Engine TGM D0836

Common-rail In-line Engines
D0836 LFL50 - LFL55

D0836 LFL60
D0836 LFL63
Copy deadline: 12.2009
Repair Manual
81.99298-6212 3rd edition A25 Stage 2
MAN Nutzfahrzeuge Aktiengesellschaft Reparaturanleitung A25 Stufe 2, 3. Ausgabe
Dachauer Str. 667 Reihenmotor Common Rail
80995 MÜNCHEN D0836 LFL50 - LFL55
oder D0836 LFL60
Postfach 50 06 20 D0836 LFL63
80995 MÜNCHEN - Englisch -
Printed in Germany
Repair Manual A25 Stage 2
3rd edition
Common-rail In-line Engines

D0836 LFL50 - LFL55
D0836 LFL60
D0836 LFL63
81.99298-6212
1
PREFACE / PRINTER’S IMPRINT
PREFACE
This manual provides assistance in performing repairs correctly on vehicles and units and reects the known
technical situation appertaining at the copy deadline.
This publication assumes that persons who use it possess the requisite technical knowledge in repairing
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always
correspond to the unit to be repaired or its peripherals.
The repair work is split up into sections and subsections. Each subsection starts with a page of jobs to do
in advance. The jobs to do in advance contain a summary of the main prerequisites for the repair section in
question. The detailed description of work can follow the jobs to do in advance. Only the tightening torques
for screw/bolt connections which deviate from the standard are indicated in the repair sections.
Important instructions relating to safety and accident prevention are specially highlighted in the text as follows.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in order to avoid
exposing people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in order to avoid
serious or irreparable damage to property.
Note
Explanatory description to aid understanding of the working and operating procedures involved.
Comply with general safety regulations when performing any repair work.
We reserve the right to make modications in the course of further development
Best wishes from
MAN Nutzfahrzeuge AG
PRINTER’S IMPRINT
© 2009 MAN Nutzfahrzeuge AG
Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN. All
rights under the copyright law are strictly reserved by MAN Nutzfahrzeuge AG. If any changes or modications
are made without the written approval of MAN Nutzfahrzeuge AG then MAN Nutzfahrzeuge AG shall not be
liable for any material defects attributable to the unauthorised changes or modications. MAN Nutzfahrzeuge
AG is not liable for any damage attributable to unauthorised changes or modications.
Redaktion: SAWDT, 2W Technische Informations GmbH/12.2009
Satz: SAWDT, 2W Technische Informations GmbH
Druck: MAN-Werksdruckerei
2 A25 Stage 2 3rd edition

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

The engine ................................................................................................................ 16
Model plate/model designation .................................................................................... 16
Characteristic data .................................................................................................. 18
Engine description ................................................................................................... 22
Engine electrics
Wiring harness ........................................................................................................... 29

Removing and installing the wiring harness .................................................................... 29
Engine electrics .......................................................................................................... 41
Removing and installing the engine electrics ................................................................... 41
Cooling system
Fan ......................................................................................................................... 45
Removing and installing the fan (variant DMR 704) ........................................................... 45
Removing and installing the fan (variant DMR 725) ........................................................... 49
Coolant manifold ......................................................................................................... 53
Removing and installing the coolant manifold .................................................................. 53
Thermostat with thermostat housing ................................................................................. 57
Removing and installing the thermostat with thermostat housing .......................................... 57
Coolant pump ............................................................................................................ 61
Removing and installing the coolant pump ..................................................................... 61
Dismantling and assembling the coolant pump ................................................................ 65
Mounted components
Power take-off ............................................................................................................ 73

Removing and installing the power take-off .................................................................... 73
Air compressor ........................................................................................................... 77
Removing and installing the 1-cylinder air compressor ....................................................... 77
Belt drive .................................................................................................................. 81
Removing and installing the belt drive (variant without Grosskopf alternator or hydraulic pump) .... 81
Removing and installing the Grosskopf alternator belt drive ................................................ 86
Removing and installing the hydraulic pump belt drive ....................................................... 89
Removing and installing the Stretchybelt belt drive (variant with one guide roller) ...................... 93
Removing and installing the Stretchybelt belt drive (variant with two guide rollers) ..................... 98
Checking and setting the refrigerant compressor belt track (D0836 LFL50 to LFL55) ................ 103
Alternator ................................................................................................................ 107
Removing and installing the alternator ........................................................................ 107
Grosskopf alternator .................................................................................................. 115
Removing and installing the Grosskopf alternator ........................................................... 115
Starter ................................................................................................................... 119
Removing and installing the starter ............................................................................ 119
Refrigerant compressor .............................................................................................. 123
Removing and installing the refrigerant compressor ........................................................ 123
Hydraulic pump ........................................................................................................ 127
Removing and installing the hydraulic pump ................................................................. 127
Common-rail system
Injectors and rail ....................................................................................................... 135

Protective sleeves, injectors and rail ........................................................................... 135
A25 Stage 2 3rd edition 3

TABLE OF CONTENTS
Removing and installing the injectors and rail ................................................................ 139

High-pressure pump .................................................................................................. 153
Protective sleeves, high-pressure pump (variant CP3.3) .................................................. 153
Removing and installing the high-pressure pump (variant CP3.3) ....................................... 155
Dismantling and assembling the high-pressure pump (variant CP3.3) .................................. 163
Protective sleeves, high-pressure pump (variant CP3.3 NH) .............................................. 167
Removing and installing the high-pressure pump (variant CP3.3 NH) ................................... 169
Fuel service centre .................................................................................................... 177
Protective sleeves, fuel service centre ........................................................................ 177
Removing and installing the fuel service centre ............................................................. 180
Dismantling and assembling the fuel service centre ........................................................ 188
Flame start system .................................................................................................... 193
Protective sleeves, ame start system ........................................................................ 193
Removing and installing the ame start system ............................................................. 195
Engine control unit .................................................................................................... 199
Removing and installing the engine control unit ............................................................. 199
Turbocharging
Intercooler ............................................................................................................... 205

Removing and installing the intercooler ....................................................................... 205
Charge-air pipes/charge-air manifold .............................................................................. 207
Removing and installing the charge-air pipes/charge-air manifold (Euro 5 and EEV variant) ....... 207
Turbocharger ........................................................................................................... 213
Removing and installing the turbocharger (variant with single-stage charging) ........................ 213
Removing and installing the turbocharger (variant with two-stage charging without intercooler) ... 218
Removing and installing the turbocharger (variant with two-stage charging with intercooler) ....... 229
Intake / exhaust system
Air distributor pipe ..................................................................................................... 243

Removing and installing the air distributor pipe .............................................................. 243
EGR module ............................................................................................................ 249
Removing and installing the EGR module (Euro 4 variant) ................................................ 249
Removing and installing the EGR module (Euro 5 and EEV variant) .................................... 256
Exhaust manifold ...................................................................................................... 267
Removing and installing the exhaust manifold (Euro 4 variant) ........................................... 267
Removing and installing the exhaust manifold (Euro 5 and EEV variant) ............................... 271
Cylinder head
Rocker arm mechanism .............................................................................................. 277

Removing and installing the rocker arm mechanism ........................................................ 277
Dismantling and assembling the rocker arm mechanism .................................................. 280
Cylinder head .......................................................................................................... 285
Removing and installing the cylinder head .................................................................... 285
Checking and setting the valve clearance .................................................................... 292
Removing and installing the valve stem seals ............................................................... 298
Valve timing
Camshaft / camshaft bearings ...................................................................................... 311

Removing and installing the camshaft/camshaft bearings ................................................. 311
Timing gears
Timing gears ............................................................................................................ 323

Removing and installing the timing gears ..................................................................... 323

TABLE OF CONTENTS
Engine lubrication
Oil module .............................................................................................................. 333

Removing and installing the oil module ....................................................................... 333
Oil sump and oil intake pipe ......................................................................................... 339
Removing and installing the oil sump and oil intake pipe (Euro 4 variant) .............................. 339
Removing and installing the oil sump lower section (Euro 5 and EEV variant) ........................ 344
Removing and installing the oil sump upper section (Euro 5 and EEV variant) ........................ 347
Oil pump ................................................................................................................. 351
Removing and installing the oil pump .......................................................................... 351
Oil injector nozzles .................................................................................................... 355
Removing and installing the oil injector nozzles ............................................................. 355
Crank mechanism
Vibration damper ...................................................................................................... 361

Removing and installing the vibration damper ............................................................... 361
Flywheel for manual gearbox ....................................................................................... 365
Removing and installing the ywheel for manual gearbox ................................................. 365
Pistons and connecting rods ........................................................................................ 375
Removing and installing the pistons and connecting rods ................................................. 375
Crankshaft .............................................................................................................. 387
Removing and installing the crankshaft ....................................................................... 387
Crankshaft oil seals
Crankshaft oil seals ................................................................................................... 399

Removing and installing the front crankshaft oil seal ....................................................... 399
Removing and installing the rear crankshaft oil seal ........................................................ 403
Engine housing
Crankcase ventilation ................................................................................................. 409

Removing and installing the crankcase ventilation (variant LFL50/53) .................................. 409
Removing and installing the crankcase ventilation (variant LFL51/52/54/55) .......................... 411
Removing and installing the crankcase ventilation (variant LFL60/63) .................................. 413
Flywheel housing ...................................................................................................... 415
Removing and installing the ywheel housing (variant without power take-off) ........................ 415
Removing and installing the ywheel housing (variant with power take-off 300 Nm) ................. 418
Removing and installing the ywheel housing (variant with power take-off 600 Nm) ................. 423
Crankcase yoke ........................................................................................................ 427
Removing and installing the crankcase yoke (variant LFL50-55) ......................................... 427
Timing case cover/timing case ...................................................................................... 431
Removing and installing the timing case cover .............................................................. 431
Removing and installing the timing case ...................................................................... 435
Power take-off
Power take-off .......................................................................................................... 441

Removing and installing the power take-off .................................................................. 441
Technical Data
Technical Data 443

INDEX
Catchword Page
A
Add-on units
Starter..................................................................................................................................................... 121
Air distributor pipe
Charge-air manifold................................................................................................................................ 259
Temperature sensor ............................................................................................................................... 246
Alternator
Coolant lines........................................................................................................................................... 110
Holder..................................................................................................................................................... 110
Support................................................................................................................................................... 111
B
Belt drive
Alternator poly-V-belt tensioner ................................................................................................................ 83
Grosskopf alternator guide roller .............................................................................................................. 87
Grosskopf alternator poly-V-belt tensioner ............................................................................................... 87
C
Characteristic data......................................................................................................................................... 18
Crank mechanism
Connecting rod bearing .......................................................................................................................... 382
Connecting rod bearing cap ................................................................................................................... 380
Piston pin................................................................................................................................................ 380
Piston pin bushing .................................................................................................................................. 382
piston ring gap........................................................................................................................................ 381
Piston rings............................................................................................................................................. 381
Thrust washers....................................................................................................................................... 394
Vibration damper .................................................................................................................................... 363
Crankcase
Crankshaft oil seal front.......................................................................................................................... 402
Oil ller neck........................................................................................................................................... 433
Crankshaft oil seals
Rear crankshaft oil seal.......................................................................................................................... 406
E
EGR positioning cylinder
Setting the positioning cylinder............................................................................................................... 265
Engine description ......................................................................................................................................... 22
Engine lubrication
Oil cooler ................................................................................................................................................ 336
Oil lter ................................................................................................................................................... 335
Oil injector nozzles ................................................................................................................................. 357
Oil pressure switch ................................................................................................................................. 336
F
Flywheel
Circlip ..................................................................................................................................................... 372
Clutch pilot bearing................................................................................................................................. 372
Flywheel ring gear .................................................................................................................................. 370
Flywheel housing
crankshaft gear....................................................................................................................................... 424
Intermediate gear ................................................................................................................................... 425
Fuel service centre
Hand pump............................................................................................................................................. 191
Heating element ..................................................................................................................................... 190
Pressure sensor ..................................................................................................................................... 190
G
Grosskopf alternator
Holder..................................................................................................................................................... 117

INDEX
H
Hydraulic pump
Support................................................................................................................................................... 129
V-belt pulley............................................................................................................................................ 129
I
Intercooler, low-pressure side
Absorber mat.......................................................................................................................................... 206
Charge-air manifold unscrewed conduits ............................................................................................... 206
M
Model plate .................................................................................................................................................... 16
O
Oil module
Draining the coolant ............................................................................................................................... 336
P
Power take-off
Poly-V-belt pulley...................................................................................................................................... 74
R
Refrigerant compressor
Bracket ................................................................................................................................................... 125
Holder..................................................................................................................................................... 125
S
Safety instructions ........................................................................................................................................... 9
General....................................................................................................................................................... 9
T
Turbocharger
Charge-air manifold................................................................................................................................ 220
Oil pressure line ..................................................................................................................................... 233
Oil return line .......................................................................................................................................... 222
Pulse valve ............................................................................................................................................. 223
V
Valve timing
Camshaft ................................................................................................................................................ 315
Camshaft bearing 1 ................................................................................................................................ 316
Camshaft bearing 5 ................................................................................................................................ 317
Camshaft bearings 2 - 4 ......................................................................................................................... 316
Flange .................................................................................................................................................... 315
Tappet..................................................................................................................................................... 315

INTRODUCTION
INTRODUCTION
SAFETY INSTRUCTIONS
General
Only trained personnel are allowed to perform operating, maintenance and repair work on trucks, buses and
coaches.
The following sections include summaries of important regulations, listed according to major topics, which
must be complied with. The intention is to provide the knowledge needed to avoid accidents which could
lead to injury, damage and environmental pollution. Please note that these are merely brief extracts taken
from various accident prevention regulations. Of course, all other safety regulations must be followed and
the necessary measures must be taken.
Additional references to danger are contained in the instructions at points where there is a potential danger.
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin
contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes,
crushing of limbs etc.
1. Regulations for preventing accidents leading to injury to personnel
Checking, setting and repair work

– Secure units during their removal.
– Support the frame when working on the pneumatic or spring suspension system.
– Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.
– Only use tools that are in perfect condition.
– Only authorised technical personnel are entitled to perform inspection, adjustment and repair work.
Working on the brake system

– A dust extractor must be used if dust is released when working on the brake system.
– Perform visual, function and effectiveness checks on the brake system after carrying out any work on it
whatsoever. These checks must be made in accordance with the safety inspection (SP).
– Check the function of ABS/ASR systems using a suitable test system (e.g. MAN-cats).
– Collect any brake uid that leaks out.
– Brake uid is poisonous! Do not allow it to come into contact with food or open wounds.
– Treat hydraulic uid/brake uid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
Working on vehicles with compressed natural gas (CNG) system

– Vehicles with a defective compressed natural gas system may not be brought into the workshop. This also
applies to vehicles whose engine cannot be switched off by automatic emptying of the removal lines.
– When working on vehicles with a compressed natural gas system, set up a gas warning device above the
vehicle roof and in the engine compartment above the pressure controller. Further gas warning devices
must be carried by the persons working on the vehicle.
– Smoking is not allowed in areas where work on vehicles with compressed natural gas systems is carried
out. All sources of ignition must be removed from these areas.
– Before carrying out welding work, the compressed gas tanks must be removed and the gas-carrying lines
must be ushed with inert gas.
– Compressed gas tanks are only allowed to be exposed to temperatures up to 60° C in paint-drying booths.
If the temperatures are any higher, the compressed gas tanks must be removed or degassed using an inert
gas such as nitrogen. The gas-carrying lines must also be ushed with inert gas.
Working on the compressed natural gas (CNG) system

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

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

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

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

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

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

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

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

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

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

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

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

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

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

– Before commencing work, switch off the heater and allow all hot components to cool down.
– Ensure that suitable collecting containers are available and no sources of ignition are present when working
on the fuel system.
– Keep suitable re extinguishing equipment nearby and within easy reach!!
– The heater may not be operated in enclosed areas such as garages or workshops unless an extractor
system is used.
2. Notes on preventing damage and premature wear on units
General information
– Units are only designed for their specied purpose - dened by the manufacturer (designated use): Any
other use is classied as not in accordance with the designated use. The manufacturer is not liable for
damage caused as a result of such other use. In the event of such other use, the user alone bears the risk.
– Designated use also includes compliance with the operating, maintenance and repair conditions specied
by the manufacturer.
– The unit may only be used, maintained and repaired by persons who are familiar with it and are fully aware
of the risks.
– Arbitrary changes to the engine mean that the manufacturer is no longer responsible for any damage
incurred as a result of such changes.
– Similarly, tampering with the injection and control system can affect the unit's performance and exhaust-gas
characteristics. This means that compliance with the statutory environmental requirements is no longer
assured.
– If malfunctions occur, determine the cause and remedy the problem immediately.
– Clean units thoroughly before repairs, ensuring that all openings where dirt is not allowed to enter for safety
or functioning reasons are closed.
– Never run a unit dry, in other words always make sure that it has been lled with oil before running it.
– Never run engines without coolant.
– Apply a suitable information sign to units that are not ready to be operated.
– Only use service products as per the MAN Recommended Service Products booklet, otherwise the
manufacturer warranty will be invalidated.
Details of approved products can be found online at: http://www.man-mn.com/ > Products & Solutions >
E-Business.
– Comply with the specied maintenance intervals.
– Do not ll engine/gear oil above the maximum level mark. Do not exceed the maximum permitted operational
tilt.
– The special measures described in MAN Works Standard M 3069 Part 3 apply if buses or trucks are to be
withdrawn from service or stored for a period longer than 3 months.
3. Limited liability for parts and accessories
General information
Only use accessories and genuine MAN parts that have been expressly approved by MAN Nutzfahrzeuge
AG for your MAN vehicle. MAN Nutzfahrzeuge AG accepts no liability for any other products.
4. Regulations for avoiding injury and environmental contamination
Health protection precautions

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

Do not use food or drink containers for draining and storing service products or excipients. Comply with
local-authority regulations when disposing of service products and excipients.
Coolant
Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority
when disposing of used coolant (mixture of antifreeze and water).

INTRODUCTION
Cleaning the cooling circuit

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

When blowing compressed air through the lter insert, make sure the lter dust is collected by a vacuum or
is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear rubber gloves or
use a skin barrier hand cream when washing out the elements, because cleaning agents have aggressive
grease-dissolving characteristics.
Engine/gear oil, lter cartridges, inserts and box-type lters, desiccant cartridges
Filter inserts, cartridges and box-type lters (oil and fuel lters, desiccant cartridges for the air dryer) are
classied as hazardous waste. Comply with local-authority regulations when disposing of the above parts.
Used engine/gear oil

Lengthy or repeated skin contact with any type of engine/gear oil removes grease from the skin. This can
cause dry skin, irritation or skin inammation. In addition to these hazards, used engine oil contains dangerous
materials which can trigger dangerous skin diseases. Wear gloves, especially when changing the oil.
Handling AdBlue®
AdBlue® is a synthetically produced 32.5 % urea/water solution which is used as an NOx reduction additive
for diesel engines with SCR catalytic converter. AdBlue® is not a hazardous substance but does decompose
into ammonium hydroxide and carbon dioxide when stored for prolonged periods. For this reason, AdBlue®
is classied as a water hazard (water hazard class 1) in Germany and is not allowed to enter sewage or the
ground. Ensure good ventilation in the workplace when working on the AdBlue® system. Do not eat, drink
or smoke in the workplace. Avoid skin and eye contact with AdBlue®, thoroughly wash your hands and use
a skin protection cream before taking breaks and before nishing work. If your skin comes into contact with
AdBlue®, wash the skin using water and a skin cleaner, change out of dirty clothes immediately. If the skin
is irritated, consult a doctor. If AdBlue® gets into your eyes, rinse your eyes with water or an eye-rinsing
products for at least 10 minutes, keeping your eyelids open. Remove any contact lenses beforehand. If
symptoms persist, consult a doctor. If AdBlue® is swallowed, consult a doctor immediately. Store AdBlue®
containers closed in liquid-tight storage areas. The storage temperature must not exceed 25°C. Soak up
leaked or spilt AdBlue® using binding agent and dispose of in the correct manner.
5. Information for working on the common rail system
General information
– A jet of fuel can cut through the skin. Risk of re due to fuel atomisation.
– Never undo the screwed connections on the fuel high-pressure side of the common-rail system whilst the
engine is running (high-pressure line from the high-pressure pump to/on the rail and on the cylinder head
to the injector). Whilst the engine is running, the lines are constantly carrying fuel under a pressure of 1800
bar or more. Before the screw connections are opened, wait at least one minute until depressurisation has
occurred, using MAN-cats to check the depressurisation on the rail as necessary.
– Avoid standing near the running engine.
– Do not touch the live parts at the injector electrical connection whilst the engine is running.
– Any changes to the original wiring can lead to the limit values specied in pacemaker regulations being
exceeded. Examples of such changes include non-twisted injector wiring or the addition of the test box
(contact box).
– There is no danger to operators and persons wearing a pacemaker if units with MAN common-rail engines
are used for their intended, i.e. approved, purpose.
– A jet of fuel can cut through the skin. Risk of re due to fuel atomisation.
– Never undo the screwed connections on the fuel high-pressure side of the common-rail system whilst the
engine is running (injection line from the high-pressure pump to/on the rail and on the cylinder head to the
injector).
– Avoid standing near the running engine.
– Whilst the engine is running, the lines are constantly carrying fuel under a pressure of 1800 bar or more.
– Before opening the screwed connections, wait for at least one minute so that the system can be
depressurised.
– Check depressurisation of the rail using MAN-cats if necessary.
– Do not touch the live parts at the injector electrical connection whilst the engine is running.

INTRODUCTION
Information for people with pacemakers

– Any changes to the original engine wiring can lead to the limit values specied in pacemaker regulations
being exceeded. Examples of such changes include non-twisted injector wiring or the addition of the test
box (contact box).
– There is no danger to drivers and co-drivers wearing a pacemaker if the vehicle is used for its intended, i.e.
approved, purpose.
– There is no danger to operators wearing a pacemaker if units with MAN common-rail engines are used for
their intended, i.e. approved, purpose.
– In its original state, the product does not violate any of the currently known pacemaker limit values.
Danger of damage due to dirt ingress

– Diesel-injection systems consist of precision engineered components that are subject to extreme loads; Due
to the highly precise nature of this technology, all work on the fuel system requires the highest possible
degree of cleanliness.
– Even dirt particles over 0.002 mm can cause component failure.
Before commencing work on the clean side

– Clean the engine and engine compartment with the fuel system closed. Do not use a powerful jet when
cleaning electrical components.
– Drive the vehicle into a clean area of the workshop where none of the work causes dust to be swirled up
(sanding, welding, brake repairs, brake checks, performance tests etc.).
– Avoid air movements (possible swirling up of dust due to starting of engines, the workshop
heating/ventilation system, due to draughts etc.).
– Clean and dry the area of the still closed fuel system using compressed air.
– Use a suitable extractor unit (industrial extractor unit) to remove loose dirt particles such as paint chippings
and insulating material.
– Use a new and clean cover in areas of the engine compartment where dirt particles can become loose, e.g.
tilted cab, bus engine compartment.
– Before removing any components, wash your hands and put on clean working clothes.
After opening the clean side

– The use of compressed air for cleaning is not permitted.
– During assembly, remove loose dirt using a suitable extractor unit (industrial extractor unit).
– Only lint-free cleaning cloths are allowed to be used on the fuel system.
– Clean tools and equipment before commencing work.
– Only use tools that show no signs of damage (cracked chrome coatings).
– Do not use materials such as cloths, cardboard or wood when removing and installing components as these
materials can produce particles and bres.
– If the undoing of connections causes the paint to chip (due to possible excess paint), carefully remove these
paint chippings before fully undoing the connection.
– All removed components on the clean side of the fuel system must be plugged immediately at their
connection openings using suitable caps.
– These caps must be stored in dustproof packaging until they are used and disposed of after they have been
used once.
– Then store the components in a clean, sealed container.
– Never use used cleaning or test uids for these components.
– New parts must not be removed from their original packaging until immediately before use.
– Work on removed components may only be carried out in a suitably equipped workplace.
– If removed parts are shipped, always use the new part's original packaging.
When carrying out work on bus engines, the instructions below must also be followed without fail:

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

INTRODUCTION
– Remove the injectors.

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

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

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

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

There are reworking levels for crankshaft bearings and connecting rod bearings as well as for pistons. The
reworking subassemblies are indicated on the type plate, e.g.:
P = crankshaft connecting rod bearing NI or NII
H = crankshaft - crankshaft bearing NI or NII
Explanation of the engine no. (Engine identication number)
Motor-Nr. / engine no. Classication terms (assignment)

218 Model number after model code
1440 Day of assembly
522 Assembly sequence (serial number on day of assembly)
1442 The last four digits of the engine no. (Motor-Nr.) are production- and
equipment-specic data.
Explanation of the model designation
Model Meaning Example

designation
D Fuel type Diesel

08 Identication number + 100 108 mm bore
3 (identication number x 10) + 100 130 mm stroke (rounded)
6 Number of cylinders 6-cylinder
L Turbocharging With turbocharger and intercooler

INTRODUCTION
F Engine installation Engine/vertical/LHD forward-control vehicle

L Engine installation Light series
51 Type identication Output/rpm/approval

INTRODUCTION
Characteristic data
D0836 LFL50
Designation Unit of Data

measurement
Emissions category Euro 4
Number of cylinders/arrangement 6 cylinders/in-line/vertical
Valves per cylinder 4
Engine weight, dry kg 625
Injection system Common rail/EDC 7
Direction of rotation as viewed onto ywheel Left
Rated output to ISO 1585-89/491 EEC in kW/hp 176/240
Bore mm 108
Stroke mm 125
Swept volume cc 6871
Firing sequence 1-5-3-6-2-4
Rated speed rpm 2300
Low idling speed rpm 570
Max. torque at engine speed Nm rpm 925 Nm at 1200-1800 rpm
D0836 LFL51

measurement
Bore mm 108
Stroke mm 125
D0836 LFL52

measurement

INTRODUCTION

Bore mm 108
Stroke mm 125
D0836 LFL53

measurement
Bore mm 108
Stroke mm 125
D0836 LFL54

measurement
Bore mm 108
Stroke mm 125

INTRODUCTION

D0836 LFL55

measurement
Bore mm 108
Stroke mm 125
D0836 LFL60
Designation Unit of Details

measurement
Emissions category EEV
Direction of rotation when looking towards Left
ywheel
Rated output to ISO 1585-89/491 EEC kW/hp 184/250
Bore mm 108
Stroke mm 125

INTRODUCTION
D0836 LFL63
Designation Unit of Details

measurement
Direction of rotation when looking towards Left
ywheel
Rated output to ISO 1585-89/491 EEC kW/hp 184/250
Bore mm 108
Stroke mm 125

INTRODUCTION
Engine description
Euro 4
(1) Charge-air manifold

(2) Coolant pump
(3) Coolant outlet pipe
(4) Alternator
(5) Air compressor
(6) Turbocharger
(7) EGR positioning cylinder
(8) Fuel service centre
(9) EGR module (exhaust gas recirculation)
(10) Air distributor pipe
(11) Engine control unit (EDC)
(12) Flywheel housing
(13) Starter
(14) Rail
(15) Crankcase yoke
(16) High-pressure pump
(17) Oil module
(19) Covering pan
(20) Vibration damper
(21) Refrigerant compressor
(22) Power take-off poly-V-belt pulley

INTRODUCTION
Euro 5 and EEV
(1) Charge-air pipe (12) Flywheel housing

(2) Coolant pump (13) Starter
(3) Coolant manifold (14) Rail
(4) Alternator (15) Oil sump upper section
(5) Air compressor (16) High-pressure pump
(6) Turbocharger (17) Oil module
(7) EGR positioning cylinder (18) Charge-air manifold
(8) Fuel service centre (19) Oil sump
(9) EGR module (exhaust gas recirculation) (20) Vibration damper
(10) Air distributor pipe (21) Refrigerant compressor
(11) Engine control unit (EDC) (22) Poly-V-belt pulley
Engine, general
The engines described here are liquid-cooled, turbocharged 6-cylinder, 4-stroke diesel engines with
exhaust-gas turbocharger. They comply with the Euro 4, Euro 5 and EEV emissions standards.
The engines operate using the common-rail high-pressure injection system in conjunction with EDC 7
(Electronic Diesel Control).
Engine monitoring
Various sensors monitor the engine. The sensors are speed and temperature sensors, for example, which
send information about the various engine operating conditions and states to the engine control unit.
The engine control unit operates according to the IPO principle:
I = Input

INTRODUCTION
P = Processing
O = Output
The engine control unit processes the information received from the sensors and controls the output signals
which are sent to the actuators. The actuators convert the signals into mechanical variables. An actuator is,
for example, the proportioning unit on the high-pressure pump.
Crankcase
The crankcase and the cylinder block are a monoblock casting made from special cast iron. The pistons run
directly in the crankcase. Ceramic honing of the cylinder liner surfaces achieves optimal results with respect
to wear resistance and oil consumption. At the rear of the crankcase, there is a ywheel housing. At the
front of the crankcase, there is a timing case cover. The ywheel housing and timing case cover are made
of aluminium. The crankshaft oil seals are installed in the timing case cover and the ywheel housing. The
crankcase blow-by gases are returned to the combustion air via an oil separator with pressure-relief valve on
the suction side of the turbocharger.
Crankshaft
The crankshaft is forged in a die using high-quality, micro-alloyed steel. It has eight cast counterweights to
balance the masses. The crankshaft is mounted in seven 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 t and high lateral stability.
Pistons
3-ring pistons made of special die-cast aluminium are used. They feature a cast ring carrier for the uppermost
piston ring. The pistons have a cast-in cooling duct for reducing the thermal load when the output is high.
They are cooled by an oil jet from the oil injector nozzles. The ring set comprises one taper-face ring and
one full keystone ring, each as compression rings, as well as one double-bevelled slotted oil control ring with
spiral-type expander as an oil scraper ring.
Cylinder head
D08 series engines are equipped with a single-section cylinder head. The cylinder head is made from special
cast iron and is tted with shrink-tted valve seat rings and pressed-in, exchangeable valve guides. The valve
guides 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 gasket has a specially designed combustion
chamber seal. There is an elastomer gasket between the cylinder head and cylinder head cover.
Camshaft
The camshaft is forged from steel and is induction hardened. It is mounted in ve bearings in the crankcase.
The camshaft drive onto the camshaft gear comes from the spur-toothed crankshaft gear.
Engine lubrication
The engine is lubricated by forced-feed lubrication for all bearing points. The engine oil lter and the oil cooler
are grouped together as an oil module. The oil level in the oil sump is measured by means of a dipstick and
using an oil level sensor.
Cooling system
The cooling circuit is a thermostat-controlled, forced-circulation cooling system with a maintenance-free
coolant pump that is driven by a poly-V-belt. The thermostat is an exchangeable insert with wax elements as
expansion elements. The connection for the heater feed is located on the thermostat housing.
Intercooler
The intercooler consists of a high-pressure section and a low-pressure section.

INTRODUCTION
Around 10% of the coolant ow is diverted from the main cooling circuit for the engine downstream of the
coolant pump. The diverted coolant ows through a dedicated, second cooler - the low-temperature coolant
cooler - which is arranged directly upstream of the main coolant cooler. The low-temperature coolant is further
cooled by the airow and is therefore cooler than the coolant in the engine circuit. The low-temperature
coolant is then directed through the low-pressure and high-pressure intercooler, each of which absorbs the
heat of the low-temperature coolant.
Advantages of this low-temperature intercooling include the increased turbocharger charging, the reduction
in the engine's thermal load, a reduction in NOx emissions, the omission of the charge-air pipes to the vehicle
front and an improvement in the specic fuel consumption.
Intake/exhaust system
The three-section exhaust manifold is made of high temperature-resistant nodular cast iron and secured to
the cylinder head using heat-resistant bolts. The maintenance-free turbocharger is mounted on the middle
exhaust manifold. The exhaust manifold is installed downstream of the turbocharger. The turbocharger is
lubricated by the engine oil circuit.
Fuel system
The fuel system consists of a low-pressure system and a high-pressure system. The low-pressure system
includes the fuel lines, the hand pump and the fuel service centre (KSC). The fuel service centre comprises
a pre-lter and a special microlter with water separation to ensure the degree of fuel purity required by the
common-rail system. The low-pressure system also includes a heating element and the ame start system.
The interface to the high-pressure system is the fuel pump.
High-pressure system
The high-pressure system consists of the ow-rate-controlled high-pressure pump with ange-mounted fuel
pump and the rail with rail-pressure sensor and pressure limiting valve. Solenoid valve-controlled injectors
with rail connections and high-pressure lines which meet the necessary requirements are also installed.
Injection pressure generation and fuel injection are separate in the high-pressure system. The injection
pressure is generated by the high-pressure pump, irrespective of the engine speed and the required injection
quantity. The injection quantity is available in the rail for injection via the injectors. The high-pressure pump
delivery quantity is controlled by a proportional valve. The injection point and the injection quantity are
calculated in the engine control unit and implemented by the solenoid valve-controlled injectors.
The solenoid valve-controlled injectors allow multiple injections:
1 Pilot injection to improve combustion, reduce combustion noise and reduce peak combustion pressures.
2 Main injection to introduce the energy for the required engine power output.
3 Post injection to reduce the pollutant emissions, main constituent NOX.
Always ensure absolute cleanliness both in and around the working area whenever carrying out work on the
highly sensitive high-pressure system.
injectors
The injectors are controlled by solenoid valve. They are arranged vertically in the cylinder head and clamped
with a pressure ange in the cylinder head.
Flame start system

Special equipment includes a ame start system which serves as a cold starting aid. The ame start system
consists of a solenoid valve and a rapid ame glow plug built into the charge-air manifold. After various
parameter enquiries (via sensors), the ame glow plug and the corresponding solenoid valve are activated
by the EDC in order to heat the intake air. The fuel is supplied by the fuel service centre (KSC).
Starter
The starter is a reduction-gear starter. The starter shaft is guided without a thrust bearing on the housing in
the starter. A mechanical relay is mounted in the starter for starter control.
Alternator
A compact, powerful, low-noise alternator is mounted for power generation. The alternator is equipped with
a multifunction controller. The voltage is controlled depending on the temperature, the battery charge level
and the current power consumption. The alternator speed is four times the engine speed.

INTRODUCTION
Air compressor
The air compressor is driven by the straight-cut camshaft gear.
Front power take-off

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

The rear power take-off is mounted on the ywheel housing. Helical intermediate gears and intermediate
gear pins are installed between the ywheel housing and the plate in the ywheel housing. The rear power
take-off is driven indirectly by an additional crankshaft gear on the ywheel side of the crankshaft. The power
is transferred from the crankshaft gear to the power take-off via the intermediate gears. The rear power
take-off serves as a permanent drive system for hydraulic pumps, for example.
Power steering pump

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

ENGINE ELECTRICS
ENGINE ELECTRICS
(1) Speed sensor (8) Heating element

(2) Oil level sensor (9) Pressure sensor
(3) Flame glow plug (10) Rail-pressure sensor
(4) Temperature sensor (11) Pressure transmitter
(5) Temperature sensor (12) Metering unit
(6) EGR positioning cylinder (13) Charge-pressure sensor
(7) Speed sensor

ENGINE ELECTRICS
WIRING HARNESS
Removing and installing the wiring harness
(1) Earth cable (3) Cable duct

(2) Cable duct cover (4) Engine wiring harness
Technical data
Cable socket mounting nut.................................... M5 ..................................................................... 5 Nm
Terminal B + mounting nut .................................... M8 ....................................................................13 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
Before removing the wiring harness, mark the installation position of the cable tie(s) and disconnect.
After installing the wiring harness, install the cable tie(s) as marked.

ENGINE ELECTRICS
Removing the wiring harness Disconnecting the charge-air manifold pressure

sensor electrical connection
Disconnecting the control valve electrical
connection (Euro 5 and EEV)
• Disconnect the electrical connection (1)
• Disconnect the electrical connection (1) Disconnecting the oil level sensor electrical
connection
Disconnecting the proportional valve electrical

• Free the oil level sensor wiring harness (1)
Disconnecting the refrigerant compressor
Disconnecting the EGR positioning cylinder electrical connection
electrical connection (Euro 5 and EEV)


ENGINE ELECTRICS
Disconnecting the alternator electrical Disconnecting the charge-pressure sensor

connection electrical connection
• Release and pull off the compact connector (3) • Disconnect the electrical connection (1) for the
• Disconnect the cable tie (2) charge-pressure sensor (2)
• Unscrew the terminal B+ mounting nut (1)
• Free the wiring harnesses Disconnecting the ame start system electrical
connections
Disconnecting the speed sensor electrical
connection
• Unscrew the mounting nut (2)

• Remove the cable lug (1) with mounting nut (2)
• Unscrew the mounting bolt (1) • Disconnect the electrical connection (3) for the
• Disconnect the electrical connection (2) solenoid valve (4)
• Free the wiring harnesses
Unclipping the engine wiring harness
• Unclip the engine wiring harness (2) from the

holder (1)

ENGINE ELECTRICS
Disconnecting the metering unit electrical Disconnecting the rail-pressure sensor

connection electrical connection (Euro 5 and EEV)
• Disconnect the electrical connection (1) for the • Disconnect the electrical connection (1)
metering unit (2)
Disconnecting the EGR module temperature
Disconnecting the pressure transmitter sensor electrical connection
electrical connection
• Disconnect the electrical connection (1) for the

• Disconnect the electrical connection (1) for the temperature sensor (2)
pressure transmitter (2)
Disconnecting the air distributor pipe
Disconnecting the rail-pressure sensor temperature sensor electrical connection
electrical connection (Euro 4)

• Disconnect the electrical connection (2) for the temperature sensor (1)
rail-pressure sensor (1)

ENGINE ELECTRICS
Disconnecting the fuel service centre electrical Removing the speed sensor
connections
• Remove the speed sensor (1) from the ywheel

housing (2)
Disconnecting the engine control unit electrical

connections
• Disconnect the pressure sensor electrical

connection (1)
• Disconnect the heating element electrical
connection (3)
• Disconnect the cable tie (2)
• Release and pull off the connectors (1), (2) and (3)
connection (Euro 4) Exposing the engine wiring harness
• Disconnect the electrical connection (1) for the • Free the engine wiring harness (1)
proportional valve (2)
• Free the wiring harness (3) for the proportional
valve (2)

ENGINE ELECTRICS
Removing the cable duct cover Removing the cable duct
• Open the locking pin (1) a quarter turn • Unscrew the mounting bolts (1)
• Remove the cable duct cover (2) • Remove the cable duct (2), place it to the side and
secure
Disconnecting the plug bracket electrical
connection
• Disconnect the electrical connections (1) for the

plug brackets
Disconnect the EGR positioning cylinder

• Disconnect the EGR positioning cylinder electrical

connections (1)

ENGINE ELECTRICS
Installing the wiring harness Mounting the cable duct cover
Mounting the cable duct
• Put on the cable duct cover (2)

• Close the locking pin (1) a quarter turn
• Position the cable duct (2) with the wiring harness
• Screw in and tighten the mounting bolts (1) Routing the engine wiring harness
Connect the EGR positioning cylinder electrical

connection
• Route the wiring harness (1) so it is not under

tension, not kinked and there are no chang points
• Secure the wiring harness (1) with cable ties
• Connect the EGR positioning cylinder electrical
connections (1)
Connecting the plug bracket electrical

connections
• Connect the plug bracket electrical connections

(1)

ENGINE ELECTRICS
Connecting the engine control unit electrical Connecting the proportional valve electrical
connections connection (Euro 4)
WARNING • Connect the electrical connection (1) for the

Danger of irreparable engine control proportional valve (2)
unit damage • Route the wiring harness (3) so it is not under
• When installing the connectors, rst tension, not kinked and there are no chang points
fully open the lock and then insert and
Connecting the fuel service centre electrical
lock the connectors
connections
• Insert and lock the connectors (1), (2) and (3) in
the engine control unit
• Route the wiring harnesses and secure using
cable ties
Installing the speed sensor
• Install the speed sensor (1) in the ywheel housing

(2)
• Connect the pressure sensor electrical connection

(1)
• Connect the heating element electrical connection
(3)
• Route the wiring harnesses so that they are not
under tension, not kinked and there are no chang
points
• Secure the wiring harnesses with cable ties (2)

ENGINE ELECTRICS
Connecting the air distributor pipe temperature Connecting the rail-pressure sensor electrical
sensor electrical connection connection (Euro 4)
• Connect the electrical connection (2) for the • Connect the electrical connection (2) for the
temperature sensor (1) rail-pressure sensor (1)
Connecting the EGR module temperature sensor Connecting the pressure transmitter electrical
electrical connection connection
• Connect the electrical connection (1) for the • Connect the electrical connection (1) for the
temperature sensor (2) pressure transmitter (2)
Connecting the rail-pressure sensor electrical Connecting the metering unit electrical
connection (Euro 5 and EEV) connection
• Connect the electrical connection (1) • Connect the electrical connection (1) for the
metering unit (2)

ENGINE ELECTRICS
Connecting the ame start system electrical Clipping in the engine wiring harness
connections
• Clip the engine wiring harness (2) into the holder

• Route the wiring harnesses so that they are not (1)
under tension, not kinked, and there are no chang
points Connecting the speed sensor electrical
• Position the cable lug (1) at the ame glow plug connection
with the mounting nut (2)
• Screw on the mounting nut (2) and tighten it to 5
Nm
• Connect the electrical connection (3) for the
solenoid valve (4)
Connecting the charge-pressure sensor

• Connect the electrical connection (2)

• Position the fastening clamp, then screw in and
tighten the mounting bolt (1)

charge-pressure sensor (2)

ENGINE ELECTRICS
Connecting the alternator electrical connection Connecting the oil level sensor electrical
connection

under tension, not kinked, and there are no chang • Route the wiring harness for the oil level sensor
points (1) so that it is not under tension, not kinked and
• Screw on the terminal B+ mounting nut (1) and there are no chang points
tighten it to 13 Nm • Connect the electrical connection (2)
• Insert and lock the compact connector (3)
• Secure the wiring harnesses with cable ties (2) Connecting the charge-air manifold pressure
Connecting the refrigerant compressor
• Connect the electrical connection (1) Connecting the EGR positioning cylinder

ENGINE ELECTRICS
Connecting the proportional valve electrical

Connecting the control valve electrical


ENGINE ELECTRICS
ENGINE ELECTRICS
Removing and installing the engine electrics
Additional jobs
– Reading out the fault memory with MAN-cats®
(1) Speed sensor (8) Heater element

(2) Oil level sensor (9) Pressure sensor
(3) Flame glow plug (10) Rail-pressure sensor
(4) Temperature sensor (11) Pressure transmitter
(5) Temperature sensor (12) Metering unit
(6) EGR positioning cylinder (13) Charge-pressure sensor
(7) Speed sensor
Technical data
Mounting bolt, speed sensor (1) ............................ M6x16-8.8 .......................................................... 8 Nm
Oil level sensor (2)................................................ M22x1.5 ............................................................25 Nm
Flame glow plug (3) .............................................. M20x1.5 ............................................................25 Nm
Temperature sensor (4)......................................... M16x1.5 ...................................................47 Nm, oiled
Pressure sensor (9) .............................................. M18x1.5 ...................................................47 Nm, oiled
Rail-pressure sensor (10)...................................... M18x1.5 ............................................................70 Nm
Pressure transmitter (11)....................................... M18x1.5 ...................................................47 Nm, oiled
Mounting bolts, charge-pressure sensor (13) ......... M6x16-10.9 .......................................................10 Nm

ENGINE ELECTRICS
WARNING
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of the
WARNING
Restricted operation due to incorrect entries in the fault memory
• Before removing switches or sensors, read out and document the fault memory
• Always install switches and sensors with new O-rings or sealing rings
• After installing switches or sensors, read out the fault memory and, if necessary, delete it.

COOLING SYSTEM
COOLING SYSTEM
(1) Fan (5) Thermostat housing

(2) Coolant manifold (6) Coolant line, heater feed
(3) Coolant outlet pipe (7) Coolant pump
(4) Thermostat (8) Adapter ange

COOLING SYSTEM
FAN
Removing and installing the fan (variant DMR 704)
(1) Fan clutch (5) Poly-V-belt pulley

(2) Fan (6) Mounting bolt
(3) Mounting bolt (7) Mounting bolt
(4) Adapter ange
Technical data
Mounting bolt (3) .................................................. M8x20-10.9 .......................................................20 Nm
WARNING
WARNING
Malfunction due to incorrect storage of fan clutch
• Always store the fan clutch in its installation position

COOLING SYSTEM
Removing the fan Removing the fan and adapter ange (variant
with hydraulic pump)
Removing the fan and adapter ange (variant
without hydraulic pump and Grosskopf
alternator)
• Unscrew the mounting bolts (1)

• Remove the fan (4)
• Remove the adapter ange (2)

• Remove the hydraulic pump V-belt, see Removing
and installing the hydraulic pump belt drive, 89
• Remove the V-belt pulley (4) and the adapter
ange (3)

COOLING SYSTEM
Removing the fan and adapter ange (variant Installing the fan
with Grosskopf alternator)
Installing the fan clutch
• Insert the fan clutch (1) into the fan (2)

• Screw in new mounting bolts (3) and tighten to 20
Nm
Mounting the fan and adapter ange (variant

without hydraulic pump and Grosskopf
alternator)

• Remove the Grosskopf alternator poly-V-belt, see
Removing and installing the Grosskopf alternator
belt drive, 86
• Remove the poly-V-belt pulley (4) and the adapter
ange (3)
Removing the fan clutch • Position the adapter ange (2) on the vibration
damper
• Screw in and tighten the mounting bolts (3)
• Position the fan (4)

• Remove the fan clutch (1) from the fan (2)

COOLING SYSTEM
Mounting the fan and adapter ange (variant with Mounting the fan and adapter ange (variant with
hydraulic pump) Grosskopf alternator)
• Position the adapter ange (3) and V-belt pulley • Position the adapter ange (3) and poly-V-belt
(4) on the vibration damper pulley (4) on the vibration damper
• Screw in and tighten the mounting bolts (5) • Screw in and tighten the mounting bolts (5)
• Mount the hydraulic pump V-belt, see Removing • Remove the Grosskopf alternator poly-V-belt, see
and installing the hydraulic pump belt drive, 89 Removing and installing the Grosskopf alternator
• Position the fan (2) belt drive, 86
• Screw in and tighten the mounting bolts (1) • Position the fan (2)

COOLING SYSTEM
(1) Fan clutch (4) Mounting nut

(2) Mounting bolt (5) Fan
(3) Adapter ange (6) Mounting bolt
Technical data
Mounting nut (4) ................................................... M8-8 .................................................................22 Nm
WARNING
WARNING
Malfunction due to incorrect setting aside of the fan clutch
• Always set aside the fan clutch in its installation position

COOLING SYSTEM
Removing the fan Removing the adapter ange (variant with

hydraulic pump)
Removing the fan support arm
• Remove the hydraulic pump V-belt, see Removing

• Disconnect the fan electrical connection and installing the hydraulic pump belt drive, 89
• Unscrew the mounting bolt (1) • Unscrew the mounting bolts (1)
• Remove the support arm (2) • Remove the adapter ange (3) with the hydraulic
pump V-belt pulley (2)
Removing the fan
Removing the adapter ange (variant with
Grosskopf alternator)

• Remove the Grosskopf alternator poly-V-belt, see
Removing the adapter ange (variant without Removing and installing the Grosskopf alternator
hydraulic pump and Grosskopf alternator) belt drive, 86
• Remove the adapter ange (3) with the Grosskopf
alternator poly-V-belt pulley (2)

• Remove the adapter ange (2)

COOLING SYSTEM
Removing the fan clutch Installing the fan

Installing the fan clutch
• Unscrew the mounting nuts (3)

• Remove the fan clutch (1) from the fan (2)
• Insert the fan clutch (1) into the fan (2)
• Screw on the new mounting nuts (3) and tighten
them to 22 Nm
Mounting the adapter ange (variant without

hydraulic pump and Grosskopf alternator)
• Position the adapter ange (2) on the vibration

damper

COOLING SYSTEM
Mounting the adapter ange (variant with Mounting the fan

hydraulic pump)
• Position the fan (1)

• Position the adapter ange (3) with the hydraulic • Screw in and tighten the mounting bolts (2)
pump V-belt pulley (2) on the vibration damper
• Screw in and tighten the mounting bolts (1) Mounting the fan support arm
• Mount the hydraulic pump V-belt, see Removing
and installing the hydraulic pump belt drive, 89
Mounting the adapter ange (variant with

Grosskopf alternator)
• Position the support arm (2)

• Screw in and tighten the mounting bolt (1)
• Connect the fan electrical connection
• Position the adapter ange (3) with the Grosskopf

alternator poly-V-belt pulley (2) on the vibration
damper
• Mount the Grosskopf alternator poly-V-belt, see
belt drive, 86

COOLING SYSTEM
COOLANT MANIFOLD
Removing and installing the coolant manifold
Additional jobs
– Removing and installing the fan (variant DMR 704), see 45
– Removing and installing the belt drive (variant without Grosskopf alternator or hydraulic pump), see 81
– Removing and installing the Grosskopf alternator belt drive, see 86
– Removing and installing the hydraulic pump belt drive, see 89
– Removing and installing the Stretchybelt belt drive (variant with one guide roller), see 93
(1) Coolant line, heater feed (4) Holder

(2) Coolant pump (5) Coolant outlet pipe
(3) Coolant manifold (6) O-ring
Technical data
Thermostat opening temperature...................................................................................................... 83 °C
WARNING
Thermostats with the incorrect opening temperature damage the engine
• Always use thermostats with the specied opening temperature

COOLING SYSTEM
WARNING

COOLING SYSTEM
Removing the coolant manifold Installing the coolant manifold

Detaching the air compressor line Mounting the coolant manifold
• Unscrew the mounting bolts (2) • Fit the coolant manifold (3) with a new gasket (1)
• Remove the fastening clamps (3) and position it
• Detach the air compressor line (1) • Screw in the new mounting bolts (2) as marked
and then tighten them
Removing the coolant manifold
Attaching the air compressor line
• Mark the installation position of the mounting bolts

(2) • Attach the air compressor line (1)
• Unscrew the mounting bolts (2) • Position the fastening clamps (3)
• Remove the coolant manifold (3) with gasket (1) • Screw in and tighten the new mounting bolts (2)
• Clean the mating faces

COOLING SYSTEM
THERMOSTAT WITH THERMOSTAT HOUSING

Removing and installing the thermostat with thermostat housing
(1) Holder (5) Bulkhead tting

(2) Coolant outlet pipe (6) Thermostat housing
(3) O-ring (7) Unscrewed conduit
(4) Thermostat (8) Gasket
Technical data
Bulkhead tting (5)................................................ M16x1.5 ............................................................45 Nm
Opening temperature of thermostat (4) ............................................................................................. 83 °C
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
WARNING
Thermostats with the incorrect opening temperature damage the engine
• Always use thermostats with the specied opening temperature
WARNING

COOLING SYSTEM
Removing the thermostat with Removing the thermostat

thermostat housing
Undoing the air compressor line
• Remove the thermostat (2) with O-ring (3) from the

thermostat housing (1)
• Unscrew the mounting bolt (1)
Detaching the heater feed coolant line
Detaching the thermostat housing coolant line

• Unlock and remove the plug connection for the • Unscrew the hollow screw (1) and remove it with
coolant line (2) by pressing the spring clip (1) the sealing rings (2)
• Remove the coolant line (3)
Detaching the coolant outlet pipe

• Remove the holder (1)
• Remove the coolant outlet pipe (2) from the
thermostat housing

COOLING SYSTEM
Removing the thermostat housing Installing the thermostat and thermostat

housing
Assembling the thermostat housing

(1) and (2)
• Unscrew the mounting bolts (1) and (2)
• Remove the thermostat housing (3) with gasket • Screw in the bulkhead tting (1) with a new sealing
(4) from the timing case ring (2) and tighten to 45 Nm
• Clean the mating faces • Thinly apply Radiator antifreeze on the new
unscrewed conduit (3)
Dismantling the thermostat housing • Insert the unscrewed conduit (3) into the
thermostat housing (4)
Mounting the thermostat housing
• Unscrew the bulkhead tting (1) and remove with

the sealing ring (2)
• Pull the unscrewed conduit (3) out of the
thermostat housing (4) • Fit the thermostat housing (3) with a new gasket
(4) and then position it on the timing case
• Screw in the new mounting bolts (1) and (2) as
marked
• Tighten the mounting bolts (1) and (2)

COOLING SYSTEM
Attaching the heater feed coolant line Attaching the thermostat housing coolant line
• Position the coolant line (3)

WARNING
• Fit the hollow screw (1) with new sealing rings (2),
Component damage due to loose plug
screw in and tighten
connection
• Check the coolant line plug connection
Installing the thermostat for rm seating after securing
• Mount the plug connection for the coolant line (2)

• If necessary, undo the plug connection for the
coolant line (2) by pressing the spring clip (1), then
reinsert and secure it
Fastening the air compressor line
• Insert the thermostat (2) into the thermostat

housing (1) with the TOP mark facing upwards
• Insert the new O-ring (3)
Attaching the coolant outlet pipe
• Screw in and tighten the new mounting bolt (1)
• Position the coolant outlet pipe (2) and holder (1)

on the thermostat housing
• Screw in and tighten the new mounting bolts (3)

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

(2) Poly-V-belt pulley (5) Gasket
(3) Mounting bolt (6) Bulkhead tting
Technical data
WARNING

COOLING SYSTEM
Removing the coolant pump Detaching the coolant pump coolant line
Removing the poly-V-belt
• Unlock and remove the plug connection for the

coolant line (2) by pressing the spring clips (1)
CAUTION
Removing the poly-V-belt pulley
The poly-V-belt tensioner is under
spring tension
• Brace the poly-V-belt tensioner
to prevent it from springing back
unintentionally
• Undo the mounting bolts (3)

• Turn the poly-V-belt tensioner (2) anti-clockwise
as far as the stop and hold it
• Remove the poly-V-belt (1)
• Carefully relieve the poly-V-belt tensioner (2)
Detaching the air compressor line

• Pull off the poly-V-belt pulley (2)
Removing the coolant pump

• Remove the fastening clamps (3)
• Detach the air compressor line (1)

(1)
• Remove the coolant pump (2) with gasket (3)

COOLING SYSTEM
Removing the bulkhead tting Installing the coolant pump

Installing the bulkhead tting
• Unscrew the bulkhead tting (1) and remove with

the O-ring (2)
• Thinly apply clean engine oil on the new O-ring (2)
• Screw in the bulkhead tting (1) with O-ring (2) and
tighten to 45 Nm
Mounting the coolant pump
• Mount the coolant pump (2) with a new gasket (3)

• Screw in the new mounting bolts (1) as marked
Mounting the poly-V-belt pulley
• Position the poly-V-belt pulley (2)

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

COOLING SYSTEM
Attaching the coolant pump coolant line Mounting the poly-V-belt
WARNING CAUTION
Component damage due to loose plug The poly-V-belt tensioner is under
connection spring tension
• Check the coolant line plug connection • Brace the poly-V-belt tensioner
for rm seating after securing to prevent it from springing back
unintentionally
• Mount the plug connection for the coolant line (2)
• If necessary, undo the plug connection for the • Turn the poly-V-belt tensioner (2) anti-clockwise
coolant line (2) by pressing the spring clip (1), then as far as the stop and hold it
reinsert and secure it • Fit the poly-V-belt (1)
Attaching the air compressor line • Tighten the mounting bolts (3)
• Attach the air compressor line (1)

• Position the fastening clamps (3)

COOLING SYSTEM
Dismantling and assembling the coolant pump

Additional jobs
– Removing and installing the coolant pump, see 61
(1) Coolant pump housing (4) Bearing

(2) Slide ring seal (5) Circlip
(3) Impeller (6) Hub
Technical data
Projection of slide ring seal (2) ........................................................................................... 10.0 - 10.4 mm
Dimension, impeller (cast iron) (3) - coolant pump housing (1) ......................................... 33.60 - 33.80 mm
Dimension, impeller (plastic) (3) - coolant pump housing (1) ............................................ 33.10 - 33.30 mm
Service products
WARNING

COOLING SYSTEM
Special tools
[1] Three-armed puller 08.99605-9014
• Pulling off the coolant pump hub
[2] Installer sleeve 80.99617-0029
• Pressing out the coolant pump slide ring seal

• Pressing out the bearing
[3] Plug-on handle 80.99617-0187
• Pressing in the coolant pump slide ring seal in

conjunction with:
• Installer [5]
• Washer [4]
[4] Washer 80.99617-0144
• Pressing in the coolant pump slide seal ring
[5] Installer 80.99617-0191
• Pressing in the coolant pump slide seal ring
[6] Depth gauge (electronic) 08.71195-9003
• Measuring the slide ring seal press-in depth

COOLING SYSTEM
Dismantling the coolant pump Removing the slide ring seal
Removing the coolant pump hub
• Press the slide ring seal (2) out of the coolant

pump housing (1) using the Installer sleeve [2]
• Brace the impeller for the coolant pump (1)
• Pull off the hub (3) using the Three-armed puller [1]
• Detach the circlip (2) from the coolant pump (1)
Removing the impeller
• Lay the coolant pump housing (3) on the opposing

sleeve (1)
• Press out the bearing (2) using the Installer
sleeve [2]
• Remove the impeller (4)

COOLING SYSTEM
Assembling the coolant pump Checking the projection
Installing the bearing
• Check the projection between the slide ring seal

and the coolant pump housing (1) using the Depth
WARNING gauge (electronic) [6] (2)
Component damage on the coolant The permitted projection is 10.0 - 10.4 mm.
pump housing due to incorrect
If the projection is more than 10.0 - 10.4 mm, adjust
pressing-in of the bearing
the slide ring seal.
• Carefully press in the new bearing at
the bearing outer race until the stop is Mounting the coolant pump hub
reached
• Use a suitable sleeve as a brace
• Press the bearing (2) into the coolant pump

housing (1) until the stop is reached
• Attach the circlip (3)
Installing the slide ring seal
• Press the hub (2) onto the bearing (1) until ush
• Thinly apply a mixture of 50 % water and

50 % Radiator antifreeze on the slide ring seal (2)
and coolant pump shaft
• Assemble the special tool consisting of the
Plug-on handle [3] (3), Washer [4] and Installer [5]
• Use the special tool to press the slide ring seal (2)
into the coolant pump housing (1) until the stop is
reached

COOLING SYSTEM
Pressing on the impeller (cast iron)
• Press on the impeller (2) until dimension A 33.60

- 33.80 mm is reached
The permitted dimension A between the impeller (2)
and the coolant pump housing (1) is 33.60 - 33.80
mm.
If the dimension A is more than 33.60 - 33.80 mm,

adjust the impeller (2).
If the dimension A is less than 33.60 - 33.80 mm,

pull off the impeller (2) and press on a new impeller
(2).
Pressing on the impeller (plastic)
• Press on the impeller (2) until dimension A 33.10

- 33.30 mm is reached
The permitted dimension A between the impeller (2)
and the coolant pump housing (1) is 33.10 - 33.30
mm.
If the dimension A is more than 33.10 - 33.30 mm,

adjust the impeller (2).
If the dimension A is less than 33.10 - 33.30 mm,

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

MOUNTED COMPONENTS
MOUNTED COMPONENTS
(1) 1-cylinder air compressor (7) Refrigerant compressor

(2) Power steering pump (8) Guide roller
(3) Coolant pump poly-V-belt pulley (9) Power take-off poly-V-belt pulley
(4) Starter (10) Alternator poly-V-belt tensioner
(5) Refrigerant compressor poly-V-belt (11) Alternator poly-V-belt
(6) Refrigerant compressor poly-V-belt (12) Alternator
tensioner

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

(2) O-ring (6) Mounting bolt
(3) Power take-off (7) Timing case cover
(4) Mounting bolt (left-hand thread)
Technical data
Mounting bolt (left-hand thread) (4)........................ M16x1.5x45-8.8 LH.......................Initial torque 100 Nm
Mounting bolt (left-hand thread) (4)........................ M16x1.5x45-8.8 LH..............................Final torque 90°
Service products
Technical Vaseline ............................................................................................................. 09.15014-0017
WARNING

MOUNTED COMPONENTS
Removing the power take-off Removing the poly-V-belt pulley
Removing the alternator poly-V-belt
Note
The mounting bolt has a left-hand thread.
CAUTION
spring tension
• Brace the poly-V-belt pulley (2)
• Remove the poly-V-belt pulley (2) from the power
unintentionally
take-off (3)

MOUNTED COMPONENTS
Removing the power take-off Installing the power take-off

Mounting the power take-off

• Remove the power take-off (4) with driver plate (2)
and O-ring (3) • Fit the driver plate (2) with the thin side on the air
compressor gear
• Thinly apply Technical Vaseline on a new O-ring
(3) and place on the power take-off (4)
• Position the power take-off (4)

MOUNTED COMPONENTS
Mounting the poly-V-belt pulley Mounting the alternator poly-V-belt
Note CAUTION
The mounting bolt has a left-hand thread. The poly-V-belt tensioner is under
spring tension
• Place the poly-V-belt pulley (2) on the power to prevent it from springing back
take-off (3) unintentionally
• Screw in the new mounting bolt (1)
• Brace the poly-V-belt pulley (2) • Turn the poly-V-belt tensioner (2) anti-clockwise
• Tighten the mounting bolt (1) to Initial torque 100 as far as the stop and hold it
Nm • Fit the poly-V-belt (1)
• Tighten the mounting bolt (1) to Final torque 90° • Carefully relieve the poly-V-belt tensioner (2)

MOUNTED COMPONENTS
AIR COMPRESSOR
Removing and installing the 1-cylinder air compressor
Additional jobs
– Removing and installing the power take-off, see 73
– Removing and installing the crankcase ventilation (variant LFL50/53), see 409
– Removing and installing the crankcase ventilation (variant LFL51/52/54/55), see 411
– Removing and installing the turbocharger (variant with single-stage charging), see 213
– Removing and installing the turbocharger (variant with two-stage charging without intercooler), see 218
(1) O-ring (6) Driver

(2) O-ring (7) O-ring
(3) 1-cylinder air compressor (8) power steering pump
(4) Pressure-relief valve (9) Mounting bolt
(5) Elbow joint (10) Support
Service products

MOUNTED COMPONENTS
WARNING

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

• Remove the support (4)
• Unscrew the mounting bolts (5) • Unscrew the mounting bolts (7)
• Remove the power steering pump (4) with driver • Pull the air compressor (3) out of the timing case
(2) and O-ring (3) from the air compressor (1) • Remove the O-rings (1) and (2)
• Remove the O-ring (3) from the power steering
pump (4)

MOUNTED COMPONENTS
Installing the air compressor Mounting the power steering pump
Installing the air compressor
• Check the driver (2) for wear and replace as

necessary
• Thinly apply Technical Vaseline on a new O-ring • Insert the driver (2) into the air compressor (1)
(1) and t it on the air compressor (3) • Fit the new O-ring (3) on the power steering pump
• Thinly apply Technical Vaseline on a new O-ring (4)
(2) and insert it into the air compressor (3) • Insert the power steering pump (4) into the air
• Insert the air compressor (3) into the timing case compressor (1)
• Screw in the mounting bolts (7) • Screw in and tighten the new mounting bolts (5)
• Position the support (4)
• Screw in the mounting bolts (5) and (6)
• Tighten the mounting bolts (7)

MOUNTED COMPONENTS
BELT DRIVE
Removing and installing the belt drive (variant without Grosskopf alternator or
hydraulic pump)
Additional jobs
(1) Coolant pump poly-V-belt pulley (6) Mounting bolt

(2) Vibration damper poly-V-belt pulley (7) Guide roller
(3) Refrigerant compressor poly-V-belt (8) Power take-off poly-V-belt pulley
(4) Refrigerant compressor poly-V-belt (9) Alternator poly-V-belt tensioner
tensioner (10) Alternator poly-V-belt
(5) Refrigerant compressor
Technical data
Poly-V-belt tensioner mounting bolt for alternator
(9) ....................................................................... M10x70-10.9......................................................47 Nm
Mounting bolt (6) .................................................. M10x70-10.9......................................................47 Nm
Mounting bolt, guide roller (7) ................................ M12x80-10.9......................................................60 Nm
WARNING

MOUNTED COMPONENTS
Removing the belt drive Removing the refrigerant compressor

poly-V-belt tensioner
Removing the refrigerant compressor
poly-V-belt

• Remove the poly-V-belt tensioner (4)
• Remove the guide roller (2) with spacer sleeve (3)
CAUTION
spring tension
unintentionally


MOUNTED COMPONENTS
Removing the alternator poly-V-belt Installing the belt drive

Mounting the alternator poly-V-belt tensioner
• Position the poly-V-belt tensioner (2)

• Screw in the new mounting bolt (1) and tighten to
47 Nm
CAUTION
spring tension
unintentionally

Removing the alternator poly-V-belt tensioner


MOUNTED COMPONENTS
Mounting the alternator poly-V-belt Mounting the refrigerant compressor poly-V-belt

tensioner
• Position the poly-V-belt tensioner (4)

47 Nm
• Position the guide roller (2) with spacer sleeve (3)
60 Nm
CAUTION
spring tension
unintentionally

• Fit the poly-V-belt (1)

MOUNTED COMPONENTS
Mounting the refrigerant compressor poly-V-belt
CAUTION
spring tension
unintentionally

• Fit the poly-V-belt (1)

MOUNTED COMPONENTS
Removing and installing the Grosskopf alternator belt drive

Additional jobs
(1) Vibration damper (4) Poly-V-belt pulley

(2) Pressure spring (5) Mounting bolt
(3) Poly-V-belt tensioner (6) Mounting bolt
Technical data
Mounting bolt, pressure spring (2) ......................... M10x45-10.9......................................................65 Nm
Mounting bolt, pressure spring (2) ......................... M12x40-10.9....................................................120 Nm
WARNING

MOUNTED COMPONENTS
Removing the belt drive Removing the Grosskopf alternator poly-V-belt

tensioner
Removing the Grosskopf alternator poly-V-belt

• Remove the pressure spring (5)
CAUTION
spring tension
unintentionally

Removing the Grosskopf alternator guide roller

• Remove the guide roller (2) with carrier (3)

MOUNTED COMPONENTS
Installing the belt drive Mounting the Grosskopf alternator poly-V-belt
Mounting the Grosskopf alternator poly-V-belt

tensioner
CAUTION
• Position the poly-V-belt tensioner (4) spring tension
• Screw in and tighten the new mounting bolt (3) • Brace the poly-V-belt tensioner
• Position the pressure spring (5) to prevent it from springing back
• Screw in the new mounting bolts (1) and (2) unintentionally
• Tighten the mounting bolt (1) to 120 Nm
• Tighten the mounting bolt (2) to 65 Nm • Turn the poly-V-belt tensioner (1) anti-clockwise
Mounting the Grosskopf alternator guide roller • Fit the poly-V-belt (2)
• Position the guide roller (2) with carrier (3)


MOUNTED COMPONENTS
Removing and installing the hydraulic pump belt drive

Additional jobs
(1) Support (4) V-belt

(2) Hydraulic pump (5) V-belt pulley
(3) Tensioning pulley (6) Mounting nut
Technical data
Tensioning force on V-belt (4) when newly mounted ..........................................................................500 N
Tensioning force on V-belt (4) after running for longer than 10 min......................................................350 N
WARNING

MOUNTED COMPONENTS
Special tools
[7] Tension tester 81.66814-6001
• Checking the V-belt tension

MOUNTED COMPONENTS
Removing the belt drive Installing the belt drive

Undoing the tensioning pulley mounting nut Tensioning the V-belt
• Undo the mounting nut (1) • Put on the V-belt (2)

• Screw in the tensioning bolt (1)
Removing the V-belt
Checking the V-belt tension
• Unscrew the tensioning bolt (1) until the V-belt (2)

has been fully relieved, or unscrew the tensioning Note
bolt (1) even further, as necessary Do not continue to apply pressure after
• Remove the V-belt (2) the spring has unclipped; this falsies the
measuring result.
The measurement must be repeated.
• Place Tension tester [7] (4) on the longest point

between two contact points of the V-belt (3)
• Press the pressure pad (2) perpendicular to the
V-belt (3) until the spring of Tension tester [7] (4)
unclips
• Read off the tension value at the point where the
upper edge of the indicator arm (1) intersects the
scale
• Tensioning force of V-belt (3), see Technical data,
89
• Re-tension the V-belt (3) if the V-belt (3) tensioning
force differs from this value

MOUNTED COMPONENTS
Tightening the tensioning pulley mounting nut
• Tighten the mounting nut (1)

MOUNTED COMPONENTS
Removing and installing the Stretchybelt belt drive (variant with one guide roller)
Additional jobs
(1) Guide roller (3) Poly-V-belts

(2) Poly-V-belt pulley (4) Poly-V-belt pulley
Technical data
Mounting bolt, guide roller (1) ................................ M 12x80-10.9.....................................................60 Nm
Length, poly-V-belt (3) ................................................................................................................1366 mm
Minimum tensioning force, poly-V-belt (3)........................................................................................... 75 N
Maximum tensioning force, poly-V-belt (3).........................................................................................121 N
Minimum tensioning force, poly-V-belt (3)............... Running time 15 minutes ...................................... 54 N
Maximum tensioning force, poly-V-belt (3).............. Running time 15 minutes .....................................102 N
WARNING

MOUNTED COMPONENTS
Special tools
[8] Assembly tool 51.99603-0003
• Removing and mounting the poly-V-belt
[9] Engine barring gear 80.99626-6008
• Cranking the engine in conjunction with:

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

MOUNTED COMPONENTS
Removing the belt drive Removing the poly-V-belt
Attaching the engine barring gear
CAUTION
• Remove the cover from the ywheel housing Risk of injury due to trapping
• Mount the Engine barring gear [9] (1) on the • Do not place your hands between the
ywheel housing poly-V-belt pulley and the poly-V-belt
when the engine is being cranked
Removing the guide roller Note
Perform the work with support.
• Place the Assembly tool [8] (2) on the poly-V-belt

pulley (1)
• Crank the engine in the engine's running direction
with the Engine barring gear [9] and the Gear
ratchet [10] whilst pulling the poly-V-belt off the
poly-V-belt pulley (1)
• Unscrew the mounting bolt for the guide roller (1)

• Remove the guide roller (1)

MOUNTED COMPONENTS
Installing the belt drive Mounting the poly-V-belt
Positioning the assembly tool

• Place the Assembly tool [8] (1) on the poly-V-belt ratchet [10] until the poly-V-belt (1) is lying fully
pulley on the poly-V-belt pulley
Pre-tensioning the poly-V-belt Removing the assembly tool
• Place a new poly-V-belt (3) on the poly-V-belt • Remove the Assembly tool [8]
pulley on the refrigerant compressor (1) and
engine Mounting the guide roller
• Pre-tension the poly-V-belt (3) using the Assembly
tool [8] (2)
• Press the poly-V-belt downwards

• Position the guide roller (1)
• Screw in the mounting bolt for the guide roller (1)
and tighten it to 60 Nm

MOUNTED COMPONENTS
Removing the engine barring gear
• Remove the Engine barring gear [9] (1) from the

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

MOUNTED COMPONENTS
Removing and installing the Stretchybelt belt drive (variant with two guide rollers)
Additional jobs
(1) Mounting bolt (4) Poly-V-belt

(2) Mounting bolt (5) Guide roller
(3) Guide roller
Technical data
Mounting bolt (1) .................................................. M10x100-10.9....................................................47 Nm
Maximum tensioning force, poly-V-belt (4).......................................................................................... 87 N
Maximum tensioning force, poly-V-belt (4).............. Running time 15 minutes ...................................... 75 N
WARNING

MOUNTED COMPONENTS
Special tools
[11] Assembly tool 51.99603-0003
• Removing and mounting the poly-V-belt

[13] Gear ratchet 80.99627-0001
[14] Tension tester 81.66814-6001
• Checking the poly-V-belt tension

MOUNTED COMPONENTS
Removing the belt drive Removing the guide roller
• Remove the cover from the ywheel housing

• Mount the Engine barring gear [12] (1) on the
ywheel housing

• Remove the guide rollers (3) with washer (5)
• Remove the spacer sleeves (2) and (4)
CAUTION
Risk of injury due to trapping
• Do not place your hands between the
poly-V-belt pulley and the poly-V-belt
when the engine is being cranked
Note
Perform the work with support.
• Put the Assembly tool [11] (1) on the poly-V-belt

pulley (2)
ratchet [13] whilst pulling the poly-V-belt (3) off the
• Remove the Assembly tool [11] (1)

MOUNTED COMPONENTS
Installing the belt drive Pre-tensioning the poly-V-belt
Mounting the guide rollers
Note
The poly-V-belt must run on the rear four
grooves of the refrigerant compressor
poly-V-belt pulley.
• Put the new poly-V-belt (1) on the poly-V-belt

pulleys (3) and (4)
• Pre-tension the poly-V-belt (1) using the Assembly
tool [11] (2)
Mounting the poly-V-belt
• Position the spacer sleeves (2) and (4)

• Position the guide rollers (3) with washer (5)
• Screw in the new mounting bolts (1) and (6)
Positioning the assembly tool

ratchet [13] until the poly-V-belt (2) is lying fully on
the poly-V-belt pulley (1)
• Remove the Assembly tool [11] (3)
• Put the Assembly tool [11] (2) on the crankshaft


MOUNTED COMPONENTS
Removing the engine barring gear Checking the V-belt tension

Note
ywheel housing
Do not continue to apply pressure after
the spring has unclipped, as this falsies
the measuring result, meaning that the
measurement has to be performed again.
• Place the Tension tester [14] (4) on the longest

point between contact points on the V-belt (3)
V-belt (3) until the spring of the Tension tester [14]
(4) unclips
scale
• V-belt tensioning force, see Technical data, 98
• Fit a new V-belt if the V-belt tensioning force differs
from this value

MOUNTED COMPONENTS
Checking and setting the refrigerant compressor belt track (D0836 LFL50 to LFL55)
Additional jobs
(1) Mounting bolt (4) Poly-V-belt pulley, crankshaft

(2) Holder (5) Guide roller
(3) Poly-V-belts (6) Poly-V-belt pulley, refrigerant compressor
Technical data
Angular offset, poly-V-belt pulley (4) to (6)................................................................................... Max. 0.5°
WARNING
specied tightening torque.
• Final tightening must always be performed manually using a torque wrench.
Note
If the refrigerant compressor attachment has been loosened or removed, the belt track must be
re-aligned.
Checking and setting of the belt track can and must only be performed for the engine variants
D0836 LFL50 to LFL55.

MOUNTED COMPONENTS
Special tools

[16] Gear ratchet 80.99627-0001
[17] Straightedge 80.99605-0167
• Checking the belt track

MOUNTED COMPONENTS
Checking the belt track Removing the engine barring gear

ywheel housing
• Remove the cover from the ywheel housing • Mount the cover on the ywheel housing
ywheel housing
Checking the poly-V-belt track
• Crank the engine twice in the engine's running

direction with the Engine barring gear [15] and
Gear ratchet [16]
• Check the alignment of the poly-V-belt at the
top and bottom between the poly-V-belt pulley
(2) and the refrigerant compressor (1) using the
Straightedge [17] (3)
The upper and lower crack of light must be the same.
If the cracks of light are different, the refrigerant

compressor must be adjusted, see Setting the belt
track, 106.

MOUNTED COMPONENTS
Adjusting the refrigerant compressor

Setting the belt track

• Adjust the refrigerant compressor (3) by moving
the holder (2)
• Tighten the mounting bolts (1) to 45 Nm
• Re-check the belt track

MOUNTED COMPONENTS
ALTERNATOR
Removing and installing the alternator
Additional jobs
(1) Support (3) Poly-V-belt pulley

(2) Holder (4) Alternator
Technical data
Mounting nut, poly-V-belt pulley (3)........................ M16x1.5 ............................................................80 Nm
Mounting nut, terminal B + .................................... M8 ....................................................................15 Nm
Hollow screw, coolant line ..................................... M14x1.5 ............................................................35 Nm
Union nut, coolant line .......................................... M14x1.5 ............................................................35 Nm
Service products
Loctite 2701 sealing compound .......................................................................................... 04.10160-9353
WARNING

MOUNTED COMPONENTS
Note
Varying alternator holders may be tted. The procedure for removal and installation is intrinsically
the same.
Special tools
[18] Special spanner 80.99603-6029
• Removing and mounting the poly-V-belt pulley in

conjunction with:
• Handle [19]
[19] Handle 08.06460-0002
• Removing and mounting the poly-V-belt pulley

MOUNTED COMPONENTS
Removing the alternator Disconnecting the alternator electrical

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

CAUTION
• Unscrew the terminal B+ mounting nut (1)
• Free, set aside and secure the wiring harnesses
spring tension
• Brace the poly-V-belt tensioner Detaching the air compressor line
unintentionally

Disconnecting the oil level sensor electrical

connection

• Remove the fastening clamps (3)
• Detach the air compressor line (1)

• Free the wiring harness for the oil level sensor (1),
put it down to the side and secure it

MOUNTED COMPONENTS
Detaching the coolant lines Removing the alternator
• Remove the fastening clamp (5)

• Unscrew the hollow screw (6) and remove it with
the sealing rings
• Unscrew the union nut for the coolant line (3)
• Unlock the plug connections (1) and (7) by
pressing the spring clip (2)
• Remove the coolant lines (3) and (4)
Removing the holder

(1) and (3)
• Remove the alternator (2)
Removing the holder

• Pull out the mounting bolt (2) and remove the
holder (1)


MOUNTED COMPONENTS
Removing the support Removing the poly-V-belt pulley
• Unscrew the mounting bolts (1) • Unscrew the mounting nut (1)
• Remove the support (2) • Remove the poly-V-belt pulley (2) from the
alternator shaft (3)
Undoing the poly-V-belt pulley mounting nut
• Mount the Special spanner [18] (2) with

Handle [19] (3) on the poly-V-belt pulley mounting
nut
• Insert the splined spanner (1) into the alternator
shaft spline
• Brace the splined spanner (1) and undo the
mounting nut

MOUNTED COMPONENTS
Installing the alternator Mounting the support
• Position the support (2)

• Slide the poly-V-belt pulley (2) onto the alternator
shaft (3) Mounting the holder
• Thinly apply Loctite 2701 sealing compound on the
thread and contact surface of the new mounting
nut (1)
• Screw on the new mounting nut (1)
Tightening the poly-V-belt pulley mounting nut
• Position the holder (2)

• Mount the Special spanner [18] (2) with

Handle [19] (3) on the poly-V-belt pulley mounting
nut
• Insert the splined spanner (1) into the alternator
shaft spline
• Brace the splined spanner (1) and tighten the
mounting nut to 80 Nm

MOUNTED COMPONENTS
Mounting the alternator Mounting the holder

• Insert the new mounting bolt (2)
• Screw on the mounting nut (3)
• Brace the mounting bolt (2) and tighten the
mounting nut (3)
Attaching the coolant lines
• Insert the alternator (2)

and (3) as marked
Attaching the air compressor line
WARNING
Component damage due to loose plug
connection
• Check the coolant line plug connections
for rm seating after securing
• Attach the coolant lines (3) and (4)

• If necessary, undo the plug connections (1) and
(7) by pressing the spring clip (2), then reinsert
and secure
• Screw in the hollow screw (6) with new sealing
• Attach the air compressor line (1) rings and then tighten it to 35 Nm
• Position the fastening clamps (3) • Screw on the union nut for the coolant line (3) and
• Screw in and tighten the new mounting bolts (2) then tighten it to 35 Nm
• Mount the fastening clamp (5)

MOUNTED COMPONENTS
Connecting the alternator electrical connection

under tension, not kinked and there are no chang
points
• Screw on the terminal B+ mounting nut (1) and
tighten it to 15 Nm
• Insert and lock the compact connector (3)
• Secure the wiring harnesses with cable ties (2)
Connecting the oil level sensor electrical

connection
• Route the wiring harness for the oil level sensor

(1) so that it is not under tension, not kinked and
there are no chang points

MOUNTED COMPONENTS
GROSSKOPF ALTERNATOR
Additional jobs
(1) Crankcase yoke (8) Grosskopf alternator

(2) Crankcase (9) Mounting bolt
(3) Engine mount (10) Holder
(6) Holder (13) Mounting bolt
(7) Bolt-on prole (14) Holder
Technical data
Mounting bolt (12) ................................................ M10x35-10.9......................................................65 Nm
Mounting bolts (11) and (13).................................. M10x30-10.9......................................................65 Nm

MOUNTED COMPONENTS
WARNING

MOUNTED COMPONENTS
Removing the Grosskopf alternator Removing the holder
Removing the holder

• Remove the holder (4) from the Grosskopf
• Unscrew the mounting bolts (1) and (4) alternator (2)
• Remove the holder (5) with bolt-on prole (3) from • Mark the installation position of the bolt-on proles
the Grosskopf alternator (2) (3)
• Mark the installation position of the bolt-on prole • Remove the bolt-on proles (3)
(3)
Removing the holder
Removing the Grosskopf alternator

• Unscrew the mounting bolts (1) (1) and (5)
• Remove the Grosskopf alternator (2) • Unscrew the mounting bolts (1) and (5)
• Remove the holder (4) and the washer (3) from
the crankcase yoke (2)

MOUNTED COMPONENTS
Installing the Grosskopf alternator Mounting the Grosskopf alternator
Mounting the holder
• Position the Grosskopf alternator (2)

• Screw in the new mounting bolts (1)
• Position the holder (4) with the washer (3) on the • Tighten the mounting bolts (1) by hand
crankcase yoke (2)
• Screw in the new mounting bolts (1) and (5) as Mounting the holder
marked
Mounting the holder
• Position the holder (5) with the bolt-on prole (3)

as marked
• Screw in the mounting bolts (1) and (4)
• Check the alignment of the Grosskopf alternator
poly-V-belt pulleys and the crankshaft and then
• Position the bolt-on proles (3) on the Grosskopf align the Grosskopf alternator axially as necessary
alternator (2) as marked • Tighten the mounting bolts (1) to 65 Nm
• Position the holder (4) • Tighten the mounting bolts (4) to 30 Nm
• Screw in the mounting bolts (1) and tighten to 30 • Tighten the mounting bolts (2) to 65 Nm
Nm

MOUNTED COMPONENTS
STARTER
Removing and installing the starter
(1) Flywheel housing (3) Mounting bolt

(2) Starter (4) Mounting nut
Technical data
Mounting nut (4) ................................................... M10...................................................................45 Nm
Starter, terminal B+............................................... M10x1.5 ............................................................22 Nm
Number of teeth, starter (2) ...................................................................................................................12
Nominal output, starter (2).................................................................................................. 5.0 kW at 24 V
WARNING

MOUNTED COMPONENTS
Special tools

[21] Gear ratchet 80.99627-0001

MOUNTED COMPONENTS
Removing the starter Installing the starter
• Unscrew the mounting bolts (4) • Crank the engine once in the engine's running
• Unscrew the mounting nut (1) direction using the Engine barring gear [20] and
• Pull the starter (3) out of the ywheel housing (2) Gear ratchet [21] whilst checking the ywheel ring
gear for damage. Fit a new ywheel ring gear if
necessary
• Insert the starter (3) into the ywheel housing (2)
Nm
• Screw on the new mounting nut (1) and tighten it
to 45 Nm

MOUNTED COMPONENTS
REFRIGERANT COMPRESSOR
Removing and installing the refrigerant compressor
Additional jobs
(1) Bracket (3) Refrigerant compressor

(2) Holder
CAUTION
Refrigerant and refrigerant oil can damage health and the environment
• Do not let refrigerant or refrigerant oil come into contact with the skin
• Dispose of refrigerant and refrigerant oil in the correct manner
WARNING

MOUNTED COMPONENTS
Note
The refrigerant compressor holder and bracket may vary, but the procedure for removal and
installation is intrinsically the same.
Note
If the refrigerant compressor attachment has been loosened or removed, the belt track must be
re-aligned.
Checking and setting of the belt track can and must only be performed for the engine variants
D0836 LFL50 to LFL55, see Checking and setting the refrigerant compressor belt track (D0836
LFL50 to LFL55), 103.
Special tools
[22] Tool insert 80.99606-0610
• Screwing on and unscrewing the plug on the

pressure connection
[23] Tool insert 80.99606-0611
• Screwing on and unscrewing the plug on the

intake connection

MOUNTED COMPONENTS
Removing the refrigerant compressor Removing the refrigerant compressor
Plugging the refrigerant connections

• Pull out the mounting bolts (1)
Note • Remove the refrigerant compressor (2) from the
The intake connection is marked with an bracket
S.
The pressure connection is marked with Removing the bracket
a D.
• Screw the plugs onto the refrigerant compressor

(1) refrigerant connections using Tool insert [22]
(2) / Tool insert [23] (3)
Removing the holder
• Mark the installation position of the bracket (2)

(1) in relation to the slots for the bracket (2)
• Remove the bracket (2)


MOUNTED COMPONENTS
Installing the refrigerant compressor Mounting the holder
Mounting the bracket

• Screw in and tighten the mounting bolts (1) and (2)
• Position the bracket (2) as marked
• Screw in the new mounting bolts (1) as marked Removing the plugs
• Check the belt track as necessary, see Checking
and setting the refrigerant compressor belt track
(D0836 LFL50 to LFL55), 103
Mounting the refrigerant compressor
• Unscrew the plugs from the refrigerant

compressor (1) using Tool insert [22] (2) / Tool
insert [23] (3)
• Position the refrigerant compressor (2) on the

bracket
• Insert the new mounting bolts (1)
• Screw on and tighten the new mounting nuts (3)

MOUNTED COMPONENTS
HYDRAULIC PUMP
Removing and installing the hydraulic pump
Additional jobs
(1) Support (4) V-belt

(2) Hydraulic pump (5) V-belt pulley
(3) Tensioning pulley (6) Mounting nut
Technical data
Mounting nut (6) ................................................... M18x1.5 ............................................................70 Nm
WARNING

MOUNTED COMPONENTS
Special tools
[24] Tension tester 81.66814-6001
• Checking the V-belt tension

MOUNTED COMPONENTS
Removing the hydraulic pump Removing the V-belt pulley
Undoing the V-belt pulley mounting nut

• Pull off the V-belt pulley (1)
• Undo the mounting nut (1) • Remove the woodruff key from the hydraulic pump
Undoing the tensioning pulley mounting nut Removing the hydraulic pump
• Undo the mounting nut (1) • Unscrew the mounting bolts (1)
• Remove the hydraulic pump (2) with adapter (3)
Removing the V-belt
Removing the support
• Unscrew the tensioning bolt (1) until the V-belt (2)

has been fully relieved, or unscrew the tensioning • Mark the installation position of the mounting bolts
bolt (1) even further, as necessary (1), (2) and (4)
• Remove the V-belt (2) • Unscrew the mounting bolts (1), (2) and (4)
• Remove the support (3)

MOUNTED COMPONENTS
Installing the hydraulic pump Mounting the V-belt pulley
Mounting the support
• Insert the woodruff key into the hydraulic pump

• Fit the V-belt pulley (1)
• Position the support (3) • Screw on the new mounting nut (2) and tighten it
• Screw in the new mounting bolts (1), (2) and (4) by hand
as marked
• Tighten the mounting bolts (1), (2) and (4) Tensioning the V-belt
Mounting the hydraulic pump
• Put on the V-belt (2)

• Screw in the tensioning bolt (1)
• Position the hydraulic pump (2) with adapter (3)

MOUNTED COMPONENTS
Checking the V-belt tension Tightening the V-belt pulley mounting nut
Note • Tighten the mounting nuts (1) to 70 Nm

Do not continue to apply pressure after
the spring has unclipped; this falsies the
measuring result.
The measurement must be repeated.
• Place the Tension tester [24] (4) on the longest

point between contact points on the V-belt (3)
V-belt (3) until the spring of the Tension tester [24]
(4) unclips
scale
• Tensioning force of V-belt (3), see Technical data,
127
• Re-tension the V-belt (3) if the V-belt tensioning
force (3) differs from this value
Tightening the tensioning pulley mounting nut

COMMON-RAIL SYSTEM
COMMON-RAIL SYSTEM
(1) Sealing ring (5) High-pressure line

(2) Injector (6) Rail-pressure sensor
(3) Mounting bolt (7) Rail
(4) Pressure ange (8) High-pressure pump

COMMON-RAIL SYSTEM
INJECTORS AND RAIL

Protective sleeves, injectors and rail
Euro 4
(1) Protective sleeve, injector nozzle

81.96002-0522
(2) Mounting bolt
(3) Cap, injector feed bore 81.96002-0523
(4) Protective sleeve Z 14 x 15
81.96002-0512
(5) End plug 81.96002-0521
81.96002-0512
(7) Cap 81.96002-0518
81.96002-0555
(9) End plug 81.96002-0521
(10) End plug 81.96002-0556
(11) End plug 81.96002-0521
(12) End plug 81.96002-0521
(13) End plug 81.96002-0519
(14) End plug 81.96002-0520
(15) Storage sleeve, injector 09.81020-1000

COMMON-RAIL SYSTEM
Euro 5 and EEV
(1) Protective sleeve 81.96002-0522 (7) End plug 81.96002-0521

(2) Mounting bolt (8) Protective sleeve Z 12 x 16 81.96002-0117
(3) Injector feed bore cap 81.96002-0523 (9) End plug 81.96002-0521
(4) Protective sleeve Z 14 x 15 (10) End plug 81.96002-0519
81.96002-0512 (11) End plug 81.96002-0520
(5) Protective sleeve 81.96002-0522 (12) Injector storage sleeve 09.81020-1000
81.96002-0555
WARNING
Note
In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is
imprinted in the protective sleeves. This is integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z 14 x 15).

COMMON-RAIL SYSTEM
Special tools
[25] Injector feed bore cap 81.96002-0523
• Plugging the injector feed bore
[26] Injector nozzle protective sleeve 81.96002-0522
• Plugging the injector nozzle
[27] Injector storage sleeve 09.81020-1000
• Storing the injectors
[28] End plug 81.96002-0520
• Plugging the cylinder head injector bore
[29] Protective sleeve Z 18 x 15 81.96002-0555
• Plugging the pressure limiting valve

• Plugging the rail-pressure sensor
• Plugging the high-pressure lines
[31] End plug 81.96002-0521
• Plugging the high-pressure lines

• Plugging the air distributor pipe bore

COMMON-RAIL SYSTEM
[32] End plug 81.96002-0519
• Plugging the rail connection hole
[33] End plug 81.96002-0556
• Plugging the rail-pressure sensor bore in the rail

• Plugging the pressure limiting valve in the rail
• Plugging the high-pressure line connection on the

rail
• Plugging the rail connection
• Plugging the high-pressure pump high-pressure
line connection
[35] Cap 81.96002-0518
• Plugging the hollow screw connections

COMMON-RAIL SYSTEM
Removing and installing the injectors and rail

Additional jobs
– Removing and installing the wiring harness, see 29
– Protective sleeves, fuel service centre, see 177
– Removing and installing the fuel service centre, see 180
– Protective sleeves, injectors and rail, see 135
(1) Sealing washer (6) High-pressure line

(2) Injector (7) Rail-pressure sensor
(3) Mounting bolt (8) Rail
(4) Pressure ange (9) Pressure screw
(5) Return line
Technical data
Mounting bolt (3) .................................................. M8x45 ............................................. Initial torque 2 Nm
Mounting bolt (3) .................................................. M8x45 ............................................ Final torque 30 Nm
Pressure screw (9) ............................................... M22x1.5 ........................................ Initial torque 10 Nm
Pressure screw (9) ............................................... M22x1.5 ......................................... Final torque 55 Nm
Injector cable mounting nuts.................................. Cable lug nut M4...............................................1.5 Nm
High-pressure line (6) ........................................... M14x1.5 ........................................ Initial torque 10 Nm
High-pressure line (6) (initial use) .......................... M14x1.5 ..............................................Final torque 60°
High-pressure line (6) (re-use)............................... M14x1.5 ..............................................Final torque 30°
High-pressure line (6) (reuse)................................ M18x1.5 ..............................................Final torque 30°
Rail-pressure sensor (7)........................................ M18x1.5 ............................................................70 Nm
Pressure limiting valve .......................................... M18x1.5 ..........................................................100 Nm

COMMON-RAIL SYSTEM
Overow valve ..................................................... M14x1.5 ............................................................32 Nm
WARNING
Damage in the common-rail system
• All work on components of the common-rail system must be performed by specially trained
personnel only.
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats®
(desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Always replace rail connections once they have been undone
• Do not reuse plugs for the high-pressure lines, the rail or injectors, even if they have only been
used once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
WARNING
• Always remove only one fuel line
• Plug the component connections immediately using new, clean protective sleeves
WARNING
Special tools
[36] Adapter 80.99602-0173
• Removing the rail connection
[37] Extractor device 80.99602-0011
• Removing the rail connection in conjunction with:

• Adapter [36]
• Extracting injectors in conjunction with:

• Knurled nut [39]
• Plate [40]
• Support [41]
• Support [42]
• Hexagon nut [43]
• Support [44]

COMMON-RAIL SYSTEM
[39] Knurled nut 80.99602-0201
• Extracting the injectors
[40] Plate 80.99602-0176
[41] Support 80.99602-0177
[42] Support 80.99602-0199
[43] Hexagon nut 06.11226-8306
[44] Support 80.99602-0198
[45] Socket, size 7 08.06141-0700
• Attaching the injector cable
[46] Torque screwdriver 08.06510-9026
• Mounting injector cable in conjunction with:

• Adapter [47]
• Socket, size 7 [45]

COMMON-RAIL SYSTEM
[47] Adapter 08.06139-9029
• Attaching the injector cable
[48] Thrust piece 80.99606-0609
• Installing the injectors
[49] Socket, size 17 80.99603-0309
• Removing and installing the high-pressure lines

in conjunction with:
• Extension [51]
[50] Socket, size 22 80.99603-0378

in conjunction with:
• Extension [51]
[51] Extension 08.06139-9025
[52] Release handle 80.99606-0597
• Opening the quick-release couplings in

conjunction with:
• Release tool, size 1 [53]
[53] Release tool, size 1 80.99606-0625
• Opening the quick-release couplings

COMMON-RAIL SYSTEM
Detaching the fuel lines (Euro 4 variant) Detaching the fuel return lines
Allowing the return duct to empty
WARNING
Danger of environmental pollution
• Collect emerging fuel in a permissible
container

the sealing rings (3)
• Remove the fuel return lines (2) and (5)
• Unscrew the adapter tting (4) and remove it with
the sealing ring
WARNING
Component damage due to fuel in the
combustion chamber
• Allow the return duct in the air
distributor pipe to empty before
extracting the injectors
WARNING
container
• Unscrew the overow valve (2) with sealing rings

(1) and allow the return duct to empty
• Remove the fuel return line

COMMON-RAIL SYSTEM
Detaching the fuel lines (Euro 5 and EEV Detaching the fuel return line on the fuel lter
variant) side
Detaching the rail-fuel service centre fuel return

line
WARNING
• Unscrew the hollow screw (2) and remove it with combustion chamber
the sealing rings (1) • Allow the return duct in the air
• Detach the fuel line (3) distributor pipe to empty before
Detaching the fuel return line on the WARNING
high-pressure pump side Danger of environmental pollution
container
• Unscrew the hollow screw (5) and remove with the

sealing rings (6) and (7)
• Pull off the fuel line (4) using the Release tool, size
2 [54] and the Release handle [52]
• Unscrew the hollow screw (2) and remove with the
sealing rings (1) and the fuel line (3)
• Allowing the return duct to empty
WARNING
combustion chamber
WARNING
container
• Unscrew the hollow screw (1) with sealing rings


COMMON-RAIL SYSTEM
Removing the injectors and rail Disconnecting the rail-pressure sensor

Detaching the high-pressure line

WARNING
Detaching the high-pressure lines
container
• Detach the high-pressure line (2) from the rail (1)

and the high-pressure pump (3) using the Socket,
size 17 [49], the Socket, size 22 [50] if necessary
and the Extension [51]
Disconnecting the rail-pressure sensor

electrical connection (Euro 4)
• Mark the installation position of the clamping

pieces (1)
• Remove the clamping pieces (1)
• Mark the installation position of the high-pressure
lines (2)
• Detach the high-pressure lines (2) using the
Socket, size 17 [49], the Socket, size 22 [50] if
necessary and the Extension [51]

rail-pressure sensor (1)

COMMON-RAIL SYSTEM
Removing the rail Removing the cylinder head cover
• Unscrew the mounting bolts (2) • Open the plug bracket bayonet ttings
• Remove the rail (1) from the air distributor pipe • Unscrew the mounting bolts (3)
• Remove the cylinder head cover (2) from the
Unscrewing the pressure screw cylinder head (1)
Disconnecting the injector electrical connection
• Unscrew the pressure screw (2) for the rail

connection (1)
Removing the rail connection • Remove the injector cable from the injector (1)
• Remove the plug bracket (3)
Unscrewing the pressure ange mounting bolt
• Extract the rail connection (2) from the bore

(1) using the Extractor device [37] (3) and the
Adapter [36]
• Remove the spherical washer (2)

COMMON-RAIL SYSTEM
Assembling the special tool Removing the injector
WARNING
Component damage due to incorrect
removal of the injector
• Always remove the relevant rail
connection before removing the injector
• Always remove one injector only
• Fitting the special tool

• Insert the Extractor device [38] into the groove for
the pressure ange
• Clamp the clamping sleeve with the Knurled
nut [39] (1)
• Extract the injector (3) from the cylinder head by
turning the Knurled nut [39] (2)
• Mount the Support [42] (2) and the Support [41] • Remove the special tool
(5) with the Hexagon nut [43] (7) on the Plate [40]
(6) Removing the injector
• Insert the Support [44] (4) into the Support [41] (5)
• Insert the Extractor device [38] (3) into the
Plate [40] (6) and screw on the Knurled nut [39]
(1)
• Remove the injector (1) with the pressure ange

(4) and the sealing washer (2)
• Pull off the O-ring (3)
• Carefully clean the injector bore

COMMON-RAIL SYSTEM
Installing the injectors and the rail Installing the rail connection
Installing the injector
WARNING
Rail connections are pressed together
Note on the cone during installation
Always install injectors together with • Do not re-use rail connections if they
pressure ange. have already been installed
It is not possible to install the pressure
ange afterwards. • Thinly apply clean diesel fuel on a new O-ring (4)
and t it on the new rail connection (2)
• Check to ensure that the hole in the cylinder head • Slide the rail connection (2) into the bore (3) so
is clean that the balls on the rail connection (2) are located
• Do not remove the injector (1) from the Injector in the grooves in the cylinder head
storage sleeve [27] until immediately before • Screw in the pressure screw (1) and tighten to
installation Initial torque 10 Nm
• Remove the protective sleeves
• Push the pressure ange (4) onto the injector Injector nal torque
(1), ensuring that the fuel inlet opening is turned
towards the rail connection mounting hole
• Insert the injector (1) into the cylinder head with a
new O-ring (3) and a new sealing washer (2)
• Press the injector (1) fully into the cylinder head
using Thrust piece [48]
Injector initial torque
• Tighten the mounting bolt (1) to Final torque 30 Nm
• Screw in the new mounting bolt (1) for the pressure

ange with the spherical washer (2)
• Tighten the mounting bolt (1) to Initial torque 2 Nm

COMMON-RAIL SYSTEM
Rail connection nal torque Mounting the cylinder head cover
• Tighten the pressure screw (1) to Final torque • Check the gasket in the cylinder head cover (2)
55 Nm and the plug bracket; replace as necessary
• Fit the cylinder head cover (2) over the plug
Connecting the injector electrical connection bracket and onto the cylinder head (1)
• Plug the bayonet ttings on the plug bracket
Mounting the rail
WARNING
Component damage due to possible
short-circuit
• When tightening the mounting nuts,
make sure that the cable plugs do not • Position the rail (1) on the air distributor pipe
touch each other • Screw in and tighten the new mounting bolts (2)
• Fit the plug bracket (3)

• Position the injector cable on the injector (1)
• Place the Socket, size 7 [45] with Adapter [47] on
the Torque screwdriver [46]
• Tighten the mounting nuts (2) to 1.5 Nm

COMMON-RAIL SYSTEM
Fitting a new rail-pressure sensor and pressure Attaching the high-pressure lines
limiting valve
WARNING
Note Component damage due to
This work step only applies to D0836 Euro non-aligned high-pressure lines
4 engines. • After initial tightening, check the
alignment of the high-pressure lines
WARNING and, if necessary, re-align them
Component damage due to lack of
lubricant • Attach the high-pressure lines (2) to the rail and
• Do not wash off the pressure limiting rail connection as marked
valve and rail-pressure sensor as the • Tighten the high-pressure lines (2) to Initial
thread and biting edge are coated with torque 10 Nm using the Socket, size 17 [49] (3),
lubricant the Socket, size 22 [50] if necessary and the
Extension [51]
• Unscrew the rail-pressure sensor (2) and pressure • If reusing, tighten the high-pressure lines (2) to
limiting valve (1) Final torque 30° using the Socket, size 17 [49]
• Screw in the new pressure limiting valve (1) and (3), the Socket, size 22 [50] if necessary and the
tighten it to 100 Nm Extension [51]
• Screw in the new rail-pressure sensor (2) and • Tighten new high-pressure lines (2) to Final torque
tighten it to 70 Nm 60° using the Socket, size 17 [49] (3), the Socket,
size 22 [50] if necessary and the Extension [51]
• Mount the clamping pieces (1) as marked
Connecting the rail-pressure sensor electrical


COMMON-RAIL SYSTEM
Connecting the rail-pressure sensor electrical Attaching the fuel lines (Euro 4 variant)
connection (Euro 4)
Attaching the fuel return lines

rail-pressure sensor (1) • Screw in the adapter tting (4) with a new sealing
ring and then tighten it
Installing the high-pressure line • Position the fuel return lines (2) and (5)
Attaching the fuel return line
WARNING
Component damage due to
non-aligned high-pressure line
• After initial tightening, check the
alignment of the high-pressure line
and, if necessary, re-align
• Attach the high-pressure line (2) at the rail (1) and

high-pressure pump (3)
• Tighten the high-pressure line (2) to Initial torque
10 Nm using the Socket, size 17 [49], the Socket,
size 22 [50] if necessary and the Extension [51]
• If reusing, tighten the high-pressure line (2) to
Final torque 30° using the Socket, size 17 [49],
the Socket, size 22 [50] if necessary and the
Extension [51]
• Tighten a new high-pressure line (2) to Final torque
60° using the Socket, size 17 [49], the Socket, size
22 [50] if necessary and the Extension [51] • Position the fuel return line
• Screw in the overow valve (2) with new sealing
rings (1) and tighten to 32 Nm

COMMON-RAIL SYSTEM
Attaching the fuel lines (Euro 5 and EEV Attaching the rail-fuel service centre fuel return
variant) line
Attaching the fuel return line on the fuel lter

side
• Attach the fuel line (3)

• Position the fuel line (3) with new sealing rings (1)
• Screw in the hollow screw (2) and tighten it by
hand
• Install the fuel line (4) with new sealing rings (6)
and (7)
hand
• Check the fuel line (4) is seated rmly; if
necessary, detach and attach again using the
Release tool, size 2 [54] and the Release
handle [52]
• Tighten the hollow screws (2) and (5)
Attaching the fuel return line on the

high-pressure pump side
hand
• Put the fuel line (3) on the tting on the
high-pressure pump
handle [52]
• Tighten the hollow screw (1)

COMMON-RAIL SYSTEM
HIGH-PRESSURE PUMP
Protective sleeves, high-pressure pump (variant CP3.3)
(1) End plug 81.96002-0521 (7) Protective sleeve Z 14 x 15

(2) Protective sleeve Z 14 x 15 81.96002-0512
81.96002-0512 (8) Protective sleeve Z 14 x 15
(3) End plug 81.96002-0521 81.96002-0512
(4) High-pressure line (9) Mounting bolt
(5) Protective sleeve Z 14 x 15 (10) End plug 81.96002-0521
81.96002-0512 (11) High-pressure pump
(6) Protective sleeve Z 14 x 15 (12) Cap 81.96002-0518
81.96002-0512 (13) End plug 81.96002-0521
WARNING
Note

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

line connection
[56] End plug 81.96002-0521
• Plugging the high-pressure line

• Plugging the fuel lines
• Plugging the high-pressure pump bore
• Plugging the air distributor pipe bore
[57] Cap 81.96002-0518

COMMON-RAIL SYSTEM
Removing and installing the high-pressure pump (variant CP3.3)

Additional jobs
– Protective sleeves, high-pressure pump (variant CP3.3), see 153
(1) High-pressure line (4) High-pressure pump

(2) Mounting nut (5) O-ring
(3) Mounting bolt
Technical data
Fuel ll quantity for high-pressure pump (4)....................................................................................... 60 ml
Filler plug for high-pressure pump (4) ..............................................................................................18 Nm
Mounting bolt (3) .................................................. M8x40-8.8 .........................................................30 Nm
Mounting nut (2) ................................................... M8 ....................................................................30 Nm
High-pressure line (initial use) (1) .......................... M14x1.5 ..............................................Final torque 60°
High-pressure line (re-use) (1)............................... M14x1.5 ..............................................Final torque 30°

COMMON-RAIL SYSTEM
WARNING
personnel only
(desired value 0)
• Do not reuse plugs for the high-pressure lines, the rail or injectors, even if they have only been
used once
WARNING
WARNING
Special tools
[58] Socket, size 17 80.99603-0309
• Removing and installing the high-pressure line in

conjunction with:
• Extension [59]
[59] Extension 08.06139-9025
• Removing and installing the high-pressure line
[60] Removing device 80.99601-6021
• Removing the high-pressure pump in conjunction

with:
• Impact tool [61]
[61] Impact tool 80.99606-6078
• Removing the high-pressure pump

COMMON-RAIL SYSTEM
Removing the high-pressure pump Detaching the fuel return line
Disconnecting the metering unit electrical

connection

metering unit (2)
Detaching the fuel return lines
WARNING
container

WARNING
container

the sealing ring

COMMON-RAIL SYSTEM
Detaching the high-pressure line Removing the high-pressure pump if

rmly seated
Detaching the fuel return lines
WARNING
container WARNING
• Remove the high-pressure line (2) from the rail (1) • Collect emerging fuel in a permissible
and the high-pressure pump (3) using the Socket, container
size 17 [58] and the Extension [59]
Removing the high-pressure pump the sealing rings (3)
the sealing ring
Note
When tting a new high-pressure pump,
remove and mount the high-pressure
pump drive gear, see Dismantling and
assembling the high-pressure pump
(variant CP3.3), 163.

• Pull the high-pressure pump (3) out of the timing
case

COMMON-RAIL SYSTEM
Detaching the fuel return line Detaching the high-pressure line
WARNING
container
• Remove the high-pressure line (2) from the rail (1)

and the high-pressure pump (3) using the Socket,
Unscrewing the high-pressure pump mounting

bolts
WARNING
container

• Unscrew the mounting bolts (1) for the


COMMON-RAIL SYSTEM
Mounting the special tool Installing the high-pressure pump

Filling the high-pressure pump with fuel
• Screw the threaded spindle (4) into the plate (3)

for the Removing device [60] (2) using the Impact
tool [61] (5) until ush WARNING
• Mount the Removing device [60] (2) on the Danger of damage due to dirt ingress
high-pressure pump (1) using two bolts • Ensure that no dirt can enter the pump
when lling with oil
Removing the high-pressure pump
• Do not tilt the high-pressure pump after
it has been lled
• Unscrew the ller plug (2) and remove it with the

sealing ring
• Use a pipette (1) to ll the high-pressure pump (3)
with 60 ml of clean, ltered diesel fuel
• Screw in the ller plug (2) with a new sealing ring
and tighten to 18 Nm
Installing the high-pressure pump
Note
When tting a new high-pressure pump,
remove and mount the high-pressure
pump drive gear, see Dismantling and
assembling the high-pressure pump
(variant CP3.3), 163.
• Extract the high-pressure pump (2) from the timing

case using the Removing device [60] (1)
• Remove the Removing device [60] (1) from the
high-pressure pump (2) • Insert the high-pressure pump (3) into the timing
case
Nm
• Screw on the new mounting nut (2) and tighten it
to 30 Nm

COMMON-RAIL SYSTEM
Installing the high-pressure line Attaching the fuel return line
WARNING
and, if necessary, reposition it

10 Nm using the Socket, size 17 [58] and the
Extension [59]
• If reusing, tighten the high-pressure line (2) to Final
torque 30° using the Socket, size 17 [58] and the
Extension [59] • Position the fuel return line
• Tighten the new high-pressure line (2) to Final • Screw in the hollow screw (2) with new sealing
torque 60° using the Socket, size 17 [58] and the rings (1) and then tighten it
Extension [59]
Attaching the fuel return lines
• Screw in the adapter tting (4) with a new sealing

ring and then tighten it
• Position the fuel return lines (2) and (5)
rings (3) and then tighten it

COMMON-RAIL SYSTEM
Connecting the metering unit electrical

connection

metering unit (2)

COMMON-RAIL SYSTEM
Dismantling and assembling the high-pressure pump (variant CP3.3)

Additional jobs
– Removing and installing the high-pressure pump (variant CP3.3), see 155
(1) Mounting nut (5) Metering unit

(2) O-ring (6) Mounting bolt
(3) Drive gear (7) Fuel pump
(4) High-pressure pump (8) Mounting bolt
Technical data
Mounting bolt (6) .................................................. M5x20 ..............................................Final torque 7 Nm
Mounting bolt (8) .................................................. M6x1.5x36.......................................................... 8 Nm
Mounting nut (1) ................................................... M18x1.5-8.8 ....................................................105 Nm
WARNING
personnel only

COMMON-RAIL SYSTEM
WARNING
Special tools
[62] Three-arm puller 08.99605-9014
• Extracting the high-pressure pump drive gear

COMMON-RAIL SYSTEM
Dismantling the high-pressure pump Removing the fuel pump
Unscrewing the mounting nut from the

high-pressure pump drive gear

• Pull out the fuel pump (1)
• Remove the O-rings (3) and (4) from the fuel pump
• Clean the high-pressure pump (3) and blow it dry (1)
using compressed air
• Brace the drive gear for the high-pressure pump Removing the metering unit
(3)
• Remove the O-ring (2)
Removing the high-pressure pump drive gear
• Mark the installation position of the metering unit

(2)
• Extract the metering unit (2) by turning slightly to
the right/left
• Extract the drive gear (2) using the Three-arm
puller [62] (1)

COMMON-RAIL SYSTEM
Assembling the high-pressure pump Mounting the high-pressure pump drive gear
Installing the metering unit
• Degrease the cone in the drive gear and on the

Note • Place the drive gear on the cone of the
When using micro-encapsulated bolts, high-pressure pump (3)
the time between the tightening stages • Fit the new O-ring (2) on the high-pressure pump
must not be longer than 2 minutes. (3)
• Screw on the new mounting nut (1)
• Insert the new metering unit (2) into the • Brace the drive gear for the high-pressure pump
high-pressure pump by turning slightly to the (3)
right/left • Tighten the mounting nut (1) to 105 Nm
• Align the metering unit (2) as marked
• Tighten the new mounting bolts (1) to Initial torque
4 Nm
• Tighten the mounting bolts (1) to Final torque 7 Nm
Installing the fuel pump
WARNING
• Ensure that no dirt can enter the pump
• Do not tilt the high-pressure pump after
• Insert the new O-rings (3) and (4) into the fuel it has been lled
pump (1)
• Insert the fuel pump (1) • Unscrew the ller plug (2) and remove it with the
• Screw in new mounting bolts (2) and tighten to 8 sealing ring
Nm • Use a pipette (1) to ll the high-pressure pump (3)
with 60 ml of clean, ltered diesel fuel
• Screw in the ller plug (2) with a new sealing ring
and tighten to 18 Nm

COMMON-RAIL SYSTEM
Protective sleeves, high-pressure pump (variant CP3.3 NH)
(1) Protective sleeve Z 18 x 15 (8) Protective sleeve Z 28 x 20

81.96002-0555 81.96002-0514
(2) Protective sleeve Z 12 x 16 81.96002-0117 (9) Protective sleeve Z 28 x 20
81.96002-0514 (10) Cap 81.96002-0518
(4) Protective sleeve Z 28 x 20 (11) Protective sleeve Z 14 x 15
81.96002-0514 81.96002-0512
(5) Cap 81.96002-0518 (12) Protective sleeve Z 14 x 15
81.96002-0514 (13) End plug 81.96002-0521
81.96002-0514
WARNING
Note

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

line connection
• Plugging the rail high-pressure line connection
• Plugging the tting for the quick-release coupling
[67] End plug 81.96002-0521
• Plugging the high-pressure pump bore
[68] Cap 81.96002-0518
• Plugging the hollow screw connection

COMMON-RAIL SYSTEM
Removing and installing the high-pressure pump (variant CP3.3 NH)

Additional jobs
– Tilting the cab forwards and backwards, see Operator's Manual
– Reading out the fault memory (MAN-cats®)
– Protective sleeves, high-pressure pump (variant CP3.3 NH), see 167
– Bleeding the fuel system, see Operator's Manual
(1) High-pressure line (4) High-pressure pump

(2) Mounting nut (5) O-ring
(3) Mounting bolt
Technical data
Fuel ll quantity, high-pressure pump (4)........................................................................................... 60 ml
Mounting nut (2) ................................................... M8-8 .................................................................30 Nm
Mounting nut, drive gear, high-pressure pump (4)... M18x1.5-8.8 ....................................................105 Nm
Filler plug, high-pressure pump (4) ..................................................................................................18 Nm

COMMON-RAIL SYSTEM
WARNING
personnel only.
(desired value 0)
• Do not reuse plugs for the high-pressure lines, the rail or the injectors, even if they have only
been used once
WARNING
WARNING
Note
Mark the installation position of the fuel lines and the holders before removal.
Route and position the fuel lines and holders as marked when installing.
Special tools
[69] Socket, size 22 80.99603-0378
• Removing and installing the high-pressure line in

conjunction with:
• Extension [71]
[70] Socket, size 17 80.99603-0309
[71] Extension 08.06139-9025
[72] Release handle 80.99606-0597

conjunction with:

COMMON-RAIL SYSTEM
[74] Three-arm puller 08.99605-9014
• Extracting the high-pressure pump drive gear

COMMON-RAIL SYSTEM
Removing the high-pressure pump Detaching the HDP-fuel service centre fuel line
Disconnecting the metering unit electrical

connection
• Disconnect the electrical connection (1) Detaching the HDP-fuel service centre fuel lines
Detaching the fuel return line on the


WARNING 1 [73] and the Release handle [72]
Component damage due to fuel in the • Pull off the fuel line (1) using the Release tool, size
combustion chamber 1 [73] and the Release handle [72]
WARNING
container
• Unscrew the hollow screw (1) with sealing rings


COMMON-RAIL SYSTEM
Detaching the high-pressure line Retting the high-pressure pump drive

gear
Unscrewing the mounting nut from the
high-pressure pump drive gear
WARNING
container
• Clean the high-pressure pump (3) and blow it dry
• Detach the high-pressure line (2) from the rail (1) using compressed air
and the high-pressure pump (3) using the Socket, • Brace the drive gear for the high-pressure pump
size 17 [70], the Socket, size 22 [69] and the (3)
Extension [71] • Unscrew the mounting nut (1)
• Remove the washer (2)
Removing the high-pressure pump
Removing the high-pressure pump drive gear
Note • Extract the drive gear (2) using the Three-arm

When tting a new high-pressure pump, puller [74] (1)
ret the high-pressure pump drive gear,
see Retting the high-pressure pump
drive gear, 173.

• Remove the high-pressure pump (3) from the
timing case

COMMON-RAIL SYSTEM
Mounting the high-pressure pump drive gear Installing the high-pressure pump
WARNING
Component damage due to incorrect
cleaning agent WARNING
• Only use white spirit, spirit, glycol Danger of damage due to dirt ingress
alcohol or isopropanol to clean the cone • Ensure that no dirt can enter the pump
• Degrease the cone in the drive gear and on the • Do not tilt the high-pressure pump after
high-pressure pump (3) it has been lled
• Put the drive gear on the cone of the high-pressure
pump (3) • Unscrew the ller plug (2) and remove it with the
• Put a new washer (2) on the high-pressure pump sealing ring
(3) • Use a pipette (1) to ll the high-pressure pump (3)
• Screw on the new mounting nut (1) with 60 ml of clean, ltered diesel fuel
• Brace the drive gear for the high-pressure pump • Screw in the ller plug (2) with a new sealing ring
(3) and tighten to 18 Nm
• Tighten the mounting nut (1) to 105 Nm
Installing the high-pressure pump
• Insert the high-pressure pump (3) into the timing

case by turning slightly to the right/left
• Screw on a new mounting nut (2) and tighten to
30 Nm
Nm

COMMON-RAIL SYSTEM
Installing the high-pressure line Attaching the HDP-fuel service centre fuel lines

WARNING
high-pressure pump and fuel service centre
handle [72]
and, if necessary, re-align
high-pressure pump
• Check for rm seating of the fuel line (4), if
necessary detach and attach again using the
10 Nm using the Socket, size 17 [70], the Socket,
handle [72]
• If reusing the high-pressure line (2), tighten to
Final torque 30° using the Socket, size 17 [70],
the Socket, size 22 [69] and the Extension [71] Attaching the HDP-fuel service centre fuel line
• Tighten a new high-pressure line (2) to Final torque
60° using the Socket, size 17 [70], the Socket, size
22 [69] and the Extension [71]

high-pressure pump and fuel service centre
handle [72]

COMMON-RAIL SYSTEM
Attaching the fuel return line on the

• Screw in the hollow screw (1) and tighten by hand
high-pressure pump
handle [72]
• Tighten the hollow screw (1)
Connecting the metering unit electrical

connection

COMMON-RAIL SYSTEM
FUEL SERVICE CENTRE

Protective sleeves, fuel service centre
Euro 4
(1) Cap 81.96002-0517

(2) End plug 81.96002-0521
(4) End plug 81.96002-0521
(5) Cap 81.96002-0518
(6) Protective sleeves Z 30 x 22
81.96002-0515
(7) Cap 81.96002-0518
81.96002-0514
(9) Cap 81.96002-0518
81.96002-0514
81.96002-0514

COMMON-RAIL SYSTEM
Euro 5 and EEV
(1) End plug 81.96002-0521 (9) Protective sleeve Z 28 x 20

(2) End plug 81.96002-0521 81.96002-0514
(3) Cap 81.96002-0518 (10) Protective sleeve Z 28 x 20
81.96002-0515 (11) Protective sleeve Z 28 x 20
(5) Cap 81.96002-0518 81.96002-0514
(6) Caps 81.96002-0518 (12) Protective sleeve Z 28 x 20
81.96002-0515 (13) Cap 81.96002-0518
(8) Protective sleeve Z 28 x 20 (14) Protective sleeve Z 12 x 16 81.96002-0117
81.96002-0514
WARNING
Note

COMMON-RAIL SYSTEM
Special tools
• Plugging the tting for the quick-release coupling
• Plugging the quick-release couplings
• Plugging the quick-release couplings
[78] Cap 81.96002-0517
[79] Cap 81.96002-0518
[80] End plug 81.96002-0521
• Plugging the hand pump connections

• Plugging the fuel service centre bores

COMMON-RAIL SYSTEM
Removing and installing the fuel service centre

Additional jobs
(1) Air distributor pipe (4) Mounting bolt

(2) Hand pump (5) Pressure sensor
(3) Fuel service centre
WARNING
WARNING
WARNING
• Collect any remaining fuel that emerges in a suitable container

COMMON-RAIL SYSTEM
Special tools
[81] Release handle 80.99606-0597

conjunction with:

COMMON-RAIL SYSTEM
Detaching the fuel lines (Euro 4 variant) Detaching the fuel lines
Detaching the fuel lines
• Unscrew the hollow screws (3) and (5) and remove

with the sealing rings (4)
• Unscrew the hollow screws (3) and (6) and remove • Detach the fuel lines (1) and (2)
with the sealing rings (2) • Pull off the fuel line (6) with the Release tool, size
• Detach the fuel lines (1) and (7) 1 [82] (7) and the Release handle [81]
• Pull off the fuel line (4) with the Release tool, size
1 [82] (5) and the Release handle [81]

• Detach the fuel line (1)
• Pull off the fuel line (5) with the Release tool, size
1 [82] (4) and the Release handle [81]

COMMON-RAIL SYSTEM
Detaching the fuel lines (Euro 5 and EEV Detaching the fuel return line on the fuel lter
variant) side
WARNING
container
2 [83] and the Release handle [81] • Unscrew the hollow screw (5) and remove with the
• Remove the fuel line (1) sealing rings (6) and (7)
• Unscrew the hollow screw (5) and remove it with • Pull off the fuel line (4) using the Release tool, size
the sealing rings (6) 2 [83] and the Release handle [81]
• Pull off the fuel line (7) using the Release tool, size • Unscrew the hollow screw (2) and remove with the
1 [82] and the Release handle [81] sealing rings (1) and the fuel line (3)
Detaching the fuel lines Detaching the fuel line
• Unscrew the hollow screw (2) and remove it with • Pull off the fuel line (1) using the Release tool, size
the sealing rings (1) 1 [82] and the Release handle [81]
• Undo the hose clamp and remove the fuel line (3)

COMMON-RAIL SYSTEM
Removing the fuel service centre Removing the proportional valve
Disconnecting the fuel service centre electrical

connections
• Disconnect the electrical connection for the

• Detach the compressed-air line (3)
• Remove the proportional valve (2)
Removing the fuel service centre
• Disconnect the pressure sensor electrical

connection (1)
• Disconnect the heating element electrical
connection (3)
• Remove the fuel service centre (1)
connection
Removing the holder

• Free the wiring harness (3) for the proportional
valve (2)

COMMON-RAIL SYSTEM
Installing the fuel service centre Connecting the proportional valve electrical
connection
Mounting the holder

• Position the holder (1) proportional valve (2)
• Screw in and tighten the new mounting bolt (2) • Route the wiring harness (3) so it is not under
tension, not kinked and there are no chang points
Mounting the fuel service centre
Connecting the fuel service centre electrical
connections
• Position the fuel service centre (1)

Mounting the proportional valve
• Connect the pressure sensor electrical connection

(1)
• Connect the heating element electrical connection
• Position the proportional valve (2) (3)
• Screw in and tighten the new mounting bolt (1) • Route the wiring harnesses so that they are not
• Attach the compressed-air line (3) under tension, not kinked, and there are no chang
• Connect the electrical connection for the points
proportional valve (2) • Secure the wiring harnesses with cable ties (2)

COMMON-RAIL SYSTEM
Attaching the fuel lines (Euro 4 variant) Attaching the fuel lines
Attaching the fuel lines
• Position the fuel lines (1) and (7)

• Fit the hollow screws (3) and (6) with new sealing
• Position the fuel lines (1) and (2) rings (2), screw in and tighten
• Fit the hollow screws (3) and (5) with new sealing • Attach the fuel line (4)
rings (4), screw in and tighten • Check that the fuel line (4) is seated rmly. Pull off
• Attach the fuel line (6) and re-attach using the Release tool, size 1 [82]
• Check that the fuel line (6) is seated rmly. Pull off (5) and the Release handle [81] if necessary
and re-attach using the Release tool, size 1 [82]
(7) and the Release handle [81] if necessary
• Position the fuel line (1)

• Attach the fuel line (5)
• Check that the fuel line (5) is seated rmly. Pull off
and re-attach using the Release tool, size 1 [82]
(4) and the Release handle [81] if necessary

COMMON-RAIL SYSTEM
Attaching the fuel lines (Euro 5 and EEV Attaching the fuel lines
variant)
Attaching the fuel line

high-pressure pump and the fuel service centre
• Check that the fuel line (4) is seated rmly. If
• Put the fuel line (1) on the tting on the necessary, pull off and re-attach using the Release
high-pressure pump and the fuel service centre tool, size 1 [82] and the Release handle [81]
• Check that the fuel line (1) is seated rmly. If • Put the fuel line (3) with the hose clamp on the
necessary, pull off and re-attach using the Release tting on the rail
tool, size 1 [82] and the Release handle [81] • Screw in the hollow screw (2) with new sealing
Attaching the fuel return line on the fuel lter • Tighten the hose clamp for the fuel line (3)
side
• Screw in the hollow screw (2) and tighten it by • Put the fuel line (4) on the tting
hand • Check that the fuel line (4) is seated rmly. If
• Install the fuel line (4) with new sealing rings (6) necessary, pull off and re-attach using the Release
and (7) tool, size 2 [83] and the Release handle [81]
• Screw in the hollow screw (5) and tighten it by • Position the fuel line (1) on the fuel service centre
hand • Screw in the hollow screw (3) with new sealing
• Check the fuel line (4) is seated rmly; if rings (2) and then tighten it
necessary, detach and attach again using the • Put the fuel line (7) on the tting on the
Release tool, size 2 [83] and the Release high-pressure pump
handle [81] • Check that the fuel line (7) is seated rmly. If
• Tighten the hollow screws (2) and (5) necessary, pull off and re-attach using the Release
tool, size 1 [82] and the Release handle [81]

COMMON-RAIL SYSTEM
Dismantling and assembling the fuel service centre

Additional jobs
(1) Fuel lter (9) Heating element

(2) Cover (10) Hollow screw
(3) Sealing ring (11) Cover
(4) Housing (12) Fuel pre-lter
(5) Pressure sensor (13) Sealing ring
(6) Water drain plug (14) Housing
(7) Mounting bolt (15) Hand pump
(8) Sealing ring (16) Mounting bolts
Technical data
Pressure sensor (5) .............................................. M18x1.5 ............................................................45 Nm
Cover (11) ......................................................................................................................................10 Nm
Cover (2)........................................................................................................................................20 Nm
Water drain plug (6) ......................................................................................................................... 3 Nm
WARNING
Dirt can cause failure of the common-rail system
• Always allow the fuel service centre to empty before changing the fuel lter
• Only use fuel lters that are designated for common-rail systems and marked as such
• Do not reuse old lter elements.

COMMON-RAIL SYSTEM
WARNING
Special tools
[84] Socket, size 36 80.99603-0325
• Removing and installing the fuel lter cover
[85] Socket, size 19 08.06141-9061
• Removing and installing the fuel pre-lter cover

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

(2)
WARNING
Removing the fuel lter
• Collect any remaining fuel that emerges
in a suitable container
• Undo the cover (1) by approx. 2 - 3 turns using

the Socket, size 36 [84]
• Open the water drain plug (2) and allow the fuel
service centre to empty
• Re-tighten the water drain plug (2) to 3 Nm
Removing the heating element

• Pull the heating element (3) and sealing ring (4)
out of the fuel service centre (1)
• Unscrew the cover (1) with Socket, size 36 [84]

• Pull the cover (1) with fuel lter (3) out of the fuel
service centre housing
• Remove the sealing ring (2)
• Unscrew the cover (7) with Socket, size 19 [85]
• Pull the fuel pre-lter (6) out of the hand pump
housing (4)
• Remove the sealing ring (5)

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

service centre (3)
• Remove the hand pump housing (1) • Position the hand pump housing (1) on the fuel
service centre (3)

COMMON-RAIL SYSTEM
Installing the fuel lter Tightening the fuel lter cover
• Tighten the fuel lter cover to 20 Nm using the

Socket, size 36 [84] (1)
Installing the pressure sensor
• Moisten the new sealing ring (5) with clean diesel

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

ring (4) into the fuel service centre (1)
• Tighten the fuel lter cover to 10 Nm using the
Socket, size 19 [85] (1)

COMMON-RAIL SYSTEM
FLAME START SYSTEM

Protective sleeves, ame start system
(1) End plug 81.96002-0521 (4) Protective sleeve A9 81.96002-0516

(2) Cap 81.96002-0518 (5) Cap 81.96002-0517
WARNING
Note

COMMON-RAIL SYSTEM
Special tools
• Plugging the ame glow plug connection
[87] Protective sleeve A9 81.96002-0516
• Plugging the ame start system fuel line
[88] Cap 81.96002-0517
• Plugging the ame start system fuel line hollow

screw connection
• Plugging the solenoid valve fuel line hollow screw
connection
[89] Cap 81.96002-0518
• Plugging the fuel service centre fuel line hollow

screw connection
[90] End plug 81.96002-0521
• Plugging the solenoid valve bore

• Plugging the fuel service centre bore

COMMON-RAIL SYSTEM
Removing and installing the ame start system

Additional jobs
– Protective sleeves, ame start system, see 193
(1) Flame glow plug (3) Fuel line

(2) Solenoid valve
Technical data
Mounting nut, cable lug......................................... M5 ..................................................................... 5 Nm
Union nuts, fuel line (3) ......................................... M10x1 ...............................................................10 Nm
Service products
Curil T sealing compound .................................................................................................. 04.90300-9030
WARNING

COMMON-RAIL SYSTEM
Removing the ame start system Removing the solenoid valve
Disconnecting the electrical connection

• Remove the solenoid valve (2)
• Unscrew the cable lug mounting nut
• Remove the electrical connection (1) Removing the ame glow plug
Detaching the ame start system fuel lines
• Undo the mounting nut (1)

• Unscrew the ame glow plug (2)

• Remove the fuel lines (1) and (3)

COMMON-RAIL SYSTEM
Installing the ame start system Attaching the ame start system fuel lines
Installing the ame glow plug
• Thinly apply Curil T sealing compound on the

thread of the ame glow plug (2)
• Screw in the ame glow plug (2) and line it up with
the solenoid valve - ame glow plug (2) fuel line
• Brace the ame glow plug (2) and tighten the
mounting nut (1) to 25 Nm
Mounting the solenoid valve

• Position the fuel line (1)
• Screw in the hollow screw with new sealing rings
• Tighten the union nut for the fuel line (1) to 10 Nm
• Tighten the hollow screw for the fuel line (1)
• Attach the fuel line (3) with new sealing rings
Connecting the electrical connection
• Position the solenoid valve (2)

• Position the electrical connection (1) at the ame

glow plug
• Screw on the cable lug mounting nut and tighten
to 5 Nm

COMMON-RAIL SYSTEM
ENGINE CONTROL UNIT

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

(2) Bracket (5) Engine control unit
(3) Rubber mount (6) Mounting bolt
Technical data
Mounting bolt (6) .................................................. M6x35-10.9 ....................................................... 11 Nm
Service products
Loctite 270 sealing compound ............................................................................................ 04.10160-9131
WARNING
Note
After the engine is installed, the engine control unit must have its parameters reset and the fault
memory must be deleted.

COMMON-RAIL SYSTEM
Removing the engine control unit Installing the engine control unit
Disconnecting the engine control unit electrical Tightening sequence for engine control unit
connections
• Follow the illustrated tightening sequence A to H

• Release and pull off the connectors (1), (2) and (3) for the mounting bolts (1) in the following work step
• Free the wiring harnesses
Mounting the engine control unit and bracket
Removing the engine control unit and bracket
• Insert the rubber mounts (1) and (2) into the

• Unscrew the mounting bolts (5) bracket
• Remove the engine control unit (4) • Thinly apply Loctite 270 sealing compound on the
• Unscrew the mounting bolts (3) thread of the new mounting bolts (3)
• Remove the bracket with rubber mounts (1) and • Position the bracket
(2) • Screw in the mounting bolts (3) and tighten them
to 13 Nm
• Position the engine control unit (4)
• Screw in the new mounting bolts (5) and tighten in
the specied sequence to 11 Nm

COMMON-RAIL SYSTEM
Connecting the engine control unit electrical

connections
WARNING
Danger of irreparable engine control
unit damage
• When installing the connectors, rst
fully open the lock and then insert and
lock the connectors
• Insert and lock the connectors (1), (2) and (3) in

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

TURBOCHARGING
TURBOCHARGING
(1) Air distributor pipe (7) Oil pressure line

(2) Charge-air manifold (8) Oil feed distributor block
(3) Turbocharger (9) Oil return line
(4) Heat shield (10) Oil pressure line
(5) Compressed-air line (11) Heat shield
(6) Pulse valve (12) Charge-air manifold

TURBOCHARGING
INTERCOOLER
Removing and installing the intercooler
(1) Mounting bolt (5) Intercooler

(2) Holder (6) O-ring
(3) Mounting bolt (7) Unscrewed conduit
(4) Mounting bolt (8) Unscrewed conduit
Service products
WARNING

TURBOCHARGING
Removing the intercooler Installing the intercooler

Removing the holder Mounting the intercooler

Note
Aluminium unscrewed conduits may be
Removing the intercooler installed, depending on the production
period. In this case, the unscrewed
conduits can be reused; however, new
O-rings must be tted before installation.
• Thinly apply Radiator antifreeze on the new

unscrewed conduits
• Insert the unscrewed conduits into the charge-air
manifold
• Insert the new O-rings (2)
• Put the intercooler (1) with absorber mat over the
unscrewed conduits and support it
• Screw in and tighten the mounting bolts
Mounting the holder
• Unscrew the mounting bolts

• Remove the intercooler (1) with the absorber mat
• Remove the O-rings (2)
• Pull the unscrewed conduits out of the charge-air
manifolds


TURBOCHARGING
CHARGE-AIR PIPES/CHARGE-AIR MANIFOLD

Removing and installing the charge-air pipes/charge-air manifold (Euro 5 and EEV
variant)
(1) Charge-air pipe

(2) Clamp
(4) Clamp

TURBOCHARGING
Removing the charge-air pipes Removing the upper charge-air manifold holder
/charge-air manifold
Removing the suction line

(1) and (2)
• Undo the jubilee clip (1) using the Hose clamp • Remove the holder (3)
pliers for jubilee clips [92] and push it onto the
suction line (4) Removing the charge-pressure sensor
• Undo the jubilee clip (3) using the Hose clamp
pliers for jubilee clips [92] and push it onto the
hose
• Unscrew the mounting bolt (5) and remove it with
the bush (2)
• Remove the suction line (4)
Removing the lower charge-air manifold holder

• Unscrew the mounting bolts (2) and remove the
charge-pressure sensor


TURBOCHARGING
Removing the charge-air manifold Removing the charge-air manifold for the
low-pressure turbocharger
• Remove the clamp (2)

• Remove the charge-air manifold (1) with O-ring (3)
• Remove the charge-air manifold (1)

• Pull the O-ring (2) off the turbocharger
• Remove the unscrewed conduit (3)
Detaching the charge-air pipe
• Remove the clamp (1)

• Remove the charge-air pipe (2)

TURBOCHARGING
Installing the charge-air pipes Mounting the charge-air manifold

/charge-air manifold
Installing the charge-air manifold for the
low-pressure turbocharger
• Position the charge-air manifold (1) with the clamp

(2) and a new O-ring (3)
• Tighten the clamp (2) to 6 Nm
• Install the low-pressure-side intercooler, see
Removing and installing the intercooler, 205
Attaching the charge-air pipe
Note
An aluminium unscrewed conduit may be
installed, depending on the production
period. In this case, the unscrewed
conduit can be reused; however, new
O-rings must be tted before installation.
• Thinly apply Radiator antifreeze on the new

unscrewed conduit (3)
• Insert the unscrewed conduit (3) into the
intercooler
• Position the charge-air pipe (2) with the clamp (1) • Insert the charge-air manifold (1) with a new O-ring
• Screw in and tighten the mounting bolt (3) (2)
• Tighten the clamp (1)

TURBOCHARGING
Mounting the charge-pressure sensor Installing the suction line
• Insert the charge-pressure sensor with a new • Install the suction line (4)
O-ring • Screw in the mounting bolt (5) with the bush (2)
• Screw in and tighten the mounting bolts (2) and then tighten it
• Connect the electrical connection (1) • Install the jubilee clips (1) and (3) using the Hose
clamp pliers for jubilee clips [92]
Mounting the upper charge-air manifold holder

• Screw in and tighten the mounting bolts (1) and
(2) as marked
Mounting the lower charge-air manifold holder


TURBOCHARGING
TURBOCHARGER
Removing and installing the turbocharger (variant with single-stage charging)
Additional jobs

(2) Gasket (10) Holder
(3) Oil pressure line (11) O-ring
(4) Gasket (12) Exhaust manifold
(5) Elbow tting (13) Mounting bolt
(6) Threaded connection (14) Heat shield
(7) Sealing ring (15) Mounting nut
(8) Gasket
Service products
WARNING

TURBOCHARGING
Removing the turbocharger Removing the exhaust manifold
Removing the charge-air pipe

• Remove the exhaust manifold (1)
• Undo the hose clamp (3) Removing the intake tting
• Pull off the charge-air pipe (2)
Removing the charge-air manifold
• Undo the clamp (1)

• Pull off the intake tting (2)
• Detach the hose (1) Detaching the oil pressure line

Removing the exhaust manifold heat shield

• Remove the oil pressure line (1) with the gasket
(3)
• Unscrew the threaded connection (4) and remove
• Unscrew the mounting bolts (2) it with the sealing ring (5)
• Remove the heat shield (1) • Clean the mating faces

TURBOCHARGING
Detaching the oil return line Installing the turbocharger

Mounting the turbocharger

• Remove the oil return line (2) with the gasket (1),
holder (5) and O-Ring (6) • Fit the turbocharger (2) with a new gasket (3)
• Clean the mating faces • Screw on and tighten the new mounting nuts (1)
Removing the turbocharger Attaching the oil return line
• Unscrew the mounting nuts (1) • Thinly apply clean engine oil on a new O-ring (6)
• Remove the turbocharger (2) with gasket (3) and t it on the oil return line (2)
• Clean the mating faces • Insert the oil return line (2) with holder (5) into the
crankcase yoke
• Fit the oil return line (2) with a new gasket (1) and
position it on the turbocharger

TURBOCHARGING
Filling the turbocharger with oil Mounting the intake tting
• Push on the intake tting (2) with the hose clamp

WARNING
(1)
If no oil is added, the turbocharger
• Tighten the hose clamp (1)
will be damaged when the vehicle is
started for the rst time Mounting the exhaust manifold
• Fill the turbocharger with clean engine
oil before attaching the oil pressure line
• Use a funnel (1) to pour clean engine oil into the

oil feed neck on the turbocharger (2) until the oil
duct in the turbocharger (2) is full
Attaching the oil pressure line
• Position the exhaust manifold (1)

Mounting the exhaust manifold heat shield
• Screw in the threaded connection (4) with a new

sealing ring (5) and tighten
• Fit the oil pressure line (1) with a new gasket (3)
and position it
them by hand
• Screw on and tighten the elbow tting for the oil
pressure line (1)
• Position the heat shield (1)


TURBOCHARGING
Mounting the charge-air manifold
• Thinly apply Technical Vaseline on a new O-ring

(3) and insert it into the charge-air manifold (2)
• Position the charge-air manifold (2) with the clamp
(4)
• Tighten the clamp (4)
• Attach the hose (1)
Installing the charge-air pipe
• Insert the charge-air pipe (2) with the hose clamp

(3)

TURBOCHARGING
Removing and installing the turbocharger (variant with two-stage charging without
intercooler)
Additional jobs
– Removing and installing the alternator, see 107
(1) Intake pipe (7) Oil pressure line

(2) Charge-air manifold (8) Oil feed distributor block
(4) Heat shield (10) Oil pressure line
(5) Compressed-air line (11) Heat shield
(6) Pulse valve (12) Charge-air manifold
Technical data
Clamp for charge-air manifold (2) ..................................................................................................... 7 Nm
Exhaust manifold clamp ................................................................................................................... 7 Nm
Service products

TURBOCHARGING
WARNING
Note
The actual charge pressure and opening pressure of the wastegate valve can only be interrogated
using the EDC electronic control unit. The turbocharger must be replaced if the specied values
are not reached.
Replace the turbocharger if the wastegate valve is defective.
Special tools
[91] Hose clamp pliers for jubilee clips 80.99625-0073
• Removing and installing jubilee clips

TURBOCHARGING
Removing the turbocharger Removing the charge-air manifold
Removing the holder
• Mark the installation position of the charge-air

manifold (1)
• Unscrew the mounting bolts (2) • Undo the clamp (3)
• Remove the holder (1) • Remove the charge-air manifold (1) with O-ring (2)
Detaching the intake pipe Removing the heat shield
• Undo the jubilee clips (3) using Hose clamp pliers • Unscrew the mounting bolts (1) and (3)
for jubilee clips [91] and push onto the intake pipe • Remove the heat shield (2)
(1)
• Undo the jubilee clip (2) using Hose clamp pliers Removing the heat shield
for jubilee clips [91] and push onto the intake
manifold
• Remove the intake pipe (1)

• Remove the heat shield (1)

TURBOCHARGING
Removing the charge-air manifold Detaching the oil pressure lines

from the turbocharger
Removing the intake tting

the sealing rings
• Detach the oil pressure lines (4) and (5)
the sealing rings
• Remove the distributor block for the oil feed (3)
• Undo the hose clamp (1)
• Pull off the intake tting (2)

TURBOCHARGING
Detaching the oil return lines Removing the exhaust manifold

• Mark the installation position of the exhaust
manifold (3)
• Remove the exhaust manifold (3)
Removing the heat shields
• Undo the jubilee clips (2) using Hose clamp pliers

for jubilee clips [91]
• Detach the oil return lines (1) and (6) with seals (7)
• Pull the connecting piece (3) with O-ring out of the
crankcase yoke

• Remove the heat shields (3), (4) and (5) from the
exhaust manifold

TURBOCHARGING
Removing the pulse valve Removing the turbocharger
• Undo the hose clamps (3) • Unscrew the mounting nuts (1)
• Pull off the hoses (1) and (2) • Pull the turbocharger (2) with gasket (3) over the
• Unscrew the mounting bolts (7) stay bolt
• Remove the pulse valve (4) • Clean the mating faces
Removing the holder

(2) and (3)

TURBOCHARGING
Installing the turbocharger Mounting the pulse valve

• Place the turbocharger (2) with new gasket (3) • Position the pulse valve (4)
over the stay bolt • Screw in and tighten the new mounting bolts (7)
• Screw on and tighten the new mounting nuts (1) • Push on the hoses (1) and (2) with hose clamps
(3)
Mounting the holder • Tighten the hose clamps (3)
Mounting the heat shields

marked • Position the heat shields (3), (4) and (5) on the
• Tighten the mounting bolts (2) and (3) exhaust manifold
and (2)

TURBOCHARGING
Mounting the exhaust manifold Attaching the oil return lines
• Position the exhaust manifold (3) with the clamp

(4) as marked
• Thinly apply clean engine oil on a new O-ring and

t it on the connecting piece (3)
• Insert the connecting piece (3) into the crankcase
yoke
• Attach the oil return lines (1) and (6) with new seals
(7)
• Mount the jubilee clips (2) with the Hose clamp
pliers for jubilee clips [91]

TURBOCHARGING
Filling the turbocharger with oil Attaching the oil pressure lines
WARNING
started for the rst time
oil before attaching the oil pressure
lines

oil feed neck on the turbocharger until the oil duct
in the turbocharger is full
• Position the distributor block for the oil feed (3)

rings
• Position the oil pressure line (5)
rings
• Position the oil pressure line (4)
• Screw on and tighten the union nuts for the oil
pressure lines (4) and (5)
• Tighten the hollow screws (1) and (2)
Mounting the intake tting
• Push on the intake tting (2) with hose clamp (1)


TURBOCHARGING
Mounting the charge-air manifold Installing the charge-air manifold
• Thinly apply Technical Vaseline on a new O-ring • Thinly apply Technical Vaseline on a new O-ring
(2) (2)
• Position the charge-air manifold (1) with O-ring (2) • Position the charge-air manifold (1) with O-ring (2)
on the turbocharger and clamp (3) as marked
• Position the clamp (3) and tighten to 7 Nm • Tighten the clamp (3)
Mounting the heat shield Mounting the intake pipe
• Position the heat shield (1) • Position the intake pipe (1)
• Screw in and tighten the new mounting bolts (2) • Mount the jubilee clip (2) with the Hose clamp
Mounting the heat shield • Mount the jubilee clip (3) with the Hose clamp

and (3)

TURBOCHARGING
Mounting the holder


TURBOCHARGING
Removing and installing the turbocharger (variant with two-stage charging with
intercooler)
Additional jobs
– Removing and installing the charge-air pipes/charge-air manifold (Euro 5 and EEV variant), see 207
– Removing and installing the intercooler, see 205
(1) Intake tting (7) Oil return line

(2) Hose clamp (8) Oil return line
(3) Oil pressure line (9) Holder
(4) Clamp (10) Heat shield
(5) Exhaust manifold (11) Heat shield
(6) Oil pressure line (12) Heat shield
Technical data
Clamp (4)............................................................. M6x50 ................................................................ 7 Nm
Clamps, charge-air manifold.................................. M6x50 ................................................................ 6 Nm
Service products
WARNING

TURBOCHARGING
WARNING
• Use a suitable container to collect any engine oil which emerges
Note
The actual charge pressure and opening pressure of the wastegate valve can only be interrogated
using the EDC electronic control unit. The turbocharger must be replaced if the specied values
are not reached.
Replace the turbocharger if the wastegate valve is defective.
Special tools
• Removing and installing jubilee clips

TURBOCHARGING
Removing the turbocharger Removing the heat shield
Detaching the oil separator vent line

• Undo the jubilee clip (1) using the Hose clamp
pliers for jubilee clips [92] and push it onto the Removing the heat shield
vent line (2)
• Undo the jubilee clip at the intake tting using the
Hose clamp pliers for jubilee clips [92] and push it
onto the hose
• Remove the vent line (2)
Removing the intake tting

• Mark the installation position of the intake tting

(1)
• Undo the hose clamp (2)
• Pull off the intake tting (1) with the hose clamp (2)

TURBOCHARGING
Removing the heat shield Removing the exhaust manifold
• Unscrew the mounting bolts (1) • Undo the clamp (2)

• Remove the heat shield (2) • Remove the exhaust manifold (3) over the
projection (1)

TURBOCHARGING
Detaching the oil pressure line Detaching the oil pressure line
• Unscrew the union nuts (1) and (3) • Unscrew the union nuts (1) and (3)
• Detach the oil pressure line (2) • Detach the oil pressure line (2)
Detaching the oil return line
• Unscrew the union nut (1)

• Remove the oil return line (2) with the gasket (5)

TURBOCHARGING
Detaching the oil return line Removing the turbocharger
• Unscrew the hollow screw (4) and remove it with • Unscrew the mounting nuts (1) and (3)
the sealing rings (1) and (5) • Unscrew the mounting bolt (4)
• Unscrew the mounting bolts (3) • Pull off the turbocharger (2) with gasket over the
• Remove the oil return line (2) with the gasket stay bolts
• Clean the mating faces • Clean the mating faces
Detaching the wastegate hose Removing the holder
• Undo the clamp (1) • Mark the installation position of the mounting bolts
• Pull the hose (2) off the wastegate (2) and (3)

TURBOCHARGING
Installing the turbocharger Attaching the wastegate hose
Mounting the holder
• Fit the hose (2) on the wastegate

• Screw in the new mounting bolts (2) and (3) as Attaching the oil return line
marked
• Position the oil return line (2) with a new gasket

• Screw in the mounting bolts (3) and tighten them
by hand
• Put on the turbocharger (2) with a new gasket over rings (1) and (5) and then tighten it
the stay bolts • Tighten the mounting bolts (3)
• Screw in the new mounting bolt (4)
• Screw on and tighten the new mounting nuts (1)
and (3)
• Tighten the mounting bolt (4)

TURBOCHARGING
Attaching the oil return line Attaching the oil pressure line
• Install the oil return line (2) with a new gasket (5)
by hand
• Screw in the mounting bolt (3) and tighten it by
hand
• Tighten the union nut (1)
Filling the turbocharger with oil
• Attach the oil pressure line (2)

• Screw on and tighten the union nuts (1) and (3)
WARNING
started for the rst time
oil before attaching the oil pressure
lines

oil feed neck on the turbocharger until the oil duct
in the turbocharger is full

TURBOCHARGING
Attaching the oil pressure line Mounting the exhaust manifold
• Attach the oil pressure line (2) • Position the exhaust manifold (3) with the clamp
• Screw on and tighten the union nuts (1) and (3) (2) over the projection (1)

TURBOCHARGING
Mounting the heat shield Mounting the heat shield

Mounting the intake tting

Mounting the heat shield
• Push on the intake tting (1) with the hose

clamp (2)
• Align the intake tting (1) as marked
Attaching the oil separator vent line

• Insert the vent line (2)

• Install the jubilee clip at the intake tting using the
Hose clamp pliers for jubilee clips [92]
• Install the jubilee clip (1) using the Hose clamp

TURBOCHARGING
Removing the control valve Installing the control valve

Disconnecting the control valve electrical Installing the control valve
connection
• Position the control valve (5)

• Disconnect the electrical connection (1) • Screw in and tighten the mounting bolts (4)
• Put on the hose (1) and tighten the hose clamps
Removing the control valve • Put on the hose (2) and tighten the hose clamp (3)
Connecting the control valve electrical

connection
• Undo the hose clamp (3) and pull off the hose (2)
• Undo the hose clamps and pull off the hose (1)
• Remove the control valve (5) • Connect the electrical connection (1)

INTAKE / EXHAUST SYSTEM
(1) Exhaust manifold (4) Air distributor pipe

(2) EGR positioning cylinder (5) Charge-air manifold
(3) EGR module (6) Gasket

AIR DISTRIBUTOR PIPE

Removing and installing the air distributor pipe
Additional jobs
– Removing and installing the injectors and rail, see 139
– Removing and installing the ame start system, see 195
(1) Gasket (3) Charge-air manifold

(2) Temperature sensor
Technical data
Temperature sensor (2)......................................... M16x1.5 ............................................................45 Nm
Service products
Renolit Si 704 silicone grease ............................................................................................ 09.15014-0102

WARNING

Removing the air distributor pipe Removing the charge-pressure sensor
Detaching the hose

the sealing rings
• Lay the hose (1) to the side
Removing the heater feed holder

Removing the charge-air manifold (Euro 4)

• Remove the charge-air manifold (4) with gasket
(2)
non-return valve housing

Removing the charge-air manifold (Euro 5 and Detaching the air distributor pipe
EEV)

• Unscrew the mounting bolts (1) (3), (4) and (5)
• Remove the charge-air manifold (4) with gasket • Unscrew the mounting bolts (3), (4) and (5)
(2) • Remove the air distributor pipe (2) with gaskets (1)
• Remove the O-ring (3) from the EGR module • Clean the mating faces
Removing the temperature sensor
• Disconnect the electrical connection for the

temperature sensor (2)
• Unscrew the temperature sensor (2) and remove
with the sealing ring (1)

Installing the air distributor pipe Mounting the charge-air manifold (Euro 5 and
EEV)
Attaching the air distributor pipe
• Thinly apply Radiator antifreeze on a new O-ring

• Position the air distributor pipe (2) with new (3)
gaskets (1) • Fit the O-ring (3) on the EGR module
• Screw in the new mounting bolts (3), (4) and (5) • Fit the charge-air manifold (4) with a new gasket
as marked and tighten by hand (2) and position it
• Tighten the mounting bolts (3), (4) and (5) • Screw in and tighten the new mounting bolts (1)
Installing the temperature sensor Mounting the charge-air manifold (Euro 4)
• Screw in the temperature sensor (2) with a new • Thinly apply Renolit Si 704 silicone grease on the
sealing ring (1) and tighten to 45 Nm new unscrewed conduit (3)
• Connect the electrical connection for the • Insert the unscrewed conduit (3) into the
temperature sensor (2) non-return valve housing
• Fit the charge-air manifold (4) with a new gasket
(2) and position it

Mounting the charge-pressure sensor Attaching the hose
• Position the hose (1)

rings and then tighten it
• Insert the charge-pressure sensor (2) with a new

O-ring

EGR MODULE
Removing and installing the EGR module (Euro 4 variant)
Additional jobs
– Removing and installing the thermostat with thermostat housing, see 57

(2) Mounting bolt (6) EGR module
(3) Shut-off valve (7) Non-return valve housing
(4) EGR positioning cylinder
Technical data
Temperature sensor, EGR module (6).................... M16x1.5 ............................................................45 Nm
Mounting nut, EGR positioning cylinder (4) ............ M8 ....................................................................16 Nm
Preload, EGR positioning cylinder (4) ................................................................................ 1.25 ± 0.25 mm
Service products
Renolit Si 704 silicone grease ............................................................................................ 09.15014-0102
WARNING
Danger of engine damage due to water being sucked in
• Do not open the tube cluster in the EGR module

WARNING
Special tools
[93] Locating pin 80.99605-0197
• Setting the EGR positioning cylinder preload in

conjunction with:
• Dial gauge holder [95]
[94] Dial gauge 08.71000-3217
• Setting the EGR positioning cylinder preload
[95] Dial gauge holder 08.71082-0005

Removing the EGR module Detaching the hose
Removing the shut-off valve

the sealing rings
• Detach the EGR positioning cylinder • Set aside the hose (1)
compressed-air line
• Disconnect the EGR positioning cylinder electrical Removing the heater feed holder
connection
• Remove the shut-off valve (2) with seal (5) from
the exhaust manifolds (1) and (6)
Dismantling the shut-off valve

• Unclip the ball head device (1)
• Remove the EGR positioning cylinder (2)
• Remove the connecting pipe (5) with seal (4) from
the shut-off valve (6)

Removing the charge pressure sensor Removing the EGR module

• Remove the EGR module (3) with seals (1)
Removing the non-return valves

charge pressure sensor (2)
WARNING
Danger of engine damage due to water
being sucked in
• Do not open the tube cluster in the EGR
module

non-return valve housing (1)
(2)
• Remove the non-return valve housing (1) with
non-return valves (4) and seal (5) from the EGR
module housing (6)
• Unscrew the mounting bolts (1) • Clean the mating faces
(2)

Removing the temperature sensor Installing the EGR module

Installing the temperature sensor
• Unscrew the temperature sensor (2) with sealing

ring (1)
• Thinly apply clean engine oil on the thread of the
temperature sensor (2)
• Screw in the temperature sensor (2) with a new
sealing ring (1) and tighten to 45 Nm
Installing the non-return valves
WARNING
Risk of exhaust gas recirculation
malfunction and non-return valve
damage
• Take care not to damage the rubber
coating on the non-return valves when
inserting into the housing
Note
The non-return valves must always be
installed in the through-ow direction.
• Carefully insert the non-return valves (4) into the

• Position the non-return valve housing (1) with a
new seal (5) on the EGR module housing (6)

Mounting the EGR module Mounting the charge pressure sensor
• Put on the EGR module (3) with new seals (1)

Mounting the charge-air manifold
• Insert the charge pressure sensor (2) with a new

O-ring
• Thinly apply Renolit Si 704 silicone grease on the Removing the heater feed holder
new unscrewed conduit (3)
• Fit the charge-air manifold (4) with a new gasket
(2) and position it

Attaching the hose Mounting the shut-off valve
• Position the hose (1) • Position the shut-off valve (2) with a new seal (5)
• Screw in the hollow screw (2) with new sealing on the exhaust manifolds (1) and (6)
rings and tighten • Screw in and tighten the new mounting bolts (3)
and (4)
Assembling the shut-off valve • Connect the EGR positioning cylinder electrical
connection
• Attach the EGR positioning cylinder
compressed-air line
Setting the EGR positioning cylinder
• Position the connecting pipe (5) on the shut-off

valve (6) with a new seal (4)
• Fit the EGR positioning cylinder (2) and clip in a
new ball head device (1)
• Screw on a new mounting nut (3) and tighten to • Fit the Dial gauge holder [95] (1) with Dial
16 Nm gauge [94] (2) and Locating pin [93] on the
shut-off valve
• Fit the Locating pin [93] on the EGR positioning
cylinder with a preload
• Unscrew the cylinder rod by several turns
• Screw in the cylinder rod until the pointer on the
Dial gauge [94] (2) no longer moves
• Turn the cylinder rod one turn further
The permitted preload on the EGR positioning
cylinder is 1.25 ± 0.25 mm.
If the preload is out of tolerance, repeat the work

step.

Removing and installing the EGR module (Euro 5 and EEV variant)
Additional jobs

(2) Mounting bolt (6) EGR module
(3) EGR positioning cylinder (7) Non-return valve housing
(4) Shut-off valve
Technical data
Mounting bolts, shut-off valve (4) ........................... M8x80 ...............................................................27 Nm
Temperature sensor, EGR module (6).................... M16x1.5 ...................................................47 Nm, oiled
Bulkhead tting..................................................... M15x1.5 ............................................................35 Nm
Preload, EGR positioning cylinder (3) .......................................................................................1 + 0.5 mm
Service products
WARNING
Danger of engine damage due to water being sucked in
• Do not open the tube cluster in the EGR module

WARNING
Special tools
[96] Dial gauge 08.71000-3217
• Setting the EGR positioning cylinder preload in

conjunction with:
• Locating pin [98]
[98] Locating pin 80.99605-0197

Removing the EGR module Disconnecting the EGR module temperature

Removing the shut-off valve

• Detach the EGR positioning cylinder
compressed-air line Removing the cable duct cover
• Disconnect the EGR positioning cylinder electrical
connection
• Remove the shut-off valve (2) with the gasket (3)
from the EGR module (4) and the exhaust line (5)
Disconnecting the air distributor pipe

temperature sensor electrical connection
• Open the locking pin (1) a quarter turn

• Remove the cable duct cover (2)

connections
• Disconnect the electrical connections (1)

Removing the cable duct Removing the charge-pressure sensor

• Remove, set aside and secure the cable duct (2)
Detaching the hose


the sealing rings
• Set aside the hose (1)

(2)
• Remove the O-ring (3) from the EGR module

Removing the EGR module Removing the temperature sensor
• Unscrew the mounting bolts (2) • Unscrew the temperature sensor (2) with sealing
• Remove the EGR module (3) with gaskets (1) ring (1)
Removing the non-return valves
WARNING
Danger of engine damage due to water
being sucked in
• Do not open the tube cluster in the EGR
module

(5)
• Remove the non-return valve housing (1) with
non-return valves (2) and gasket (3) from the EGR
module housing (4)

Dismantling the shut-off valve Assembling the shut-off valve
• Unscrew the mounting nuts (1) and (2) • Position the EGR positioning cylinder at the
• Remove the EGR positioning cylinder from the shut-off valve (3)
shut-off valve (3) • Screw on and tighten the new mounting nuts (1)
and (2)
• Set the EGR positioning cylinder, see Setting the
EGR positioning cylinder, 265

Installing the EGR module Mounting the EGR module
Installing the temperature sensor
• Put on the EGR module (3) with new gaskets (1)

temperature sensor (2) Mounting the charge-air manifold
• Screw in the temperature sensor (2) with a new
sealing ring (1) and tighten to 47 Nm, oiled
Installing the non-return valves
• Thinly apply Radiator antifreeze on a new O-ring

(3)
• Fit the O-ring (3) on the EGR module
• Position the charge-air manifold (4) with a new
WARNING gasket (2)
Risk of exhaust gas recirculation • Screw in and tighten new mounting bolts (1)
malfunction and non-return valve
damage
• Take care not to damage the rubber
coating on the non-return valves when
inserting into the housing
Note
The non-return valves must always be
installed in the through-ow direction.
• Carefully insert the non-return valves (2) into the

• Position the non-return valve housing (1) with a
new gasket (3) on the EGR module housing (4)

Mounting the charge pressure sensor Attaching the hose
• Position the hose (1)

rings and tighten
Mounting the cable duct
• Insert the charge pressure sensor (2) with a new

O-ring
Mounting the heater feed holder

• Position the cable duct (2) on the cylinder head
cover
Connecting the plug bracket electrical

connections
• Connect the electrical connections (1)

Mounting the cable duct cover Mounting the shut-off valve
• Put on the cable duct cover (2) • Position the shut-off valve (2) with a new gasket
• Close the locking pin (1) a quarter turn (3) on the EGR module (4) and the exhaust line
(5)
Connecting the EGR module temperature sensor • Screw in new mounting bolts (1) and tighten to 27
electrical connection Nm
• Screw in a new mounting bolt (6) and tighten it to
27 Nm
• Connect the EGR positioning cylinder electrical
connection
• Attach the EGR positioning cylinder
compressed-air line
Connecting the air distributor pipe temperature


Setting the EGR positioning cylinder
• Fit the Dial gauge holder [97] (3) with the Dial
gauge [96] (2) and the Locating pin [98] on the
shut-off valve
• Place the Locating pin [98] on the EGR positioning
cylinder with a preload
• Unscrew the cylinder rod by several turns
• Screw in the cylinder rod until the pointer on the
Dial gauge [96] (2) no longer moves
• Turn the cylinder rod one turn further
The permissible AGR positioning cylinder preload is
1 + 0.5 mm.
If the preload is out of tolerance, repeat the work

step.

EXHAUST MANIFOLD
Removing and installing the exhaust manifold (Euro 4 variant)
Additional jobs
– Removing and installing the 1-cylinder air compressor, see 77
(1) connecting pipe (6) Gasket

(2) Mounting bolt (7) Exhaust manifold front
(3) Gasket (8) Mounting bolt
(5) Exhaust manifold rear (10) Exhaust manifold centre
Technical data
Mounting bolt (4) .................................................. M8x40-GA ..................................... Initial torque 25 Nm
Mounting bolt (4) .................................................. M8x40-GA ............................................ 2nd torque 45°
Mounting bolt (4) .................................................. M8x40-GA ...........................................Final torque 45°


Mounting bolts, shut-off valve ................................ M8x80-GA .........................................................27 Nm
WARNING

Removing the exhaust manifold Disassembling the exhaust manifold
Removing the connecting pipe
• Remove the exhaust manifold sections (1) and (3)

from exhaust manifold section (2)
• Unscrew the mounting bolts (2) • Remove the multi-piece rings (4) from exhaust
• Remove the connecting pipe (1) with gaskets (3) manifold sections (1) and (2)
• Clean the mating faces • Clean the mating faces
Removing the exhaust manifold

• Remove the exhaust manifold (3) with gaskets (5)

Installing the exhaust manifold Attaching the connecting pipe
Assembling the exhaust manifold
• Fit the connecting pipe (1) with new gaskets (3)

and position it
• Insert new multi-piece rings (4) into exhaust • Screw in and tighten the new mounting bolts (2)
manifold sections (1) and (2)
• Insert exhaust manifold sections (1) and (3) into
exhaust manifold section (2)
Mounting the exhaust manifold
WARNING
Component damage due to leaking
exhaust manifold
• Do not reuse exhaust manifold
mounting bolts that have already been
used
• Fit the exhaust manifold (3) with new gaskets (5)

and position it
• Screw in the new mounting bolts (1) and (2) and
tighten by hand
• Tighten the mounting bolts (1) to Initial
torque 25 Nm
• Tighten the mounting bolts (2) to Initial torque 25
Nm
• Tighten the mounting bolts (1) to 2nd torque 45°
• Tighten the mounting bolts (2) to 2nd torque 45°
• Tighten the mounting bolts (1) to Final torque 45°
• Tighten the mounting bolts (2) to Final torque 45°
Nm

Removing and installing the exhaust manifold (Euro 5 and EEV variant)
Additional jobs
– Removing and installing the turbocharger (variant with two-stage charging with intercooler), see 229
(1) Exhaust line (8) Mounting bolt

(2) Gasket (9) Exhaust manifold centre
(3) Gasket (10) Multi-piece rings
(4) Gasket (11) Exhaust manifold rear
(5) Exhaust manifold front (12) Mounting bolt
(6) Multi-piece rings (13) Mounting bolt
(7) Mounting bolt
Technical data
Mounting bolt (7), (12) .......................................... M8x40-GA ..................................... Initial torque 25 Nm
Mounting bolt (7), (12) .......................................... M8x40-GA ............................................ 2nd torque 45°
Mounting bolt (7), (12) .......................................... M8x40-GA ...........................................Final torque 45°
Mounting bolt (8) .................................................. M8x80-SD ..................................... Initial torque 25 Nm
Mounting bolt (8) .................................................. M8x80-SD ............................................ 2nd torque 45°
Mounting bolt (8) .................................................. M8x80-SD ...........................................Final torque 45°

WARNING

Removing the exhaust manifold Dismantling the exhaust manifold
Removing the heat shields
• Pull the exhaust manifold (3) out of the exhaust

manifold (2)
• Unscrew the mounting bolts (3) • Pull the exhaust manifold (2) out of the exhaust
• Remove the crane hook lug (4) manifold (1)
• Unscrew the mounting bolts (1) • Remove the multi-piece rings (4) from exhaust
• Remove the heat shield (2) manifolds (2) and (3)
• Repeat the same procedure for the other heat • Clean the mating faces
shield
Removing the exhaust manifold

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

Installing the exhaust manifold Mounting the heat shields
Assembling the exhaust manifold

• Mount the new multi-piece rings (4) on the exhaust • Repeat the same procedure for the other heat
manifolds (2) and (3) shield
• Line up the gaps of the multi-piece rings (4) at 90° • Position the crane hook lug (4)
offset to one another • Screw in and tighten the new mounting bolts (3)
• Insert the exhaust manifold (2) into the exhaust
manifold (1)
• Insert the exhaust manifold (3) into the exhaust
manifold (2)
Mounting the exhaust manifold
WARNING
Exhaust system leaks
• Note the gap of the gaskets
• Position the exhaust manifold with new gaskets

(1)
• Screw in the new mounting bolts (2) and (3) and
tighten them by hand as marked
• Tighten the mounting bolts (2) and (3) to Initial
torque 25 Nm
• Tighten the mounting bolts (2) and (3) to 2nd
torque 45°
• Tighten the mounting bolts (2) and (3) to Final
torque 45°

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

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

CYLINDER HEAD
ROCKER ARM MECHANISM

Removing and installing the rocker arm mechanism
Additional jobs
– Checking and setting the valve clearance, see 292

(3) Valve bridge, exhaust valve (7) Valve bridge, intake valve
(4) Mounting bolt
WARNING

CYLINDER HEAD
Removing the rocker arm mechanism Removing the rocker arm mechanism
Removing the cable duct cover
Note
Do not unscrew the mounting bolt for the
rocker arm shaft in order to remove the
• Remove the cable duct cover (2)
rocker arm mechanism.
connection
• Remove the rocker arm mechanism (1)
• Disconnect the electrical connections (1) for the

plug brackets
Removing the cylinder head cover
• Open the plug bracket bayonet ttings

cylinder head (1)

CYLINDER HEAD
Installing the rocker arm mechanism Connecting the plug bracket electrical
connections
Installing the rocker arm mechanism
• Connect the plug bracket electrical connections

• Thinly apply clean engine oil on the ball cups of (1)
the push rods
• Fit the rocker arm mechanism (1) onto the cylinder Mounting the cable duct cover
head and align it whilst inserting the adjusting
screw balls for the rocker arms into the push rod
crosswise
Mounting the cylinder head cover
• Put on the cable duct cover (2)

• Close the locking pin (1) a quarter turn
• Check the gasket in the cylinder head cover (2)

and the plug bracket; replace as necessary
bracket and onto the cylinder head (1)
• Plug the plug bracket bayonet ttings

CYLINDER HEAD
Dismantling and assembling the rocker arm mechanism

Additional jobs
– Removing and installing the rocker arm mechanism, see 277
(1) Exhaust valve rocker arm (9) Thrust washer

(2) Exhaust valve adjusting screw (10) Pressure spring
(3) Thrust washer (11) Thrust washer
(4) Pressure spring (12) Intake valve rocker arm
(5) Thrust washer (13) Rocker arm shaft
(6) Intake valve adjusting screw (14) Rocker arm bracket
(7) Intake valve rocker arm (15) Mounting bolt
(8) Exhaust valve rocker arm
Technical data
Inside diameter, rocker arms (1), (7), (8), (12) ............................................................. 28.000 - 28.021 mm
Outside diameter, rocker arm shaft (13) ...................................................................... 27.957 - 27.970 mm
Inside diameter, rocker arm bracket (14) ..................................................................... 27.985 - 28.006 mm
Service products
White T assembly paste..................................................................................................... 09.16012-0117

CYLINDER HEAD
WARNING
Special tools
[99] Installer 80.99617-0143
• Removing the rocker arm shaft
[100] Micrometer, 25-50 mm 08.71200-9002
• Checking the rocker arm shaft
[101] Dial gauge 08.71000-3217
• Checking the rocker arm inside diameter

• Checking the rocker arm bracket inside diameter

CYLINDER HEAD
Dismantling the rocker arm mechanism Checking the rocker arm mechanism
Checking the rocker arm shaft outside diameter
• Mark the installation position of the rocker arms (1)

and (5), thrust washers (2) and (4) and pressure
spring (3) • Clean the rocker arm shaft (1)
• Unscrew the mounting bolt (8) • Check the diameter of the rocker arm shaft (1)
• Press the rocker arm shaft (6) out of the rocker using the Micrometer, 25-50 mm [100] (2)
arm bracket (7) with the Installer [99] and leave The permissible diameter of the rocker arm shaft (1)
the Installer [99] in the rocker arm bracket (7) is 27.957 - 27.970 mm.
• Slowly pull the Installer [99] out of the rocker arm
If the diameter is out of tolerance, t a new rocker
bracket (7) whilst removing the rocker arms (1)
arm shaft (1), rocker arm and rocker arm bracket.
and (5), thrust washers (2) and (4) and pressure
spring (3)

CYLINDER HEAD
Checking the rocker arm inside diameter Checking the rocker arm bracket inside diameter
• Clean the rocker arm bracket (2)

• Check the inside diameter of the rocker arm
bracket (2) using the Dial gauge [101] (1)
The permissible diameter of the rocker arm bracket
pin (2) is 27.985 - 28.006 mm.

arm shaft, rocker arm and rocker arm bracket (2).
• Clean the rocker arm (2)

• Check the inside diameter of the rocker arm (2)
using the Dial gauge [101] (1)
The permissible diameter of the rocker arm (2) is
28.000 - 28.021 mm.

arm shaft, rocker arm (2) and rocker arm bracket.

CYLINDER HEAD
Assembling the rocker arm mechanism
• Insert the rocker arms (1) and (5) into the rocker
arm bracket (7) as marked
• Insert the thrust washers (2) and (4) with pressure
spring (3) into the rocker arm bracket (7) as
marked
• Thinly apply White T assembly paste on the rocker
arm shaft (6)
• Align the rocker arm shaft (6) with the bore for the
mounting bolt (8)
• Insert the rocker arm shaft (6) into the rocker arm
bracket (7)

CYLINDER HEAD
CYLINDER HEAD
Removing and installing the cylinder head
Additional jobs
– Removing and installing the coolant manifold, see 53
– Removing and installing the EGR module (Euro 4 variant), see 249
– Removing and installing the exhaust manifold (Euro 4 variant), see 267
– Removing and installing the air distributor pipe, see 243

CYLINDER HEAD

(3) Valve bridge, exhaust valve (7) Valve bridge, intake valve
(4) Mounting bolt
Technical data
Cylinder head bolts............................................... 14x2 (E18)..................................... Initial torque 80 Nm
Cylinder head bolts............................................... 14x2 (E18)......................................2nd torque 150 Nm
Cylinder head bolts............................................... 14x2 (E18)............................................. 3rd torque 90°
Cylinder head bolts............................................... 14x2 (E18)............................................. 4th torque 90°
Cylinder head bolts............................................... 14x2 (E18)...........................................Final torque 90°
WARNING

CYLINDER HEAD
Special tools
[102] Eye-bolt M8 80.99606-0660
• Removing and mounting the cylinder head
[103] Socket, size 22 80.99612-0024
• Undoing and tightening the cylinder head bolts in

conjunction with:
• Socket [105]
• Support [106]
• Torque angle gauge [107]
• Stop pin [108]
• Pan head screw [109]
• Connecting pin [110]
• Rubber ring 42 mm [111]
• Washer [112]
[104] Torque multiplier i = 1 : 3.3 80.99619-0006
• Undoing and tightening the cylinder head bolts
[105] Socket 80.99612-0023
[106] Support 80.99606-0551
[107] Torque angle gauge 80.99607-0172
[108] Stop pin 80.99606-0585

CYLINDER HEAD
[109] Pan head screw 06.02191-0407
[110] Connecting pin 06.22729-0006
[111] Rubber ring 42 mm 08.06142-9006
[112] Washer 80.99609-0033

CYLINDER HEAD
Removing the cylinder head Undoing the cylinder head bolts
Removing the valve bridges and push rods
• Fit the special tool (1) on the cylinder head bolt to

be undone with the Socket [105] (2x)
• Mark the installation position of the valve bridges • Unscrew all the cylinder head bolts using the
(2) and (3) special tool (1)
• Remove the valve bridges (2) and (3)
• Pull out the push rods (1) Removing the cylinder head
Assembling the special tool
• Unscrew the cylinder head bolts (2)

• Screw in and tighten the Eye-bolt M8 [102] (4x) at
• Insert the Torque multiplier i = 1 : 3.3 [104] (1) into the corners of the cylinder head (1)
the Support [106] (2) • Lift off the cylinder head (1) using the lifting device
• Fit the Stop pin [108] (5) with Pan head screw [109] • Clean the mating faces
(4) and Washer [112] (3) on the Support [106] (2) • Unscrew the Eye-bolt M8 [102] (4x)
• Place the Torque angle gauge [107] (9) onto the
Torque multiplier i = 1 : 3.3 [104] (1)
• Place the Socket, size 22 [103] (7) onto the Torque
multiplier i = 1 : 3.3 [104] (1) and secure with
the Connecting pin [110] (8) and Rubber ring 42
mm [111] (6)

CYLINDER HEAD
Removing the cylinder head gaskets Installing the cylinder head

Fitting the cylinder head gaskets
• Remove the cylinder head gaskets (2) over the

alignment pins (1)
• Clean the mating face • Place the new cylinder head gaskets (2) over the
• Clean the tapped holes for the cylinder head bolts alignment pins (1)
Mounting the cylinder head
WARNING
Component damage due to leaking
cylinder head gasket
• Do not reuse old cylinder head bolts,
even if they have only been used once
• Screw in and tighten the Eye-bolt M8 [102] (4x) at

the corners of the cylinder head (1)
• Place the cylinder head (1) onto the crankcase
using the lifting device
• Unscrew the Eye-bolt M8 [102] (4x)
• Thinly apply clean engine oil on the contact
surfaces of the new cylinder head bolts (2)
• Screw in the cylinder head bolts (2) and tighten
them by hand

CYLINDER HEAD
Tightening sequence for cylinder head Installing the valve bridges and push rods
• Follow the illustrated tightening sequence 1 to 24 • Thinly apply clean engine oil on the balls of the
in the following work step push rods (1)
• Insert the push rods (1) into the ball cups of the
Tightening the cylinder head bolts tappets
• Fit the valve bridges (2) and (3) as marked
Note
Note the ratio: Torque multiplier i = 1 :
3.3 [104].
• Fit the special tool (1) on the cylinder head bolt to

be tightened with Socket [105] (2x)
• Tighten the cylinder head bolts to Initial torque 80
Nm, in the correct sequence, with special tool (1)
• Tighten the cylinder head bolts to 2nd torque 150
Nm, in the correct sequence, with special tool (1)
• Tighten the cylinder head bolts to 3rd torque 90°,
in the correct sequence, with special tool (1)
• Tighten the cylinder head bolts to 4th torque 90°,
• Tighten the cylinder head bolts to Final torque 90°,

CYLINDER HEAD
Checking and setting the valve clearance
(1) Valve bridge, intake valve (4) Adjuster screw, exhaust valve
(2) Valve bridge, exhaust valve (5) Adjuster screw, intake valve
(3) EVB adjusting screw
Technical data
Lock nuts, adjusting screws (3), (4), (5).................. M10x1-8.8 .........................................................40 Nm
Intake valve clearance ................................................................................................................ 0.50 mm
Exhaust valve clearance ............................................................................................................. 0.50 mm
EVB brace adjustment dimension ................................................................................................ 0.35 mm
WARNING
Note
The valve clearance values for the intake and exhaust valve for engines with and without EVB are
the same.
The checking and setting procedure for engines without EVB is intrinsically the same.

CYLINDER HEAD
Special tools

[114] Gear ratchet 80.99627-0001
[115] Holding device 08.75300-0000
• Checking and setting the valve clearance in

conjunction with:
• Feeler gauge leaf 0.5 [117]
• Checking and setting the EVB clearance in
conjunction with:
• Feeler gauge leaf 0.35 [116]
[116] Feeler gauge leaf 0.35 80.99607-0175
• Checking and setting the EVB clearance
[117] Feeler gauge leaf 0.5 80.99607-0177
• Checking and setting the valve clearance

CYLINDER HEAD
Checking and setting the valve Attaching the engine barring gear
clearance
Removing the cable duct cover
• Remove the cover from the ywheel housing

ywheel housing
• Remove the cable duct cover (2) Moving the engine to the adjusting position

connections
A Rocker arms in overlap

B Rocker arms free
• Disconnect the electrical connections (1) • Crank the engine in the engine's running direction
using the Engine barring gear [113] and the Gear
Removing the cylinder head cover ratchet [114] until the rocker arms are in overlap
• Adjust free rocker arms as per table
• Open the bayonet ttings on the plug bracket

cylinder head (1)

CYLINDER HEAD
Checking the intake valve clearance Checking the exhaust valve clearance
• Insert the Feeler gauge leaf 0.5 [117] (2) with the • Insert the Feeler gauge leaf 0.5 [117] (2) with the
Holding device [115] (3) between the rocker arm Holding device [115] (3) between the rocker arm
(1) and the valve bridge (4) (1) and the valve bridge (4)
Adjust the valve clearance if the valve clearance is Adjust the valve clearance if the valve clearance is
not 0.50 mm. not 0.50 mm.
Setting the intake valve clearance Moving the EVB piston to the adjusting position
• Undo the lock nut (1) and adjusting screw (2) WARNING
• Insert the Feeler gauge leaf 0.5 [117] (4) with the Danger of incorrect valve clearance
Holding device [115] (5) between the rocker arm • It must be possible to fully push the EVB
(3) and the valve bridge (6) piston into the valve bridge
• Screw in the adjusting screw (2) until the Feeler
gauge leaf 0.5 [117] (4) can be moved between Note
the rocker arm (3) and the valve bridge (6) with This procedure only needs to be
little resistance performed in the case of engines with
• Brace the adjusting screw (2) and tighten the lock EVB.
nut (1) to 40 Nm
• Check the setting again and, if necessary, repeat • Undo the lock nut (2) and unscrew it several turns
the setting procedure • Screw in the adjusting screw (3) to press the valve
bridge downwards several times until the stop is
reached
All the engine oil must escape from the EVB piston
(1).

CYLINDER HEAD
Setting the exhaust valve clearance Checking the adjustment dimension for the EVB
piston
• Undo the lock nut (6)

• Screw in the adjusting screw (1) to press the valve
Note
bridge (4) downwards as far as the pressure point
This procedure only needs to be
• Block the valve bridge (4) in this position with the
performed in the case of engines with
adjusting screw (5)
EVB.
• Insert the Feeler gauge leaf 0.5 [117] (2) with the
Holding device [115] (3) between the rocker arm • Lightly push down the valve bridge (4)
and the valve bridge (4) • Insert the Feeler gauge leaf 0.5 [117] (2) with the
• Unscrew the adjusting screw (1) until the Feeler Holding device [115] (3) between the adjusting
gauge leaf 0.5 [117] (2) can be moved between screw (1) and the valve bridge (4)
the rocker arm and the valve bridge (4) with little Adjust the EVB clearance if the adjustment
resistance dimension is not 0.35 mm.
• Brace the adjusting screw (1) and tighten the lock
nut (6) to 40 Nm
• Check the setting again and, if necessary, repeat
the setting procedure

CYLINDER HEAD
Setting the EVB clearance Connecting the plug bracket electrical

connections
Note • Connect the electrical connections (1)

This procedure only needs to be
performed in the case of engines with Mounting the cable duct cover
EVB.
Note
The valve bridge must not move the
exhaust valve when the adjusting screw
is screwed in.
• Undo the lock nut (1)

• Unscrew the adjusting screw (2) until the Feeler
gauge leaf 0.35 [116] (3) can be inserted with
Holding device [115] (4)
• Screw in the adjusting screw (2) with Feeler gauge
leaf 0.35 [116] (3) inserted until the valve bridge (5)
reaches the stop – this can be felt by a noticeable
increase in force
• Brace the adjusting screw (2) and tighten the lock
nut (1) to 40 Nm • Put on the cable duct cover (2)
• Check the setting again and, if necessary, repeat • Close the locking pin (1) a quarter turn
the setting procedure
Mounting the cylinder head cover

• Check the gasket in the cylinder head cover (2) ywheel housing
and the plug bracket; replace as necessary • Mount the cover on the ywheel housing
bracket and onto the cylinder head (1)
• Plug the bayonet ttings on the plug bracket

CYLINDER HEAD
Removing and installing the valve stem seals

Additional jobs
(1) Valve (4) Valve spring

(2) Cylinder head (5) Valve collet
(3) Valve stem seal
WARNING

CYLINDER HEAD
Special tools

[119] Gear ratchet 80.99627-0001
[120] Valve-spring compressor 80.99613-6000
• Removing and installing the valve springs in

conjunction with:
• Adapter [121]
• Holder [124]
• Holder [125]
• Extension [123]
• Assembly device [122]
[121] Adapter 80.99613-0041
• Removing and installing the valve springs
[122] Assembly device 80.99606-6092
[123] Extension 80.99606-6094
[124] Holder 80.99613-0052

CYLINDER HEAD
[125] Holder 80.99613-0053
[126] Magnetic pick-up tool 80.99639-0009
• Removing the valve cotters
[127] Assembly device 80.99606-6088
• Removing the valve stem seal

• Installing the valve stem seal in conjunction with:
• Assembling sleeve [128]
[128] Assembling sleeve 80.99606-0634
• Installing the valve stem seal

CYLINDER HEAD
Removing the valve stem seals Removal and installation position of valve stem
seals
• Remove and install the free valve stem seals as

• Remove the cover from the ywheel housing per the table
ywheel housing Removing the rocker arm mechanism
Turning the engine to the TDC mark
Note
Do not unscrew the mounting bolt for the
• Turn the engine in the engine's running direction
rocker arm shaft in order to remove the
with the Engine barring gear [118] (1) and the Gear
rocker arm mechanism.
ratchet [119] until the 1st cylinder is at the TDC
mark (2) • Unscrew the mounting bolts (2)
• Remove the rocker arm mechanism (1)

CYLINDER HEAD
Removing the valve bridges and push rods Assembling the special tool
• Mark the installation position of the valve bridges

(2) and (3)
• Remove the valve bridges (2) and (3)
• Pull out the push rods (1)
Note
Retaining washer and Holder [125] have
left-hand threads.
• Position the Holder [124] (5) and the Holder [125]

(3) on the Valve-spring compressor [120] (1) and
then screw on by turning the threaded spindle (4)
• Screw on the retaining washers (2) and (6)
• Position the lever (8) on the Valve-spring
compressor [120] (1) and secure using the
mounting bolt (7)

CYLINDER HEAD
Fitting the mounting device Mounting the valve-spring compressor
• Screw the Adapter [121] (1) into the cylinder head • Position the Holder [124] (4) and the Holder [125]
• Screw the Assembly device [122] (2) into the on the spring cap and tension by turning the
Adapter [121] (1) threaded spindle (5)
• Hook the Valve-spring compressor [120] (2) in the
Assembly device [122] (3)
• Place the Extension [123] (1) onto Valve-spring
compressor [120] (2)

CYLINDER HEAD
Removing the valve cotters Removing the valve springs
CAUTION
Risk of injury due to springing back of
the valve springs
• Ensure that the Holder [124] and
Holder [125] are seated correctly on
the spring cap
• Do not remove the valve cotters from
the valve spring with your bare hands
• Push down the Valve-spring compressor [120] (1)

with the Extension [123]
• Remove the valve cotters (2) from the valve stem
(3) with the Magnetic pick-up tool [126]
• Release the Valve-spring compressor [120] (1)
• Repeat the same procedure for all the valves • Remove the washer (3), valve spring (2) and
• Remove the special tool spring cap (1) over the valve stem
• Repeat the same procedure for all the valves
Removing the valve stem seals
• Push the Assembly device [127] (2) over the valve

stem seal (1)
• Clamp the Assembly device [127] (2)
• Pull the valve stem seal (1) off the valve guide with
the impact weight (3)

CYLINDER HEAD
Installing the valve stem seals Installing the valve springs
Installing the valve stem seals
• Insert the washer (3), valve spring (2) and spring

cap (1) over the valve stem
• Thinly apply clean engine oil on the Assembling • Repeat the same procedure for all the valves
sleeve [128] (2) and valve stem seal (3)
• Push the Assembling sleeve [128] (2) over the
valve stem (1)
• Insert the valve stem seal (3) into the Assembly
device [127] (4) and clamp
• Push the Assembly device [127] (4) over the
Assembling sleeve [128] (2)
• Knock the valve stem seal (3) onto the valve stem
(1) using the impact weight (5)
• Remove the Assembly device [127] (4) and the
Assembling sleeve [128] (2)

CYLINDER HEAD
Fitting the mounting device Mounting the valve-spring compressor
• Screw the Adapter [121] (1) into the cylinder head • Position the Holder [124] (4) and the Holder [125]
• Screw the Assembly device [122] (2) into the on the spring cap and tension by turning the
Adapter [121] (1) threaded spindle (5)
• Hook the Valve-spring compressor [120] (2) in the
Assembly device [122] (3)
• Place the Extension [123] (1) onto Valve-spring
compressor [120] (2)

CYLINDER HEAD
Installing the valve cotters Moving the engine into the removal and
installation position
CAUTION
Risk of injury due to springing back of Note
the valve springs The procedure described below must
• Ensure that the Holder [124] and also be carried out for the remaining
Holder [125] are seated correctly on cylinders.
the spring cap
• Do not insert the valve cotters into the • Turn the engine a further 120° in the engine's
valve spring with your bare hands running direction with the Engine barring
gear [118] and the Gear ratchet [119]
• Push down the Valve-spring compressor [120] (1) • Remove and install the free valve stem seals
with the Extension [123] as per the table, see Removal and installation
• Use a suitable tool to insert the valve cotters (2) so position of valve stem seals, 301
that the valve cotters (2) are seated in the grooves
of the valve stem (3) Installing the valve bridges and push rods
• Release the Valve-spring compressor [120] (1)
• Remove the special tool
• Thinly apply clean engine oil on the balls of the

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

CYLINDER HEAD
Installing the rocker arm mechanism
• Thinly apply clean engine oil on the ball cups of

the push rods
• Fit the rocker arm mechanism (1) onto the cylinder
head and align it whilst inserting the adjusting
screw balls for the rocker arms into the push rod
crosswise

ywheel housing

VALVE TIMING
VALVE TIMING
(1) Tappet (2) Camshaft

VALVE TIMING
CAMSHAFT / CAMSHAFT BEARINGS

Removing and installing the camshaft/camshaft bearings
Additional jobs
– Draining and topping up the engine oil
– Removing and installing the Grosskopf alternator, see 115
– Removing and installing the refrigerant compressor, see 123
– Removing and installing the hydraulic pump, see 127
– Removing and installing the vibration damper, see 361
– Removing and installing the starter, see 119
– Removing and installing the ywheel for manual gearbox, see 365
– Removing and installing the high-pressure pump (variant CP3.3 NH), see 169
– Removing and installing the front crankshaft oil seal, see 399
– Removing and installing the timing case cover, see 431
– Removing and installing the cylinder head, see 285
– Removing and installing the oil sump and oil intake pipe (Euro 4 variant), see 339
– Removing and installing the crankcase yoke (variant LFL50-55), see 427
– Removing and installing the timing gears, see 323
– Removing and installing the timing case, see 435
– Removing and installing the rear crankshaft oil seal, see 403
– Removing and installing the ywheel housing (variant without power take-off), see 415
– Removing and installing the ywheel housing (variant with power take-off 300 Nm), see 418
– Removing and installing the pistons and connecting rods, see 375
– Removing and installing the crankshaft, see 387

VALVE TIMING
(1) Tappet (2) Camshaft
WARNING
Note
For design reasons, there are seven bearing seats for the camshaft in the crankcase; however,
only ve camshaft bearings are installed.
The camshaft bearings are located in camshaft bearing seats 1, 2, 3, 5 and 7.

VALVE TIMING
Special tools
[129] Insertion pin 80.99617-6008
• Removing and installing the camshaft in

conjunction with:
[130] Pan head screw 06.02099-0357
• Removing and installing the camshaft
[131] Centring device 80.99606-6102
• Removing camshaft bearings 2, 3 and 4 in

conjunction with:
• Press-out plate [136]
• Centring plate [137]
• Installing camshaft bearings 1, 2, 3, 4 and 5 in
conjunction with:
• Impact punch [132]
• Installer sleeve [133]
• Centring plate [137]
[132] Impact punch 80.99606-0546
• Installing camshaft bearings 1 and 5
• Installing camshaft bearing 5
• Installing camshaft bearings 2, 3, 4 and 5
• Installing camshaft bearing 1

VALVE TIMING
[136] Press-out plate 80.99602-0162
• Removing camshaft bearings 2, 3 and 4
[137] Centring plate 80.99606-6110
• Removing camshaft bearings 2, 3 and 4

• Installing camshaft bearings 1, 2, 3 and 4
[138] Impact extractor 80.99602-0016
• Removing camshaft bearings 1 and 5 in

conjunction with:
• Extractor device [139]
• Removing camshaft bearings 1 and 5

VALVE TIMING
Removing the camshaft Removing the tappet
Removing the ange
• Pull the tappet (2) out of the crankcase (1)

• Remove the ange (2)
Mounting the special tool
• Position the adapter (3) from the Insertion pin [129]

(1) on the camshaft (4)
• Screw in and tighten the Pan head screw [130] (2)
• Screw the Insertion pin [129] (1) into the adapter
(3)
Removing the camshaft
• Pull the camshaft (2) out of the crankcase (1)

towards the ywheel end

VALVE TIMING
Removing the camshaft bearings Removing camshaft bearing 1
Removal sequence
• Pull out the camshaft bearing (2) with the Impact

extractor [138] (1) and Extractor device [139] (3)
Note
Removing camshaft bearings 2 - 4
Reference is made to the illustrated
sequence in all the following steps.
• Stick to the removal sequence for the camshaft

bearings (1) in the following work steps
Inserting the special tool for camshaft bearing 1
Note
The procedure described below must
also be carried out for camshaft bearings
3 and 4.
• Insert the Press-out plate [136] (1) into the

• Push the Impact extractor [138] (1) through camshaft bearing (2)
the camshaft bearing (3) with the Extractor • Insert the short end of Centring device [131] (3)
device [139] (2) folded up into the Press-out plate [136] (1) until the washer
• Fold down the Extractor device [139] (2) behind (5) reaches the stop
the camshaft bearing (3) and centre in the • Push the Centring plate [137] (4) onto the Centring
camshaft bearing bore device [131] (3) and engage in the crankcase oil
bore
• Remove the camshaft bearing (2)

VALVE TIMING
Inserting the special tool for camshaft bearing 5 Installing the camshaft bearings
Installation instructions for camshaft bearings
• Push the Impact extractor [138] (2) through

the camshaft bearing (3) with the Extractor
device [139] (1) folded up • Push on the camshaft bearing (1) with the notch
• Fold down the Extractor device [139] (1) behind (5) to Installer sleeve [134] (2) so that the ball (3)
the camshaft bearing (3) and centre in the engages in the oil bore (4)
camshaft bearing bore A centring bore can be seen in the second oil bore.
Removing camshaft bearing 5 Installation sequence
• Pull out the camshaft bearing (2) with the Impact Note
extractor [138] (1) and Extractor device [139] (3) Reference is made to the illustrated
sequence in all the following steps.
• Stick to the installation sequence for the camshaft

bearings (1) in the following work steps

VALVE TIMING
Installing camshaft bearing 4 Installing camshaft bearings 3 and 2
• Insert the Centring plate [137] (1) into bearing

Note
seat 6 as marked so that the spring-loaded ball
The procedure described below must
engages in the oil bore
also be carried out for camshaft bearing
• Position the Installer sleeve [134] (2) at bearing
2.
seat 5 with the camshaft bearing pushed on
To ensure rocker arm lubrication, only one
• Insert the short end of the Centring device [131]
oil bore is free at camshaft bearing 2.
(3) into the Installer sleeve [134] (2) and Centring
plate [137] (1)
• Insert the Centring plate [137] (5) into bearing
• Push the second Centring plate [137] over the
seat 4 as marked so that the spring-loaded ball
Centring device [131] (3) as marked and insert
into bearing seat 1 so that the spring loaded ball
• Position the Installer sleeve [134] (3) at bearing
seat 3 with the camshaft bearing (4) pushed on
• Install the camshaft bearing
• Insert the long side of the Centring device [131]
(1) into the Installer sleeve [134] (3) and Centring
plate [137] (5)
• Push the second Centring plate [137] (2) over the
Centring device [131] (1) as marked and insert
into bearing seat 1 so that the spring loaded ball
• Install the camshaft bearing (4)
• Leave the Centring plate [137] (5) in bearing seat
4

VALVE TIMING
Installing camshaft bearing 1 Installing camshaft bearing 5
Note Note
The notch on the camshaft bearing must The notch on the camshaft bearing must
be facing the timing case end. be facing the timing case end.
• Push the Installer sleeve [135] (3) with pushed-on • Insert the Installer sleeve [134] (5) into camshaft
camshaft bearing (4) onto the long side of the bearing seat 4 as marked so that the spring-loaded
Centring device [131] (2) ball engages in the oil bore
• Insert the Centring device [131] (2) into the • Push the Installer sleeve [133] (2) with pushed-on
Centring plate [137] (5) with the Installer camshaft bearing (1) onto the long side of the
sleeve [135] (3) Centring device [131] (4)
• Knock in the camshaft bearing (4) with the Impact • Insert the Centring device [131] (4) into the
punch [132] (1) until ush Installer sleeve [134] (5) with the Installer
sleeve [133] (2)
• Knock in the camshaft bearing (1) with the Impact
punch [132] (3) until ush
Checking the oil bores
• Check that the oil bores (2) for the camshaft

bearings (1) are in the correct position
The oil bores for the camshaft bearings must
match up with the oil bores in the crankcase (3);
if necessary, remove the camshaft bearings and
install new camshaft bearings correctly.

VALVE TIMING
Installing the camshaft Mounting the ange
Installing the tappet
• Position the ange (2)

• Insert the tappet (2) into the crankcase (1)
Installing the camshaft
WARNING
Camshafts can be damaged during
installation
• Always install the camshaft using
special tools
• Thinly apply clean engine oil on the camshaft (2)

and camshaft bearings
• Mount the adapter on the camshaft (2) with the
Pan head screw [130]
• Screw the Insertion pin [129] into the adapter
• Insert the camshaft (2) into the crankcase (1)
• Remove the Insertion pin [129]

TIMING GEARS
TIMING GEARS
(1) Intermediate gear 2 (4) Crankshaft gear

(2) Oil pump drive gear (5) Camshaft gear
(3) Intermediate gear pin

TIMING GEARS
TIMING GEARS
Removing and installing the timing gears
Additional jobs

TIMING GEARS
(1) Intermediate gear 2 (4) Crankshaft gear

(2) Oil pump drive gear (5) Camshaft gear
(3) Intermediate gear pin
Technical data
Mounting bolts, camshaft gear (5).......................... M10x1.25x38-10.9 .............................................65 Nm
Mounting nut, oil pump drive gear (2)..................... M12x1.5-6S .......................................................45 Nm
Timing gear installation play

Radial play, intermediate gear 1 ..................................................................................... 0.060 - 0.109 mm
Axial play, intermediate gear 1........................................................................................ 0.200 - 0.280 mm
Radial play, intermediate gear 2 (1) ................................................................................ 0.035 - 0.076 mm
Axial play, intermediate gear 2 (1)................................................................................... 0.100 - 0.200 mm
Timing gear backlash

Crankshaft gear (4) - camshaft gear (5) .......................................................................... 0.051 - 0.149 mm
Camshaft gear (5) - air compressor gear......................................................................... 0.051 - 0.185 mm
Crankshaft gear (4) - intermediate gear 1........................................................................ 0.050 - 0.187 mm
Intermediate gear 1 - intermediate gear 2 (1) .................................................................. 0.051 - 0.175 mm
Intermediate gear 1 - oil pump drive gear (2) ................................................................... 0.053 - 0.190 mm
Service products

TIMING GEARS
WARNING
Special tools
• Blocking the engine

[141] Gear ratchet 80.99627-0001

TIMING GEARS
Removing and installing the Setting the timing gears to the mark
intermediate gears
Fixing the crankshaft gear
• Crank the engine with the Engine barring

gear [140] and the Gear ratchet [141] until
the marks on the camshaft gear (1) and on the
• Fix the crankshaft gear (2) using two mounting crankshaft gear (2) match up
bolts (1) • Block the Engine barring gear [140]
Attaching the engine barring gear Undoing the oil pump drive gear mounting nut
• Remove the cover from the ywheel housing • Undo the mounting nut (1)
ywheel housing Removing intermediate gear 2

• Remove the intermediate gear pin (2) and
intermediate gear (3)

TIMING GEARS
Removing intermediate gear 1 Installing the oil pump drive gear
• Mark the installation position of the mounting bolts • Thinly apply Loctite 648 sealing compound on the
(1) and (2) cone in the drive gear for the oil pump (2) and on
• Unscrew the mounting bolts (1) and (2) the oil pump
• Remove the intermediate gear pin (3) and • Fit the drive gear for the oil pump (2)
intermediate gear (4) • Screw on the mounting nut (1)
Removing the oil pump drive gear Mounting intermediate gear 1
• Unscrew the mounting nut (1) • Thinly apply clean engine oil on the intermediate
• Pull off the drive gear for the oil pump (2) gear pin (3)
• Position the intermediate gear pin (3) with the
intermediate gear (4)
and (2) as marked

TIMING GEARS
Mounting intermediate gear 2 Removing and installing the camshaft

gear and crankshaft gear
Unscrewing the camshaft gear mounting bolts
• Thinly apply clean engine oil on the intermediate

gear pin (2)
• Position the intermediate gear pin (2) with the
intermediate gear (3) • Unscrew the mounting bolts (1)
Removing the camshaft gear
Tightening the oil pump drive gear mounting nut
• Pull the camshaft gear (1) off the camshaft (2)

• Tighten the mounting nut (1) to 45 Nm
Mounting the camshaft gear
• Line up the marks on the camshaft gear (1) and

crankshaft gear
• Line up the camshaft (2) with the hole pattern for
the camshaft gear (1), as necessary
• Place the camshaft gear (1) over the guide pin and
onto the camshaft (2)

TIMING GEARS
Screwing in the camshaft gear mounting bolts Fitting the crankshaft gear
• Screw in new mounting bolts (1) and tighten to 65 • Apply a thin coat of Loctite 574 sealing compound
Nm on the back of the crankshaft gear (1)
• Line up the marks on the camshaft gear and
Unscrewing the crankshaft gear mounting bolts crankshaft gear (1)
• Place the crankshaft gear (1) over the guide pin
(3) and onto the crankshaft (2)
Fixing the crankshaft gear
• Release the crankshaft gear (2) by unscrewing the

mounting bolts (1)
Removing the crankshaft gear

• Fix the crankshaft gear (2) using two mounting
bolts (1)
• Pull the crankshaft gear (1) off the crankshaft (2)

• Clean the contact surfaces of the crankshaft gear
(1), crankshaft (2) and guide pin (3)

TIMING GEARS
Checking the overlap marking
• Release the Engine barring gear [140] and turn

the crankshaft through 720°
• Check that the marks on the camshaft gear (1) and
crankshaft gear (2) match up
If the marks do not match up, remove the camshaft
gear (1) and then re-insert it as marked.
Unscrewing the crankshaft gear mounting bolts
• Release the crankshaft gear (2) by unscrewing the

mounting bolts (1)

ywheel housing

ENGINE LUBRICATION
ENGINE LUBRICATION
(1) O-rings (8) Pressure-relief valve

(2) Oil cooler (9) Oil intake pipe
(3) Gasket (10) Covering pan
(4) Pressure transmitter (11) Mounting bolt
(5) Oil module (12) Oil pump
(6) Gasket (13) Coupling sleeve
(7) Oil sump

ENGINE LUBRICATION
OIL MODULE
Removing and installing the oil module

(2) Oil module (8) Screw plug
(3) Pressure transmitter (9) Gasket
(4) Sealing ring (10) Gasket
(5) Screw-in tting (11) Oil cooler
(6) Mounting bolt
Technical data
Oil lter cover .................................................................................................................................25 Nm
Mounting bolt (1) .................................................. M6x20 ...............................................................12 Nm
Pressure transmitter (3) ........................................ M18x1.5 ............................................................47 Nm
Screw-in tting (5) ................................................ M30x1.5 ............................................................60 Nm
Screw plug (8) ...................................................... M18x1.5 ............................................................42 Nm
Service products
WARNING

ENGINE LUBRICATION
Special tools
[142] Oil lter wrench 80.99606-0581
• Removing and installing the oil lter cover

ENGINE LUBRICATION
Removing the oil lter Installing the oil lter

Removing the oil lter
• Insert the new oil lter (3) into the oil lter cover (2)
• Screw the oil lter cover (2) into the oil module (4)
• Unscrew the oil lter cover (2) from the oil module with the Oil lter wrench [142] (1) and tighten to 25
(4) with the Oil lter wrench [142] (1) Nm
• Pull the oil lter (3) out of the oil lter cover (2)
Renewing the sealing rings
• Remove the O-ring (4) from the oil lter cover (3)
• Remove the O-rings (1) and (2)
• Fit the new O-ring (4) on the oil lter cover (3)
• Fit new O-rings (1) and (2)
• Thinly apply clean engine oil on the O-rings (1),
(2) and (4)

ENGINE LUBRICATION
Removing the oil module Detaching the oil module
Draining the coolant
Note
If the screw-in tting has come loose, it
WARNING must be unscrewed.
Danger of engine damage due to oil
emulsion
• Unscrew the pressure transmitter (1) and remove
• Drain all the coolant before removing
with the sealing ring (2)
the oil module, otherwise coolant will
• Unscrew and clean the screw-in tting (3) if
enter the oil sump when the oil module
necessary
is removed from the crankcase
(4)
• Unscrew the screw plug (1) and remove with the
sealing ring
• Remove the oil module (5) with gasket (6)
• Drain the coolant
Disconnecting the pressure transmitter
Removing the oil cooler
• Disconnect the electrical connection (1) for the • Put the oil module (3) aside so as not to damage
pressure transmitter (2) the oil cooler (4)
• Remove the oil cooler (4) with gasket (2) from the
oil module (3)

ENGINE LUBRICATION
Installing the oil module Connecting the pressure transmitter electrical

connection
Installing the oil cooler

• Insert the oil cooler (4) with a new gasket (2) into pressure transmitter (2)
the oil module (3)
• Screw in new mounting bolts (1) and tighten to 12 Screwing in the screw plug
Nm
Mounting the oil module
• Screw in the screw plug (1) with a new sealing ring

• Tighten the screw plug (1) to 42 Nm
• Position the oil module (5) with a new gasket (6)

• If necessary, thinly apply Loctite 2701 sealing
compound on the outer thread of the screw-in
tting (3)
• If necessary, screw the screw-in tting (3) into the
oil module and tighten it to 60 Nm
pressure transmitter (1)
• Screw the pressure transmitter (1) with a new
sealing ring (2) into the screw-in tting and then
tighten to 47 Nm

ENGINE LUBRICATION
OIL SUMP AND OIL INTAKE PIPE

Removing and installing the oil sump and oil intake pipe (Euro 4 variant)
Additional jobs
(1) Covering pan (6) Oil sump

(2) Mounting bolt (7) Absorber mat
(3) Spacer (8) Holding piece
(4) Crankcase yoke (9) Mounting bolt
(5) Gasket
Technical data
Oil level sensor..................................................... M18x1.5 ............................................................25 Nm
Oil drain plug........................................................ M22x1.5-5.8 ......................................................75 Nm
WARNING

ENGINE LUBRICATION
Removing the oil sump and oil intake Removing the covering pan
pipe
Disconnecting the oil level sensor electrical
connection

• Free, set aside and secure the wiring harness for
the oil level sensor (1)
Removing the oil level sensor

• Remove the covering pan (2) with the absorber
mat (1) and spacers (4)
• Unscrew the oil level sensor (1) and remove with

the sealing ring (2)

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

sealing ring (2)
• Remove the pressure spring (3) with piston (4)
from the crankcase

• Remove the holding pieces (1)
• Remove the oil sump (3)
• Pull the gasket (4) off the oil sump (3)
Removing the oil intake pipe

• Pull the oil intake pipe (3) out of the crankcase
yoke (1)
• Remove the O-ring (2) from the crankcase yoke
(1)

ENGINE LUBRICATION
Installing the oil sump and oil intake pipe Mounting the oil sump
Installing the oil excess pressure valve
• Thinly apply clean engine oil on the piston (4)

• Insert the piston (4) with pressure spring (3) into
the crankcase
• Screw in the screw plug (2) with a new sealing ring
(1) and tighten it
Installing the oil intake pipe
• Fit a new gasket (4) on the oil sump (3)

• Position the oil sump (3)
• Fit the holding pieces (1)
them by hand
• Thinly apply clean engine oil on the new O-ring (2)

and insert into the crankcase yoke (1)
• Insert the oil intake pipe (3) into the crankcase
yoke (1)

ENGINE LUBRICATION
Mounting the covering pan Connecting the oil level sensor electrical
connection
• Route the wiring harness for the oil level sensor

(1) so that it is not under tension, not kinked and
there are no chang points
• Insert the absorber mat (1) into the covering pan

(2)
• Position the covering pan (2) with spacers (4)
Installing the oil level sensor

oil level sensor (1)
• Screw in the oil level sensor (1) with a new sealing
ring (2) and then tighten it to 25 Nm

ENGINE LUBRICATION
Removing and installing the oil sump lower section (Euro 5 and EEV variant)
(1) Oil sump upper section (4) Holding piece

(3) Oil sump lower section
WARNING

ENGINE LUBRICATION
Removing the oil sump Installing the oil sump

Removing the oil sump Installing the oil intake pipe
• Position the oil intake pipe (3) with a new gasket

(2)
by hand
• Position the pipe clamp with washer on the oil
sump upper section (1)
• Remove the covering pan

• Remove the holding pieces (3)
• Remove the oil sump (2) with the gasket (1)
Removing the oil intake pipe
• Unscrew the mounting bolt (5) and remove it with

the washer
• Remove the oil intake pipe (3) with gasket (2) from
the oil sump upper section (1)

ENGINE LUBRICATION
Installing the oil sump
• Fit a new gasket (1) on the oil sump (2)

• Position the oil sump (2)
• Position the holding pieces (3)
• Mount the covering pan

ENGINE LUBRICATION
Removing and installing the oil sump upper section (Euro 5 and EEV variant)
Additional jobs
– Removing and installing the oil sump lower section (Euro 5 and EEV variant), see 344
– Removing and installing the intercooler, see 205
(1) Mounting bolt (3) Crankcase

(2) Oil sump upper section
Technical data
Oil level sensor..................................................... M18...................................................................45 Nm
Service products
WARNING

ENGINE LUBRICATION
Removing the oil sump upper section Removing the oil level probe
• Disconnect the electrical connection for the oil

level probe (1)
• Unscrew the union nut (1) • Unscrew the oil level probe (1) and remove the
• Unscrew the mounting bolt (3) sealing ring (2)
• Remove the oil return line (2) with the gasket (5) Removing the oil sump

• Remove the oil sump (2) from the crankcase (3)
the sealing rings (1) and (5)
• Remove the oil return line (2) with the gasket

ENGINE LUBRICATION
Installing the oil sump upper section Attaching the oil return line
Mounting the oil sump upper section
• Position the oil return line (2) with a new gasket

• Thinly apply Loctite 5900 sealing compound on by hand
the contact surfaces of the crankcase (3) • Screw in the hollow screw (4) with new sealing
• Position the oil sump (2) on the crankcase (3) rings (1) and (5) and then tighten it
• Screw in and tighten the mounting bolts (1) • Tighten the mounting bolts (3)
Installing the oil level probe Attaching the oil return line
• Screw in the oil level probe (1) with a new sealing • Install the oil return line (2) with a new gasket (5)
ring (2) and tighten it to 45 Nm • Screw in the mounting bolts (4) and tighten them
• Connect the electrical connection for the oil level by hand
probe (1) • Screw in the mounting bolt (3) and tighten it by
hand
• Tighten the union nut (1)

ENGINE LUBRICATION
OIL PUMP
Removing and installing the oil pump
Additional jobs

ENGINE LUBRICATION
(1) Oil pump gear (4) O-rings

(2) Oil pump gear (5) Coupling sleeve
(3) Oil pump housing
Technical data
Oil pump gear axial play................................................................................................. 0.050 - 0.114 mm
Radial play, oil pump shaft ............................................................................................. 0.050 - 0.078 mm
WARNING
Special tools
[143] Straightedge 80.99605-0167
• Checking the oil pump gear axial play

ENGINE LUBRICATION
Removing the oil pump Checking the oil pump gear axial play
Unscrewing the oil pump mounting bolts
• Place the Straightedge [143] (3) with measuring

edge on the oil pump housing (4)
• Unscrew the mounting bolts (1) • Check the axial play between the oil pump gears
(2) and the Straightedge [143] using a feeler gauge
Detaching the oil pump (1)
The permitted axial play is 0.050 - 0.114 mm
Dismantling the oil pump
• Pull the coupling sleeve (1) out of the oil pump (3)
• Pull the oil pump (3) out of the timing case
• Remove the O-rings (2) from the coupling sleeve
(1) • Pull the oil pump gears (1) and (3) out of the oil
pump housing (2)

ENGINE LUBRICATION
Installing the oil pump Screwing in the oil pump mounting bolts
Assembling the oil pump

• Check that the oil pump gears run freely; repeat
Note the above procedure if necessary
Each of the oil pump gears is marked with
a point on one of the teeth on the face of
the gear.
• Thinly apply clean engine oil on the oil pump gears

(1) and (3)
• Insert the oil pump gears (1) and (3) into the oil
pump housing (2) so that the marks are in line
Mounting the oil pump
• Thinly apply clean engine oil on the new O-rings

(2)
• Fit the O-rings (2) on the coupling sleeve (1)
• Insert the coupling sleeve (1) into the oil pump (3)
until the stop is reached
• Insert the oil pump (3) into the timing case

ENGINE LUBRICATION
OIL INJECTOR NOZZLES

Removing and installing the oil injector nozzles
Additional jobs
– Draining and topping up the engine oil
(1) Oil injector nozzle (3) Oil pressure valve

(2) Spring washer
Technical data
Oil pressure valve (3)............................................ M12...................................................................40 Nm

ENGINE LUBRICATION
WARNING

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

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

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

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

CRANK MECHANISM
CRANK MECHANISM
(1) Flywheel (4) Vibration damper

(2) Crankshaft (5) Connecting rod
(3) Bearing cap (6) Piston

CRANK MECHANISM
VIBRATION DAMPER
Removing and installing the vibration damper
Additional jobs
(1) Mounting bolt (4) Poly-V-belt pulley

(2) Washer (5) Vibration damper
(3) Mounting bolt
Technical data
Mounting bolt (1) .................................................. M14x1.5x95-10.9 ..........................Initial torque 150 Nm
Mounting bolt (1) .................................................. M14x1.5x95-10.9 .................................Final torque 90°
WARNING

CRANK MECHANISM
Note
An oil slinger is mounted on the rear of the vibration damper. When removing and installing the
vibration damper, check the oil slinger for damage and, if necessary, replace it.
Special tools
• Barring the engine

CRANK MECHANISM
Removing the vibration damper Installing the vibration damper

Attaching the engine barring gear Mounting the vibration damper
• Remove the cover from the ywheel housing • Position the vibration damper (3) with washer (2)
• Mount and lock the Engine barring gear [144] (1) • Screw in new mounting bolts (1) and tighten to
Initial torque 150 Nm
Removing the poly-V-belt pulley • Tighten the mounting bolts (1) to Final torque 90°
• Mark the installed position of the poly-V-belt pulley

(2) relative to the vibration damper (3)
• Unscrew the mounting bolts (1) • Position the poly-V-belt pulley (2) on the vibration
• Remove the poly-V-belt pulley (2) damper (3) as marked
Removing the vibration damper

• Remove the vibration damper (3) with washer (2)

CRANK MECHANISM
• Release and remove the Engine barring gear [144]

(1)

CRANK MECHANISM
FLYWHEEL FOR MANUAL GEARBOX

Removing and installing the ywheel for manual gearbox
(1) Flywheel (3) Flywheel housing

(2) Mounting bolt
Technical data, ywheel housing without power take-off

Lateral runout, ywheel (1)....................................................................................................Max. 0.5 mm
Flywheel ring gear installation temperature .............................................................................220 - 240 °C
Technical data, ywheel housing with power take-off

WARNING

CRANK MECHANISM
Special tools
[145] Internal extractor 08.99615-1410
• Pulling out the clutch pilot bearing in conjunction

with:
• Internal extractor [145]
[146] Support 08.99615-0015
• Extracting the clutch pilot bearing
[147] Dial gauge 08.71000-3217
• Checking the ywheel lateral runout in

conjunction with:
• Locating pin [149]
• Checking the ywheel lateral runout
[149] Locating pin 80.99605-0197
• Checking the ywheel lateral runout
[150] Pressing plate 80.99604-0302
• Pressing in the clutch pilot bearing in conjunction

with:
• Thrust disc [151]
• Plug-on handle [152]
[151] Thrust disc 80.99617-0144
• Pressing in the clutch pilot bearing
[152] Plug-on handle 80.99617-0187
• Pressing in the clutch pilot bearing

CRANK MECHANISM
[153] Guide pin 80.99617-0163
• Removing and installing the ywheel
• Undoing and tightening the ywheel mounting

bolts in conjunction with:
• Support [156]
• Stop pin [158]
• Washer [162]
[155] Socket, size 22 80.99612-0024

bolts
[156] Support 80.99606-0551

bolts

bolts
[158] Stop pin 80.99606-0585

bolts
[159] Pan head screw 06.02191-0407

bolts

CRANK MECHANISM
[160] Connecting pin 06.22729-0006

bolts
[161] Rubber ring 42 mm 08.06142-9006

bolts
[162] Washer 80.99609-0033

bolts

CRANK MECHANISM
Removing the ywheel Unscrewing the ywheel mounting bolts
• Unscrew two opposite-facing mounting bolts (1)
• Insert the Torque multiplier i = 1 : 3.3 [154] (1) into Screwing in the guide pins
the Support [156] (2)
• Mount the Stop pin [158] (5) on the Support [156]
(2) with the Pan head screw [159] (4) and
Washer [162] (3)
• Fit the Torque angle gauge [157] (9) on the Torque
multiplier i = 1 : 3.3 [154] (1)
• Fit the Socket, size 22 [155] (7) on the Torque
multiplier i = 1 : 3.3 [154] (1) and secure with
the Connecting pin [160] (8) and Rubber ring 42
mm [161] (6)
Undoing the ywheel mounting bolts
• Screw in the Guide pin [153] (1) and (2)

• Unscrew the remaining mounting bolts
Pulling off the ywheel
• Put the special tool (1) on the mounting bolt that is

going to be undone
• Undo all the mounting bolts
CAUTION
Danger of injury due to heavy
components
• Use lifting gear to remove the ywheel
• Pull off the ywheel (1) over the Guide pin [153]
(2)

CRANK MECHANISM
Cleaning the ywheel Removing and installing the ywheel

ring gear
Removing the ywheel ring gear
• Clean the ywheel

• Check the ywheel for cracks, t a new ywheel if
necessary
• Check the friction surface (1) for burns and traces WARNING
of running in; t a new ywheel if necessary Component damage due to
• Check the teeth (2) on the ywheel ring gear for spot-drilling of the ywheel
wear; t a new ywheel ring gear if necessary • Take care not to damage the ywheel
when spot-drilling the ywheel ring gear
• Renew the spot-drilled ywheel
• Spot-drill the ywheel ring gear (1) force it open

• Remove the ywheel ring gear (1) from the
ywheel (2)
• Clean the contact surfaces of the ywheel (2) and
check for damage
Mounting the ywheel ring gear
CAUTION
Danger of injury due to hot
components
• Mount the ywheel ring gear whilst
wearing protective gloves
• Heat the ywheel ring gear (1) to 220 - 240 °C

• Fit the ywheel ring gear (1) so that the chamfer
(3) on the teeth is facing away from the ywheel
(2) and then line up the holes in the ywheel ring
gear (1) with the ywheel (2)
• Adjust the ywheel ring gear (1) as necessary

CRANK MECHANISM
Installing the ywheel Unscrewing the aligning tools
Checking the ywheel lateral runout
• Screw in the new ywheel mounting bolts

• Unscrew the Guide pin [153] (1) and (2)
• Clamp the ywheel (1)
• Mount the Dial gauge holder [148] (2) with the Dial Screwing in the ywheel mounting bolts
gauge [147] (3) and Locating pin [149]
• Position the Locating pin [149] on the ywheel (1)
with a preload
• Zero the Dial gauge [147] (3)
• Turn the ywheel (1) a few turns and, at the same
time, read off the deection of the Dial gauge [147]
(3)
The permitted lateral runout of the ywheel (1) is
Max. 0.5 mm.
If the lateral runout is out of tolerance, t a new

ywheel (1).
Fitting the ywheel
• Screw in the new mounting bolts (1)
CAUTION
components
• Use lifting gear to install the ywheel
• Line up the ywheel (1) with the crankshaft

alignment pin
• Fit the ywheel (1) over the Guide pin [153] (2)

CRANK MECHANISM
Tightening the mounting bolts Removing the clutch pilot bearing

Removing the circlip
Note
• Detach the circlip (2) using internal circlip pliers (1)
3.3 [154].
Mounting the extractor device
• Tighten the mounting bolts to Initial torque 100 Nm
using the special tool (1)
• Tighten the mounting bolts to Final torque 90°
• Insert the Internal extractor [145] (2) into the clutch

pilot bearing and expand as far as the stop
• Mount the Support [146] (1) on the Internal
extractor [145] (2)
Extracting the clutch pilot bearing
• Extract the clutch pilot bearing (2) using the special

tool (1)

CRANK MECHANISM
Installing the clutch pilot bearing

Pressing in the clutch pilot bearing
• Assemble the special tool (1), consisting of

Plug-on handle [152], Thrust disc [151] and
Pressing plate [150]
• Use the special tool (1) to press the new clutch
pilot bearing (2) into the ywheel until the stop is
reached
Installing the circlip
• Attach the circlip (2) using internal circlip pliers (1)

CRANK MECHANISM
PISTONS AND CONNECTING RODS

Removing and installing the pistons and connecting rods
Additional jobs

CRANK MECHANISM
(1) Connecting rod bearing bolt (6) Piston

(2) Connecting rod bearing cap (7) Keystone ring
(3) Connecting rod (8) Taper-face ring
(4) Circlip (9) Double-bevelled ring
(5) Piston pin
Technical data
Connecting rod bearing bolt (1) ............................. M11x1.5x60-11.9............................ Initial torque 55 Nm
Connecting rod bearing bolt (1) ............................. M11x1.5x60-11.9..................................Final torque 90°
Connecting rod
Connecting rod length, piston pin bushing centre - connecting rod bearing centre ................. 196 ± 0.02 mm
Inside diameter, connecting rod eye......................................................................... Ø 44.050 - 44.066 mm
Hole for bearing shells in connecting rod (connecting rod big end)............................. Ø 74.000 - 74.019 mm
Weight difference per set of connecting rods in an engine........................................................... Max. 50 g
Connecting rod bearings

Connecting rod bearing........................................................................................... Ø 69.981 - 70.000 mm
Wall thickness of connecting rod bearing shells

Connecting rod bearing shell thickness .................. Normal ............................................. 1.975 - 1.987 mm
Connecting rod bearing shell thickness .................. Normal size 1.................................... 2.025 - 2.037 mm
Connecting rod bearing shell thickness .................. Repair level 1.................................... 2.100 - 2.112 mm
Connecting rod bearing shell spread......................................................................................Max. 1.5 mm
Piston diameter
D1 measured 17 mm above lower edge of piston .....................................................107.851 - 107.860 mm
D3 measured 84.9 mm above piston bottom edge....................................................107.573 - 107.564 mm

CRANK MECHANISM
Piston diameter, Nüral piston class A without cooling duct

D2 measured 59 mm above lower edge of piston ............................................... (DNeff - 0.115) ± 0.007 mm
D3 measured 84.9 mm above lower edge of piston ............................................ (DNeff - 0.277) ± 0.012 mm
Piston diameter, Nüral piston Class B without cooling duct

Piston diameter, Nüral piston class A with cooling duct

Piston diameter, Nüral piston class B with cooling duct

Piston diameter, KS piston class A with cooling duct

Piston diameter, KS piston class B with cooling duct

Piston height
Overall height..........................................................................................................................103.00 mm
Piston height (centre of piston pin - piston crown)............................................................ 63.85 - 63.90 mm
Piston ring (keystone ring)

Piston ring height..................................................................................................... 3 mm (nominal value)
Piston ring width ................................................................................................................ 4.25 - 4.60 mm
Ring gap ........................................................................................................................... 0.35 - 0.50 mm
Piston ring (taper faced ring)

Piston ring height............................................................................................................... 2.47 - 2.50 mm
Ring gap ........................................................................................................................... 0.50 - 0.65 mm
Axial play .......................................................................................................................... 0.06 - 0.11 mm
Piston ring (double-bevelled ring)

Ring gap ........................................................................................................................... 0.30 - 0.60 mm
Axial play, KS piston .......................................................................................................... 0.05 - 0.09 mm
Axial play, Nüral piston....................................................................................................... 0.03 - 0.07 mm
Piston pin
Piston pin diameter................................................................................................. Ø 43.994 - 44.000 mm
Radial play in connecting rod ......................................................................................... 0.050 - 0.072 mm
Radial play in piston ...................................................................................................... 0.006 - 0.021 mm
Piston standout
Piston standout (crankcase - piston) ............................................................................... 0.087 - 0.389 mm

CRANK MECHANISM
Piston weight
Piston weight difference per set in one engine............................................................................ Max. 40 g
WARNING
Crack surfaces are sensitive. The principle involved can cause chipping
• Exchange the connecting rod if the crack surfaces are damaged
• Protect crack surfaces against damage caused by hard and sharp objects
• To clean the crack surfaces on the connecting rods, always rinse them in clean cleaning agent
• After cleaning, use compressed air to blow-dry the crack surfaces
• Do not allow rinsed-out particles to enter the engine
WARNING
Note
The piston diameter is always measured perpendicular to the piston pin bore.
Pistons are identied with A or B.
Special tools
[163] Piston ring pliers 83.09144-6090
• Removing and installing piston rings
[164] Feeler gauge 08.75310-0806
• Checking the piston ring axial play and ring play
[165] Dial gauge 08.71000-3217
• Checking the piston pin bushing

• Checking the piston standout in conjunction with:
• Dial gauge stand [166]
[166] Dial gauge stand 80.99605-0172
• Checking the piston standout
[167] Piston ring compressor 80.99613-0039
• Installing the piston

CRANK MECHANISM
[168] Setting tool 80.99622-0052
• Aligning the connecting rod bearing shells
[169] Depth gauge (electronic) 08.71195-9003
• Checking the piston ring insertion depth

CRANK MECHANISM
Removing pistons and connecting rods Removing and checking the piston
Removing the connecting rod bearing cap Removing the piston pin
WARNING • Mark the relative positions of the piston (3), piston

Crack surfaces are sensitive. The pin (2) and connecting rod (5)
principle involved can cause chipping • Detach the circlips (1) and (4)
• Exchange the connecting rod if the • Press the piston pin (2) out of the piston (3)
crack surfaces are damaged • Remove the piston (3) from the connecting rod (5)
• Protect crack surfaces against damage
Checking the piston pin diameter
caused by hard and sharp objects
• Mark the connecting rod bearing cap (2) and

connecting rod bearing shells (1) to indicate
correct assignment and installation position
• Unscrew the connecting rod bearing bolts (3)
• Remove the connecting rod bearing cap (2)
with connecting rod bearing shell (1) from the
crankshaft
• Push the piston and connecting rod out in the
direction of the cylinder head
Removing the piston
• 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.
If the diameter is out of tolerance, t a new piston

with piston pin (1).
• Extract the piston (1) with connecting rod from the

crankcase (2)
• Mark the connecting rod and connecting rod
bearing shell to indicate their installation position
and assignment
• Remove the connecting rod bearing shell from the
connecting rod

CRANK MECHANISM
Checking the piston ring axial play Checking the piston ring gap
Note Note
An axial play cannot be measured on the The ring gap is only allowed to be
keystone ring. checked if the piston bore has the correct
inside diameter, otherwise a false ring
• Measure the axial play between the piston rings gap reading would be obtained.
(1) and (2) and the piston (3) using the Feeler Check the piston bore inside diameter.
gauge [164] (4)
The permitted taper-face ring (1) axial play is • Insert the piston ring (3) evenly deep into the piston
0.06 - 0.11 mm. bore (1)
• Check even insertion depth of the piston ring (3)
The permissible axial play on the double-bevelled using Depth gauge (electronic) [169]
ring (2) is 0.05 - 0.09 mm for KS pistons and • Use the Feeler gauge [164] (2) to check the ring
0.03 - 0.07 mm for Nüral pistons. gap
The permitted keystone ring gap is 0.35 - 0.50 mm.
If the axial plays are out of tolerance, t a new piston
(3) with piston rings (1), (2) and keystone ring. The permitted taper-face ring gap is 0.50 - 0.65 mm.
Removing the piston rings The permitted double-bevelled ring gap is 0.30 - 0.60
mm.
If the ring gaps are out of tolerance, t new piston

rings.
• Set the Piston ring pliers [163] (1) to the piston

diameter
• Detach the piston rings (2) from the piston (3)
using Piston ring pliers [163] (1)
• Carefully clean the piston ring grooves

CRANK MECHANISM
Checking the connecting rods and Checking the connecting rod bearing inside
connecting rod bearings diameter
Checking the connecting rod bearing shell

spread
• Insert the upper connecting rod bearing shell into

the connecting rod (2) as marked
• Insert the lower connecting rod bearing shell into
the connecting rod bearing cap (3) as marked
Note
• Screw in the connecting rod bearing bolts and
The difference between dimension A and
tighten them to Initial torque 55 Nm
dimension B gives the connecting rod
• Use the Dial gauge [165] (4) with the internal
bearing shell spread.
calliper (1) to check the connecting rod bearing
inside diameter
• Clean the connecting rod bearing shells (2) and
The permitted inside diameter of the connecting rod
put them together on a at surface as marked
bearing is Ø 69.981 - 70.000 mm.
• Check dimension A using a micrometer (1)
• Check dimension B using a micrometer (1) If the inside diameter is out of tolerance, t new
The permissible spread of the connecting rod connecting rod bearing shells.
bearing shells (2) is Max. 1.5 mm.
If the spread is out of tolerance, t new connecting

rod bearing shells (2).
Checking the piston pin bushing
• Use the internal calliper (3) and Dial gauge [165]

(2) to check the piston pin bushing inside diameter
The permitted piston pin bushing inside diameter is
Ø 44.050 - 44.066 mm.
If the inside diameter is out of tolerance, t a new

connecting rod (1).

CRANK MECHANISM
Installing pistons and connecting rods Installing the piston pin
Installing the piston rings
• Attach a new circlip (4) in the groove in the piston

(3)
WARNING • Fit the piston (3) over the connecting rod (5) as
Piston rings can break marked
• Install piston rings using correctly set • Thinly apply clean engine oil on the piston pin (2)
piston ring pliers • Push the piston pin (2) through the piston (3) and
the connecting rod (5) as marked until the stop is
• Set the Piston ring pliers [163] (1) to the piston reached
diameter • Attach a new circlip (1) in the groove in the piston
• Use the Piston ring pliers [163] (1) to insert the (3)
piston rings (2) into the corresponding ring groove • Check that the circlips (1) and (4) are seated
in the piston (3), ensuring that the TOP mark is correctly
facing the piston crown If the circlips (1) and (4) have not engaged correctly,
remove and re-attach the circlips (1) and (4),
ensuring that they are seated correctly.

CRANK MECHANISM
Piston installation with piston ring compressor Mounting the connecting rod bearing cap
band
WARNING
Note Crack surfaces are sensitive. The
There is an installation arrow on the principle involved can cause chipping
piston surface. This must point towards • Exchange the connecting rod if the
the coolant pump during installation. crack surfaces are damaged
• Protect crack surfaces against damage
• Move the crankshaft for the cylinder concerned to caused by hard and sharp objects
TDC
• Line up the gaps in the piston rings at 120° offset • Insert the lower connecting rod bearing shell (1)
to one another into the connecting rod bearing cap (2)
• Thinly apply clean engine oil on the upper • Check the alignment of the lower connecting rod
connecting rod bearing shell bearing shell (1) and, if necessary, adjust with
• Insert the upper connecting rod bearing shell into Setting tool [168]
the connecting rod • Thinly apply clean engine oil on the lower
• Thinly apply clean engine oil on the piston (1) connecting rod bearing shell (1)
• Place the Piston ring compressor [167] (2) onto • Position the connecting rod bearing cap (2) on the
the piston (1) and clamp connecting rod as marked
• Push the piston (1) with connecting rod into the • Screw in the new connecting rod bearing bolts (3)
piston bore until the piston (1) has been pushed and tighten to Initial torque 55 Nm
out of the Piston ring compressor [167] (2) • Tighten the connecting rod bearing bolts (3) to
• Push in the piston (1) until the connecting rod Final torque 90°
with connecting rod bearing shell is lying on the
crankshaft

CRANK MECHANISM
Checking the piston standout
• Move the piston (2) to TDC

• Mount the Dial gauge [165] (3) with the Dial gauge
stand [166] (5)
• Locate the dial gauge tip (1) on the crankcase (4)
and zero the Dial gauge [165] (3)
• Locate the dial gauge tip (1) on the piston (2) and
read off the difference (piston standout)
The permitted piston standout is 0.087 - 0.389 mm.

CRANK MECHANISM
CRANKSHAFT
Removing and installing the crankshaft
Additional jobs
– Removing and installing the ywheel housing (variant without power take-off), see 415
– Removing and installing the pistons and connecting rods, see 375

CRANK MECHANISM
(1) Crankshaft bearing shell (5) Thrust washer

(2) Crankshaft bearing shell (6) Crankshaft
(3) Bearing cap (7) Thrust washer
(4) Mounting bolt (8) Crankcase
Technical data
Mounting bolt (4) .................................................. M14x118-10.9 ...............................Initial torque 115 Nm
Mounting bolt (4) .................................................. M14x118-10.9 ......................................Final torque 90°
Crankshaft
Hardness, crankshaft (6)......................................................................................................... 53 ± 3 HRC
Permitted curvature of journals...................................................................................................0.004 mm
Axial play, crankshaft (6) ................................................................................................ 0.200 - 0.395 mm
Connecting rod bearing journal................................................................................ Ø 69.981 - 70.000 mm
Crankshaft bearing journal ...................................................................................... Ø 86.981 - 87.000 mm
Crankshaft bearing
Crankshaft bearing inside diameter ......................................................................... Ø 89.520 - 89.554 mm
Wall thickness of crankshaft bearing shells (1), (2) .......................................................... 2.468 - 2.480 mm
Wall thickness, thrust washers (5), (7) ............................................................................ 2.850 - 2.900 mm
Crankshaft bearing spread ....................................................................................................Max. 1.5 mm
WARNING

CRANK MECHANISM
Special tools
[170] Locating pin 80.99605-0197
• Checking the crankshaft axial play in conjunction

with:
• Dial gauge [171]
• Dial gauge stand [172]
[171] Dial gauge 08.71000-3217
• Checking the crankshaft axial play
[172] Dial gauge stand 08.71082-0005
• Checking the crankshaft axial play
[173] Socket, size 22 80.99612-0024
• Undoing and tightening the bearing cap mounting

bolts in conjunction with:
• Support [175]
• Torque multiplier i = 1 : 3.5 [174]
• Stop pin [177]
• Washer [181]

bolts
[175] Support 80.99606-0551

bolts

bolts

CRANK MECHANISM
[177] Stop pin 80.99606-0585

bolts
[178] Pan head screw 06.02191-0407

bolts
[179] Connecting pin 06.22729-0006

bolts
[180] Rubber ring 42 mm 08.06142-9006

bolts
[181] Washer 80.99609-0033

bolts
[182] Setting tool 80.99622-0052
• Aligning the crankshaft bearing shells

CRANK MECHANISM
Removing the crankshaft Undoing the bearing cap mounting bolts
Checking the crankshaft axial play
• Place the special tool (1) onto the mounting bolt

that is going to be undone
• Mount the Dial gauge stand [172] (2) with the Dial • Undo all the mounting bolts
gauge [171] (1) and the Locating pin [170]
• Position the Locating pin [170] on the crankshaft Removing the bearing cap
(3) with a preload
• Push the crankshaft (3) horizontally into the end
position towards the ywheel housing
• Zero the Dial gauge [171] (1)
• Pull the crankshaft (3) into the end position,
towards Dial gauge [171] (1), and read off the
difference
The permitted axial play on the crankshaft (3) is
0.200 - 0.395 mm.
If the axial play is out of tolerance, install new thrust

washers.
• Mark the bearing cap (2) to indicate its installation

position and correct assignment
• Remove the bearing cap (2)
• Mark the crankshaft bearing shell (3) to indicate its
installation position and correct assignment and
then remove it
• Repeat the work step for bearing caps 2, 3, 5 and
7
• Insert the Torque multiplier i = 1 : 3.5 [174] (1) into

the Support [175] (2)
• Mount the Stop pin [177] (5) with Pan head
screw [178] (4) and Washer [181] (3) on the
Support [175] (2)
• Put the Torque angle gauge [176] (9) on the Torque
multiplier i = 1 : 3.5 [174] (1)
• Put the Socket, size 22 [173] (7) on the Torque
multiplier i = 1 : 3.5 [174] (1) and secure with the
Connecting pin [179] (8) and the Rubber ring 42
mm [180] (6)

CRANK MECHANISM
Removing the bearing cap axial washers Removing the crankshaft
CAUTION
components
• Remove the crankshaft with support
WARNING
Component damage due to unsuitable
lifting gear
• Do not use steel cables or other
sharp-edged tools to lift out the
crankshaft
• Lift the crankshaft (2) out of the crankcase (1)

• Mark the crankshaft bearing shells to indicate their
• Mark the bearing cap (2) to indicate its installation installation position and correct assignment and
position and correct assignment then remove them from the crankcase (1)
• Remove the bearing cap (2) with thrust washers
(1) and (4)
• Mark the crankshaft bearing shells to indicate their
installation position and correct assignment and
then remove them
Removing the upper thrust washers
• Remove the thrust washers (2) from bearing seat

4 (1)

CRANK MECHANISM
Checking the crankshaft and crankshaft Checking the crankshaft bearing inside diameter
bearings
Checking the crankshaft bearing spread
• Insert the upper and lower crankshaft bearing shell

into the bearing seat as marked
• Fit the bearing cap (3) as marked
Note • Screw in the mounting bolts for the bearing cap (3)
The difference between dimension A and and tighten them to Initial torque 115 Nm
dimension B is the spread or expansion • Use the internal calliper (2) and Dial gauge [171]
of the crankshaft bearings. (1) to check the crankshaft bearing
• Repeat the check several times at 120° offset
• Clean the crankshaft bearing shells (2) and put • Remove the bearing cap (3) again after the check
them together on a at surface as marked The permitted crankshaft bearing inside diameter is
• Check dimension A using a micrometer (1) Ø 89.520 - 89.554 mm.
• Check dimension B using a micrometer (1)
If the inside diameter is out of tolerance, t new
The permitted spread of the camshaft bearings is
crankshaft bearing shells.
Max. 1.5 mm.
Checking the outside diameter of the connecting
If the spread is out of tolerance, t new crankshaft
rod bearing journal
bearing shells (2).
• Clean the crankshaft connecting rod bearing

journal (2)
• Check the connecting rod bearing journal using a
micrometer (1)
• Repeat the check several times at 120° offset
The permitted outside diameter of the connecting
rod bearing journal is Ø 69.981 - 70.000 mm.
If the outside diameter is out of tolerance, t a new

crankshaft (2).

CRANK MECHANISM
Installing the crankshaft Installing the bearing cap axial washers
Installing the crankshaft
WARNING
Component damage due to unsuitable
lifting gear
• Do not use steel cables or other
sharp-edged tools to lift in the
crankshaft
• Thinly apply clean engine oil on the crankshaft

bearing shells
• Insert the crankshaft bearing shells into the
bearing seats as marked and align with the
Setting tool [182]
• Insert the crankshaft (2) into the crankcase (1) • Thinly apply clean engine oil on the crankshaft
bearing shell and thrust washers (1) and (4)
Installing the upper thrust washers • Insert the crankshaft bearing shell into the bearing
cap (2) as marked and align with the Setting
tool [182]
• Insert the thrust washers (1) and (4) into the
bearing cap (2) with the oil grooves facing the
crankshaft
• Fit the bearing cap (2) with thrust washers (1) and
(4) on bearing seat 4
them by hand
• Thinly apply clean engine oil on the thrust washers

(2)
• Insert the thrust washers (2) at bearing seat 4 with
the oil grooves facing the crankshaft (1)
• Insert the thrust washers (2) into the bearing seat
by pressing lightly

CRANK MECHANISM
Mounting the bearing cap
• Thinly apply clean engine oil on the crankshaft

bearing shell (3)
• Insert the crankshaft bearing shell (3) into the
bearing cap (2) as marked and align with the
Setting tool [182]
• Fit the bearing cap (2)
• Thinly apply clean engine oil on the contact
surface for the heads of the new mounting bolts
(1)
by hand
Tightening the bearing cap mounting bolts
Note
3.5 [174].
• Tighten the mounting bolts to Initial torque 115 Nm

• Tighten the mounting bolts to Final torque 90°
• Check the crankshaft for ease of movement
If the crankshaft cannot be turned or only turned
with difculty, remove the crankshaft with crankshaft
bearings.
Recheck the crankshaft bearings and the crankshaft

and, if necessary, t a new crankshaft or crankshaft
bearings.

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

(2) Timing case (5) Front crankshaft oil seal


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

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

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

conjunction with:
• Threaded spindle [185]
• Crossmember [187]
• Pressure plate [188]
• Hook [189]
• Installing the front crankshaft oil seal in
conjunction with:
• Hexagon collar nut [190]
[184] Pan head screw 06.02191-2713
• Removing and installing the front crankshaft oil

seal
[185] Threaded spindle 80.99606-0299

seal
[186] Hexagon nut 06.11065-2318

seal
[187] Crossmember 80.99606-0298
• Removing the front crankshaft oil seal
[188] Pressure plate 80.99609-0038

[189] Hook 80.99606-6013
[190] Hexagon collar nut 06.11222-0311
• Installing the front crankshaft oil seal
• Installing the front crankshaft oil seal

Removing the crankshaft oil seal Installing the crankshaft oil seal
Positioning the crankshaft oil seal
• Mount the Guide plate [183] (2) on the crankshaft

with the Pan head screw [184] (6)
• Screw the Pressure plate [188] into the Guide • Remove the Pressure plate [188]
plate [183] (2) • Place the new crankshaft oil seal (3) with transport
• Screw the Hexagon nut [186] (5) onto the sleeve (2) onto the Guide plate [183] (1)
Threaded spindle [185] and secure with a second • Push the crankshaft oil seal (3) onto the Guide
Hexagon nut [186] (5) plate [183] (1)
• Screw the Threaded spindle [185] into the • Remove the transport sleeve (2)
Crossmember [187] (4)
• Insert the Hook [189] (3) through the Pressing in the crankshaft oil seal
Crossmember [187] (4) at between the
crankshaft oil seal (1) and the crankshaft
• Turn the Hook [189] (3) through 90° so that the
recess of the Hook [189] (3) is facing outwards
• Extract the crankshaft oil seal (1) by screwing in
the Threaded spindle [185]
• Push the Installer sleeve [191] (2) onto the Guide

plate [183]
• Screw the Hexagon collar nut [190] onto the
Threaded spindle [185] (3)
• Screw the Threaded spindle [185] (3) into the
Guide plate [183]
• Press in the crankshaft oil seal (1) until the stop
is reached by screwing in the Hexagon collar
nut [190]

Removing and installing the rear crankshaft oil seal

Additional jobs
(1) Flywheel housing (2) Crankshaft oil seal
WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or grease before
installation
• Clean the crankshaft and insertion tool before assembly
WARNING

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

with:
• Crossmember [196]
• Hook [197]
• Pressure plate [198]
• Installing rear crankshaft oil seal in conjunction
with:
• Hexagon collar nut [200]
[193] Threaded spindle 80.99606-0299
• Removing and installing the rear crankshaft oil

seal
[194] Pan head screw 06.02191-2713

seal
[195] Hexagon nut 06.11065-2318

seal
[196] Crossmember 80.99606-0298
• Removing the rear crankshaft oil seal
[197] Hook 80.99606-6013

[198] Pressure plate 80.99609-0038
• Installing the rear crankshaft oil seal
[200] Hexagon collar nut 06.11222-0311
• Installing the rear crankshaft oil seal

Removing the crankshaft oil seal Installing the crankshaft oil seal
Mounting the special tool Positioning the crankshaft oil seal
• Mount the Guide plate [192] (4) on the crankshaft • Remove the Pressure plate [198]
with the Pan head screw [194] (6) • Unscrew the Pan head screw [194]
• Screw the Pressure plate [198] (5) into the Guide • Position the new crankshaft oil seal (1) with
plate [192] (4) transport sleeve (2) on the Guide plate [192] (3)
• Screw the Hexagon nut [195] onto the Threaded • Push the crankshaft oil seal (1) onto the Guide
spindle [193] and secure with a second Hexagon plate [192] (3)
nut [195] • Remove the transport sleeve (2)
• Screw the Threaded spindle [193] into the • Screw in the Pan head screw [194]
Crossmember [196] (2)
• Insert the Hook [197] (1) through the Pressing in the crankshaft oil seal
Crossmember [196] (2) at between the
crankshaft oil seal (3) and the crankshaft
• Turn the Hook [197] (1) through 90° so that the
recess of the Hook [197] (1) is facing outwards
• Insert the Crossmember [196] (2) into the
Hook [197] (1)
Extracting the crankshaft oil seal
WARNING
Component damage caused by
incorrect installation
• Ensure that the special tool is tted with
the recess downwards, above the curve
on the ywheel housing
• Push the Installer sleeve [199] (2) onto the Guide

• Extract the crankshaft oil seal (1) by screwing in
plate [192] with the recess facing downwards
the Threaded spindle [193] (2)
• Screw the Hexagon collar nut [200] (1) onto the
Threaded spindle [193]
• Screw the Threaded spindle [193] into the Guide
plate [192]
• Press in the crankshaft oil seal (3) until the stop
is reached by screwing in the Hexagon collar
nut [200] (1)

ENGINE HOUSING
ENGINE HOUSING
(1) Oil separator (5) Crankcase

(2) Mounting bolt (6) Timing case
(3) O-ring (7) Timing case cover
(4) Flywheel housing (8) Sealing ring

ENGINE HOUSING
CRANKCASE VENTILATION
Removing and installing the crankcase ventilation (variant LFL50/53)
(1) Insulating hose (8) Sealing ring

(2) Jubilee clip (9) Mounting bolt
(3) Vent line with pipe clamp (to intake (10) Oil return line
manifold) (11) Holder
(4) Oil return line (12) Mounting bolt
(5) O-ring (13) Oil separator with pressure control valve
(6) Vent line (14) Jubilee clip
(7) O-ring (15) Hose
Technical data
Oil return line (4)................................................... M24x1.5 ............................................................. 4 Nm
Service products
WARNING

ENGINE HOUSING
Note
Unlock and pull off the vent line (6) and the oil return line (10) by pressing together the spring
shackles (arrow).
New mounting bolts (9) and (11) must be tted.
New O-rings (5) and (6) and a new sealing ring (8) must be tted.
Apply Loctite 242 sealing compound on the thread of the oil return line (4) and tighten to 4 Nm.
Special tools
• Removing and installing the jubilee clips

ENGINE HOUSING
Removing and installing the crankcase ventilation (variant LFL51/52/54/55)

(2) Vent line (11) O-ring
(3) Jubilee clip (12) Vent line
(4) Oil return line (13) Mounting bolt
(5) Oil return line (14) Jubilee clip
(6) Sealing ring (15) Hose
(7) Hose (16) Oil separator
(8) Jubilee clip (17) Jubilee clip
(9) Sealing ring (18) Hose
Technical data
Service products
WARNING
specied tightening torque.
• Final tightening must always be performed manually using a torque wrench.

ENGINE HOUSING
Note
Fit new mounting bolts, sealing rings and O-rings.
Also t new hoses if exchanging the crankcase ventilation.
Thinly apply Loctite 242 sealing compound on the thread of the oil return line (in oil sump).
Special tools

ENGINE HOUSING
(1) Vent line (6) Jubilee clip

(2) Oil separator (7) Hose
(3) Hose (8) Jubilee clip
(4) Hose (9) Ventilation housing
(5) Vent line (10) Oil return line
WARNING
Note
In order to remove and install the ventilation housing, it is also necessary to remove and install the
turbocharger, see Removing and installing the turbocharger (variant with two-stage charging with
intercooler), 229.
Note
Fit new hoses, mounting bolts, sealing rings and O-rings when exchanging the crankcase
ventilation.

ENGINE HOUSING
Special tools

ENGINE HOUSING
FLYWHEEL HOUSING
Removing and installing the ywheel housing (variant without power take-off)
Additional jobs
(1) Crankcase (5) Mounting bolt

(3) Cap (7) Gasket
Technical data
Mounting bolt (5) .................................................. M14x105-10.9..................................................170 Nm
Service products
WARNING

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

Removing the speed sensor Positioning the ywheel housing
• Disconnect the electrical connection for the speed • Fit the ywheel housing (3) with a new gasket
sensor (1) (2) and position it over the alignment pins on the
• Remove the speed sensor (1) from the ywheel crankcase (1)
housing (2)
Screwing in the mounting bolts
Unscrewing the mounting bolts
• Screw in the new mounting bolts (1) and (2)

• Unscrew the mounting bolts (1) and (2) • Tighten the mounting bolts (2) to 105 Nm
• Tighten the mounting bolts (1) to 170 Nm
Removing the ywheel housing
• Remove the ywheel housing (3) with gasket (2)

from the crankcase (1)

ENGINE HOUSING

contact surfaces of the speed sensor (1)
(2)
• Connect the electrical connection for the speed
sensor (1)

ENGINE HOUSING
Removing and installing the ywheel housing (variant with power take-off 300 Nm)
Additional jobs
(1) Plate (4) Intermediate gear pin

(2) Flywheel housing (5) Intermediate gear
(3) Thrust washers (6) Crankshaft gear
Service products
WARNING

ENGINE HOUSING
Removing the ywheel housing Removing the ywheel housing
Removing the speed sensor
CAUTION
• Disconnect the electrical connection for the speed Danger of injury due to heavy
sensor (1) components
• Remove the speed sensor (1) from the ywheel • Use lifting gear to remove the ywheel
housing (2) housing
Unscrewing the mounting bolts • Remove the ywheel housing (3) with gasket (2)
from the crankcase (1)

(1)
• Mark the installation position of the crankshaft
gear (1)
• Pull the crankshaft gear (1) off the crankshaft
• Clean the contact surfaces

ENGINE HOUSING
Dismantling the ywheel housing Assembling the ywheel housing

Removing the plate Mounting the intermediate gears

(2) and (3)
• Remove the plate (1)
Removing the intermediate gears
Note
The thrust washer grooves must be facing
the intermediate gear pins.
• Position the thrust washers (4) as marked

• Thinly apply clean engine oil on the intermediate
gear pins (2)
• Position the intermediate gears (1) and
intermediate gear pins (2) as marked
• Position the thrust washers (3) as marked
• Mark the intermediate gears (1), intermediate gear

pins (2) and thrust washers (3) and (4) to indicate
their installation position and assignment
• Remove the thrust washers (3)
• Remove the intermediate gears (1) and
intermediate gear pins (2)
• Remove the thrust washers (4)

ENGINE HOUSING
Mounting the plate Installing the ywheel housing

Mounting the crankshaft gear
• Position the plate (1)

marked • Thinly apply Loctite 573 sealing compound on the
• Tighten the mounting bolts (2) and (3) contact surfaces of the crankshaft gear (1)
• Push the crankshaft gear (1) onto the crankshaft
as marked
Positioning the ywheel housing
CAUTION
components
housing
• Fit the ywheel housing (3) with a new gasket

(2) and position it over the alignment pins on the
crankcase (1)

ENGINE HOUSING
Screwing in the mounting bolts


contact surfaces of the speed sensor (1)
(2)
sensor (1)

ENGINE HOUSING
Additional jobs

(3) Mounting bolt (9) Flywheel housing
(4) Gasket (10) Intermediate gear pin
(5) Mounting bolt (11) Intermediate gear
(6) Mounting bolt (12) Plate
Technical data
Speed sensor, crankshaft...................................... M6x16-10.9 ........................................................ 8 Nm
Service products
Omnit sealing compound.................................................................................................. 04.10160-9249
WARNING

ENGINE HOUSING
Removing the ywheel housing Removing the ywheel housing
CAUTION
• Disconnect the electrical connection for the speed Danger of injury due to heavy
sensor (1) components
• Unscrew the mounting bolt (2) • Use lifting gear to remove the ywheel
• Remove the speed sensor (1) from the ywheel housing
housing
• Remove the ywheel housing (3) with gasket (2)
Unscrewing the mounting bolts from the crankcase (1)

(1), (2), (3), (4), (5) and (6)
• Unscrew the mounting bolts (1), (2), (3), (4), (5)
and (6) • Mark the installation position of the crankshaft
gear (1)
• Detach the circlip
• Remove the deep-groove ball bearing
• Pull the crankshaft gear (1) off the crankshaft
• Clean the contact surfaces

ENGINE HOUSING
Removing the intermediate gear Installing the ywheel housing

Mounting the plate

• Remove the intermediate gear (3) and the
intermediate gear pin (2) • Fit a new gasket (3)
• Position the plate (2)
Removing the plate • Screw in and tighten the new mounting bolts (1)
Mounting the intermediate gear

• Remove the plate (2) and the gasket (3)
• Clean the mating faces • Position the intermediate gear (3) with the
intermediate gear pin (2)

ENGINE HOUSING
Mounting the crankshaft gear Screwing in the mounting bolts
• Thinly apply Omnit sealing compound on the • Screw in the new mounting bolts (1), (2), (3), (4),
contact surfaces of the crankshaft gear (1) (5) and (6) as marked
• Push the crankshaft gear (1) onto the crankshaft • Tighten the mounting bolts (1), (2), (3), (4), (5) and
as marked (6)
• Install the deep-groove ball bearing
• Attach the circlip Installing the speed sensor
Positioning the ywheel housing
• Fit a new O-ring on the speed sensor (1)

• Insert the speed sensor (1) into the ywheel
housing
CAUTION
• Screw in the mounting bolt (2) and tighten to 8 Nm
components
sensor (1)
housing
• Position the ywheel housing (3) with a new gasket

(2) over the alignment pins on the crankcase (1)

ENGINE HOUSING
CRANKCASE YOKE
Removing and installing the crankcase yoke (variant LFL50-55)
Additional jobs
(1) Crankcase yoke (3) Mounting bolt

(2) Crankcase
Service products

ENGINE HOUSING
WARNING
Note
No crankcase yoke is tted in the D0836 LFL60 and LFL63 engine variants. An oil sump upper
section is tted instead, see Removing and installing the oil sump upper section (Euro 5 and EEV
variant), 347.

ENGINE HOUSING
Removing the crankcase yoke Installing the crankcase yoke
• Unscrew the mounting bolts (1) • Thinly apply Loctite 5900 sealing compound on
• Remove the crankcase yoke (2) from the the contact surfaces of the crankcase (3)
crankcase (3) • Position the crankcase yoke (2) on the crankcase
• Clean the mating faces (3)

ENGINE HOUSING
TIMING CASE COVER/TIMING CASE

Removing and installing the timing case cover
Additional jobs

ENGINE HOUSING
(1) Timing case (4) Mounting bolt

(2) Mounting bolt (5) Timing case cover
(3) Oil ller neck (6) Gasket
Technical data
Oil ller neck (3) ................................................... M38x1.5 ............................................................35 Nm
Service products
WARNING
Special tools
[204] Socket, 27 mm 08.06556-9300
• Removing and installing the oil ller neck

ENGINE HOUSING
Removing the timing case cover Removing the timing case cover gasket
• Remove the gasket (1) from the timing case (2)

• Disconnect the electrical connection for the speed
sensor (1)
• Pull out the speed sensor (1)
• Remove the O-ring from the speed sensor (1)
Removing the timing case cover
• Unscrew the oil ller neck (4) using the Socket, 27

mm [204]
(1), (2) and (5)
• Unscrew the mounting bolts (1), (2) and (5)
• Remove the timing case cover (3)

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

• Position the new gasket (1) over the alignment • Connect the electrical connection for the speed
pins on the timing case (2) sensor (1)
Mounting the timing case cover
• Position the timing case cover (3) over the

alignment pins
• Screw in the mounting bolts (1), (2) and (5) as
marked and then tighten them
thread of the oil ller neck (4)
• Screw in the oil ller neck (4) using the Socket, 27
mm [204] and tighten to 35 Nm

ENGINE HOUSING
Removing and installing the timing case

Additional jobs

ENGINE HOUSING
(1) Timing case (2) Gasket
WARNING

ENGINE HOUSING
Removing the timing case Installing the timing case

Removing the timing case Positioning the timing case gasket
• Position the new gasket (1) over the alignment

Note
pins on the crankcase (2)
To move the timing case, it may be
necessary to remove and install the oil Mounting the timing case
pump, see Removing and installing the
oil pump, 351.

(1)
• Pull the timing case (2) off the crankcase (3)
Removing the timing case gasket
• Fit new oil pump coupling sleeve O-rings and thinly

apply clean engine oil, see Mounting the oil pump,
354
• Align the oil pump coupling sleeve with the
crankcase (3)
• Position the timing case (2) over the alignment
pins
and tighten them by hand
• Remove the gasket (1) from the crankcase (2)

POWER TAKE-OFF
POWER TAKE-OFF
(1) Mounting bolt (2) Power take-off

POWER TAKE-OFF
POWER TAKE-OFF
(1) Mounting bolt (2) Power take-off
WARNING

POWER TAKE-OFF
Removing the power take-off Installing the power take-off
• Unscrew the mounting bolts (1) • Thinly apply clean engine oil on a new O-ring (3)
• Pull the power take-off (2) with O-ring (3) out of and t it on the power take-off (2)
the ywheel housing • Insert the power take-off (2) into the ywheel
housing

TECHNICAL DATA
TECHNICAL DATA
Removing and installing the wiring harness

Cable socket mounting nut.................................... M5 ..................................................................... 5 Nm
Terminal B + mounting nut .................................... M8 ....................................................................13 Nm
Removing and installing the engine electrics

Oil level sensor (2)................................................ M22x1.5 ............................................................25 Nm
Pressure sensor (9) .............................................. M18x1.5 ...................................................47 Nm, oiled
Rail-pressure sensor (10)...................................... M18x1.5 ............................................................70 Nm
Pressure transmitter (11)....................................... M18x1.5 ...................................................47 Nm, oiled
Mounting bolts, charge-pressure sensor (13) ......... M6x16-10.9 .......................................................10 Nm


Mounting nut (4) ................................................... M8-8 .................................................................22 Nm
Removing and installing the coolant manifold

Thermostat opening temperature...................................................................................................... 83 °C
Removing and installing the thermostat with thermostat housing

Opening temperature of thermostat (4) ............................................................................................. 83 °C
Removing and installing the coolant pump

Dismantling and assembling the coolant pump

Projection of slide ring seal (2) ........................................................................................... 10.0 - 10.4 mm
Dimension, impeller (cast iron) (3) - coolant pump housing (1) ......................................... 33.60 - 33.80 mm
Dimension, impeller (plastic) (3) - coolant pump housing (1) ............................................ 33.10 - 33.30 mm

Mounting bolt (left-hand thread) (4)........................ M16x1.5x45-8.8 LH.......................Initial torque 100 Nm
Mounting bolt (left-hand thread) (4)........................ M16x1.5x45-8.8 LH..............................Final torque 90°
Removing and installing the belt drive (variant without Grosskopf alternator or hydraulic pump)
Poly-V-belt tensioner mounting bolt for alternator
(9) ....................................................................... M10x70-10.9......................................................47 Nm
Mounting bolt, guide roller (7) ................................ M12x80-10.9......................................................60 Nm
Removing and installing the Grosskopf alternator belt drive

Mounting bolt, pressure spring (2) ......................... M10x45-10.9......................................................65 Nm
Mounting bolt, pressure spring (2) ......................... M12x40-10.9....................................................120 Nm
Removing and installing the hydraulic pump belt drive

Removing and installing the Stretchybelt belt drive (variant with one guide roller)
Mounting bolt, guide roller (1) ................................ M 12x80-10.9.....................................................60 Nm
Maximum tensioning force, poly-V-belt (3).........................................................................................121 N

TECHNICAL DATA

Maximum tensioning force, poly-V-belt (3).............. Running time 15 minutes .....................................102 N
Removing and installing the Stretchybelt belt drive (variant with two guide rollers)
Maximum tensioning force, poly-V-belt (4).......................................................................................... 87 N
Maximum tensioning force, poly-V-belt (4).............. Running time 15 minutes ...................................... 75 N
Checking and setting the refrigerant compressor belt track (D0836 LFL50 to LFL55)
Angular offset, poly-V-belt pulley (4) to (6)................................................................................... Max. 0.5°
Removing and installing the alternator

Mounting nut, poly-V-belt pulley (3)........................ M16x1.5 ............................................................80 Nm
Mounting nut, terminal B + .................................... M8 ....................................................................15 Nm
Hollow screw, coolant line ..................................... M14x1.5 ............................................................35 Nm
Union nut, coolant line .......................................... M14x1.5 ............................................................35 Nm

Mounting bolt (12) ................................................ M10x35-10.9......................................................65 Nm
Mounting bolts (11) and (13).................................. M10x30-10.9......................................................65 Nm
Removing and installing the starter

Mounting nut (4) ................................................... M10...................................................................45 Nm
Starter, terminal B+............................................... M10x1.5 ............................................................22 Nm
Number of teeth, starter (2) ...................................................................................................................12
Nominal output, starter (2).................................................................................................. 5.0 kW at 24 V
Removing and installing the hydraulic pump

Mounting nut (6) ................................................... M18x1.5 ............................................................70 Nm
Removing and installing the injectors and rail

Mounting bolt (3) .................................................. M8x45 ............................................ Final torque 30 Nm
Pressure screw (9) ............................................... M22x1.5 ........................................ Initial torque 10 Nm
Pressure screw (9) ............................................... M22x1.5 ......................................... Final torque 55 Nm
Injector cable mounting nuts.................................. Cable lug nut M4...............................................1.5 Nm
High-pressure line (6) (re-use)............................... M14x1.5 ..............................................Final torque 30°
High-pressure line (6) (reuse)................................ M18x1.5 ..............................................Final torque 30°
Rail-pressure sensor (7)........................................ M18x1.5 ............................................................70 Nm
Pressure limiting valve .......................................... M18x1.5 ..........................................................100 Nm
Overow valve ..................................................... M14x1.5 ............................................................32 Nm
Removing and installing the high-pressure pump (variant CP3.3)

Mounting nut (2) ................................................... M8 ....................................................................30 Nm

TECHNICAL DATA

Dismantling and assembling the high-pressure pump (variant CP3.3)

Mounting bolt (6) .................................................. M5x20 ..............................................Final torque 7 Nm
Mounting bolt (8) .................................................. M6x1.5x36.......................................................... 8 Nm
Mounting nut (1) ................................................... M18x1.5-8.8 ....................................................105 Nm
Removing and installing the high-pressure pump (variant CP3.3 NH)

Fuel ll quantity, high-pressure pump (4)........................................................................................... 60 ml
Mounting nut (2) ................................................... M8-8 .................................................................30 Nm
Mounting nut, drive gear, high-pressure pump (4)... M18x1.5-8.8 ....................................................105 Nm
Filler plug, high-pressure pump (4) ..................................................................................................18 Nm
Dismantling and assembling the fuel service centre

Pressure sensor (5) .............................................. M18x1.5 ............................................................45 Nm
Cover (11) ......................................................................................................................................10 Nm
Cover (2)........................................................................................................................................20 Nm
Water drain plug (6) ......................................................................................................................... 3 Nm
Removing and installing the ame start system

Mounting nut, cable lug......................................... M5 ..................................................................... 5 Nm
Union nuts, fuel line (3) ......................................... M10x1 ...............................................................10 Nm
Removing and installing the engine control unit

Mounting bolt (6) .................................................. M6x35-10.9 ....................................................... 11 Nm
Removing and installing the turbocharger (variant with two-stage charging without intercooler)
Clamp for charge-air manifold (2) ..................................................................................................... 7 Nm
Exhaust manifold clamp ................................................................................................................... 7 Nm
Removing and installing the turbocharger (variant with two-stage charging with intercooler)
Clamp (4)............................................................. M6x50 ................................................................ 7 Nm
Clamps, charge-air manifold.................................. M6x50 ................................................................ 6 Nm
Removing and installing the air distributor pipe

Temperature sensor (2)......................................... M16x1.5 ............................................................45 Nm
Removing and installing the EGR module (Euro 4 variant)

Temperature sensor, EGR module (6).................... M16x1.5 ............................................................45 Nm
Mounting nut, EGR positioning cylinder (4) ............ M8 ....................................................................16 Nm
Preload, EGR positioning cylinder (4) ................................................................................ 1.25 ± 0.25 mm
Removing and installing the EGR module (Euro 5 and EEV variant)
Temperature sensor, EGR module (6).................... M16x1.5 ...................................................47 Nm, oiled
Bulkhead tting..................................................... M15x1.5 ............................................................35 Nm
Preload, EGR positioning cylinder (3) .......................................................................................1 + 0.5 mm

TECHNICAL DATA
Removing and installing the exhaust manifold (Euro 4 variant)

Mounting bolts, shut-off valve ................................ M8x80-GA .........................................................27 Nm
Removing and installing the exhaust manifold (Euro 5 and EEV variant)
Mounting bolt (7), (12) .......................................... M8x40-GA ..................................... Initial torque 25 Nm
Mounting bolt (7), (12) .......................................... M8x40-GA ............................................ 2nd torque 45°
Mounting bolt (7), (12) .......................................... M8x40-GA ...........................................Final torque 45°
Mounting bolt (8) .................................................. M8x80-SD ..................................... Initial torque 25 Nm
Mounting bolt (8) .................................................. M8x80-SD ............................................ 2nd torque 45°
Mounting bolt (8) .................................................. M8x80-SD ...........................................Final torque 45°
Dismantling and assembling the rocker arm mechanism

Inside diameter, rocker arms (1), (7), (8), (12) ............................................................. 28.000 - 28.021 mm
Outside diameter, rocker arm shaft (13) ...................................................................... 27.957 - 27.970 mm
Inside diameter, rocker arm bracket (14) ..................................................................... 27.985 - 28.006 mm
Removing and installing the cylinder head

Cylinder head bolts............................................... 14x2 (E18)..................................... Initial torque 80 Nm
Cylinder head bolts............................................... 14x2 (E18)......................................2nd torque 150 Nm
Cylinder head bolts............................................... 14x2 (E18)............................................. 3rd torque 90°
Cylinder head bolts............................................... 14x2 (E18)............................................. 4th torque 90°
Cylinder head bolts............................................... 14x2 (E18)...........................................Final torque 90°
Checking and setting the valve clearance

Lock nuts, adjusting screws (3), (4), (5).................. M10x1-8.8 .........................................................40 Nm
Intake valve clearance ................................................................................................................ 0.50 mm
Exhaust valve clearance ............................................................................................................. 0.50 mm
EVB brace adjustment dimension ................................................................................................ 0.35 mm

Mounting bolts, camshaft gear (5).......................... M10x1.25x38-10.9 .............................................65 Nm
Mounting nut, oil pump drive gear (2)..................... M12x1.5-6S .......................................................45 Nm

Radial play, intermediate gear 1 ..................................................................................... 0.060 - 0.109 mm
Axial play, intermediate gear 1........................................................................................ 0.200 - 0.280 mm
Radial play, intermediate gear 2 (1) ................................................................................ 0.035 - 0.076 mm
Axial play, intermediate gear 2 (1)................................................................................... 0.100 - 0.200 mm

Crankshaft gear (4) - camshaft gear (5) .......................................................................... 0.051 - 0.149 mm
Camshaft gear (5) - air compressor gear......................................................................... 0.051 - 0.185 mm
Crankshaft gear (4) - intermediate gear 1........................................................................ 0.050 - 0.187 mm
Intermediate gear 1 - intermediate gear 2 (1) .................................................................. 0.051 - 0.175 mm
Intermediate gear 1 - oil pump drive gear (2) ................................................................... 0.053 - 0.190 mm
Removing and installing the oil module

Oil lter cover .................................................................................................................................25 Nm
Mounting bolt (1) .................................................. M6x20 ...............................................................12 Nm
Pressure transmitter (3) ........................................ M18x1.5 ............................................................47 Nm
Screw-in tting (5) ................................................ M30x1.5 ............................................................60 Nm
Screw plug (8) ...................................................... M18x1.5 ............................................................42 Nm

TECHNICAL DATA
Removing and installing the oil sump and oil intake pipe (Euro 4 variant)
Oil level sensor..................................................... M18x1.5 ............................................................25 Nm
Oil drain plug........................................................ M22x1.5-5.8 ......................................................75 Nm
Removing and installing the oil sump upper section (Euro 5 and EEV variant)
Oil level sensor..................................................... M18...................................................................45 Nm
Removing and installing the oil pump

Oil pump gear axial play................................................................................................. 0.050 - 0.114 mm
Radial play, oil pump shaft ............................................................................................. 0.050 - 0.078 mm
Removing and installing the oil injector nozzles

Oil pressure valve (3)............................................ M12...................................................................40 Nm
Removing and installing the vibration damper




Connecting rod bearing bolt (1) ............................. M11x1.5x60-11.9............................ Initial torque 55 Nm
Connecting rod bearing bolt (1) ............................. M11x1.5x60-11.9..................................Final torque 90°

Connecting rod length, piston pin bushing centre - connecting rod bearing centre ................. 196 ± 0.02 mm
Inside diameter, connecting rod eye......................................................................... Ø 44.050 - 44.066 mm
Hole for bearing shells in connecting rod (connecting rod big end)............................. Ø 74.000 - 74.019 mm
Weight difference per set of connecting rods in an engine........................................................... Max. 50 g

Connecting rod bearing........................................................................................... Ø 69.981 - 70.000 mm

Connecting rod bearing shell thickness .................. Normal ............................................. 1.975 - 1.987 mm
Connecting rod bearing shell thickness .................. Normal size 1.................................... 2.025 - 2.037 mm
Connecting rod bearing shell thickness .................. Repair level 1.................................... 2.100 - 2.112 mm
Connecting rod bearing shell spread......................................................................................Max. 1.5 mm

D3 measured 84.9 mm above piston bottom edge....................................................107.573 - 107.564 mm



TECHNICAL DATA






Overall height..........................................................................................................................103.00 mm
Piston height (centre of piston pin - piston crown)............................................................ 63.85 - 63.90 mm

Piston ring height..................................................................................................... 3 mm (nominal value)
Ring gap ........................................................................................................................... 0.35 - 0.50 mm

Ring gap ........................................................................................................................... 0.50 - 0.65 mm
Axial play .......................................................................................................................... 0.06 - 0.11 mm

Ring gap ........................................................................................................................... 0.30 - 0.60 mm
Axial play, KS piston .......................................................................................................... 0.05 - 0.09 mm
Axial play, Nüral piston....................................................................................................... 0.03 - 0.07 mm

Piston pin diameter................................................................................................. Ø 43.994 - 44.000 mm
Radial play in connecting rod ......................................................................................... 0.050 - 0.072 mm
Radial play in piston ...................................................................................................... 0.006 - 0.021 mm

Piston standout (crankcase - piston) ............................................................................... 0.087 - 0.389 mm

Piston weight difference per set in one engine............................................................................ Max. 40 g

Mounting bolt (4) .................................................. M14x118-10.9 ...............................Initial torque 115 Nm
Mounting bolt (4) .................................................. M14x118-10.9 ......................................Final torque 90°

TECHNICAL DATA

Hardness, crankshaft (6)......................................................................................................... 53 ± 3 HRC
Permitted curvature of journals...................................................................................................0.004 mm
Axial play, crankshaft (6) ................................................................................................ 0.200 - 0.395 mm
Connecting rod bearing journal................................................................................ Ø 69.981 - 70.000 mm
Crankshaft bearing journal ...................................................................................... Ø 86.981 - 87.000 mm

Crankshaft bearing inside diameter ......................................................................... Ø 89.520 - 89.554 mm
Wall thickness of crankshaft bearing shells (1), (2) .......................................................... 2.468 - 2.480 mm
Wall thickness, thrust washers (5), (7) ............................................................................ 2.850 - 2.900 mm
Crankshaft bearing spread ....................................................................................................Max. 1.5 mm

Removing and installing the crankcase ventilation (variant LFL51/52/54/55)

Removing and installing the ywheel housing (variant without power take-off)
Mounting bolt (5) .................................................. M14x105-10.9..................................................170 Nm
Speed sensor, crankshaft...................................... M6x16-10.9 ........................................................ 8 Nm
Removing and installing the timing case cover

Oil ller neck (3) ................................................... M38x1.5 ............................................................35 Nm

Engine TGM D0836

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Engine TGM D0836

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Common-rail In-line Engines

D0836 LFL50 - LFL55

Copy deadline: 12.2009

Common-rail In-line Engines

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

Best wishes from

© 2009 MAN Nutzfahrzeuge AG

Redaktion: SAWDT, 2W Technische Informations GmbH/12.2009

Satz: SAWDT, 2W Technische Informations GmbH

2 A25 Stage 2 3rd edition

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

Wiring harness ........................................................................................................... 29

Power take-off ............................................................................................................ 73

Injectors and rail ....................................................................................................... 135

A25 Stage 2 3rd edition 3

Removing and installing the injectors and rail ................................................................ 139

Intercooler ............................................................................................................... 205

Intake / exhaust system

Air distributor pipe ..................................................................................................... 243

Rocker arm mechanism .............................................................................................. 277

Camshaft / camshaft bearings ...................................................................................... 311

Timing gears ............................................................................................................ 323

4 A25 Stage 2 3rd edition

Oil module .............................................................................................................. 333

Vibration damper ...................................................................................................... 361

Crankshaft oil seals

Crankshaft oil seals ................................................................................................... 399

Crankcase ventilation ................................................................................................. 409

Power take-off .......................................................................................................... 441

Technical Data 443

A25 Stage 2 3rd edition 5

A25 Stage 2 3rd edition 7

8 A25 Stage 2 3rd edition

1. Regulations for preventing accidents leading to injury to personnel

Checking, setting and repair work

Working on the brake system

Working on vehicles with compressed natural gas (CNG) system

Working on the compressed natural gas (CNG) system

A25 Stage 2 3rd edition 9

Attachments and special bodies

Working on high-pressure lines

Checking injector nozzles

Working on the vehicle electrical system

Important! Battery gases are explosive!

Caution! Battery acid is poisonous and corrosive!

10 A25 Stage 2 3rd edition

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

Working with the cab tilted forwards

Working on the air-conditioning system

Working on airbag or belt tensioner units

A25 Stage 2 3rd edition 11

Working on the independent heater

2. Notes on preventing damage and premature wear on units

3. Limited liability for parts and accessories

4. Regulations for avoiding injury and environmental contamination

Health protection precautions

Service products and excipients

12 A25 Stage 2 3rd edition

Cleaning the cooling circuit

Cleaning the lter insert