
ing elements and spacer sleeves.
Removing the cable duct cover
• Unscrew the mounting bolts (4)
• Remove the cylinder head cover (3) with gasket
(2) from the cylinder head (1)
• Clean the cylinder head cover (3) and the gasket
(2)
Check the gasket (2) for damage. Remove from
the cylinder head cover (3) and replace if required
• Set aside the cylinder head cover (3) on a clean
surface with the gasket (2) facing downwards
If this is not done, engine oil can enter the gasket
section (2). When the cylinder head cover (3) is
tightened, this oil is then pressed out, causing sup-
posed leakage
Turning the engine to the TDC mark Removing the valve bridges
Note
The cylinder head can also be removed
whilst the rocker arm mechanism is in-
stalled, depending on the type of repairs
involved. • Insert the Torque multiplier i = 1 : 3.5 [125] (1) into
the Support [126] (2)
• Unscrew the mounting bolts (5) • Install the Holding device [128] (5) with Stud
• Remove the EVB brace (6) bolt [129] (3) and Adapter [132] (4) at the Sup-
• Unscrew the mounting bolts (3) and (4) port [126] (2)
• Remove the rocker arm mechanism (2) with rocker • Put the protractor [127] (10) on the Torque multi-
arm bearing bracket (1) plier i = 1 : 3.5 [125] (1)
• Put Socket, size 22 [133] (8) on the Torque mul-
tiplier i = 1 : 3.5 [125] (1) and secure with the
connecting pin [130] (9) and the Rubber ring [131]
(7)
• Insert the Socket [134] (6) into the Socket, size
22 [133] (8)
Note
Undo the cylinder head bolts from the
outside inwards.
Tightening sequence for cylinder head Screw in the cylinder head bolts
WARNING
Component damage due to leaky
cylinder head seal
• Do not reuse old cylinder head bolts,
even if they have only been used once
Checking the camshaft TDC mark Installing the rocker arm mechanism
• Check the TDC mark (1) on the camshaft (3) • Put the rocker arm bearing bracket (1) on the
The TDC mark (1) must be in line with the cylinder cylinder head
head face (2). • Put the rocker arm mechanism (2) on the rocker
arm bearing bracket (1)
If the marks are not in line, the camshaft (3) must be • Screw in the mounting bolts (3) and (4)
removed and reinserted at the mark. • Tighten the mounting bolt (4) to 105 Nm
• Tighten the mounting bolt (3) to 105 Nm
Fitting the valve crossheads • Place the EVB brace (6)
• Screw in and tighten the mounting bolts (5)
Note
The valve crosshead recesses must al-
ways face towards the camshaft.
A Intake side
B Exhaust side
Mounting the cylinder head cover Connecting the speed sensor electrical connec-
tion
Technical data
Intake valve clearance .................................................................................................................. 0.5 mm
Exhaust valve clearance ............................................................................................................... 0.8 mm
EVB brace setting dimensions....................................................................................................... 0.6 mm
Lock nuts (2), (4) .................................................. M10x1-8.8 .........................................................45 Nm
Lock nut, EVB brace (5) ........................................ M14x1-8.8 .........................................................45 Nm
Mounting bolts, cylinder head cover.................................................................................................10 Nm
Important information
WARNING
Danger of reduced engine output or engine damage
• Do not perform setting if the engine temperature is above 50 °C
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50 % of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Checking the intake valve clearance Forcing the engine oil out of the EVB piston
Adjusting the inlet valve clearance • Undo the union nut (2) and unscrew it several turns
• Screw in the adjusting screw (1) to press the valve
bridge (3) downwards several times until the stop
is reached
All the engine oil must fully escape from the EVB
piston (4)
Checking the setting dimensions for the EVB Adjusting the exhaust valve clearance
piston
WARNING
• Push down the valve crosshead (1)
Risk of incorrect valve clearance
• Insert the Feeler gauge [147] (3) with 0.6 mm leaf
• Before setting the valve clearance,
(2) between the ball cup brace (4) and the valve
force all the engine oil out of the EVB
crosshead (1)
piston
If the setting is not 0.6 mm, the valve clearances
for the exhaust valve and the EVB piston must be
• Undo the lock nut for the adjusting screw (1)
adjusted
• Push the EVB piston into the valve bridge (6)
until the stop is reached. To do this, screw in the
adjusting screw (2) and push the valve bridge (6)
downwards up to the pressure point (the valve
bridge must not move the exhaust valve)
• Block the valve crosshead (6) in this position with
the adjusting screw (1)
• Insert the Feeler gauge [147] with leaf 0.8 mm (5)
between the ball cup (4) and the valve crosshead
(6)
• Unscrew the adjusting screw (2) until the Feeler
gauge [147] with the 0.8 mm leaf (5) can be moved
between the ball cup (4) and the valve crosshead
(6) with little resistance
• Align adjusting screw (2) and brace with Valve
setting tool AF 14 [148], Ratchet [150] and Grip-
per [151]
• Tighten the lock nut (3) with Torque wrench [152]
with 45 Nm
• Check the setting again and, if necessary, repeat
the setting procedure
Setting the clearance for the EVB piston Tightening sequence for cylinder head cover
WARNING
Risk of incorrect valve clearance
• Set the exhaust valve clearance before
setting
Note
The valve crosshead must not move the
exhaust valve when the adjusting screw
is screwed in.
Technical data
Mounting bolts, cylinder head cover.................................................................................................10 Nm
Stud bolt bell crank support ................................... M12x60-10.9....................................................105 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Note
The lock washer and Holder [160] have
left-hand threads.
• Screw in the intermediate piece [156] (2) into the • Position Holder [159] (4) and Holder [160] at the
bracket (1) spring disc and tension by turning the threaded
• Screw the Assembly device [157] (3) into the in- spindle (5)
termediate piece [156] (2) • Hook the valve spring tensioner [155] (2) into the
Assembly device [157] (3)
• Put the Extension [158] (1) on the valve spring
tensioner [155] (2)
CAUTION
Risk of injury from springing back of
the valve spring
• Ensure that the Holder [159] und
Holder [160] are seated correctly on
the spring disc
• Do not remove the valve separators
from the valve spring with your bare
hands
• Screw in the intermediate piece [156] (2) into the • Position Holder [159] (4) and Holder [160] at the
bracket (1) spring disc and tension by turning the threaded
• Screw the Assembly device [157] (3) into the in- spindle (5)
termediate piece [156] (2) • Hook the valve spring tensioner [155] (2) into the
Assembly device [157] (3)
• Put the Extension [158] (1) on the valve spring
tensioner [155] (2)
CAUTION
Risk of injury from springing back of
the valve spring
• Ensure that the Holder [159] und
Holder [160] are seated correctly on
the spring disc
• Do not insert the valve separators into
the valve spring with your bare hands
Note
The valve crosshead recesses must al-
ways face towards the camshaft.
Installing the rocker arm mechanism Tightening sequence for cylinder head cover
A Intake side
B Exhaust side
VALVE CONTROL
CAMSHAFT/CAMSHAFT BEARING
Remove and fit camshaft/camshaft bearing
Additional jobs
– Checking and adjusting valve clearance, see 305
– Checking the valve timing, see 341
Technical data
Mounting bolts camshaft gear (1) .......................... M8x30-10.9 .......................................1st torque 15 Nm
Mounting bolts camshaft gear (1) .......................... M8x30-10.9 .........................................Final torque 90°
Mounting bolts intermediate gear (2)...................... M8x30-10.9 .......................................................30 Nm
Mounting bolts, cylinder head cover.................................................................................................10 Nm
Rocker arm mechanism mounting bolts ................. M12x60-10.9....................................................105 Nm
Service products
Omnifit 200M..................................................................................................................... 04.10160-9301
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Checking the rocker arm radial play Removing the rocker arm mechanism
Removing the rocker arm mechanism
Dismantling the rocker arm mechanism Checking the rocker arm shaft outside diameter
Unscrew the EVB adjusting screw Assembling the rocker arm mechanism
Screwing in the adjusting screw
Check outside diameter of the camshaft bearing Check installation depth camshaft gear
Remove the camshaft intermediate gear Remove the camshaft intermediate gear
Checking the camshaft TDC mark Installing the rocker arm mechanism
Fitting the valve crossheads
Tightening sequence for cylinder head cover Mounting the cable duct cover
A Intake side
B Exhaust side
VALVE TIMING
Checking the valve timing
Additional jobs
– Checking and adjusting valve clearance, see 305
Technical data
Valve lift during measurement ............................................................................................ 7.90 - 8.50 mm
Mounting bolts, cylinder head cover.................................................................................................10 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
The valve timing must be checked with the valve clearance set correctly.
Special tools
Note
The mounting bolts can only be removed
from the cylinder head cover with damp-
• Crank the flywheel in the engine's running direc- ing elements and spacer sleeves.
tion with Engine barring gear [175] (1) and Gear
ratchet [176] until the TDC mark on the flywheel is • Unscrew the mounting bolts (4)
lined up with the TDC mark (2) • Remove the cylinder head cover (3) with gasket
Rocker arms of cylinder 6 Cylinders must be in over- (2) from the cylinder head (1)
lap. • Clean the cylinder head cover (3) and the gasket
(2)
Upright rocker arm 6. If the cylinder is not in overlap, Check the gasket (2) for damage. Remove from
turn the flywheel a further 360° to the TDC mark. the cylinder head cover (3) and replace if required
• Set aside the cylinder head cover (3) on a clean
surface with the gasket (2) facing downwards
If this is not done, engine oil can enter the gasket
section (2). When the cylinder head cover (3) is
tightened, this oil is then pressed out, causing sup-
posed leakage
Checking the valve lift Tightening sequence for cylinder head cover
WARNING
Falsified measurement result by
cranking the engine against the en-
gine's running direction
• Only crank the engine in the running
direction
• Put Dial gauge [172] (4) with Caliper pin [174] (2)
and gauge holder [173] (3) on the 3rd cylinder inlet
valve disc
• Zero the Dial gauge [172] (4)
• Continue cranking the engine in the engine's run-
ning direction until the dial gauge pointer stops
moving
In this position, the correct valve lift must be A Intake side
7.90 - 8.50 mm. B Exhaust side
TIMING GEARS
Technical data
Mounting bolt (3) .................................................. M12x50-10.9....................................................105 Nm
A 41 Stage 2 4th edition 349
TIMING GEARS
Backlash, crankshaft gear (4) - high-pressure pump drive intermediate gear (1)................ 0.057 - 0.183 mm
Axial play, high-pressure pump drive intermediate gear (1) .............................................. 0.100 - 0.290 mm
Radial play, high-pressure pump drive intermediate gear (1) ............................................ 0.060 - 0.109 mm
Height, high-pressure pump drive intermediate gear (1)............................................... 21.000 - 21.500 mm
Inside diameter, high-pressure pump drive intermediate gear (1)............................... Ø 60.000 - 60.030 mm
Outside diameter, intermediate gear pin (2).............................................................. Ø 59.921 - 59.940 mm
Height, intermediate gear pin (2) ................................................................................ 27.200 - 27.240 mm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
The intermediate gear and pin do not have to be exchanged as a set.
They can also be replaced individually, depending on the degree of wear.
Special tools
• Checking backlash
• Checking the ring gear axial and radial play of the
intermediate gear
• Checking backlash
• Checking the ring gear axial and radial play of the
intermediate gear
Checking the front drive gears Checking the axial play on the high pressure
pump drive intermediate gear
Fixing the crankshaft gear
Checking the radial play on the high-pressure Removing the crankshaft gear
pump drive intermediate gear
Unscrew the mounting bolt
Removing the high-pressure pump drive Checking the inside diameter of the high pres-
intermediate gear sure pump drive intermediate gear
Checking the outside diameter of the intermedi- Installing the front drive gears
ate gear pin
Installing the intermediate gear
Technical data
Mounting bolt (5) .................................................. M14x80-10.9.................................... 1st torque 105 Nm
Mounting bolt (5) .................................................. M14x80-10.9........................................Final torque 90°
Mounting bolt (3) .................................................. M12x55-10.9.................................................... 115 Nm
Mounting bolts for small intermediate gear (6) ........ M8x20-10.9 .......................................................30 Nm
Backlash
Tooth backlash, large intermediate gear (4) - rear crankshaft gear (1)............................... 0.052 - 0.176 mm
Backlash, large intermediate gear (4) - Small intermediate gear (6) ................................. 0.052 - 0.176 mm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
The intermediate gear and pin do not have to be exchanged as a set.
They can also be replaced individually, depending on the degree of wear.
Note
The intermediate gear to the air compressor is designed in two parts for noise reduction and
pre-stressed.
Backlash cannot be measured at this point.
Special tools
• Checking backlash
• Checking the axial and radial play of intermediate
gears
• Checking backlash
• Checking the axial and radial play of intermediate
gears
Check the tooth flank clearance of the Setting the crankshaft gear to the marks
timing gears
Fixing the crankshaft gear
Checking the crankshaft gear/large - intermedi-
ate gear backlash
If the backlash is outside the tolerance, the small • Release the crankshaft gear (1) by unscrewing the
intermediate gear (4) and large intermediate gear mounting bolts (2) and (3)
must be replaced.
Removing the large intermediate gear Checking the radial play on the large intermedi-
ate gear
Checking the axial play on the large intermediate
gear
Checking the height of the large intermediate Checking the height of the large intermediate
gear gear pin
• Clean large intermediate gear (1) • Clean large intermediate gear pin (1)
• Check dimension A of large intermediate gear with • Check the height of the large intermediate gear
a micrometre (1) pin (1) using Depth gauge (electronic) [187] (2)
The permitted dimension A is 52.950 - 53.000 mm. The permitted installation height is
56.200 - 56.240 mm.
If dimension A is out of tolerance, the large interme-
diate gear (1) must be replaced. If the height is out of tolerance, the large intermedi-
ate gear pin (1) must be replaced.
Checking the inside diameter of the large inter-
mediate gear Checking the outside diameter of large interme-
diate gear pin
If the inside diameter is out of tolerance, the large If the outside diameter is out of tolerance, the large
intermediate gear (3) must be replaced. intermediate gear pin (1) must be replaced.
Removing the small intermediate gear Checking the radial play on the small intermedi-
ate gear
Checking the axial play on the small intermediate
gear
Check the height of the small intermediate gear Checking the height of the intermediate gear pin
• Clean the small intermediate gear (1) • Clean small intermediate gear pin (1)
• Check dimension A of small intermediate gear (1) • Check the height of the small intermediate gear
The permitted dimension A is 17.000 - 17.500 mm. pin (1) using Depth gauge (electronic) [187] (2)
The permitted height of the small intermediate gear
If dimension A is out of tolerance, the small interme- pin (1) is 21.200 - 21.240 mm.
diate gear (1) must be replaced.
If the height is out of tolerance, the small intermedi-
Checking the inside diameter of the small inter- ate gear pin (1) must be replaced.
mediate gear
Checking the outside diameter of the small in-
termediate gear pin
Checking the radial play on the air compressor Screwing in the guide mandrel
intermediate gear
Checking the height of the intermediate gear air Checking the height of the air compressor inter-
compressor mediate gear pin
• Clean the intermediate gear air compressor (1) • Clean the air compressor intermediate gear pin (1)
and contact washer (2) • Check the height of the intermediate gear pin of
• Check the height of the intermediate gear air the air compressor (1) using Depth gauge (elec-
compressor (1) and the thickness of the contact tronic) [187] (2)
washer (2) The permitted height of the intermediate gear pin (1)
The permitted dimension A is 25.900 - 26.000 mm. is 26.100 - 26.140 mm.
If dimension A is out of tolerance, the intermediate If the height is out of tolerance, the air compressor
gear air compressor (1) must be replaced. intermediate gear pin (1) must be replaced.
The permitted thickness of the contact washer (2) is Checking the outside diameter of the air com-
4.800 - 5.000 mm. pressor intermediate gear pin
• Thinly apply clean engine oil to the intermediate • Thinly apply clean engine oil to the small interme-
gear pin air compressor (3) diate gear pin (2)
• Place the intermediate gear pin air compressor (3) • Position the small intermediate gear (4) with a
into the intermediate gear air compressor (1) flat approach surface (3) to the small intermediate
• Position the contact washer (2) with the more gear pin (2)
chamfered side to the crankcase pointing towards • Install small intermediate gear (4) with small inter-
the intermediate gear pin air compressor (3) mediate gear pin (2) in crankcase
• Screw in new mounting bolts (1) and tighten to
30 Nm
• Turn the crankshaft until the centring pin (4) is • Check that the mark (1) on the large intermediate
perpendicular to the oil sump gear and the mark (2) on the crankshaft gear are
• Screw in the Centring mandrel [182] (3) and (5) in line
• Align the crankshaft gear (1) with the centring pin If the marks (1) and (2) are not in line, remove the
(4) large intermediate gear and re-insert it at the mark.
• Push the crankshaft gear (1) onto the crankshaft
• Unscrew the Centring mandrel [182] (3) and (5)
Removing, installing the timing gear (crankshaft seal, crankshaft gear Version)
Additional jobs
– Remove and install coolant manifold (version without retarder), see 35
– Removing/installing the coolant manifold (version with retarder), see 40
– Flame-start system protective sleeves, see 235
– Removing and installing the flame-start system, see 237
– Remove and install the charge air pipe, see 247
– Removal and installation the thermostats, see 45
– Removing and installing the thermostat housing, see 47
– Protective sleeves for fuel service centre, see 223
– Removal and installation of the fuel service centre, see 225
– Removal and installation of the turbocharger, see 253
– Removal and installation of the engine control unit, see 241
– Removing and installing the EGR module without an intermediate plate, see 263
– Removal and installation of the oil module, see 387
– Removal and installation of the exhaust manifold, see 287
– Protective sleeves for injectors and pressure pipe, see 181
– Removing and installing the injectors and pressure pipe, see 184
– Removal and installation of the cylinder head, see 293
– Removal and installation of the starter, see 151
– Removing and installing flywheel (crankshaft seal crankshaft gear version) for manually operated gear-
boxes, see 455
– Removing and installing flywheel (with race) for the automatic gearbox, see 465
– Removing and installing dual-mass flywheel (crankshaft seal crankshaft gear version), see 471
– Removing and installing flywheel housing/timing case, see 505
– Removal and installation of rear crankshaft seal (crankshaft seal version flywheel), see 423
– Removing, installing the rear crankshaft seal for Crankshaft gear with stud, see 428
– Checking and adjusting valve clearance, see 305
– Checking the valve timing, see 341
Technical data
Mounting bolt (5) .................................................. M14x80-10.9.................................... 1st torque 105 Nm
Mounting bolt (5) .................................................. M14x80-10.9........................................Final torque 90°
Mounting bolt (3) .................................................. M12x55-10.9.................................................... 115 Nm
Mounting bolts for small intermediate gear (6) ........ M8x20-10.9 .......................................................30 Nm
Backlash
Tooth backlash, large intermediate gear (4) - rear crankshaft gear (1)............................... 0.052 - 0.176 mm
Backlash, large intermediate gear (4) - Small intermediate gear (6) ................................. 0.052 - 0.176 mm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50 % of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
The intermediate gear and pin do not have to be exchanged as a set.
They can also be replaced individually, depending on the degree of wear.
Note
The intermediate gear to the air compressor is designed in two parts for noise reduction and
pre-stressed.
Backlash cannot be measured at this point.
Special tools
Check the tooth flank clearance of the Setting the crankshaft gear to the marks
timing gears
Fixing the crankshaft gear
Checking the crankshaft gear/large - intermedi-
ate gear backlash
If the backlash is outside the tolerance, the small • Release the crankshaft gear (3) by unscrewing the
intermediate gear (4) and large intermediate gear mounting bolts (1) and (2)
must be replaced.
Removing the large intermediate gear Checking the radial play on the large intermedi-
ate gear
Checking the axial play on the large intermediate
gear
Checking the height of the large intermediate Checking the height of the large intermediate
gear gear pin
• Clean large intermediate gear (1) • Clean large intermediate gear pin (1)
• Check dimension A of large intermediate gear with • Check the height of the large intermediate gear
a micrometre (1) pin (1) using Depth gauge (electronic) [193] (2)
The permitted dimension A is 52.950 - 53.000 mm. The permitted installation height is
56.200 - 56.240 mm.
If dimension A is out of tolerance, the large interme-
diate gear (1) must be replaced. If the height is out of tolerance, the large intermedi-
ate gear pin (1) must be replaced.
Checking the inside diameter of the large inter-
mediate gear Checking the outside diameter of large interme-
diate gear pin
If the inside diameter is out of tolerance, the large If the outside diameter is out of tolerance, the large
intermediate gear (3) must be replaced. intermediate gear pin (1) must be replaced.
Removing the small intermediate gear Checking the radial play on the small intermedi-
ate gear
Checking the axial play on the small intermediate
gear
Check the height of the small intermediate gear Checking the height of the intermediate gear pin
• Clean the small intermediate gear (1) • Clean small intermediate gear pin (1)
• Check dimension A of small intermediate gear (1) • Check the height of the small intermediate gear
The permitted dimension A is 17.000 - 17.500 mm. pin (1) using Depth gauge (electronic) [193] (2)
The permitted height of the small intermediate gear
If dimension A is out of tolerance, the small interme- pin (1) is 21.200 - 21.240 mm.
diate gear (1) must be replaced.
If the height is out of tolerance, the small intermedi-
Checking the inside diameter of the small inter- ate gear pin (1) must be replaced.
mediate gear
Checking the outside diameter of the small in-
termediate gear pin
Checking the radial play on the air compressor Screwing in the guide mandrel
intermediate gear
Checking the height of the intermediate gear air Checking the height of the air compressor inter-
compressor mediate gear pin
• Clean the intermediate gear air compressor (1) • Clean the air compressor intermediate gear pin (1)
and contact washer (2) • Check the height of the intermediate gear pin of
• Check the height of the intermediate gear air the air compressor (1) using Depth gauge (elec-
compressor (1) and the thickness of the contact tronic) [193] (2)
washer (2) The permitted height of the intermediate gear pin (1)
The permitted dimension A is 25.900 - 26.000 mm. is 26.100 - 26.140 mm.
If dimension A is out of tolerance, the intermediate If the height is out of tolerance, the air compressor
gear air compressor (1) must be replaced. intermediate gear pin (1) must be replaced.
The permitted thickness of the contact washer (2) is Checking the outside diameter of the air com-
4.800 - 5.000 mm. pressor intermediate gear pin
• Thinly apply clean engine oil to the intermediate • Thinly apply clean engine oil to the small interme-
gear pin air compressor (3) diate gear pin (2)
• Place the intermediate gear pin air compressor (3) • Position the small intermediate gear (4) with a
into the intermediate gear air compressor (1) flat approach surface (3) to the small intermediate
• Position the contact washer (2) with the more gear pin (2)
chamfered side to the crankcase pointing towards • Install small intermediate gear (4) with small inter-
the intermediate gear pin air compressor (3) mediate gear pin (2) in crankcase
• Screw in new mounting bolts (1) and tighten to
30 Nm
• Turn the crankshaft until the centring pin (2) is • Check that the mark (1) on the large intermediate
perpendicular to the oil sump gear and the mark (2) on the crankshaft gear are
• Screw in the Centring mandrel [188] (3) and (4) in line
• Align the crankshaft gear (1) with the centring pin If the marks (1) and (2) are not in line, remove the
(2) large intermediate gear and re-insert it at the mark.
• Push the crankshaft gear (1) onto the crankshaft
• Unscrew the Centring mandrel [188] (3) and (4)
ENGINE LUBRICATION
OIL MODULE
Removal and installation of the oil module
Technical data
Oil cooler mounting bolts (2).................................. M8x55-8.8 .........................................................27 Nm
Oil cooler mounting bolts (2).................................. M8x80-8.8 .........................................................27 Nm
Sealing cap oil module (7)..................................... M38x1.5 ............................................................80 Nm
Screw-in fitting (4) ................................................ M24x1.5 ............................................................. 4 Nm
Screw-in fitting (8) ................................................ M24x1.5 ............................................................. 4 Nm
Pressure relief valve ............................................. M27x1.5 ............................................................45 Nm
Oil filter lid ......................................................................................................................................45 Nm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
Loctite 242 ........................................................................................................................ 04.90300-9025
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Unscrew the oil filter cover (1) from the oil module
(4) with the Socket, size 32 [194]
• Remove the O-ring (2) from the oil filter cover (1)
• Pull the oil filter (3) out of the oil filter cover (1)
• Insert the oil cooler (3) with new seals (2) into the
oil module (1)
• Screw in the new mounting bolts (4) by hand as
marked
• Lay the oil module (1) so that the oil cooler does
not get damaged
• Tighten the mounting bolts (3) to 27 Nm
• Tighten the mounting bolts (2) to 27 Nm
• Screw in the sealing cap (3) with a new sealing ring • Push the vent line (1) completely on the oil sepa-
(2) into the oil module (1) and tighten to 80 Nm rator
• Place the jubilee clips (2) using Hose clamp pliers
Installing bleed line for jubilee clips [195]
Technical data
Dimension of connecting-rod bearing bolt - oil intake pipe............................................................... 5.0 mm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Technical Vaseline ............................................................................................................. 09.15014-0001
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
Oil sumps are installed with an oil drain pipe or a blank flange.
The sealing for both versions varies.
The version fitted with an oil drain tube is sealed with Loctite 5900.
The version with a blank flange is sealed with a seal.
Special tools
Removing the oil sump and oil intake Remove the oil drain pipe
pipe
Removing the oil dipstick guide tube
Detaching the oil filler tube Removing the oil intake pipe
• Unscrew the mounting bolts (1) and (3) • Unscrew the mounting bolts (1)
• Remove the oil filler tube (2) with seal • Pull the oil intake pipe (2) out of the crankcase
• Clean the mating faces • Pull the O-ring (3) out of the crankcase
• Unscrew the mounting bolts (2) • Undo the hose clamp (4)
• Remove the oil sump (1) with seal (3) • Unscrew the mounting bolt (2)
• Clean the mating faces • Remove oil return line (1) with hose (3)
Install oil sump and oil intake pipe Mount engine cranking unit
• Thinly apply Technical Vaseline on a new O-ring • Crank the engine with Engine barring gear [196]
(3) and insert it into the crankcase and Gear ratchet [197] in the direction of rotation
• Insert the oil intake pipe (2) into the crankcase of the engine
• Screw in and tighten the new mounting bolts (1) • Check distance between connecting-rod bearing
bolts and oil intake pipe
The allowed measure A between connecting-rod
bearing bolt and oil intake pipe is 5.0 mm.
• Remove the Engine barring gear [196] (1) from the • Position the oil filler tube (2) with a new seal
flywheel housing/timing case • Screw in and tighten the new mounting bolts (3)
• Mount the cap on the flywheel housing/timing case • Screw in and tighten the new mounting bolt (1)
Installing the oil drain pipe Installing the oil dipstick guide tube
• Thinly apply Loctite 5900 on the mating faces of • Installing the guide tube (1)
the oil drain pipe (2) • Pushing in the oil dipstick
• Insert the oil drain pipe (2)
• Screw in and tighten the new mounting bolts (1)
and (3) as marked
Technical data
Oil level sensor (8)................................................ M22x1.5 ............................................................25 Nm
Important information
Note
Oil sumps are installed with an oil drain pipe or a blank flange.
The sealing for both versions varies.
The version with a blank flange is sealed with a seal.
The version fitted with an oil drain tube is sealed with Loctite 5900.
Removing and installing the oil drain pipe, see Removing and installing the oil sump and oil intake
pipe, 395
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
• Unscrew the mounting bolt (2) • Insert the oil nozzle (1) into the crankcase (3)
• Pull out the oil nozzle (1) from the crankcase (3) • Screw in and tighten the new mounting bolt (2)
OIL PUMP
Removal and installation the oil pump
Additional jobs
– Draining and topping up engine oil
– Removing and installing belt drive, see 153
– Remove and install coolant manifold (version without retarder), see 35
– Removing/installing the coolant manifold (version with retarder), see 40
– Removal and installation the thermostats, see 45
– Removing and installing the thermostat housing, see 47
– Removing and installing alternators 1 and 2, see 159
– Removing and installing the coolant pump, see 51
– Remove and install the charge air pipe, see 247
– Removal and installation the distributor housing, see 55
– Removal and installation of the vibration damper, see 435
– Remove the ribbed V-belt of the coolant compressor, see 156
– Installing the ribbed V-belt for the coolant compressor, see 158
– Removal and installation of the coolant compressor, see 173
– Removing and installing the high pressure pump/high pressure pump drive (fuel-lubricated), see 199
– Removing and installing the high pressure pump/high pressure pump drive (fuel-lubricated), see 207
– Removal and installation cover, see 507
– Removal and installation of front crankshaft seal, see 417
Technical data
Mounting bolt (1) .................................................. M6x20-10.9 .......................................................15 Nm
Mounting bolt (4) .................................................. M10x65-10.9......................................................65 Nm
Important information
WARNING
Component damage at oil pump and storage
• If repairing, always fit a new oil pump complete with the bearing
• Always ensure absolute cleanliness when installing the oil pump
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50 % of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Checking backlash
• Checking the ring gear axial and radial play
Checking the oil pump Checking the ring gear axial play
• Screw in the Centring mandrel [200] (3) and (4) • Install the gauge holder [199] (3) with Dial
• Pull off the crankshaft gear (2) gauge [198] (1)
• Unscrew the Centring mandrel [200] (3) and (4) • Position the tracer pin of the Dial gauge [198] (1)
• Clean the contact surfaces of the crankshaft gear against the ring gear (2) with a pre-load
(2) and crankshaft (1) • Push the ring gear (2) outwards into the end posi-
tion
• Zero the Dial gauge [198] (1)
• Push the ring gear (2) into the end position towards
Dial gauge [198] (1) and check the difference
The permitted radial play of the ring gear (2) is
0.053 - 0.210 mm.
• Remove the ring gear (1) and the oil pump pinion
(2) from the crankcase (3)
Checking the internal diameter of the oil pump Checking the height of the oil pump pinion
pinion
WARNING
Component damage due to shavings
WARNING in the oil sump
Component damage due to use of in- • Cover the opening to the oil sump
correct bearing bush and incorrect
press-in tool WARNING
• Before stripping the equipment down, Component damage on bearing seat
determine which bearing bush is in- • Position the puller so that the bearing
stalled bush is pulled off straight rather than at
an angle
• For a bearing bush with a lubrication groove (1),
the Drive-up tool [204] must be used for pressing • Insert the extractor [202] (3) into the bearing bush
in (5) and expand it
• Fit the hose clamp (4) over the extractor [202] (3)
Bearing bush with lubricating hole and tighten it
• Mount the Adapter [203] (2)
• Screw the Extractor [201] (1) into the Adapter [203]
(2)
• Extract the bearing bush (4) using the Extrac-
tor [201]
WARNING
Component damage due to use of
wrong press-in tool
• Use the correct press-in device for
bearing bushes with lubricating hole
Install bearing bush with lubricating Prepare the press-in tool for bearing bush with
hole lubricating hole
WARNING
Component damage due to use of
WARNING wrong press-in tool
Component damage due to use of • Use the refitted press for bearing
wrong press-in tool bushes with lubricating hole
• Convert the press-in tool for pressing
the bearing bush with lubricating hole • Align the recess on the bearing bush (2) with the
mark on the special tool (1)
• Put the Plate [206] (1) on Pressure shim [205] (2) • Fit a new bearing bush (2)
and secure using bolts (3)
• Unscrew the guide pins (4) from Drive-up tool [204] Fitting the guide plate
and attach to Plate [206] (1)
Pressing in the bearing bush with lubricating Installing the oil pump
hole
Installing the oil pump pinion shaft
CRANKSHAFT SEALS
CRANKSHAFT SEALS
Removal and installation of front crankshaft seal
Additional jobs
– Remove the ribbed V-belt of the coolant compressor, see 156
– Installing the ribbed V-belt for the coolant compressor, see 158
– Removing the ribbed V-belt for alternator 3, see 157
– Installing the ribbed V-belt for alternator 3, see 157
– Removal and installation of the vibration damper, see 435
Important information
WARNING
PTFE seals are rendered unusable if they come into contact with oil or grease before instal-
lation
• Clean the crankshaft and insertion tool before assembly
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the front crankshaft oil seal Installing the front crankshaft oil seal
Determining the crankshaft oil seal repair level Positioning the crankshaft seal
Installing crankshaft seal 1. repair level Installing crankshaft seal 2. repair level
• Push Press-in bushing [212] (2) with Washer • Place the Press-in bushing [212] (2) on the Guide
3 mm [220] to Guide plate [216] plate [216]
• Screw hex collar nut [218] (3) on to spindle [214] • Screw hex collar nut [218] (3) on to spindle [214]
(4) (4)
• Screw Hex nut [213] on to spindle [214] (4) • Screw Hex nut [213] on to spindle [214] (4)
• Screw the second Hex nut [213] onto spindle [214] • Screw the second Hex nut [213] onto spindle [214]
(4) and brace with Hex nut [213] (4) and brace with Hex nut [213]
• Screw the spindle [214] (4) into the Guide • Screw the spindle [214] (4) into the Guide
plate [216] with the Washer [217] plate [216] with the Washer [217]
• Brace Hex nut [213] against spindle [214] (4) • Brace Hex nut [213] against spindle [214] (4)
• Press in the crankshaft seal (1) by screwing on • Press in the crankshaft seal (1) by screwing on
the hex collar nut [218] (3) until the Press-in bush- the hex collar nut [218] (3) until the Press-in bush-
ing [212] (2) with Washer 3 mm [220] is at the ing [212] (2) is at the Guide plate [216]
Guide plate [216] • Remove the special tool
• Remove the special tool
WARNING
Risk of leaks in the engine
• When reaching the 3rd repair stage, the
crankshaft gear must be replaced
Removal and installation of rear crankshaft seal (crankshaft seal version flywheel)
Additional jobs
– Removal and installation of the gearbox flywheel (Flywheel crankshaft seal), see 439
– Removing and installing flywheel (crankshaft seal crankshaft gear version) for manually operated gear-
boxes, see 455
– Removing and installing flywheel of automatic gearbox (crankshaft seal flywheel version), see 449
– Removing and installing flywheel (with race) for the automatic gearbox, see 465
– Removing and installing dual-mass flywheel (crankshaft seal crankshaft gear version), see 471
Technical data
Installation temperature for race ............................................................................................ about 120 °C
Service products
Loctite Antipor ................................................................................................................... 04.90300-9011
Important information
WARNING
PTFE seals are rendered unusable if they come into contact with oil or grease before instal-
lation
• Clean the crankshaft and insertion tool before assembly
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the rear crankshaft oil seal Installing the rear crankshaft oil seal
• Pull the crankshaft oil seal (3) out of the flywheel • Push Guide bushing [230] (4) onto crankshaft
housing/timing case with Impact extractor [222] (1) • Assemble press plate [231] (6) with Plug-on han-
and Extractor hook [223] (2) dle [227] (1) and Washer [229] (2)
• Place crankshaft gear (3) with sealed side on the
special tool
• Push the special tool to Guide bushing [230] (4)
• Press in the crankshaft seal (3) by screwing on
the flywheel housing/timing case (5) until the press
plate [231] (6) is at the Guide bushing [230] (4)
• Remove the special tool
Removing, installing the rear crankshaft seal for Crankshaft gear with stud
Additional jobs
– Removal and installation of the gearbox flywheel (Flywheel crankshaft seal), see 439
– Removing and installing flywheel of automatic gearbox (crankshaft seal flywheel version), see 449
Important information
WARNING
Component damage due to leaks
• Do not allow the crankshaft seal (PTFE sealing ring) to come into contact with oil or grease before
installing it
• Clean the crankshaft and special tool before assembly
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50 % of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the rear crankshaft oil seal Extracting the crankshaft oil seal
WARNING
Component damage on crankshaft
• Install the Guide plate [216] (1) with Stud bolt [215]
gear
(3) (two opposite) on crankshaft gear
• If run-in grooves should be visible on
• Screw in the Pressure plate [233] (2)
the crankshaft gear, detach the fly-
wheel housing and replace the crank-
shaft gear, see Removing and installing
flywheel housing/timing case, 505
Replacing the crankshaft gear, see Re-
moving and installing rear timing gears
(Version crankshaft seal flywheel), 357
Installing the rear crankshaft oil seal Pressing in the crankshaft oil seal
CRANKSHAFT DRIVE
VIBRATION DAMPER
Removal and installation of the vibration damper
Additional jobs
– Remove the ribbed V-belt of the coolant compressor, see 156
– Installing the ribbed V-belt for the coolant compressor, see 158
– Removing the ribbed V-belt for alternator 3, see 157
– Installing the ribbed V-belt for alternator 3, see 157
Technical data
Mounting bolt (1) .................................................. M16x1.5x85-10.9 ............................. 1st torque 155 Nm
Mounting bolt (1) .................................................. M16x1.5x85-10.9 .................................Final torque 90°
Important information
WARNING
Component damage through incorrect position of the vibration damper
• Depending on version, the vibration damper is equipped with cooling fins for cooling
• Take care not to damage the vibration damper cooling fins
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Technical data
Mounting bolt (3) .................................................. M16x1.5x80-12.9 ..........................Initial torque 105 Nm
Mounting bolt (3) .................................................. M16x1.5x80-12.9 ............................... Final torque 180°
Installation temperature starting ring gear ...............................................................................200 - 230 °C
Flywheel axial run-out (2)...................................................................................................... max. 0.5 mm
Dimension of flywheel bridge to friction surface (maximum) .................................................... max. 7.0 mm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Insert the Torque multiplier i = 1 : 3.5 [251] (1) into Screwing on centring mandrels
the Support [252] (9)
• Install the Holding device [254] (6) with Stud
bolt [256] (8) and Adapter [255] (7) at the Sup-
port [252] (9)
• Position protractor [253] (2) on Torque multiplier i
= 1 : 3.5 [251] (1)
• Put the Socket, size 19 [259] (3) on the Torque
multiplier i = 1 : 3.5 [251] (1) and secure with the
connecting pin [257] (5) and the Rubber ring [258]
(4)
CAUTION
Danger of injury due to heavy compo-
nents
• Use lifting gear to remove the flywheel
Remove the clutch pilot bearing Mounting the starter ring gear
• Remove the clutch pilot bearing (2) from the fly- • Heat starting ring gear (1) to 200 - 230 °C
wheel (1) • Place the starting ring gear (1) so that the chamfer
(3) at the toothing points away from the flywheel
Detaching the starter ring gear (2) and that the starter ring (1) is aligned with the
flywheel (2)
• Adjust the starting ring gear (1) as necessary
WARNING
Component damage due to
spot-drilling of the flywheel
• Take care not to damage the flywheel
when spot-drilling the starting ring gear
• Fit a new spot-drilled flywheel
CAUTION
Danger of injury due to heavy compo-
nents
• Use lifting gear to install the flywheel
Note
Note the multiplication ratio of the power
amplifier wrench i = 1 : 3.5.
Technical data
Mounting bolt (6) .................................................. M16x1.5x93-10.9 ............................. 1st torque 105 Nm
Mounting bolt (6) .................................................. M16x1.5x93-10.9 ............................... Final torque 180°
Installation temperature for starter ring gear (2) .......................................................................200 - 230 °C
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Insert the Torque multiplier i = 1 : 3.5 [264] (1) into Screwing on centring mandrels
the Support [266] (9)
• Install the Holding device [268] (6) with Stud
bolt [269] (8) and Adapter [272] (7) at the Sup-
port [266] (9)
• Position protractor [267] (2) on Torque multiplier i
= 1 : 3.5 [264] (1)
• Put the Socket, size 19 [265] (3) on Torque multi-
plier i = 1 : 3.5 [264] (1) and secure with connecting
pin [270] (5) and Rubber ring [271] (4)
WARNING
Component damage due to
spot-drilling of the flywheel
• Take care not to damage the flywheel
when spot-drilling the starting ring gear
• Fit a new spot-drilled flywheel
Place flywheel
Note
Note the multiplication ratio of the power
amplifier wrench i = 1 : 3.5.
Technical data
Mounting bolt (3) .................................................. M16x1.5x80-12.9 ..........................Initial torque 105 Nm
Mounting bolt (3) .................................................. M16x1.5x80-12.9 ............................... Final torque 180°
Installation temperature for starter ring gear (2) .......................................................................200 - 230 °C
Flywheel axial run-out (1)...................................................................................................... max. 0.5 mm
Dimension of flywheel bridge to friction surface (maximum) .................................................... max. 9.5 mm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50 % of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Insert the Torque multiplier i = 1 : 3.5 [282] (1) into Screwing on centring mandrels
the Support [283] (9)
• Install the Holding device [285] (6) with Stud
bolt [287] (8) and Adapter [286] (7) at the Sup-
port [283] (9)
• Position protractor [284] (2) on Torque multiplier i
= 1 : 3.5 [282] (1)
• Put the Socket, size 19 [290] (3) on the Torque
multiplier i = 1 : 3.5 [282] (1) and secure with the
connecting pin [288] (5) and the Rubber ring [289]
(4)
CAUTION
Danger of injury due to heavy compo-
nents
• Use lifting gear to remove the flywheel
Remove the clutch pilot bearing Mounting the starter ring gear
WARNING
Component damage due to
spot-drilling of the flywheel
• Take care not to damage the flywheel
when spot-drilling the starting ring gear
• Fit a new spot-drilled flywheel
CAUTION
Danger of injury due to heavy compo-
nents
• Use lifting gear to install the flywheel
Note
Note the multiplication ratio of the power
amplifier wrench i = 1 : 3.5.
Technical data
Mounting bolt (5) .................................................. M16x1.5x93-10.9 ............................. 1st torque 105 Nm
Mounting bolt (5) .................................................. M16x1.5x93-10.9 ............................... Final torque 180°
Installation temperature for starter ring gear (1) .......................................................................200 - 230 °C
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50 % of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Insert the Torque multiplier i = 1 : 3.5 [292] (1) into Screwing on centring mandrels
the Support [293] (9)
• Install the Holding device [295] (6) with Stud
bolt [296] (8) and Adapter [299] (7) at the Sup-
port [293] (9)
• Position protractor [294] (2) on Torque multiplier i
= 1 : 3.5 [292] (1)
• Put the Socket, size 19 [300] (3) on Torque multi-
plier i = 1 : 3.5 [292] (1) and secure with connecting
pin [297] (5) and Rubber ring [298] (4)
WARNING
Component damage due to
spot-drilling of the flywheel
• Take care not to damage the flywheel
when spot-drilling the starting ring gear
• Fit a new spot-drilled flywheel
Place flywheel
Note
Note the multiplication ratio of the power
amplifier wrench i = 1 : 3.5.
Technical data
Mounting bolt (3) .................................................. M16x1.5x122-12.9 ........................... 1st torque 105 Nm
Mounting bolt (3) .................................................. M16x1.5x122-12.9 .........................2. Tightening by 90°
Mounting bolt (3) .................................................. M16x1.5x122-12.9 ...............................Final torque 90°
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pre-tightening to max. 50 % of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
CAUTION
Danger of injury due to heavy compo-
nents
• Use lifting gear to remove the flywheel
Put on the dual-mass flywheel Screw in mounting bolts for dual-mass flywheel
Note
Note the multiplication ratio of the power
amplifier wrench i = 1 : 3.5.
Technical data
Connecting-rod bearing bolt (3) ............................. M12x1.5x64-11.9 ............................. 1st torque 100 Nm
Connecting-rod bearing bolt (3) ............................. M12x1.5x64-11.9 .................................Final torque 90°
Piston weights
Piston weight Nüral piston...................................................................................................... 1940 ± 30 g
Piston weight Mahle piston............................................................................................................. 1906 g
Piston weight difference per set of an engine ..............................................................................max. 60 g
Piston pins
Piston pins ............................................................................................................. Ø 51.992 - 52.000 mm
Piston projection
Piston projection (crankcase - piston) .................................................................... 0.3 mm (nominal value)
Important information
WARNING
Cracked surfaces are weakened and may lead to material breaking off
• Exchange the connecting rod if the crack surfaces are damaged
• Protect crack surfaces against damage caused by hard and sharp objects
• To clean the crack surfaces on the connecting rods, always rinse them in clean cleaning agent
• After cleaning, use compressed air to blow-dry the crack surfaces
• Do not allow flushed-out particles to enter the engine
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
The piston diameter is always measured across to the piston pin bore.
Special tools
Check the connecting rod Checking the connecting rod radial play
If the axial play is out of tolerance, check the width of Check the connecting rod inside diameter, see
the connecting rod (4), see Checking the connecting Checking the connecting rod bearing inside diame-
rod width, 486. ter, 485.
Removing the piston and connecting Remove and check the piston
rod
Remove piston pin
Remove the connecting rod bearing cap
Checking the piston ring axial play Checking the piston ring gap
Note Note
An axial play cannot be measured on the The ring gap is only allowed to be
keystone ring. checked if the cylinder liner has the cor-
rect inside diameter, otherwise a false
• Check axial play between piston rings (2) and (3) ring gap reading would be obtained.
and piston (4) with Feeler gauge [315] (1) Checking cylinder liner inside diameter,
The permitted axial play of the bevelled-edge ring see Removal and installation the cylinder
(3) is 0.03 - 0.07 mm. liner, 509.
The permitted axial play on the Taper-faced com- • Insert the piston ring (3) evenly deep into the cylin-
pression ring (2) is 0.08 - 0.13 mm. der liner (1)
• Check for even insertion depth of the piston ring
If the axial plays are out of tolerance, the piston (4) (3) using the Depth gauge (electronic) [320]
with piston rings (2), (3) and double-bevelled ring • Repeat the check with various insertion depths
must be replaced. • Check ring gap with Feeler gauge [315] (2)
The permitted ring gap of the keystone ring is
Removing the piston rings 0.40 - 0.55 mm.
Checking the connecting rods and con- Checking the connecting rod bearing inside di-
necting rod bearings ameter
Checking the connecting rod bearing shell Installing the piston and connecting rod
spread
Installing the piston rings
Note • Set Piston ring pliers [314] (1) to the piston diam-
The difference between dimension A and eter
dimension B gives the connecting rod • Insert the piston rings (2) with TOP mark facing
bearing shell spread. the piston crown with Piston ring pliers [314] (1) in
the respective ring groove in the piston (3)
• Clean the connecting rod bearing shells (2) and
place them together on a flat surface as marked Install piston pin
• Check dimension A with a micrometer (1)
• Check dimension B using a micrometer (1)
The permitted spread of the connecting rod bearing
shells (2) is max. 2.0 mm.
Installation instructions for connecting rod bear- Piston installation with piston ring clamping
ing shells sleeve
WARNING Note
Cracked surfaces are weakened and There is an installation arrow on the pis-
may lead to material breaking off ton surface. This must point towards the
• Exchange the connecting rod if the coolant pump during installation.
crack surfaces are damaged
• Protect crack surfaces against damage • Move the crankshaft for the cylinder concerned to
caused by hard and sharp objects TDC
• Line up the gaps in the piston rings at 120° offset
• Clean the contact surfaces of the connecting rod to one another
bearing shells in the connecting rod and connect- • Thinly apply clean engine oil on the upper con-
ing rod bearing cap necting rod bearing shell
• Place the lower connecting rod bearing shell into • Insert the upper connecting rod bearing shell into
the connecting rod bearing cap so that the lug (1) the connecting rod
engages in the recess (4) • Thinly apply clean engine oil on the piston (1) and
• Place the upper connecting rod bearing shell into cylinder liner (3)
the connecting rod so that the lug (2) engages in • Put the Piston ring clamping sleeve [321] (2) on
the recess (3) the piston (1) and clamp it
• Use the settling tools [322] to align the connecting • Push the piston (1) with connecting rod into the
rod bearing shells in the connecting rod and con- cylinder liner (3) until the piston has been pushed
necting rod bearing cap out of the Piston ring clamping sleeve [321] (2)
• Push in the piston (1) until the connecting rod
with connecting rod bearing shell is lying on the
crankshaft
Checking the connecting rod alignment Installing the connecting rod bearing cap
WARNING WARNING
Cracked surfaces are weakened and Cracked surfaces are weakened and
may lead to material breaking off may lead to material breaking off
• Exchange the connecting rod if the • Exchange the connecting rod if the
crack surfaces are damaged crack surfaces are damaged
• Protect crack surfaces against damage • Protect crack surfaces against damage
caused by hard and sharp objects caused by hard and sharp objects
• Check the alignment of the connecting rod bearing • Insert the lower connecting rod bearing shell (2)
shell (2) in the connecting rod (1) and, if necessary, into the connecting rod cap (3)
adjust using the settling tools [322] (3) • Check the alignment of the lower connecting rod
bearing shell (2) and, if necessary, reseat using
settling tools [322]
• Thinly apply clean engine oil on the lower connect-
ing rod bearing shell (2)
• Position the connecting rod bearing cap (3) on the
connecting rod (1) as marked
• Screw in new connecting rod bolts (4) and tighten
to 1st torque 100 Nm
• Tighten the connecting rod bearing bolts (4) to
Final torque 90°
Checking the connecting rod for ease of move- Checking the piston protrusion
ment
CRANKSHAFT
Removal and installation of crankshaft
Additional jobs
– Draining and topping up engine oil
– Remove and install coolant manifold (version without retarder), see 35
– Removing/installing the coolant manifold (version with retarder), see 40
– Removal and installation the thermostats, see 45
– Removing and installing the thermostat housing, see 47
– Removing and installing belt drive, see 153
– Removing and installing alternators 1 and 2, see 159
– Removing and installing alternator 3, see 167
– Removal and installation of the oil module, see 387
– Removal and installation of the turbocharger, see 253
– Removing and installing the EGR module without an intermediate plate, see 263
– Removal and installation of the exhaust manifold, see 287
– Removal and installation of the engine control unit, see 241
– Protective sleeves for fuel service centre, see 223
– Removal and installation of the fuel service centre, see 225
– Protective sleeves for injectors and pressure pipe, see 181
– Removing and installing the injectors and pressure pipe, see 184
– Removal and installation of the cylinder head, see 293
– Removal and installation the distributor housing, see 55
– Removing and installing the oil sump and oil intake pipe, see 395
– Removal and installation of the starter, see 151
– Removal and installation of the gearbox flywheel (Flywheel crankshaft seal), see 439
– Removing and installing flywheel (crankshaft seal crankshaft gear version) for manually operated gear-
boxes, see 455
– Removing and installing flywheel of automatic gearbox (crankshaft seal flywheel version), see 449
– Removing and installing flywheel (with race) for the automatic gearbox, see 465
– Removing and installing dual-mass flywheel (crankshaft seal crankshaft gear version), see 471
– Removing and installing flywheel housing/timing case, see 505
– Removal and installation of the vibration damper, see 435
– Removal and installation cover, see 507
– Removing and installing rear timing gears (Version crankshaft seal flywheel), see 357
– Removing, installing the timing gear (crankshaft seal, crankshaft gear Version), see 371
– Removal and installation of front drive gears, see 349
– Removal and installation of piston and connecting rod, see 477
– Checking and adjusting valve clearance, see 305
Technical data
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 .....................................1st torque 50 Nm
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 ..................................2nd torque 150 Nm
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 ...................................3rd torque 315 Nm
Mounting bolts for crankshaft bearing cover (4) ...... M18x2x160.5 .......................................Final torque 90°
Crankshaft measurements
Centring of crankshaft bearing pin for front crankshaft gear.......................................... 99.975 - 99.995 mm
Standard measurements for crankshaft bearing journal ........................................ Ø 103.998 - 104.000 mm
Crankshaft bearing pin, normal dimension I.......................................................... Ø 103.898 - 103.900 mm
Crankshaft bearing pin, repair stage I .................................................................. Ø 103.748 - 103.750 mm
Crankshaft bearing pin, repair stage II ................................................................. Ø 103.448 - 103.500 mm
Wall thickness for crankshaft bearing cover, normal dimension I........................................ 3.516 ± 0.12 mm
Wall thickness for crankshaft bearing cover, repair level I.................................................. 3.591 ± 0.12 mm
Wall thickness for crankshaft bearing cover, normal dimension II....................................... 3.716 ± 0.12 mm
Spread, crankshaft bearing ................................................................................................... max. 1.2 mm
Important information
WARNING
Cracked surfaces are weakened and may lead to material breaking off
• Exchange the connecting rod if the crack surfaces are damaged
• Protect crack surfaces against damage caused by hard and sharp objects
• To clean the crack surfaces on the connecting rods, always rinse them in clean cleaning agent
• After cleaning, use compressed air to blow-dry the crack surfaces
• Do not allow flushed-out particles to enter the engine
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. max. 50 % of
the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Install corresponding contact washer, see Dimen- Checking the crankshaft bearing journals external
sions of thrust washers, 493. diameter, see Checking the outer diameter of the
crankshaft bearing journal, 499.
Removing the crankshaft Remove the crankshaft bearing cover axial com-
pensation
Assembling the special tool
CAUTION
Danger of injury due to heavy compo-
nents
• Remove the crankshaft including sup- Note
port The difference between dimension A and
dimension B gives the crankshaft bearing
WARNING spread.
Component damage due to unsuitable
lifting device • Clean the crankshaft bearing shells (2) and place
• Do not use steel wire or other them together on a flat surface as marked
sharp-edged tools to lift the crankshaft • Check dimension A with a micrometer (1)
out • Check dimension B using a micrometer (1)
The permitted spread of the crankshaft bearing is
• Lift crankshaft (3) from crankcase (2)
max. 1.2 mm.
• Mark the crankshaft bearing shells (1) to indicate
correct assignment and installation position and If the spread is out of tolerance, fit new crankshaft
remove from crankcase (2) bearing shells.
Remove the upper thrust washers
Check the crankshaft bearing inner diameter Checking the outer diameter of the crankshaft
bearing journal
Note
Only fit contact washers with the same
WARNING wall thickness for the upper and lower
Component damage due to unsuitable contact washers.
lifting device
• Do not use steel wire or other • Examine contact washers (2), see Check crank-
sharp-edged tools to lift the crankshaft shaft axial play, 496
in. • Thinly apply clean engine oil on the thrust washers
(2)
• Thinly apply clean engine oil on the crankshaft • Insert the thrust washers (2) on bearing seat 6 with
bearing shells (1) oil grooves to the crankshaft (1)
• Place the crankshaft bearing shells (1) in the • Screw in the thrust washers (2) by pressing them
bearing seats as marked, and align with settling slightly into the bearing seat
tools [335]
• Insert the crankshaft (3) in the crankcase (2)
WARNING
• Thinly apply clean engine oil on the crankshaft
Cracked surfaces are weakened and
bearing shell and the thrust washers (2) and (3)
may lead to material breaking off
• Place the crankshaft bearing shells in the bear-
• Exchange the crankcase if the crack
ing cover (4) as marked, and align with settling
surfaces on the bearing cover or
tools [335]
crankcase are damaged
• Insert the thrust washers (2) and (3) with oil
• Protect crack surfaces against damage
grooves to the crankshaft in the bearing cover (4)
caused by hard and sharp objects
• Position bearing cover (4) with contact washers
(2) and (3)
• Thinly apply clean engine oil on the crankshaft
• Screw in new mounting bolts (1) and, with
bearing shells (1)
1st torque 50 Nm
• Place the crankshaft bearing shells (1) in the bear-
• Check the crankshaft for ease of movement
ing cover (2) as marked, and align with settling
If the crankshaft turns not at all or only with difficulty,
tools [335]
the crankshaft has to be removed together with the
• Put on the bearing cover (2)
crankshaft bearings.
• Thinly apply clean engine oil on the screw head
Re-check the crankshaft bearing and crankshaft, if contact area of the new mounting bolts (3)
needed replace crankshaft bearing or crankshaft. • Screw in the mounting bolts (3) and tighten to
1st torque 50 Nm
• Tighten the mounting bolts (3) to
2nd torque 150 Nm
Note
Note the multiplication ratio of the power
amplifier wrench i = 1 : 3.5.
ENGINE CASE
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
CAUTION
Danger of injury due to heavy compo- • Thinly apply sealing agent Loctite 5900 (1) on the
nents mating face as illustrated
• Removing flywheel housing/timing case
with support Mounting flywheel housing/timing case
CAUTION
Danger of injury due to heavy compo-
nents
• Mounting flywheel housing/timing case
with support
COVER
Removal and installation cover
Additional jobs
– Draining and topping up engine oil
– Remove and install coolant manifold (version without retarder), see 35
– Removing/installing the coolant manifold (version with retarder), see 40
– Removing and installing belt drive, see 153
– Removing and installing alternators 1 and 2, see 159
– Removal and installation the thermostats, see 45
– Removing and installing the thermostat housing, see 47
– Removing and installing the coolant pump, see 51
– Removal and installation the distributor housing, see 55
– Removal and installation of the vibration damper, see 435
– Removing and installing the oil sump and oil intake pipe, see 395
– Removal and installation of front crankshaft seal, see 417
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
• Mark the installation position of the mounting bolts • Position the cover (1) with a new gasket (4)
(2) and (3) • Screw in the new mounting bolts (2) and (3) as
• Unscrew the mounting bolts (2) and (3) marked and tighten them by hand
• Remove the cover (1) with the seal (4) • Tighten the mounting bolts (2) and (3)
• Clean the mating faces
CYLINDER LINERS
Removal and installation the cylinder liner
Additional jobs
– Draining and topping up engine oil
– Remove and install coolant manifold (version without retarder), see 35
– Removing/installing the coolant manifold (version with retarder), see 40
– Removing and installing the EGR module without an intermediate plate, see 263
– Removal and installation of the turbocharger, see 253
– Removal and installation of the exhaust manifold, see 287
– Remove and install the charge air pipe, see 247
– Removal and installation of the oil module, see 387
– Protective sleeves for fuel service centre, see 223
– Removal and installation of the fuel service centre, see 225
– Removal and installation of the engine control unit, see 241
– Protective sleeves for injectors and pressure pipe, see 181
– Removing and installing the injectors and pressure pipe, see 184
– Removal and installation of the cylinder head, see 293
– Removal and installation of piston and connecting rod, see 477
– Removing and installing the oil sump and oil intake pipe, see 395
– Checking and adjusting valve clearance, see 305
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
WARNING
Risk of engine damage from damaged
oil nozzles
• Take care not to damage the oil nozzles
when inserting the extractor plate [337]
ENGINE BRAKE
Removal and installation the engine brake
Technical data
Adjusting cylinder pre-load (2) ................................................................................................1.0 - 1.5 mm
Screw-in coupling for adjusting cylinder (2) ............ M16x1.5 ............................................................15 Nm
Service products
Multi-purpose grease MAN 285 Li-PF2 ............................................................................... 09.15001-0012
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50%
of the specified tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Detach the compressed air pipe (1) • Fit the positioning cylinder (2)
• Detach the air pipe (2) from the adjusting cylinder • Screw on and tighten the new mounting nut (1)
(3) • Attach the ball coupling (3)
• Unscrew the mounting bolts (1) • Loosen the lock nut (3) and unscrew piston rod for
• Remove proportional valve (2) from bracket (3) the adjusting cylinder (4) until the gap between the
lever (2) and limit stop (1) is min. 1 mm
Removing the positioning cylinder • Screw in the piston rod of the positioning cylinder
(4) until the lever (2) is at the stop (1)
• Screw in the piston rod of the positioning cylinder
(4) by approx. 1 to 1.5 turns
• Tighten the lock nut (3)
The permitted pre-load of the positioning cylinder (4)
is 1.0 - 1.5 mm.
• Position proportional valve (2) on the bracket (3) • Attach the air pipe (1)
• Screw in and tighten the new mounting bolts (1) • Screw the retaining screw into the adjusting cylin-
der (3) and tighten it to 15 Nm
Repair the compressed-air connection of the ad- • Check compressed air pipe (2) for a firm seat using
justing cylinder Test tool [344]
• If the connector comes out of the retaining screw,
repeat the procedure
TECHNICAL DATA
Removing and installing the 1-cylinder air compressor with steering and hydraulic pump
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolts for hydraulic pump (4) .................... M10x40-10.9......................................................55 Nm
Removing and installing the 1-cylinder air compressor with steering and hydraulic pump
Axial play of PTO drive shaft .......................................................................................... 0.100 - 0.700 mm
Removing and installing the 1-cylinder air compressor with two steering pumps
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Removing and installing the 1-cylinder air compressor with two steering pumps
Axial play of PTO drive shaft .......................................................................................... 0.100 - 0.700 mm
Removing and installing of 1-cylinder air compressor with power steering pump and two hydraulic
pumps
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolt for hydraulic pump 1 (4) ................... M10x150-10.9....................................................55 Nm
Mounting bolts for hydraulic pump 2 (5) ................. M10x205-10.9....................................................55 Nm
Removing and installing of 1-cylinder air compressor with power steering pump and two hydraulic
pumps
Axial play of PTO drive shaft .......................................................................................... 0.100 - 0.700 mm
Removing and installing 1-cylinder air compressor with two power-steering pumps and hydraulic
pump
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolts for hydraulic pump (4) .................... M10x150-10.9....................................................65 Nm
Mounting bolts for power steering pump 2 (5)......... M10x175-10.9....................................................65 Nm
Removing and installing 1-cylinder air compressor with two power-steering pumps and hydraulic
pump
Axial play of PTO drive shaft .......................................................................................... 0.100 - 0.700 mm
Removing and installing 2-cylinder air compressor with power steering pump
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Removing and installing the 2-cylinder air compressor with steering and hydraulic pump
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolts for hydraulic pump (4) .................... M10x40-10.9......................................................55 Nm
Removing and installing the 2-cylinder air compressor with steering and hydraulic pump
Axial play of PTO drive shaft .......................................................................................... 0.100 - 0.700 mm
Removing and installing 2-cylinder air compressor with two power-steering pumps and hydraulic
pump
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolts for hydraulic pump (4) .................... M10x150-10.9....................................................65 Nm
Removing and installing 2-cylinder air compressor with two power-steering pumps and hydraulic
pump
Axial play of PTO drive shaft .......................................................................................... 0.100 - 0.700 mm
Removing and installing of 2-cylinder air compressor with power steering pump and two hydraulic
pumps
GE union.............................................................. M26x1.5 ............................................................45 Nm
connecting union .................................................. M16x1.5 ............................................................30 Nm
Pressure relief valve ............................................. M26x1.5 ............................................................90 Nm
Mounting bolt for hydraulic pump 1 (4) ................... M10x150-10.9....................................................65 Nm
Mounting bolts for hydraulic pump 2 (5) ................. M10x205-10.9....................................................55 Nm
Removing and installing of 2-cylinder air compressor with power steering pump and two hydraulic
pumps
Axial play of PTO drive shaft .......................................................................................... 0.100 - 0.700 mm
Removing and installing the high pressure pump/high pressure pump drive (fuel-lubricated)
Mounting bolts for high pressure pump (2) ............. M10x50-10.9......................................................65 Nm
High pressure pump drive mounting bolts (7) ......... M12x90-10.9.................................................... 115 Nm
High-pressure line (8) .....................................................................................................1st torque 10 Nm
High-pressure line (8) .......................................................................................................Final torque 60°
Fuel-fill level for high pressure pump (2) ........................................................................................... 60 ml
Fuel-filling screw for high pressure pump (2) .......... M10x1 ...............................................................18 Nm
Removing and installing the high pressure pump/high pressure pump drive (fuel-lubricated)
Mounting bolts for high pressure pump (2) ............. M10x50-10.9......................................................65 Nm
High pressure pump drive mounting bolts (7) ......... M12x90-10.9.................................................... 115 Nm
High-pressure line (8) .....................................................................................................1st torque 10 Nm
High-pressure line (8) .......................................................................................................Final torque 60°
Oil fill amount for the high pressure pump (2) .................................................................................... 40 ml
Oil filler plug of high pressure pump (2).................. M10x1 ...............................................................18 Nm
Inside diameter, high-pressure pump drive intermediate gear (1)............................... Ø 60.000 - 60.030 mm
Outside diameter, intermediate gear pin (2).............................................................. Ø 59.921 - 59.940 mm
Height, intermediate gear pin (2) ................................................................................ 27.200 - 27.240 mm
Removing and installing rear timing gears (Version crankshaft seal flywheel)
Mounting bolt (5) .................................................. M14x80-10.9.................................... 1st torque 105 Nm
Mounting bolt (5) .................................................. M14x80-10.9........................................Final torque 90°
Mounting bolt (3) .................................................. M12x55-10.9.................................................... 115 Nm
Mounting bolts for small intermediate gear (6) ........ M8x20-10.9 .......................................................30 Nm
Removing and installing rear timing gears (Version crankshaft seal flywheel)
Tooth backlash, large intermediate gear (4) - rear crankshaft gear (1)............................... 0.052 - 0.176 mm
Backlash, large intermediate gear (4) - Small intermediate gear (6) ................................. 0.052 - 0.176 mm
Removing and installing rear timing gears (Version crankshaft seal flywheel)
Axial play, intermediate gear air compressor (2) .............................................................. 0.100 - 0.190 mm
Radial play intermediate gear air compressor (2)............................................................. 0.060 - 0.109 mm
Intermediate gear height, air compressor (2) ............................................................... 25.900 - 26.000 mm
Height contact washer intermediate gear air compressor (2) ............................................ 4.800 - 5.000 mm
Inside diameter, intermediate gear air compressor (2)...................................................Ø 60.00 - 60.03 mm
Outside diameter, air compressor intermediate gear pin............................................ Ø 59.921 - 59.940 mm
Height, air compressor intermediate gear pin .............................................................. 26.100 - 26.140 mm
Removing and installing rear timing gears (Version crankshaft seal flywheel)
Axial play, large intermediate gear (4) ............................................................................. 0.100 - 0.290 mm
Radial play, large intermediate gear (4)........................................................................... 0.060 - 0.109 mm
Height of large intermediate gear (4)........................................................................... 52.950 - 53.000 mm
Inside diameter of large intermediate gear (4) .......................................................... Ø 80.000 - 80.035 mm
Outside diameter, large intermediate gear pins......................................................... Ø 79.921 - 79.940 mm
Height, large intermediate gear pins ........................................................................... 56.200 - 56.240 mm
Removing and installing rear timing gears (Version crankshaft seal flywheel)
Axial play of small intermediate gear (6).......................................................................... 0.100 - 0.290 mm
Radial play of small intermediate gear (6) ....................................................................... 0.060 - 0.109 mm
Height of small intermediate gear (6) .......................................................................... 17.000 - 17.500 mm
Inside diameter of small intermediate gear (6) .......................................................... Ø 60.000 - 60.030 mm
Outside diameter of intermediate gear pins .............................................................. Ø 59.921 - 59.940 mm
Height of small intermediate gear pins ........................................................................ 21.200 - 21.240 mm
Removing, installing the timing gear (crankshaft seal, crankshaft gear Version)
Mounting bolt (5) .................................................. M14x80-10.9.................................... 1st torque 105 Nm
Mounting bolt (5) .................................................. M14x80-10.9........................................Final torque 90°
Mounting bolt (3) .................................................. M12x55-10.9.................................................... 115 Nm
Mounting bolts for small intermediate gear (6) ........ M8x20-10.9 .......................................................30 Nm
Removing, installing the timing gear (crankshaft seal, crankshaft gear Version)
Tooth backlash, large intermediate gear (4) - rear crankshaft gear (1)............................... 0.052 - 0.176 mm
Backlash, large intermediate gear (4) - Small intermediate gear (6) ................................. 0.052 - 0.176 mm
Removing, installing the timing gear (crankshaft seal, crankshaft gear Version)
Axial play, intermediate gear air compressor (2) .............................................................. 0.100 - 0.190 mm
Radial play intermediate gear air compressor (2)............................................................. 0.060 - 0.109 mm
Intermediate gear height, air compressor (2) ............................................................... 25.900 - 26.000 mm
Height contact washer intermediate gear air compressor (2) ............................................ 4.800 - 5.000 mm
Inside diameter, intermediate gear air compressor (2)...................................................Ø 60.00 - 60.03 mm
Outside diameter, air compressor intermediate gear pin............................................ Ø 59.921 - 59.940 mm
Height, air compressor intermediate gear pin .............................................................. 26.100 - 26.140 mm
Removing, installing the timing gear (crankshaft seal, crankshaft gear Version)
Axial play, large intermediate gear (4) ............................................................................. 0.100 - 0.290 mm
Radial play, large intermediate gear (4)........................................................................... 0.060 - 0.109 mm
Height of large intermediate gear (4)........................................................................... 52.950 - 53.000 mm
Removing, installing the timing gear (crankshaft seal, crankshaft gear Version)
Axial play of small intermediate gear (6).......................................................................... 0.100 - 0.290 mm
Radial play of small intermediate gear (6) ....................................................................... 0.060 - 0.109 mm
Height of small intermediate gear (6) .......................................................................... 17.000 - 17.500 mm
Inside diameter of small intermediate gear (6) .......................................................... Ø 60.000 - 60.030 mm
Outside diameter of intermediate gear pins .............................................................. Ø 59.921 - 59.940 mm
Height of small intermediate gear pins ........................................................................ 21.200 - 21.240 mm
Removing and installing the oil sump and oil intake pipe
Dimension of connecting-rod bearing bolt - oil intake pipe............................................................... 5.0 mm
Removal and installation of rear crankshaft seal (crankshaft seal version flywheel)
Installation temperature for race ............................................................................................ about 120 °C
Removing and installing flywheel of automatic gearbox (crankshaft seal flywheel version)
Mounting bolt (6) .................................................. M16x1.5x93-10.9 ............................. 1st torque 105 Nm
Mounting bolt (6) .................................................. M16x1.5x93-10.9 ............................... Final torque 180°
Removing and installing flywheel (crankshaft seal crankshaft gear version) for manually operated
gearboxes
Mounting bolt (3) .................................................. M16x1.5x80-12.9 ..........................Initial torque 105 Nm
Mounting bolt (3) .................................................. M16x1.5x80-12.9 ............................... Final torque 180°
Installation temperature for starter ring gear (2) .......................................................................200 - 230 °C
Flywheel axial run-out (1)...................................................................................................... max. 0.5 mm
Dimension of flywheel bridge to friction surface (maximum) .................................................... max. 9.5 mm
Removing and installing flywheel (with race) for the automatic gearbox
Mounting bolt (5) .................................................. M16x1.5x93-10.9 ............................. 1st torque 105 Nm
Mounting bolt (5) .................................................. M16x1.5x93-10.9 ............................... Final torque 180°
Installation temperature for starter ring gear (1) .......................................................................200 - 230 °C
Removing and installing dual-mass flywheel (crankshaft seal crankshaft gear version)
Mounting bolt (3) .................................................. M16x1.5x122-12.9 ........................... 1st torque 105 Nm
Mounting bolt (3) .................................................. M16x1.5x122-12.9 .........................2. Tightening by 90°
Mounting bolt (3) .................................................. M16x1.5x122-12.9 ...............................Final torque 90°