Service Information

Document Title: Function Group: Information Type: Date:

Engine, assembling 210 Service Information 17/12/2024
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D16F

Engine, assembling
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D16F

Op nbr 210-078

Total procedure time (hr): 19.00

Tools:
885811 Timing tool
9990157 Press tool
9990157 Press tool
9990157 Press tool
9990157 Press tool
9990157 Press tool
9990157 Press tool
9990166 Installation tool
9992000 Handle
9992479 Retainer
9993590 Gear wheel
9996963 Puller plate
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998264 Lifting tool
9998318 Press tool
9998601 Installation tool
88800021 Installation tool
88800031 Setting tool
88800083 Extractor
88800313 Piston ring compressor
88800352 Lifting tool
88880003 Bracket

Dial indicator with magnetic stand

Graphite paste 85132765, GRAFEX GTL or GRAFOIL GTS
Lifting eye M12, 2 psc.
Sealant 11713514
This operation also includes required tools and times for applicable parts of the following operations:

¡ Cylinder head, installing

¡ Cylinder block, liners removed, milling of all liner locations
 ¡ Valves, adjusting

NOTE!
The method is performed on D16H.

Cylinder liner, installing

1. Clean and check the cylinder block's liner shelf for damage. Install the cylinder liners without O-rings and fixate
them with 9990157 Press tool.

2. Install a dial indicator in 9992479 Retainer. Place the holder with the dial indicator over the cylinder liner. Reset the
dial indicator to zero with a couple of millimetre's preload against the cylinder block's face.

Figure 1

3. Measure the height between the cylinder liner and the cylinder block's face. Measure the height in three different
places that are well away from each other.
NOTE!
The sealing surface is convex. Always measure on the sealing surface's highest point.

Calculate the average value of the three measurements. For correct liner height over the block face, see Engine,
specifications. If the liner's height above the block face is outside given tolerance, the liner shelf in the cylinder
block shall be machined. Machining shall be done in an authorized workshop. See Cylinder block, liners removed,
milling of all liner locations. Mark the liner's position in the cylinder block with a marker, so that it ends up in the
same position when installing. Repeat the procedure for the remaining cylinder liners.

4. Remove the press tools. Pull out the cylinder liner from the block using the tool 9996963 Puller plate. Place the
cylinder liners in the same order as they were installed, together with the associated adjusting shims. For correct
adjusting shims, see the Parts catalogue.

5. Install one of the black sealing rings on the cylinder liner.

 Figure 2

6. Lube the remaining sealing rings with the lubricant included in the liner kit and install them in the cylinder block.
NOTE!
The violet sealing ring must be installed in the lower groove.

Figure 3

7. If the cylinder liner is installed without shims, apply a bead of sealant 11713514, approx. Ø 0.8 mm (0.031 in), on the
underside of the cylinder liner's collar.
 Figure 4
Applying sealant on cylinder liner
If adjusting shims are used, apply the sealant bead on the liner shelf in the cylinder block.

Figure 5
Applying sealant in cylinder block

8. Tighten down one of the cylinder head's bolts. Install 9996963 Puller plate on top of the cylinder liner together with
suitable spacer. Press down the cylinder liner with a pry bar.

Figure 6

1. Cylinder head bolts

2. Pry bar
3. 9996963 Puller plate
4. Spacer
 9. Secure the liner with 9990157 Press tool.

Crankshaft, installing

10. Check the crankshaft's oil channels, bearing surfaces, as well as the main bearing caps and the engine block. These
shall have been thoroughly cleaned and be free from any damage. Install new main bearing cups in the engine
block and in the main bearing caps.
NOTE!
Make sure that the main bearing cups installed in the engine block have oil holes.

Install thrust washers for the middle main bearing, the thrust bearing. The fixing slots mean that the thrust washers
can only be installed in one position. The thrust bearings should be turned with the lubrication groove facing out.

Figure 7

11. Lube the crankshaft's bearing journals and the bearing cups with engine oil.

12. Carefully lift the crankshaft into place, make sure that it faces the right way in relation to the block.
Weight, crankshaft: approx. 160 kg (353 lb)

Figure 8

13. Install the bearing shells in the main bearing caps. Oil in the main bearing bolts. Install the main bearing caps. The
caps are asymmetrical and can only be installed in one way.
Tightening torque, see Engine, tightening torques.
NOTE!
The main bearing caps are marked. The arrow shall point in the direction against the engine's inlet side.

14. Install thrust washers for the middle main bearing, the thrust bearing. The fixing slots mean that the thrust washers
can only be installed in one position. Tighten the bolts according to Engine, tightening torques and check
afterwards that the shaft does not bind on any of the bearings.
 Figure 9

1. Thrust bearing with lubrication groove

15. Check the engine's axial run-out, see Engine, tightening torques.

Figure 10

16. Use oil to lube the cylinder bore, bearings cups and the crankshaft bearing (big-end) pins.

Pistons, installing

17. Install the piston rings with 88800083 Extractor.

NOTE!
Turn the two upper piston rings according to their markings. Check that the spring is placed correctly in the oil
scraper ring's groove. The piston rings' gap shall be displaced approx. 120° from each other.

Figure 11

All piston rings (the oil scraper ring as well) are marked with letters or point marks. The markings shall face up.
18. Assemble the piston and connecting rod. Install the lock ring.
NOTE!
The connecting rod shall face according to its marking.

Figure 12

19. NOTE!
9990157 Press tool shall be removed temporarily when 88800313 Piston ring compressor is used. When the piston
is in place, then 9990157 Press tool shall be reinstalled. The pistons may slide due to their own weight, so rotate the
engine so that the pistons can be inserted horizontally in the cylinder liner.

Oil in the piston. Install the piston and connecting rod with front marking facing forward, against cylinder 1. Use
88800313 Piston ring compressor to guide down the piston rings in the cylinder liner.

Figure 13
Marking, piston/connecting rod

Figure 14
 1. 88800313 Piston ring compressor
2. 9990157 Press tool

20. Install the big-end bearing caps. Oil in the bearing shells. Tighten the bolts crosswise. Use 885811 Timing tool.
Tightening torque, see Engine, tightening torques.

Figure 15

1. 885811 Timing tool

21. Clean the piston cooling nozzle and check that it is not damaged. Install the piston cooling nozzle with new O-ring.
Tightening torque, see Lubrication system, tightening torques.
NOTE!
Apply locking fluid to the bolts.

Figure 16

Ladder frame, installing

22. Install the ladder frame.

Tightening torque, see Engine, tightening torques.

Transmission, installing

23. Apply a 2 mm (0.08 in) thick bead of sealant 11713514 on the timing gear plate according to diagram. Install the
timing gear plate.
Tightening torque, see Engine, tightening torques.
NOTE!
Installation must take place within 20 minutes of applying the sealant.
 Figure 17
Sealant

24. Install a new O-ring on the crankshaft.

Figure 18

1. O-ring

25. Oil in the transfer gear's (2) bearing surface and spacer plate. Install the transfer gear.
 Figure 19
Engine timing gear

1. Camshaft gear with vibration damper

2. Transfer gear, upper
3. Double gear
4. Crankshaft gear
5. Transfer gear, lower
6. Oil pump gear
7. Spacer washer
8. Bracket for bolt for compressor

26. Tap the crankshaft gear into place.

Tightening torque, see Engine, tightening torques.

27. Install the double gear with its hole marking between the two hole markings on the crankshaft gear.
Tightening torque, see Engine, tightening torques.
 Figure 20

28. Install a new seal ring and the lower transfer gear for compressor and fuel pump.

Figure 21

1. Seal ring
2. Transfer gear

Lubrication oil pump, installing

29. Install the lubrication oil pump and the oil suction pipe.
Tightening torque, see Lubrication system, tightening torques.
NOTE!
Use new O-rings for the pipes.
 Figure 22
Seal positions, O-rings

Flywheel housing (for ART, also casing for power take-off), installing

30. Apply a 2 mm (0.08 in) thick bead of sealant 11713514 on the timing gear casing according to the figure.
NOTE!
Installation must take place within 20 minutes of applying the sealant.

For ART, the power take-off shall also be overhauled, see Power take-off, between engine and gearbox,
reconditioning.

Figure 23

31. Secure the flywheel housing with approved lifting tools. Use two M12 lifting eyes. Lift the timing gear casing into
place. Align it with the timing gear plate.
Tightening torque, see Engine, tightening torques.
 Figure 24

Crankshaft seal (rear), installing

32. Install the plate (included in 9990166 Installation tool) on the crankshaft and bolt down. Install the spacer ring on
the stud bolt.
NOTE!
Make sure that the plate ends up correctly on the crankshaft's guide pin, and has solid contact against the
crankshaft before tightening the bolts. The spacer ring decides how far in the seal should be installed.

Figure 25

1. 9990166 Installation tool

33. The seal is delivered with a plastic installation ring. Install the seal without removing the installation ring.

34. Install the cover together with the handle.

 Figure 26

35. Press in the seal by turning the handle. When the cover bottoms out, the seal is in the correct position.

Figure 27

Flywheel, installing

36. Install the flywheel with thrust plate and flex plate.
Tightening torque, see Engine, tightening torques.

Figure 28

Figure 29
Oil cooler, installing

37. Install the seals. Install the oil cooler and cover.
Tightening torque, see Lubrication system, tightening torques. See also Oil cooler, leakage check.
NOTE!
Use new seals and gasket.

Figure 30

1. Sealing
2. Oil cooler
3. Gasket
4. Cover

Oil filter bracket, installing

38. Install the plate with the gasket. Install the oil filter bracket.
Tightening torque, see Lubrication system, tightening torques.

Crankshaft seal (front), installing

39. Clean the crank pin.

40. Apply a 2 mm (0.08 in) thick bead of sealant 11713514 on the housing for the crankshaft seal.
NOTE!
Installation must take place within 20 minutes of applying the sealant.

Figure 31
Sealant

41. Install the housing for the crankshaft seal. Tighten the bolts according to diagram.
Tightening torque, see Engine, tightening torques.

42. The seal is delivered with a plastic installation ring. Install the installation ring on the crank pin and carefully move
 the seal over from the installation ring to the crank pin.

Figure 32

1. Installation ring
2. Sealing

43. Place 9992000 Handle in 88800021 Installation tool middle hole and carefully tap in the seal until the drifts bottom
out.
NOTE!
Check that the drifts are clean and undamaged. Damaged tools may cause damage to the crankshaft seal. The seal
should be installed without lubricant.

Figure 33

1. 9992000 Handle
2. 88800021 Installation tool
3. Sealing

44. Fit the coolant pump.

NOTE!
The pump is replaced as a complete unit.

45. Install the bracket. Install the belt pulley.

Tightening torque, see Engine, tightening torques.
 Figure 34
Belt pulley, version for ART and WLO

1. Pulley
2. Bracket
3. Spacer

46. Check the temperature and level sensor. See Service manual, section 3021, FX1006, description and measuring.

Figure 35

Install a new O-ring in the leadthrough in the oil sump. Install the oil sump with new gasket according to the
tightening diagram.
Tightening torque, see Lubrication system, tightening torques.

47. NOTE!
Handle the vibration damper with care. Damage to the vibration damper could lead to vibrations and engine
damage

Install the combined belt pulley/vibration damper. Use new bolts.

Tightening torque, see Engine, tightening torques.

Cylinder head, installing

48. See: Cylinder head, installing

Unit injectors and valve yokes, installing

NOTE!
There are two versions of unit injector, one with tapered end and steel sleeve (for D16H/J), and one with flat end and sealing
washer and copper sleeve (for D16F). When replacing a unit injector on engine D16H/J, always replace the steel sleeve with a
new one.
Figure 36

1. Unit injector for copper sleeve

2. Unit injector for steel sleeve

49. Install new O-rings on the unit injectors. Lubricate the O-rings with diesel.

Figure 37
Tapered unit injector used with steel sleeve, only one O-ring

Figure 38
Flat unit injector used with steel washer and copper sleeve, two O-rings
50. For steel sleeve: Lubricate the unit injector's tapered part with graphite paste 85132765 , GRAFEX GTL or GRAFOIL
GTS as shown in the figure.

Figure 39

1. Graphite paste
2. Tapered surface

51. NOTE!
The tightening torque is different for the steel sleeve and copper sleeve.

Install and centre the unit injectors between the valve springs.
Tightening torque, see Fuel system, tightening torques.

Figure 40

1. Attaching yoke

NOTE!
If the unit injectors are not installed immediately, then 9998251 Sealing plug must be installed.

52. Install the valve yokes. Valve yoke with guide pin (exhaust valves): Loosen the adjusting screw so that it does not
have contact with the valve spindle. Then tighten the adjusting screw so that it has contact with the valve spindle
and then another hex edge (60º). Tighten the lock nut.
 Tightening torque, see Engine, tightening torques.
NOTE!
When the adjusting screw is screwed down, the valve yoke must be pressed down to contact with the valve stem so
that the yoke is parallel with the guide pin. It is very important that the pressure is applied as close as possible to
the adjusting screw.

Figure 41

1. Valve yoke, inlet

2. Valve yoke, exhaust

Figure 42
Valve yoke with guide pin

A. Lock nut
B. Adjusting screw

Camshaft/rocker arm shaft, installing

53. Rotate the crankshaft with 9993590 Gear wheel to top dead centre (TDC). Check that the flywheel's marking stands
at 0. For correct setting the flywheel shall be rotated in the engine's rotational direction, that is, counter-clockwise
with the engine seen from behind.

Figure 43

54. Install the bearing brackets. Tap them down carefully with a plastic hammer.

55. Install the lower bearing shells in the bearing brackets and lubricate them with engine oil.
NOTE!
The surface between bearing shell and bearing bracket shall be dry.

Figure 44

56. Carefully lift the camshaft into place. Use 9998264 Lifting tool. The camshaft's marking "TDC" should be centred
between the markings on bearing bracket 7.
Weight, camshaft: approx. 40 kg (88 lb)
 Figure 45

1. 9998264 Lifting tool

57. Use oil to lube the bearings cups and install the caps on each bearing bracket.
NOTE!
The surface between bearing shell and bearing bracket shall be dry.

58. Install spacers on bearing caps 6 and 7 as shown in the figure: one pc. 40 mm long and 19 mm inside Ø as well as
two that are 40 mm long and have approx. 12 mm inside Ø and max. 18 mm outside Ø. Tighten the bolts
temporarily with 50 Nm (37 lbf ft). This is done so that the camshaft will be in correct position for adjusting the
backlash (gear flank clearance).

Figure 46

59. Check that the piston of cylinder 1 is at TDC, 0°, on the flywheel. The TDC mark on the camshaft should be between
the marks on the bearing cap.
 Figure 47

60. NOTE!
Handle the vibration damper with care. Damage to the vibration damper could lead to vibrations and engine
damage.

Fit the vibration damper and camshaft gear. Check that the hole mark in the timing gear plate is between the mark
points on the camshaft gear. Use new bolts (because they may only be angle-tightened once).
Tightening torque, see Engine, tightening torques.

Figure 48

Adjusting tooth flank clearance

61. Undo the bolts of the transfer gear and fit new ones. New bolts are used because the bolts may only be angle-
tightened once. Position a 0.10 mm (0.0039 in) feeler gauge on the pressure side between the camshaft gear and
the transfer gear. Adjust the transfer gear so that there is resistance when the feeler gauge is pulled out.
Tightening torque, see Engine, tightening torques.
 Figure 49

The arrows show the gears' rotational direction

Checking gear flank clearance

62. Install a dial indicator with magnetic stand so that the tip of the gauge rests against a tooth on the camshaft gear.
Lock the transfer gear in place with a screwdriver. Check gear flank clearance by rotating the camshaft gear in both
directions. Read off the clearance on the dial indicator. For correct values, see Engine, specifications. If clearance is
not correct, adjustment is required.
Tightening torque, see Engine, tightening torques.

Figure 50

63. Check tooth flank clearance again using a dial indicator.

64. Remove the spacers.

65. Install the valve yokes, lube them and the camshaft lobes with engine oil. Install the rocker arm shaft using
88800352 Lifting tool and 88880003 Bracket.
Weight, rocker arm shaft: approx. 36 kg (79 lb)
Tighten the bolts evenly all along the rocker arm shaft so that it is not bent and to make sure that the guide pins in
the camshaft's support bearing fits correctly.
Tightening torque, see Engine, tightening torques.
 Figure 51

1. 88800352 Lifting tool

2. 88880003 Bracket

66. Adjust the valves according to Valves, adjusting.

67. Check that the guide pin is positioned directly opposite the bowl in the spring plate. Tighten down the spring
plates.
Install new gaskets on the pipe between the control valve (1) and the rocker arm shaft. Install the control valve.
Tightening torque, see Engine, tightening torques.

Figure 52
 1. VCB valve
2. Spring plate

Upper timing gear casing, installing

68. Clean the contact faces on the timing gear casing and timing gear plate.

69. Install new seals.

Figure 53

70. Apply sealant 11713514 (1) in the corners between the lower timing gear casing and the timing gear plate as well
as on the timing gear casing as shown.
NOTE!
Installation must take place within 20 minutes of applying the sealant.

Figure 54
Sealant

71. Apply sealant 11713514 on the upper timing gear casing. Install the upper timing gear casing. Install the bolts and
tighten to contact. Install 9998318 Press tool and 9998601 Installation tool. Tighten them down so that the timing
gear casing's sealing face against the valve cover is flush with the sealing face on the cylinder head.
Tightening torque, see Engine, tightening torques.
NOTE!
Leave the press tools in place until the sealant has dried (approx. 30 minutes).
 Figure 55
Sealant

Figure 56

1. 9998601 Installation tool

2. 9998318 Press tool

72. Rotate the crankshaft with 9993590 Gear wheel so that a tooth on the vibration damper stands directly opposite
the camshaft sensor. Install 88800031 Setting tool in the hole for the camshaft sensor to decide how many
adjusting shims are needed to maintain correct distance between the sensor and the teeth:

¡ No lug outside = No adjusting shim

¡ One lug outside = One adjusting shim
¡ Two lugs outside = Two adjusting shims.

Figure 57

73. Install the camshaft sensor. Install the cover (2). Install the engine speed (rpm) sensor in the same way.
 Figure 58

1. Upper timing gear plate

2. Shield

74. Install the thermostat.

75. Install the front engine mount and the rear frame or engine mounts.
Tightening torque, see Engine, tightening torques.

76. Install the lifting plate at the rear and the front lifting eye. Secure the engine with approved lifting tools.

77. Continue with Engine, removing from work stand.