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Specifications

Note: As the same illustrations are reused for different variants, some details may differ for the
variant you are working on. However, the essential information in the illustrations is always correct.

Contents
 General
 Engine
 Valve mechanism
 Engine transmission
 Crank mechanism
 Lubricating and lubricating oil system
 Fuel system
 Inlet and exhaust system
 Cooling system
 Engine control system
 Tightening torques and order

General

1 Torque
Type Output power
designation
Max torque at 16.7 -25.0 rps (1000 -1500
Max output at 30.0 rps (1800 rpm)
rpm)
D13B 360 265 kW (360 hp) 1800 Nm (1000–1400 rpm)
D13B 400 294 kW (400 hp) 2000 Nm (1000–1400 rpm)
D13B 440 324 kW (440 hp) 2150 Nm (1000–1400 rpm)
D13B 500 368 kW (500 hp) 2400 Nm (1050-1500 rpm)

1
Net power in accordance with ISO 1585. Smoke demands fulfil ECE regulations. 24 Federal
Register and Swedish demands.

Number of cylinders.....6

Cylinder bore.....131 mm

Stroke.....158 mm

Swept volume.....12.78 litres

Injection sequence.....1-5-3-6-2-4
Compression ratio.....16:1

Slow idling.....10 rps (600 rpm)

Fast idling.....35.8 rps (2150 rpm)

Highest full load engine speed.....31.7 rps (1900 rpm)

Weight, engine (production engine without vehicle details) .....≈1,200 kg


(production engine with vehicle details) .....≈1,300 kg

Total length.....max 1,366 mm

Total width.....max 971 mm

Total height.....max 1,170 mm

Engine
Cylinder head

Max unevenness (bottom surface).....0.1 mm

Cylinder head screws

Quantity/cylinder head.....38

Thread dimension.....M16

Length.....200 mm

Cylinder block

Length.....1,052 mm
Height, upper block face - crankshaft centre.....422 mm

Height, lower block face - crankshaft centre.....120 mm

Cylinder liner

Type.....Wet, exchangeable

Height of sealing surface above block face.....0.15 - 0.21 mm

Number of sealing rings per cylinder liner.....1 + 3

Piston

Height above cylinder block face


steel piston.....0.1 (min) – 0.7 (max) mm

Number of ring grooves.....3

Marking ―Front‖.....Arrow facing forwards

Piston rings
Compression rings

Quantity.....2

Marking.....Up (colour splash to left of gap)

Piston ring clearance in grooves:


upper compression ring.....(trapezoid profile)
lower compression ring.....0.09 - 0.14 mm

Piston ring gap measured in ring opening

upper compression ring .....0.40 – 0.55 mm


Wear tolerance < 0.65 mm

lower compression ring .....1.30 — 1.50 mm


Wear tolerance < 1.65 mm

Oil scraper ring

Quantity.....1

Marking.....Up (colour splash to left of gap)


Piston ring clearance in grooves.....0.05 - 0.10 mm

Piston ring gap measured in ring opening .....0.30 – 0.55 mm


Wear tolerance < 0.70 mm

Valve mechanism
Valves

Valve head, diameter:


Inlet.....42 mm
Exhaust.....40 mm

Valve stem, diameter:


Inlet/exhaust.....8 mm

Valve seat angle (A):


Inlet.....24,5°± 0,2
Exhaust.....39,5°

Seat angle in cylinder head (B):


Inlet.....25°
Exhaust.....40°
Specifications Wear
value

Measurement (A) between valve Max 1.7


head and cylinder head face: mm
Inlet.....min 1.0 mm Max 2.1
Exhaust.....min 1.35 mm mm

Valve clearances, cold engine, setting values:


Inlet.....0.2 mm
Exhaust, VGT .....0.8 mm
Exhaust, VEB7 .....1.0 mm

Valve clearance, cold engine, check value:


Inlet.....0.15 -0.25 mm
Exhaust, VGT .....0.75 -0.85 mm
Exhaust, VEB7 .....0.95 -1.05 mm

Rocker arm brake VEB7


Standard setting and control

This setting or control of brake clearance is measured at the roller and while using a feeler gauge to
totally eliminate the exhaust valve clearance.

Rocker arm brake VEB7, setting


value.....2.50 mm

1
Rocker arm brake VEB7, control value
.....2.45 — 2.55 mm

1
The control check is only valid for engines that are well run in or directly after loading when
adjusting.

Fault control

This fault check does not replace the above check that is done without using a feeler gauge to
eliminate exhaust valve clearance.

Feeling gauge thickness.....3.20 mm

It should be very easy to insert the feeler gauge.

Note: This dimension cannot be used for adjustment!


Valve seats

Standard Oversize

Outside diameter (A): 45.3 mm


Inlet.....45.1 mm 43.3 mm
Exhaust.....43.1 mm

Height (B) :
Inlet.....7.55 mm
Exhaust.....7.5 mm

Valve seat position

Standard Oversize

Diameter (C): 45.2 mm


Inlet.....45.0 mm 0+0.025
Exhaust.....43.0 mm 43.2 mm
0+0.025

Depth (D):
Inlet.....11.8 ± 0.13 mm
Exhaust.....11.2 ± 0.13
mm

Seat bottom radius (R) :


Inlet/exhaust.....max 0.8
mm
Valve guides

Length:
Inlet/exhaust.....83.5 mm

Inside diameter:
Inlet/exhaust.....8 mm

Height above cylinder head spring surface:


Inlet/exhaust.....24.5±0.2 mm

Wear valueSee picture

1
Play, valve stem - guide:
Inlet.....max 0.7 mm
Exhaust.....max 0.7 mm

1
The measurements are calculated for the measurement method described in the service literature,
see group 214.

Rocker arms
Wear value

Bearing play (1).....max 0.1 mm


Rocker arm roller, play (2).....max 0.1 mm

Valve springs

Inlet

length unloaded.....73.8 mm

Exhaust

Outer valve spring:


length unloaded.....73.8 mm

Inner valve spring:


length unloaded.....70.5 mm

Engine transmission
Timing gears

Gear wheels:

1. Drive gear, crankshaft


2. Idler gear: outer gear wheel
inner gear wheel

3. Idler gear (adjustable)

4. Drive gear and oscillation damper,


camshaft

5. Idler gear

6. Drive gear, steering servo pump and fuel


feed pump

7. Compressor drive gear

8. Drive gear, lubrication oil pump

9. Engine-mounted power take-off (extra


equipment)

Backlash adjustable intermediate gear to


camshaft drive gear.....0.05 -0.15 mm

Backlash, oil pump.....0.05 -0.40 mm

Backlash, other.....0.05 -0.17 mm

Diametrical play for intermediate


gear.....max 0.05 mm

Camshaft

Control of camshaft settings, cold engine and valve clearance for cylinder 1 inlet valve =
0.
The inlet valve for no. 1 cylinder shall be open 1.6±0.3 mm when the flywheel is at 6° after Top
Dead Centre.
When checking, the timing gears shall rotate in the correct direction (clockwise seen from the
front) to take up all the backlash.
Drive device.....gear

Number of bearings.....7

Diameter, bearing journals, standard.....69.97 -70.00 mm

Diameter, bearing journals, undersize:


0.25 mm (0.01 inch).....69.72 -69.78 mm
0.50 mm (0.02 inch).....69.47 -69.53 mm
0.75 mm (0.03 inch).....69.22 -69.28 mm

Valve lift at zero clearance:


Inlet.....12.9 mm
Exhaust, VEB7 .....13.1 mm
Exhaust (EBR VGT/UEBRAKE).....12.3 mm

Permitted wear, entire camshaft profile.....max 0.1 mm

Unit injector, stroke.....18 mm

Wear value

Max end float.....0.24 mm

Bearings, max permitted diametrical play.....0.1 mm

Camshaft bearings

Camshaft bearing thickness, standard.....1.92 mm


Oversize:
0.25 mm.....2.04 mm
0.50 mm.....2.17 mm
0.75 mm.....2.29 mm

Crank mechanism
Crankshaft

Wear value

1
Crankshaft axial clearance .....max 0.4 mm

Machining values

Ovality for main bearing journals and big-


end journals.....max 0.006 mm

Taper for main bearing journals and big-end


journals.....max. 0.02 mm

Runout of middle bearing.....max 0.15 mm

1
Measurements apply to lubricated components.

Main bearings journals

Diameter (Ø) standard.....108.0 mm

Undersize:
0.25 mm.....107.75 mm
0.50 mm.....107.50 mm
1.00 mm.....107.00 mm

Surface finish, main bearing journals.....Ra 0.25

Surface finish, radius.....Ra 0.4

Width, axial bearing journal (A), standard.....47.0 mm

Oversize:
0.2 mm, axial bearing 0.1 mm.....47.2 mm
0.4 mm, axial bearing 0.2 mm.....47.4 mm
0.6 mm, axial bearing 0.3 mm.....47.6 mm

Recess radius (R) .....4.0 mm

Thrust washers (axial bearing)

Width (B) standard.....3.18 mm

Oversize:
0.1 mm.....3.28 mm

Main bearing shells

Thickness (D) standard.....2.48 mm

Oversize:
0.25 mm.....2.61 mm
0.50 mm.....2.74 mm
1.00 mm.....2.98 mm

Big-end bearing journals


Diameter (Ø) .....99.0 mm

Undersize:
0.25 mm.....98.75 mm
0.50 mm.....98.50 mm
1.00 mm.....98.00 mm

Surface finish, big-end journals.....Ra 0.25

Surface finish, radius.....Ra 0.4


Width (A) .....57.0 mm

Recess radius (R) .....4.0 mm

Big end bearing shell

Thickness (C) standard.....2.39 mm

Oversize:
0.25 mm.....2.51 mm
0.50 mm.....2.64 mm
1.00 mm.....2.89 mm

Connecting rod

Marking:
FRONT on the connecting rod is turned
forward.

The connecting rod and bearing cap are


marked as a pair with a three-figure number
(see figure).

Wear value

Axial clearance, connecting rod - crankshaft


1
.....max 0.35 mm

1
Big-end bearing, diametrical clearance
.....max 0.1 mm

1
Measurements apply to lubricated components.

Flywheel, installed

Axial runout, (manual gearbox) measurement radius 150 mm.....<0.20 mm

Flywheel housing, installed

Axial mismatch for mating surface against clutch housing.....max 0.2 mm

Radial mismatch for guide against clutch housing.....max 0.26 mm

Lubricating and lubricating oil system


Oil

Oil change volume, see service information group 175.

Oil pressure

Operating speed (over 1100 rpm).....300-550 kPa

Cold engine (above 1100 rpm).....– 650 kPa

Low idle (min.).....min 250 kPa

Piston cooling pressure, hot engine (above 1100 rpm).....200-300 kPa

Oil Pressure, rocker arm shaft


Non-activated VEB7 .....80-120 kPa

Activated VEB7 (900–2300 rpm).....min 220 kPa

Oil temperature

1
Warm engine, engine running (coolant temperature 75-95°C).....90 -110 °C

1
Up to 125°C with heavy load

Oil filter

Quantity

Full flow filter.....2

Bypass filter.....1

Oil valves
1. Safety valve, engine block
Marking.....Yellow

2. Thermostat valve, oil cooler


Opening temperature.....105 -107 °C

3. Overflow valve, full flow filter


Spring, free length.....69 mm
with a load of 13 - 15 N.....40 mm

Fuel system
Feed pump
Feed pressure at:
600 rpm.....min 100 kPa
1200 rpm.....min 300 kPa
full load.....min 300 kPa

Overflow valves

Opening pressure.....300-550 kPa

Tightening torques.....48± 5 Nm

Unit injectors
Pre-load
Tighten the adjustment screw to zero
clearance against the camshaft, then turn
3-4 flats (0.75 ± 0.1 mm), see the
illustration.

Inlet and exhaust system


Variable turbocharger VGT (Variable Geometry Turbocharger)
End float turbine rotor shaft.....0.038 -0.093
mm

Radial play.....0.329 -0.501 mm

Pressure drop indicator

The pressure drop indicator check lamp lights with underpressure in relation to the ambient air
pressure of.....5 ± 0.5 kPa

Heat retention function

Heat retention activated:


engine load.....<low idling

Heat retention deactivated:


coolant temperature.....>80 °C
engine load..... >low idling
outer temperature.....>50 °C

Engine brake

Two-way switch can give 0 % or 100 % braking effect.


Three-way switch can give 0 %, 50 % or 100 % braking effect.
Four-way switch can give 0 %, 40%, 70 % or 100 % braking effect.
Five/six-way switch can give 0 %, 40%, 70 % or 100 % braking effect, and also 50% in A-
position.

VEB7

Braking force (%) VCB (on/off) Charge pressure (1300 rpm)

40% off 170 kPa

1
50% on 185 kPa

70% on 240 kPa


100% on 300 kPa

1
50% braking effect can only be obtained in automatic position or with three-way switch.

Activated:
engine speed.....> approx 900/950 rpm
vehicle speed..... > approx. 15 km/h
engine oil temperature..... >55 °C
Charge pressure..... Not applicable

Deactivated:
engine speed.....< approx 800/900 rpm
vehicle speed.....< approx 15 km/h
engine oil temperature..... <50 °C
Charge pressure..... Not applicable

Charge pressure values

1
D13B Euro4 (EM EC06)

1200 rpm 1400 rpm 1600 rpm 1800 rpm

360 194 kPa 219 kPa 216 kPa 228 kPa

400 210 kPa 236 kPa 224 kPa 213 kPa

440 233 kPa 247 kPa 229 kPa 203 kPa

500 252 kPa 239 kPa 228 kPa 199 kPa

1
If environmental (green) diesel fuel is used, reduce the table values by 5 kPa.

Exhaust back-pressure

Exhaust back-pressure, max......12 kPa

Cooling system
General

Pressure valve opens at.....75 kPa

Thermostat

Quantity.....1

Opening temperature
I-shift, Geartronic, R/SR-manual.....<82 °C
Compact retarder.....<82° C

Coolant


Type.....Volvo Coolant VCS


Colour.....Yellow
Contains.....Glycol and anti-corrosion
additives
Mixed with.....Water (STD 1285,1)

Electronically controlled viscos fan

Activated Notes Conditions Fan engagement


system

1
Air -engine speed 1200 rpm
conditioning (>1500 rpm)
Activated Notes Conditions Fan engagement
system

system inlet temp. > 40 °C


-ambient temp. > 40
°C
-vehicle speed <45
km/h

1
Air -engine speed 1000 rpm
conditioning (>1200 rpm)
system inlet temp. > 30 °C
-ambient temp. >30
°C
-vehicle speed <45
km/h

1
Air inlet temp. > 35 °C 1200 rpm
conditioning -ambient temp.
system >35°C
-vehicle speed < 10
km/h

1
Air inlet temp. > 20 °C 600 rpm
conditioning -ambient temp. >20
system °C
-vehicle speed <20
km/h

1
Pneumatic Vehicles with pneumatically -engine speed (>750 800 rpm
system controlled air drying and air rpm)
suspension -inlet temp. > 12 °C
-ambient temp. > 12
°C
-vehicle speed < 35
km/h
-system pressure
<1020 kPa
-system pressure
1020–1200 kPa and
rising

1
Pneumatic Vehicles with pneumatically -engine speed (>750 800 rpm
system controlled air drying and leaf- rpm)
spring suspension -inlet temp. > 12 °C
-ambient temp. > 12
°C
-vehicle speed < 35
Activated Notes Conditions Fan engagement
system

km/h
-pressure switch
open (compressor
charging)

1
Pneumatic Vehicles with electrically -engine speed (>750 800 rpm
system controlled air drier rpm)
-inlet temp. > 12 °C
-ambient temp. > 12
°C
-vehicle speed < 35
km/h
-compressor
charging

Coolant I-shift Coolant temperature Activation depends


temperature Geartronic 96°C on coolant
R/SR-manual temperature

Coolant Compact retarder Coolant temperature Activation depends


temperature 93 °C on coolant
temperature

EECU-temp. EECU-temp. > 100 1200 rpm


°C

1
Charge air charge air temp. > 65 580 rpm
1
temp. °C 1180 rpm
charge air temp. > 70
°C

1
Retarder Compact retarder Request for fan 1200 rpm
2
Powertronic retarder activation is sent:
-vehicle speed >0
3
m/s
AND
-retarder torque >0 %
AND
propeller shaft speed
>400 rpm
AND
-retarder coolant
temperature > 100 °C
OR
Activated Notes Conditions Fan engagement
system

retarder oil
temperature >170 °C
Request for fan
4
activation is sent:
-vehicle speed =0
m/s
AND
-retarder torque = 0
%
OR
propeller shaft speed
<300 rpm
AND
-retarder's coolant
temperature. <99 °C
OR
retarder oil
temperature. <150 °C

1
1.5 second delay after engine brake has been activated.

2
NOTE! A request for fan activation is sent when the demands for vehicle speed AND retarder
torque AND propeller shaft speed AND (retarder's coolant temperature OR retarder oil temperature)
are met.

3
40 seconds after retarder braking has been started

4
NOTE! A request for fan activation is sent when the demands for vehicle speed AND (retarder
torque OR propeller shaft speed) AND (retarder coolant temperature OR retarder oil temperature)
are met.

Engine control system


Sensors

Engine oil temperature sensor


Temperature Impedance Impedance Impedance
R min R nom R max

(°C) (°F) (Ω) (Ω) (Ω)

- 50 89 496,5 105 290,0 121 083,5

- 40 - 40 45 163,6 52 394,0 59 624,4

- 30 - 22 23 871,0 27 375,0 30 879,0

- 20 -4 13 181,5 14 945,0 16 708,5

- 10 14 7 555,7 8 480,0 9 404,3

0 32 4 477,9 4 981,0 5 484,1

10 50 2 747,3 3 029,0 3 310,7


20 68 1 736,6 1 900,0 2 063,4

30 86 1 127,3 1 224,0 1 320,7

40 104 750,0 809,1 868,2

50 122 510,4 547,0 583,6

60 140 354,5 377,9 401,3

70 158 251,6 266,5 281,4

80 176 181,4 191,2 201,0

90 194 133,1 139,7 146,3

100 212 99,2 103,6 108,0

110 230 75,0 78,0 81,0

120 248 57,6 59,6 61,6

130 266 44,7 46,1 47,5

140 284 34,8 36,0 37,2

150 302 27,4 28,5 29,6

Coolant temperature sensor


Temperature Impedance Impedance Impedance
R min R nom R max

(°C) (°F) (Ω) (Ω) (Ω)

- 40 - 40 40 490 45 313 50 136

- 30 - 22 23 580 26 114 28 647

- 20 -4 14 096 15 462 16 827

- 10 14 8 642 9 377 10 152

0 32 5 466 5 896 6 326

10 50 3 542 3 792 4 043


20 68 2351 2 500 2 649

25 77 1941 2 057 2 173

30 86 1615 1 707 1 798

40 104 1118 1 175 1 231

50 122 798 834 870

60 140 573 596 618

70 158 421 435 451

80 176 313 323 332

90 194 237 243 250

100 212 182 186 191

110 230 140 144 148

120 248 109 113 116

130 266 86 89 93

140 284 68 71 74

Charge air temperature sensor


Temperature Impedance Impedance Impedance
R min R nom R max

(°C) (°F) (Ω) (Ω) (Ω)

- 40 - 40 45 301,0 48 153,0 51 006,0

- 30 - 22 25 350,0 26 854,0 28 359,0

- 20 -4 14 785,0 15 614,0 16 443,0

- 10 14 8 951,0 9 426,0 9 901,0

0 32 5 605,0 5 887,0 6 168,0


10 50 3 618,7 3 791,1 3 963,5

20 68 2 401,9 2 510,6 2 619,3

30 86 1 644,7 1 715,4 1 786,2

40 104 1 152,4 1 199,6 1 246,7

50 122 819,1 851,1 883,0

60 140 590,3 612,3 634,2

70 158 431,0 446,3 461,6

80 176 318,68 329,48 340,27

90 194 238,43 246,15 253,86

100 212 180,42 186,0 191,58

110 230 137,63 142,08 146,52

120 248 106,09 109,65 113,21

130 266 82,58 85,45 88,32

Pressure drop indicator

Active.....V = 0.48 × Ubat ± 10 %

Inactive.....V = 0.12 × Ubat ± 10 %

Camshaft sensor

Distance to gear teeth.....1.1±0.4 mm


Crankcase pressure sensor

Sensor alarm limit.....5 kPa


Crankcase pressure, normal value.....<1.0
kPa

Tightening torques and order


Tightening torques Group 20

General tightening torques

M6 standard bolt 8.8.....10±1.5 Nm


M8 standard bolt 8.8.....24 ± 4 Nm
M10 standard bolt 8.8.....48±8 Nm
M12 standard bolt 8.8.....85±15 Nm
M14 standard bolt 8.8.....140±25 Nm
M16 standard bolt 8.8.....190 ± 35 Nm

Only torque-tightened bolts can be refitted.

Torque and angle tightened/yield limit tightened bolts:


8.8.....must/should not be refitted
10.9.....can be re-used
12.9.....can be re-used

Note: Check the screws before reuse. Screws that show signs of damaged, e.g. cuts under
heads, etc shall be scrapped.

Tightening torques Group 21


Front engine mounting, cylinder block
Step 1: Tighten bolt 1 .....80±15 Nm
Step 2: Tighten bolts 2–4 .....105±15 Nm
Step 3: Angle tighten bolts 2–4 in numerical order.....60±5°
Step 4: Tighten bolt 1 .....105±15 Nm
Step 5: Angle tighten bolt 1 .....60±5°
Step 6: Tighten bolt 5 .....standard screw torque

Front engine mounting, front engine pad


normal and difficult road surfaces.....140±25 Nm
very difficult road surfaces.....140 ± 25 Nm (CONC-NAM 160 ± 25 Nm)

Front engine pad, vibration damper.....48±8 Nm

Front engine pad, cross member.....175±30 Nm

Rear engine mounting, flywheel housing.....300 ± 45 Nm

Rear engine mounting, rear engine pad:.....540±90 Nm

Rear engine mounting pad, frame.....140±25 Nm

Main bearing cap:


Step 1.....150±20 Nm
Stage 2 (angle tightening).....120±5°
Connecting rod cap
Step 1.....20±3 Nm
Step 2.....60±5 Nm
Stage 3 (angle tightening).....90±5°

Stiffening frame

Stiffening frame:
Step 1: Tighten bolts 1-24 in numerical order......45±5 Nm
Step 2: Tighten bolts 1-24 in numerical order (angle tightening)......60±5°

Note: Tighten the bolts in numerical order as illustrated. The bolts must not be reused.

Timing gear plate


Note: Apply silicon in a 2 mm thick bead outside the groove as illustrated above, max 20
minutes before assembly.
Timing gear plate:
Tighten all bolts in numerical order with the following torque:
M8 bolts.....28±4 Nm

Timing gears
1. Drive gear, crankshaft.....24 ± 4 Nm

2. Idler gear, outer drive:


Stage 1.....25±3 Nm
Stage 2 (angle tightening).....110±5°

Note: Torque tighten the nuts in the order illustrated.


3. Idler gear, adjustable:
Step 1.....35±4 Nm
Stage 2 (angle tightening).....120±5°

Note: Torque tighten the nuts in the order illustrated.


4. Drive gear, camshaft (including vibration damper):
Step 1.....45±5 Nm
Stage 2 (angle tightening).....90±5°

Note: Torque tighten the nuts in the order illustrated.


5. Idler gear.....140±10 Nm
6. Drive gear, steering servo and fuel feed pump.....100±10 Nm

7. Compressor drive gear.....200+50/-0 Nm

8. Engine-mounted power take-off (extra equipment)

Flywheel and timing gear cover


Flywheel housing:
Tighten all bolts in numerical order with the following torque:
M14 bolts.....140 ± 20 Nm
M10-bolts.....48±8 Nm
M8 bolts.....24 ± 4 Nm

Note: Apply silicon in a 2 mm thick bead as illustrated above, max 20 minutes before
assembly.

Timing gear cover, upper


Note: Apply silicon in a 2 mm thick bead as illustrated above, max 20 minutes before
assembly, and carefully tighten the contact surfaces that are illustrated in the enlarged part of
the figure.

Mount the cover in two stages:


Step 1: Secure the cover with bolts 1 and 2. Use the special tool to press the cover into
place......4±1 Nm
Step 2: Tighten the bolts in numerical order as illustrated......24 ± 4 Nm

Flywheel
Flywheel:
Step 1: Tighten the bolts in numerical order as illustrated......60±5 Nm
Step 2: (angle tightening).....120±10°

Note: Make sure the flange is dry and clean. Tighten the bolts in numerical order as illustrated.

Cover, crankshaft seal


Note: Apply silicon in a 2 mm thick bead as illustrated above, max 20 minutes before
assembly.

Cover, crankshaft seal:


Step 1: Secure the cover with bolts 2 and 7 and tighten until there is contact
Step 2: Tighten bolts 2 and 7.....24 ± 4 Nm
Step 3: Tighten the bolts in numerical order 1,3 - 6,8 as illustrated......24 ± 4 Nm

Oscillation damper, crankshaft


Oscillation damper on crankshaft:
Tighten the bolts in two stages in numerical order as illustrated.
Stage 1.....35±5 Nm
Stage 2.....90±10 Nm

Note: The vibration damper's 8.8 bolts may not be reused.

Cylinder head
Cylinder head:

Note: The cylinder head must be fitted according to instructions, see 21124-1 Cylinder head,
installation Group 21.

Step 1: Tighten the bolts in numerical order as illustrated......100±5 Nm


Stage 2 (angle tightening).....120±5°
Stage 3 (angle tightening).....90±5°

Bearing cap, camshaft/rocker arm shaft


Camshaft: (camshaft and bearing caps in place)
Fit a mandrel onto the number 7 bearing bracket, to protect the guide sleeve.
Step 1: Tighten bolts 1-7.....25±3 Nm
Step 2: (with shorter additional bolts) Tighten bolts 8-13 and 20.....60±5 Nm
Step 3: Angle-tighten bolts 1-7.....90±5 °
Step 4: Remove the extra bolts 8-13 and 20
Remove the mandrel from the number 7 bearing bracket.
Rocker arm shaft: (rocker arm shaft in place)
Step 5: Tighten bolts 8-13 and 20 consecutively in the order 11, 10, 12, 9, 13, 8, 20.....60±5
Nm
Step 6: Tighten bolts 14-19.....25±3 Nm
Step 7: Angle-tighten bolts 14-19.....120±5 °
Step 8: Loosen bolts 8-13
Step 9: Tighten bolts 8-13.....25±3 Nm
Step 10: Angle tighten bolts 8–13 and 20.....120±5 °

Valves/floating valve bridge/braking rocker arm VGT/VEB7

Lock nuts (A), valve adjustment screw:


1
(angle tightening).....60±5°

Locknut (B), floating valve bridge:


1
(angle tightening).....30+15/–0°

Lock nut (C), engine braking rocker arm (VEB7):


1
(angle tightening).....45±5°

1
after contact

Spring tab
Spring tab.....25 ± 3 Nm

Rocker cover
Rocker cover
Tighten the bolts in numerical order as illustrated......24 ± 4 Nm

Tightening torques Group 22

Oil sump
Oil sump, sheet metal and plastic respectively
Fix the oil sump with screws A and B and torque to.....24 ± 4 Nm
Tighten the screws from the centre outwards, in order 1-4 as in the illustration above.....24 ± 4
Nm
Finish by check-torqueing screws A and B......24 ± 4 Nm

Drain plug, oil sump (sheet metal and plastic respectively).....60 ± 10 Nm

Oil cooler
Oil cooler, securing screws.....27±4 Nm

Note: Tighten the bolts diagonally and finish by tightening the first bolt again.

Oil cooler cover


Place the cover on the engine block and fit screw A into the oval hole. Press the cover against
the water pump housing with a fitting tool and fit screw B, Check that the cover is in position,
see service instruction
Fit screws C and D and torque them.....24 ± 4 Nm
Tighten the cover screws from the centre outwards, in order 1-4 as in the illustration
above.....24 ± 4 Nm
Finish by check-torqueing screws C and D......24 ± 4 Nm
Oil filter housing
Thermostat valve, oil cooler, bolt (1).....M6 standard bolt torque
Safety valve, oil pressure, plug (2).....50±5 Nm
Plug, overflow valve (3).....55±5 Nm

Tightening torques Group 23

Retaining yoke / unit injectors

Caution
Avoid mixing the different types of yoke in the same engine.
Avoid mixing different types of injectors in the same engine.

Retaining yoke low version / injector with washer


Retaining yoke, unit injector (when replacing the sleeve)
Earlier version, low (A ≈ 30 mm)
(Screw ≈ 50 mm)

Note: The specified torques apply to lubricated screws.

First tightening
Step 1.....20 +5/-0 Nm
Stage 2 (angle tightening)..... 180°±5°
Step 3 Untighten the retaining yoke screw before the second tightening......-150°
Second tightening, earlier version, low:
Step 1.....20 +5/-0 Nm
Stage 2 (angle tightening)..... 90±5°

Note: When replacing / disassembling an injector with washer, a new washer must always be used.
Never reuse the washer.

Note: When replacing, the high yoke is recommended.

Retaining yoke high version / injector with washer


Later version, high (B ≈ 40 mm)
(Screw ≈ 60 mm)

Note: The specified torques apply to lubricated screws.

First tightening
Step 1.....20 +5/-0 Nm
Stage 2 (angle tightening)..... 180°±5°
Step 3 Untighten the securing yoke screw before the second tightening...... -150°
Second tightening, later version, high:
Step 1.....20 +5/-0 Nm
Stage 2 (angle tightening)..... 90°±5°

Note: When replacing / disassembling an injector with washer, a new washer must always be used.
Never reuse the washer.

Note: When replacing, the high yoke is recommended.

Retaining yoke high version / conical unit injector


Later version, high (B ≈ 40 mm)
(Screw ≈ 60 mm)

Note: The specified torques apply to lubricated screws.

First tightening
Step 1.....20 +5/-0 Nm
Step 2 (angle tightening).....180°±5°
Step 3 Untighten the securing yoke screw before the second tightening...... -150°
Step 4.....20 +5/-0 Nm
Step 5 (angle tightening)..... 60°±5°

Note: When replacing, the high yoke is recommended. The longer 60 mm screw must be used for
the high yoke.

Note: When replacing, only use conical injector.


Lock nut for adjusting screw, unit injector
Tightening torques.....52±4 Nm

Servo steering pump (incl. fuel pump).....24 ± 2 Nm

Fuel pump (mounted on servo pump).....8 +2/-0 Nm

Overflow valve / fuel line fixture


Fuel line fixture, tightening torque:
(A) .....18±3 Nm
(B) .....24 ± 4 Nm
(C) .....30±4 Nm
(D) .....35±5 Nm
(E) .....40 ± 5 Nm
(F) .....48±5 Nm

Tightening torques Group 25

Inlet pipe
Mixing chamber, pre-heater/dummy:
Step 1.....10±2 Nm
Step 2.....24 ± 3 Nm

Note: Torque tighten diagonally as illustrated.


Plug, M10 (inlet pipe).....20±3 Nm

Exhaust manifold
Exhaust manifold:
Step 1:
Tighten screws 1, 4 and 5, 8 and 9, 12 to contact.....(10±1.5 Nm)
Step 2:
Tighten bolts 3 and 2 .....48±8 Nm
Tighten bolts 7 and 6 .....48±8 Nm.
Tighten bolts 11 and 10 .....48±8 Nm.
Tighten bolts 1 and 4 .....48±8 Nm.
Tighten bolts 5 and 8 .....48±8 Nm.
Tighten bolts 9 and 12 .....48±8 Nm

Turbocharger
Tightening torque, turbo:
(A) .....12±3 Nm
(B) .....8.5±0.8 Nm
(C) .....48±5 Nm
(D) .....12±3 Nm
(E) .....38±6 Nm
(F) .....48±5 Nm
Tightening torque, turbo:
Step 1, tighten screws 1-4.....20 ± 4 Nm
Step 2, tighten screws 1-4.....48±8 Nm

Note: Torque tighten diagonally as illustrated.

EGR
Flange bolts (A)
Step 1: Tighten bolts 1-4.....20±4 Nm
Step 2: Tighten bolts 1-4.....61±3 Nm

Note: Torque tighten diagonally as illustrated.


V-clamp (B) .....10±2 Nm
Clamp (C) .....12±2 Nm
(D) Tightening torque, nuts.....12±2 Nm
Tightening torque, screws.....12±2 Nm
Drain cock (E) .....3±0.5 Nm
Torque M12 (F)......15 ± 3 Nm
V-clamp (G) .....20 ± 4 Nm
Tightening torques Group 26

1
Fan hub , studs (A).....14 ± 3 Nm

Note: Tighten the studs in the order shown in the illustration.


Round nut (B).....310±10 Nm

1
only applies to part number 20855514 for FM

Tightening torques Group 28

Sensors
1. Level sensor for water separator.....not replaceable, integrated in the cabling

2. Oil level and oil temperature sensor.....M6 standard torque

3. Fuel pressure sensor.....30 ± 5 Nm

4. Rotational speed sensor, cooling fan.....threaded shaft

5. Coolant level sensor.....stick-in type

6. Charge pressure sensor.....M6 standard torque


7. Coolant temperature sensor.....22 ± 3 Nm

8. Charge air temperature sensor.....M6 standard torque

9. Camshaft position sensor.....M6 standard torque

10. Pressure drop indicator.....clamp

11. Sensor for flywheel position and speed.....M6 standard torque, 8±2 Nm

12. Oil pressure sensor.....30 ± 5 Nm

13. Crankcase pressure sensor.....30±5

14. EGR, delta pressure sensor.....M8 standard torque

15. EGR temperature sensor.....45±5 Nm

16. Turbo speed sensor.....3±0.5 Nm, (use locking fluid)