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Cylinder head, guides to cylinder
block

P0006009

In order to facilitate installation and exact positioning
of the cylinder head on the cylinder block, there are
three guide washers on the left side of the engine –
two on the cylinder block (

1

) and one on the cylinder

head (

2

). These washers determine the transverse

position of the cylinder head, while the timing plate
(

3

) determines the longitudinal position. In this way it

is possible to precisely fit the cylinder head trans-
versely and longitudinally.

The convex indentations in the cylinder head gasket
allow the cylinder head to be slid on the gasket without
damaging the rubber seals.

20-0 Engine Information, General

7748841 06-2010

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Summary of Contents for TAD1343GE

Page 1: ...Workshop and repair manual V VO OL LV VO O E En ng gi in ne e T TA AD D1 13 34 43 3G GE E T TA AD D1 13 34 44 4G GE E T TA AD D1 13 34 45 5G GE E 7748841 01 06 2010 33525078101_0_1 ...

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Page 3: ...hop Manual Group 00 08 20 26 32 I 5 0 TAD1341GE TAD1342GE TAD1343GE TAD1344GE TAD1345GE TAD1340VE TAD1341VE TAD1342VE TAD1343VE TAD1344VE TAD1345VE TAD1350GE TAD1351GE TAD1352GE TAD1353GE TAD1354GE TAD1355GE ...

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Page 5: ...rs and Shaft 201 21 6 Crank Mechanism 211 Lubricating and Oil System 22 1 Oil pump and Line 229 22 2 Oil filter 233 22 3 Oil cooler 239 Fuel System 23 0 Fuel System General 245 23 3 Fuel Feed Pump and Filter 248 23 7 Injectors and Delivery Pipes 255 23 8 Control System ECM Data Sets 266 Inlet and Exhaust System 25 0 Inlet and Exhaust System General 268 25 1 Inlet and Exhaust Manifolds 269 25 5 Tur...

Page 6: ...rts not approved by Volvo Penta will be compensated by any warranty undertaking Certified engines When carrying out service and repair on emis sion certified engines it is important to be aware of the following Certification means that an engine type has been inspected and approved by the relevant authority The engine manufacturer guarantees that all engines of the same type are manufactured to co...

Page 7: ...nction Above all when working on fuel systems hydraulic systems lubrication systems turbochargers inlet systems bearings and seals it is of the utmost impor tance that dirt and foreign objects are kept away as malfunctions or shortened service intervals may oth erwise result Our mutual responsibility Each product comprises a large number of interacting systems and components A deviation from the t...

Page 8: ...s correctly carried out it is important that the correct type of sealants and locking fluids are used on joints where such are required In each service manual section concerned the seal ants used in product manufacture are indicated The same sealants or sealants with equivalent proper ties must be used for maintenance work Make sure that mating surfaces are dry and free from oil grease paint and a...

Page 9: ...onous gases WARNING Always use chloroprene rubber gloves gloves for chemicals handling and goggles Handle the removed seal in the same way as corrosive acid All residue including ash can be highly corrosive Never use compressed air to blow clean Put the remains in a plastic container seal it and apply a warning label Wash the gloves under running water before removing them The following seals are ...

Page 10: ...th a so called visco fan When the fan is removed the viscous coupling must always stand upright The coupling contains oil that will run out if it is laid on its side and because the oil cannot run back in the fan will seize 00 9 Miscellaneous 6 7748841 06 2010 ...

Page 11: ... 15 Nm 62 7 11 1 lbf ft M14 standard bolt 8 8 140 25 Nm 103 3 18 4 lbf ft M16 standard bolt 8 8 220 35 Nm 162 3 25 8 lbf ft NOTICE Only torqued bolts may be re installed Angle tightened stretch limit bolts 8 8 Must not be re installed 10 9 May be re installed 12 9 May be re installed IMPORTANT Check bolts which are to be re installed Damaged bolts e g with shear marks under heads must be scrapped ...

Page 12: ...105 15 Nm 77 44 11 06 lbf ft Stage 5 Angle tighten bolt 1 60 5 Stage 6 Tighten bolt 5 standard bolt torque Tighten the upward facing engine bolts 6 275 10 Nm 202 83 7 376 lbf ft Front and rear L brackets Tighten the bolts 7 220 35 Nm 162 3 25 8 lbf ft Main bearing caps Stage 1 150 20 Nm 110 6 14 75 lbf ft Stage 2 angle tightening 120 5 Big end bearing cap Stage 1 20 3 Nm 14 75 2 21 lbf ft Stage 2 ...

Page 13: ...69 lbf ft stage 2 Tighten the bolts 1 24 in sequence angle tight ening 60 5 Timing gear plate P0005221 25 22 21 16 26 20 24 27 28 19 23 18 17 2 10 11 12 13 14 3 4 5 6 7 8 9 15 1 29 P0005222 NOTICE Run an approx 2 mm 0 0787 in silicone bead outside the groove as illustrated above max 20 min before installation Timing gear plate Tighten all bolts in sequence to the following torque 28 4 Nm 20 65 2 9...

Page 14: ...strated 3 Intermediate gear adjustable Stage 1 35 4 Nm 25 81 2 95 lbf ft Stage 2 angle tightening 120 5 NOTICE Tighten in the order illustrated 4 Drive gear camshaft incl vibration damper Stage 1 45 5 Nm 33 19 3 69 lbf ft Stage 2 angle tightening 90 5 NOTICE Tighten in the order illustrated 5 Intermediate gear 140 10 Nm 103 3 7 38 lbf ft 6 Drive gear power steering and fuel feed pump 100 10 Nm 73 ...

Page 15: ... 0787 in silicone bead as illustrated above max 20 min before installation Flywheel housing Tighten all bolts in sequence to the following torque M14 bolts 140 20 Nm 103 3 14 75lbf ft M10 bolts 48 8 Nm 35 4 5 9 lbf ft M8 bolts 24 4 Nm 17 7 2 95 lbf ft 03 2 Specifications Engine 7748841 06 2010 11 ...

Page 16: ... min before installation Tighten the contact surfaces carefully Install the cover in two stages stage 1 Fasten the cover with bolts 1 and 2 Use the special tool to press the cover into position 4 1 Nm 2 95 0 738 lbf ft stage 2 Tighten the bolts in sequence as illustrated 24 4 Nm 17 7 2 95 lbf ft 03 2 Specifications Engine 12 7748841 06 2010 ...

Page 17: ... illustrated Cover crankshaft seal P0005229 1 2 3 4 5 6 7 8 P0005230 NOTICE Run an approx 2 mm 0 0787 in silicone bead as illustrated above max 20 min before installation Cover crankshaft seal stage 1 Fasten the cover with bolts 2 and 7 and tighten until it makes contact stage 2 Torque bolts 2 and 7 24 4 Nm 17 7 2 95 lbf ft stage 3 Tighten the bolts in the sequence 1 3 6 8 as illustrated 24 4 Nm 1...

Page 18: ...8 bolts may not be re used Cylinder Head 14 38 37 10 30 29 4 18 17 2 19 20 5 25 26 8 33 34 11 32 31 7 24 23 3 16 15 1 13 36 35 9 28 27 6 22 21 12 P0005232 NOTICE The cylinder head must be installed according to the Installation section in 21 1 Cylinder Head Change Cylinder Head stage 1 Tighten the bolts in sequence as illustrated 100 5 Nm 73 76 3 69 lbf ft stage 2 angle tightening 120 5 stage 3 an...

Page 19: ...mshaft camshaft and bearing caps in place stage 1 Tighten bolts 1 7 25 3 Nm 18 44 2 21 lbf ft stage 2 with shorter extra bolts Tighten bolts 8 13 and 20 60 5 Nm 44 25 3 69 lbf ft stage 3 Angle tighten bolts 1 7 90 5 stage 4 Remove the extra bolts 8 13 and 20 Rocker arm shaft rocker arm shaft in place stage 5 Tighten bolts 8 13 and 20 in stages in the sequence 11 10 12 9 13 8 20 60 5 Nm 44 25 3 69 ...

Page 20: ...olt B floating rocker arm angle tightening 30 15 0 1 Locking nut C EGR rocker arm angle tightening 45 5 1 Locking nut unit injector D valve adjuster screw 52 4 Nm 38 35 2 95 lbf ft 1 after contact Spring plate P0005235 Spring plate 25 3 Nm 18 44 2 21 lbf ft 03 2 Specifications Engine 16 7748841 06 2010 ...

Page 21: ...Valve Cover 10 1 15 16 12 11 13 14 6 2 3 8 7 9 4 5 19 20 18 17 p0005236 Valve Cover Tighten the bolts in sequence as illustrated 24 4 Nm 17 7 2 95 lbf ft 03 2 Specifications Engine 7748841 06 2010 17 ...

Page 22: ... and torque them 24 4 Nm 17 7 2 95 lbf ft Tighten the bolts outwards from the center in the sequence 1 4 as illustrated above 24 4 Nm 17 7 2 95 lbf ft Finish off by checking the torque of bolts A and B 24 4 Nm 17 7 2 95 lbf ft Drain plug oil sump 60 10 Nm 44 25 7 38 lbf ft 03 2 Specifications Engine 18 7748841 06 2010 ...

Page 23: ...the oval hole Press the cover toward the water pump housing with an installation tool and install bolt B Check that the cover is in position refer to the service instruction Install bolts C and D and torque them 24 4 Nm 17 7 2 95 lbf ft Tighten the cover bolts outwards from the center in the sequence 1 4 as illustrated above 24 4 Nm 17 7 2 95 lbf ft Finish off by checking the torque of bolts C and...

Page 24: ...ermostat valve or pressure valve oil cooler bolt 1 M6 standard bolt torque Safety valve oil pressure plug 2 50 5 Nm 36 88 3 69 lbf ft Overflow valve oil filter plug 3 55 5 Nm 40 57 3 69 lbf ft 03 2 Specifications Engine 20 7748841 06 2010 ...

Page 25: ... 0 Nm 14 75 3 69 0 lbf ft stage 2 angle tightening 180 5 NOTICE Loosen the yoke bolt before the second tighten ing Second tightening stage 1 20 5 0 Nm 14 75 3 69 0 lbf ft stage 2 angle tightening 90 5 p0005242 Locknut for adjuster screw unit injector 52 4 Nm 38 35 2 95 lbf ft 03 2 Specifications Engine 7748841 06 2010 21 ...

Page 26: ...1 P0012337 Bolts 1 for adapter incl fuel pump 24 2 Nm 17 7 1 48 lbf ft P0012338 1 Bolts 1 for fuel pump installed on adapter 8 2 0 Nm 5 90 1 48 0 lbf ft 03 2 Specifications Engine 22 7748841 06 2010 ...

Page 27: ...rackets tightening torques A 18 3 Nm 13 28 2 21 lbf ft B Brackets 24 4 Nm 17 7 2 95 lbf ft standard tightening torque C 30 4 Nm 22 13 2 95 lbf ft D 35 5 Nm 25 81 3 69 lbf ft E 40 5 Nm 29 50 3 69 lbf ft F 48 5 Nm 35 40 3 69 lbf ft 03 2 Specifications Engine 7748841 06 2010 23 ...

Page 28: ...anifold Stage 1 Tighten the bolts 1 4 and 5 8 and 9 12 until they make contact 10 1 5 Nm 7 38 1 11 lbf ft Step 2 Torque bolts 3 and 2 48 8 Nm 35 4 5 9 lbf ft Torque bolts 7 and 6 48 8 Nm 35 4 5 9 lbf ft Torque bolts 11 and 10 48 8 Nm 35 4 5 9 lbf ft Torque bolts 1 and 4 48 8 Nm 35 4 5 9 lbf ft Torque bolts 5 and 8 48 8 Nm 35 4 5 9 lbf ft Torque bolts 9 and 12 48 8 Nm 35 4 5 9 lbf ft 03 2 Specifica...

Page 29: ...6 Oil level and oil temperature sensor standard bolt torque 7 Fuel pressure sensor 30 5 Nm 8 Pressure drop indicator Air temperature clamp 9 Coolant level sensor insertable type 10 Coolant temperature sensor 22 3 Nm 11 Piston cooling oil pressure 30 5 Nm 12 Flywheel position and rotation speed M6 standard bolt torque 13 Camshaft position sensor M6 standard bolt torque Group 26 Cooling System Refer...

Page 30: ...TAD1352GE TAD1353GE TAD1354GE TAD1355GE No of cylinders 6 Cylinder diameter std 131 mm 5 16 in Stroke 158 mm 6 22 in Cylinder volume 12 78 liter 779 9 in3 Injection sequence 1 5 3 6 2 4 Compression ratio 18 1 1 Compression 3 7 MPa 537 psi Low idle 900 rpm High idle 1800 rpm Dry weight engine 1295 kg 2855 lb Dry weight engine with generator set 1715 kg 3781 lb Wet weight engine 1325 kg 2921 lb Wet ...

Page 31: ...ane crankshaft center 422 mm 16 61 in Height lower block plane crankshaft center 120 mm 4 72 in Cylinder Liner Type Wet replaceable Sealing surface height above block plane 0 15 0 21 mm 0 00591 0 00827 in No of seal rings per cylinder liner 1 3 Piston Height above cylinder block plane steel pistons 0 1 min 0 7 max mm 0 00394 0 0276 in No of ring grooves 3 Front marking Forward pointing arrow 03 2 ...

Page 32: ... ring opening upper compression ring 0 40 0 55 mm 0 0157 0 0217 in Wear tolerance 0 65 mm 0 0256 in lower compression ring 1 30 1 50 mm 0 0512 0 0591 in Wear tolerance 1 65 mm 0 065 in Oil Scraper Ring Quantity 1 Marking Up color marking to left of gap Piston ring clearance in groove 0 05 0 10 mm 0 00197 0 00394 in Piston ring gap measured at ring opening 0 30 0 55 mm 0 0118 0 0217 in Wear toleran...

Page 33: ...315 in Valve seat angle A Inlet 24 5 0 2 Exhaust 39 5 Seat angle in cylinder head B Inlet 25 Exhaust 40 A p0005203 Specifications Min A Wear value Dimension A between valve head and cylinder head plane Inlet 1 0 mm 0 0394 in Max 1 7 mm 0 0669 in Exhaust 1 35 mm 0 0531 in Max 2 1 mm 0 0827 in 03 2 Specifications Engine 7748841 06 2010 29 ...

Page 34: ...EGR adjustment Allow the feeler gauge to remain in place after adjust ing the valve clearance and adjust the EGR rocker arm by loosening the locking nut and adjusting the screw until no clearance is attained Check by rotating the rocker arm roller at the camshaft P0004953 Undo the adjuster screw 1 turns 630 Tighten the lock nut Remove the feeler gauge from the exhaust valve P0004526 03 2 Specifica...

Page 35: ...n Valve seats A B p0005205 Outer diameter A Standard Oversize dimen sion Inlet 45 1 mm 1 7756 in 45 3 mm 1 7835 in Exhaust 43 1 mm 1 6968 in 43 3 mm 1 7047 in Height B Inlet 7 55 mm 0 2972 in Exhaust 7 5 mm 0 2952 in 03 2 Specifications Engine 7748841 06 2010 31 ...

Page 36: ...et exhaust max 0 8 mm 0 0315 in Valve guides p0005207 999 9696 998 9876 Length Inlet exhaust 83 5 mm 3 287 in Inner diameter Inlet exhaust 8 mm 0 315 in Height above cylinder head spring plane Inlet exhaust 24 5 0 2 mm 0 9645 0 00787 in Wear value See figure Clearance valve stem guide 1 Inlet max 0 7 mm 0 0276 in Exhaust max 0 7 mm 0 0276 in 1 The dimension is calculated for the measurement method...

Page 37: ...earing play 1 max 0 1 mm 0 00394 in Roller cam follower clearance 2 max 0 1 mm 0 00394 in Valve springs Inlet Length uncompressed 73 8 mm 2 9055 in Exhaust Length uncompressed 73 8 mm 2 9055 in 03 2 Specifications Engine 7748841 06 2010 33 ...

Page 38: ...Drive gear power steering pump and fuel feed pump 7 Drive gear lubrication oil pump Gear lash adjustable intermediate gear to camshaft drive gear 0 05 0 15 mm 0 00197 0 00591 in Gear lash oil pump 0 05 0 40 mm 0 00197 0 0157 in Gear lash other 0 05 0 17 mm 0 00197 0 00669 in Radial clearance for intermediate gear max 0 05 mm 0 00197 in p0005209 03 2 Specifications Engine 34 7748841 06 2010 ...

Page 39: ...22 69 28 mm 2 725 2 728 in Permissible wear entire camshaft profile max 0 1 mm 0 00394 in Unit injector stroke 18 mm 0 709 in Wear value Max end float 0 24 mm 0 00945 in Bearing max permissible radial wear 0 1 mm 0 00394 in Camshaft Bearings Camshaft bearing thickness standard 1 92 mm 0 0756 in Oversize dimension 0 25 mm 0 00984 in 2 04 mm 0 0803 in 0 50 mm 0 0197 in 2 17 mm 0 0854 in 0 75 mm 0 02...

Page 40: ...25 mm 0 00984 in 107 75 mm 4 242 in 0 50 mm 0 0197 in 107 50 mm 4 232 in 1 00 mm 0 0394 in 107 00 mm 4 213 in Surface fineness main bearing journals Ra 0 25 9 84 10 6 in Surface fineness radius Ra 0 4 1 575 10 5 in Width thrust bearing journal A standard 47 0 mm 1 850 in Oversize dimension 0 2 mm 0 00787 in thrust bearing 0 1 mm 0 00394 in 47 2 mm 1 858 in 0 4 mm 0 01575 in thrust bearing 0 2 mm 0...

Page 41: ...n 3 28 mm 0 1291 in 0 2 mm 0 00787 in 3 38 mm 0 1331 in 0 3 mm 0 0118 in 3 48 mm 0 1370 in Main bearing cup Thickness D standard 2 48 mm 0 0976 in Oversize dimension 0 25 mm 0 00984 in 2 61 mm 0 1028 in 0 50 mm 0 0197 in 2 74 mm 0 1079 in 1 00 mm 0 0394 in 2 98 mm 0 1173 in 03 2 Specifications Engine 7748841 06 2010 37 ...

Page 42: ... 25 9 84 10 6 in Surface fineness radius Ra 0 4 1 575 10 5 in Width A 57 0 mm 2 244 in Fillet radius R 4 0 mm 0 1575 in Connecting rod big end diameter D 103 84 mm 4 0882 in Connecting rod length E 267 5 mm 10 5315 in Connecting rod small end diameter G 58 0 mm 2 2835 in Connecting rod bearing cup Thickness C standard 2 39 mm 0 0941 in Oversize dimension 0 25 mm 0 00984 in 2 51 mm 0 09882 in 0 50 ...

Page 43: ...1 End float connecting rod crankshaft max 0 35 mm 0 01378 in Connecting rod bearing radial clearance max 0 1 mm 0 00394 in 1 Dimensions refer to greased components Flywheel installed Runout measured radius 150 mm 5 905 in 0 20 mm 0 0787 in Flywheel housing installed Runout for contact surface max 0 2 mm 0 0787 in Radial play for steering max 0 26 mm 0 01024 in 03 2 Specifications Engine 7748841 06...

Page 44: ...3 5 79 8 psi Cold engine above 1100 rpm 650 kPa 94 3 psi Low idle min min 250 kPa min 36 3 psi Piston cooling pressure hot engine above 1100 rpm 200 300 kPa 29 43 5 psi Oil pressure rocker arm shaft Non activated EGR 80 120 kPa 11 6 17 4 psi Activated EGR 900 2300 rpm min 220 kPa min 31 9 psi Oil temperature Max oil temperature in oil sump 130 C 266 F 03 2 Specifications Engine 40 7748841 06 2010 ...

Page 45: ...3 2 1 3 1 Thermostat valve oil cooler Opening temperature 105 107 C 221 224 6 F 2 Safety valve block Marking Yellow 3 Bypass valve full flow filter Spring free length 69 mm 2 717 in Compressed 13 15 N 2 9 3 4 lbf 40 mm 1 575 in 03 2 Specifications Engine 7748841 06 2010 41 ...

Page 46: ...s Feed pump Feed pressure at 600 rpm 100 kPa 14 5 PSI 1200 rpm 300 kPa 43 5 PSI full load 300 kPa 43 5 PSI Bypass valve Opening pressure 300 550 kPa 43 5 79 8 PSI Unit injector Pre load Tighten the adjuster screw to zero clearance against the camshaft Then turn 4 flats see illustration p0005214 03 2 Specifications Engine 42 7748841 06 2010 ...

Page 47: ...System Technical Data Pressure drop indicator The pressure drop indicator control lamp lights up at a pres sure drop relative to ambient air pressure of 50 5 kPa 7 25 0 7 PSI 03 2 Specifications Engine 7748841 06 2010 43 ...

Page 48: ...tains Ethylene glycol and anti corrosion additives Mix with Water According to ASTM D4985 Mixing proportions conc coolant water 40 60 NOTICE Do not use Volvo Coolant VCS yellow in color in Volvo Penta engines NOTICE Do not mix different kinds of coolant Refill quantity Coolant quantity engine radiator and hoses TAD1340 53 GE VE 44 liter 46 49 quart 03 2 Specifications Engine 44 7748841 06 2010 ...

Page 49: ...375 0 30879 0 20 4 13181 5 14945 0 16708 5 10 14 7555 7 8480 0 9404 3 0 32 4477 9 4981 0 5484 1 10 50 2747 3 3029 0 3310 7 20 68 1736 6 1900 0 2063 4 30 86 1127 3 1224 0 1320 7 40 104 750 0 809 1 868 2 50 122 510 4 547 0 583 6 60 140 354 5 377 9 401 3 70 158 251 6 266 5 281 4 80 176 181 4 191 2 201 0 90 194 133 1 139 7 146 3 100 212 99 2 103 6 108 0 110 230 75 0 78 0 81 0 120 248 57 6 59 6 61 6 13...

Page 50: ...0 140 144 148 120 248 109 113 116 130 266 86 89 93 140 284 68 71 74 Charge air temperature sensor Ω p0005218 Tempera ture Impe dance Rmin Impedance Rnom Impe dance Rmax C F Ω Ω Ω 40 40 45301 0 48153 0 51006 0 30 22 25350 0 26854 0 28359 0 20 4 14785 0 15614 0 16443 0 10 14 8951 0 9426 0 9901 0 0 32 5605 0 5887 0 6168 0 10 50 3618 7 3791 1 3963 5 20 68 2401 9 2510 6 2619 3 30 86 1644 7 1715 4 1786 ...

Page 51: ...10 Inactive V 0 12 Ubat 10 Camshaft sensor Distance to gearwheel 1 1 0 4 mm 0 0433 0 01575 in Crankcase sensor Sensor alarm limit 5 kPa 0 725 PSI Crankcase pressure normal value 1 0 kPa 0 145 PSI 03 3 Specifications Electrical 7748841 06 2010 47 ...

Page 52: ... injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate personal injury IMPORTANT Is used to draw your attention to something that may cause minor damage or a minor malfunction to the product or property NOTICE Is used to draw your attention t...

Page 53: ...n the tur bocharger can cause severe injury Foreign objects entering the intake ducts can also cause mechanical damage Install all protective cov ers before the engine is started Ensure that the warning symbols or information decals on the product are always clearly visible Replace decals which have been damaged or painted over Only start the engine in a well ventilated space When running in a con...

Page 54: ...plosive A spark which can be caused by incorrect battery connection is sufficient to cause a battery to explode and cause damage Do not touch the connections during start attempts Sparking hazard Do not lean over batteries Never work alone when removing heavy com ponents even when using lifting devices such as locking tackle lifts When using a lifting device two people are usually required to do t...

Page 55: ...efer to the Operator s Manual for the product in question Use of fuels that are of a lower grade may damage the engine the injection pump and the injectors On a diesel engine low grade fuel can cause the control rod to bind and the engine to over rev with the risk of engine damage and personal injury as a result Low fuel and oil grades may result in high service maintenance and repair costs Never ...

Page 56: ...398 Manom eter Flywheel bearing P0006822 P0006269 P0006765 9988539 Compression meter 9990006 Puller 9990013 Slide hammer P0004314 P0006785 P0006793 9990124 Nipple 9990166 Mounting tool 9990185 Lifting tool Banjo fitting for use with 9996398 Manometer Crankshaft seal Lifting rocker arm bridge P0006779 P0004328 P0006784 9990192 Puller 9992000 Handle 9993590 Rotation tool Crankshaft seal Replacement ...

Page 57: ...el bearing For use with cylinder liners P0004333 P0004348 p0006803 9996666 Nipple 9998007 Adapter 9998248 Adapter For use with among other things 9996398 Manometer For use with 9996400 Slide hammer Compression test 6 pcs required P0006805 P0004349 9998249 Protective sleeve 9998251 Protection plug 9998339 Manometer Protects removed injectors Replacement for removed injec tors Checking charge air pr...

Page 58: ...ng pliers Removal of filters Removal of crankshaft seal Installation of piston rings P0006806 P0006810 P0006811 9998250 Sealing ring 9998252 Thread cutting tool 88800191 Extractor Cylinder head fuel ducts the kit contains 12 pcs Removal of copper sleeve Removal of copper sleeve P0010363 P0008420 P0008418 88800196 Drift 9809668 Extractor 9809667 Thread tap Installation of copper sleeve Removal of c...

Page 59: ...8674 Adapter Pressure testing cooling system For use with 88800003 Fixture Removal of camshaft cap P0010359 P0010361 P0010360 9996966 Press tool 3883671 Protective sleeve 3883672 Protective sleeve Holds cylinder liner in place O ring for injector O ring for injector P0010362 P0010364 P0010365 9992955 Plate 88800031 Measuring tool 9998598 Sleeve Removal of cylinder liner Shimming sensors Removal of...

Page 60: ...aft Installation of upper timing cover Installation of upper timing cover P0006782 P0006792 9998531 Piston ring compres sor 9809726 Pneumatic hydraulic pump 9809729 Hydraulic cylinder Fitting rings to pistons Valves and valve guides Valves and valve guides P0006786 P0006788 P0006789 9990176 Press tool 9996159 Adapter 88800064 Drift Valves and valve guides For 9809729 Hydraulic cylinder Valve guide...

Page 61: ...Cylinder head Valve springs Valve springs P0006780 P0006778 P0006791 9990210 Valve spring com pressor 9990165 Guide sleeve 9992479 Holder for dial indica tor Valve stem seals For use with 9989876 Dial indi cator P0006787 P0007596 9998267 Guide sleeve 9992269 Drift 9990263 Nipple Timing gear plate Replacement of flywheel bear ings Measuring oil pressure P0004580 9998493 Hose 08 2 Special Service To...

Page 62: ...nch For use with e g fuel pressure lines For use with e g the crankshaft P0002784 P0004342 P0004343 885648 Counterhold 885812 Timing tool 885822 Magnetic pen For use with 885633 Torque multiplier P0001859 P0001879 P0001875 9998511 Lever 9999696 Magnetic stand 9989876 Dial indicator For use with 9989876 Dial indi cator 2 0 1 0 0 0 2 0 P0001881 P0006823 9999683 Dial indicator short probe 885811 Timi...

Page 63: ...hassis number B Serial number A B C D E F G P0002052 2 A Engine designation B Engine power net without fan C Max engine speed D Main software E Dataset 1 F Data set 2 G Product number P0002053 3 A Engine designation B Specification number C Serial number 20 0 Engine Information General 7748841 06 2010 59 ...

Page 64: ... unit injectors In order to fulfill Euro 4 emission standards the engine is equip ped with an EGR Exhaust Gas Recirculation system TAD1350 55GE The turbocharger has waste gate control for engine charge pressure The engine has optional open or closed crankcase ventilation The risk of oil droplets is eliminated with closed crankcase ventilation which is a legal require ment in most markets P0006477 ...

Page 65: ...d and located at the front right side A Each cylinder has separate inlet ducts to one side of the cylinder and separate exhaust ducts on the other side so called crossflow B The fuel channel to the unit injectors is drilled length wise through the cylinder head and has a machined ring shaped space around each unit injector C There is a plug at the front D that leads to a channel for measuring rock...

Page 66: ...P0006001 There are two guide pins on the right side of the cyl inder head that ensure the valve cover is fitted in the correct position 20 0 Engine Information General 62 7748841 06 2010 ...

Page 67: ...pairs by so called floating valve yokes that transfer rocker arm movement from the camshaft to the valve pair The valves have three grooves and matching collets D The design of the collets allows the valves to rotate on their seats For improved heat resistance and heat conduction more material is used in the exhaust valve discs and the diameter is somewhat smaller than that of the inlet valves The...

Page 68: ...istaken for copper sleeves for other variants P0006004 The unit injectors are sealed against the cylinder head with two O rings located in the injector s ring shaped notch The injector s lower part is sealed against the copper sleeve by a steel gasket The steel gasket has three projections that keep it in place on the injector The steel gasket has a sealant coating that requires the gasket to be r...

Page 69: ...is the main lubrication duct gallery and on the right side there is a piston cooling duct Both ducts are plugged at the front of the engine with plugs equipped with O rings At the rear of the engine the ducts are covered by the timing plate and the main lubrication gallery discharges into the cast duct that supplies the engine timing with oil 20 0 Engine Information General 7748841 06 2010 65 ...

Page 70: ... of main bearing caps they are guided into position by cast asymmetrically located tabs 1 into correspond ing chamfers 2 in the cylinder block The main bear ing caps are made from nodular iron and are individ ually adapted In order for them not to be confused at installation they are marked 1 2 3 5 and 6 respec tively counting from the front of the engine The cen ter and rear main bearing caps are...

Page 71: ...eet steel and is bolted in place to the lower block plane A The oil sump 2 is made from injection molded plastic composite The plastic sump seal is made of a rubber strip man ufactured in one piece and located in a groove around the rim The oil sump is bolted in place with 22 pcs spring loaded steel bolts B The plastic sump drain plug C is threaded into a replaceable steel rein forcement 20 0 Engi...

Page 72: ...differ ent colors to prevent confusion The two upper black rings are made from EPDM rubber and are therefore resistant to coolant while the lower purple is fluoro rubber and resistant to oil The gasket C between the cylinder head block and liner is made from steel and has integral vulcanized rubber seals for the coolant and oil channels In order to protect the rubber seals during cylinder head ins...

Page 73: ...nd one on the cylinder head 2 These washers determine the transverse position of the cylinder head while the timing plate 3 determines the longitudinal position In this way it is possible to precisely fit the cylinder head trans versely and longitudinally The convex indentations in the cylinder head gasket allow the cylinder head to be slid on the gasket without damaging the rubber seals 20 0 Engi...

Page 74: ...in iron alloy The inside of the liner has a crosshatch machining pattern honing 4 The final cylinder liner fine surface machining is performed using a method called plateau honing 5 where the sharpest apexes from the basic machining are ground away The connecting rod is C forged and split at the lower end big end using a method known as fracture split ting The upper end small end has a pressed in ...

Page 75: ...heel There are also teeth on the vibration damper for the camshaft sensor NOTICE The vibration damper must absolutely not be confused with vibration dampers for other variants Figure A shows a section through the valve mech anism for one pair of exhaust valves Each rocker arm acts on a so called floating valve yoke 3 that opens the valves The rocker arm 4 is supported by a bushing 6 on the rocker ...

Page 76: ...down and opens the exhaust valve The pump piston is located immediately under the EGR rocker arm 10 and it is the pump piston the EGR rocker arm is able to press down The exhaust rocker arm 4 is designed so that the EGR rocker arm 10 lies above the exhaust rocker arm and when lubrication oil pressure is sufficiently high the clearance between the two rocker arms is reduced and the brake rocker arm...

Page 77: ...xhaust rocker arm 4 In this situation the exhaust valves are not affected by the EGR cam lobe EGR activation P0006029 2 The control valve raises the oil pressure to system pressure the pressure is above 2 bars in the rocker arm shaft The piston 8 is moved backwards but the check valve 7 is held open by the oil flow The high pressure is sufficient to lift the pump piston to its upper position When ...

Page 78: ... The piston is pushed down and the exhaust valves open The check valve 7 is held closed by the high oil pressure during the time the exhaust valves are open P0006031 4 After the exhaust valves have closed and the EGR rocker arm no longer depresses the pump piston the oil that forced the power piston 6 down flows back to the pump piston 5 The system is replenished by the check valve 7 opening and a...

Page 79: ...ker arm shaft drops to around 1 bar The piston 8 opens the check valve 7 so that oil can flow back to the rocker arm shaft The pump piston spring then forces the pump piston 5 back to its lower position and the EGR rocker arm 10 can no longer contact the pump piston 20 0 Engine Information General 7748841 06 2010 75 ...

Page 80: ...main bearing B comprising four half moon shaped washers 2 Front end A sealing is by means of a Teflon seal 3 against the front crankshaft flange There is also a Teflon seal 4 at the rear C that seals against a machined surface on the crankshaft gearwheel 5 The gearwheel is fastened to the crankshaft with a locating pin 6 and two bolts 7 There is a groove in the rear crankshaft flange for an O ring...

Page 81: ... The space between the damper housing and the oscillating mass is filled with silicone oil of high viscosity When the crankshaft rotates torsional stresses arise in the crankshaft from piston impulses The viscous silicone oil evens out the movement between the pul sating crankshaft rotation and the smooth rotation of the oscillating mass thus reducing the stresses The flywheel 7 and the intermedia...

Page 82: ...e the groove There is a drilled hole in the timing plate which together with the marking on the camshaft gear A is used for installing the camshaft correctly The crankshaft gear and the double intermediate gear are marked B for correct installation 1 Timing gear plate 2 Crankshaft gear 3 Intermediate gear bull gear 4 Intermediate gear adjustable 5 Camshaft gear 6 Drive gear power steering and fuel...

Page 83: ...5 The locating sleeve 6 guides the intermediate gear in the timing plate This intermediate gear with two gear wheels bearing and hub is a complete unit that cannot be disassem bled but must be replaced as a complete assem bly C The adjustable intermediate gear is supported by a bushing 7 on the hub 8 The bushing and the thrust washer 9 are pressure lubricated via a duct 10 that runs between the cy...

Page 84: ... against the timing plate with sealant The seal between the two covers is by a rub ber strip 1 placed in a groove in the upper cover The upper timing gear cover seals against the timing plate with two rubber sealings 2 The upper timing gear cover is also sealed with sealant in the join between the rubber strip and the timing plate There are two holes in the flywheel housing One hole is intended fo...

Page 85: ... into a cast channel for timing gear lubrication A centrally located drilled channel through the cylinder block and cylinder head lead lubrication oil to the control valve and the drilled rocker arm shaft which lubricates the camshaft and rocker arm bearings through oil channels The oil filter housing is bolted to the right side of the engine and has two full flow filters and one bypass filter The...

Page 86: ...ass valve for full flow filter E Opening valve for piston cooling F Control valve for piston cooling G Pressure take off for piston cooling pressure measurement The piston cooling valves E and F are integrated in the filter housing and are not replaceable The reduction valve A is integrated in the oil pump and cannot be replaced separately 20 0 Engine Information General 82 7748841 06 2010 ...

Page 87: ...e 10 Two external hoses supply the turbocharger 11 with oil filtered in the full flow filters 7 The fine filtered oil from the bypass filter 12 is mixed in with piston cooling oil which is led to the cylinder block piston cooling channel From here oil is sprayed against the underside of the pistons through nozzles 13 A Reduction valve maintains oil pressure within the correct values B Safety valve...

Page 88: ...driven by a gear wheel 1 directly from the engine timing The pump gearwheel teeth are cut at an angle for lower noise levels and its shafts are supported via bearings directly in the pump housing which is of aluminum The pressure reduction valve 2 is installed in the oil pump and regulates pressure in the lubrication sys tem 20 0 Engine Information General 84 7748841 06 2010 ...

Page 89: ...er seals and is in one of two lengths depending on installation The delivery pipe 3 is made of steel and is fastened to the cylinder block bearing caps and sealed with rubber seals A connection pipe from the oil filter housing leads oil to the main lubrication channel The oil cooler 4 is bolted directly to the oil cooler housing 5 and is entirely surrounded by coolant thanks to the flow plate 6 20...

Page 90: ...piston cooling channels The piston cooling nozzle is directed such that the oil jet hits the inlet hole to the piston cooling chamber By regulating the piston cooling flow via a control valve a so called optimized piston cooling system is arrived at with a constant flow regardless of engine rpm 20 0 Engine Information General 86 7748841 06 2010 ...

Page 91: ...ve General P0006033 The control valve regulates oil pressure to the rocker arm mechanism and is controlled by the engine con trol unit ECU via the solenoid valve 20 0 Engine Information General 7748841 06 2010 87 ...

Page 92: ...n orifice for control flow 13 Return orifice 14 Calibration orifice 15 Hole for oil flow to rocker arm Normal operations During normal engine operation the solenoid 9 is not activated The solenoid is in the control position and forces oil through the orifice 15 to the rocker arm at the same time as oil is able to flow through the cali bration orifice 14 and on to the return orifice 13 This reduces...

Page 93: ...d the EGR function takes over Deactivation of EGR When the engine is running and the EGR function released the solenoid 9 is de energized The high pressure that is present in the rocker arm shaft causes the valve slide 3 to rapidly shut so that the oil return connection 13 opens and oil drains out When the oil pressure falls to 1 bar 100 kPa 14 5 PSI the valve slide is returned to the control posi...

Page 94: ...ontrol unit ECU which receives signals from a number of sensors The illustration shows the main components included in the fuel system The engine is also equipped with a hand pump located on the fuel filter housing 1 Strainer fuel gauge sensor 2 Feed pump 3 Fuel filter housing 4 Pre filter with water separator 5 Venting valve 6 Fuel filter 7 Overflow valve 8 Unit injector 9 Fuel channel in cylinde...

Page 95: ...valve 11 regulates fuel feed pressure to the injectors Return fuel from the cylinder head fuel channel passes through the overflow valve 11 back to the fuel filter housing Return fuel is mixed in the fuel filter housing through channel with fuel from the tank and is drawn on to the feed pump inlet suction side There are two valves in the fed pump The safety valve 7 allows the fuel to flow back to ...

Page 96: ...re after the fuel filter A fault code is shown on the instrument panel if feed pressure falls below the value according to the fault code book There is a level sensor in the water separator that provides a signal to the operator if there is water in the system The hand pump 4 is located on the fuel filter housing and is used for pumping up fuel engine stopped when the fuel system has been emptied ...

Page 97: ...zle section The valve section contains two solenoid valves the spill valve 8 and the needle valve 11 with solenoids 9 and 10 and return springs During the filling phase the pump piston moves up and fuel from the cylinder head fuel channels is forced into the unit injector During the spill phase he pump piston moves down and fuel is forced back out into the cylinder head fuel channels During the pe...

Page 98: ...13 closes The entire injection process is controlled by the engine management system EMS There are three markings on the injector electrical connection 16 part number 17 trim code 18 and production number 19 When changing one or more injectors the engine control unit ECU must be pro grammed with new injector trim codes because each unit injector is unique and the engine is tuned for opti mal fuel ...

Page 99: ...Group 25 Inlet and Exhaust System Exhaust Manifold and Turbo P0003286 20 0 Engine Information General 7748841 06 2010 95 ...

Page 100: ...e is influenced by turbo pressure via an actuator and a lever A Exhaust flow at low turbo pressure is shown here The valve is closed and the entire exhaust flow is through the turbine rotor B When the turbo pressure reaches a certain level the valve starts to open Some of the exhaust gases flow via the valve and by pass the turbine thus reducing turbine revolutions C When the engine is working har...

Page 101: ...gine is equipped with two oil traps one located in the upper timing gear cover 1 and the other in the valve cover 2 and an external pipe 3 to lead away crankcase gasses There is an oil trap in the timing gear cover designed as a labyrinth with a connection 4 to the crankcase in front of the center of the intermediate gear Intermediate gear rotation creates a relatively oil free area There is an oi...

Page 102: ...e side of the separator that shuts off the flow to the separator if too great a pressure drop occurs After having passed the oil traps in the upper timing gear cover and valve cover refer to Open crankcase ventilation the crankcase gasses are led to the inlet in the top of the separator via a hose connection 1 and enter the separator from above directly over the center of the rotating discs The oi...

Page 103: ...the largest part of the coolant is forced through the holes 6 to the upper liner cooling jackets From there the coolant flows to the cylinder head via the channels 7 The cylinder head has a horizontal intermediate baffle that forces coolant past the hottest parts for effective heat removal The coolant then passes through the thermostat 8 which sends coolant via the cooler or via the pipe 9 back to...

Page 104: ...t engine C the coolant pump cover 1 is made of alumi num There are channels in the rear section 8 of the pump for coolant distribution and the cover contains a plastic impeller 2 shaft seal 3 bearing 4 and belt pulley 5 The shaft bearing is a permanently lubricated combined roller bearing Between the shaft seal and the bearing there is a ventilated space 6 that dis charges behind the belt pulley 7...

Page 105: ...throttle and a number of sensors on the engine in order to control the amount of fuel and injection timing Harness connectors for engine sensors have DIN standard connectors In the control unit there are sensors for atmospheric pressure and temperature the other sensors are 1 Auxiliary stop 2 Charge air pressure and temperature sensor 3 Oil pressure sensor 4 Crankcase pressure sensor 5 Water separ...

Page 106: ... be stopped 2 5 Starter motor does not rotate 1 2 3 4 5 6 7 24 Starter motor rotates slowly 1 2 Starter motor rotates normally but engine does not start 8 9 10 11 Engine starts but stops again 8 9 10 11 13 Engine does not reach correct operating speed at full throttle 9 10 11 12 13 21 25 26 Engine runs roughly 10 11 High fuel consumption 12 13 15 25 Black exhaust smoke 12 13 Blue or white exhaust ...

Page 107: ...r filter air leakage between the turbo and the engine s intake manifold dirty compressor part in the turbocharger faulty turbo compressor poor engine room ventilation 14 Coolant temperature too high 15 Coolant temperature too low 16 Oil level too low 17 Coolant level too low 18 Air in the coolant system 19 Faulty circulation pump 20 Defective thermostat 21 Blocked charge air cooler 22 Oil level to...

Page 108: ...em is blocked it must be cleaned External dirt Check that the cooler and or the charge air cooler are not clogged If you cannot see light through at least one third the cooler should be removed and cleaned Check if there is any internal or external leakage in the cooling system Internal contamination Check that the cooler and or the charge air cooler are not clogged External cleaning 1 Remove guar...

Page 109: ... with the injector retainers 3 Oil valve caliper cam shaft ridges and the rocker bridge 4 Fit the rocker bridge with 9990185 Lifting tool Torque the screws evenly along the rocker arm to avoid that the rocker arm bends or warps Make sure that guide pins fit in the camshaft sup port bearing Torque the rocker bridge as speci fied in Engine General page 26 Use torque wrench 5 Install the middle piece...

Page 110: ...n the engine for more than 15 seconds at a time with intervals of 60 seconds Run the engine with the starter motor until the compression meter needle has stopped max compression reading Read the value Move the compression meter to the next cylinder Repeat the test on all cylinders 11 Remove the middle piece and the oil pipe for the rocker bridge 12 Remove the rocker bridge screws equally in stages...

Page 111: ...at guide pins fit in the camshaft sup port bearing Torque the rocker bridge as speci fied in Engine General page 26 Use torque wrench 16 Install the middle piece and the oil pipe to the rocker bridge 17 Adjust valves and unit injectors see Valves and Unit Injectors Adjustment page 177 18 Check and if needed change the valve cover bearing Install the valve cover 19 Re install the fuel lines Use new...

Page 112: ...line seals Cooling System Pressure Testing Alternative 1 WARNING Do not open the coolant filler cap when the engine is warm Steam or hot fluid could spray out causing severe burns Tools 3849613 Pressure testing kit 1 Check that all hoses and clamps are undamaged and intact 2 Check the coolant level in the expansion tank 3 Replace the filler cap on the expansion tank with a suitable cover from 3849...

Page 113: ... 3 Replace the filler cap with 9996441 Cover with connecting nipple Connect 9996662 Pressure testing kit to the cap Connect compressed air to the equipment and open the cock Adjust the pressure to 70 kPa 0 7 bar with the adjuster knob Then close the tap 4 Pressure must not drop for a two minute test period for the cooling system to be regarded as being free from leakage 5 Release the excess pressu...

Page 114: ...emove the drain hose from the test equipment and empty the coolant from the hose Re install the rubber plug in the engine drain valve 7 Check the coolant level in the expansion tank 8 Start the engine and check that no leakage occurs Charge Pressure Troubleshooting Charge Air Pressure Check Tools 9998339 Manometer 9998493 Hose 9996666 Nipple 1 Connect the nipple with hose and pressure gauge to the...

Page 115: ...ntaminated with oil on the inside this indicates oil leakage in the turbo charger turbine shaft seal In this case the tur bocharger should be changed as a unit IMPORTANT If there is oil in charge air pipes and charge air hoses the charge air cooler and all pipes and hoses in the charge air system must be very thor oughly cleaned inside before the engine is started Charge Air Cooler External Cleani...

Page 116: ...rrect com pressor housing If the wrong compressor hous ing is installed on the turbocharger the compres sor wheel might have been damaged or have too much clearance between wheel and housing In both cases charge air pressure will be too low 3 Remove the inlet manifold from the turbocharger 4 Check the turbocharger for damage to the com pressor wheel and excessive end float on the tur bine shaft 5 ...

Page 117: ... screw press in the tool firmly so that it is in contact with the cover Press in the center part of the tool until it contacts the gearwheel and tighten the lock screw Rove the tool and inspect the center section posi tion in its sleeve 4 Determine further actions according to the following P0010219 If the center section of the tool is entirely below the sleeve s upper edge no shims are required P...

Page 118: ...P0010220 If the two center section surfaces are above the sleeve s top edge two shims are required 5 Install the sensor with a new seal and any shims 20 0 Engine Information General 114 7748841 06 2010 ...

Page 119: ...perature as specified in Engine General page 26 2 If the thermostat does not open at specified tem perature it should be replaced 3 Install the thermostat see Thermostat Change page 288 NOTICE Always use a new seal even if the ther mostat is not replaced P0005072 Closed thermostat P0005073 Open thermostat 20 0 Engine Information General 7748841 06 2010 115 ...

Page 120: ...ire harnesses and hoses are positioned on the engine IMPORTANT When work on the engine is finished wire harnesses and hoses that were removed must be reinstalled exactly as illustrated Incorrect installation will result in vibration damage P0010532 21 0 Engine Complete General 116 7748841 06 2010 ...

Page 121: ...P0010531 P0010586 P0010587 21 0 Engine Complete General 7748841 06 2010 117 ...

Page 122: ...s to the fuel pump and allow the fuel to run out into a suitable container Also loosen the upper connection on the cooling coil and water drain 3 Remove the hoses from the radiator and the expansion tank 4 Remove the heat shield above the turbo if fitted P0006865 P0006866 21 0 Engine Complete General 118 7748841 06 2010 ...

Page 123: ...pening 8 Remove the crankcase breather with its bracket and oil separator 9 Remove the pipe between the inlet manifold and the charge air cooler Cover all openings 10 Remove the safety cover above the alternator if fitted 11 Remove the radiator fan safety cover grille and remove the fan the hub and its brackets to the cylinder head 12 Remove the coolant pipe from the thermostat 13 Remove the belt ...

Page 124: ...g all fuel unions 2 Remove the wire harness from the starter motor and sensor the rear wire harness Remove the relay and stop button holder Hang the wire har ness in front of the fuel filter bracket 3 Remove the fuel filter bracket refer to Fuel Filter Bracket Change page 248 4 First remove the fuel hose and then the engine block attachment P0009966 P0009967 21 0 Engine Complete General 120 774884...

Page 125: ...117 Plate and fasten it with the bolts supplied 6 Fix 88800003 Fixture to the plate and tighten it Hoist the engine and attach it to the engine stand P0009968 P0009969 21 0 Engine Complete General 7748841 06 2010 121 ...

Page 126: ... the bolts in their intended locations on the plate 2 Install and fasten the fuel hose attachment to the engine Install the fuel hose 3 Install the fuel filter bracket Refer to Fuel Filter Bracket Change page 248 4 Install the engine control unit and connect the fuel lines with new seals P0009969 P0009967 21 0 Engine Complete General 122 7748841 06 2010 ...

Page 127: ... holder Retrieve the wire harness and connect it to the sensor and starter motor Secure the wire harness with clamps 6 Vent the fuel system refer to Fuel system bleed ing page 245 P0009966 21 0 Engine Complete General 7748841 06 2010 123 ...

Page 128: ...emoved refer to Cylinder Head Removal page 153 Tools 9993590 Rotation tool 9998511 Lever 9998267 Guide sleeve 1 Remove the front engine mount 2 Remove the oil sump bolts and remove the sump P0010123 P0010454 21 0 Engine Complete General 124 7748841 06 2010 ...

Page 129: ...tor 4 Remove the fuel pump with drive unit refer to Fuel Feed Pump Change page 252 5 Remove the two timing gear cover caps Remove the flywheel sensor P0010157 P0004300 P0010158 21 0 Engine Complete General 7748841 06 2010 125 ...

Page 130: ...se 9993590 Rota tion tool as a counterhold while undoing the bolts Hoist the flywheel using suitable lifting eyes 7 Remove the lower timing gear cover bolts on the starter motor side 2 pcs 8 Remove the bolts on the fuel pump side 6 pcs P0010159 P0010160 P0010161 21 0 Engine Complete General 126 7748841 06 2010 ...

Page 131: ...g eyes and connect the lifting tool 10 Use 9998511 Lever to loosen the cover from the intermediate plate on the fuel pump side 11 Use the pry bar in the same way on the starter motor side P0010162 P0010163 P0010164 21 0 Engine Complete General 7748841 06 2010 127 ...

Page 132: ...ot be separated it is always replaced complete If the oil pump gear requires replacing remove the fuel pump refer to Lubrication Oil Pump Change page 229 13 Check that the crankshaft gear marking corre sponds to the double gear P0010179 P0010180 21 0 Engine Complete General 128 7748841 06 2010 ...

Page 133: ...pcs 9998267 Guide sleeve must be installed on the engine block tighten to 60 Nm 44 lbf ft This is to ensure that the plate is replaced in exactly the same position It is now possible to remove the timing gear plate Remove all bolts Using a pry bar carefully prise the plate free held in place by sealant but do not prise such that the guide sleeves are budged or damaged P0010181 P0010182 9998267 P00...

Page 134: ...e engine block and cylinder head sealing sur faces but do not remove the plate guide sleeves Lube Oil Pump Removal 1 Remove the oil pump refer to Lubrication Oil Pump Change page 229 Pistons Removal Tools 885822 Magnetic pen 1 Remove the carbon uppermost in the cylinder bore Make sure the press tool cannot touch the pistons when the pistons are removed P0010185 P0010153 9996966 P0010048 21 0 Engin...

Page 135: ...necting rods are marked mark the position if more than one is removed from the engine 4 Undo the connecting rod bolts a couple of turns Tap the bolt heads so that the bearing cap is freed from the connecting rod P0010126 5 6 P0010127 1 P0010128 21 0 Engine Complete General 7748841 06 2010 131 ...

Page 136: ...ting rod and catch it under the engine Make sure it does not fall out and become damaged The connecting rod separation plane surface is very sensitive and must not be exposed to impact or knocks 7 Replace the bearing cap on the connecting rod immediately to protect the separation plane sur faces 8 Remove the remaining pistons the same way P0010129 P0010130 P0010131 21 0 Engine Complete General 132...

Page 137: ...ect the connecting rod refer to Connecting Rod Check page 176 Cylinder Liners Removal Tools 9992955 Plate 9996645 Puller 9996394 Support 9996395 Support 1 Turn the engine so that the crankshaft is at the bottom P0010132 P0010133 21 0 Engine Complete General 7748841 06 2010 133 ...

Page 138: ...ate 9996645 Puller and 9996394 Support 4 Insert the tools in the liner to be removed Make sure the plate ends up directly under the liner Screw down on the nut so that the liner is drawn up P0010134 9996394 9992955 9996645 P0010135 P0010136 21 0 Engine Complete General 134 7748841 06 2010 ...

Page 139: ...s the same way 8 Inspect the liners refer to Cylinder Liner and Pis tons Inspection page 175 9 Remove the liner O rings from the engine block Check the O ring grooves for corrosion or any other damage Crankshaft Removal Tools 9990114 Puller 9990013 Slide hammer 1 Remove the crankshaft belt pulleys refer to Drive Belts page 290 Alternator Belts Change page 298 2 Remove the crankshaft seal holder 99...

Page 140: ...e lifting strap to the front and rear end of the crankshaft according to the following steps 5 Crank the crankshaft so that the timing mark ends up exactly as illustrated The crankshaft can only be removed in this position Insert a bolt in the top hole in the timing gear 6 In the same manner insert a bolt into the other end of the shaft and attach the lifting strap P0010165 P0010167 P0010168 21 0 ...

Page 141: ...shaft 8 Remove the thrust washers Remove the main bearing cups and wipe the bearing seats dry Fit new bearings Make sure the tabs fit into the notch in the bearing seat and that the oil holes correspond to each other Oil the bearings with engine oil P0010169 P0010170 21 0 Engine Complete General 7748841 06 2010 137 ...

Page 142: ...nd the crankshaft in a lifting strap refer to Crankshaft Removal page 135 Lubricate all bearing surfaces with engine oil 3 Lower the crankshaft carefully into position Align the gearwheel markings with each other IMPORTANT Make sure that no connecting rod ends up in the wrong position The connecting rod separation planes are very sensitive 4 When the crankshaft has been lowered onto the main beari...

Page 143: ...ts using 885811 Timing tool 885633 Torque multiplier and 885648 Counterhold according to Special Tightening Torques page 8 Check once more that the crankshaft can be rotated 7 Check crankshaft end float with the aid of 9999696 Magnetic stand and 9989876 Dial indi cator Use 9998511 Lever move the crankshaft back and forth Read off the value on the dial indicator and compare to Technical Data page 2...

Page 144: ...ecial Tightening Tor ques page 8 11 Install a new crankshaft seal and belt pulley refer to Crankshaft seal replace front page 211 Cylinder Liner Installation Tools 9996966 Press tool 9992479 Holder for dial indicator 9989876 Dial indicator 9998511 Lever 9992955 Plate 1 Check the engine block liner seat for damage If the liner seat is damaged it must be repaired P0005229 1 2 3 4 5 6 7 8 P0005230 P0...

Page 145: ...culate the average of the two measurements For correct liner height above block plane refer to specifications If the liner height is outside specified tolerances the liner seat must be repaired milled Always measure the highest point on the liner sealing surface Mark the liner s position with a felt pen in order to re install it in the exact same position P0010134 P0006964 P0006965 21 0 Engine Com...

Page 146: ...ier marking if necessary use 9992955 Plate a suit able socket and 9998511 Lever against a cylinder head bolt Press the liner down using two 9996966 Press tool 6 Install the remaining liners the same way Pistons Installation Tools 9996966 Press tool 9998531 Piston ring compressor 1 Rotate the crankshaft so that the big end journal for the piston to be installed ends up as low as possible Remove the...

Page 147: ... crankshaft Install the big end bearing caps and align it pre cisely with the crankshaft big end bearing oiled Install the bolts Torque the bolts and check that the crankshaft can be rotated 3 Install the remaining pistons the same way 4 Clean the piston cooling nozzles and check that they are not damaged Install the nozzles using new bolts Check that the nozzles are aimed directly at the piston o...

Page 148: ... outside the groove on the timing plate max 20 min before installation 2 Align the plate with the locator sleeves Install all the bolts and tighten them in sequence according to Special Tightening Torques page 8 P0005221 25 22 21 16 26 20 24 27 28 19 23 18 17 2 10 11 12 13 14 3 4 5 6 7 8 9 15 1 29 P0005222 21 0 Engine Complete General 144 7748841 06 2010 ...

Page 149: ...ankshaft hole and make sure the oil pump gear meshes with the crankshaft gear Install the bolts and tighten them alternately so that the gearwheel is not skewed Torque accord ing to Special Tightening Torques page 8 5 Clean the upper intermediate gear hub Check the oil holes are open Fit the washer onto the locator sleeve Check that the bolt holes align P0010186 P0010187 P0010186 21 0 Engine Compl...

Page 150: ...ine oil Install the intermediate gear turned so that the bearing is located outward 8 Check that the plate lubricating hole is open Lubricate the rear of the plate 9 Fit the plate onto the centering guide and install the bolts Tighten the bolts until they touch Check that the gearwheel rotates easily P0010189 P0010190 P0010191 21 0 Engine Complete General 146 7748841 06 2010 ...

Page 151: ...t Align the upper inter mediate gear teeth and fit the locator pin into the center hole Turn the hub so the bolt holes align Install the bolts and tighten according to Special Tightening Torques page 8 11 Install the lower intermediate gear P0010192 P0010324 21 0 Engine Complete General 7748841 06 2010 147 ...

Page 152: ...is moved to the left so that a large gear lash measurement between the camshaft gear and the intermediate gear is obtained When the camshaft gear is rotated counterclock wise until it stops the intermediate gear is moved to the right so that a no gear lash measurement between the camshaft gear and the intermediate gear is obtained In order to adjust gear lash to the correct value insert a 0 10 mm ...

Page 153: ...e the bolts and spacers from the camshaft gear Install the vibration damper bolts and washer Tighten the bolts refer to Special Tightening Tor ques page 8 16 Remove the crankshaft seal from the flywheel housing Clean the flywheel housing contact sur faces Check that the locator sleeves are in place 17 Apply a 2 mm 0 08 bead of sealant according to Special Tightening Torques page 8 must be torqued ...

Page 154: ...ear Ring Fywheel Replace page 204 20 Install a new crankshaft seal refer to Crankshaft Sealing Change rear page 219 Install the fly wheel Check the flywheel with regard to distortion refer to Flywheel Indication page 203 21 Install the covers with new seals Install the crank shaft sensor with a new seal refer to Sensors Adjustment page 113 10 8 6 2 4 11 9 7 1 3 5 P0005225 P0010159 P0010158 21 0 En...

Page 155: ...y Check to see if the oil sump rubber seal requires replacement Cut away excess sealant from the front crank shaft seal cover Cut away excess sealant from the timing plate and the flywheel housing Apply new sealant to the joints and install the oil sump within 20 min P0004300 P0010157 P0010147 21 0 Engine Complete General 7748841 06 2010 151 ...

Page 156: ...ip stick 26 Install the front engine mount and tighten the bolts according to Special Tightening Torques page 8 27 Install the cylinder head according to Cylinder Head Installation page 162 P0010122 P0010123 21 0 Engine Complete General 152 7748841 06 2010 ...

Page 157: ...pter 9990006 Puller 9990013 Slide hammer 885822 Magnetic pen 9998249 Protective sleeve 9998251 Protection plug 9996239 Lifting tool 9996966 Press tool 9998264 Lifting tool 1 Remove the air cleaner with attachment plate and the turbocharger pipe 2 Remove the rear engine lifting eye 3 Remove the turbocharger refer to Turbo Change page 275 P0010027 P0010028 21 1 Cylinder Head 7748841 06 2010 153 ...

Page 158: ...pes 2 pcs Remove the thermostat cover and thermostat refer to Ther mostat Change page 288 6 Remove the ventilation pipe and valve cover 7 Remove the wire harness Begin with the wires under the valve cover P0010029 P0010030 21 1 Cylinder Head 154 7748841 06 2010 ...

Page 159: ...ad 9 Remove the inlet manifold refer to Inlet Manifold Change page 269 10 TAD1350 53GE Remove the springs from the EGR rocker arms NOTICE Do not drop the bolts into the timing gear P0010031 P0010032 P0010033 21 1 Cylinder Head 7748841 06 2010 155 ...

Page 160: ...adjust the rocker arm holders This is done so that the rocker arms can be kept together per cylinder The higher holders must be used Lift the rocker arm bridge away Make sure the pistons in the exhaust rocker arms and the adjuster screw ball do not fall out 13 Mark and then remove the valve yokes P0010034 P0004965 3 2 4 5 6 P0010035 21 1 Cylinder Head 156 7748841 06 2010 ...

Page 161: ... and vibration damper bolts Lift away the vibration damper IMPORTANT make sure the vibration damper is protected from impact and shocks Remove the camshaft gear 16 Remove the camshaft cap bolts Check that the caps are marked 1 2 P0010036 P0010037 P0010038 21 1 Cylinder Head 7748841 06 2010 157 ...

Page 162: ...ck a unit injector loose using 9990006 Puller and 9990013 Slide hammer Check that the seal washer steel washer comes out with the injector If it is still in the copper sleeve remove it using 885822 Magnetic pen NOTICE The seal washer must always be replaced when installing an injector 999 6400 999 8674 P0010039 999 8264 P0010040 P0010040 9990013 9990006 P0001370 21 1 Cylinder Head 158 7748841 06 2...

Page 163: ...tive sleeve 22 Insert 9998251 Protection plug in the cylinder head 23 Remove the remaining injectors the same way 24 remove the coolant temperature sensor 999 8249 P0010041 999 8251 P0010042 P0010043 21 1 Cylinder Head 7748841 06 2010 159 ...

Page 164: ...ear is in the same position as illustrated Remove the bolts that hold the intermediate plate against the cylinder head 6 pcs Remove the upper bolts from the timing gear 4 pcs 27 Remove the cylinder head bolts P0010044 P0010045 P0010046 21 1 Cylinder Head 160 7748841 06 2010 ...

Page 165: ...way until it is free Lower the cylinder head onto a clean surface IMPORTANT The sealing surface must not be damaged 29 Remove the cylinder head gasket Install 9996966 Press tool to keep the liners in place Make sure the press tools are not able to damage the pistons if they are to be removed 999 6239 P0010047 9996966 P0010048 21 1 Cylinder Head 7748841 06 2010 161 ...

Page 166: ...els and unit injector copper sleeves Install protection plugs immediately after cleaning 3 Install a new cylinder head gasket and align it with the liners Make sure the two bolts and washers are in place and tightened 4 Apply sealant outside the timing plate groove 2 mm 0 08 wide bead The cylinder head must be finally tightened 20 min after the application of sealant 5 Make sure that the bolt and ...

Page 167: ...uence torque and angle tight ening in Special Tightening Torques page 8 When all the cylinder head bolts have been tight ened install the six bolts for the timing plate and tighten them 7 Check that the cam bearings are in position and fault free Oil the cam bearings Use 9998264 Lifting tool to lift the camshaft into position CAUTION Cutting hazard Protect your hands P0010051 14 38 37 10 30 29 4 1...

Page 168: ...ighten the caps according to Special Tightening Torques page 8 Check that the cam shaft can be rotated 10 Check that the flywheel marking is at zero Install the camshaft gear so that the locator pin aligns with the hole in the camshaft and the gear mark ing against the hole in the timing plate 11 Install at least three bolts with suitable spacers in the gear and tighten them P0010052 P0010053 P001...

Page 169: ...fer to Technical Data page 27 If the meas urement must be adjusted refer to Timing Gear Installation page 144 13 Remove the bolts and spacers from the camshaft gear Install the vibration damper bolts and washer Torque according to Technical Data page 27 14 Clean the upper timing cover Install new rubber seals on the cover 9999696 9999683 P0010055 P0010056 P0010057 21 1 Cylinder Head 7748841 06 201...

Page 170: ...e cover with the two bolts located in the oval holes Torque to 4 Nm 3 lbf ft 17 Fit 885810 Fixture and 9998601 Fixture Press down the cover so that it arrives at the same height as the upper side of the cylinder head P0005290 P0010058 999 8601 885 810 P0010059 21 1 Cylinder Head 166 7748841 06 2010 ...

Page 171: ...h a new seal and heat shield refer to Sensors Adjust ment page 113 20 Remove the protective plug for one unit injector where necessary use 9990156 Adapter and 9996400 Slide hammer Clean the copper sleeve with 9998599 Cleaning kit Protect the fuel channel with two 9998250 Sealing ring 1 2 4 5 P0005227 3 9990156 9996400 P0010061 21 1 Cylinder Head 7748841 06 2010 167 ...

Page 172: ...the marking made at removal 24 Remove the extra bolts located in the rocker arm bridge position Lubricate the valve yokes and the unit injector ball seats Lift the rocker arm bridge into place Guide all rocker arms so they arrive in the correct positions Make sure that the exhaust rocker arm pistons and the adjuster screw balls are in place Remove the lifting tool from the rocker arm bridge Instal...

Page 173: ...he bolts the bolts are tightened after valve adjustment 26 Install the valve and rocker arm lubrication oil pipe with new seals 27 Adjust the valves and unit injectors refer to Valves and Unit Injectors Adjustment page 177 28 Install the inlet manifold refer to Inlet Manifold Change page 269 P0010033 P0010034 21 1 Cylinder Head 7748841 06 2010 169 ...

Page 174: ... care to keep fuel unions clean Even minimal amounts of dirt in the fuel system can cause engine breakdown 30 Install the coolant temperature sensor if it was removed 31 Install the thermostat and cover with a new seal P0010031 P0010032 P0010064 21 1 Cylinder Head 170 7748841 06 2010 ...

Page 175: ...out of the manifold Bolt the new exhaust manifold gaskets onto the manifold the gaskets are marked Up and Mani fold side 34 Lift the manifold into position Tighten the bolts Make sure the gaskets do not come awry Tighten according to Special Tightening Torques page 8 P0010065 P0010320 1 1 3 5 7 9 11 12 10 6 8 4 2 P0005246 21 1 Cylinder Head 7748841 06 2010 171 ...

Page 176: ...cers and tighten the bolts Install the oil return pipe with new seals Fill the turbocharger with clean engine oil before the pressure hose is installed on the turbocharger Install the hose and actuator heat shield on the turbocharger and clamp it as illustrated NOTICE Do not tighten too hard P0010029 P0010096 21 1 Cylinder Head 172 7748841 06 2010 ...

Page 177: ...tach the wire harness with two clamps behind the belt pulley and one clamp on the inlet mani fold 38 Install the connectors to the temperature sensor and wastegate control valve Secure the wire harness with cable ties Make sure the wire harness does not touch the rear of the belt pulley 39 Install the connectors to the unit injectors and oil valve Clamp the wire harness under the valve cover with ...

Page 178: ...8 41 The remaining wire harness is secured after the engine fixture has been removed 42 Install the rear lifting eye 43 Install air filters with holders and turbocharger pipes 44 Install new oil filters and fill with engine oil 10 1 15 16 12 11 13 14 6 2 3 8 7 9 4 5 19 20 18 17 p0005236 P0010028 P0010027 21 1 Cylinder Head 174 7748841 06 2010 ...

Page 179: ...r as the base value 2 Measure the cylinder liner at top and bottom dead centers and at several places vertically At each measurement location measurement must be lengthwise and crosswise in relation to the engine 3 If wear is greater than 0 45 0 50 mm a new com plete lining kit must be used piston liner piston rings piston pin and seals Oil consumption also affects when cylinder liners must be cha...

Page 180: ...ks occur on the split line this may affect strength after torquing IMPORTANT If the connecting rod or bearing cap are damaged change the connecting rod Connecting Rod Bushing Check up 1 Check the connecting rods for cracking straight ness and twist before any piston pin bush replacement Scrap the connecting rod if it is cracked bent or twisted When the piston pin bush is changed the bush must be m...

Page 181: ...e valve cover 2 Rotate the crankshaft with tool 9993590 Rotation tooluntil the camshaft mark is located centrally between the marks on the bearing cap the marks for the cylinder to be adjusted NOTICE It is important that the line marked on the camshaft is centered between the two marks on the bearing cap when adjustment is carried out P0004806 5 3 5 1 4 TDC P0002568 21 4 Valve Mechanism 7748841 06...

Page 182: ...2 mm 0 0079 with the aid of a feeler gauge Tighten the lock nut 4 Check the valve play for the exhaust valves with the aid of a feeler gauge The play must be 0 8 mm 0 0315 Tighten the lock nut P0012060 P0012061 21 4 Valve Mechanism 178 7748841 06 2010 ...

Page 183: ...he play disappears by feel until the roller can no longer be rotated Tighten the adjuster screw a further 240 4 sides of the hexagon Tighten the lock nut 6 Rotate the crankshaft to the next camshaft mark and adjust the remaining valves in the same man ner P0012062 240 5 3 5 1 4 TDC P0002568 21 4 Valve Mechanism 7748841 06 2010 179 ...

Page 184: ...on tool from the toothed rim Valves and Unit Injectors Adjustment TAD1350GE TAD1351GE TAD1352GE TAD1353GE TAD1354GE TAD1355GE Tools 9993590 Rotation tool 1 Remove the valve cover 2 Loosen all hexagon socket cap screws to the EGR rocker arm springs P0004806 P0004806 21 4 Valve Mechanism 180 7748841 06 2010 ...

Page 185: ...rks for the cylinder to be adjusted NOTICE It is important that the line marked on the camshaft is centered between the two marks on the bearing cap when adjustment is carried out 4 Adjust the valve play for the inlet valves to 0 2 mm 0 0079 with the aid of a feeler gauge 5 3 5 1 4 TDC P0002568 P0004951 21 4 Valve Mechanism 7748841 06 2010 181 ...

Page 186: ...ntil the play disappears by feel until the roller can no longer be rotated Tighten the adjuster screw a further 240 4 sides of the hexagon Tighten the lock nut 6 Check the valve play for the exhaust valves with the aid of a feeler gauge The play must be 0 8 mm 0 0315 P0004952 P0004528 21 4 Valve Mechanism 182 7748841 06 2010 ...

Page 187: ...haft drive NOTICE Use a wrench on the yoke as a coun terhold during removal If the shims must be replaced undo the screw on the yoke while holding the yoke fast with a wrench so that the valves are not bent P0004594 21 4 Valve Mechanism 7748841 06 2010 183 ...

Page 188: ...8 When replacing shims press them home firmly P0004596 Example showing incorrectly installed shims P0004596 Example showing correctly installed shims 21 4 Valve Mechanism 184 7748841 06 2010 ...

Page 189: ...0 0315 10 Allow the feeler gauge to remain in place after adjustment and adjust the EGR rocker arm by loosening the locknut and adjusting the screw until no play is attained Check by rotating the rocker arm roller at the camshaft 11 Undo the adjuster screw 1 and 3 4 turns 630 Tighten the lock nut Remove the feeler gauge from the exhaust valve P0004594 P0004526 P0004953 21 4 Valve Mechanism 7748841...

Page 190: ...y between the camshaft and the roller on the EGR rocker arm The play must be between 3 7 mm 0 146 and 3 9 mm 0 154 13 Rotate the crankshaft to the next camshaft mark and adjust the remaining valves in the same man ner P0005197 5 3 5 1 4 TDC P0002568 21 4 Valve Mechanism 186 7748841 06 2010 ...

Page 191: ...gs NOTICE Ensure that the springs position cor rectly on the pressure points 15 Check the valve cover gasket Change as nec essary Install the valve cover 16 Remove tool 9993590 Rotation tool from the toothed rim P0004806 21 4 Valve Mechanism 7748841 06 2010 187 ...

Page 192: ...e in the valve guide with the valve stem end in the same plane as the edge of the guide Use a suitable counterhold under the valve stem 4 Place tool 9989876 Dial indicator and tool 9999696 Magnetic stand so that the dial indicator tip is touching the valve disc edge Move the valve sideways in the direction of the exhaust or inlet duct Read off the value on the dial gauge 5 Check all valve guides I...

Page 193: ...ive to 9809726 Removal 1 Install tool 9990176 Press tool into the cylinder head retaining bolt holes NOTICE Put washers between the nuts and the cylinder head plane 2 Tighten the nuts of the tool 3 Install tool 9996159 Adapter in the hydraulic cyl inder 4 Fit tool 9809729 Hydraulic cylinder into tool 9990176 Press tool and press out the valve guide using tool 88800147 Drift and9809726 Pneu matic h...

Page 194: ...head plane 9 Remove the tool from the cylinder head IMPORTANT After the valve guides have been changed the cylinder head must be cleaned carefully to prevent dirt particles from getting into the fuel and oil ducts Contamination may cause failure or malfunction of the unit injectors Option 2 Tools 9992000 Handle 88800147 Drift 88800062 Drift NOTICE If the valve seats must also be changed this must ...

Page 195: ...N Risk of eye injury Eye protection required 4 Tap in the valve guide for the inlet valve using tool 88800062 Drift Tap in the exhaust valve guide using the same tool 5 Tap until the tool bottoms against the cylinder head plane 6 Repeat the procedure for the remaining valve guides IMPORTANT After the valve guides have been changed the cylinder head must be cleaned carefully to prevent dirt particl...

Page 196: ...e 1 1 Fit tool 9809729 Hydraulic cylinder into tool 9990176 Press tool 2 Install tool 9996159 Adapter and tool 9998246 Drift inlet or tool 9990174 Drift outlet on the hydraulic cylinder Place the tool in the holes for the cylinder head retaining bolts Tighten the tool nuts 3 Connect tool 9809726 Pneumatic hydraulic pump alternatively 9992670 Hand pump 4 Press the valve spring washer down and remov...

Page 197: ...jector yoke M10 x 30 3 Place the moving part of the tool over the valve spring to be removed Screw down the wing nut on the tool until the valve washer has been pressed down so far that the collets can be removed NOTICE Put the valves and springs in a marked stand to facilitate putting components back in the same places in the cylinder head 4 Remove the remaining valves in the same way as above 5 ...

Page 198: ...tool 9990165 Guide sleeve on the valve stem and press the new oil seals down over the valve guides NOTICE Check that the oil seals are pressed down properly If necessary use 88800151 Drift and tap carefully with a plastic mallet Alternative 1 3 Install the valve caliper guide pins Install the springs and valve spring washers Carefully press down the valve spring washer and install the collets Use ...

Page 199: ... 9990210 Valve spring compressor 1 Alternatively tool 9990210 Valve spring com pressor may be used instead of the hydraulic cyl inder in the same way as for Valves Removal P0006997 21 4 Valve Mechanism 7748841 06 2010 195 ...

Page 200: ...ve an unnecessary amount of material only remove enough material to give the valve seat the correct shape and a good mating surface 3 Grind new seats down so far that the dimension between the cylinder head plane and the valve disc surface is in accordance with specifications refer also to Technical Data page 27 4 Check the valve seat angle with a valve seat gauge once the seat mating surface has ...

Page 201: ... greater than the wear tolerance as specified in Technical Data page 27 the valve must be changed NOTICE Always change a valve with a bent valve stem 2 Check valve sealing with marker dye If there is any leakage grind the valve seat again refer to Valve Seat Grinding then do a new check Once the results of grinding are acceptable the valve and seat may be lapped in with fine grinding paste P000700...

Page 202: ...nce A exceeds the value stated in the specification refer to Technical Data page 27 2 Grind the head off an old valve and weld it onto the valve seat Use a MAG welder or a conven tional arc welder with a stainless welding elec trode IMPORTANT Carefully cover the other surfaces on the cylinder head to prevent any weld spatter from fastening P0007000 P0007001 P0007002 21 4 Valve Mechanism 198 774884...

Page 203: ...e cylinder head Determine whether a standard or oversize dimension valve seat must be used Carry out any necessary machining to the valve seat bed refer to Technical Data page 27 6 Cool the seat in carbon dioxide snow between 60 C 76 F and 70 C 94 F and heat the cylinder head by flushing with hot water or by some other method Install the new valve seat using a drift NOTICE Align the seat with the ...

Page 204: ...Slide tool 88800151 Drift over the valve stem and tap the seal down carefully with a plastic mal let 8 Install the valve springs valve spring washers and collets Carefully tap with a plastic mallet to make sure the collets end up in the right position 9 Transfer the valve spring compressor to no 6 cyl inder and repeat the tasks as above Then crank the engine so that no 3 and no 4 cylinder are at T...

Page 205: ...nes for replacement In normal conditions unevenness may occur on the sur face of engine camshaft lobes This does not mean that the camshaft has to be changed These marks do not have any negative influence on either engine perform ance or the durability of the engine and its components Examples of acceptable wear and unacceptable wear are shown below Lighter scratches The camshaft does not need to ...

Page 206: ...factory installed bearing housings are machined with the cylinder head and are therefore not replacea ble If a bearing housing is damaged the complete cyl inder head must be replaced P0007018 21 5 Timing Gears and Shaft 202 7748841 06 2010 ...

Page 207: ...d check the min and max deflections on the dial indicator The value should not exceed 0 20 mm 0 0079 3 If the distortion is greater and this is not the result of a damaged surface where the dial indicator is applied remove the flywheel and check that there is no waste material or damage to the contact flange on the flywheel and crankshaft Clean the flanges or change the flywheel if it is damaged T...

Page 208: ... up to 180 200 C 356 392 F with a welding torch or in an oven The gear ring must be evenly heated Be careful not to heat the gear ring up far with annealing as a result Check the heat by polishing the ring bright at sev eral places Stop heating when the polished sur faces become blued 4 Put the heated gear ring onto the flywheel and tap it into place with a soft mandrel and hammer Leave the gear r...

Page 209: ...ck screw press in the tool firmly so that it is in contact with the cover Press in the center part of the tool until it contacts the gearwheel and tighten the lock screw Rove the tool and inspect the center section posi tion in its sleeve 4 Determine further actions according to the following P0010219 If the center section of the tool is entirely below the sleeve s upper edge no shims are required...

Page 210: ...P0010220 If the two center section surfaces are above the sleeve s top edge two shims are required 5 Install the sensor with a new seal and any shims 21 5 Timing Gears and Shaft 206 7748841 06 2010 ...

Page 211: ...gs with the crankshaft in place in the engine Tools 9990013 Slide hammer 9990114 Puller 9993590 Rotation tool Removal 1 Fit tool 9993590 Rotation tool 2 Remove the oil suction pipe and oil pump Remove the bracing frame P0006884 P0010124 21 5 Timing Gears and Shaft 7748841 06 2010 207 ...

Page 212: ... are changed NOTICE If case of uncertainty check in Techni cal Data page 27 which oversize dimensions are available Installation 7 Lubricate the shaft journal and the new bearing shells with engine oil 8 Install the upper bearing shell by turning the crankshaft using tool 9993590 Rotation tool against the direction of rotation with the pin in the oil hole NOTICE Check that the pressed out bearing ...

Page 213: ...seize by turning it using tool 9993590 Rotation tool 11 Check crankshaft end float and replace the thrust washers if the clearance is too great or if the thrust washers are damaged NOTICE Measure the end float with a dial gauge Thrust bearings are available in a number of over size dimensions Refer to Technical Data page 27 for oversize dimensions and axial play The crankshaft thrust bearing is lo...

Page 214: ...acing frame and torque according to the tightening chart refer to Technical Data page 27 15 Install the oil pump and oil suction pipe 16 Remove tool 9993590 Rotation tool from the fly wheel housing and install the cover 17 Install the oil pan Add oil and change the oil filter Check the oil pressure P0006975 21 5 Timing Gears and Shaft 210 7748841 06 2010 ...

Page 215: ...emove the radiator where fitted IMPORTANT Do not lay the fan down Oil may run out that can not run back in again 3 Remove the cooling fan 4 Remove the right belt guard refer to Belt Protec tor page 296 5 Remove the belts For the drive belt refer to Drive Belts page 290 For the alternator belt refer to Alternator Belts Change page 298 6 Remove the automatic belt tensioner P0004682 21 6 Crank Mechan...

Page 216: ... a counterhold 8 Remove the bolts to the outer oscillation damper 9 NOTICE The oscillation damper weighs approx 15 kg Make sure that it is not damaged Carefully remove the outer vibration damper P0004786 P0004785 21 6 Crank Mechanism 212 7748841 06 2010 ...

Page 217: ...rift 13 Drill two holes Ø3 5 mm in the seal with the aid of the guide hole in the tool Bush grease on the drill to prevent dirt from getting into the engine 14 Screw in two suitable sheet metal screws 1 length approx 50 mm through the holes in the tool so that they fasten firmly in the seal 15 Fit two long threaded M10x60 bolts 2 and screw them in until the seal releases P0004787 P0004788 P0004789...

Page 218: ...Installation 9992000 Handle 9993590 Rotation tool 88800021 Drift 17 Check that the plastic ring is correctly in place in the new seal NOTICE If the plastic ring is not in place in the new seal the seal ring may be damaged and must not be used 18 Clean the crankshaft sealing surface and cover Check that these are damage free 19 Install the new seal ring and plastic ring onto the crankshaft journal ...

Page 219: ...20 Press the seal toward the cover by hand 21 Remove the plastic ring P0004792 P0004793 21 6 Crank Mechanism 7748841 06 2010 215 ...

Page 220: ...re that the crankshaft belt pulleys and hub mating surfaces are clean and damage free 24 Fit the inner belt pulley vibration damper 25 Install the outer belt pulley 26 Install the hub 27 Where necessary use tool 9993590 Rotation tool as a counterhold P0004794 P0004786 21 6 Crank Mechanism 216 7748841 06 2010 ...

Page 221: ...ing Torques page 7 29 Ensure that the outer oscillation damper surfaces are clean and damage free 30 Install the outer oscillation damper 31 Torque the oscillation damper bolts according to specifications Refer to General Tightening Tor ques page 7 P0004787 P0004785 21 6 Crank Mechanism 7748841 06 2010 217 ...

Page 222: ...efer to 703 Drive Belt Change 35 Ensure the belts track in their grooves 36 Install the right belt guard Refer to Belt Protec tor page 296 37 Install the cooling fan 38 Install the radiator where fitted 39 Refill with coolant Refer to Coolant Level Check ing and Topping Up page 280 P0004682 21 6 Crank Mechanism 218 7748841 06 2010 ...

Page 223: ...Crankshaft Sealing Change rear Tools 9990166 Mounting tool 9990192 Puller 9996400 Slide hammer Removal 1 Remove the flywheel sensor P0004796 21 6 Crank Mechanism 7748841 06 2010 219 ...

Page 224: ...ting device 4 Remove the last bolt and lift away the flywheel 5 Fit 9996400 Slide hammer and 9990192 Puller Check that the tools are free from burrs and grime 6 NOTICE Be careful not to damage the crank shaft Incline the tool inwards to ensure a good grip in the seal Knock out the seal P0004795 P0004954 21 6 Crank Mechanism 220 7748841 06 2010 ...

Page 225: ...and bottoms firmly against the crankshaft before the bolts are tight ened Fit 9990166 Mounting tool onto the crankshaft and screw it in place 8 Fit the spacer ring to the pin bolt NOTICE The spacer ring determines how far in the seal must be 9 The seal is supplied with a plastic installation ring The plastic ring must not be removed from the seal P0004960 P0004957 21 6 Crank Mechanism 7748841 06 2...

Page 226: ...g 11 Install the cover together with its handle Press in the seal by rotating the handle NOTICE When the cover bottoms the seal is in the correct position 12 Remove the tool and the installation ring P0004959 P0004958 21 6 Crank Mechanism 222 7748841 06 2010 ...

Page 227: ...e keyway Install one bolt to render the lift safe 14 Install the remainder of the bolts Torque according to specifications Refer to Gen eral Tightening Torques page 7 15 Install the flywheel sensor P0004795 P0004796 21 6 Crank Mechanism 7748841 06 2010 223 ...

Page 228: ...als If there is any damage on the surface layer the shaft must be re ground 3 Place the shaft pair of V blocks under 1st and 7th main bearing journals Alternatively hold the crankshaft between the two centers 4 Measure crankshaft axial displacement throw on the 4th main bearing For maximum permissible values refer to Tech nical Data page 27 IMPORTANT Crankshaft straightening is not permitted 5 Che...

Page 229: ...n bearings with the crankshaft in place in the engine Tools 9990013 Slide hammer 9990114 Puller missing tool Removal 1 Fit tool missing toolreference 2 Remove the oil suction pipe and oil pump Remove the bracing frame P0006884 P0010124 21 6 Crank Mechanism 7748841 06 2010 225 ...

Page 230: ...ells are changed NOTICE If case of uncertainty check in Techni cal Data page 27 which oversize dimensions are available Installation 7 Lubricate the shaft journal and the new bearing shells with engine oil 8 Install the upper bearing shell by turning the crankshaft using tool missing toolreference against the direction of rotation with the pin in the oil hole NOTICE Check that the pressed out bear...

Page 231: ...ot seize by turning it using tool missing toolre ference 11 Check crankshaft end float and replace the thrust washers if the clearance is too great or if the thrust washers are damaged NOTICE Measure the end float with a dial gauge Thrust bearings are available in a number of over size dimensions Refer to Technical Data page 27 for oversize dimensions and axial play The crankshaft thrust bearing i...

Page 232: ... bracing frame and torque according to the tightening chart refer to Technical Data page 27 15 Install the oil pump and oil suction pipe 16 Remove tool missing toolreference from the fly wheel housing and install the cover 17 Install the oil pan Add oil and change the oil filter Check the oil pressure P0006975 21 6 Crank Mechanism 228 7748841 06 2010 ...

Page 233: ...ine oil drained Removal 1 Remove the oil filler with attachment and the oil dipstick Remove the oil level sensor connector 2 Remove the oil sump bolts and remove the sump 3 Remove the oil filters P0010122 P0010454 22 1 Oil pump and Line 7748841 06 2010 229 ...

Page 234: ...to the pump remove the delivery pipe from the pump Remove the connection pipe 5 Remove the reinforcement plate CAUTION Cutting hazard Protect your hands 6 Remove the oil pump P0010535 P0010536 P0010536 22 1 Oil pump and Line 230 7748841 06 2010 ...

Page 235: ...zard Protect your hands 9 Use new seals for all pipes Install the delivery pipe from the pump Install the connection pipe Tighten all bolts to the reinforcement plate in the sequence and torques according to Special Tightening Torques page 8 Install the suction strainer and pipe to the oil pump P0010536 P0010535 22 1 Oil pump and Line 7748841 06 2010 231 ...

Page 236: ... Cut away excess sealant from the timing plate and the flywheel housing Apply new sealant to the joints and install the oil sump within 20 min 11 Tighten the oil sump bolts and install the engine mount and tighten according to Special Tighten ing Torques page 8 Install new oil filters Fill with engine oil P0010147 22 1 Oil pump and Line 232 7748841 06 2010 ...

Page 237: ...chnical Data page 40 2 Remove the plug and attach 9990263 Nipple 3 Install 9996398 Manometer 4 Start the engine and check the oil pressure If the oil pressure measurement shows that the pressure is below the minimum value as speci fied continue troubleshooting by checking the oil filters If the oil pressure measurement using an external pressure sensor shows that the pressure is within tolerance b...

Page 238: ... 2 Remove the front oil pipe 1 located between the oil cooler and filter bracket Remove the oil hose 2 to the turbocharger Remove the pressure sensor connector 3 3 Remove the rear oil pipe located between the oil cooler and filter bracket P0010000 P0009999 22 2 Oil filter 234 7748841 06 2010 ...

Page 239: ...racket Remove the gasket Installation 6 Move over the parts that are to be reused to the new bracket 7 Thoroughly clean the engine block contact surfa ces for the bracket IMPORTANT Sealant may absolutely not be used The use of sealant may result in engine breakdown P0010001 P0010002 P0010003 22 2 Oil filter 7748841 06 2010 235 ...

Page 240: ...0 Install the front and rear pipes to the oil cooler with new seals Install the hose to the turbocharger with a new seal Install the pressure sensor connector Clamp the heat shield to the pressure sensor Install new oil filters Clamp the hose to the waste gate controller 11 Replenish or change the oil 12 Start the engine and check oil system function and integrity 13 Switch the engine off and chec...

Page 241: ...afety valve and make sure the O rings come with it Check that there is no dirt on the valve sealing surface on the engine block 4 Install a new O ring on the valve cover Brush a little grease on the O ring and press it in place so that it is secure 5 Install the valve half way into the cover P0010334 P0010335 P0010336 22 2 Oil filter 7748841 06 2010 237 ...

Page 242: ...acket Change page 234 in order to gain access to the overflow valve 2 Remove the overflow valve plug Remove the seal washer spring and valve body and replace with new parts Clean the oil channels and check the seal seat in the bracket Install the valve body with the spring and the plug with the seal washer 3 Install the oil filter bracket with a new seal refer to Oil Filter Bracket Change page 234...

Page 243: ...e oil cooler Remove the coolant drain pipe Remove the thermostat housing bolts One of the rear bolts is saved until last One bolt behind the water pump must remain in place in the cover when the former is removed Carefully prise the cover away from the engine block Lift the cover and oil cooler away to the rear P0009970 P0009971 P0009972 22 3 Oil cooler 7748841 06 2010 239 ...

Page 244: ...4 Remove the oil cooler cover plate 5 Remove the oil cooler 6 Remove the two seal rings 7 Clean all sealing surfaces P0009973 P0009974 P0009975 P0009976 22 3 Oil cooler 240 7748841 06 2010 ...

Page 245: ...nst the water pump and replace as necessary Installation 9 Install new seal rings on the oil cooler 10 Install the oil cooler 11 Install the oil cooler plate P0009977 P0009975 P0009974 P0009973 22 3 Oil cooler 7748841 06 2010 241 ...

Page 246: ...e groove 13 Install bolt 1 which will end up behind the water pump in the cover Lift the cover into place Install a bolt 2 in the oval hole 14 Press the cover forward and install another bolt Install the remaining bolts and tighten them according to the chart in Special Tightening Tor ques page 8 15 Install the oil pipes with new seals and tighten them install the coolant drain pipe 16 Fill the co...

Page 247: ...nd the air cleaner Check the engine oil level and top up if necessary Thermostat Oil Cooler Change 1 Clean the surface around the thermostat 2 Remove the thermostat housing bolts Remove the thermostat and O ring P0009971 P0010338 P0010339 22 3 Oil cooler 7748841 06 2010 243 ...

Page 248: ...rt in the oil ducts Clean the O ring groove 4 Install a new O ring in the groove Install a new thermostat Tighten the bolts 5 Start the engine and check that no oil leakage is present P0010340 22 3 Oil cooler 244 7748841 06 2010 ...

Page 249: ...el filter bracket 3 Open the nipple on the front fuel connection Con nect a drain hose 4 Purge the fuel system by pumping with the hand pump until fuel flows Close the nipple and secure the hand pump 5 Start the engine and allow it to idle fast for about 10 minutes 6 Perform a leakage and function check P0004969 P0004970 23 0 Fuel System General 7748841 06 2010 245 ...

Page 250: ... fuel connections at the cylinder head rear end 2 Remove the purging hose screw Remove the two clamps 3 Remove the fuel supply line on the engine topside coming from the filter bracket Remove the two clamps NOTICE Do not remove the lower union at the filter bracket P0005062 P0005061 23 0 Fuel System General 246 7748841 06 2010 ...

Page 251: ... the fuel channel in the cylinder head so that it runs out into the receptacle 6 NOTICE If a compression test must be carried out do not connect the fuel lines until the test has been completed Otherwise the cylinder head fuel channels will fill with fuel again 7 When installing the fuel hoses use new seals P0005059 P0005060 23 0 Fuel System General 7748841 06 2010 247 ...

Page 252: ...o specifications Refer to Engine Gen eral page 26 3 Remove the tool Install new fuel line seals Fuel Filter Bracket Change IMPORTANT Take great care to keep fuel system unions clean Even minimal amounts of dirt can cause engine break down Removal 1 Switch off battery power 2 Thoroughly clean the fuel filter bracket fuel hoses and unions and the area around the bracket P0005070 23 3 Fuel Feed Pump ...

Page 253: ...urn fuel line from the bracket Remove the pump supply line from the bracket 5 Remove the inlet line to the bracket Remove the pump line from the bracket Remove the bracket s rear attachment bolt Retain the rubber bushing located behind the bracket Remove the supply line banjo bolt P0009988 P0009989 P0009990 23 3 Fuel Feed Pump and Filter 7748841 06 2010 249 ...

Page 254: ...e bracket Lift away the bracket Installation 7 Move over any parts that are to be reused to the new bracket 8 Install two retaining bolts and the rubber bushings to the bracket the lower one and the front one P0009989 p0009992 P0009989 23 3 Fuel Feed Pump and Filter 250 7748841 06 2010 ...

Page 255: ...bushing and the bracket s rear bolt 10 Install the upper fuel lines with new seals 11 Install new fuel filters and connect the connector Vent the fuel system Start the engine and check fuel system integrity P0009990 P0009989 P0009994 23 3 Fuel Feed Pump and Filter 7748841 06 2010 251 ...

Page 256: ...un out into the container Remove the bolts that attach the entire unit to the engine 3 Lift away the pump ad drive 4 Remove the bolts that attach the pump to the drive device Remove the pump 5 Retain the intermediate section to the drive Check that the drive bearings feel serviceable and that the gearwheel is not damaged P0004300 P0010541 P0010543 P0010543 23 3 Fuel Feed Pump and Filter 252 774884...

Page 257: ...w pump Turn the gearwheel so that the intermediate piece fits against the pump and tighten the pump bolts refer to General Tighten ing Torques page 7 8 Clean the sealing surfaces and install a new O ring on the drive unit P0010542 P0010541 P0010540 23 3 Fuel Feed Pump and Filter 7748841 06 2010 253 ...

Page 258: ...ing the gearwheel into the timing and then tighten the bolts Install the fuel lines with new seals 11 Vent the fuel system refer to Fuel system bleed ing page 245 12 Start the engine and check fuel system integrity P0010539 P0004300 23 3 Fuel Feed Pump and Filter 254 7748841 06 2010 ...

Page 259: ...98599 Cleaning kit includes 9808570 Brush 9808616 Extender 9998580 Protective sleeve For valves and unit injector adjustment refer to Valves and Unit Injectors Adjustment page 177 Removal 1 Remove the ventilation pipe and valve cover 2 Undo the connectors to the unit injectors and oil valve 3 Remove the EGR rocker arm springs NOTICE Do not drop the bolts into the timing gear P0010099 P0010033 23 7...

Page 260: ...gether for each cylinder The higher holders must be used Lift the rocker arm bridge away Make sure the pistons in the exhaust rocker arms and the adjuster screw ball do not fall out 6 Mark and remove the valve yokes 7 Empty the cylinder head fuel channels refer to Draining Fuel Duct in Cylinder Head page 246 8 Remove the bolts for the unit injector retaining yoke P0010034 P0004965 3 2 4 5 6 P00100...

Page 261: ...ing 885822 Magnetic pen IMPORTANT The seal washer must always be replaced when installing an injector 10 Put the injector in 9998249 Protective sleeve 11 Insert 9998251 Protection plug in the cylinder head Clean the copper sleeves thoroughly with the aid of 9998599 Cleaning kit 9990013 9990006 P0001370 999 8249 P0010041 999 8251 P0010042 23 7 Injectors and Delivery Pipes 7748841 06 2010 257 ...

Page 262: ...tective sleeve and 3883672 Protec tive sleeve and install a new steel washer on the injector sealing surface IMPORTANT The steel washer must be replaced every time an injector is installed Install the injector and injector yoke Turn the injector so that the wiring connections are exactly opposite the valve springs Install the retaining bolt and tighten according to Special Tightening Torques page ...

Page 263: ...e rocker arm shaft bolts Check that the valve calipers are positioned correctly on the valve stem Tighten the bolts alternately so that the rocker arm shaft is not bent Make sure the shaft guides the locator sleeves on the bearing caps Tighten the bolts refer to Special Tightening Tor ques page 8 17 Install the EGR rocker arm springs Make sure the springs are positioned correctly on the rocker arm...

Page 264: ... and oil valve Clamp the wire harness under the valve cover with original cable ties heat and oil resist ant 21 Install the valve cover Replace gasket as neces sary Tighten according to Special Tightening Torques page 8 22 Vent the fuel system refer to Fuel system bleed ing page 245 P0010034 P0010099 10 1 15 16 12 11 13 14 6 2 3 8 7 9 4 5 19 20 18 17 p0005236 23 7 Injectors and Delivery Pipes 260 ...

Page 265: ...ooling System page 278 2 If necessary remove tool 9998251 Protection plug 3 Install 2 seal rings tool 9998250 Sealing ring to prevent dirt from getting into the fuel ducts when the copper sleeve is removed NOTICE Ensure that the piston is in its lower position 4 Lubricate the tap tool 9809667 Thread tap M9 with grease in order to prevent swarf from falling into the cylinder Screw the tap at least ...

Page 266: ...me time as the pin is held secure 8 Use cleaning kit tool 9998599 Cleaning kit and a power drill before fitting the new copper sleeve Install tool 9998580 Protective sleeve in the injec tor hole and secure it with a holder IMPORTANT Tool 9998580 Protective sleeve must be used to prevent dirt from getting into the fuel duct 9 Clean the cylinder head walls for the copper sleeve with part no 9808618 ...

Page 267: ...is must be done so that tool no 9998688 does not damage the piston due to its length 14 Always use the new version copper sleeve with two grooves at the upper edge when replacing IMPORTANT The steel gasket supplied with the new copper sleeve must be used when installing the unit injec tor Lubricate the O ring on the copper sleeve with soapy water IMPORTANT Always use a new O ring P0007011 999 8580...

Page 268: ... NOTICE The tool only fits the new version cop per sleeve 16 Place 88800196 together with the copper sleeve in the cylinder head Make sure the copper sleeve bottoms in the cylinder head Install the unit injector yoke Use tool 1159794 Torque wrench to press in the copper sleeve torque 80 Nm 59 lbf ft 88800196 P0003616 88800196 P0003617 23 7 Injectors and Delivery Pipes 264 7748841 06 2010 ...

Page 269: ...washer refer to Unit Injector Replace page 255 20 Put the valve yoke back in accordance with the marking 21 Install the rocker arm bridge and check the clear ance of the valves and unit injectors 22 Install the valve cover 23 Fill up with coolant and check that no leakage occurs Refer also to Coolant Level Checking and Topping Up page 280 88800196 P0003618 9998250 P0003619 23 7 Injectors and Deliv...

Page 270: ...ware refer to Service manual EMS 2 IMPORTANT Exchange of control units between engines during fault tracing or repair must never be performed under any circumstances 1 Clean thoroughly around the control unit fuel con nections 2 Disconnect power from the engine by disconnect ing the negative battery terminal 3 Remove the lower part of the crankcase breather pipe 4 Remove the upper and lower cable ...

Page 271: ...Connect the upper and lower fuel connections to the cooling element with new sealing washers 11 Install the harness and clamps 12 Install the crank case breather lower pipe 13 Bleed the fuel system Refer to Fuel system bleeding page 245 Start the engine and check for error codes Refer to the Service Manual EMS 2 P0010470 23 8 Control System ECM Data Sets 7748841 06 2010 267 ...

Page 272: ...w and engine performance will be affected If the pipes are contaminated with oil on the inside this indi cates oil leakage in the turbocharger turbine shaft seal In this case the turbocharger should be changed as a unit NOTICE If there is any oil in the charge air pipes and charge air hoses the charge air cooler and all pipes and hoses in the charge air system must be cleaned very carefully before...

Page 273: ...tween the inlet pipe and the charge air cooler 2 Remove the hose to the waste gate actuator 3 Remove the connection to the engine control unit and the wire harness clamps Remove the relay holder and stop button bolts Remove the wire harness clamp bolts P0009981 P0009983 25 1 Inlet and Exhaust Manifolds 7748841 06 2010 269 ...

Page 274: ...pipe 5 Remove the bolts for the fuel hose holders and place the holders on the valve cover Remove the inlet pipe bolts and lift away the pipe Installation 6 Inspect and clean the sealing surfaces on the cyl inder head and inlet manifold P0009984 P0009985 P0009987 25 1 Inlet and Exhaust Manifolds 270 7748841 06 2010 ...

Page 275: ...ains Apply a thin bead of sealant 1161771 in the groove max 20 mins before the inlet manifold is installed 9 Spread out the sealant with a finger so that only a thin layer is in the groove 10 Press the new seal into the groove Make sure that the seal joint arrives in the intended notch and that the seal s flat surface reaches the bottom of the groove P0010332 P0010241 P0010242 25 1 Inlet and Exhau...

Page 276: ...e Install the connector for the charge air pressure sensor and secure the wiring with cable ties 13 Install the relay holder on the engine block and bolt the wire harness to the inlet manifold Install the connectors to the engine control unit and the wire harness clamps P0010333 P0009984 P0009983 25 1 Inlet and Exhaust Manifolds 272 7748841 06 2010 ...

Page 277: ...ator hose 15 Install the hose between the charge air cooler and the inlet pipe 16 Switch on battery power and start the engine 17 Check inlet manifold airtight integrity P0009981 25 1 Inlet and Exhaust Manifolds 7748841 06 2010 273 ...

Page 278: ...ve too much clearance between wheel and housing In both cases charge air pressure will be too low 3 Remove the inlet manifold from the turbocharger 4 Check the turbocharger for damage to the com pressor wheel and excessive end float on the tur bine shaft 5 If there is any damage on the compressor wheel or excessive end float on the turbine shaft the turbocharger must be changed as a unit 6 Remove ...

Page 279: ... cooler 4 Remove the exhaust pipe muffler 5 Remove the hose heat shield 1 and lay it to one side 6 Remove the hose 2 to the waste gate actuator 7 Remove the oil supply pipes 3 from the turbo charger 8 Remove the oil supply pipe 4 and the union by undoing the bolts beneath the turbocharger Pull the pipe from the engine block P0004694 P0004693 25 5 Turbocharger 7748841 06 2010 275 ...

Page 280: ...e Blow through the manifold and check that there is no contamination in the pipe Install a new gasket on the exhaust manifold Installation 12 Lift the turbocharger into position Install the spacer sleeves and nuts and fasten the turbo charger refer to General Tightening Tor ques page 7 P0004784 P0004783 P0004784 25 5 Turbocharger 276 7748841 06 2010 ...

Page 281: ... the turbocharger inlet pipe is thor oughly clean internally before it is installed between the air filter and turbocharger Check that the pipe between the turbocharger and charge air cooler is clean internally if there is contamination in the pipe the charge air cooler also requires internal cleaning Install the pipe between the turbocharger and the charge air cooler Install the exhaust system St...

Page 282: ... Open all drain points Drain the coolant from the radiator and engine block using tool 9996049 Draining hose The drain nipples are sit uated under the radiator on the right side of the engine block 3 Check that all coolant drains out Deposits may be found inside the drain plug tap and need to be cleared away There is otherwise a risk that cool ant could remain and cause frost damage Check whether ...

Page 283: ... be done with coolant Otherwise continue as in stage 8 below 4 Fill the cooling system with 15 20 mixture of concentrated coolant Use only Volvo Penta rec ommended concentrated coolant mixed with clean water 5 Drain the coolant after 1 2 days of operation Remove the filler cap and the lower radiator hose if necessary to increase emptying speed To prevent suspended material from settling back in th...

Page 284: ...ping Up IMPORTANT Only use the coolant recommended by Volvo Penta 1 NOTICE Open only the filler cap 1 Do not open the pressure cap 2 2 Check that the coolant level is above the MIN mark on the expansion tank 3 Top up with coolant as required so that the level is between the MIN and MAX marks Filling a completely empty system NOTICE Mix the correct amount of coolant in advance to ensure that the co...

Page 285: ...s 3849613 Pressure testing kit 1 Check that all hoses and clamps are undamaged and intact 2 Check the coolant level in the expansion tank 3 Replace the filler cap on the expansion tank with a suitable cover from 3849613 Pressure testing kit 4 Connect the pump and pump up a pressure of 70 kPa 0 7 bar 5 Pressure must not drop for a two minute test period for the cooling system to be regarded as bein...

Page 286: ...Draining hose 1 Check that all hoses and clamps are undamaged and intact 2 Check the coolant level in the expansion tank 3 Connect 9996662 Pressure testing kit to 9996049 Draining hose and close the cock Con nect the hose to the engine drain valve 1 Open the cock and adjust the pressure to 70 kPa 0 7 bar with the adjuster knob Then close the tap 4 Pressure must not drop for a two minute test perio...

Page 287: ...Re install the rubber plug in the engine drain valve 7 Check the coolant level in the expansion tank 8 Start the engine and check that no leakage occurs 26 0 Cooling System General 7748841 06 2010 283 ...

Page 288: ...ain the coolant Refer to Draining the Cooling System page 278 2 Remove the right belt guard Refer to Belt Pro tector page 296 3 Wind off the belt Refer to Drive Belts page 290 4 Remove the three bolts to the automatic belt ten sioner P0004682 26 2 Coolant Pump Thermostat 284 7748841 06 2010 ...

Page 289: ...t pump Remove the coolant pump Installation 6 Clean and check the sealing surfaces 7 Where necessary transfer the belt pulley to the new pump 8 Install a new rubber gasket P0004683 P0004684 26 2 Coolant Pump Thermostat 7748841 06 2010 285 ...

Page 290: ...9 Install the pump and the six bolts 10 Check the idler and tensioner pulleys on the auto matic belt tensioner P0004683 P0004686 26 2 Coolant Pump Thermostat 286 7748841 06 2010 ...

Page 291: ... NOTICE Make sure the key engages in the key way Tighten the bolts 12 Wind on the belt Refer to Drive Belts page 290 13 Install the right belt guard Refer to Belt Protec tor page 296 P0004682 26 2 Coolant Pump Thermostat 7748841 06 2010 287 ...

Page 292: ...the Cooling System page 278 Drain off coolant sufficient for its level to drop below the thermostat housing 2 Remove the upper belt guard refer to Belt Pro tector page 296 3 Remove the thermostat housing cover 4 Remove the thermostat P0004690 P0004691 26 2 Coolant Pump Thermostat 288 7748841 06 2010 ...

Page 293: ...he bolts 8 Install the upper belt guard Refer to Belt Protec tor page 296 IMPORTANT Ensure that engine wiring is not pinched 9 Refill with new coolant refer to Coolant Level Checking and Topping Up page 280 10 Start the engine and check for leaks Pressurize the cooling system refer to Cooling System Pressure Testing page 108 P0005071 P0004691 P0004690 26 2 Coolant Pump Thermostat 7748841 06 2010 2...

Page 294: ... Belts Right belt guard removed refer to Belt Protec tor page 296 Removal 1 Lift the lever CAUTION Pinch hazard Keep fingers clear Wind off the belt P0004685 26 2 Coolant Pump Thermostat 290 7748841 06 2010 ...

Page 295: ...Installation 1 Check the belt tensioner pulleys 2 Lift the lever CAUTION Pinch hazard Keep fingers clear Wind on the belt P0004686 P0004685 26 2 Coolant Pump Thermostat 7748841 06 2010 291 ...

Page 296: ...urn wheel Remove the unit 2 Unbolt the return wheel or tensioner or replace the complete unit Installation 3 Install the tensioner complete with attachment Align the guide pin on the attachment to the instal lation hole and tighten the bolts Check the condition of the drive belts 4 Re install the belts refer to Drive Belts page 290 P0004682 P0009982 26 2 Coolant Pump Thermostat 292 7748841 06 2010...

Page 297: ...mperature as specified in Engine General page 26 2 If the thermostat does not open at specified tem perature it should be replaced 3 Install the thermostat see Thermostat Change page 288 NOTICE Always use a new seal even if the ther mostat is not replaced P0005072 Closed thermostat P0005073 Open thermostat 26 2 Coolant Pump Thermostat 7748841 06 2010 293 ...

Page 298: ...sult in signifi cantly reduced engine life In respect of engine work requiring more than five liters of new coolant to be added a new coolant filter must always be installed Removal 1 Shut the filter housing tap 2 Clean around the filter and remove it with the aid of tool 9999179 Extractor oil filter P0004963 Closed tap 26 2 Coolant Pump Thermostat 294 7748841 06 2010 ...

Page 299: ...apy water Install the new filter Screw the filter down until the gasket touches the sealing surface Then tighten a further turn 4 Open the tap on the filter housing 5 Start the engine and check for leaks P0004962 Open tap 26 2 Coolant Pump Thermostat 7748841 06 2010 295 ...

Page 300: ...Undo and remove the bolts Remove the guard 2 Installation Install the guard and the bolts Tighten the bolts IMPORTANT Never lay the fan down Oil will run out that cannot run back which will result in the fan seizing P0004681 26 3 Fan Fan Shroud 296 7748841 06 2010 ...

Page 301: ... will run out that cannot run back which will result in the fan seizing Upper belt guard 1 Removal Undo and remove the bolts Remove the guard 2 Installation Install the guard and the bolts Tighten the bolts IMPORTANT Never lay the fan down Oil will run out that cannot run back which will result in the fan seizing P0004680 P0004689 26 3 Fan Fan Shroud 7748841 06 2010 297 ...

Page 302: ...to Belt Protec tor page 296 Coolant pump belt removed refer to Drive Belts page 290 Removal 1 Depress the lever CAUTION Pinch hazard Keep fingers clear Wind off the belt Installation 1 Check the belt tensioner pulleys P0004688 P0004687 32 1 Alternator 298 7748841 06 2010 ...

Page 303: ...nator Belts Change page 298 Removal 1 Remove the tensioner retaining bolt and remove the tensioner Installation 2 Install the tensioner Align the guide pin on the attachment with the installation hole and tighten the bolts Check the condition of the drive belts 3 Install the alternator belt refer to Alternator Belts Change page 298 4 Check that the belt is correctly positioned on the belt pulleys ...

Page 304: ......

Page 305: ...lete General 116 Engine control system 101 Engine Disassembly 124 Engine Fixture Removal 122 Engine Information General 59 Engine Transmission 34 78 Engine General 26 Exposing 118 Exposing the Engine 116 Fan 6 Fan Fan Shroud 296 Fitting the Fixture 120 Flywheel Indication 203 Fuel Feed Pressure Check 108 248 Fuel Feed Pump and Filter 248 Fuel Feed Pump Change 252 Fuel feed system principle 91 Fuel...

Page 306: ...Removal 124 Timing Gears and Shaft 201 Troubleshooting 102 Turbo Change 275 Turbocharger 274 Turbocharger Inspection 112 274 Unit Injector Replace 255 Unit injectors 93 Valve Guides Inspection 188 Valve Guides Replacing 189 Valve Mechanism 177 Valve mechanism 29 Valve Seat Change 198 Valve Seats and Valve Grinding 196 Valve Stem Sealings Replace 200 Valves and Unit Injectors Adjustment 177 180 Val...

Page 307: ...References to Service Bulletins Group No Date Refers to 303 ...

Page 308: ......

Page 309: ... this page write your comments down and send them to us The address is at the bottom We would prefer you to write in English or Swedish From Refers to publication Publication No Date of issue Proposal motivation Date Signed AB Volvo Penta Technical Information Dept 42200 SE 405 08 Göteborg Sweden ...

Page 310: ...7748841 English 06 2010 ...

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