Engine

Note: Illustrations are used for several different variants. Some details may therefore differ from the variant you are
working on. The essential information in the illustrations is, however, always correct.
Contents
 Engine
o Cylinder block
o Cylinder head
o Cylinder head bolt
o Cylinder liner
o Piston
o Piston rings
 Valve mechanism
o Valves
o Valve guides
o Valve seats
o Valve seat location
o Valve springs
o Rocker arms
 Engine transmission
o Timing gears
o Camshaft
o Camshaft bearings
 Crank mechanism
o Crankshaft
o Main bearing journals
o Thrust washers (axial bearing)
o Main bearing shells
o Big-end bearing journal
o Big end bearing shells
o Connecting rod
o Flywheel, fitted
o Flywheel housing (installed)
 Tightening torques and order
o Engine mounting
o Bearing cap
o Stiffening frame
o Flywheel
o Oscillation damper, crankshaft
o Flywheel casing
o Casing, crankshaft seal
o Valve cover
o Oil cooler cover
o Cylinder head
o Lifting eye, cylinder head
o Valve EPG/VEB
o Bearing caps, camshaft/rocker arm shaft
o Timing gear plate
o Timing gears
o Timing gear cover
Engine
Cylinder block
Length.....967 mm
Height upper block face-crankshaft centre.....379 mm
Height, lower block face - crankshaft centre.....120 mm
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Cylinder head
Maximum runout (at surface of base).....0.4 mm
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Cylinder head bolt
Quantity.....26
Thread size.....M16
Length.....200 mm
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Cylinder liner
Type.....Wet, replaceable
Total height.....250 mm
Height of sealing surface above block face.....0.14 - 0.21 mm
Number of sealing rings per cylinder liner.....3
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Piston
Type.....steel
Height above cylinder block face.....–0.1 (min) – 0.5 (max) mm
Number of ring grooves.....3
Front marking.....Arrow pointing forwards
Gudgeon pin(Ø).....54 mm
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Piston rings

Compression rings
Quantity.....2
Piston ring clearance in grooves:
upper compression ring.....(trapezoidal form)
lower compression ring.....0.1 – 0.15 mm
Piston ring gap (measured at the ring opening):
upper compression ring.....0.4 – 0.5 mm
lower compression ring.....1.0 - 1.2 mm
Oil scraper ring
Quantity.....1
Width including spring.....3.2 – 3.4 mm
Piston ring clearance in the grooves.....0.05 – 0.1 mm
Oil scraper ring aperture (measured at the ring aperture).....0.3 – 0.5 mm
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Valve mechanism
Valves
Valve disc (Ø):
Inlet.....40 mm
Exhaust.....38 mm
Valve stem, l (Ø):
Inlet/Exhaust.....8 mm
Valve clearance with cold engine (adjustment value):
Intake .....0.2 ± 0.05 mm
Exhaust, EPG.....0.8 ± 0.05 mm
Exhaust, VEB.....1.60 ± 0.05 mm
Valve clearance with cold engine (check value):
Intake .....0.15 - 0.25 mm
Exhaust .....0.75 - 0.85 mm
Valve clearance, shim free (adjustment screw)
Inlet .....0.2 ± 0.05 mm
Exhaust .....0.8 ± 0.05 mm

Valve seat angle (A):

Inlet/Exhaust.....29° 30'
Seat angle in cylinder head (B):
Inlet/Exhaust.....30°
Measurement (A) between valve disc and cylinder head face:
Inlet.....min. 1.1 - 1.6 mm
Exhaust.....min. 0.4 - 0.9 mm
Note: When replacing the valve seats, the valves must also be replaced.
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Valve guides
Length:
Inlet/Exhaust.....83.5 mm
Inner diameter:
Inlet/Exhaust.....8 mm
Height above cylinder head spring face:
Inlet.....24.5 ± 0.5 mm
Exhaust.....16.5 ± 0.5 mm
Clearance valve stem — guide (dry valve stem):1
Inlet.....max. 0.5 mm
Exhaust.....max. 0.5 mm
1Themeasurements are calculated for the measurement method described in the service literature, see group 214.
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Valve seats

Standard Oversize
Outer diameter (A) 42.1 mm
Inlet.....42.0 mm 40.1 mm
Exhaust.....40.0 mm
Height (B): -
Inlet.....7.3 mm -
Exhaust.....6.4 mm
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Valve seat location

Standard Oversize
Diameter (C) -
Inlet.....42.0 mm -
Exhaust.....40.0 mm
Depth (D) -
Inlet.....11.5 mm -
Exhaust.....9.9 mm
Seat bottom radius (R) -
Inlet/Exhaust.....max 0.8 mm
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Valve springs
Inlet/Exhaust
Outer valve spring:
Length (without load).....73 - 74 mm
Inner valve spring:
Length (without load).....70 - 71 mm
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Rocker arms

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

Rocker arm roller clearance (2).....max 0.1 mm
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Engine timing gear
Timing gears
Gear wheels:
1. Drive gear, crankshaft
2. Idler gear, outer bull gear
Idler gear, inner bull gear
3. Idler gear, adjustable
4. Drive gear (with oscillation damper), camshaft
5. Idler gear, servo pump
6. Drive gear, steering servo and fuel feed pump
7. Drive gear, air compressor
8. Drive gear, lubricating oil pump
9. Engine power take-off (extra equipment)
Backlash.....0.05 - 0.17 mm
Shaft journal for idler gear, diameter.....100 mm
Idler gear bush, diameter.....100 mm
Diametrical clearance for idler gear.....max 0.05 mm
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Camshaft
Note: Checking the camshaft settings, cold engine and valve clearance for the intake valve of cylinder 1 =
0.
The intake valve for cylinder 1 must be open by 1.7 ± 0.4 mm, with the flywheel positioned at 6° after TDC.
When checking, the timing gears must be turned in the correct direction (clockwise, seen from the front) to absorb
all of the backlash.
Drive.....by gear
Number of bearings.....7
Bearing journals (standard diameter).....70.0 mm
For any undersize dimensions, refer to the Parts Catalogue.
Valve lift:
inlet.....13.1 mm
exhaust (VEB).....13.1 mm
Permissible wear, entire cam profile.....max 0.1 mm
Unit injector, stroke.....13 mm
Wear tolerance
Max end float.....0.2 mm
Max permitted ovality (with new bearing).....0.1 mm
Bearing, max. permitted run-out wear.....0.1 mm
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Camshaft bearings
Camshaft bearing thickness, standard.....1.9 mm
For any oversize dimensions, refer to the Parts Catalogue.
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Crank mechanism
Crankshaft
Length.....1066 mm
Crankshaft axial clearance1.....max. 0.3 mm
Ovality of main bearing journals and big-end bearing journals
.....max 0.01 mm
Taper of main bearing journals and big-end bearing journals.....max 0.01
Runout of middle bearing.....0.15 mm
1Dimensions for lubricated components.
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Main bearing journals
Note: Reference values only, not for machining.
Diameter (Ø)
standard.....108.0 mm
For any undersize dimensions, refer to the Parts Catalogue.
Surface finish, main bearing journal.....Ra 0.25
Surface finish, curvature.....Ra 0.4
Width, axial bearing pin (A) (standard).....42 mm
For any oversize dimensions, refer to the Parts Catalogue.
Fillet radius (R).....4.5 mm
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Thrust washers (axial bearing)
Width (B) (standard).....3.2 mm
For any oversize dimensions, refer to the Parts Catalogue.
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Main bearing shells
Outer diameter (C).....113 mm
Thickness ((D) (standard).....2.5 mm
For any oversize dimensions, refer to the Parts Catalogue.
Diametrical clearance, main bearing.....max 0.1 mm
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Big-end bearing journal
Note: Reference values only, not for machining.
Diameter (Ø).....86 mm
For any undersize dimensions, refer to the Parts Catalogue.
Surface finish, connecting rod bearing journal.....Ra 0.25
Surface finish, curvature.....Ra 0.4
Width (A).....54 mm
Fillet radius (R).....4.5 mm
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Big end bearing shells
Outer diameter (B).....91 mm
Thickness ((C) (standard).....2.4 mm
For any oversize dimensions, refer to the Parts Catalogue.
Diameter, bearing shell bearing seat (D).....90.8 mm
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Connecting rod
Length centre - centre (E).....225 mm
Internal diameter of connecting rod bushing (G).....54 mm
End float, connecting rod - crankshaft1.....max. 0.3 mm
Big-end bearing, radial play1.....max 0.1 mm
Runout2.....0.06 mm
Torsion2.....0.15 mm
1Measurements are for lubricated components.
2Maximum deviation in measuring length of 100 mm
Marking:
FRONT on the rod is turned forward.
Connecting rod and cap are marked as a pair with a serial number (see illustration).
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Flywheel, fitted

Axial runout (manual gearbox) within a measuring radius of 150 mm

.....max. 0.2 mm
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Flywheel housing (installed)
Axial run-out of contact surface against clutch housing
.....max. 0.2 mm

Radial run-out of guide against clutch housing

.....max. 0.2 mm
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Tightening torques
Engine mounting
Front engine mounting, cylinder block.....275 ± 45 Nm
Front engine mounting, front mounting pad.....140 ± 25 Nm
Front engine pad, cross member.....80 ± 15 Nm
Rear engine mounting, flywheel housing.....300 ± 40 Nm
Rear engine mounting, rear engine pad.....540 ± 90 Nm
Rear engine pad, frame.....140 ± 25 Nm
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Bearing cap
Main bearing cap
Step 1:.....150 ±20 Nm
Step 2 (angle tightening).....120 ± 5°
Connecting rod cap
Step 1:..... 30 ± 3 Nm
Tightening stage 2 (torque to angle):.....180 ± 6°
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Stiffening frame
Reinforcement frame.....48 ± 8 Nm
Note: Tighten the bolts in sequence, from the centre and outwards
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Flywheel

Flywheel
Note: Make sure the flange is dry and clean. Tighten the bolts in the order shown in the illustration.
Step 1:.....60 ±5 Nm
Step 2 (angle tightening).....135 ± 10°
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Oscillation damper, crankshaft
Oscillation damper/pulley, crankshaft
Note: Tighten the bolts in the sequence shown in the diagram.
Class 8.8 bolts used in the vibration damper must not be reused.
Step 1:.....40 ±4 Nm
Step 2:.....90 ± 10 Nm
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Flywheel casing
Flywheel housing
Step 1: M8, M12, M14 bolts.....24 ±14 Nm
Step 2: M12 bolts.....85 ±15 Nm
Step 3: M14 bolts.....140 ± 25 Nm
Note: Apply silicone as shown in figure below

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Casing, crankshaft seal
Note: Apply a 2 mm-thick bead of silicone, as shown above, no more than 20 minutes before installation.
Casing crankshaft seal
Step 1: Fit the cover with bolts 2 and 7 and tighten until contact.
Step 2: Tighten bolts 2 and 7.....24 ±4 Nm
Step 3: Tighten the bolts in numerical sequence 1, 3–6, 8, as shown.....24 ± 4 Nm
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Valve cover
Valve cover.....24 ± 4 Nm
Note: Tighten the bolts in the order shown in the illustration.
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Oil cooler cover

Oil cooler cover

Note: Check that the gasket is within its groove before tightening the screws.
Tighten the bolts in sequence as illustrated.....24 ± 4 Nm
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Cylinder head
Cylinder head
Torque tighten the bolts in the number sequence shown in the illustration.
Step 1:.....65 ±5 Nm
Step 2 (tighten until contact):.....65 ±5 Nm
Step 3 (angle tightening).....120 ± 5°
Step 4 (angle tightening).....90 ± 5°
Note: The cylinder head screws can be reused 5 times. If this is done, do not apply locking fluid to the bolts. Do
not apply locking fluid to new bolts as these are pretreated.
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Lifting eye, cylinder head

Lifting eye
Step 1:.....30 ±3 Nm
Step 2 (angle tightening).....80 ± 5°
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Valve EPG/VEB

Lock nut (A), valve.....38 ± 4 Nm

.....(Angular torque 60 ± 5° after contact)
Lock nut (B), gauge.....38 ± 4 Nm

.....(Angular torque 30 +15/–0° after contact)

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Bearing caps, camshaft/rocker arm shaft
Note: To prevent the rocker arm from misaligning during installation, the bolts must be tighten according to the steps
described below.
Step 1:
Tighten bolts 1-7.....25 ± 3 Nm
Step 2:
Tighten bolts 11, 9 and 13.....90 ± 5 Nm
Step 3
Tighten bolts 8, 10, 12, 14.....60 ± 5 Nm
Step 4:
Loosen bolts 9, 13 and 11.
Step 5:
Tighten bolts 11, 9 and 13.....60 ± 5 Nm
Step 6:
Use angle tightening to tighten bolts 1–7.....90 ± 5°
Step 7:
Use angle tightening to tighten bolts 8–14.....100 ± 5°
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Timing gear plate
Timing gear plate.....28 ± 4 Nm
Note: Apply silicone and tighten the bolts in the order shown in the illustration.
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Timing gears
1. Drive gear (with oscillation damper), crankshaft.....24 ± 4 Nm
2. Idler gear
Torque tighten the bolts in the number sequence shown in the illustration.
Step 1:.....25 ±3 Nm
Step 2 (angle tightening).....110 ± 5°
3. Idler gear, adjustable
Torque tighten the bolts in the number sequence shown in the illustration.
Step 1:.....35 ±4 Nm
Step 2 (angle tightening).....120 ± 5°
4. Drive gear, camshaft
Torque tighten the bolts in the number sequence shown in the illustration.
Step 1:.....45 ±5 Nm
Step 2 (angle tightening).....90±5°
5. Drive gear, steering servo and fuel feed pump.....100 ± 10 Nm

6. Drive gear, air compressor..... 200 + 50/– 0Nm

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Timing gear cover
Apply a 2 mm thick bead of silicone, as shown above, max. 20 minutes before assembly.
Install the cover in two steps.
Step 1: Fasten the cover with bolts 1 and 21.....4 ± 1 Nm
Tighten the bolts in the numeric sequence shown in the diagram.....24 ± 4 Nm
1Use the special tool to press the cover into place.
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