General Contents

Complete engine, crankcase ventilation, cylinder head, crankcase

Crank assembly

Engine timing

Mixture formation

Air intake, supercharging

Air compressor, belt drives

Exhaust manifold, engine brake, emission control system

Electrical system – engine

Engine lubrication, engine oil cooling

Engine cooling system

Fuel system


 
Complete engine, crankcase ventilation, cylinder head, crankcase

Complete engine, crankcase ventilation,

cylinder head, crankcase

 Contents 

Inspect cylinders with light probe ....................................................................................... 3

Testing compression pressure ........................................................................................... 7

Check engine parts for wear and damage ........................................................................ 11

During engine repair additional test work at cylinder head and cylinder head gasket ........ 13

Remove/install cylinder head cover ................................................................................. 15

Remove/install oil separator ............................................................................................ 17

Check cylinder head and cylinder head gasket for wear and damaqe............................... 19

Remove/install cylinder head ........................................................................................... 23

Check/face grind cylinder head contact surfaces ............................................................. 29

Check cylinder barrel for wear and damage ..................................................................... 33

Remove/install housing cover at front .............................................................................. 39

Remove/install cover of camshaft sprocket ...................................................................... 45

Measure cylinder bores ................................................................................................... 47

Remove/install oil pan ..................................................................................................... 51

Remove/install constant-speed throttle ............................................................................ 53

Remove/install timing case .............................................................................................. 57

 
Complete engine, crankcase ventilation, cylinder head, crankcase


  Crank assembly

Crank assembly

 Contents 

Check piston and conrod for wear and damage ............................................................... 61

During engine repair additional test work at piston/conrod .............................................. 67

and at cylinder contact surface

Remove/install piston ...................................................................................................... 69

Remove/install piston rings ............................................................................................ 75

Additional tests when carrying out a repair to the crankshaft, ........................................... 77

main bearing or connecting rod bearing

Remove/install race on crankshaf .................................................................................... 79

Replace front crankshaft radial seal................................................................................. 81

Replace rear crankshaft radial seal.................................................................................. 85

Remove/install crankshaft gear........................................................................................ 87

Remove/install belt pulley/vibration damper ..................................................................... 89

Remove/install flywheel ................................................................................................... 95

Check flywheel, re-machine............................................................................................. 97

Replace ring gear of flywheel .......................................................................................... 99

Remove/install race on flywheel .................................................................................... 101

Remove/install guide bearing in flywheel ....................................................................... 103



Crank assembly 



 
Engine timing

Engine timing

 Contents 

Remove/install rocker arms assembly............................................................................ 105

Assemble/disassemble rocker arms assembly ............................................................... 107

Remove/install camshaft sprocket ................................................................................. 109

Remove/install camshaft ................................................................................................111

Replace valve stem seals .............................................................................................. 113

Remove/install valves.................................................................................................... 117

Set valve clearance ....................................................................................................... 121



 
Engine timing



 
Mixture formation

Mixture formation

 Contents 

Remove/install nozzle holder combination ..................................................................... 127

Clean nozzle holder combination ................................................................................... 131

Remove/install MR/PLD control unit............................................................................... 133

Remove MR/PLD unit pump, install ............................................................................... 135

Remove/install injection lines MR/PLD........................................................................... 139



 
Mixture formation



 
Air intake, supercharging

Air intake, supercharging


 Contents 

Remove/install air intake hose ....................................................................................... 141

Check turbocharger....................................................................................................... 143

Remove/instal exhaust gas turbocharger ....................................................................... 147

Remove/instal charge air pipe ....................................................................................... 149

Remove/instal charge air pressure, charge air temperature sensor ................................ 151

Remove/instal charge air manifold ................................................................................. 153




 
Air intake, supercharging



 Air compressor, belt drives

Air compressor, belt drives


 Contents 

Remove/instal alternator poly-V-belt .............................................................................. 155

Remove/install poly-V-belt fan ....................................................................................... 157

Remove/install poly-V-belt tensioning device ................................................................. 159

Remove/install poly-V-Belt tensioning device for fan drive.............................................. 161

Check compressor for oil ejection .................................................................................. 163

Remove/install compressor ........................................................................................... 167

Remove/install cylinder head compressor ...................................................................... 169



Air compressor, belt drives



 Exhaust manifold, engine brake, emission control system

Exhaust manifold, engine brake,

emission control system

 Contents 

Remove/install exhaust manifold ................................................................................... 171

Remove/install engine brake flap fittings ........................................................................ 175




Exhaust manifold, engine brake, emission control system



 
Electrical system - engine

Electrical system - engine


 Contents 

Remove/install starter.................................................................................................... 177

Remove/install alternator............................................................................................... 179

Remove/install belt pulley for alternator ......................................................................... 181

Remove/install controller for alternator .......................................................................... 183




 
Electrical system - engine



 
Engine lubrication, engine oil cooling

Engine lubrication, engine oil cooling


 Contents 

Engine: change oil and replace filter .............................................................................. 185

Check oil pressure ........................................................................................................ 189

Fill engine oil circuit....................................................................................................... 191

Remove/install oil spray nozzles (piston) ....................................................................... 193

Remove/install oil pressure relief valve .......................................................................... 197

Remove/install oil pump ................................................................................................ 199

Remove/install oil filter housing ..................................................................................... 201

Remove/install oil/water heat exchanger........................................................................ 205

Remove/install oil pressure, oil temperature sensor ....................................................... 207




 
Engine lubrication, engine oil cooling



 
Engine cooling system

Engine cooling system


 Contents 

Remove/install coolant pump......................................................................................... 209

Remove/install coolant thermostat ................................................................................. 211

Remove/install fan......................................................................................................... 213

Remove/install bracket for viscous fan........................................................................... 215




 
Engine cooling system



 
Fuel system

Fuel system

 Contents 

Remove/install main fuel filter........................................................................................ 217

Remove/install fuel pump .............................................................................................. 219

Remove/install bearing for fuel pump drive .................................................................... 221

Remove/install fuel heat exchanger ............................................................................... 223




 
Fuel system