MAN ENGINE SHOP MANUAL - D0834 LFL Axx

Repair Manual
Common rail In-line Engine

D0834 LFLAxx
81.99185-6122 “Translation of the original instructions”

Introduction
Preface
This repair manual provides assistance in performing repairs correctly on vehicles and units and reflects
the known technical situation appertaining at the copy deadline.
This publication assumes that persons who use it possess the requisite technical knowledge in repairing
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always
correspond to the unit to be repaired or its peripherals.
The repair work is broken down into chapters and sub-chapters. Each subsection starts with a page of jobs
to do in advance. The jobs to do in advance contain a summary of the main prerequisites for the repair
section in question. The detailed description of work can follow the jobs to do in advance. Only the
tightening torques for screw/bolt connections which deviate from the standard are indicated in the repair
sections.
Important instructions concerning technical safety and the safety of personnel are specifically highlighted,
as indicated below.
Comply with general safety regulations when performing any repair work.
We reserve the right to make modifications in the course of further development.
Yours faithfully,
MAN Truck & Bus AG
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.
Technical status as on: 04.2016
Read the manual thoroughly before starting any work!

This particularly applies to the chapter “General Safety Instructions” and the respective
safety instructions in the chapters. 3
Preface
Explanation of icons
Warning notices
Warnings in this operator's manual are identified by symbols. The information has been
introduced with signal words that express the extent of risk or danger.
Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and
material damage.
DANGER
Describes an immediate dangerous situation that will lead to severe injuries or death if it is not avoided.
WARNING
Describes a potentially dangerous situation that may lead to severe injuries or death if it is not avoided.
CAUTION
Describes a potentially dangerous situation that may lead to minor or moderate injuries if it is not
avoided.
NOTE
Describes a potentially dangerous situation that may lead to damage to property if it is not avoided.
Tips and Recommendations
Tip for users

Tips and recommendations as well as information for efficient and trouble-free operation.
ENVIRONMENTAL NOTE
Tips on conduct for environmental protection.
GENERAL NOTES
• This symbol indicates a listing at the first level.
► This symbol indicates an action / sequence of actions.
1 This symbol indicates an item of a graphic display in the text.
[1] This symbol indicates the position of a special tool in the text after it is listed in the chapter.

4 safety instructions in the chapters.
Content
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Publication data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Explanation of icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Regulations for preventing accidents leading to injury to personnel . . . . . . . . . . . . . . . . . . . 9
2. Information on how to avoid damage and premature wear on units . . . . . . . . . . . . . . . . . . . 13
3. Liability limitations for spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Regulations to prevent damage to health and the environment . . . . . . . . . . . . . . . . . . . . . . 14
5. Information about working on the common rail system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6. Limp-home programme for units with electronic control units . . . . . . . . . . . . . . . . . . . . . . . . 18
7. Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
The engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Model plate/Model designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Description of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removing/installing the engine on the assembly device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Removing/installing the engine on the assembly device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Engine electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removing/installing the cable harness ................................................ 46
Removing/installing the engine electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Removing/installing the Visco fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Removing/installing the flange (fan flange) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Removing/installing the coolant pump coolant manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Removing/installing the thermostat insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Removing/installing the thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Dismantling/assembling the thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Removing/installing the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Dismantling and assembling the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Removing/installing the coolant pre-heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Content
Add-on units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Removing/installing the steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Remove/install the PTO coolant pump/alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Remove/install the air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Dismantling/assembling the air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Removing/installing the ribbed V-belt for the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Removing/installing the automatic belt tensioner for the alternator . . . . . . . . . . . . . . . . . . . . . . . . 176
Removing/installing the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Removing/installing the starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Removing/installing the ribbed V-belt for the refrigerant compressor . . . . . . . . . . . . . . . . . . . . . . . 196
Removing/installing the ribbed V-belt for the refrigerant compressor . . . . . . . . . . . . . . . . . . . . . . . 202
Removing/installing the refrigerant compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Removing/installing the bracket for the refrigerant compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Removing/installing the bracket for the refrigerant compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Remove/install the hydraulic pump V-belt/ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Removing/installing the hydraulic pump/single pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Removing/installing the hydraulic pump/double pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Common Rail system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Removing/installing the injector with nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Removing/installing the rail (common rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Removing/installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Dismantling/assembling the high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Removing/installing the fuel service centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Removing/installing the flame-start system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Removing/installing the electronic diesel control (EDC) control unit . . . . . . . . . . . . . . . . . . . . . . . . 308
Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Removing/installing the charge-air pipe for the turbo charger/intercooler . . . . . . . . . . . . . . . . . . . 316
Removing/installing the intercooler charge-air pipe/turbo charger (HD) . . . . . . . . . . . . . . . . . . . . 320
Removing/installing the intercooler (low-pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Removing/installing the charge-air pipe of the intercooler turbo charger
(low pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Removing/installing the charge-air pipe for the turbo charger/intercooler . . . . . . . . . . . . . . . . . . . 332
Removing/installing the exhaust turbocharger module/exhaust module . . . . . . . . . . . . . . . . . . . . 338
Removing/installing the turbo charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Removing/installing the charge-air manifold with EGR connection . . . . . . . . . . . . . . . . . . . . . . . . . 360
Removing/installing the charge-air pipe with throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Intake/exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

Removing/installing the exhaust manifold HCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Removing/installing the HCI system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Removing/installing the exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Removing/installing the engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Removing/installing the engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Disassembling, assembling the engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Removing/installing the housing with EGR module shut-off flap . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Removing/installing the EGR module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Removing, installing the air distributor pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

Content
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429

Removing/installing the cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
Removing/installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
Removing and installing the rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Checking, setting the valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Disassembling, assembling the rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Removing/installing the valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
Valve control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476

Removing/installing the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Removing/installing the camshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497

Removal, installation of timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515

Removing/installing the oil module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
Removing/installing the oil filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Removing and installing the oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
Removing and installing the oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
Removing/installing the oil pump excess pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
Removing/installing the oil pump excess pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
Remove/install the upper part of the oil sump housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
Remove/install the upper part of the oil sump housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
Removing, installing the suction line/intake pipe of the oil pump .......................... 570
Removing, installing the suction line/intake pipe of the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . 572
Removing/installing the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
Dismantling/assembling the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
Removing/installing the oil injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
Crankshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590

Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592
Removing/installing the flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596
Removing/installing the piston with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Removing/installing the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
Crankshaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636

Removing, installing the rear crankshaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638
Installing the front crankshaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
Engine case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650

Removing/installing the crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
Remove/install the flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
Removing/installing the timing case cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672
Removing/installing the timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676
Removing, installing the engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681

Content
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691
Checking and setting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713

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
pollution. Please note that these are merely brief extracts taken from various accident prevention
regulations. Of course, all other safety regulations must be followed and the necessary measures
must be taken.
Additional references to danger are contained in the instructions at points where there is a potential danger.
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident involves
skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into
eyes, crushing limbs, etc.
1. Regulations for preventing accidents leading to injury to personnel
Checking, adjusting and repair work

S Secure units during removal.
S Support the frame when working on the air or spring suspension system.
S Keep units, ladders, stairs, steps and the surrounding area free of oil and grease.
S Do not use any tools that are not in perfect condition.
S Checking, setting and repair work may only be performed by authorised specialist personnel.
Working on the brake system

S If dust is generated when working on the brake system, a dust extraction device must be used.
S After any type of work on the brake system, perform a visual, functional and effectiveness check
in accordance with the safety inspection (SI).
S Use a suitable test system (e.g. MAN-cats®) to check the function of ABS/ASR systems.
S Collect any brake fluid that leaks out.
S Brake fluid is toxic. Do not allow brake fluid to come into contact with food or open wounds.
S Hydraulic fluid and brake fluid are hazardous waste! Comply with the safety regulations for preventing
environmental pollution.
Working on vehicles with a compressed natural gas (CNG) system

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

Introduction
Working on the compressed natural gas (CNG) system

S Work on the compressed natural gas system may only be carried out by specifically trained personnel .
S The working area for the compressed natural gas system must be equipped with a ventilation system.
The ventilation system must replace the air in the room with new air at least three times per hour.
S After following the prescribed procedures to replace standard-fit components of the compressed natural
gas system, check the installation areas for leaks. Perform these checks using leak detection spray or a
gas warning device.
Operating the engine

S The engine may only be started and operated by authorised personnel.
S When the engine is running, maintain a safe distance from rotating parts and wear close-fitting work
clothing. Use an extractor system if working in enclosed spaces.
S Risk of burns when working on engines at operating temperature.
S Risk of scalding when opening the hot cooling circuit.
Suspended loads
S Do not stand or walk underneath suspended loads.
S Only use suitable and serviceable lifting equipment and lifting gear with sufficient load-bearing capacity .
Bodies and special bodies

S Observe the safety instructions and regulations issued by the body manufacturer in question if bodies
and special attachments are fitted.
Working on high-pressure lines

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

S Wear appropriate personal protective equipment.
S When checking the injectors, do not allow any body parts to come into contact with the fuel jet.
S Do not inhale fuel vapour; ensure adequate ventilation.
Work on the vehicle electrical system

S Do not disconnect the batteries while the engine is running!
S Always disconnect the batteries when working on the vehicle electronics, central electrical system,
alternator or starter. Disconnect the negative terminals first when disconnecting batteries. Connect the
positive terminals first when connecting.
S For measurements on wiring connections, only use suitable test leads and test adapters.
S If you expect temperatures in excess of 80°C (e.g. in the dryer after painting), set the main battery
switch to “OFF” and then remove the control units.
S The chassis frame is not intended for use as an earth connector. If attachments are to be fitted to the
vehicle (e.g. a wheelchair lift), additional ground cables with an adequate cross-section must be fitted as
well. Otherwise the ground connection may be created along wire cables, cable harnesses, gearbox
shafts, gears etc. Severe damage could result.

Introduction
Important: battery gases are explosive!

S Oxyhydrogen gas may build up in enclosed battery boxes. Take particular care after long journeys and
after charging with a battery charger.
S When the batteries are disconnected, the gas may be ignited by sparks produced by continuously
operating consumers, tachographs, etc. that cannot be switched off. Blow compressed air through the
battery box before disconnecting the batteries!
S Only tow-start a vehicle with the batteries connected. Only tow-start if the check lamps are still brightly
lit, although the batteries do not have enough charge to start the engine.
Do not use a boost-charger to jump-start the vehicle!
S Always disconnect the positive cable and ground cable before boost-charging or charging batteries!
S Do not boost-charge lead gel or maintenance-free batteries. (Not for “zero-maintenance acc. to DIN”)
Maximum charging power is 10% of the specified capacity of each battery. Parallel connection
increases the capacity, in accordance with the total number of batteries connected in parallel.
S Risk of short circuit if polarity is reversed!
S Do not place metallic items (wrenches, pliers, etc.) on the batteries as this may short circuit the
terminals. Risk of short circuit!
S If vehicles are parked for a prolonged period, disconnect the batteries and recharge every 4 weeks.
CAUTION! Battery acid is toxic and corrosive!

S Wear suitable protective clothing (gloves) when handling batteries. Do not tip or tilt batteries as acid
may emerge. Do not tilt gel batteries either.
S Only perform voltage measurements using suitable measuring devices! The input resistance of the
measurement device must be at least 10 MΩ.
S Only connect and/or disconnect the plug connectors of electrical control units when the ignition
is switched off.
Electric welding
S Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number 80.78010.-0002)
in accordance with the instructions accompanying the device.
S If this device is not available, disconnect the batteries and connect the positive cable to the ground
cable so that a conductive circuit is created.
S If the main battery switch is manual, turn it to the driving mode position. If the main battery switch is
electronic, bridge the “negative” at the contacts of the power (bridging cable > 1 mm2) and the “positive”
at the load contacts of the load relay. In addition, switch on many loads such as: engine start switch
(ignition) to driving mode position, hazard warning lamp switch, lighting switch to "headlamps on", fan
S to maximum output. The more the number of consumers switched on, the greater is the protection.
After ending the welding work, first switch off all consumers, remove all bypass jumpers (restore the
original condition) and then connect the batteries.
S In any case, make sure that the earth clamp of the welding unit is attached as close to the welding
position as possible. Do not lay the cables to the welding equipment in parallel to electrical cables in the
vehicle.
Work on plastic tubes – risk of damage and fire

S Plastic tubes must not be subjected to mechanical or thermal load.
Painting work
S When carrying out painting, 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.

Introduction
Working with a tilted cab

S Keep the tilting area in front of the cab clear.
S Do not stand between the cab and the chassis while the cab is being tilted! Danger zone!
S Always tilt the cab over the tipping point or prop the cab up with a supporting rod.
Work on the air-conditioning system

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

S Work on airbags or belt pre-tensioner units must only be performed by personnel who have completed
a specialist course at the MAN Service Academy.
S Mechanical loads, vibrations, heat above 140°C and electrical impulses, including electrostatic
discharge, may trigger the airbags or belt tensioners unintentionally.
S Hot gases are released explosively when the airbags or belt tensioners are triggered. Airbags or belt
tensioners that are not correctly fitted could be sent flying uncontrollably through the air.
This poses a risk of injury to people in or near the cab.
S Risk of burning when touching the hot surfaces after the airbag has been triggered.
S Do not open a triggered airbag or air cushion.
S Do not touch a triggered airbag with a destroyed air cushion with your bare hands. Wear nitrile rubber
gloves.
S Before performing any work or checks on airbags or belt pre-tensioner units or working on the vehicle
where vibrations are likely, switch off the ignition, remove the ignition key from the ignition lock,
disconnect the ground cable from the battery and disconnect the plug connector for the airbag and belt
pre-tensioner power supply.
S Fit the driver airbag restraint system, MAN item number 81.66900-6035, to the airbag steering wheel as
instructed in the Operator's Manual.
S Only perform inspections on airbag and belt pre-tensioner units with devices specifically intended for this
purpose. Do not use inspection lamps, voltmeters or resistance meters.
S 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, finally, connect the battery. There must be
no-one in the cab whilst this work is going on.
S Only place airbag units to one side individually and with the bag facing upwards.
S Do not treat airbag units and belt tensioners with grease or cleaning agents.
S Only store and transport airbag units and belt tensioners in their original packaging. Transport in the
passenger area is not permitted.
S Airbag and belt pre-tensioner units may only be stored in storage areas that can be locked, and up to a
maximum of 200 kg.
Working on the independent heating

S Before starting work, switch off the heater unit and allow all hot components to cool down.
S Ensure that suitable containers/drip trays are available and there are no sources of ignition when
working on the fuel system.
S Keep suitable fire fighting equipment nearby and within easy reach!
S The heater unit must not be operated in enclosed spaces, such as garages or workshops, unless
an extraction system is used.

Introduction
2. Information on how to avoid damage and premature wear on units
General
S 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.
S The intended use also includes adherence to the operating and maintenance conditions defined by the
manufacturer.
S The unit must only be used, maintained and repaired by personnel who are acquainted with it and have
been instructed about any potential danger.
S The manufacturer does not assume any liability for damage to property or personal injury resulting from
unauthorised modifications to the engine.
S Similarly, tampering with the injection and control system can also influence the performance and
emissions behaviour of the unit. This means that compliance with the statutory environmental
requirements is no longer assured.
S Should malfunctions occur, the cause must be determined and rectified immediately.
S 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.
S Never allow units to run dry, i.e. without lubrication.
S Never allow engines to run without coolant.
S If units are not ready for operation, attach a relevant sign to them to indicate this.
S Only use service fluids that comply with the MAN service fluid recommendations as the manufacturer's
warranty will be invalidated otherwise. You can find a list of approved products on the Internet at:
https://mmrepro.mn.man.de/bstwebapp/BSTServlet
S Adhere to the specified service intervals.
S Do not fill engine/gearbox oil above the maximum level mark. Do not exceed the maximum permitted
operational tilt.
S The special measures described in MAN Works Standard M 3069 Part 3 are necessary if
buses/coaches or trucks are to be withdrawn from service or held in storage for longer than 3 months.
3. Liability limitations for spare parts and accessories
General
S Only use 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.

Introduction
4. Regulations to prevent damage to health and the environment
Health protection precautions

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

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

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

When blowing compressed air through the filter insert, make sure the filter dust is collected by an extractor
system, or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear suitable
rubber gloves or use a skin barrier cream when washing out the element, because cleaning agents have
aggressive grease-dissolving characteristics.
Engine/gearbox oil, filter cartridges, inserts and box-type filters, desiccant

cartridges
Filter inserts, cartridges and box-type filters (oil and fuel filters, desiccant cartridges for the air dryer) are
classified as hazardous waste. Always observe the regulations issued by the local authorities When
disposing of the parts mentioned above.
Used engine/gearbox oil

Prolonged or repeated skin contact with any type of engine/gearbox oil causes the loss of natural skin oils.
This can cause dry skin, irritation or skin inflammation. In addition to these hazards, used engine oil
contains dangerous materials which can cause dangerous skin diseases. It is particularly important to wear
gloves during an oil change.

Introduction
Handling AdBlue®
AdBlue® is a synthetically produced 32.5% aqueous urea solution. It is used as an additive to reduce NOx
in diesel engines with SCR catalytic converters. AdBlue® is not a hazardous substance. However, it breaks
down into ammonium hydroxide and carbon dioxide during storage. In Germany, AdBlue® is therefore
categorised as hazardous to water (WGK 1) and must not be allowed to seep into the drainage system or
into the ground. Ensure good ventilation in the workplace when working on the AdBlue® system. Do not
eat, drink or smoke in the work place. Avoid skin and eye contact with AdBlue®, thoroughly wash your
hands and apply skin protection cream before taking breaks or finishing work. If your skin comes into
contact with AdBlue®, wash the skin using water and a skin cleaner, change out of dirty clothes
immediately. Consult a doctor if the skin is irritated. If AdBlue® gets into your eyes, rinse your eyes with
water or an eye-rinsing products for at least 10 minutes, keeping your eyelids open. Remove any contact
lenses beforehand. Seek medical assistance if symptoms persist. If AdBlue® is swallowed, seek medical
assistance immediately. AdBlue® containers should be stored closed in water-tight storage rooms.
The storage temperature must not exceed 25°C. Soak up leaked or spilt AdBlue® using binding agent
and dispose of properly.
5. Information about working on the common rail system
General
S Jets of fuel can penetrate the skin. Risk of fire due to fuel atomisation.
S 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
below a fuel pressure of 1800 bar or more. Before threaded connections are opened, wait for at least
one minute until the pressure has dropped; if necessary, check that pressure in the rail has dropped
using MAN-cats®.
S Avoid remaining in the vicinity of the engine when it is running.
S Do not touch live components at the electrical connection of the injectors when the engine is running.
S Any alterations to the original wiring layout could violate the limit values of cardiac stimulator regulations
(pacemakers), e.g. untwisted fuel injector wiring or insertion of a break box (bushing box).
S No risk is posed to operating personnel and individuals with pacemakers providing equipment fitted with
MAN common rail engines is used in the authorised manner.
S Jets of fuel can penetrate the skin. Risk of fire due to fuel atomisation.
S Never undo the 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).
S Avoid remaining in the vicinity of the engine when it is running.
S The lines are constantly under a fuel pressure of 1800 bar and above when the engine is running.
S Wait for at least one minute before undoing bolt connections to allow the pressure to drop.
S If necessary, check that pressure in the rail has dropped using MAN-cats®.
S Do not touch live components at the electrical connection of the injectors when the engine is running.

Introduction
Information for people with pacemakers

S Any alterations to the original wiring layout of the engine could violate the limit values of cardiac
stimulator regulations (pacemakers), e.g. untwisted fuel injector wiring or insertion of a break box
(bushing box).
S No risk is posed to drivers and co-drivers with pacemakers providing equipment is used in the
authorised manner.
S No risk is posed to operating personnel and individuals with pacemakers providing equipment fitted with
MAN common rail engines is used in the authorised manner.
S None of the limit values currently specified for cardiac stimulators are exceeded provided the design
S of the product is unaltered.
Risk of damage due to ingress of dirt

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

S Clean the engine and engine compartment with the fuel system closed. When doing this, do not aim
strong water jets at electrical components.
S Drive the vehicle into a clean area of the workshop where no work that could swirl up dust is performed
(grinding or welding work, brake repairs, brake and power testing, etc.).
S Avoid air movements (possible swirling up of dust due to starting of engines, the workshop
heating/ventilation system, due to draughts etc.).
S The area of the fuel system that is still closed must be cleaned and dried using compressed air.
S Use a suitable extractor unit (industrial extractor unit) to remove loose dirt particles such as paint
chippings and insulating material.
S Cover areas of the engine compartment from which dirt particles could become detached, e.g. tilted
cab, engine compartment of bus engines, with new and clean foil covering sheets.
S Hands must be washed and clean work clothing should be put on before any disassembly work.

Introduction
After opening the clean side

S The use of compressed air for cleaning purposes is not permitted.
S During assembly, remove loose dirt using a suitable extractor unit (industrial extractor unit).
S Only lint-free cleaning cloths are allowed to be used on the fuel system.
S Clean tools and equipment before starting work.
S Only use tools that show no signs of damage (e.g. cracked chromium plating).
S Materials such as cloths, cardboard or wood must not be used when removing and fitting components,
as particles and fibres may become detached from such materials.
S If paint flakes should be produced when undoing connections (e.g. due to painting over the
connections), these must be carefully removed before the bolt connection is finally undone.
S All removed components on the clean side of the fuel system must be plugged immediately at their
connection openings using suitable caps.
S These caps must be stored in dustproof packaging until they are used and disposed of after use
(use only once).
S The components should then be stored in a clean, sealed container.
S Never use used cleaning or test fluids for these components.
S New parts should only be removed from their original packaging immediately prior to use.
S Work on removed components may only be performed at a work place equipped for this purpose.
S If removed parts need to be sent anywhere, always use the new part's original packaging.
When performing work on bus/coach engines, the measures described as follows must be strictly
adhered to:
Risk of damage due to ingress of dirt

S Before opening the clean side of the fuel system:
Clean the engine areas around the pressure sockets, fuel-injection lines, rail and cylinder head cover
with compressed air.
S Remove the cylinder head cover and then clean the engine areas around the pressure sockets,
fuel-injection lines and rail once again.
S Only loosen the pressure pipe sockets initially: Loosen the pressure pipe socket union nuts and unscrew
four turns. Lift the pressure pipe sockets with a special tool. Reason: only remove the pressure pipe
sockets completely once the injectors have been removed so that no dirt can fall into the injectors from
above.
S Remove the fuel injectors.
S After removal, rinse out the injectors with a cleaning fluid, making sure that the high-pressure
connection hole is facing downwards.
S Remove the pressure pipe socket by unscrewing the union nut of the pressure pipe socket.
S Clean the injector hole in the cylinder head.

Introduction
6. Limp-home programme for units with electronic control units
GENERAL NOTES
The units have an electronic control system that monitors itself (self-diagnostics) and the unit.
As soon as there is a malfunction, the malfunction is evaluated and one of the following measures
is initiated automatically:
S Output of an fault message with a diagnostic memory entry.
S Switchover to suitable replacement functions for continued but restricted operation. Have malfunctions
remedied by MAN after-sales immediately.
S The diagnostic memory entry is issued directly in conjunction with MAN-cats®.
7. Installation instructions
Fitting nuts and bolts

S Lightly oil the threads of nuts and bolts and the contact surface of the bolt head.
S For bolted connections without special tightening torque specifications, see reference values according
to works standard M 3059.
Assembly of connecting pieces, banjo screws and screw plugs

S See table of assembly tightening torques for hollow screws, unions, screw plugs, tube connectors and
unions with cutting ring thread joint in Technical Data section.
Installation of micro-encapsulated bolts

S Observe the application guidelines in MAN Works Standard 222 when using micro-encapsulated bolts.
Reuse of bolts and nuts

S Check bolt heads, threads and nuts for wear and ease of movement, replace if necessary.
S Only reuse bolts and nuts if they are not worn!
Assembling pipes
S Pipes must not be mechanically deformed during assembly work; risk of fracture!
Mounting gaskets
S Only use genuine MAN seals.
S Make sure that the areas to be sealed are undamaged and clean.
S Do not use sealing agent or adhesive agent. To aid assembly, a little grease can be used if necessary
so that the seal adheres to the part to be installed.
S Tighten the bolts evenly to the specified tightening torque.
Mounting O-rings
S Only use genuine MAN O-rings.
S Make sure that the areas to be sealed are undamaged and clean.

Introduction
Engine overhaul
S The engine's service life is influenced by a range of very different factors. It is therefore not possible to
indicate the exact number of operating hours or miles before a major overhaul is due.
S We are of the opinion that there is no need to dismantle an engine or perform a general overhaul, as
long as the engine has good compression values and the following operating values do not deviate
considerably from those determined and approved during commissioning.
- Charging pressure
- Exhaust gas temperature
- Coolant and lubricating oil temperature
- Oil pressure and oil consumption
- Smoking characteristics
The following criteria have considerable influence on the engine's service life:
S Correct performance rating commensurate with the type of use
S Professional installation
S Approval of the installation by authorised personnel
S Regular maintenance according to the maintenance schedule

Introduction

Introduction
The engine
Model plate/Model designation
Explanation of the model plate
1 Engine type 3 Engine serial number

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

There are remachining steps for crankshaft bearings, connecting-rod bearings, and pistons.
The remachined component groups are indicated on the model plate, e.g.
P = crankshaft - connecting-rod bearing NI or NII
H = crankshaft - crankshaft bearing NI or NII
Explanation of the engine No. (Engine identification number)

Engine No. Classification key
059 Model number according to model code
0340 Day of assembly
136 Assembly order (sequential number on day of assembly)
1241 The last four digits of the motor number/engine number are production and
equipment-specific data.

Introduction
Explanation of model designation

Model designation Explanation Example
D Fuel type Diesel
08 Figure + 100 108 mm bore
3 (Figure x 10) +100 130 mm stroke (rounded)
4 Number of cylinders 4 Cylinder
L Turbocharging with turbocharging and intercooler
F Engine installation Engine/stationary/front left-hand drive
L Engine installation Light series
Axx Model identifier Rating/speed/approval
Characteristic data
D0834 LFLAAA
Designation Unit Figures

Emission category Euro 6c
No. of cylinders / arrangement 4 Cylinder / row / vertical
Valves per cylinder 4
engine weight dry kg 505
Injection system Common rail / EDC 17
Maximum engine rating according kW / hp 110 / 150
to ISO 1585-88/491 EEC
Bore mm 108
Stroke mm 125
Displacement cc 4580
Firing order 1-3-4-2
Nominal rpm 1/min 2300
Low idling speed 1/min 700
Max. torque at engine speed Nm rpm 570 at 1400

Introduction
D0834 LFLABA

to ISO 1585-88/491 EEC
Bore mm 108
Stroke mm 125
D0834 LFLABB

to ISO 1585-88/491 EEC
Bore mm 108
Stroke mm 125

Introduction
D0834 LFLACA

to ISO 1585-88/491 EEC
Bore mm 108
Stroke mm 125
Max. torque at engine speed Nm rpm 850 at 1300 - 1800
D0834 LFLACB

Maximum engine rating according kW / hp 162/220
to ISO 1585-88/491 EEC
Bore mm 108
Stroke mm 125

Introduction
D0834 LFLADA

engine weight dry kg 492.3
to ISO 1585-88/491 EEC
Bore mm 108
Stroke mm 125
D0834 LFLAEA

to ISO 1585-88/491 EEC
Bore mm 108
Stroke mm 125

Introduction

Introduction
Description of engine
1 Charge-air manifold 7 Starter motor

2 Alternator 8 Oil module
3 Cylinder head cover 9 Throttle valve
4 Intake fitting 10 Oil sump
5 Fuel filter with heating 11 Refrigerant compressor
6 EGR module 12 Ribbed V-belt disc
Read the Operator's Manual thoroughly before starting any work!

This applies in particular to the chapter “General Safety Instructions” and the respective
Introduction
1 Oil separator 6 Air compressor

2 Cable harness 7 Exhaust manifold
3 Flame start system 8 Turbo charger
4 Ribbed V-belt disc 9 Intake fitting
5 Oil sump

Introduction
Engine, general
The engines described here are liquid-cooled, charged, 4-cylinder, 4-stroke diesel engines with turbo
chargers according to emission standards Euro 6 or EEV.
The engines use the common rail high-pressure injection system in conjunction with EDC 17 (Electronic
Diesel Control).
Engine monitoring
Various sensors monitor the engine. The sensors may be speed and temperature sensors, sending
information about the various operating conditions and states of the engine to the ME7 control unit.
The ME7 control unit operates according to the IPO principle:
I = Input
P = Processing
O = Output
The ME7 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. One actuator,
for example, is the proportional valve on the high pressure pump.
Crankcase
The crankcase and the cylinder block are a mono block casting made from special cast iron. The pistons
run directly in the crankcase. By ceramic honing of the cylinder linings, optimal results are achieved with
respect to wear resistance and oil consumption. The flywheel housing is located at the rear of the
crankcase and the timing case cover is at the front of the crankcase. The flywheel housing and the timing
case cover are both made of aluminium. The crankshaft seals are installed in the timing case cover and in
the flywheel housing. The crankcase blow-by gases are returned to the combustion air via an oil separator
with a pressure relief valve on the suction side of the turbo charger.
Crankshaft
The crankshaft is forged in a die using high-quality, micro-alloyed steel. It has eight cast counterweights to
balance the masses. The crankshaft is mounted in 5- bearings in the crankcase. The crankshaft journals
and crank pins are mounted in ready-to-install three-component bearings. They are axially mounted in
thrust washers inserted in the crankcase at the 4th bearing seat. The connecting-rod bearings are supplied
with oil via a bore in the crankshaft bearing.
Connecting rods (“cracked” connecting rods)

The “cracked” connecting rods are precision forged in a die using quenched and tempered steel. The large
connecting rod eye is split diagonally by “cracking” the connecting rod bearing cap. The surface structure
resulting from cracking results in a tooth engagement effect between the connecting rod bearing cap and
the connecting rod with a precise, non-interchangeable fit and high lateral stability.
Piston
3-ring pistons made of special die-cast aluminium are used. They feature a cast ring carrier for the
uppermost piston ring. The pistons have a cast-in cooling duct for reducing the thermal load when the
output is high. They are cooled by an oil jet from the oil injector nozzles. The ring set comprises one
taper-face ring and one full keystone ring, each as compression rings, as well as one double-bevelled
slotted oil control ring with spiral-type expander as an oil scraper ring.

Introduction
Cylinder head
Series D08 engines are equipped with a single-piece cylinder head. The cylinder head is made from special
cast iron and is fitted with shrink-fitted valve seat rings and pressed-in, exchangeable valve guides. The
valve guides have valve stem seals at all four valves. The valves are actuated by individually exchangeable
rocker arms on rocker shafts. 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 in 5 bearings in the crankcase.
The camshaft is driven by the spur-toothed crankshaft gear stump onto the camshaft gear.
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 level in the oil sump is measured in the oil pan with
the help of an oil dipstick and via an oil level sensor.
Cooling system
The cooling circuit is a thermostat-controlled forced circulation cooling system with a maintenance-free
coolant pump driven by a ribbed V-belt. The thermostats is a exchangeable insert with wax expansion
elements. The connection for the heating flow is located on the thermostat housing.
Intake/exhaust system
The 2-section exhaust manifold is cast from high temperature-resistant nodular cast iron and secured to the
cylinder head using heat-resistant bolts. The maintenance-free turbo charger is mounted on the exhaust
manifold. The exhaust manifold is located after the turbo charger. 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 (fuel filter system, F- S -C). The fuel
service centre comprises a pre-filter and a special microfilter with water separation to ensure the degree of
fuel purity required by the common-rail system. The low-pressure system also includes a heating element
and the flame-start system. The interface to the high-pressure system is the fuel supply pump.
High-pressure system
The high-pressure system consists of the flow-rate-controlled high pressure pump with flange-mounted fuel
supply pump and the pressure pipe with rail pressure sensor and pressure-limiting valve. Solenoid
valve-controlled injectors with pressure pipe sockets and high-pressure lines which meet the necessary
requirements are also installed.
Injection pressure generation and fuel injection are separate in the high-pressure system. The injection
pressure is generated by the high pressure pump, irrespective of the engine speed and the required
injection quantity. The injection quantity is available in the pressure pipe for injection via the injectors.
The high pressure pump supply quantity is controlled by a proportional valve. The injection point and the
injection quantity are calculated in the ME7 control unit and implemented by the solenoid valve-controlled
injectors.
The solenoid valve-controlled injectors allow multiple injections:

Introduction
1. Pre-injection to improve combustion, reduce combustion noise and reduce peak combustion pressures.
2. Main injection to introduce the energy for the required engine power output.
3. Post-injection to reduce the pollutant emissions, main constituent NOx.
Always ensure absolute cleanliness both in and around the working area whenever carrying out work
on the highly sensitive high-pressure system.
The injectors are controlled by solenoid valve. They are arranged vertically in the cylinder head and
clamped with a pressure flange in the cylinder head.
Flame start system

Special equipment includes a flame-start system which serves as a cold starting aid. The flame-start
system consists of a solenoid valve and a rapid flame glow plug built into the charge air manifold. After
various parameter enquiries (via sensors), the flame glow plug and the corresponding solenoid valve are
activated by the EDC in order to heat the intake air. The fuel is supplied by the fuel service centre (FSC).
Starter motor
The starter motor is a reduction-gear starter motor with a free-engaging pinion construction. Free-engaging
means that the starter motor pinion is mounted on the housing in the starter motor without a thrust bearing.
A mechanical relay is mounted in the starter motor for starter motor control.
Alternators
Compact, powerful, low-noise alternators are fitted for power generation. The alternators seats are
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 a straight-geared camshaft gear.
PTO
The PTO serves as an alternator drive and consists of the housing, the power take-off shaft with ball
bearings and the ribbed V-belt pulley. The PTO is indirectly driven by the air compressor gear. Two cast
lugs have been positioned at each power take-off shaft and at the air compressor gear. The drive plate with
its cross-slots engages with these lugs as a flexible connection, thus ensuring a driven effect. The ribbed
V-belt disc is mounted on the power take-off shaft to drive the alternators via ribbed V-belts.
Power steering pump

The power steering pump is mounted at the rear of the air compressor, in accordance with its design.
Refrigerant compressor
The refrigerant compressor is driven by a ribbed V-belt (stretchy belt).

Introduction

Engine on assembly device
Removing/installing the engine on the assembly device
1 Assembly device 3 Engine

2 Hoop mounting plate D08


Removing/installing the engine on the assembly device
Additional jobs
S Removing/installing the charge-air pipe, see 144
S Removing/installing the intercooler charge-air pipe, see 320
S Removing/installing the intercooler (low pressure), see 324
S Removing/installing the intercooler (low pressure) charge-air pipe, see 328
S Removing/installing the hydrocarbon injection, see 380
S Removing/installing the hydrocarbon injection exhaust manifold, see 374
S Removing/installing the engine brake, see 392
S Removing/installing the steering pump, see 140
1 Assembly device 3 Engine

2 Hoop mounting plate D08
Important information
NOTE
Risk of material damage due to incorrectly tightened threaded connections
Components will get damaged.
For this reason:
S Use the impact screwdriver for preliminary tightening to max. 50 % of the final torque value specified.
S The final tightening must always be done with the torque wrench.

CAUTION
Risk of injury due to component weight
For this reason:
S Transporting the engine with lifting gear.
WARNING
Risk of death due to suspended load
During lifting operations, loads sway out and fall down.
For this reason:
S Never step under or in the swaying area of suspended loads.
S Only move loads under supervision.
S Only make use of approved hoists and lifting gear with adequate load-bearing capacity.
S Do not use torn or chafed lifting gear such as cables and belts.
S Lifting gear such as cables and belts should not be placed on sharp edges or corners, knotted
or twisted.
S Set the load down when leaving the workplace.
WARNING
Risk of injury by transport package swaying out
Transport package causes injuries and damage to property.
For this reason:
S Ensure that during transport no persons, objects or obstacles are located in the swivel range
of the transport package.
Special tools
[1] Crossbeam 80.99629-6008

S Lifting the engine
[2] Assembly device 80.99606-6177

S Fastening the engine in conjunction with:
S Hoop mounting plate D08 [3]

[3] Hoop mounting plate D08 80.99606-5003

S Fastening the engine
[4] Lifting gear for engine 80.99606-6152

S Lifting the engine

Positioning the engine on the assembly device
Attaching hoop mounting plate D08
► Attaching hoop mounting plate D08 3 [3] to the

engine
► Screw in and tighten the mounting bolts 2 with
washers 1
Mounting the lifting device
► Hooking the lifting gear for the engine 2 [4] into

the lifting eye 3 and crossbeam 1 [1]
► Hooking the crossbeam 1 [1] into the lifting
eyes 4 and 5

Fastening the engine
CAUTION
For this reason:
S Transporting engine with lifting gear
► Lifting the engine using the lifting gear for
engines 1 [4]
► Positioning the engine with its attached hoop
mounting plate D08 2 [3] on the assembly
device 3 [2]
► Screwing in and tightening the mounting bolts

Removing the lifting device
► Unhooking the crossbeam 1 [1] from the lifting

eyes 4 and 5
► Unhooking the lifting gear for the engine 2 [4]
from the lifting eyes 3

Detaching the engine from the assembly device
Mounting the lifting tackle
► Hooking the lifting gear for the engine 2 [4] into

the lifting eye 3 and crossbeam 1 [1]
► Hooking the crossbeam 1 [1] into the lifting
eyes 4 and 5

Unfastening the engine
CAUTION
For this reason:
S Transporting engine with lifting gear
► Support engine using lifting gear for engine 1
[4]
► Unscrew the mounting bolts
► Remove engine with attached hoop mounting
plate D08 2 [3] from the assembly device
3 [2]
► Positioning the engine in the prepared mount

Removing the lifting tackle
► Unhooking the crossbeam 1 [1] from the lifting

eyes 4 and 5
► Unhooking the lifting gear for the engine 2 [4]
from the lifting eyes 3
Removing the hoop mounting plate D08
► Remove the mounting bolts 2 with washers 1

► Removing the hoop mounting plate D08 3 [3]
from the engine

Engine electronics
Engine electronics
1 Cable harness 5 EGR pressure sensor

2 Cable duct 6 Relays
3 Flame glow plug 7 Solenoid valve
4 Throttle valve

Engine electronics

Engine electronics
Removing/installing the cable harness
1 Cable harness 2 Cable ductcover
Technical data
Tightening torques
Mounting nut B1+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Nm
Terminal 30 mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Flame glow plug mounting nut . . . . . . . . . . . . . . . . . . . . . . . M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
CAUTION
Risk of injury from sharp edges
Sharp ends on the cable ties if wrong tool is used.
For this reason:
S Only tighten and trim cable ties using the cable tie pliers [1].

Engine electronics
NOTE
For this reason:
S Use the impact screwdriver for preliminary tightening to max. 50% of the final torque value specified.
NOTE
Risk of material damage from incorrect installation
Electrical cable damage due to over-tightening.
For this reason:
S Follow the operating instructions for the cable tie pliers [1].
NOTE
Risk of material damage due to short circuit
Components of the electrical system will get damaged.
For this reason:
S Switch off the main battery switch.
S Disconnect the ground cable from the battery.
NOTE
Risk of property damage from incorrect wiring harness routing
For this reason:
S Document the routing of the cable harness and mark the installation position.
S Mark the installation position, method of attachment and the position of the cable harness fasteners.
Tip for users

Before removal, mark the installation position of the cables, plugs and cable ties.
When installing, route and secure the cables, plugs and cable ties as marked without tension, kings or
chafing.
Special tools
[1] Cable tie pliers 08.02960-0100

S Tightening and cutting cable ties

Engine electronics
Removing the engine electrics
Removing the cable duct cover
► Open the locking pin 2 a quarter turn

► Remove the cable duct cover 1
Disconnecting the plug bracket electrical connections
► Disconnect the electrical connections 1
Disconnecting the electrical connection to the starter motor
► Unscrew the mounting nut 2

► Remove the cable harness 1

Engine electronics
Disconnecting the electrical connection to the cable harness
► Disconnect the cable ties

► Disconnect the electrical connection 3
► Unscrew the mounting bolt 2
► Expose the cable harness 1
Disconnecting the pressure sensor electrical connection
► Disconnect the electrical connection 1 from the

pressure sensor 2

Engine electronics
Disconnect the electrical connection to the solenoid valve

solenoid valve 1
Disconnecting the electrical connection to the charge-air manifold temperature sensor
Disconnecting the electrical connection from the speed sensor


Engine electronics
Disconnect the electrical connection of relay
► Disconnect the electrical connection 2 from

the relay 1
Disconnecting the oil module pressure sensor electrical connection

pressure sensor 1
Disconnecting the air distributor pipe temperature sensor electrical connection

temperature sensor 1

Engine electronics
Disconnecting the EGR temperature sensor electrical connection
Disconnecting the electrical connection to the FSC
► Disconnect the electrical connection 2 from

the temperature KSC 1

Engine electronics
Disconnect the electrical connection from the oil level sensor
Disconnecting the electrical connections to the proportional valve
► Mark the installation position of the electrical

connections 1 , 2 , 3 , 4
► Disconnect the electrical connections
1, 2, 3, 4
Disconnecting the NOx electrical connection

Engine electronics
Installing the engine electrics
Connecting the NOx electrical connection
► Connecting the electrical connection 1
Connecting the electrical connections to the proportional valve
► Connect the electrical connections 1 , 2 , 3 , 4

as marked
Connect the electrical connection for the oil level sensor

Engine electronics
Connecting the pressure sensor electrical connection
Connecting the electrical connection to the FSC
► Connect the KSC 1 electrical connection 2
Connecting the exhaust gas recirculation temperature sensor electrical connection

Engine electronics
Connecting the electrical connection between the temperature sensor and the air distributor pipe
► Connect the temperature sensor electrical

connection 2 , 1
Connecting the electrical connections to the oil module pressure sensor
► Connect the electrical connection 2 to the

pressure sensor 1
Connecting the electrical connection to the relay

relay 1

Engine electronics
Connect the electrical connection to the speed sensor

► Screw in and tighten the mounting bolts 1
Connecting the electrical connection to the charge-air manifold temperature sensor
Connecting the electrical connection for the flame glow plug

flame glow plug 3
► Screw on and tighten the mounting nut 2
Tightening torque . . . . . . . . . . . . . . . . . . . . . . 5 Nm

Engine electronics
Connect the solenoid valve electrical connection

solenoid valve 1

pressure sensor 2
Connecting the electrical connection to the alternator
► Plug in and lock the compact connector 3

► Connect the electrical connection 2
Tightening torque . . . . . . . . . . . . . . . . . . . . . 14 Nm
► Secure the cable harness with cable ties
► Tighten and cut ends of cable ties using cable
tie pliers [1]

Engine electronics
Connecting the electrical connection to the starter motor
► Attach the cable harness 1

Connecting the plug bracket electrical connections
► Connect the electrical connections 1
Mounting the cable duct cover
► Reset the cable duct cover 1

► Tighten the locking pin 2 a quarter turn

Engine electronics
Removing/installing the engine electrical system
1 Solenoid valve 5 Throttle valve

2 EGR temperature sensor 6 Relays
3 Coolant pre-heating 7 Camshaft speed sensor
4 EGR pressure sensor 8 Flame glow plug

Engine electronics
1 Proportional valve 4 NOx sensor

2 Flame glow plug 5 Sensor
3 Lambda probe 6 EGR shut-off flap servomotor
Technical data
Tightening torques
Flame glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Camshaft speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm
Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
KSC pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Temperature sensor EGR . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Temperature sensor air distributor pipe . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Flame glow plug hollow screw . . . . . . . . . . . . . . . . . . . . . . . M10x1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Oil level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Speed sensor for flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . M6x16-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm
EGR pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x20-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nm
Flame glow plug mounting nut . . . . . . . . . . . . . . . . . . . . . . . M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
Service products
WEICON Anti-Seize “High-Tech” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09.16012-0133

Engine electronics
NOTE
For this reason:
CAUTION
For this reason:
NOTE
For this reason:
NOTE
Risk of component damage due to incorrect installation
Avoid jammed exhaust gas sensors.
For this reason:
S Apply a thin layer of suitable assembly paste to the thread of the exhaust sensors.
S Observe the manufacturer's instructions.
Tip for users

Restricted driving mode due to defective entries in the fault memory
S Before removing switches or sensors, read out and document the diagnostic memory.
S Always install switches and sensors with new O-rings or seals.
S After installing switches or sensors, read out the diagnostic memory and delete it if necessary.
Tip for users

Mark the installation position of the cable ties
S Before removal, mark the installation position of the cables, plugs and cable ties.
S When installing, route and secure the cables, plugs and cable ties as marked without tension, kinks or
chafing.
ENVIRONMENTAL NOTE
Collect any fuel that escapes in a suitable container.

Engine electronics
Special tools

[2] Release handle 80.99606-0597

S Removing the pressure lines in conjunction with:
S Size 1 unlocking tool [3]
[3] Size 1 unlocking tool 80.99606-0625

S Removing fuel lines
[4] Lambda probe wrench 08.06141-9065

S Removing/installing the engine electrics
S Removing/installing the exhaust system turbo charger - flexible exhaust pipe
S Removing/installing the oil sump
[5] Protective sleeve Z 12 x 16 81.96002-0117

S Plugging the fitting for the quick coupling

Engine electronics
Removing the engine electrical system
Disconnecting the EGR pressure sensor electrical connection

pressure sensor 2
Removing the EGR pressure sensor

► Pulling out the pressure sensor 2

solenoid valve 1

Engine electronics
Removing fuel lines
ENVIRONMENTAL NOTE
Collect any fuel that escapes in a suitable con-
tainer.
► Unscrew the hollow screw 1
► Unscrew the fuel line union nut 6
► Remove the fuel line 6 together with the
sealing rings 2
► Remove the fuel line 5 together with the
sealing rings 3
Removing the solenoid valve
► Unscrew the mounting bolts 1

► Remove the solenoid valve 2
Disconnecting the electrical connection to the flame glow plug
► Unscrewing the mounting nut 2 from the flame

glow plug 3

Engine electronics
Disconnecting the electrical connection to the charge-air manifold temperature sensor
Removing the temperature sensor

► Pull the temperature sensor 1 out

Engine electronics
Disconnecting the electrical connection from the speed sensor

Removing the speed sensor

► Pulling out the speed sensor 1

relay 1

Engine electronics
Detach the relay

► Removing the relay 2

pressure sensor 1
Removing the pressure sensor
► Unscrewing the pressure sensor 2

► Remove the seal 1

Engine electronics
Disconnecting the air distributor pipe temperature sensor electrical connection

temperature sensor 1
Removing the air air distributor pipe pressure sensor
► Unscrewing the temperature sensor 1 with

its seal
Disconnecting the EGR temperature sensor electrical connection

Engine electronics
Removing the EGR temperature sensor
► Unscrew the temperature sensor 1 and

remove it with the seal 2

temperature KSC 1

Engine electronics
► Unscrewing the pressure sensor 1 and

removing it together with the seal 2
Detaching the oil level sensor
► Unscrewing the oil level sensor 1 and


Engine electronics
Disconnecting the HCI proportional valve electrical connection
► Mark the installation position of the electrical

connections 1 , 2 , 3 , 4
► Disconnect the electrical connections
1, 2, 3, 4
Removing fuel lines
ENVIRONMENTAL NOTE
tainer.
► Removing the fuel line 3 using unlocking tool

insert Size1 [3] and removing the unlocking tool
handle [2] from the proportional valve 1
► Plug the connections with the protective sleeve
Z 12 x 16 [5]
► Sealing the fuel line union nut 2 with protective
cap Z 12 x 16 [5]
Detaching the proportional valve

► Removing the proportional valve 1

Engine electronics
Disconnecting the NOxelectrical connection
Removing the lambda probe
► Mark the installation position of the cable ties

► Remove cable ties
► Unscrewing the lambda probe 1 with a lambda
probe key [4]
► Clean the sealing surfaces
Removing the NOx sensor

► Unscrew the NOx sensor 1

Engine electronics
Disconnecting the flywheel speed sensor electrical connection
► Disconnecting the electrical connection from

the speed sensor 1
Removing the flywheel speed sensor

► Pulling out the flywheel speed sensor 2

Engine electronics
Installing the engine electrical system
Installing the flywheel speed sensor
► Inserting the flywheel speed sensor 2

Connecting the flywheel speed sensor electrical connection
► Connecting the electrical connection 1 to the

flywheel speed sensor
Attaching the NOx sensor
► Thinly coating the NOx sensor 1 thread with

WEICON Anti-Seize
► Screw the NOx sensor 1 into place and
tighten it
► Ground cable ties as marked
tie pliers [1]
Tip for users

The thread of new NOx sensors is already
coated with suitable assembly paste.

Engine electronics
Installing the lambda probe
► Apply a thin layer of WEICON Anti-Seize to

thread of Lambda probe 1
► Screw the lambda probe 1 in with the lambda
probe wrench [4] and tighten
tie pliers [1]
Tip for users

The thread of new lambda sensors is already

Engine electronics
Attaching the proportional valve
► Attaching the proportional valve 1

Attach the fuel lines
► Removing the protective cap Z 12 x 16 [5]

► Installing the fuel line 3
► Checking the secure fit of the fuel line; 3 if
necessary, using unlocking tool insert Size1 [3]
and unlocking tool handle [2] to remove and
refit
► Position the fuel line 2
► Fitting the fuel line union nut 2 and bracing
it holding the socket
► Tightening the fuel line union nut 2
Connecting the HCI proportional valve electrical connections
► Connect electrical connections 1 , 2 , 3 and 4

Engine electronics
Install the oil level sensor
► Screwing in and tightening the oil level sensor

1 with a new seal 2
Installing the pressure sensor
► Screw the pressure sensor 1 in with a new

seal 2 and tighten

Engine electronics

KSC 1
Installing the EGR temperature sensor
► Screw in and tighten the temperature sensor 1

with a new seal 2

Engine electronics
Connecting the exhaust gas recirculation temperature sensor electrical connection
Installing the air distributor pipe temperature sensor

with a new seal
Connecting the electrical connection between the temperature sensor and the air distributor pipe
► Connect the temperature sensor electrical

connection 2 , 1

Engine electronics
► Screwing in and tightening the pressure sensor

2 with its seal 1

pressure sensor 1
Install the relay
► Positioning the relay 2


Engine electronics

relay 1
Installing the camshaft speed sensor
► Installing the speed sensor 1

Connecting the speed sensor electrical connection camshaft


Engine electronics
Attaching the temperature sensor
► Installing the temperature sensor 1

Connecting the electrical connection to the charge-air manifold temperature sensor
Connecting the electrical connection for the flame glow plug

flame glow plug 3

Engine electronics
Attaching the solenoid valve
► Attach the solenoid valve 2

Removing fuel lines
► Attaching the fuel line 5 with its sealing

rings 3
► Screw the hollow screw 4 in and tighten
► Attaching the fuel line 6 with its sealing
rings 2
► Screwing in the hollow screw 1
► Fitting and tightening the fuel line union nut 6
► Tighten the hollow screw 1

solenoid valve 1

Engine electronics
Installing the EGR pressure sensor
► Inserting the pressure sensor 2

Connecting the EGR pressure sensor electrical connection

pressure sensor 2

Cooling system
Cooling system
1 Outlet nozzle 4 Coolant manifold

2 Thermostat housing 5 Ribbed V-belt disc
3 Coolant line

Cooling system

Cooling system
Removing/installing the Visco fan
1 Visco fan
Technical data
Tightening torques
Fan clutch mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nm
NOTE
For this reason:
NOTE
Risk of malfunctions
Incorrect setting aside of the fan clutch may cause malfunctions.
For this reason:
S Always store the fan clutch in installation position.

Cooling system
Removing the Visco fan
Detaching the fan clutch

► Removing the Visco fan 2
Detaching the fan clutch
► Removing the fastener nuts 2

► Remove the fan clutch 1 from the Visco fan 3

Cooling system
Installing the Visco fan
Install the fan clutch
► Insert the fan clutch 1 into the Visco fan 3

► Fitting and tightening the fastener nuts 2
Install the fan clutch
► Fitting the Visco fan 2

► Screw in and tighten 1 the mounting bolts

Cooling system

Cooling system
Removing/installing the flange (fan flange)

Version 68
Additional jobs
S Remove/install the Visco fan, see 88
1 Fan flange
NOTE
For this reason:

Cooling system
Removing the fan flange

► Removing the fan flange 2
Installing the fan flange
► Fitting the fan flange 2

► Screwing in and tightening the mounting
bolts 1

Cooling system

Variants 66, 67
Additional jobs
1 Fan flange
NOTE
For this reason:

Cooling system


bolts 1

Cooling system

Variant 68 with hydraulic pump
Additional jobs
S Removing/installing the ribbed V-belt for the hydraulic pump, see 218
1 Fan flange 2 Ribbed V-belt disc
NOTE
For this reason:

Cooling system

► Removing the fan flange 3 with its ribbed
V-belt disc 2
► Attaching the fan flange 3 with its ribbed V-belt

disc 2
bolts 1

Cooling system

Variant 66, 67 with hydraulic pump
Additional jobs
1 Fan flange 2 Ribbed V-belt disc
NOTE
For this reason:

Cooling system


bolts 1

Cooling system
Removing/installing the coolant pump coolant manifold
Additional jobs
S Remove/install the flange (fan flange), see 92
S Remove/install the alternator ribbed V-belt, see 172
1 Coolant manifold
Technical data
Tightening torques
GE bulkhead fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Service products
Radiator antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Maintenance and service product regulations

Cooling system
NOTE
For this reason:

Cooling system
Removing the coolant manifold
Detach the coolant line

► Unlocking and removing the plug connectors for
the coolant line 2 by pressing the spring clip
► Unlocking and removing the plug connector for

Removing the coolant manifold

► Remove the coolant manifold 3 together with
the seal 2

Cooling system
Unscrew the GE bulkhead fitting
► Unscrewing the GE bulkhead fittings 1 and 2
Installing the coolant manifold
Screwing in the GE bulkhead fitting
► Screwing in and tightening the GE bulkhead

fittings 1 and 2
Mounting the coolant manifold
► Position the coolant manifold 3 with a new

seal 2

Cooling system
Installing the coolant line
NOTE
Component damage due to loose plug
connections
For this reason:
S Check the coolant line plug connections are
firmly seated after securing.
S If the connections are loose, undo them by
pushing the spring clip, plug in again and
secure.
► Fitting the plug connector for the coolant line 1

► Checking the plug connector for the coolant
line 1
NOTE
connections
For this reason:
secure.

► Checking the plug connector for the coolant
line 2

Cooling system

Cooling system
Removing/installing the thermostat insert
1 Coolant outlet
Technical data
Thermostat opening temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 - 85C
Service products

Cooling system
NOTE
Risk of material damage due to wrong thermostat
Thermostats with incorrect opening temperature damage the engine.
For this reason:
S Only use thermostats with the correct opening temperature.
NOTE
For this reason:
Tip for users

chafing.
CAUTION
For this reason:
Special tools


Cooling system
Removing the thermostat insert
Detach the brake line

► Unscrewing the brake line union nuts 2
► Removing the brake line 2
Remove the bracket
► Marking the installation position of the mounting

bolts 1 and 4
► Unscrew mounting bolts 1 and 4
► Removing the bracket 2 and cable harness 3
Removing the coolant outlet

► Removing the coolant outlet 2

Cooling system
Remove thermostat
► Removing the thermostat 2 with its seal 1


Cooling system
Installing the thermostat insert
Install thermostat
NOTE
Risk of material damage from incorrect
thermostats
Thermostats with the incorrect opening
temperature damage the engine.
For this reason:
S Only use thermostats with the correct opening
temperature.
► Inserting the thermostat 2 into the thermostat

housing with the top marking facing upwards
► Apply a thin layer of radiator antifreeze to the
new O-ring 1
► Insert the new O-ring 1
Installing the coolant outlet
► Positioning the coolant outlet 2

Attaching the bracket
► Positioning the bracket 3 and cable harness 2

► Securing the cable harness with cable ties after
marking it
tie pliers [1]

Cooling system
Fitting the brake line
► Positioning the brake line 2

► Screwing on and tightening the brake line union
nuts 2

Cooling system
Removing/installing the thermostat housing
Additional jobs
S Remove/install the thermostat insert see 106
1 Thermostat housing
NOTE
For this reason:

Cooling system
Removing the thermostat housing
Detaching the heating flow coolant line
► Unscrewing the mounting bolts 2 and 3

► Unscrew the hollow screw 5 along with the
seals 1
► Detach the heating flow coolant line 4
Releasing the coolant line
► Removing the union nut 1 from the thermostat

housing
Detaching the thermostat housing
► Mark the installation position of the mounting

bolts 1 and 2
► Unscrew the mounting bolts 1 and 2
► Removing the thermostat housing 3 with its
seal 4 from the timing case

Cooling system
Installing the thermostat housing
Mounting the thermostat housing
► Position the thermostat housing 3 on

the timing case along with a new seal 4
► Screw the mounting bolts 1 and 2 in
as marked
► Tightening the mounting bolt 1 and 2
Attach the coolant line
► Screwing on and tightening the union nut 1
Attaching the heating flow coolant line
► Positioning the coolant line to the heating feed

line 4 with its sealing rings 1
► Hand-tightening the hollow screw 5
► Screwing in and hand-tightening mounting
bolts 2 and 3
► Tighten the mounting bolts 2 and 3

Cooling system

Cooling system
Dismantling/assembling the thermostat housing
Additional jobs
S Removing/installing the thermostat housing see 116
S Remove/install the thermostat insert see 106
1 Thermostat housing
Service products
NOTE
For this reason:

Cooling system
Dismantling the thermostat housing
Dismantling the thermostat housing
► Unscrew the bulkhead union 1 and remove it

together with the seal 2
► Pull the coupling pipe 4 out of the thermostat
housing 3
Assembling the thermostat housing
Assembling the thermostat housing
► Screw the bulkhead union 1 in with a new seal

2 and tighten
new coupling pipe 4
► Install the coupling pipe 4 in the thermostat
housing 3

Cooling system
Removing/installing the coolant pump
Additional jobs
S Removing/installing the flange (fan flange), see 92
S Remove, install the ribbed V-belt for the alternator, see 172
1 Coolant pump 2 Ribbed V-belt disc
Technical data
Checking and setting values
Hollow screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
NOTE
For this reason:

Cooling system
Removing the coolant pump

► Unscrewing the brake line union nuts 2

► Unlocking and removing the plug connectors for
Removing the coolant outlet

► Removing the coolant outlet 2

Cooling system
Detaching the coolant lines
► Bracing the mounting nut and removing the

mounting bolt 2
► Unscrew the mounting bolt 5 and remove it
with the bush
► Unscrew the hollow screw 1 and remove it
with the seals
► Unlock plug connector 4 by pressing the spring
clip and remove
► Remove the plug connector O-ring 4
► Remove the coolant line 3
Undoing the ribbed V-belt disc
► Undo the mounting bolts 1
Removing the ribbed V-belt for the alternator
CAUTION
Risk of injury from spring tension
Springing back of the ribbed V-belt tensioner.
For this reason:
S Secure the ribbed V-belt tensioner from
springing back inadvertently by holding it
down.
► Fit the tool 2 on the ribbed V-belt tensioner 3

► Turn the ribbed V-belt tensioner 3
anti-clockwise until it stops and hold it
► Remove the ribbed V-belt 1 from the ribbed
V-belt disc
► Carefully slacken the ribbed V-belt tensioner 3

Cooling system
Detaching the ribbed V-belt disc

► Remove the ribbed V-belt disc 2
Removing the coolant pump

bolts 1 and 4
► Remove the coolant pump 2 together with the
seal 3

Cooling system
Installing the coolant pump
Mounting the coolant pump
► Position the coolant pump 2 with a new seal 3

► Screw in and tighten the mounting bolts 1 and
4 as marked
Mount the poly-V-belt pulley
► Position the ribbed V-belt disc 2

► Screw the mounting bolts 1 in and tighten
by hand
Installing the ribbed V-belt for the alternator
CAUTION
For this reason:
springing back inadvertently by holding
it down.

anti-clockwise and hold it
► Fit the ribbed V-belt 1
► Remove the tool 2 from the ribbed V-belt
tensioner 3

Cooling system
► Tighten the mounting bolts 1
Attaching the coolant lines
NOTE
connections
For this reason:

firmly seated after securing
S Loose plug-in connectors must be released
by pressing the spring clip, again positioned
and then secured
► Fit a new O-ring on the plug connector 4

► Position the coolant line 3
► Attach the plug connector 4
► If required, undo the plug connector 4 by
pressing the spring clip, insert again and secure
► Screw the hollow screw 1 in with new seals
and tighten it by hand
► Position the bush with a retaining clamp and
screw the mounting bolt 5 in and tighten
► Positioning the coolant line clamps 3
► Insert the mounting bolt 2 , then screw the
mounting nut on and tighten it

Cooling system
Installing the coolant outlet
► Positioning the coolant outlet 2

NOTE
connections
For this reason:

firmly seated after securing
and then secured

► Loosening the plug connector of the coolant line
1 by pressing the spring clip if necessary,
reinserting and securing it

nuts 2

Cooling system

Cooling system
Dismantling and assembling the coolant pump
Additional jobs
S Remove/install the coolant pump, see 118
1 Hub 4 Coolant pump housing

2 Locking ring 5 Axial face seal
3 Bearing 6 Impeller
Technical data
Impeller dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.10 - 33.30 mm
Service products

Cooling system
NOTE
For this reason:
Special tools
[1] Electronic depth gauge 08.71195-9003

S Check the dimensions of the impeller to the coolant pump housing in
conjunction with:
S Measuring attachment [2]
[2] Measuring attachment 08.71109-0000

S Checking the dimensions of the impeller to the coolant pump housing
[3] Separator 08.99605-9003

S Pressing the hub off in conjunction with:
S Mandrel [4]
[4] Mandrel 80.99617-0029

S Pressing out the axial face seal
S Pressing out the bearing
S Pressing the hub off
[5] Press-in mandrel 80.99617-0191

S Pressing in the coolant pump axial face seal in conjunction with:
S Washer [7]
S Detachable handle [6]
S Washer [10]
[6] Detachable handle 80.99604-0344

S Pressing the coolant pump axial face seal in
S Pressing the hub on
S Pressing bearings in

Cooling system
[7] Washer 80.99617-0144

S Pressing the coolant pump axial face seal in
[8] Pressing sleeve 80.99604-0432

S Pressing bearings in
S Washer [7]
S Detachable handle [6]
S Sleeve [9]
S Pressing tool [11]
[9] Sleeve 80.99616-0133
S Pressing bearings in and out
[10] Washer 80.99616-0134

S Pressing the impeller on
S Press the axial face seal in
[11] Pressing tool 80.99604-0461

S Determining the installation dimensions of the impeller
S Pressing the impeller on

Cooling system
Dismantling the coolant pump
Determine the installation size of the impeller
Tip for users

After adjustment, the pressing tool must rest on
the impeller . The internal hexagon bolt must be
positioned on the hub shaft after adjustment.
► Place the pressing tool [11] 1 on the impeller 4

► Screw the internal hexagon bolt 2 in until it is
in contact with the hub shaft 3 . The pressing
tool [11] 1 must lift off the impeller 4 in the
process.
Measuring the determined installation dimensions
► Determine and make a note of the distance A

between upper edge of internal hexagon bolt 1
and the pressing tool 2 using the electronic
depth gauge [1]
Detach the hub of the coolant pump
► Insert the separator [3] 1 under the hub 3

and clamp it
► Position the separator [3] 1 on the counter
supports of the hydraulic press
► Press the coolant pump 4 out of the hub 3
using the mandrel [4] 2

Cooling system
Removing the locking ring
► Remove the locking ring 1 from the coolant

pump 2
Removing the impeller
CAUTION
Risk of injury due to splinters
Impeller splits when pressed out of the bearing.
For this reason:
S Wear safety goggles and protective clothing.
S Cover the impeller while pressing it out.
► Insert the coolant pump housing 2 in the
sleeve [9] 4
► Press the bearing 3 out of the coolant pump
housing 2 using the mandrel [4]
► Remove the impeller 1

Cooling system
Remove axial face seal
► Press the axial face seal 1 out of the coolant

pump housing 2 using the mandrel [4]
Assemble the coolant pump
Install bearing
NOTE
Risk of material damage due to incorrect
exertion of the pressing force
Component damage of the coolant pump
housing and bearing.
For this reason:
S Carefully press the new bearing onto the
outer bearing race as far as the stop.
S Use a suitable sleeve to brace.
► Assemble the special tool, consisting of the

pressing sleeve [8] 3 , detachable handle [6] 1
and washer [7] 2
► Place the coolant pump housing 5 on the
sleeve [9] 6 and align centrally with the bore
► Carefully press in the bearing 4 as far as the
stop using the special tool

Cooling system
Fitting the locking ring
► Install the locking ring 1 in the coolant pump 2

Check that the locking ring is seated correctly. If
necessary, remove and install the locking ring
again.
Press on the hub of the coolant pump
► Assemble the special tool, consisting of the

pressing sleeve [8] 3 , detachable handle [6] 1
and washer [7] 2
► Place the hub shaft on the washer [10] 5
on the impeller side and hold it straight
► Press the hub 4 flush onto the bearing using
the special tool

Cooling system
Install the axial face seal
► Apply a thin layer of a mixture consisting of

50% water and 50% radiator antifreeze to the
axial face seal 2 and the coolant pump shaft
► Place the hub centrally on the washer [10] 4
► Assemble the special tool 1 , consisting of the
detachable handle [6], the washer [7] and the
press-in mandrel [5]
► Press the axial face seal 2 into the coolant
pump housing 3 until it reaches the stop using
the special tool
Verify the determined installation size
► Check the distance A between upper edge of

the internal hexagon bolt 1 and the pressing
tool 2 using the electronic depth gauge [1]
► If necessary, set dimension A to the previously
noted dimension, see Measuring the
determined installation dimensions

Cooling system
Pressing the impeller on
► Place the coolant pump housing 3 on

the sleeve [10] 4 on the hub side
► Carefully press the impeller 2 on using the
pressing tool [11] 1 until the internal hexagonal
bolt is in contact with the hub shaft.
Check the measurement impeller to housing coolant pump
► Check the dimension A using the electronic

depth gauge [1] and the measuring attachment
[2]
The permissible dimension A between the
impeller 2 and the coolant pump housing 1
is 33.10 - 33.30 mm.
If the dimensions A exceed 33.10-33.30 mm,

adjust the impeller 2 .
If the dimensions A are less than

33.10 - 33.30 mm, pull the impeller 2
off and press a new impeller 2 on.

Cooling system

Cooling system
Removing/installing the coolant pre-heating
Additional jobs
S Remove/install the oil module, see 517
1 Pre-heater
Technical data
Tightening torques
GE bulkhead fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
NOTE
For this reason:

Cooling system
Removing the pre-heater
Detaching the pre-heater
► Loosening the mounting bolt 2

► Detaching the pre-heater 1
Installing the pre-heater
Attaching the pre-heater
► Inserting the pre-heater 1

► Tightening the mounting bolt 2

Add-on units
Add-on units
1 Alternator 3 Refrigerant compressor

2 Starter motor 4 Ribbed V-belt disc

Add-on units
1 Alternator 3 Air compressor

2 Refrigerant compressor

Add-on units
Removing/installing the steering pump
Additional jobs
S Remove/Install the charge-air pipe, see 320
1 Power steering pump

Add-on units
NOTE
For this reason:
NOTE
Risk of material damage from dirt
Malfunction of the steering pump.
For this reason:
S Before starting work, thoroughly clean the steering pump, steering connections and the environment.
S Immediately seal any open oil pipes with plugs.

Add-on units
Removing the steering pump
Remove clamping piece

► Removing the clamp 2
Detaching the pressure line
► Removing the pressure line union nut 1

► Remove the pressure line 1
Detaching the steering pump

► Remove the steering pump 5 with its seal 4
and driver 3

Add-on units
Installing the steering pump
Attaching the steering pump
► Position the steering pump 5 with a new seal

4 and driver 3
washers 2
Attaching the pressure line
► Position the pressure line 1

► Screw on and tightening the pressure line union
nut 1
Fitting the clamp
► Position the clamp 2


Add-on units
Remove/install the PTO coolant pump/alternator
Additional jobs
S Removing/installing the belt drive of the alternator ribbed V-belt, see 172
1 Mounting bolt (left-handed thread) 5 Drive plate

2 Ribbed V-belt disc 6 Timing case
3 Power take-off 7 Mounting bolt
4 O-ring
Technical data
Tightening torques
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . 1st tightening 100 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . . . Final tightening 90
Service products
Technical vaseline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Maintenance and service product regulations

Add-on units
NOTE
For this reason:

Add-on units
Removing the PTO
Tip for users

The mounting bolt has a left-handed thread
► Counterhold the ribbed V-belt disc 2
► Remove the ribbed V-belt disc 2 from
the PTO 3
Detaching the PTO

► Take the PTO 1 off along with the
O-ring 3 and the clutch drive plate 2

Add-on units
Installing the PTO
Attaching the PTO
► Position the drive plate 2 with the thin side

on the air compressor gear and align
► Fitting the PTO 1 with its new O-ring 3
Tip for users

► Position the ribbed V-belt disc 2 on the PTO 3
► Screw in and tighten the new mounting bolt 1
Tightening torque
1st Tightening . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
Final tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Add-on units
Remove/install the air compressor
Additional jobs
S Remove/install the charge-air pipe, see 316
1 Air compressor
Technical data
Tightening torques
Mounting bolt PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . 1st tightening 100 Nm
Mounting bolt PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . . . Final tightening 90
Mounting bolt guide roller . . . . . . . . . . . . . . . . . . . . . . . . . . . M12x65-10.9 LH . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Service products
Technical vaseline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Maintenance and service product regulations

Add-on units
NOTE
For this reason:
Special tools
[1] Hose clamp pliers for spring band clamps 80.99625-0073

S Removing/installing spring band clamps
[2] Hose clamp pliers 08.04099-0007

S Removing and installing hose clamps

Add-on units
Remove air compressor
Tip for users

► Remove the ribbed V-belt disc 1 from the PTO
Removing intermediate gear roller

► Remove the guide roller 1
Remove the bracket

► Remove the bracket 3

Add-on units

► Remove the clamps 2
► Unscrew the brake line union nuts 4
Detach coolant line bracket

bolts 1 and 3
► Remove the mounting bolt 1 and the nut 2
► Unlock plug connector 3 by pressing the spring

clip and remove
► Detach the coolant line 2 with the seals 4

Add-on units
► Unscrew the coolant line union nut 2

Remove the bracket
► Remove the mounting bolt 1 and the nut 2
Detaching the intake line
► Undo the hose clamp 2 using the hose clamp

pliers [2]
► Pulling off the intake line 1

Add-on units
Detaching the support bracket

► Remove the support bracket 2
Detaching the air compressor

► Removing the air compressor 1

Add-on units
Installing air compressor
Attaching the air compressor
► Positioning the air compressor 1

Attaching the support bracket
► Position the support bracket 2

► Screw in the mounting bolts 1 and 3
and tighten
Attaching the intake line
► Pushing the intake line 1 onto the air

compressor fitting
► Attach the hose clamp 2 using hose
clamp pliers [2]

Add-on units
Mounting the bracket
► Positioning the mounting nut 2

► Positioning the coolant line 2 with new seals 3

► Screw on the coolant line union nut 2
► Screw the hollow screw 1 in and tighten
Tightening torque . . . . . . . . . . . . . . . . . . 35 Nm
► Tightening the coolant line union nut 2

Add-on units
Attaching the coolant line
NOTE
connections
For this reason:
secure.

► Attach the plug connector 3
► Loosening the plug connector, 3 if necessary
by pressing the spring clip, then reinserting and
securing it
Attaching the coolant line bracket
► Screwing on and tightening the mounting bolt

1 with mounting nut 2
► Screwing on and tightening the brake line

union nuts 4
► Positioning the clamps 2
and tighten

Add-on units
► Position bracket 3
and tighten
Attach the guide roller
► Position the guide roller 1

Tightening torque
Preliminary tightening torque . . . . . . . . . . . . . 60 Nm
Tip for users

► Position the ribbed V-belt disc 1 on the PTO
► Screw in and tighten the new mounting bolt 2
Tightening torque
1st Tightening . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm

Add-on units
Dismantling/assembling the air compressor
Additional jobs
S Remove/install the air compressor 148
S Remove/install the ribbed V-belt for the alternator, see 172
1 Locking ring 16 Pressure valve

2 Piston pins 17 Gasket
3 Piston sealing rings 18 Cylinder head
4 Locking ring 19 Gasket
5 Piston 20 Mounting bolts
6 Connecting rod 21 Cover
7 Pressure relief valve 22 Gasket
8 Seal 23 Mounting bolts
9 Mounting bolts 24 Support bracket
10 Adjustable angular union 25 Connecting rod bearing cap
11 Mounting bolts 26 Cover
12 Intake elbow 27 Mounting bolts
13 Mounting nut 28 Mounting bolt
14 Cylinder head cover for air compressor 29 Crankshaft drive wheel
15 Mounting bolt 30 Air compressor housing

Add-on units
Technical data
Tightening torques
Mounting bolt for drive wheel . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . 1st tightening 100 Nm
Drive wheel mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . Final torque 90°
Intake elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
Threaded union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Connecting-rod bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

Opening pressure of pressure relief valve for air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-22 bar
Service products

Add-on units
NOTE
For this reason:
Special tools
[1] Disassembly tool 80.99606-6118

S Locking the air compressor crankshaft
[2] Feeler gauge 08.75310-3309

S Checking the piston ring gap
[3] Piston ring pliers 83.09144-6090

S Dismantling/assembling air compressor (1-cylinder)
S Removing/installing the piston and connecting rod
[4] Piston ring clamping strap 80.99613-0035

[5] Torque wrench 08.06450-0002


Add-on units
Dismantling the air compressor
Attaching removal device to air compressor
► Attach the removal device [1] 1 to the

air compressor 2 with mounting bolts
Detaching the intake elbow
► Marking the installation position for the

intake elbow 2
► Unscrewing the intake elbow 2
Detaching the adjustable angular union
► Unscrewing the adjustable angular

union 1 with seal 2

Add-on units
Detaching the crankshaft drive wheel

► Removing the crankshaft drive wheel 2
Detaching the pressure relief valve
► Unscrewing the excess pressure relief valve 1

with seal 2
Detaching the air compressor cylinder head cover

bolts 1 and 2

Add-on units
Removing the air compressor cylinder head cover
► Removing the cylinder head cover 1

► Unscrewing the mounting bolt 3 and removing
it, along with the washer 2 and pressure valve
► Removing the seal 4
Removing the cylinder head
► Removing the cylinder head 1 with seal 2

Removing the cover

► Removing the cover 2 with seal 3

Add-on units
Detaching the cover
► Remove the cap 1
Removing the connecting-rod bearing cover

► Detaching the connecting-rod bearing cover 2
Removing the piston
► Pulling the piston 1 with connecting rod

out of the air compressor housing

Add-on units
Remove piston pin
► Marking the relative positions of the piston 3 ,

piston bolt 2 and connecting rod 5
► Detach the locking rings 1 and 4
► Push the piston pin 2 out of the piston 3
► Remove the piston 3 from the connecting
rod 5
Removing the piston rings
► Mark the installation position of the piston

rings 3
► Set the piston ring pliers [3] 1 to the piston
diameter
► Remove the piston rings 3 with piston ring
pliers [3] 1
► Carefully clean the piston ring grooves in
the piston 2

Add-on units
Assembling the air compressor
Installing the piston rings

diameter
► Insert piston rings 3 with top marking facing
the piston base using piston ring pliers [3] 1
as marked into the piston 2
Install piston pin
► Insert a new locking ring 4 into the groove in

the piston 3
► Fit the piston 3 over the connecting rod 5 as
marked
► Apply a thin layer of clean engine oil to the
piston pin 2
► Push the piston pin 2 through the piston 3
and the connecting rod 5 as marked until the
stop is reached
the piston 3
► Check that the locking rings 1 and 4 are
seated correctly
If the locking rings 1 and 4 have not engaged
correctly, remove and re-attach the locking rings
1 and 4 , ensuring that they are seated correctly.
Installing the piston
► Placing crankshaft on UT
► Aligning the gaps in the piston rings with an
offset of 120°
► Thinly coating the piston 1 and cylinder
running surface with clean engine oil
► Positioning the piston ring clamping strap [4]
on the piston 1 and clamping it
► Push the piston 1 with connecting rod into the
cylinder liner until the piston 1 has been
pushed out of the piston ring clamping strap [4]
► Push in the piston 1 until the connecting rod
rests on the crankshaft

Add-on units
Installing the connecting rod bearing cap
► Turn the crankshaft to the installation position

► Position the connecting-rod bearing cover 2 on
the connecting rod
► Screw in the new mounting bolt 1
► Tighten the mounting bolt 1 using a torque
wrench [5]
Installing the cover
► Install a new cap 1 in the air compressor using

a soft hammer
Mounting the cover
► Positioning the cover 2 with a new seal 3


Add-on units
Fitting the cylinder head
► Fitting the cylinder head 1 with a new seal 2
Fitting the air compressor cylinder head cover
► Fitting a new seal 4

► Screwing in and tightening the mounting bolt 3
with disc 2 and pressure valve
► Positioning the cylinder head cover 1
Fitting the air compressor cylinder head cover

2 as marked

Add-on units
Fitting the pressure relief valve
► Screwing in and tightening the excess pressure

relief valve 1 with a new seal 2
Fitting the crankshaft drive wheel
► Positioning the crankshaft drive wheel 2

► Screwing in and tightening the new mounting
bolt 1 (left-handed thread) with torque wrench
[6]
Tightening torque
Preliminary tightening torque . . . . . . . . . . . 100 Nm
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Fitting the adjustable angular union
► Screw the adjustable angular union 1 in with

a new seal 2 and then tighten
Tightening torque . . . . . . . . . . . . . . . . . 100 Nm

Add-on units
Fitting the intake elbow
► Screwing in the intake elbow 2 with mounting

nut 1 as marked
► Bracing the intake elbow 2 with the mounting
nut 1
Detaching removal device from the air compressor
► Unscrewing the mounting bolts of the removal

device
► Detaching the removal device [1] 1 from the air
compressor 2

Add-on units

Add-on units
Removing/installing the ribbed V-belt for the alternator
1 Alternator ribbed V-belt

Add-on units
NOTE
For this reason:

Add-on units
Removing the alternator ribbed V-belt
Removing the ribbed V-belt for the alternator
CAUTION
For this reason:
springing back inadvertently by holding it
down.
► Fit the tool 2 on the ribbed V-belt tensioner 3

anti-clockwise until it stops and hold it
► Remove the ribbed V-belt 1 from the ribbed
V-belt disc
Installing the alternator ribbed V-belt
Installing the ribbed V-belt for the alternator
CAUTION
For this reason:
springing back inadvertently by holding
it down.

anti-clockwise and hold it
► Fit the ribbed V-belt 1
► Remove the tool 2 from the ribbed V-belt
tensioner 3

Add-on units

Add-on units
Removing/installing the automatic belt tensioner for the alternator
Additional jobs
1 Alternator ribbed V-belt tensioner
Technical data
Tightening torques
Mounting bolt of ribbed V-belt tensioner . . . . . . . . . . . . . . M10x70-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm

Add-on units
NOTE
For this reason:

Add-on units
Removing the ribbed V-belt tensioner of the alternator
Removing the poly-V-belt tensioner

► Remove the ribbed V-belt tensioner 2
Installing the ribbed V-belt tensioner of the alternator
Attaching the ribbed V-belt tensioner
► Position the ribbed V-belt tensioner 2

► Screw in and 1 tighten the mounting bolts

Add-on units

Add-on units
Removing/installing the alternator
Additional jobs
1 Alternator
Technical data
Tightening torques
Poly-V-belt pulley mounting nut
LEB10 alternator 120 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Nm
V-belt disc mounting nut
NCB1 alternator 80A, NCB2 110A . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Mounting nut for terminal B1+ . . . . . . . . . . . . . . . . . . . . . . . M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Nm
Mounting bolt Ribbed V-belt disc . . . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . 1st tightening 100 Nm
Mounting bolt for ribbed V-belt disc . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . . . Final tightening 90

Add-on units

Alternator operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28V
Alternator charging current . . . . . . . . . . . . . . . . . . . . . . . . . LEB10 120 A . . . . . . . . . . . . . . . . 50 A at 1800 rpm
Alternator charging current . . . . . . . . . . . . . . . . . . . . . . . . . LEB10 120 A . . . . . . . . . . . . . . . 120 A at 6000 rpm
Alternator charging current . . . . . . . . . . . . . . . . . . . . . . . . . NCB1 80 A . . . . . . . . . . . . . . . . . 35 A at 1800 rpm
Alternator charging current . . . . . . . . . . . . . . . . . . . . . . . . . NCB1 80 A . . . . . . . . . . . . . . . . . 80 A at 6000 rpm
Alternator charging current . . . . . . . . . . . . . . . . . . . . . . . . . NCB2 110 A . . . . . . . . . . . . . . . . 40 A at 1800 rpm
Alternator charging current . . . . . . . . . . . . . . . . . . . . . . . . . NCB2 110 A . . . . . . . . . . . . . . . 110 A at 6000 rpm

Add-on units
CAUTION
For this reason:
S Cable ties should only be tightened and cut off with cable tie pliers [3]
NOTE
For this reason:
S Follow the operating instructions for the cable tie pliers [3] .
NOTE
For this reason:
Special tools
[1] Special wrench set 80.99603-6029

S Removing and installing the ribbed V-belt disc in conjunction with:
S Handle [2]
[2] Handle 08.06460-0002

S Removing and installing the ribbed V-belt disc


Add-on units
Removing the alternator
Disconnecting the electrical connection to the alternator
► Release the compact connector 3 and pull it

off
► Unscrewing the mounting nuts 1 for terminal
B2+ and B1+
► Disconnect the electrical connection from the oil

level sensor 1
► Expose the wiring harness
Disconnecting the electrical connection to the cable harness

► Expose the cable harness 1

Add-on units

► Loosening the brake line union nuts 2
Detaching the alternator

bolts 2 and 3
► Remove the alternator 1
Tip for users


Add-on units
Remove the bracket

bolts 1 , 2 and 3
► Unscrew the mounting bolts 1 , 2 and 3
► Remove the brackets 4 and 5
Removing the poly-V-belt tensioner

► Remove the ribbed V-belt tensioner 1
Removing the bracket

► Removing the bracket 2

Add-on units
Removing the ribbed V-belt disc mounting nut
► Positioning the special wrench set [1] 1 with

handle [2] 3 on the ribbed V-belt mounting nut
► Insert the multiple-tooth key 2 into the
alternator shaft toothing
► Bracing the multiple-tooth key 2 and loosening
the mounting nut

► Pulling the ribbed V-belt disc 2 off the
alternator shaft 3

Add-on units
Installing the alternator
► Push the ribbed V-belt disc 2 onto the

alternator shaft 3
► Apply a thin layer of Loctite to the alternator
shaft 3
► Screw on the mounting nut 1
Tightening the ribbed V-belt disc mounting nut
► Positioning the special wrench set [1] 1 with

handle [2] 3 on the ribbed V-belt disc mounting
nut
► Inserting the special wrench [1] 2 into the
alternator shaft teething
► Bracing the special wrench [1] 2 and tightening
the mounting nut
Tightening torque
LEB10 alternator 120 A . . . . . . . . . . . . . . . . . 97 Nm
NCB1 alternator 80A, NCB2 110A . . . . . . . . 80 Nm
► Position the bracket 2


Add-on units
Attaching the ribbed V-belt tensioner
► Position the ribbed V-belt tensioner 1

► Screw 2 in and tighten the mounting bolts
► Position the brackets 4 and 5

► Screw in the mounting bolts 1 , 2 and 3 as
marked and tighten
Tip for users

► Positioning the ribbed V-belt disc 1
► Screw in the new mounting bolt 2
► Tighten the new mounting bolt 2
Tightening torque
1st Tightening . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm

Add-on units
Mount the alternator
► Inserting the alternator 1

► Screw the mounting bolts 2 and 3 in
as marked and tighten

nuts 2
Connecting the electrical connection to the cable harness

► Route the cable harness 1 and secure using
cable ties
tie pliers [3]

Add-on units
► Connect the electrical connection for the oil

level sensor 1
► Route the cable harness so that it is free of

tension and kinks and does not chafe
► Plug in and lock the compact connector 3
► Screwing on and tightening the mounting
nuts 1 for terminal B1+ and B2+
► Secure the cable harness with cable ties
tie pliers [3]

Add-on units

Add-on units
Removing/installing the starter motor
1 Starter motor
Technical data
Tightening torques
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10x35-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Mounting nut for terminal 30 on relay . . . . . . . . . . . . . . . . . M10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm

Number of starter pinion teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Starter motor capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 kw at 24 V

Add-on units
NOTE
For this reason:
NOTE
Risk of material damage due to short circuit
Components of the electrical system will get damaged.
For this reason:
S Switch off the main battery switch.
S Disconnect the ground cable from the battery.
Special tools
[1] Engine cranking unit 80.99626-6008

S Cranking the engine in conjunction with:
S Gear ratchet [2]
[2] Gear ratchet 80.99627-0001

S Cranking the engine

Add-on units
Removing the starter motor
Disconnecting the electrical connection to the alternator

► Remove the cable harness 1
Removing the starter motor

bolts 3
► Remove the starter motor 4 from the
flywheel housing 2
Installing the starter motor
Installing the starter motor
► Crank the engine once in the running direction

using the engine cranking unit [1] and gear
ratchet [2] while checking the starter ring gear
for damage; replace starter ring gear if
necessary.
► Insert the starter motor 4 into the flywheel
housing 2
► Screw the mounting bolts 3 in as marked
► Tightening the mounting nut 1

Add-on units
► Attach the cable harness 1


Add-on units
Removing/installing the ribbed V-belt for the refrigerant compressor
Additional jobs
1 Poly-V-belt 3 Refrigerant compressor

2 Guide roller
Technical data
Tightening torques
Mounting bolt of guide roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Nm
NOTE
For this reason:

Add-on units
Special tools
[1] Assembly tool 51.99603-0003

S Removal/installation of the ribbed V-belt

S Gear ratchet [3]
[3] Gear ratchet 80.99627-0001


Add-on units
Removing the belt drive
Mount engine cranking unit
► Remove the cover from the flywheel housing

► Mount the engine cranking unit [2] 1 on the
flywheel housing
Removing the ribbed V-belt
CAUTION
Risk of injury from crushing
For this reason:

S Do not reach between the ribbed V-belt disc
and the ribbed V-belt while cranking the
engine.
Tip for users

This should be done with assistance.
► Position the assembly tools [1] 1 on the ribbed
V-belt pulley
► Crank the engine in the running direction using
the engine cranking unit [2] and gear ratchet [3]
while pulling the ribbed V-belt off the ribbed
V-belt disc
► Remove the assembly tools [1] 1

Add-on units

► Remove guide roller 3
Installing the belt drive
► Position the guide rollers 3

► Screw the mounting bolts 1 in with the
washers 2 and tighten
Attaching the ribbed V-belt

V-belt disc 2
► Positioning the ribbed V-belt 6 on the ribbed
V-belt disc 5 and guide rollers 1 and 4
► Pre-tension the ribbed V-belt 6 using the
assembly tools [1] 3
► Cranking the engine in the engine's running
direction using the engine cranking unit [2] and
gear ratchet [3] until the ribbed V-belt 6 is
completely on the ribbed V-belt disc 2

Add-on units
Removing the assembly tool
► Check that the ribbed V-belt is seated correctly

on the ribbed V-belt disc and the guide rollers.
Repeat the procedure if necessary
Removing engine cranking device
► Remove the engine cranking unit [2] 1 from

the flywheel housing
► Fit the cap on the flywheel housing

Add-on units

Add-on units
Removing/installing the ribbed V-belt for the refrigerant compressor

Variants 66, 67
Additional jobs
1 Poly-V-belt 3 Poly-V-belt
2 Ribbed V-belt disc 4 Refrigerant compressor
Technical data
Tightening torques
NOTE
For this reason:

Add-on units
Special tools
[1] Assembly tool 51.99603-0003

S Removal/installation of the ribbed V-belt

S Gear ratchet [3]
[3] Gear ratchet 80.99627-0001


Add-on units

flywheel housing
CAUTION
Risk of injury from crushing
For this reason:

S Do not reach between the ribbed V-belt disc
and the ribbed V-belt while cranking the
engine.
Tip for users

This should be done with assistance.
V-belt pulley
► Crank the engine in the running direction using
the engine cranking unit [2] and gear ratchet [3]
while pulling the ribbed V-belt 2 off the ribbed
V-belt disc

Add-on units
► Removing the mounting bolts 1 and

washers 2
► Removing the guide rollers 3 with spacers 4
► Positioning the guide rollers 3 with spacers 4

Attaching the ribbed V-belt

V-belt disc 2
► Positioning the ribbed V-belt 6 on the ribbed
V-belt disc 5 and guide rollers 1 and 4
► Pre-tension the ribbed V-belt 6 using the
assembly tools [1] 3
► Cranking the engine in the engine's running
gear ratchet [3] until the ribbed V-belt 6 is
completely on the ribbed V-belt disc 2

Add-on units
Removing the assembly tool
► Check that the ribbed V-belt is seated correctly

2 on the ribbed V-belt disc and the guide
rollers. Repeat the procedure if necessary.

► Fit the cap on the flywheel housing

Add-on units

Add-on units
Removing/installing the refrigerant compressor
Additional jobs
S Removing/installing the ribbed V-belt for the refrigerant compressor, see 196
1 Refrigerant compressor
CAUTION
Risk of injury due to chemical substances
Health risk due to refrigerant and refrigerant oil.
For this reason:
S Do not let refrigerant or refrigerator oil come into contact with the skin.

Add-on units
CAUTION
For this reason:
S Cable ties should only be tightened and cut off with cable tie pliers [3] .
NOTE
For this reason:
S Follow the operating instructions for the cable tie pliers [3] .
NOTE
For this reason:
ENVIRONMENTAL NOTE
Disposing of refrigerant and refrigerator oil in the correct manner
Special tools
[1] Tool insert 80.99606-0610

S Screwing on and unscrewing the plug of the pressure shim
[2] Tool insert 80.99606-0611

S Screwing on and unscrewing the plug of the intake connection


Add-on units
Removing the refrigerant compressor
Disconnecting the electrical connection to the refrigerant compressor
► Disconnect the 2 cable ties

► Disconnecting the electrical connection
to the refrigerant compressor 1
Closing the refrigerant connections
Tip for users

The suction port is marked with an S.
The pressure port is marked with a D.
► Screw the plug and tool insert [1] 1 or tool
insert [2] 3 onto the refrigerant connections of
the refrigerant compressor 2
Removing the refrigerant compressor Variant 68

► Removing the mounting bolt 4 with
washers 1 and 5
► Remove the refrigerant compressor 3 from
the console

Add-on units
Detaching the refrigerant compressor Variants 66, 67
► Unscrewing the mounting nuts 3 with

washers 2
► Removing the mounting bolts 6 with
washers 5 and bracket 1
► Remove the refrigerant compressor 4 from
the console

Add-on units
Installing the refrigerant compressor
Fitting the refrigerant compressor Variants 66, 67
► Position the refrigerant compressor 4 to the

console
► Inserting the mounting bolts 6 with bracket 1
and washers 5
► Screwing on the mounting bolts 3 with discs 2
Attaching the refrigerant compressor Variant 68
► Position the refrigerant compressor 3 to the

console
► Inserting mounting bolts 4 with discs 5
► Screwing on the mounting bolts 2 with discs 1
Removing the plugs
► Unscrewing the plug from the refrigerant

compressor 1 using tool insert [1] 3 or tool
insert [2] 2

Add-on units
Connecting the electrical connection to the refrigerant compressor
► Connecting the electrical connection of the

refrigerant compressor 1 and securing it with
cable ties 2
tie pliers [3]

Add-on units
Removing/installing the bracket for the refrigerant compressor
Additional jobs
S Removing/installing the ribbed V-belt for the refrigerant compressor, see 196
S Removing/installing the refrigerant compressor, see 208
1 Console for coolant compressor
NOTE
For this reason:

Add-on units
Removing the refrigerant compressor bracket

bolts 2 and 3
► Remove the refrigerant compressor bracket 1
Installing the refrigerant compressor bracket
Mounting the refrigerant compressor bracket
► Position the refrigerant compressor bracket 1

3 as marked

Add-on units
Removing/installing the bracket for the refrigerant compressor

Variants 66, 67
Additional jobs
S Removing/installing the ribbed V-belt for refrigerant compressor variants 66, 67, see 202
S Removing/installing the refrigerant compressor, see 208
1 Console for coolant compressor
NOTE
For this reason:

Add-on units

► Remove the refrigerant compressor bracket 2
Installing the refrigerant compressor bracket
► Position the refrigerant compressor bracket 2


Add-on units
Remove/install the hydraulic pump V-belt/ribbed belt
1 Ribbed V-belt 3 Tension pulley

2 Hydraulic pump 4 Ribbed V-belt disc
Technical data
Tightening torques
Mounting bolt (double pump variant) . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Nm
Mounting bolt (single pump variant) . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Nm
NOTE
For this reason:

Add-on units
► Loosening the hex bolt 1 and relieving the load

on the ribbed V-belt tensioner 2
► Removing the ribbed V-belt 3
Detaching the tension pulley

► Removing the tension pulley 4 with splash
rings 2 and Nilos rings 3
► Unscrew hex bolt 5
► Remove the pin 6
► Unscrewing the mounting nut 1 with washer 2


Add-on units
Installing the ribbed V-belt disc (hydro double pump variant)

► Screw on and tighten the mounting nut 1 with
washer 2
Tightening torque
Attaching the ribbed V-belt disc (hydro single pump variant)

washer 2
Tightening torque
Attaching the tension pulley
► Inserting the bolts 6

► Screwing the hex bolt 5 into the bolt 6
► Positioning the tension pulley 4 with splash
rings 2 and Nilos rings 3

Add-on units
Attaching the V-belt
► Fit the V-belt 3

► Screwing in the hex bolt 1 and tensioning
the ribbed V-belt tensioner 2

Add-on units
Removing/installing the hydraulic pump/single pump
Additional jobs
1 Bracket 2 Hydraulic pump
NOTE
For this reason:

Add-on units
Removing the hydraulic pump
Detaching the hydraulic pump

► Detaching the hydraulic pump 1
Remove the bracket


Add-on units
Install the hydraulic pump
and tighten
Attaching the hydraulic pump
► Positioning the hydraulic pump 1


Add-on units

Add-on units
Removing/installing the hydraulic pump/double pump
Additional jobs
1 Bracket 2 Hydraulic pump
NOTE
For this reason:

Add-on units
Removing the hydraulic pump
Detaching the hydraulic pump

► Removing the hydraulic pump 2 with
intermediate union 3
Remove the bracket


Add-on units
Install the hydraulic pump
► Screw in the mounting bolts 1 and 2 and
tighten
Attaching the hydraulic pump
► Positioning the hydraulic pump 2 with

intermediate union 3

Add-on units

Common Rail system
Common Rail system
1 Injector 4 Rail pressure pipe

2 Fuel filter with heating 5 High-pressure pump
3 Electronic diesel control unit 6 Flame start system

Common Rail system

Common Rail system
Removing/installing the injector with nozzle
Additional jobs
S Removing/installing the EDC control unit, see 308
S Remove/install cable harness, see 46
S Remove/install cylinder head cover, see 431
1 Mounting nut 6 Rail pressure pipe

2 Mounting bolt 7 Rail pressure sensor
3 spherical washer 8 High-pressure pump
4 Pressure flange 9 O-ring
5 High-pressure line 10 Injector
Technical data
Tightening torques
Mounting bolt Pressure flange . . . . . . . . . . . . . . . . . . . . . . . M8x45 . . . . . . . . . . . . . . . . . . . 1st tightening 2 Nm
Mounting bolt Pressure flange . . . . . . . . . . . . . . . . . . . . . . . M8x45 . . . . . . . . . . . . . . . Final tightening 25 +90°
Pressure screw for pressure pipe socket . . . . . . . . . . . . . M22x1.5 . . . . . . . . . . . . . . . . . 1st tightening 10 Nm
Pressure bolt for pressure pipe socket . . . . . . . . . . . . . . . M22x1.5 . . . . . . . . . . . . . Final tightening 20 + 60°
Injector cable mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Nm
High-pressure line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . 1st tightening 10 Nm
High-pressure line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . Final tightening torque 60°
High-pressure line (when using again) . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . 1st tightening 10 Nm
High-pressure line (reuse) . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . Final tightening torque 30°

Common Rail system
Pipe clamp mounting bolt for the high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
Service products
Diesel fuel . . . . . . . . . . . . . . . . . . see Maintenance Recommendations and Recommended Service Products
CAUTION
Risk of injury from common rail system
Residual pressure in the common rail system leads to injuries.
For this reason:
S The engine must be stationary for at least 5 minutes before starting work on the engine to
depressurise the pressure pipe, or depressurisation must be checked by means of MAN-cats (desired
value 0).
S The common rail system must be depressurised before starting work.
NOTE
Risk of material damage due to incorrectly performed work on the common rail system
Components on the common rail system are damaged.
For this reason:
S Work on the common rail system may only be performed by specially trained personnel.
S Ensure absolute cleanliness when working on the system.
S Avoid moisture.
S Replace pressure pipe sockets that have been undone.
S Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been
used once.
S Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the
pressure pipe socket.
NOTE
Risk of material damage due to dirt ingress
The ingress of dirt can damage the common-rail system.
For this reason:
S Close the component connections immediately using new, clean protective sleeves.
NOTE
Risk of material damage caused by wrong removal or installation
Functional impairment due to incorrect installation of injectors.
For this reason:
S Always allocate removed injectors to the correct cylinders.
S Allocate new injectors to the correct cylinders using MAN-cats®. For a description see EDC system
description.
NOTE
Risk of material damage caused by wrong installation
Missing pipe clamps lead to component damage on high-pressure lines.
For this reason:
S Always attach the pipe clamps taken from the wire harness in their original places.
S Always refit all of the pipe clamps removed.
S Tighten pipe clamps using the prescribed torque.

Common Rail system
NOTE
For this reason:
NOTE
Risk of injury from leaks
Fuel escapes from leaking high-pressure lines at high pressure.
For this reason:
S Carefully inspect the high-pressure lines for damage and deformation of the sealing cone before
re-installation.
S Check the high-pressure lines for crushing and deformation.
S Replace damaged high-pressure lines.
S Fit the high-pressure lines so they are free of tension.
S After fitting, check the lines for leaks using MAN-cats® DBV test.
Tip for users

In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped
on it.
ENVIRONMENTAL NOTE

Common Rail system
Special tools
[1] Fuel feed injector cap 81.96002-0523

S Plugging the injector feed bore
[2] Injector nozzle protective sleeve 81.96002-0522

S Plugging the injector nozzle
[3] Injector storage sleeve 09.81020-1000

S Storing the injectors
[4] End plug 81.96002-0520

S Plugging the cylinder head injector bore
[5] End plug 81.96002-0521

S Sealing the high-pressure line


S Sealing the connection of the high-pressure line pressure pipe (rail)
S Sealing the connection between the return line and the high pressure pump
S Plugging the pressure pipe socket

Common Rail system
[8] Shaft puller 80.99602-0011

S Removing the pressure pipe socket in conjunction with:
S Adapter [9]
[9] Adapter 80.99602-0173

S Removing the pressure pipe socket
[10] Extractor tool 80.99602-6015

S Pulling out the injector in conjunction with:
S Plate [11]
S Column [12]
S Column [13]
S Hex nut [14]
S Column [15]
[11] Plate 80.99602-0176
S Pulling out the injector
[12] Column 80.99602-0177

[13] Column 80.99602-0199

[14] Hex nut 06.11226-8306


Common Rail system
[15] Column 80.99602-0198

[16] Torque wrench 08.06510-9026

S Attaching the injector cable in conjunction with:
S Adapter [17]
S Size 7 socket [18]
[17] Adapter 08.06139-9029

S Attaching the injector cable
[18] Size 7 socket 08.06141-0700

S Attaching the injector cable
[19] Pressure shim 80.99606-0609

S Installing the injector
[20] Size 17 socket 80.99603-0309

S Installing and removing the high-pressure lines in conjunction with:
S Extension [22]
[21] Size 22 socket 80.99603-0378

S Removal/fitting of high-pressure lines in conjunction with:
S Extension [22]

Common Rail system
[22] Extension 08.06139-9025

S Removal/fitting of high-pressure lines
[23] Cap 81.96002-0518

S Plugging the fuel line connection
S Plugging the hollow screw connections

S Plugging the fuel line quick coupling

S Plugging the connections between the high-pressure line and the pressure
pipe
[26] Protective sleeve A9 81.96002-0516

S Plugging the fuel line

Common Rail system
Removing the injector
Detaching high-pressure lines cylinder 1-4
NOTE
The ingress of dirt can damage the common-rail
system.
For this reason:
S Close the component connections immediate-
ly using new, clean protective sleeves.
Tip for users

High-pressure lines can be replaced as a set or
individually.
► Mark the installation position of the pipe
clamps 1
► Unscrewing the mounting bolts of the pipe
clamps 1
► Removing the pipe clamps 1
► Mark the installation position of the
high-pressure lines 2
► Removing the high-pressure line 2 using
a socket wrench insert SW 17 [20], socket
wrench insert SW 22 [21] and an extension [22]
► Seal the high-pressure line 2 with an end plug

[5] and close the protective sleeve Z 12 x 16 [7]
► Seal the pressure bot with a protective sleeve Z
14 x 15 [6]
► Seal the pressure pipe with a protective sleeve
Z 18 x 15 [25] and A9 [26]
► Repeat this procedure for all of the
high-pressure lines
Tighten the pressure screw
► Unscrew the pressure screw 2 from

the pressure pipe socket 1
► Plug the pressure pipe socket 1 with protective
sleeve Z 14 x 15 [6]

Common Rail system
Removing the pressure pipe socket
► Pull the pressure pipe socket 2 out of the hole

using the extractor tool [8] 4 and the adapter
[9]
► Detach the O-ring 3
► Seal the cylinder head with an end plug [5] 1
Disconnect the electrical connection from the injector
► Unscrew the mounting nuts 1

► Remove the injector cable from the injector 4
► Detach the plug bracket 3
Unscrew the mounting bolts for the pressure flange

► Remove the spherical washer 2

Common Rail system
Assembling the special tool
► Attach the column [13] 5 along with the hex

nut [14] 7 to the plate [11] 6
► Attach the column [12] 3 along with the hex
nut [14] 2 to the plate [11] 6
► Insert column [12] 4 into column [15] 3
► Insert the extractor tool [10] 1 into the plate
[11] 6
Extracting the injector
NOTE
removal of the injector
The injector may be damaged.
For this reason:
S Before removing the injector always remove
the respective pressure pipe socket.
S Never detach more than one injector
at a time.
► Put on the special tool

► Insert the extractor tool [10] into the groove for
the pressure flange
► Clamp the clamping sleeve with the knurled
nut 1
► Extract the injector 3 from the cylinder head
by turning the knurled nut 2
► Remove the special tool

Common Rail system
Removing the injector
NOTE
Risk of material damage caused by wrong
removal or installation
Functional impairment due to incorrect installati-
on of injectors.
For this reason:
S Always allocate removed injectors to the
correct cylinders.
S Allocate new injectors to the correct cylinders
using MAN-cats®. For a description see EDC
system description.
► Mark the installation position of the injector 1

► Remove the injector 1 with the pressure
ٛ ange 2 and the gasket 5
► Close the injector feed bore with a cap [1] 3
► Pull the O-ring 6 off the injector 1
► Plug the injector nozzle with the protective
sleeve [2]
► Put the injector 1 into the injector storage
sleeve [3] immediately after removal
► Carefully clean the injector bore
► Plug the injector bore with the end plug [4] 4

Common Rail system
Installing the injector
Inserting the injector
NOTE
Risk of material damage
For this reason:
S Always allocate removed injectors to the
correct cylinders.
S Allocate new injectors to the correct cylinders
using MAN-cats®. For a description see EDC
system description.
► Check to ensure that the bore in the cylinder

head is clean
► Do not remove the injector 1 from the injector
storage sleeve [3] until immediately before
installation
► Remove the protective sleeves and end plugs
► Push the pressure flange 2 onto the injector
1 , ensuring that the fuel inlet opening is facing
towards the pressure pipe socket mounting
hole
► Insert the injector 1 into the cylinder head with
a new O-ring 4 and a new gasket 3 as
marked
► Press the injector 1 completely into the
cylinder head with the pressure shim [19]
Injector initial torque
► Screw in the mounting bolt 1 with spherical

washer 2
► Tighten the mounting bolt 1
Tightening torque
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Nm

Common Rail system
Installing the rail connection
NOTE
Risk of material damage if pressure pipe
socket is reused
Pressure pipe sockets are compressed during
installation in the cone.
For this reason:
S Do not reuse pressure pipe sockets once they
have been installed.
► Remove end plug [5] from cylinder head 1

► Apply a thin layer of clean diesel fuel to the
new O-ring 4 and fit it on the pressure pipe
socket 3
► Push the pressure pipe socket 3 into the bore
so that the balls on the pressure pipe socket 3
are located in the grooves in the cylinder head
► Screw the pressure screw 2 in and tighten it
Injector final torque
► Tighten the mounting bolts 1 to final torque

Tightening torque
Final tightening . . . . . . . . . . . . . . . . . . . . 25 Nm +90°

Common Rail system
Pressure screw final torque
► Tighten the pressure screw 1 to final torque

Tightening torque
Final tightening . . . . . . . . . . . . . . . . . . . . . 20 Nm 60°
Connect the electrical connection to the injector
NOTE
installation
Short circuit due to cable lugs touching.
For this reason:
S Cable lugs must not come into contact after
assembly.
► Attach the plug bracket 3

► Position the injector cable on the injector 4
► Screw the mounting nuts 1 on by hand
► Put the size 7 socket [18] onto the torque
wrench [16] with the adapter [17]
► Tighten the mounting nuts 1 to final torque
Tightening torque . . . . . . . . . . . . . . . . . . . . 1.5 Nm

Common Rail system
Attaching high-pressure lines cylinder 1-4
NOTE
Risk of material damage from improperly
aligned high-pressure lines
Incorrectly aligned high-pressure lines could
break while in operation.
For this reason:
S Check the alignment of the high-pressure
lines after the initial tightening, realign if
necessary.
NOTE
installation of the pipe clamps
For this reason:
S Always fit cable harness pipe clamps that
have been undone in their original positions.
S Tighten pipe clamps using the prescribed
torque.
► Remove the protective sleeves

► Install the high-pressure lines 2 on the
pressure pipe and pressure pipe socket as
marked
► When reusing, tighten the high-pressure lines
2 with socket wrench insert SW 22 [21] (on the
rail), socket wrench insert SW 17 [20] (on the
injector) and extension [22]
► Tighten new high pressure lines 2 with socket
wrench insert SW 22 [21] (on rail), socket
wrench insert SW 17 [20] (on the injector) and
extension [22]
► Attach the pipe clamps 1 as marked and
tighten by hand
► When reusing, tighten high-pressure lines 2
with socket wrench insert SW 22 [21] (on the
injector) and extension [22] with final tightening
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . 30°
► Tighten new high-pressure lines 2 with socket
wrench insert SW 22 [21] (on the rail), socket
extension [22] with final tightening
► Tighten the pipe clamp 1 mounting bolts
► Tighten the pipe clamps 1

Common Rail system
Removing/installing the rail (common rail)
Additional jobs
S Removing/installing the EDC control unit, see 308
S Remove/install cable harness, see 46
1 Rail pressure pipe 2 Injection lines
Technical data
Tightening torques
Mounting bolts for pressure pipe . . . . . . . . . . . . . . . . . . . . . M8x25-10.9 . . . . . . . . . . . . . . 1. tightening 1.5 Nm
Pressure pipe mounting bolts . . . . . . . . . . . . . . . . . . . . . . . M8x25-10.9 . . . . . . . . . . . . . . . Final torque 35 Nm
Rail pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Pressure-limiting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
Pipe clamp mounting bolt for the high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm

Common Rail system
CAUTION
For this reason:
depressurise the pressure pipe, or depressurisation must be checked by means of MAN-cats
(desired value 0).
NOTE
For this reason:
S Avoid moisture.
used once.
NOTE
For this reason:
S Never detach more than one fuel line at a time.
NOTE
For this reason:
Tip for users

on it.
ENVIRONMENTAL NOTE

Common Rail system
NOTE
For this reason:
S Carefully inspect the high-pressure lines for damage and deformation of the sealing cone before
re-installation.
NOTE
For this reason:

Common Rail system
Special tools
[1] End plug 81.96002-0521

[2] End plug 81.96002-0556

S Plugging the rail pressure sensor bore in the pressure pipe (rail)
S Plugging the pressure-limiting valve bore in the pressure pipe


S Plugging the return line connection for the high pressure pump
[5] Size 17 socket 80.99603-0309

S Extension [7]
[6] Size 22 socket 80.99603-0378

S Extension [7]
[7] Extension 08.06139-9025


Common Rail system


[10] Cap 81.96002-0518



pipe

S Plugging the fuel line
[13] Plug 81.96002-0680

S Plugging the pressure-limiting valve

Common Rail system
Removing the high-pressure lines and the pressure pipe
Removing the fuel line of the high pressure pump air air distributor pipe
ENVIRONMENTAL NOTE
tainer.
with the seals 1
► Pull off the fuel line 2 using the unlocking tool
insert Size1 [9] and unlocking tool handle [8]
► Sealing the fuel line 2 with a cap [10] and
protective sleeve Z 28 x 20 [11]
► Plug the screw-in connectors on the high
pressure pump 3 with protective sleeve
Z 14 x 15 [3]
► Sealing the air distributor pipe with a plug [1]
Removing the high pressure line of the high pressure pump pressure pipe
ENVIRONMENTAL NOTE
tainer.
► Remove the high pressure line 2 from the
pressure pipe 1 and the high pressure pump
3 using a size 17 socket wrench insert [5],
a size 22 socket [6] and an extension [7]
► Seal the high-pressure line 2 with protective
sleeve Z 12 x 16 [4] and end plugs [1]
► Sealing connections with protective sleeve
Z 18 x 15 [12] and protective sleeve
Z 14 x 15 [3]

Common Rail system
Detaching high-pressure lines cylinder 1-4
NOTE
The ingress of dirt can damage the common-rail
system.
For this reason:
S Never detach more than one fuel line at
a time.
S Close the component connections immediate-
ly using new, clean protective sleeves.
► Mark the installation position of the pipe

clamps 1
► Unscrewing the mounting bolts of the pipe
clamps 1
► Removing the pipe clamps 1
high-pressure lines 2
► Detach the high-pressure line 2 using a size
17 socket wrench insert [5], a size 22 socket
wrench insert [6] and an extension [7]
► Seal the high-pressure line 2 with an end plug
[1] and close the protective sleeve Z 12 x 16 [4]
► Seal the pressure bot with a protective sleeve
Z 14 x 15 [3]
► Seal the pressure pipe with a protective sleeve
Z 18 x 15 [12] and A9 [13]
► Repeat this procedure for all of the
high-pressure lines
Disconnecting the pressure pipe electrical connection
► Disconnecting the rail pressure sensor 2

electrical connection 1

Common Rail system
Detaching the pressure pipe

► Detaching the pressure pipe 1 from the
air distributor pipe

Common Rail system
Removing the rail pressure sensor and pressure-limiting valve
NOTE
Risk of material damage due to lack
of lubricant
Components are damaged by a lack of
lubricant.
For this reason:
S Do not clean the pressure-limiting valve and
rail pressure sensor as the thread and biting
edge are coated with lubricant.
► Unscrew the pressure-limiting valve 3

► Unscrew the rail pressure sensor 1
► Seal the pressure pipe 2 with an end plug [2]
► Sealing the pressure-limiting valve 3 with an
end plug [13]
► Sealing the rail pressure sensor 1 with

Common Rail system
Installing the high-pressure lines and the pressure pipe
Installing the rail pressure sensor and pressure-limiting valve
NOTE
Risk of material damage due to lack of
lubricant
Components are damaged by a lack of
lubricant.
For this reason:
S Do not clean the pressure-limiting valve and
rail pressure sensor as the thread and biting
edge are coated with lubricant.
► Removing the protective sleeves from the rail

pressure sensor 1 , the pressure-limiting valve
3 and the end plug from the pressure pipe 2
► Screwing the rail pressure sensor 1 into the
pressure pipe 2 and tightening it
► Screwing the pressure-limiting valve 3 into the
pressure pipe and tightening it
Tightening torque . . . . . . . . . . . . . . . . . . . 100 Nm
Mounting the pressure pipe
► Position the pressure pipe 1 on the intake pipe

Tightening torque
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Nm
Final tightening . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm

Common Rail system
Connecting the pressure pipe electrical connection

rail pressure sensor 2
Attaching high-pressure lines cylinder 1-4
NOTE
For this reason:
necessary.
► Install the high-pressure lines 2 on the
pressure pipe and pressure pipe socket as
marked
► When reusing, tighten the high-pressure lines
2 with socket wrench insert SW 22 [6] (on the
injector) and extension [7]
► Tighten new high pressure lines 2 with socket
wrench insert SW 22 [6] (on rail), socket
extension [7]
► Position pipe clamps 1 as marked
► Screw in and tighten the mounting bolts of the
pipe clamps 1
► When reusing, tighten high-pressure lines 2
with socket wrench insert SW 22 [6] (on the
injector) and extension [7] with final tightening
► Tighten new high-pressure lines 2 with socket
wrench insert SW 22 [6] (on the rail), socket
extension [7] with final tightening

Common Rail system
Attaching the fuel line of the high pressure pump air air distributor pipe
► Removing the protective sleeves and end plugs

from the fuel line 2 and high pressure pump 3
and air distributor pipe
► Screw the hollow screw 4 in with new seals 1
and tighten it by hand
necessary, using unlocking tool insert Size1
[9] and unlocking tool handle [8] to remove
and refit
Installing the high pressure pipe of the high pressure pump pressure pipe
NOTE
For this reason:
necessary.

► Installing the high pressure line 2 on the
pressure pipe 1 and the high pressure
pump 3
► Tightening the new high-pressure line 2 with
socket wrench insert SW 22 [6], socket wrench
insert SW 17 [5] and extension [7]
Tightening torque
1st tightening . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Final tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
► When reusing, tightening the new high-pressure
line 2 with socket wrench insert SW 22 [6],
socket wrench insert SW 17 [5] and extension
[7]
Tightening torque
1st tightening . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

Common Rail system
Removing/installing the high pressure pump
Additional jobs
1 High-pressure line 2 High-pressure pump
Technical data
Tightening torques
Mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Nm
Mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
High-pressure line (initial use) . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . 1st tightening 10 Nm
High-pressure line (initial use) . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . Final tightening 60°
Unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm

Common Rail system
CAUTION
For this reason:
depressurise the pressure pipe, or depressurisation must be checked by means of MAN-cats (desired
value 0).
NOTE
For this reason:
S Avoid moisture.
used once.
NOTE
For this reason:
NOTE
For this reason:
Tip for users

on it.
ENVIRONMENTAL NOTE

Common Rail system
NOTE
For this reason:
S Carefully inspect the high-pressure lines for damage and deformation of the sealing cone before re-
installation.
NOTE
For this reason:

Common Rail system
Special tools

[2] End plug 81.96002-0521

[3] Cap 81.96002-0518


S Plugging the return line connection for the high pressure pump


pipe
[7] Size 17 socket 80.99603-0309

S Extension [9]

Common Rail system
[8] Size 22 socket 80.99603-0378

S Extension [9]
[9] Extension 08.06139-9025

[10] Release handle 80.99606-0597


[12] Three-arm puller 08.99605-9014

S Pulling off the high pressure pump drive wheel
[13] End plug 81.96002-0519

S Plugging the fuel line connections

Common Rail system
Removing the high pressure pump
Detach the fuel line
ENVIRONMENTAL NOTE
Collect any fuel that escapes in a suitable
container.
with the seals 1
insert Size 1 [11] and unlocking tool handle [10]
► Plug the fuel line 3 with protective sleeve
Z 28 x 20 [5] and cap [3]
► Detach the fuel line 3
► Plug the connections with protective sleeve
Z12 x 16 [4] and end plugs [13]
Removing fuel lines
ENVIRONMENTAL NOTE
container.
Z 28 x 20 [5]
Z 12 x 16 [4]
Removing fuel lines
ENVIRONMENTAL NOTE
container.
with the seals 2
Z 28 x 20 [5] and cap [3]

Common Rail system
Removing the fuel lines from the high pressure pump air air distributor pipe
ENVIRONMENTAL NOTE
tainer.
with the seals 1
► Sealing the fuel line 2 with a cap [3] and
► Plug the screw-in connectors on the high
pressure pump 3 with protective sleeve
Z 12 x 16 [4]
► Sealing the air distributor pipe with a plug [2]
Disconnecting the electrical connection to the proportional valve
Removing the high pressure line from the high pressure pump pressure pipe
ENVIRONMENTAL NOTE
tainer.
► Remove the high pressure line 2 from the
pressure pipe 1 and the high pressure pump
3 using a size 17 socket wrench insert [7],
a size 22 socket [8] and extension [9].
► Seal the high-pressure line 2 with protective
sleeve Z 12 x 16 [4] and end plugs [2]
► Sealing connections with protective
sleeve Z 18 x 15 [6] and protective sleeve
Z 12 x 16 [4]

Common Rail system
Detaching unions
► Unscrewing the union 1 and removing it with

the seals 2
Detaching the high pressure pump
Tip for users

When replacing the high pressure pump, rebuild
the high pressure pump drive wheel.
► Unscrewing the mounting nut 4 with washer 3
► Unscrewing the stud bolt 1
► Removing the high pressure pump 2 from the
timing case

Common Rail system
Rebuilding the drive wheel high-pressure pump
Unscrewing the high pressure pump drive wheel mounting nut
► Clean the high pressure pump 4 and blow it

dry using compressed air
► Counterhold the high pressure pump drive
wheel
► Remove the washer 2 along with the O-ring 3
Removing the high-pressure pump drive wheel
► Pull the drive wheel 2 off using the three arm

puller [12] 1

Common Rail system
Attaching the high pressure pump drive wheel
NOTE
cleaning agent
For this reason:
S Only use test benzene, spirits, glycol alcohol
or isopropanol to clean the cone
► Degrease the cone in the drive wheel and on
the high pressure pump 4
► Positioning the drive wheel on the high
pressure pump cone
► Attaching disc 2 and new seal 3 to high
pressure pump 4
wheel
Installing the high-pressure pump
Installing the high-pressure pump
► Screw in the stud bolt 1

► Insert high pressure pump 2 into the timing
case
disc 3

Common Rail system
Installing unions

► Screwing in union 1 with new seals 2 and
tightening
Installing the high pressure pipe of the high pressure pump pressure pipe
NOTE
For this reason:
necessary.

► Installing the high pressure line 2 on the
pressure pipe 1 and the high pressure
pump 3
► Tightening the new high-pressure line 2 with
socket wrench insert SW 22 [8], socket wrench
insert SW 17 [7] and extension [9]
Tightening torque
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
► When reusing, tightening the new high-pressure
line 2 with socket wrench insert SW 22 [8],
socket wrench insert SW 17 [7] and
extension [9]
Tightening torque
1st tightening . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

Common Rail system
Connecting the electrical connection to the proportional valve
Attaching fuel line to high pressure pump air air distributor pipe
► Removing the protective sleeves and end plugs

from the fuel line 2 and high pressure pump 3
and air distributor pipe
► Install the fuel line 2
► Screw the hollow screw 4 in with new seals
and tighten it 1 by hand
and refit
► Removing protective sleeve Z 12 x 16 [4],

protective sleeve Z 28 x 20 [5] and end
plug [13]
► Screwing in the hollow screw 1 with
new seals 2
and refit
and 5

Common Rail system
► Remove protective sleeve Z 12 x 16 [4]

protective sleeve Z 28 x 20 [5] and the caps [3]
and refit
and then tighten
Attach the fuel line
► Remove protective sleeve Z 12 x 16 [4] and

► Attach the fuel line 1
and refit

Common Rail system
Dismantling/assembling the high-pressure pump
Additional jobs
S Remove/install the high pressure pump, see 259
1 High-pressure pump 3 Fuel supply pump

2 Metering unit 4 Drive wheel
Technical data
Tightening torques
High pressure pump mounting bolt . . . . . . . . . . . . . . . . . . . M8x40-8.8. . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
High pressure pump mounting nut . . . . . . . . . . . . . . . . . . . M8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Mounting bolt for drive wheel of high pressure pump . . . M18x1.5-8.8. . . . . . . . . . . . . . . . . . . . . . . . . 105 Nm
Proportional valve mounting bolt . . . . . . . . . . . . . . . . . . . . . M5x20-10.9 . . . . . . . . . . . . . . . 1st tightening 4 Nm
Proportional valve mounting bolt . . . . . . . . . . . . . . . . . . . . . M5x20-10.9 . . . . . . . Final tightening torque 7 Nm
Fuel supply pump mounting bolt . . . . . . . . . . . . . . . . . . . . . M6x1.5x36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nm
Swivelling fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Adapter fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm

Common Rail system
CAUTION
For this reason:
depressurise the pressure pipe, or depressurisation must be checked by means of MAN-cats
(desired value 0).
NOTE
For this reason:
S Avoid moisture.
used once.
NOTE
For this reason:
NOTE
For this reason:
Tip for users

on it.
ENVIRONMENTAL NOTE

Common Rail system
Special tools

S Pulling off the high pressure pump drive wheel

Common Rail system
Dismantling the high-pressure pump
Unscrewing the high pressure pump drive wheel mounting nut
► Clean the high pressure pump 4 and blow it

dry using compressed air
wheel 4
► Remove the washer 2 along with the O-ring 3
Removing the high-pressure pump drive wheel
► Pull the drive wheel 2 off using the three arm

puller [1] 1
Removing the fuel supply pump

► Pull out the fuel supply pump 1
► Removing the O-rings 3 and 4 from the fuel
supply pump 1

Common Rail system
Removing the proportional valve
► Marking the installation position of the

proportional valve 2
► Pulling out the proportional valve 2 with
a slight turn to the right/left
Assembling the high pressure pump
Removing the proportional valve
Tip for users

When using micro-encapsulated bolts, the time
span between the tightening stages must not be
longer than 2 minutes.
► Inserting the new proportional valve 2 in the

high pressure pump with a slight turn to the
right/left
► Align the proportional valve 2 as marked
Tightening torque
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nm
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Nm
Removing the fuel supply pump
► Inserting new O-rings 3 and 4 into the fuel

supply pump 1
► Position the fuel supply pump 1

Common Rail system
Attaching the high-pressure pump drive wheel
NOTE
cleaning agent
For this reason:
S Only used white spirit, denatured alcohol,
ethylene glycol or isopropyl alcohol to clean
the cone.
► Degrease the cone in the drive wheel and

on the high pressure pump 4
► Positioning the drive wheel on the high
pressure pump cone 4
► Attaching disc 2 and new seal 3 to high
pressure pump 4
wheel

Common Rail system
Removing/installing the fuel service centre
1 Fuel service centre
Technical data
Tightening torques
Hollow screw of fuel line . . . . . . . . . . . . . . . . . . . . . . . . . . . M10x1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
NOTE
For this reason:

Common Rail system
NOTE
For this reason:
Tip for users

on it.
ENVIRONMENTAL NOTE
Special tools



[4] End plug 81.96002-0521

[5] Cap 81.96002-0518


Common Rail system

S Plugging the quick-release couplings
[7] End plug 81.96002-0519


S Plugging the fitting for the quick coupling


Common Rail system
Removing the fuel service center
► Disconnect the electrical connection 1 and 2

from the KSC
ENVIRONMENTAL NOTE
tainer.
with the seals 1
insert Size 1 [2] and unlocking tool handle [1]
Z 28 x 20 [6] and cap [5]
ENVIRONMENTAL NOTE
tainer.
Z 28 x 20 [6]
Z 12 x 16 [8]

Common Rail system
ENVIRONMENTAL NOTE
tainer.
with the seals 2
► Pull the fuel line 3 off using the size 1
unlocking tool insert [2] and unlocking tool
handle [1]
Z 28 x 20 [6] and cap [5]
ENVIRONMENTAL NOTE
tainer.
along with the seals 2 and 5
pliers [3]
Z 12 x 16 [8] and cap [5]
► Plug the pressure pipe connection with
► Sealing the KSC connection with protective
sleeve 12 x 16 [8]
ENVIRONMENTAL NOTE
tainer.
along with mounting nut 5
with the seals 1
► Pull the fuel line 4 off using the size 1
unlocking tool insert [2] and unlocking tool
handle [1]
Z 28 x 20 [6] and cap [5]

Common Rail system
ENVIRONMENTAL NOTE
tainer.
with the seals 1
Z 28 x 20 [6] and cap [5]
► Close the connections with the end plugs [4]
ENVIRONMENTAL NOTE
tainer.
with the seals 5
with the seals 3
► Plug the fuel line 2 with the caps [5]
Detaching the proportional valve

► Sealing the fuel line union nut 3 with protective
cap Z 12 x 16 [8]
► Removing the proportional valve 2
Z 12 x 16 [8]

Common Rail system
Detaching the fuel service centre

► Removing KSC 1 with bracket 2
Remove the bracket


Common Rail system
Installing the fuel service center
and tighten
► Positioning KSC 1 with bracket 2

Attaching the proportional valve

and tighten
► Positioning fuel line and screwing on
and tightening the union nut 3

Common Rail system
► Remove end plug [4] and cap [5]

and then tighten
and then tighten

and then tighten

and protective sleeve Z 28 x 20 [6]
and then tighten

Common Rail system
► Removing caps [5], protective sleeve Z 8 x 22

[6] and protective sleeve 12 x 16 [8]
and 5 and tighten
► Attach the hose clamp 1 using the hose clamp
pliers [3]
► Remove protective sleeve Z 28 x 20 [6],

the cap [5] and the end plug [4]
refit
and then tighten
tighten
► Remove protective sleeve Z 12 x 16 [8] and

refit

Common Rail system

protective sleeve Z 28 x 20 [6] and the caps [5]
refit
and then tighten
► Connect the electrical connections 1 and 2

Common Rail system

Common Rail system
Dismantling/assembling the fuel service center

S Removing/installing the fuel service centre, see 278
1 Housing 9 Mounting bolt

2 Fuel filter 10 Cover
3 Cover 11 Fuel pre-filter
4 O-ring 12 O-ring
5 Pressure sensor 13 Housing
6 Water drain plug 14 Hand pump
7 O-ring 15 Mounting bolts
8 Heater element
Tightening torques
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Water drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Nm
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
Service products
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Maintenance and Service Product Regulations

Common Rail system
NOTE
For this reason:
S Run fuel service centre dry before changing the fuel filter
S Use filters intended and marked for common rail systems
S Used filter elements may not be reused
NOTE
For this reason:
ENVIRONMENTAL NOTE
Special tools
[1] Size 36 socket wrench 80.99603-0325

S Removing/installing fuel filter cover
[2] Size 19 socket 08.06141-9061

S Removing/installing fuel pre-filter cover

Common Rail system
Dismantling the fuel service center
Allowing the fuel service centre to empty
ENVIRONMENTAL NOTE
tainer.
► Open the water drain plug 2 and allow the fuel

service centre to empty
► Screw in the water drain plug 2 and tighten
► Undo the cover 1 using a size 36 socket [1]
with approx 2 to 3 revolutions
Removing the heating element

► Pull the heating element 2 out of the
FSC 1 with O-ring 4
► Unscrew pressure sensor 1 with seal 2

Common Rail system
► Unscrew the cover 1 using a size 36 socket [1]

► Pull the cover 1 out of the FSC housing with
the fuel filter 7
► Pull fuel filter element 7 out of the cover 1
► Remove the O-ring 2
► Unscrew the cover 3 using a size 19 socket
insert [2]
► Pull the fuel pre-filter 4 out of the hand pump
housing 6
Removing the hand pump housing
► Unscrew the mounting bolts 1 from the

KSC housing 3
► Remove the hand pump housing 2
Remove support dome
► Remove the support dome 2 with the O-ring 1

Common Rail system
Assembling the fuel service center
Installing the support dome
► Install the support dome 2 with a new

O-ring 1
Mounting the hand pump housing
► Position the hand pump housing 2 on the

FSC housing 3
Installing the fuel filter
► Apply a thin layer of clean fuel to the new

O-ring 5
► Fit the O-ring 5 on the hand pump housing 6
► Insert a new fuel pre-filter 4
► Screw the cover 3 on and tighten by hand
► Insert the new fuel filter 7 into the cover 1
► Apply a thin layer of clean fuel to the new
O-ring 2
► Screw the cover 1 in with the O-ring 2 and
tighten by hand

Common Rail system
Tightening the fuel pre-filter cover
► Tighten the fuel pre-filter cover using the socket

wrench size 19 [2]
Tightening the fuel filter cover
► Tighten the fuel filter cover using the socket

wrench size 36 [1]
► Screw in the pressure sensor 1 with

a new seal 2
► Tighten the pressure sensor 1

Common Rail system
Installing the heater element
► Insert the heating element 2 into the FSC 1

with a new O-ring 4

Common Rail system

Common Rail system
Removing/installing the flame-start system
1 Solenoid valve 3 Flame glow plug

2 Relays
Technical data
Tightening torques
Fuel line union nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Mounting nut for cable lug . . . . . . . . . . . . . . . . . . . . . . . . . . M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
Hollow screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10x1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Service products
Curil T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04.90300-9030

Common Rail system
NOTE
For this reason:
NOTE
For this reason:
Tip for users

on it.
ENVIRONMENTAL NOTE
Special tools

S Seal the flame glow plug return line

S Plugging the flame-start system fuel line
[3] End plug 81.96002-0521

S Sealing the solenoid valve

Common Rail system
[4] Cap 81.96002-0517

S Plugging the flame glow plug - solenoid valve fuel line
[5] Cap 81.96002-0518


Common Rail system
Removing the flame-start system
ENVIRONMENTAL NOTE
tainer.
with the seals 5
with the seals 3
► Plug the fuel line 2 with the caps [5]
Removing fuel lines
ENVIRONMENTAL NOTE
tainer.
► Unscrewing the hollow screw 1 and removing
it with the seals 2
► Remove the fuel line 3
► Sealing the fuel line 3 with protective cap A9
[2] and cover caps [4]
► Plug the flame glow plug connection with
► Sealing the solenoid valve with an end plug [3]

Common Rail system

► Remove the solenoid valve 2
Removing the flame glow plug
► Marking the installation position of the flame

glow plug 3
► Removing the cable lug 2
► Loosening the locknut of the flame glow plug 3
► Unscrewing the flame glow plug 3

relay 1

Common Rail system
Detach the relay

► Removing the relay 2

Common Rail system
Installing the flame-start system
Install the relay
► Positioning the relay 2


relay 1
Attaching the flame glow plug
► Apply a thin layer of Curil T sealing agent to the

thread of the flame glow plug 3
► Screw in the flame glow plug 3 and align as
marked
► Counterhold the flame glow plug 3 and tighten
the mounting nut
► Positioning the cable lug 2

Common Rail system
► Attach the solenoid valve 2

► Removing the protective cap Z 10 x 10 [1],

protective cap A9 [2] and caps [4]
► Screwing in the hollow screw 1 with new
seals 2
► Fitting and tightening the fuel line union nut 3

► Screwing in the hollow screw 1 with new
seals 5
and then tighten

Common Rail system

Common Rail system

Common Rail system
Removing/installing the electronic diesel control (EDC) control unit
1 Engine control unit
Technical data
Tightening torques
ME7 control unit mounting bolts . . . . . . . . . . . . . . . . . . . . . M6x30-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm
Console mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x40-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Nm
NOTE
For this reason:
Tip for users

After installation of the engine, the ME7 control unit needs to be reconfigured and the diagnostic
memory cleared.

Common Rail system
CAUTION
For this reason:
NOTE
For this reason:
Tip for users

chafing.
Special tools


Common Rail system
Removing engine control unit
Disconnecting the ME7 control unit electrical connections
► Fully releasing the plug 1 , 2 and 3 removing

it from the EDC control unit 4
► Free the wiring harnesses
Remove the bracket

► Remove the brackets 2 and 4
Detaching the ME7 control unit

► Remove the ME7 control unit 1 from the
bracket 3

Common Rail system
Removing the ME7 control unit bracket

► Remove the console 4 with the rubber
bearings 1 and 2
Installing the ME7 control unit
Mounting the ME7 control unit bracket
► Position the console 4 with the rubber

bearings 1 and 2

Common Rail system
Mounting the ME7 control unit
► Position the ME7 control unit 1 on the

bracket 3
► Screw the mounting bolts 2 in and tighten by
hand
► Position the brackets 2 and 4

► Screwing in and hand-tightening mounting
bolts 1 and 3
Tightening sequence for ME7 control unit
► Tightening the mounting bolts of ME7 control

unit in the tightening sequence

Common Rail system
Connecting the ME7 control unit electrical connections
NOTE
locking
Irreparable damage to the engine control unit
For this reason:
S When installing the plugs, first open the plug
lock completely and then insert and lock the
plug connector.
► Insert the plugs 1 , 2 und 3 in the ME7

control unit 4 and lock it
► Route the cable harnesses and secure using
cable ties
tie pliers [1]

Turbocharging
Turbocharging
1 Intercooler charge-air pipe 5 Charge-air pipe

2 Charge-air manifold 6 Intercooler ND
3 Charge-air throttle valve 7 Charge-air pipe
4 Charge-air pipe 8 Turbo charger

Turbocharging

Turbocharging
Removing/installing the charge-air pipe for the turbo charger / intercooler

Version 68
1 Charge-air pipe
Technical data
Tightening torques
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
Service products
Technical vaseline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09.15014.0001

Turbocharging
NOTE
For this reason:

Turbocharging
Removing the charge-air pipe
Remove the charge-air pipe
► Mark the installation position of the charge-air

pipe 4
► Remove the profiled clamp 1
► Remove the charge-air pipe 4 along with the
O-ring 2
Installing the charge-air pipe
Attaching the charge-air pipe
► Coating the new O-ring 2 with technical

vaseline
► Positioning the charge-air pipe 4 with its new
O-ring 2 as marked
► Fitting the profiled clamp 1 and
hand-tightening it
► Tighten the profiled clamp 1

Turbocharging

Turbocharging
Removing/installing the intercooler charge-air pipe / turbo charger (HD)
1 Intercooler charge-air pipe
Service products

Turbocharging
NOTE
For this reason:

Turbocharging
Removing the intercooler charge-air pipe
Detaching the intercooler charge-air pipe
► Unscrewing mounting bolts 1 and 2

► Removing the intercooler charge-air pipe 4
► Pulling out the coupling pipe 3
Installing the intercooler charge-air pipe
Attaching the intercooler charge-air pipe
► Coating the coupling pipe 3 with technical

vaseline
► Inserting the coupling pipe 3 into the
intercooler
► Positioning the intercooler charge-air pipe 4
bolt 1 and 2

Turbocharging

Turbocharging
Removing/installing the intercooler (low-pressure)
1 Low-pressure intercooler
NOTE
For this reason:
ENVIRONMENTAL NOTE
Collect any coolant that emerges in a suitable container.

Turbocharging
Removing the intercooler (low-pressure)
Removing the low-pressure intercooler
ENVIRONMENTAL NOTE
Using a suitable container to collect any coolant
that emerges.
► Removing the intercooler 5
► Remove the O-rings 2
► Pull the coupling pipes 1 and 3 out
of the intercooler 5

Turbocharging
Installing the intercooler (low-pressure)
Installing the low-pressure intercooler
► Coating new coupling pipes 1 and 3 with

technical vaseline
► Inserting new coupling pipes 1 and 3 into
the intercooler 5
► Insert new O-rings 2
► Positioning the intercooler 5 via new coupling
pipes 1 and 3

Turbocharging

Turbocharging
Removing/installing the charge-air pipe of the intercooler turbo charger

(low pressure)
1 Intercooler charge-air pipe
Technical data
Tightening torques
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
Service products

Turbocharging
NOTE
For this reason:

Turbocharging
Removing the intercooler charge-air pipe
Detaching the intercooler charge-air pipe
► Detaching the profiled clamp 3 and pushing it

onto the intercooler charge-air pipe 1
► Turning the intercooler charge-air pipe 1 into
the removal position
► Removing the intercooler charge-air pipe 1
with O-ring 2 and profiled clamp 3
► Pulling out the coupling pipe 4
Installing the intercooler charge-air pipe
Attaching the intercooler charge-air pipe
► Coating a new O-ring 1 and coupling pipe 2

with technical vaseline
► Inserting the coupling pipe 2 into the
intercooler
► Positioning the charge-air pipe 3 with its new
O-ring 1 and profiled clamp 4 and turning it to
the installation position
► Attaching and tightening the profiled clamp 4

Turbocharging

Turbocharging
Removing/installing the charge-air pipe for the turbo charger / intercooler

Variants 66, 67
1 Charge-air manifold 3 Hose

2 Charge-air pipe
Technical data
Tightening torques
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
Service products

Turbocharging
NOTE
For this reason:

Turbocharging
Removing the charge-air pipe
Remove the charge-air pipe
► Loosen the hose clamp 1

the bush
the bush with its washers and insulation
washers
► Removing the charge-air pipe 2
Removing the charge-air manifold
► Marking the installation position of the profiled

clamp 1
► Loosening the profiled clamp 1
► Removing the charge-air manifold 3 with
O-ring 2
Dismantling the charge-air pipe

► Detaching the hose 1
► Unscrew the screw plug 3 and the seal 4

Turbocharging
Installing the charge-air pipe
Assembling the charge-air pipe
► Screwing in and tightening the screw plug 3

with its seal 4
► Pushing the hose 1 onto the charge-air pipe
► Tighten the hose clamp 2
Mounting the charge-air manifold
► Thinly coating a new O-ring 2 with technical

vaseline
► Positioning the charge-air manifold 3 with its
new O-ring 2 as marked
► Installing and hand-tightening the profiled
clamp 1
Attaching the charge-air pipe
► Positioning the charge-air pipe 2 with its hose

clamp 1
► Screwing in and hand-tightening the mounting
bolt 4 with bush
bolt 3 with its bushes, washers and insulation
washers

Turbocharging
Tightening the charge-air manifold


Turbocharging

Turbocharging
Removing/installing the exhaust turbocharger module/exhaust module
Additional jobs
S Remove/install the engine brake, see 392
S Removing/installing the intercooler charge-air pipe (low pressure), see 328
S Remove/install the exhaust manifold HCI, see 374
1 Oil feed line 3 Oil feed line

2 Heat shield 4 Turbo charger
Service products
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Maintenance and service product regulations
Assembly paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09.16012-0117

Turbocharging
NOTE
For this reason:
Tip for users

The actual charging pressure and opening pressure of the wastegate valve can only be interrogated
using the EDC electronic control unit. If the specified values are not achieved the turbo charger must
be exchanged.
If the waste gate valve is defective, the turbo charger must be exchanged.
Special tools



Turbocharging
Removing the turbo charger
Removing the heat shield
► Unscrewing the mounting bolts 1 , 3 and 4

with washers
► Remove the heat shield 2
Detaching the hose
► Loosening the spring band clamp 2 with hose

clamp pliers for spring band clamps [2]
► Pulling off the moulded hose 1
Removing the intake fitting
► Mark the installation position of the intake

fitting 1
► Pull the intake fitting 1 with its hose clamp 2

Turbocharging
Detaching the oil feed line
ENVIRONMENTAL NOTE
Collect emerging engine oil using a suitable
container.
► Unscrewing the union nuts 1 and 3 from
the oil intake pipes 2 and 4
► Detaching the oil intake pipe 2 and 4
with seals

Turbocharging
Removing the high-pressure turbo charger oil return line

► Unscrew the mounting bolts 2 and remove
together with the washers
► Unscrew the union nut 5
► Removing the oil return line 4 with seal 1 and
sealing ring 6
Removing the low-pressure turbo charger oil return line

► Removing the oil return line 8 with seal 9
and sealing ring 5
► Unscrew the union 1
► Remove the ring union 3 along with the seals
2 and 4 remove

Turbocharging
Detaching the wastegate hose

pliers [1]
► Pulling the hose 2 off the wastegate socket
Remove the bracket
► Unscrewing the mounting bolts 2 and 3 with

washer 4
Detaching the turbocharger
CAUTION
Due to the relatively heavy weight of the ex-
haust turbocharger there is a risk of injury or
health and safety hazards.
For this reason:
S Remove the exhaust turbocharger with
assistance.
► Unscrew the mounting nuts 1

► Removing the turbo charger 2

Turbocharging
Installing the turbocharger
Mounting the turbocharger
CAUTION
For this reason:
S Attaching the turbo charger with support.
► Positioning the turbo charger 2

► Screw on and tighten the mounting nuts 1
2 and 3 with washer 4
Attaching the wastegate hose
► Pushing the hose 2 onto the wastegate socket

pliers [1]

Turbocharging
Attaching the low-pressure turbo charger oil return line
► Positioning the ring union 3 with a new seal 2

and 4 position it
► Screw in the union 1
► Apply a thin layer of assembly paste 6 to the
oil return line 9 , as illustrated
► Insert the new seal 5 into the union nut 7
► Position the oil return line 9
► Screwing on the union nut 7 of the oil return
line 9 until it is hand-tight
washers
► Tightening the union nut of the oil return line 3
► Tightening the union 1
Attaching the oil return line

► Insert the new seal 7 into the union nut 5 on
the oil return line 2
► Position the oil return line 2 with the seal 1
► Screwing on the union nut of the oil return line
5 until it is hand-tight
washers
► Bracing the union
► Tightening the union nut 5 of the oil return
line 2

Turbocharging
Filling the turbo charger with oil
NOTE
handling of the exhaust turbocharger
If it is not filled with oil, the turbocharger will be
damaged when started for the first time.
For this reason:
S Fill the turbo charger with clean engine oil
before the oil pressure lines are attached.
► Filling clean engine oil into the oil inlet nozzles

1 on 2 the turbo charger with a funnel, until
the oil duct in the turbocharger has been filled
Attaching the oil feed lines
► Positioning the oil feed lines 2 and 4

► Positioning the hollow screw 5 with seals and
ring unions
► Screwing in 5 and hand-tightening the hollow
screw
► Screwing on and tightening the union
nuts 1 , 3 and 2 on the oil pressure
line 4 and

Turbocharging
Attach the intake fitting
► Positioning the intake fitting 1 with hose

clamp 2 as marked
Attaching the hose
► Positioning the moulded hose 1 with spring

band clamp 2
► Installing the spring band clamp 2 with hose
Attaching the heat shield
► Position the heat shield 2

1 , 3 and 4 with washers

Turbocharging
Removing/installing the turbo charger

Variants 66, 67
Additional jobs
S Removing/installing the charge-air pipe variants 66, 67, see 332
1 Turbo charger
Service products

Turbocharging
NOTE
For this reason:
Tip for users

The actual charging pressure and opening pressure of the wastegate valve can only be interrogated
using the EDC electronic control unit. If the specified values are not achieved the turbo charger must
be exchanged.
If the waste gate valve is defective, the turbo charger must be exchanged.
Special tools


Turbocharging
Removing the turbo charger
Detaching the wastegate hose
► Undo the hose clamps 2 using the hose

clamp pliers [1]
► Pulling the hose 1 off the wastegate socket
Removing the intake fitting
► Mark the installation position of the intake

fitting 3
pliers [1]
► Pull the intake fitting 3 with its hose clamp 2
Detaching the intake line

the mounting nut 1
pliers [1]
► Pulling off the intake line 2

Turbocharging
Remove the bracket

bracket 1
► Unscrew the mounting bolt 3 with washer 2

Detaching the oil feed line
ENVIRONMENTAL NOTE
container.
► Unscrewing union nuts 1 and 2
► Detaching the oil intake line 3

Turbocharging
Detaching the swivelling fitting
► Unscrewing the swivelling fittings 1 from

the transition joint 2
Detaching the oil return line
ENVIRONMENTAL NOTE
container.
the bush 3
► Removing the oil return line 2 with seals 4
and 1

Turbocharging
Detaching the turbocharger
CAUTION
For this reason:
S Remove the exhaust turbocharger with
assistance.

bolts 1
► Unscrew mounting bolts 1 and 2
► Removing the turbo charger 3

Turbocharging
Installing the turbocharger
Mounting the turbocharger
CAUTION
For this reason:
S Attaching the turbo charger with support.
► Positioning the turbo charger 3

► Screw in and tighten the mounting
bolts 1 and 2 as marked

Turbocharging
► Positioning the oil return line 2 with

new seals 1 and 4
bolts 7 with washers 8
► Screw in the mounting bolts 5 and tighten
them by hand
bolt 6 with bush 3
► Tightening the mounting bolts 5 and 7
Filling the turbo charger with oil
NOTE
Risk of property damage due to incorrect
handling of the turbocharger
If it is not filled with oil, the turbocharger will be
damaged when started for the first time.
For this reason:
S Fill the turbo charger with clean engine oil
before the oil pressure lines are attached.
► Filling clean engine oil 1 into the oil inlet

nozzles 3 on the turbo charger 2 with
a funnel, until the oil duct in the turbocharger
has been filled

Turbocharging
Attaching the swivelling fitting
► Screwing the swivelling fittings 1 into

the transition joint 2
Attaching the oil feed lines
► Positioning the oil intake line 3

► Screw on and tighten the mounting
nuts 1 and 2
Installing the heat shield

► Screw the mounting bolts 1 in with
the washers 2 and tighten

Turbocharging
► Positioning the bracket 1 as marked

► Screw the mounting bolt 3 with washer
2 and tighten
Attaching the intake line
► Pushing the intake line 2 with its hose clamp

3 onto the air compressor fitting
► Attach the hose clamp 3 using hose clamp
pliers [1]
Attach the intake fitting
► Positioning the intake fitting 3 with hose

clamps 2 and and hose clamp 1 as marked
pliers [1]

Turbocharging
Attaching the wastegate hose
► Pulling the hose 1 off the wastegate

► Attach the hose clamps 2 using hose clamp
pliers [1]

Turbocharging

Turbocharging
Removing/installing the charge-air manifold with EGR connection
Additional jobs
S Remove/install the flame-start system, see 298
S Remove/install the charge-air pipe with throttle valve, see 366
1 Charge-air manifold
Technical data
Tightening torques
Service products

Turbocharging
NOTE
For this reason:

Turbocharging
Removing the charge air manifold with EGR connection
Disconnect the electrical connection
► Disconnecting electrical connections 1 and 2

► Pull the temperature sensor 1 out
Removing the Visco fan EGR pressure sensor

► Pulling out the pressure sensor 1

Turbocharging
Removing the charge-air manifold with EGR connection

► Remove the charge-air manifold 3 along with
the seal 2 and the O-ring 1
► Clean the sealing surface

Turbocharging
Installing the charge air manifold with EGR connection
Installing the charge-air manifold with EGR connection
► Thinly coating a new O-ring 1 with technical

vaseline
► Position the charge-air manifold 3 along with
a new seal 2 and a new O-ring 1
Attaching the Visco fan EGR pressure sensor
► Inserting the pressure sensor 1

Attaching the temperature sensor
► Installing the temperature sensor 1


Turbocharging
Connect the electrical connection
► Connect the electrical connections 1 and 2

Turbocharging
Removing/installing the charge-air pipe with throttle valve
Additional jobs
1 Throttle valve 2 Charge-air pipe
Technical data
Tightening torques
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x145-10.9 . . . . . . . Pre-tightening torque 5 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x145-10.9 . . . . . . . . . . . . . . Final torque 12 Nm
Service products
Loctite 270 sealing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04.10160-9131

Turbocharging
NOTE
For this reason:
NOTE
For this reason:
CAUTION
For this reason:
Tip for users

Before removal, mark the installation position of the cables, plugs and cable ties.
When installing, route and secure the cables, plugs and cable ties as marked without tension, kings
or chafing.
Special tools


Turbocharging
Removing the charge-air pipe with throttle valve
Detaching the cable harness
► Disconnect the 1 cable ties

► Expose the cable harness
► Unscrewing the mounting bolts 3 and

hollow screw 4

Turbocharging
Removing the charge-air manifold with throttle valve

► Removing the charge-air manifold 6 with
O-ring 4
► Removing the throttle valve 3 with O-ring 2

Turbocharging
Installing the charge-air pipe with throttle valve
Removing the charge-air manifold with throttle valve
► Positioning the throttle valve 3 with a new

O-ring 2
► Positioning the charge-air manifold 6 with
a new O-ring 4
► Thinly coating mounting bolt 1 and 5 with
Loctite 270
► Screwing in and hand-tightening mounting bolts
1 and 5
Tightening torque
Preliminary tightening torque . . . . . . . . . . . . . . 5 Nm
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm

3

Turbocharging
Attaching the cable harness
► Routing the cable harness

► Secure the cable harness with cable ties 1
tie pliers [1]

1 EGR module 3 Intake manifold

2 Housing with shut-off flap

1 Metering unit 4 Exhaust manifold HCI

2 EGR module 5 Exhaust manifold
3 Engine brake

Removing/installing the exhaust manifold HCI
Additional jobs
1 Exhaust manifold HCI
Technical data
Tightening torques
Hose clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6X60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Nm
NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Service products
WEICON Anti-Seize “High-Tech” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09.16012-0133

NOTE
For this reason:
NOTE
Risk of component damage due to incorrect installation
Avoid jammed exhaust gas sensors.
For this reason:
S Apply a thin layer of suitable assembly paste to the thread of the exhaust sensors.
S Observe the manufacturer's instructions.
Special tools

S Removing/installing the lambda probe


Removing the HCI exhaust manifold

► Unscrew Lambda probe 1 using Lambda
probe wrench [1]

Remove the bracket
► Loosen the mounting bolt 5

► Tilt bracket 3 and remove plates 2 and 4

Removing the HCI exhaust manifold
► Remove the profiled clamp 1

► Remove the HCI exhaust manifold 2
Installing the exhaust manifold
Attaching the HCI exhaust manifold
► Position HCI exhaust manifold 2 into place

with profiled clamp 1

► Bringing the plates 2 and 4 with bracket 3

into the installation position
bolts 1
► Thinly coating the NOx sensor 1 thread with

WEICON Anti-Seize
► Screw the NOx sensor 1 into place and
tighten it
tie pliers [2]
Tip for users

► Apply a thin layer of WEICON Anti-Seize

to thread of Lambda probe 1
► Screw Lambda probe 1 into place and tighten
it using Lambda probe wrench [1]
tie pliers [2]
Tip for users



Removing/installing the HCI system
1 Hydrocarbon injection system
Technical data
Tightening torques
Union nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nm
NOTE
For this reason:

Special tools

S Closing the hydrocarbon injection system
S Plugging the HCI fuel line

Removing the HCI system
Detaching the connections of the hydrocarbon injection system
► Unscrew the fuel line union nuts 1

► Unscrewing the union nuts of the cooling
pipes 2
Removing the hydrocarbon injection system pipes

► Remove the fuel line 2
Z 12 x 16 [1]
► Removing the coolant pipes 3 and 4
Detaching the hydrocarbon injection system
► Closing the hydrocarbon injection system 2

with a protective sleeve Z 12 x 16 [1]
► Removing the hydrocarbon injection system 2
with seal 3

Installing the hydrocarbon injection system
Attaching the hydrocarbon injection system
► Positioning the hydrocarbon injection unit 2

with a new sealing ring 3
Attaching the hydrocarbon injection system pipes
► Positioning the coolant lines 3 and 4

tighten
Tightening the hydrocarbon injection system connections
► Bracing the socket and tightening the union

nuts of the fuel line 1
► Counterhold the connecting piece and tighten
the union nut on the coolant lines 2

Removing/installing the exhaust manifold
Additional jobs
S Remove/install the turbo charger module/exhaust module, see 338
S Removing/installing the charge-air pipe variants 66, 67, see 332
1 Exhaust manifold heat shield
Technical data
Tightening torques
Exhaust manifold mounting bolt ..................... M8x40-GA . . . . . . . . . . . . . . . 1st tightening 25 Nm
Exhaust manifold mounting bolt ..................... M8x40-GA . . . . . . . . . . . . . . . . . 2nd tightening 45°
Exhaust manifold mounting bolt ..................... M8x40-GA . . . . . . . . . . Final tightening torque 45°
Exhaust manifold mounting bolt ..................... M8x58-GA . . . . . . . . . . . . . . . . . 2nd tightening 45°
Exhaust manifold mounting bolt ..................... M8x58-GA . . . . . . . . . . Final tightening torque 45°

Exhaust manifold mounting bolt . . . . . . . . . . . . . . . . . . . . . M8x80-GA . . . . . . . . . . . . . . . . . 2nd tightening 45°

Exhaust manifold mounting bolt . . . . . . . . . . . . . . . . . . . . . M8x80-GA . . . . . . . . . . . . . . . . . . . Final torque 45°
Mounting nut exhaust manifold . . . . . . . . . . . . . . . . . . . . . . M8-GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm
NOTE
Risk of material damage if bolts are reused
After being used once, exhaust manifold mounting bolts do not ensure a safe seal between the exhaust
manifold and the cylinder head.
For this reason:
S Do not reuse exhaust manifold mounting bolts.
NOTE
For this reason:

Removing the exhaust manifold
Remove the lifting eye
► Unscrew the 2 mounting bolts

► Removing the lifting eye 1
Remove the bracket

bracket 1

► Unscrew the mounting bolts 3 with the

washers 2
► Removing the heat shield 1

washers 3
► Removing the heat shields 1 and 2
CAUTION
For this reason:
S Detaching the exhaust manifold with support
► Marking the installation position of the mounting
bolts 5 , 7 , 8 and 9 turning them out
hexagonal screws 2 with washers and turning
them out
► Unscrewing the mounting nuts 6 from the
Cylinder head stud bolts 3
► Removing the exhaust manifold 10 with seals
1 and 4

Dismantling the exhaust manifold
► Pull exhaust manifold 1 out of exhaust

manifold 3
► Detaching the oil rings 2 from the exhaust
manifolds
Installing the exhaust manifold
Assembling the exhaust manifold
► Attach new laminar sealing rings 2 onto

exhaust manifold 3
► Insert exhaust manifold 3 in 1
Tightening sequence for exhaust manifold
► Tightening all mounting bolts crosswise

in tightening sequence 1 to 4

Mounting the exhaust manifold
CAUTION
For this reason:
S Detaching the exhaust manifold with support
NOTE
Exhaust system leakage
For this reason:
S Take note of the gap in the seals
NOTE
Once used, exhaust manifold mounting bolt do
not ensure a safe seal between the exhaust gas
manifold and the cylinder head
For this reason:
S Do not reuse exhaust manifold mounting
bolts.
► Positioning the exhaust manifold 10 with

new seals 1 and 4
► Screw in new mounting bolts 5 , 7 , 8 and 9
as marked and tighten
Tightening torque
2nd torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
► Screwing the mounting nuts 6 onto the stud
bolts 3 and tightening them
► Screwing in the mounting bolt 2 with washer
and tightening it

Mounting the heat shield
► Positioning the heat shields 1 and 2


► Positioning the bracket 1 as marked

► Screw the mounting bolt 3 with
washer 2 and tighten

Attach the lifting eye
► Position the lifting eye 1


Removing/installing the engine brake
Additional jobs
1 Engine brake 2 Compressed air support cylinder

NOTE
For this reason:

Removing the engine brake
ENVIRONMENTAL NOTE
container.
► Unscrewing the union nut of the oil return
line 2
► Removing the oil return line 2 with seal 1
and 3

bolts 1 and 2
► Removing the exhaust manifold 3

Remove the bracket


Installing the engine brake
► Screw in the mounting bolt 1 with washer 2
and tighten
Attaching the exhaust manifold
► Positioning the exhaust manifold 3

and 2 as marked

► Positioning the oil return line 2 with new

seals 1 and 3
► Screwing on the union nut of the oil return
washers 5

Removing/installing the engine brake

Variants 66, 67
Additional jobs
1 Exhaust manifold 2 Compressed air support cylinder

NOTE
For this reason:

Removing the engine brake

bolts 1 and 2
► Removing the exhaust manifold 3
Installing the engine brake
Attaching the exhaust manifold
► Positioning the exhaust manifold 3



Disassembling, assembling the engine brake
Additional jobs
S Remove/installthe exhaust manifold HCI, see 374
S Removing, installing the engine brake Versions 66, 67, see 398
1 Lock nut 7 Ball pin

2 Hex nut 8 Locking screws
3 Securing clip 9 Cylinder console
4 Ball cup 10 Threaded bolt
5 Washer 11 Washer
6 Exhaust manifold 12 Compressed-air cylinder
Technical data
Tightening torques
Corrugated head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Nm
Distance dimension A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 - 2.0 mm

Service products
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See maintenance and service product regulations
NOTE
For this reason:

Dismantle the engine brake
Removing the fuel retaining bar
► Detach the securing clip 2 from the ball cup 1
Detaching the lock nut
► Unscrew the lock nut 2 from the

compressed-air cylinder 1
Removing the compressed-air cylinder

compressed-air cylinder
► Detach the compressed-air cylinder 1 from the
ball pin 3 and the threaded bolt
► Removing the washer 2 from the threaded bolt

Dismantling the compressed-air cylinder
► Unscrew the ball cup 3 and the lock nut 2

from the compressed-air cylinder 1
Detaching the cylinder console
► Unscrew the locking screws 1
Remove the washer
► Remove the washer 1 from the cylinder

console 3 and threading it out along the
linkage with ball pin 2

Remove the cylinder console
► Wriggle the cylinder console 1 off the exhaust

manifold 3 over the linkage with the ball pin 2

Assemble the engine brake
Attaching the cylinder console
► Wriggle the cylinder console 1 over the linkage

with the ball pin 2 and put it on the exhaust
manifold 3
Mounting the washer
► Wriggle the washer 1 along the linkage with

ball pin 2 and put it onto the cylinder
console 3
Attaching the cylinder console
► Screw in the new mounting bolts 1 and tighten


Assembling the compressed-air cylinder
► Screwing the ball cup 3 with a new lock

nut 2 onto the compressed-air cylinder 1
Fitting the compressed-air cylinder
► Positioning the washer 2 on the threaded

bolt 3
► Fit the compressed-air cylinder 1 onto
threaded bolt 3 as marked
Fit ball cup
► Set the distance dimension A between ball

cup 2 and the ball pin 1 as shown
Distance dimension A . . . . . . . . . . . 1.5 - 2.0 mm

Brace ball cup
Tip for users

Do not change the installation position
of the ball cup when bracing the hex nut
► Brace the hex nut 1 with the ball cup
Fit ball cup
► Grease the ball pin 2 and put the ball

cup 1 in place
Attaching the lock nut
► Screw a new lock nut 1 onto the threaded

bolt 2 and tighten

Installing the retaining bar
► Insert the securing clip 2 into the ball cup 1

and secure

Removing/installing the housing with EGR module shut-off flap
1 Housing with shut-off flap
Technical data
Tightening torques
Pulse valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M5x12-8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Nm

CAUTION
For this reason:
NOTE
For this reason:
S Take note of the operating instructions of the cable tie pliers [2].
NOTE
For this reason:
Special tools



Removing the housing with shut-off flap
NOTE
Risk of component damage from incorrect
setting
System servomotor - exhaust gas recirculation
flap does not work any more and results in
malfunction and error entries.
For this reason:
S Do not loosen the servomotor mounting bolts
for the EGR flap.

washers 2
► Removing the heat shield 1
Separating the electrical connection of the servomotor
NOTE
Risk of component damage due to incorrect
removal.
For this reason:

S Do not disconnect the plug-in connector at the
servomotor.

► Releasing the slide valve 2
► Not separating the electrical connection 3 from
the servomotor
► Turning out the hollow screws 1 with seals 2

► Detaching the hose clamps 4 and 5 with the
hose clamp pliers [1]

Removing the safety flap
NOTE
Risk of component damage from incorrect
setting
System servomotor - exhaust gas recirculation
flap does not work any more and results in
malfunction and error entries.
For this reason:
S Do not loosen the servomotor mounting bolts
for the EGR flap.

► Remove the shut-off flap 1 together with
the seal 2

Installing the housing with shut-off flap
Attaching the shut-off flap
► Position the safety flap 1 with new seal 2

tighten

► Screwing in and tightening the hollow
screws 1 with new seals 2
► Attach the hose clamps 4 and 5 using the
hose clamp pliers [1]
Establishing the electrical connection to the servomotor
► Establishing the electrical connection using

the 1 plug 3
► Installing the slide valve 2
tie pliers [2]



Removing/installing the EGR module
Additional jobs
S Removing, installing the charge-air pipe with exhaust gas recirculation connection, see 360
S Remove/install the cable harness, see 46
S Remove/install the housing with EGR module shut-off flap, see 411
1 EGR module
Technical data
Tightening torques
GE union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
Cable duct bottom part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x16-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm
Service products

NOTE
For this reason:

Removing the EGR module
Detaching the bottom part of the cable duct

► Removing the bottom part of the cable duct 2
Removing the EGR module

bolts 2 and 4 and turn them out
► Remove the EGR module 3 together with the
seals 5
► Remove the coupling pipe 1


► Unscrewing the temperature sensor 3 with

seal 4
► Turning out the GE union 1 seal 2
Removing the exhaust manifold with EGR module

► Removing the exhaust manifold 2 with seal 3

Installing the EGR module
Installing the exhaust manifold with EGR module
► Positioning the exhaust manifold 2 with a new

seal 3
Install temperature sensor

with a new seal 4
► Screw the GE union 1 in with a new seal 2
and then tighten
Installing the heat shield

washers 2

Installing the EGR module

new coupling pipe 1
► Insert the new coupling pipe 1 into the exhaust
manifold
► Position the EGR module 3 with new
gaskets 5
and 4 as marked
Attaching the bottom part of the cable duct
► Positioning the bottom part of the cable duct 2


Removing, installing the air distributor pipe
Additional jobs
S Remove/install the fuel service Centre, see 278
1 Air distributor pipe
Technical data
Tightening torques
Charge air temperature sensor . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm

NOTE
Component damage due to incorrectly tightened screw/bolt connections
For this reason:
S If impact screwdrivers are used, these may only be used for preliminary tightening to max. 50% of the
specified tightening torque
S Final tightening must always be performed manually using a torque wrench

Remove air distributor pipe
► Unscrewing the temperature sensor 3 from the

air distributor pipe 1 and taking off the seal 2



Removing the distributor pipe

bolts 3
► Remove the air distributor pipe 2 along with
the seals 1

Install air distributor pipe
Mount the air distributor pipe
► Position the air distributor pipe 2 with new

seals 1
► Screw the mounting bolts 3 in as marked
and tighten
and tighten

Install temperature sensor
► Screwing the temperature sensor 3 with

a new seal 2 into the air distributor pipe 1
and tightening it

Cylinder head
Cylinder head
1 Mounting bolt 5 Rocker arm mechanism

2 Cylinder head cover 6 Valve crosshead, intake valve
3 Gasket 7 Valve crosshead, exhaust valve
4 Mounting bolt 8 Cylinder head

Cylinder head

Cylinder head
Removing/installing the cylinder head cover
1 Cylinder head cover
Technical data
Tightening torques
Cylinder head cover mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
NOTE
Risk of materialdamage due to incorrectly tightened threaded connections
For this reason:

Cylinder head
Removing the cylinder head cover
Removing the cable duct cover
► Open the locking pin 2 a quarter turn

► Remove the cable duct cover 1
Disconnecting the plug bracket electrical connections
► Disconnect the electrical connections 1
Removing the cylinder head cover
Tip for users

If this is not done, engine oil may enter the seal,
which may cause an apparent leak when the
cylinder head cover is tightened and this oil is
pressed out.
► Unlock and remove the bayonet fittings 3 on

the plug bracket
► Remove the cylinder head cover 2 with seal 5
from the cylinder head 4
► Cleaning cylinder head cover 2 and seal 5
► Check the seal 5 for damage. Remove from
the cylinder head cover 2 and replace if
required
► Set the cylinder head cover 2 and the seal 5
down on a clean surface

Cylinder head
Installing the cylinder head cover
Mounting the cylinder head cover
► Check the plug bracket; renew if necessary.

► Fit the cylinder head cover 2 , if necessary with
a new seal 5 , over the plug bracket on the
cylinder head 4
► Connect the bayonet catches 3 to the plug
bracket
Connecting the plug bracket electrical connections
► Connect the electrical connections 1
Mounting the cable duct cover
► Reset the cable duct cover 1

► Tighten the locking pin 2 a quarter turn

Cylinder head

Cylinder head
Removing/installing the cylinder head
Additional jobs
S Checking and setting the valve clearance, see 452
S Remove/install the rocker arm mechanism, see 448
S Remove/install the cylinder head cover, see 431
S Remove/install the fuel service Centre, see 278
S Removing, installing the air distributor pipe, see 423
S Removing, installing the EGR module, see 417
S Remove/install the rail pressure pipe (common rail), see 247
S Remove/install the turbo charger module/exhaust module, see 348

Cylinder head
1 Cylinder head 4 Valve crosshead, intake valve

2 Tappet pushrod 5 Cylinder head bolt
3 Valve crosshead, exhaust valve
Technical data
Tightening torques
Cylinder head Cylinder head bolts . . . . . . . . . . . . . . . . . . . 14x2 (E18) . . . . . . . . . . . . . . . 1st tightening 80 Nm
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14x2 (E18) . . . . . . . . . . . . . 2nd tightening 150 Nm
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14x2 (E18) . . . . . . . . . . . . . . . . . 3rd tightening 90°
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14x2 (E18) . . . . . . . . . . . . . . . . . 4th tightening 90°
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14x2 (E18) . . . . . . . . . . . . . . . . . final tightening 90°

Inlet valve depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.60 mm
Exhaust valve depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 - 0.90 mm
Nozzle projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.830 - 3.680 mm
Consumables

Cylinder head
NOTE
Once used, cylinder head bolts do not ensure a safe seal between the cylinder head and the crankcase.
For this reason:
S Do not reuse old cylinder head bolts.
NOTE
For this reason:
Special tools
[1] Lifting gear 80.99606-6152

S Remove/install the cylinder head in conjunction with:
S Cross beam [2]
S Slinging chain [3]
S Lifting eye bolt [4]
[2] Crossbeam 80.99629-6008

S Removing, installing the cylinder head
[3] Slinging chain 80.99629-6009

[4] M8 lifting eye bolt 80.99606-0660


Cylinder head
[5] Power amplifier wrench i = 1 : 33 80.99619-0006

S Loosening and tightening cylinder head bolts in connection with:
S Size 22 socket [6]
S Socket [7]
S Support [8]
S Torque angle gauge [9]
S Stop pin [10]
S Stud bolt [11]
S Connecting pin [12]
S Rubber ring 42 mm [13]
S Washer [14]
S Loosening and tightening the cylinder head bolts
[7] Socket 80.99612-0023

S Loosening and tightening the cylinder head screws
[8] Support 80.99606-0551

[9] Angle gauge 80.99607-0172

[10] Stop pin 80.99606-0585

[11] Stud bolt 06.02191-0407


Cylinder head
[12] Connecting pin 06.22729-0006

[13] 42 mm rubber ring 08.06142-9006

[14] Adapter 80.99606-0552

[15] Dial gauge 08.71000-3217

S Checking the valve recess
S Checking the injection nozzle protrusion
[16] Dial gauge holder 08.71082-0005

S Checking the valve recess
S Checking the injection nozzle protrusion

Cylinder head
Removing the cylinder head
Remove valve crossheads and tappet pushrods
► Mark the installation position of the valve

crossheads 2 and 3
► Remove the valve crossheads 2 and 3
► Pull out the tappet pushrods 1
► Insert the power amplifier wrench i = 1 : 3.3

[5] 1 into the support [8] 2
► Attaching the stop pin [10] 5 with stud bolt [11]
3 and adapter [14] 4 onto the support [8] 2
► Place the angle gauge [9] 9 on the power
amplifier wrench i = 1 : 3.3 [5] 1
► Put the size 22 socket [6] 7 on the power
amplifier wrench i = 1 : 3.3 [5] 1 and secure
it with the connecting pin [12] 8 and the 42 mm
rubber ring [13] 6

Cylinder head
Undo the cylinder head bolts
► Position the special tool 1 with the socket

wrench insert [7] (2x) 2 onto the cylinder head
bolt to be loosened
► Undo all of the Cylinder head bolts using the
special tool 1
Remove the cylinder head
► Unscrew the Cylinder head bolts 1

► Screw in the M8 lifting eye bolt [4] (4x) onto the
corners of the cylinder head 2 and tighten
► Lift the cylinder head 2 off using lifting gear [1]
► Unscrew the M8 lifting eye bolt [4] (4x)

Cylinder head
Removing the cylinder head gasket
► Removing the cylinder head gasket 1 from the

alignment pins 2
► Clean the sealing surface
► Clean the threaded bores of the cylinder head
bolts

Cylinder head
Installing the cylinder head
Fit the cylinder head gasket
► Place the new cylinder head gaskets 1 over

the alignment pins 2
Checking the valve recess
► Positioning the dial gauge holder [16] 2 with

dial gauge [15] 1 on the cylinder head [3]
► Positioning the dial gauge tip with preliminary
tension on the cylinder head 3
► Zero the dial gauge [15] 1
► Positioning the dial gauge tip carefully on the
valve disk 4 and reading the difference
The permitted valve recess for inlet valves
is 0.30 - 0.60 mm
The permitted valve recess for exhaust valves
is 0.60 - 0.90 mm
Checking then nozzle protrusion
► Positioning the dial gauge holder [16] 3 with

dial gauge [15] 2 on the cylinder head 4
► Positioning the dial gauge tip with preliminary
tension on the cylinder head 4
► Positioning the dial gauge tip carefully on the
nozzle protrusion 1 and reading the difference
The permitted nozzle protrusion is 2.830 - 3.680 mm

Cylinder head
Mount the cylinder head
NOTE
Once used, cylinder head bolts do not ensure
a safe seal between the cylinder head and the
crankcase.
For this reason:
S Do not reuse the cylinder head bolts once
they have been loosened.
► Screw in the M8 lifting eye bolt [4] (4x) onto the

corners of the cylinder head 2 and tighten
► Position the cylinder head 2 with lifting gear [1]
on the crankcase
► Unscrew the M8 lifting eye bolt [4] (4x)
contact surfaces of the new cylinder head
bolts 1
► Tighten the cylinder head bolts 1 by hand

Cylinder head
Tightening sequence for cylinder head
► Adhere to the tightening sequence 1 to 16

shown in the following work step
Tightening the cylinder head bolts
Tip for users

Observe the transmission gear ratio of the
power amplifier wrench i = 1 : 3.3 [5].
► Position the special tool 1 with socket wrench
insert [7] (2x) 2 onto the cylinder head bolt to
be tightened
► Tightening the cylinder head bolts with the
special tool 1 according to the tightening
sequence
Tightening torque
Second torque . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
Third torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°
Fourth torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°

Cylinder head
Install valve crossheads and tappet pushrods
► Apply a thin layer of clean engine oil to the balls

of the tappet pushrods 1
► Insert the push tappets 1 into the ball cups
of the tappets
► Install the valve crossheads 2 and 3
as marked

Cylinder head

Cylinder head
Removing and installing the rocker arm mechanism
Additional jobs
1 Bayonet fittings 6 Rocker arm mechanism

2 Mounting bolt 7 Valve crosshead, intake valve
3 Cylinder head cover 8 Valve crosshead, exhaust valve
4 Gasket 9 Cylinder head
5 Mounting bolt
NOTE
For this reason:

Cylinder head
Removing the rocker arm mechanism
Removing the rocker arm mechanism
Tip for users

Do not turn out the mounting bolt for the rocker
arm shaft when removing the rocker arm
mechanism.

► Remove the rocker arm mechanism 2

Cylinder head
Installing the rocker arm mechanism
Installing the rocker arm mechanism
► Apply a thin layer of clean engine oil to the ball

sockets of the tappet pushrods
► Position and align rocker arm mechanism 2 on
the cylinder head inserting the balls of the
adjusting screws for the rocker arm into the
tappet pushrod
► Screw in the mounting bolts 1 and tighten
crosswise

Cylinder head

Cylinder head
Checking, setting the valve clearance
Additional jobs
1 Adjusting screw, exhaust valve 3 Valve crosshead, intake valve

2 Adjusting screw, intake valve 4 Valve crosshead, exhaust valve
Technical data
Tightening torques
Locknuts of adjusting screws . . . . . . . . . . . . . . . . . . . . . . . . M10x1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm

Valve clearance inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm
Valve clearance exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm
Setting dimensions brace EVB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm

Cylinder head
NOTE
For this reason:

Cylinder head
Special tools

S Gear ratchet [2]
[2] Gear ratchet 80.99627-0001

[3] Feeler gauge 08.75310-3309

S Checking/adjusting the valve clearance
[4] Size 14 valve adjusting wrench 80.99603-6031

S Adjusting the valve clearance
[5] Ratchet adapter 08.06410-9072

[6] Handle 08.06460-0003

[7] Torque wrench 08.06450-0006


Cylinder head
Checking the valve clearance

flywheel housing
Placing the engine in the setting position
► Crank the engine in the engine's running

gear ratchet [2] until the rocker arms overlap
► Adjust free rocker arms as per table
A = rocker arm in an overlapping position
B = rocker arms free

Cylinder head
Checking the inlet valve clearance
► Insert the feeler gauge 0.5 mm leaf [3] 3

between the rocker arm 1 and the valve
connection 2
The valve clearance must be adjusted if it is not
0.50 mm.
Adjusting the intake valve clearance
► Undo the locknut 3 and the adjusting screw 2

connection 4
► Screw in the adjusting screw 2 until the
0.50 mm leaf of the feeler gauge [3] 5 can
be moved between the rocker arm 1 and
the valve connection 4 with little resistance
► Bracing the adjustment screw 2 with the size
14 valve adjusting wrench [4], plug-in ratchet [5]
and handle [6] and fastening the locknut 3 with
a torque wrench [7]
► Check the setting again and, if necessary,
repeat the setting procedure
Checking the exhaust valve clearance

connection 2
The valve clearance must be adjusted if it is not
0.50 mm.

Cylinder head
Place the EVB piston in the setting position
NOTE
Danger of material damage due to incorrect
valve clearance
Wrongly installed EVB pistons cause engine
damage.
For this reason:
S Check whether it is possible to push the EVB
pistons completely into the valve crosshead.
► Undo the locknut 2 and unscrew it several

turns
► Screw in the adjusting screw 1 to press the
valve connection down several times until the
stop is reached
All the engine oil must have drained from the EVB
piston 3 .
Adjusting the exhaust valve clearance
► Undo the locknut 2 and the adjusting screw 1

connection 4
► Screw in the adjusting screw 1 until the 0.50
mm leaf of the feeler gauge [3] 5 can be
moved between the rocker arm 3 and the
valve connection 4 with little resistance
► Bracing the adjustment screw 1 with the size
14 valve adjusting wrench [4], plug-in ratchet [5]
and handle [6] and fastening the locknut 2 with
a torque wrench [7]
Checking the setting dimensions for the EVB piston
► Push the valve connection 3 down gently

between the adjusting screw 1 and the valve
connection 3
If the setting dimension is not 0.35 mm the EVB
clearance must be adjusted.

Cylinder head
Adjusting the EVB clearance
Tip for users

The valve crosshead must not move the
exhaust valve when the adjusting screw is
screwed in.
► Undo the locknut 2

► Unscrew the adjusting screw 1 until the feeler
gauge can be screwed out 0.35 mm [3] 3 with
the support
► Screw the adjusting screw in with the inserted
feeler gauge 0.35 mm [3] 3 until the valve
connection 4 stops - this can be felt by a
noticeable increase in force
► Bracing the adjustment screw 1 with a valve
adjustment spanner SW 14 [4], plug-in ratchet
[5] and handle [6] and tightening the locknut 2

► Mount the cap on the flywheel housing

Cylinder head

Cylinder head
Disassembling, assembling the rocker arm mechanism
Additional jobs
1 Exhaust valve rocker arm 8 Contact washer

2 Contact washer 9 Pressure spring
3 Pressure spring 10 Contact washer
4 Contact washer 11 Intake valve rocker arm
5 Intake valve rocker arm 12 Rocker shaft
6 Mounting bolt 13 rocker bracket
7 Exhaust valve rocker arm
Technical data
Service products
White T assembly paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09.16012-0117

Cylinder head
NOTE
For this reason:
Special tools

S Remove the rocker arm shaft

Cylinder head
Dismantling the rocker arm mechanism
Dismantling the rocker arm mechanism
► Mark the installation position of the rocker arms

1 and 5 , contact washers 2 and 4 and
pressure springs 3
► Pressing the rocker arms shaft 7 with the
press-in mandrel [1] out of the rocker arm
bracket 8 and leaving the press-in mandrel [1]
in the rocker arm bracket 8
► Pulling the press-in mandrel [1] slowly out of
the rocker arm bracket 8 while removing the
rocker arms 1 and 5 , the contact washers 2
and 4 and the pressure spring 3
Assembling the rocker arm mechanism
Assembling the rocker arm mechanism
► Insert the rocker arms 1 and 5 into the rocker

arm bracket 8 as marked
► Insert the thrust washers 2 and 4 with the
pressure spring 3 into the rocker arm bracket
8 as marked
► Covering the rocker arm shaft 7 thinly with
White T assembly paste
► Align the rocker arm shaft 7 with the hole of
the mounting bolt 6
► Insert the rocker arm shaft 7 into the rocker
arm bracket 8

Cylinder head

Cylinder head
Removing/installing the valve stem seals
Additional jobs
S Removing, installing the injectors with nozzle, see 232
S Remove/install the rail pressure pipe (common rail), see 247
1 Valve cotter 5 Valve-stem seal

2 Cylinder head 6 Valve
3 Valve crosshead, exhaust valve 7 Valve spring
4 Valve crosshead, intake valve

Cylinder head
Technical data
Valve recess (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.6 mm
Valve recess (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 - 0.9 mm
NOTE
For this reason:
Special tools

S Gear ratchet [2]
[2] Gear ratchet 80.99627-0001

[3] Valve spring compressor 80.99613-6000

S Removing/installing valve springs in conjunction with:
S Intermediate piece [4]
S Assembly device [5]
S Extension [6]
S Bracket [7]
S Bracket [8]
[4] Intermediate piece 80.99613-0042
S Removing/installing valve springs


Cylinder head
[6] Extension 80.99606-6094

[7] Bracket 80.99613-0052

[8] Bracket 80.99613-0053

[9] Magnetic pick-up tool 80.99639-0009

S Removing valve keys

S Removing the valve stem seal
S Installing the valve stem seal in conjunction with:
S Assembly sleeve [11]
[11] Assembly sleeve 80.99606-0634

S Installing the valve stem seal

Cylinder head
Removing the valve stem seals

flywheel housing
Cranking the engine to the OT mark
► Crank the engine in the engine's running

direction using the engine cranking unit [1] 1
and the gear ratchet [2] until the 1. cylinder is at
the OT mark 2
Removal and installation position for valve-stem seals
► Removing and installing free valve stem seals

according to the table

Cylinder head
Remove valve crossheads and tappet pushrods
► Mark the installation position of the valve

crossheads 2 and 3
► Remove the valve crossheads 2 and 3
► Pull out the tappet pushrods 1
Tip for users

Lock washer and support [8] have left-handed
threads.
► Position bracket [7] 5 and bracket [8] 3 on the
valve spring compressor [3] 1 and screw them
on by turning the threaded spindle 4
► Screw on the lock washers 2 and 6
► Position the lever 8 on the valve spring
compressor [3] 1 and secure using the
mounting bolt 7

Cylinder head
Mounting the assembly device
► Screw the intermediate piece [4] 2 into the

cylinder head
► Screw the assembly device [5] 1 into the
intermediate piece [4] 2
Mounting the valvespring compressor

spring disc and tension by turning the threaded
spindle 6
► Hook the valve spring compressor [3] 2 into
the assembly device [5] 3
► Put the extension [6] 1 on the valve spring
compressor [3] 2
Remove valve separator
CAUTION
Risk of injury due to valve spring snapping
back
For this reason:
S Ensure that support [7] and support [8] are
correctly attached to the spring disc
S Do not take the valve keys with bare hands
out of the valve spring
► Push the valve spring compressor [3] 1 down

with the extension [6]
► Remove the valve keys 3 from the valve
stem 2 using the magnetic pick-up tool [9]
► Slacken the valve spring compressor [3] 1
► Repeat the same procedure for all the valves

Cylinder head
Remove valve spring
► Remove the washer 3 , valve spring 2 and

spring disc 1 over the valve stem
Removing the valve stem seals
► Push the assembly device [10] 2 over the

valve stem seal 3
► Clamp the assembly device [10] 2
► Pull the valve stem seal 3 off the valve
guide with the impact weight 1

Cylinder head
Installing the valve stem seals
Installing the valve stem seals

assembly sleeve [11] 4 and the valve stem
seal 3
► Push the assembly sleeve [11] 4 over the
valve stem 5
► Insert the valve stem seal 3 into the assembly
device [10] 2 and tension
► Push the assembly device [10] 2 over the
assembly sleeve [11] 4
► Knock the valve stem seal 3 onto the valve
stem 5 using the impact weight 1
► Remove the assembly device [10] 2 and the
assembly sleeve [11] 4
Installing the valve springs
► Insert the washer 3 , valve spring 2 and spring

disc 1 over the valve stem

Cylinder head
Mounting the assembly device
► Screw the intermediate piece [4] 2 into the

cylinder head
► Screw the assembly device [5] 1 into the
intermediate piece [4] 2
Mounting the valve spring compressor

spring disc and tension by turning the threaded
spindle 6
► Hook the valve spring compressor [3] 2 into
the assembly device [5] 3
► Put the extension [6] 1 on the valve spring
compressor [3] 2
Install valve separators
CAUTION
Risk of injury due to valve spring snapping
back
For this reason:
S Ensure that support [7] and support [8] are
correctly attached to the spring disc
S Do not insert the valve keys with bare hands
into the valve spring
► Push the valve spring compressor [3] 1 down

with the extension [6]
► Use a suitable tool to insert the valve keys 3
so that the valve keys 3 are seated in the
grooves of the valve stem 2
► Slacken the valve spring compressor [3] 1

Cylinder head
Moving the engine into the removal and installation position
NOTE
The process described below must be
performed in the same way for the remaining
cylinders
► Rotate the engine in the engine's running

direction by a further 120° using the engine
cranking unit [1] and the gear ratchet [2]
► Removing and installing free valve stem seals
according to the table
Install valve crossheads and tappet pushrods
► Apply a thin layer of clean engine oil to the balls

of the tappet pushrods 1
► Insert the push tappets 1 into the ball cups
of the tappets
► Install the valve crossheads 2 and 3
as marked

Cylinder head


Cylinder head

Valve control
Valve control
1 Camshaft 5 Camshaft bearing 1

2 Camshaft bearing 4 6 Flange
3 Camshaft bearing 3 7 Tappet
4 Camshaft bearing 2

Valve control

Valve control
Removing/installing the camshaft
Additional jobs
S Removing and installing the automatic belt tensioner for the alternator, see 176
S Removing, installing the ribbed V-belt for the refrigerant compressor, see 196
S Removing, installing the ribbed V-belt for the refrigerant compressor, Versions 66, 67, see 202
S Removing, installing the V-belt, ribbed V-belt of the hydraulic pump 218
S Removing, installing the holder for the refrigerant compressor, see 214
S Removing, installing the holder for the refrigerant compressor, Version 66, 67, see 216
S Removing, installing the refrigerant compressor, see 208
S Removing, installing the hydraulic pump / double pump, see 226
S Removing, installing the hydraulic pump / single pump, see 222
S Removing, installing the exhaust pipe, see 172
S Remove/install the alternator, see 180
S Removing, installing the exhaust manifold, see 100
S Remove/install the thermostat insert, see 106
S Remove/install the thermostat housing, see 112
S Removing, installing the auxiliary PTO, see 144
S Remove, install the vibration damper, see 592
S Removing, installing exhaust pipe Versions 66, 67, see 332
S Removing, installing the injectors and pressure pipe, see 232
S Remove/install the cylinder head, see 435
S Remove, install the timing case cover, see 672
S Remove/install the timing gears, see 499
S Remove, install the timing case, see 676
S Removing, installing the starter motor, see 192
S Removing, installing the flywheel, see 596
S Remove the flywheel housing, see 658
S Remove and install the oil sump, see 529
S Removing, installing the oil sump, Versions 66, 67, see 532
S Remove/install the upper section of the oil sump, see 545
S Removing, installing the upper section of the oil sump housing, Versions 66, 67, see 557
S Removing, installing the piston with connecting rod, see 606
S Remove/install the crankshaft, see 621
S Removing, installing the crankcase ventilation, see 652
S Remove/install the turbo charger, see 338
S Removing, installing the exhaust turbo charger, Versions 66, 67, see 348
S Remove/install the front crankshaft seal, see 644
S Remove/install the rear crankshaft seal, see 638

Valve control
1 Camshaft 3 Tappet
2 Flange
Technical data
Camshaft axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.140 - 0.270 mm
Camshaft radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 - 0.120 mm
Timings
Inlet valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6° crankshaft angle before upper dead centre
Inlet valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32° crankshaft angle after lower dead centre
Exhaust valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63° crankshaft angle before lower dead centre
Exhaust valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13° crankshaft angle after upper dead centre
Consumables

Valve control
NOTE
For this reason:
Special tools
[1] Insertion mandrel 80.99617-6008

S Removing and installing the camshaft in connection with:
S Stud bolt [2]
[2] Stud bolt 06.02099-0357

S Removing/installing the camshaft

S Checking the camshaft axial play in connection with:
S Dial gauge [2]
[4] Dial gauge 08.71000-3217

S Checking the camshaft axial play

Valve control
Removing the camshaft
Removing the flange

► Removing the flange 2 from the camshaft
Fitting the special tool
► Position the adapter 2 of the guide pin [1] 4

on the camshaft 1
► Screw in the stud bolt [2] 3 and tighten
► Screw the guide pin [1] 4 into the adapter 2
Removing the camshaft
► Pulling the camshaft 2 out of the crankcase

in direction of the flywheel 1

Valve control
Removing the tappet
NOTE
Risk of material damage due to metallic
wear debris on the tappets
Component damage due to the metal wear
debris remaining on the magnet.
For this reason:
S Do not remove the tappet with a magnet,
since residual magnetism may cause metal
wear debris to collect on the tappets.
► Pull the tappet 1 out of the crankcase 2

Valve control
Installing the camshaft
Installing the tappet
NOTE
Risk of material damage due to metallic
wear debris on the tappets
Component damage due to the metal wear
debris remaining on the magnet.
For this reason:
S Do not install the tappet with a magnet, as the
remaining magnetism leads to accumulation
of wear debris on the tappets.

tappet 1
► Insert the tappet 1 into the crankcase 2
Installing the camshaft
NOTE
installation of the camshaft
The camshaft bearing may be damaged.
For this reason:
S Only install the camshaft using the special
tool.

camshaft 2 and the camshaft bearings
► Attach the adapter to the camshaft 2 with the
stud bolt [2]
► Screw the guide pin [1] 3 into the adapter
► Insert the camshaft 2 into the crankcase 1
► Remove the guide pin [1] 3

Valve control
Attaching the flange
► Position the flange 2

Check camshaft axial play
Mount the camshaft gear
► Place the camshaft gear 1 onto the camshaft

2 over the guide pin 3
► Secure the camshaft gear 1 with two bolts 4
Check camshaft axial play
► Put the dial gauge [4] 1 on the crankcase with

the dial gauge holder [3] 3
► Position the tracer pin of the dial gauge [4] 1
against the camshaft drive wheel 2
► Push the camshaft 2 to one end position and
zero the dial gauge [4] 1
► Push the camshaft 2 to the other end position
and read the difference off the dial gauge [4] 1
The permitted axial play of the camshaft is
0.140 - 0.270 mm.

Valve control

Valve control
Removing/installing the camshaft bearing
Additional jobs
S Remove, install the camshaft, see 478

Valve control
1 Camshaft bearing 4 3 Camshaft bearing 2

2 Camshaft bearing 3 4 Camshaft bearing 1
Consumables
NOTE
For this reason:
Tip for users

In the camshaft bearing for bearing seat 1 there is only one oil bore, distinguishing it from the other
camshaft bearings.

Valve control
Tip for users

For design reasons, there are five camshaft bearing seats in the crankcase, but only four camshaft
bearings are installed. The camshaft bearings are mounted at the camshaft bearing seats 1, 2, 3 and 5.

Valve control
Special tools
[1] Guide mandrel 80.99606-0762

S Remove and install the camshaft bearings in connection with:
S Press-in bush [7]
S Press-in bush [8]
S Press-out bush [4]
S Stop [6]
S Fork [2]
S Centering disk[5]
[2] Yoke 80.99606-0763
S Removing/installing camshaft bearings
[3] Centring disk 80.99606-0765

[4] Press-out bush 80.99602-0768

S Removing camshaft bearings
[5] Centring disk 80.99606-0767

S Removing camshaft bearings
[6] Limit stop 80.99606-0766

S Installing camshaft bearings
[7] Press-fit bush 80.99606-0769

S Installing camshaft bearing 1

Valve control
[8] Press-fit bush 80.99606-0764

S Installing camshaft bearings
[9] Slide hammer puller 80.99602-0016

S Removing camshaft bearings 1 and 4 in connection with:
S Extractor tool[10]
[10] Extractor tool 80.99602-6012

S Removing camshaft bearings 1 and 4

Valve control
Removing the camshaft bearings
Removal order for camshaft bearings
Tip for users

All of the following steps refer to the removal
order for the camshaft bearings illustrated here.
► Adhere to the removal 1 sequence to 4
Inserting the special tool for camshaft bearing 4
► Push the slide hammer puller [9] 2 through the

camshaft bearing 3 with the extractor tool [10]
1 folded back
► Fold the extractor tool [10] 1 behind the
camshaft bearing 3 and center in the camshaft
bearing bore
Removing camshaft bearing 4 from bearing seat 5
► Pull the camshaft bearing 3 out using the slide

hammer puller [9] 2 a nd the extractor tool
[10] 1

Valve control
Inserting the centering disk into bearing seat 4
Tip for users

The centering disk [5] remains fitted throughout
the removal and installation process.
Insert the centring disk [5] in such a way that
the guide rod in the centring disk [5] is facing up
towards the sealing surface of the oil bore and
engages in the oil sump.
► Inserting the centering disk [5] 2 into bearing

seat 4 1
Inserting the press-in bush in bearing seat 1
Tip for users

The press-in bush [7] has “Front top” written on
the outside.
Insert the press-in bush [7] in such a way that
the marking is facing towards the sealing
surface of the oil bore and engages in the oil
sump.
► Inserting the press-in bush [7] 2 into bearing

seat 1 1
Inserting the centring disc in bearing seat 5
Tip for users

The centring disk [5] has “Rear top” written on
the outside.
Insert the centring disk [5] in such a way that
the marking is facing towards the sealing
surface of the oil bore and engages in the oil
sump.
► Inserting the centring disc [5] 2 in bearing

seat 5 1

Valve control
Note on removing camshaft bearings
Tip for users

The fork [2] must be attached in the appropriate
position for the camshaft bearing being
removed.
► Put the fork [2] in position 1 for the camshaft

bearing on bearing seat 3
Removing the camshaft bearings from bearing seats 2, 3
► Insert the press-out bush [4] 2 into camshaft

bearing 2
► Inserting the long side of the guide mandrel [1]
1 without limit stop through the press-out bush
[4] 2 into the centring plates in bearing seats 1,
4 and 5
► Position the fork [2] 3
► Knock camshaft bearing 2 out
► Repeating the process for the camshaft
bearings at bearing seat 3 and shifting the
press-out bush [4] 2 with yoke [2] 3
accordingly

Valve control
Installing the camshaft bearing
Preparing to install the camshaft bearings
► Put the camshaft bearing 2 on the press-in

bush [8] 4
► The notch 5 in the camshaft bearing 2 must
be facing the timing case side of the engine
► Snap the spring-loaded ball 3 into the oil
bore 1
The centring hole of the press-in tool can be seen
through the second oil bore.
Installation order for camshaft bearings
► Stick to the installation order 1 to 4

All of the following steps refer to the installation
order illustrated here.
Note on installing camshaft bearings
Tip for users

The fork [2] must be attached in the appropriate
position for the camshaft bearing being
installed. No fork [2] is required for the
camshaft bearing in bearing seat 1.


Valve control
Installing the camshaft bearings in bearing seats 2, 3, 5
► Push the stop [6] onto the guide mandrel [1] 2

with the side that is not recessed
► Position the press-in bush [8] 3 on bearing
seat 2 with the camshaft bearing 4 pushed
onto it
► Inserting the long side of the guide mandrel
[1] 2 through the press-in bush [8] 3 into the
centring discs in bearing seats 1 and 4
► Insert the fork [2] 1 accordingly, see the note
on installing camshaft bearings
► Knock the camshaft bearing 4 into bearing
seat 2 until the stop [6] is up against the
crankcase
► Repeating the process for the camshaft bearing
in bearing seat 3
► Removing the centring disc [5] at bearing seat 5
and pressing the camshaft bearing
Removing the press-in bush from bearing seat 1
► Removing the press-in bush [7] 2 from bearing

seat 1 1
Inserting the special tool into camshaft bearing 1
► Push the slide hammer puller [9] 1 through

camshaft bearing 1 3 with the extractor tool
[10] 2 folded back
► Fold the extractor tool [10] 2 behind camshaft
bearing 1 3 and center in the camshaft bearing
bore

Valve control
Removing camshaft bearing 1

► Pull camshaft bearing 1 3 out using the slide
hammer puller [9] 1 and the extractor tool
[10] 2
Installing camshaft bearing 1
► Insert the press-in bush [8] into bearing

seat 2 and snap into the oil bore
► Push the stop [6] 6 onto the guide mandrel
[1] 2 with the side that is not recessed
► Push the press-in bush [7] 5 onto the guide
mandrel [1] 2 with the camshaft bearing 4
pushed onto it
► Insert the guide mandrel [1] 2 with the long
side in the press-in bush [8] and the centring
disk [3] 1 , ensuring that the guide mandrel [1]
2 is guided into the centring disk [3] 1 by the
rod
► Position the press-in bush [7] 5 on bearing
seat 1 3 with the camshaft bearing 4 pushed
onto it
► Knock the press-in bush [7] 5 and the
camshaft bearing 4 into bearing seat 1 3 until
the stop [6] is up against the crankcase
Checking the oil holes
► Check that the oil bores 2 in the camshaft

bearing 3 are in the right position
The oil holes in the camshaft bearing must align
with the oil bores in the crankcase 1 , if necessary,
remove the camshaft bearing and install a new
camshaft bearing correctly.

Timing gears
Timing gears
1 Camshaft gear wheel 4 Drive gear oil pump

2 Idler 2 5 Idler 1
3 Crankshaft gear wheel 6 Intermediate gear stud

Timing gears

Timing gears
Removal, installation of timing gears
Additional jobs
S Remove/install the vibration damper, see 592
1 Camshaft gear wheel 4 Drive gear oil pump

2 Idler 2 5 Idler 1
3 Crankshaft gear wheel 6 Intermediate gear stud

Timing gears
Technical data
Tightening torques
Mounting bolts intermediate gear 1 . . . . . . . . . . . . . . . . . . M14x1.75x45-8.8 . . . . . . . . . . . . . . . . . . . . 115 Nm
Camshaft gear mounting bolts . . . . . . . . . . . . . . . . . . . . . . M10x1.25-10.9 . . . . . . . . . . . . . . . . . . . . . . . 65 Nm
Oil pump drive wheel mounting nut . . . . . . . . . . . . . . . . . . M12x1.5-6S . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Installation play of the timing wheels

Intermediate gear 1 radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 - 0.109 mm
Axial play of intermediate gear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.200 - 0.280 mm
Check the tooth flank clearance of the timing gears

Crankshaft timing gear - camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 - 0.149 mm
Camshaft gear - air compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 - 0.185 mm
Crankshaft gear - intermediate gear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 - 0.187 mm
Intermediate gear 1 - intermediate gear 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 - 0.175 mm
Intermediate gear 1 - oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.053 - 0.190 mm
Intermediate gear 2 - injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 - 0.177 mm
Service products
Loctite 573 sealing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04.90300-9018
Loctite 648 sealing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04.90300-9024
NOTE
Risk of damage to goods due to defective timing gears
Damage to components of the high pressure pump due to defective timing gears.
For this reason:
S Removing and checking defective timing gears.
NOTE
For this reason:
S Use the impact screwdriver for preliminary tightening to max. 50 % of the final torque value specified.

Timing gears
Special tools

S Gear ratchet [2]
[2] Gear ratchet 80.99627-0001


Timing gears
Remove idler
Fixing the crankshaft gear
► Secure the crankshaft gear 2 with two

mounting bolts 1

flywheel housing
Setting timing gears as marked
► Crank the engine using the engine cranking unit

[1] and the gear ratchet [2] until the marks on
the camshaft gear 1 and the crankshaft gear
2 are aligned
► Block the engine cranking unit [1]
Detaching intermediate gear 2

Timing gears
► Remove the intermediate gear pin 2 and the

intermediate gear 3
Detaching intermediate gear 1

► Remove the intermediate gear pin 2 and the
intermediate gear 3

Timing gears
Detaching the oil pump drive gear
► Removing the mounting nut 1 with spring

washer 2
► Pull off the oil pump drive gear 3
Install idler
Installing the oil pump drive gear
► Covering the cone in the oil pump drive gear 3

and the oil pump thinly with Loctite 648 sealing
agent
► Positioning the oil pump drive gear 3 with
spring washer 2
Mounting intermediate gear 1

intermediate gear pin 2
► Position the intermediate gear pin 2 along with
the intermediate gear 3

Timing gears
Mounting intermediate gear 2

intermediate gear pin 2
► Position the intermediate gear pin 2 along with
the intermediate gear 3


Timing gears
Removing the camshaft gear

mounting bolts 1

flywheel housing

2 are aligned

Timing gears
Unscrewing the camshaft gear mounting bolts
Removing camshaft gear
► Pull the camshaft gear 1 off the camshaft 2

Timing gears
Install the camshaft gear
Mount the camshaft gear
► Align the marks on the camshaft gear 1 and

the crankshaft gear
► Align the camshaft 2 with the hole pattern of
the camshaft gear 1 , if necessary
► Place the camshaft gear 1 onto the camshaft
Screwing in the camshaft gear mounting bolts
► Screw in the camshaft gear mounting bolts 1

and tighten crosswise

Timing gears
Check marking overlap
► Unlock the engine with the engine cranking unit

[1] and crank the crankshaft 2 by 720°
► Check that the marks on the camshaft gear 1
and the crankshaft gear 2 are aligned
If the marks are not in line, the camshaft gear 1
must be removed and reinserted at the mark.
Unscrew the crankshaft gear mounting bolts
► Release the crankshaft gear 2 by unscrewing

the mounting bolts 1


Timing gears
Removing the crankshaft gear

mounting bolts 1

flywheel housing

2 are aligned

Timing gears

Removing the crankshaft gear
► Pull the crankshaft gear 1 off the crankshaft 3

► Clean the contact surfaces of the crankshaft
gear 1 , the crankshaft 3 and the guide pin 2

Timing gears
Installing the crankshaft gear
Fitting the crankshaft gear
► Apply a thin layer of sealing agent Loctite 573

to the rear face of the crankshaft gear 1
► Align the marks on the camshaft gear and the
crankshaft gear 1
► Put the crankshaft gear 1 onto the crankshaft

mounting bolts 1
Check marking overlap
► Unlock the engine cranking unit [1] and crank

the crankshaft by 720°
► Check that the marks on the camshaft gear 1
and the crankshaft gear 2 are aligned
If the marks are not in line, the camshaft gear 1
must be removed and reinserted at the mark

Timing gears



Timing gears

Engine lubrication
Engine lubrication
1 Upper part of the oil sump 3 Lower part of oil sump

2 Oil module

Engine lubrication

Engine lubrication
Removing/installing the oil module
1 Oil module
Technical data
Tightening torques
Screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
GE bulkhead union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Nm
Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Nm
Oil cooler round-head screw . . . . . . . . . . . . . . . . . . . . . . . . M6x20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
Consumables

Engine lubrication
NOTE
For this reason:
ENVIRONMENTAL NOTE
Collect emerging engine oil using a suitable container.

Engine lubrication
Removing the oil module
NOTE
Risk of material damage due to oil emulsion
When removing the oil module, coolant flows
from the crankcase to the oil sump.
For this reason:
S Completely drain coolant before removing the
oil module.

► Unlocking the plug connectors of the coolant
pipe 1 by pressing the spring clips
► Clicking the coolant pipe out of the 1 pipe
bracket
► Remove the coolant line 1

pressure sensor 1
Removing the oil module

bolts 3 and 4
► Remove the oil module 1 together with the
seal 2

Engine lubrication
► Unscrew pressure sensor 3 with seal 2

► Turning out the union 1
Removing the oil cooler
► Unscrew the GE bulkhead fitting 3

Removing the oil cooler
NOTE
Risk of material damage as a result of
putting down incorrectly
The oil cooler will be damaged.
For this reason:
S Put the oil module aside so as not to damage
the oil cooler.
► Turning out the round-head screws 1

► Removing the oil cooler 2 with seal 3 from the
oil module

Engine lubrication
Installing the oil module
Installing the oil cooler
► Inserting the oil cooler 2 with new seal 3 into

the oil module
► Screwing in and fastening the round-head
screws 1
Installing the oil cooler
► Screw the screw plug 2 in with a new seal 1

and tighten
► Covering the GE bulkhead unions 3 thinly with
Loctite 242 sealing agent
► Screwing in and tightening the GE bulkhead
unions 3
► Covering the union 6 thinly with Loctite 242
sealing agent
► Screw the union 6 in and tighten
and tighten
► Covering the union 1 thinly with Loctite 242

sealing agent
► Screwing in the union 1 and tightening it
► Screwing in and fastening the pressure sensor
3 with new seal 2

Engine lubrication
Tightening sequence for oil module
► Adhere to the oil module tightening sequence

1 to 9 in the following work step
Mounting the oil module
► Position the oil module 1 with a new seal 2

4 as marked

Engine lubrication

pressure sensor 1
NOTE
connections
For this reason:
S Check the plug-in connections of the coolant
lines for after securing for firm attachment
and then secured
► Attaching the coolant pipe 1 with plug

connectors
► Clicking in the coolant pipe 1 into the pipe
bracket

Engine lubrication

Engine lubrication
Removing/installing the oil filter insert
1 Oil module
Technical data
Tightening torques
Oil filter lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Service products
NOTE
For this reason:
ENVIRONMENTAL NOTE

Engine lubrication
Special tools
[1] Socket 80.99603-0325

S Removing and installing the oil filter lid

Engine lubrication
Removing the oil filter insert
Removing the oil filter insert
► Turning out the oil filter lid 1 using the socket

2 [1]
► Pulling the oil filter insert 4 out of the oil
module 5
► Pulling the O-ring 3 off the oil filter cover 1

Engine lubrication
Installing the oil filter insert
Installing the oil filter insert
► Apply a thin layer of clean engine oil to the new

O-ring 3
► Putting a new O-ring 3 onto the oil filter
cover 1
► Inserting the new oil filter insert 4 into the oil
module 5
► Screwing the oil filter cover 1 with the socket
insert 2 [1] onto the oil module 5 and
tightening it

Engine lubrication
Removing and installing the oil sump
1 Oil sump
Technical data
Tightening torques
Oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M22x1.5-5.8 . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
NOTE
For this reason:
ENVIRONMENTAL NOTE

Engine lubrication
Removing the oil sump
Turning out the oil drain plug
► Turning out the oil drain plug 2 with seal 1
Detach the oil sump
► Turning out the mounting bolts 3 with holders

2 and removing them
► Remove the oil sump 4 together with the
seal 1
Installing the oil sump
Mounting the oil sump
► Positioning a new seal on the 1 oil sump 4

► Positioning of the oil sump 4
► Positioning support units 2 , screwing in the
mounting bolts 3 and tightening them

Engine lubrication
Screwing in the oil drain plug
► Screwing in the oil drain plug 2 with new

seal 1

Engine lubrication
Removing and installing the oil sump

Variants 66, 67
1 Oil sump
Technical data
Tightening torques
NOTE
For this reason:
ENVIRONMENTAL NOTE

Engine lubrication
Turning out the oil drain plug
► Turning out the oil drain plug 2 with seal 1
Detach the oil sump
► Turning out the mounting bolts 4 with holders

3 and removing them
► Remove the oil sump 1 together with the
seal 2
Mounting the oil sump
► Positioning a new seal on the 2 oil sump 1

► Positioning of the oil sump 1
► Positioning support units 3 , screwing in the
mounting bolts 4 and tightening them

Engine lubrication
Attaching the oil drain screw
► Screwing in the oil drain plug 2 with new

seal 1

Engine lubrication
Removing/installing the oil pump excess pressure relief valve

Versions 68
Additional jobs
1 Pressure relief valve
Technical data
Tightening torques
Oil pump excess pressure relief valve screw plug . . . . . M24x1.5-5.8 . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Consumables

Engine lubrication
NOTE
For this reason:
ENVIRONMENTAL NOTE

Engine lubrication
Removing the oil pump pressure relief valve
NOTE
Tightening of the oil pressure-relief valve can
cause component damage excessive pressure
in the engine housing.
For this reason:
S Check that the oil pump excess pressure
relief valve is not worn, and use a repair level
if necessary.
► Unscrew the screw plug 4 and remove it along

with the seal 3 and the pressure spring 2
► Pull the piston 1 out of the crankcase

Engine lubrication
Installing the oil pump pressure relief valve

piston 1
► Lift the piston 1 into the crankcase with the
pressure spring 2
and tighten

Engine lubrication
Installing the oil pump excess pressure relief valve repair kit
► Fit a new O-ring 2 on the bush 1

► Insert the bush 1 into the crankcase
valve piston 3
► Insert the valve piston 3 into the bush 1 with
the pressure spring 4
and a pressure spring 5 and tighten

Engine lubrication
Removing/installing the oil pump excess pressure relief valve

Variants 66, 67
1 Pressure relief valve
Technical data
Tightening torques
Oil pump excess pressure relief valve screw plug . . . . . M24x1.5-5.8 . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Consumables
NOTE
For this reason:

Engine lubrication
ENVIRONMENTAL NOTE

Engine lubrication
NOTE
Tightening of the oil pressure-relief valve can
cause component damage excessive pressure
in the engine housing.
For this reason:
S Check that the oil pump excess pressure
relief valve is not worn, and use a repair level
if necessary.
► Unscrew the screw plug 3 and remove it along

with the seal 4 and the pressure spring 2
► Pull the piston 1 out of the crankcase

Engine lubrication

piston 1
► Lift the piston 1 into the crankcase with the
pressure spring 2
► Put a new seal 4 onto the screw plug 3
and tighten
Installing the oil pump excess pressure relief valve repair kit
► Positioning the new O-ring 2 onto the bush 1

► Insert the bush 1 into the crankcase
valve piston 3
► Insert the valve piston 3 into the bush 1 with
the pressure spring 6
and a pressure spring 5 and tighten

Engine lubrication

Engine lubrication
Remove/install the upper part of the oil sump housing

Versions 68
Additional jobs
1 Oil dipstick 3 Oil return line

2 Upper part of the oil sump
Technical data
Tightening torques
Mounting bolts for crankcase yoke . . . . . . . . . . . . . . . . . . . M8x45-8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Service products
Assembly paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09.16012-0117

Engine lubrication
NOTE
For this reason:
ENVIRONMENTAL NOTE
Special tools

S Removing, installing the spring band clamps
[2] Hexagonal shank screw 06.99606-6152

S Removing, installing the upper part of the oil sump

Engine lubrication
Remove the upper part of the oil sump housing
Removing the oil dipstick
► Pulling the oil dipstick 1 out of the guide

tube 4
► Turning the union 3 with guide tube 4 out
of the upper part of the oil sump
► Removing the guide tube 4 with seal 2 and
union 3

Engine lubrication
Removing the oil level sensor

Removing the ventilation pipe

► Remove the bleed line 3
Removing the oil return line
► Turning the union 1 with seal 2 out

of the upper part of the oil sump
► Pull out the oil return line

Engine lubrication
Removing the high-pressure turbo charger oil return line

sealing ring 6
Removing the low-pressure turbo charger oil return line

sealing ring 5
► Remove the ring union 3 along with the
seals 2 and 4 remove

Engine lubrication
Removing the upper part of the oil sump

bolts 1 and 3
► Turning out the mounting bolts 1 and 3 and
removing them with the bushes
► Removing the upper part of the oil sump 2
Pushing off the upper part of the oil sump
Tip for users

The oil sump is hard to detach, therefore push
off the oil sump with a hexagonal shank screw
[2].
► Screwing in the hexagonal shank screws 2 [2]

and pushing off the upper part of the oil sump
1 from the crankcase
► Turning out the hexagonal shank screws 2 [2]

Engine lubrication
Installing the upper part of the oil sump
Attaching the upper part of the oil sump
NOTE
Risk of material damage to components due
to leaking oil sump
For this reason:

S The sealing surface must be fat-free.
S The bead of sealing agent must be
continuous and not wider than 2 mm
S Check that the bead of sealing agent is
closed
► Applying Loctite 5900 1 thinly to the area

to be sealed on the crankcase as shown

Engine lubrication
Tightening sequence for the upper section of the oil sump housing
► Tightening all mounting bolts according to the

tightening sequence 1 to 19
► Positioning the upper part of the oil sump 2

► Screwing in the mounting bolts 1 and 3 with
bushes as marked
► Tightening the mounting bolts 1 and 3
according to the tightening sequence

Engine lubrication
Attaching the low-pressure turbo charger oil return line
► Positioning the ring union 3 with a new

seal 2 and 4 position it
► Screw in the union 1
► Insert the new seal 5 into the union nut 7
► Position the oil return line 9
► Screwing on the union nut 7 of the oil return
► Screw in and tighten the mounting bolts
8 with washers

► Insert the new seal 7 into the union nut 5 on
the oil return line 2
► Position the oil return line 2 with the seal 1
► Screwing on the union nut of the oil return line
5 until it is hand-tight
washers
► Bracing the union
► Tightening the union nut 5 of the oil return
line 2
Installing the oil return line
► Inserting the oil return line

► Turning the union 1 with new seal 2 into the
upper part of the oil sump and tightening it

Engine lubrication
Attaching the bleed line
► Positioning the 3 bleed line

► Screw on the union nut 2 and tighten
Attaching the oil level probe
► Screwing in and tightening the oil level

sensor 1 with new seal 2

Engine lubrication
Installing the oil dipstick
► Screwing in the union 3 with seal 2 into the

upper part of the oil sump
► Sliding the guide tube 4 up to the limit stop into
the upper part of the oil sump and pulling it
briefly back to lock it
► Inserting the oil dipstick 1 into the guide tube 4

Engine lubrication

Engine lubrication
Remove/install the upper part of the oil sump housing

Variants 66, 67
Additional jobs
S Installing, removing the oil sump Versions 66, 67, see 532
1 Upper section of the oil sump housing
Technical data
Tightening torques
Service products

Engine lubrication
NOTE
For this reason:

Engine lubrication
Special tools

[2] Hexagonal shank screw 06.99606-6152

S Removing, installing the upper part of the oil sump

Engine lubrication
Removing the oil dipstick
► Pulling the oil dipstick 1 out of the guide

tube 4
► Turning the union 3 with guide tube 4 out of
the upper part of the oil sump
► Detaching the pinch bolting of the screw-in
fitting and pulling the guide tube 4 out of the
union 3

Engine lubrication
Removing the oil level sensor


pliers [1]
► Pulling the oil return line 4 out of the hose and
removing it

Engine lubrication
ENVIRONMENTAL NOTE
container.
the bush 3
► Removing the oil return line 2 with seals 1
and 4
Removing the refrigerant compressor holder


Engine lubrication
Removing the upper part of the oil sump

► Removing the upper part of the oil sump 2
Pushing off the upper part of the oil sump
Tip for users

The oil sump is hard to detach, therefore push
off the oil sump with a hexagonal shank
screw [2].
► Screwing in the hexagonal shank screw 1 [2]

and pushing the upper part of the oil sump 2
off the crankcase
► Turning out the hexagonal shank screw 1 [2]
Removing the oil return line
► Turning the union 1 with seal 2 out of the

► Pull out the oil return line

Engine lubrication
NOTE
to leaking oil sump
For this reason:

S The sealing surface must be fat-free.
closed
► Applying Loctite 5900 1 thinly to the area to

be sealed on the crankcase as shown
Installing the oil return line
► Inserting the oil return line

► Screwing in the union 1 with seal 2 and
tightening it

Engine lubrication
Tightening sequence for the upper section of the oil sump housing
► Tightening all mounting bolts according to the

tightening sequence 1 to 17
► Positioning the upper part of the oil sump 2

► Screw in the mounting bolts 1
► Tightening the mounting bolts 1 according to
the tightening sequence

Engine lubrication
Attaching the refrigerant compressor holder
► Positioning the oil return line 2 with new

seals 1 and 4
washers 8
► Screwing in and tightening the mounting bolt
6 with bush 3

Engine lubrication
► Pushing the oil return line 4 into the hose

► Screwing the union nut 3 onto the union
► Bracing the union and tightening the union
nut 3
► Attach the hose clamp 1 using the hose
clamp pliers [1]
Attaching the oil level probe
► Screwing in and tightening the oil level sensor

1 with new seal 2

Engine lubrication
Installing the oil dipstick
► Turning the union 3 with new seal 2 into the

► Sliding the guide tube 4 up to the limit stop into
the upper part of the oil sump and pulling it
briefly back to lock it
► Inserting the oil dipstick 1 into the guide
tube 4

Engine lubrication

Engine lubrication
Removing, installing the suction line / intake pipe of the oil pump
Versions 68
Additional jobs
1 Oil suction line
NOTE
For this reason:
S Use the impact screwdriver during preliminary tightening with max. 50% of the specified final
tightening torque.
ENVIRONMENTAL NOTE

Engine lubrication
Removing the oil suction line
► Unscrewing the mounting bolts 3 and 4 with

washer 5
► Removing the oil suction line 2
► Removing the seal 1 and bush 6
Installing the oil suction line
► Positioning the sleeve 6 and a new seal 1

► Positioning the oil suction line 2
3 and 4 with washer 5

Engine lubrication
Removing, installing the suction line / intake pipe of the oil pump
Variants 66, 67
Additional jobs
S Installing, removing the oil sump Versions 66, 67, see 532
1 Oil suction line
NOTE
For this reason:
S Use the impact screwdriver during preliminary tightening with max. 50% of the specified final
tightening torque.
ENVIRONMENTAL NOTE

Engine lubrication

► Pulling the oil suction line 3 out of the
crankcase yoke
► Taking the O-ring 1 out of the crankcase yoke
► Covering the new O-Ring 1 thinly with clean

engine oil and inserting it in the crankcase yoke
► Positioning the oil suction line 3 on the
crankcase yoke

Engine lubrication
Removing/installing the oil pump
Additional jobs

Engine lubrication
1 Oil pump housing 4 Spring washer

2 Mounting bolt 5 Oil pump gear
3 Mounting nut

Engine lubrication
Technical data
Tightening torques
Mounting bolt for oil pump on timing case . . . . . . . . . . . . . M820-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Axial play of the oil pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 - 0.114 mm
Radialplay of the oil pump shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 - 0.078 mm
Service products
Loctite 242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04.90300-9025
NOTE
For this reason:
ENVIRONMENTAL NOTE
Special tools
[1] Straightedge 80.99605-0167

S Check the axial play of the oil pump gears in conjunction with:
S Feeler gauge [2]
S Support [3]
[2] Feeler gauge 08.75310-0806

S Check the axial play of the oil pump gears
[3] Support 80.99606-0551

S Check the axial play of the oil pump gears

Engine lubrication
Removing the oil pump
Unscrew the oil pump mounting bolts
► Turning the mounting bolts 1 with washers out

of the oil pump housing
Remove oil pump
► Pull the oil pump 3 out of the timing case

► Pull the coupling sleeve 1 out of the oil
pump 3
► Removing the O-rings 2 from the coupling
sleeve 1
Check the oil pump gear axial clearance
► Place the oil pump on the supports [3] (2x) 1

► Put the straightedge [1] 2 on the oil pump
housing with the measuring edge on the oil
pump housing 4
► Check the axial play between the oil pump
gears 3 and the straightedge [1] 2 with the
feeler gauge [2] 5
The permissible axial play is 0.050 - 0.114 mm.
If the axial play is outside the tolerance, the oil
pump must be replaced.

Engine lubrication
Installing the oil pump
Mounting the oil pump
► Apply a thin layer of clean engine oil to the new

O-rings 2
► Fit the O-rings 2 on the coupling sleeve 1
► Inserting the coupling sleeve 1 up to the limit
stop into the oil pump housing 3
► Insert the oil pump 3 into the timing case
through the hole provided for this purpose
Screw in the oil pump mounting bolts
► Clean the threaded bores on the oil pump

housing
► Apply a thin layer of Loctite 242 2 to the new
mounting bolts 1
► Check that the oil pump gears move freely,
if necessary, repeat the procedure

Engine lubrication

Engine lubrication
Dismantling/assembling the oil pump
Additional jobs
S Remove/install the oil pump, see 574

Engine lubrication
1 Oil pump gear 4 O-rings

2 Oil pump gear 5 Coupling sleeve
3 Oil pump housing
NOTE
For this reason:

Engine lubrication
Disassemble oil pump
Disassemble oil pump
► Pulling the oil pump gears 2 and 3 out of the

oil pump housing 1
Assemble the oil pump
Assemble the oil pump
Tip for users

The oil pump gears are marked at the front of
the gears by a dotted mark at one tooth.
► Apply a thin layer of clean engine oil to the oil

pump gears 2 and 3
► Insert the oil pump gears 2 and 3 into the oil
pump housing 1 so that the marks are in line

Engine lubrication

Engine lubrication
Removing/installing the oil injection nozzles
Additional jobs
S Remove/install the oil pump intake line/intake pipe, see:, see 570
S Removing, installing the suction line/intake pipe of the oil pump Versions 66, 67, see 572

Engine lubrication
1 Oil nozzle 3 Oil pressure valve

2 Spring washer
Technical data
Tightening torques
Oil pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
NOTE
For this reason:

Engine lubrication
Special tools
[1] Torque wrench 08.06450-0006

S Tighten the oil pressure valve
[2] Adjustmentgauge 80.99607-6055

S Align the oil injection nozzles

Engine lubrication
Removing the oil nozzles
Removing the oil nozzles
► Unscrew the oil pressure valve 1 and remove

with the spring washer
► Remove the oil nozzle 2

Engine lubrication
Install oil nozzles
Insert oil nozzles
► Inserting the oil nozzle 3 with spray nozzle

oriented towards the liner piston
► Screw the oil pressure valve 1 in with a new
spring washer 2 and tighten by hand
Aligning and tightening the oil pressure valve
NOTE
Risk of material damage due to overheating
The pistons may overheat if the oil nozzles are
misaligned.
For this reason:
S Align the oil nozzles correctly using a setting
gauge.
S The setting gauge must lie flat on the bearing
seat of the crankshaft.
► Clean the flat faces of the bearing seats of the

crankshaft
► Inserting the adjustmentgauge [2] 4 into
bearing seat holes while taking care that the oil
nozzle 1 is locked in the recess 3
► Check that the oil nozzle 1 is seated correctly.
Realign if necessary
► Tighten the oil pressure valve 2 using the
torque wrench [1]
► Remove the setting gauge [2]

Engine lubrication

Crankshaft drive
Crankshaft drive
1 Vibration damper 4 Flywheel

2 Connecting rod 5 Crankshaft
3 Piston

Crankshaft drive

Crankshaft drive
Removing and installing vibration damper
Additional jobs
1 Vibration damper 3 Mounting bolts

2 Ribbed V-belt disc
Technical data
Tightening torques
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5-10.9 . . . . . . . . . . . 1st tightening 150 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5-10.9 . . . . . . . . . . . . . . . . Final torque 90°
NOTE
For this reason:
S Do not reuse vibration damper mounting bolts.

Crankshaft drive
NOTE
For this reason:
Special tools

S Locking the engine

Crankshaft drive
Removing vibration damper

flywheel housing and lock
► Marking the installation position of the ribbed

V-belt disc 2 relative to the vibration damper
Detaching the vibration damper

► Remove the washer 3
► Removing the vibration damper 1 with
splash guard 2

Crankshaft drive
Installing vibration damper
Installing vibration damper
NOTE
For this reason:
S Do not reuse vibration damper mounting
bolts.
► Positioning the splash ring 2 with vibration
damper 1
► Screwing in and tightening the new mounting
bolts 4 with washer 3
Tightening torque
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°
► Positioning the ribbed V-belt disc 2 after

marking on the vibration damper

► Unlocking and removing the cover of the
flywheel housing

Crankshaft drive
Removing/installing the flywheel
1 Flywheel housing 3 Mounting bolt

2 Flywheel
Technical data
Tightening torques
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5x35-10.9 . . . . . . . . 1st tightening 100 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5x35-10.9 . . . . . . . . . . . . . Final torque 90°

Flywheel axial run-out deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm
Starter ring gear installation temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 - 240°
NOTE
For this reason:
S Do not reuse flywheel mounting bolts.

Crankshaft drive
NOTE
For this reason:
S Use impact screwdriver for preliminary tightening to max. 50% of the fastening torque specified.
S Final tightening must always be performed manually using a torque wrench.
Special tools
[1] Dial gauge 08.71000-3217

S Checking the flywheel axial run-out deviation

S Checking the flywheel axial run-out deviation
[3] Tracer pin 80.99605-0197

S Checking the flywheel axial runout in conjunction with:
S Dial gauge [1]
S Dial gauge holder [2]
[4] Guide mandrel 80.99617-0163

S Removing/installing the flywheel

S Undo the flywheel bolts and tighten in conjunction with:
S Support [7]
S Power amplifier wrench i = 1: 3.3 [6]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]
S 42 mm rubber ring [12]
S Washer [13]

Crankshaft drive
[6] Power amplifier wrench i = 1 : 3.3 80.99619-0006

S Socket [5]
S Support [7]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]
[7] Support 80.99606-0551
S Socket [5]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]
[8] Angle gauge 80.99607-0172
S Socket [5]
S Support [7]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]
[9] Stop pin 80.99606-0585
S Socket [5]
S Support [7]
S Angle gauge [8]
S Stud bolt [10]
S Washer [13]
[10] Stud bolt 06.02191-0407
S Socket [5]
S Support [7]
S Angle gauge [8]
S Stop pin [9]
S Washer [13]

Crankshaft drive
[11] Connecting pin 06.22729-0006

S Socket [5]
S Support [7]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]
[12] 42 mm rubber ring 08.06142-9006
S Socket [5]
S Support [7]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]
[13] Adapter 80.99606-0552
S Socket [5]
S Support [7]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]

Crankshaft drive
Removing the flywheel
► Insert the power amplifier wrench i =1 : 3.3 [6]

1 into the support [7] 2
► Attaching the stop pin [9] 5 with stud bolt [10]
3 and adapter [13] 4 to the support [7] 2
amplifier wrench i = 1 : 3.3 [6] 1 and secure it
with the connecting pin [11] 8 and the 42 mm
rubber ring [12] 6
Undo flywheel mounting bolts
► Position the special tool 1 on the respective

mounting bolt to be loosened 2
► Loosen all mounting bolts 2
Unscrewing the flywheel mounting bolts
► Unscrew two diametrically opposed mounting

bolts 1 from the flywheel

Crankshaft drive
Screwing in the aligning tools
► Screwing in the guide mandrel [4] 1

► Turning out the remaining mounting bolts 2
Pulling off the flywheel
CAUTION
For this reason:

S Using hoists to remove the flywheel
► Pull the flywheel 1 off over the guide mandrel
[4] 2
Cleaning and checking the flywheel
► Clean the flywheel 1

► Check the flywheel 1 for cracks, replace the
flywheel 1 if necessary
► Checking thefriction surface for burnt spots and
signs of running in, replace the flywheel 1 as
required
► Check the teeth of the starter ring gear 2 for
wear, and replace the starter ring gear 2 if
necessary

Crankshaft drive
Removing and installing the starter ring gear
Detaching the starter ring gear
NOTE
Risk of material damage due to drilling
The flywheel may be damaged.
For this reason:
S Do not damage the flywheel when drilling and
opening the starter ring gear.
S Replace the flywheel if it is drilled into or
damaged.
► Spot-drill the flywheel ring gear 1 and force

it open
► Remove flywheel ring gear 1 from the
flywheel 2
► Cleaning the contact areas of the flywheel 2
and checking them for damage
Mounting the starter ring gear
CAUTION
Danger of injury due to hot components
For this reason:

S Removing the starter ring gear with protective
gloves
► Heating the new starter ring gear 1 to
220 - 240°C
► Positioning the new starter ring gear 1 so that
the chamfer 3 at the teeth points away from
the flywheel 2
► Inserting a new starter ring gear 1 as required

Crankshaft drive
Installing the flywheel
Checking the flywheel axial run-out
► Clamp the flywheel 1

► Attach the dial gauge holder [2] 2 with the dial
gauge [1] 3 and the tracer pin [3]
► Position the pre-loaded tracer pin [3] onto the
flywheel 1
► Turn flywheel 1 several turns and while doing
so read the displacement indicated on the dial
gauge [1] 3
The permitted axial run-out deviation of the
flywheel 1 is 0 1 mm.
If the axial runout is out of tolerance, the flywheel
1 must be replaced.
Positioning the flywheel
CAUTION
For this reason:

S Using hoists to install the flywheel
► Line up the flywheel 1 with the crankshaft
alignment pin
► Place the flywheel 1 over the guide mandrel
[4] 2
Screw in mounting bolts
NOTE
For this reason:
S Do not reuse flywheel mounting bolts.
► Screwing in new mounting bolts 2
► Unscrew the guide mandrel [4] 1
► Unscrewing the remaining mounting bolts

Crankshaft drive
Tighten the mounting bolts
Tip for users

Observe ratio:
Power amplifier wrench i = 1 : 3.3 [6].
► Tighten the mounting bolts 2 using the special
tool 1
Tightening torque
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm

Crankshaft drive

Crankshaft drive
Removing/installing the piston with connecting rod
Additional jobs

Crankshaft drive
1 Piston pins 3 Connecting rod

2 Piston 4 Connecting rod bearing cap
Technical data
Tightening torques
Connecting-rod bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . M11x1.5x60-11.9 . . . . . . . . . 1st tightening 55 Nm
Connecting rod bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . M11x1.5x60-11.9 . . . . . . . . . . . . . Final torque 90°
Connecting rods
Connecting-rod length from middle of connecting rod
eye to middle of connecting-rod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.98 - 196.02 mm
Internal diameter of connecting-rod eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 44.050 - 44.066 mm
Connecting-rod journal width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.78 - 36.88 mm
Hole for bearing shells in the connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 74.000 - 74.019 mm
Axial play connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.220 - 0.520 mm
Connecting-rod bearings
Connecting-rod bearing standard dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 70.026 - 70.069 mm
Connecting-rod bearing, Repair Level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 69.926 - 69.969 mm
Connecting-rod bearing, Repair Level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 69.776 - 69.819 mm
Weight difference per set of connecting rods for one engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 50 g
Radial play of connecting-rod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.026 - 0.088 mm

Crankshaft drive
Wall thickness of connecting-rod bearing

Strength of connecting-rod bearing normal dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.975 - 1.987 mm
Strength of connecting-rod bearing, Repair Level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.025 - 2.037 mm
Strength of connecting-rod bearing, Repair Level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.100 - 2.112 mm
Piston diameter Ø 108 mm piston without cooling channel Class A (double-bevelled ring height 3 mm)
D1 measured 17 mm above the lower edge of the piston . . . . . . . . . . . . . . . . . . . . . . . 107.866 - 107.875 mm
D3 measured 84.9 mm above the lower edge of the piston . . . . . . . . . . . . . . . . . . . . . . 107.589 - 107.598 mm
Piston diameter Ø 108 mm piston without cooling channel Class B (double-bevelled ring height 3 mm)
Piston diameter Ø 108 mm piston with cooling channel Class A (double-bevelled ring height 3 mm)
D4 measured 96.7 mm above the lower end of the piston . . . . . . . . . . . . . . . . . . . . . . . 106.151 - 106.160 mm
Piston diameter Ø 108 mm piston with cooling channel Class B (double-bevelled ring height 3 mm)
Piston height Ø 108 mm piston without cooling channel (double-bevelled ring height 3 mm)
Overall height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.00 mm
Piston height from middle of piston pin to piston head / PH level 0 . . . . . . . . . . . . . . . . . . . . . . . . . . 63.90 mm
Total height, under-size I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.80 mm
Piston height from middle of piston pin to piston head / PH level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 63.70 mm
Keystone compression ring

Piston ring height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.570 - 2.595 mm
Piston ring width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25 - 4.6 mm
End gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 - 0.50 mm
Taper-faced compression ring

Piston ring width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 - 4.60 mm
End gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 - 0.65 mm
Axial play in the piston ring groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm
Bevelled-edge ring
Piston ring width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40 - 3.65 mm
End gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.6 mm
Axial play in the piston ring groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm

Crankshaft drive
Piston pins
Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 43.994 - 44.00 mm
Piston pin play (radial) in the connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 - 0.072 mm
Piston pin play (radial) in the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 - 0.021 mm
Piston projection
Piston clearance from the top edge of the crankcase to the piston head . . . . . . . . . . . . . . . 0.087 - 0.389 mm
Piston weight
Piston weight difference per set in one engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 40 g
Service products
NOTE
Risk of material damage due to incorrect handling
Crack surfaces will get damaged.
For this reason:
S The connecting rod must be replaced if the crack surfaces on the connecting rod are damaged.
S Protect crack surfaces from damage by hard or sharp objects.
S To clean the crack surfaces on the connecting rods, only rinse them with clean cleaning agent.
S Use compressed air to blow-dry the crack surfaces after cleaning.
S Do not allow any particles that are rinsed out to get into the engine.
NOTE
For this reason:
S Do not reuse old connecting rod bearing bolts.
NOTE
For this reason:
Tip for users

Always measure the piston diameter transverse to the piston pin hole.
The pistons are marked with A or B.

Crankshaft drive
NOTE
Risk of engine damage due to dirt ingress during removal/fitting of lead-free bearings
Dust and dirt on components in the oil circuit can cause engine damage
For this reason:
S Ensure extreme cleanliness when handling components (M3576).
S Ensure extreme cleanliness of working environment, working equipment and tools.
S Particles larger than 600 µm cause engine damage.
S Never expose these components to used cleaning fluids.
S Prior to repairs, thoroughly clean assemblies and seal all openings where no ingress of dirt is allowed
to avoid safety issues or malfunction.
S Only lint-free cleaning cloths are allowed to be used.
S Repair the engine in a clean area of the workshop where none of the work causes dust to be swirled
up (sanding, welding, brake repairs, brake checks, performance tests etc.).
S Avoid air movements (possible swirling up of dust due to starting of engines, the workshop heating/
ventilation system, due to draughts etc.).
S Use a new and clean cover in areas of the working environment where dirt particles can become
loose.
S Loose dirt must be removed during assembly work using a suitable suction device (industrial vacuum
cleaner).

Crankshaft drive
Special tools
[1] Dial gauge 08.71000-3217

S Checking the piston protrusion

S Checking the piston protrusion
[3] Tracer pin 80.99605-0197

S Checking the internal diameter of the piston pin bearing and connecting-rod
bearing in connection with:
S Dial gauge [1]

S Removing/installing piston rings
[5] Feeler gauge 08.75310-3309

S Checking the piston ring axial play and end gap
[6] Piston ring collet 80.99613-0039

S Installing pistons

Crankshaft drive
[7] Setting tool 80.99622-0052

S Aligning connecting rod bearing shells

S Checking the piston ring insertion depth

Crankshaft drive
Removing the piston and connecting rod
Remove the connecting rod bearing cap
NOTE
handling
For this reason:
S The connecting rod must be replaced if the
crack surfaces on the connecting rod are
damaged.
S Protect crack surfaces from damage by hard
or sharp objects.
S To clean the crack surfaces on the
connecting rods, only rinse them with
clean cleaning agent.
S Use compressed air to blow-dry the crack
surfaces after cleaning.
S Do not allow any particles that are rinsed out
to get into the engine.
► Mark the connecting-rod bearing cap 2 and

connecting rod bearing shells 1 to indicate
correct installation position and assignment
► Unscrew the connecting rod bearing bolts 3
► Remove connecting-rod bearing cap 2 from
the crankshaft together with connecting rod
bearing shells 1
► Push out the piston and connecting rod towards
the cylinder head
Removing the piston
► Mark the installation position and orientation

of the piston 3 relative to the crankcase 1
► Pull the piston 3 out of the crankcase 1 along
with the connecting rod 2
► Remove the connecting rod bearing shell from
the connecting rod 2

Crankshaft drive
Remove piston pin
► Marking the relative positions of the piston 3 ,

piston bolt 2 and connecting rod 5
► Detach the locking rings 1 and 4 from the
piston 3
► Push the piston pin 2 out of the piston 3
► Removing the piston 3 from the connecting
rod 5
Checking the piston pin diameter
► Check the diameter of the piston pin 1 using

a micrometer 2
The permitted diameter of the piston pin 1 is
Ø 43.994 - 44.000 mm.
The piston with piston pin must be exchanged
when the diameter is outside the 1 tolerance
range.
Checking the piston ring axial play
Tip for users

An axial play cannot be measured on the key-
stone ring.
► Measure the axial play between the piston rings
2 and 3 and the piston 1 using the feeler
gauge [5] 4
The permitted axial play of the double-bevelled
ring 3 is 0.15 mm.
The permitted axial play of the tapered
compression ring 2 is 0.15 mm.
The piston 1 with piston rings 2 , 3 and keystone
ring must be exchanged when the axial plays are
outside the tolerance range.

Crankshaft drive
Removing the piston rings

diameter
► Detach the piston rings 2 , 3 and 4 from
the piston using the piston ring pliers [4] 1
► Carefully clean the piston ring grooves
Checking the piston ring gap
Tip for users

The ring gap is only allowed to be checked if
the piston bore has the correct inside diameter,
otherwise a false ring gap reading would be
obtained. Check the piston bore inner diameter.
► Inserting the piston ring 2 evenly deep into the

piston bore 1
► Checking the insertion depth of the piston ring
2 with the depth gauge (electronic) [8]
► Checking the permitted ring gap with the feeler
gauge [5] 3 The permitted ring gap of the
keystone ring is 0.35 - 0.50 mm.
The permitted ring gap for the taper-face ring is
0.50 - 0.65 mm.
The permitted ring gap for the double-bevelled ring
is 0.30 - 0.60 mm.
If the ring gaps are out of tolerance, the piston
rings must be replaced.

Crankshaft drive
Checking the connecting rods and connecting-rod bearings
Checking the piston pin bushing
► Checking the inner diameter of the piston pin

bearing with internal measuring gauge and 2
and dial gauge [1] 1
The permitted inner diameter of the piston pin
bearing is Ø 44.050 - 44.066 mm.
If the inside diameter is out of tolerance, the
connecting rod 3 must be replaced.
Checking the connecting-rod bearing inside diameter
► Insert the upper connecting rod bearing shell

into the connecting rod 1
► Insert the lower connecting rod bearing shell
into the connecting rod bearing cap 2
► Screwing in and tighten the connection rod
bearing bolts
► Checking the inner diameter of the
connecting-rod bearing with dial gauge [1] 3
internal measuring gauge 4
The permitted inner diameter of the connecting-rod
bearing is Ø 70.026 - 70.069 mm.
If the inside diameter is out of tolerance, the
connecting rod bearing shells must be replaced.

Crankshaft drive
Installing the piston and connecting rod
Installing the piston rings
NOTE
handling
Piston rings break.
For this reason:
S Install the piston rings using correctly adjus-
ted piston ring pliers.

diameter
► Insert the piston rings 2 , 3 and 4 into the
respective ring groove in the piston with the
TOP marking facing the piston crown with the
piston ring pliers [4] 1
Install piston pin
► Insert a new locking ring 4 in the groove in the

piston
► Fit the piston 3 over the connecting rod 5 as
marked
piston pin 2
► Push the piston pin 2 through the piston 3
and the connecting rod 5 in accordance with
its marking until it stops
the piston 3
► Check that the locking rings 1 and 4 are
seated correctly
If the locking rings 1 and 4 have not engaged
correctly, remove and re-attach the locking rings
1 and 4 , ensuring that they are seated correctly.

Crankshaft drive
Installing the piston
Tip for users

There is an installation arrow on the piston sur-
face. When installing, this arrow must point to-
wards the coolant pump.
► Move the crankshaft for the cylinder concerned

to TDC
► Align the ends of the piston rings offset to one
another by 120°
upper connecting rod bearing shell
► Insert the upper connecting rod bearing shell
into the connecting rod
piston 1
► Positioning the piston ring collet [4] 2 on the
piston 1 and tightening it
► Inserting the piston 1 with connecting rod into
the piston bore until the piston 1 has been
pushed out of the piston ring collet [4] 2
► Inserting the piston 1 until the connecting rod
with connecting rod bearing shell is resting on
the crankshaft

Crankshaft drive
Attaching connecting-rod bearing cap
NOTE
handling
For this reason:
S The connecting rod must be replaced if the
crack surfaces on the connecting rod are
damaged.
S Protect crack surfaces from damage by hard
or sharp objects.
S To clean the crack surfaces on the connec-
ting rods, only rinse them with clean cleaning
agent.
S Use compressed air to blow-dry the crack
surfaces after cleaning.
S Do not allow any particles that are rinsed out
to get into the engine.
NOTE
For this reason:
S Do not reuse old connecting rod bearing
bolts.
► Insert the lower connecting rod bearing shell 1
into the connecting rod bearing cap 2
► Check the alignment of the lower connecting
rod bearing shell 1 and adjust using the setting
tool [7], if necessary
lower connecting rod bearing shell 1
► Position the connecting-rod bearing cap 2 on
the connecting rod as marked
► Screw in the new connecting-rod bearing bolts
3 and tighten
Tightening torque

Crankshaft drive
Checking the piston protrusion
► Set piston 1 to OT
► Put the dial gauge [1] 2 with dial gauge holder
[2] 3 on the crankcase 4
► Put the dial gauge tip 5 onto the crankcase 4
and zero the dial gauge [1] 2
► Put the dial gauge tip 5 onto the piston 1 and
read off the difference (piston protrusion)
The permitted piston clearance is 0.087 - 0.389 mm.

Crankshaft drive
Removing/installing the crankshaft
Additional jobs
S Remove/ install the alternator, see 180

Crankshaft drive
1 Mounting bolt for crankshaft bearing cover 4 Crankcase

2 Crankshaft axial compensation 5 Crankshaft bearing crankcase
contact washer 6 Crankshaft
3 Crankshaft axial compensation 7 Crankshaft bearing cover
contact washer 8 Crankshaft bearing cap
Technical data
Tightening torques
Mounting bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x118-10.9 . . Preliminary tightening torque 115 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x118-10.9 . . . . . . . . . . . . . . . . . . . . . Final torque 90°
Crankshaft
Crankshaft hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 + 3 HRC
Permitted crowning of the bearing journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 mm
Crankshaft axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.200 - 0.395 mm
Connecting rod bearing journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 69.981 - 70.000 mm
Crankshaft bearing journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 86.978 - 87.000 mm

Crankshaft drive
Crankshaft bearing
Inner diameter of the crankshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 87.040 - 87.086 mm
Inner diameter of the crankshaft bearing repair level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 86.940 - 86.986 mm
Inner diameter of the crankshaft bearing repair level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 86.790 - 86.836 mm
Crankshaft bearing shell wall thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.468 - 2.480 mm
Wall thickness of crankshaft bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.518 - 2.530 mm
Wall thickness of crank shaft bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.593 - 2.605 mm
Crankshaft bearing spread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.50 - 94.00 mm
Thrust washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.850 - 2.900 mm
Thrust washers repair level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.100 - 3.150 mm
Service products
Special tools
NOTE
For this reason:
S Do not reuse the mounting bolts of the crankshaft bearing cover.
NOTE
For this reason:

Crankshaft drive
NOTE
Risk of engine damage due to dirt ingress during removal/fitting of lead-free bearings
Dust and dirt on components in the oil circuit can cause engine damage
For this reason:
S Ensure extreme cleanliness when handling components (M3576).
S Ensure extreme cleanliness of working environment, working equipment and tools.
S Particles larger than 600 µm cause engine damage.
S Never expose these components to used cleaning fluids.
S Prior to repairs, thoroughly clean assemblies and seal all openings where no ingress of dirt is allowed
to avoid safety issues or malfunction.
S Only lint-free cleaning cloths are allowed to be used.
S Repair the engine in a clean area of the workshop where none of the work causes dust to be swirled
up (sanding, welding, brake repairs, brake checks, performance tests etc.).
S Avoid air movements (possible swirling up of dust due to starting of engines, the workshop heating/
ventilation system, due to draughts etc.).
S Use a new and clean cover in areas of the working environment where dirt particles can become
loose.
S Loose dirt must be removed during assembly work using a suitable suction device (industrial vacuum
cleaner).
[1] Dial gauge 08.71000-3217

S Check the axial play of the crankshaft in conjunction with:

S Checking the axial play of the crankshaft
S Dial gauge [1]
S Tracer pin [3]
[3] Tracer pin 80.99605-0197

S Check the inner diameter of the crankshaft bearing in conjunction with:
S Dial gauge [1]

Crankshaft drive
[4] Setting tool 80.99622-0052

S Align the crankshaft bearing shells
S Positioning of the bearing shell on the crack connecting rod

S Support [5]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]
S Socket [5]
S Support [7]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]
[7] Support 80.99606-0551
S Socket [5]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]
[8] Angle gauge 80.99607-0172
S Socket [5]
S Support [7]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]

Crankshaft drive
[9] Stop pin 80.99606-0585

S Socket [5]
S Support [7]
S Angle gauge [8]
S Stud bolt [10]
S Washer [13]
[10] Stud bolt 06.02191-0407
S Socket [5]
S Support [7]
S Angle gauge [8]
S Stop pin [9]
S Washer [13]
[11] Connecting pin 06.22729-0006
S Socket [5]
S Support [7]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]
[12] 42 mm rubber ring 08.06142-9006
S Socket [5]
S Support [7]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]
S Washer [13]
[13] Washer 80.99609-0033
S Socket [5]
S Support [7]
S Angle gauge [8]
S Stop pin [9]
S Stud bolt [10]

Crankshaft drive
Removing the crankshaft
Check crankshaft axial play
► Attach the dial gauge [1] 3 with the dial gauge

holder [2] 2 and the tracer pin [3]
crankshaft 1
► Push the crankshaft 1 horizontally towards the
flywheel housing to the end position
► Pull the crankshaft 1 towards the dial gauge to
the end position and read off the difference
The permitted axial play of the crankshaft 1 is
0.200 - 0.395 mm.
If the axial play is out of tolerance, install new
thrust washers.
► Insert the power amplifier wrench i =1 : 3.3 [6]

1 into the support [7] 2
► Attach the stop pin [9] 5 with stud bolt [10] 3
and washer [13] 4 to the support [7] 2
amplifier wrench i = 1 : 3.3 [6] 1 and secure it
with the connecting pin [11] 7 and the 42 mm
rubber ring [12] 6
Undoing the bearing cover mounting bolts
► Put the special tool 1 onto the mounting bolt

which is going to be undone
► Undo all the mounting bolts

Crankshaft drive
Removing the crankshaft bearing caps
► Mark the bearing cover 2 to indicate the

► Remove the bearing cover 2
► Mark the crankshaft bearing shell 3 to indicate
the correct installation position and assignment
and then remove them
► Repeat the procedure for the other bearing
covers 2
Removing the crankshaft bearing cap axial compensation
► Mark the bearing cover 5 to indicate the

► Remove the bearing cover 5 with contact
washers 2 and 4
► Mark the crankshaft bearing shells 3 to
indicate the correct installation position and
assignment and then remove them
Remove the upper thrust washers
► Remove the thrust washers 1 from bearing

seat 4 2

Crankshaft drive
Removing the crankshaft
CAUTION
For this reason:

S Removing the crankshaft with support
NOTE
Risk of material damage due to unsuitable
lifting gear
For this reason:
S Do not use steel cables or other sharp-edged
tools to lift the crankshaft out.
► Lift the crankshaft 1 out of the crankcase 2
using hoist
► Mark the crankshaft bearing shells 3 to
indicate correct installation position and
assignment and remove from the crankcase 2

Crankshaft drive
Check crankshaft and crankshaft bearing
Check the crankshaft bearing spread
Tip for users

The difference between dimension A and
dimension B results in the spread of the
crankshaft bearings.
► Clean the crankshaft bearing shells 2

and place them together on a flat surface
as marked
► Check dimension A with a micrometer 1
► Check dimension B using a micrometer 1
The permitted maximum spread of the crankshaft
bearings is 1.5 mm.
The crankshaft bearing shells must be replaced
when the spread is outside the tolerance range 2 .
Check the crankshaft bearing inner diameter
► Place the top and bottom crankshaft bearing

shell 2 into the bearing seat as marked
► Put the crankshaft bearing cap 3 in place
as marked
► Screw 4 the crankshaft bearing cap mounting
bolts in and tighten 3
Pre-tightening torque . . . . . . . . . . . . . . . . . 115 Nm
► Check the crankshaft bearing using an internal
touch probe 5 and a dial gauge [1] 1
► Repeat the test procedure several times at
120° offset
► Perform the measurement for all of the
crankshaft bearings
► After completing the measurement process,
remove the crankshaft bearing cap 3
The permitted inner diameter of the crankshaft
bearings is Ø 87.040 - 87.086 mm.
The crankshaft bearing shells must be replaced if
the inner diameter is outside the tolerance.

Crankshaft drive
Checking the connecting rod bearing journals

outside diameter
► Cleaning the crankshaft connecting-rod bearing

journal 1
► Checking the connecting-rod bearing journal
using a 2 micrometer
120° offset
The permitted outer diameter of the connecting-rod
bearing journal is Ø 69.981 - 70.000 mm.
The crankshaft must be replaced when the outer
diameter is outside the tolerance range.
Checking the outer diameter of the crankshaft bearing journal
► Cleaning the crankshaft bearing journal 1 of

the crankshaft
► Checking the crankshaft bearing journal 1 with
a micrometer 2
120° offset
The permitted outer diameter of the crankshaft
bearing journal is Ø 86.978 - 87.000 mm.
The crankshaft must be replaced when the outer
diameter is outside the tolerance range.

Crankshaft drive
Installing the crankshaft
Installing the crankshaft
NOTE
Risk of material damage due to unsuitable
lifting gear
For this reason:
S Do not use steel cables or other sharp-edged
tools to lift the crankshaft out.
crankshaft bearing shells 3
► Inserting the crankshaft bearing shells 3
according to the markings at the bearing seats
and aligning them with a setting tool
► Lift the crankshaft 1 into the crankcase 2
using hoist
Install the upper thrust washers
Tip for users

Ensure that the installation orientation and posi-
tion are correct.
thrust washers 1
► Insert the thrust washers 1 on bearing seat 4
with the oil grooves facing the crankshaft 2
► Pressing gently, twist the contact washers 1
into the bearing seat

Crankshaft drive
Installing the bearing cover axial

compensation
NOTE
For this reason:
S Do not reuse the mounting bolts of the
crankshaft bearing cover.
crankshaft bearing shell 3 and the thrust
washers 2 and 4
► Insert the crankshaft bearing shell 3 according
to the markings into the bearing cover and
aligning it with a setting tool [4]
► Insert the thrust washers 2 and 4 into the
bearing cover with the oil grooves facing the
crankshaft
► Position the bearing cover 5 and the contact
washers 2 and 4 on bearing seat 4
► Screw the new mounting bolts 1 in and tighten
them by hand
Attaching the crankshaft bearing caps
NOTE
For this reason:
S Do not reuse the mounting bolts of the
crankshaft bearing cover.
crankshaft bearing shell 3
► Inserting the crankshaft bearing shell 3
according to the marking into the bearing cover
2 and aligning it with a setting tool
► Put the bearing cover 2 on
contact areas of the heads of the new mounting
bolts 1
► Screw the mounting bolts 1 in and tighten
by hand

Crankshaft drive
Tightening crankshaft bearing cover mounting bolts
Tip for users

Observe gear ratio:
Power amplifier wrench i = 1 : 3.3.
► Put the assembled special tool 1 onto the
mounting bolt
► Tighten the mounting bolts
Tightening torque
Preliminary tightening torque . . . . . . . . . 115 Nm
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
► Check the crankshaft for ease of movement
If the crankshaft turns not at all or only with
difficulty, the crankshaft has to be removed
together with the crankshaft bearings.
Re-check the crankshaft bearing and crankshaft,
if needed replace crankshaft bearing or crankshaft.
Check crankshaft axial play
► Attaching the dial gauge [1] 3 with dial gauge

holder [2] 2 and tracer pin [3]
crankshaft 1
► Push the crankshaft 1 horizontally towards the
flywheel housing to the end position
► Setting the dial gauge 3 to zero
► Pull the crankshaft 1 towards the dial gauge to
the end position 3 and read off the difference
The permitted axial play of the crankshaft 1 is
0.200 - 0.395 mm.
If the axial play is out of tolerance, install new
thrust washers.

Crankshaft drive

Crankshaft seal
Crankshaft seal
1 Timing case 3 Crankshaft seal, rear

2 Flywheel housing 4 Crankshaft seal, front

Crankshaft seal

Crankshaft seal
Removing, installing the rear crankshaft seal
Additional jobs
1 Flywheel housing 2 Crankshaft seal, rear

Crankshaft seal
NOTE
PTFE seals may start to leak.
For this reason:
S Clean the crankshaft and insertion tool before assembly.
NOTE
For this reason:
Special tools
[1] Guide plate 80.99606-0316

S Removing the rear crankshaft seal in connection with
S Stud bolt [2]
S Threaded spindle [3]
S Hex nut [4]
S Cross member [5]
S Pressure plate [6]
S Hook [7]
S Installing the rear crankshaft seal in connection with:
S Hex nut [4]
S Hex collar nut [8]
S Stud bolt [2]
[2] Stud bolt 06.02191-2713
S Removing, installing the rear crankshaft seal
[3] Threaded spindle 80.99606-0299

[4] Hex nut 06.11065-2318


Crankshaft seal
[5] Cross member 80.99606-0298

S Removing the rear crankshaft seal
[6] Pressure plate 80.99609-0038

[7] Hook 80.99606-6013

[8] Hex collar nut 06.11222-0311

S Installing the rear crankshaft seal

S Installing the rear crankshaft seal

Crankshaft seal
Removing the rear crankshaft seal
► Attach the guide plate [1] 5 to the crankshaft

with the stud bolt [2] 7
► Screw the pressure plate [6] 4 into the guide
plate [1] 5
► Screw hex nut [4] 1 onto the threaded spindle
[3] 2 and lock with a second hex nut [4] 7
► Screw in the threaded spindle [3] 2 into the
cross member [5] 3
► Inserting the catch [7] 8 through the crossbar
[5] 3 so that it lies flat between the crankshaft
seal 6 and the crankshaft
► Turn the hook [7] 8 through 90° so that the
notch in the hook [7] 8 is facing outwards
► Insert the cross member [5] 3 into the hook
[7] 8
Remove the crankshaft seal
► Pulling out the crankshaft seal 2 by turning

in the threaded spindle [3] 1
Install the crankshaft seal
Positioning the crankshaft seal
► Remove the pressure plate [6]

► Position the new crankshaft seal 2 with
transport covering 1 at the guide plate [1] 3
► Sliding the crankshaft seal onto 2 the guide
plate [1] 3
► Remove the transport sleeve 1

Crankshaft seal
Pressing in the crankshaft seal
NOTE
Risk of damage to good due to inappropria-
te installation
Component gets damaged
For this reason:
S Ensure that the milled-out portion of the
special tool points downwards above the
arch of the flywheel housing.
► Push the pressure plate [9] 3 onto the guide

plate [1] 4
► Screw the hex collar nut [8] 1 onto the
threaded spindle [3] 2
► Screw the threaded spindle [3] 2 into the guide
plate [1] 4
► Pressing in the crankshaft seal to the limit stop
5 by turning in the hexagon nut with collar
[8] 1

Crankshaft seal

Crankshaft seal
Installing the front crankshaft seal
Additional jobs
1 Timing case cover 2 Crankshaft seal, front

Crankshaft seal
NOTE
PTFE seals may start to leak.
For this reason:
S Clean the crankshaft and insertion tool before assembly.
NOTE
For this reason:
Special tools
[1] Guide plate 80.99604-0411

S Removing the front crankshaft seal in connection with
S Stud bolt [2]
S Hex nut [4]
S Cross member [5]
S Hook [7]
S Installing the front crankshaft seal in connection with:
S Hex nut [4]
S Hex collar nut [8]
S Stud bolt [2]
[2] Stud bolt 06.02191-2713
S Removing, installing the front crankshaft seal

[4] Hex nut 06.11065-2318


Crankshaft seal
[5] Cross member 80.99606-0298

S Removing the front crankshaft seal

[7] Hook 80.99606-6013

[8] Hex collar nut 06.11222-0311

S Installing the front crankshaft seal

S Installing the front crankshaft seal

Crankshaft seal
► Attach the guide plate [1] 5 to the crankshaft

with the stud bolt [2] 7
► Screw the pressure plate [6] 4 into the guide
plate [1] 5
► Screw hex nut [4] 1 onto the threaded spindle
[3] 2 and lock with a second hex nut [4] 1
► Screw in the threaded spindle [3] 2 into the
cross member [5] 3
► Inserting the catch [7] 8 through the crossbar
[5] 3 so that it lies flat between the crankshaft
seal 6 and the crankshaft
► Turn the hook [7] 8 through 90° so that the
notch in the hook [7] 8 is facing outwards
► Insert the cross member [5] 3 into the hook
[7] 8
► Pulling out the crankshaft seal 2 by turning in

the threaded spindle [3] 1
Install the crankshaft seal
Positioning the crankshaft seal
► Remove the pressure plate [6]

► Position the new crankshaft seal 2 with
transport covering 1 at the guide plate [1] 3
► Sliding the crankshaft seal onto 2 the guide
plate [1] 3
► Remove the transport sleeve 1

Crankshaft seal
Pressing in the crankshaft seal
NOTE
Risk of damage to good due to
inappropriate installation
Component gets damaged
For this reason:
S Ensure that the milled-out portion of the spe-
cial tool points downwards above the arch
of the flywheel housing.
► Push the pressure plate [9] 3 onto the guide

plate [1] 4
► Screw the hex collar nut [8] 1 onto the
threaded spindle [3] 2
► Screw the threaded spindle [3] 2 into the guide
plate [1] 4
► Pressing in the crankshaft seal to the limit stop
5 by turning in the hexagon nut with collar
[8] 1

Crankshaft seal

Engine case
Engine case
1 Flywheel housing 2 Timing case

Engine case
1 Crankcase ventilation 2 Flywheel housing

Engine case
Removing/installing the crankcase ventilation
1 Oil separator 2 Oil return line
NOTE
For this reason:

Engine case
Special tools



Engine case
Removing the crankcase ventilation
Removing the bleed line

pliers [1]
► Undo the spring band clamps 3 using the hose
Removing the oil separator
► Undo the hose clamps 1 and 3 using the hose

clamp pliers [1]
► Removing the 2 oil separator
► Undo the hose clamps 6 and 5 using the hose
clamp pliers [1]
► Pulling off the hoses 4 and 7

Engine case

Removing the connecting piece

connecting piece 3
► Unscrew the union 1 and remove it together
with the seal 6
► Unscrew the mounting bolt 5 and remove it
with the seal 4
► Removing the connecting piece 3 with
O-ring 2


Engine case
Installing the crankcase ventilation

Removing theconnection piece
► Positioning the connection piece 3 with a new

O-ring 2 after marking
► Screw in the mounting bolt 5 with a new seal
4 and tighten
► Screw in the union 1 with a new seal 6 and
tighten


Engine case
Attach the oil separator
► Pushing the hoses 4 and 7 onto the bleed

lines with spring band clamps 5 and 6
► Installing the spring band clamps 5 and 6 with
hose clamp pliers for spring band clamps [2]
► Positioning the oil separator 2 with spring band
clamps 1 and 3
► Installing the spring band clamps 1 and 3 with
hose clamp pliers for spring band clamps [2]
► Positioning the bleed line 2 with hose clamp 1

and spring band clamp 3
► Installing the hose clamp 1 with hose clamp
pliers [1]
► Installing the spring band clamp 3 with hose

Engine case
Remove/install the flywheel housing
Additional jobs
S Remove/install the starter/starter motor, see 658
S Remove/install the HCI system, see 380
1 Flywheel housing
Technical data
Tightening torques
Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x16-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm
Straight bulkhead union . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm
NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Service products
Multi-purpose grease MAN 285 LiPF2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09.15001-0012
Loctite 5900 sealing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04.10394-9292

Engine case
NOTE
For this reason:
Special tools


S Removing/installing the lambda probe


Engine case
Remove flywheel housing
Separating the electrical connection of the NOx sensor

► Unscrewing the lambda probe 1 with a lambda
probe key [2]


Engine case
Removing the NOx control unit

► Removing the NOx control unit 1
Removing the holder

► Removing the bracket 1
Separating the electrical connection of the speed sensor

Engine case

► Pull out the 2 speed sensor
► Removing the O-ring from the 2 speed sensor
Removing coolant lines
► Turning out the mounting bolts 3 with

sleeves 7
► Turning out the hollow screws 9 with sealing
washers 1
► Turning out the hollow screws 5 with sealing
washers 4 and 6

Engine case
► Unlocking and removing the plug-in

connections of the coolant pipes 1 and 2
by pressing the spring clips
► Unscrewing the union nuts of the coolant pipes

1 and 2
Removing the distributor coupling

► Removing the distributor coupling 1
with bracket 2

Engine case
Dismantling the distributor coupling
► Unscrew the straight bulkhead union 5 and

remove it along with the O-ring 6
► Unscrew the screw plug 1 along with the
straight bulkhead union 2
► Remove the seal 4 and the ring piece 7
► Unscrewing the union nuts of the coolant

pipes 1 and 2
Remove the bracket
► Loosen the mounting bolt 5

► Tilt bracket 3 and remove plates 2 and 4

Engine case
Remove the flywheel housing
CAUTION
For this reason:
S Use a hoist to remove the flywheel housing.
bolts 3 and 4
► Removing the flywheel housing 1 with seal 2
from the locating pins on the crankcase

Engine case
Install the flywheel housing
Note on installing the flywheel housing
NOTE
to leaking oil sump
For this reason:

S The sealing surface must be free of grease
closed
► Apply a thin layer of Loctite 5900 1 to the

contact surfaces of the flywheel housing, as
illustrated
Attaching the flywheel housing
CAUTION
For this reason:
S Use hoist to install the flywheel housing.
► Position the flywheel housing 1 with a new
seal 2 over the alignment pins on the
crankcase
4 as marked
► Bringing the plates 2 and 4 with bracket 3

into the installation position
bolts 1

Engine case

► Screwing on the union nuts of the coolant pipes
1 and 2
► Tightening the union nuts of the coolant
lines 1 and 2
Assembling the distributor coupling
► Screw the straight bulkhead union 5 in with

a new O-ring 6 and then tighten
► Screw the straight bulkhead union 2 in with
a new O-ring 3 and then tighten
► Insert the plug 1
► Install the ring piece 7 with a new seal 4
Mounting the distributor coupling
► Positioning the distributor coupling 1 with

bracket 2

Engine case

► Screwing on and tightening the union nuts
of the coolant pipes 1 and 3
► Tightening the hollow screws 2
NOTE
connections
For this reason:
S Check the plug-in connections of the coolant
lines for after securing for firm attachment
and then secured
► Position the coolant lines 1 and 2
► Establishing the plug-in connections for
the coolant pipes 1 and 2

Engine case
► Position the coolant lines 2 and 8

► Screwing in the mounting bolts 3 with
sleeves 7
► Screwing in and tightening the hollow
screws 9 with new seals 1
► Screwing in the hollow screws 5 with
new seals 4 and 6 and tightening them
Attaching the speed sensor
► Greasing the new O-ring with MAN 285 LiPF2

multi-purpose grease
► Pulling a new O-ring onto the speed sensor 2
► Inserting the speed sensor 2

Engine case
Connect the electrical connection for the speed sensor

Installing the NOxcontrol unit
► Positioning the NOxcontrol unit 1


Engine case
► Screw the NOx sensor 1 into place and tighten

it
tie pliers [3]
Tip for users

► Screw the lambda probe 1 in with the lambda

probe wrench [2] and tighten
tie pliers [3]
Tip for users


Engine case
Removing/installing the timing case cover
Additional jobs
1 Timing case cover 3 Mounting bolt

2 Gasket
Technical data
Tightening torques
Camshaft speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x16-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nm
Service products
Loctite 648 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04.10160-9164

Engine case
NOTE
For this reason:

Engine case
Remove timing case cover
► Disconnecting the electrical connection from

the speed sensor 1
► Pull out the speed sensor 1
► Remove the O-ring from the speed sensor 1
Removing the timing case cover

bolts 2 , 3 and 4
► Unscrew the mounting bolts 2 , 3 and 4
► Remove the timing case cover 1
Removing the timing case cover seal
► Remove the timing case cover seal 2 from the

timing case 1

Engine case
Installing the timing case cover
Fitting the timing case cover seal
► Position the new seal 2 over the alignment

pins on the timing case 1
Attach timing case cover
► Position the timing case cover 1 on the

timing case
► Screw in the mounting bolts 2 , 3 and 4 as
marked and tighten
Installing the speed sensor
► Inserting the speed sensor 1 with a new O-ring

► Connect the electrical connection to the speed
sensor 1

Engine case
Removing/installing the timing case
Additional jobs
1 Timing case 2 Gasket

Engine case
Technical data
Tightening torques
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x18-10.9 . . . . . . . . . . . . . . 1st tightening 20 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x18-10.9 . . . . . . . . . Final tightening torque 60°
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x45-10.9 . . . . . . . . . . . . . . . . . . Final torque 60°
Service products
Loctite 5900 sealing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04.10394-9292
NOTE
For this reason:

Engine case
Install timing case
Remove timing case

bolts 1
bolts (3x) in the oil sump
► Unscrew the mounting bolts (3x) from the
oil sump
► Pull the timing case 2 off the crankcase 3
Remove the timing case seal
► Remove the seal 1 from the crankcase 2


Engine case
Installing the timing case
Placing the timing case seal
► Position a new seal 1 over the alignment pins

on the crankcase 2
Installation instructions for the timing case
NOTE
to leaking oil sump
For this reason:

S The sealing surface must be free of grease
closed
► Apply a thin layer of Loctite 5900 1 to the

contact surfaces of the timing case, as
illustrated
Tightening sequence for the timing case
► Observe the illustrated tightening sequence 1

to 15 in the following work step

Engine case
Installing the timing case
► Apply a thin layer of Loctite 5900 to the sealing

surface of the oil sump
► Position the timing case 2 over the alignment
pins
► Screw the mounting bolts 1 in as marked and
tighten
► Screw in the mounting bolts 2 to 15 as
marked and tighten
Tightening torque
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°

Engine case
Removing, installing the engine bracket
1 Lifting eye 3 Engine bracket

2 Lifting eye
NOTE
For this reason:

Engine case
De-installing the engine bracket
Detaching the engine bracket

► Removing the engine bracket 1
Detaching the engine bracket

bolts 2 and 3
Detaching the engine bracket Versions 66, 67

bolts 2 and 3

Engine case

► Removing the holder 3
De-installing the lifting eye

Separating the electrical connection of the NOx control unit

Engine case
De-installing the NOx control unit

► Removing the NOx control unit 1

► Removing the support 1 with rubber bearing 2
De-installing the console

► Removing the console 1

Engine case
Remove the lifting eye


Engine case
Installing the engine bracket
Attach the lifting eye
► Position the lifting eye 1

and tighten
Installing the console
► Positioning the console 1

► Positioning the holder 1 with rubber bearing 2


Engine case
Installing the NOx control unit
► Positioning the NOx control unit 1

Establish the electrical connection to the NOx control unit
Installing the lifting eye
► Positioning the lifting eye 1


Engine case
Installing the holder

bolts 1 and 2
Installing the engine bracket Versions 66, 67
► Positioning the engine bracket 1



Engine case

► Screwing in and tightening the
mounting bolts 2

Engine case

Technical data
Technical data
Tightening torques
Tip for users

All bolted connections whose purpose is not listed in the table below must be tightened in accordance
with the reference values given in Works Standard M 3059 (see page 697). Apply a thin layer of oil to
bolts and screws before fitting!
Engine electronics
Cable harness
Mounting nut terminal B1+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Nm
Mounting nut terminal B2+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Nm
Terminal 30 mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Engine electronics
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm
NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
KSC pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Temperature sensor air distributor pipe . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Flame glow plug hollow screw . . . . . . . . . . . . . . . . . . . . . . . M10x1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x16-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm
Cooling system
Coolant pump coolant manifold
GE bulkhead fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Coolant pump
Add-on units
PTO for coolant pump/alternator
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . 1st tightening 100 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . . . . . . Final torque 90
Air compressor
Mounting bolt PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . 1st tightening 100 Nm
Mounting bolt PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . . . Final tightening 90
Mounting bolt guide roller . . . . . . . . . . . . . . . . . . . . . . . . . . . M12x65x-10.9 LH . . . . . . . . . . . . . . . . . . . . . 60 Nm
Mounting bolt for drive wheel . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . 1st tightening 100 Nm
Drive wheel mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . Final torque 90°
Intake elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
Threaded union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Connecting rod bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

Technical data
Opening pressure of pressure relief

valve for air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . 19-22 bar
Ribbed V-belt of alternator belt drive
Ribbed V-belt tensioner mounting bolt . . . . . . . . . . . . . . . . M10x70-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Alternator
Poly-V-belt pulley mounting nut
LEB10 alternator 120 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Nm
V-belt disc mounting nut
NCB1 alternator 80A, NCB2 110A . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Mounting bolt Ribbed V-belt disc . . . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . 1st tightening 100 Nm
Mounting bolt for ribbed V-belt disc . . . . . . . . . . . . . . . . . . M16x1.5x45-8.8 LH . . . . . . . . Final tightening 90
Ribbed V-belt for the refrigerant compressor

Technical data
Starter motor
Mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Terminal 30 mounting nut on relay . . . . . . . . . . . . . . . . . . . M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Common Rail system

Injector with nozzle
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x45 . . . . . . . . . . . . . . . . . . . 1st tightening 2 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x45 . . . . . . . . . . . . . . . . Final tightening 30 Nm
Pressure screw for pressure pipe socket . . . . . . . . . . . . . M22x1.5 . . . . . . . . . . . . . . . . . 1st tightening 10 Nm
Pressure pipe socket pressure screw . . . . . . . . . . . . . . . . M22x1.5 . . . . . . . . . . . . . . . . . . Final torque 55 Nm
Injector cable mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Nm
Rail pressure pipe (common rail)
Mounting bolts for pressure pipe . . . . . . . . . . . . . . . . . . . . . M8x25-10.9 . . . . . . . . . . . . . . 1. tightening 1.5 Nm
Pressure pipe mounting bolts . . . . . . . . . . . . . . . . . . . . . . . M8x25-10.9 . . . . . . . . . . . . . . . Final torque 35 Nm
Rail pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Pressure-limiting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
High-pressure pump
Mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Nm
Mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Dismantling/assembling the high pressure pump
Mounting bolt high pressure pump . . . . . . . . . . . . . . . . . . . M8x40-8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
High pressure pump mounting nut . . . . . . . . . . . . . . . . . . . M8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Mountingbolt drive wheel high pressure pump . . . . . . . . . M18x1.5-8.8 . . . . . . . . . . . . . . . . . . . . . . . . 105 Nm
Proportional valve mounting bolt . . . . . . . . . . . . . . . . . . . . . M5x20-10.9 . . . . . . . . . . . . . . . 1st tightening 4 Nm
Proportional valve mounting bolt . . . . . . . . . . . . . . . . . . . . . M5x20-10.9 . . . . . . . Final tightening torque 7 Nm
Fuel supply pump mounting bolt . . . . . . . . . . . . . . . . . . . . . M6x1.5x36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nm
Swivelling fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Adapter fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Fuel service centre
Hollow screw for fuel line . . . . . . . . . . . . . . . . . . . . . . . . . . . M10x1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Dismantling/assembling the fuel service centre
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Water drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Nm
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
Flame start system
Fuel line union nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Mounting nut for cable lug . . . . . . . . . . . . . . . . . . . . . . . . . . M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
Hollow screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10x1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm

Technical data
Engine control unit

ME7 control unit mounting bolts . . . . . . . . . . . . . . . . . . . . . M6x30-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm
Console mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x40-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Nm
Turbocharging
Charge-air pipe
Hose clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
Intercooler charge-air pipe (low-pressure)
Hose clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
Charge-air pipe Versions 66, 67
Hose clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
Charge-air pipe with exhaust gas recirculation connection
EGR pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6X20-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nm
Charge-air pipe with throttle valve
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x145-10.9 . Preliminary tightening torque 5 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x145-10.9 . . . . . . . . . . . . . . Final torque 12 Nm
Exhaust manifold HCI
Spring clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
Exhaust manifold
Exhaust manifold mounting bolt . . . . . . . . . . . . . . . . . . . . . M8x40-GA . . . . . . . . . . . . . . . 1st tightening 25 Nm
Exhaust manifold mounting bolt . . . . . . . . . . . . . . . . . . . . . M8x40-GA . . . . . . . . . . Final tightening torque 45°
Exhaust manifold mounting bolt . . . . . . . . . . . . . . . . . . . . . M8x58-GA . . . . . . . . . . Final tightening torque 45°
Exhaust manifold mounting bolt . . . . . . . . . . . . . . . . . . . . . M8x80-GA . . . . . . . . . . . . . . . . . . . Final torque 45°
Mounting nut exhaust manifold . . . . . . . . . . . . . . . . . . . . . . M8-GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm
Compressed-air cylinder
Corrugated head screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Nm
EGR module
GE union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
Cable duct bottom part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x16-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm
Air distributor pipe
Charge air temperature sensor . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Cylinder head
Cylinder head
Cylinder head bolts ................................ 14x2 (E18) . . . . . . . . . . . . . . . 1st tightening 80 Nm
Cylinder head bolts ................................ 14x2 (E18) . . . . . . . . . . . . . 2nd tightening 150 Nm
Cylinder head bolts ................................ 14x2 (E18) . . . . . . . . . . . . . . . . . 3rd tightening 90°
Cylinder head bolts ................................ 14x2 (E18) . . . . . . . . . . . . . . . . . 4th tightening 90°
Cylinder head bolts ................................ 14x2 (E18) . . . . . . . . . . . . . . . . . final tightening 90°
Valve clearance
Locknuts of adjusting screws . . . . . . . . . . . . . . . . . . . . . . . . M10x1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm

Technical data
Timing gears
Camshaft gear mounting bolts . . . . . . . . . . . . . . . . . . . . . . M10x1.25-10.9 . . . . . . . . . . . . . . . . . . . . . . . 65 Nm
Oil pump drive wheel mounting nut . . . . . . . . . . . . . . . . . . M12x1.5-6S . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Engine lubrication
Oil module
Screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
GE bulkhead union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Nm
Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Nm
Oil filter insert
Oil filter lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Oil sump
Oil nozzles
Oil pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm

Technical data
Crankshaft drive
Vibration damper
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5-10.9 1st tightening 150 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5-10.9 . . . . . . . . . . . . . . . . Final torque 90°
Flywheel
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5x35-10.9 . . . . . . . . 1st tightening 100 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.5x35-10.9 . . . . . . . . . . . . . Final torque 90°
Connecting rods
Connecting-rod bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . M11x1.5x60-11.9 . . . . . . . . . 1st tightening 55 Nm
Connecting rod bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . M11x1.5x60-11.9 . . . . . . . . . . . . . Final torque 90°
Crankshaft
Mounting bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x118-10.9 . . . . . . . . . . . 1st tightening 115 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x118-10.9 . . . . . . . . . . . . . . . . Final torque 90°
Engine case
Timing case cover
Camshaft speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x16-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nm
Timing case
Mounting bolt ..................................... M10x50-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Mounting bolt ..................................... M8x18-10.9 . . . . . . . . . . . . . . 1st tightening 20 Nm
Mounting bolt ..................................... M8x18-10.9 . . . . . . . . . Final tightening torque 60°
Mounting bolt ..................................... M8x45-10.9 . . . . . . . . . . . . . . . . . . Final torque 60°

Technical data
Assembly tightening torques in accordance with Works Standard M 3059

Screws/bolts/nuts with outer hex or inner hex threads, head without collar or flange
Thread size Property classes / Tightening torque values in Nm

x pitch
for 8.8 / 8 for 10.9 / 10 for 12.9 / 12
M4 2.5 4.0 4.5
M5 5.0 8.0 9.0
M6 9.0 13.0 15,0
M7 14.0 20.0 25.0
M8 22.0 30.0 35.0
M8x1 23.0 35.0 40.0
M10 45.0 65.0 75.0
M10x1.25 45.0 67.0 75.0
M10X1 50.0 70.0 85.0
M12 75.0 110.0 125.0
M12x1.5 75.0 115.0 130.0
M12x1.25 80.0 120.0 135.0
M14 115.0 175.0 200.0
M14x1.5 125.0 185.0 215.0
M16 180.0 265.0 310.0
M16x1.5 190.0 280.0 330.0
M18 260.0 365.0 430.0
M18x2 270.0 385.0 450.0
M18x1.5 290.0 405.0 480.0
M20 360.0 515.0 600.0
M20x2 380.0 540.0 630.0
M20x1.5 400.0 565.0 670.0
M22 490.0 700.0 820.0
M22x2 510.0 725.0 860.0
M22x1.5 540.0 750.0 900.0
M24 620.0 890.0 1040.0
M24x2 680.0 960.0 1130.0
M24x1.5 740.0 1030.0 1220.0

Technical data
Assembly tightening torques for hollow screws, unions, screw plugs, hose fittings, unions with
cutting ring fittings
S Applicable for screw connections with Cu and BS sealing rings
S Also applicable for screw connections with aluminium nut threads
S Also applicable for components with an external thread of steel in accordance with DIN 3859-1
S Pulse screws may not be used for assembly
S Components that are significantly weakened in comparison to standard components must be examined
separately
Valid for: Applicable for:

-Hollow screws (DIN 7643 or Unions (DIN 3901, MAN 200 etc. for
similar) self-cutting screw union connections of
-Unions (DIN 3901 / MAN 200 or continuing pipes
similar for a cutting ring screw
connection of a continuing pipe *)
-Lock screws with internal
The self-cutting screw union
or external hexagonal head
cannot be counterheld during
(DIN 908, DIN 910 / DIN 7604 o.ä.)
tightening or loosening.
-Hose connectors and fittings for
plug-in connections.
Thread size
x pitch
M8X1 11 Nm 21 Nm
M10X1 21 Nm 32 Nm
M12X1.5 32 Nm 42 Nm
M14x1.5 42 Nm 70 Nm
M16X1.5 52 Nm 130 Nm
M18X1.5 65 Nm 130 Nm
M20X1.5 75 Nm 190 Nm
M22X1.5 85 Nm 190 Nm
M24X1.5 95 Nm 190 Nm
M26X1.5 105 Nm 190 Nm
M27X2 105 Nm ----
M28X1.5 105 Nm 262 Nm
M30X1.5 125 Nm ----
M32X1.5 125 Nm ----
M33X2 125 Nm ----
M36X1.5 157 Nm ----
M38X1.5 157 Nm ----

Technical data
M42X1.5 190 Nm ----

M45x1.5 190 Nm ----
M48X1.5 190 Nm ----
*) Tighten the self-cutting screw union
Tip for users

The self-cutting screw union can be counterheld
during tightening or loosening.

Technical data
Cooling system
Thermostat
1 Stroke of at least 8 mm at 95 C
Thermostat opening temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 - 85C
Coolant pump
1 Bore of the hub: Ø 25.000 - 25.021 mm

Bearing shaft: Ø 25.048 - 25.061 mm
2 Bearing location hole in the housing:
Ø 54.894 - 54.924 mm
Bearing: Ø 54.981 - 54.994 mm
3 Bearing shaft bore in impeller:
Ø 16.000 - 16.018 mm
Bearing shaft: Ø 16.045 - 16.056 mm
4 Impeller: Ø 135 - 136 mm
1 Gap dimension between the impeller and

the housing 2.0 - 2.6 mm
2 Installation dimension: 33.10 - 33.30 mm

Technical data
Add-on units
Air compressor
Air compressor excess pressure relief valve opening excess pressure . . . . . . . . . . . . . . . . . . . . . . . . . 19 - 22 bar
Alternator
Manufacturer: Bosch
Model: NCB1
Type: Three-phase
Nominal voltage: 28 V
Maximum current: 35 - 80 A
Manufacturer: Bosch
Model: LEB10
Type: Three-phase
Maximum current: 50 - 120 A
Alternator
Charging current alternator ......................... Alternator 80 A . . . . . . . . . . . . 35 A at 1800 1/min
Charging current alternator ......................... Alternator 80 A . . . . . . . . . . . . 80 A at 6000 1/min
Charging current alternator ......................... Alternator 120 A . . . . . . . . . . . 50 A at 1800 1/min
Charging current alternator ......................... Alternator 120 A . . . . . . . . . . 120 A at 6000 1/min
Starter motor
Manufacturer: Mitsubishi
Model: 85P50
Type: Screw-push starter
Starter motor pinion:

Number of teeth: Z = 12
Module: 3
Nominal power output: 5.0 kW


Technical data
Cylinder head
Rocker arm mechanism
1 Ø 28.000 - 28.021 mm
Cylinder head
1 Valve guide outer diameter:

Ø 13.020 - 13.046 mm
Repair level 1: Ø 13.270 - 13.296 mm
2 Valve guide inner diameter:
Ø 7.000 - 7.015 mm
Valve seat ring outer diameter:
3 Intake valve: Ø 40.000 - 40.025 mm
4 Exhaust valve: Ø 36.000 - 36.025 mm
1 Inlet valve: Ø 6.966 - 6.980 mm

2 Exhaust valve: Ø 6.946 - 6.960 mm

Technical data
1 Valve recess
Inlet valve: 0.30 - 0.60 mm
Exhaust valve: 0.60 - 0.90 mm
1 Nozzle projection: 2.830 - 3.680 mm
Valve clearance
Only set the valve clearance whilst the engine is cold
Inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm
1 Length (L) untensioned, approx. 66.10 mm

Spring force for L = 48.50 mm: 348 - 382 N
Spring force for L = 39.00 mm: 601 - 659 N
The minimum value of the spring force is also the
wear limit.

Technical data
Valve control
Camshaft
1 Ø 54.910 - 54.940 mm
Camshaft bushing, inner diameter:
Ø 55.000 - 55.030 mm
Camshaft axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.140 - 0.270 mm

Camshaft radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 - 0.120 mm
Timings
Inlet valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6° before TDC
Inlet valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32° after BDC
Exhaust valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63° before TDC
Exhaust valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13° after TDC
Valve tappet
1 Ø 19.944 - 19.965 mm
Associated bore in the crankcase:
Ø 20.000 - 20.021 mm
Timing gears
Installation play of the timing wheels
Radial play intermediate gear 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 - 0.076 mm
Check the tooth flank clearance of the timing gears
Crankshaft timing gear - camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 - 0.149 mm
Camshaft gear - air compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 - 0.185 mm
Crankshaft gear - intermediate gear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 - 0.187 mm
Intermediate gear 1 - intermediate gear 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 - 0.175 mm
Intermediate gear 1 - oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.053 - 0.190 mm
Intermediate gear 2 - injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 - 0.177 mm

Technical data
Engine lubrication
Oil pump
Axial play of the oil pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 - 0.940 mm
Radial play of the oil pump shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 - 0.078 mm
1 Shaft: Ø 15.940 - 15.950 mm

Bore in the housing: Ø 16.000 - 16.018 mm
2 Press-in depth: 16.00 mm
Pressing force: 8,000 N
3 Shaft: Ø 15.940 - 15.950 mm
Bore in the housing: Ø 16.000 - 16.018 mm
4 Press-in depth: 16.00 mm
Pressing force: 8,000 N
1 Housing depth: 25.000 - 25.033 mm

Gear width: 24.960 - 24.939 mm
Press-on force: 8,000 N

Technical data
Crankshaft drive
Flywheel
Flywheel axial runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 0.1 mm
Installation temperature for the starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 - 240C
1 Flywheel: Ø 398.435 - 398.492 mm

Inner diameter of the sprocket:
Ø 397.671 - 397.76 mm
2 Number of teeth: Z = 143, module 3
Mating gear: Starter pinion (Z =11)
Backlash: 0.40 - 0.70 mm
Connecting rods
1 Internal diameter of the connecting rod end:

Ø 44.050 - 44.066 mm
2 Hole for the bearings shells in the connecting rod:
Ø 74.000 - 74.019 mm
Do not re-install stained or dirty connecting rods
on the connecting rod big ends.
Measure the bearing bore in the directions of
measurement shown
Connecting rod length from the centre of the big end to the centre of the big end bearing . . . 195.98 - 196.02 mm
Crankpin width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.78 - 36.88 mm
Weight difference per set of connecting rods for one engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 50 g
1 Cracked connecting rods and connecting rod

bearing caps that do not belong together that
have been inadvertently screwed in may no
longer be used

Technical data
Connecting-rod bearings
1 Thickness of connecting rod bearing shells:

1.975 - 1.987 mm
Repair level 1: 2.025 - 2.037 mm
Kingpin inclination angle: 74.50 - 76.00 mm
If there are traces of wear (scoring, damaged
running surface), replace both bearing shells
Important: Observe the installation position
(the rod shell has red marks on the side)
1 Inner diameter of the bearing as installed:

Ø 70.026 - 70.069 mm
Repair level 1: Ø 69.926 - 69.969 mm
Repair level 2: Ø 69.776 - 69.819 mm

Technical data
Piston
1 Piston height, centre of piston

pin - piston crown:
63.850 - 63.900 mm
2 Ø 44.009 - 44.015 mm
Piston pin diameter:
Ø 43.994 - 44.000 mm
3 Piston diameter 108 mm Piston with
class A cooling channel
D1 measured 17 mm above lower
edge of piston:
Ø 107.851-107.860 mm
D2 measured 59 mm above lower
edge of piston:
Ø 107.726-107.735 mm
D3 measured 84.9 mm above lower
edge of piston:
Ø 107.564-107.573 mm
D4 measured 96.7 mm above lower
edge of piston:
Ø 106.151-106.160 mm
Piston diameter 108 mm Piston with

class B cooling channel
D1 measured 17 mm above lower edge of piston:
Ø 107.860-107.869 mm
Ø 107.735-107.744 mm
D3 measured 84.9 mm above lower edge of piston:
Ø 107.573-107.582 mm
Ø 106.160-106.169 mm
Piston diameter 108 mm Piston without

cooling channel Class A
D1 measured 17 mm above the lower piston edge:
Ø 107.866-107.875 mm
Ø 107.751-107.760 mm
Ø 107.589-107.598 mm
Ø 106.166-106.175 mm
Piston diameter 108 mm Piston without

cooling channel Class B
D1 measured 17 mm above the lower piston edge:
Ø 107.875-107.884 mm
Ø 107.760-107.769 mm
Ø 107.598-107.607 mm
Ø 106.175-106.184 mm
Total piston height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.00 mm

Piston weight difference per set in one engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 40 g
Piston projection (crankcase to piston) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.087 - 0.389 mm
Technical data
1 3.080 - 3.100 mm
2 2.560 - 2.580 mm
3 3.020 - 3.040 mm
Piston rings
1 1.5 mm
2 1st ring - double-sided keystone
compression ring
Piston ring height: 2.570 - 2.595 mm
at dimension 1
Piston ring width: 4.25 - 4.60 mm
3 2nd ring - taper-face ring
4 3rd ring - double-bevelled ring
5 End gap:
1st ring: 0.35 - 0.50 mm
2nd ring: 0.50 - 0.65 mm
3rd ring: 0.30 - 0.60 mm

Technical data
Crankshaft
1 Connecting rod bearing journals:

Ø 69.981 - 70.000 mm
2 Crankshaft bearing pin:
Ø 86.981 - 87.000 mm
Crankshaft hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 + 3 HRC

Permitted crowning of the bearing journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 mm
1 Thrust washers: 2.850 - 2.900 mm

2 Locating bearing journal: 33.000 - 33.062 mm
3 26.967 - 27.000 mm
Crankshaft axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.200 - 0.395 mm

Technical data
Crankshaft bearing
1 Inner diameter of the crankshaft bearing:

Ø 87.040 - 87.086 mm
Repair level 1: Ø 86.940 - 86.986 mm
Repair level 2: Ø 86.790 - 86.836 mm
2 Wall thickness of the crankshaft bearing shells:
2.468 - 2.480 mm
Crankshaft bearing inclination angle:
92.50 - 94.00 mm
Engine case
Crankcase
1 Ø 108.000 - 108.022 mm
Maximum wear limit:
0.1 mm below standard dimension

Technical data

Special tools
Special tools

Special tools

Special tools
Special tools
[1] Stud bolt 06.02099-0357

S Removing, installing the camshaft
[2] Stud bolt 06.02191-0407

S Remove/install the cylinder head
S Removing/installing the crankshaft
[3] Stud bolt 06.02191-2713

S Remove/install the front crankshaft seal
S Remove/install the rear crankshaft seal
[4] Hex nut 06.11065-2318

[5] Hex collar nut 06.11222-0311

[6] Hex nut 06.11226-8306

S Removing, installing the injector with nozzle (common rail)
[7] Connecting pin 06.22729-0006


Special tools

S Remove/install the alternator
S Removing/installing the cable harness
S Removing/installing the refrigerant compressor
S Removing/installing the ME7 control unit
[9] Extension 08.06139-9025
S Remove/install the injector with nozzle
S Removing/installing the high pressure pump
S Removing/installing the air distributor pipe
[10] Adapter 08.06139-9029

[11] Size 7 socket 08.06141-0700

[12] 42 mm rubber ring 08.06142-9006

[13] Torque wrench 08.06450-0006

S Removing, installing the oil injection nozzles
[14] Handle 08.06460-0002


Special tools
[15] Dial gauge 08.71000-3217


[17] Measuring attachment 08.71109-0000

S Dismantling and assembling the coolant pump

S Removing/installing the piston with connecting rod
[19] Feeler gauge 08.75310-0806

S Removing/installing the oil pump
[20] Feeler gauge 08.75310-3309

S Dismantling and assembling the air compressor
[21] Separator 08.99605-9003


Special tools

[23] Injector storage sleeve 09.81020-1000

[24] Shaft puller 80.99602-0011

[25] Slide hammer puller 80.99602-0016

S Removing, installing camshaft bearings
[26] Adapter 80.99602-0173

[27] Plate 80.99602-0176

[28] Column 80.99602-0177


Special tools
[29] Column 80.99602-0198

[30] Column 80.99602-0199

[31] Press-out bush 80.99602-0768

[32] Extractor tool 80.99602-6012

[33] Extractor tool 80.99602-6015

[34] Size 17 socket 80.99603-0309

[35] Size 22 socket 80.99603-0378


Special tools
[36] Special wrench 80.99603-6029

[37] Detachable handle 80.99604-0344

[38] Pressing sleeve 80.99604-0432

[39] Pressing tool 80.99604-0461

[40] Straightedge 80.99605-0167


[42] Tracer pin 80.99605-0197


Special tools
[43] Cross member 80.99606-0298


[45] Pressure plate 80.99606-0315

[46] Guide plate 80.99606-0316

[47] Support 80.99606-0551

[48] Pressure plate 80.99606-0567

[49] Guide plate 80.99606-0568


Special tools
[50] Stop pin 80.99606-0585

[51] Pressure shim 80.99606-0609

[52] Assembly sleeve 80.99606-0634

S Removing/installing the valve stem seals
[53] M8 lifting eye bolt 80.99606-0660

[54] Guide mandrel 80.99606-0762

[55] Yoke 80.99606-0763

[56] Press-fit bush 80.99606-0764


Special tools
[57] Centring disk 80.99606-0765

[58] Limit stop 80.99606-0766

[59] Centring disk 80.99606-0767

[60] Press-fit bush 80.99606-0769

[61] Hook 80.99606-6013


[63] Assembly tool 51.99603-0003

S Removing/installing the refrigerant compressor belt drive

Special tools

[65] Extension 80.99606-6094

[66] Disassembly tool 80.99606-6118

S Dismantling and assembling the air compressor
[67] Lifting gear 80.99606-6152

[68] Angle gauge 80.99607-0172

[69] Adjustment gauge 80.99607-6055

S Removing, installing the oil injection nozzles
[70] Washer 80.99609-0033


Special tools
[71] Pressure plate 80.99609-0038

[72] Socket 80.99612-0023


[74] Release handle 80.99606-0597

[75] Release tool 80.99606-0625

S Removing/installing the fuel service center
[76] Intermediate piece 80.99613-0042

[77] Bracket 80.99613-0052


Special tools
[78] Bracket 80.99613-0053

[79] Valve spring compressor 80.99613-6000

[80] Sleeve 80.99616-0133

[81] Washer 80.99616-0134

[82] Mandrel 80.99617-0029


S Dismantling/assembling the rocker arm mechanism
[84] Washer 80.99617-0144


Special tools
[85] Guide mandrel 80.99617-0163


[87] Insertion mandrel 80.99617-6008


[89] Setting tool 80.99622-0052

[90] Piston ring collet 80.99613-0039


S Remove/install the air compressor
S Removing/installing the turbo charger
S Removing/installing the exhaust manifold
S Removing/installing the oil sump
S Removing/installing the oil sump (version 66, 67)
S Removing/installing the crankcase ventilation

Special tools

S Removing/installing the ribbed V-belt for the refrigerant compressor
(versions 66, 67)
S Removing, installing the starter motor
S Removing/installing the timing gears
S Removing/installing the vibration dampers
[93] Gear ratchet 80.99627-0001
(versions 66, 67)
S Removing, installing the starter motor
S Removing/installing the timing gears
S Removing/installing the vibration dampers
[94] Tool insert 80.99606-0610
[95] Tool insert 80.99606-0611

[96] Crossbeam 80.99629-6008

[97] Slinging chain 80.99629-6009

[98] Magnetic pick-up tool 80.99639-0009


Special tools

S Removing/installing the HCI

S Air distributor pipe

S Removing/installing the rail pressure pipe (common rail)

S Removing/installing the flame-start system
[103] Cap 81.96002-0518


[105] End plug 81.96002-0520


Special tools
[106] End plug 81.96002-0521

S Removing/installing the fuel service center
[107] Injector nozzle protective sleeve 81.96002-0522

[108] Fuel feed injector cap 81.96002-0523


[110] End plug 81.96002-0556




Special tools
[113] Size 14 valve adjusting wrench 80.99603-6031

[114] Ratchet adapter 08.06410-9072

[115] Handle 08.06460-0003

[116] Torque wrench 08.06450-0006


S Removing/installing the HCI exhaust manifold

Special tools

Keywords
2 D
2-stage exhaust turbocharger, 338 Disassembling, assembling the rocker
2-stage turbo charger, 348 arm mechanism, 460
Dismantling the coolant pump, 126
A Dismantling the exhaust manifold, 388
Air compressor, 148 Dismantling/assembling the air compressor, 158
Air distributor pipe, 423 Dismantling/assembling the fuel service
centre, 290
Alternator, 180
E
B
EGR module, 411, 417
Bracket for refrigerant compressor, 214
Engine case, 650
Bracket for the refrigerant compressor
(version 66, 67), 216 Engine control unit, 308
Engine electronics, 44, 60, 138, 139
C Engine lubrication, 515
Cable harness, 46 Engine ventilation, 654, 682, 686
Camshaft, 478 Engine views, 27
Camshaft bearing, 486 Exhaust manifold, 384
Camshaft gear wheel, 506 Exhaust manifold HCI, 374
Charge-air pipe (variants 66, 67), 332 Exhaust system, 372
Charge-air pipe with exhaust gas Explanation of icons, 4
recirculation connection, 360
F
Charge-air pipe with throttle valve, 366
Fan flange, 92, 94, 96, 98
Checking and setting values, 700
Fastening the engine, 35
Checking the connecting rods and
connecting-rod bearings, 616 Flame start system, 298
Flywheel, 596
Checking the crankshaft, 627
Flywheel housing, 658
Common Rail system, 230
Fuel service centre, 278
Compressed-air cylinder, 402
Connecting rod bearing cap, 613 H
Coolant pump, 118 High pressure pump, 259
Coolant pump coolant manifold, 100 High pressure pump drive wheel, 267
Cooling system, 33, 86 High-pressure lines, 239, 253
Crankcase ventilation, 652, 681 High-pressure pump, 272
Crankshaft, 621 Hydraulic pump V-belt/ribbed V-belt, 218
Crankshaft bearing cap, 628 Hydraulic pump/double pump, 226
Crankshaft drive, 590 Hydraulic pump/single pump, 222
Crankshaft gear wheel, 510 Hydrocarbon injection system, 380
Crankshaft seal, front, 644
Crankshaft seal, rear, 638 I
Crankshaft seals, 636 Injector, 239, 241
Cylinder head, 435 Injector with nozzle, 232
Intake system, 372
Cylinder head cover, 431
Intercooler, 324
Cylinder head gasket, 443
Intercooler charge-air pipe, 320
Intercooler charge-air pipe (low-pressure), 328
Intermediate gears, 502

Keywords
O U
Oil module, 517, 525 Upper part of the oil sump, 550, 562, 563
Oil module pressure relief valve, 535, 540
Oil nozzles, 584 V
Oil pump, 580 Valve bridges and tappet pushrods, 440, 468
Oil pump, 570, 572, 574 Valve clearance, 452
Oil separator, 654, 657 Valve control, 476
Oil sump, 529, 532, 545, 557 Valve springs, 470
Valve stem seals, 464
P Vibration damper, 592
Piston, 613 Visco fan, 88
Piston pins, 614
Piston rings, 614
Piston with connecting rod, 606
Power steering pump, 140
Power take-off, 144, 316, 392
Pre-heater for coolant, 136
Preface, 3
Pressure pipe, 253, 254, 257
Pressure-limiting valve, 255
PTO for coolant pump/alternator, 144
Publication data, 3
R
Rail pressure pipe (common rail), 247
Rail pressure sensor, 255
Refrigerant compressor, 208
Ribbed V-belt for the refrigerant compressor
(version 66, 67), 202
Ribbed V-belt of alternator belt drive, 172, 176
Rocker arm mechanism, 448
S
Special tools, 713
Starter motor, 192
Starter ring gear, 602
T
Technical data, 691
Thermostat housing, 112
Thermostat insert, 106
Tightening torques, 691
Timing case, 676
Timing case cover, 672
Timing gears, 497, 499

MAN Truck & Bus AG
Vogelweiherstrasse 33
90441 Nürnberg
Germany
A member of the MAN Group
Printed in Germany 81.99185-6122

MAN ENGINE SHOP MANUAL - D0834 LFL Axx

Uploaded by

Copyright:

Available Formats

MAN ENGINE SHOP MANUAL - D0834 LFL Axx

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MAN ENGINE SHOP MANUAL - D0834 LFL Axx

Uploaded by

Copyright:

Available Formats

Repair Manual

Common rail In-line Engine

81.99185-6122 “Translation of the original instructions”

Technical status as on: 04.2016

Read the manual thoroughly before starting any work!

Tips and Recommendations

Tip for users

Read the manual thoroughly before starting any work!

Removing/installing the engine on the assembly device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Read the manual thoroughly before starting any work!

Add-on units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Common Rail system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Intake/exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

Read the manual thoroughly before starting any work!

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429

Valve control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476

Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497

Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515

Crankshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590

Crankshaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636

Engine case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650

Read the manual thoroughly before starting any work!

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713

Read the manual thoroughly before starting any work!

1. Regulations for preventing accidents leading to injury to personnel

Checking, adjusting and repair work

Working on the brake system

Working on vehicles with a compressed natural gas (CNG) system

Read the manual thoroughly before starting any work!

Working on the compressed natural gas (CNG) system

Operating the engine

Bodies and special bodies

Working on high-pressure lines

Testing injection nozzles

Work on the vehicle electrical system

Read the manual thoroughly before starting any work!

Important: battery gases are explosive!

CAUTION! Battery acid is toxic and corrosive!

Work on plastic tubes – risk of damage and fire

Read the manual thoroughly before starting any work!

Working with a tilted cab

Work on the air-conditioning system

Work on the airbag or belt pre-tensioner units

Working on the independent heating

Read the manual thoroughly before starting any work!

2. Information on how to avoid damage and premature wear on units

3. Liability limitations for spare parts and accessories

Read the manual thoroughly before starting any work!

4. Regulations to prevent damage to health and the environment

Health protection precautions

Service products and process materials

Clean the cooling circuit

Cleaning the filter insert

Engine/gearbox oil, filter cartridges, inserts and box-type filters, desiccant

Used engine/gearbox oil

Read the manual thoroughly before starting any work!

5. Information about working on the common rail system

Read the manual thoroughly before starting any work!