MC11 Series Diesel Engine Maintenance Manual

Sinotruk
MC11 Series Engine

Maintenance Manual
China National Heavy Duty Truck Group Co., Ltd.

December, 2012
MC11 Series Engine Maintenance Manual
Preface
This manual provides assistance in performing repairs correctly on vehicles and units and reflects
the known technical situation appertaining at the copy deadline. Pictures and the corresponding
descriptions are typical one-time representations; they do not always correspond to the unit to be
repaired or its peripherals.
This publication assumes that persons who use it possess the requisite technical knowledge in
repairing vehicles and units.
The bolts are specified in this manual as follows: M the nominal diameter (×fine pitch) ×length
---property classification, e.g. M8×40-10.9, which refers to a bolt that has the nominal diameter as
8mm, standard thread pitch, 40mm in length, and the property class 10.9; and by M8×0.75×
40-8.8, the bolt has the nominal diameter as 8mm, the fine pitch 0.75mm, and 40mm in length, with
the property class as 8.8.
This manual specifies both the maintenance device and the tooling in two different numbers. For
instance, the piston ring pliers is numbered both as JD6805-0018 and 80.99602-0016, in which the
former is the serial number created by Sinotruk, and the latter by MAN, so that the service station
can make a decision on which to purchase to satisfy their need.
The repair work is split up into chapters and sections. Each section starts with a page of jobs to do
in advance. The jobs to do in advance contain a summary of the main prerequisites for the repair
section in question. The detailed description of work can follow the jobs to do in advance.
Important instructions relating to safety and accident prevention are specially highlighted in the text
as follows.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in
order to avoid exposing people to risk
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in
order to avoid serious or irreparable damage to property.
Note
Explanatory description to aid understanding of the working and operating procedures
involved.
Comply with general safety regulations when performing any repair work.
This repair manual is created under organization by the leading team of Sinotruk product promotion
and sales.
Chief Editor: Zhang Xiaodong
Chief Auditor: Jiang Ailiang
Revised by: Li Wenge
Edited by: Yang Biao, Zhu Ping, Zhang Zongyuan, Liu Bin
Page 2 of 315
We acknowledge Sinotruk all the companies who have offered help in creating the manual,
specially appreciate Sinotruk Technology & Development Center for the enormous support
they have provided, and Sinotruk Power for their massive assistance.
Understanding will be appreciated in case of any mistakes or errors in the manual due to a tight
schedule, and suggestions and differences over the manual are always welcome and cherished!
The right of final interpretation on the manual is reserved by CHINA NATIONAL HEAVY
DUTY TRUCK GROUP CO., LTD.
Page 3 of 315
Safety Instructions
General
Only trained personnel are allowed to perform operating, maintenance and repair
work on trucks.
Additional references to danger are contained in the instructions at points where there
is a potential danger.
Accidents may happen in spite of all precautionary measures having been taken. In
such an eventuality, obtain immediate medical assistance from a doctor. This is
particularly important if the accident involves skin contact with corrosive acid, fuel
penetration under the skin, scalding by hot oil, antifreeze spraying into eyes, crushing
of limbs etc.
1. Regulations for preventing accidents leading to injury to personnel
1) Checking, setting and repair work
- Secure units during their removal.
- Support the frame when working on the pneumatic or spring suspension system.
- Keep units, ladders, stairs, steps and the surrounding area free from oil and
grease.
- Only use tools that are in perfect condition.
- Only authorised technical personnel are entitled to perform inspection,
adjustment and repair work.
2) Engine operation
- Only authorised personnel are permitted to start and operate an engine.
- Do not approach moving parts of a running engine too closely and do not wear
baggy clothing.
- Danger of burns when working on engines at operating temperature.
- Danger of scalding when opening the hot cooling circuit.
3) Suspended loads
- People are not allowed to stand below suspended loads.
- Only use suitable lifting and gear that is in perfect working order. Use lifting
devices with sufficient load-carrying capacity.
4) Working on high-pressure lines
- Do not attempt to tighten or loosen pipe lines and hoses when they are under
pressure (e.g. lubrication circuit, coolant circuit and hydraulic oil circuit):
Risk of injury due to pressurised fluids emerging!
5) Checking injector nozzles
- Wear suitable protective equipment.
- Do not hold any part of your body under the jet of fuel when checking the injector
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nozzles.
- Do not inhale fuel vapours. Ensure that there is adequate ventilation
6) Working on the vehicle electrical system
- Do not disconnect batteries whilst the engine is running!
- Always disconnect batteries when working on the vehicle electronic system,
central electrical system, alternator and starter! When disconnecting batteries,
remove the negative terminals first. When connecting batteries, fit the positive
terminals first.
- Always use suitable test lines and test adapters when measuring at plug
connections!
- If temperatures of over 80°C are to be expected, switch the battery master switch
to "OFF" and then remove the control units (EDC).
7) Electric welding
- Disconnect the batteries and connect the positive cable to the negative cable in
order to make a firm conductive connection. Otherwise severe damage could
result in the electrical system, like EDC.
- After completing welding work, first switch off all the consumers and remove all
jumpers (re-create original state), then connect the batteries.
- Always earth the welding equipment as close as possible to the welding area. Do
not lay the cables to the welding equipment in parallel to electrical cables in the
vehicle.
8) Working with the cab tilted forwards
- Keep the tilting area in front of the cab clear.
- Keep out of the area between the cab and the chassis during the tilting process.
This is a danger area!
- Always tilt the cab past the tilting point and secure the cab using a support rod.
2. Notes on preventing damage and premature wear on units
1.) General information
- Units are only designed for their specified purpose – (defined by the
manufacturer designated use): Any other use is classified as not in accordance
with the designated use. The manufacturer is not liable for damage caused as a
result of such other use. In the event of such other use, the user alone bears the
risk.
- Designated use also includes compliance with the operating, maintenance and
repair conditions specified by the manufacturer.
- The unit may only be used, maintained and repaired by persons who are familiar
with it and are fully aware of the risks.
- Arbitrary changes to the engine mean that the manufacturer is no longer
responsible for any damage incurred as a result of such changes.
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- Similarly, tampering with the injection and control system can affect the unit's
performance and exhaust-gas characteristics. This means that compliance with
the statutory environmental requirements is no longer assured.
- If malfunctions occur, determine the cause and remedy the problem immediately.
- Clean units thoroughly before repairs, ensuring that all openings where dirt is not
allowed to enter for safety or functioning reasons are closed.
- Never run an engine dry, in other words always make sure that it has been filled
with oil and coolant before running it.
- Apply a suitable information sign to units that are not ready to be operated.
- Comply with the specified maintenance intervals.
- Do not fill engine/gear oil above the maximum or the minimum level mark.
- Do not exceed the maximum permitted operational tilt.
3. Limit liability for parts and accessories.
Only use accessories and genuine Sinotruk parts that have been expressly approved
by Chinese National Heavy Duty Truck Group Co., Ltd. for your Sinotruk engines,
which, otherwise, are not covered in the warranty of repair, replacement, and refund
by Chinese National Heavy Duty Truck Group Co., Ltd.
4. Regulations for avoiding injury and environmental contamination
1) Health protection precautions
Avoid prolonged, excessive or repeated skin contact with service products,
excipients, thinners or solvents, etc. Protect your skin using a suitable skin
protection (e.g. protective gloves.)
2) Service products and excipients
Do not use food or drink containers for draining and storing service products or
excipients.
3) Cleaning the filter insert
When blowing compressed air through the filter insert, make sure the filter dust is
collected by a vacuum or is blown into a dust collection bag. Otherwise, use a
respiratory protection mask. Wear rubber gloves or use a skin barrier hand cream
when washing out the elements, because cleaning agents have aggressive
grease-dissolving characteristics.
4) Used engine/gear oil
Lengthy or repeated skin contact with any type of engine/gear oil removes grease
from the skin. This can cause dry skin, irritation or skin inflammation. In addition
to these hazards, used engine oil contains dangerous materials which can trigger
dangerous skin diseases. Wear gloves, especially when changing the oil.
5. Information for working on the common rail system
1) General information
- A jet of fuel can cut through the skin. Risk of fire due to fuel atomisation.
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- Never undo the screwed connections on the fuel high-pressure side of the
common-rail system whilst the engine is running (high-pressure line from the
high-pressure pump to/on the rail, and from the rail to the injector). Whilst the
engine is running, the lines are constantly carrying fuel under a pressure of 1800
bar or more. Before the screw connections are opened, wait at least one minute
until depressurisation has occurred, using Sinotruk-cats to check the
depressurisation on the rail as necessary.
- Do not touch the live parts at the injector electrical connection whilst the engine
is running.
2) Danger of damage due to dirt ingress
- Diesel-injection systems consist of precision engineered components that are
subject to extreme loads; Due to the highly precise nature of this technology, all
work on the fuel system requires the highest possible degree of cleanliness.
- Even dirt particles over 0.002 mm can cause component failure.
3) Before commencing work on the fuel system
- Clean the engine and engine compartment with the fuel system closed. Do not
use a powerful jet when cleaning electrical components.
- Drive the vehicle into a clean area of the workshop where none of the work
causes dust to be swirled up (sanding, welding, brake repairs, brake checks,
performance tests etc.).
- Avoid air movements (possible swirling up of dust due to starting of engines, the
workshop heating/ventilation system, due to draughts etc.).
- Clean and dry the area of the still closed fuel system using compressed air.
- Use a new and clean cover in areas of the engine compartment where dirt
particles can become loose, e.g. tilted cab, bus engine compartment.
- Before removing any components, wash your hands and put on clean working
clothes.
4) When commencing work on the fuel system
- Clean tools and equipment before commencing work. Only use tools that show
no signs of damage (cracked chrome coatings.)
- During disassembly, remove loose dirt using a suitable extractor unit. The use of
compressed air for cleaning is not permitted.
- Do not use materials such as cloths, cardboard or wood when removing and
installing components as these materials can produce particles and fibres.
- If the undoing of connections causes the paint to chip, carefully remove these
paint chippings before fully undoing the connection.
- All removed components on the clean side of the fuel system must be plugged
immediately at their connection openings using suitable caps. Then store the
components in a clean, sealed container.
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- New parts must not be removed from their original packaging until immediately
before use.
- Work on removed components may only be carried out in a suitably equipped
workplace.
- If removed parts are shipped, always use the new part's original packaging.
5) Danger of damage on the fuel system due to dirt ingress
- Before opening the clean side of the fuel system: Clean the areas of the engine
around pressure line fittings, injection lines, the rail and valve cover using
compressed air.
- Remove the valve cover and then re-clean the areas of the engine around the
pressure line fittings, injection lines and rail.
- Only remove the rail connections completely once the injectors have been
removed so that no dirt can fall into the injectors from above.
- Clean the injector hole, making sure that the high-pressure connection hole is
facing downwards.
6. Limp-home program for units with electronic control units
General information
The units have an electronic control system (EDC) that monitors the unit as well as
itself (self-diagnosis).
As soon as a malfunction occurs, the malfunction is evaluated and one of the
following measures is implemented automatically:
- Output of a fault message with fault code.
- Switch over to suitable default function for further operation, albeit with
restrictions. Have malfunctions remedied immediately.
- If Sinotruk-cats is used, the fault code is output directly.
7. Installation instructions
1) Installation of piping
- Mechanical deformation of piping is not permitted when performing installation
work - risk of fracture!
2) Installation of gaskets
- Only use genuine Sinotruk gaskets.
- Make sure the surfaces to be sealed are undamaged and clean.
- Do not use adhesives or sealing compounds. If necessary, to facilitate installation,
use a little grease to stick the gasket to the part to be mounted.
- Tighten the bolts evenly to the specified tightening torque.
3) Engine overhaul
- A range of very different factors affect the engine service life. It is therefore not
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possible to indicate the exact number of operating hours or miles before a major
overhaul is due. In our judgment, it is not advisable to open an engine or perform
a major overhaul if the engine has good compression values and the following
operating values have not changed significantly since they were measured and
taken during the initial start-up:
♦ Charge pressure
♦ Exhaust gas temperature
♦ Coolant and lubricating oil temperature
♦ Oil pressure and oil consumption
♦ Smoke characteristics
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Content
PREFACE ......................................................................................................................................... 2
SAFETY INSTRUCTIONS .............................................................................................................. 4
CHAPTER I. MC11 SERIES ENGINE INTRODUCTION ........................................................... 12
SECTION 1. ENGINE, GENERAL ..................................................................................................... 12
SECTION 2. MC11 SERIES ENGINE CHARACTERISTICS DATA ................................................... 15
CHAPTER 2. MC11 SERIES ENGINE COMPONENTS REMOVING AND INSTALLING
........................................................................................................................................................ 18
SECTION 1. ENGINE ELECTRICS ................................................................................................. 18
1. Sensors ............................................................................................................................... 18
2. Electric control unit （EDC） ........................................................................................ 20
SECTION 2. COOLING SYSTEM.................................................................................................... 24
1. Fan ...................................................................................................................................... 25
2. Fan bracket ........................................................................................................................ 27
3. Coolant manifold ............................................................................................................... 34
4. Thermostat ......................................................................................................................... 39
5. Thermostat housing .......................................................................................................... 41
6. Water pump ....................................................................................................................... 44
7. The distributor housing .................................................................................................... 47
SECTION 3. ENGINE COMPONENTS ............................................................................................ 49
1. Air compressor .................................................................................................................. 50
2. Starter................................................................................................................................. 56
3. The belt drive ..................................................................................................................... 59
4. Alternator........................................................................................................................... 62
SECTION 4. INTAKE AND EXHAUST SYSTEM ............................................................................... 67
1. Exhaust manifold .............................................................................................................. 69
2. Suction line ........................................................................................................................ 73
3. Intake manifold ................................................................................................................. 75
4. Turbocharger ..................................................................................................................... 77
SECTION 5. CYLINDER HEAD ...................................................................................................... 82
1. Cylinder head .................................................................................................................... 83
2. Checking and setting the valve clearance ....................................................................... 97
3. Valve stem seal ................................................................................................................. 105
SECTION 6. VALVE TIMING ....................................................................................................... 117
1. Camshaft/camshaft bearing shell................................................................................... 118
2. Valve timing ..................................................................................................................... 135
3. Rear timing gear.............................................................................................................. 141
SECTION 7. FUEL SUPPLY .......................................................................................................... 155
1. Injectors and rail ............................................................................................................. 156
2. High-pressure pump / High-pressure pump ................................................................. 172
3. Fuel service center ........................................................................................................... 181
SECTION 8. ENGINE LUBRICATION ........................................................................................... 191
1. Oil module........................................................................................................................ 192
2. Oil sump and oil intake pipe .......................................................................................... 200
3. Oil injector nozzles .......................................................................................................... 202
4. Oil pump .......................................................................................................................... 204
5. Front crankshaft oil seal ................................................................................................. 214
6. Rear crankshaft oil seal .................................................................................................. 219
SECTION 9. ENGINE HOUSING .................................................................................................. 223
1. Flywheel housing ............................................................................................................. 224
2. Front cover....................................................................................................................... 226
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3. Cylinder liners ................................................................................................................. 228

SECTION 10. CRANK MECHANISM ............................................................................................ 233
1. Damper............................................................................................................................. 234
2. Flywheel ........................................................................................................................... 238
3. Pistons and conrods......................................................................................................... 247
4. Crankshaft ....................................................................................................................... 259
5. Front drive gears ............................................................................................................. 270
CHAPTER III MALFUNCTION AND TROUBLESHOOTING .......................................... 277
SECTION 1. ELECTRICAL MALFUNCTION ................................................................................ 277
SECTION 2. ENGINE DIFFICULT TO START ................................................................................ 279
SECTION 3.INSUFFICIENT POWER ............................................................................................ 281
SECTION 4. FUEL CONSUMPTION HIGH .................................................................................... 285
SECTION 5. ABNORMAL SMOKE ............................................................................................... 286
SECTION 6. LUBRICATION SYSTEM MALFUNCTION ................................................................. 287
SECTION 7. WATER TEMPERATURE HIGH ................................................................................ 288
SECTION 8. EARLY WEAR- OUT ................................................................................................ 289
SECTION 9. ABNORMAL NOISE ................................................................................................. 290
APPENDIX .................................................................................................................................. 291
MC11 SERIES ENGINE MAINTENANCE SPECIAL TOOL LIST .................................................. 291
MC11 SERIES ENGINE CHIEF SCREW BOLT, NUT AND PLUG, AND PIPE FITTING
TIGHTENING TORQUE AND FINAL TIGHTENING .............................................................. 308
MC11 SERIES ENGINE PRIMARY PARTS AND COMPONENTS FITTING
CLEARANCE ............................................................................................................................. 312
MC11 SERIES ENGINE SEALANT APPLICATION LIST .................................................. 315
Page 11 of 315
Chapter I. MC11 Series Engine Introduction

Section 1. Engine, general
MC11 series engine, totally based on MAN D20 engine, is a wholly new developed
engine launched by MAN in 2004. MC11 series engine is designed with the concept
of torque boost other than power boost, as well as the module design, so that the
engine is featured as economy of fuel, high reliability and performance, light-weight
and low oil consumption, and in addition it complies with Euro V emission standard.
1. Crankcase
The crankcase is made of vermicular graphite cast iron. The structure of deep skirt
ensures the crankcase with higher rigidity. Both the front and the rear end bottoms of
the crankcase are structured with cross-pieces, which work as sealing surface for the
oil sump.
The main bearings are made using the cracked technology. The surface structure
resulting from cracking results in a precise, non-interchangeable fit and high lateral
stability, which benefits the bearing cap in less wearing, and longer lifetime.
The cylinder liner, wet, suspends on the top of the cylinder bore. The water jacket
works as sealing at the cylinder liner bottom with the two O-rings inserted in the
crankcase.
There are seven main bearings of the same width in the cylinder block. The thrust
discs are inserted on both sides of the 6th main bearing seat.
2. Crankshaft
The crankshaft is forged in a die using high-quality, micro-alloyed steel. It has seven
main bearing journals and four counterweights to balance the masses. In the circular
surface of the counterweight is machined with the radial hole to achieve the final
dynamic balance on the crankshaft; at the front end of the crankcase is equipped with
a silicone oil damper, high strength and rigidity in the structure.
3. Connecting rods
The “cracked “connecting rods are precision forged in a die using quenched and
tempered steel. The surface structure resulting from cracking results in a tooth
engagement effect between the connecting rod bearing cap and the connecting rod
with a precise, non-interchangeable fit and high lateral stability, avoiding mistake fit
while assembling.
4. Piston
The pistons, made of new material to resist higher heat load, have a cast-in cooling
duct for reducing the thermal load when the output is high. The small end of the
connecting rod is keystone to enhance the piston on the strength.
The piston has two compression air rings and one oil scraper ring. The first
compression ring is a taper-face ring, PVD coated on the working surfaces, benefiting
for wear-in, scoring and wearing resistance, and resulting in good effect on cohesive
force and heat transfer; the second compression ring is a full keystone ring, chrome
coated; and the third is a double-bevelled slotted chromed oil control ring, cast iron,
Page 12 of 315
with spiral-type expander as an effective oil scraper ring,

5. Cylinder head
MC11 series engines are equipped with a single-section cylinder head, overhead
camshaft. The cylinder head is made of grey cast iron. Integrated with the intake
manifold, the cylinder head has less sealing positions. The valve guides have valve
stem seals at all four valves. The design of four valves in each cylinder ensures the
engine with evener fuel injection, higher charging efficiency, and as a result, the
emission is decreased effectively. In the cylinder head are lined with the intake and
the exhaust ducts on two sides, and a certain turbulence produces in the intake duct,
required as the direct injection combustion system. In the cylinder head is casted in a
boss to assemble the injector, so that the injector is improved in heat rejection and
high work reliability. The coolant flows in transverse direction, better designed and
better effect.
6. Camshaft
The camshaft is forged from steel and is carbonitriding hardened. It is mounted in
seven bearings of the camshaft bearing caps in the cylinder head. The camshaft is
driven by means of the cylindrical gear on the flywheel side.
7. Engine lubrication
The engine is lubricated by forced-feed lubrication from the oil pump. The crankcase
bleeder, the engine oil filter and the oil cooler are all grouped together as an oil
module, in which the crankcase bleeder is cyclone structure, with no additional
expense on maintenance; The oil filter element is non-metal structure and burns up
totally after replaced, with no pollution to the environment, and it costs less in
maintenance, compared with the conventional filter element which is metal cyclone.
8. Cooling system
The cooling circuit of MC11 series engine is a thermostat-controlled,
forced-circulation cooling system with a coolant pump that is driven by a poly-V-belt.
The thermostat is an exchangeable insert with wax elements as expansion elements.
Engines for vehicles for all purposes are equipped with bimetal strip silicone oil fans.
The fan is driven by the front end gear of the crankshaft (maintenance free), and is
made of plastics in circular form, the diameter: Ф704mm/Ф750mm.
The expansion tank can eliminate the vapor produced by the low pressure in the
cooling system, with no result in air bound, but in addition of coolant. The pressure in
the expansion tank remains at approximately 75+20 kPa
9. Intake/exhaust system
The three-section exhaust manifold is made of high temperature-resistant nodular cast
iron and connected with each other using multiple metal sealing rings to good effect;
in the middle manifold is installed with the radial turbocharger with the relief valve,
and the boosted air goes into the engine after cooled in the intercooler. After the
turbocharger, the exhaust manifold is installed with the engine brake butterfly valve to
boost the engine braking efficiency.
10. Fuel system
Page 13 of 315
The fuel system consists of a low-pressure system and a high-pressure system. The
low-pressure system includes the fuel lines, the hand pump and the fuel filter. The fuel
module ensures the degree of fuel purity required by the common rail system. The
low-pressure system also includes a heating element and the flame start system. The
interface to the high-pressure system is the fuel pump.
The high-pressure system consists of the flow-rate-controlled high-pressure pump, the
high pipes, the common rail pipes with the rail pressure sensor, and the relief valve.
Injection pressure generation and fuel injection are separate in the high-pressure
system. The injection pressure is generated by the high-pressure pump, irrespective of
the engine speed and the required injection quantity. The high-pressure pump delivery
quantity is controlled by a proportional valve. The injection point and the injection
quantity are calculated in the engine control unit (ECU) and implemented by the
solenoid valve-controlled injectors,
11. Engine brake system
MC11 series engines are standard featured with EVB devices. Compared with the
conventional engine butterfly valve, the EVB brake increases 60% of the brake
efficiency. In the exhaust valve bridge is installed a hydraulic piston and a relief vent.
The hydraulic piston works under the pressure of the engine oil, and the oil pressure
releases through the relief vent. Over the valve bridge is a reverse bracket, on which
the pressure element closes the relief vent when the exhaust valve closes; and the
relief vent opens when the valve opens, eliminating the oil pressure in front of the
hydraulic piston. When the valve closes as a result of the engine brake overcoming
the elasticity of the torsion spring with the assist of the driven cylinder, the pressure
wave built up in the exhaust pipe opens the exhaust valve in a short time, i.e. the
exhaust valve opens again for a short time every time it closes, and the hydraulic
piston subjected to oil pressure will be pushed as the piston leaps for a short time, and
can’t return home as the reverse bracket closes the relief vent and the check valve
closes the oil supply hole. As a result, the exhaust valve keeps opening during the
strokes of compression and expansion, thus increasing the engine brake efficiency.
12. Starter
The starter is a direct-current starter, solenoid controlled, gear driven, and torque
transferred by friction lining unidirectional piece. The rated power is 5.5kW.
13. Generator
The rated voltage is 28V, with the transistor regulator. The generator works together
with the battery in the vehicle, self excitated at working. The generator speed is 4
times of the engine speed.
Page 14 of 315
SECTION 2. MC11 SERIES ENGINE CHARACTERISTICS DATA

Table 1-1 MC11 Series Engine Chinese Ⅲ Characteristics Data
Unit of Model
SN Designation measurement
MC11.43-30 MC11.39-30 MC11.35-30 MC11.31-30
1 Number of cylinders 6
2 Bore mm 120
3 Stroke mm 155
4 Valves per cylinder 4
5 Total stroke volume L 10.518
6 Compression ratio 19:1
7 Max. rated net power (KW) kW 316 287 257 228
8 Rated speed rpm 1900
9 Max. torque Nm 2100 1900 1750 1550
10 Speed at max. torque rpm 1000～1400
11 Total power test min. specific g/kWh ≤186

fuel consumption
12 Fuel specific consumption at g/kWh ≤210
rated condition
13 Max. no load speed rpm 2150±20
14 Idle speed rpm 550±50
15 Firing sequence 1－5－3－6－2－4

Intake valve clearance mm 0.5±0.03
16 (cold state )
Exhaust valve clearance mm 0.8±0.03
（cold state）
17 EVB setting clearance (cold mm 0.6±0.03
state)
18 Lubricating oil sump capacity L 40
19 Net mass kg 975

(excl. After treatment)
20 Cranking direction Clockwise(viewed from free end)
21 Max. Permissible engine rpm 2400

braking speed
Cold start -20
22 (with no intake air heating ) ℃
Cold start -40
(with intake air heating )
Max.allowable inclination ° 15
23 angle (lateral)
Max.allowable inclination ° 15
angle(lengthwise)
Page 15 of 315
Table 1-2 MC11 Series Engine Chinese IV Characteristics Data

Unit of Model
SN Designation measurement MC11.44-40 MC11.40-40 MC11.36-40 MC11.32-40
2 Bore mm 120
3 Stroke mm 155
9 Max. torque N·m 2100 1900 1800 1600
Total power test min.
11 g/kW·h ≤186
specific fuel consumption
12 Fuel specific consumption at g/kW·h ≤210
rated condition
16 Intake valve clearance mm 0.5±0.03
(cold state )
（cold state）
17 EVB setting clearance mm 0.6±0.03
(cold state)
18 Lubricating oil sump L 40
capacity
19 Net mass kg 975

braking speed
Cold start -20
Cold start -40
Max.allowable inclination 15
23 angle (lateral) °
angle(lengthwise)
Page 16 of 315
Table 1-3 MC11 Series Engine Chinese V Characteristics Data

SN Designation
Unit of Model
measurement MC11.44-50 MC11.40-50 MC11.36-50 MC11.32-50
2 Bore mm 120
3 Stroke mm 155
9 Max. torque N·m 2100 1900 1800 1600
Total power test min.
11 g/kW·h ≤186
specific fuel consumption
12 Fuel specific consumption at g/kW·h ≤210
rated condition
16 Intake valve clearance mm 0.5±0.03
(cold state )
17 （cold state）
17 EVB setting clearance mm 0.6±0.03
(cold state)
18 Lubricating oil sump L 40
capacity
19 Net mass kg 975

braking speed
Cold start -20
Cold start -40
23 angle (lateral) °
angle(lengthwise)
Page 17 of 315
Chapter 2. MC11 series engine components removing and

installing
Section 1. Engine electrics
1. Sensors
Fig 2-1 Engine sensors

(1) Oil pressure sensor (4) Camshaft signal sensor
(2) Intake temperature pressure (5) Speed sensor
sensor (6) Rail-pressure sensor
(3) Water temperature (7) Fuel pressure sensor
1.1 Technical data
Designation Specification Technical parameters
Oil pressure sensor M18×15 45+5 Nm
Intake temperature pressure M4×14 2~5 Nm
sensor
Water temperature sensor M16×15 45+5 Nm
Camshaft signal sensor M6×16 8-10 Nm
Speed sensor M6×12 8-10 Nm
Rail-pressure sensor M18×15 70 Nm
Page 18 of 315
1.2 Important information

WARNING
Component damage due to incorrectly tightened screw/bolt
connections
• If impact wrenches are used, these may only be used for pretightening
to max. 50% of the specified tightening torque.
• Final tightening must always be performed manually using a torque
wrench.
Page 19 of 315
2. Electric control unit （EDC）
Fig. 2–2 Electric control unit（EDC）

(1) Bracket mounting bolt (3) Engine control unit (EDC)
(2) EDC mounting bolt (4) Electric control unit bracket
2.1 Technical data
Mounting bolt（2） M6×30-10.9 10±2Nm
Bracket mounting bolt（1） M8×40-10.9 12-14Nm
2.2. Service products
Loctite 270
2.3. Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections.
• If impact wrenches are used, these may only be used for pretightening to
max. 50% of the specified tightening torque.
wrench.
Page 20 of 315
Note
• After the engine is installed, the engine control unit must have its
parameters reset and the fault memory must be deleted.
Page 21 of 315
Removing the engine control unit bracket

2.4. Removing the engine control unit
Disconnecting the engine control unit
electrical connections
·Unscrew the mounting bolt（1）

·Remove the bracket (3) with rubber mounts
(2).
- Disconnect the wiring harnesses (3).

- Release and pull off the connectors (1) and
(2).
Removing the engine control unit

·Remove the engine control unit (1).
Page 22 of 315
2.5 Mounting the engine control unit Connecting the engine control unit electrical
Mounting the engine control unit and connections
bracket
·Thinly apply Loctite 270 on the thread of the

new mounting bolts (1).
·Position the bracket (3) with the rubber
mounts (2).
·Screw in and tighten the mounting bolts (1) to
12-14Nm.
Mounting the engine control unit
WARNING
Danger of irreparable engine control
unit damage
·When installing the connectors, first fully open

the lock and then insert and lock the
connectors.
·Insert and lock the connectors (1) and (2) in
the engine control unit.
·Route the wiring harnesses and secure using
cable ties (3).
·Position the engine control unit (1).

·Screw in and tighten the new mounting bolts
(2) diagonally to 10±2Nm.
Page 23 of 315
Section 2. Cooling system
1 3
Fig. 2–3. Cooling system lines

(1) Coolant elbow line (2) Coolant line (3) Thermostat housing
1 2
Fig 2–4 Cooling system distributor housing

(1)Water pump (2) Distributor housing
Page 24 of 315
1. Fan
Figure 2– 5 Fan
(1) Silicone oil clutch (3) Mounting bolt
(2) Fan (4) Fan bracket
1.1 Technical data

Mounting bolt (3) M8×1.25 22 Nm
CAUTION
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50%
of the specified tightening torque
• The angle must always be performed manually using a torque wrench.
Page 25 of 315
1.3. Removing the fan 1.4 Installing the fan

Removing the fan Installing the silicone oil fan clutch
• Unscrew the mounting bolts (1).

• Insert the silicone oil fan clutch (1) into
• Remove the fan (3) off the bracket (2). fan (3) from the front end.
Removing the silicone oil fan clutch • Screw in and tighten the mounting bolts (2)
to 22 Nm.
Installing the fan
• Unscrew the mounting bolt (2).

• Remove the silicone oil clutch (1) off the fan
(3) in the direction of forward..
• Position the fan (3) onto the bracket (2).

• Screw in and tighten the new mounting bolts
(1).
Page 26 of 315
2. Fan bracket
2.1 Additional jobs
-Removing and installing the fan, see P25.
- Removing and installing coolant manifold, see P34.
- Removing and installing distributor housing, see P47.
- Removing and installing the belt drive, see P59
- Removing and installing the front crankshaft oil seal, see P214.
- Removing and installing the front cover, see P226
- Removing and installing the damper, see P 234.
Figure 2–6 Fan bracket

(1) Mounting bolt (2) Fan bracket (3) Fan hub (4) Mounting bolt (left-handed)
2.2 Technical data
Initial tightening:100 Nm
Tightening bolt (left-handed)(4) M16×55
Final tightening 90°
Axial play, fan bracket (2) 0.20 – 0.55 mm
Radial play, fan bracket (2) 0.035-0.076 mm
Inside diameter, fan shaft bearing 35.000 – 35.025 mm
device
Outside diameter, fan shaft 34.949 – 34.965 mm
Page 27 of 315
2.3 Service products

Loctite5900
Lubricant oil
CAUTION
PTFE sealing rings are rendered unusable if they come into contact with oil,
grease or dust of any kind before installation.
•Clean the fan bracket housing and insertion tool before assembly.
CAUTION
• Final tightening must always be performed manually using a torque wrench.
2.5 Special tools
No. Drawings Description Sinotruk No. MAN No.
[1] Impact extractor JD6805-0018 80.99602-0016
• Removing the slide ring seal in
conjunction with:
• Extractor hook [2]
[2] Extractor hook JD6805-0019 80.99602-0137

• Extracting the slide ring seal
[3] Plug-on handle JD6805-0020 80.99617-0187

• Pressing in the slide ring seal in
conjunction with:
• Impact punch [5]
• Washer [4]
[4] Washer JD6805-0021 80.99617-0144
• Pressing in the slide ring seal
Page 28 of 315
[5] Impact punch JD6805-0022 80.99604-0289

• Pressing in the slide ring seal
[6] Engine barring gear JD6805-0023 80.99626-6008

• Locking the engine crankshaft
[7] Dial gauge JD6805-0024 08.71000-3217

• Checking the inside diameter of
the fan shaft bearing
• Checking the fan bracket axial
play and radial play in
conjunction with:
• Dial gauge stand [8]
• Locating pin[9]
[8] Dial gauge stand JD6805-0025 08.71082-0005
• Checking the fan bracket
axial play and the radial play
in the fan bracket.
[9] Locating pin JD6805-0026 80.99605-0197

• Checking the axial play and
the radial play in the fan
bracket.
Page 29 of 315
Checking the fan bracket

Checking the fan bracket axial play Checking the fan bracket radial play
• Fit the Dial gauge stand [8] (2) with Dial • Fit the Dial gauge stand [8] (2) with Dial
gauge [7] (1) and Locating pin [9]. gauge [7] (3) and Locating pin [9].
• Place the Locating pin [9] on the drive gear • Place the Locating pin [9] on the fan hub (1)
(3) with a preload. with a preload.
• Press the drive gear (3) in the direction of • Press the fan hub (1) left-handed
the crankcase. horizontally until it doesn’t move any
• Zero the dial gauge [7] (1). further.
• Pull the drive gear (3) to the end position • Zero the dial gauge [7] (3).
and read off the difference. • Pull the fan hub (1) in the direction of Dial
The permitted axial play is 0.20 – 0.55 mm. gauge [7] (3) to the end position and read
off the difference.
If the axial play is out of tolerance, the fan
bracket must be replaced. The permitted radial play is 0.035 – 0.076
mm.
If the radial play is out of tolerance, check the
fan shaft and bearing.
Check the fan shaft outside diameter, see P32.
Check the fan shaft inside diameter, see P32.
Page 30 of 315
Removing the fan bracket Pull out the fan bracket slide ring seal
Installing the Engine barring gear
• Use the impact extractor [1] (4) and the

hook [2] (3) to pull the slide ring seal (2)
• Remove the flywheel housing seal cap. out of the fan bracket (1)
• Install and lock the Engine barring gear [6] Removing the fan bracket
(1) on the flywheel housing.
Removing the fan hub
• Mark the installation position of the

mounting bolts (1) and (2).
• Fix the crankshaft gear (4) using the • Unscrew the mounting bolts (1) and (2).
mounting bolts (5). • Remove the O-ring (4)
• Unscrew the mounting bolts (left-handed • Remove the fan bracket (3)
thread) (1)
• Remove the fan hub (2) from the fan
bracket (3).
Page 31 of 315
Checking the fan shaft outside diameter

Checking the fan bracket
Disassembling the fan bracket
• Check the fan shaft outside diameter using

the micrometer (1) on the working
surfaces (2) and (3).
• Pull the fan shaft (2) out of the housing (1). The permitted outside diameter of the
Checking the fan shaft bearing inside working surfaces (2) and (3) is Ø34.949 –
diameter 34.965 mm.
If the outside diameter is out of tolerance, the
fan shaft must be replaced.
Assembling the fan bracket
• Check the inside diameter of the front

bearing (2) using the Dial gauge [7] (1)
and the internal caliper (4).
• Repeat the same procedure for the rear
bearing.
• Thinly apply clean engine oil on the fan
The permitted bearing (2) inside diameter is Ø
shaft (2) journal.
35.000 – 35.025 mm.
• Install the fan shaft (2) in the housing (1).
If the inside diameter is out of the tolerance,
the housing (3) must be replace.
Page 32 of 315
Installing the fan bracket Installing the fan hub

Installing the fan bracket
• Thinly apply lubricating oil on the new • Install the new fan hub (2) in the fan
O-ring (4). bracket (3).
• Insert the O-ring (4). • Thinly apply Loctite 5900 (5) on the hub
contact surface.
• Install the fan bracket (3).
• Screw in and tighten the bolts (left-handed
• Screw in the bolts (1) and (2) as marked.
thread) (1) to initial torque 100 Nm.
• Tighten the bolts (1) and (2).
• Tighten the bolts (left-handed thread) (1) to
Pressing in the slide ring seal 90°.
• Unscrew the bolts (4).
Removing Engine barring gear
• Use the Plug-on handle [3] (4), the Washer

[4] and the Impact punch [5] (3) to press
the slide ring seal (2) in the fan bracket
• Remove the Engine barring gear [6] (1)
(1) until the stop is reached.
off the flywheel housing, and install the
seal cap on the flywheel housing /timing
gear housing.
Page 33 of 315
3. Coolant manifold
Fig. 2–7 Coolant manifold

(1) O-ring (4) Unscrewed conduit
(2) Coolant manifold (5) Unscrewed conduit
(3) Tightening bolt (6) Coolant elbow
3.1. Technical data
Designation Specifications Technical parameter
Water temperature sensor M16×15 45-50Nm
3.2. Service product
Cooling device antifreeze, technical Vaseline
CAUTION
3.4. Special tools
Page 34 of 315
No. Drawing Description Sinotruk MAN No.

No.
[10] Hose clamp pliers for jubilee clips JD6805-0028 08.99605-9003
• Removing and installing the air
compressor intake line
Page 35 of 315
3.5 Removing the coolant manifold Removing the coolant manifold

Removing the intake line
• Unscrew the tightening bolt(1)

• Pull out the coolant manifold (2)
• Remove the O-ring (5)
• Pull out the unscrewed conduit (3) and (4)
Removing the water temperature sensor
• Unscrew the tightening bolts (1).

• Undo the jubilee clip (3) using the Hose clamp
pliers for jubilee clips [10].
• Repeat the procedure for the turbocharger
intake line connection jubilee clips.
• Remove the intake line (2).
• Remove the formed hose (6) jubilee clips
off the cable harness bracket.
• Undo the jubilee clip (4) using the Hose Note
clamp pliers for jubilee clips [10]. The water temperature sensor can
• Pull the formed hose (6) off the connection be removed and installed with the
(5). coolant manifold assembled.
• Unscrew the water temperature sensor (1)

with the seal ring (2) off the coolant
manifold (3).
Page 36 of 315
Removing the coolant manifold
• Unscrew the tightening bolt (3)

• Remove the coolant elbow (2) with the
O-ring (1).
• Clean the sealing surface.
Page 37 of 315
3.6. Installing the coolant manifold Installing the coolant manifold

Installing the coolant elbow
• Attach the coolant elbow pipe (2)with the

new O-ring (1). • Thinly apply technical Vaseline on the new
unscrewed conduits (3) and (4) mating
• Screw in and tighten the new mounting bolt surfaces.
(3).
• Install the unscrewed conduits (3) and (4) in
Installing the water temperature the coolant manifold (2).
sensor
• Thinly apply technical Vaseline on the new
O-ring (5) and insert it in the coolant
manifold (2).
• Install the coolant manifold (2).
• Screw in and tighten the new mounting bolt
(1).
• Screw in the water temperature sensor (1)

with the new seal ring (2) in the coolant
manifold (3) and tighten to 45-50 Nm.
Page 38 of 315
4. Thermostat
Fig. 2–8 Thermostat

(1) Tightening bolt (3) Thermostat elbow
(2) Tightening bolt (4) Thermostat
4.1 Technical data
Designation Technical parameter
Opening temperature of thermostat (5) 83°C
CAUTION
Thermostats with the incorrect opening temperature damage the engine.
• Always use thermostats with the specified opening temperature.
CAUTION
Page 39 of 315
4.3 Removing the thermostat 4.4 Installing the thermostat

Removing the thermostat Installing the thermostat
• Mark the installation position of the • Insert the new seal ring (2) in the thermostat
mounting bolts (4) and (5). housing (3).
• Unscrew the mounting bolts (4) and (5). • Install the thermostat (1), and keep the ball
valve or the mark TOP upwards..
• Remove the thermostat elbow (2) and the
bracket (3) (The present engine type Installing the thermostat elbow
doesn’t have this bracket.)
• Remove the O-ring (1) off the thermostat.
• Clean the sealing surfaces.
Removing the thermostat
• Install the new O-ring (1) in the thermostat.

• Install the thermostat elbow (2) in the
thermostat housing.
• Screw in and tighten the new mounting
bolts (4) and (5) as marked.
• Remove the thermostat (1) with the seal
ring(2) out of the thermostat housing
(3).
Page 40 of 315
5. Thermostat housing
5.1 Additional jobs
- Removing and installing the thermostat, see P399
Fig. 2–9 Thermostat housing

(1). Thermostat housing (4) Big washer
(2). Hose connection (5) Mounting bolt
(3) Composite seal ring (6) O-ring
5.2 Service product
Technical Vaseline
CAUTION
Page 41 of 315
5.4 Dismantling the thermostat housing Replacing the unscrewed conduit

Unscrew the mounting bolt
• Unscrew the mounting bolt (1) from the • Pull the unscrewed conduit (2) and (3)out of
distributor housing (2). the thermostat housing (1).
Dismantling the thermostat housing • Thinly apply technical Vaseline on the mating
surfaces of the new unscrewed conduit (2)
and (3).
• Insert the unscrewed conduit (2) and (3) into
the thermostat housing (1).
• Removing the thermostat housing (1) and

the unscrewed conduit.
• Remove the gasket (3) from the distributor
housing (2).
Page 42 of 315
5.5. Mounting the thermostat housing

Mounting the thermostat housing
• Fit the thermostat housing (1) with a new

gasket (3) and the new unscrewed
conduit on the distributor housing (2).
Screw the mounting bolt
• Screw in and tighten the new mounting bolt

(1) in the distributor housing (2).
Page 43 of 315
6. Water pump
Fig. 2–10 Water pump

(1) Mounting bolt (5) Distributor housing
(2) Mounting bolt (6) Poly-V-belt pulley
(3) Water pump (7) Mounting bolt
(4) Gasket
CAUTION
• If impact wrenches are used, these may only be used for pretightening to max.
50% of the specified tightening torque
• Final torque must always be performed manually using a torque wrench.
Page 44 of 315
6.2 Removing the water pump Removing the poly-V-belt pulley

Undoing the mounting bolt
• Unscrew the mounting bolt（1）

• Pull the poly-V-belt pulley (2) from the
hub (3).
CAUTION
The poly-V-belt tensioner is Removing the water pump
under spring tension.
• Brace the poly-V-belt
tensioner to prevent it from
springing back
unintentionally.
• Undo the mounting bolt (2).
• Turn the poly-V-belt tensioner (1) clockwise
as far as the stop and hold it.
• Remove the poly-V-belt (3)
• Carefully relieve the poly-V-belt tensioner
(1).

mounting bolt (1) and (4).
• Unscrew the mounting bolt (1) and (4).
• Remove the water pump (2) and the
gasket (3).
Page 45 of 315
6.3 Installing the water pump Tightening the mounting bolt

Installing the water pump
• Install the water pump (2) with the gasket CAUTION

(3). The poly-V-belt tensioner is
• Screw in and tighten the new mounting bolt under spring tension.
(1) and (4) as marked. • Brace the poly-V-belt
Mounting the poly-V-belt pulley tensioner to prevent it
from springing back
unintentionally.
• Turn the poly-V-belt tensioner (1)
clockwise as far as the stop and hold it.
• Fit the poly-V-belt (3).
• Carefully relieve the poly-V-belt tensioner
(1).
• Tightening the mounting bolt (2).
• Install the poly-V-belt (2) in the hub (3).

• Tighten the mounting bolt (1) manually.
Page 46 of 315
7. The distributor housing

7.1. Additional jobs
-Removing and installing the fan, see P25
- Removing and installing the belt drive, see P59,
- Removing and installing the coolant manifold, see P34
- Removing and installing the thermostat housing, see P41
- Removing and installing the water pump, see P44
Fig. 2–11 Distributor housing

(1) Mounting bolt (3) Distributor housing
(2) Mounting bolt (4) Mounting bolt
CAUTION
Page 47 of 315
7.3 Removing the distributor housing 7.4 Installing the distributor
• Mark the installation position of the • Install the distributor (3) with the
mounting bolt (1) and (2). new gasket.
• Unscrew the mounting bolt (1) and (2). • Screw in and tighten the mounting
• Remove the distributor housing (3) with bolt (1) and (2) as marked.
the gasket.
Page 48 of 315
Section 3. Engine components
Fig 2-12 Engine components
(1) Starter (8) High-pressure drive gear poly-V-belt

pulley
(2) Suction line
(9) Poly-V-belt tensioner
(3) 1-cylinder air compressor
(10) Refrigerant compressor
(4) Steering pump (1)
(11) Poly-V-belt
(7) Alternator poly-V-belt pulley
(12) Formed hose
Page 49 of 315
1. Air compressor
Fig. 2-13 Air compressor

(1) Suction line (3) 1-cylinder air compressor
(2) Formed hose (4) Steering pump
1.1 Technical data
Designation Specification Technical parameter
Rotary straight joint M16×15 30-35 Nm
Air line joint M26×15 45 Nm

Loctite 5900
Page 50 of 315
CAUTION
connections.
• If impact wrenches are used, these may only be used for
pretightening to max. 50% of the specified tightening torque
wrench.
1.4 Special tools
No. Drawing Description Sinotruk No. MAN No.
[27] Hose clamp pliers for JD6805-0028 08.99605-900

jubilee clips 3
• Removing and installing
air compressor intake line
Page 51 of 315
1.5 Removing the air compressor Removing the coolant line

Removing the suction line
• Unlock and remove the plug

connection for coolant line (1) by
pressing the spring clip (2).
• Repeat the procedure for the other
coolant line.
• Unscrew the mounting bolt (1)

• Undo the jubilee clip (3) using the Hose
clamp pliers for jubilee clips [27] and push
it onto the suction line (2).
• Repeat the procedures for the jubilee clip
on the turbocharger suction line
connections.
• Remove the suction line (2)
• Remove the fastening clamps of the
formed hose(6) from the cable harness
holder.
• Undo the jubilee clip (4) using the Hose
clamp pliers for jubilee clips [27] and push
it onto the connection (5).
• Pull the formed hose (6) from the connection
(5).
Page 52 of 315
Removing the air compressor

Removing the pipe connections

mounting bolt (1) and (2).
• Unscrew the mounting bolt (1) and (2).
• Remove the air compressor (3).
• Clean the sealing surfaces
• Undo the reducing joint of the suction

line (2)and the outlet line (3) and
remove them with the seal ring.
• Unscrew and remove the connection (1)
with the seal ring.
Page 53 of 315
1.6. Installing the air compressor Note to the installing the air compressor
Attaching the line connection
• Thinly apply Loctite 5900 (1) on the

surfaces as shown in the drawing.
Installing the air compressor
• Screw the female connection in the

suction line (2) and the outlet line (3)
with the new seal ring, and tighten it to
30-35 Nm. • Install the air compressor (3).
• Screw in the connection (1) with the new • Screw in and tighten the mounting bolt(1)
seal ring and tighten it to 45Nm. and (2) as marked.
Page 54 of 315
Installing the coolant line Installing the suction line
Note
Component damage due
to loose plug connection.
• Check the coolant line
plug connections for
firm seating after
securing.
f h l i l • Push the formed hose (6) with the jubilee
clip (4) onto the connection (5).
• Fit the formed hose (6) clamp on the
• Attach the coolant line (1) and the plug. cable harness holder.
• If necessary, undo the plug connections (1) • Install the jubilee clip (4) using the Hose
by pressing the spring clip (2), then clamp pliers for jubilee clips [27].
reinsert and secure.
• Attach the suction line (2) and the jubilee
• Repeat the procedure for the other coolant clip (3).
line.
• Screw in and tighten the new tightening
bolt (1).
• Install the jubilee clip (3) using the Hose
clamp pliers for jubilee clips [27].
• Repeat the procedure for the turbocharger
suction line connection.
Page 55 of 315
2. Starter
Fig. 2-14 Starter

(1) Mounting bolt (2) Starter (3) Flywheel housing
2.1 Technical data
Mounting bolt (1) M12×35-10.9 110Nm
Mounting nut
M10 22 Nm
（Terminal）
Starter pinion gear tooth 12
Starter power 5.5 kW，24 V
CAUTION
connections
to max. 50% of the specied tightening torque
wrench
Page 56 of 315
2.3 Special tools
No. Drawing Description Sinotruk No. MAN NO.

08
• Cranking the engine
in conjunction with:
• Gear ratchet
[60][60]
[60] Gear ratchet JD6805-0038 80.99627-00

01
Page 57 of 315
Removing the engine barring gear

Installing the starter
Installing the engine barring gear
• Remove the engine barring gear[59] (1)

• Remove the seal cover from the
from the flywheel housing and install the flywheel housing/ the timing case.
seal cover on the flywheel housing/the • Install the engine barring gear [59]
timing case. (1) on the flywheel housing.
Installing the starter
Removing the starter
Unscrewing the mounting bolts(1)
• Crank the engine 360° in the

engine's running direction using
the Engine barring gear [59] and
Gear ratchet[60]whilst checking
the flywheel ring gear for
• Pull the starter (2) out of the damage. Fit a new flywheel ring
flywheel housing. gear if necessary.
• Insert the starter (2) into the
flywheel housing/the timing
case.
• Screw in the new mounting
bolt(1) and tighten to 110Nm.
Page 58 of 315
3. The belt drive
Fig. 2-15 Belt drive

(
1)Poly-V-belt pulley (5)High-pressure drive housing
(2) Mounting bolt poly-V-belt pulley
(3) Poly-V-belt tensioner (6) Mounting bolt
(4) Alternator poly-V-belt (7) Refrigerant compressor
tensioner poly-V-belt pulley
3.1. Technical data
Mounting bolt (6) M10×70-10.9 42-52Nm
Mounting bolt (2) M12×55-10.9 50-70 Nm
CAUTION
Component damage due to incorrectly tightened screw/bolt connections 。
• If impact wrenches are used, these may only be used for pretightening to max.
50% of the specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Page 59 of 315
3.3 Removing the belt drive Removing the poly-V-belt tensioner

Removing the poly-V-belt

CAUTION • Remove the poly-V-belt tensioner (2).
The poly-V-belt tensioner is under
spring tension
• Brace the poly-V-belt tensioner to
prevent it from springing back
unintentionally.
• Turn the poly-V-belt tensioner (1)-clockwise as
far as the stop and hold it
• Carefully relieve the poly-V-belt tensioner (1)
Removing the guide roller
• Mark the installation position for the

guide roller (3) and the space sleeve (4).
• Unscrew the mounting bolt (1).
• Remove the washer (2).
• Remove the guide roller(3) and the space
sleeve (4)
Page 60 of 315
3.4 Installing the belt drive Installing the poly-V-belt

Installing the the poly-V-belt tensioner
CAUTION
• Install the poly-V-belt tensioner(2) on the The poly-V-belt tensioner
distributor housing. is under spring tension
• Screw in and tighten the new mounting • Brace the poly-V-belt
bot (1) to 47Nm. tensioner to prevent it from
Installing the guide roller springing back
unintentionally.
• Turn the poly-V-belt tensioner

(1)-clockwise as far as the stop and
hold it.
• Fit in the poly-V-belt (2)
• Carefully relieve the poly-V-belt
tensioner (1)
• Install the guide roller (3) and the space

sleeve (4) as marked.
• Insert the washer (2)
• Screw in and tighten the new mounting
bolt (1) to 60Nm.
Page 61 of 315
4. Alternator
Fig.2-16 Alternator
(1) The threaded bracket bracket
(2) Turbocharger elbow bracket (5) Mounting bolt
(3) Alternator 6) The poly-V-belt pulley
(4) High-pressure pump drive housing (7) Mounting bolt
4.1 Technical data
Technical
Designation Specification
parameter
Mounting (7) M16 80-100Nm
Terminal B+ mounting nut M8 9-13Nm
4.2 Service product
Loctite270
CAUTION
connections.
to max. 50% of the specified tightening torque
wrench.
Page 62 of 315
4.4 Special tools
[61] Special spanner JD6805-0039 80.99603-60

29
• Removing and
installing the
poly-V-belt pulley
in conjunction
with：
• Handle [62]
[62] Handle JD6805-0040 08.06460-00

02
• Removing and
mounting the
poly-V-belt pulley
Page 63 of 315
4.5 Removing the alternator Removing the high-pressure drive bracket

Removing the poly-V-belt
• Unscrew the mounting nut (3) from the

CAUTION mounting bolt (1).
The poly-V-belt tensioner is under • Unscrew the mounting bolt (4) and remove
spring tension the holder (2).
• Brace the poly-V-belt tensioner to Removing the support
prevent it from springing back
unintentionally.
• Turn the poly-V-belt tensioner (1) clockwise as
far as the stop and hold it.
• Carefully relieve the poly-V-belt tensioner (1)
Disconnecting the alternator electrical
connection
• Unscrew the mounting nut (4)

• Remove the alternator
• Unscrew the mounting bolt (2) and
remove the support (1)
•Release and pull off the compact connector(3)

• Disconnect the cable tie (2)
• Unscrew the terminal B+ mounting nut (1)
• Free, set aside and secure the wiring
harnesses
Page 64 of 315
Undoing the poly-V-belt mounting nut 4.6 Installing the alternator

Mounting the poly-V-belt pulley
• Mount the Special spanner [61] (2) with

the Handle [62] (3) on the poly-V-belt
pulley mounting nut
• Insert the splined spanner (1) into the •Slide the poly-V-belt pulley (2) onto the
alternator shaft spline. alternator shaft (3)
• Brace the splined spanner (1) and undo the • Thinly apply Loctite270 sealing compound
mounting nut. on the thread and contact surface of the
Removing the poly-V-belt pulley new mounting nut (1)
• Screw on the new mounting nut (1)
Tightening the poly-V-belt pulley mounting
nut
• Unscrew the mounting nut (1)

• Remove the poly-V-belt pulley (2) from the
alternator shaft (3). • Mount the Special spanner [61] (2) with
Handle [62] (3) on the poly-V-belt pulley
mounting nut.
• Insert the splined spanner (1) into the
alternator shaft spline
• Brace the splined spanner (1) and tighten
the mounting nut to 80-100 Nm
Page 65 of 315
Mounting the support Connecting the alternator electrical
connection
• Position the support (1) and screw in the new

• Route the wiring harnesses.
mounting bolt (2).
• Screw on the terminal B+ mounting nut
• Insert the alternator. (1) and tighten it to 9-13 Nm.
• Screw in the new mounting bolt (3) • Insert and lock the compact connector (3)
• Screw in and tighten the new mounting nut • Secure the wiring harnesses with cable ties
(4). (2)
• Tighten the mounting bolt (2) and (3). Installing the poly-V-belt
Mounting the high-pressure drive gear

bracket
CAUTION
The poly-V-belt tensioner is
under spring tension
• Brace the poly-V-belt
tensioner to prevent it from
•Position the support (2) and screw in the new
springing back
mounting bolt (4). unintentionally.
• Screw in the new mounting bolt (1) and the
new mounting nut (3). • Turn the poly-V-belt tensioner (1) clockwise
• Screw in the mounting nut (3) and meantime as far as the stop and hold it.
fix the mounting bolt (1). • Install the poly-V-belt (2)
• Tighten the mounting bolt (4). • Carefully relieve the poly-V-belt tensioner (1)
Page 66 of 315
Section 4. Intake and exhaust system
Fig 2-17 Turbocharger

(5) Gasket
(1) Turbocharger
(6) Exhaust manifold
(2) Gasket
(7) Mounting nut
(3) Oil return line
(8) Mounting nut
(4) Mounting bolt
(9) Oil inlet line
Page 67 of 315
Fig 2–18 Exhaust manifold

(1) Heat shield
(2) Rear exhaust manifold
(3) Exhaust manifold gasket
(4) Mid-exhaust manifold
(5) Front exhaust manifold
Page 68 of 315
1. Exhaust manifold
1.1 Additional jobs

- Removing and installing the turbocharger，see P77
- Removing and installing the oil module，see P192
Fig. 2 –19 Exhaust manifold

(1) Mounting bolt (4) Cylinder head 6) Heat shield
(2) Exhaust manifold (5) Mounting bolt (7) Mounting bolt
(3) Gasket (8) Heat shield
1.2 Technical data

Mounting bolt（5） M10×50
Mounting bolt（5） M10×50 Initial torque60Nm
Mounting bolt（1） M10×95 Final torque90°
Mounting bolt（1） M10×95
Page 69 of 315
WARNING
· If impact wrenches are used, these may only be used for pretightening to max.
· Final tightening must always be performed manually using a torque wrench
Page 70 of 315
1.4 Removing the exhaust manifold Removing the exhaust manifold
· Pull the exhaust manifold (1) and (3)

· Unscrew the mounting bolt（2） out of the exhaust manifold (2).
· Remove the heat shield (1) and (3). · Remove the seal ring from the exhaust
Removing the exhaust manifold manifold (1) and (3).
· Clean the contact surfaces.
· Mark the installation position of the

mounting bolt（2）and （3.
· Unscrew the mounting bolt (2) and (3).
· Remove the exhaust manifold（4）with
the gasket (1).
Page 71 of 315
1.5 Installing the exhaust manifold Installing the exhaust manifold
Assembling the exhaust manifold
· Position the gasket (1) so that the

projection faces the exhaust manifold
· Insert the new seal ring in the exhaust (4).
manifold (1) and (3). Line up the gaps · Position the exhaust manifold (4)
of the 4 rings at 90° offset to teach · Screw in the new mounting bolt（2）and
other. （3） as shown.
· Insert the exhaust manifold (1) and (3) · Tighten the mounting bolt（2）and 3）
into the exhaust manifold (2). in the sequence as shown to
Tightening sequence of the exhaust initial torque 60Nm.
manifold · Tighten the mounting bolt (2) and (3)
in the sequence as shown and final
tightening 90°.
Installing the heat shield
· Start from A, and then follow the

sequence as B, C, D, E, and F to
tighten the exhaust manifold (1).
· Position the heat shield (1) and (3).
· Screw in and tighten the new mounting
bolt(2).
Page 72 of 315
2. Suction line
Fig. 2-20 Suction line

(1) Mounting bolt (6) Suction line
(2) Support (7)Intake manifold
(3) Mounting bolt (8) Screw plug
(4) Mounting nut (9) Seal ring
(5) Suction line
(10) Mounting bolt
2.6 Technical data
Designation Specifications Technical
parameter
Intake manifold M6 10Nm
(7)jubilee clip
2.7 Service product
Technical Vaseline
WARNING
Page 73 of 315
Note
Varying suction lines may be fitted.
The procedure for removal and installation is intrinsically the same.
2.9 Removing the suction line 2.10 Installing the suction line
· Unscrew the mounting bolt (1) (2) and ·Position the intake manifold (4) on the
(7). turbocharge with the jubilee clip (5),
and align it with the suction line (6).
· Remove the suction line (6).
·Thinly apply technical Vaseline on the
· Undo the jubilee clip (5).
new O-ring (3) and insert it into the
· Remove the intake manifold (4) with intake manifold (4).
the O-ring (3).
· Insert it into the suction line (6)
bolt(1).
bolt(2).
· Insert the new mounting bolt (7), and
then screw in and tighten new
mounting nut.
· Tighten the jubilee clip (5) to10Nm.
Page 74 of 315
3. Intake manifold
3.1 Additional jobs
Fig. 2-21 Intake manifold

(1) Flame glow plug (specially (6) Mounting bolt
equipped) (7) Intake manifold
(2) Solenoid valve (8) Intake pressure sensor
(3) Mounting bolt (9) Mounting bolt
(4) Bracket
3.2 Service product
Loctite5900
WARNING
connections.
· If impact wrenches are used, these may only be used for pretightening
to max. 50% of the specified tightening torque
· Final tightening must always be performed manually using a torque
wrench.
Page 75 of 315
3.4 Removing the intake manifold 3.5 Installing the intake manifold
Removing the bracket Installing the intake manifold
· Unscrew the mounting bolt (1) and

(2)to remove the bracket (3).
Removing the intake manifold
· Thinly apply Loctite5900 on the

contact surfaces.
· Position the intake manifold (2).
· Screw in the new mounting bolt (1).
· Insert it and the new O-ring in the
turbocharger (4).
· Screw in and tighten the mounting bolt
(5).
· Connect the electrical connection (3).
Installing the bracket
· Disconnect the electrical connection

(3)
·Unscrew the mounting bolt (5) and
remove the turbocharger (4).
· Unscrew the mounting bolt (1).
· Removing the intake manifold (2). ·Position the bracket (3).
· Clean the contact surfaces. ·Screw in the new mounting bolt (1) and
(2).
·Tighten the mounting bolt (2)
·Tighten the mounting bolt (1).
Page 76 of 315
4. Turbocharger
4.1. Additional jobs
Removing and installing the suction line, see P73
Fig. 2- 22 Turbocharger
(1) Turbocharger (5) Gasket
(2) Gasket (6) Exhaust elbow
(3) Oil return line (7) Mounting nut
(4) Mounting bolt (8) Oil inlet line
4.2 Technical data
Mounting nut（8） M10 Initial torque10Nm
Mounting nut（8） M10 Final torque90°
Lithium base grease
WARNING
· Final tightening must always be performed manually using a torque wrench.
Page 77 of 315
4.5 Special tools
[165] Box spanner, size, JD6805-0083 80.99603-0323
dimension 15i=1:1.22
·Unscrew and tighten
the mounting nut in
the turbocharger.
[166] Detector JD6805-0168 80.99606-0399
·Check the compressed
air plug
Page 78 of 315
4.6 Removing the turbocharger Removing the oil return pipe
Removing the compressed air line
·Unscrew the mounting bolt (3)

·Unscrew the oil return pipe (2) at the
thread.
·Remove the gasket (4) and the seal
· Remove the compressed air line（1） ring(1).
· Remove the compressed air line (2) ·Clean the contact surfaces.
from the butterfly cylinder (3). Removing the turbocharger
Removing the exhaust elbow
·Unscrew the bolt off the jubilee clip · Unscrew the mounting nut (1) with the
(3). box spanner [165].
·Remove the gasket and the exhaust · Remove the turbocharger and the
elbow (2) from the turbocharger (1). gasket (3).
·Clean the contact surfaces. ·Clean the contact surfaces.
Removing the oil pressure pipe
·Remove the oil inlet pipe(1).
Page 79 of 315
4.7 Installing the turbocharger Turbocharger mounting nut, bottom
Mounting the turbocharger left
WARNING WARNING
Component damage due to Component damage due to
incorrect use of the special tools. incorrect use of the special tools.
· Fit the turbocharger (2) with a new ·Screw in and tighten the new mounting
gasket (3). nut using the Box spanner [165] (1)
· Screw in and tighten the new mounting and the torque wrench (2) to initial
nut (1) using the Box spanner [165] to torque10Nm.
initial torque10Nm · Tighten the mounting nut to final
· Tighten the mounting nut (1) to final torque 90°
torque 90° Connecting the oil return pipe
Turbocharger mounting nut, bottom
right
·Screw the oil return pipe (2) and the

new seal ring (1) into the crankcase.
· Position the oil return pipe (2) and the
new gasket (4).
WARNING · Screw in and tighten the new mounting
Component damage due to bolt (3).
incorrect use of the special tools. · Tighten the oil return pipe (2) nut.
nut using the Box spanner [165] (1)
and the torque wrench (2) to initial
torque10Nm.
· Tighten the mounting nut to final
torque 90°
Page 80 of 315
Filling the turbocharger with oil Mounting the exhaust elbow
· Position the exhaust elbow (2) with the

WARNING new gasket on the turbocharger (1).
If no oil is added, the turbocharger · Screw in and tighten the jubilee clip
will be damaged when the vehicle is bolt (3).
started for the first time. Attaching the compressed air line
• Fill the turbocharger with clean engine
oil before attaching the oil pressure
line.
· Use a funnel (1) to pour clean engine
oil into the oil feed neck on the
turbocharger (2) until the oil duct in
the turbocharger (2) is full.
Attaching the oil pressure line
· Attach the compressed air line (1).

· Screw in and tighten the new nut on
the butterfly cylinder. (3).
· Combine the compressed air line
(2)and check with the Detector [166]
if they are fasten.
· Repeat the procedures if the
connections are loose from the lock
bolt.
· Attach the oil inlet pipe(1).
· Tighten the nut of the oil inlet pipe (1).
Page 81 of 315
Section 5. Cylinder head
Fig 2-23 Cylinder head

(1) Crankcase
(2) Cylinder gasket
(3) Cylinder head
(4) Mounting bolt
(5) Cylinder head cover
Page 82 of 315
1. Cylinder head
1.1 Additional jobs
- Removing and installing the engine control unit, see P20
- Removing and installing the exhaust manifold, see P69
- Removing and installing the suction line, see P73
- Removing and installing the turbocharger, see P77
- Checking and setting the valve clearance, see P97
- Removing and installing the injector pump and the rail, see P156
- Removing and installing the fuel service center, see P181
- Removing and installing the oil module，see P192
Fig. 2-24 Cylinder head

(1) Crankcase (4) Mounting bolt
(2) Cylinder gasket (5) Cylinder head cover
(3) Cylinder head
1.2 Technical data

Cylinder head bolt M18×2×246-10.9 Initial torque10Nm
Cylinder head bolt M18×2×246-10.9 2nd torque 150Nm
Cylinder head bolt M18×2×246-10.9 3rd torque 300Nm
Cylinder head bolt M18×2×246-10.9 Final torque90°
Page 83 of 315
Rocker arm mechanism M12×60-10.9 105+10Nm
mounting bolt
Mounting bolt（4） 10Nm
Cylinder liner standout 0.035-0.085mm
1.3 Service product

White T——thinly apply White T on the support surface of the cylinder head bolt
when the cylinder head is reassembled.
WARNING
Component damage due to the damaged support surface of the cylinder
head bolt.
·Do not reuse the cylinder head bolts, even if they have only been used
once.
WARNING
Damage in the rail system.
·All work on components of the common-rail system must be performed by
specially trained personnel only.
•The engine must be stationary for at least 5 minutes before commencing
work in order to enable depressurisation in the rail, or depressurisation must
be checked by means of SINOTRUK-cats® (desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever.
• Always replace rail connections once they have been undone.
•Do not reuse plugs for the high-pressure lines, the rail or injectors, even if they have
only been used once.
• Follow the sequence described when tightening injection pump,
high-pressure lines, the rail and rail connections.
WARNING
If impact wrenches are used, these may only be used for pretightening to
max. 50% of the specified tightening torque
wrench
1.5 Special tools
No. Drawing Description Sinotruk MAN NO.
No.
Page 84 of 315
No.
[175] Torque
multiplier=1:3.5
· Undoing and
tightening the
cylinder head bolt,
in conjunction
with:
· Support [176]
· Socket, size
22[183]
· Socket [184] JD6805-0084 80.99619-0007
· Torque angle
gauge [177]
· Stop pin [178]
· Pan head
screw[179]
· Connecting pin
[180]
· Rubber ring
42mm[181]
· Washer[182]
[176] Support
·Undoing and
JD6805-0085 80.99606-0551
tightening the
cylinder head bolt
[177] Torque angle
gauge
·Undoing and JD6805-0086 80.99607-0172
tightening the
cylinder head bolt
[178] Stop pin
·Undoing and
tightening cylinder
head bolt JD6805-0087 80.99606-0641
[179] Pan head screw

·Unscrew and
tighten the JD6805-0088 06.02191-0407
cylinder head bolt
Page 85 of 315
No.
[180] Connecting pin
·Unscrew and
tighten the JD6805-0089 06.22729-0006
cylinder head bolt
[181] Rubber ring 42mm

·Unscrew and
tighten the
JD6805-0090 08.06142-9006
cylinder head bolt
[182] Washer
·Unscrew and
tighten the JD6805-0091 80.99609-0033
cylinder head bolt
[183] Socket, size22

·Unscrew and
tighten the JD6805-0092 80.99612-0024
cylinder head bolt
[184] Socket
·Unscrew and
tighten the
JD6805-0093 80.99603-0327
cylinder head bolt
[185] Engine barring

gear
·Cranking the
engine in JD6805-0023 80.99626-6008
conjunction with:
· Gear ratchet
[186]
[186] Gear ratchet
·Cranking the
engine in
conjunction with: JD6805-0038 80.99627-0001
Page 86 of 315
No.
[187] Cross member
·Removing and
installing the
cylinder head, in JD6805-0094 80.99629-6008
conjunction with:
·Hook chain[188]
·Crane hook[189]
[188] Hook chain
·Removing and
installing the
JD6805-0095 80.99629-6009
cylinder head
[189] Crane hook

·Removing and
installing the JD6805-0096 80.99629-0040
cylinder head
[190] Dial gauge stand

·Checking the
cylinder liner
Checking the
cylinder liner
standout, in
JD6805-0024 08.71000-3217
conjunction with:：
·Dial gauge[191]
·Measuring
plate[192]
·Hex bolt[193]
·Washer[194]
[191] Dial gauge
·Checking the
cylinder liner
JD6805-0024 08.71000-3217
standout
[192] Measuring plate

Checking the
cylinder liner
JD6805-0097 80.99605-0286
standout
Page 87 of 315
No.
[193] Hexagon bolt
·Checking the
cylinder liner
JD6805-0098 06.01499-0015
standout
[194] Washer
·Checking the
cylinder liner
JD6805-0099 06.15013-0417
standout
Page 88 of 315
1.6 Removing the cylinder head Removing the cylinder head cover
Disconnecting the plug bracket
electrical connection of the speed
sensor
Note
Always remove the mounting
bolts from the cylinder head
·Disconnect the electrical connections together with the cylinder head
(1) cover gasket and the spacer.
Remove the wiring harness cover · Unscrew the mounting bolt(3)
· Remove the cylinder head cover (2)
from the cylinder head (1)
Attaching engine barring gear
· Turn 90° to unlock the lock pin (2)

· Remove the wiring harness cover (1)
Unclipping the wiring harness holder
· Remove the cover from the flywheel
housing.
• Mount the Engine barring gear [185]
(1) on the flywheel housing.
· Unscrew the mounting bolt（1）

· Put aside and fasten the wiring harness
with the holder (2).
Page 89 of 315
Turning the engine to the TDC mark Removing the valve bridge
· Turn the engine in the engine's running Note

direction with the Engine barring Removing the cylinder head can
gear[185](1) and the Gear ratchet be done when installing the valve
[186] until the 1st cylinder is at the bridge depending on the engine model
TDC mark (2). in maintenance.
Removing the rocker arm mechanism · Mark the installation position of the
valve bridge (1) and (2).
· Remove the valve bridge (1) and (2).
Assembling the special tool
Note
Removing the cylinder head can
be done when installing the rocker · Insert the Torque multiplier
arm mechanism depending on the i=1: 3.5[175] (1) into the Support
engine model in maintenance. [176] (2)
• Mount the Stop pin [178] (5) on the
· Unscrew the mounting bolt（5） Support [176] (2) using the Pan head
screw [179] (4) and Washer [182] (3)
· Remove the EVB plate（6） • Fit the Torque angle gauge[177](10) on
the Torque multiplier i = 1 : 3.5 [175]
· Unscrew the mounting bolt (3) and (4).
(1)
· Remove the valve bridge (2) and the • Fit the Socket, size 22 [183] (8) on the
rocker arm bracket (1). Torque multiplier i = 1 : 3.5 [175] (1)
and secure with the Connecting pin
[180] (9) and Rubber ring 42 mm
[181] (7)
·Insert the Socket [184]（6）into the
Socket, size22[183]（8）.
Page 90 of 315
Undoing the cylinder head bolt Removing the cylinder head
Note
Undoing the cylinder head bolts
from outside to inside.
· Fit the special tool (1) on the cylinder
head bolt to be undone.
· Unscrew all the cylinder head bolts · Fit in all the Crane hook [189]（6）on
using the special tool (1) and the the cylinder head(4) and the
wrench (2). camshaft.
Unscrewing the cylinder head · Fit in the Hook chain [188]（3）on the
Crane hook[189]（6）and the Cross
member [187]（5）.
· Lift off the cylinder head (4) from the
crankcase using the lifting device .
· Remove the cylinder head gasket(2).
· Clean the plug hole of the cylinder
head bolt .
· Remove the special tool.
·Unscrew the cylinder head bolt (1)
Page 91 of 315
1.7 Installing the cylinder head Installing the cylinder head
Moving the camshaft to TDC
· Turn the camshaft (3) to align TDC

mark (1) with the cylinder head
surface(2).
Checking the cylinder liner standout
· Fit in the Crane hook [189]（6）on the

cylinder head(4) and the camshaft.
· Fit in the Hook chain [188]（3）on the
Crane hook[189]（6）and the Cross
member [187]（5）.
· Install the new cylinder gasket (2) on
the locating pin in the crankcase(1).
· Mount the cylinder head (4) on the
· Mount the Measuring plate [192]（2） crankcase (1.)
on the cylinder liner. · Remove the special tool.
· Screw in and tighten the Washer[194]
（5） and the Hexagon bolt[193]（4）
·Mount the Dial gauge stand [190]（6）
and the Dial gauge[191]（3）on the
Measuring plate [192](2).
· Zero the Dial gauge[191]（3）.
· Carefully locate the dial gauge tip
(1)on the cylinder liner (1) and read
off the difference in the dial gauge.
· The permitted cylinder liner standout is
035-0.085mm.
· If the cylinder liner standout is out of
tolerance, install a new cylinder
liner/crankcase, see P228 for Removing
and installing the cylinder liner.
Page 92 of 315
Tightening sequence for cylinder head Screwing the cylinder head bolt
WARNING
Component damage due to the
damaged support surface of the
cylinder head bolt.
·Do not reuse the cylinder head bolts,
even if they have only been used once.
·Thinly apply White T grease on the new
cylinder head bolt(1) contact
surfaces.
· Screw in and manually tighten the
cylinder head bolt (1).
A. Intake side · Tighten the cylinder head bolt (1) to
initial torque 10Nm as the illustrated
B. Exhaust side
sequence.
·Follow the illustrated tightening · Tighten the cylinder head bolt (1) to
sequence 1 to 26 in the following 2nd torque 150Nm as the illustrated
work step sequence.
· Tighten the cylinder head bolt (1) to 3rd
torque 300Nm as the illustrated
sequence.
Final tightening the cylinder head bolt
·Install the special too1(1)on the

cylinder head bolt to be done.
· Tighten the cylinder head bolt to 90°
using the special tool (1) and the
wrench(2)as the illustrated sequence.
Page 93 of 315
Checking the camshaft TDC mark
Assembling the rocker arm
mechanism
·Check the TDC mark(1)on the camshaft

(3) . ·Mount the rocker arm seat bracket (1)
The TDC mark (1) must be aligned with on the cylinder head.
the cylinder head surface (2). · Install the valve rocker bridge (2) on
· If not, remove the camshaft (3) and the rocker arm seat bracket (1)
repeat the installation. ·Screw the mounting bolt（3）and（4）
Installing the valve bridge ·Tighten the mounting bolt(4)to
105+10Nm
·Tighten the mounting bolt(3)to
105+10Nm
· Install the EVB plate（6）
·Screw in and tighten the mounting
bolt(5).
Tightening sequence for cylinder head
cover
Note
Always direct the valve bridge
recess towards the camshaft.
·Install the valve bridge (1) and (2) as
illustrated.
A. Intake side B. Exhaust side
Page 94 of 315
·Follow the illustrated tightening sequence Mounting the cylinder head cover
1 to 18 in the following work step
·Check the gasket in the cylinder head

cover (2), replace if necessary
• Clean the oil dirt off the gasket and the
groove before installing the cylinder
head cover.
Remember the gasket mounting bolts
are different: on the exhaust side are
tightened with 8 bolts without the
rubber mounts, and the other 10 bolts
are with the rubber mounts.
• Install the cylinder head cover (2) onto
the cylinder head (1)
• Screw in the mounting bolts (3)
• Tighten the mounting bolt (3) to
10Nm as the illustrated sequence.
Mounting the cable duct bracket
·Route the cable duct bracket (2)with the

wiring harness so that it is not under
tension, not kinked and there are no
chafing points.
· Screw in and tighten the mounting
bolt(1).
Page 95 of 315
Mounting the cable duct cover
· Put on the cable duct cover (1)

• Close the locking pin (2) a 90° turn
Connecting the speed sensor electrical
connections
·Connect the electrical connection

plug(1).
· Remove the Engine barring gear [185]

(1) from the flywheel housing
• Mount the cover on the flywheel
housing.
Page 96 of 315
2. Checking and setting the valve clearance
Fig 2-25Adjusting the valve clearance

(1) Adjuster screw, exhaust valve (4) Lock nut
(2) Lock nut (5) EVB lock nut
(3) Adjuster screw, intake valve (6) EVB adjusting screw
2.1 Technical data
Intake valve clearance 0.5±0.03mm
Exhaust valve clearance 0.8±0.03mm
EVB Adjusting clearance 0.6±0.03mm
Lock nut（2），（4） 45Nm
EVB Lock nut（5） 45Nm
Cylinder head cover mounting bolt 10Nm
WARNING
Inefficient of engine output or engine damage.
·Adjusting the valve clearance can be done in case of cold engine.
WARNING
· If impact wrenches are used, these may only be used for pretightening to
Page 97 of 315
2.3 Special tools
No.
gear
·Cranking the
engine in
JD6805-0023 80.99626-6008
conjunction
with:
·Gear
ratchet[196]
[196] Gear ratchet
·Cranking the
engine
JD6805-0038 80.99627-0001
[197] Holding device

·Checking and
setting the valve
and EVB
clearance in
conjunction
with:
·Feeler
gauge0.5[198]
·Feel
gauge0.6[199] JD6805-0100 08.75300-0000
·Feel
gauge0.8[200]
·Valve adjusting
wrench, size
14[201]
·Valve adjusting
wrench, size
21[202]
·Torque
wrench[203]
Page 98 of 315
No.
[198] Feeler gauge 0.5
·Checking and
setting the valve JD6805-0101 80.99607-0177
clearance

·Checking and
setting the valve
JD6805-0102 80.99607-0178
clearance

·Checking and
clearance
[201] Valve adjusting

wrench, size 14
·Checking and
JD6805-0104 80.99603-6031
setting the valve
clearance
[202] Valve adjusting

wrench, size 21
·Checking and
clearance
[203] Torque wrench

·Setting valve
and EVB
JD6805-0036 08.06450-0006
clearance
Page 99 of 315
2.4 Checking and setting the valve Attaching the engine barring gear
clearance
Remove the wiring harness cover
·Remove the cover from the flywheel

housing.
·Turn 90° to unlock the lock pin (2) • Mount the Engine barring gear [195]
·Remove the wiring harness cover (1) (1) on the flywheel housing.
Removing the cylinder head cover Moving the engine to the adjusting
position
A. Rocker arms in overlap

B. Rocker arms free
Note • Crank the engine in the engine's
Always remove the mounting running direction using the Engine
bolts from the cylinder head barring gear [195] and the Gear
together with the cylinder head cover ratchet [196] until the rocker arms are
gasket and the spacer. in overlap
· Unscrew the mounting bolt(3) • Adjust free rocker arms as per table
· Remove the cylinder head cover (2)
from the cylinder head (1)
Page 100 of 315

Checking the intake valve Checking the exhaust valve clearance
clearance
· Repeatedly press the valve bridge (2)

to drain the oil in the EVB piston
• Insert the Feeler gauge 0.5 [198] (2) (5) .
with the Holding device [197] (4) · Insert the Feeler gauge 0.8[200](4)
between the rocker arm (1) and the with the Holding device [197]（3）
valve bridge (3). between the rocker arm (1) and the
Adjust the valve clearance if it is not valve bridge (2).
0.50 mm. Adjust the valve clearance if the valve
Setting the intake valve clearance clearance is not 0.8 mm.
Moving the EVB piston to the
adjusting position
• Undo the lock nut (2) and adjusting

screw (1)
• Insert the Feeler gauge 0.5 [198] (6) WARNING
with the Holding device [197] (5) Danger of incorrect valve
between the rocker arm (3) and the clearance
valve bridge (4). ·It must be possible to fully push
• Screw in the adjusting screw (1) until the EVB piston into the valve
the Feeler gauge 0.5 [198] (6) can be bridge.
moved between the rocker arm (3) · Undo the lock nut (2) and unscrew it
and the valve bridge (4) with little several turns.
resistance. · Screw in the adjusting screw (1) to
• Brace the adjusting screw (1) using the press the valve bridge （ 3 ）
Valve adjusting wrench, size14[201] . downwards several times until the
• Tighten the lock nut (2) to 45 Nm stop is reached.
using the Torque wrench [203]. All the engine oil must escape from
• Check the setting again and, if the EVB piston (4).
necessary, repeat the setting
procedure.
Page 101 of 315

Setting the exhaust valve clearance • Insert the Feeler gauge 0.6 [199] (2)
with the Holding device [197] (3)
between the reverse bracket (4) and
the valve bridge (1)
Adjust the EVB clearance if the
adjustment dimension is not 0.6 mm.
Setting the EVB clearance
·Undo the lock nut (3).

·Screw in the adjusting screw (2) to
press the valve bridge (6) downwards
several times until the stop is reached.
· Block the valve bridge (6) in this
position with the adjusting screw (1).
· Insert the Feeler gauge 0.8 [200] (5) Note
with the Holding device [197] The valve bridge must not move the
between the rocker arm (4) and the exhaust valve when the adjusting
valve bridge (6). screw is screwed in.
· Screw in the adjusting screw (2) until · Undo the lock nut (2)
the Feeler gauge 0.8 [200] (5) can be · Unscrew the adjusting screw (1) until
moved between the rocker arm (4) the Feeler gauge 0.6 [199](4) can be
and the valve bridge (6) with little inserted with the Holding device [197]
resistance. (3).
· Brace the adjusting screw (2) using the · Screw in the adjusting screw(1) with
Valve adjusting wrench, size14[201] . Feeler gauge 0.6[199](4) inserted
• Tighten the lock nut (3) to 45 Nm until the valve bridge reaches the stop
using the Torque wrench, size [203] – this can be felt by a noticeable
• Check the setting again and, if increase in force
necessary, repeat the setting procedure • Brace the adjusting screw (1) using the
Checking the adjustment dimension Valve adjusting wrench, size21[202].
for the EVB piston • Tighten the lock nut (2) to 45Nm using
the Torque wrench [203]
• Check the setting again and, if
necessary, repeat the setting procedure
· Lightly push down the valve bridge (1)
Page 102 of 315

Removing the engine barring Tightening sequence for cylinder head
gear cover
· Remove the Engine barring

gear[195](1) from the flywheel
housing.
• Mount the cover on the flywheel
housing
A Intake side
B Exhaust side
· Follow the illustrated tightening
sequence 1 to 18 in the following
work step
Page 103 of 315

Mounting the cylinder head cove

cover (2), replace if necessary
head cover.
are different. On the exhaust side are
the cylinder head (1).
• Tighten the mounting bolt (3) to 10
Nm as the illustrated sequence.
Mounting the wiring harness cover
·Position the wiring harness cover (1)

• Close the locking pin (2) a 90° turn
Page 104 of 315

3. Valve stem seal
3.1 Additional jobs

- Checking and setting the valve clearance，P97
- Removing and installing the injector and the rail, see P156
Fig. 2-26 Valve spring and valve seal

(1) Cylinder head (3) Valve spring
(2) Valve stem seal (4) Valve keeper
3.2 Technical data

Rocker arm seat bracket pan head M12×60-10.9 105+10Nm
bolt
Page 105 of 315

WARNING
connections.
wrench
3.4 Special tools

No.
JD6805-0023 80.99626-6008
gear
• Crank the
engine, in
conjunction with:
• Gear ratchet
[205]
[205] Gear ratchet JD6805-0038 80.99627-0001
• Cranking the
engine
[206] Valve-spring
JD6805-0106 80.99613-6000
compressor
• Removing and
installing the
valve springs in
conjunction
with :
• Adapter [207]
• Holder [211]
• Holder [210]
• Extension [209]
•Assembly device
[208]
[207] Adapter JD6805-0107 80.99613-0042
• Removing and
installing the
valve springs
Removing and
installing the
valve spring
Page 106 of 315

No.
[208] Assembly device JD6805-0108 80.99606-6092
•Removing and
installing the
valve spring
[209] Extension JD6805-0109 80.99606-6094

• Removing and
installing the
valve spring
[210] Holder JD6805-0110 80.99613-0052

• Removing and
installing the
valve spring
[211] Holder JD6805-0111 80.99613-0053

·Removing and
installing the
valve spring
[212] Magnetic pick-up

tool
• Removing the JD6805-0112 80.99639-0009
valve keeper, in
conjunction with:
• Adapter [207]
• Holder [210]
• Holder [211]
• Valve spring
compressor [206]
•
Extension[209]
• Assembly
device [208]
Page 107 of 315

No.
[213] Assembly device JD6805-0113 80.99606-6088
• Removing the
valve stem seal
[214] Assembly sleeve JD6805-0114 80.99606-0287

• Installing the
valve stem seal,
in conjunction
with:
·Assembly
device[213]
Page 108 of 315

3.5 Removing the valve stem seals Attaching the engine barring gear
Removing the wiring harness
cover
· Remove the cover from the flywheel

housing.
·Open the locking pin (2) a 90° turn • Mount the Engine barring gear [204]
• Position the wiring harness cover (1) on the flywheel housing
Removing the cylinder head cover Moving the engine to the adjusting
position
A. Rocker arms in overlap

Note B. Rocker arms free
Always remove the mounting • Crank the engine in the engine's
bolt from the cylinder head with running direction using the Engine
the cylinder head cover gasket and the barring gear [204] and the Gear
spacer. ratchet [205] until the rocker arms are
· Undo the mounting bolt（3） in overlap with the valve bridge.
· Remove the cylinder head cover (2) • Adjust free valve stem seal as per
from the cylinder head (1). table.
Page 109 of 315

Removing the rocker arm mechanism Assembly special device
·Undo the mounting bolt（5）

·Remove the EVB (6)）
·Unscrew the mounting bolt (3) and (4).
·Remove the rocker arm mechanism (2)
with the rocker arm seat bracket (1).
Removing the valve bridge Note
Retaining washer and Holder
[211] have left-hand threads.
• Position the Holder [210] (5) and the
Holder [211] (3) on the Valve-spring
compressor [206] (1) and then screw
on by turning the threaded spindle.
• Screw on the retaining washers (2) and
(6)
• Position the lever (8) on the
Valve-spring compressor [206] (1)
·Mark the installation position of the and secure using the mounting bolt
valve bridge (1) and (2). (7).
·Remove the valve bridge (1) and (2).
Page 110 of 315

Fitting the mounting device • Position the Holder [210] (4) and the
Holder [211] on the spring cap and
the extension by turning the threaded
spindle (5).
• Hook the Valve-spring compressor
[206] (2) in the Assembly device [208]
(3)
• Place the Extension [209] (1) onto
Removing the valve keeper
•Screw the Adapter [207] (2) into the CAUTION

bearing support (1) Risk of injury due to
• Screw the Assembly device [208] (3) springing back of the valve
into the Adapter [207] (2)· springs
Mounting the valve-spring • Ensure that the Holder [210]
compressor and Holder [211] are seated
correctly on the spring cap.
• Do not remove the valve keeper from
the valve spring with your
bare hands.
·Push down the Valve spring compressor
[206]（1）with the Extension [209].
·Remove the valve keeper (2) (2) from
the valve stem (3) using the Magnetic
pick-up tool [212].
• Release the Valve-spring compressor
[206] (1)
• Remove the valve spring with the
washer and the spring seat.
• Repeat the same procedure for all the
valves.
• Remove the special tool.
Page 111 of 315

3.6 Installing the valve stem seals
Removing the valve stem seals Installing the valve stem seals
·Push the Assembly device [213] (2)

over the valve stem seal (1).
·Clamp the Assembly device [213]（2）
·Pull the valve stem seal (1) off the
valve guide with the impact weight.
Note
The stem seals are different in
color for the intake and the
exhaust valves. The red is
installed in the intake valve and the
brown in the exhaust.
•Thinly apply clean engine oil on the
Assembling sleeve [214] (2) and
valve stem seal (3)
• Push the Assembling sleeve [214] (2)
over the valve stem (1)
• Insert the valve stem seal (3) into the
Assembly device [213] (4) and clamp
it.
• Push the Assembly device [213] (4)
over the Assembling sleeve [214] (2)
• Knock the valve stem seal(3) onto the
valve stem (1) using the impact
weight (5)
• Remove the Assembly device [213] (4)
and the Assembling sleeve [214] (2)
Page 112 of 315

Fitting the mounting device Mounting the Valve-spring
compressor
·Screw the Adapter [207]（2）into the

bearing support (1) · Position the Holder [210] (4) and the
·Screw the Assembly device [208]（3） Holder [211] on the spring cap and
into the Adapter [207](2). the extension by turning the threaded
spindle (5)
• Hook the Valve-spring compressor
[206](2) in the Assembly device [208]
(3)
• Place the Extension [209] (1) onto
Page 113 of 315

Installing the valve springs bare hands.
· Push down the Valve spring
compressor [206](1)with the
Extension [209].
· Insert the valve keeper (2) into the
valve stem (3) using the suitable tool
so that the valve keeper is seated in
the groove of the valve stem (3).
• Release the Valve-spring compressor
[206] (1)
• Remove the special tool.
Installing the valve bridge
• Insert the washer (3), valve spring (2)

and spring cap (1) over the valve
stem.
• Repeat the same procedure for all the
valves. Note
Installing the valve keeper
Always keep the groove of the
valve bridge facing the camshaft.
marked.
CAUTION
Risk of injury due to
springing back of the valve
springs
• Ensure that the Holder [210]
and Holder [211] are seated
correctly on the spring cap.
• Do not insert the valve keeper
into the valve spring with your
Page 114 of 315

Installing the rocker arm mechanism Tightening sequence for cylinder head
cover
·Fit the rocker arm seat bracket(1) on the

cylinder head.
· Fit the rocker arm mechanism (2) on
the rocker arm seat (1).
· Screw in the mounting bolt (3) and (4).
· Tighten the mounting bolt (4) to
105Nm
· Tighten the mounting bolt (3) to
105Nm
· Install the EVB (6)
(5).
A Intake side
B Exhaust side
·Follow the illustrated tightening
work step.
·Remove the Engine barring gear [204]

(1) from the flywheel housing
• Mount the cover on the flywheel
housing.
Page 115 of 315

Mounting the cylinder head cover Mounting the wiring harness cover
·Position the wiring harness cover (1)

·Close the locking pin (2) a 90°turn.

cover (2), replace as necessary
head cover.
• Tighten the mounting bolt (3) to 10
Nm as the illustrated sequence.
Page 116 of 315

Section 6. Valve timing
Fig 2-27 Valve timing

(1) Camshaft gear (4) Cylinder head
(2) Intermediate gear (5) Camshaft bearing shell cover
(3) Camshaft
Page 117 of 315

1. Camshaft/camshaft bearing shell
1.1 Additional jobs
- Checking the valve timing, see P135
Fig. 2-28 Camshaft/camshaft bearing

(1) Camshaft gear (4) Cylinder head
(2) Intermediate gear (5) Camshaft bearing cap
(3) Camshaft
1.2 Technical data

Camshaft gear mounting bolt（1） M8×30-10.9 Initial torque15Nm
Mounting bolt, camshaft gear（1） M8×30-10.9 Final torque 90°
Intermediate gear mounting bolt（2） M8×30-10.9 30Nm
Rocker arm mechanism mounting bolt M12×60-10.9 105+10Nm
Camshaft axial play（3） 0.05-0.85mm
Camshaft bearing journal diameter Ø 39.925 - 39.950mm
Camshaft bearing shell depth 42.095-42.150 mm
Camshaft gear installation depth（1） 9.000-9.100mm
7th camshaft bearing shell seat width 32.500-32.700mm
Camshaft bearing shell width 25.700-26.000mm
Page 118 of 315

Radial play, rocker arm 0.030-0.066mm
Inside diameter, rocker arm bracket Ø 32.005-32.025 mm
Outside diameter, rocker arm shaft Ø 31.959-91.975 mm
1.3 Service product

WARNING
connections
· If impact wrenches are used, these may only be used for pretightening
to max. 50% of the specified tightening torque.
wrench.
1.5 Special tools
No.
[215] Dial gauge JD6805-0024 08.71000-3217
• Checking the camshaft
axial play and the
radial play, in
conjunction with:
• Checking the rocker
arm radial play, in
conjunction with:
• Dial gauge stand [216]
• Locating pin[217]
JD6805-0025 08.71082-0005

axial play and the
radial play.
arm radial play
Page 119 of 315

No.
[217] Locating pin JD6805-0026 80.99605-0197
axial play and the
radial play.
arm radial play
[218] Depth gauge
JD6805-0032 08.71195-9003
(electronic)
bearing shell depth
gear installation depth
[219] Plug-on handle JD6805-0020 80.99617-0187
• Knocking in the seal
cap, in conjunction
with:
• Press-out plate [220]
[220] Press-out plate JD6805-0115 80.99604-0301
• Knocking in the seal
cap

• Crank the engine, in
conjunction with:
• Gear ratchet[222]
[222] Gear ratchet JD6805-0038 80.99627-0001

Page 120 of 315

Checking the rocker arm Attaching the engine barring gear
Removing the wiring harness cover
• Remove the cover from the flywheel

·Open the locking pin (2) a 90° turn housing.
• Remove the wiring harness cover (1) • Mount the Engine barring gear [221]
Removing the cylinder head cover on the flywheel housing
Moving the engine to the adjusting
position
Note A. Rocker arms in overlap

Always remove the mounting B. Rocker arms free
bolt from the cylinder head • Crank the engine in the engine's
cover with the cylinder head running direction using the Engine
cover gasket and the spacer. barring gear [221] and the Gear
·Undo the mounting bolt（3） ratchet [222] until the rocker arms are
·Remove the cylinder head cover in overlap with the valve bridge.
(2)from the cylinder head (1) • Check the free rocker arm as per table.
Page 121 of 315

Checking the rocker arm radial play Removing the rocker arm mechanism
· Fit the Dial gauge stand [216](2) with · Undo the mounting bolt（5）
the Dial gauge[215]（3）and the · Remove the EVB pressure plate (6)）
locating pin[217]. · Unscrew the mounting bolt (3) and (4).
· Position the Locating pin · Remove the rocker arm mechanism (2)
[217]opposite the rocker arm（1） with the rocker arm seat bracket(1).
with a preload. Removing the valve bridge
· Press down the rocker arm （ 1 ）
vertically to stop..
· Zero the Dial gauge[215](3).
· Pull up the rocker arm（1）to the end
and then read off the difference.
· Repeat the procedure for the rest
rocker arms.
The permissible rocker arm (1) radial
play is 0.030-0.066mm.
If the radial play is out of tolerance,
valve bridge (1) and (2).
check the rocker arm （ 1 ） inside
• Remove the valve bridge (1) and (2).
diameter and the rocker arm shaft
outside diameter.
Checking the rocker arm （ 1 ） inside

diameter, see Checking the rocker arm
seat inside diameter, P123.
Checking the rocker arm shaft outside

diameter, see Checking the rocker arm
shaft outside diameter, seeP123.
Page 122 of 315

Dismantling the rocker arm Checking the rocker arm shaft outside
mechanism diameter
· Clean the rocker arm（2）.

· Remove the spring washer (4) · Check the rocker arm shaft (2) outside
· Remove the washer (3） diameter using the micrometer（1）.
· Mark the installation position of the · Repeat the procedure for the other
rocker arm (1) rocker arm shaft (2).
· Pull the rocker arm (1) out of the
The permitted rocker arm shaft (2)
rocker arm shaft (2 ).
outside diameter is Ø
Checking the rocker arm seat bracket 31.959-31.975mm。
insider diameter
If the inside diameter is out of tolerance,
install a new rocker arm (1).
Undoing the adjusting screw
· Remove the rocker arm (1) from the

bearing.
· Check the rocker arm seat bracket
inside diameter using the Dial · Undo the lock nut（1）
gauge[215] （ 3） and the internal · Unscrew the adjusting screw (3) from
calliper（2） the rocker arm(2)
· Repeat the procedure for the other
rocker arms.
The permitted rocker arm inside
diameter is Ø 32.005-32.025 mm。
If the inside diameter is out of tolerance,
fit a new rocker arm (1).
Page 123 of 315

Unscrewing the EVB adjusting bolt Assembling the rocker arm
mechanism
Screwing in the adjusting bolt
· Undo the lock nut （3）

· Undo the adjusting screw (1) from the · Screw the adjusting bolt（3）in the
EVB pressure plate (2). rocker arm（2）
· Screw in the lock nut（1）
Screwing the EVB adjusting bolt
· Screw the adjusting bolt（1）in the EVB

pressure plate（2）
· Screw in the lock nut（3）
Page 124 of 315

Assembling the rocker arm Checking the camshaft
mechanism Checking the camshaft axial play
·Thinly apply clean engine oil on the · Fit the Dial gauge stand[216]（2）with
rocker arm shaft（2）. the Dial gauge[215]（1）and the
·Press the rocker arm (1) into the rocker locating pin[217].
arm shaft (2) as in the picture. · Position the Locating pin
·Fix the washer（3）. [217]opposite the camshaft（3）with
·Install the circlip（4） a preload.
· Push the camshaft（3） horizontally to
the flywheel housing to the end
position.
· Zero the Dial gauge[215](1).
· Pull up the camshaft（3）to the end to
face the Dial gauge[215]（1）and then
read off the difference.
The permissible camshaft (3) axial play
is 0.05-0.85mm.
If the axial play is out of tolerance,
check the camshaft bearing shell
depth, the camshaft gear installation
depth and the 7th camshaft bearing
shell width.
Checking the camshaft bearing shell

depth, see Checking the 7th camshaft
bearing shell depth, Page128
·Checking the camshaft gear installation
depth, see Checking the camshaft gear
installation depth, Page128
·Checking the 7th camshaft bearing shell
width, see Checking the 7th camshaft
bearing shell width, Page129
Page 125 of 315

Checking the camshaft radial play
· Fit the Dial gauge stand[216]（1）with

the Dial gauge[215]（2）and the
locating pin[217]
·Position the Locating pin [217]opposite
the camshaft（3）with a preload.
·Press the camshaft（3）vertically down
to stop.
·Zero the Dial gauge[215](2).
· Pull up the camshaft（3）to the end to
face the Dial gauge[215]（2）and then
The permissible camshaft (3) radial play
is 0.024-0.090mm.
If the radial play is out of tolerance,

check the camshaft bearing shell
inside and outside diameters
inside diameter, see Checking the
camshaft bearing shell, see 128
outside diameter, see 128
Page 126 of 315

Removing the camshaft
Turning the engine to the TDC mark Removing the camshaft
· Crank the engine in the engine's

running direction with the Engine ·Mark the installation position of the
barring gear [221] (1) and the Gear bearing cap(1).
ratchet [222] until the 1st cylinder is ·Undo the mounting bolt（2）
at the TDC mark (2) ·Mark the installation position of the
camshaft bearing shell.
Checking the camshaft TDC mark
·Remove the camshaft bearing shell and
the bearing cap (1).
·Remove the camshaft bearing shell and
the camshaft (3).
Removing the camshaft gear
·Check the camshaft(3) TDC mark

(1). The camshaft（3）TDC mark（1）
must match up the cylinder head
surface(2). ·Unscrew the mounting bolt（4）
·Pull the pressure plate (3) and the
If the marks don’t match up, keep on camshaft gear (2) off the camshaft.
cranking the engine 360 ° in the
direction of the engine running until
the flywheel TDC mark is reached.
Fix the Engine barring gear[221].
Page 127 of 315

Checking the camshaft bearing shell spread Checking the outside diameter of the
camshaft journal
Note
The difference between Dimension
· Clean the camshaft (3).
A and Dimension B gives the · Check the outside diameter of the
camshaft bearing shell spread. camshaft journal (1) using a
·Clean the camshaft bearing shells (2) and put micrometer (2)
them together on a flat surface as marked. · Repeat the procedure for the rest
• Check Dimension A using a micrometer (1) camshaft journals.
• Check Dimension B using a micrometer (1)
The permissible camshaft bearing shell spread The permissible outside diameter of the
is Max. 1.00 mm. camshaft journal (1) is Ø 39.925 –
If the spread is out of tolerance, fit new 39.950 mm.
camshaft bearing shells (2).
Checking the camshaft bearing shell If the outside diameter is out of
tolerance, fit a new camshaft (3).
Checking the 7th camshaft bearing
shell depth
·Clean the bearing cap（1）and the camshaft

bearing shell.
·Insert the bearing cap (1) and the camshaft · Check the 7th camshaft bearing shell
bearing shells on the cylinder head (4) as depth using the Depth gauge
marked. (electronic)[218](1).
·Use the Dial gauge [215] (3) and the internal The permitted 7th camshaft bearing
calliper (2) to check the camshaft bearing shell(2) depth is 42.095-42.150mm.
inside diameter.
If the depth is out of tolerance, fit a new
The permitted inside diameter of the camshaft
camshaft.
bearing is Ø 39.974 - 40.015 mm.
If the inside diameter is out of tolerance, fit
new camshaft bearing shells.
Page 128 of 315

Checking the installation depth of the Removing the camshaft intermediate
camshaft gear gear
Removing the seal cover
· Clean the camshaft gear (2).

· Check the installation depth of the
camshaft gear using the Depth
·Insert the screwdriver (1) at the sleeve
gauge (electronic) [218](1).
The permitted installation depth of the (2) base edge.
camshaft gear (2) is 9.000-9.100mm. ·Pry out the sleeve (2).
Unscrew the mounting bolt of the
If the installation depth is out of
intermediate gear
tolerance, fit a new camshaft gear (2).
Checking the 7th bearing shell seat
width of camshaft
· Unscrew the mounting bolt（2）from

the intermediate gear (1).
· Clean the 7th camshaft bearing shell
seat (2).
· Check the 7th camshaft bearing shell
seat width (2) using a
micrometer (1).
The permitted 7th camshaft bearing shell
seat width (2) is 32.500-32.700mm.
If the width is out of tolerance, fit a new

cylinder head.
Page 129 of 315

Removing the camshaft intermediate Mounting the camshaft intermediate
gear gear
Mounting the intermediate gear of the
camshaft
· Use the intermediate gear shaft(2) to

pull the intermediate gear (1) up out
of the cylinder head. · Apply clean engine oil on the
· Pull the intermediate gear (1) out of the intermediate gear shaft (2).
intermediate gear shaft (2). · Insert the intermediate gear shaft (2)
into the intermediate gear (1).
· Insert the intermediate gear (1) and the
intermediate gear shaft (2) into the
cylinder head from above.
Unscrewing the intermediate gear
mounting bolt
· Align the intermediate gear(1), the

intermediate gear shaft and the
cylinder head hole.
（2）to 30Nm
Page 130 of 315

Installing the bowl plug Assembling the camshaft
Assembling the camshaft gear
· Thinly apply Omnifit 200 on the

contact surface of the new sleeve. · Align the camshaft gear (3), the
· Assemble the Press-out plate[220]（1） pressure plate (4) and the locating pin
and the Plug-on handle [219]（2） (2).
· Use the special tool to insert the sleeve ·Install the camshaft gear (3) and the
until the stop is reached. pressure plate (4) in the camshaft (1).
·Screw in and tighten the mounting bolt
（5）to initial torque 15Nm.
·Tighten the mounting bolt（5）to final
torque 90°.
Installing the camshaft
·Apply clean engine oil on the lower

·Insert the lower camshaft bearing shell
as marked.
·Insert the camshaft (5) and align the
TDC mark (1) with the cylinder head
surface (2).
·Apply clean engine oil on the upper
·Insert the upper camshaft bearing shell
into the bearing cap (3) as marked.
·Install the bearing cap (3).
Page 131 of 315

·Screw in and manually tighten the new Checking the camshaft TDC mark
mounting bolt（4）evenly. Never turn
the camshaft (5).
Fixing the mounting bolt of the camshaft
bearing shell
· Check the camshaft (3) TDC mark (1).

The camshaft (3) TDC mark(1)
must be in alignment with the
cylinder head surface (2).
If the marks are not in alignment,
·Tighten the mounting bolt（1）
remove the camshaft(3) as marked and
Releasing the Engine barring gear
insert it again.
· Release the Engine barring

gear[221](1)
Checking the engine timing
· Crank the crankshaft 720 ° in the

engine running direction using the Gear
ratchet[222] until the TDC mark (2).
·Fix the Engine barring gear[221]（1）
Page 132 of 315

Installing the rocker arm mechanism Tightening sequence for cylinder head
Installing the valve bridge cover
Note
Always keep the concave of the
valve bridge facing the camshaft.
marked
Installing the rocker arm mechanism
A Intake side
B Exhaust side
· Mount the rocker arm seat bracket (1) work step.
on the cylinder head. Installing the cylinder head cover
· Install the rocker arm mechanism (2)
on the rocker arm seat bracket (1).
· Screw in the mounting bolt（3）and（4）
· Tighten the mounting bolt （ 4 ） to
105Nm
· Tighten the mounting bolt （ 3 ） to
105Nm
· Install the EVB sub-bracket（6）
· Check the cylinder head cover(2)
·Screw in and tighten the mounting bolt gasket, and replace it if necessary..
（5）. · Clean the oil dirt off the gasket and the
Page 133 of 315

head cover.
Remember the gaskets mounting bolts
• Install the cylinder head cover (2) on
• Tighten the mounting bolt (3) to
10 Nm as the illustrated sequence..
· Position the cable duct cover (1)

· Close the locking pin (2) a 90° turn.
Removing the Engine barring gear
· Remove the Engine barring gear[221]

（1）from the flywheel housing.
· Install the cover on the flywheel
housing.
Page 134 of 315

2. Valve timing
2.1 Additional jobs
- Checking and setting valve clearance, see P97
Fig. 2-29 Valve timing

(1) Camshaft
(2) Flywheel housing
(3) .Engine barring gear
2.2 Technical data
Valve lift continuous check Intake valve 10±0.2mm
Exhaust valve 12±0.2mm

WARNING
max. 50% of the specified tightening torque,
wrench.
Note
Page 135 of 315

Valve checking must always be performed with the correctly set valve clearances.
2.4 Special tools
[223] Dial gauge JD6805-0024 08.71000-3217
·Checking the valve
timing, in conjunction
with：
·Dial gauge stand[224]
·Locating pin[225]
·Checking the valve
timing
[225] Locating pin· JD6805-0026 80.99605-0197

Checking the valve
timing

·Crank the engine, in
conjunction with：
·Gear ratchet[227]
[227] Gear ratchet JD6805-0038 80.99627-0001

·Crank the engine
Page 136 of 315

2.5 Checking the valve timing Connecting the Engine barring gear
Removing the cable duct cover
·Remove the cover from the flywheel

·Open the locking pin (2) a 90° turn. housing.
·Remove the cable duct cover (1) ·Install the Engine barring gear[226]（1）
Removing the cylinder head cover on the flywheel housing.
Turning the engine to the TDC mark
Note ·Turn the flywheel in the engine's

Always remove the mounting bolt running direction with the Engine
with the cylinder head cover barring gear [226] (1) and the Gear
gasket and the insulator from the ratchet [227] until the flywheel TDC
cylinder head cover. mark (2) is at the TDC mark .
· Undo the mounting bolt（3） The rocker arm of cylinder 6 must be
· Remove the cylinder head cover (2) reached.
from the cylinder head (1). If not, keep turning the flywheel 360°
until the TDC mark is reached.
Page 137 of 315

Checking the valve lift Tightening sequence for cylinder head
cover
WARNING
Mistake reading off due to the
engine running in the counter
direction.
·Always crank the engine in the
direction of the engine running.
·Mount the Dial gauge [223]（4）and the
Dial gauge stand[224]（3）with the
Locating Pin[225] （ 2 ） on the
intake valve plate of cylinder 3.
· Zero the Dial gauge [223]（4）.
· Keep cranking the engine in the engine
running direction until the pointer
on the Dial gauge no longer moves. A Intake side
B Exhaust side
At this position, the right valve lift shall
be: intake valve 10±0.2mm, and exhaust
valve 12±0.2mm.
work step.
Page 138 of 315

Mounting the cylinder head cover
·Check the cylinder head cover

(2)gasket, replace as necessary
head cover.
• Tighten the mounting bolt (3) to 10Nm
as the illustrated sequence.
Page 139 of 315

· Position the cable duct cover (1)

· Close the locking pin (2) a 90° turn
Removing the Engine barring gear
·Remove the Engine barring gear[226]（1）

from the flywheel housing.
·Install the cover on the flywheel housing.
Page 140 of 315

3. Rear timing gear

3.1 Additional jobs
- Removing and installing the engine control unit, see P20,
- Removing and installing the starter, see P56
- Removing and installing the suction line, see P73
- Removing and installing the cylinder head, see P83
- Checking the valve timing, see P135
- Removing and installing the injector and the rail, see 156
- Removing and installing the oil module, see P192
- Removing and installing the rear crankshaft oil seal, see P219
- Removing and installing the flywheel, see P238
Fig. 3-36 Engine rear gear

(1) Rear crankshaft gear (4) Rear intermediate gear assembly
(2) Air compressor intermediate gear (5) Mounting bolt
(3) Mounting bolt (6) Crankcase intermediate gear
Page 141 of 315

3.2 Technical data
Mounting bolt（5） M14×80-10.9 Initial torque150Nm
Mounting bolt（5） M14×80-10.9 Final torque90°
Mounting bolt（3） M12×55-10.9 115Nm
Mounting bolt(6), M8×20-10.9
30Nm
crankcase intermediate gear
Gear clearance, rear intermediate gear
0.052-0.176mm
assembly (4)- rear crankshaft gear (1)
Gear clearance, rear intermediate gear
assembly (4) -crankcase intermediate 0.052-0.176mm
gear(6)
Axial play, air compressor intermediate
0.100-0.240mm
gear（2）
Height, air compressor intermediate gear
25.900-26.000mm
（2）
Height, thrust disc, air compressor
4.800-5.000mm
intermediate gear（2）
Inside diameter, air compressor
Ø 60.00 - 60.03 mm
Outside diameter, air compressor
Ø 59.921 - 59.940 mm
intermediate gear shaft
Height, air compressor intermediate gear
26.100-26.140mm
shaft
Axial play, rear intermediate gear assembly
0.100-0.290mm
(4)
Radial play, rear intermediate gear
0.060-0.109mm
assembly (4)
Height, rear intermediate gear assembly（4） 52.950-53.000mm
Inside diameter, rear intermediate gear
Ø 80.000 - 80.030 mm
assembly（4）
Outside diameter, rear intermediate gear
Ø 79.921 - 79.940 mm
assembly shaft
Height, rear intermediate gear assembly
56.200-56.240mm
shaft
Axial play, crankcase intermediate gear(6) 0.100-0.290mm
Radial play, crankcase intermediate gear(6) 0.060-0.109mm
Height, crankcase intermediate gear(6) 17.950-18.000mm
Inside diameter, crankcase intermediate
Ø 60.000 - 60.030 mm
gear(6)
Outside diameter, crankcase intermediate
Ø 59.921 - 59.940 mm
gear shaft
Height, crankcase intermediate gear shaft 21.200-21.240mm
Page 142 of 315

WARNING
wrench.
Note
The intermediate gear and the gear pin don’t have to be replaced in pairs.
Replace them separately as per the wear rate.
Note
The air compressor intermediate gear is composed of two parts to reduce the
noise.
The gear clearance can’t be checked at this position.
3.4 Special tools

No.
[233] Guide pin JD6805-0117 80.99617-0020
• Removing and
installing the crankshaft
rear gear
[234] Centering device JD6805-0118 80.99617-0209
·Removing and installing
the air compressor
intermediate gear
[235] Dial gauge JD6805-0024 08.71000-3217
·Checking the
intermediate gear inside
diameter
·Checking the
intermediate gear
clearance，in conjunction
with：
·Checking the
intermediate gear axial
and radial plays, in
conjunction with ：
·Dial gauge stand[236]
·Locating pin [237]
Page 143 of 315

·Checking the
intermediate gear
clearance
·Checking the
and radial plays
[237] Locating pin· JD6805-0026 80.99605-0197

Checking the
intermediate gear
clearance
·Checking the
and radial plays
[238] Depth gauge JD6805-0032 08.71195-9003
·Checking the
height
Page 144 of 315

Checking the timing gear clearance the Dial gauge [235]（1） and the
Locating Pin [237] (3).
Checking gear clearance of the
·Fit the Locating pin [237] (3)in the
crankshaft gear/rear intermediate
crankcase intermediate gear (4) with a
gear assembly
preload.
·Check the gear clearance of the
crankcase intermediate gear (4).
The permitted gear clearance is
0.052-0.176mm.
If the gear clearance is out of tolerance,
fit a new crankcase intermediate
gear (4) and a new rear
intermediate gear assembly.
Setting the crankshaft gear to the
·Fit the Dial gauge stand[236]（3）with
mark
the Dial gauge [235]（2） and the
Locating Pin [237]. Fixing the crankshaft gear
·Fit the Locating pin [237]in the rear
intermediate gear assembly(1) with a
preload.
·Check the gear clearance between the
crankshaft gear (4) and the rear
intermediate gear assembly (1).
The permitted gear clearance is
0.052-0.176mm.
If the gear clearance is out of tolerance,
fit a new crankshaft gear (4) and
rear intermediate gear ·Fix the crankshaft gear (1) using two
assembly(1). mounting bolts (2) and (3).
Checking the gear clearance of the
Setting the crankshaft gear to the
intermediate gear/rear intermediate
mark
gear assembly
·Crank the engine until Mark (1)

matches up Mark (2).
Page 145 of 315

Unscrewing the mounting bolt of the If the axial play is out of tolerance,
crankshaft gear check the height of the rear
intermediate gear assembly（1）and the
rear intermediate gear assembly
shaft .
Checking the rear intermediate gear

assembly（1）height, see P147
Checking the rear intermediate gear

assembly shaft (4) height, see P147
Removing the rear intermediate gear
·Remove the crankshaft gear (1) by
assembly
unscrewing the two mounting bolts (2)
and (3).
Removing the rear intermediate gear

assembly
Checking the axial play of the rear
intermediate gear assembly

·Remove the intermediate gear shaft
（2）and the rear intermediate gear
assembly（3）.

the Dial gauge [235]（2） and the
Locating Pin [237]
·Fit the Locating pin [237] in rear
intermediate gear assembly(1)with a
preload.
·Push the rear intermediate gear
assembly（1）to stop.
·Zero the Dial gauge [235]（2）.
·Pull the rear intermediate gear assembly
（1）to the end position, and read off
the difference.
The permitted axial play is
0.100-0.290mm.
Page 146 of 315

Checking the height of the rear Checking the height of the
intermediate gear assembly intermediate gear shaft
· Clean the rear intermediate gear

assembly（1） ·Clean the intermediate gear shaft (1).
· Check Dimension A of the rear · Use the Depth gauge (electronic)[238]
intermediate gear assembly（1）（2）to check the rear intermediate
The permitted Dimension A is gear assembly shaft (1) height.
52.950-53.000mm. The permitted height is
56.200-56.240mm.
If Dimension A is out of tolerance, fit a
If the height is out of tolerance, fit a new
（1）.
new rear intermediate gear assembly
rear intermediate gear assembly shaft
Checking the inside diameter of the (1).
rear intermediate gear assembly Checking the outside diameter of the
rear intermediate gear assembly shaft
·Use the Dial gauge [235]（2）and the

internal calliper （1） to check the ·Use the micrometer (2) to check the
rear intermediate gear assembly（3） outside diameter of the rear
inside diameter. intermediate gear assembly shaft (1)
The permissible inside diameter is Ø The permitted outside diameter is Ø
80.000 - 80.030 mm. 79.921 - 79.940 mm.
If the inside diameter is out of the If the outside diameter is out of
tolerance, fit a new rear intermediate tolerance, fit a new rear intermediate
gear assembly（3）. gear assembly shaft (1).
Page 147 of 315

Removing the crankcase intermediate Removing the crankcase intermediate
gear gear
Checking the axial play of the
crankcase intermediate gear

· Fit the Dial gauge stand[236]（3）with · Remove the crankcase intermediate
the Dial gauge [235]（1）and the gear shaft （ 2 ） and the crankcase
Locating pin[237]. intermediate gear（3）.
· Fit the Locating pin [237] in the
crankcase intermediate gear (3)
·Push the crankcase intermediate gear
（3）to stop.
·Zero the Dial gauge [235]（1）
·Pull the crankcase intermediate gear（3）
to the end position and read off
the difference.
0.100-0.290mm.
check the height of the crankcase
intermediate gear（3）and the crankcase
intermediate gear shaft.
Checking the crankcase intermediate
gear（3）height, see P148
gear shaft height, see P148
Page 148 of 315

gear shaft height
gear height
·Clean the crankcase intermediate gear

（1） ·Clean the crankcase intermediate gear
shaft (1).
·Check Dimension A of the crankcase
· Use the Depth gauge
(electronic)[238](2) to check the
The permitted Dimension A is
height of the crankcase intermediate
17.950-18.000mm.
gear shaft (1).
If Dimension A is out of tolerance，fit a The permitted height of the crankcase
new crankcase intermediate gear（1）. intermediate gear shaft (1) is
21.200-21.240mm.
gear inside diameter If the height is out of tolerance, fit a new
crankcase intermediate gear shaft(1).
gear shaft outside diameter
·Use the Dial gauge [235]（2）and the

internal calliper(1) to check the
crankcase intermediate gear (3 ）
inside diameter.
·Use the micrometer (2) to check the
The permissible inside diameter is Ø
60.000 - 60.030 mm. outside diameter of the crankcase
intermediate gear shaft (1)
If the inside diameter is out of tolerance, The permitted outside diameter is Ø
fit a new crankcase intermediate gear 59.921 - 59.940 mm.
（3）. If the outside diameter is out of
tolerance, fit a new crankcase
intermediate gear shaft (1).
Page 149 of 315

Removing the crankshaft gear Removing the air compressor
intermediate gear
Checking the axial play of the air
compressor intermediate gear
·Press out the crankshaft gear(2) out of

the crankshaft (1) using a pry.

the Dial gauge [235]（3）and the
Locating pin[237].
·Fit the Locating pin [237] in the air
compressor intermediate gear (2)
·Push the air compressor intermediate
gear （2）to stop.
· Pull the air compressor intermediate
gear（2）to the end position and
0.100-0.240mm.

check the height of the air compressor
intermediate gear(2)and the intermediate
gear shaft.
Checking the air compressor

intermediate gear（2）height, see P149
Checking the air compressor

intermediate gear shaft height, see P152
Page 150 of 315

Screwing in the centering device Checking the air compressor
intermediate gear height
· Unscrew a mounting bolt（1）

·Screw in the Centering device [234]（2） ·Clean the air compressor intermediate
·Unscrew the rest mounting bolt (1) gear (1) and the thrust disc (2).
from the air compressor ·Check the air compressor intermediate
gear (1) height and the thrust disc (2)
thickness.
Removing the air compressor The permitted Dimension A is
intermediate gear 25.900-26.000mm.
If Dimension A is out of tolerance, fit a
new air compressor intermediate gear
(1).
The permitted thrust disc thickness is
4.800-5.000mm.
If the thickness is out of tolerance, fit a
new thrust disc.
Checking the inside diameter of the
air compressor intermediate gear
WARNING
Danger of thrust disc falling
into the oil sump.
Make sure no thrust discs falling off
before removing the intermediate
gear.
·Clamp the thrust disc (2) behind the air
compressor intermediate gear(1).
·Clean the air compressor intermediate gear
· Undo the Centering device [234] (3).
· Remove the thrust disc（2）and the air ·Use the Dial gauge [235](2)and the
compressor intermediate gear shaft (3) internal calliper(1) to check the air
with the air compressor intermediate compressor intermediate gear(3)inside
diameter.
gear (1).
The permissible inside diameter is Ø
60.000- 60.03 mm.
If the inside diameter is out of tolerance, fit
Page 151 of 315

a new air compressor intermediate gear(3). Checking the height of the air
compressor intermediate gear shaft
· Clean the air compressor intermediate

gear shaft (1).
· Use the Depth gauge (electronic)
[238](2)to check the height of the air
(1).
The permitted air compressor
intermediate gear shaft (1) height is
26.100-26.140mm.

shaft(1).
Checking the outside diameter of the
shaft
·Clean the air compressor intermediate

gear shaft (1).
·Use the micrometer (2) to check the
Page 152 of 315

outside diameter of the air compressor ·Insert the air compressor intermediate
intermediate gear shaft (1) gear shaft（3）into the air compressor
The permitted outside diameter is Ø intermediate gear（1）.
59.921 - 59.940 mm.
·Install the thrust disc (2) in the air
If the outside diameter is out of
compressor intermediate gear shaft(3),
tolerance, fit a new air compressor
and make sure the side with a bigger
chamfering facing the crankcase.
Installing the timing gear
Installing the air compressor
Installation illustration of the air
intermediate gear
compressor intermediate gear.
·Insert the air compressor intermediate

·When installing the air compressor that
gear and the air compressor
includes two parts, make sure the
intermediate gear shaft (3) with the
wider surface (1) facing the
thrust disc into the crankcase, and fix
crankcase.
them using the Centering device
Keep the air compressor intermediate
[234](2).
gear rubber element facing the
·Screw in the new mounting bolt（1）
crankcase.
·Undo the Centering device [234]（2）
Positioning the air compressor
·Screw in the rest new mounting bolt（1）
intermediate gear
·Tighten the mounting bolt(1)to 115Nm.
Installing the crankcase intermediate
gear
· Apply clean engine oil on the air

(3).
Page 153 of 315

·Apply clean engine oil on the crankcase ·Apply clean engine oil on the rear
intermediate gear shaft（2）. intermediate gear assembly shaft（2）.
·Install the crankcase intermediate gear ·Insert the rear intermediate gear
（4）so that its flat contact surface assembly shaft (2)into the rear
（3）faces the crankcase intermediate intermediate gear assembly（3）
gear shaft（2）. ·Install the rear intermediate gear
· Insert the crankcase intermediate gear assembly(3) so that the rear
shaft （ 2 ） and the crankcase intermediate gear assembly（3）mark
intermediate gear （ 4 ） into the matches with that of the crankshaft
crankcase. gear, see Checking the crankshaft gear
· Screw in and tighten the new mounting mark.
bolt（1）to 30Nm ·Screw in and tighten the new mounting
bolt（1）to initial torque 150Nm
Installing the crankshaft gear
·The final torque for the mounting bolt
（1）is 90°.
Checking the crankshaft gear mark
·Crank the engine until the centering pin

(4) is vertical to the oil sump .
·Screw in the Guide pin [233](3)and (5). ·Check if the rear intermediate gear
·Match the crankshaft gear (1)and the assembly mark（1）matches with that
centering pin(4). of the crankshaft gear mark（2）.
·Push the crankshaft gear(1)to the If the marks（1）and （2） are not in line,
crankshaft. dismantle the rear intermediate gear
·Undo the Guide pin[233]（3）and（5） assembly and install it again at the
mark.
Installing the rear intermediate gear
assembly
Page 154 of 315

Section 7. Fuel supply
Fig. 2–30 Fuel supply

(1) Mounting Nut (9) Mounting bolt
(2) Injector wiring harness (10) Poly-Poly-V-belt pulley
(3) Common rail connection pipe (11) Mounting bolt
(4) Pressure nut (12) High-pressure line
(5) Fuel service center bracket (13) Cylinder head
(6) Fuel service center (14) Pressure Flange
(7) Fuel pump (15) Mounting bolt
(8) High-pressure pump (16) Injector
Important information
WARNING
Components damage due to incorrectly tightened screw/bolt
connections
•·If impact wrenches are used, these may only be used for pre-tightening
to max. 50 % of the specified tightening torque
wrench.
Page 155 of 315

1. Injectors and rail
1.1 Additional jobs
- Removing and installing the engine control unit, see P20.
Fig. 2–30 Injectors and the rail

(1) Pressure nut (6) Injector
(2) Common rail connection pipe (7) Mounting nut
(3) Cylinder head (8) Injector wiring harness
(4) Pressure flange (9) The rail
(5) Pressure bolt (10) Mounting bolt
1.2 Technical data
High-pressure line (initial use) Initial torque 10Nm

High-pressure line (initial use) Final torque 60°
High-pressure line(re-use) Initial torque 10Nm
High-pressure line(re-use) Final torque 30°
Mounting bolt (10) M8×50-10.9 Manual tightening
Page 156 of 315

Mounting bolt(10) M8×50-10.9 Final torque 35Nm

Pressure screw(1) Initial torque 10Nm
Pressure screw(1) Final torque 20Nm + 60°
Mounting bolt (5) M8×50-10.9 Initial torque 1-2Nm
Mounting bolt (5) M8×50-10.9 Final torque 20Nm + 90°
Mounting bolt (7) Cable Socket nut M4 1.8+0.25Nm
Testing pressure loss 4+0.5 bar
pressurizing
Pressure drop 0.1bar/10 min
Common rail pressure sensor M18×15 70±5Nm
Pressure limiting valve M18×15 100±5Nm
Injector wiring harness M6×16-10.9 15Nm
mounting bolt
Cylinder head cover mounting 10Nm
bolt
Technical Vaseline
WARNING
Damage in the common rail
Damage in the common rail system
· All work on components of the common rail must be performed by
· The engine must be stationary for at least 5 minutes before commencing
work in order to enable depressurization in the rail, or depressurization
must be checked by means of EOL, Sinotruk-cat (desired value 0).
· Ensure absolute cleanliness in all areas when carrying out all works.
· Avoid any moisture whatsoever.
· Always replace rail connections once they have been undone.
· Do not reuse plugs for the high-pressure lines, the rail or injectors.
· Follow the sequence described when tightening injectors, high-pressure
lines, the rail and rail connections
WARNING
Damage due to dirt ingress
·Plug the fuel line component connections immediately using new, clean
protective sleeves every time the fuel line is removed.
WARNING
Page 157 of 315

Components damage due to incorrectly tightened screw/bolt
connections
wrench.
1.5 Special tools
[79] Adapter
·Removing the rail
connection in JD6805-0053 80.99603-0173
conjunction with :
·Extractor device 80]
[80] Extractor device
·Removing the rail
connection JD6805-0054 80.99602-0011
[81] Socket, size 17

· Removing and
installing the
JD6805-0055 80.99603-0309
high-pressure lines in
conjunction with:·
· Extension [83]
· Removing and
installing the
JD6805-0056 80.99603-0310
high-pressure lines in
conjunction with:
· Extension [83]
[83] Extension
· Removing and
installing the JD6805-0057 08.06139-9025
high-pressure lines

·Extracting the injectors
in
conjunction with:
JD6805-0058 80.99601-6022
·Plate [85]
·Stud 66mm[86]
·Stud 70mm[87]
· Hexagon nut M12[88]
Page 158 of 315

[85] Plate
·Extracting the injector
JD6805-0059 80.99602-0176
[86] Stud 66mm

JD6805-0060 80.99602-0193
[87] Stud 70mm

JD6805-0061 80.99602-0194
[88] Hexagon nut M12

JD6805-0062 06.11226-8306
[89] Torque screwdriver

· Mounting injector cable
in conjunction with: JD6805-0063 08.06510-9024
·Adapter [90]
·Socket, size 7 [91]
[90] Adapter
·Attaching the injector
JD6805-0064 08.06139-9029
cable
[91] Socket, size 7

·Attaching the injector
cable JD6805-0065 08.06141-0700
[92] Thrust piece

·Installing the injectors
JD6805-0066 80.99606-0609
Page 159 of 315

[93] Pressure loss detector
·Checking the pressure
leakage in the
high-pressure system in
conjunction with:
JD6805-0067 80.99607-6027
·Adapter [94]
·Thread connection [95]
·Elastic lip seal [98]
·Hollow bolt [96]
·Ring connection [97]
[94] Adapter
leakage in the JD6805-0068 80.99620-0033
high-pressure system
[95] Threaded connection

leakage in the JD6805-0069 81.98130-0614
[96] Hollow bolt

leakage in the
JD6805-0070 51.98150-0715
[97] Ring connection

leakage in the
high-pressure system JD6805-0071 51.98103-0037
[98] Elastic lip seal

leakage in the
JD6805-0072 06.56639-0017
Page 160 of 315

Removing the injector and the rail Removing the fuel return lines
Disconnecting the rail-pressure sensor
electrical connection
WARNING
·Disconnect the electrical connector (1). Component damage due to fuel
Removing the oil dipstick in the combustion chamber
bracket ·Allow the return duct to
empty before extracting the
injector.
WARNING
Danger of environmental
pollution
·Collect emerging fuel in a
permissible container.
· Unscrew the hollow bolt (1) and

allow the return duct to empty.
·Unscrew the bolt (2). · Unscrew the fuel line (2) off the
·Fasten the oil dipstick bracket (1). T-joint (3).
· Unscrew the fuel line (4) off the
T-joint (3).
· Unscrew the T-joint (3) off the Ring
connection[97] (6).
· Unscrew the hollow bolt (5).
· Remove the Ring connection[97]
(6) with the Seal ring.
Removing the high-pressure line
Page 161 of 315

·Unscrew the mounting bolt (2).

· Detach the high pressure line (3) from
he the pump (4) and the rail (1),
using the Socket wrench, size 19 [82]
and the Extension [83].
Page 162 of 315

Removing the high-pressure line
Removing the rail-pressure sensor
and the pressure limiting valve
WARNING
Danger of damage due to dirt WARNING
ingress. Component damage due to
·Clean protective sleeves lack of lubricant
should be used to plug the ·Do not wash off the pressure
connections when removing the pipe. limiting valve and
· Mark the high-pressure line rail-pressure sensor as the
position. thread and biting edge are
· Remove the high-pressure line(2) coated with lubricant.
using the Socket wrench, size 17 ·Unscrew the valve（1）.
[81](1), and the Extension[83](3). ·Unscrew the sensor（2）.
Removing the rail
Removing the harness cover
·Unscrew the bolt（2）.

·Unscrew the lockpin（2）a 90°turn.
·Remove the rail（1）.
·Remove the cover（1）.
Page 163 of 315

Removing cylinder head cover Removing the injector cable
·Unscrew the bolt（3）. ·Remove the nut（2）.

·Remove the cover（2）from the head ·Remove the injector cable（1）
（1）. Removing the injector wiring harness
Removing the rail connection
· Carefully remove the injector wiring

· Unscrew the nut（3）
harness（4）from the camshaft bush
· Extract the rail connection（2） from
（1）.
the head using the Adapter and the
· Unscrew the bolt（3）.
Extractor device.
· Remove the flange（2）from the head
carefully.
· Carefully extract the harness（4）
through the cylinder hole .
Page 164 of 315

Unscrewing the pressure flange Assembling the Special tool
mounting bolt
· Mount the Stud 66mm[86]（1）, the

· Unscrew the mounting bolt （2）and Stud 70mm[87]（5）and the Hexagon
remove it with the spherical nut M12[88]（2）on the Plate[85].
washer（1）. · Insert the Extractor device [84]（3）
into the Plate [85]（4）.
Removing the injector
WARNING
Component damage due to
incorrect removal of the
injector.
·Always remove the
relevant connection
before removing the
injector.
·Always remove one injector
only.
· Fit the Special tool（1）.
· Insert the Extractor device[84] into
the groove for the pressure flange.
· Clamp the clamping sleeve（5）with
the knurled nut（2）.
· Extract the injector（4）from the
cylinder head by turning the knurled
nut（3）.
Page 165 of 315

Installing injectors and the rail Injector initial torque
Installing injectors
· Screw in the new mounting bolt (2)

Note for the pressure flange with the
Always install injectors spherical washer(1)
together with pressure flange. ·Tightening the mounting bolt（2）to
It is not possible to install the initial torque 1-2Nm.
pressure flange afterwards.
Installing the rail connection
· Remove the used seal washer（5）.
· Check to ensure that the hole in the
cylinder head is clean.
· Do not remove the injector（2）from
the injector Storage sleeve [69] until
immediately before installation.
· Remove the protective sleeves.
· Push the pressure flange （1） onto
the injector（2）, ensuring that the
fuel inlet opening（3） is turned
towards the injector inlet connection WARNING
（4）. Rail connections are pressed
· Insert the injector （ 2 ） into the together on the cone during
cylinder head with a new O-ring（6） installation.
and a new seal washer（5）. ·Do not reuse rail connections if
· Press the injector（2） fully into the they have already been installed.
cylinder head using the Thrust piece ·Slide the rail connection（2）into the
[92]. bore（1）so that the balls on the rail
connection are located in the grooves
in the cylinder head.
·Screw in the pressure screw（3）and
tighten to initial torque 10Nm
Page 166 of 315

Injector final torque · Tighten the bolt（3）to 15Nm.
· Carefully insert the harness（4）into
the camshaft bush（1）.
Connecting the injector harness
·Tighten the mounting bolt (1) to final

torque 25Nm+90MG°
Rail connection final torque
WARNING
possible short-circuit
·Make sure that the cable
plugs do not touch each other
when tightening the
mounting nuts.
·Assemble the Special tool with Socket,
size7[91]（2）, Adapter[90] and Torque
screwdriver [89]（3）.
·Tighten the pressure screw（1）to
·Tighten the mounting nut（1）with the
20Nm+60°.
Special tool to 1.8+0.25Nm.
Connecting the injector wiring
harness
· Apply thinly Vaseline on the（4）new

O-ring of injector harness.
· Carefully insert the harness（4）
through the cylinder hole.
· Carefully insert the flange（2） into
the cylinder head.
Page 167 of 315

Tightening sequence of cylinder head bolt assembly without the rubber
cover bolts damper and the other 10 with the
damper.
·Fit the cover（2）onto the cylinder head
（1）.
·Screw in the mounting bolt（3）.
· Tighten the mounting bolt （ 3 ） as
described to 10Nm.
Mounting the wiring harness cover
·Position the wiring harness cover（1）.

·Close the locking pin（2）a 90°turn.
A inlet B exhaust
· Follow the illustrated tightening Screwing in the rail pressure sensor
sequence 1 to 18 in the following and the pressure limiting valve
work step.
Mounting the cylinder head cover
WARNING
Component damage due to lack
of lubricant
（2）
· Check the gasket in the head cover · Do not wash the valve and the
and replace it as necessary. sensor as the thread and lip
· Clean the gasket and wash off the edge are coated with lubricant.
oil deposit in the groove before · Screw in the new sensor（2）and
mounting the cover and notice the tighten it to 70±5Nm.
bolt differences when mounting the · Screw in the new valve（1）and
gasket: 8 bolts in the exhaust side are tighten it to 100±5Nm.
Page 168 of 315

Mounting the rail The rail final torque
·Make sure the rail（1） position in the ·Tighten the bolt（1）to final torque
cylinder head. 35Nm.
·Screw in the new bolt（2）and tighten
it manually. High-pressure line final torque
Attaching the high-pressure lines
·If reusing the high-pressure line(2),

tighten it to 30° using the Socket,
size17(1) and the Extension(3)
WARNING ·Tighten the new line to 60°using the
Component damage due to Socket, size17 and the Extension.
no-aligned pipes
·Check the alignment of the
high-pressure lines after initial
tightening and re-align them if
necessary.
·Connect the high-pressure line（2）, the
rail（3）and the rail connection（1）
as marked..
·Tighten the high-pressure line with the
Socket, size 17[81] and the Extension
[83] to initial torque 10Nm.
Page 169 of 315

Attaching the high-pressure line Checking the pressure loss
· Attach the high-pressure line(3) to WARNING

the rail(1) and the high-pressure Injector damage
pump(4). ·The max. pressure of the
· Tighten the high-pressure line to leakage test shall be
initial torque 10Nm, using the 4+0.5bar.
Socket, size 19 and the Extension. · Pressurize the Detector [93] with
· Check to ensure the line without compressed air 4+0.5bar.
pressure. · Disconnect the compressed air
· Screw in and tighten the new connection（2）.
bolt(2). · Check the the pressure gauge for the
· If reusing the line, tighten it to 30° permitted pressure loss (1).
using the Socket, size19 and the The permitted max. pressure loss is
Extension. 0.1bar within 10min.
· Tighten the line to final torque 60°
Attaching the fuel return line
using the Socket, size19 and the
Extension.
Assembling the pressure loss detector
·Position the Ring connection (6) with

a new seal ring.
·Screw in the hollow screw (5).
· Screw the Ring connection [97] into
the cylinder head with the Hollow ·Screw the T-joint into the ring
bolt [96] and the Seal ring [98]. connection and tighten it.
· Mount the Adapter [94](1), the ·Attach the return line (2) to the T-joint.
Threaded connection[95] and the ·Attach the return line (4) to the T-joint.
Pressure loss detector[93] onto the ·Screw in the bolt (1) with a new seal
Ring connection [97]. ring and tighten it.
Page 170 of 315

·Tighten the hollow screw (5).
·Tighten the line (2) and (3) pressure
nuts.
Assembling the oil dipstick bracket
·Position the oil dipstick bracket (1)

with the dipstick.
·Screw in and tighten the bolt (2).
Connecting the rail pressure sensor
electrical connection
·Connect the electrical connection (1).
Page 171 of 315

2. High-pressure pump / High-pressure pump
2.1 Additional jobs
- Removing and assembling the alternator , see P62
Fig. 2–31 High-pressure pump and drive

(1) Fuel service center
(2) High-pressure pump
(3) Fuel inlet opening
(4) Bolt
(5) Poly-Poly-V-belt pulley
(6) Gasket
(7) Mounting bolt
(8) High-pressure pump drive
(9) High-pressure line
(10) Bracket
Page 172 of 315

2.2 Technical data
High-pressure pump (2)mounting bolt M10×55-10.9 60-70Nm
Fuel inlet opening (3) M38×15 35Nm
Mounting bolt,
M12×90-10.9 115Nm
High-pressure pump drive(8)
High-pressure line (9)（initial use） Initial torque 10Nm
High-pressure line (9)（initial use） Final torque 60°
High-pressure line (9)（reuse） Initial torque 10Nm
High-pressure line (9)（reuse） Final torque 30°

Loctite 5900
Curil T
WARNING
Damage in the common rail
· All work on components of the common rail must be performed by
· The engine must be stationary for at least 5 minutes before commencing
work in order to enable depressurization in the rail, or depressurization
must be checked by means of EOL, Sinotruk-cat (desired value 0).
· Ensure absolute cleanliness in all areas when carrying out all works.
· Avoid any moisture whatsoever.
· Always replace rail connections once they have been undone.
· Do not reuse plugs for the high-pressure lines, the rail or injectors.
WARNING
·Plug the fuel line component connections immediately using new, clean
protective sleeves every time the fuel line is removed.
WARNING
PTFE seal rings are rendered unusable if they come into contact with oil
or grease before installation.
·Clean the high-pressure pump drive and installation sleeve before
assembly.
WARNING
wrench.
2.5 Special tools
Page 173 of 315
[103] Impact tool JD6805-0076 80.99606-6078
·Removing the
high-pressure
pump with
· Removing device
[104]
[104] Removal tool JD6805-0077 80.99601-6021
·Removing the
high-pressure pump
[105] Impact extractor JD6805-0018 80.99602-0016

·Extracting the slide
ring seal with
·Hook [106]
[106] Hook JD6805-0019 80.99602-0137

·Extracting the slide
ring seal
[107] Plug-on handle JD6805-0020 80.99617-0187

·Pressing in the slide
ring seal with
·Impact punch [109]
·Washer[108]
[108] Washer JD6805-0021 80.99617-0144
ring seal
[109] Impact punch JD6805-0022 80.99604-0289

ring seal
Page 174 of 315

[110] Socket JD6805-0078 08.06556-9300
·Removing and
assembling the fuel
inlet opening
[111] Release tool, size 1 JD6805-0079 80.99606-0625

·Open the
quick-release
couplings
with:
·Release handle [104]
[112] Release handle JD6805-0080 80.99606-0597
·Opening the
quick-release
couplings
[113] Socket wrench, size 19 JD6805-0056 80.99603-0310

·Removing and
assembling the
high-pressure line
with:
·Extension [114]
[114] Extension JD6805-0057 08.06139-9025
·Removing and
assembling the
high-pressure line
Page 175 of 315

Removing the high-pressure pump Removing the high-pressure pump
Removing the fuel inlet opening
·Unscrew the fuel inlet opening using ·Unscrew the mounting bolt (1).
the Socket, size 27[110] (2). ·Remove the high-pressure pump (2)
from the drive (4).
Detaching the high-pressure line ·Pull the intermediate drive shaft (3) out
of the drive shaft.
·Disconnect the electrical connection (2)

for the metering unit.
· Remove the high-pressure line (4)
from the pump (5) and the rail (1)
using the Socket, size 19[113] and
the Extension [114].
Page 176 of 315

Removing the high-pressure pump Mounting the Special tool
Detaching the high-pressure line
·Disconnect the electrical connection (2)

for the metering unit.
· Remove the high-pressure line (4)
from the pump (5) and the rail (1)
the Extension [114].
· Remove the fuel service center. See

P181 for removing and assembling
the fuel service center.
· Unscrew the high-pressure pump (5)
mounting bolt.
· Screw the Threaded spindle (2) into
the Plate[85] (3) for the Removal
tool[104](4)using the Impact
tool[103] (1) until flush.
· Mount the Removal tool[104]（4）
on the high-pressure pump (5)with
two bolts.
Removing the high-pressure pump
·Use the Impact tool[103](1)and Removal

tool[104](2) to slightly knock and remove
the high-pressure pump(3)from the drive.
Page 177 of 315

Removing the high-pressure pump Removing the high-pressure pump
drive drive
Removing the poly -V-belt pulley
·Unscrew the mounting bolt (1) and (2). ·Unscrew the bolt (1) and remove the
·Remove the Washer (3). high-pressure pump drive (2).
·Pull the poly-V-belt pulley (4)out of the ·Clean the contact surfaces.
spline shaft (5).
Removing the high-pressure pump
drive slide ring seal
· Remove the slide ring seal (2) using

the Impact extractor[105](1) and the
Hook[106] (3).
Page 178 of 315

Assembling the high-pressure drive Pressing in the slide ring seal
High pressure pump installation
instruction
· Press a new slide ring seal(4) into

the drive gear(3), using the Plug-on
·Thinly apply the Loctite 5900 (1) on the handle[107](1), the Washer[108] and
contact surfaces as described in the the Impact punch[109](2).
drawing.
Mounting the Poly-V-belt pulley
Installing the high-pressure pump
drive
Note
·Position the high-pressure pump drive
Always replace the slide ring seal
(2).
with the poly-V-belt pulley.
·Screw a new mounting bolt (1) and
·Thinly apply the Loctite 5900 on the
tighten it to 115Nm.
new Poly-V-belt pulley(4) teeth.
·Position the Washer(3) and screw in a
new mounting bolt (2).
·Push the poly-V-belt pulley (4)onto the
spline shaft (5) until stop.
·Screw and tighten a new bolt (1).
·Tighten the bolt (2).
Page 179 of 315

Installing the high-pressure pump · Screw and tighten a new mounting
Installing the high-pressure pump bolt (3).
· If reusing the line, tighten it to final
torque30°, using the Socket, size
19[113] and the Extension[114].
· Tighten the line to final torque 60°,
the Extension[114].
· Connect the electrical connection
(metering unit)(2).
Installing the fuel inlet opening
Note
Install the fuel service center
before the high-pressure pump if
the pump is removed and
assembled by Special tool.
·Put the intermediate drive shaft (3) on
the high-pressure pump (2) drive
shaft.
·Insert the high-pressure pump (2) into
the drive gear with a new O-ring. ·Thinly apply the Curil T on the fuel
·Screw a new mounting bolt (1) and inlet opening (1).
tighten it to 60-70Nm. ·Screw the fuel inlet opening into the
· Install the fuel service center if high-pressure pump drive gear using
necessary. See P181 for removing and the Socket,size 27[110] (2).
installing the fuel service center. ·Tighten the fuel inlet opening to 35Nm.
Attaching the high-pressure line
· Attach the line (4) to the rail(1) and

the high-pressure pump (5).
· Tighten the line (4) to initial torque
10Nm, using the Socket, size
19[113] and the Extension[114].
· Check to ensure the line without
pressure.
Page 180 of 315

3. Fuel service center
Fig. 2-32 Fuel service center

(1) Intake manifold (11) Fuel line（Fuel tank ---Fuel service
(2) Flame glow plug center）
(3) Magnetic valve
(4) Hollow bolt (12) Fuel line（Fuel service center --- Fuel
(5) Ring connection pump）
(6) T-joint (13) Fuel line（Fuel service center ---
(7) Fuel return line (Cylinder head ---The High-pressure pump）
rail）
(14) Fuel line（Fuel pump --- Fuel service
(8) Fuel return line（The rail --- Fuel
center）
service center）
(15) Fuel line（Fuel service center ---
(9) Fuel return line（Fuel service
Solenoid valve）
center/High-pressure pump --- fuel tank）
(10) Fuel service center
3.1 Technical data

Overflow valve working pressure 1.1-1.5bar

WARNING
·Plug the component connections immediately using new, clean protective
Page 181 of 315

sleeves.
WARNING
Danger of environmental pollution
·Collect any remaining fuel that emerges in a suitable container.
WARNING
wrench.
Note
Mark the correct alignment and installing position of the formed fuel lines
before removing them.
3.3 Special tools
[142] Release tool, size 1 JD6805-0079 80.99606-0625
·Opening the
quick-release
couplings
with:
·Release handle [143]
[143] Release handle JD6805-0080 80.99606-0597
·Opening the
quick-release
couplings
Page 182 of 315

3.4 Removing the fuel service center Detaching the fuel line of the fuel service
Detaching the fuel return line of center ---the high-pressure pump
the rail
·Pull out the fuel lines (1) and (2) using

·Detach the fuel return line (5). the Release tool, size 1[142] and the
·Unscrew the hollow bolt (2). Release handle [143].
·Remove the fuel return line (3). Detaching the fuel return line of the
·Unscrew the mounting bolt (4) and fuel service center.
remove the T-joint (1).
Detaching the fuel line of the fuel
service center and the fuel pump
· Undo the clamp (1) mounting bolt.

· Pull out the fuel return line (2) using
·Unscrew the mounting bolt (1). the Release tool, size 1[142] and the
· Pull out the fuel lines (2) and (3) Release handle [143].
using the Release tool, size 1[142] Detaching the solenoid valve---the fuel
and the Release handle [143]. service center line
·Unscrew the bolts (1) and (3)）remove

them with the Washer.
·Detach the line (2).
Page 183 of 315

Removing the fuel service center 3.5 Installing the fuel service center
Installing the fuel service center

·Remove the fuel service center (3). · Position the holder（4）.
·Unscrew the mounting bolt (2). · Screw in and tighten the new
·Remove the holder (4). mounting bolt（1）.
· Position the fuel service center（3）.
· Screw in and tighten the new
mounting bolt（2）.
Attaching the solenoid valve---the fuel
service center line
· Position the fuel line（2）.

· Screw in the new washer and the
mounting bolt (3)..
washer and the mounting bolt (1).
· Tighten the mounting bolt（3）to
15Nm.
Page 184 of 315

Attaching the fuel return line of the Attaching the fuel line of the fuel
fuel service center service center and the fuel pump
· Attach the line（2）. ·Attach the lines（2）and（3）.

· Check if the line（2）is seated firmly. ·Check that the lines (2) and (3)are
If necessary, pull it out using the seated firmly.
Release tool, size 1[142] and the Pull off the lines (2) and (3) using the
Release handle [143] and re-attach Release tool, size 1[142] and the
it.. Release handle [143] and re-attach
· Screw in and tighten the new clamp them if necessary.
（1）bolt. ·Screw in and tighten the new mounting
Attaching the fuel line of the fuel bolt（1）.
service center and the high-pressure Attaching the fuel return line of the
pump rail
· Attach the lines（1）and（2）. · Position the T-joint (1) and screw in

· Check that the line（2）is seated the hollow bolt (4) with a new seal
firmly. ring.
· Pull off the line using the Release ·Screw the line (3) into the T-joint.
tool, size 1[142] and the Release ·Screw in and tighten a new washer and
handle [143] and re-attach it if the mounting bolt (2).
necessary. ·Tighten the line (3) nut.
·Tighten the hollow bolt (4).
·Attach the line (5) to the nut and
tighten it.
Page 185 of 315

3.6 Replace the fuel filter
3.6.1 Additional jobs
—Removing and assembling the fuel service center, see P181.
Fig.2-33 Fuel service center
(1) Fuel filter (9) Heating element

(2) Cover (10) Hollow screw
(3) Seal ring (11) Cover
(4) Housing (12) Fuel pre-filter
(5) Pressure sensor (13) Seal ring
(6) Water drain plug (14) Housing
(7) Mounting bolt (15) Hand pump
(8) Seal ring (16) Mounting bolt
Page 186 of 315

3.6.2 Technical data
Pressure sensor（5） M18×15 45Nm
Cover（11） 20+2.5Nm
Cover（2） 25Nm
Water drain plug（6） 3Nm
3.6.3 Important information

WARNING
Dirt can cause failure of the common-rail system
·Always allow the fuel service center to empty before changing the fuel
filter.
·Only use fuel filters that are designated for common-rail systems and
marked as such.
·Do not reuse old filter elements.
WARNING
wrench.
3.6.4 Special tools

No. Drawing Illustration Sinotruk No. MAN No.
Socket, size 36
·Removing and
[153] JD6805-0081 80.99603-0325
installing the fuel filter
cover
Socket, size 19
·Removing and
[154] JD6805-0082 08.06141-9061
installing the fuel
pre-filter cover
Page 187 of 315

3.6.5 Removing the fuel service center Removing the pressure sensor
Allowing the fuel service center to
empty
·Unscrew the pressure sensor（1）with

the seal ring（2）.
Removing the fuel filter
WARNING
Danger of environmental
pollution
·Collect any remaining fuel
that emerges in a suitable container.
· Undo the cover (1) by 2-3 turns,
using the Socket, size 36 [153].
· Open the water drain plug（2）and
allow the fuel service center to
empty.
· Re-tighten the water drain plug（2）
to 3Nm.
Removing the heating element
· Unscrew the cover (1) using the

Socket, size 36[153].
· Pull the cover (1) and the filter
element (3) out of the fuel service
center housing.
· Remove the seal ring（2）.
· Unscrew the cover (7) using the
· Unscrew the mounting bolt（2） Socket, size 19[154].
· Pull the heating element（3）and the · Pull the filter element（6） out of the
seal ring（4）out of the fuel service hand pump housing（4）.
center（1）. · Remove the seal ring（5）.
Page 188 of 315

Removing the hand pump housing 3.6.6 Assembling the fuel service
center
Mounting the hand pump
housing
·Unscrew the mounting bolt（2） from

the fuel service center（3）.
·Remove the hand pump housing（1）.
· Position the hand pump housing（1）
on the fuel service center（3）.
Page 189 of 315

Installing the fuel filter ·Tighten the hand pump housing with
the Socket, size19[154](1)to
20+2.5Nm.
Tightening the fuel filter cover
·Tighten the fuel filter cover with the

Socket, size 36[153]（1）to 25Nm.
Installing the pressure sensor
· Moisten the new seal ring(5) with

clean diesel fuel.
· Fit the seal ring（5）on the hand
pump housing（4）. · Screw in the pressure sensor （1）
· Insert a fuel pre-filter（6）. with a new seal ring（2）.
· Screw in the cover (7) and tighten it · Tighten the pressure sensor（1）to
manually. 45Nm.
· Insert a new filter element (3) into Installing the heating element
the cover (1).
· Moisten the new seal ring(2) with
clean diesel fuel.
· Screw in the seal ring (2)and the
cover(1) and tighten them manually.
Tighten the hand pump housing
· Insert the heating element (3) with a

new seal ring (4) into the fuel service
center (1).
·Screw in and tighten the new bolt (2).
Page 190 of 315

Section 8. Engine lubrication
Fig. 2-37 Engine lubrication

(1) Oil sump (4) Oil cooler
(2) Oil intake pipe (5) Oil module
(3) Oil pump
一步到位步步到位第 191 页共 315 页

1. Oil module
1.1 Additional jobs
- Removing and assembling the suction pipe, see P73.
Fig. 2–38 Oil module

(1) Oil cooler (5) Mounting bolt
(2) Gasket (6) Oil module
(3) Screw-in fitting (7) Screw-in fitting
(4) Breather pipe (8) Mounting bolt
1.2 Technical data

Oil module screw plug（6） M38×15 80+10Nm
Screw-in fitting（3） M24×15 4Nm
Screw-in fitting（7） M24×15 4Nm
Pressure relief valve M27×15 40+5Nm
Oil filter cover 40+10Nm
Oil cooler mounting bolt（1） M8×55-8.8 30-35Nm
Oil cooler mounting bolt（1） M8×80-8.8 30-35Nm

Loctite 243
Multi-purpose Lithium Grease
Lubricant P80

WARNING
Danger of engine damage due to oil emulsion
·Drain all the coolant before removing the oil module, otherwise
coolant will enter the oil sump when the oil module is removed
from the crankcase.
WARNING
wrench.
1.5 Special tools

[239] Socket（size 32） JD6805-0119 80.99603-0326
· Removing and
installing the fuel filter
cover
[240] Hose clamp pliers for JD6805-0028 08.99605-9003

jubilee chips
·Removing the suction
pipe out of the air
compressor
[241] Detector JD6805-0168 80.99606-0399
· Checking the push-in
connection of the
compressed air

Removing the oil module Removing the oil module pipe
Removing the heat shield
· Remove the jubilee clips（2）, using

the hose clamp pliers [240].
·Remove the heat shield（1）. · Pull out the oil separator breather
Removing the oil separator return pipe（1）.
line Draining the coolant
·Unscrew the mounting bolt（1）.

·Pull the return line（3） out of the WARNING
screw- in fittings（2）and（4）. Danger of engine damage due
·Unscrew the screw-in fittings（2）and to oil emulsion
（4）. ·Drain all the coolant before
Unscrewing the water pump mounting removing the oil module,
bolt otherwise coolant will enter
the oil sump when the oil
module is removed from the
crankcase.
· Unscrew the screw plug（3）with the
seal ring（2） out of the oil module
（1）.
·Drain the coolant.
·Unscrew the water pump bolts (1) (2 )

out of the oil module.

Instruction of removing the oil Removing the oil cooler
module
WARNING
incorrectly placing the oil
·Do not unscrew the oil cooler module
mounting bolts（2）and（3）when ·Put the oil module aside so as
removing the oil module（1）. not to damage the oil cooler.
Removing the oil module ·Mark the installation position of the
·Remove the oil cooler（3）and the
gasket（2） out of the oil module（1）.
·Clean the mating faces.
Removing the relief valve
·Mark the installation position of

mounting bolts（4）and（5）.
·Unscrew the mounting bolts（4）and
（5）.
·Remove the oil module（1）with the
gasket（2） out of the crankcase（3）.
· Unscrew the relief valve（2）out of the
oil module（1）.

Removing the connection manifold Removing the oil filter
· Remove the unscrewed conduit（5）

off the angle flange（3）.
· Unscrew the mounting bolt（4）.
· Remove the angle flange (3) and the
Gasket(1) off the oil module（2）.
· Clean the mating faces.
Removing the oil separator
· Unscrew the oil filter cover(1) out

of the oil module(4), using the
Socket (size 32)[239].
· Remove the O-ring(2) out of the
filter cover (1).
· Remove the filter element（3） out
of the cover (1).

· Pull the oil separator（2） out of the
oil module.

Assembling the oil module Installing the oil separator
Installing the oil filter
· Put a new O-ring（2） on the filter

cover（1）and apply clean engine oil ·Insert the oil separator(2)into the oil module.
on the ring.
(1).
· Insert a new filter element（3） into Installing the connection manifold
the cover(1).
· Screw the oil filter cover(1) into the
oil module(4) and tighten it to
40+10Nm, using the Socket[239]
（size 32）.
· Position the connection manifold

(3)and a new gasket(1)on the oil
module(2).
bolt(4).
·Apply thinly Grease P80 on the new
unscrewed conduit(5)and insert it into the
connection manifold (2).

Installing the relief valve Mounting the oil module
Mounting the oil module
·Screw the relief valve（2）into the oil

module（1）. WARNING
·Tighten the relief valve（2） to 40+5Nm. Component damage due to
Installing the oil cooler incorrect tightening sequence
·Follow the tightening sequence
as follows, otherwise the
housing will be broken.
·Position the oil module（1）with the
new gasket（2）on the crankcase（3）.
·Screw in the new bolts（4）and（5）
and tighten them manually.
Screwing in the water pump mounting
bolt
·Insert the oil cooler（3）with the new
gasket（2）into the oil module（1）.
·Screw in the new mounting bolt（4）
and tighten it manually.
Tightening the oil cooler mounting
bolt
·Screw in and tighten the new bolts（1）

and（2）.
·Tighten the oil module mounting bolt.
· Put the oil module aside so as not to

damage the oil cooler.
·Tighten the bolt（3）to 30-35Nm.
·Tighten the bolt（2）to 30-35Nm.

Screwing in the screw plug Installing the oil module pipe
· Push the breather pipe（1）completely

to the oil separator.
·Screw the plug（3） with the new seal ·Install the jubilee clips（2）, using the
（2）into the oil module（1）and tighten Hose clamp pliers[240] .
it to 80+10Nm. Installing the heat shield
Installing the breather pipe
·Install the heat shield（1）.
·Apply Loctite 242 on the thread of

screw-in fitting（4）.
·Screw the screw-in fitting(4) into the
crankcase and tighten it to 4Nm.
·Apply Loctite 242 on the thread of
screw-in fitting（2） .
·Screw the screw-in fitting (2)into the
oil module and tighten it to 4Nm.
·Install the breather pipe（3）.
（1）.

2. Oil sump and oil intake pipe
Fig.2-39 Oil sump and oil intake pipe

(1) Oil sump gasket (4) Oil sump holding piece
(2) Oil sump (5) Mounting bolt
(3) Oil sump holding piece (6) Oil intake pipe

Technical Vaseline
WARNING
wrench.
Page 200 of 315

Removing the oil sump and the oil Installing the oil sump and the oil
intake pipe intake pipe
Removing the oil sump Install the oil intake pipe
· Unscrew the mounting bolt（4）. · Apply thinly technical Vaseline on

· Remove the holding piece（3）. the new O-ring（3）.
· Remove the oil sump（2）. · Insert the O-ring into the crankcase.
· Pull the gasket(1)out of the oil · Insert the oil intake pipe（2）into the
sump. crankcase.
· Clean the mating faces. · Screw in and tighten the new
Removing the oil intake pipe mounting bolt（1）.
Mounting the oil sump

·Pull the oil intake pipe（2）out of ·Fit a new gasket（1）on the oil sump
the crankcase. （2）.
·Remove the O-ring（3）out of ·Position the oil sump（2）.
the crankcase. ·Fit the holding piece（3）.
·Screw in the new bolt（4）and tighten
it manually.
·Tighten the mounting bolt（4）.
Page 201 of 315

3. Oil injector nozzles
3.1 Additional jobs
- Removing and installing the oil sump and oil intake pipe, see P200
Fig. 2-30 Oil injector nozzles

(1) Oil nozzle (2) Mounting bolt
3.2 Technical data
Designation Specification Technical Parameter

WARNING
wrench.
Page 202 of 315

Removing the oil injector nozzle Installing the oil injector nozzle
· Unscrew the mounting bolt（2）. · Insert the oil injector nozzle（1）into

· Pull the oil injector nozzle（1）out of the crankcase（3）.
the crankcase（3）. · Screw in and tighten the new bolt
（2）to 15Nm.
Page 203 of 315

4. Oil pump
4.1 Additional jobs
- Removing and installing the fan,see P25
- Removing and installing the fan bracket, see P27
- Removing and installing the thermostat, P 39
- Removing and installing the distributor housing, see P47
- Removing and installing the high pressure pump / drive, see P172
- Removing and installing the front crankshaft seal, see P214
- Removing and installing the damper, see P234
Fig.2-31 Oil pump
(1) Mounting bolt (6) Shaft

(2) Gear ring (outer rotor) (7) Bearing shell
(3) Oil pump pinion gear (inner rotor) (8) Crankcase
(4) Mounting bolt (9) Oil pump cover
(5) O-ring (10) Mounting bolt
Page 204 of 315

4.2 Technical data
Crankcase gear backlash, gear ring(outer rotor)(2)-- 0.092-0.272mm
Axial play, gear ring (outer rotor)(2) 0.030-0.093mm
Radial play, gear ring (outer rotor)(2) 0.1-0.210mm
Outer diameter, Bearing, Gear ring (outer rotor) (2) 96.853-96.888mm
Height, gear ring (outer rotor)(2) 29.952-29.970mm
Outside diameter, shaft（6） 36.950-36.965mm
Height, oil pump pinion gear（inner rotor）（3） 29.955-25.970mm
Inside diameter, oil pump pinion gear(inner rotor)(3) 36.985-37.050mm

WARNING
Crankcase damage due to damaged pump
·Always keep the oil pump absolutely clean when it is assembled.
WARNING
wrench.
4.4 Special tools
[242] Dial gauge
·Checking the gear backlash
·Checking the gear ring (outer
rotor) axial and radial play, JD6805-0024 08.71000-3217
using:
·Dial gauge holder [243]
·Locating pin [244]
[243] Dial gauge holder
rotor) axial and radial play JD6805-0025 08.71082-0005
Page 205 of 315

[244] Locating pin
·Checking the gear ring (outer JD6805-0026 80.99605-0197
rotor) axial and radial play
[245] Guide pin
·Removing and installing the
JD6805-0117 80.99617-0020
crankshaft front gear
[246] Impact extractor

·Extracting the bearing shell,
using: JD6805-0018 80.99602-0016
·Adapter [248]
·Extractor device [247]
·Extracting the bearing shell
JD6805-0120 80.99602-0300
[248] Adapter
·Extracting the bearing shell
JD6805-0121 80.99602-0207
[249] Tool
·Pressing in the bearing shell
JD6805-0122 80.99604-6038
[250] Depth gauge（electronic）

·Checking the oil pump pinion
gear (inner rotor) height JD6805-0032 08.71195-9003
rotor) height
Page 206 of 315

Checking the oil pump crankshaft gear and the crankshaft(2).
Checking the crankshaft gear/ ring Checking the axial play of the gear
gear (outer rotor) backlash ring (outer rotor)
· Install the Dial gauge holder [243] (2)

with the Dial gauge[242] (1) and the · Install the Dial gauge holder [243] (1)
Locating pin[244]. with the Dial gauge [242] (3) and the
· Mount the Locating pin[244] on the Locating pin[244].
gear ring (outer rotor) (3) with a · Mount the Locating pin[244] on the
preload. gear ring (outer rotor) (2) with a
· Check the backlash between the preload.
crankshaft gear and the gear ring · Press in the gear ring (outer rotor) (2)
(outer rotor)（3）. towards the crankcase.
The permitted backlash is · Zero the Dial gauge [242]（3）.
0.092-0.272mm. · Pull out the gear ring (outer rotor) (2)
towards the oil pump cover and read
Fit new crankshaft gear and oil pump
off the difference.
if the backlash is out of the tolerance.
The permitted axial play of the gear
Removing the crankshaft gear
ring (outer rotor) is 0.030-0.093mm.
Install a new oil pump if the play is
out of tolerance.
Checking the radial play of the gear
ring (outer rotor)
· Screw in the Guide pin[245]（3）and

（4）.
· Pull out the crankshaft gear（2）.
· Unscrew the Guide pin [245]（3）and
（4）. ·Install the Dial gauge holder[243] (3)
· Clean the mating faces of the with the Dial gauge[242] (1) and the
Page 207 of 315

Locating pin[244].
Removing the oil pump
·Mount the Locating pin[244] on the
Removing the oil pump cover
gear ring (outer rotor) (2) with a
preload.
·Push the gear ring (outer rotor) (2)
horizontally to the end.
·Pull the gear ring (outer rotor) (2) to
the end towards the Dial gauge [242]
（1）and read off the difference.
The permitted radial play of the gear
ring (outer rotor) is 0.100-0.210mm.
·Remove the cover（2）out of the
crankcase（3）.
Removing the oil pump
·Remove the gear ring (outer rotor)

（1）and the oil pump pinion gear
(inner rotor)（2）out of the crankcase
（3）.
Removing the oil pump pinion
Gear (inner rotor) shaft
Page 208 of 315

·Remove the shaft（3）with the Checking the oil pump bearing
O-ring（2）out of the crankcase. Checking the outside diameter
of the gear ring (outer rotor) bearing
Removing the bearing shell
·Clean the gear ring (outer rotor)（1）.

·Check the outside diameter of the gear
·Insert the Extractor device [247]（2）
ring (outer rotor), using the
into the bearing shell（4）and expand
micrometer（2）.
the opening.
The permitted outside diameter is
·Install the jubilee clip（3）on the
96.853-96.888mm。
Extractor device [247]（2）and tighten
it. Fit a new oil pump with bearings if
·Install the Adapter[248]（1）. the outside diameter is out of tolerance.
·Screw in the Impact extractor device
Checking the height of the gear ring
[246] into the Adapter[248]（1）.
(outer rotor)
·Pull off the bearing shell(4), using the
Impact extractor device[246].
· Clean the gear ring (outer rotor)（2）.

· Check the height of the gear ring (outer
rotor)(2), using the Depth gauge
[250]（1）
The permitted height is
29.952-29.970mm.
Install a new oil pump with bearings
Page 209 of 315

if the height is out of tolerance. Checking the height of the oil pump
Checking the inside diameter of the pinion gear (inner rotor)
oil pump pinion gear (inner rotor)
·Clean the oil pump pinion gear (inner ·Clean the oil pump pinion gear (inner
rotor)（2）. rotor)（2）.
·Check the inner diameter of the pinion ·Check the height of the pinion gear
gear (inner rotor)(2), using the Dial (inner rotor) (2), using the Depth
gauge [242] （ 1 ） and the Internal gauge (electronic) [250](1).
caliper. The permitted height is
The permitted diameter is 29.955-29.970mm.
36.985-37.050mm.
Install a new oil pump with bearings if
Install a new oil pump with bearings if the height is out of tolerance.
the inner diameter is out of tolerance.
Page 210 of 315

Checking the shaft outside diameter Installing the oil pump
Screwing in the Threaded spindle
·Clean the shaft（1）.

·Check the shaft（1）outside diameter ,
using the micrometer（2）. · Clean the Threaded spindle（1）.
The permitted diameter is · Clean the mating faces of the
36.950-36.965mm. Threaded spindle (1) in the
crankcase.
Install a new oil pump with bearings if
· Screw in and tighten the Threaded
the outside diameter is out of
spindle (1), using the Special tool
tolerance.
[249].
Preparing the installer
·Align the bearing shell（2）notch to

the mark in the Special tool [249]（1）.
·Tighten the bearing shell (2).
Page 211 of 315

Fixing the Guide plate Installing the oil pump pinion gear
(inner rotor) shaft
·Insert the Guide plate（2）with the

bearing shell（1） so as to slide the Note
sub-bracket（3）into the oil pump bore The shaft installation position
（4）. depends on the Locating pin.
Pressing in the bearing shell · Apply thinly clean engine oil on the
new O-ring（2）.
· Install the O-ring on the shaft（3）.
· Insert the shaft into the crankcase
（4）.
· Screw in and tighten the new bolt
（1）.
Installing the oil pump
· Screw in the Hexagon nut（1）.

· Press in the bearing shell by screwing
in the Hexagon nut（3） until it can’t
move any more
·Remove the Special tool [249]（2）.
·Apply clean engine oil on the bearing

area of the gear ring (outer rotor)（1）
and on the pinion gear (inner rotor)
（2）.
·Insert the gear ring (outer rotor) into
the crankcase（3）.
·Slide the pinion gear (inner rotor) on
the shaft to make the mark（4） visible.
Page 212 of 315

Installing the oil pump cover
· Position the oil pump cover（2） on

the crankcase（3）.
· Screw in and tighten the new bolt
（1）to 15Nm.
Installing the crankshaft gear
·Screw in the Guide pin [245]

（3）and（4）.
·Install the gear（2）on the crankshaft
（ 1 ） and make sure it reaches the
bottom.
·Unscrew the Guide pin[245] (3) and
(4).
Page 213 of 315

5. Front crankshaft oil seal
5.1 Additional jobs
- Removing and installing the fan, see P25
- Removing and installing the damper, see P234.
Fig.2-32 Front crankshaft oil seal

(1) Cover (2) Crankshaft oil seal
5.2 Important Information

WARNING
·Clean the crankshaft and insert tool before assembly.
WARNING
•·If impact wrenches are used, these may only be used for pre-tightening to
max. 50 % of the specified tightening torque
wrench.
5.3 Special tools
Page 214 of 315
[251] Crossmember
·Removing crankshaft oil
seal in conjunction
with:
·Pressure plate [252] 80.99606-029
JD6805-0123
·Hexagon nut [255] 8
·Hook [253]
·Threaded spindle [256]
·Pan head screw [257]
·Guide plate [258]
[252] Pressure plate
·Removing crankshaft
oil seal 80.99609-003
JD6805-0124
8
[253] Hook
·Removing crankshaft 80.99606-601
JD6805-0125
oil seal 3
[254] Press-in sleeve

·Pressing in crankshaft
oil seal in conjunction
with:
·Hexagon nut [255]
·Threaded spindle [256] 80.99606-065
JD6805-0126
·Pan head screw [257] 9
·Guide plate [258]
·Washer [259]
·Hexagon collar nut [260]
·Washer, 6mm [261]
·Washer, 3mm [262]
[255] Hexagon nut
oil seal 06.11069-006
JD6805-0127
·Pressing in crankshaft 4
oil seal
[256] Threaded spindle

80.99606-029
oil seal JD6805-0128
9
oil seal
Page 215 of 315
06.02191-282
2
oil seal
[258] Guide plate
oil seal 80.99606-065
JD6805-0130
·Pressing in crankshaft 8
oil seal
[259] Washer
oil seal 06.15230-060
JD6805-0131
9
[260] Hexagon collar nut

·Pressing in crankshaft 06.11222-021
JD6805-0132
oil seal 1
[261] Washer, 6mm

81.90711-019
5
[262] Washer, 3mm

81.90712-098
4
[263] Depth gauge (electronic)

· Check the crankshaft oil
08.71195-900
seal press depth JD6805-0032
3
Page 216 of 315

Removing the crankshaft oil seal Installing the front crankshaft oil seal
Positioning the crankshaft oil seal
WARNING
Damage on the oil seal
·Carefully remove the plate
from the transport sleeve（3）,
using a proper tool.
· Install the Guide plate [258]（4）onto
the crankshaft（1） with a Pan head
screw [257].
· Mount the Guide plate[258]（3）, the · Place the oil seal（2）with transport
Pressure plate [252] and the Pan sleeve (3) and push it onto the
head screw [257] （ 1 ） on the Guide plate [258] (4).
crankshaft. · Remove the transport sleeve (3).
· Screw in the Threaded spindle [256]
（6） with the Hexagon nut [255] into
the Cross-member [251]（5）.
· Screw a second Hexagon nut [255]
into the Threaded spindle [256] (6)
and secure using the Hexagon nut
[255].
· Insert the Hook [253] (4) through
the Cross member [251]（5）flat
between the crankshaft oil seal (2)
and the crankshaft.
· Turn the Hook [253] (4) through
90° so as to make its recess face
outwards.
· Hold the Hexagon nut on the
Cross-member [251] (5) firmly.
· Extract the oil seal (2) by screwing
in the Threaded spindle [256] (6).
· Removing the special tools.
Page 217 of 315

Pressing in the crankshaft oil seal
· Push the Press-in sleeve[254]（2） Hexagon nut [255].

with the Washer, 3mm[262] onto · Screw the Threaded spindle [256]
the Guide plate [258]. (4) together with the Washer [259]
· Screw the Hexagon collar nut into the guide plate [258].
[260] · Firmly hold the Hexagon nut [255]
（3）onto the Threaded spindle on the Threaded spindle [256] (4) .
[256]（4）. · Press in the oil seal （ 1 ） by
· Screw the Hexagon nut [255] onto screwing in the Hexagon collar nut
the Threaded spindle [256] (4). [260] (3) until the Press-in sleeve
· Screw a second Hexagon nut [255] [254] (2) with the Washer, 3mm
onto the Threaded spindle [256] (4) [262] locates on the Guide plate.
and secure using the Remove the special tool.
Page 218 of 315

6. Rear crankshaft oil seal
6.1 Additional jobs
- Removing and installing the flywheel, see P238.
Fig.2-33 Rear crankshaft oil seal

(1) Crankshaft oil seal (2) Flywheel housing
6.2 Technical data
The sleeve installing temperature is approx. 120 ℃.
Loctite Antipor Sealant（Loctite 5900）
WARNING
·Clean the crankshaft and insertion tool before assembly.
WARNING
wrench.
6.5 Special tools

Page 219 of 315
[264] Impact extractor
·Extracting the crankshaft
oil seal in conjunction JD6805-0018 80.99602-0016
with:
·Hook [265]
[265] Hook
·Removing the crankshaft
oil seal JD6805-0135 80.99602-0175
[266] Removal device

·Pulling off the sleeve in
·Threaded spindle [267]
·Pressure plate [268]
[267] Threaded spindle
·Pulling off the sleeve
JD6805-0137 80.99601-0156
[268] Pressure plate

·Pulling off the sleeve
JD6805-0138 80.99601-0183
[269] Plug-on handle

·Pressing in the sleeve in
conjunction with:
·Washer [270]
·Installing the crankshaft JD6805-0020 80.99617-0187
oil seal in conjunction
with:
·Washer [270]
·Guide sleeve [272]
Page 220 of 315

[270] Washer
·Pressing in the sleeve
·Installing the crankshaft
JD6805-0021 80.99617-0144
oil seal
[271] Impact punch

·Pressing in the sleeve
JD6805-0139 80.99617-0017
[272] Guide sleeve

oil seal JD6805-0140 80.99604-0286
[273] Impact punch

oil seal JD6805-0141 80.99604-0069
Page 221 of 315

Extracting the rear crankshaft oil seal Installing the rear crankshaft oil seal
·Extracting the oil seal（3） out of the ·Push the guide sleeve [272]（4）into the
flywheel housing, using the Impact crankshaft.
extractor device[264] (1) and the ·Assemble the Impact punch [273]（6）,
Hook[265]（2） the Plug-on handle [269]（1）and the
Washer [270]（2）.
·Install the seal surface of the oil seal (3)
on the special tool.
·Push the special tool onto the Guide
sleeve [272]（4）.
·Press the oil seal (3) into the flywheel
housing（5）until the Impact punch
[273]（6）locates on the Guide sleeve
[272] (4).
·Remove the special tool
Page 222 of 315

Section 9. Engine housing
Fig. 2-34 Engine housing

(1) Mounting bolt (5) Flywheel housing
(2) Hub (6) Front cover
(3) O-ring (7) Damper
(4) Cylinder liner (8) (8) Mounting bolt
Page 223 of 315

1. Flywheel housing
1.1 Additional jobs
- Removing and installing the flywheel, see P238
Fig. 2-35 Flywheel housing

(1) Mounting bolt (2) Flywheel housing
1.2 Technical data
Mounting bolt (1), flywheel housing M10×30-10.9 65Nm
Mounting bolt (1), flywheel housing M10×40-10.9 65Nm
Mounting bolt (1), flywheel housing M16×1.5×55-10.9 280Nm
Loctite 5900
WARNING
• Final tightening must always be performed manually using a
torque
wrench.
Page 224 of 315
Removing the flywheel housing Installing the flywheel housing
Removing the flywheel housing Flywheel housing installation
Instruction
· Apply Loctite 5900（1） on the mating

faces as described in the figure.
Installing the flywheel housing
CAUTION
Danger of injury due to heavy
components
·Use lifting gear to remove the flywheel
housing.
·Remove the flywheel housing（2）.
CAUTION
components
·Use lifting gear to remove the flywheel
housing.
·Install the flywheel housing（2）on the
position pins.
·Screw in ang tighten the new bolt（1）.
·Tightening torque：
M10: 65Nm
Page 225 of 315

M16 : 280Nm
2. Front cover
2.1 Additional jobs
- Removing and installing the fan
- Removing and installing the front crankshaft oil seal, see P214
Fig.2-36 Front cover

(1) Mounting bolt (2) Front cover (3) Gasket (4) Fan bracket (5) Crankcase
2.2 Technical data

Loctite 5900, Technical Vaseline
WARNING
• Final tightening must always be performed manually using a
torque
wrench.
Page 226 of 315
Removing the front cover Installing the front cover
Front cover installation instruction
· Mark the mounting bolt（1）position.

· Unscrew the mounting bolt. · Install the new O-ring（2）.
· Remove the front cover（2）with the · Apply technical Vaseline on the
gasket（3）from the crankcase. O-ring.
· Clean the mating faces. · Apply Loctite 5900（1） on the
mating faces as described in the
figure.
Installing the front cover
· Position the front cover

（2）with the
new washer（3）.
· Screw in the new bolt （1） as
described in the figure and tighten it
manually.
· Tighten the bolt（1）.
Tightening torque:
M8: 35Nm
M12: 115Nm
Page 227 of 315

3. Cylinder liners
3.1 Additional jobs
- Removing and installing the coolant manifold, see page P34
- Removing and installing the alternator, see P62
- Removing and installing the suction pipe, see P73
- Removing and installing the intake manifold, see P75
- Removing and installing the injectors and the rail, see P156
- Removing and installing the oil sump and the oil intake pipe, see P200
- Removing and installing the piston and the conrod, see P247
Fig.2-37 Cylinder liners

(1) Crankcase (2) O-ring (3) Cylinder liner
Page 228 of 315

3.2 Technical data
Cylinder liner standout 0.035-0.085mm
Crankcase cylinder liner seat depth 8.0±0.015mm
O-ring insertion hole Ø 139.500 - 139.540 mm

connections.
Wrench.
3.4 Special tools
[330] Extracting tool
· Extracting the cylinder liner in
conjunction with:
JD6805-0169 80.99602-6035
·Extracting plate [331]
[331] Extracting plate

·Extracting the cylinder liner
JD6805-0170 80.99601-0217
[332] Dial gauge

· Checking the cylinder liner
diameter
· Checking the liner standout in
· Dial gauge stand [333]
· Measure plate [334]
· Hexagon bolt [335]
· Washer [336]
· Checking the liner standout
JD6805-0147 80.99605-0172
Page 229 of 315

[334] Measuring plate
JD6805-0097 80.99605-0286
[335] Hexagon bolt

JD6805-0098 06.01499-0015
[336] Washer
JD6805-0099 06.15013-0417

·Checking the cylinder liner seat
JD6805-0032 08.71195-9003
Page 230 of 315

Removing the cylinder liner Extracting the cylinder liner
Checking the cylinder liner diameter
· Fix the Extracting tool[330]（3）with

·Measure the cylinder liner（3）, using the nut（2）.
the Dial gauge [332]（2） and the · Extracting the cylinder liner（1）with
internal caliper（1）. the Extracting tool[330]（3）.
·Check several times at 120° offset. · Clean the cylinder liner (1).
·Repeat the check at 4 different heights. Removing the O-ring
·If the cylinder liner is elliptical, fit a
new one.
Installing the Extracting tool
· Remove the O-ring（2） from the

crankcase.
WARNING · Clean the cylinder liner seat（1）and
Danger of engine damage due the O-ring seat.
to damaged oil nozzle
· Do not damage the oil nozzle when

inserting the Extracting plate [331] .
· Mark the correct arrangement and
installation position of the cylinder
liner（1）.
· Push the Extracting tool[330]（3）
and the folded Extracting plate[331]
（2）into the cylinder liner.
Page 231 of 315

Installing the cylinder liner on the cylinder liner and read off the
Checking the cylinder liner seat difference.
The permitted liner standout is
0.035-0.085mm.
Install a new crankcase /cylinder liner
if the liner standout is out of
tolerance.
Installing the cylinder liner
· Check the cylinder liner seat, using

the Depth gauge (electronic) [337]
（1）.
· Measure the cylinder liner seat at
four opposite points.
The permitted liner seat depth is
8.0±0.015mm. · Apply clean engine oil on the
O-ring（2）and insert it to the O-ring
Install a new crankcase if the liner
seat in the crankcase.
seat is out of tolerance.
· Apply clean engine oil on the outer
Checking the cylinder liner standout
area of the cylinder liner lower
section.（1）.
· Insert the cylinder liner (1) as
described in the figure and push it to
the bottom as much as possible.
·Put the Measuring plate [334](2) on the

liner.
·Screw in and tighten the Hexagon
bolt[335](4) with the Washer
[336](5).
·Put the Dial gauge stand[333](6) with
the Dial gauge[332](3) on the
Measuring plate [334] (2).
·Put the Dial gauge probe(1) on the
crankcase.
·Zero the Dial gauge [332](3).
·Carefully put the Dial gauge probe (1)
Page 232 of 315

Section 10. Crank mechanism
Fig.2-38 Crank mechanism

(1) Flywheel (2) Crankshaft (3) Conrod (4) Bearing cap (5) Damper (6) Piston
Page 233 of 315

1. Damper
1.1 Additional jobs
Fig.2-39 Damper
(1) Mounting bolt (2) Damper (3) Mounting bolt (4) Hub
1.2 Technical data
Initial torque 150+10Nm
Mounting bolt（3） M16×85-10.9
Final torque 90+10°
Mounting bolt（1） M10×25-8.8 50-55Nm

WARNING
connections.
Wrench.
Page 234 of 315

1.4 Special tools
[274] Engine barring gear J D6805-0023 80.99626-6008
· Barring the engine

· Unscrewing and
tightening the damper
mounting bolt.
Page 235 of 315

Removing the damper Removing the hub
Attaching the Engine barring gear

· Remove the hub （ 1 ） from the
· Remove the observing hole cover damper（2）.
from the flywheel housing.
· Mount and lock the Engine barring
gear [274](1) on the flywheel
housing.
Removing the damper
· Unscrew the mounting bolt（1）,

using the Socket, size14 [275]
· Remove the damper（3）and the hub
（2）from the crankshaft gear.
Page 236 of 315

Installing the damper Removing the Engine barring gear
Installing the hub
· Insert the hub（1）into the damper · Remove the Engine barring

（2）. gear[274] （1） from the flywheel
· Screw in the mounting bolt（3）and housing.
tighten to 50-55Nm. · Mount the observing hole cover on
the flywheel housing.
Installing the damper
· Fix the damper（3）with the hub（2）.

· Screw in the mounting bolt（1）.
· Tighten the mounting bolt to initial
torque 150Nm, using the Socket,
size 14[275].
· Tighten the mounting bolt to final
torque 90°, using the Socket, size
14[275].
Page 237 of 315

2. Flywheel
2.1 Additional jobs
Fig.2-40 Flywheel
(1) Flywheel (2) Mounting bolt (3) Flywheel housing
Page 238 of 315

2.2 Technical data
Mounting bolt（2） M16×1.5×81-12.9 Initial torque 100+10Nm
Mounting bolt（2） M16×1.5×81-12.9 Angle 180°+10°
Flywheel ring gear installation 200-230 ℃
temperature
Max. dimension, Max. 9.5mm
flywheel wall to friction surface

WARNING
connections.
wrench.
2.4 Special tools
[280] Guide pin
· Removing and installing
the flywheel JD6805-0117 80.99617-0020
[281] Dial gauge

· Checking the flywheel
lateral runout in
JD6805-0024 08.71000-3217
conjunction with:
· Dial gauge holder [282]
· Locating pin[283]
lateral runout
JD6805-0025 08.71082-0005
[283] Locating pin

JD6805-0026 80.99605-0197
lateral runout
Page 239 of 315

wear in conjunction with: JD6805-0032 08.71195-9003
· Additional bridge
[285]
[285] Additional bridge
JD6805-0142 08.71109-0000
wear
[286] Torque multiplier i=1:3.5

· Undoing and tightening
the flywheel mounting
bolts in conjunction with:
· Support [287]
· Torque angle gauge [288]
JD6805-0084 80.99619-0007
· Stop pin [289]
· Washer [290]
· Pan head screw [291]
· Connecting pin [292]
· Rubber ring 42mm[293]
· Socket, size 19[294]
[287] Support
Undoing and tightening the
JD6805-0085 80.99606-0551
flywheel mounting bolts
[288] Torque angle gauge

the flywheel mounting JD6805-0086 80.99607-0172
bolts
[289] Stop pin

JD6805-0143 80.99606-0553
bolts
[290] Washer
bolts
Page 240 of 315

bolts

bolts
[293] Rubber ring 42mm

JD6805-0090 08.06142-9006
bolts

bolts
[295] Plug-on handle

· Pressing in the clutch
pilot bearing JD6805-0020 80.99617-0187
· Thrust disc [296]
· Impact punch [297]
[296] Thrust disc
pilot bearing JD6805-0021 80.99617-0144
[297] Impact punch

JD6805-0145 80.99604-0302
pilot bearing
Page 241 of 315

Removing the flywheel Unscrewing the flywheel mounting
Assembling the Special tool bolts
· Insert the Torque multiplier i=1:3.5

[286]（1）into the Support [287]（9）. · Unscrew two opposite-facing
· Mount the Stop pin [289]（6）on the mounting bolts（1）.
Support [287]（9）with the Pan head
Screwing in the Guide pins
screw[291]（8）and the Washer [290]
（7）.
· Fit the Torque angle gauge[288]（2）
on the Torque multiplier i=1:3.5
[286] (1).
· Fit the Socket, size19 [294] (3) on
the Torque multiplier i=1:3.5 [286]
(1) and screw with the Connecting
pin[292](5) and the Rubber ring
42mm[293] (4).
Undoing the flywheel mounting bolts
· Screw in the Guide pin [280]（1）and

（2）.
· Unscrew the remaining mounting
bolts.
Pulling off the flywheel
· Put the special tool （ 1 ） on the

mounting bolt that is going to be
undone.
· Undo all the mounting bolts.
Page 242 of 315

CAUTION Removing the flywheel ring gear
components
· Use lifting gear to remove the
flywheel.
· Pull off the flywheel（1）over the
Guide pin[280]（2）.
Removing the clutch pilot bearing
WARNING
spot-drilling of the flywheel
· Take care not to damage the

flywheel when spot-drilling the
flywheel ring gear.
· Spot-drill the flywheel ring gear（3）
· Remove the clutch pilot bearing（2）
to force it open, using the electric
from the flywheel（1）.
drill（2）.
· Remove the flywheel ring gear（3）
from the flywheel（1）.
· Clean the contact surfaces of the
flywheel and flywheel ring gear and
check for damage.
Page 243 of 315

Mounting the flywheel ring gear Checking the flywheel
Checking the flywheel wear
· Heat the flywheel ring gear（1）to

200-230 ℃.
· Fit the flywheel ring gear（1）so that · Clean the flywheel.
the chamfer（3）on the teeth is facing · Check the flywheel for cracks and
away from the flywheel（2）. fit a new flywheel if necessary.
· Fit the flywheel ring gear（1）to line · Check the friction surface（1）for
up the holes in the flywheel ring burns and traces of running in and
gear with the flywheel（2）. fit a new flywheel if necessary.
· Adjust the flywheel ring gear if · Check the teeth（2）on the flywheel
necessary. ring gear for wear and fit a new
flywheel if necessary.
Checking the dimension from the
flywheel wall to the friction surface
(only for flywheel with gasket)
· Check the dimension from the

flywheel wall to the friction surface,
using the Depth gauge
(electronic)[284](2) and the
Additional bridge[285]（3）.
The permitted dimension from the
flywheel wall to the friction surface
after working is max. 9.5mm.
Fit a new flywheel if the dimension
is out of tolerance .
Page 244 of 315
Installing the flywheel Fitting the flywheel
Pressing in the clutch pilot bearing
CAUTION
components
· Use lifting gear to install the
flywheel.
· Line up the flywheel（1）with the
crankshaft gear alignment pin.
· Fit the flywheel over the Guide
pin[280]（2）.
Unscrewing the Guide pin
· Assemble the Special tool,

consisting of the Plug-on
handle[295]（1）, the Thrust disc[296]
（2）and the Impact punch [297]
（3）.
· Use the special tool to press the
clutch pilot bearing（4）into the
flywheel（5）until the stop is reached.
· Screw in the new flywheel

· mounting bolts.
· Unscrew the Guide pin[280]（1）and
（2）.
Page 245 of 315

Screwing in the flywheel mounting
bolts
· Screw in the remaining mounting

bolts（1）.
Tightening the mounting bolts
Note
Note the ratio: Torque
multiplier i=1:3.5.
· Tighten the mounting bolts to initial
torque100+10Nm, using the special
tool (1).
· Tighten the mounting bolts to final
torque 180°+10°, using the special
tool (1).
Page 246 of 315

3. Pistons and conrods
3.1 Additional jobs
- Removing and installing the suction pipe, see P73
- Removing and installing the injectors and rail, see P156
Fig.2-41 Pistons and conrods

(1) Piston (6) Circlip
(2) Conrod (7) Piston rings
(3) Conrod bolt (8) Conrod bearing shell (lower)
(4) Conrod bearing cap (9) Conrod bearing shell (upper)
(5) Piston pin
Page 247 of 315

3.2 Technical data
Initial torque 100±10 Nm
Conrod bolt（3） M12×64-11.9
Final torque 90°+10°
Conrod axial play 0.130-0.330mm
Conrod radial play 0.044-0.106mm
Piston pin bush inside diameter Ø 52.060 - 52.065 mm
Conrod width 43.170-43.270mm
Bearing shell holes in conrod Ø 95.000 - 95.022 mm
Weight difference per set of Max. 50g
conrods in an engine
Spread of conrod bearing shells Max. 2.0mm
（8）and（9）
Conrod bearing shells（8）and（9） Ø 90.060 - 90.102 mm
( normal size )
Wall thickness of conrod bearing 2.468+0.010mm
shells（8）and（9）( normal size )
Ring gap（keystone ring） 0.40-0.55mm
Ring gap（taper-faced ring） 0.9-1.1mm
Axial play 0.08-0.13mm
Ring gap（oil ring） 0.25-0.55mm
（double-beveled ring）
Axial play 0.03-0.07mm
Piston weight difference per set in Max. 60g
one engine
Piston pin Ø 51.992 - 52.000 mm
Piston standout 0.0235-0.3435mm
（crankcase-piston）

WARNING
Crack surfaces are sensitive. The principle involved can cause chipping.
· Exchange the conrod if the crack surfaces are damaged.
· Protect crack surfaces against damage caused by hard and sharp objects.
· To clean the crack surfaces on the conrods, always rinse them in clean
cleaning agent.
· Blow-dry the crack surfaces after cleaning with the compressed air.
· Do not allow rinsed-out particles to enter the engine.
WARNING
Note
Page 248 of 315
The piston diameter is always measured perpendicular to piston pin bore.
3.4 Special tools

[308] Piston ring pliers
· Removing and
installing piston rings JD6805-0034 83.09144-6090
[309] Feeler gauge

· Checking the piston ring
JD6805-0146 08.75310-0808
axial play and ring gap
[310] Dial gauge

· Checking the conrod
bearing shells and piston
bush inside diameter
· Checking the piston
standout in conjunction
with: JD6805-0024 08.71000-3217
· Checking the conrod axial
and radial play in
conjunction with:
· Locating pin [313]
standout JD6805-0147 80.99605-0172

and radial play JD6805-0025 08.71082-0005
[313] Locating pin

JD6805-0026 80.99605-0197
and radial play
Page 249 of 315

JD6805-0032 08.71195-9003
insertion depth
[315] Piston ring compressor

· Installing the piston
JD6805-0148 80.99613-0038
[316] Setting tool

· Aligning conrod
JD6805-0149 80.99622-0052
bearing shells
Page 250 of 315

Checking the conrods
Checking the conrod axial play Checking the conrod radial play
· Mount the Dial gauge stand[312] · Mount the Dial gauge stand[312]
（2）with the Dial gauge[310]（1）（1）with the Dial gauge[310]（2）
and the Locating pin[313] on the and the Locating pin[313] on the
crankcase（3）. crankcase（3）
· Mount the Locating pin[313] on the · Mount the Locating pin[313] on the
conrod（4）with a preload. conrod（4）with a preload.
· Push the conrod (4) horizontally · Press the conrod (4) vertically into
into the end position towards the the end position.
flywheel housing. · Zero the Dial gauge[310]（2）.
· Zero the Dial gauge [310]（1）. · Pull the conrod (4) into the end
· Pull the conrod (4) into the end position towards the Dial gauge
position towards the Dial gauge [310] (2) and read off the difference.
[310] (1) and read off the difference. · Repeat the check procedure for the
· Repeat the check procedure for the rest conrods.
rest conrods. The permitted conrod radial play is
The permitted conrod axial play is 0.044-0.106mm。
0.130-0.330mm.
Check the conrod bearing shell and
Check the conrod width (see P255) journal if the radial play is out of
if the axial paly is out of tolerance. tolerance.
Check the conrod bearing shell
inside diameter, see P255.
Check the conrod journal outside
diameter, see page 266.
Page 251 of 315

Removing pistons and conrods (4).
Removing the conrod bearing cap · Mark the conrod (2) and conrod
bearing shell（3）to indicate their
installation position and assignment.
· Remove the conrod bearing shell (3)
from the conrod (2).
WARNING
Crack surfaces are
sensitive. The principle
involved can cause
chipping.
·Exchange the conrod if
the crack surfaces are
damaged.
· Protect crack surfaces
against damage caused by
hard and sharp objects.
· Mark the conrod bearing cap（3）and
conrod bearing shell（2）to indicate
correct assignment and installation
position.
· Unscrew the conrod bearing bolt(4).
· Remove the conrod bearing cap (3)
with the bearing shell (2).
· Push the piston and conrod（1）out in
the direction of the cylinder head.
Removing the piston
· Extract the piston (1) with the

conrod (2)from the cylinder liner
Page 252 of 315

Removing and checking the piston Checking the piston ring axial play
Removing the piston pin
Note
An axial play cannot be
· Mark the relative positions of the measured on the keystone ring.
piston（1）, piston pin（5）and conrod · Measure the axial play between the
（3）. piston rings (2) and (3) and the
· Detach the circlips（2）and（4）. piston (4) using the Feeler gauge
· Press the piston pin（5）out of the [309] (1).
piston（1）. · The permissible axial play（3）on the
· Remove the piston（1）from the double-beveled ring is
conrod（3）. 0.03-0.07mm.
Checking the piston pin diameter The permitted taper-face ring（2）
axial play is 0.08-0.13mm.
If the axial plays are out of
tolerance, fit a new piston with
piston rings（2）and（3）and keystone
ring.
Removing the piston rings
· Check the diameter of the piston pin

（2）using a micrometer（1）.
The permitted diameter of the piston
pin (2) is Ø 51.992 - 52.000 mm.
If the diameter is out of tolerance,
fit a new piston with piston pin (2). · Set the piston ring pliers[308]（1）
to the piston diameter.
· Detach the piston rings（2）from the
piston(3) using the Piston ring
pliers[308]（1）.
· Carefully clean the piston ring
grooves.
Page 253 of 315
Checking the piston ring gap Checking the conrods and conrod
bearings
Correctly matching the conrod and
conrod bearing cap
Note
The ring gap is only allowed to be
checked if the cylinder liner has
the correct inside diameter, WARNING
otherwise a false ring gap reading Component damage due to
would be obtained. incorrectly matching the
· Check the cylinder liner inside conrod and conrod bearing
diameter. (Removing and cap.
installing the cylinder liner, see Make sure to correctly match the
P228 ) conrod and conrod bearing cap.
· Insert the piston ring（3）evenly deep · Check the match numbers（1）and
into the cylinder liner（1）. （2）of the conrod（3）and conrod
· Check the even insertion depth of bearing cap（4）.
the piston ring（3）, using the
Depth gauge[314].
· Repeat the inspection steps for
different insertion depths.
· Check the ring gap, using the
Feeler gauge [309]（2）.
The permitted keystone ring gap is
0.40-0.55mm.
The permitted taper-face ring gap is
0.9-1.1mm.
The permitted double-bevelled ring
gap is 0.25-0.55mm.
If the ring gaps are out of tolerance,
fit new piston rings.
Page 254 of 315

Checking the conrod bearing inside （3）and the Dial gauge [310]（2）.
diameter The permitted inside diameter of the
piston pin bushing is Ø 52.060 -
52.065 mm.
If the inside diameter is out of
tolerance, fit a new conrod.
Checking the conrod width
· Insert the upper conrod bearing

shell into the conrod（4）as marked.
· Insert the lower conrod bearing
shell into the conrod bearing cap
（1）.
· Screw in the conrod bolts and
tighten them to initial torque
100Nm.
· Check the conrod bearing inside
diameter with the Dial gauge [310]
· Check the conrod（1）width.
（2）and internal caliper（3）.
· Remove the conrod bearing cap.
The permitted inside diameter of the
The permitted conrod width A is
conrod bearing is Ø 90.060 - 90.102
43.170-43.270mm。
mm.
If the conrod width A is out of
tolerance, fit a new conrod（1）.
tolerance, fit new conrod bearing
shells.
Checking the piston pin bushing
· Check the piston pin bushing inside

diameter with the internal caliper
Page 255 of 315
Installing pistons and conrods If the circlips（2）and（4）have not
Installing the piston rings engaged correctly, remove and
re-attach the circlips（2）and（4）,
ensuring that they are seated
correctly.
Installation instruction of the conrod
bearing shells
· Set the Piston ring pliers [308]（1）

to the piston diameter.
· Insert the piston ring（2）into the
corresponding ring groove in the
piston （ 3 ） with the Piston ring
pliers[308]（1）, ensuring that the
TOP mark is facing the piston WARNING
crown. Crack surfaces are sensitive.
The principle involved can
Installing the piston pin
cause chipping.
· Exchange the conrod if
damaged.
hard and sharp objects
· Clean the mating surfaces of the
conrod bearing shell and the conrod
bearing cap.
· Insert the lower conrod bearing
· Attach a new circlip （2） in the
shell into the conrod bearing cap so
groove in the piston.
that the flange（1）is embedded in
· Fit the piston（1）over the conrod
the recess（4）.
（3）as marked.
· Thinly apply clean engine oil on the
shell into the conrod so that the
piston pin（5）.
flange（2）is embedded in the recess
· Push the piston pin（5）through the
（3）.
piston（1）and the conrod（3）as
· Align the conrod bearing shells with
marked until the stop is reached.
the conrod bearing cap using the
· Attach a new circlip （ 4）in the
Setting tool [316].
groove in the piston.
· Check that the circlips（2）and（4）
are seated correctly.
Page 256 of 315

Piston installation with piston ring Checking the conrod assignment
compressor
WARNING
Crack surfaces are
sensitive. The principle
involved can cause
Note chipping.
There is an installation arrow ·Exchange the conrod if
on the piston surface. This the crack surfaces are
must point towards the water damaged.
pump during installation. · Protect crack surfaces
· Move the crankshaft for the cylinder against damage caused by
concerned to TDC. hard and sharp objects.
· Line up the gaps in the piston rings · Check the alignment of the conrod
at 120°offset to one another. bearing shell（2）in the conrod（1）
· Thinly apply clean engine oil on the and, if necessary, adjust with the
upper conrod bearing shell. Setting tool [316]（3）.
Mounting the conrod bearing cap
shell into the conrod.
piston（1）and cylinder liner（3）.
· Place the Piston ring compressor
[315]（2） onto the piston (1) and
clamp .
· Push the piston (1) with the conrod
into the cylinder liner (3) until the
piston has been pushed out of the
Piston ring compressor [315] (2).
WARNING
· Push in the piston (1) until the
Crack surfaces are sensitive.
conrod with conrod bearing shell is
lying on the crankshaft.
cause chipping.
· Exchange the conrod if
damaged.
Page 257 of 315

hard and sharp objects the Dial gauge stand [311]（1, and
· Check the alignment of the lower position the Locating pin [313]（3）
conrod bearing shell (2) and, if on the crankcase（5）with a preload.
necessary, adjust with the Setting · Zero the Dial gauge [310]（4）.
tool [316]（3） · Mount the Dial gauge[310]（4）with
· Thinly apply clean engine oil on the the Dial gauge stand [311]（1）and
lower conrod bearing shell（2）. the Locating pin[313]（3）on the
· Position the conrod bearing cap（3） piston（2）and read off the difference
on the conrod（1）as marked. （piston standout）.
· Screw in the new conrod bearing The permitted piston standout is
bolts（4）and tighten to initial torque 0.0235-0.3435mm.
100±10Nm.
· Tighten the conrod bearing bolts（4）
to final torque 90°+10°.
Checking the conrod clearance
· Check the conrod clearance by

moving the conrod （ 1 ） in the
lengthwise direction of the engine.
If the conrod（1）can not move freely,
check if the conrod and conrod
bearing cap match correctly.
Check the conrod bearing shell. If
the shell is incorrect, fit a new one.
Checking the piston standout
· Move the piston（2）to TDC.

· Mount the Dial gauge[310]（4）with
Page 258 of 315
4. Crankshaft
4.1 Additional jobs
-Removing and installing the belt drive, see P59
- Removing and installing the injectors and rail, see P156
- Removing and installing the front drive gears, see P269
- Removing and installing the rear timing gears, see P141
- Removing and installing the pistons and conrods, see P247
Fig. 2-42 Crankshaft

(1) Flywheel (2) Cranshaft (3) Conrod (4) Crankshaft bearing cap (5) Piston
Page 259 of 315
4.2 Technical data
Initial torque 50Nm
Mounting bolt (4), crankshaft Torque (2nd ) 150Nm
M18×160.5
bearing cap Torque (3rd) 300（0/30）Nm
Final torque 90°+10°
Crankshaft axial play（2） 0.200-0.401mm
Crankshaft bearing journal, 99.975-99.995mm
centering，crankshaft front gear
Crankshaft bearing journal, Ø 103.980 - 104.000 mm
normal size
Crankshaft bearing shell, normal Ø 104.044 - 104.090 mm
size
Wall thickness, 3.466+0.012mm
crankshaft bearing shell , normal
size
Crankshaft bearing shell spread Max. 1.2mm
Conrod journal, normal size Ø 89.980 - 90.000 mm
Wall thickness, thrust washer, 3.350-3.400mm
normal size

WARNING
Crack surfaces are sensitive. The principle involved can cause chipping.
· Exchange the conrod if the crack surfaces are damaged.
· Protect crack surfaces against damage caused by hard and sharp objects.
· To clean the crack surfaces on the conrods, always rinse them in clean
cleaning agent.
· Blow-dry the crack surfaces after cleaning with the compressed air.
· Do not allow rinsed-out particles to enter the engine.
WARNING
connections.
wrench.
Page 260 of 315

4.4 Special tools
[317] Dial gauge
· Checking the
crankshaft bearing
inside diameter
· Checking the
crankshaft axial play JD6805-0024 08.71000-3217
and radial play in
conjunction with:
· Dial gauge stand
[318]
· Checking the
crankshaft axial play JD6805-0025 08.71082-0005
and radial play
[319] Locating pin

· Checking the
JD6805-0026 80.99605-0197
crankshaft axial play
and radial play
[320] Torque multiplier i=1:3.5
· Undoing and
tightening the
crankshaft bearing
cap mounting bolts
· Support [321]
· Torque angle gauge
[322] JD6805-0084 80.99619-0007
· Stop pin [323]
· Washer [324]
· Pan head screw
[325]
· Connecting pin [326]
· Rubber ring
42mm[327]
· Socket, size 27[328]
[321] Support
· Undoing and
JD6805-0085 80.99606-0551
tightening the
crankshaft bearing
Page 261 of 315
cap mounting bolts
[322] Torque angle gauge
· Undoing and
tightening the JD6805-0086 80.99607-0172
crankshaft bearing
cap mounting bolts
[323] Stop pin
· Undoing and
tightening the
JD6805-0150 80.99606-0584
crankshaft bearing
cap mounting bolts
[324] Washer
· Undoing and
crankshaft bearing
cap mounting bolts
· Undoing and
crankshaft bearing
cap mounting bolts
· Undoing and
crankshaft bearing
cap mounting bolts
[327] Rubber ring, 42mm
· Undoing and
tightening the
JD6805-0090 08.06142-9006
crankshaft bearing
cap mounting bolts

· Undoing and
crankshaft bearing
cap mounting bolts
[329] Setting tool
· Aligning the
JD6805-0149 80.99622-0052
crankshaft bearing
shells
Page 262 of 315

Checking the crankshaft
Checking the crankshaft axial play
· Mount the Dial gauge stand[318]

（3）with the Dial gauge [317]（2）
and position the Locating pin[319]
on the crankshaft（1）with a preload.
· Push the crankshaft (1) horizontally
into the end position towards the
flywheel housing
· Zero the Dial gauge[317]（2）
· Pull the crankshaft (1) into the end
position towards the Dial gauge
[317] (2) and read off the difference.
The permitted axial play on the
crankcase is 0.200-0.401mm.
install new thrust washers.
Install correct thrust washers. The
thrust washer thickness is
3.350-3.400mm.
Page 263 of 315

Removing the crankshaft special tool（1）
Assembling the special tool
· Insert the Torque multiplier

i=1:3.5[320]（1）into the Support
[321]（9）.
· Mount the Stop pin [323]（6）with
Pan head screw [325] (8) and the
Washer [324]（7）on the Support[321]
（9）.
· Put the Torque angle gauge [322] (2)
on the Torque multiplier i=1:3.5
[320]（1）.
· Put the Socket, size 27[328]（3）on
the Torque multiplier i=1:3.5 [320]
（1）and screw with the Connecting
pin [326]（5）and the Rubber ring
42mm [327]（4）.
Undoing the bearing cap mounting
bolts
Undo the mounting bolts with the
Page 264 of 315

Removing the bearing cap thrust to indicate its installation position
washers and correct assignment and then
remove it.
· Repeat the procedure as described
for bearing shells 2, 3, 4, 5 and 7.
Removing the crankshaft
WARNING
·Protect crack surfaces against
damage caused by hard and
sharp objects.
· Mark the bearing cap（4）to indicate
its installation position and correct
CAUTION
assignment.
· Unscrew the mounting bolts（1）.
components
· Remove the bearing cap
with thrust washers（2）and
WARNING
（3）.
Component damage due to unsuitable
· Mark the crankshaft bearing shells
lifting gear
to indicate their installation position
· Remove the crankshaft with
and correct assignment and then
support.
remove them.
· Do not use steel cables or other
Removing the bearing cap sharp-edged tools to lift out the
crankshaft.
· Lift the crankshaft（3）out of the
crankcase（2）.
· Mark the crankshaft bearing shell (1)
to indicate their installation position
and correct assignment and then
remove it from the crankcase (2).
Removing the upper thrust washer
· Mark the bearing cap（2）to indicate

its installation position and correct
assignment.
· Remove the bearing cap（2）.
· Mark the crankshaft bearing shell (1)
Page 265 of 315

· Remove the thrust washer（2）and Checking the crankshaft and
（3）from the 6th bearing seat（1）. crankshaft bearing
Checking the crankshaft bearing
inside diameter
· Insert the upper and lower

crankshaft bearing shell into the
bearing seat as marked.
· Fit the bearing cap（3）as marked.
· Screw in the mounting bolts for the
bearing cap（3）and tighten them to
initial torque 50Nm.
· Check the crankshaft bearing with
the internal caliper（2）and the Dial
gauge [317]（1）.
· Repeat the check several times at
120°offset.
· Remove the bearing cap (3) again
after the check.
The permitted crankshaft bearing
inside diameter, see P259 for
Technical data.
tolerance, fit new crankshaft bearing
shells.
Page 266 of 315

Checking the outside diameter of the Installing the crankshaft
conrod bearing journal Installing the crankshaft
· Clean the conrod bearing journal WARNING

（1）. Component damage due to
· Check the conrod bearing journal unsuitable lifting gear
using a micrometer（2）. ·Do not use steel cables or
· Repeat the check several times at other sharp-edged tools to
120°offset. lift
out the crankshaft.
The outside diameter of the conrod
bearing journal, see P259 for
crankshaft bearing shell（1）.
Technical data.
· Insert the crankshaft bearing shell
If the outside diameter is out of （1）into the bearing seat as marked
tolerance, fit a new crankshaft.（1）. and align with the Setting tool
[329].
· Insert the crankshaft（3）into the
crankcase（2）.
Installing the upper thrust washer
Note
· Only use the upper and
lower thrust washers in the
same thickness.
· Decide the thrust washer（2）to be
used. See page 错误！未定义书签。
Page 267 of 315

for checking the crankshaft axial Recheck the crankshaft and crankshaft
play bearing shells, if necessary, fit a new
· Thinly apply clean engine oil on the crankshaft or crankshaft bearing shells.
thrust washer（2）.
· Insert the thrust washer（2）into the
6th bearing seat with the oil groove
facing the crankshaft（1）.
· Insert the thrust washer（2）into the
bearing seat by pressing lightly.
Installing the crankshaft bearing cap
axial washer

crankshaft bearing shell and thrust
washers（1）and（2）.
· Insert the crankshaft bearing shell
into the bearing cap（3）as marked
and align with the Setting tool
[329].
· Insert thrust washers（1）and（2）
into the bearing cap（3）with the oil
groove facing the crankshaft.
· Fit the bearing cap with thrust
washers（1）and（2）.
· Screw in the new mounting bolt（4）
and tighten to initial torque 50Nm.
· Tighten the mounting bolt（4）to the
2nd torque 150Nm.
· Check the crankshaft for ease of
movement.
If the crankshaft cannot be turned or
only turned with difficulty, remove the
crankshaft with the crankshaft bearing
shells.
Page 268 of 315

Mounting the crankshaft bearing tighten to initial torque 50Nm.
cap · Tighten the new mounting bolt（3）
to the second torque 150Nm.
Tightening the bearing cap
mounting bolt
WARNING
Crack surfaces are sensitive.
cause chipping.
·Exchange the conrod if
damaged. Note
· Protect crack surfaces Note the ratio: Torque
against damage caused by multiplier i=1:3.5
hard and sharp objects. · Tighten the mounting bolt to the
· Thinly apply clean engine oil on 3rd torque 315Nm using a special
the crankshaft bearing shell（1）. tool（1）
· Insert the crankshaft bearing shell · Tighten the mounting bolt to final
（1）into the bearing cap（2）as torque 90°using a Special tool
marked and align with the Setting （1）.
tool.
· Fit the bearing cap（2）.
· Apply thinly clean engine oil on
the head of the mounting bolt (3)
· Screw in the mounting bolt（3）and
Page 269 of 315

5. Front drive gears

5.1 Additional jobs
- Removing and installing the fan bracket, see P27
- Removing and installing the high-pressure pump/ pump drive, see P172
- Removing and installing the front crankshaft oil seal, see P214
Fig.2–35 Front engine gears

(1) Intermediate gear, high-pressure (4) Front crankshaft gear
pump drive (5) Oil pump
(2) Intermediate gear shaft
(3) Mounting bolt, intermediate gear
shaft
Page 270 of 315

5.2 Technical data
Mounting bolt, M12×50-10.9 110Nm
Backlash, 0.057-0.183mm
crankshaft gear--- high-pressure pump
drive intermediate gear
Axial play, 0.100-0.029mm
high-pressure pump drive intermediate
gear
Radial play, 0.060-0.109mm
gear
Height, 21.950-22.000mm
gear
Inside diameter, Ø 60.000 - 60.030 mm
gear
Outside diameter, Ø 59.921 - 59.940 mm
Height, 27.200-27.240mm

WARNING
connections.
wrench.
Note
The intermediate gear and the pin don’t have to be replaced in pairs, which
can be replaced individually depending on the wearing.
5.4 Special tools
[228] Guide pin JD6805-0117 80.99617-0020
· Removing and
installing the front
crankshaft gear
Page 271 of 315

[229] Dial gauge JD6805-0024 08.71000-3217
· Checking the gear
backlash in
conjunction with:
· Checking the
intermediate gear
axial and radial play
Backlash
· Checking the
intermediate gear
[231] Locating pin JD6805-0026 80.99605-0197
Backlash
· Checking the
intermediate gear
[232] Depth gauge JD6805-0032 08.71195-9003
· Checking the
intermediate shaft
height
Page 272 of 315

Checking the front drive gears Checking the axial play of the
Fixing the crankshaft gear high-pressure pump intermediate
gear

（3）.
· Screw in and tighten the mounting · Mount the Dial gauge stand[230]
bolt（2）. （2）with the Dial gauge[229]（3）
and the Locating pin[231] on the
Checking the backlash of the
intermediate gear（1）with a preload.
crankshaft gear and the high-pressure
· Push the intermediate gear (1) to the
pump intermediate gear
bottom.
· Zero the Dial gauge [229] (3).
· Pull the intermediate gear (1) to the
end and read off the difference.
The permitted intermediate gear (1)
axial play is 0.100-0.290mm.
If the axial play is out of difference,
check the height of the intermediate
gear (1) and its shaft.
（4）with the Dial gauge[229]（3） Check the height of the intermediate
and the Locating pin[231] on the gear (1), see P274
intermediate gear（1）with a preload. Check the height of the intermediate
· Check the backlash of the gear shaft, see P147.
crankshaft gear（2）and intermediate
gear（1）.
The permitted backlash is
0.057-0.183mm.
If the backlash is out of tolerance,
fit a new crankshaft gear (2) and
intermediate gear (1).
Page 273 of 315

Checking the radial play of the Unscrewing the mounting bolt
high-pressure pump intermediate
gear

（1）with the Dial gauge[229]（2）
and the Locating pin[231] on the
intermediate gear（3）with a preload.
· Push the intermediate gear (3) to the
bottom.
· Zero the Dial gauge [229] (2).
· Pull the intermediate gear (3) to the
end towards the Dial gauge [235] (2)
and read off the difference.
The permitted intermediate gear (3) · Pull the crankshaft gear（2）off the
radial play is 0.060-0.109mm. crankshaft..
If the radial play is out of difference,
（4）.
check the intermediate gear (3) and
· Clean the contact surface of the
its shaft.
crankshaft gear (2) and crankshaft
Check the inside diameter of the （1）.
intermediate gear (3), see P274.
Check the outside diameter of the
intermediate gear shaft, see P275.
Page 274 of 315

Removing the intermediate gear of the
high-pressure pump Measuring the inside diameter of the
Removing the intermediate gear intermediate gear
· Unscrew the mounting bolt（2）. · Clean the intermediate gear（3）.

· Pull off the intermediate gear（1） · Measure the inside diameter of the
together with the shaft（3）. intermediate gear (3) with the Dial
gauge[229] （ 2 ） and the internal
Measuring the height of the
caliper（1）.
intermediate gear
The permitted inside diameter of the
intermediate (3) is Ø 60.000 -
60.030 mm.
tolerance, fit a new intermediate
gear.
Measuring the height of the
· Clean the intermediate gear（1）
· Measure the height A of the
intermediate gear.
The permitted height A is
21.950-22.000mm.
If the height A is out of tolerance,
fit a new intermediate gear.
· Clean the intermediate gear shaft

(1).
· Measure the height of the
intermediate gear shaft with the
Depth gauge [232]（2）.
The permitted height of the
Page 275 of 315
intermediate gear shaft (1) is If the outside diameter is out of
27.200-27.240mm. tolerance, fit a new intermediate
gear shaft (1).
Fitting the front drive gears
Measuring the outside diameter of the Fitting the intermediate gear

· Measure the outside diameter of the intermediate gear shaft（3）.
intermediate gear shaft（1）with a · Insert the intermediate gear shaft（3）
micrometer（2）. into the intermediate gear（1）
· Fit the intermediate gear (1) and its
The permitted outside diameter of
shaft (3) on the crankcase.
the intermediate gear shaft (1) is Ø
· Screw in the new mounting bolt（2）.
59.921 - 59.940 mm.
Fitting the crankshaft gear
Tightening the intermediate gear shaft
mounting bolt

（4）.
· Place the crankshaft gear（2）on the
Tighten the mounting bolt（1）to
crankshaft（1）and make sure that it
110Nm.
reaches the bottom.
（4）.
Page 276 of 315

Chapter III Malfunction and Troubleshooting
Section 1. Electrical malfunction
1.1 Diagnosis device and EDC communication connection failure
Possible causes Troubleshooting
1.Vehicle key switch at “OFF” Switch Vehicle key to “ON”
2.Low or no voltage at the engine harness Check the engine harness connection
connection battery voltage
3.No voltage in EDC of ECU Check ECU connection voltage
4. Engine harness fuse burnt Replace engine ECU fuse
5.Data interface connector fault Check data interface line voltage and
polarity
1.2 Generator stops
1. Connection broken or short circuit, Check and fix the generator and Ammeter
connector loose connection.
2. Rotor and stator coil circuit broken, short or
Fix or replace the assembly
earthed
3. Rectifier damaged Replace the assembly
4. Low regulating voltage Fix
5. Regulator contact melt Fix or replace the assembly
1.3 Insufficient power generating
1. Connection broken or short circuit,
Fix
connector loose
2. Rotor and stator coil circuit partly broken,
Fix or replace the assembly
short or earthed
3. Generator belt loose Check and adjust the belt tension
4. Generator rectifier damaged, brush
Fix
contacting poor
5. Low regulating voltage at regulator Adjust
6. Regulator magnet coil or electrical
Fix or replace
resistance connection broken
7. Low battery electrolyte, or old battery Fill in electrolyte, or replace the battery
1.4 Charging current unstable
1. Rotor or stator coil circuit broken or short
Fix or replace
soon
2. Brush contact poor Fix
3. Terminal loose, contact poor Fix
4. Voltage regulator damaged Fix
Page 277 of 315

5. Improper voltage regulating Check and adjust
1.5 Generator overcharging
1. Battery inside short circuit Fix or replace
2. Regulator over voltage Fix and adjust
3. Regulator earthing poor Fix
4. Regulator contact fault, polluted, voltage
coil or electrical resistance connection Fix or replace
broken
Page 278 of 315

Section 2. Engine difficult to start

2.1 Engine difficult to start (starter does not engage or weak generator)
1. Insufficient battery charge Charge or replace battery
2. Poor contact at battery connection Clear the line, tighten the terminal
3. Poor brush contact Clean the brush or replace it
Check and fix the generator, replace the
4. Starter failure
assembly
5. Switch poor contact Check and fix the switch
Adjust clutch work torque or replace the
6. Friction clutch skid
assembly
7. Excessive engine oil viscosity Change for recommended oil
8. Electrical system failure Please consult the authorized service station
2.2 Engine fails to start (starter normally engages )
1. Electronic control unit EDC
Plug in Electronic control unit EDC connector
connector not plugged in
2. No voltage on electronic control unit
Do diagnostic lamp test
EDC
3. Fault code shown Check the fault code table and find a solution
4. Fuel lines such as fuel pump fuel inlet
Check for dirt removal and fuel cleanliness
filter or hose are blocked
5. Empty fuel tank Fill in fuel
Dismantle filter housing, remove internal dirt
6. Fuel filter clogging
and moisture, replace filter element if necessary
7. Air in the fuel system Drain air and check sealing of joint and fix it
8. Incorrect valve timing Check and adjust
9. Water in the fuel tank Drain water
10. Air intake blockage (air filter element Check air filter and suck line, clear or replace
blockage) filter element
11. Fuel supply pump defective Replace fuel supply pump
12. Injector defective Check fuel injector atomization, fix it
13. High-pressure pipe damage and fuel
Fix and replace it
leakage
14. Insufficient cylinder compression Check valve seal, cylinder gasket seal, and
pressure piston ring wear, repair or replace them
15. Too low temperature In addition of start-up auxiliary
2.3 Engine shutdown again after a second

1. Fuel filter clogging Dismantle filter housing, remove internal dirt
and moisture, replace filter element if necessary
2. Air in fuel system Check fuel pipe and connection seal, bleed
screw tightening, and drain the air storage
Page 279 of 315
3. Poor fuel quality and excessive water Clean filter housing, replace fuel
content
4. Too low idle speed Re-calibrating idle setting of control system
2.4 Unexpected stall or accidental shutdown at deceleration

1. Fault code Check the fault code table and find a solution
2. Electronic control unit EDC power Check battery power lines and control system
supply voltage is too low fuses
Check key switch circuit for loose connection or

3. Failure of key switch or other line
short circuit
Page 280 of 315

Section 3.Insufficient power
3.1 Engine surge at idle speed

1. Fault code shown Check the fault table to find a solution
2. Engine temperature too low Heat the engine to the operating temperature for
2 to 3 minutes
3. Overload at idle speed Reduce idle load
4. Accelerator pedal loose Check accelerator pedal, fix or replace
5. Intercooler or connection Check intercooler, connecting hose or
leakage connection
6. Intake system leakage Check intake system connection, connecting
hose
7. Incorrect valve timing Adjusting valve clearance
3.2 Engine idling rough

8. Engine temperature too low Heat the engine to the operating temperature for
2 to 3 minutes
2. Overload at idle speed Reduce idle load
3. Accelerator pedal loose Check accelerator pedal, fix or replace
4. Incorrect valve timing Check timing, adjusting the valve clearance
5. Mechanical failure Check if crankshaft, pistons, camshafts and
other mechanical parts are damaged
3.3 Poor acceleration performance

2. Accelerator pedal movement
Check and fix accelerator pedal
blocked
Check intercooler, connecting hose or connection
3. Air intake system leakage
sealing, fasten connection, replace hose
4. Intake blocked (air filter Check air filter, intake line, clean or replace filter
blocked ) element
Check if exhaust line is blocked, adjust or fix if
5. Excessive exhaust back pressure
necessary
6. Electronic control unit EDC
Re-calibration
calibration error
7. Intake pressure sensor failure Check or replace
8. Turbocharger bleed valve always
Check and fix
opens
9. Incorrect valve timing Checking valve timing and valve clearance
3.4 Engine working rough or lack of fire

Page 281 of 315
2. Engine cooling system
Check and fix
temperature too low
3. Incorrect valve timing Adjusting the valve clearance
4. Camshaft timing error Check gear meshing and camshaft gear position
5. Camshaft or rocker roller

Check camshaft and roller
damaged
3.5 Insufficient engine power

2. The accelerator pedal not fully

Check and fix
stepped
3. Intake blocked (air filter Check air filter, intake line, clean or replace filter
blocked ) element
4. Excessive exhaust back pressure Check if exhaust line is blocked, and fix
5. Insufficient pressure on boosting

Check, make sure no leakage at pipe connection
system
6. Turbocharger failure Replace assembly

6.1 Booster, too much dirt in turbine
Clean or replace
passage
6.2 Floating bearings failure Replace
6.3 Turbine, booster backlash deposit
Clean
carbon and oil dirt
Check exhaust bleed valve, air pressure reducer
6.4 Turbocharger waste gate always
outlet pressure, and check waste gate magnetic valve
open
using diagnosis device
6.5 Oil seal failure Replace
7. Intercooler damaged, leakage Replace or fix
Check if fuel line and connection are well sealed,

8. Fuel line leakage or blocked filter pollution and fuel line, fix or clean , replace
filter element
9. Air in fuel system Bleed air to ensure fuel line sealing

Page 282 of 315
Clean fuel tank, filter housing and fuel pipe, replace
10. Poor fuel quality
for qualified diesel
Dismantle filter housing, remove internal dirt and

11. Fuel filter clogging
moisture, replace filter element if necessary

13. Oil sump too high oil level Check oil dipstick, drain excessive oil
14. Cylinder gasket leakage Replace the damaged cylinder gasket
15. Piston ring wear fracture, bearing
Replace wearing parts, or engine overhaul
clearance oversize
16. Cylinder liner or piston wear or
Overhaul
scoring
17. System low voltage or abnormal Check ECU fuse and relay voltage
Check intake pressure sensor using diagnosis device

18. Intake pressure sensor failure
or replace
19. Brake jamming Please consult the authorized service station
20. Shutdown brake tensioned Fully reverse shutdown brake control level
3.6 Engine decelerates too slow

2. Accelerator pedal movement blocked or

Check accelerator pedal and the line
failure in connection or line
3. Incorrect calibration of deceleration air Re-calibrate control system deceleration

shut-off device
3.7 Speed instability

1. Poor quality fuel Poor quality fuel Clean fuel system and replace fuel
Check fuel line and connection tightness, bleed
2. Air leakage in fuel suck line
air
3. Unstable atomization of oil nozzles Check and fix
Check and clean booster passage, remove dirt and
4. Turbocharger surges
clear waste gas passage
5. Turbocharger bearing damaged Replace
Page 283 of 315

3.8 Engine toque limits
1.Excessive pressure in low pressure fuel Check if fuel passage is blocked,
passage replace fuel filter element
2. Too high water temperature Check cooling system
3.Too low intake pressure or too much intake
Check intake line
resistance
4. Excessive exhaust resistance Check if exhaust system is blocked
5. Sensor short circuit Check electrical circuit
Page 284 of 315

Section 4. Fuel consumption high

Check air filter, intake line, clean or

1. Intake blocked (air filter blocked )
replace filter element
Check exhaust line, muffler, and brake

2. Excessive exhaust back pressure
valve
3. Fuel line leakage or blocked Check and fix
4. Poor quality fuel Replace for high quality fuel
5. Poor injector atomization Check, adjust or fix
7. Insufficient cylinder compression Check tightness in valve, piston ring and

pressure cylinder liner, cylinder gasket, fix
8. Excessive bearing shell gap Check and overhaul

9. Insufficient pressure in turbocharging Check to eliminate leakage in boosting
system system piping
10. Turbocharger bypass valve fails to
Check and fix
open
11. Turbocharger failure Fix or replace assembly
12. Intercooler damaged or leakage Fix or replace
13. Engine needs overhaul Timely overhaul
14. Insufficient tire inflation Adjust to required inflation
15. Clutch skids Check clutch pedal free play
Please consult the authorized service
16. Brake drags
station
17. Fault code shown See the fault code table to find a solution
Page 285 of 315

Section 5. Abnormal smoke

5.1 Exhaust black smoke
1. Intake blocked (air filter blocked)or Check air filter, intake line, clean or replace
excessive exhaust back pressure filter element
2. Poor quality fuel Clean or replace
3. Incorrect valve timing Adjust as per
4. Poor oil nozzle atomization Check, fix or replace
5. Insufficient pressure in turbocharging Check to eliminate leakage in boosting
system system piping
6. Turbocharger failure Fix or replace assembly
7. Intercooler damaged or air leakage Replace or fix
8. Too high idle speed Re-calibrate control unit idle speed setting
9. Quick step on accelerator pedal Avoid such action
Please consult the authorized service
10. Check if engine fault lamp is on
station
5.2 Exhaust white and blue smoke

1. Poor quality fuel ， excessive water
Replace fuel
content
Check thermostat working temperature,
2. coolant temperature too low
replace it if necessary
3. Incorrect valve timing Adjust as per
4. Poor oil nozzle atomization Check, fix or replace
5. Low compression pressure, incomplete Check piston ring, cylinder liner and gasket,
combustion and piston expansion fix
6. Piston ring and cylinder liner still unfit
Continue to fit-in
in
7. Piston ring gaps no offset Reset, and refit
8. Piston oil ring failure Replace
9. Piston and cylinder liner too big fitting
Fix and replace
play
10. Turbocharger seal ring wears Check and replace
11. Turbocharger thrust bearing wears Check and replace
12. Turbocharger oil return line blocked Clean or fix
Page 286 of 315

Section 6. Lubrication system malfunction
6.1 Turbocharger inlet and intake line oil enrichment
1. Turbocharger seal failure Fix or replace turbocharger
2. Oil sump oil level too high, too much oil
Check and drain oil as per
filling in
6.2 Oil pressure too low

1. Oil sump oil level too low or oil
Check oil level and leakage, fill in oil
shortage
2. Main oil passage regulating valve defect Check valve, clean and fix
3. Oil strainer, oil line, connection gasket Check for any casting loose in oil strainer,
blocked or broken pipe connection and oil passage , and fix
4. Oil brand inconformity with requirement Replace oil as per, select the proper oil brand
5. Oil pump inlet leakage Check oil pipe, connection, fix or replace
6. coolant temperature too high, oil
Check cooling system, correct
temperature too high
7. Oil filter excessive resistance Replace for new filter element
8. Oil cooler blocked Check and clear
9. Main oil passage blocked Check and clear
10. Bearing shell clearance oversize, or
Check and replace
bearing shell damaged
11. Components wear out, overhaul Check engine working hours, overhaul
6.3 Oil pressure too high

1. Oil gauge defect Check it
2. Excessive oil viscosity Replace for recommended oil
3. Relief valve failure Check/replace valve relief
Check cooling system, fan or thermostat, replace
4. Cooling system temperature too low
if necessary
6.4 Oil consumption too high
1. Improper oil Replace for recommended oil
2. Too high oil level Drain excessive oil
Check and fix installation surface and related
3. Check oil leakage
screw plug
4. Oil replacing skipped Replace oil at right interval
5. Oil filter blocked Replace filter element
6. Engine warm-up skipped Warm up engine properly
7. Crankcase over-pressure, press oil out Piston ring, cylinder liner wear, and piston ring
of oil separator gap no offset, check and fix
8. Turbocharger oil leakage into intake or Check air line connection for oil leakage, fix or
exhaust system replace turbocharger assembly
Page 287 of 315

Section 7. Water temperature high

1. Water tank water level too low Check for water leakage, fill in water
2. Water tank blocked Check water tank, clear or fix
3. Water pump belt loose Adjust tension as per
4. Water pump gasket damaged, water
Check, fix or replace
pump impeller wear
5. Thermostat failure Replace
Check water pipe, connection, gasket, replace
6. Water pipe damaged, air mixed
damaged parts
Check oil level and leakage, fix and fill in oil
shortage
Page 288 of 315

Section 8. Early wear- out

1. Air filter element disqualified or
Check and replace for qualified filter element
damaged
Check intake line, washer, connection
2. Intake system short circuit
bush,fix or replace
Check oil level and leakage, fix and fill in oil
shortage
4. Oil passage blocked Clear oil passage
5. Oil brand inconformity Change for oil as per
6. Piston ring fracture or wear out Replace damaged parts
7. Cylinder liner or piston ring wears out or Dismantle piston and cylinder liner, fix or
scoring replace
8. Oil filter element replacement untimely Replace as per
9. Component worn out, overhaul Check mileage
10. Crankshaft and driven parts main shaft
Check installation bracket , fix
non-coaxiality
11. Disqualified oil Replace for qualified oil
Page 289 of 315

Section 9. Abnormal noise

9.1 Unusual engine noise
1. Belt loose Adjust belt to specified tension
2. Short of engine oil Fill in engine oil
9.2 Too much noise

1. Poor quality fuel Replace fuel
2. coolant temperature too low Check thermostat, replace if necessary
3. Incorrect valve timing Check, fix and reset
4. Oil nozzle atomization poor Check and fix
Check for damage, connection screw, and
5. Damper damaged
replace damaged parts
6. Valve leakage or valve clearance
Dismantle valve, adjust valve clearance
incorrect setting
7. Gear play oversize or gear broken Check and replace damaged parts
8. Cylinder liner or piston wear out or
Check, fix or replace
scoring
9. Piston ring fracture or wear Check and replace damaged parts
10. Bearing shell too over wearing Check and replace bearing shell
11. Crankshaft thrust clearance oversize Replace thrust plate
12. Main bearing shell non-coaxiality Check and fix
13. Crankshaft driven parts main shaft
Check installation bracket bolt, fix
non-coaxiality
14. Components worn out, overhaul Check mileage, fix an overhaul
Clear booster passage, and exhaust passage
15. Turbocharger surges
deposit carbon
16. Turbocharger seal ring burnt Replace assembly
17. Turbocharger bearing damage, motion
Replace assembly
parts friction with fixed parts
18. Foreign matter in turbocharger turbine or
Replace assembly
boosting impeller
9.3 Excessive engine vibration
1. Engine speed unstable See engine speed unstable
2. Engine idle speed setting too low Re-calibrate control unit idle speed setting
3. Engine support base loose or damage Check engine support , replace if necessary
4. Fan or auxiliary defective Check and replace damping parts
5. Fan connecting flange defective Check/replace fan connecting flange
6. Damper damaged Check /replace damper
7. Crankshaft driven parts main shaft
Check mounting bracket bolt, fix
non-coaxiality
8. Components worn out, overhaul Check mileage, overhaul
Page 290 of 315
Appendix
MC11 Series Engine Maintenance Special Tool List

Sinotruk No. MAN No. Designation Description Drawing
Checking the cylinder

JD6805-0098 06.01499-0015 Hexagon bolt
liner standout
Removing and
Pan head
JD6805-0088 06.02191-0407 installing the cylinder
screw
head
Extracting and
Pan head
JD6805-0129 06.02191-2822 pressing in the
screw
crankshaft oil seal
Extracting and
JD6805-0127 06.11069-0064 Hexagon nut pressing in the
crankshaft oil seal
Hexagon Pressing in the

JD6805-0132 06.11222-0211
collar nut crankshaft oil seal
Hexagon
JD6805-0062 06.11226-8306 Extracting the injector
collar nut
Checking the cylinder

JD6805-0099 06.15013-0417 Washer
liner standout
Pressing in the
JD6805-0131 06.15230-0609 Washer
crankshaft oil seal
Connecting For crankshaft main

JD6805-0089 06.22729-0006
pin bearing
Page 291 of 315

Checking the leakage

JD6805-0072 06.56639-0017 Elastic lip seal of high-pressure
system
e
Removing and
JD6805-0057 08.06139-9025 Extension installing the
high-pressure line
JD6805-0064 08.06139-9029 Adapter Attaching the injector
JD6805-0065 08.06141-0700 Socket Attaching the injector
Removing and
installing
JD6805-0082 08.06141-9061 Socket M19
the fuel pre-filter
cover
JD6805-0090 08.06142-9006 Rubber ring For crankcase seal
Torque
JD6805-0037 08.06450-0002 Checking the torque
wrench
Torque
JD6805-0036 08.06450-0006 Checking the torque
wrench
Removing and
JD6805-0040 08.06460-0002 Handle mounting the
poly-V-belt pulley
Page 292 of 315

Torque Installing the injector

JD6805-0063 08.06510-9024
screwdriver cable
Removing and
JD6805-0078 08.06556-9300 Socket installing the oil filler
neck
Checking the
JD6805-0024 08.71000-3217 Dial gauge
clearance
Dial gauge Checking the

JD6805-0025 08.71082-0005
holder clearance
Additional
Checking the flywheel
JD6805-0142 08.71109-0000 bridge
installation
Depth gauge Checking the gear

JD6805-0032 08.71195-9003
shaft height
Holding Checking and setting

JD6805-0100 08.75300-0000
device the EVB clearance
Dismantling
JD6805-0028 08.99605-9003 Dismantling
device
Page 293 of 315

Three-armed Pulling off the water

JD6805-0029 08.99605-9014
puller pump shaft
JD6805-0043 09.81020-1000 Storage sleeve Storing the injectors
Testing the pressure

Ring
JD6805-0071 51.98103-0037 leakage in the
connection
Threaded
JD6805-0137 80.99601-0156 Pulling off the sleeve
spindle
Removal
JD6805-0136 80.99601-0182 Pulling off the sleeve
device
JD6805-0138 80.99601-0183 Pressure plate Pulling off the sleeve
Extracting Extracting the cylinder

JD6805-0170 80.99601-0217
plate liner
Removing Removing the

JD6805-0077 80.99601-6021
device high-pressure pump
Extractor
JD6805-0058 80.99601-6022 Extracting the injector
device
Page 294 of 315

Extractor Removing the rail

JD6805-0054 80.99602-0011
device connection
Impact Extracting the fuel

JD6805-0018 80.99602-0016
extractor pump slide ring seal
Extracting the fuel

JD6805-0019 80.99602-0137 Hook
pump slide ring seal
JD6805-0059 80.99602-0176 Plate Extracting the injector
JD6805-0060 80.99602-0193 Stud 66mm Extracting the injector
JD6805-0061 80.99602-0194 Stud 70mm Extracting the injector
Extracting Extracting the cylinder

JD6805-0169 80.99602-6035
tool liner
Page 295 of 315

Removing and
installing the
JD6805-0055 80.99603-0309 Socket
high-pressure line
M17
Removing and
Socket installing the
JD6805-0056 80.99603-0310
wrench high-pressure line
M19
Undoing and
JD6805-0144 80.99603-0311 Socket tightening the flywheel
mounting bolt
Removing the
JD6805-0151 80.99603-0312 Socket M27
installation tool
Unscrewing and
JD6805-0083 80.99603-0323 Box spanner mounting the
turbocharger nut
Removing and
JD6805-0081 80.99603-0325 Socket M36 installing the fuel filter
cover
Removing and
JD6805-0119 80.99603-0326 Socket M32 installing the fuel filter
cover
Unscrewing and
JD6805-0093 80.99603-0327 Socket tightening the cylinder
head bolt
Page 296 of 315

Removing and
Special
JD6805-0039 80.99603-6029 installing the
spanner
poly-V-belt pulley
Valve
adjusting Checking and setting
JD6805-0104 80.99603-6031
wrench, size the valve clearance
14
Valve
adjusting Checking and setting
JD6805-0105 80.99603-6032
wrench, size the valve clearance
21
Installing the
JD6805-0141 80.99604-0069 Impact punch
crankshaft oil seal
Installing the
JD6805-0140 80.99604-0286 Guide sleeve
crankshaft oil seal
Pressing in the fuel

JD6805-0022 80.99604-0289 Impact punch
pump slide ring seal
Press-out Knocking in the seal

JD6805-0115 80.99604-0301
plate cap
Dial gauge Checking the liner

JD6805-0147 80.99605-0172
stand standout
Page 297 of 315

Checking the gear

JD6805-0026 80.99605-0197 Locating pin backlash, axial and
radial play
Measuring Checking the liner

JD6805-0097 80.99605-0286
plate standout
Assembly Installing the valve

JD6805-0114 80.99606-0287
sleeve stem seal
Removing the
JD6805-0123 80.99606-0298 Crossmember
crankshaft oil seal
Threaded Removing the

JD6805-0128 80.99606-0299
spindle crankshaft oil seal
Check the compressed

JD6805-0168 80.99606-0399 Detector
air plug
Mounting the main

JD6805-0085 80.99606-0551 Support
bearing bolt
Undoing and
JD6805-0143 80.99606-0553 Stop pin tightening the flywheel
bolt
Page 298 of 315

Undoing and
tightening the
JD6805-0150 80.99606-0584 Stop pin
crankshaft main
bearing bolt
Opening the
quick-release
Release couplings in
JD6805-0080 80.99606-0597
handle conjunction with
JD6805-0079/80.9960
6-0625
JD6805-0066 80.99606-0609 Thrust piece Installing the injector
Screwing in and
JD6805-0041 80.99606-0610 Tool insert unscrewing the
high-pressure line plug
Screwing in and
JD6805-0042 80.99606-0611 Tool insert unscrewing the suction
pipe plug
Opening the
quick-release
couplings in
JD6805-0079 80.99606-0625 Release tool
conjunction with
JD6805-0080/80.9960
6-0597
Unscrewing and
JD6805-0087 80.99606-0641 Stop pin tightening the cylinder
head bolt
Removing the
JD6805-0130 80.99606-0658 Guide plate
crankshaft oil seal
Page 299 of 315

Press-in Pressing in the

JD6805-0126 80.99606-0659
sleeve crankshaft oil seal
Installing the
JD6805-0165 80.99606-0692 Locating pin
PriTarder
Removing and
JD6805-0164 80.99606-0693 Sleeve
installing the PriTarder
Removing and
JD6805-0166 80.99606-0697 Pin
installing the PriTarder
Removing the
JD6805-0162 80.99606-0698 Pin
PriTarder
Special Removing and

JD6805-0163 80.99606-0699
extractor installing the PriTarder
Removing the rear

JD6805-0125 80.99606-6013 Hook
crankshaft oil seal
Removing the
JD6805-0076 80.99606-6078 Impact tool
high-pressure pump
Page 300 of 315

Assembly Removing the valve

JD6805-0113 80.99606-6088
device stem seal
Removing and
Assembly
JD6805-0108 80.99606-6092 installing the valve
device
spring
Removing and
JD6805-0109 80.99606-6094 Extension installing the valve
spring
Fixing air compressor

JD6805-0033 80.99606-6118 Locator
angle device
Torque angle Checking the bolt

JD6805-0086 80.99607-0172
gauge angle
Feeler gauge Checking the valve

JD6805-0101 80.99607-0177
0.5mm clearance
Feeler gauge Checking the EVB

JD6805-0102 80.99607-0178
0.6mm clearance
Page 301 of 315

Feeler gauge Checking the valve

JD6805-0103 80.99607-0179
0.8mm clearance
Pressure loss Checking the pressure

JD6805-0067 80.99607-6027
detector loss
Undoing and
JD6805-0091 80.99609-0033 Washer tightening the main
bearing bolt
Removing the
JD6805-0124 80.99609-0038 Pressure plate
crankshaft oil seal
Undoing and
JD6805-0092 80.99612-0024 Socket tightening the cylinder
head bolt
Piston
JD6805-0035 80.99613-0035 installation Installing the piston
clamp
Piston ring
JD6805-0148 80.99613-0038 Installing the piston
compressor
Removing and
JD6805-0107 80.99613-0042 Adapter installing the valve
spring
Page 302 of 315

Removing and
JD6805-0110 80.99613-0052 Holder installing the valve
spring
Removing and
JD6805-0111 80.99613-0053 Holder installing the valve
spring
Removing and
Valve-spring
JD6805-0106 80.99613-6000 installing the valve
compressor
spring
Unscrew the hydraulic

JD6805-0167 80.99615-0036 Threaded bolt
retarder bolt
Removing and
JD6805-0154 80.99617-0013 Punch pin
installing the bearing
Pressing Pressing in the seat

JD6805-0139 80.99617-0017
sleeve ring
Installing the
JD6805-0117 80.99617-0020 Guide pin crankshaft gear and
flywheel
Page 303 of 315

Installer Pressing out the

JD6805-0030 80.99617-0029
sleeve bearing
Pressing in the clutch

JD6805-0021 80.99617-0144 Thrust disc
pilot bearing
Plug-on Pressing in the slide

JD6805-0020 80.99617-0187
handle ring seal
Pressing in the seal

JD6805-0031 80.99617-0191 Installer
ring
Centering Installing the timing

JD6805-0118 80.99617-0209
device gear
Undoing and
Torque
JD6805-0084 80.99619-0007 tightening the bearing
multiplier
cap mounting bolt
Checking the pressure

JD6805-0068 80.99620-0033 Adapter leakage in the
Aligning the
JD6805-0149 80.99622-0052 Setting tool crankshaft bearing
shells
Auxiliary pump flange

JD6805-0153 80.99622-6002 Support
bar
Page 304 of 315

Removing and
Hose clamp
installing jubilee chips
JD6805-0028 08.99605-9003 pliers for
of the air compressor
jubilee chips
suction pipe
Engine
JD6805-0023 80.99626-6008 Cranking the engine
barring gear
JD6805-0038 80.99627-0001 Gear ratchet Cranking the engine
Removing and
JD6805-0096 80.99629-0040 Crane hook installing the cylinder
head
Removing and
JD6805-0094 80.99629-6008 Crossmember installing the cylinder
head
Removing and
JD6805-0095 80.99629-6009 Hook chain installing the cylinder
head
Connecting
JD6805-0155 80.99632-0012 Installing the bearing
device
Magnetic Removing the valve

JD6805-0112 80.99639-0009
pick-up tool cotters
Page 305 of 315

Pressing in crankshaft
JD6805-0133 81.90711-0195 Washer, 6 mm
oil seal
Pressing in crankshaft
JD6805-0134 81.90712-0984 Washer, 3 mm
oil seal
Plugging the fitting for

Protective
JD6805-0073 81.96002-0117 the quick-release
sleeve
coupling Z12*16

Protective
sleeve
coupling Z14*15

Protective
sleeve
coupling Z28*20
Plugging the fuel

service center fuel line
JD6805-0050 81.96002-0518 Cap
hollow screw
connection
Plugging the cylinder

JD6805-0044 81.96002-0520 End plug
head injector bore
Plugging the fuel line

JD6805-0048 81.96002-0521 End plug
and high-pressure line
Page 306 of 315

Protective Plugging the injector

JD6805-0045 81.96002-0522
sleeve nozzle
Injector feed Plugging the injector

JD6805-0046 81.96002-0523
bore cap feed bore
Plugging the
JD6805-0047 81.96002-0541 End plug
high-pressure line
Plugging the
Protective
rail-pressure sensor
JD6805-0052 81.96002-0555 sleeve
and pressure limiting
Z 18 x 15
valve
Plugging the pressure

limiting valve and the
JD6805-0051 81.96002-0556 End plug
rail-pressure sensor
bore in the rail
Checking the pressure

Threaded
JD6805-0069 81.98130-0614 leakage in the
connection
Piston ring Removing and

JD6805-0034 83.09144-6090
pliers installing piston rings
Page 307 of 315

MC11 Series Engine Chief Screw Bolt, Nut and Plug, and Pipe Fitting Tightening Torque and Final Tightening
Bolt Final
Strength Class/ Tightening Pretightening
Designation Specification tightening Remarks
Material Torque Nm Nm
（mm） ∡
50
Apply thinly oil on the support
1 Main bearing bolt M18×2 10.9 150 90°+10°
surface. No reuse.
300+30
Crankcase
2 M22×1.5 80+5
lock bolt
3 Con-rod bolt M13×1.5 11.9 100±10 90°+10°
surface. No reuse.
Damper and hub
4 M10 8.8 50＋5
fitting-up bolt
Damper and crankshaft
5 M16×1.5 10.9 150＋10 90°+10°
fitting-up bolt
6 Flywheel bolt M16×1.5 12.9 100＋10 180°＋10°
surface. No reuse.
Oil thinly on the bearing in case
10 of a new cylinder head, and
7 Cylinder head bolt M18×2 10.9 150 3×90° apply white-T instead in case
300 of any scratch on the cylinder
head; No reuse.
Cylinder head screw
8 M16×1.5 40
plug
Page 308 of 315

9 Rocker arm seat screw M12 10.9 105＋10

10 Rocker adjusting nut M10×1 45
EVB tension plate
11 M14×1 45
adjusting nut
12 Camshaft gear bolt M8 10.9 15 90°
Rear intermediate gear
13 M14 10.9 150＋10 90°
assembly shaft
14 Oil sump drain plug M22×1.5 80
15 Oil module plug M16×1.5 25+5
16 Oil module plug M33×2 80+10
17 Oil module plug M38×1.5 80+10
18 Relief valve M27×1.5 40+5
19 Oil filter M20 40+10
Oil separator oil return
20 M24×1.5 PA66-GF30 4±0.5 Loctite 242
pipe
21 Filler pipe M38×1.5 PA6-GF30 35
Fan hub and shaft
22 M16×1.5-LH 850-1000N/mm2 100 90°＋10°
fitting-in bolt
23 Distributor shell plug M14×1.5 30
The short exhaust Heat-resistant
24 M10 60＋5 90°＋10°
manifold bolt bolt
Page 309 of 315

The long exhaust Heat-resistant

25 M10 60＋5 90°＋10°
manifold bolt bolt
Turbocharger tightening
26 M10 21CrMoV5-7 10+5 90°＋10°
nut
Injector tension plate 1-2
27 M8 10.9 90°＋10°
bolt 25
10
28 Filler pipe fix nut M24×1.5 40Cr 60°
20
Common rail tightening
29 M8 10.9 35±5
bolt
Cyl 1-6 high pressure
30 M14×1.5 10 60°
pipe nut
High pressure pipe from
31 M14×1.5 10 60°
pump to rail
32 Injector harness M4 1.8+0.25
EDC bracket tightening
33 M8 10.9 12-14
bolt
34 EDC tightening bolt M6 10.9 10±2
High pressure pump and
35 M10 10.9 60-70
gearbox fitting-up bolt
36 Fuel filter cap SW39 25+5
Fuel preliminary filter
37 SW19 10+5
cap
Page 310 of 315

Low pressure passage

38 M14×1.5 30-35
swivel fitting
Water temperature
39 M16×1.5 45-50
sensor
40 Speed sensor M6 10.9 8-10
41 Engine front bracket M14 12.9 230
Air compressor swivel
42 M16×1.5 30-35
fitting NG12
Air compressor clamp
43 M26×1.5 45-50
fitting
Automatic tension
44 M10 10.9 42-52
pulley counter screw
45 Idler bolt M12 10.9 50-70
High pressure pump
46 M38×1.5 35
gearbox filler pipe
47 Oil dipstick tube fitting M14×1.5 30
Page 311 of 315

MC11 Series Engine Primary Parts and Components

Fitting Clearance
Fitting Value
SN Item
（mm）
+0.0235 ～
1 Standout of piston over crankcase top
+0.3435
-0.0615 ～
2 Standout of piston over cylinder liner top
+0.3085
3 Standout of cylinder liner over crankcase top +0.035～+0.085
4 Crankshaft axial clearance 0.200～0.401
5 Main bearing radial clearance 0.044～0.110
6 Conrod bearing radial clearance 0.044～0.106
7 Conrod axial clearance 0.130～0.330
Radial clearance,
8 0.055～0.073
conrod small end bush and piston pin seat hole
9 Radial clearance, piston pin and piston pin seat hole 0.010～0.024
10 Radial clearance, piston and cylinder liner Min 0.101
11 Protrusion of intake and exhaust valve guides 16.1～16.5
12 Camshaft radial clearance 0.024～0.090
13 Camshaft axial clearance 0.05～0.85
14 Rocker arm radial clearance 0.030～0.066
15 Intake valve stem radial clearance 0.023～0.052
16 Exhaust valve stem radial clearance 0.036～0.065
17 Intake valve recession 0.5～0.8
18 Exhaust valve recession 0.5～0.8
19 Cold state intake valve clearance 0.47～0.53
20 Cold state exhaust valve clearance 0.77～0.83
21 EVB clearance 0.57～0.63
22 Oil pump outer rotor axial clearance 0.030～0.093
23 Oil pump outer rotor radial clearance 0.10～0.210
24 Oil pump inner rotor axial clearance 0.030～0.090
25 Oil pump inner rotor radial clearance 0.02～0.10
26 Clearance, water pump shell and impeller 3.7～4.3
Page 312 of 315

Fitting Value
SN Item
（mm）
24CA before
27 Intake valve opening
TDC
28 Intake valve closed 12CA after TDC
60CA before
29 Exhaust valve opening
TDC
30 Exhaust valve closed 30CA after TDC
31 Fan drive shaft axial clearance 0.2～0.55
32 Fan drive shaft radial clearance 0.035～0.076
Backlash,
33 0.052～0.176
rear crankshaft gear and rear intermediate gear wheel
Backlash, rear intermediate pinion and crankcase
34 0.052～0.176
intermediate gear
Backlash, crankcase intermediate gear and cylinder head
35 0.052～0.232
intermediate gear
Backlash, cylinder head intermediate gear and camshaft
36 0.054～0.180
gear
Backlash, crankshaft rear gear and air compressor
37 0.051～0.177
intermediate gear
38 Air compressor intermediate gear and air compressor gear 0.051～0.177
39 Backlash, air compressor gear and steering pump gear 0.050～0.244
40 Backlash, rear intermediate gear wheel and PTO gear 0.051～0.177
41 Backlash, front crankshaft gear and front intermediate gear 0.057～0.183
Backlash, front intermediate gear and high pressure pump
42 0.053～0.247
gear
43 Backlash, front intermediate gear and fan gear 0.054～0.246
44 Backlash, front crankshaft gear and oil pump outer rotor 0.092～0.272
45 Radial clearance, rear intermediate gear assembly 0.060～0.109

46 Axial clearance, rear intermediate gear assembly 0.100～0.290
Radial clearance, crankcase intermediate gear and cylinder

47 0.06～0.109
head intermediate gear
48 Axial clearance, crankcase intermediate gear 0.100～0.290

49 Axial clearance, cylinder head intermediate gear 0.200～0.390
50 Radial clearance, air compressor intermediate gear 0.060～0.109
51 Axial clearance, air compressor intermediate gear 0.100～0.240
52 Radial clearance, front intermediate gear 0.060～0.109
Page 313 of 315
Fitting Value
SN Item
（mm）
53 Axial clearance, front intermediate gear 0.100～0.290
54 Axial clearance, high pressure pump drive shaft 0.200～0.700
55 Radial clearance, high pressure pump drive shaft 0.035～0.076
56 Axial clearance, air compressor PTO shaft 0.100～0.700
57 Radial clearance, air compressor PTO shaft 0.040～0.100
58 Axial clearance, air compressor shaft 0.100～0.400
59 Radial clearance, air compressor shaft 0.0400～0.100
Page 314 of 315

MC11 Series Engine Sealant Application List

Sealant Brand Color Function Applying area
Fitting surface of high pressure
pump drive shell and crankcase
Air compressor fitting surface
Rear crankcase end
Refrigerant compressor surface
High pressure pump and pulley
drive shaft
Sealant 5900 grey Sealing
Fan hub and bolt
High pressure drive shaft
Front crankcase end
PTO intermediate gear assembly
Intake pipe after intercooling
and cylinder head fitting
surfaces
Oil separator oil return pipe
Sky fitting
Loctite243 Loose-proof
blue EVB exhaust valve bridge
assembly bolt
Loctite 2701 Red Sealing Generator pulley and drive shaft

Apply thinly white T on the bolt
Grease
White Wear-proof bearing when reassembling the
White T
cylinder head.
Remarks: The sealant can be different in colors depending on
manufacturers.
Page 315 of 315

MC11 Series Diesel Engine Maintenance Manual

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Sinotruk

MC11 Series Engine

China National Heavy Duty Truck Group Co., Ltd.

3. Cylinder liners ................................................................................................................. 228

Chapter I. MC11 Series Engine Introduction

with spiral-type expander as an effective oil scraper ring,

SECTION 2. MC11 SERIES ENGINE CHARACTERISTICS DATA

4 Valves per cylinder 4

5 Total stroke volume L 10.518

6 Compression ratio 19:1

7 Max. rated net power (KW) kW 316 287 257 228

8 Rated speed rpm 1900

9 Max. torque Nm 2100 1900 1750 1550

10 Speed at max. torque rpm 1000～1400

11 Total power test min. specific g/kWh ≤186

14 Idle speed rpm 550±50

15 Firing sequence 1－5－3－6－2－4

19 Net mass kg 975

21 Max. Permissible engine rpm 2400

Table 1-2 MC11 Series Engine Chinese IV Characteristics Data

21 Max. Permissible engine rpm 2400

Table 1-3 MC11 Series Engine Chinese V Characteristics Data

21 Max. Permissible engine rpm 2400

Chapter 2. MC11 series engine components removing and

Fig 2-1 Engine sensors

1.2 Important information

2. Electric control unit （EDC）

Fig. 2–2 Electric control unit（EDC）

Removing the engine control unit bracket

·Unscrew the mounting bolt（1）

- Disconnect the wiring harnesses (3).

·Unscrew the mounting bolt（2）

·Thinly apply Loctite 270 on the thread of the

·When installing the connectors, first fully open

·Position the engine control unit (1).

Section 2. Cooling system

Fig. 2–3. Cooling system lines

Fig 2–4 Cooling system distributor housing

1.1 Technical data

1.3. Removing the fan 1.4 Installing the fan

• Unscrew the mounting bolts (1).

• Unscrew the mounting bolt (2).

• Position the fan (3) onto the bracket (2).

Figure 2–6 Fan bracket

2.3 Service products

[2] Extractor hook JD6805-0019 80.99602-0137

[3] Plug-on handle JD6805-0020 80.99617-0187

[5] Impact punch JD6805-0022 80.99604-0289

[6] Engine barring gear JD6805-0023 80.99626-6008

[7] Dial gauge JD6805-0024 08.71000-3217

[9] Locating pin JD6805-0026 80.99605-0197

Checking the fan bracket

• Use the impact extractor [1] (4) and the

• Mark the installation position of the

Checking the fan shaft outside diameter

• Check the fan shaft outside diameter using

• Check the inside diameter of the front

Installing the fan bracket Installing the fan hub

• Use the Plug-on handle [3] (4), the Washer

Fig. 2–7 Coolant manifold