Repair Manual

MAN Industrial Gas Engines

E3268 LE212 / LE222

E3262 LE202 / LE212

MAN Engines
A Division of MAN Truck & Bus
Repair Manual AE15
2st edition

MAN Industrial Gas Engines

E3268 LE212, E3268 LE222
E3262 LE202, E3262 LE212

51.99598-8313

1
PREFACE / PRINTER’S IMPRINT

PREFACE

This manual provides assistance in performing repairs correctly on units and reects the known technical
situation appertaining at the copy deadline.

This publication assumes that persons who use it possess the requisite technical knowledge in repairing units.

Pictures and the corresponding descriptions are typical one-time representations; they do not always
correspond to the unit to be repaired or its peripherals.

The repair jobs are divided up into sections and subsections. Each subsection 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. Only the tightening torques
for screw/bolt connections which deviate from the standard are indicated in the repair sections.

Important instructions concerning technical safety and the safety of personnel are specically highlighted, as
indicated below.
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
An explanatory note which is useful for understanding the working or operating procedure to be
performed.

Comply with general safety regulations when performing any repair work.

We reserve the right to make modications in the course of further development.

Best wishes from

MAN Truck & Bus AG

PRINTER’S IMPRINT

© 2015 MAN Truck & Bus AG

Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN
Truck & Bus AG. All rights under the copyright law are strictly reserved by MAN Truck & Bus AG. If any
changes or modications are made without the written approval of MAN Truck & Bus AG then MAN Truck &
Bus AG shall not be liable for any material defects attributable to the unauthorised changes or modications.
MAN Truck & Bus AG is not liable for any damage attributable to unauthorised changes or modications.

Redaktion: EPEGG, technical status 05.2015

Satz: EPEGG

Druck: EPEGR

2 AE15 2st edition

 TABLE OF CONTENTS

Content Chapter/Page

Index 7

Introduction

Notes on safety ........................................................................................................... 9

The engine ................................................................................................................ 13
Model plate/model designation .................................................................................... 13
Characteristic data .................................................................................................. 15
Engine description ................................................................................................... 18

Troubleshooting chart

Malfunctions and their probable causes ............................................................................. 23

Engine electrics

Engine electrics .......................................................................................................... 29

Removing and installing the engine electrics ................................................................... 29
Removing and installing the engine wiring harness ........................................................... 37

Cooling system

Coolant connection V8 ................................................................................................. 47

Removing and installing coolant connection V8 ............................................................... 47
Coolant connection V12 ................................................................................................ 51
Removing and installing coolant connection V12 .............................................................. 51
Connection housing ..................................................................................................... 55
Removing and installing the connection housing .............................................................. 55
Inlet coolant manifold ................................................................................................... 59
Removing and installing the coolant manifold .................................................................. 59
Coolant lines .............................................................................................................. 63
Removing and installing the coolant lines ....................................................................... 63

Add-on units

Air compressor cover ................................................................................................... 71

Removing and installing the air compressor cover ............................................................ 71
Starter ..................................................................................................................... 73
Removing and installing the starter .............................................................................. 73

Charge-mixture system

Charge-mixture system ................................................................................................. 79

Removing and installing the charge-mixture system .......................................................... 79
Removing and installing the air distribution pipes ............................................................. 88

Ignition system

Spark plugs ............................................................................................................... 95

Removing and installing the spark plugs ........................................................................ 95

Turbocharging

Intake manifold V8 ...................................................................................................... 99

Removing and installing the intake manifold ................................................................... 99
Exhaust gas turbocharger V8 ....................................................................................... 103
Removing and installing the exhaust gas turbocharger V8 ................................................ 103

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TABLE OF CONTENTS

Exhaust gas turbocharger V12 ...................................................................................... 115

Removing and installing the exhaust gas turbocharger V12 .............................................. 115

Intake/exhaust system

Exhaust manifold V8 .................................................................................................. 131

Removing and installing the exhaust manifold V8 ........................................................... 131
Intake manifold V12 ................................................................................................... 135
Removing and installing the intake manifold V12 ............................................................ 135
Exhaust pipes .......................................................................................................... 139
Removing and installing the exhaust pipes V8 ............................................................... 139
Removing and installing the exhaust pipes V12 ............................................................. 142

Cylinder head

Cylinder head .......................................................................................................... 153

Removing and installing the cylinder head cover ............................................................ 153
Removing and installing the rocker arm mechanism ........................................................ 156
Dismantling and assembling the rocker arm mechanism .................................................. 158
Removing and installing the cylinder head .................................................................... 162
Removing and installing the valve stem seals ............................................................... 170
Checking and setting the valve clearance .................................................................... 178

Valve timing

Camshaft ................................................................................................................ 185

Removing and installing the camshaft/camshaft bearings ................................................. 185
Valve timing ............................................................................................................. 191
Checking the valve timing ........................................................................................ 191

Timing gears/drive gears

Front drive gears ....................................................................................................... 197

Removing and installing the front drive gears ................................................................ 197
Rear timing gears ...................................................................................................... 199
Removing and installing the rear timing gears ............................................................... 199

Engine lubrication

Oil lter and oil separator ............................................................................................ 205

Removing and installing the oil lter ........................................................................... 205
Removing and installing the oil modules ...................................................................... 209
Removing and installing the oil cooler ......................................................................... 215
Dismantling and assembling the oil module .................................................................. 217
Oil injector nozzles .................................................................................................... 221
Removing and installing the oil injector nozzles ............................................................. 221
Oil sump ................................................................................................................. 223
Removing and installing the oil sump V8 ...................................................................... 223
Removing and installing the oil sump V12 .................................................................... 226
Dismantling and assembling the oil sump V8 ................................................................ 229
Dismantling and assembling the oil sump V12 ............................................................... 236
Oil pumps ............................................................................................................... 241
Removing and installing the oil pumps ........................................................................ 241

Crankshaft oil seals

Crankshaft oil seals ................................................................................................... 247

Removing and installing the front radial shaft seal .......................................................... 247
Removing and installing the rear radial shaft seal ........................................................... 250

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 TABLE OF CONTENTS

Crankshaft drive

Vibration damper ...................................................................................................... 259

Removing and installing the vibration damper ............................................................... 259
Intermediate ring ....................................................................................................... 265
Removing and installing the intermediate ring (variant) .................................................... 265
Additional ywheel mass ............................................................................................. 267
Removing and installing the additional ywheel mass (variant) ........................................... 267
Flywheel ................................................................................................................. 271
Removing and installing the ywheel .......................................................................... 271
Pistons and connecting rods ........................................................................................ 279
Removing, installing the piston with connecting rod ........................................................ 279
Crankshaft .............................................................................................................. 289
Removing and installing the crankshaft ....................................................................... 289

Crankcase

Engine ventilation, V8 ................................................................................................. 311

Removing and installing the engine ventilation .............................................................. 311
Engine ventilation, V12 ............................................................................................... 313
Removing and installing the engine ventilation .............................................................. 313
Cover .................................................................................................................... 317
Removing and installing the cover ............................................................................. 317
Flywheel housing ...................................................................................................... 321
Removing and installing the ywheel housing ............................................................... 321
Dismantling and assembling the ywheel housing .......................................................... 326
Cylinder liner ........................................................................................................... 329
Removing and installing the cylinder liner .................................................................... 329
Engine mount .......................................................................................................... 335
Removing and installing the engine mounts .................................................................. 335

Technical Data

Technical Data 339

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 INDEX

Catchword Page

A
Add-on units
Air compressor cover ............................................................................................................................... 72
Air compressor cover
Installation instructions ............................................................................................................................. 72

C
Camshaft
Anti-rotation device................................................................................................................................. 188
Insertion pin............................................................................................................................................ 187
Roller tappet ........................................................................................................................................... 188
Charge-mixture system ................................................................................................................................. 77
Charge-mixture cooler.............................................................................................................................. 86
Crankshaft
Axial play ................................................................................................................................................ 294
Crank pin ................................................................................................................................................ 301
Crankcase lower section ........................................................................................................................ 295
Crankshaft bearing shell......................................................................................................................... 299
Crankshaft gear...................................................................................................................................... 299
Marks...................................................................................................................................................... 308
Thrust washers....................................................................................................................................... 298
Crankshaft drive
Lower connecting rod bearing ................................................................................................................ 285
Piston pin................................................................................................................................................ 283
Piston pin bore ....................................................................................................................................... 285
Cylinder head
Final tightening ....................................................................................................................................... 169
Preliminary tightening............................................................................................................................. 168
Tightening diagram................................................................................................................................. 168
Cylinder liner
Cylinder liner standout............................................................................................................................ 332
Sectional sealing rings ........................................................................................................................... 333

D
Drive gears
Crankshaft gear...................................................................................................................................... 198

E
Engine description ......................................................................................................................................... 18
Engine housing
Cover...................................................................................................................................................... 319
Engine timing
Checking the valve lift ............................................................................................................................ 193

I
Ignition system............................................................................................................................................... 93
Spark plugs .............................................................................................................................................. 95

L
Left air distribution pipe ................................................................................................................................. 90
Left charge-air manifold................................................................................................................................. 80

M
Model plate .................................................................................................................................................... 13

N
Notes on safety................................................................................................................................................ 9
General....................................................................................................................................................... 9

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INDEX

O
Oil cooler
Oil cooler ................................................................................................................................................ 216
Oil injector nozzles
Mounting bolt.......................................................................................................................................... 221
Oil pump
Axial play ................................................................................................................................................ 243

R
Right charge-air manifold ............................................................................................................................ 123

T
Technical data
Cylinder liner .......................................................................................................................................... 329
Flywheel ................................................................................................................................................. 271
Oil injector nozzles ................................................................................................................................. 221
Vibration damper .................................................................................................................................... 259
Troubleshooting chart
Malfunctions ............................................................................................................................................. 23

V
Vibration damper
Hub......................................................................................................................................................... 262

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 INTRODUCTION

INTRODUCTION

NOTES ON SAFETY

General
Only trained personnel are allowed to carry out operation, service and repair work on engines.

The following sections include summaries of important regulations, listed according to major topics, which
must be complied with. The intention is to provide the knowledge needed to avoid accidents which could
lead to injury, damage and environmental pollution. Please note that these are merely brief extracts taken
from various accident prevention regulations. Of course, all other safety regulations must be followed and
the necessary measures must be taken.

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

Checking, setting and repair work

– Secure units during their removal.
– 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 checking, setting and repair work.

Operating the engine

– Only authorised personnel are permitted to start and operate an engine.
– When the engine is running, do not get too close to rotating parts. Do not wear baggy working clothes. Use
an extractor system if working in enclosed spaces.
– Danger of burns when working on engines at operating temperature.
– Danger of scalding when opening the hot cooling circuit.

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 sufcient
load-carrying capacity.

Attachments and special bodies

– Comply with the safety instructions and regulations issued by the body builder in question if attachments or
special bodies have been tted.

Be careful as battery gases are explosive!

– Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after long journeys or after
charging the batteries with a battery charger.
– When the batteries are disconnected this gas may be ignited by sparks produced by other continuously
operating consumers that cannot be shut down. Blow compressed air through the battery box before
disconnecting the batteries!
– Always disconnect the positive and negative leads before charging and rapid-charging batteries!
– Do not rapid-charge lead-gel and maintenance-free batteries! (not in the case of "maintenance-free acc. to
DIN") The maximum charging capacity is 10% of the indicated capacity per battery. In parallel circuits, the
capacity is increased, in accordance with the total number of batteries connected in parallel.
– Risk of short-circuits due to incorrect battery polarity!
– Do not put metal objects (spanners, mole grips, etc.) on the batteries, since they may connect the terminals
together. Risk of short-circuit!
– Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in use for prolonged periods.

Caution! Battery acid is poisonous and corrosive!

– Wear appropriate protective clothing (gloves) when handling batteries. Do not tip or tilt batteries as acid
may emerge. Similarly, do not tilt gel batteries.
Do not tilt batteries, acid may leak out. Similarly, do not tilt gel batteries.

AE15 2st edition 9

INTRODUCTION

– Measure voltage only using suitable testers! The input resistance of the measurement device must be at
least 10 MΩ.
– Only disconnect and connect plug connections for electronic control unit when the ignition is switched off!

Electric welding
– Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number 80.78010.0002) as
described in the instructions accompanying the device.
– If this device is not available, disconnect the batteries and connect the positive cable to the negative cable
in order to make a rm conductive connection.
– 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.

Working on plastic tubes – Danger of damage and re!

– Mechanical or thermal loading of plastic tubes is not permitted.

Painting
– If paint spraying is to be carried out, do not expose the electronic components to high temperatures (max.
95 °C) for more than brief periods; a time of up to 2 hours is permissible at a maximum of 85 °C. Disconnect
the batteries.

2. Notes on preventing damage and premature wear on units

General
– Units are only designed for their specied purpose - dened by the manufacturer (designated use): Any
other use is classied 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 specied
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.
– 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 plugged.
– Never run a unit dry, in other words always make sure that it has been lled with oil before running it.
– Never run engines without coolant.
– Apply a suitable information sign to units that are not ready to be operated.
– Only use service products as per the MAN Recommended Service Products booklet, otherwise the
manufacturer warranty will be invalidated.
Details of approved products can be found online at: https://mmrepro.mn.man.de/bstwebapp/BSTServlet
– Comply with the specied maintenance intervals.
– Do not ll engine/gear oil above the maximum level mark. Do not exceed the maximum permitted operational
tilt.
– If an engine is taken out of operation for a prolonged period, temporary corrosion protection to MAN Works
Standard M 3069 is necessary.

3. Limited liability for parts and accessories

General
Use only accessories expressly approved by MAN Truck & Bus AG and genuine MAN parts for your MAN
vehicle. MAN Truck & Bus AG accepts no liability for any other products.

4. Regulations for avoiding injury and environmental contamination

Health protection precautions

Avoid prolonged, excessive or repeated skin contact with service products, excipients, thinners or solvents.
Protect your skin using a suitable skin protection agent or protective gloves. Do not use service products,
excipients, thinners or solvents to clean the skin. Apply a greasy skin cream after cleaning your skin.

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 INTRODUCTION

Service products and excipients

Do not use food or drink containers for draining and storing service products or excipients. Comply with
local-authority regulations when disposing of service products and excipients.

Coolant
Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority
when disposing of used coolant (mixture of antifreeze and water).

Cleaning the cooling circuit

Do not pour cleaning uids and rinsing water down the drain if this practice is restricted by specic local
regulations. However, the cleaning uid and rinsing water must, in all cases, be passed through an oil
separator with a sludge trap.

Cleaning the lter insert

When blowing compressed air through the lter insert, make sure the lter dust is collected by a vacuum
or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear suitable rubber
gloves or use a skin barrier cream when washing out the insert, because cleaning agents have aggressive
grease-dissolving characteristics.

Engine/gear oil, lter cartridges, inserts and box-type lters, desiccant cartridges
Filter inserts, cartridges and box-type lters (oil and fuel lters, desiccant cartridges for the air dryer) are
classied as hazardous waste. Comply with local-authority regulations when disposing of the above parts.

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 inammation. 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. Special notes when handling gaseous fuels

The principal components of gaseous fuels are methane, propane and butane as well as trace amounts
of higher hydrocarbons and inert components such as carbon dioxide and nitrogen.

– It is vital to observe the regulations for gas installations.

– Do not smoke and do not use a naked ame to provide illumination of the working
area.
– Exhaust gases are poisonous. Comply with the regulations for installing MAN
industrial gas engines intended for operation in enclosed rooms. Provide sufcient
ventilation.
– Leaks in the gas supply system represent a risk of explosion and must be repaired
without delay.
– Make sure a re extinguisher and other re-ghting equipment are close at hand and
accessible.
– Do not store any ammable material in the engine compartment.

Procedure in the event of a gas escape

– Close the gas supply stopcock.
– Switch off the master switch of the electrical system.
– Cordon off the danger area. Direct any onlookers away from the danger area.
– Immediately report an escape of gas to the responsible ofcials and initiate repair action.

Procedure in case of re

– Call the re brigade.
– Immediately provide assistance to injured people, inform paramedics of what has happened.
– Do not extinguish the gas ame of a pure gas re. Cool down the burning object if necessary (e.g. by
cutting off the oxygen supply: close doors and windows).
Burning gas = Controlled gas!
– Prevent the ames spreading to the surroundings.
– If the ames begin to spread to the surroundings, combat the re with a re extinguisher.

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INTRODUCTION

– Keep calm!

6. Limp-home program for units with electronic control units

General information
The units have an electronic control system 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.

– Switchover to suitable default function for further operation, albeit with restrictions. Have malfunctions
remedied by MAN after-sales immediately.
– In conjunction with MAN-cats®, the fault code is output directly.

7. Installation instructions

Installation of bolts and nuts

– Lightly oil bolts and nuts on the thread and the contact surface of the bolt head.
– Refer to the reference values in works standard M 3059 for screw connections without specially prescribed
tightening torques.

Installation of ttings, hollow screws and screw plugs

– For tightening torques, see table of installation tightening torques for hollow screws, screw-in ttings, screw
plugs, hose ttings and screw-in ttings with cutting ring connections in the Technical Data section.

Installation of micro-encapsulated bolts

– Comply with the application guidelines in works standard MAN 222 when using micro-encapsulated bolts.

Reuse of bolts and nuts

– Check bolt heads, threads and nuts for wear and ease of movement, replace if necessary
– Only reuse bolts and nuts if they are not worn!

Installation of piping
– Mechanical deformation of piping is not permitted when performing installation work - risk of fracture!

Installation of gaskets
– Only use genuine MAN gaskets
– Make sure the mating faces 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 specied tightening torque.

Installation of O-rings
– Only use genuine MAN O-rings.
– Make sure the mating faces are undamaged and clean.

Engine overhaul
– A range of very different factors affect the engine service life. It is therefore not possible to indicate the
exact number of operating hours or miles before a major overhaul is due.
– In our judgement, 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 signicantly since they were
measured and taken during the initial start-up:
– Charge pressure
– Exhaust temperature
– Coolant and lubricating oil temperature
– Oil pressure and oil consumption
– Smoke characteristics

The following criteria have a major inuence on the engine service life:
– Correct power setting for the application type
– Correct installation
– Approval of the installation by authorised personnel
– Regular maintenance as per the maintenance schedule

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 INTRODUCTION

THE ENGINE

Model plate/model designation

Explanation of the model plate

(1) NI/NII rework levels (3) Engine serial number

(2) Engine type

Explanation of rework levels

Rework levels apply to crankshafts, crankshaft bearings and connecting rod bearings as well as pistons and
cylinder liners. The reworked assemblies are indicated on the model plate, e.g.:

P = crankshaft - connecting rod bearing NI or NII

H = crankshaft - crankshaft bearing NI or NII

Explanation of the engine no. (Engine identication number)

Engine no. Classication terms Example

(assignment)
812 Type number according to
type code
1124 Assembly day
021 Assembly sequence
(progression number on
assembly day)
1120 First day of plan period e.g. period 23/2004 = 11.08.2004 = 0798

Explanation of the model designation

Model Meaning Example

designation

E Fuel type Natural gas

32 Identication number + 100 132 mm bore
6 Identication number for stroke 160 mm stroke
(rounded)
8/2 Number of cylinders 8 / 12 cylinders
L Turbocharging with turbocharging and intercooling

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INTRODUCTION

E Engine installation Auxiliary engine

202 Type identication 2 = Dry exhaust manifold
0 = Development status
2 = Combined heat and power unit

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 INTRODUCTION

Characteristic data

E3268 LE212/LE222

Designation Details
Design V 90°
Mode of operation 4-stroke petrol/gas engine, turbocharged with mixture cooling
Number of cylinders 8
Cylinder bore 132 mm
Cylinder stroke 157 mm
Displacement 17,188 cc
Compression ratio 12:1
Engine weight, dry approx. 1430
Direction of rotation as viewed onto Left
ywheel
Output if "TA Luft" requirements 370 kW at 1500 rpm
(Technical Instructions on Air Quality 390 kW at 1800 rpm
Control) are met
in case of natural-gas operation
The output gures apply to operation with natural gas with a caloric value of 10 kWh/m3 and a methane
number > 80. If the caloric value is lower, the output is correspondingly lower. Consultation with MAN
required.
Output if "TA Luft" requirements 370 kW at 1500 rpm
(Technical Instructions on Air Quality
Control) are met
in case of biogas operation
The output gures apply to operation with biogas (60% CH4, 40% CO2) with a caloric value of 6 kWh/m3
and a methane number of 140.
Firing sequence 1-5-7-2-6-3-4-8
Rated speed 1500/1800
Valve clearance when the engine is cold
Intake valve 0.50 mm
Exhaust valve 0.60 mm
Valve timing 12° before TDC
Intake opens 48° after BDC
Intake closes 61° before BDC
Intake opens 11° after TDC
Intake closes
Ignition point - crankshaft angle before Natural-gas operation (E3268LE212)
TDC 18° ± 1°
1500 rpm - "TA-Luft" (Technical in progress
Instructions on Air Quality Control)
1800 rpm - "TA-Luft" (Technical
Instructions on Air Quality Control)
Ignition point - crankshaft angle before Biogas operation (E3268LE222)
TDC 20° ± 1°
1500 rpm - "TA-Luft" (Technical in progress
Instructions on Air Quality Control)
1800 rpm - "TA-Luft" (Technical
Instructions on Air Quality Control)
Engine lubrication Forced-feed lubrication

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INTRODUCTION

Lube oil pressure during operation must be monitored by oil pressure monitor/display units
(depending on engine speed, oil
temperature and engine load)
Oil lter 2 oil lters, main ow lters each with 1 paper lter cartridge
Oil quantity in the oil sump Max. 95 l
Engine cooling Liquid cooling
Coolant temperature 80/88° C, engine inlet/outlet
Coolant ll quantity in engine approx. 34 l
Starter 24V; 7kW

E3262 LE202/LE212

Designation Data
Design V 90°
Mode of operation 4-stroke petrol/gas engine, turbocharged with mixture cooling
Number of cylinders 12
Cylinder bore 132 mm
Cylinder stroke 157 mm
Displacement 25,782 cc
Compression ratio 12:1
Engine weight, dry approx. 1850
Direction of rotation when looking towards Left
ywheel
Output if "TA Luft" requirements 550 kW at 1500 rpm
(Technical Instructions on Air Quality 580 kW at 1800 rpm
Control) are met
in case of natural-gas operation
The output gures apply to operation with natural gas with a caloric value of 10 kWh/m3 and a methane
number > 80. If the caloric value is lower, the output is correspondingly lower. Consultation with MAN
required.
Output if "TA Luft" requirements 550 kW at 1500 rpm
(Technical Instructions on Air Quality
Control) are met
in case of biogas operation
The output gures apply to operation with biogas (60% CH4, 40% CO2) with a caloric value of 6 kWh/m3
and a methane number of 140.
Firing sequence 1-12-2-11-3-10-6-7-5-8-4-9
Rated speed 1500/1800
Valve clearance when the engine is cold
Intake valve 0.50 mm
Exhaust valve 0.60 mm
Valve timing 12° before TDC
Intake opens 48° after BDC
Intake closes 61° before BDC
Intake opens 11° after TDC
Intake closes

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 INTRODUCTION

Ignition point - crankshaft angle before Natural-gas operation (E3262 LE202)

TDC 16° ± 1°
1500 rpm - "TA-Luft" (Technical 20° ± 1°
Instructions on Air Quality Control)
1800 rpm - "TA-Luft" (Technical
Instructions on Air Quality Control)
Ignition point - crankshaft angle before Biogas operation (E3262 LE202)
TDC 20° ± 1°
1500 rpm - "TA-Luft" (Technical 20° ± 1°
Instructions on Air Quality Control)
1800 rpm - "TA-Luft" (Technical
Instructions on Air Quality Control)
Engine lubrication Forced-feed lubrication
Lube oil pressure during operation must be monitored by oil pressure monitor/display units
(depending on engine speed, oil
temperature and engine load)
Oil lter 2 oil lters, main ow lters each with 1 paper lter cartridge
Oil quantity in the oil sump Max. 105 l
Engine cooling Liquid cooling
Coolant temperature 80/88° C, engine inlet/outlet
Coolant ll quantity in engine approx. 50 l
Starter 24V; 7kW

AE15 2st edition 17

INTRODUCTION

Engine description

Engine E3268 LE212/LE222, front left view

(1) Turbocharger (5) Coolant outlet

(2) Exhaust manifold (6) Ventilation housing for coolant
(3) Exhaust pipe with heat shield (7) Charge-mixture cooler
(4) Protective cover for crankshaft and
vibration damper

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 INTRODUCTION

Engine E3268 LE212/LE222, front right view

(1) Oil module (3) Cylinder head cover

(2) Oil ller pipe (4) Throttle valve

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INTRODUCTION

Engine E3262 LE202/LE212, front left view

(1) Intake manifold (5) Coolant outlet

(2) Turbocharger (6) Ventilation housing for coolant
(3) Exhaust pipe with heat shield (7) Charge-mixture cooler
(4) Protective cover for crankshaft and
vibration damper

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 INTRODUCTION

Engine E3262 LE202/LE212, front right view

(1) Oil module (3) Cylinder head cover

(2) Oil ller neck (4) Charge-mixture elbow

Engine, general
The 8 and 12-cylinder gas engines described here are liquid-cooled, 4-stroke engines with turbocharger and
intercooler.

Gas line
The gas line, consisting of the ballcock, gas lter, solenoid valves, gas pressure regulator, gas mixer and air
lter, is not supplied by MAN.

Crankcase
The crankcase consists of the crankcase upper section and the crankcase lower section. Both sections cast
from different special cast irons. The wet cylinder liners made from special, highly wear-resistant centrifugal
casting are exchangeable. The cylinder liners are sealed at the bottom using elastomer sealing rings. At the
rear of the crankcase, there is a ywheel housing. At the front of the crankcase, there is a housing cover.
The ywheel housing and housing cover are made of aluminium. The radial shaft seals are installed in the
housing cover and the ywheel housing.

Crankshaft
The crankshaft is forged in a die using high-quality, micro-alloyed steel. It has mounted counterweights
to balance the masses. The crankshaft is mounted in bearings in the crankcase. The crankshaft journal
and crank pin are mounted in ready-to-install three-compound bearings. The axial bearing is provided by a
crankshaft thrust bearing in the last bearing seat at the ywheel end. The oil for the connecting rod bearings
is supplied from the main bearing through a hole.

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INTRODUCTION

Connecting rods (“cracked” connecting rods)

The “cracked” connecting rods are precision forged in a die using quenched and tempered steel. The large
connecting rod eye is split diagonally by "cracking" the connecting rod bearing cap. 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 t and high lateral stability.

Pistons
3-ring aluminium pistons are used. The pistons have a cooling duct for relieving the thermal load. This area
is covered by exible metal containing a bore into which the oil jet from the oil injection nozzles is injected
for cooling. The ring set comprises one half keystone ring and taper-face ring each as compression rings as
well as a double-bevelled ring as oil scraper ring. The pistons can be removed from above together with the
connecting rods.

Camshaft
The camshaft is forged from steel and induction hardened. It has 5 bearing points in the crankcase in the
8-cylinder engine and 7 such bearing points in the 12-cylinder engine. The camshaft drive onto the camshaft
gear comes directly from the crankshaft gear.

Engine lubrication
The engine is lubricated by forced-feed lubrication for all bearing points. The engine oil lter and the oil cooler
are grouped together as an oil module. The oil level in the oil sump is measured using a dipstick.

Cooling system
The coolant circuit is designed by the manufacturer of the combined heat and power unit. Combined heat
and power unit engines are preferably operated with hydrostatic primary pressure (1 mWs corresponding to
0.1 bar). This prevents any gradual pressure loss in the cooling system.

Cylinder head
The cylinder head is made from special cast iron and is equipped with shrink-tted valve seat rings and
pressed-in, exchangeable valve guides. The valve guide is provided with a valve stem seal at the induction
valve. The valves are actuated by individually exchangeable rocker arms on rocker shafts. The cylinder head
is secured with high-strength Torx screws (cylinder head bolts). The single-layer steel cylinder head gasket
has a specially designed combustion chamber seal.

Induction and exhaust system

The exhaust manifolds are cast from high temperature-resistant spheroidal graphite cast iron and are secured
on the cylinder heads with heat resistant bolts. Maintenance-free turbochargers are mounted at the exhaust
manifolds (V12 - two turbochargers / V8 one turbocharger). The turbochargers are lubricated by the main
ow oil circuit of the engine, which supplies oil to the oil pressure port on the turbochargers. The bearing
pedestal and the turbine housing are liquid-cooled.

Starter
The starter is a sliding-gear starter. When the starter is operated, the sliding gear guides the pinion into the
ring gear by means of a starter solenoid.

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 TROUBLESHOOTING CHART

TROUBLESHOOTING CHART

MALFUNCTIONS AND THEIR PROBABLE CAUSES

We recommend the following:

Repairs can only be considered complete when both the problem that occurred and the possible causes
have been remedied. Finding out what caused a problem is often more difcult than remedying the problem
itself. We therefore recommend that, before “removing and dismantling”, you have the malfunction described
in detail. Then narrow down the probable causes by asking specic questions. Once this is done, use the
chart and your own experience to examine the probable causes one after the other and rectify the problem.
This method helps reduce repairs to acceptable levels and counteracts possible complaints regarding “rash”
exchange of parts and expensive labour time and downtime.

Note:

The following chart is designed to serve as a memory aid for experts, the aim being to ensure that no probable
causes are overlooked when troubleshooting. The specialist is expected to be familiar with the repair manual
for the engine as well as the corresponding operating instructions and the “Service Products for MAN Industrial
Gas Engines”.

AE15 2st edition 23

TROUBLESHOOTING CHART

Troubleshooting chart - part 1, malfunctions 1-11

Malfunction
The starter does not turn the engine or only turns it slowly, magnetic switch picks up (“clicking”
can be heard)
Starter turns, engine is not turned
Starter turns the engine, engine does not start / poor starting
Misring
Irregular engine running
Engine stops during operation and no longer starts
Engine “shaking”
Engine only runs at idling speed
Idling speed unstable
Engine does not reach its rated speed
Engine does not reach its rated power
Possible causes
x Flat batteries, loose or corroded battery cable connections,
discontinuity in circuit
x Starter defective (carbon brushes loose/worn, coil defective, ground
short)
x Engaging lever / bearing pin of engaging lever broken
x Crankshaft drive blocked
x Engine oil viscosity inappropriate, not suitable for the ambient
temperature
x Ignition control unit defective
x Pulse sensor defective / gap set incorrectly
x x x Spark plug defective
x x x Spark plug cable defective
x x x Ignition coil defective
x x x x Ignition point setting is wrong
x Throttle valve does not open / operating linkage sticking / positioning
device deenergised or defective
x x Throttle valve not in full-load position / operating linkage sticking /
throttle valve incorrectly adjusted
x x Shut-off solenoid valve of gas supply closed / does not open
x x Zero pressure controller of the gas supply not set correctly / defective
x x x Gas metering valve defective
x x Gas / air mixture too rich or too lean
x x Defective compression or more than 3 bar pressure difference
between the individual cylinders
x x x Incorrect valve clearance
x x x Valve seats leaking
x x x Piston rings severely worn, broken (excess pressure in crankcase)
x x Air lter very dirty
x x Charge-mixture cooler contaminated / leaking

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 TROUBLESHOOTING CHART

Malfunction
The starter does not turn the engine or only turns it slowly, magnetic switch picks up (“clicking”
can be heard)
Starter turns, engine is not turned
Starter turns the engine, engine does not start / poor starting
Misring
Irregular engine running
Engine stops during operation and no longer starts
Engine “shaking”
Engine only runs at idling speed
Idling speed unstable
Engine does not reach its rated speed
Engine does not reach its rated power
Possible causes
x x Charge-mixture piping leaking
x Engine mounting unsuitable / worn

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TROUBLESHOOTING CHART

Troubleshooting chart - part 2, malfunctions 12-20

Malfunction
Excessive fuel consumption
Oil consumption too high
Engine too “loud” / mechanical noises
High blue smoke output
High white smoke output
Exhaust temperature / exhaust backpressure too high (thermal overload)
Lubricating oil pressure too low
Temperature differential between engine outlet / engine inlet too great
Coolant temperature too high
Possible causes
x Engine oil viscosity inappropriate, not suitable for the ambient temperature
x x Ignition point setting is wrong
x Gas / air mixture too rich or too lean
x Incorrect valve clearance
x x Valve guides severely worn
x Valve seats leaking
x x Piston rings severely worn, broken (excess pressure in crankcase)
x x Air lter very dirty
x Charge-mixture cooler contaminated / leaking
x Charge-mixture piping leaking
x x Turbine and compressor wheel in turbocharger contaminated (not running
smoothly, imbalance)
x Coolant is getting into the combustion chamber (cylinder head gasket
leaking)
x Engine in cold-running phase
x x Positive crankcase ventilation blocked
x Oil level in oil sump too high
x Safety valve in oil circuit defective (does not close, spring fatigue or spring
broken)
x Severe bearing wear
x Oil pump severely worn
x Safety valve in oil circuit defective (does not open), oil lines / oil ducts blocked
x Unsuitable exhaust pipe routing, heat exchanger and catalytic converters
have excessive resistance
x Flow resistance of the cooling system too great
x x Contamination of the cooling system
x Coolant level too low, air in coolant circuit
x Coolant pump not large enough
x x Coolant lines leaking, blocked or twisted

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 ENGINE ELECTRICS

ENGINE ELECTRICS

(1) Data acquisition (6) Oil temperature sensor, right

(2) Engine wiring harness (7) Oil pressure sensor, right
(3) Exhaust gas temperature sensor (8) Coolant temperature sensor, coolant inlet
(4) Oil pressure sensor, left (9) Coolant temperature sensor, coolant outlet
(5) Oil temperature sensor, left (10) Charge-air pressure sensor

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 ENGINE ELECTRICS

ENGINE ELECTRICS
Removing and installing the engine electrics

(1) Data acquisition (6) Oil temperature sensor, right

(2) Engine wiring harness (7) Oil pressure sensor, right
(3) Exhaust gas temperature sensor (8) Coolant temperature sensor, coolant inlet
(4) Oil pressure sensor, left (9) Coolant temperature sensor, coolant outlet
(5) Oil temperature sensor, left (10) Charge-air pressure sensor

Technical data
Temperature sensor.............................................. M16x1.5 ............................................................47 Nm
Pressure sensor ................................................... M18x1.5 ............................................................47 Nm
Mounting bolt, charge-air pressure sensor ............. M6x16-10.9 ........................................................ 9 Nm

Service products
Engine oil..................................see Maintenance Recommendations and Recommended Service Products

Important information
CAUTION
Danger of injury due to sharp-edged protrusions on the cable ties
• Always use Cable tie pliers [1] to tighten and cut cable ties

WARNING
Electrical system damage caused by overvoltage
• Deenergise the electrical system before working on it so as to avoid damage to the electrics
(overvoltage as a result of disconnecting connectors)

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ENGINE ELECTRICS

WARNING
Electrical line damage due to overtightening
• Follow the operating instructions for the Cable tie pliers [1]

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
Mark the installation position of the cable ties and disconnect the cable ties before removing
switches or sensors.
Install the cable ties as marked after installing switches or sensors.
Note
The installation and removal procedure for the sensors on the left and right oil module is identical

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 ENGINE ELECTRICS

Removing the oil pressure sensor Removing the oil temperature sensor
Disconnecting the electrical connection Disconnecting the electrical connection

• Disconnect the electrical connection (1) • Disconnect the electrical connection (1)

Removing the left oil pressure sensor Removing the left oil temperature sensor

Note Note
The installation and removal procedure The installation and removal procedure
for the sensors on the left and right oil for the sensors on the left and right oil
module is identical module is identical

• Unscrew the oil pressure sensor (1) with sealing • Unscrew the oil temperature sensor (1) with
ring (2) sealing ring (2)

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ENGINE ELECTRICS

Removing the coolant inlet temperature Removing the coolant outlet

sensor temperature sensor
Disconnecting the electrical connection Disconnecting the electrical connection

• Disconnect the electrical connection (1) • Disconnect the electrical connection (1)

Removing the temperature sensor Removing the temperature sensor

• Unscrew the temperature sensor (2) with sealing • Unscrew the temperature sensor (2) with sealing
ring (1) ring (1)

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 ENGINE ELECTRICS

Removing the charge-air pressure Removing the exhaust gas temperature

sensor sensor
Disconnecting the electrical connection Removing the exhaust gas temperature sensor

• Disconnect the electrical connection (1) • Disconnect the electrical connection

• Unscrew the exhaust gas temperature sensor (2)
Removing the charge-air pressure sensor with sealing ring (1)

• Unscrew the mounting bolts (1)

• Pull out the pressure sensor (2)

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ENGINE ELECTRICS

Installing the exhaust gas temperature Installing the charge-air pressure

sensor sensor
Installing the exhaust gas temperature sensor Installing the charge-air pressure sensor

• Screw in and tighten the exhaust gas temperature • Insert the pressure sensor (2) with a new O-ring
sensor (2) with a new sealing ring (1) • Screw in the mounting bolts (1) and tighten them
• Connect the electrical connection to 9 Nm

Connecting the electrical connection

• Connect the electrical connection (1)

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 ENGINE ELECTRICS

Installing the coolant outlet temperature Installing the coolant inlet temperature
sensor sensor
Installing the temperature sensor Installing the temperature sensor

• Thinly apply clean Engine oil on the thread of the • Thinly apply clean Engine oil on the thread of the
temperature sensor (2) temperature sensor (2)
• Screw in the temperature sensor (2) with a new • Screw in the temperature sensor (2) with a new
sealing ring (1) and tighten to 47 Nm sealing ring (1) and tighten to 47 Nm

Connecting the electrical connection Connecting the electrical connection

• Connect the electrical connection (1) • Connect the electrical connection (1)

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ENGINE ELECTRICS

Installing the oil temperature sensor Installing the oil pressure sensor
Installing the left oil temperature sensor Installing the left oil pressure sensor

Note Note
The installation and removal procedure The installation and removal procedure
for the sensors on the left and right oil for the sensors on the left and right oil
module is identical module is identical

• Thinly apply clean Engine oil on the thread of the • Thinly apply clean Engine oil on the thread of the
oil temperature sensor (2) oil pressure sensor (1)
• Screw in the oil temperature sensor (2) with a new • Screw in the oil pressure sensor (1) with a new
sealing ring (1) and tighten to 47 Nm sealing ring (2) and tighten to 47 Nm

Connecting the electrical connection Connecting the electrical connection

• Connect the electrical connection (1) • Connect the electrical connection (1)

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 ENGINE ELECTRICS

Removing and installing the engine wiring harness

(1) Data acquisition (2) Engine wiring harness

Important information
CAUTION
Danger of injury due to sharp-edged protrusions on the cable ties
• Always use to tighten and cut cable ties

WARNING
Electrical line damage due to overtightening
• Follow the instructions

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Restricted operation due to defective entries in the fault memory
• Before removing switches or sensors, read out and document the fault memory
• Always install switches and sensors with new O-rings or sealing rings
• After installing switches or sensors, read out the fault memory and, if necessary, delete it
WARNING
Component damage caused by incorrect wiring harness routing
• Document the wiring harness routing and mark the installation position
• Mark the installation position, fastening type and position of the wiring harness fastenings

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ENGINE ELECTRICS

Note
Mark the installation position of the cable ties and disconnect the cable ties before removing
switches or sensors.
Install the cable ties as marked after installing switches or sensors.

Special tools

[1] Cable tie pliers 08.02960-0100

• Tightening and cutting off the cable ties

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 ENGINE ELECTRICS

Removing the engine wiring harness Disconnecting the oil module electrical
connections
Exposing the wiring harness

• Mark the installation position of the wiring harness

• Mark the installation position of the wiring harness (2)
(1) • Disconnect the electrical connections (1)
• Unclip the wiring harness (1) from the pipe holder • Expose the wiring harness (2)
• Leave the wiring harness (1) lying on the holder
• Mark the installation position of the cable ties and Disconnecting the data acquisition electrical
fastening points connections
• Disconnect the wiring harness

Disconnecting the exhaust gas temperature

sensor electrical connection

WARNING
Danger of irreparable data acquisition
system damage
• When removing the connectors, rst
• Disconnect the electrical connection (1)
open the lock completely, then pull off
• Unclip the wiring harness (2) from the pipe holder
the connector
• Expose the wiring harness (2)
• Mark the installation position of the wiring harness
(2)
• Disconnect the electrical connection (1)
• Release and pull off the connector (3)
• Expose the wiring harness (2)

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ENGINE ELECTRICS

Releasing the pipe clamp Removing the holder for the data acquisition
wiring harness

• Unscrew the mounting bolt (1)

• Turn the pipe clamp (2) • Unscrew the mounting bolts (1)
• Remove the holder for the wiring harness (2)
Removing the data acquisition
Removing the holder for the wiring harness

• Unscrew the mounting bolts (1)

• Remove the holder for the wiring harness (2) with
bushes (3)

Removing the holder

• Unscrew the mounting bolts (1)

• Remove the data acquisition (3) with the washers
(2) and the holder (4)
• Unscrew the circular mount (5)

• Unscrew the mounting bolt (1)

• Remove the holder (2) with the washer (3) and the
bush (4)

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 ENGINE ELECTRICS

Removing the holder for the wiring harness Installing the engine wiring harness
Mounting the holder for the wiring harness

• Unscrew the mounting bolts (1)

• Remove the holder (2)
• Position the holder (2)
• Screw in and tighten the mounting bolts (1)

Mounting the holder

• Position the holder (2) with the washer (3) and the
bush (4)
• Screw in and tighten the mounting bolt (1)

Mounting the holder for the wiring harness

• Position the holder for the wiring harness (2) with

bushes (3)
• Screw in and tighten the mounting bolts (1)

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ENGINE ELECTRICS

Mounting the holder for the data acquisition Mounting the pipe clamp
wiring harness

• Turn the contact surface of the pipe clamp (2) on

• Position the holder for the wiring harness (2) the holder
• Screw in and tighten the mounting bolts (1) • Screw in and tighten the mounting bolt (1)

Mounting the data acquisition Fastening the wiring harness

• Check the wiring harness (1) and wiring harness

fastenings for damage, replace if necessary
• Clip the wiring harness (1) into the pipe holder as
marked
• Fasten the wiring harness (1) at the marked points
using cable ties
• Tighten and cut off cable ties using the Cable tie
pliers [1]

• Screw in and tighten the circular mount (5)

• Position the data acquisition (3) with the washers
(2) and the holder (4)
• Screw in and tighten the mounting bolts (1)

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 ENGINE ELECTRICS

Connecting the data acquisition electrical Connecting the exhaust gas temperature sensor
connections electrical connection

• Clip the wiring harness (2) into the pipe holder

WARNING
• Connect the electrical connection (1)
Danger of irreparable data acquisition
system damage
• When installing the connectors, rst
fully open the lock and then insert and
lock the connectors

• Route the wiring harness (2) as marked

• Connect the electrical connection (1)
• Insert the connector (3) into the data acquisition
and lock it

Connecting the oil module electrical

connections

• Route the wiring harness (2) as marked

• Connect the electrical connections (1)

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 COOLING SYSTEM

COOLING SYSTEM

(1) Coolant manifold, coolant inlet (3) Ventilation housing

(2) Connection housing (4) Coolant line

AE15 2st edition 45

 COOLING SYSTEM

COOLANT CONNECTION V8
Removing and installing coolant connection V8

(1) Coolant lines (3) Coolant line

(2) Ventilation housing (4) Adapter for ventilation housing

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 47

COOLING SYSTEM

Removing the V8 coolant line Removing the ventilation housing

Detaching the right coolant line

• Unscrew the union nuts (1)

• Detach the coolant line (2)

Detaching the left coolant line

• Unscrew the mounting bolts (3)

• Remove the ventilation housing (1) with the O-ring
(2)
• Clean the mating faces

Dismantling the ventilation housing

• Unscrew the union nuts (1)

• Detach the coolant line (2)

Detaching the coolant line

• Unscrew the hollow screw (1) with the sealing

rings and the ring connectors (2) and (3)
• Unscrew the adapter tting (4) with the sealing ring
• Unscrew the hollow screw (5) with the sealing
rings and the ring connector (6)
• Unscrew the mounting bolt (3) • Unscrew the hollow screw (7) with the sealing
• Unscrew the union nuts (1) rings and the ring connector (8)
• Detach the coolant line (2) • Unscrew the adapter plug (9) with the sealing ring

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 COOLING SYSTEM

Removing the adapter for the ventilation Installing the V8 coolant line
housing
Mounting the adapter for the ventilation housing

• Unscrew the mounting bolts (3)

• Remove the adapter for the ventilation housing (1) • Clean the mating faces
with the O-ring (2) • Position the adapter for the ventilation housing (1)
• Clean the mating faces with the new O-ring (2)
• Screw in the mounting bolts (3) and tighten them

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COOLING SYSTEM

Assembling the ventilation housing Attaching the coolant line

• Screw in and tighten the adapter plug (9) with a • Position the coolant line (2) so that it is free of
new sealing ring strain
• Screw in and tighten the hollow screw (7) with new • Screw in and tighten the mounting bolt (3)
sealing rings and ring connector (8) • Screw on and tighten the union nuts (1)
• Screw in and tighten the adapter tting (4) with a
new sealing ring Attaching the left coolant line
• Screw in and tighten the hollow screw (1) with new
sealing rings and ring connectors (2) and (3)
• Screw in and tighten the hollow screw (5) with new
sealing rings and ring connector (6)

Mounting the ventilation housing

• Position the coolant line (2) so that it is free of

strain
• Screw on and tighten the union nuts (1)

Attaching the right coolant line

• Clean the mating faces • Position the coolant line (2) so that it is free of
• Position the ventilation housing (1) with a new strain
O-ring (2) • Screw on and tighten the union nuts (1)
• Screw in and tighten the mounting bolts (3)

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 COOLING SYSTEM

COOLANT CONNECTION V12

Removing and installing coolant connection V12

(1) Coolant line (2) Ventilation housing

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 51

COOLING SYSTEM

Removing the coolant line Removing the ventilation housing

Detaching the right coolant line

• Unscrew the mounting nut (3)

• Remove the mounting bolt (4) with washer
• Unscrew the union nuts (1)
• Detach the coolant line (2)

Detaching the left coolant line

• Unscrew the mounting bolts (3)

• Remove the ventilation housing (1) with the O-ring
(2)
• Clean the mating faces

Dismantling the ventilation housing

• Unscrew the mounting nut (4)

• Remove the mounting bolt (3) with washer
• Unscrew the union nuts (1)
• Detach the coolant line (2)

• Unscrew the hollow screw (1) with the sealing

rings and the ring connectors (2) and (3)
• Unscrew the adapter tting (4) with the sealing ring
• Unscrew the hollow screw (5) with the sealing
rings and the ring connector (6)
• Unscrew the screw plug (7) with sealing ring

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 COOLING SYSTEM

Installing the coolant line Attaching the left coolant line

Assembling the ventilation housing

• Position the coolant line (2) so that it is free of

strain
• Screw in and tighten the adapter tting (4) with a • Screw on and tighten the union nuts (1)
new sealing ring • Insert the mounting bolt (3) with washer
• Screw in and tighten the hollow screw (1) with new • Screw on and tighten the mounting nut (4)
sealing rings and ring connectors (2) and (3)
• Screw in and tighten the hollow screw (5) with new Attaching the right coolant line
sealing rings and ring connector (6)
• Screw in and tighten the screw plug (7) with a new
sealing ring

Mounting the ventilation housing

• Position the coolant line (2) so that it is free of

strain
• Screw on and tighten the union nuts (1)
• Insert the mounting bolt (4) with washer
• Screw on and tighten the mounting nut (3)

• Clean the mating faces

• Position the ventilation housing (1) with a new
O-ring (2)
• Screw in and tighten the mounting bolts (3)

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 COOLING SYSTEM

CONNECTION HOUSING
Removing and installing the connection housing
Additional jobs
– Removing and installing coolant connection V8, see 47
– Removing and installing coolant connection V12, see 51

(1) Connection housing (2) Screw plug

Technical data
Coolant temperature sensor .................................. M16x1.5 ............................................................47 Nm

Service products
Engine oil..................................see Maintenance Recommendations and Recommended Service Products

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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COOLING SYSTEM

Removing the connection housing Unscrewing the connection housing mounting

bolts
Disconnecting the electrical connection

• Unscrew the mounting bolts (1) and (2)

• Disconnect the electrical connection (1) • Undo the union nut (3)

Removing the coolant temperature sensor Removing the connection housing

• Unscrew the coolant temperature sensor (1) with • Remove the connection housing (1) with the
the sealing ring (2) O-rings (2) and (3)
• Clean the mating faces
Detaching the feed coolant line
Dismantling the connection housing

• Undo the union nuts (2)

• Remove the coolant line (1) • Unscrew the screw plug (1) with the sealing ring
• Unscrew the tting (2) with the sealing ring

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 COOLING SYSTEM

Installing the connection housing Screwing in the connection housing mounting

bolts
Assembling the connection housing

• Screw in and tighten the mounting bolts (1) and (2)

• Screw in and tighten the screw plug (1) with a new • Screw on and tighten the union nut (3)
sealing ring
• Screw in and tighten the tting (2) with a new Attaching the feed coolant line
sealing ring

Mounting the connection housing

• Position the coolant line (1)

• Screw on and tighten the union nuts (2)

• Clean the mating faces Mounting the coolant temperature sensor

• Position the connection housing (1) with new
O-rings (2) and (3)

• Thinly apply clean Engine oil on the thread of the

coolant temperature sensor (1)
• Screw in the coolant temperature sensor (1) with
a new sealing ring (2) and tighten it to 47 Nm

AE15 2st edition 57

COOLING SYSTEM

Connecting the electrical connection

• Connect the electrical connection (1)

58 AE15 2st edition

 COOLING SYSTEM

INLET COOLANT MANIFOLD

Removing and installing the coolant manifold

(1) Coolant manifold (3) Holder for wiring harness

(2) Mounting bolt

Technical data
Coolant temperature sensor .................................. M16x1.5 ............................................................47 Nm

Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
Curil T sealing compound .................................................................................................. 04.90300-9030
Engine oil..................................see Maintenance Recommendations and Recommended Service Products

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 59

COOLING SYSTEM

Removing the coolant manifold Detaching the coolant line

Disconnecting the electrical connections

• Undo the union nuts (2)

• Remove the coolant line (1)
• Mark the installation position of the electrical
connections (2) Unscrewing the adapter ange mounting bolts
• Disconnect the electrical connections (2)
• Unclip and expose the wiring harness (1)

Removing the coolant temperature sensor

• Unscrew and remove the mounting bolts (1) and

(2)

Removing the coolant manifold

• Unscrew the coolant temperature sensor (2) with
the sealing ring (1)

Removing the holder for the wiring harness

• Unscrew the mounting bolts (3) and (4)

• Remove the coolant manifold (1) with O-ring (2)
• Clean the mating faces

• Unscrew the mounting bolts (1)

• Remove the holder (2)

60 AE15 2st edition

 COOLING SYSTEM

Removing the adapter ange Installing the coolant manifold

Assembling the coolant manifold

• Remove the adapter anges (2)

• Remove the unscrewed conduits (1) and the
O-rings (3) • Screw in and tighten the screw plug (1) with a new
sealing ring (2)
Dismantling the coolant manifold • Screw in and tighten the tting (3) with a new
sealing ring (4)

Positioning the adapter ange

• Unscrew the screw plug (1) with sealing ring (2)

• Unscrew the tting (3) with the sealing ring (4)

• Thinly apply Radiator antifreeze on the contact

surfaces of the new unscrewed conduits (1)
• Insert the unscrewed conduits (1) into the coolant
manifold
• Insert the new O-rings (3) into the adapter anges
(2)
• Place the adapter anges (2) on the unscrewed
conduits (1)

AE15 2st edition 61

COOLING SYSTEM

Mounting the coolant manifold Mounting the holder for the wiring harness

• Clean the mating faces • Position the holder (2)

• Position the coolant manifold (1) with a new O-ring • Screw in the mounting bolts (1) and tighten them
(2)
• Screw in and tighten the mounting bolts (3) and (4) Mounting the coolant temperature sensor

Screwing in the adapter ange mounting bolts

• Thinly apply clean Engine oil on the thread of the

coolant temperature sensor (2)
• Screw in and tighten the mounting bolts (1) and (2) • Screw in the coolant temperature sensor (2) with
a new sealing ring (1) and tighten it to 47 Nm
Attaching the coolant line
Connecting the electrical connections

• Position the coolant line (1)

• Screw on and tighten the union nuts (2) • Route and clipn in the wiring harness (1)
• Connect the electrical connections (2) as marked

62 AE15 2st edition

 COOLING SYSTEM

COOLANT LINES
Removing and installing the coolant lines

(1) Coolant lines (3) Coolant line

(2) Coolant lines, ventilation, exhaust gas
turbocharger

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[2] Hose clamp pliers for jubilee clips 80.99625-0073

• Installing and removing the jubilee clips

AE15 2st edition 63

COOLING SYSTEM

Removing the left coolant lines Detaching the exhaust gas turbocharger
ventilation coolant line
Detaching the left coolant line

• Unscrew the union nut (2)

• Unscrew the mounting nut (4) • Remove the exhaust gas turbocharger ventilation
• Remove the mounting bolt (3) with the washer coolant line (1)
• Unscrew the union nuts (1)
• Remove the coolant line (2) Detaching the left vent line

Detaching the left exhaust gas turbocharger

ventilation coolant line

• Undo the jubilee clips (3) and (5) using the Hose
clamp pliers for jubilee clips [2]
• Unscrew the mounting bolts (2)
• Unscrew the mounting nuts (4) • Remove the vent line (4) with the bushes (1)
• Remove the mounting bolts (3) with the washers
• Unscrew the union nuts (1) Removing the coolant line
• Remove the left exhaust gas turbocharger
ventilation coolant line (2)

• Unscrew the hollow screws (1) and the hollow

screw ttings (2) with the sealing rings
• Remove the coolant line (3) with the sealing rings

64 AE15 2st edition

 COOLING SYSTEM

Installing the left coolant lines Installing the exhaust gas turbocharger
ventilation coolant line
Installing the coolant line

• Position and align the exhaust gas turbocharger

• Position the coolant line (3) with new sealing rings ventilation coolant line (1)
• Screw in and tighten the hollow screws (1) and • Screw on and tighten the union nut (2)
hollow screw ttings (2) with new sealing rings
Installing the left exhaust gas turbocharger
Installing the left vent line ventilation coolant line

• Position the vent line (4) and pull on the hoses with • Position the left exhaust gas turbocharger
the jubilee clips (3) and (5) ventilation coolant line (2)
• Position the bushes (1) • Screw on and tighten the union nuts (1)
• Screw in the mounting bolts (2) and tighten them • Insert the mounting bolts (3) with the washers
• Tighten the jubilee clips (3) and (5) using the Hose • Screw on and tighten the mounting nuts (4)
clamp pliers for jubilee clips [2]

AE15 2st edition 65

COOLING SYSTEM

Installing the left coolant line Removing the right coolant lines
Detaching the right coolant line

• Position the coolant line (2)

• Screw on and tighten the union nuts (1)
• Insert the mounting bolt (3) with the washer • Unscrew the mounting nut (3)
• Screw on and tighten the mounting nut (4) • Remove the mounting bolt (4) with the washer
• Unscrew the union nuts (1)
• Remove the coolant line (2)

Detaching the right exhaust gas turbocharger

ventilation coolant line

• Unscrew the mounting nuts (4)

• Remove the mounting bolts (3) with the washers
• Unscrew the union nuts (1)
• Remove the right exhaust gas turbocharger
ventilation coolant line (2)

66 AE15 2st edition

 COOLING SYSTEM

Detaching the exhaust gas turbocharger Installing the right coolant lines
ventilation coolant line
Installing the coolant line

• Unscrew the union nut (2)

• Remove the exhaust gas turbocharger ventilation • Position the coolant line (3) with new sealing rings
coolant line (1) • Screw in and tighten the hollow screws (1) and
hollow screw ttings (2) with new sealing rings
Detaching the right vent line
Installing the right vent line

• Undo the jubilee clips (3) and (5) using the Hose
clamp pliers for jubilee clips [2] • Position the vent line (4) and pull on the hoses with
• Unscrew the mounting bolts (1) the jubilee clips (3) and (5)
• Remove the vent line (4) with the bushes (2) • Position the bushes (2)
• Screw in and tighten the mounting bolts (1)
Removing the coolant line • Tighten the jubilee clips (3) and (5) using the Hose
clamp pliers for jubilee clips [2]

• Unscrew the hollow screws (1) and the hollow

screw ttings (2) with the sealing rings
• Remove the coolant line (3) with the sealing rings

AE15 2st edition 67

COOLING SYSTEM

Installing the exhaust gas turbocharger Installing the right coolant line
ventilation coolant line

• Position the coolant line (2)

• Position and align the exhaust gas turbocharger • Screw on and tighten the union nuts (1)
ventilation coolant line (1) • Insert the mounting bolt (4) with the washer
• Screw on and tighten the union nut (2) • Screw on and tighten the mounting nut (3)

Installing the right exhaust gas turbocharger

ventilation coolant line

• Position the exhaust gas turbocharger ventilation

coolant line (2)
• Screw on and tighten the union nuts (1)
• Insert the mounting bolts (3) with the washers
• Screw on and tighten the mounting nuts (4)

68 AE15 2st edition

 ADD-ON UNITS

ADD-ON UNITS

(1) Starter

AE15 2st edition 69

 ADD-ON UNITS

AIR COMPRESSOR COVER

Removing and installing the air compressor cover

(1) Mounting bolt (2) Cap

Service products
Loctite 5900 ...................................................................................................................... 04.10394-9272

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 71

ADD-ON UNITS

Removing the air compressor Installing the air compressor cover

coverRemoving the air compressor
cover Cover installation instructions

Removing the air compressor cover

WARNING
Component damage due to non-sealed
• Unscrew the mounting bolts (1) air compressor cover
• Remove the cover (1) • The mating face must be free of grease
• Clean the mating faces • The sealing bead must be continuous
and no wider than 2 mm
• Check that the sealing bead is
continuous

• Thinly apply Loctite 5900 sealing compound (1) on

the mating face as illustrated

Installing the air compressor cover

• Clean the mating faces

• Position the cover (1)
• Screw in and tighten the mounting bolts (1)

72 AE15 2st edition

 ADD-ON UNITS

STARTER
Removing and installing the starter

(1) Starter (4) Terminal 30

(2) Terminal 50 and 85 (5) Terminal 31
(3) Mounting bolt, starter

Technical data
Mounting nut, terminal 30 (+)................................. M12...................................................................25 Nm
Mounting nut, terminal 31 (-) ................................. M12...................................................................25 Nm
Terminal 50 mounting nut...................................... M6 ..................................................................... 4 Nm
Mounting nut, terminal 85...................................... M6 ..................................................................... 4 Nm
Mounting bolts, starter .......................................... M12x40-10.9......................................................70 Nm
Number of starter pinion teeth ............................................................................................................... 11
Starter power .......................................................................................................................... 24 V/7 KW

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 73

ADD-ON UNITS

Special tools

[3] Engine barring gear 80.99626-6008

• Cranking the engine in conjunction with:

• Gear ratchet [4]

[4] Gear ratchet 80.99627-0001

• Cranking the engine

74 AE15 2st edition

 ADD-ON UNITS

Removing the starter Installing the starter

Removing the starter Attaching the engine barring gear

• Unscrew and remove the mounting bolts (2) • Remove the sealing cap from the ywheel housing
• Remove the starter (1) from the ywheel housing /timing case
/timing case • Mount the Engine barring gear [3] (1) on the
ywheel housing/timing case

Installing the starter

• Crank the engine 360° using Engine barring

gear [3] and Gear ratchet [4] whilst checking the
starter ring gear for damage. Fit a new starter ring
gear if necessary
• Insert the starter (1) into the ywheel housing
/timing case
• Screw in and tighten the mounting bolts (2)

AE15 2st edition 75

ADD-ON UNITS

Removing the engine barring gear

• Remove the Engine barring gear [3] (1) from the

ywheel housing/timing case
• Mount the sealing cap on the ywheel housing
/timing case

76 AE15 2st edition

 CHARGE-MIXTURE SYSTEM

CHARGE-MIXTURE SYSTEM

(1) Charge-mixture manifold downstream of (5) Charge-mixture manifold

charge-mixture cooler (6) Corrugated hose
(2) Charge-mixture cooler (7) Charge air manifold
(3) Data acquisition (8) Air distribution pipe, left
(4) Throttle valve

AE15 2st edition 77

 CHARGE-MIXTURE SYSTEM

CHARGE-MIXTURE SYSTEM
Removing and installing the charge-mixture system

(1) Charge-mixture manifold downstream of (4) Throttle valve

charge-mixture cooler (5) Charge-mixture manifold
(2) Charge-mixture cooler (6) Charge-air hose
(3) Data acquisition (7) Charge-air manifold

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 79

CHARGE-MIXTURE SYSTEM

Removing the charge-mixture system Removing the holder for data acquisition

Removing the wiring harness

• Unscrew the mounting bolts (1) and (2)

• Remove the holder (1)
WARNING • Repeat the procedure for the second holder
Danger of irreparable data acquisition
Dismantling the holder for data acquisition
system damage
• When removing the connectors, rst
open the lock completely, then pull off
the connector

• Fully unlock and pull off the connector (1)

• Expose the wiring harness (2)

Removing the data acquisition

• Unscrew the mounting bolts (2)

• Remove the holder (1)

Removing the left charge-air manifold

• Unscrew the mounting bolts (1) with washers (2)

• Remove the data acquisition (3)
• Unscrew the mount (4)

• Unfasten the clamps (3) and (6)

• Pull the charge-air manifold (4) off the charge-air
hose (2) with the O-ring (5) and the clamp (6)
• Undo the clamp (1)
• Pull off the charge-air hose (2)

80 AE15 2st edition

 CHARGE-MIXTURE SYSTEM

Removing the right charge-air manifold Removing the throttle valve

• Unfasten the clamps (3) and (6) • Unscrew the mounting bolts (1)
• Pull the charge-air manifold (4) off the charge-air • Remove the throttle valve (2) with the O-ring (3)
hose (2) with the O-ring (5) and the clamp (6) • Clean the mating faces
• Undo the clamp (1)
• Pull off the charge-air hose (2) Dismantling the throttle valve

Removing the charge-mixture manifold

• Undo the mounting nut (3)

• Pull off the adjusting lever (1)
• Unscrew the mounting bolts (3) • Unscrew the mounting nut (3)
• Remove the charge-mixture manifold (2) with the • Remove the mounting bolt (2)
O-ring (1)
• Clean the mating faces

Dismantling the charge-mixture manifold

• Unscrew the screw plugs (1) with the sealing rings

(2)

AE15 2st edition 81

CHARGE-MIXTURE SYSTEM

Removing the charge-mixture cooler Removing the charge-mixture manifold

downstream of the charge-mixture cooler

• Unscrew the mounting bolts (5)

• Remove the crane hook lug (6)
• Unscrew the mounting bolts (3) and (4)
• Remove the charge-mixture manifold (1) with the
gasket (2)
• Clean the mating faces

Removing the charge-mixture manifold

upstream of the charge-mixture cooler

CAUTION
Danger of injury due to heavy
components
• Remove the charge-mixture cooler with
support

• Unscrew the mounting bolts (2)

• Remove the charge-mixture cooler (1) with lifting
device
• Remove the unscrewed conduits (4) with the
O-rings (3) and (5) • Unscrew the mounting bolts (4)
• Remove the crane hook lug (5)
• Unscrew the mounting bolts (3)
• Remove the charge-mixture manifold (2) with the
gasket (1)

82 AE15 2st edition

 CHARGE-MIXTURE SYSTEM

Dismantling the charge-mixture manifold Installing the charge-mixture system

upstream of the charge-mixture cooler
Assembling the charge-mixture cooler

• Unscrew the screw plugs (1) with the sealing rings

(2) • Clean the mating faces
• Position the anges (2) and (5) with new gaskets
Dismantling the charge-mixture cooler (3) and (6)
• Screw in and tighten the mounting bolts (1) and (4)

Assembling the charge-mixture manifold

upstream of the charge-mixture cooler

• Unscrew the mounting bolts (1) and (4)

• Remove the anges (2) and (5) with the gaskets
(3) and (6)
• Clean the mating faces
• Screw in and tighten the screw plugs (1) with the
sealing rings (2)

AE15 2st edition 83

CHARGE-MIXTURE SYSTEM

Mounting the charge-mixture manifold upstream Mounting the charge-mixture cooler

of the charge-mixture cooler

• Clean the mating faces

• Position the charge-mixture manifold (2) with a
new gasket (1)
• Screw in and tighten the mounting bolts (3)
• Position the crane hook lug (5)
• Screw in the mounting bolts (4) and tighten them

Mounting the charge-mixture manifold

downstream of the charge-mixture cooler

CAUTION
Danger of injury due to heavy
components
• Mount the charge-mixture cooler with
support

• Insert new O-rings (3) and (5) into the unscrewed

conduits (4)
• Insert the unscrewed conduits (4)
• Mount the charge-mixture cooler (1) with lifting
• Clean the mating faces device
• Position the charge-mixture manifold (1) with a • Screw in and tighten the mounting bolts (2)
new gasket (2)
• Screw in and tighten the mounting bolts (3) and (4)
• Position the crane hook lug (6)
• Screw in the mounting bolts (5) and tighten them

84 AE15 2st edition

 CHARGE-MIXTURE SYSTEM

Assembling the throttle valve Mounting the charge-mixture manifold

• Insert the mounting bolt (2) into the adjusting lever • Clean the mating faces
(1) • Position the charge-mixture manifold (2) with a
• Screw on the mounting nut (3) new O-ring (1)
• Insert the adjusting lever (1) • Screw in and tighten the mounting bolts (3)
• Tighten the mounting nut (3)
Mounting the right charge-air manifold
Mounting the throttle valve

• Pull the charge-air hose (2) with clamps (1) and

• Clean the mating faces (3) onto the charge-air manifold (4)
• Position the throttle valve (2) with a new O-ring (3) • Tighten the clamp (3)
• Screw in and tighten the mounting bolts (1) • Insert the new O-ring (5) into the charge-air
manifold (4)
Assembling the charge-mixture manifold • Pull on and align the charge-air manifold (4) with
the clamp (6) and the charge-air hose (2)
• Tighten the clamps (1) and (6)

• Screw in and tighten the screw plugs (1) with new

sealing rings (2)

AE15 2st edition 85

CHARGE-MIXTURE SYSTEM

Mounting the left charge-air manifold Mounting the holder for data acquisition

• Pull the charge-air hose (2) with clamps (1) and • Position the holder (1)
(3) onto the charge-air manifold (4) • Screw in and tighten the mounting bolts (1) and (2)
• Tighten the clamp (3) • Repeat the procedure for the second holder
• Insert the new O-ring (5) into the charge-air
manifold (4) Mounting the data acquisition
• Pull on and align the charge-air manifold (4) with
the clamp (6) and the charge-air hose (2)
• Tighten the clamps (1) and (6)

Assembling the holder for data acquisition

• Screw on and tighten the mount (4)

• Position the data acquisition (3)
• Screw in and tighten the mounting bolts (1) with
new washers (2)

• Position the holder (1)

• Screw in and tighten the mounting bolts (2)

86 AE15 2st edition

 CHARGE-MIXTURE SYSTEM

Mounting the wiring harness

WARNING
Danger of irreparable data acquisition
system damage
• When installing the connectors, rst
fully open the lock and then insert and
lock the connectors

• Route the wiring harness (2)

• Insert the connector (1) into the data acquisition
and lock it

AE15 2st edition 87

CHARGE-MIXTURE SYSTEM

Removing and installing the air distribution pipes

Additional jobs
– Removing and installing the charge-mixture system, see 79

(1) Holder for charge-air cooler, right (4) Holder for charge-air cooler, left
(2) Air distribution pipe, right (5) Charge-mixture manifold, left
(3) Air distribution pipe, left (6) Charge-mixture manifold, right

Technical data
Mounting bolts, charge-pressure sensor ................ M6x16-10.9 ........................................................ 9 Nm

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

88 AE15 2st edition

 CHARGE-MIXTURE SYSTEM

Detaching the left air distribution pipe Removing the left air distribution pipe

Removing the holder for the charge-air cooler,

left

• Unscrew the mounting bolts (3) and (4)

• Remove the air distributor pipe (1) with the gaskets
(2)
• Unscrew the mounting bolts (2) • Clean the mating faces
• Remove the holder (1)

Removing the left charge-mixture manifold

• Unscrew the mounting bolts (3) and (4)

• Remove the charge-mixture manifold (1) with the
gasket (2)
• Clean the mating faces

AE15 2st edition 89

CHARGE-MIXTURE SYSTEM

Mounting the left air distribution pipe Mounting the holder for the charge-air cooler,
left
Mounting the left air distribution pipe

• Position the holder (1)

• Clean the mating faces • Screw in and tighten the mounting bolts (2)
• Position the air distributor pipe (1) with the new
gaskets (2)
• Screw in and tighten the mounting bolts (3) and (4)

Mounting the left charge-mixture manifold

• Clean the mating faces

• Position the charge-mixture manifold (1) with a
new gasket (2)
• Screw in and tighten the mounting bolts (3) and (4)

90 AE15 2st edition

 CHARGE-MIXTURE SYSTEM

Detaching the right air distribution pipe Dismantling the right charge-mixture manifold

Disconnecting the electrical connection

Note
• Disconnect the electrical connection (1) The charge-air pressure sensor can
also be removed if the charge-mixture
Removing the holder for the charge-air cooler, manifold is still mounted
right
• Unscrew the screw plug (1) with sealing ring (2)
• Unscrew the mounting bolts (4)
• Remove the charge-air pressure sensor (3)
• Clean the mating faces

Removing the right air distribution pipe

• Unscrew the mounting bolts (2)

• Remove the holder (1)

Removing the right charge-mixture manifold

• Unscrew the mounting bolts (3) and (4)

• Remove the air distributor pipe (1) with the gaskets
(2)
• Clean the mating faces

• Unscrew the mounting bolts (3) and (4)

• Remove the charge-mixture manifold (1) with the
gasket (2)
• Clean the mating faces

AE15 2st edition 91

CHARGE-MIXTURE SYSTEM

Attaching the right air distribution pipe Mounting the right charge-mixture manifold

Mounting the right air distribution pipe

• Clean the mating faces

• Position the charge-mixture manifold (1) with a
• Clean the mating faces new gasket (2)
• Position the air distributor pipe (1) with the new • Screw in and tighten the mounting bolts (3) and (4)
gaskets (2)
• Screw in and tighten the mounting bolts (3) and (4) Mounting the holder for the charge-air cooler,
left
Assembling the right charge-mixture manifold

• Position the holder (1)

• Screw in and tighten the mounting bolts (2)
Note
The charge-air pressure sensor can Connecting the electrical connection
also be mounted if the charge-mixture
manifold is still mounted

• Screw in and tighten the screw plug (1) with a new

sealing ring (2)
• Insert the charge-air pressure sensor (3) with a
new O-ring
• Screw in the mounting bolts (4) and tighten them
to 9 Nm

• Connect the electrical connection (1)

92 AE15 2st edition

 IGNITION SYSTEM

IGNITION SYSTEM

(1) Spark plug

AE15 2st edition 93

 IGNITION SYSTEM

SPARK PLUGS
Removing and installing the spark plugs

(1) Spark plug

Technical data
Spark plug (dry thread) .........................................M14x1.25 ..........................................................40 Nm

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[5] Socket for spark plugs 51.97710-0005

• Removing and installing spark plugs

AE15 2st edition 95

IGNITION SYSTEM

Removing spark plugs Installing spark plugs

Unscrewing spark plugs Screwing in spark plugs

• Unscrew the spark plugs (1) with Socket for spark • Screw in the spark plugs (1)
plugs [5] • Tighten spark plugs (1) with a dry thread using
Socket for spark plugs [5] (2) to 40 Nm

96 AE15 2st edition

 TURBOCHARGING

TURBOCHARGING
V8

(1) Intake manifold

(2) Exhaust gas turbocharger

AE15 2st edition 97

TURBOCHARGING

V12

(1) Coolant line, ventilation, exhaust gas (10) Coolant line, feed, EGT, left
turbocharger, right (11) Hose line, coolant
(2) Oil pressure line, right (12) Oil return line, left
(3) Coolant line, return, right (13) Exhaust gas turbocharger (EGT), left
(4) Charge-air manifold (14) Oil pressure line, left
(5) Coolant line, return (15) Coolant line, return, left
(6) Exhaust gas turbocharger (EGT), right (16) Coolant line, return
(7) Coolant line, feed, EGT, right (17) Charge-air manifold
(8) Oil return line, right (18) Coolant line, ventilation, EGT, left
(9) Hose line, coolant

98 AE15 2st edition

 TURBOCHARGING

INTAKE MANIFOLD V8
Removing and installing the intake manifold

(1) Holder for intake manifold (2) Intake manifold

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[6] Hose clamp pliers for jubilee clips 80.99625-0073

• Removing and installing the jubilee clips

AE15 2st edition 99

TURBOCHARGING

Removing the intake manifold Dismantling the intake manifold

Pulling off the vent line hose

• Unscrew the screw plugs (3) with the sealing rings

• Mark the installation position of the intake manifold
• Undo the jubilee clip (1) using the Hose clamp (2)
pliers for jubilee clips [8] and push it onto the hose • Undo the mounting nut (1)
• Pull the hose off the tting • Unscrew the intake manifold (2) with the sealing
ring
Removing the intake manifold
Removing the holder for the intake manifold

• Unscrew the mounting bolts (4)

• Undo the clamp (2) • Mark the installation position of the mounting bolts
• Remove the intake manifold (3) with the clamp (2) (2) and (3)
and the O-ring (1) • Unscrew the mounting bolts (2) and (3)
• Clean the mating faces • Remove the holder for the intake manifold (1)

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Installing the intake manifold Mounting the intake manifold

Mounting the holder for the intake manifold

• Clean the mating faces

• Insert the new O-ring (1)
• Position the holder for the intake manifold (1) • Position and align the intake manifold (3) with the
• Screw in and tighten the mounting bolts (2) and clamp (2)
(3) as marked • Screw in the mounting bolts (4) and tighten them
• Tighten the clamp (2)
Assembling the intake manifold
Inserting the vent line hose

• Screw in and tighten the screw plugs (3) with new

sealing rings • Pull the hose onto the tting
• Screw in the intake manifold (2) with the mounting • Mount the jubilee clip (1) in the installation position
nut (1) and a new sealing ring with the Hose clamp pliers for jubilee clips [8]
• Align the intake manifold (2) according to its
installation position
• Tighten the mounting nut (1)

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EXHAUST GAS TURBOCHARGER V8

Removing and installing the exhaust gas turbocharger V8

(1) Coolant line (6) Oil return line

(2) Charge-air manifold for compressor (7) Hose line, coolant drain
(3) Oil pressure line (8) Hose line
(4) Turbocharger (9) Hose line, coolant feed
(5) Coolant line, feed, bearing block

Technical data
Mounting nuts, exhaust gas turbocharger............... M10...................................................................60 Nm

Service products
Technical Vaseline ............................................................................................................. 09.10160-9353

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 103

TURBOCHARGING

Special tools

[7] Hose clamp pliers for jubilee clips 80.99625-0073

• Removing and installing the jubilee clips

104 AE15 2st edition

 TURBOCHARGING

Removing the exhaust gas turbocharger Removing the intake manifold

Detaching the coolant line

• Unscrew the mounting bolts (4)

• Undo the clamp (2)
• Unscrew the mounting bolt (3) • Remove the intake manifold (3) with the clamp (2)
• Unscrew the union nuts (1) and the O-ring (2)
• Remove the coolant line (2) • Clean the mating faces

Pulling off the vent line hose Detaching the oil pressure line

• Undo the jubilee clip (1) using the Hose clamp • Unscrew the mounting nut (3)
pliers for jubilee clips [7] and push it onto the hose • Remove the mounting bolt (2)
• Pull the hose off the tting • Detach the oil pressure line (1)

Detaching the coolant drain hose line

• Detach the hose line (1)

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Detaching the bearing block feed coolant line Dismantling the two-hole ange

• Detach the coolant line (1) • Unscrew the elbow tting (1)
• Unscrew the ttings (2) and (3) with the sealing
Detaching the coolant feed hose line rings
• Clean the mating faces

Detaching the coolant drain hose line

• Unscrew the mounting nut (4)

• Remove the mounting bolt (5)
• Unscrew the union nuts (1) and (2)
• Detach the hose line (3) • Unscrew the union nuts (2) and (3)
Mark the installation position of the mounting bolts
Removing the two-hole ange (5) and the spacer sleeves
• Detach the hose line (1)
Mark the installation position of the mounting bolts
(5) and the spacer sleeves

• Unscrew the mounting bolts (1)

• Remove the two-hole ange (2) with the gasket (3)
• Clean the mating faces

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Removing the ange for the oil pressure line Removing the oil return line two-hole ange

• Unscrew the mounting bolts (1) • Unscrew the mounting bolts (1)
• Remove the ange (2) with the gasket (3) • Remove the two-hole ange (2) with the gasket (3)
• Clean the mating faces • Clean the mating faces

Dismantling the ange for the oil pressure line Dismantling the oil return line two-hole ange

• Unscrew the tting (1) with the sealing ring • Unscrew the tting (1) with the sealing ring
• Clean the mating faces • Clean the mating faces

Removing the oil return line

• Remove the oil return line (1)

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Removing the exhaust gas turbocharger Dismantling the exhaust gas turbocharger

• Mark the installation position of the ring connector

(3)
• Unscrew the hollow screw (2) with the ring
connector (3) and the sealing rings
• Unscrew the adapter plug (1) with the sealing ring
• Unscrew the ttings (4), (9) and (10) with the
sealing rings
• Unscrew the adapter ttings (5) and (11) with the
sealing rings
• Unscrew the mounting nuts (8)
• Remove the ange (7) with the gasket (6)
• Clean the mating faces

CAUTION
Danger of injury due to heavy
components
• Remove the turbocharger with support

• Undo the clamp (2)

• Unscrew the mounting nuts (6) and remove them
with the spacer bushes (5)
• Remove the exhaust gas turbocharger (3) with the
clamp (2)
• Remove the gasket (4) and the O-ring (1)
• Clean the mating faces

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Installing the exhaust gas turbocharger Mounting the exhaust gas turbocharger

Assembling the exhaust gas turbocharger

• Clean the mating faces

• Position the ange (7) with a new gasket (6)
• Screw in and tighten the mounting nuts (8)
• Screw in and tighten the adapter ttings (5) and
(11) with new sealing rings
• Screw in and tighten the ttings (4), (9) and (10)
with new sealing rings
• Screw in and tighten the adapter plug (1) with a
new sealing ring
• Screw in the hollow screw (2) with the ring
connector (3) and new sealing rings
• Align the ring connector (3) according to its
installation position
• Tighten the hollow screw (2) CAUTION
Danger of injury due to heavy
components
• Remove the turbocharger with support

• Clean the mating faces

• Insert the new O-ring (1)
• Position the exhaust gas turbocharger (3) with the
clamp (2) and a new gasket (4)
• Screw in the new mounting nuts (6) with the spacer
bushes (5) and tighten to 60 Nm

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Assembling the oil return line two-hole ange Filling the exhaust gas turbocharger with oil

• Clean the mating faces

WARNING
• Screw in and tighten the tting (1) with a new
If no oil is added, the turbocharger
sealing ring
will be damaged when the vehicle is
Mounting the oil return line two-hole ange started for the rst time
• Fill the turbocharger with clean

• Use a funnel (1) to pour clean engine oil into the

oil feed neck on the exhaust gas turbocharger (2)
until the oil duct in the exhaust gas turbocharger
is full

Assembling the ange for the oil pressure line

• Clean the mating faces

• Position the two-hole ange (2) with a new gasket
(3)
• Screw in and tighten the mounting bolts (1)

Attaching the oil return line

• Clean the mating faces

• Screw in and tighten the tting (1) with a new
sealing ring

• Mount the oil return line (1)

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Mounting the ange for the oil pressure line Assembling the two-hole ange

• Clean the mating faces • Clean the mating faces

• Position the ange (2) with a new gasket (3) • Screw in and tighten the ttings (2) and (3) with
• Screw in and tighten the mounting bolts (1) new sealing rings
• Screw in and tighten the elbow tting (1)
Attaching the coolant drain hose line
Mounting the two-hole ange

• Attach the hose line (1)

Mark the installation position of the mounting bolts • Clean the mating faces
(5) and the spacer sleeves • Position the two-hole ange (2) with a new gasket
• Screw on and tighten the union nuts (2) and (3) (3)
Mark the installation position of the mounting bolts • Screw in and tighten the mounting bolts (1)
(5) and the spacer sleeves

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Attaching the coolant feed hose line Attaching the oil pressure line

• Attach the hose line (3) • Attach the oil pressure line (1)
• Screw on and tighten the union nuts (1) and (2) • Insert the mounting bolt (2) into the clamp
• Insert the mounting bolts (5) into the clamp • Screw on and tighten the mounting nut (3)
• Screw on and tighten the mounting nut (4)
Mounting the intake manifold
Attaching the bearing block feed coolant line

• Clean the mating faces

• Fit the coolant line (1) • Insert the new O-ring (1)
• Position and align the intake manifold (3) with the
Attaching the coolant drain hose line clamp (2)
• Screw in and tighten the mounting bolts (4)
• Tighten the clamp (2)

• Attach the hose line (1)

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Inserting the vent line hose

• Pull the hose onto the tting

• Mount the jubilee clip (1) in the installation position
with the Hose clamp pliers for jubilee clips [7]

Attaching the coolant line

• Position and align the coolant line (2)

• Screw on and tighten the union nuts (1)
• Screw in and tighten the mounting bolt (3)

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EXHAUST GAS TURBOCHARGER V12

Removing and installing the exhaust gas turbocharger V12

(1) Coolant line, ventilation, exhaust gas (10) Coolant line, feed, EGT, left
turbocharger, right (11) Hose line, coolant
(2) Oil pressure line, right (12) Oil return line, left
(3) Coolant line, return, right (13) Exhaust gas turbocharger (EGT), left
(4) Charge-air manifold (14) Oil pressure line, left
(5) Coolant line, return (15) Coolant line, return, left
(6) Exhaust gas turbocharger (EGT), right (16) Coolant line, return
(7) Coolant line, feed, EGT, right (17) Charge-air manifold
(8) Oil return line, right (18) Coolant line, ventilation, EGT, left
(9) Hose line, coolant

Technical data
Mounting nuts, exhaust gas turbocharger............... M10...................................................................60 Nm

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
The installation and removal procedure for the right exhaust gas turbocharger is identical

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Special tools

[8] Hose clamp pliers for jubilee clips 80.99625-0073

• Removing and installing the jubilee clips

116 AE15 2st edition

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Removing the left exhaust gas Detaching the return coolant line
turbocharger
Removing the left charge-air manifold

• Detach the return coolant line (1)

Detaching the oil pressure line

• Unfasten the clamps (1) and (4)
• Remove the charge-air manifold (2) with the O-ring
(3) and the clamp (4)

Detaching the left exhaust gas turbocharger

ventilation coolant line

• Unscrew the mounting nut (5)

• Remove the mounting bolt (1)
• Unscrew the union nuts (3) and (4)
• Detach the oil pressure line (2)

Detaching the left exhaust gas turbocharger feed

• Unscrew the mounting nuts (4) coolant line
• Remove the mounting bolts (3) with the washers
• Unscrew the union nuts (1)
• Remove the left exhaust gas turbocharger
ventilation coolant line (2)

• Detach the coolant line (1)

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Detaching the feed coolant line Detaching the return coolant line

• Detach the coolant line (1) • Detach the return coolant line (1)

Detaching the feed coolant line Detaching the return coolant line

• Unscrew the mounting nut (4) • Unscrew the union nut (2)
• Remove the mounting bolt (3) with the washer • Unscrew the mounting nut (3)
• Unscrew the union nut (1) • Remove the mounting bolt (4) with washer
• Detach the feed coolant line (2) • Detach the return coolant line (1)

Removing the two-hole ange Detaching the oil return line

• Unscrew the mounting bolts (2) • Unfasten the jubilee clip (4) with the Hose clamp
• Remove the ange (1) with the gasket (3) pliers for jubilee clips [8] and push onto the hose
• Clean the mating faces • Unscrew the mounting bolts (1)
• Detach the oil return line (2) with the gasket (3)
• Clean the mating faces

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Removing the left exhaust gas turbocharger Dismantling the exhaust gas turbocharger

• Mark the installation position of the ring connector

(3)
• Unscrew the hollow screw (2) with the ring
connector (3) and the sealing rings
• Unscrew the adapter plug (1) with the sealing ring
• Unscrew the ttings (4) and (8) with the sealing
rings
• Unscrew the mounting nuts (6)
• Remove the ange (5) with the gasket (7)
• Clean the mating faces

• Undo the clamp (2)

• Unscrew and remove the mounting nuts (6)
• Remove the spacer sleeves (5)
• Remove the exhaust gas turbocharger (3) with the
intake tting and the clamp (2)
• Remove the gasket (4) and the O-ring (1)
• Clean the mating faces

Removing the intake tting

• Remove the intake tting (2) with the O-ring (1)

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Installing the left turbocharger Mounting the left exhaust gas turbocharger

Assembling the exhaust gas turbocharger

• Clean the mating faces

• Position the ange (5) with a new gasket (7)
• Screw in and tighten the mounting nuts (6)
• Screw in and tighten the ttings (4) and (8) with
new sealing rings
• Screw in and tighten the adapter plug (1) with a
new sealing ring
• Screw in the hollow screw (2) with the ring
connector (3) and new sealing rings
• Align the ring connector (3) according to its
installation position
• Tighten the hollow screw (2)

Mounting the intake tting • Clean the mating faces

• Insert the new O-ring (1) into the intake tting
• Position the exhaust gas turbocharger (3) with a
new gasket (4)
• Align the intake tting
• Screw on new mounting nuts (6) with spacer
sleeves (5)
• Tighten the mounting nuts (6) to 60 Nm

Attaching the oil return line

• Insert the intake tting (2) with a new O-ring (1)

• Clean the mating faces

• Attach the oil return line (2) with a new gasket (3)
• Screw in and tighten the mounting bolts (2)
• Mount the jubilee clip (4) in the installation position
with the Hose clamp pliers for jubilee clips [8]

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Filling the exhaust gas turbocharger with oil Attaching the return coolant line

• Attach the coolant line (1)

WARNING
If no oil is added, the turbocharger Mounting the two-hole ange
will be damaged when the vehicle is
started for the rst time
• Fill the turbocharger with clean

• Use a funnel (1) to pour clean engine oil into the

oil feed neck on the exhaust gas turbocharger (2)
until the oil duct in the exhaust gas turbocharger
(2) is full

Attaching the return coolant line

• Clean the mating faces

• Position the ange (1) with a new gasket (3)
• Screw in and tighten the mounting bolts (2)

Attaching the feed coolant line

• Position and align the coolant line (1)

• Screw on the union nut (2) and tighten it by hand
• Insert the mounting bolt (4) with the washer
• Screw on and tighten the mounting nut (3)
• Tighten the union nut (2)

• Position and align the feed coolant line (2)

• Screw on the union nut (1) and tighten it by hand
• Insert the mounting bolt (3) with the washer
• Screw on and tighten the mounting nut (4)
• Tighten the union nut (1)

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Attaching the feed coolant line Attaching the return coolant line

• Attach the feed coolant line (1) • Attach the return coolant line (1)

Attaching the left exhaust gas turbocharger feed Attaching the left exhaust gas turbocharger
coolant line ventilation coolant line

• Attach the coolant line (1) • Position the left exhaust gas turbocharger
ventilation coolant line (2)
Attaching the oil pressure line • Screw on and tighten the union nuts (1)
• Insert the mounting bolts (3) with the washers
• Screw on and tighten the mounting nuts (4)

Mounting the left charge-air manifold

• Position the oil pressure line (2)

• Screw on and tighten the union nuts (3) and (4)
• Insert the mounting bolt (1)
• Screw on and tighten the mounting nut (5)
• Insert the charge-air manifold (2) with a new O-ring
(3) and the clamp (4)
• Tighten the clamps (1) and (4)

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Removing the right exhaust gas Detaching the return coolant line
turbocharger
Removing the right charge-air manifold

• Detach the return coolant line (1)

Detaching the oil pressure line

• Unfasten the clamps (1) and (4)
• Remove the charge-air manifold (2) with the O-ring
(3) and the clamp (4)

Detaching the right exhaust gas turbocharger

ventilation coolant line

• Unscrew the mounting nut (4)

• Remove the mounting bolt (2)
• Unscrew the union nuts (3) and (5)
• Detach the oil pressure line (1)

Detaching the right exhaust gas turbocharger

• Unscrew the mounting nuts (4) feed coolant line
• Remove the mounting bolts (3) with the washers
• Unscrew the union nuts (1)
• Remove the right exhaust gas turbocharger
ventilation coolant line (2)

• Detach the coolant line (1)

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Detaching the feed coolant line Detaching the return coolant line

• Detach the coolant line (1) • Detach the return coolant line (1)

Detaching the feed coolant line Detaching the return coolant line

• Unscrew the mounting nut (2) • Unscrew the union nut (3)
• Remove the mounting bolt (3) with the washer • Unscrew the mounting nut (2)
• Unscrew the union nut (4) • Remove the mounting bolt (1) with the washer
• Detach the feed coolant line (1) • Detach the return coolant line (4)

Removing the two-hole ange Detaching the oil return line

• Unscrew the mounting bolts (3) • Unfasten the jubilee clip (4) with the Hose clamp
• Remove the ange (1) with the gasket (2) pliers for jubilee clips [8] and push onto the hose
• Clean the mating faces • Unscrew the mounting bolts (1)
• Detach the oil return line (2) with the gasket (3)
• Clean the mating faces

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Removing the right exhaust gas turbocharger Dismantling the exhaust gas turbocharger

• Mark the installation position of the ring connector

(3)
• Unscrew the hollow screw (2) with the ring
connector (3) and the sealing rings
• Unscrew the adapter plug (1) with the sealing ring
• Unscrew the ttings (4) and (8) with the sealing
rings
• Unscrew the mounting nuts (6)
• Remove the ange (5) with the gasket (7)
• Clean the mating faces

• Undo the clamp (1) and push onto the hose

• Unscrew and remove the mounting nuts (6)
• Remove the spacer sleeves (5)
• Remove the exhaust gas turbocharger (3) with the
intake tting (2)
• Remove the gasket (4)
• Clean the mating faces

Removing the intake tting

• Remove the intake tting (2) with the O-ring (1)

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Installing the right exhaust gas Mounting the right exhaust gas turbocharger
turbocharger
Assembling the exhaust gas turbocharger

• Clean the mating faces

• Position the ange (5) with a new gasket (7)
• Screw in and tighten the mounting nuts (6)
• Screw in and tighten the ttings (4) and (8) with
new sealing rings
• Screw in and tighten the adapter plug (1) with a
new sealing ring
• Screw in the hollow screw (2) with the ring
connector (3) and new sealing rings
• Align the ring connector (3) according to its
installation position
• Tighten the hollow screw (2) • Clean the mating faces
• Insert the new gasket (4)
Mounting the intake tting
• Position the exhaust gas turbocharger (3) with the
intake tting (2)
• Screw on new mounting nuts (6) with spacer
sleeves (5)
• Tighten the mounting nuts (6) to 60 Nm

Attaching the oil return line

• Insert the intake tting (2) with a new O-ring (1)

• Clean the mating faces

• Attach the oil return line (2) with a new gasket (3)
• Screw in and tighten the mounting bolts (1)
• Mount the jubilee clip (4) in the installation position
with the Hose clamp pliers for jubilee clips [8]

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Filling the exhaust gas turbocharger with oil Attaching the return coolant line

• Attach the coolant line (1)

WARNING
If no oil is added, the turbocharger Mounting the two-hole ange
will be damaged when the vehicle is
started for the rst time
• Fill the turbocharger with clean

• Use a funnel (1) to pour clean engine oil into the

oil feed neck on the exhaust gas turbocharger (2)
until the oil duct in the exhaust gas turbocharger
(2) is full

Attaching the return coolant line

• Clean the mating faces

• Position the ange (1) with a new gasket (2)
• Screw in and tighten the mounting bolts (3)

Attaching the feed coolant line

• Position and align the coolant line (4)

• Screw on the union nut (3) and tighten it by hand
• Insert the mounting bolt (1) with the washer
• Screw on and tighten the mounting nut (2)
• Tighten the union nut (3)

• Position and align the feed coolant line (1)

• Screw on the union nut (4) and tighten it by hand
• Insert the mounting bolt (3) with the washer
• Screw on and tighten the mounting nut (2)
• Tighten the union nut (4)

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Attaching the feed coolant line Attaching the return coolant line

• Attach the feed coolant line (1) • Attach the return coolant line (1)

Attaching the right exhaust gas turbocharger Mounting the right exhaust gas turbocharger
feed coolant line ventilation coolant line

• Attach the coolant line (1) • Position the right exhaust gas turbocharger
ventilation coolant line (2)
Attaching the oil pressure line • Screw on and tighten the union nuts (1)
• Insert the mounting bolts (3) with the washers
• Screw on and tighten the mounting nuts (4)

Mounting the right charge-air manifold

• Position the oil pressure line (1)

• Screw on and tighten the union nuts (3) and (5)
• Insert the mounting bolt (2)
• Screw on and tighten the mounting nut (4)
• Insert the charge-air manifold (2) with a new O-ring
(3) and the clamp (4)
• Tighten the clamps (1) and (4)

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INTAKE/EXHAUST SYSTEM
V8

(1) Exhaust manifold, long

(2) Exhaust manifold Y
(3) Exhaust manifold, short

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INTAKE/EXHAUST SYSTEM

V12

(1) Hose clamp (4) Corrugated hose

(2) Exhaust manifold, right (5) Exhaust manifold, left
(3) Intake manifold (6) Heat protection hood

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EXHAUST MANIFOLD V8
Removing and installing the exhaust manifold V8
Additional jobs
– Removing and installing the exhaust gas turbocharger V8, see 103

(1) Exhaust manifold, long (3) Exhaust manifold, short

(2) Exhaust manifold Y

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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Removing the exhaust manifold V8 Dismantling the exhaust manifold

Removing the exhaust gas temperature sensor

• Remove the short exhaust manifold (1) and the

long exhaust manifold (3)
• Disconnect the electrical connection • Mark the number of multi-piece rings (2) and
• Unscrew the exhaust gas temperature sensor (2) crinkle washers (4)
with sealing ring (1) • Remove the multi-piece rings (2) and crinkle
washers (4)
Removing the exhaust manifold • Clean the grooves on the exhaust manifold (5)
• Clean the mating faces

• Mark the installation position of the mounting bolts

(1), (6) and (10) with spacer bushes (2), (7) and
(11)
• Unscrew the mounting bolts (1), (6) and (10) with
spacer bushes (2), (7) and (11)
• Remove the exhaust manifold (5)
• Remove the multi-piece rings (3) and (9) and
the crinkle washers (4) and (8) from the exhaust
manifold (5) and the exhaust pipe
• Clean the grooves in the exhaust manifold (5)
• Clean the mating faces

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Installing the exhaust manifold V8 Installing the exhaust gas temperature sensor

Assembling the exhaust manifold

• Screw in and tighten the exhaust gas temperature

sensor (2) with a new sealing ring (1)
• Clean the mating faces • Connect the electrical connection
• Clean the grooves on the exhaust manifold
• Insert the multi-piece rings (2) and crinkle washers
(4) as marked
• Insert the short exhaust manifold (1) and the long
exhaust manifold (3) into the exhaust manifold (5)
until the stop is reached

Installing the exhaust manifold

• Mark the installation position of the mounting bolts

(1), (6) and (10) with spacer bushes (2), (7) and
(11)
• Clean the mating faces
• Clean the grooves on the exhaust manifold (5)
• Insert the multi-piece rings (3) and (9) with crinkle
washers (4) and (8) into the exhaust manifold (5)
and the exhaust pipe as marked
• Mount the exhaust manifold (5)
• Screw in and tighten the mounting bolts (1), (6)
and (10) with spacer bushes (2), (7) and (11) as
marked

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INTAKE MANIFOLD V12

Removing and installing the intake manifold V12

(1) Moulded hose (5) Holder for intake manifold

(2) Hose clamp (6) Corrugated hose
(3) Intake tting (7) Hose clamp
(4) Intake manifold (8) Prole clip

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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INTAKE/EXHAUST SYSTEM

Removing the intake manifold Removing the intake manifold

Removing the corrugated hose

• Unfasten the clamps (1) and (2)

• Unscrew the mounting bolts (5)
• Unfasten the clamps (1) and (5) • Remove the intake manifold (4)
• Remove the corrugated hose (3) • Remove the O-ring from the intake tting (3)
• Remove the O-rings (2) and (4)
Dismantling the intake manifold
Dismantling the corrugated hose

• Undo the clamps (6)

• Unfasten the clamps (1) and (2) • Remove the moulded hose (4) with the intake
• Pull off the intake ttings (3) and (4) tting (5)
• Pull the moulded hose (4) off the intake tting (5)
Removing the intake tting • Undo the mounting nut (2)
• Unscrew the intake manifold (1) with the mounting
nut (2) and the sealing ring
• Unscrew the screw plug (3) with the sealing ring

• Pull off the intake tting (2) with the O-ring (1)

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Removing the holder for the intake manifold Installing the intake manifold
Mounting the holder for the intake manifold

• Unscrew the mounting bolts (2)

• Remove the holder (1)
• Position the holder (1)
• Screw in and tighten the mounting bolts (2)

Assembling the intake manifold

• Screw in and tighten the screw plug (3) with a new

sealing ring
• Screw in the intake manifold (1) with the mounting
nut (2) and a new sealing ring
• Tighten the mounting nut (2)
• Insert the moulded hose (4) with the clamps (6)
into the intake tting (5)
• Insert the moulded hose (4) with the intake tting
(5) into the intake manifold
• Tighten the clamps (6)

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Installing the intake manifold Installing the corrugated hose

• Insert the new O-ring into the intake manifold (3) • Insert the new O-rings (2) and (4)
• Mount the intake manifold (4) • Mount the corrugated hose (3) with the clamps (1)
• Screw in the mounting bolts (5) and tighten them and (5)
• Tighten the clamps (1) and (2) • Tighten the clamps (1) and (5)

Installing the intake tting

• Insert the intake tting (2) with a new O-ring (1)

Assembling the corrugated hose

• Insert the intake ttings (3) and (4) with the clamps
(1) and (2) into the corrugated hose
• Tighten the clamps (1) and (2)

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EXHAUST PIPES
Removing and installing the exhaust pipes V8

(1) Exhaust pipe, left (2) Heat protection hood

Technical data
Exhaust manifold mounting bolt............................. M10x108-SD.................................. Initial torque 60 Nm
Mounting bolt, exhaust manifold ............................ M10x108-SD...................................Final tightening 90°

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
Removal and installation of the left and right exhaust pipes is identical.

Note
Exhaust pipes are shown without integral insulation

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Removing the exhaust pipes Removing the bracket for the heat protection
hood
Removing the heat protection hood

• Unscrew the mounting bolts (1) and (4) with

• Unscrew the mounting bolts (3) with washers (2) washers (2) and (5)
• Remove the heat protection hood (1) • Remove the bracket (3)
• Repeat the procedure for the second bracket
Detaching the exhaust pipe

Note
Removal of the left and right exhaust
pipes is identical

• Unscrew the mounting bolts (6) with the spacer

bushes (5)
• Remove the exhaust pipe (4) with the gaskets (1)
• Mark the number of multi-piece rings (2)
• Remove the multi-piece rings (2) and the crinkle
washer (3)
• Clean the mating faces

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Installing the exhaust pipes Mounting the heat protection hood

Mounting the bracket for the heat protection

hood

• Mount the heat protection hood (1)

• Screw in and tighten the mounting bolts (3) with
new washers (2)
• Position the bracket (3)
• Screw in and tighten the mounting bolts (1) and
(4) with new washers (2) and (5)
• Repeat the procedure for the second bracket

Attaching the exhaust pipe

Note
Installation of the left and right exhaust
pipes is identical

• Clean the mating faces

• Insert the multi-piece rings (2) and crinkle washer
(3) as marked
• Position the exhaust pipe (4) with new gaskets (1)
• Screw in the new mounting bolts (6) with spacer
bushes (5)
• Tighten the mounting bolts (6) to Initial torque 60
Nm
• Tighten the mounting bolts (6) to Final torque 90°

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Removing and installing the exhaust pipes V12

Additional jobs
– Removing and installing the exhaust gas turbocharger V12, see 115

(1) Heat protection hood (5) Exhaust manifold, left

(2) Exhaust manifold, right (6) Mounting nut
(3) Mounting nut (7) Exhaust pipe, left
(4) Exhaust pipe, right (8) Heat protection hood

Technical data
Mounting bolt, exhaust manifold ............................ M10x108-SD.................................. Initial torque 60 Nm
Mounting bolt, exhaust manifold ............................ M10x108-SD........................................Final torque 90°

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
Exhaust pipes are shown without integral insulation

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Removing the left exhaust pipes Removing the left exhaust pipe

Disconnecting the electrical connection

• Unscrew the mounting bolts (4) with spacer

bushes (3)
• Disconnect the electrical connection (1) • Remove the exhaust pipe (2) with the gaskets (1)
• Clean the mating faces
Removing the exhaust gas temperature sensor
Removing the bracket for the heat protection
hood

• Unscrew the exhaust gas temperature sensor (1)

with the sealing ring (2)
• Unscrew the mounting bolts (1) and (4) with
Removing the heat protection hood washers (2) and (5)
• Remove the bracket (3)
• Repeat the procedure for the second and third
brackets

• Unscrew the mounting bolts (3) with washers (2)

• Remove the heat protection hood (1)

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Removing the exhaust manifold Installing the left exhaust pipes

Installing the multipiece rings

• Unscrew the mounting nuts (3) with spacer bushes

(4)
• Remove the exhaust manifold (2) with the gasket • Install the new multi-piece rings (1) and new
(1) crinkle washer (2) as marked
• Remove the mounting bolts (5) • Insert the exhaust pipe (3)
• Clean the mating faces
Assembling the exhaust manifold
Dismantling the exhaust manifold

• Screw in and tighten the screw plug (1) with a new

• Unscrew the screw plug (1) with sealing ring (2) sealing ring (2)

Removing the multi-piece rings

• Pull off the exhaust pipe (3)

• Mark the number of multi-piece rings (1)
• Remove the multi-piece rings (1) and the crinkle
washer (2)

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Mounting the exhaust manifold Mounting the left exhaust pipe

• Clean the mating faces • Clean the mating faces

• Insert the mounting bolts (5) • Position the exhaust pipe (2) with new gaskets (1)
• Position the exhaust manifold (2) with a new • Screw in the new mounting bolts (4) with spacer
gasket (1) bushes (3)
• Screw on and tighten the mounting nuts (3) with • Tighten the mounting bolts (4) to Initial torque 60
the spacer bushes (4) Nm
• Tighten the mounting bolts (4) to Final torque 90°
Mounting the bracket for the heat protection
hood Mounting the heat protection hood

• Position the bracket (3) • Mount the heat protection hood (1)
• Screw in and tighten the mounting bolts (1) and • Screw in and tighten the mounting bolts (3) with
(4) with new washers (2) and (5) new washers (2)
• Repeat the procedure for the second and third
brackets

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Installing the exhaust gas temperature sensor Removing the right exhaust pipes
Disconnecting the electrical connection

• Screw in and tighten the exhaust gas temperature

sensor (1) with a new sealing ring (2)
• Disconnect the electrical connection (1)
Connecting the electrical connection
Removing the exhaust gas temperature sensor

• Connect the electrical connection (1)

• Unscrew the exhaust gas temperature sensor (1)
with sealing ring (2)

Removing the heat protection hood

• Unscrew the mounting bolts (3) with washers (2)

• Remove the heat protection hood (1)

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Removing the right exhaust pipe Removing the exhaust manifold

• Unscrew the mounting bolts (4) with spacer • Unscrew the mounting nuts (3) with spacer bushes
bushes (3) (4)
• Remove the exhaust pipe (2) with the gaskets (1) • Remove the exhaust manifold (2) with the gasket
• Clean the mating faces (1)
• Remove the mounting bolts (5)
Removing the bracket for the heat protection • Clean the mating faces
hood
Dismantling the exhaust manifold

• Unscrew the mounting bolts (1) and (4) with

washers (2) and (5) • Unscrew the screw plug (1) with sealing ring (2)
• Remove the bracket (3)
• Repeat the procedure for the second and third Removing the multi-piece rings
brackets

• Pull off the exhaust pipe (3)

• Mark the number of multi-piece rings (1)
• Remove the multi-piece rings (1) and the crinkle
washer (2)

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Installing the right exhaust pipes Mounting the exhaust manifold

Installing the multipiece rings

• Clean the mating faces

• Insert the mounting bolts (5)
• Install the new multi-piece rings (1) and new • Position the exhaust manifold (2) with a new
crinkle washer (2) as marked gasket (1)
• Insert the exhaust pipe (3) • Screw on and tighten the mounting nuts (3) with
the spacer bushes (4)
Assembling the exhaust manifold
Mounting the bracket for the heat protection
hood

• Screw in and tighten the screw plug (1) with a new

sealing ring (2)
• Position the bracket (3)
• Screw in and tighten the mounting bolts (1) and
(4) with new washers (2) and (5)
• Repeat the procedure for the second and third
brackets

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Mounting the right exhaust pipe Installing the exhaust gas temperature sensor

• Clean the mating faces • Screw in and tighten the exhaust gas temperature
• Position the exhaust pipe (2) with new gaskets (1) sensor (1) with a new sealing ring (2)
• Screw in the new mounting bolts (4) with spacer
bushes (3) Connecting the electrical connection
• Tighten the mounting bolts (4) to Initial torque 60
Nm
• Tighten the mounting bolts (4) to Final torque 90°

Mounting the heat protection hood

• Connect the electrical connection (1)

• Mount the heat protection hood (1)

• Screw in and tighten the mounting bolts (3) with
new washers (2)

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CYLINDER HEAD

(1) Cylinder head (3) Cylinder head cover

(2) Mounting bolt, cylinder head

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CYLINDER HEAD
Removing and installing the cylinder head cover

(1) Mounting bolt, cylinder head (3) Cylinder head cover

(2) Plug

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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Removing the cylinder head cover Installing the cylinder head cover
Removing the cylinder head cover Mounting the guide tube for the spark plug

• Unscrew the mounting bolts (1) • Insert the guide tube (2) with a new O-ring
• Remove the cylinder head cover (2) with gasket • Position the pressure ange (3)
(3) • Screw in and tighten the mounting bolt (4)
• Remove the O-ring (4)
• Clean the mating faces Installing the plug

Removing the plug

• Insert the plug (1) into the new gasket

• Press the plug (1) out of the gasket

Removing the guide tube for the spark plug

• Unscrew the mounting bolt (4)

• Remove the pressure ange (3)
• Pull out the guide tube (2) with the O-ring (1)

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Mounting the cylinder head cover

• Clean the mating faces

• Check the gasket (3) for damage, replace if
necessary
• Insert the new O-ring (4) into the guide tube
• Insert the cylinder head cover (2) with a new
gasket (3)
• Screw in and tighten the mounting bolts (1)

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Removing and installing the rocker arm mechanism

Additional jobs
– Removing and installing the cylinder head cover, see 153

(1) Push rods (4) Valve bridge, exhaust

(2) Rocker arm mechanism mounting bolts (5) Rocker arm mechanism
(3) Valve bridge, intake

Technical data
Rocker arm mechanism mounting bolt ................... M12x80-10.9......................................................90 Nm
Mounting bolt, rocker arm mechanism ................... M12x80-10.9...................................Final tightening 90°

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Removing the rocker arm mechanism Installing the rocker arm mechanism
Removing the rocker arm mechanism Mounting the rocker arm mechanism

• Unscrew the mounting bolts (2) • Thinly apply clean engine oil on the ball cups of
• Remove the rocker arm mechanism (4) the push rods (1)
• Mark the installation position of the valve bridges • Thinly apply clean engine oil on the balls of the
(3) rocker arms
• Remove the valve bridges (3) • Put on the rocker arm mechanism (4) so that the
• Remove the push rods (1) balls of the rocker arms lie in the ball cups of the
push rods (1)
• Oil the valve bridges (3)
• Install the valve bridges (3) as marked
• Screw in new mounting bolts (2) and tighten them
to 90 Nm
• Tighten the mounting bolts (2) to Final
tightening 90°

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Dismantling and assembling the rocker arm mechanism

Additional jobs
– Removing and installing the rocker arm mechanism, see 156
– Checking and setting the valve clearance, see 178

(1) Circlip (7) Lock nut

(2) Washer (8) Washer
(3) Rocker arm (9) Circlip
(4) Lock nut (10) Adjuster screw
(5) Rocker arm bracket (11) Adjuster screw
(6) Rocker arm

Rocker arm mechanism technical data

Rocker arm radial play ................................................................................................... 0.030 - 0.066 mm
Rocker arm bearing inside diameter ........................................................................ Ø 34.005 - 34.025 mm
Rocker arm shaft outside diameter .......................................................................... Ø 33.959 - 33.975 mm

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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Special tools

[9] Dial gauge 08.71000-3217

• Measuring the rocker arm bearing inside diameter

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Dismantling the rocker arm mechanism Measuring the rocker arm shaft outside diameter

Dismantling the rocker arm mechanism

• Clean the rocker arm shaft (2)

• Check the outside diameter of the rocker arm shaft
• Detach the circlip (1) (2) using a micrometer (1)
• Remove the washer (2) • Repeat the procedure for the remaining rocker arm
• Mark the installation position of the rocker arm (3) shafts (2)
• Pull the rocker arm (3) off the rocker arm shaft (4) The permitted outside diameter of the rocker arm
• Repeat the procedure for the other rocker arms shaft (2) is Ø 33.959 - 33.975 mm.

Measuring the rocker arm bearing inside If the outside diameter is out of tolerance, the rocker
diameter arm bracket must be replaced.

Unscrewing the adjusting screw

• Clean the rocker arm (1) with bearing

• Use the Dial gauge [9] (3) and internal calliper (2)
to check the rocker arm bearing inside diameter • Unscrew the lock nut (1)
• Repeat the procedure for the remaining rocker • Unscrew the adjusting screw (3) from the rocker
arms arm (2)
The permitted rocker arm bearing inside diameter is
Ø 34.005 - 34.025 mm.

If the inside diameter is out of tolerance, t a new

rocker arm (1).

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Assembling the rocker arm mechanism

Screwing in the adjusting screw

• Screw the adjusting screw (3) into the rocker arm

(2)
• Screw on the lock nut (1)

Assembling the rocker arm mechanism

• Thinly apply clean engine oil on the rocker arm

shaft (4)
• Push on the rocker arm (3) as marked
• Fit the washer (2)
• Attach a new circlip (1)
• Repeat the procedure for the other rocker arms

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Removing and installing the cylinder head

Additional jobs
– Removing and installing the cylinder head cover, see 153
– Removing and installing the rocker arm mechanism, see 156
– Removing and installing the charge-mixture system, see 79
– Removing and installing the air distribution pipes, see 88
– Removing and installing the exhaust pipes V12, see 142
– Checking and setting the valve clearance, see 178
– Removing and installing the coolant lines, see 63

(1) Cylinder head (3) Valve spring cap

(2) Cylinder head bolts

Technical data
Cylinder head bolts............................................... M18x2x246.................................... Initial torque 50 Nm
Cylinder head bolts............................................... M18x2x246.....................................2nd torque 150 Nm
Cylinder head bolts............................................... M18x2x246......................................3rd torque 300 Nm
Cylinder head bolts............................................... M18x2x246............................................ 4th torque 90°
Cylinder head bolts............................................... M18x2x246............................................ 5th torque 90°
Cylinder head bolts............................................... M18x2x246..........................................Final torque 90°
Mounting bolt, rocker arm mechanism ................... M12x40-10.9.................................. Initial torque 90 Nm
Mounting bolt, rocker arm mechanism ................... M12x40-10.9........................................Final torque 90°
Cylinder liner protrusion ................................................................................................. 0.035 - 0.085 mm

Service products
White T assembly paste..................................................................................................... 09.16012-0122

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Important information
WARNING
Component damage due to leaking cylinder head gasket
• Do not reuse old cylinder head bolts, even if they have only been used once

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[10] Socket, size 22 80.99612-0024

• Undoing and tightening the cylinder head bolts in

conjunction with:
• Torque multiplier i = 1 : 3.3 [11]
• Support [12]
• Angle measuring disc [13]
• Holding xture [14]
• Cheese-head screw [15]
• Connecting pin [16]
• Rubber ring 42 mm [17]
• Socket [19]
[11] Torque multiplier i = 1 : 3.3 80.99619-0006

• Undoing and tightening the cylinder head bolts in

conjunction with:
• Socket, size 22 [10]
• Support [12]
• Angle measuring disc [13]
• Holding xture [14]
• Cheese-head screw [15]
• Connecting pin [16]
• Rubber ring 42 mm [17]
• Socket [19]
[12] Support 80.99606-0551

• Undoing and tightening the cylinder head bolts in

conjunction with:
• Socket, size 22 [10]
• Torque multiplier i = 1 : 3.3 [11]
• Angle measuring disc [13]
• Holding xture [14]
• Cheese-head screw [15]
• Connecting pin [16]
• Rubber ring 42 mm [17]
• Socket [19]

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[13] Angle measuring disc 80.99607-0172

• Undoing and tightening the cylinder head bolts in

conjunction with:
• Socket, size 22 [10]
• Torque multiplier i = 1 : 3.3 [11]
• Support [12]
• Holding xture [14]
• Cheese-head screw [15]
• Connecting pin [16]
• Rubber ring 42 mm [17]
•
• Socket [19]
[14] Holding xture 80.99606-0641

• Undoing and tightening the cylinder head bolts in

conjunction with:
• Socket, size 22 [10]
• Torque multiplier i = 1 : 3.3 [11]
• Support [12]
• Angle measuring disc [13]
• Cheese-head screw [15]
• Connecting pin [16]
• Rubber ring 42 mm [17]
• Socket [19]
[15] Cheese-head screw 06.02191-0407

• Undoing and tightening the cylinder head bolts in

conjunction with:
• Socket, size 22 [10]
• Torque multiplier i = 1 : 3.3 [11]
• Support [12]
• Angle measuring disc [13]
• Holding xture [14]
• Connecting pin [16]
• Rubber ring 42 mm [17]
• Socket [19]
[16] Connecting pin 06.22729-0006

• Undoing and tightening the cylinder head bolts in

conjunction with:
• Socket, size 22 [10]
• Torque multiplier i = 1 : 3.3 [11]
• Support [12]
• Angle measuring disc [13]
• Holding xture [14]
• Cheese-head screw [15]
• Rubber ring 42 mm [17]
• Socket [19]

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[17] Rubber ring 42 mm 08.06142-9006

• Undoing and tightening the cylinder head bolts in

conjunction with:
• Socket, size 22 [10]
• Torque multiplier i = 1 : 3.3 [11]
• Support [12]
• Angle measuring disc [13]
• Holding xture [14]
• Cheese-head screw [15]
• Connecting pin [16]
• Socket [19]
[18] Adapter 80.99606-0552

• Undoing and tightening the cylinder head bolts

[19] Socket 80.99603-0327

• Undoing and tightening the cylinder head bolts in

conjunction with:
• Socket, size 22 [10]
• Torque multiplier i = 1 : 3.3 [11]
• Support [12]
• Angle measuring disc [13]
• Holding xture [14]
• Cheese-head screw [15]
• Connecting pin [16]
• Rubber ring 42 mm [17]
[20] Aligning bar 80.99606-0582

• Aligning cylinder heads

[21] Dial gauge holder 80.99605-0172

• Checking the cylinder liner protrusion in

conjunction with:
• Dial gauge [22]
• Measuring plate [23]
• Hexagon shank bolt [24]
• Washer [25]
[22] Dial gauge 08.71000-3217

• Checking the cylinder liner protrusion in

conjunction with:
• Dial gauge holder [21]
• Measuring plate [23]
• Hexagon shank bolt [24]
• Washer [25]

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[23] Measuring plate 80.99605-0289

• Checking the cylinder liner standout in

conjunction with:
• Dial gauge holder [21]
• Dial gauge [22]
• Hexagon shank bolt [24]
• Washer [25]
[24] Hexagon shank bolt 06.01499-0015

• Checking the cylinder liner standout in

conjunction with:
• Dial gauge holder [21]
• Dial gauge [22]
• Measuring plate [23]
• Washer [25]
[25] Washer 06.15013-0417

• Checking the cylinder liner standout in

conjunction with:
• Dial gauge holder [21]
• Dial gauge [22]
• Measuring plate [23]
• Hexagon shank bolt [24]

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Removing the cylinder head Unscrewing the cylinder head bolts

Assembling the special tool

• Put the special tool (1) on the cylinder head bolt to

be undone
• Insert the Torque multiplier i = 1 : 3.3 [11] (1) into • Unscrew all cylinder head bolts in the unscrewing
the Support [12] (2) sequence using the special tool (1)
• Mount the Holding xture [14] (5) with the
Cheese-head screw [15] (4) and the Adapter [109] Removing the cylinder head
(3) on the Support [12] (2)
• Put the Angle measuring disc [13] (9) on Torque
multiplier i = 1 : 3.3 [11] (1)
• Put the Socket, size 22 [10] (8) on the Torque
multiplier i = 1 : 3.3 [11] (1) and secure with the
Connecting pin [16] (7) and the Rubber ring 42
mm [17] (5)
• Insert the Socket [19] (6) into the Socket, size
22 [10] (8)

Unscrewing sequence of cylinder head bolts

• Unscrew the cylinder head bolts (3)

• Remove the cylinder head (2)
• Remove the cylinder head gasket (1)
• Clean the mating faces
• Clean the tapped holes in the crankcase

• Unscrew the cylinder head bolts in the unscrewing

sequence (1) to (6)

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Installing the cylinder head Tightening sequence for cylinder head

Checking the cylinder liner standout

• Tighten the cylinder head bolts in the tightening

sequence 1 to 6
• Place the Measuring plate [23] (2) on the cylinder
liner Preliminary tightening of the cylinder head bolts
• Screw in the Hexagon shank bolt [24] (4) with the
Washer [25] and tighten
• Fit the Dial gauge holder [21] (5) on the Measuring
plate [23] (2) with Dial gauge [22] (3)
• Place the dial gauge tip (1) on the crankcase
• Zero the Dial gauge [22] (3)
• Carefully place the dial gauge tip (1) on the
cylinder liner and note the difference on the dial
gauge
The permissible cylinder liner standout is 0.035 -
0.085 mm.

If the cylinder liner standout is out of tolerance,

the cylinder liner/crankcase must be replaced, see
Checking the cylinder liner, 333.
• Mount the Aligning bar [20] (2) on the exhaust side
Fitting the cylinder head
of the cylinder heads
• Tighten the cylinder head bolts (1) as per the
tightening sequence using a socket and a torque
wrench
• Tighten the cylinder head bolts (1) to Initial torque
50 Nm
• Tighten the cylinder head bolts (1) to 2nd torque
150 Nm
• Tighten the cylinder head bolts (1) to 3rd torque
300 Nm

• Place the new cylinder head gasket (1) over the

alignment pins
• Place the cylinder head (2) over the alignment pins
• Lightly apply White T assembly paste on the
contact surface of the new cylinder head bolts (1)
• Screw in the cylinder head bolts (3)

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Final tightening of cylinder head bolts

Note
Note the torque multiplier ratio, i = 1 : 3.3.

• Tighten the cylinder head bolts to 4th torque 90°,

in the correct sequence, with special tool (1)
• Tighten the cylinder head bolts to 5th torque 90°,
in the correct sequence, with special tool (1)
• Tighten the cylinder head bolts to Final torque 90°,
in the correct sequence, with special tool (1)
• Disassemble the special tool (1)
• Remove the Aligning bar [20] (2)

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Removing and installing the valve stem seals

Additional jobs
– Checking and setting the valve clearance, see 178

(1) Cylinder head (5) Valve

(2) Valve spring (6) Valve stem seal
(3) Valve spring cap (7) Valve guide
(4) Valve cotters

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

170 AE15 2st edition

 CYLINDER HEAD

Special tools

[26] Engine barring gear 80.99626-6009

• Cranking the engine in conjunction with:

• Gear ratchet [27]

[27] Gear ratchet 80.99627-0001

• Cranking the engine in conjunction with:

• Engine barring gear [26]

[28] Adapter 80.99606-0588

• Removing and installing the valve springs in

conjunction with:
• Holder [32]
• Holder [33]
• Valve-spring compressor [31]
• Extension [30]
• Assembly device [29]
[29] Assembly device 80.99606-6092

• Removing and installing the valve springs in

conjunction with:
• Adapter [28]
• Holder [32]
• Holder [33]
• Valve-spring compressor [31]
• Extension [30]
[30] Extension 80.99606-6094

• Removing and installing the valve springs in

conjunction with:
• Adapter [28]
• Holder [32]
• Holder [33]
• Valve-spring compressor [31]
• Assembly device [29]
[31] Valve-spring compressor 80.99613-6000

• Removing and installing the valve springs in

conjunction with:
• Adapter [28]
• Holder [33]
• Holder [32]
• Extension [30]
• Assembly device [29]

AE15 2st edition 171

CYLINDER HEAD

[32] Holder 80.99613-0050

• Removing and installing the valve springs in

conjunction with:
• Adapter [28]
• Holder [33]
• Valve-spring compressor [31]
• Extension [30]
• Assembly device [29]
[33] Holder 80.99613-0051

• Removing and installing the valve springs in

conjunction with:
• Adapter [28]
• Holder [32]
• Valve-spring compressor [31]
• Extension [30]
• Assembly device [29]
[34] Magnetic pick-up tool 80.99639-0009

• Removing the valve cotters in conjunction with:

• Adapter [28]
• Holder [32]
• Holder [33]
• Valve-spring compressor [31]
• Extension [30]
• Assembly device [29]
[35] Assembly device 80.99606-6088

• Removing and installing the valve stem seal in

conjunction with:
• Mounting sleeve [36]

[36] Mounting sleeve 80.99606-0287

• Installing the valve stem seal in conjunction with:

• Assembly device [35]

172 AE15 2st edition

 CYLINDER HEAD

Removing the valve stem seals Cranking the engine to the setting position

Removing the cylinder head cover

A = Rocker arms in overlap

B = Rocker arms free for valve clearance
• Unscrew the mounting bolts (1) setting
• Remove the cylinder head cover (2)
• Crank the engine until the rocker arms are in
Attaching the engine barring gear overlap
• Adjust the free rocker arms as indicated in the
table

Assembling the special tool

• Remove the cover with the gasket and the TDC

marking plate from the ywheel housing
• Mount the Engine barring gear [37] (1) on the
ywheel housing
Note
Retaining washer and Holder [33] have
left-hand threads.

• Position the Holder [32] (5) and Holder [33] (3)

on the Valve-spring compressor [31] (1) and then
screw on by turning the threaded spindle (4)
• Screw on the locking washers (2) and (6)
• Position the lever (8) on the Valve-spring
compressor [31] (1) and secure using the
mounting bolt (7)

AE15 2st edition 173

CYLINDER HEAD

Mounting the assembly device Removing the valve cotters

• Screw the Adapter [28] (3) into the cylinder head

CAUTION
(1)
Risk of injury due to springing back of
• Screw the Assembly device [29] (2) into the
the valve springs
Adapter [28] (3)
• Ensure that the Holder [32] and
Mounting the valve-spring compressor Holder [33] are seated correctly on
the spring cap
• Do not remove the valve cotters from
the valve spring with your bare hands

• Push down the Valve-spring compressor [31] with

Extension [30] (1)
• Remove the valve cotters (3) from the valve stem
(4) with Magnetic pick-up tool [34] (2)
• Release the Valve-spring compressor [31] (1)
• Remove the valve spring together with the washer
and spring cap
• Repeat the same procedure for all the valves
• Removing the special tool

Removing the valve stem seals

WARNING
Injector damage
• Spring compressor must not come into
contact with the injector

• Position the Holder [32] (4) and Holder [33] (5) on

the spring cap and tension by turning the threaded
spindle (6)
• Hook the Valve-spring compressor [31] (2) in the
Assembly device [29] (3)
• Place the Extension [30] (1) onto the Valve-spring
compressor [31] (2)

• Push the Assembly device [35] (2) over the valve

stem seal (3)
• Clamp the Assembly device [35] (2)
• Pull the valve stem seal (3) off the valve guide with
impact weight (1)

174 AE15 2st edition

 CYLINDER HEAD

Installing the valve stem seals Installing the valve springs

Installing the valve stem seals

Note
Mount the green valve stem seals on the
intake side and the brown valve stem
seals on the exhaust side

• Thinly apply clean engine oil to MAN Standard

3277 on the Mounting sleeve [36] (4) and the valve
stem seal (3)
• Push the Mounting sleeve [36] (4) over the valve
stem (5)
• Insert the valve stem seal (3) into the Assembly
device [35] (2) and tension it
• Push the Assembly device [35] (2) over the • Put on the inner valve spring (3), outer valve spring
Mounting sleeve [36] (4) (2) and valve spring cap (1) over the valve stem
• Knock the valve stem seal (3) onto the valve stem • Repeat the same procedure for all the valves
(5) using the impact weight (1)
• Remove the Assembly device [35] (2) and the Mounting the assembly device
Mounting sleeve [36] (4)

• Screw the Adapter [28] (3) into the cylinder head

(1)
• Screw the Assembly device [29] (2) into the
Adapter [28] (3)

AE15 2st edition 175

CYLINDER HEAD

Mounting the valve-spring compressor Installing the valve cotters

WARNING CAUTION
Injector damage Risk of injury due to springing back of
• The spring compressor must not come the valve springs
into contact with the injector • Ensure that the Holder [32] and
Holder [33] are seated correctly on
• Position the Holder [32] (5) and Holder [33] (6) on the spring cap
the spring cap and tension by turning the threaded • Do not insert the valve cotters into the
spindle (6) valve spring with your bare hands
• Hook the Valve-spring compressor [31] (2) into the
Assembly device [29] (3) • Press the spring cap (4) down fully with
• Put the Extension [30] (1) on the Valve-spring Valve-spring compressor [31] (3) and
compressor [31] (2) Extension [30] (2)
• Insert the valve cotters (3) into the valve stem (4)
with the Magnetic pick-up tool [34] (2)
• Carefully undo the Valve-spring compressor [31]
(3)
• Check the valve cotters (1) for correct seating and,
if necessary, repeat the procedure above

Mounting the cylinder head cover

• Check the condition of the gasket and, if

necessary, replace it
• Put on the cylinder head cover (2)
• Screw in and tighten the mounting bolts (1)

176 AE15 2st edition

 CYLINDER HEAD

Removing the engine barring gear

• Remove the Engine barring gear [26] (1) from the

ywheel housing
• Mounting the TDC marking plate
• Mount the cover on the ywheel housing with a
new gasket

AE15 2st edition 177

CYLINDER HEAD

Checking and setting the valve clearance

(1) Exhaust valve adjusting screw (3) Intake valve bridge

(2) Intake valve adjusting screw (4) Exhaust valve bridge

Technical data
Intake valve clearance ................................................................................................................ 0.50 mm
Exhaust valve clearance ............................................................................................................. 0.60 mm
Rocker arm adjusting screw lock nut................................................................................................45 Nm

Important information
WARNING
Engine damage caused by incorrectly set valves
• Do not adjust the valves unless the engine is cold

178 AE15 2st edition

 CYLINDER HEAD

Special tools

[37] Engine barring gear 80.99626-6009

• Cranking the engine in conjunction with:

• Gear ratchet [27]

[38] Gear ratchet 80.99627-0001

• Cranking the engine in conjunction with:

• Engine barring gear [26]

[39] Holding device 08.75300-0000

• Checking and adjusting the valve clearance in

conjunction with:
• Feeler gauge leaf 0.5 [40]
• Feeler gauge leaf 0.6 [41]
• Valve adjusting spanner, size 14 [42]
[40] Feeler gauge leaf 0.5 80.99607-0177

• Checking and adjusting the valve clearance in

conjunction with:
• Holding device [39]
• Valve adjusting spanner, size 14 [42]

[41] Feeler gauge leaf 0.6 80.99607-0178

• Checking and adjusting the valve clearance in

conjunction with:
• Holding device [39]
• Valve adjusting spanner, size 14 [42]

[42] Valve adjusting spanner, size 14 80.99603-6031

• Adjusting the valve clearance in conjunction with:

• Handle [43]

[43] Handle 08.06460-0003

• Adjusting the valve clearance in conjunction with:

• Valve adjusting spanner, size 14 [42]

AE15 2st edition 179

CYLINDER HEAD

Checking and adjusting the valve Cranking the engine to the setting position
clearance
Removing the cylinder head cover, cylinder 1

A = Rocker arms in overlap

B = Rocker arms free for valve clearance
setting
• Unscrew the mounting bolts (1)
• Remove the cylinder head cover (2) • Crank the engine until the rocker arms are in
overlap
Attaching the engine barring gear • Adjust the free rocker arms as indicated in the
table

Checking the intake valve clearance

• Remove the cover with the gasket and the TDC

marking plate from the ywheel housing
• Mount the Engine barring gear [37] (1) on the
ywheel housing • Insert the Holding device [39] (1) with Feeler
gauge leaf 0.5 [40] (2) between the valve bridge
(3) and the ball socket (4)
Adjust the valve clearance if the valve clearance is
not 0.50 mm

180 AE15 2st edition

 CYLINDER HEAD

Adjusting the intake valve clearance Adjusting the exhaust valve clearance

• Undo the lock nut (4) • Undo the lock nut (4)
• Turn back the adjusting screw (5) until the Holding • Turn back the adjusting screw (5) until the Holding
device [39] (1) with Feeler gauge leaf 0.5 [40] (2) device [39] (1) with Feeler gauge leaf 0.6 [41] (2)
can be inserted between the ball socket (6) and can be inserted between the ball socket (6) and
the valve bridge (3) the valve bridge (3)
• Screw in the adjusting screw (5) until the Holding • Screw in the adjusting screw (5) until the Holding
device [39] (1) with Feeler gauge leaf 0.5 [40] (2) device [39] (1) with Feeler gauge leaf 0.6 [41] (2)
can be moved between the ball socket (6) and the can be moved between the ball socket (6) and the
valve bridge (3) with little resistance (suction) valve bridge (3) with little resistance (suction)
• Brace the adjusting screw (5) with the Valve • Brace the adjusting screw (5) with the Valve
adjusting spanner, size 14 [42] adjusting spanner, size 14 [42]
• Brace the adjusting screw (5) and tighten the lock • Brace the adjusting screw (5) and tighten the lock
nut (4) to 45 Nm nut (4) to 45 Nm
• Check the setting once more • Check the setting once more

Checking the exhaust valve clearance Mounting the cylinder head cover

• Insert the Holding device [39] (1) with Feeler • Check the condition of the gasket and, if
gauge leaf 0.6 [41] (2) between the valve bridge necessary, replace it
(3) and the ball socket (4) • Put on the cylinder head cover (2)
Adjust the valve clearance if the valve clearance is • Screw in and tighten the mounting bolts (1)
not 0.60 mm

AE15 2st edition 181

CYLINDER HEAD

Removing the engine barring gear

• Remove the Engine barring gear [37] (1) from the

ywheel housing
• Mount the TDC marking plate
• Mount the cover on the ywheel housing with a
new gasket

182 AE15 2st edition

 VALVE TIMING

VALVE TIMING

(1) Rocker arm mechanism (4) Camshaft

(2) Roller tappet (5) Push rod
(3) Anti-rotation device

AE15 2st edition 183

 VALVE TIMING

CAMSHAFT
Removing and installing the camshaft/camshaft bearings
Additional jobs
– Removing and installing the vibration damper, see 259
– Removing and installing the exhaust gas turbocharger V8, see 103
– Removing and installing the exhaust gas turbocharger V12, see 115
– Removing and installing the ywheel, see 271
– Removing and installing the oil sump V12, see 226
– Removing and installing the oil injector nozzles, see 221
– Removing, installing the piston with connecting rod, see 279
– Removing and installing the cylinder head, see 162
– Removing and installing the cover, see 317
– Removing and installing the cover, see 317
– Removing and installing the front radial shaft seal, see 247
– Removing and installing the rear radial shaft seal, see 250

(1) Camshaft (4) Anti-rotation device

(2) Camshaft gear (5) Roller tappet
(3) Mounting bolt

Camshaft technical data

Anti-rotation device............................................... M8x1x44............................................................22 Nm
Axial play, camshaft ........................................................................................................... 0.10 - 0.20 mm
Radial play, camshaft...................................................................................................... 0.030- 0.066 mm

AE15 2st edition 185

VALVE TIMING

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[44] Insertion pin 80.99617-6009

• Removing and installing the camshaft

186 AE15 2st edition

 VALVE TIMING

Removing the camshaft Removing the camshaft

Removing the camshaft gear

• Push out the camshaft (1) towards the ywheel

housing with Insertion pin [44]
• Unscrew the mounting bolts (2) • Unscrew the Insertion pin [44]
• Pull off the camshaft gear (1) over the alignment
pin Unscrewing the anti-rotation device

Removing the axial shim

• Unscrew the anti-rotation devices (1) and (2)

• Unscrew the mounting bolts (2) Removing the roller tappet

• Remove the axial shim (1)

Attaching the insertion pin

• Extract the roller tappet (1) from the crankcase (2)

• Screw the Insertion pin [44] (1) into the camshaft

AE15 2st edition 187

VALVE TIMING

Installing the camshaft Installing the camshaft

Installing the roller tappetInstalling the roller

tappet

• Lightly apply clean engine oil to MAN Standard

3277 on the camshaft bearing
• Screw the Insertion pin [44] into the camshaft (1)
• Thinly apply clean engine oil on the roller tappet • Push in the camshaft (1) carefully from the
(1) ywheel side with the Insertion pin [44]
• Align the roller tappet (1) with the recess (2) facing
the tapped hole for the anti-rotation device (3) Detaching the insertion pin
• Insert the roller tappet (1) into the crankcase (4)

Screwing in the anti-rotation deviceScrewing in

the anti-rotation device

• Unscrew the Insertion pin [44] (1) from the

camshaft

Mounting the axial shim

WARNING
Danger of damage to the roller tappets
or anti-rotation devices
• Ensure that the anti-rotation device
engages in the roller tappet recess

• Screw in the new anti-rotation devices (1) and (2)

• Tighten the anti-rotation devices (1) and (2) to 22
Nm

• Position the axial shim (1)

• Screw in and tighten the mounting bolts (2)

188 AE15 2st edition

 VALVE TIMING

Mounting the camshaft gear

• Position the camshaft gear (1) over the alignment

pin
• Screw in and tighten the mounting bolts (2)

AE15 2st edition 189

 VALVE TIMING

VALVE TIMING
Checking the valve timing
Additional jobs
– Checking and setting the valve clearance, see 178

(1) Intake valve, cylinder 1

Technical data
Valve lift ............................................................................................................................ 11.5 - 11.8 mm

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 191

VALVE TIMING

Special tools

[45] Engine barring gear 80.99626-6009

• Cranking the engine in conjunction with:

• Gear ratchet [46]

[46] Gear ratchet 80.99627-0001

• Cranking the engine in conjunction with:

• Engine barring gear [45]

[47] Dial gauge holder 08.71082-0005

• Checking the valve timing in conjunction with:

• Dial gauge [48]

[48] Dial gauge 08.71000-3217

• Checking the valve timing in conjunction with:

• Dial gauge holder [47]

192 AE15 2st edition

 VALVE TIMING

Checking the valve timing Checking the valve lift

Removing the cylinder head cover, cylinder 1

• Mount the Dial gauge [48] (1) with Dial gauge

holder [47] (2) on on the cylinder head for cylinder
• Unscrew the mounting bolts (1) 1
• Remove the cylinder head cover (2) • Place the measuring tip (3) of the Dial gauge [48]
(1) on the valve disc for the intake valve (4)
Attaching the engine barring gear • Zero the Dial gauge [48] (1)
• Continue cranking the engine in the engine’s
running direction until the dial gauge pointer stops
moving
In this position, the correct valve lift must be
11.5 - 11.8 mm.

If the valve lift is outside the tolerance of 11.5 - 11.8

mm, check the camshaft, transmission components
of the valve timing and timing gears and replace if
necessary.

Mounting the cylinder head cover

• Remove the cover with the gasket and the TDC

marking plate from the ywheel housing
• Clean the mating faces
• Mount the Engine barring gear [45] (1) on the
ywheel housing
• Turn the engine in the engine’s running direction
with the Engine barring gear [45] (1) and Gear
ratchet [46] until the 1st cylinder valves overlap
• Check the TDC mark on the ywheel, line it up
exactly with the TDC mark if it does not match up
• Turn the engine opposite to the direction of rotation
of the engine to 50° before TDC
• Turn the engine in the direction of rotation of the • Check the gasket and, if necessary, replace it
engine to 30° before TDC • Put on the cylinder head cover (1)
• Screw in the mounting bolts (2) and tighten them

AE15 2st edition 193

 TIMING GEARS/DRIVE GEARS

TIMING GEARS/DRIVE GEARS

Drive gears in the housing cover at the front

(1) Crankshaft gear

AE15 2st edition 195

TIMING GEARS/DRIVE GEARS

Timing gears in the ywheel housing

(1) Crankshaft gear (2) Camshaft gear

196 AE15 2st edition

 TIMING GEARS/DRIVE GEARS

FRONT DRIVE GEARS

Removing and installing the front drive gears
Additional jobs
– Removing and installing the oil modules, see 209
– Removing and installing the vibration damper, see 259
– Removing and installing the cover, see 317

(1) Crankshaft gear

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[49] Aligning punch 80.99617-0020

• Removing and installing the front crankshaft gear

AE15 2st edition 197

TIMING GEARS/DRIVE GEARS

Removing the front drive gears Installing the front drive gears
Removing the crankshaft gear Installing the crankshaft gear

• Screw in the Aligning punch [49] (2) and (3) • Push on the crankshaft gear (1) over the Aligning
• Pull off the crankshaft gear (1) over the Aligning punch [49] (2) and (3) as far as the stop
punch [49] (2) and (3) • Unscrew the Aligning punch [49] (2) and (3)
• Clean the contact surfaces of the crankshaft gear
(1) and crankshaft

198 AE15 2st edition

 TIMING GEARS/DRIVE GEARS

REAR TIMING GEARS

Removing and installing the rear timing gears
Additional jobs
– Removing and installing the ywheel housing, see 321

(1) Crankshaft gear (2) Camshaft gear

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[50] Aligning punch 80.99617-0220

• Installing the rear crankshaft gear

AE15 2st edition 199

TIMING GEARS/DRIVE GEARS

Setting the crankshaft gear to the marks Removing the rear timing gears
Fixing the crankshaft gear Removing the crankshaft gear

• Fix the crankshaft gear (2) by screwing in the • Screw in the Aligning punch [50] (2) and (3)
mounting bolts (1) and (3) • Pull off the crankshaft gear (1)

Setting the crankshaft gear to the marks

• Crank the engine on the engine barring gear until

the mark (1) is aligned with the mark (2)

Unscrewing the crankshaft gear mounting bolts

• Unscrew the mounting bolts (1) and (2)

200 AE15 2st edition

 TIMING GEARS/DRIVE GEARS

Installing the rear timing gears

Installing the crankshaft gear

• Screw in the Aligning punch [50] (2) and (3)

• Align the bore in the crankshaft gear (1) with the
centring pin
• Push the crankshaft gear (1) onto the crankshaft
• Unscrew the Aligning punch [50] (2) and (3)

Checking the crankshaft gear mark

• Check the mark (1) and mark (2) match up

If the marks (1) and (2) do not match up, remove the
crankshaft gear and re-insert it at the mark.

AE15 2st edition 201

 ENGINE LUBRICATION

ENGINE LUBRICATION

(1) Oil module, right (3) Oil sump

(2) Oil module, left

AE15 2st edition 203

 ENGINE LUBRICATION

OIL FILTER AND OIL SEPARATOR

Removing and installing the oil lter

(1) Oil separator (4) O-ring

(2) O-ring (5) Oil lter
(3) Oil lter cover

Technical data
Mounting bolts, oil separator ................................. 6x20 .................................................................. 11 Nm
Oil lter cover .................................................................................................................................45 Nm
Support dome ................................................................................................................................25 Nm

Important information
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
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

AE15 2st edition 205

ENGINE LUBRICATION

Special tools

[51] Socket, size 36 80.99603-0325

• Removing and installing the oil lter cover

206 AE15 2st edition

 ENGINE LUBRICATION

Removing the oil lter and oil separator Removing the support dome

Removing the oil separator

• Unscrew the support dome (1)

• Unscrew the mounting bolts (2) Removing the drain valve

• Pull the oil separator (1) out of the oil module
• Remove the O-rings (3) and (4)

Removing the oil lter

• Remove the drain valve (1)

WARNING
Engine oil contamination
• Always allow all of the engine oil to drain

• Undo the oil lter cover (1) 2-3 turns with the
Socket, size 36 [51]
• Unscrew and remove the oil lter cover (1) with
Socket, size 36 [51] after approx. 1-2 minutes
• Remove the oil lter insert (3) from the oil lter
cover (1)
• Remove the O-ring (2)

AE15 2st edition 207

ENGINE LUBRICATION

Installing the oil lter and oil separator Installing the oil separator

Installing the support dome

• Insert new O-rings (3) and (4)

• Insert the oil separator (1) into the oil module and
• Screw in and tighten the support dome (1) align it
• Screw in the mounting bolts (2) and tighten them
Installing the drain valve to 11 Nm

• Insert the drain valve (1)

Installing the oil lter

• Pull the new O-ring (2) onto the oil lter cover (1)
• Thinly apply clean engine oil on the O-ring (2)
• Insert the new oil lter insert (3) into the oil lter
cover (1)
• Screw in the oil lter cover (1) with Socket, size
36 [51] and tighten to 45 Nm

208 AE15 2st edition

 ENGINE LUBRICATION

Removing and installing the oil modules

Additional jobs
– Draining the coolant, see Operator's Manual
– Draining the engine oil, see Operator's Manual

(1) Oil module, right

(2) Oil module, left

AE15 2st edition 209

ENGINE LUBRICATION

(1) Filter bypass valve (3) Pressure-relief valve

(2) Drain valve (4) Oil return to oil sump

Technical data
Oil pressure sensor .............................................. M18x1.5 ............................................................47 Nm

Service products
Engine oil..................................see Maintenance Recommendations and Recommended Service Products

Important information
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
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
Note
The right oil module is removed and installed in exactly the same way

210 AE15 2st edition

 ENGINE LUBRICATION

Special tools

[52] Hose clamp pliers for jubilee clips 80.99625-0073

• Removing and installing the jubilee clips

AE15 2st edition 211

ENGINE LUBRICATION

Removing the oil module Unfastening the clips

Disconnecting the electrical connections

• Unfasten the jubilee clips (1) and (2) using the

Hose clamp pliers for jubilee clips [52] and push
• Disconnect the electrical connections (2) onto the hose
• Expose the wiring harness (1)
Removing the vibration damper cover
Removing the oil pressure sensors

• Unscrew the mounting bolts (2) and (3)

• Unscrew the oil pressure sensors (1) and (2) with • Remove the vibration damper cover (1)
the sealing rings
Oil module removal instructions
Removing the left oil return lines

• Do not unscrew the oil cooler mounting bolts (1)

• Unscrew the mounting bolts (1) to remove the oil module
• Detach the oil return lines (2) and (3)

212 AE15 2st edition

 ENGINE LUBRICATION

Removing the left oil module mounting bolts Installing the oil module
Installing the left oil module

• Mark the installation position of the mounting bolts

(1) - (3)
• Unscrew the mounting bolts (1) - (3) • Clean the mating faces
• Insert new O-rings (1) and (4)
Removing the left oil module • Position the oil module (2) with a new gasket (3)
• Screw in one mounting bolt (5) as marked and
tighten by hand

Left oil module tightening diagram

• Remove the oil module (2) with the O-ring (1) and
the gasket (3)
• Remove the O-rings (4)
• Clean the mating faces
• Screw in the remaining mounting bolts (1) - (3) as
marked and tighten by hand
• Tighten the mounting bolts (1)
• Undo the mounting bolts (1) by 60°
• Tighten the mounting bolts (2) and (3)
• Tighten the mounting bolts (1)

AE15 2st edition 213

ENGINE LUBRICATION

Mounting the vibration damper cover Installing the oil pressure sensors

• Position the vibration damper cover (1) • Thinly apply clean Engine oil on the oil pressure
• Screw in and tighten the mounting bolts (2) and (3) sensors (1) and (2)
• Screw in the oil pressure sensors (1) and (2) with
Tightening the clips new sealing rings and tighten to 47 Nm

Disconnecting the electrical connections

• Push the clips (1) and (2) onto the hose

• Tighten the clips (1) and (2) with Hose clamp pliers
for jubilee clips [52] • Route the wiring harness (1)
• Connect the electrical connections (2)
Attaching the left oil return lines

• Attach the oil return lines (2) and (3)

• Screw in and tighten the mounting bolts (1)

214 AE15 2st edition

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Removing and installing the oil cooler

Additional jobs
– Removing and installing the oil modules, see 209

(1) Oil cooler (3) Mounting bolts, oil cooler

(2) Oil cooler (4) Mounting bolts, oil cooler

Technical data
Mounting bolts...................................................... M6X65 ..............................................................28 Nm
Mounting bolts...................................................... M6X95 ..............................................................28 Nm

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 215

ENGINE LUBRICATION

Removing the oil cooler Installing the oil cooler

Removing the oil cooler Installing the oil cooler

• Insert the oil cooler (2) with new gaskets (1)

WARNING
• Screw in the mounting bolts (3) and (4) as marked
Component damage due to setting
and then tighten them by hand
aside the oil module incorrectly
• Tighten the mounting bolts (3) and (4) to 28 Nm
• Put the oil module aside so as not to
damage the oil cooler

• Mark the installation position of the mounting bolts

(3) and (4)
• Unscrew the mounting bolts (3) and (4)
• Remove the oil cooler (2) with the gaskets (1)
• Clean the mating faces

216 AE15 2st edition

 ENGINE LUBRICATION

Dismantling and assembling the oil module

Additional jobs
– Removing and installing the oil modules, see 209

(1) Oil separator (4) Oil lter cover

(2) Oil lter insert (5) Oil cooler
(3) Support dome (6) Oil module

Technical data
Screw plug .......................................................... M33x2 ...............................................................85 Nm
Screw plug .......................................................... M26x1.5 ............................................................85 Nm
Screw plug .......................................................... M18x1.5 ............................................................27 Nm
Pressure-relief valve ............................................ M27x1.5 ............................................................42 Nm

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 217

ENGINE LUBRICATION

Dismantling the oil module Assembling the oil module

Unscrewing the ttings Installing the pressure-relief valve

• Unscrew the ttings (1) and (2) with the sealing • Screw in the screw plug (1) with a new sealing ring
rings and tighten to 85 Nm
• Screw in the pressure-relief valve and tighten to
Unscrewing the screw plugs 42 Nm

Screwing in the screw plugs

• Unscrew the screw plugs (1), (2) and (3) with the
sealing rings
• Screw in and tighten the screw plug (1) with a new
Removing the pressure-relief valve sealing ring
• Screw in the screw plug (2) with a new sealing ring
and tighten to 27 Nm
• Screw in the screw plug (3) with a new sealing ring
and tighten to 85 Nm

• Unscrew the screw plug (1) with the sealing ring

• Unscrew the pressure-relief valve (2)

218 AE15 2st edition

 ENGINE LUBRICATION

Screwing in the ttings

• Screw in and tighten the ttings (1) and (2) with

new sealing rings

AE15 2st edition 219

 ENGINE LUBRICATION

OIL INJECTOR NOZZLES

Removing and installing the oil injector nozzles
Additional jobs
– Removing and installing the oil sump V12, see 226
– Removing and installing the oil sump V8, see 223

(1) Oil injector nozzle (2) Mounting bolt

Technical data
Mounting bolt ....................................................... M14x20-10.9....................................................120 Nm

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
Replace the mounting bolts and spring washers when exchanging the oil injector nozzle.

AE15 2st edition 221

ENGINE LUBRICATION

Removing the oil injector nozzle Installing the oil injector nozzle

• Unscrew the mounting bolt (1) • Insert the oil injector nozzle (2) into the crankcase
• Extract the oil injector nozzle (2) from the • Screw in the mounting bolt (1) and tighten to
crankcase 120 Nm

222 AE15 2st edition

 ENGINE LUBRICATION

OIL SUMP
Removing and installing the oil sump V8
Additional jobs
– Draining and topping up the engine oil, see Operator's Manual

(1) Screw plug (5) Oil return line upstream of separator, right
(2) Oil sump (6) Oil return line downstream of separator,
(3) Screw plug right
(4) Manifold for oil suction line

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 223

ENGINE LUBRICATION

Removing the oil sump Removing the oil sump

Detaching the left oil return line

• Unscrew the mounting bolts (3)

• Remove the oil sump (2) with the gasket (1)
• Detach the oil return lines (1) and (2) • Clean the mating faces

Detaching the right oil return line

• Detach the oil return lines (1) and (2)

Removing the manifold for the oil suction line

• Unscrew the mounting bolts (5) and (8)

• Remove the manifold (4) with the unscrewed
conduit (3) and the O-ring (2)
• Remove the manifold (7) with the unscrewed
conduit (6) and the O-ring (1)
• Clean the mating faces

224 AE15 2st edition

 ENGINE LUBRICATION

Installing the oil sump Attaching the right oil return line

Installing the oil sump

• Position the oil return lines (1) and (2) so that they
are free of strain
• Clean the mating faces • Tighten the union nuts for the oil return lines (1)
• Position the oil sump (2) with a new gasket (1) and (2)
• Screw in and tighten the mounting bolts (3)
Attaching the left oil return line
Mounting the manifold for the oil suction line

• Position the oil return lines (1) and (2) so that they
• Clean the mating faces are free of strain
• Thinly apply engine oil on the new O-rings • Tighten the union nuts for the oil return lines (1)
• Position the manifold (7) with a new unscrewed and (2)
conduit (6) and a new O-ring (1)
• Screw in and tighten the mounting bolts (8)
• Position the manifold (4) with a new unscrewed
conduit (3) and a new O-ring (2)
• Screw in and tighten the mounting bolts (5)

AE15 2st edition 225

ENGINE LUBRICATION

Removing and installing the oil sump V12

Additional jobs
– Draining and topping up the engine oil, see Operator's Manual

(1) Screw plug (4) Oil return line, left

(2) Dipstick (5) Oil return line, left
(3) Screw plug with magnetic stopper (6) Manifold for oil suction line

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

226 AE15 2st edition

 ENGINE LUBRICATION

Removing the oil sump Removing the manifold for the oil suction line

Detaching the left oil return line

• Unscrew the mounting bolts (5) and (8)

• Remove the manifold (4) with the unscrewed
• Unscrew the mounting bolts (1) conduit (3) and the O-ring (2)
• Detach the oil return lines (2) and (3) • Remove the manifold (7) with the unscrewed
conduit (6) and the O-ring (1)
Detaching the right oil return line • Clean the mating faces

Removing the oil sump

• Unscrew the mounting bolts (3)

• Detach the oil return lines (1) and (2)
• Unscrew the mounting bolts (3)
• Remove the oil sump (2) with the gasket (1)
• Clean the sealing surfaces

AE15 2st edition 227

ENGINE LUBRICATION

Installing the oil sump Attaching the left oil return line

Installing the oil sump

• Position the oil return lines (2) and (3) so that they
are strain-free
• Position the oil sump (2) with a new gasket (1) • Tighten the union nuts for the oil return lines (2)
• Screw in and tighten the mounting bolts (3) and (3)
• Mount the fastening (1)
Mounting the manifold for the oil suction line
Attaching the right oil return line

• Thinly apply engine oil on the new O-rings (1) and

(2) • Position the oil return lines (1) and (2) so that they
• Position the manifold (4) with a new unscrewed are strain-free
conduit (3) and a new O-ring (2) • Tighten the union nuts for the oil return lines (1)
• Screw in and tighten the mounting bolts (5) and (2)
• Position the manifold (7) with a new unscrewed • Mount the fastening (3)
conduit (6) and a new O-ring (1)
• Screw in and tighten the mounting bolts (8)

228 AE15 2st edition

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Dismantling and assembling the oil sump V8

Additional jobs
– Removing and installing the oil sump V8, see 223

(1) Oil sump (5) Screw plug

(2) Oil ller neck (6) Screw plug
(3) Oil dipstick (7) Screw plug
(4) Oil suction lines (8) Connection pipe

Technical data
Connection pipe ................................................... M26x1.5 ..........................................................150 Nm
Screw plug with magnetic stopper ......................... M26x1.5 ............................................................80 Nm

Service products
Loctite 2701 ...................................................................................................................... 04.10160-9353
Loctite 648 ........................................................................................................................ 04.90300-9024

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 229

ENGINE LUBRICATION

Dismantling the oil sump Removing the oil ller neck

Pulling out the oil dipstick

• Undo the mounting nut (2)

• Unscrew the oil ller neck (1) with the mounting
• Pull out the oil dipstick (1) nut (2)
• Unscrew the tting (3) with the sealing ring (4)
Pulling out the guide tube
Removing the oil suction lines

• Unscrew the upper bolt (2) on the tting

• Pull out the guide tube (1) • Unscrew the mounting bolts (3) and (4) with
washers
Removing the tting • Remove the oil suction lines (2) and (5)
• Remove the O-rings (1) and (6) from the oil suction
lines (2) and (5)
• Clean the mating faces

• Unscrew the tting (1) with the sealing ring (2)

230 AE15 2st edition

 ENGINE LUBRICATION

Dismantling the oil suction lines Removing the oil return lines

• Unscrew the mounting nuts (4) and (5) • Unscrew the mounting bolts (1)
• Remove the mounting bolts (6) and (7) • Unscrew the union nuts for the oil return lines (2)
• Disconnect the holder (3) and the oil suction lines and (4)
(1) and (2) • Remove the oil return lines (2) and (4) with the
holder (3)
Removing the oil suction line screen plate
Dismantling the oil return lines

• Remove the snap ring (2)

• Remove the screen plate (1) from the oil suction • Mark the installation position of the oil return lines
line (4), (5), (8) and (9) relative to the holder (1)
• Clean the screen plate (1) • Unscrew the mounting nuts (2) and (3)
• Remove the mounting bolts (6) and (7)

AE15 2st edition 231

ENGINE LUBRICATION

Unscrewing the connection pipe Unscrewing the screw plugs with magnetic
stoppers

• Mark the installation position of the connection

pipe (1) • Unscrew the screw plugs (1) and (2) with the
• Unscrew the connection pipe (1) with the sealing sealing rings
rings • Clean the mating faces
• Clean the mating faces

Unscrewing the screw plugs

• Unscrew the screw plugs (1) - (5) with the sealing

rings
• Clean the mating faces

232 AE15 2st edition

 ENGINE LUBRICATION

Assembling the oil sump Screwing in the connection pipe

Screwing in the screw plugs with magnetic

stoppers

• Clean the mating faces

• Thinly apply Loctite 2701 (2) on the thread of the
connection pipe (1) in the head area
• Screw in the screw plugs (1) and (2) with new • Screw in the connection pipe (1) with the sealing
sealing rings and tighten to 80 Nm rings and tighten to 150 Nm
Screwing in the screw plugs Assembling the oil return lines

• Clean the mating faces • Position the oil return lines (4), (5), (8) and (9) to
• Screw in and tighten the screw plugs (1) - (5) with the holder (1) as marked
new sealing rings • Insert the mounting bolts (6) and (7)
• Screw on and tighten the mounting nuts (2) and
(3)

AE15 2st edition 233

ENGINE LUBRICATION

Installing the oil return lines Assembling the oil suction lines

• Insert the oil return lines (2) and (4) into the oil • Position the holder (3) at the clips for the oil suction
sump with the holder (3) lines (1) and (2)
• Screw on and tighten the union nuts for the oil • Insert the mounting bolts (6) and (7)
return lines (2) and (4) • Screw on and tighten the mounting nuts (4) and
• Screw in and tighten the mounting bolts (1) (5)

Installing the oil suction line screen plate Installing the oil suction lines

• Clean the screen plate (1) • Insert new O-rings (1) and (6) into oil suction lines
• Insert the screen plate (1) into the oil suction line (2) and (5)
• Install the snap ring (2) • Insert oil suction lines (2) and (5) up to the stop
• Screw in and tighten the mounting bolts (3) and
(4) with washers

234 AE15 2st edition

 ENGINE LUBRICATION

Installing the oil ller neck Inserting the oil dipstick

• Screw in and tighten the tting (3) with a new • Insert the oil dipstick (1) into the guide tube (2)
sealing ring (4)
• Thinly apply Loctite 648 on the thread of the oil
ller neck (5)
• Screw in the oil ller neck (3) with the mounting
nut (2) and a new sealing ring (1)
• Tighten the mounting nut (2)

Installing the tting

• Screw in and tighten the tting (1) with a new

sealing ring (2)

Inserting the guide tube

• Push the guide tube (1) into the tting (2) as far as
the stop and pull back briey for locking

AE15 2st edition 235

ENGINE LUBRICATION

Dismantling and assembling the oil sump V12

Additional jobs
– Removing and installing the oil sump V12, see 226

(1) Oil sump (5) Oil dipstick

(2) Oil ller neck (6) Screw plug with magnetic stopper
(3) Oil suction line (7) Fitting
(4) Screw plug

Technical data
Screw plug with magnetic stopper ......................... M26x1.5 ............................................................80 Nm

Service products
Loctite 648 ........................................................................................................................ 04.90300-9024

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

236 AE15 2st edition

 ENGINE LUBRICATION

Dismantling the oil sump Removing the oil ller neck

Pulling out the oil dipstick

• Undo the mounting nut (2)

• Unscrew the oil ller neck (3) with the sealing ring
• Pull out the oil dipstick (1) (1)

Pulling out the guide tube Removing the oil suction lines

• Undo the upper bolt (2) on the tting • Unscrew the mounting bolts (3) and (4) with
• Pull out the guide tube (1) washers
• Remove the oil suction lines (2) and (5)
Removing the tting • Remove the O-rings (1) and (6) from the oil suction
lines (2) and (5)
• Clean the mating faces

• Unscrew the tting (1) with the sealing ring (2)

AE15 2st edition 237

ENGINE LUBRICATION

Dismantling the oil suction line Unscrewing the screw plugs with magnetic
stoppers

• Remove the snap ring (2)

• Remove the screen plate (1) from the oil suction • Unscrew the screw plugs (1), (2) and (3) with the
line sealing rings
• Clean the screen plate (1) • Clean the screw plugs (1), (2) and (3)

Unscrewing the ttings

• Mark the installation position of the ttings (1) and

(2)
• Unscrew the ttings (1) and (2) with the sealing
rings

Unscrewing the screw plugs

• Unscrew the screw plugs (1) and (2) with the

sealing rings

238 AE15 2st edition

 ENGINE LUBRICATION

Assembling the oil sump Assembling the oil suction line

Screwing in the screw plugs with magnetic

stoppers

• Clean the screen plate (1)

• Insert the screen plate (1) into the oil suction line
• Install the snap ring (2)
• Screw in the screw plugs (1), (2) and (3) with new
sealing rings and tighten to 80 Nm Installing the oil suction lines
Clean the screw plugs (1), (2) and (3)

Screwing in the screw plugs

• Clean the mating faces

• Insert new O-rings (1) and (6) into oil suction lines
(2) and (5)
• Screw in and tighten the screw plugs (1) and (2) • Insert oil suction lines (2) and (5) up to the stop
with new sealing rings • Screw in and tighten the mounting bolts (3) and
(4) with washers
Screwing in the ttings

• Screw in and tighten the ttings (1) and (2) with

new sealing rings

AE15 2st edition 239

ENGINE LUBRICATION

Installing the oil ller neck Inserting the oil dipstick

• Thinly apply Loctite 648 (4) on the thread of the oil • Insert the oil dipstick (1) into the guide tube (2)
ller neck (3)
• Screw in the oil ller neck (3) with the mounting
nut (2) and a new sealing ring (1)
• Tighten the mounting nut (2)

Installing the tting

• Screw in and tighten the tting (1) with a new

sealing ring (2)

Inserting the guide tube

• Push the guide tube (1) into the tting (2) as far as
the stop and pull back briey for locking

240 AE15 2st edition

 ENGINE LUBRICATION

OIL PUMPS
Removing and installing the oil pumps
Additional jobs
– Removing and installing the cover, see 317
Removing and installing the coolant lines, see 63

(1) Oil pump (2) Oil pump

Technical data
Backlash, ring gear - crankshaft gear.............................................................................. 0.060 - 0.240 mm
Axial play, ring gear ....................................................................................................... 0.040 - 0.090 mm
Axial play, rotor.............................................................................................................. 0.035 - 0.080 mm
Mounting bolt, oil pump......................................... M6x40-10.9 .......................................................15 Nm

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 241

ENGINE LUBRICATION

Special tools

[53] Dial gauge holder 80.99605-0172

• Checking the ring gear axial and radial play in

conjunction with:
• Dial gauge [54]

[54] Dial gauge 08.71000-3217

• Checking the ring gear axial and radial play in

conjunction with:
• Dial gauge holder [53]

242 AE15 2st edition

 ENGINE LUBRICATION

Removing the oil pumps Checking the oil pump

Removing the oil pumps Checking the ring gear axial play

• Mark the installation position of the mounting bolts • Put the Dial gauge holder [53] (2) with the Dial
(1) and (4) gauge [54] (1) on the oil pump
• Unscrew the mounting bolts (1) and (4) • Position the Dial gauge [54] (1) against the ring
• Remove the oil pumps (2) and (3) gear (3) with a preload
• Press the ring gear (3) towards the drive gear
• Zero the Dial gauge [54] (1)
• Press the ring gear (2) towards the Dial gauge [54]
(1) and check the difference
The permissible axial play on the ring gear (3) is
0.040 - 0.090 mm.

If the axial play is out of tolerance, t a new oil pump.

Checking the rotor axial play

• Put the Dial gauge holder [53] (2) with the Dial
gauge [54] (1) on the oil pump
• Position the Dial gauge [54] (1) against the rotor
(3) with a preload
• Press the rotor (3) towards the drive gear
• Zero the Dial gauge [54] (1)
• Press the rotor (2) towards the Dial gauge [54] (1)
and check the difference
The permissible axial play on the rotor (3) is 0.035 -
0.080 mm.

If the axial play is out of tolerance, t a new oil pump.

AE15 2st edition 243

ENGINE LUBRICATION

Installing the oil pumps

Installing the oil pumps

• Position the oil pumps (2) and (3)

• Screw in the mounting bolts (1) and (4) as marked
and tighten them by hand
• Tighten the mounting bolts (1) and (4) to 15 Nm

244 AE15 2st edition

 CRANKSHAFT OIL SEALS

CRANKSHAFT OIL SEALS

(1) Front radial shaft seal

(2) Cover

AE15 2st edition 245

CRANKSHAFT OIL SEALS

(1) Rear radial shaft seal (2) Flywheel housing

246 AE15 2st edition

 CRANKSHAFT OIL SEALS

CRANKSHAFT OIL SEALS

Removing and installing the front radial shaft seal
Additional jobs
– Removing and installing the vibration damper, see 259

(1) Front radial shaft seal (2) Cover

Important information
WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or grease before
installation.
• Clean the vibration dampers and installer sleeve before assembly
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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

AE15 2st edition 247

CRANKSHAFT OIL SEALS

Special tools

[55] Impact extractor 80.99602-0016

• Extracting the radial shaft seal in conjunction with:

• Extractor hook [56]

[56] Extractor hook 80.99602-0175

• Extracting the radial shaft seal in conjunction with:

• Impact extractor [55]

[57] Aligning punch 80.99617-0020

• Installing the radial shaft seal in conjunction with:

• Plug-on handle [58]
• Washer [59]
• Pressing plate [60]

[58] Plug-on handle 80.99617-0187

• Installing the radial shaft seal in conjunction with:

• Aligning punch [57]
• Washer [59]
• Pressing plate [60]

[59] Washer 80.99617-0144

• Installing the radial shaft seal in conjunction with:

• Aligning punch [57]
• Plug-on handle [58]
• Pressing plate [60]

[60] Pressing plate 80.99604-0342

• Installing the radial shaft seal in conjunction with:

• Aligning punch [57]
• Plug-on handle [58]
• Washer [59]

248 AE15 2st edition

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Removing the front radial shaft seal Installing the front radial shaft seal

• Assemble the Pressing plate [60] (3) with the

WARNING
Plug-on handle [58] (1) and the Washer [59] (2)
Danger of component damage on the
• Put the closed side of the radial shaft seal (4) on
cover
the special tool
• Ensure that the Extractor hook [56] (2)
• Screw in the Aligning punch [57] (5)
does not hook in behind the cover
• Push the special tool onto the Aligning punch [57]
• Extract the radial shaft seal (1) using the Impact (5)
extractor [55] (3) and the Extractor hook [56] (2) • Press in the radial shaft seal (4) as far as the stop
using the special tool
• Remove the special tool

AE15 2st edition 249

CRANKSHAFT OIL SEALS

Removing and installing the rear radial shaft seal

Additional jobs
– Removing and installing the ywheel, see 271

(1) Rear radial shaft seal (2) Flywheel housing

Important information
WARNING
Component damage due to inadequate positive locking of the crankshaft gear because the
front face of the crankshaft gear is shot-peened
• The crankshaft gear must be replaced every time after the crankshaft gear screw connection is
unscrewed
WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or grease before
installation
• Clean the crankshaft gear and installer sleeve before assembly
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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

250 AE15 2st edition

 CRANKSHAFT OIL SEALS

Special tools

[61] Engine barring gear 80.99626-6009

• Blocking the engine

[62] Impact extractor 80.99602-0016

• Extracting the crankshaft gear and radial shaft

seal in conjunction with:
• Extractor device [63]
• Aligning punch [68]

[63] Extractor device 80.99601-6033

• Extracting the crankshaft gear and radial shaft

seal in conjunction with:
• Impact extractor [62]
• Aligning punch [68]

[64] Plug-on handle 80.99617-0187

• Installing the radial shaft seal in conjunction with:

• Washer [65]
• Guide plate [66]
• Press-in bush [67]
• Aligning punch [68]
[65] Washer 80.99617-0144

• Installing the radial shaft seal in conjunction with:

• Plug-on handle [64]
• Guide plate [66]
• Press-in bush [67]
• Aligning punch [68]
[66] Guide plate 80.99606-0703

• Installing the radial shaft seal in conjunction with:

• Plug-on handle [64]
• Washer [65]
• Press-in bush [67]
• Aligning punch [68]

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[67] Press-in bush 80.99604-0340

• Installing the radial shaft seal in conjunction with:

• Plug-on handle [64]
• Washer [65]
• Guide plate [66]
• Aligning punch [68]
[68] Aligning punch 80.99617-0220

• Removing and installing the ywheel

• Installing the radial shaft seal in conjunction with:
• Plug-on handle [64]
• Washer [65]
• Guide plate [66]
• Press-in bush [67]
• Extracting the crankshaft gear and radial shaft
seal in conjunction with:
• Impact extractor [62]
• Extractor device [63]

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Extracting the rear radial shaft seal Checking the valves for unobstructed
movement, 1st cylinder
Removing the cylinder head cover, cylinder 1

• Check the 1st cylinder rocker arms (1) and (2) for
• Unscrew the mounting bolts (1) unobstructed movement
• Remove the cylinder head cover (2) If the 1st cylinder rocker arms (1) and (2) cannot
move unobstructed, crank the engine a further 360°
Attaching the engine barring gear using the engine barring gear.

Mounting the cylinder head cover, cylinder 1

• Remove the cover with the gasket and the TDC

marking plate from the ywheel housing
• Clean the mating faces • Check the gasket and, if necessary, replace it
• Mount and lock the Engine barring gear [61] (1) • Put on the cylinder head cover (2)
• Screw in and tighten the mounting bolts (1)

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Mounting the special tool Installing the rear radial shaft seal
Installation position of crankshaft gear

• Insert the Extractor device [63] (3) into the

crankshaft gear (4)
• Clamp the Extractor device [63] (3) at the clamping • Align the marks on the crankshaft gear (1) and the
bolts (2) mark on the camshaft gear (2) with one another
• Screw in two ywheel bolts (1) and (5) opposite
one another Installing the crankshaft gear

Extracting the radial shaft seal

WARNING
Component damage due to
• Screw the Impact extractor [62] (1) into the insufciently tight t
Extractor device [63] (2) • Replace the crankshaft gear every
• Extract the crankshaft gear (4) with the Impact time after the crankshaft gear/ywheel
extractor [62] (1) screw connection is undone
• Unscrew the ywheel bolts (5)
• Remove the radial shaft seal (3) from the • Align the alignment pin (3) for the crankshaft gear
crankshaft gear (4) (2) with the bore in the crankshaft (1)
• Put on the crankshaft gear (2) and install using a
soft hammer until the stop is reached

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Checking the crankshaft gear marks in relation Pressing in the radial shaft seal
to the camshaft gear

• Assemble the Press-in bush [67] (2) with the

• Check the marks on the crankshaft gear (1) in Plug-on handle [64] (5) and Washer [65] (3)
relation to the camshaft gear (2) • Push the special tool onto the Guide plate [66]
Marks (1) and (2) match up. over the Aligning punch [68] (1) and (4)
• Press in the radial shaft seal into the ywheel
If the marks (1) and (2) do not match up, remove the housing (6) with the special tool until the Pressing
crankshaft gear and install at the mark. Align the plate [60] (2) is in contact with the Guide plate [66]
crankshaft with the alignment pin if necessary.
• Remove the special tool
Preparing to install the radial shaft seal
Removing the engine barring gear

• Separate two opposite-facing discs from the

transport sleeve in each case • Remove the Engine barring gear [61] (1) from the
• Position the radial shaft seal (4) with supplied ywheel housing
transport sleeve at the Guide plate [66] (3) • Mount the TDC marking plate
• Carefully push the radial shaft seal (4) onto the • Mount the cover on the ywheel housing with a
Guide plate [66] (3) new gasket
• Push the Guide plate [66] (3) over the Aligning
punch [68] (1) and (2)
• Remove the transport sleeve

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CRANKSHAFT DRIVE

(1) Flywheel (5) Bearing cap

(2) Piston (6) Crankshaft
(3) Connecting rod (7) Vibration damper
(4) Crankcase (8) Cover

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VIBRATION DAMPER
Removing and installing the vibration damper

(1) Cover (3) Cover mounting bolt

(2) Plug (4) Indicator

Technical data
Mounting bolts, vibration damper........................... M16x1.5x117-10.9.........................Initial torque 190 Nm
Vibration damper mounting bolt ............................. M16x1.5x117-10.9................................Final torque 90°

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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Special tools

[69] Aligning punch 80.99617-0020

• Removing and installing the vibration damper

[70] Engine barring gear 80.99626-6009

• Cranking the engine in conjunction with:

• Gear ratchet [71]

[71] Gear ratchet 80.99627-0001

• Cranking the engine in conjunction with:

• Engine barring gear [70]

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Removing the vibration damper Removing the engine barring gear

Attaching the engine barring gear

• Unscrew the mounting bolts (1)

• Remove the engine barring gear (2)
• Remove the cover with the gasket and the TDC
marking plate from the ywheel housing Unscrewing the mounting bolts
• Clean the mating faces
• Mount and lock the Engine barring gear [70] (1)

Removing the cover

• Unscrew two opposite mounting bolts (1) and (2)

Screwing in the aligning punches

• Unscrew the mounting bolts (2) and (3)

• Remove the cover (1)

Dismantling the cover

• Screw in the Aligning punch [69] (1) and (2)

• Unscrew the mounting bolts (1)

• Remove the indicator (2)
• Press out the plug (3)

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Pulling off the vibration damper Dismantling the vibration damper

CAUTION WARNING
Danger of injury due to heavy Component damage due to putting the
components and removal and vibration damper aside incorrectly
installation position that is difcult • Do not lay the vibration damper down
to access on the discs
• Use the lifting device or lift off with
support • Unscrew the mounting bolts (3)
• Remove the hub (1) from the vibration damper
• Unscrew the remaining mounting bolts (1) (2)Remove the hub (1) from the vibration damper
• Pull off the vibration damper (2) (2)
• Unscrew the Aligning punch [69] (3) and (4)

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Assembling the vibration damper Installing the vibration damper

Putting on the vibration damper

• Insert the hub (1) into the vibration damper (2)

• Screw in and tighten the mounting bolts (3)
• Screw in the Aligning punch [69] (3) and (4)
• Put on the vibration damper (2)
• Screw in the new mounting bolts (1) and tighten
them by hand

Unscrewing the aligning punches

• Unscrew the Aligning punch [69] (1) and (2)

Tightening the mounting bolts

• Screw in the remaining mounting bolts (1) and (2)

• Tighten all the mounting bolts to Initial torque 190
Nm
• Tighten all the mounting bolts to Final torque 90°

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Mounting the engine barring gear Removing the engine barring gear

• Position the engine barring gear (2) • Remove the Engine barring gear [70] (1)
• Screw in and tighten the mounting bolts (1) • Mount the TDC marking plate

Assembling the cover

• Insert the plug (3)

• Position the indicator (2)
• Screw in and tighten the mounting bolts (1)

Mounting the cover

• Position the cover (1)

• Screw in and tighten the mounting bolts (2) and (3)

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INTERMEDIATE RING
Removing and installing the intermediate ring (variant)

(1) Intermediate ring (3) Mounting nut

(2) Stud bolt

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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Removing the intermediate ring Mounting the intermediate ring

Removing the intermediate ring Screwing in the stud bolts

• Screw in and tighten the stud bolts (1)

CAUTION
Danger of injury due to heavy Mounting the intermediate ring
components
• Use lifting gear to remove the
intermediate ring

• Unscrew the mounting nuts (3) with washers (2)

• Remove the intermediate ring (1)

Unscrewing the stud bolts

CAUTION
Danger of injury due to heavy
components
• Use lifting gear to install the
intermediate ring

• Position the intermediate ring (1) up to the stop

• Unscrew the stud bolts (1) • Screw in and tighten the mounting nuts (3) with
new washers (2)

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ADDITIONAL FLYWHEEL MASS

Removing and installing the additional ywheel mass (variant)
Additional jobs
– Removing and installing the intermediate ring (variant), see 265

(1) Flywheel mounting bolt (3) Additional ywheel mass

(2) Flywheel

Service products
Loctite 589 ........................................................................................................................ 04.10160-9062

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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Special tools

[72] Eye-bolt 06.05110-0103

• Removing and installing the ywheel

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Removing the additional ywheel mass Mounting the additional ywheel mass
Removing the additional ywheel mass Mounting the additional ywheel mass

CAUTION CAUTION
Danger of injury due to heavy Danger of injury due to heavy
components components
• Use lifting gear to remove the additional • Use lifting gear to install the additional
ywheel mass ywheel mass

• Screw the Eye-bolt [72] into the additional ywheel • Screw the Eye-bolt [72] into the additional ywheel
mass (1) mass (1)
• Attach the lifting gear in the Eye-bolt [72] • Attach the lifting gear in the Eye-bolt [72]
• Unscrew the mounting bolts (2) • Thinly apply Loctite 589 on the thread (3) of the
• Remove the additional ywheel mass (1) new mounting bolts
• Detach the lifting gear • Position the additional ywheel mass (1) on the
• Unscrew the Eye-bolt [72] ywheel
• Screw in and tighten the mounting bolts (2)
• Detach the lifting gear
• Unscrew the Eye-bolt [72]

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FLYWHEEL
Removing and installing the ywheel

(1) Mounting bolt (2) Flywheel

Technical data
Mounting bolt ....................................................... M18x1.5x91-12.9 ..........................Initial torque 100 Nm
Mounting bolt ....................................................... M18x1.5x91-12.9 .................................. 2nd torque 90°
Mounting bolt ....................................................... M18x1.5x91-12.9 .................................Final torque 90°
Installation temperature, ywheel ring gear ................................................................................ 200-230℃

Important information
WARNING
Component damage due to reused mounting bolts
• Replace ywheel mounting bolts once they have been undone

WARNING
Component damage due to inadequate positive locking of the crankshaft gear because the
front face of the crankshaft gear is shot-peened
• The crankshaft gear must be replaced every time after the crankshaft gear screw connection is
unscrewed
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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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Special tools

[73] Aligning tool 80.99617-0220

• Removing and mounting the ywheel

[74] Socket, size 22 80.99612-0024

• Undoing and tightening the ywheel bolts in

conjunction with:
• Support [76]
• Torque multiplier i = 1 : 3.3 [75]
• Torque angle gauge [77]
• Holding device [78]
• Pan head screw [79]
• Connecting pin [80]
• Rubber ring, 42 mm [81]
[75] Torque multiplier i = 1 : 3.3 80.99619-0006

• Undoing and tightening the ywheel bolts in

conjunction with:
• Socket, size 22 [74]
• Support [76]
• Torque angle gauge [77]
• Holding device [78]
• Pan head screw [79]
• Connecting pin [80]
• Rubber ring, 42 mm [81]
[76] Support 80.99606-0551

• Undoing and tightening the ywheel bolts in

conjunction with:
• Socket, size 22 [74]
• Torque multiplier i = 1 : 3.3 [75]
• Torque angle gauge [77]
• Holding device [78]
• Pan head screw [79]
• Connecting pin [80]
• Rubber ring, 42 mm [81]
[77] Torque angle gauge 80.99607-0172

• Undoing and tightening the ywheel bolts in

conjunction with:
• Socket, size 22 [74]
• Support [76]
• Torque multiplier i = 1 : 3.3 [75]
• Holding device [78]
• Pan head screw [79]
• Connecting pin [80]
• Rubber ring, 42 mm [81]

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[78] Holding device 80.99606-0641

• Undoing and tightening the ywheel bolts in

conjunction with:
• Socket, size 22 [74]
• Support [76]
• Torque multiplier i = 1 : 3.3 [75]
• Torque angle gauge [77]
• Pan head screw [79]
• Connecting pin [80]
• Rubber ring, 42 mm [81]
[79] Pan head screw 06.02191-0407

• Undoing and tightening the ywheel bolts in

conjunction with:
• Socket, size 22 [74]
• Support [76]
• Torque multiplier i = 1 : 3.3 [75]
• Torque angle gauge [77]
• Holding device [78]
• Connecting pin [80]
• Rubber ring, 42 mm [81]
[80] Connecting pin 06.22729-0006

• Undoing and tightening the ywheel bolts in

conjunction with:
• Socket, size 22 [74]
• Support [76]
• Torque multiplier i = 1 : 3.3 [75]
• Torque angle gauge [77]
• Holding device [78]
• Pan head screw [79]
• Rubber ring, 42 mm [81]
[81] Rubber ring, 42 mm 08.06142-9006

• Undoing and tightening the ywheel bolts in

conjunction with:
• Socket, size 22 [74]
• Support [76]
• Torque multiplier i = 1 : 3.3 [75]
• Torque angle gauge [77]
• Holding device [78]
• Pan head screw [79]
• Connecting pin [80]
[82] Adapter 80.99606-0552

• Undoing and tightening the cylinder head bolts

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[83] Socket 80.99603-0327

• Undoing and tightening the vibration damper

mounting bolts in conjunction with:
• Socket, size 22 [10]
• Torque multiplier i = 1 : 3.3 [11]
• Support [12]
• Angle measuring disc [13]
• Holding xture [14]
• Cheese-head screw [15]
• Connecting pin [16]
• Rubber ring 42 mm [17]
[84] Eye-bolt 06.05110-0103

• Removing and installing the ywheel

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Removing the ywheel Unscrewing the ywheel mounting bolts

Assembling the special tool

• Unscrew two opposite mounting bolts (1) and (2)

• Insert the Torque multiplier i = 1 : 3.3 [75] (10) into Screwing in the centring pins
the Support [76] (1)
• Mount the Holding device [78] (4) with the Pan
head screw [79] (2) and the Adapter [109] (3) on
the Support [76] (1)
• Put the Torque angle gauge [77] (9) on the Torque
multiplier i = 1 : 3.3 [75] (10)
• Put the Socket, size 22 [74] (8) on the Torque
multiplier i = 1 : 3.3 [75] (10) and secure with
the Connecting pin [80] (7) and the Rubber ring,
42 mm [81] (5)
• Insert the Socket [83] (6) into the Socket, size
22 [74] (8)

Undoing the ywheel mounting bolts

• Screw in the Aligning tool [73] (1) and (2)

• Unscrew the remaining mounting bolts

• Put the special tool (2) on the mounting bolt (1) to

be undone
• Undo the mounting bolts (1) using the special tool
(2) in conjunction with the Socket [83]

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Pulling off the ywheel Removing and installing the ywheel

ring gear
Drilling the ywheel ring gear

CAUTION
Danger of injury due to heavy
components
• Use lifting gear to remove the ywheel WARNING
Danger of injury from metal chips
• Screw the Eye-bolt [84] into the ywheel • Wear protective equipment
• Attach the lifting gear in the Eye-bolt [84]
WARNING
• Pull off the ywheel (3) over the Aligning tool [73]
Component damage due to
(1) and (2)
spot-drilling of the ywheel
• Detach the lifting gear
• Take care not to damage the ywheel
when spot-drilling the ywheel ring gear
• Renew the spot-drilled ywheel

• Spot-drill the ywheel ring gear (1) and force it

open
• Remove the ywheel ring gear (1) from the
ywheel (2)
• Clean the contact surfaces of the ywheel ring
gear (1) and ywheel (2) and then check for
damage

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Installing the ywheel ring gear Installing the ywheel

Fitting the ywheel

• Heat the ywheel ring gear (1) to 200-230℃

• Fit the ywheel ring gear (1) so that the chamfer
on the teeth (3) is facing away from the ywheel CAUTION
(2) Danger of injury due to heavy
• Fit the ywheel ring gear (1) so that the bores of components
the ywheel ring gear (1) and the ywheel (2) are • Use lifting gear to install the ywheel
in line
• Adjust the ywheel ring gear (1) as necessary WARNING
Component damage due to reused
ywheel bolts
• Renew mounting bolts once they have
been undone

• Align the dowel hole in the ywheel (3) with the

crankshaft alignment pin
• Fit the ywheel (3) over the Aligning tool [73] (1)
and (2)

Unscrewing the centring pins

• Screw in the new ywheel mounting bolts

• Unscrew the Aligning tool [73] (1) and (2)

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Screwing in the ywheel mounting bolts Tightening the ywheel mounting bolts

• Screw in the remaining new mounting bolts (1) and

Note
(2)
Note the torque multiplier ratio, i = 1 : 3.3.
Tightening diagram

• Tighten the mounting bolts (1) to Initial torque

100 Nm as per the tightening diagram
• Tighten the mounting bolts (1) using the special
tool (2) in conjunction with the Socket [83]
• Tighten the mounting bolts (1) to 2nd torque 90°
as per the tightening diagram
• Tighten the mounting bolts (1) to Final torque 90°
as per the tightening diagram

• Tighten the mounting bolts in the sequence (1) -

(10)

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PISTONS AND CONNECTING RODS

Removing, installing the piston with connecting rod
Additional jobs
– Removing and installing the exhaust gas turbocharger V8, see 103
– Removing and installing the exhaust gas turbocharger V12, see 115
– Removing and installing the oil sump V8, see 223
– Removing and installing the oil sump V12, see 226
– Removing and installing the exhaust pipes V12, see 142
– Removing and installing the cylinder head, see 162
– Removing and installing the charge-mixture system, see 79
– Removing and installing the air distribution pipes, see 88

(1) Piston (5) Connecting rod

(2) Full keystone ring (6) Piston pin
(3) Taper-face ring (7) Snap ring
(4) Double-bevelled ring

Technical data
Connecting rod bearing bolt .................................. M14x1.5x66-10.9 ..........................Initial torque 100 Nm
Connecting rod bearing bolt .................................. M14x1.5x66-10.9 ............................Final tightening 90°

Connecting rods
Connecting rod length, small end bush centre - connecting rod bearing centre................ 282.45 - 282.5 mm

Connecting rod bearing dimensions

Connecting rod bearing normal dimension .................................................................. 96.047 - 96.099 mm
Connecting rod radial play.............................................................................................. 0.060 - 0.128 mm

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Connecting rod axial play............................................................................................... 0.240 - 0.438 mm

Spread......................................................................................................................................... 2.0 mm

Piston diameter
D1 measured 17.5 mm above lower edge of piston ..................................................131.871 - 131.889 mm

Piston ring (keystone ring)

Piston ring (keystone ring)..................................................................................... 3.5 mm (nominal value)
Piston ring width ................................................................................................................ 5.10 - 5.50 mm
Ring gap ........................................................................................................................... 0.40 - 0.55 mm

Piston ring (taper-face ring)

Piston ring height............................................................................................................... 2.47 - 2.50 mm
Piston ring width ................................................................................................................ 5.10 - 5.50 mm
Axial play .......................................................................................................................... 0.08 - 0.13 mm
Ring gap ........................................................................................................................... 0.70 - 0.90 mm

Piston ring (double-bevelled ring)

Piston ring height............................................................................................................... 3.47 - 3.49 mm
Piston ring width ................................................................................................................ 4.20 - 4.45 mm
Axial play .......................................................................................................................... 0.03 - 0.07 mm
Ring gap ........................................................................................................................... 0.25 - 0.55 mm

Piston height
Overall height.............................................................................................................................. 125 mm
Piston height from middle of piston pin to piston crown / PH level 0 .................................. 78.45 - 78.50 mm

Piston pin/piston pin bore

Piston pin diameter.................................................................................................... 54.994 - 55.000 mm
Gudgeon pin hole .......................................................................................................... 55.06 - 55.08 mm

Piston
Piston recess measured from crankcase to piston (compression)................................0.5120 to 0.8535 mm
Piston recess measured from crankcase to piston (gas exchange dead centre) ...........0.1440 to 0.5380 mm

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Crack surfaces are sensitive. The principle involved can cause chipping
• Exchange the connecting rod if the crack surfaces are damaged
• Protect crack surfaces against damage caused by hard and sharp objects
• To clean the crack surfaces on the connecting rods, always rinse them in clean cleaning agent
• After cleaning, use compressed air to blow-dry the crack surfaces
• Do not allow rinsed-out particles to enter the engine
Note
The piston diameter is always measured perpendicular to the gudgeon pin hole.

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Special tool

[85] Feeler gauge 08.75310-0806

• Checking the piston ring axial play and gap

[86] Dial gauge holder 80.99605-0172

• Checking the piston standout in conjunction with:

• Dial gauge [88]

[87] Piston ring compressor pliers 83.09144-6090

• Removing and installing piston rings

[88] Dial gauge 08.71000-3217

• Checking the piston standout in conjunction with:

• Dial gauge holder [86]

[89] Piston ring compressor pliers 80.99613-6004

• Installing pistons

[90] Setting tool 80.99622-0052

• Positioning the bearing shell, cracked connecting

rod

[91] Depth gauge (electronic) 08.71195-9003

• Checking the piston ring insertion depth

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Removing the pistons and connecting Removing the piston

rods
Undoing the connecting rod bearing bolts

• Mark the installation position and orientation of the

piston (4) relative to the cylinder liner (1)
• Extract the piston (4) with connecting rod (3) from
• Installation position and allocation of the the cylinder liner (2)
connecting rod bearing shell and connecting • Remove the small end bearing (2) from the
rod bearing connecting rod
• Turn the crankshaft to BDC for unscrewing the
connecting rod bearing bolts (1)
• Unscrew the connecting rod bearing bolts (1) by
one turn

Removing the connecting rod bearing cap

• Turn the crankshaft so that the connecting rod

bearing journal is located before the cylinder of
the piston to be removed (TDC)
• Unscrew the connecting rod bearing bolts (1)
• Remove the connecting rod bearing cap (2) and
big end bearing (3)

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Removing the piston Measuring the pistons, piston rings and

connecting rods
Removing the piston pin
Measuring the piston pins

• Mark the relative positions of the piston (2), piston

pin (4) and connecting rod (5) • Measure the piston pin (1) using a micrometer (2)
• Detach the snap rings (1) and (3) If the dimension of the gudgeon pin (1) is out of
• Press the piston pin (4) out of the piston (2) tolerance of 54.994 - 55.000 mm, t a new piston
• Remove the piston (2) with gudgeon pin (1).

Measuring the piston ring axial play

Note
The axial play cannot be measured on the
full keystone ring

• Measure the axial play between the

double-bevelled ring (3) and the piston (4)
at several points using the Feeler gauge [85] (1)
• Measure the axial play between the taper-face ring
(2) and the piston (4) at several points using the
Feeler gauge [85] (1)
The axial play on the double-bevelled ring (3) must
be 0.03 - 0.07 mm.

The axial play on the taper-face ring (2) must be

0.08 - 0.13 mm.

If the axial play is out of tolerance, replace the piston

with the piston rings.

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Removing the piston rings Installing the piston rings

• Set the Piston ring compressor pliers [87] (1) to

WARNING
the piston diameter
Component damage due to incorrect
• Remove the piston rings (2) using the Piston ring
installation of the piston rings
compressor pliers [87] (1)
• Take care not to damage the jacket
• Carefully clean the piston ring grooves in the
surface of the piston when installing the
piston (3)
piston rings
Measuring the piston ring gap • Only install piston rings using correctly
set piston ring compressor pliers
Note
Install the joint of the double-bevelled
ring and the tube spring offset by 180°
in relation to one another.

• Set the Piston ring compressor pliers [87] (1) to

the piston diameter
• Insert the new piston rings (2) into the correct
piston ring grooves in the piston (3) using the
Piston ring compressor pliers [87] (1), ensuring
that the gaps are 120° offset

• Clean the piston rings

• Insert the piston ring (2) evenly deep into the
cylinder liner (1)
• Obtain the same depth for the piston ring (2) with
Depth gauge (electronic) [91]
• Measure the ring gap with the Feeler gauge [85]
The keystone ring gap must be 0.40 - 0.55 mm.

The taper-face ring gap must be 0.70 - 0.90 mm.

The double-bevelled ring gap must be 0.25 - 0.55

mm.

If the ring gaps are out of tolerance, the piston rings

must be replaced (as a set only, not individually).

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Measuring the connecting rod bearings Measuring the piston pin bore

Measuring the connecting rod bearing inside

diameter

• Use the internal calliper (1) and Dial gauge [88] (3)
to check the gudgeon pin hole
If the dimension of the gudgeon pin hole is out of
• Insert the cleaned upper connecting rod bearing tolerance of 55.06 - 55.08 mm, t a new connecting
shell into the cleaned connecting rod (1) rod (2).
• Insert the cleaned lower connecting rod bearing
shell into the cleaned connecting rod bearing cap
(2)
• Insert the connecting rod bearing shell into the
corresponding connecting rod bearing cap (2)
according to the marking and pairing; position
using the Setting tool [90] if necessary
• Fit the connecting rod bearing cap (2) with inserted
connecting rod bearing shell onto the connecting
rod as marked, taking care not to damage the
contact surfaces between the connecting rod
bearing shell (2) and the connecting rod
• Screw in the connecting rod bearing bolts and
tighten them to Initial torque 100 Nm
• Use the Dial gauge [88] (4) and internal calliper
(3) to check the connecting rod bearing inside
diameter
Connecting rod bearing inside diameter,
96.047 - 96.099 mm.

If the inside diameter is out of tolerance, t new

connecting rod bearing shells.

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Installing the piston and connecting rod Piston installation with piston ring compressor
pliers
Installing the piston pin

WARNING
Note Component damage due to incorrect
There is an arrow on the piston crown. piston installation position
• Check the direction of the arrow on the
piston crown
• Attach a new snap ring (3) in the groove in the
piston (2) • Turn the crankshaft so that the connecting rod
• Align the connecting rod (5) with the piston (2) so bearing journal is located before the cylinder of
that the long connecting rod big end is pointing in the piston to be installed (2) (TDC)
the direction of the arrow • Align the gaps in the piston rings so they are each
• Fit the piston (2) over the connecting rod (5) as offset 120° from one another and then thinly apply
marked engine oil to MAN Standard 3277 on the piston (2)
• Thinly apply clean engine oil to MAN Standard and connecting rod bearing
3277 on the piston pin (4) • Insert the upper connecting rod bearing into the
• Push the piston pin (4) through the piston (2) and connecting rod, positioning it using the Setting
the connecting rod (5) as marked until the stop is tool [90] if necessary
reached • Align the piston (2) so that the arrow on the piston
• Attach a new snap ring (1) in the groove in the crown is facing the centre of the engine
piston (2) • Open Piston ring compressor pliers [89] (1) and t
• Check that the snap rings (1) and (3) are seated over the piston (2)
correctly • Clamp the Piston ring compressor pliers [89] (1)
If the snap rings (1) and (3) have not engaged • Push the piston (2) through the Piston ring
correctly, remove and re-attach the snap rings (1) compressor pliers [89] (1) into the cylinder liner
and (3), ensuring that they are seated correctly. as marked
• Carefully push the piston (2) through the cylinder
If the connecting rod (5) is installed in the incorrect liner until the connecting rod bearing is lying on
position relative to the piston (2), repeat the the crankshaft
procedure.

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Installing the connecting rod bearing cap Installation instructions for connecting rod
bearing shells

WARNING
Crack surfaces are sensitive. The WARNING
principle involved can cause chipping Crack surfaces are sensitive. The
• Exchange the connecting rod if the principle involved can cause chipping.
crack surfaces are damaged • Exchange the connecting rod if the
• Protect crack surfaces against damage crack surfaces are damaged
caused by hard and sharp objects • Protect crack surfaces against damage
caused by hard and sharp objects
• Insert the connecting rod bearing shell (3) into
the corresponding connecting rod bearing cap (2) • Clean the contact surfaces of the connecting rod
according to the marking and pairing; position bearing shells in the connecting rod and connect
using the Setting tool [90] if necessary rod bearing cap
• Fit the connecting rod bearing cap (2) with • Insert the lower connecting rod bearing shell into
inserted connecting rod bearing shell (3) onto the connecting rod bearing cap so that the lug (1)
the connecting rod as marked, taking care engages in the recess (4)
not to damage the contact surfaces between • Insert the upper connecting rod bearing shell into
the connecting rod bearing shell (2) and the the connecting rod so that the lug (2) engages in
connecting rod the recess (3)
• Screw in the new connecting rod bearing bolts (1) • With the , align the connecting rod bearing shells
and tighten them until nger-tight in the connecting rod and connecting rod bearing
cap

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Tightening the connecting rod bearing shells

• Turn the crankshaft to BDC for tightening the

connecting rod bearing bolts (1)
• Check the alignment of the connecting rod
bearings, remove the connecting rod bearing
shells and position the connecting rod bearings
again with Setting tool [90], then t the connecting
rod bearings back on
• Tighten the new connecting rod bearing bolts (1)
to Initial torque 100 Nm
• Tighten the connecting rod bearing bolts (1) to
Final tightening 90°

Measuring the piston recess

• Move the piston (2) to top dead centre

• Put the Dial gauge [88] (3) with the Dial gauge
holder [86] (4) on the crankcase (1)
• Locate the dial gauge tip (5) on the crankcase (1)
and zero the Dial gauge [88] (3)
• Locate the dial gauge tip (5) on the piston (2) and
read off the difference
The permissible piston recess is 0.5120 to 0.8535
mm (compression)

The permissible piston recess is 0.1440 to 0.5380

mm (gas exchange dead centre)

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CRANKSHAFT
Removing and installing the crankshaft
Additional jobs
– Removing and installing the engine ventilation, see 313
– Removing and installing the vibration damper, see 259
– Removing and installing the intake manifold V12, see 135
– Removing and installing the exhaust gas turbocharger V8, see 103
– Removing and installing the exhaust gas turbocharger V12, see 115
– Removing and installing the exhaust pipes V12, see 142
– Removing and installing the oil sump V12, see 226
– Removing and installing the cylinder head, see 162
– Removing, installing the piston with connecting rod, see 279
– Removing and installing the cover, see 317
– Removing and installing the front radial shaft seal, see 247
– Removing and installing the rear radial shaft seal, see 250
– Removing and installing the ywheel, see 271
– Removing and installing the charge-mixture system, see 79
– Removing and installing the air distribution pipes, see 88

(1) Crankshaft (3) Main bearing shell, crankcase

(2) Crankcase lower section

Technical data
Mounting bolts, crankcase lower section ................ M8x35-10.9 .......................................................35 Nm
Mounting bolts, crankcase lower section ................ M8x50-10.9 .......................................................35 Nm
Mounting bolts, crankcase lower section ................ M10x170-10.9....................................................65 Nm

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Mounting bolts, crankcase lower section ................ M18x2x200...................................Initial torque 160 Nm

Mounting bolts, crankcase lower section ................ M18x2x200........................................... 2nd torque 90°
Mounting bolts, crankcase lower section ................ M18x2x200..........................................Final torque 90°

Crankshaft technical data

Crankshaft axial play ..................................................................................................... 0.200 - 0.401 mm
Crankshaft radial play .................................................................................................... 0.060 - 0.128 mm

Crankshaft dimensions
Crankshaft journal, normal dimension ................................................................... Ø 111.966 - 111.988 mm

Connecting rod journal dimensions

Connecting rod bearing journal normal dimension .................................................... Ø 95.966 - 95.988 mm

Glyco main bearing dimensions

Main bearing Ø, normal dimension .......................................................................... 112.036 - 112.126 mm

Glyco main bearing dimensions

Wall thickness main bearing normal dimension ............................................................... 2.959 - 2.971 mm
Wall thickness, main bearing, normal dimension II........................................................... 3.084 - 3.096 mm
Wall thickness, main bearing, repair level I...................................................................... 3.209 - 3.221 mm
Wall thickness, main bearing, repair level II ..................................................................... 3.334 - 3.346 mm
Spread......................................................................................................................................... 2.0 mm

Glyco thrust washer dimensions

Thrust washer thickness, normal dimension .................................................................... 3.350 - 3.400 mm

Service products
Loctite 5900 ...................................................................................................................... 04.10394-9272

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[92] Dial gauge 08.71000-3217

• Checking the crankshaft axial and radial play in

conjunction with:
• Dial gauge holder [93]
• Locating pin [94]

[93] Dial gauge holder 08.71082-0005

• Checking the crankshaft axial and radial play in

conjunction with:
• Dial gauge [92]
• Locating pin [94]

[94] Locating pin 80.99605-0197

• Checking the crankshaft axial and radial play in

conjunction with:
• Dial gauge holder [93]
• Dial gauge [92]

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[95] Setting tool 80.99622-0052

• Positioning the bearing shell – cracked

connecting rod

[96] Aligning punch 80.99617-0020

• Removing and installing the crankshaft in

conjunction with:
• Aligning punch [97]

[97] Aligning punch 80.99617-0220

• Removing and installing the crankshaft in

conjunction with:
• Aligning punch [96]

[98] Forcing bolt 80.99615-0039

(nicht
• Removing the crankcase lower section freigegeben)
• Aligning punch [96]

[99] Eye-bolt 80.99606-0660

• Removing and installing the crankcase lower

section

[100] Three-arm puller 08.99605-9014

• Pull off the crankshaft gear

[101] Socket, size 22 80.99612-0024

• Undoing and tightening the crankcase lower

section mounting bolts in conjunction with:
• Torque multiplier i = 1 : 3.3 [102]
• Support [103]
• Angle measuring disc [104]
• Holding device [105]
• Pan head screw [106]
• Connecting pin [107]
• Rubber ring 42 mm [108]
• Socket [110]

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[102] Torque multiplier i = 1 : 3.3 80.99619-0006

• Undoing and tightening the crankcase lower

section mounting bolts in conjunction with:
• Socket, size 22 [101]
• Support [103]
• Angle measuring disc [104]
• Holding device [105]
• Pan head screw [106]
• Connecting pin [107]
• Rubber ring 42 mm [108]
• Socket [110]
[103] Support 80.99606-0551

• Undoing and tightening the crankcase lower

section mounting bolts in conjunction with:
• Socket, size 22 [101]
• Torque multiplier i = 1 : 3.3 [102]
• Angle measuring disc [104]
• Holding device [105]
• Pan head screw [106]
• Connecting pin [107]
• Rubber ring 42 mm [108]
• Socket [110]
[104] Angle measuring disc 80.99607-0172

• Undoing and tightening the crankcase lower

section mounting bolts in conjunction with:
• Socket, size 22 [101]
• Torque multiplier i = 1 : 3.3 [102]
• Support [103]
• Holding device [105]
• Pan head screw [106]
• Connecting pin [107]
• Rubber ring 42 mm [108]
• Socket [110]
[105] Holding device 80.99606-0641

• Undoing and tightening the crankcase lower

section mounting bolts in conjunction with:
• Socket, size 22 [101]
• Torque multiplier i = 1 : 3.3 [102]
• Support [103]
• Angle measuring disc [104]
• Pan head screw [106]
• Connecting pin [107]
• Rubber ring 42 mm [108]
[106] Pan head screw 06.02191-0407

• Undoing and tightening the crankcase lower

section mounting bolts in conjunction with:
• Socket, size 22 [101]
• Torque multiplier i = 1 : 3.3 [102]
• Support [103]
• Angle measuring disc [104]
• Holding device [105]
• Connecting pin [107]
• Rubber ring 42 mm [108]
• Socket [110]

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[107] Connecting pin 06.22729-0006

• Undoing and tightening the crankcase lower

section mounting bolts in conjunction with:
• Socket, size 22 [101]
• Torque multiplier i = 1 : 3.3 [102]
• Support [103]
• Angle measuring disc [104]
• Holding device [105]
• Pan head screw [106]
• Rubber ring 42 mm [108]
• Socket [110]
[108] Rubber ring 42 mm 08.06142-9006

• Undoing and tightening the crankcase lower

section mounting bolts in conjunction with:
• Socket, size 22 [101]
• Torque multiplier i = 1 : 3.3 [102]
• Support [103]
• Angle measuring disc [104]
• Holding device [105]
• Pan head screw [106]
• Connecting pin [107]
• Socket [110]
[109] Adapter 80.99606-0552

• Undoing and tightening the cylinder head bolts

[110] Socket 80.99603-0327

• Undoing and tightening the crankcase lower

section mounting bolts in conjunction with:
• Socket, size 22 [101]
• Torque multiplier i = 1 : 3.3 [102]
• Support [103]
• Angle measuring disc [104]
• Holding device [105]
• Pan head screw [106]
• Connecting pin [107]
• Rubber ring 42 mm [108]

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Checking the crankshaft Checking the crankshaft radial play

Checking the crankshaft axial play

• Position the Dial gauge [92] (1) with the Dial

gauge holder [93] (3) and Locating pin [94] on the
• Position the Dial gauge [92] (1) with the Dial gauge crankshaft (2) with a preload
holder [93] (2) and the Locating pin [94] on the • Push the crankshaft (2) into the end position,
crankshaft (3) with a preload towards the Dial gauge [92] (1)
• Push the crankshaft (3) horizontally into the end • Zero the Dial gauge [92] (1)
position towards the ywheel housing • Pull the crankshaft (2) in the opposite direction
• Zero the Dial gauge [92] (1) The permissible radial play on the crankshaft (2) is
• Pull the crankshaft (3) into the end position, 0.060 - 0.128 mm.
towards the Dial gauge [92] (1), and read off the
difference If the radial play is out of tolerance, check the outside
The permissible axial play on the crankshaft (3) is diameter of the crankshaft bearing journal and the
0.200 - 0.401 mm. inside diameter of the crankshaft bearing.

If the axial play is out of tolerance, install Check the crankshaft bearing journal outside
suitable thrust washers, see Glyco thrust washer diameter, see Checking the main bearing journal,
dimensions, 290. 300.

Check the crankshaft bearing inside diameter,

see Checking the crankshaft bearing shell inside
diameter, 300.

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Removing the crankshaft Undoing the outer crankcase lower section

mounting bolts, V8 engine
Setting the timing gears to the mark

• Align the marks on the crankshaft gear (1) and

camshaft gear (2) with one another

Unscrewing the crankcase lower section

mounting bolts

• Unscrew the mounting bolts 1 to 10 and remove

the washers

• Mark the installation position of the mounting bolts

(1)
• Unscrew the mounting bolts (1)

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Undoing the outer crankcase lower section Assembling special tool 1

mounting bolts, V12 engine

• Insert the Torque multiplier i = 1 : 3.3 [102] (10)

into the Support [103] (1)
• Mount the Holding device [105] (4) with the Pan
head screw [106] (2) and the Adapter [109] (3) on
the Support [103] (1)
• Put the Angle measuring disc [104] (9) on the
Torque multiplier i = 1 : 3.3 [102] (10)
• Put the Socket, size 22 [101] (8) on the Torque
multiplier i = 1 : 3.3 [102] (10) and secure with
the Connecting pin [107] (7) and the Rubber ring
42 mm [108] (5)
• Insert the Socket [110] (6) into the Socket, size
22 [101] (8)

• Unscrew the mounting bolts 1 to 14 and remove

the washers

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Undoing the crankcase lower section inner Undoing the crankcase lower section inner
mounting bolts, V8 engine mounting bolts, V12 engine

• Undo the mounting bolts 1 to 20 using the special • Undo the mounting bolts 1 to 28 using the special
tool tool
• Unscrew the mounting bolts 1 to 20 • Unscrew the mounting bolts 1 to 28
• Dismantle the special tool • Dismantle the special tool

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Removing the crankcase lower section Removing the main bearing shells from the
crankcase lower section

CAUTION • Mark the installation position of the crankshaft

Danger of injury due to heavy bearing shells (1)
components • Remove the crankshaft baring shells (1)
• Lift off the crankcase lower section with • Check for completeness of the dowel bushings (2)
support for the V8 engine (10 pcs.) and the V12 engine
WARNING (14 pcs.)
Component damage due to main
bearing shells falling out Removing the thrust washers at the bottom
• Make sure the main bearing shells do
not fall out when lifting off the crankcase
lower section

• Screw the Forcing bolt [98] into the crankcase

lower section at the positions (1) for V8 engine
and (2) for V12 engine
• Tighten the Forcing bolt [98] by hand
• Screw in the Forcing bolt [98] alternately, one turn
at a time
• After this is done three times, the Forcing bolt [98]
bolt head comes into contact
Do not tighten the Forcing bolt [98]
• Lift off the crankcase lower section (5) in
conjunction with the Eye-bolt [99] (3) and (4)
• Clean the mating faces • Mark the installation position of the thrust washers
(1)
• Remove the thrust washers (1)

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Screwing in the centring pins Removing the crankshaft bearing shells from the
crankcase

• Screw in the Aligning punch [96] (1) at the front of

the crankshaft • Mark the crankshaft bearing shells (1) to indicate
• Screw in the Aligning punch [97] (2) at the rear of correct assignment and installation position
the crankshaft • Remove the crankshaft baring shells (1)
• Mark the installation position of the thrust washers
Lifting out the crankshaft (2)
• Remove the thrust washers (2)

Pulling off the crankshaft gear

CAUTION
Danger of injury due to incorrect lifting
gear • Pull the crankshaft gear (2) off the crankshaft (3)
• Use separate lifting gear with equal with Three-arm puller [100] (1)
length for each centring pin
WARNING
Component damage due to incorrect
lifting gear
• Do not use any lifting gear or steel
cables with sharp edges to lift out the
crankshaft

• Attach the lifting gear using the centring pins

• Lift out the crankshaft (1)
• Unscrew the Aligning punch [96] at the front
• Unscrew the Aligning punch [97] at the rear

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Checking the crankshaft and crankshaft Checking the crankshaft bearing shell inside
bearings diameter

Checking the crankshaft bearing shell

expansion

• Insert the crankshaft bearing shells into the

crankcase and lower crankcase section (3) as
marked
• Put on the crankcase lower section (3)
Note
• Screw the old mounting bolts (4) into the lower
The difference between dimension A and
crankcase section (3) and tighten to 65 Nm
dimension B is the expansion of the
• Check the crankshaft bearing using the internal
crankshaft bearings.
calliper (2) in conjunction with the Dial gauge [92]
(1)
• Clean the bearing shells (2) and put them together
• Repeat the measurement on all the crankshaft
on a at surface as marked
bearings
• Check dimension A using a micrometer (1)
• Remove the crankcase lower section (3)
• Check dimension B using a micrometer (1)
If the crankshaft bearing dimensions are out of
If the maximum permissible expansion of 2.0 mm is
tolerance, see Glyco main bearing dimensions, 290,
exceeded, new bearing shells must be tted.
the main bearing shells must be replaced.

Checking the main bearing journal

• Clean the main bearing journal of the crankshaft

(1)
• Measure the main bearing journal of the
crankshaft (1) using a micrometer (2)
• Repeat the measurement for each main bearing
journal
The dimensions of the crankshaft bearing
journals must be within the specied tolerances,
Ø 111.966 - 111.988 mm.

Replace the crankshaft if the dimensions are out of

tolerance

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Checking the crank pins Installing the crankshaft

Inserting the main bearing shells into the
crankcase lower section

• Clean the crankshaft (1)

• Measure the connecting rod bearing journal using
a micrometer (2)
• Measure the connecting rod bearing journal at • Check for completeness of the dowel bushings (2)
several points for the V8 engine (10 pcs.) and the V12 engine
• Repeat the measurement for each connecting rod (14 pcs.)
bearing journal • Thinly apply clean engine oil to MAN Standard
• The permitted connecting rod bearing journal 3277 on the main bearing shells (1)
diameter is Ø 95.966 - 95.988 mm • Insert the main bearing shells (1) into the bearing
Replace the crankshaft if the dimensions are out seats as marked and align with the Setting tool [95]
of tolerance
Inserting the main bearing shells into the
crankcase

Note
Only install thrust washers with the same
wall thickness.

• Insert the cleaned main bearing shells (1) into the

bearing seats on the crankcase (1) as marked and
align with the Setting tool [95]
• Thinly apply clean engine oil to MAN Standard
3277 on the main bearing shells (1)
• Determine the thrust washers (2) to be used, see
Checking the crankshaft axial play, 294
• Thinly apply clean engine oil to MAN Standard
3277 on the cleaned thrust washers (2)
• Insert the thrust washers (2) into the nal bearing
seat as marked, with the oil grooves facing the
crankshaft

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Inserting the crankshaft Unscrewing the centring pins

• Unscrew the Aligning punch [96] (1) at the front of

CAUTION
the crankshaft
Danger of injury due to incorrect lifting
• Unscrew the Aligning punch [97] (2) at the rear of
gear
the crankshaft
• Use separate lifting gear with equal
length for each centring pin Installing the thrust washers at the bottom
WARNING
Component damage due to incorrect
lifting gear
• Do not use any lifting gear or steel
cables with sharp edges to lift out the
crankshaft
WARNING
Component damage when inserting
the crankshaft
• Make sure that the crankshaft does not
collide with other components when
being installed

• Screw in the Aligning punch [96] at the front of the

crankshaft (1)
• Thinly apply clean engine oil to MAN Standard
• Screw in the Aligning punch [97] at the rear of the
3277 on the cleaned thrust washers (1)
crankshaft (1)
• Put the thrust washers (1) onto the nal bearing
• Attach the lifting gear using the centring pins
seat as marked, with the oil grooves facing the
• Thinly apply clean engine oil to MAN Standard
crankshaft
3277 on the main bearing journal of the crankshaft
(1)
• Insert the crankshaft (1) into the crankcase

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Crankcase installation instructions Putting on the crankcase lower section

CAUTION
Danger of injury due to heavy
components
• Lift off the crankcase lower section with
support
WARNING
Component damage due to main
bearing shells falling out
• Make sure the main bearing shells
do not fall out when putting on the
crankcase lower section

• Check the bushings (4) for completeness (2 pcs.)

• Thinly apply Loctite 5900 (1) on the crankcase • Attach the lifting gear at the Eye-bolt [99] (3)
mating faces as illustrated • Lift the crankcase lower section (2) onto the
crankcase
• Centre the crankcase lower section (2) using the
mounting bolts (1) when putting it on
• Remove the mounting bolts (1) and the
Eye-bolt [99] after putting on

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Tightening sequence for outer mounting bolts, Tightening sequence for outer mounting bolts,
V8 engine V12 engine

• Evenly tighten the mounting bolts (1) and (2) • Evenly tighten the mounting bolts (1) and (2)
alternately until the crankcase lower section alternately until the crankcase lower section
comes into contact comes into contact
• Tighten the mounting bolts 1 to 10 as per the • Tighten the mounting bolts 1 to 10 as per the
tightening sequence (1-10) tightening sequence (1-14)

Tightening the outer mounting bolts

• Thinly apply clean engine oil to MAN Standard

3277 on the contact surfaces and threads of the
new mounting bolts (1)
• Screw in the new outer mounting bolts (1) with
washers (2) as marked
• Tighten the outer mounting bolts (1) to 65 Nm as
per the tightening diagram

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Assembling special tool 1 Tightening sequence for inner mounting bolts,

V8 engine

• Insert the Torque multiplier i = 1 : 3.3 [102] (10)

into the Support [103] (1)
• Mount the Holding device [105] (4) with the Pan
head screw [106] (2) and the Adapter [109] (3) on
the Support [103] (1)
• Put the Angle measuring disc [104] (9) on the
Torque multiplier i = 1 : 3.3 [102] (10)
• Put the Socket, size 22 [101] (8) on the Torque
multiplier i = 1 : 3.3 [102] (10) and secure with
the Connecting pin [107] (7) and the Rubber ring
42 mm [108] (5)
• Insert the Socket [110] (6) into the Socket, size
22 [101] (8)

• Tighten the mounting bolts 1 to 20 as per the

tightening sequence (1-20)

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Tightening sequence for inner mounting bolts, Screwing in the crankcase lower section
V12 engine mounting bolts

• Screw in the mounting bolts (1) as marked and

tighten them to 35 Nm

Checking the crankshaft for unobstructed

movement

• Tighten the mounting bolts 1 to 28 as per the

tightening sequence (1-28)

Tightening the inner mounting bolts

• Turn the crankshaft (1)

It must be easy to turn the crankshaft (1), and the
crankshaft must not touch other components.

If this is not the case, repeat the procedure for

removing and installing the crankshaft.

• Thinly apply clean engine oil to MAN Standard

3277 on the contact surfaces and threads of the
new mounting bolts (1)
• Screw in the new inner mounting bolts (1) as
marked
• Tighten the inner mounting bolts (1) to Initial torque
160 Nm as per the tightening diagram
• Tighten the inner mounting bolts (1) to 2nd torque
90° as per the tightening diagram
• Tighten the inner mounting bolts (1) to Final torque
90° as per the tightening diagram

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Checking the crankshaft axial play Checking the crankshaft radial play

• Position the Dial gauge [92] (1) with the Dial • Position the Dial gauge [92] (1) with the Dial
gauge holder [93] (2) and Locating pin [94] on the gauge holder [93] (3) and Locating pin [94] on the
crankshaft (3) with a preload crankshaft (2) with a preload
• Push the crankshaft (3) horizontally into the end • Push the crankshaft (2) into the end position,
position towards the ywheel housing towards the Dial gauge [92] (1)
• Zero the Dial gauge [92] (1) • Zero the Dial gauge [92] (1)
• Pull the crankshaft (3) into the end position, • Pull the crankshaft (2) in the opposite direction
towards the Dial gauge [92] (1), and read off the The permissible radial play on the crankshaft (2) is
difference 0.060 - 0.128 mm.
The permissible axial play on the crankshaft (3) is
0.200 - 0.401 mm. If the radial play is out of tolerance, check the outside
diameter of the crankshaft bearing journal and the
If the axial play is out of tolerance, install inside diameter of the crankshaft bearing.
suitable thrust washers, see Glyco thrust washer
dimensions, 290. Check the crankshaft bearing journal outside
diameter, see Checking the main bearing journal,
300.

Check the crankshaft bearing inside diameter,

see Checking the crankshaft bearing shell inside
diameter, 300.

Installing the crankshaft gear

• Place the crankshaft gear (1) over the alignment

pin (2) as far as the stop on the crankshaft (3)

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Crankshaft installation position

• Align the marks on the crankshaft gear (1) and

camshaft gear (2) with one another
If the marks (1) and (2) do not match up, remove the
crankshaft gear and install it again with the marks
(1) aligned with the mark on the camshaft gear (2).

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CRANKCASE

(1) Cover (3) Flywheel housing

(2) Engine ventilation

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ENGINE VENTILATION, V8
Removing and installing the engine ventilation
Additional jobs
– Draining and topping up the coolant, see Operator's Manual

(1) Left vent line (3) Vent line

(2) Right vent line

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[111] Hose clamp pliers for jubilee clips 80.99625-0073

• Removing and installing the jubilee clips

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Removing the engine ventilation Mounting the engine ventilation

Detaching the left vent line Attaching the right vent line

• Unfasten the jubilee clips (3) and (5) using the • Attach the vent line (4)
Hose clamp pliers for jubilee clips [111] and push • Position the bushes (2)
onto the hose • Screw in and tighten the mounting bolts (1)
• Unscrew the mounting bolt (1) and remove it with • Install the jubilee clips (3) and (5) in the installation
the bush (2) position with the Hose clamp pliers for jubilee
• Detach the vent line (4) clips [111]

Detaching the right vent line Attaching the left vent line

• Unfasten the jubilee clips (3) and (5) using the • Attach the vent line (4)
Hose clamp pliers for jubilee clips [111] and push • Position the bush (2)
onto the hose • Screw in and tighten the mounting bolt (1)
• Unscrew the mounting bolts (1) and remove them • Install the jubilee clips (3) and (5) in the installation
with the bushes (2) position with the Hose clamp pliers for jubilee
• Detach the vent line (4) clips [111]

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ENGINE VENTILATION, V12

Removing and installing the engine ventilation
Additional jobs
– Draining and topping up the coolant, see Operator's Manual

(1) Right vent line (2) Left vent line

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[112] Hose clamp pliers for jubilee clips 80.99625-0073

• Removing and installing the jubilee clips

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Removing the left engine ventilation Mounting the left engine ventilation

• Unfasten the jubilee clips (3) and (5) using the • Position the vent line (4) and pull on the hoses with
Hose clamp pliers for jubilee clips [112] and push the jubilee clips (3) and (5)
onto the hose • Position the bushes (1)
• Unscrew the mounting bolts (2) • Screw in and tighten the mounting bolts (2)
• Remove the vent line (4) with the bushes (1) • Tighten the jubilee clips (3) and (5) using the Hose
clamp pliers for jubilee clips [112]

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Removing the right engine ventilation Mounting the right engine ventilation

• Unfasten the jubilee clips (3) and (5) using the • Position the vent line (4) and pull on the hoses with
Hose clamp pliers for jubilee clips [112] and push the jubilee clips (3) and (5)
onto the hose • Position the bushes (1)
• Unscrew the mounting bolts (2) • Screw in and tighten the mounting bolts (2)
• Remove the vent line (4) with the bushes (1) • Tighten the jubilee clips (3) and (5) using the Hose
clamp pliers for jubilee clips [112]

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COVER
Removing and installing the cover
Additional jobs
– Removing and installing the vibration damper, see 259
– Removing and installing the oil modules, see 209
– Removing and installing the front radial shaft seal, see 247

(1) Oil pump crankshaft gear (4) Coolant temperature sensor

(2) Manifold for oil suction line (5) Mounting bolt
(3) Cover

Technical data
Coolant temperature sensor .................................. M16x1.5 ............................................................47 Nm

Service products
Engine oil..................................see Maintenance Recommendations and Recommended Service Products

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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Special tools

[113] Aligning punch 80.99617-0020

• Removing and installing the vibration damper

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Removing the cover Removing the cover

Removing the coolant temperature sensors

• Mark the installation position of the mounting bolts

(2) and (5)
• Unscrew the coolant temperature sensors (1) and • Unscrew the mounting bolts (2) and (5)
(2) with sealing rings • Remove the cover (1) with the gasket (3) and the
O-rings (4)
Removal instructions for cover • Clean the mating faces

Removing the oil pump crankshaft gear

• To remove the cover, do not unscrew mounting

bolts (1) and (2)
• Screw in the Aligning punch [113] (2) and (3)
• Pull off the crankshaft gear over the Aligning
punch [113] (2) and (3)
• Clean the contact surfaces of the crankshaft gear
(1) and crankshaft

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Fitting the cover Mounting the coolant temperature sensors

Installing the oil pump crankshaft gear

• Thinly apply clean Engine oil on the thread of the

coolant temperature sensors (1) and (2)
• Push on the crankshaft gear over the Aligning • Screw in the coolant temperature sensors (1) and
punch [113] (2) and (3) as far as the stop (2) with new sealing rings and tighten to 47 Nm
• Unscrew the Aligning punch [113] (2) and (3)

Mounting the cover

Note
Mount the gasket with the textured side
facing the crankcase.

• Clean the mating faces

• Position the cover (1) with a new gasket (3) and
new O-rings (5)
• Screw in and tighten the mounting bolts (2) and
(6) as marked

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FLYWHEEL HOUSING
Removing and installing the ywheel housing
Additional jobs
– Removing and installing the starter, see 73
– Removing and installing the rear radial shaft seal, see 250
– Removing and installing the intake manifold V12, see 135
– Removing and installing the exhaust manifold V8, see 131

(1) Flywheel housing (2) Mounting bolt

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[114] Hose clamp pliers for jubilee clips 80.99625-0073

• Removing and installing the jubilee clips

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Removing the ywheel housing Removing the left cover

Detaching the right oil return line hose (V12

variant)

• Unscrew the mounting bolts (1)

• Remove the cover (2)
• Remove the O-rings (3) and (4) from the cover (2)
• Undo the jubilee clips (2) using the Hose clamp • Clean the mating faces
pliers for jubilee clips [114]
• Pull off the hose (1) Removing the right cover

Detaching the left oil return line hose (V12

variant)

• Unscrew the mounting bolts (1)

• Remove the cover (2)
• Remove the O-ring (3) from the cover (2)
• Undo the jubilee clips (2) using the Hose clamp • Clean the mating faces
pliers for jubilee clips [114]
• Pull off the hose (1)

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Removing the rear HDDPE cover Removing the engine mounts

• Mark the installation position of the mounting bolts • Unscrew the mounting bolts (1)
(1) and (4) • Remove the right engine mount (2)
• Unscrew the mounting bolts (1) and (4) • Unscrew the mounting bolts (4)
• Remove the cover (2) • Remove the left engine mount (3)
• Remove the O-ring (3)
• Clean the mating faces Removing the crane hook

Removing the ywheel housing

• Unscrew the mounting bolts (1) and (2)

• Remove the crane hook (3)
CAUTION
Danger of injury due to heavy
components
• Remove the ywheel housing/timing
case with support

• Mark the installation position of the mounting bolts

(3) and (4)
• Unscrew the mounting bolts (3) and (4)
• Remove the ywheel housing (1) with the gasket
(2)
• Clean the mating faces

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Mounting the ywheel housing Mounting the ywheel housing

Mounting the crane hook

CAUTION
• Position the crane hook (3) Danger of injury due to heavy
• Screw in and tighten the mounting bolts (1) and (2) components
• Remove the ywheel housing/timing
Mounting the engine mounts case with support

• Clean the mating faces

• Position the ywheel housing (1) with a new gasket
(2)
• Screw in the mounting bolts (3) and (4) as marked
and tighten them by hand
• Tighten the mounting bolts (3) and (4) crosswise

Mounting the rear HDDPE cover

• Position the left engine mount (3)

• Screw in and tighten the mounting bolts (4)
• Position the right engine mount (2)
• Screw in and tighten the mounting bolts (1)

• Clean the mating faces

• Insert a new O-ring (3) into the cover (2)
• Insert the cover (2) into the ywheel housing
• Screw in and tighten the mounting bolts (1) and (4)

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Mounting the right cover Attaching the left oil return line hose (V12
variant)

• Clean the mating faces

• Insert a new O-ring (3) into the cover (2) • Pull on the hose (1) with the jubilee clips (2)
• Insert the cover (2) into the ywheel housing • Tighten the jubilee clips (2) using the Hose clamp
• Screw in and tighten the mounting bolts (1) pliers for jubilee clips [114]

Mounting the left cover Attaching the right oil return line hose (V12
variant)

• Clean the mating faces

• Insert new O-rings (3) and (4) into the cover (2) • Pull on the hose (1) with the jubilee clips (2)
• Insert the cover (2) into the ywheel housing • Tighten the jubilee clips (2) using the Hose clamp
• Screw in and tighten the mounting bolts (1) pliers for jubilee clips [114]

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Dismantling and assembling the ywheel housing

Additional jobs
– Removing and installing the ywheel housing, see 321
– Removing and installing the air compressor cover, see 71

(1) Screw plugs (4) Cover

(2) Screw tting (5) Screw plug
(3) Cover

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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Dismantling the ywheel housing Dismantling the ywheel housing

Removing the cover

• Unscrew the ttings (1) and (2) with the sealing

rings
• Unscrew the mounting bolts (1) • Unscrew the screw plugs (3) and (4) with the
• Remove the cover (2) sealing rings

Removing the cap Unscrewing the screw plugs

• Unscrew the mounting bolts (3) • Unscrew the screw plugs (1) and (2) with the
• Remove the cover (2) with the gasket (1) sealing rings
• Clean the mating faces

Removing the OT indicator adjuster

• Unscrew the mounting bolts (2)

• Remove the adjuster (1)

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Assembling the ywheel housing Installing the cover

Screwing in the screw plugs

• Clean the mating faces

• Position the cover (2) with a new gasket (1)
• Screw in and tighten the screw plugs (1) and (2) • Screw in and tighten the mounting bolts (3)
with the sealing rings
Mounting the cover
Assembling the ywheel housing

• Position the cover (2)

• Screw in and tighten the ttings (1) and (2) with • Screw in and tighten the mounting bolts (1)
new sealing rings
• Screw in and tighten the screw plugs (3) and (4)
with new sealing rings

Mounting the OT indicator adjuster

• Position the adjuster (1)

• Screw in and tighten the mounting bolts (2)

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CYLINDER LINER
Removing and installing the cylinder liner
Additional jobs
– Removing and installing the exhaust gas turbocharger V8, see 103
– Removing and installing the exhaust gas turbocharger V12, see 115
– Removing and installing the oil sump V8, see 223
– Removing and installing the oil sump V12, see 226
– Removing and installing the cylinder head, see 162
– Removing, installing the piston with connecting rod, see 279

(1) Sectional sealing ring (3) Sectional sealing ring

(2) Cylinder liner (4) Crankcase

Cylinder liner standard

Total height, cylinder liner............................................................................................... 261.5 - 262.5 mm
Outside diameter, cylinder liner at collar...................................................................... 163.15 - 163.35 mm
Outside diameter, cylinder liner, stem ......................................................................149.439 - 149.457 mm
Standard liner height...................................................................................................... 10.04 - 10.07 mm
Inside diameter, cylinder liner ..................................................................................... 131.99 - 132.01 mm

Technical data
Cylinder liner standout ................................................................................................... 0.035 - 0.085 mm
Depth of collar recess in crankcase .............................................................................. 9.985 - 10.015 mm

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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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

Special tools

[115] Extractor device 80.99601-6018

• Extracting the cylinder liner in conjunction with:

• Extractor plate [116]

[116] Extractor plate 80.99601-0278

• Extracting the cylinder liner in conjunction with:

• Extractor device [115]

[117] Dial gauge holder 80.99605-0172

• Checking the cylinder liner standout in

conjunction with:
• Dial gauge [118]
• Measuring plate [119]

[118] Dial gauge 08.71000-3217

• Checking the cylinder liner standout in

conjunction with:
• Dial gauge holder [117]
• Measuring plate [119]

[119] Measuring plate 80.99605-0289

• Checking the cylinder liner standout in

conjunction with:
• Dial gauge holder [117]
• Dial gauge [118]

[120] Bolt 06.01499-0015

• Checking the cylinder liner standout in

conjunction with:
• Dial gauge holder [117]
• Dial gauge [118]
• Measuring plate [119]
• Washer [121]

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[121] Washer 06.15013-0417

• Checking the cylinder liner standout in

conjunction with:
• Dial gauge holder [117]
• Dial gauge [118]
• Measuring plate [119]
• Bolt [120]
[122] Depth gauge (electronic) 08.71195-9003

• Checking the cylinder liner seating

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Removing the cylinder liner Mounting the extractor device

Checking the cylinder liner standout

WARNING
• Put the Measuring plate [119] (2) on the cylinder Component damage due to damaged
liner or bent oil injector nozzles
• Screw in the Bolt [120] (4) with the Washer [121] • Insert the Extractor device [115] without
and tighten to 40 Nm damaging the oil injector nozzle
• Fit the Dial gauge holder [117] (5) on the
Measuring plate [119] (2) with the Dial gauge [118] • Mark the cylinder liners (1) to indicate their correct
(3) assignment and installation position
• Place the dial gauge tip (1) on the crankcase • Mount the Extractor plate [116] (1) on the Extractor
• Zero the Dial gauge [118] (3) device [115] (3)
• Carefully place the dial gauge tip (1) on the • Carefully insert the Extractor device [115] (3) with
cylinder liner and note the difference on the dial folded Extractor plate [116] (1) into the cylinder
gauge liner (2)
The permitted cylinder liner standout is 0.035 -
Extracting the cylinder liner
0.085 mm.

If the cylinder liner standout is out of tolerance, t a

new cylinder liner/crankcase.

Checking the cylinder liner diameters

• Clamp the Extractor device [115] (1) with the

hexagon nut (2)
• Extract the cylinder liner (3) by screwing in the
hexagon nut (2)

• Use the Dial gauge [118] and the internal calliper

(1) to check the cylinder liner (2)
• Repeat the measurement several times at 120°
offset
• Repeat the measurement at four different heights
If the cylinder liner (2) has become oval, it must be
replaced.

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Removing the sectional sealing rings Checking the cylinder liner

Checking the cylinder liner seat

• Remove the sectional sealing rings (1) and (2)

from the crankcase Remove the sectional sealing
rings (1) and (2) from the crankcase • Check the cylinder liner seat with the Depth gauge
• Clean the cylinder liner seat and sectional sealing (electronic) [122] (1)
ring seats • Check the cylinder liner seat at four
• Check the sectional sealing ring seats on the opposite-facing points
cylinder liner for wear The permitted collar recess depth is 9.985 - 10.015
• Check the cylinder liners for porosity mm

If the seat depth is out of tolerance, the crankcase

must be replaced with the cylinder liners.

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Installing the cylinder liner

Installing the cylinder liner

• Thinly apply clean engine oil on the new sectional

sealing rings (1) and (2) and then insert them into
the sectional sealing ring seats (4)
• Thinly apply clean engine oil in the outer lower
area of the cylinder liner (3) on the outside
• Insert the cylinder liner (3) into the crankcase as
marked, ensuring that the stop is reached

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ENGINE MOUNT
Removing and installing the engine mounts

(1) Left crane hook (3) Crane hook

(2) Right crane hook (4) Engine mount, counter-ywheel

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
specied tightening torque
• Final tightening must always be performed manually using a torque wrench

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Removing the engine mounts Removing the crane hook (V8)

Removing the counter-ywheel engine mounts

• Unscrew the mounting bolts (5) and (6)

• Remove the left crane hook (1)
• Unscrew the mounting bolts (1) • Unscrew the mounting bolts (3) and (4)
• Remove the left engine mount (2) • Remove the right crane hook (2)
• Unscrew the mounting bolts (4)
• Remove the right engine mount (3) Removing the crane hook

Removing the crane hook (V12)

• Unscrew the mounting bolts (1)

• Remove the left crane hook (2)
• Unscrew the mounting bolts (2) • Unscrew the mounting bolts (4)
• Remove the crane hook (1) • Remove the right crane hook (3)
Detaching the oil return line (V8)

• Unscrew the union nut (1)

• Expose the oil return line

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Installing the engine mounts Attaching the oil return line (V8)

Mounting the crane hooks

• Screw on and tighten the union nut (1) for the oil
return line
• Position the right crane hook (3)
• Screw in and tighten the mounting bolts (4) Mounting the crane hook (V12)
• Position the left crane hook (2)
• Screw in and tighten the mounting bolts (1)

Mounting the crane hooks (V8)

• Position the crane hook (1)

• Screw in and tighten the mounting bolts (2)

Mounting the counter-ywheel engine mounts

• Position the right crane hook (2)
• Screw in and tighten the mounting bolts (3) and (4)
• Position the left crane hook (1)
• Screw in and tighten the mounting bolts (5) and (6)

• Position the engine mount (3)

• Screw in the mounting bolts (4) and tighten them
• Position the left engine mount (2)
• Screw in and tighten the mounting bolts (1)

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TECHNICAL DATA

339
TECHNICAL DATA

340
 TECHNICAL DATA

Technical data

Tightening torques

Important information

User tip
All bolted connections, the purpose of which is not stated in the following table, are to be tightened in
accordance with the guideline values given in our Works Standard M 3059 (see page 344). Oil bolts
lightly prior to assembly!

Engine electrics
Engine electrics
Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm, oiled
Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm, oiled
Mounting bolt, pressure sensor for charge air . . . . . . . . . M6x16-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm

Cooling system

Coolant manifold, inlet / connection housing

Coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm, oiled

Add-on units

Starter
Mounting bolt, terminal 30 (+) . . . . . . . . . . . . . . . . . . . . . . . M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Mounting bolt, terminal 31 (-) . . . . . . . . . . . . . . . . . . . . . . . . M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Mounting bolt, terminal 50 . . . . . . . . . . . . . . . . . . . . . . . . . . M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nm
Mounting bolt, terminal 85 . . . . . . . . . . . . . . . . . . . . . . . . . . M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nm
Mounting bolts, starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12x40-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm

Charge-mixture system

Air distribution pipes

Mounting bolt, pressure sensor for charge air . . . . . . . . . M6x16-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm

Ignition system

Spark plugs
Spark plug (dry thread) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm

Turbocharging

Exhaust turbocharger
Mounting nuts, exhaust turbocharger . . . . . . . . . . . . . . . . . M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm

Intake/exhaust system

Exhaust pipes
Mounting nuts, exhaust manifold . . . . . . . . . . . . . . . . . . . . M10x108-SD . . . . . . . . . . . . . . Initial torque 60 Nm
Mounting nuts, exhaust manifold . . . . . . . . . . . . . . . . . . . . M10x108-SD . . . . . . . . . . . . . . . . . Final torque 90°

341
 TECHNICAL DATA

Cylinder head

Rocker arm mechanism

Mounting bolts, rocker arm mechanism . . . . . . . . . . . . . . . M12x80-10.9 . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Mounting bolts, rocker arm mechanism . . . . . . . . . . . . . . . M12x80-10.9 . . . . . . . . . . . . . . . . . Final torque 90°

Cylinder head
Cylinder head bolts ................................ M18x2x246-10.9 . . . . . . . . . . . Initial torque 10 Nm
Cylinder head bolts ................................ M18x2x246-10.9 . . . . . . . . . . . 2nd torque 150 Nm
Cylinder head bolts ................................ M18x2x246-10.9 . . . . . . . . . . . 3rd torque 300 Nm
Cylinder head bolts ................................ M18x2x246-10.9 . . . . . . . . . . . . . . . 4th torque 90°
Cylinder head bolts ................................ M18x2x246-10.9 . . . . . . . . . . . . . . . 5th torque 90°
Cylinder head bolts ................................ M18x2x246-10.9 . . . . . . . . . . . . . . . final torque 90°

Cylinder head tightening diagram

Observe the tightening sequence for the mounting bolts

Checking and adjusting the valve/valves

Lock nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10x1-8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm

Valve timing

Camshaft/camshaft bearing
Anti-rotation device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x1x44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm

Engine lubrication

Oil filter and oil separator

Mounting bolts, oil separator . . . . . . . . . . . . . . . . . . . . . . . . 6x20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Oil filter cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Support dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm

Oil modules
Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm

Oil cooler
Mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm
Mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm

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 TECHNICAL DATA

Dismantling and assembling the oil modules

Screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33x2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Nm
Screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Nm
Screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm
Pressure-relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M27x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm

Oil injection nozzles

Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x20-10.9 . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
Connection pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
Screw plug with magnetic stopper . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm

Dismantling and assembling the oil sump, V8

Connection pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
Screw plug with magnetic stopper . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm

Dismantling and assembling the oil sump, V12

Screw plug with magnetic stopper . . . . . . . . . . . . . . . . . . . M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm

Oil pump
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x40-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

Crank drive

Vibration damper
Mounting bolt, vibration damper . . . . . . . . . . . . . . . . . . . . . M16x1.5x90-10.9 . . . . . . . . . Initial torque 190 Nm
Mounting bolt, vibration damper . . . . . . . . . . . . . . . . . . . . . M16x1.5x90-10.9 . . . . . . . . . . . . . Final torque 90

Flywheel
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x91-12.9 . . . . . . . . . Initial torque 100 Nm
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x91-12.9 . . . . . . . . . . . . . . 2nd torque 90
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5x91-12.9 . . . . . . . . . . . . . Final torque 90

Pistons and connecting rods

Connecting rod bearing bolt . . . . . . . . . . . . . . . . . . . . . . . . . M13x1.5x66-11.9 . . . . . . . . . Initial torque 100 Nm
Connecting rod bearing bolt . . . . . . . . . . . . . . . . . . . . . . . . . M13x1.5x66-11.9. . . . . . . . . . . . . Final torque 90

Crankshaft
Mounting bolts, crankcase lower section .............. M8x35-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Mounting bolts, crankcase lower section .............. M8x35-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Mounting bolts, crankcase lower section .............. M10x170-10.9 . . . . . . . . . . . . . . . . . . . . . . . . 65 Nm
Mounting bolts, crankcase lower section .............. M8x2x200 . . . . . . . . . . . . . . . Initial torque 160 Nm
Mounting bolts, crankcase lower section .............. M8x2x200 . . . . . . . . . . . . . . . . . . . . 2nd torque 90°
Mounting bolts, crankcase lower section .............. M8x2x200 . . . . . . . . . . . . . . . . . . . Final torque 90°

Crankcase

Cover
Coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Flywheel housing/timing case
Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x16-10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nm
Threaded pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm

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TECHNICAL DATA

Installation tightening torques according to company standard M 3059

Bolts/nuts with external or internal hexagon, head without collar or flange

Thread size Strength class/tightening torques in Nm

x pitch
for 8.8 / 8 for 10.9 / 10 for 12.9 / 12
M4 2.5 4.0 4.5
M5 5.0 8.0 9.0
M6 9.0 13.0 15.0
M7 14.0 20.0 25.0
M8 22.0 30.0 35.0
M8x1 23.0 35.0 40.0
M10 45.0 65.0 75.0
M10x1.25 45.0 67.0 75.0
M10x1 50.0 70.0 85.0
M12 75.0 110.0 125.0
M12x1.5 75.0 115.0 130.0
M12x1.25 80.0 120.0 135.0
M14 115.0 175.0 200.0
M14x1.5 125.0 185.0 215.0
M16 180.0 265.0 310.0
M16x1.5 190.0 280.0 330.0
M18 260.0 365.0 430.0
M18x2 270.0 385.0 450.0
M18x1.5 290.0 405.0 480.0
M20 360.0 515.0 600.0
M20x2 380.0 540.0 630.0
M20x1.5 400.0 565.0 670.0
M22 490.0 700.0 820.0
M22x2 510.0 725.0 860.0
M22x1.5 540.0 750.0 900.0
M24 620.0 890.0 1040.0
M24x2 680.0 960.0 1130.0
M24x1.5 740.0 1030.0 1220.0

344
 TECHNICAL DATA

Installation tightening torques for hollow screws, screw-in fittings, plug screws, hose fittings and
screw-in fittings with cutting ring screw connection
S Valid for threaded connections with Cu and BS sealing rings
S Also valid threaded connections in aluminium - nut thread
S Also valid for components with male thread made of steel materials to DIN 3859-1
S Pulse screws/bolts must not be used for installation
S Components that are much weaker than standard parts must be tested separately

Valid for: Valid for:

-Hollow screws (DIN 7643 or similar) Screw-in fittings (DIN 3901, MAN 200
-Screw-in fittings (DIN 3901 / MAN 200, or similar for cutting ring connection of a
or similar for cutting ring connection of a further pipeline)
further pipeline *)
-Plug screws with hexagon socket or he­
xagon head (DIN 908, DIN 910 / DIN Bracing is not possible when
7604 or similar) tightening and undoing the cut­
-Hose fittings and fittings for plug ting ring connection.
connections.

Thread size
x pitch

M8X1 11 Nm 21 Nm
M10x1 21 Nm 32 Nm
M12X1.5 32 Nm 42 Nm
M14x1.5 42 Nm 70 Nm
M16X1.5 52 Nm 130 Nm
M18X1.5 65 Nm 130 Nm
M20X1.5 75 Nm 190 Nm
M22X1.5 85 Nm 190 Nm
M24X1.5 95 Nm 190 Nm
M26X1.5 105 Nm 190 Nm
M27X2 105 Nm ----
M28X1.5 105 Nm 262 Nm
M30X1.5 125 Nm ----
M32X1.5 125 Nm ----
M33X2 125 Nm ----
M36X1.5 157 Nm ----
M38X1.5 157 Nm ----
M42X1.5 190 Nm ----

345
TECHNICAL DATA

M45X1.5 190 Nm ----

M48X1.5 190 Nm ----

*) Tighten cutting ring connection

User tip
Bracing is possible when tightening and un­
doing the cutting ring connection.

346
 TECHNICAL DATA

Test and settings values

Starter

Manufacturer: Mitsubishi
Type: M009T83279
Operating method: pre−engaged starter

Starter pinion:
Number of teeth: Z = 11
Module: 3.5

Rated output: 7 kW
Rated voltage: 24 V

Cylinder head
Rocker arm mechanism

1 Inside diameter, rocker arm bearing

Ø 34.005 - 34.025 mm

Radial play, rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.066 mm

Outside diameter, rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 33.959 - 33.975 mm

347
 TECHNICAL DATA

Cylinder head

1 18.100 - 18.500 mm
2 Inside valve guide - exhaust valve
Ø 9.000 - 9.015 mm
3 Inside valve guide - intake valve:
Ø 9.000 - 9.015 mm
Exhaust valve β = 60°
Intake valve α = 60°
Bore in cylinder head for valve guide
Ø 15.000 - 15.018 mm
Valve guide outside diameter
Ø 15.028 - 15.046 mm

Valves

1 Outside diameter, exhaust valve:

Ø 8.930 - 8.944 mm
2 Outside diameter, intake valve
Ø 8.963 - 8.977 mm
3 Bore in cylinder head - intake:
Ø 46.000 - 46.025 mm
4 Bore in cylinder head - exhaust:
Ø 44.000 - 44.025 mm

Valve recess

1 Valve recess
Intake valve: 0 - 0.39 mm
Exhaust valve: 0.19 - 0.59 mm

Valve clearance
Valve clearance only to be set with engine in cold condition
Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm
Lock nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10x1-8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm

348
 TECHNICAL DATA

Valve spring, outside

1 Untensioned length (L), approx. 75,23 mm
Spring force when L = 45 mm: 257 - 283 N
Spring force when L = 33 mm: 372 -408 N
The lowest spring force is at the same time the
wear limit value.

Valve spring, inside

1 Untensioned length (L), approx. 58.08 mm
Spring force when L = 38 mm: 95 - 105 N
Spring force when L = 26 mm: 156 -172 N
The lowest spring force is at the same time the
wear limit value.

349
TECHNICAL DATA

Valve timing
Camshaft

1 Ø 79,91 - 79,94 mm
Camshaft bushing inner diameter:
80,000 - 80,061 mm
Camshaft axial play:
0.10 - 0.20 mm
Camshaft radial play:
0.030 - 0.066 mm
2 Replace if signs of wear are present

Valve timing

1 Engine cranking device 1

2 TDC 3
2 Intake valve opens 12° before TDC
3 Exhaust valve closes 1° after TDC
4 Exhaust valve opens 61° before BDC
5 Exhaust valve closes 48° after BDC 6 7
6 Exhaust valve opening angle 252°
7 Intake valve opening angle 240°
Valve stroke with valve clearance:
Intake valve: 10 mm 5 4
Exhaust valve: 12 mm
BDC

Valve stroke during measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 - 11.8 mm

Engine lubrication
Oil pump

1 Outer rotor
Axial play: 0.04 - 0.09 mm
Radial play: 0.122 - 0.194
2 Inner rotor
Axial play: 0.035 - 0.080 mm
Radial play: 0.025 - 0.061
3 Gear width: 34 mm
Gear axial play: 0.060 - 0.240 mm

350
 TECHNICAL DATA

Crank drive
Flywheel
Flywheel lateral runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 0.1 mm
Installation temperature, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 - 230 C

1 Flywheel: Ø 432.490 - 432.645 mm

Ring gear inside diameter:
Ø 432.000 - 432.097 mm
m = 66.29 kg
J = 2.49 kgm2
2 Number of teeth: Z = 137, module 3.5
Mating gear: starter pinion (Z = 11)

Connecting rod

1 Piston pin socket inside diameter:

Ø 55.060 - 52.075 mm
2 Bore for bearing shells in connecting rod:
Ø 101.000 - 101.022 mm
Conrods which are discoloured at the big end must
not be reinstalled.
Bearing bore in measuring directions 1, 2 and 3
and on measuring planes a and b:
Ø 96.047 - 96.099 mm
Boundary condition:
New conrod bearing fitted,
conrod assembled

Conrod length, centre conrod eye-centre conrod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . 282.45 - 282.50 mm

1 After inadvertent bolting of cracked conrods

and conrod bearing caps that do not belong
together, the parts must not be reused

351
TECHNICAL DATA

Connecting rod bearing

1 Connecting rod bearing thickness: 2.480 -

2.495 mm
Spread: max. 2.0 mm
If traces of wear are present (Traces of scoring,
running layer damaged), replace both bearing
shells
Caution: Installation note installation position (Rod
shell has red paint marking on the side)

1 Bearing inside diameter in installed

state: Ø Ø 96.047 - 96.099 mm

352
 TECHNICAL DATA

Piston

1 Piston height, middle of piston pin-piston crown:

78.45 - 78.50 mm
2 Piston pin bore
Ø 55.06 - 55.08 mm
Piston pin diameter:
Ø 54.994 - 55.000 mm
3 Piston diameter 132 mm
D1 measured 17.5 mm above lower edge of
piston:
Ø 131.871 - 131.889 mm
D2 measured 67.5 mm above lower edge of
piston: Ø 131.754 - 131.792 mm
D3 measured 100 mm above lower edge of
piston: Ø
131.475 - 131.517 mm
D4 measured 115.55 mm above lower edge of
piston:
Ø 131.236 - 131.278 mm

Piston overall height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 mm

Compression
Piston recess (crankcase to piston) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5120 - 0.8535 mm
Gas exchange dead centre
Piston recess (crankcase to piston) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1440 - 0.5380 mm

1 3.60 - 3.62 mm
2 2.58 - 2.60 mm
3 3.52 - 3.54 mm

353
TECHNICAL DATA

Piston rings

1 3.30 - 3.60 mm
2 () 1st ring - full keystone ring
Piston ring height: 3.50 mm (nominal value)
Piston ring width: 5.10 - 5.50 mm
3 2nd ring - tapered compression ring
Piston ring height: 2.47 - 2.50 mm
Piston ring width: 5.10 - 5.50 mm
4 3rd ring - double-bevelled ring
Piston ring height: 3.47 - 3.49 mm
Piston ring width: 4.20 - 4.45 mm
5 Ring end clearance:
1st ring: 0.40 - 0.55 mm
2nd ring: 0.70 - 0.90 mm
3rd ring: 0.25 - 0.55 mm

354
 TECHNICAL DATA

Crankshaft

1 Connecting rod bearing journal: Ø 95.966 -

95.988 mm

2 Crankshaft journal:
Ø 111.966 - 111.988 mm

1 Thickness of thrust washers: 3.300 - 3.350 mm

Repair size 1: 3.425 - 3.475 mm
Repair size 2: 3.550 - 3.600 mm
Repair size 3: 3.675 - 3.725 mm
2 39.00 - 39.08 mm

Crankshaft axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.200 - 0.401 mm

Crankshaft radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.044 - 0.110 mm

355
TECHNICAL DATA

Crankshaft bearing

1 Wall thickness, crankshaft bearing shells:

2.959 - 2.971 mm
Standard size 1: 3.084 - 3.096 mm
Repair size 1: 3.209 - 3.221 mm
Repair size 2: 3.334 - 3.346 mm
2 Inside diameter of crankshaft bearing shell in
installed state: Ø 104.044 - 104.090 mm
Standard size 1: Ø 104.144 104.190 mm
Repair size 1: Ø 104.294 104.340 mm
Repair size 2: Ø 104.544 - 104.590 mm
Crankshaft bearing spread: max. 2.0 mm

Engine housing

Crankcase

1 9.985 - 10.015 mm
2 Ø 163.40 - 163.60 mm
3 Ø 158.80 - 158.84 mm
4 Ø 149.50 - 149.54 mm

356
 TECHNICAL DATA

Cylinder liner

1 Ø 163.15 - 163.35 mm
2 10.04 - 10.07 mm
3 Ø 149.7 - 150.0 mm
4 Ø 131.99 - 132.01 mm
Maximum wear limit:
0.15 mm less than basic dimension
5 Ø 149.439 - 149.457 mm

Cylinder liner protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 - 0.085 mm

357
TECHNICAL DATA

358
 Special tools

Special tools

359
Special tools

360
 Special tools

Special tools

[1] Cable tie pliers 08.02960-0100

S Removing and installing the engine electrics
S Removing and installing the engine wiring harness

[2] Hose clamp pliers for jubilee clips 80.99625-0073

S Removing and installing the coolant lines
S Removing and installing the intake manifold
S Removing and installing the exhaust turbocharger
S Removing and installing the oil modules
S Removing and installing the engine ventilation
S Removing and installing the flywheel housing
[3] Engine cranking device 80.99626-6009
S Removing and installing the starter
S Removing and installing the valve stem seals
S Checking the valve timing
S Removing and installing the rear crankshaft sealing ring
S Removing and installing the vibration damper

[4] Gear ratchet 80.99627-0001

S Removing and installing the starter
S Removing and installing the valve stem seals
S Checking the valve timing
S Removing and installing the vibration damper

[5] Socket for spark plugs 51.97710-0005

S Removing and installing the spark plugs

[6] Dial gauge 08.71000-3217

S Dismantling and assembling the rocker arm mechanism
S Removing and installing the oil pumps
S Removing and installing the pistons and connecting rods
S Removing and installing the crankshaft
S Removing and installing the cylinder liner

[7] Dial gauge holder 08.71082-0005

S Checking the valve timing
S Removing and installing the crankshaft

361
Special tools

[8] Dial gauge holder 80.99605-0172

S Removing and installing the cylinder head
S Removing and installing the oil pumps
S Removing and installing the pistons and connecting rods
S Removing and installing the cylinder liner

[9] Socket size 22 80.99612-0024

S Removing and installing the cylinder head
S Removing and installing the flywheel
S Removing and installing the crankshaft

[10] Torque multiplier i = 1 : 3.3 80.99619-0006

S Removing and installing the cylinder head
S Removing and installing the flywheel
S Removing and installing the crankshaft

[11] Support 80.99606-0551

S Removing and installing the cylinder head
S Removing and installing the flywheel
S Removing and installing the crankshaft

[12] Angle measuring disc 80.99607-0172

S Removing and installing the cylinder head
S Removing and installing the flywheel
S Removing and installing the crankshaft

[13] Holder 80.99606-0641

S Removing and installing the cylinder head
S Removing and installing the flywheel
S Removing and installing the crankshaft

[14] Cheese-head screw 06.02191-0407

S Removing and installing the cylinder head
S Removing and installing the flywheel
S Removing and installing the crankshaft

362
 Special tools

[15] Connecting pin 06.22729-0006

S Removing and installing the cylinder head
S Removing and installing the flywheel
S Removing and installing the crankshaft

[16] Rubber ring 42 mm 08.06142-9006

S Removing and installing the cylinder head
S Removing and installing the flywheel
S Removing and installing the crankshaft

[17] Adapter 80.99606-0552

S Removing and installing the cylinder head
S Removing and installing the flywheel
S Removing and installing the crankshaft

[18] Socket 80.99603-0327

S Removing and installing the cylinder head
S Removing and installing the flywheel
S Removing and installing the crankshaft

[19] Aligning bar 80.99606-0582

S Removing and installing the cylinder head

[20] Measuring plate 80.99605-0289

S Removing and installing the cylinder head
S Removing and installing the cylinder liners

[21] Hexagon shank bolt 06.01499-0015

S Removing and installing the cylinder head
S Removing and installing the cylinder liners

363
Special tools

[22] Washer 06.15013-0417

S Removing and installing the cylinder head
S Removing and installing the cylinder liners

[23] Intermediate piece 80.99606-0588

S Removing and installing the valve stem seals

[24] Assembly jig 80.99606-6092

S Removing and installing the valve stem seals
S Intermediate piece [4]

[25] Extension 80.99606-6094

S Removing and installing the valve stem seals

[26] Valve spring compressor 80.99613-6000

S Removing and installing the valve stem seals

[27] Holder 80.99613-0050

S Removing and installing the valve stem seals

[28] Holder 80.99613-0051

S Removing and installing the valve stem seals

364
 Special tools

[29] Magnetic pickup 80.99639-0009

S Removing and installing the valve stem seals

[30] Assembly jig 80.99606-6088

S Removing and installing the valve stem seals

[31] Assembly sleeve 80.99606-0287

S Removing and installing the valve stem seals

[32] Feeler gauge 08.75310-3309

S Checking and adjusting the valve clearance

[33] Valve adjustment spanner size 14 80.99603-6031

S Checking and adjusting the valve clearance

[34] Handle 08.06460-0003

S Checking and adjusting the valve clearance

[35] Insertion pin 80.99617-6009

S Removing and installing the camshaft

365
Special tools

[36] Aligning tool 80.99617-0020

S Removing and installing the front drive gears
S Removing and installing the front crankshaft sealing ring
S Removing and installing the vibration damper
S Removing and installing the flywheel
S Removing and installing the crankshaft

[37] Socket size 36 80.99603-0325

S Removing and installing the oil filter cover

[38] Impact extractor 80.99602-0016

S Removing and installing the front crankshaft sealing ring
S Removing and installing the rear crankshaft sealing ring

[39] Extractor hook 80.99602-0175

S Removing and installing the front crankshaft sealing ring

[40] Detachable handle 80.99617-0187

S Removing and installing the front crankshaft sealing ring
S Removing and installing the rear crankshaft sealing ring

[41] Washer 80.99617-0144

S Removing and installing the front crankshaft sealing ring
S Removing and installing the rear crankshaft sealing ring

[42] Pressing plate 80.99604-0342

S Removing and installing the front crankshaft sealing ring
S Removing and installing the rear crankshaft sealing ring

[43] Guide plate 80.99606-0703

S Removing and installing the rear crankshaft sealing ring

366
 Special tools

[44] Press-in bushing 80.99604-0340

S Removing and installing the rear crankshaft sealing ring

[45] Aligning tool 80.99617-0220

S Removing and installing the rear crankshaft sealing ring
S Removing and installing the crankshaft

[46] Extractor 80.99601-6033

S Removing and installing the rear crankshaft sealing ring

[47] Eye-bolt 06.05110-0103

S Removing and installing the flywheel

[48] Feeler gauge 08.75310-0806

S Removing and installing the pistons and connecting rods

[49] Piston-ring pliers 83.09144-6090

S Removing and installing the pistons and connecting rods

[50] Piston ring compressor pliers 80.99613-6004

S Removing and installing the pistons and connecting rods

367
Special tools

[51] Set tool 80.99622-0052

S Removing and installing the pistons and connecting rods
S Removing and installing the crankshaft

[52] Depth gauge (electronic) 08.71195-9003

S Removing and installing the pistons and connecting rods
S Removing and installing the cylinder liners

[53] Feeler 80.99605-0197

S Removing and installing the crankshaft

[54] Forcing bolt 80.99617-0220

S Removing and installing the crankshaft

[55] Eye-bolt 80.99606-0660

S Removing and installing the crankshaft

[56] Three-armed puller 08.99605-9014

S Removing and installing the crankshaft

368
 Special tools

[57] Extractor 80.99601-6018

S Removing and installing the cylinder liners

[58] Extractor plate 80.99601-0278

S Removing and installing the cylinder liners

369
Special tools

370
MAN Truck & Bus AG
Vogelweiherstraße 33
90441 Nuremberg
Germany
[email protected]
www.man-engines.com

MAN Truck & Bus – a member of the MAN Group