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Workshop Manual 2(0) B D4-210i-A,D4-210A-A, D6-310i-A, D6-310A-A Contents Safety precautions ............................................... 4 General information ................................................ 7 Repair instructions ................................................. 8 Special tools .......................................................... 11 Other special equipment ........................................ 14 Repair Instructions Engine, dismantling ................................................ 15 Engine, assemble .................................................. 39 Tightening torques ................................................. 91 Tightening schedules ............................................. 93 Advance Copy This publication is an Advance Copy and can not be ordered as printed copy. All data and all descriptions in this Advance Copy are based on verified information that was available at the given issue date for this publication. All non verified information has been left out. This publication may not have complete data or descriptions. References to publication numbers, tool numbers, part numbers etc., may not be valid and active in order systems before the final release of this publication. The final release will keep the same publication number as this Advance Copy and can be ordered as printed copy. The final release will supersede this Advance Copy in any and all forms or media. Safety Precautions Introduction This Workshop Manual contains technical data, descriptions and repair instructions for Volvo Penta products or product versions contained in the contents list. Ensure that the correct workshop literature is being used. Read the safety information and the Workshop Manual “General Information” and “Repair Instructions” carefully before starting work. Important In this book and on the engine you will find the following special warning symbols. WARNING! If these instructions are not followed there is a danger of personal injury, extensive damage to the product or serious mechanical malfunction. IMPORTANT! Used to draw your attention to something that can cause damage, product malfunction or damage to property. NOTE! Used to draw your attention to important information that will facilitate work or operations. Below is a summary of the risks and safety precautions you should always observe or carry out when operating or servicing the engine. Immobilize the engine by turning off the power supply to the engine at the main switch (switches) and lock it (them) in the OFF position before starting work. Set up a warning notice at the engine control point or helm. Generally, all servicing should be carried out with the engine switched off. Some work (carrying out certain adjustments for example) requires the engine to be running. Approaching a running engine is dangerous. Loose clothing or long hair can fasten in rotating parts and cause serious personal injury. If working in proximity to a running engine, careless movements or a dropped tool can result in personal injury. Avoid burns. Take precautions to avoid hot surfaces (exhausts, turbochargers, charge air pipes and starter elements etc.) and liquids in supply lines and hoses when the engine is running or has been turned off immediately prior to starting work on it. Reinstall all protective parts removed during service operations before starting the engine. Check that the warning or information decals on the product are always clearly visible. Replace decals that have been damaged or painted over. Never start the engine without installing the air cleaner (ACL). The rotating compressor in the Turbo can cause serious personal injury. Foreign objects entering the intake ducts can also cause mechanical damage. Never use start spray or similar to start the engine. The starter element may cause an explosion in the inlet manifold. Danger of personal injury. Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out at the same time as the pressure which has built up is lost. Open the filler cap slowly, and release the pressure in the cooling system if the filling cap or tap has to be opened, or if a plug or coolant hose has to be removed when the engine is hot. Steam or hot coolant can stream out in an unexpected direction. Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before commencing work on it. Never start or operate the engine with the oil filler cap removed, otherwise oil could be ejected. Stop the engine and close the sea cock before carrying out operations on the engine cooling system. Only start the engine in a well-ventilated area. If operating the engine in an enclosed space, ensure that exhaust gases and crankcase ventilation emissions are ventilated out of the working area. Always use protective goggles where there is a danger of pieces of metal, sparks from grinding, acid or other chemicals being thrown into your eyes. Your eyes are very sensitive, injury can lead to loss of sight! Avoid skin contact with oil. Long-term or repeated contact with oil can remove the natural oils from your skin. The result can be irritation, dry skin, eczema and other skin problems. Used oil is more dangerous to health than new oil. Use protective gloves and avoid using oil- soaked clothes and rags. Wash regularly, especially before meals. Use the correct barrier cream to prevent dry skin and to make cleaning your skin easier. Most chemicals used in products (engine and transmission oils, glycol, petrol and diesel oil) and workshop chemicals (solvents and paints) are hazardous to health Read the instructions on the product packaging carefully! Always follow safety instructions (using breathing apparatus, protective goggles and gloves for example). Ensure that other personnel are not unwittingly exposed to hazardous substances (by breathing them in for example). Ensure that ventilation is good. Handle used and excess chemicals according to instructions. Be extremely careful when tracing leaks in the fuel system and testing fuel injection nozzles. Use protective goggles! The jet ejected from a fuel injection nozzle is under very high pressure, it can penetrate body tissue and cause serious injury There is a danger of blood poisoning. All fuels and many chemicals are inflammable. Ensure that a naked flame or sparks cannot ignite fuel or chemicals. Combined with air in certain ratios, petrol, some solvents and hydrogen from batteries are easily inflammable and explosive. Smoking is prohibited! Ensure that ventilation is good and that the necessary safety precautions have been taken before carrying out welding or grinding work. Always have a fire extinguisher to hand in the workplace. Store oil and fuel-soaked rags and fuel and oil filters safely. In certain conditions oil-soaked rags can spontaneously ignite. Used fuel and oil filters are environmentally dangerous waste and must be deposited at an approved site for destruction together with used lubricating oil, contaminated fuel, paint remnants, solvent, de- greasing agents and waste from washing parts. Never allow a naked flame or electric sparks near the batteries. Never smoke in proximity to the batteries. The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas - oxyhydrogen. This gas is easily ignited and highly volatile. Incorrect connection of the battery can cause a spark which is sufficient to cause an explosion with resulting damage. Do not disturb battery connections when starting the engine (spark risk) and do not lean over batteries. Never mix up the positive and negative battery terminals when installing. Incorrect installation can result in serious damage to electrical equipment. Refer to wiring diagrams. Always use protective goggles when charging and handling batteries. The battery electrolyte contains extremely corrosive sulfuric acid. If this comes into contact with the skin, wash immediately with soap and plenty of water. If battery acid comes into contact with the eyes, immediately flush with copious amounts of water and obtain medical assistance. Turn off the engine and turn off power at main switch(es) before carrying out work on the electrical system. The clutch must be adjusted with the engine shut off. Use the lifting eyes mounted on the engine/reverse gear when lifting the drive unit. Always check that lifting equipment is in good condition and has sufficient load capacity to lift the engine (engine weight including reverse gear and any extra equipment installed). To ensure safe handling and to avoid damaging engine components on top of the engine, use a lifting beam to raise the engine. All chains and cables should run parallel to each other and as perpendicular as possible in relation to the top of the engine. If extra equipment is installed on the engine altering its center of gravity, a special lifting device is required to achieve the correct balance for safe handling. Never carry out work on an engine suspended on a hoist. Never remove heavy components alone, even where secure lifting equipment such as secured blocks are being used. Even where lifting equipment is being used it is best to carry out the work with two people; one to operate the lifting equipment and the other to ensure that components are not trapped and damaged when being lifted. When working on-board ensure that there is sufficient space to remove components without danger of injury or damage. Components in the electrical and fuel systems on Volvo Penta products have been designed to minimize the risks of explosion and fire. The engine must not be operated in environments with adjacent explosive media. Fuel delivery pipes must not be bent or straightened under any circumstances. Damaged pipes must be replaced. Remember the following when washing with a high pressure washer: Never aim the water jet at seals, rubber hoses or electrical components. Never use a high pressure washer for engine cleaning. Always use fuels recommended by Volvo Penta. Refer to the Instruction Book. The use of lower quality fuels can damage the engine. On a diesel engine poor quality fuel can cause the control rod to seize and the engine to overrev with the resulting risk of damage to the engine and personal injury. Poor fuel quality can also lead to higher maintenance costs. © 2003 AB VOLVO PENTA We reserve the right to make modifications without prior notice. Printed on environmentally compatible paper. General information About the workshop manual Certified engines This workshop manual contains technical specification, descriptions and instructions for repairing the standard versions of the following engines D4/D6. The workshop manual displays the operations carried out on any of the engines above. As a result the illustrations and pictures in the manual that show certain parts on the engines, do not in some cases apply to all the engines listed above. However the repair and service operations described are the same in all essential details. Where they are not the same this is stated in the manual and where the difference is considerable the operations are described separately. Engine designations and numbers are given on the number plate. The engine designation and number should be given in all correspondence about the engine. This Workshop Manual has been developed primarily for Volvo Penta service workshops and qualified personnel. Persons using this book are assumed to have a grounding in marine drive systems and be able to carry out related mechanical and electrical work. Volvo Penta is continuously developing their products. We therefore reserve the right to make changes. All the information contained in this book is based on product data available at the time of going to print. Any essential changes or modifications introduced into production or updated or revised service methods introduced after the date of publication will be provided in the form of Service Bulletins. Replacement parts Replacement parts for electrical and fuel systems are subject to statutory requirements (US Coast Guard Safety Regulations for example). Volvo Penta Genuine parts meet these requirements. Any type of damage which results from the use of non-original Volvo Penta replacement parts for the product will not be covered under any warranty provided by Volvo Penta. When doing service and repair on emission certified engines, it is important to be aware of the following: Certification means that an engine type has been checked and approved by the relevant authority. The engine manufacturer guarantees that all engines made of the same type are equivalent to the certified engine. This makes special demands on service and repair work, as follows: • Maintenance and service intervals recommended by Volvo Penta must be complied with. • Only Volvo Penta original spares may be used. • Service to injection pumps, pump settings and injectors must always be done by an authorized Volvo Penta workshop. • The engine must not be converted or modified, except for the accessories and service kits which Volvo Penta has approved for the engine. • No installation changes to the exhaust pipe and engine air inlet ducts may be done. • No seals may be broken by unauthorized personnel. The general advice in the instruction book about operation, care and maintenance applies. IMPORTANT! Delayed or inferior care/maintenance, and the use of non-original spares, mean that AB Volvo Penta can no longer be responsible for guaranteeing that the engine complies with the certified version. Damage, injury and/or costs which arise from this will not be compensated by Volvo Penta. Repair instructions The working methods described in the Service Manual apply to work carried out in a workshop. The engine has been removed from the boat and is installed in an engine fixture. Unless otherwise stated reconditioning work which can be carried out with the engine in place follows the same working method. Warning symbols occurring in the Workshop Manual (for their meaning see Safety information) WARNING! IMPORTANT! NOTE! are not in any way comprehensive since it is impossible to predict every circumstance under which service work or repairs may be carried out. For this reason we can only highlight the risks that can arise when work is carried out incorrectly in a well-equipped workshop using working methods and tools developed by us. All procedures for which there are Volvo Penta special tools in this Workshop Manual are carried out using these. Special tools are developed to rationalize working methods and make procedures as safe as possible. It is therefore the responsibility of any person using tools or working methods other than the ones recommended by us to ensure that there is no danger of injury, damage or malfunction resulting from these. In some cases there may be special safety precautions and instructions for the use of tools and chemicals contained in this Workshop Manual. These special instructions should always be followed if there are no separate instructions in the Workshop Manual. Certain elementary precautions and common sense can prevent most risks arising. A clean workplace and engine eliminates much of the danger of injury and malfunction. It is of the greatest importance that no dirt or foreign particles get into the fuel system, lubrication system, intake system, turbocharger, bearings and seals when they are being worked on. The result can be malfunction or a shorter operational life. Our joint responsibility Each engine consists of many connected systems and components. If a component deviates from its technical specification the environmental impact of an otherwise good engine may be increased significantly. It is therefore vital that wear tolerances are maintained, that systems that can be adjusted are adjusted properly and that Volvo Penta Genuine Parts as used. The engine Maintenance Schedule must be followed. Some systems, such as the components in the fuel system, require special expertise and special testing equipment for service and maintenance. Some components are sealed at the factory for environmental reasons. No work should be carried out on sealed components except by authorized personnel. Bear in mind that most chemicals used on boats are harmful to the environment if used incorrectly. Volvo Penta recommends the use of biodegradable de- greasing agents for cleaning engine components, unless otherwise stated in a workshop manual. Take special care when working on-board, that oil and waste is taken for destruction and is not accidentally pumped into the environment with bilge water. Tightening torques Tightening torques for vital joints that must be tightened with a torque wrench are listed in chapter “Tightening Torques” and are contained in work descriptions in this Manual, printed in bold type. All torques apply for cleaned threads, screw heads and mating surfaces. Torques apply for lightly oiled or dry threads. If lubricants, locking fluid or sealing compound are required for a screwed joint this information will be contained in the work description. Where tightening torque in work descriptions are printed in normal type, general tightening torques applies. The tightening torques stated are a guide and the joint does not have to be tightened using a torque wrench. Tightening torques-protractor (angle) tightening Tightening using both a torque setting and a protractor angle requires that first the recommended torque is applied using a torque wrench and then the recommended angle is added according to the protractor scale. Example: a 90° protractor tightening means that the joint is tightened a further 1/4 turn in one operation after the stated tightening torque has been applied. Tolerance classes Screws and nuts are divided into different strength classes, the class is indicated by the number on the bolt head. A high number indicates stronger material, for example a bolt marked 10-9 indicates a higher tolerance than one marked 8-8. It is therefore important that bolts removed during the disassembly of a bolted joint must be reinstalled in their original position when assembling the joint. If a bolt must be replaced check in the replacement parts catalogue to make sure the correct bolt is used. Sealants etc. A number of sealants and locking liquids are used on the engines. The agents have varying properties and are used for different types of jointing strengths, operating temperature ranges, resistance to oil and other chemicals and for the different materials and gap sizes in the engines. To ensure service work is correctly carried out it is important that the correct sealant and locking fluid type is used on the joint where the agents are required. In this Volvo Penta Service Manual the user will find that each section where these agents are applied in production states which type was used on the engine. During service operations use the same agent. Make sure that mating surfaces are dry and free from oil, grease, paint and anti-corrosion agent before applying sealant or locking fluid. Always follow the manufacturer’s instructions for use regarding; temperature range, curing time and any other instructions for the product. Tow different basic types of agent are used on the engine and these are: RTV agent (Room temperature vulcanizing). Uses when two flexible flanges are assembled without gaskets. RTV agent is clearly visible when a component has been dismantled; old RTV must be removed before the joint is resealed. Old sealant can be removed using gasket scraper 885 516 and methylated spirits. The following RTV agents are mentioned in the Service Manual: Sealant (black), Part No. 888 661 Anaerobic agents. These agents cure in an absence of air. They are used when two solid parts, for example valve cover-cylinder head, are installed face-toface without a gasket. They are also commonly used to secure plugs, threads in stud bolts, cocks, oil pressure switches and so on. The cured material is glass-like and it is therefore colored to make it visible. Cured anaerobic agents are extremely resistant to solvents. Old sealant can be removed using gasket scraper 885 516 and methylated spirits. The following anaerobic agents are mentioned in the Service Manual: Sealant (red), Part No. 1161 059 Sealant (brown), Part No. 1161 370 Two different lubricants are use on the engine: Lubricant, Part No. 3588347. Used on bottom of the cylinder head bolt heads to prevent seizure against cylinder head. Lubricant, Part No. 3588346. Used on the camshafts, balance shafts and on the injectors. Safety precautions for Fluorine rubber Fluorine rubber is a common material in sealing rings for shafts and O rings. When fluorine rubber is exposed to high temperatures (over 300°C) it can release highly corrosive hydrofluoric acid. Exposing the skin to this chemical can cause serious burns. If splashed in the eyes it can cause malignant ulcers. Breathing the fumes can damage the respiratory tract. WARNING! Take the greatest care when working on engines that have been operating at high temperatures, for example an overheated engine that has seized or an engine involved in a fire. The seals must never be burned off when disassembling or be burnt afterwards in anything other than a special disposal site. • Always used chloroprene rubber gloves (gloves for handling chemicals) and protective glasses. • Treat removed seals in the same way as corrosive acid. All remains, even the ash can be extremely corrosive. Never use compressed air jets for blowing clean. • Put old seal remnants in a plastic container, close it and stick a warning label on it. Wash gloves under running water before removal. The following seals are very likely to contain fluorine rubber: Crankshaft, camshaft and intermediate shaft seals O rings, wherever used. O rings for cylinder liner sealing are almost always fluorine rubber. Note that seals not exposed to high temeratures can be handled normally. Special tools In all cases where it´s practical the tool number has been stamped on the tool. 885 238884 168 885 023884 994 885 261 885 289 885 341 885 490 885 493 885 494 885 495 885 496 885 497 885 498 885 499 884 168 1) Mandrel, sealing ring termostat housing 884 994 1) Puller, polygon hub crankshaft 885 023 1) Valve spring compressor 885 238 1) Reamer, valve guide 885 261 1) Mandrel, valve guide 885 289 1) Brush, seat in injector sleeve 885 341 1) Puller, sealing ring termostat housing (used with slide hammer 999 6400) 885 490 Socket tool, injector pipe 885 493 885 494 885 495 885 496 885 497 885 498 885 499 Locking pin, camshaft (2 pcs/kit) Guide pin, tooth wheel camshaft Mandrel, rear crankshaft seal Mandrel, front crankshaft seal Mandrel, coolant pump Socket (used with valve spring compres sor 885 023) Piston ring compressor 1) Tool is used on one or more of Volvo Penta´s previously products 885 500 885 501 885 502 885 503 885 504 885 505 885 506 885 507 885 508 885 509 885 512 885 513 885 514 885 515 885 517 885 519 885 531 885 533 885 536 885 539 885 500 Socket tool, oil pipe turbo 885 501 Guide pin, connecting rod 885 502 Puller injector sleeve 885 503 Reaming tool, injector sleeve 885 504 Locking tool, flywheel 885 505 Adapter, compression tester 885 506 Mandrel, camshaft and tooth wheel 885 507 Engine fixture, D4 885 508 Engine fixture, D6 885 509 Torx socket E-20 885 512 reamer (included in 885 503) 885 513 Mounting plate, gear wheel high pressure pump 885 514 Mandrel, valve guide 885 515 Puller, injector 885 517 Mounting plate, valve guide (2 pcs/kit) 885 519 Guide pins, camshaft cover, oil sump (2pcs/kit) 885 531 Pressure testing kit, cooling system 885 533 Expander plug, small (used with 885 531) 885 536 Expander plug, medium (used with 885 531) 885 539 Expander plug, medium (closed) (used with 885 531) 1) Tool is used on one or more of Volvo Penta´s previously products 885 648 885 649 885 650 885 685 885 686 981 2546 999 0150 999 2479 999 2679 999 6066 999 6398 999 6400 999 0263 999 8493 885 648 Extension, used with torque converter 885 633) 885 649 Mandrel, oil channel non-return valve 885 650 Adjustment tool, camshaft chain 885 685 Guide pins, flywheel casing (2 pcs/kit) 885 686 Guide pins, side plate oil sump (2 pcs/ kit) 981 2546 1) Brush, seat for injector sleeve 999 0150 1) Vacuum gauge, fuel line 999 0263 Nippel, oil pressure measuring 999 2479 1) Stand for dial indicator 998 9876 999 2679 1) Puller, gear wheel high pressure pump 999 6066 1) Nippel, fuel line 999 6398 1) Oil pressure gauge 999 6400 1) Slide hammer (used with 885 341) 999 8493 1) Vacuum hose (to vcuummanometer 999 0150 1) Tool is used on one or more of Volvo Penta´s previously products Other special equipment 885 510 885 511 885 516 885 633 885 636 998 6485 998 8539 998 9876 999 9179 999 9683 999 9696 885 510 Protective caps, fuel system 998 8359 1) Compression tester 885 511 Roller, sealant 998 9876 1) Dial gauge 885 516 Gasket scraper 999 9179 1) Filter puller 885 633 Torque converter 999 9683 1) Rocker indicator 885 636 Roller (spare part for 885 511) 999 9696 1) Magnetic base 998 6485 1) Engine stand 1) Tool is used on one or more of Volvo Penta´s previously products Engine, dismantling 1 Remove the upper and rear covers (1). Keep the rubber dampers (2) and (3) safe. 2 Remove the expansion tank (1) including hoses (2). Don’t forget to detach the connector (3) to the coolant level sensor. 3 Remove the air filter housing (1) and the rubber elbow (2) for the turbocharger. Remove the crankcase ventilation filter (1) and its hoses (2). Also remove the hose (3) between the crankcase ventilation cover and the camshaft gear cover. 5 Undo the bolts for the multi-V belt tension roller (1) and remove the belt and tension roller. Also remove the belt’s idler gear (2) (6 cyl engines have double idler gears). 6 Detach the three control unit connectors (1) by turning down the locking arms while pulling out the connectors. Release the three clamps (2) for the cables. Detach the temperature sensor connector (3). Remove the control unit and its mounting bracket. 1 21 121 8 Disconnect the cables to the alternator. Remove the alternator. Keep the washers (1) and the insulating sleeves (2) safe. 9 Lift the engine using a suitable lifting device with the lifting force as directly above the engine’s lifting lugs as possible. Remove the front starboard engine mounting bracket. 10 Fit the engine fixtures 885 507 (D4) and 885 508 (D6) to the engine. Use the following bolts: – 4 off M12 x 30. Tightening torque 80 Nm (59 lbf ft) – 2 off M10 x 40. Tightening torque 50 Nm (36.88 lbf ft) – 1 off M8 x 25. Tightening torque 25 Nm (18.44 lbf ft) The suspension jig is mounted onto stand 998 6485. 11 Unscrew the oil filters using filter wrench 999 9179. The oil filters are equipped with non-return valves to prevent oil spill. Leave the filters to a destruction plant. 12 Press in the locking clip and detach connector (1) to the monitor for water in the fuel filter. Drain the filter by unscrewing the combined monitor and bottom plug (2). Unscrew the fuel filter using filter wrench 999 9179. Make sure neither of the two filter sealing rings are left in the fuel filter bracket. Leave the filter to a destruction plant. Detach all the fuel hoses between the fuel filter, high pressure pump, pressure retaining valve and return fuel cooler. IMPORTANT! Fit protective caps to all fuel connections. Use protective caps in kit 885 510. 14 Press in the locking clip and detach the connector (1) to the fuel filter fuel temperature sensor. Remove the fuel filter bracket (2) and the bracket (3) for the dipstick. 15 (AQ model only) Remove the sea water filter and its mounting bracket. Undo the hose clips to the return fuel cooler hoses and remove the cooler and hoses. 17 Detach the connector to the DC/DC converter and remove it. 18 Remove the intercooler support bracket. Undo the hose clamps for the coolant hose on the oil cooler and the hose clamps for the hose connecting piece on the turbocharger. Undo the four bolts on the intake manifold. Place a lever as illustrated and carefully pry the intercooler away from the intake manifold. Remove the port bracket for the upper cover. 20 Remove the return fuel line (1) between the injectors and the return fuel block by pressing in the locking clip and wiggling loose the nipple. Remove the return fuel block (2). 21 Remove the delivery pipe between the high pressure pump and the rail as well as the delivery pipes to the injectors. Use nozzle tool 885 490. Detach the injector connectors. IMPORTANT! Fit protective caps to all fuel connections. Use protective caps in kit 885 510. 22 Remove the bolt and spacer sleeve for the injector caliper. Fit puller 885 515 and prise up the injector. IMPORTANT! Apply the tool only to the location described above, never anywhere else. IMPORTANT! Fit protective caps on the injector tip and electrical connection. Use protective caps in kit 885 510. 23 Detach the connector to the rail pressure sensor. Remove the rail. 24 Remove the cable harness in one piece. Detach the following connectors on the port side of the engine: – Charge air pressure/charge air temperature sensor (1) – Oil pressure switch/Oil pressure sensor (2) – Starter motor (3) (detach only the cables belonging to the engine cable harness) – Rail pressure sensor (detached earlier) – Monitor for water in fuel filter (detached earlier) – Rail pressure sensor (detached earlier) – High pressure pump (4) Detach the cable harness from the cable irons (5) bolted to the oil sump screws. The following cable connections are detached from above: – Injectors (detached earlier) Undo the clamps (1) holding the cable harness to the valve cover. Remove the cable harness to the injectors. 26 The following connections are detached from astern: – DC/DC converter (detached earlier) – Flywheel timing sensor (1) (the sensor can be detached from the engine including the bracket (2)). 27 Detach the following connectors on the starboard side of the engine: – Camshaft sensor (1) (the sensor can be detached from the engine). – Coolant temperature sensor (detached earlier) – Alternator (detached earlier) – Coolant level alarm (detached earlier) Detach the cable harness from the cable irons (2) bolted to the oil sump screws. Undo the nuts and bolts holding the starboard bracket (1) to the upper cover and remove the complete cable harness. Refer to workshop manual ”Electrical System EVC” for troubleshooting and repairing the electrical system. 29 Remove the exhaust pipe elbow. Remove the turbocharger support bracket. 30 Remove the turbocharger air inlet elbow. Discard the O-ring between the compressor housing and the air pipe elbow Remove the turbocharger oil feed hose (1). Use oil pipe tool 885 500 for the nipple in the cylinder block. Remove the oil return pipe (2). IMPORTANT! Plug the turbocharger oil connections. 32 Remove the turbocharger. 33 Remove the thermostat housing (1) with its thermostat. Carefully pry loose the housing with two screwdrivers. Remove the exhaust pipe (1). 35 Remove the sea water pump. 36 Remove the port engine mounting bracket. Remove the starter motor. Use a 14 mm socket and long extension bar. 38 Remove the heat exchanger/oil cooler. 39 Remove the return fuel cooler bracket (1) and the intake manifold. NB! Do not forget to undo the bolt under the attaching lugs for the fuel filter bracket. Loosen the intake manifold by carefully pry between the timing chain tensioner and the intake manifold. Remove the fuel pump and its spacer flange as one unit. Remove the gear and spacer flange if necessary; refer to ”High pressure pump, replace”. 41 Remove the circulation pump belt pulley. Use a suitable screwdriver as a counterhold. 42 Remove the circulation pump. Discard the gasket. Fit lock pin 885 504 into the flywheel housing. Press in the lock pin while turning the crankshaft until the pin engages in the flywheel. Remove the crankshaft belt pulley (1) and the oscillation damper (2). 44 Remove the crankcase ventilation cover if necessary (leakage or sever fouling). 45 Remove the cover over the timing chain sprockets. Carefully tap in a knife to break the gasket seal. Remove the two studs (1) from the cover (to allow the camshafts to be removed later). Remove the plugs from the valve cover and fit lock pin 885 493 (2 off). Make sure the lock pins engage in the camshafts (rotate the crankshaft 360°). 47 Remove the chain tensioner. IMPORTANT! The crankshaft and camshafts must not be rotated after removing the chain tensioner until the valve cover has been removed. This is so that the valves will not collide with the pistons. 48 Remove the upper chain guide. NB! Be caruful not to drop the bolts. 49 Undo the bolts on the timing chain sprockets and remove the sprockets. NB! The bolts are left-hand thread. Lock pins 885 493 act as a backstop. 50 Undo the bolt (1) with its sealing washer (2) and lift out the starboard chain guide (3). 51 Undo the bolts on the valve cover (camshaft housing). Place a lever as illustrated and carefully pry loose the valve cover. Remove the lock pins 885 493, lift off the valve cover and place it on the work bench with the camshafts up. Remove the camshaft thrust washer. 53 Put the valve cover on one end. Screw in drift 885 506 (left-hand thread) on the starboard camshaft and knock carefully with a plastic mallet until the tooth wheel (1) comes loose. 54 Remove the tooth wheel and carefully lift up the camshaft using the drift. Transfer the tool to the port camshaft and lift it up. Remove the valve caliper (1) together with the finger followers (2) and place them in a vessel containing clean engine oil. NB! The finger followers may only be washed in clean engine oil. 56 Undo the cylinder head bolts with power socket 885 509. If necessary, for example when working in confined engine compartments, use torque amplifier 885 633 together with counterhold 885 648. Place the counter- hold in the front or rear lifting eye depending on which bolt is being loosened. Undo the bolts gradually, start with the front and rear. If torque amplifier is used the front lifting eye must temporarily be removed when the front cylinder head bolts are loosened. Lift off the cylinder head. 57 IMPORTANT! Remove the non-return valves in the cylinder head oil passages before washing. Refer also to the chapter ”Cylinder head disassembly”. Turn over the engine and undo the bolts in the oil sump. Mark the location of the brackets for the cable harness to facilitate assembly. Hammer in a putty knife between the cylinder block and the oil sump to break the gasket seal. Realign the sump with a plastic mallet afterwards if necassary. The oil sump side plates are removed only if deemed necessary (leaks). 59 Remove the bolts and carefully lift off the oil pump from its locating pins. 60 Mark up where the oil splash plate (1) is located. Remove the balance shaft housing (2) D4 and the reinforcing housing D6. Remove the pipes for draining the crankcase ventilation and the oil extractor. Use an M8 bolt to knock them out with a plastic mallet. 62 Remove the flywheel. Use lock pin 885 504 as a counterhold. 63 Undo all the bolts (do not forget the M8 bolts in the recess for the high pressure pump) and remove the rear lifting eye and flywheel housing. Tap carefully with a plastic mallet to break the adhesive seal. Lift off the timing chain. Undo the bolts for the front crankshaft cover. Place a lever as illustrated and carefully pry loose the crankshaft cover. 65 Turn the crankshaft so that the piston cooling nozzle is visible and remove the nozzle. Repeat this process on the remaining cylinders. NB! The piston cooling nozzles must be removed at this stage to enable the pistons to be removed. 66 Undo the big-end bearing caps with an external TX E14 socket. Fit guide pin 885 501 and press/knock out the piston and connecting rod. Where necessary, scrape away the carbon from the top of the cylinder. IMPORTANT! Handle the connecting rod and cap with care. The split surfaces are very impact sensitive. Discard if damaged. NB! The connecting rod and cap should be washed separately. Undo the main bearing caps using power socket 885 509 and lift out the crankshaft. 68 Undo the idler gear centre bolt (1) and lift off the idler gear (2) from the journal. 69 Remove the idler gear journal. Undo the bolts (1) in the side plate (2). Tap carefully with a plastic mallet to break the adhesive seal. 71 Remove the plug (1) and pull out the spring and the piston cooling valve. Remove the oil pressure/temperature sensor (2). 72 Remove the plugs (1) and (2) from the cylinder block oil passages at the front and rear ends. Wash all engine components. Take special care when flushing the oil passages in the cylinder block and cylinder head. Engine, assemble 1 Fit the plugs into the cylinder block oil passages at the front and rear ends. Apply sealant (brown) to the plugs, part number 1161 370. 2 Fit the idler gear journal. Tightening torque 25 Nm. 3 beforehand: IMPORTANT! The next part to assemble is the side plate but to ensure a good seal between the cylinder block and the side plate, it is extremely important that the flywheel housing be fitted and torque tightened within 30 minutes of fitting the side plate. The following should therefore be prepared a. Lay out the idler wheel with its washer and bolt. Oil the bearing bushing. b. Fit new main bearings in the cylinder block and caps. Place the main bearing shells with oil grooves in the cylinder block. Place the main bearing shells with associated axial bearings (1) in the rear main bearing position and the associated cap (marked ”5” (D4) and ”7” (D6) respectively). Oil all the main bearing shells. c. Lay out the crankshaft, washed and blown well clean. d. Lay out the timing chain and flywheel housing. Check and fit the port chain guide (1). Change the chain guide if it has deep chafing marks. Torque tighten the bolt for the chain guide to 25 Nm. Fit the lower attaching bolt (2) for the starboard chain guide if it was removed. Tightening torque 25 Nm. IMPORTANT! Clean the mating surfaces on the engine block and the flywheel housing with methylated spirits 885 516. Pieces of old sealant must be completely removed to allow good resealing. e. Lay out the necessary tools: Torque wrench 25 and 130 Nm, long draw handle, power socket 885 509, sockets 12 and 18 mm, guide pins 885 685, sealant part nos. 888 661 and 1161 059. f. the engine block and the side plate with methylated spirits 885 516. Pieces of old sealant must be completely removed to allow good resealing. Apply a thin layer of sealant (red), part number 1161 059, to the side plate as illustrated. Use roller 885 511. 4 25 Nm. Fit a new O-ring (1). Fit the side plate. Take care not to scrape off the sealant when fitting. Torque tighten the bolts (2) to IMPORTANT! Torque tightening must be done immediately after assembly. 5 Fit the idler gear (1), put in place the washer (2) and torque tighten the bolt (2) to 25 Nm. Lift the crankshaft into place. Fit the main bearing caps. Make sure the bearing shell lock lugs (1) and (2) are turned as illustrated. The main bearing caps are numbered 1-5 (D4) and 1-7 (D6) respectively. Number ”1” is placed at the front (towards the circulation pump). 7 Fit oiled main bearing bolts and tighten in two stages. Use power socket 885 509. NB! New bolts must be used. Stage 1: 130 Nm Stage 2: 180° angle tightening 8 Check the crankshaft axial play. Use magnetic stand 999 9696 and dial gauge 998 9876. Permitted play 0.10-0.27 mm. 9 ed. Apply a 1.8 mm thick bead of sealant (black) part number 888 661 to the timing gear casing as illustrat- IMPORTANT! As the sealant starts to harden immediately on contact with air moisture, the parts should be assembled immediately after application (<3 min). 10 Place the timing chain (1) on the idler wheel. Screw in locating pins 885 685. Put the flywheel housing (2) onto the locating pins. Take great care not to damage the sealant bead when fitting. Unscrew the locating pins once the flywheel casing has engaged the cylinder block’s guide pins. Fit the lifting eye (3) and torque tighten all bolts immediately. Do not forget the M8 bolts in the recess for the high pressure pump. Tightening torque: M8: 25 Nm M14: 135 Nm NB! Excess sealant must not be wiped off. Wiping it off can cause leaks. Assemble the piston and connecting rod. Oil the piston, gudgeon pin and connecting rod. Fit one of the lock rings in the piston. Position the piston and connecting rod so that ”FRONT” on the connecting rod and the arrow on the piston are pointing the same way. Carefully press in the gudgeon pin and fit the other lock ring. 12 Fit the piston rings onto the piston using a suitable pair of piston ring pliers. The oil ring (1) must be fitted first and can be either way round. The lower compression ring (2) must be fitted with ”TOP” up. The upper compression ring (3) must be fitted with ”TOP” up. Fit the big-end bearing shells. Place the shell with the oil hole into the connecting rod. Take great care with the split surfaces on the connecting rod and cap. Screw in locating pin 885 501 in the connecting rod before fitting the piston/connecting rod into the cylinder block to protect the connecting rod and the crankshaft. 14 Oil the piston, piston rings and big-end bearings. Turn the piston rings so that the gaps are offset 120° to each other. NB! If oversize pistons are being used, a piston ring compressor of ”universal model” must be used. Turn the piston so that the arrow at the top is pointing forward. The connecting rods are marked 1-4 (4 cyl) and 1-6 (6 cyl) respectively. Crankshaft ”1” is fitted at the front (towards the circulation pump). 16 Fit the big-end bearing caps so that the mark (1) agrees with the connecting rod. Oil and torque tighten the connecting rod bolts (2). NB! New bolts must be used Tightening torque: Stage 1 65 Nm Stage 2 90° angle tightening Turn the crankshaft so that the piston cooling nozzles (1) can be fitted. Torque tighten the bolts to 10 Nm. 18 Undo the centre bolt on the crankshaft polygon hub. NB! Lubricate the sealing ring and crankshaft mating surfaces with silicone grease, part number 1161447 Place the sealing ring on mounting ring 885 495 and press it in place with the tool’s centre bolt. Tighten the bolt until the tool bottoms on the crankshaft polygon hub. Remove the tool. Wait to refit the polygon hub centre bolt until the flywheel has been fitted. 19 Fit the flywheel. Make sure the locating pin is fitted in the crankshaft and engages in the flywheel. NB! Fit new bolts. Torque tighten the bolts. Use lock pin 885 504 as a counterhold. Tightening torque: Stage 1: 100 Nm Stage 2: 45° (angle tightening) Refit the polygon hub centre bolt. Tightening torque: Stage 1: 100 Nm Stage 2: 45° Use lock pin 885 504 as a counterhold. 21 illustrated. IMPORTANT! Clean the mating surfaces on the engine block and the front cover with methylated spirits and gasket scraper 885 516. Pieces of old sealant must be completely removed to allow good resealing. Apply a 1.8 mm (0.071") thick bead of sealant part number 888 661 (black) to the timing gear casing as IMPORTANT! As the sealant starts to harden immediately on contact with air moisture, the parts should be assembled immediately after application (<3 min). 22 Fit locating pins 885 519 into the cylinder block and fit the front cover. NB! Take great care not to damage the sealant bead when fitting. Remove the locating pins once the cover has entered the cylinder block guide pin. Torque tighten all bolts immediately. Tightening torque 25 Nm. NB! Excess sealant must not be wiped off. Wiping it off can cause leaks. NB! Lubricate the sealing ring and crankshaft mating surfaces with silicone grease, part number 1161447 Fit the sealing ring (1) over the crankshaft and press it in place with mounting ring 885 496. Use the bolts for the crankshaft belt pulley. Tighten the bolts evenly until the mounting ring bottoms on the crankshaft. Make sure the sealing ring is not askew and adjust it if necessary. (When using a new crankshaft, the sealing ring must be pressed on only until it is flush with outer part of the cover). 24 Make sure the locating pins for the balance shaft housing (1) (D4 only) and the oil pump (2) are fitted in the cylinder block. Fit lock pin 885 504 into the flywheel housing and turn the crankshaft until the lock pin engages into the flywheel. 25 (D4 only) Fit the balance shaft housing assembly. With regard to assembly, refer to ”Balance shaft housing, overhaul”. Position the balance shaft housing over the locating pins. Turn the balance shafts so that the mark (3 punch marks) is pointing towards the crankshaft mark (4 punch marks). Also check that the balance shafts have been correctly fitted relative to each other with the mark on one shaft (1 punch mark) pointing to the mark on the other shaft (2 punch marks). Put in place the oil splash plate (1). Torque tighten all bolts according to the adjacent tightening diagram. Tightening torque 25 Nm. 1 27 (D4 only) Fit the protective plate (1) over the balance shaft gears. Torque tighten the bolts to 10 Nm. 28 (D6 only) Fit the reinforcing housing and the oil splash plate (1). Torque tighten the bolts. Tightening torque 25 Nm. 29 Fit the oil pump. IMPORTANT! Clean the mating surfaces on the engine block and the oil pump with methylated spirits and gasket scraper 885 516. Pieces of old sealant must be completely removed to allow good resealing. Apply a thin layer of sealant (red), part number 1161 059, to the oil pump sealing surface (1). Use roller 885 511. Torque tighten the bolts to 25 Nm. 30 Apply sealant (brown), part number 1161 370 to the pipes for the crankcase ventilation drain (1) and the oil extractor (2). Knock in them with a plastic mallet and an M8 bolt. Make sure the pipes go free of the oil pump. Bend them carefully as necessary. 31 dismantled). Fit the oil sump side plates (if they have been IMPORTANT! Clean the mating surfaces on the oil sump and the side plates with methylated spirits and gasket scraper 885 516. Pieces of old sealant must be completely removed to allow good resealing. Apply a 2.1 mm thick bead of sealant partnumber 888 661 (black) as illustrated. IMPORTANT! As the sealant starts to harden immediately on contact with air moisture, the parts should be assembled immediately after application (<3 min). Fit locating pins 885 686. Put in place the side plate. Take great care not to damage the sealant bead when fitting. Fit two of the bolts, undo the locating pins and fit the remaining two bolts. Tighten the bolts to 10 Nm. NB! Excess sealant must not be wiped off. Wiping it off can cause leaks. 33 as necessary. IMPORTANT! Clean the mating surfaces on the oil sump and the cylinder block with methylated spirits and gasket scraper 885 516. Pieces of old sealant must be completely removed to allow good resealing.Check that the sealing surface is flat by placing the oil sump on a flat surface and align Apply a 2.6 mm thick bead of sealant (black), part number 888 661, as illustrated. IMPORTANT! As the sealant starts to harden immediately on contact with air moisture, the parts should be assembled immediately after application (<3 min). 34 Fit the locating pins 885 519 (2 off) into the cylinder block. Carefully place the oil sump over the locating pins without damaging the sealant bead. Fit the bolts and angle irons to the cable harness as illustrated. Top picture shows D4, lower D6. Remove the locating pins and screw in the remaining two bolts. Torque tighten the bolts to 25 Nm. NB! Excess sealant must not be wiped off. Wiping it off can cause leaks. 36 Turn over the engine. Make sure the locating pin (1) is fitted and put on a new cylinder head gasket (2). Lower down the timing chain and angle the chain guide (3) towards starboard so that they do not get in the way when the cylinder head is lifted in place. Use a suitable lifting device to lift the cylinder head in place. 37 Fit the cylinder head bolts. Oil the threads lightly. NB! Use new bolts IMPORTANT! Grease the bottom of the cylinder head bolt heads with grease, part number. 3588347. 38 Torque tighten the bolts in five stages according to the adjacent tightening diagram: Stage 1: 30 Nm Stage 2: 80 Nm Stage 3: 150 Nm Stage 4: 180° (angle tightening) Stage 5: 90° (angle tightening) 39 Use power socket 885 509 to tighten with. To facilitate angle tightening, torque multiplier 885 633 together with counterhold 885 648. Place the counterhold in the front or rear lifting eye depending on which bolt is being tightened. Lubricate the camshafts (lobes, bearings and axial bearing seat) with assembly compound , part number 3588346. Fit drift 885 506 onto the inlet camshaft (marked ”IN”) and carefully lower the camshaft into its position. Move over the tool and fit the exhaust camshaft (marked ”OUT”). The camshafts for intake and exhaust are different. The exhaust camshaft is located on the starboard side of the engine. This differs in that it has room for the tooth wheel, etc. Leave the tool in place on the exhaust camshaft as it will be needed later. 41 Fit the camshaft axial bearings (1). Torque tighten the bolts to 25 Nm (18.44 lbf ft). 42 Fit the lock pin 885 493 (2 off). Turn the camshafts so the are locked in ”zero position”. Place locating pin 885 494 into the valve cover so that the tooth wheel can be fitted in the correct position. Heat the tooth wheel to 140°C (284°F). Turn the side marked ”OUT” out (up) and align the tooth wheel so that it engages on the locating pin. 44 Use the remaining part of the tool 885 506 to press on the tooth wheel. NB! Do not forget to remove the locating pin 885 494 after assembly. IMPORTANT! Clean the mating surfaces on the cylinder head and the valve cover with methylated spirits and gasket scraper 885 516. Pieces of old sealant must be completely removed to allow good resealing.Apply a thin layer of sealant (red), part number 1161 059, to the valve cover as illustrated. Use roller 885 511. 45 Take the valve calipers (1) and the finger followers (2) out of the oil bath and leave them to drip dry. Put them in place in the cylinder head. 47 IMPORTANT! Make sure the crankshaft and camshaft lock pins are fitted and engaged. Screw in locating pins 885 519 (2 pcs) into the cylinder head to facilitate assembly. IMPORTANT! Make sure all the rocker arms (1) are in their correct positions. Lower the valve cover carefully over the locating pins while keeping an eye on the rocker arms. Keep fingers away from the sealant. Tighten the bolts evenly until the valve cover is tight against the cylinder head. Undo the locating pins and screw in the two remaining bolts. Torque tighten the bolts immediately in two stages according to the adjacent tightening diagram. Tightening torque: Stage 1 15 Nm Stage 2 25 Nm Retrieve the timing chain with a steel wire. Inspect the starboard chain guide (1) and change if necessary. Mount the chain guide on its lower attaching point (2). Fit a new gasket (3) (steel/rubber washer) onto the bolt (4). Torque tighten the upper chain guide attachment to 25 Nm (18.44 lbf ft) 49 Place the timing chain onto the camshaft gears and screw in the bolts with washers. The bolts are left-hand thread. IMPORTANT! Screw in the bolts by hand until only a slight play can be felt between the camshaft gears and the camshafts. Final tightening is done later. 1 2 50 Pull away the chain tensioner (1) from the housing (2) with a pair of pliers. Put a protecting cloth round the chain tensioner. Drain the oil from the chain tensioner by pressing the plungers together, simultaneously as the non-return valve (1) is held open with a small drift. Press until the inner plunger is completely in. 1 2 2 1 52 Fit a new O-ring (1) in the housing and push in the chain tensioner in the housing. 53 Fit the chain tensioner housing assembly. Use new O-rings (2). Torque tighten the bolts to 25 Nm. 54 Activate the chain tensioner by pressing out the chain/chain tensioner with a suitable copper drift as illustrated. After the chain is released, the inner plunger in the chain tensioner will spring out again with a ”clicking” sound and the chain will be tensioned. Fit tool 885 650 onto the exhaust camshaft gear. Stretch the chain by hand and tighten the centre bolt. Tightening torque 95 Nm. 56 Transfer the tool 885 560 to the intake camshaft gear. Stretch the chain by hand and tighten the centre bolt. Tightening torque 95 Nm. 57 Fit the upper chain guide (1). Tightening torque 25 Nm. Fit the lower studs (1) to the camshaft gear cover. Apply sealant (brown), part number 1161 370, to the thread. 59 illustrated. IMPORTANT! Clean the mating surfaces on the valve cover and the camshaft gear cover with methylated spirits and gasket scraper 885 516. Pieces of old sealant must be completely removed to allow good resealing. Apply a 1.6 mm thick bead of sealant part number 888 661 (black) to the valve cover as IMPORTANT! As the sealant starts to harden immediately on contact with air moisture, the parts should be assembled immediately after application (<3 min). 60 Put on the camshaft gear cover. Take great care not to damage the sealant bead when fitting. Tighten the bolts to 25 Nm. NB! Excess sealant must not be wiped off. Wiping it off can cause leaks. 61 (Applies only in cases where the crankcase ventilation cover has been removed ). IMPORTANT! Clean the mating surfaces on the valve cover and the crankcase ventilation cover with methylated spirits and gasket scraper 885 516. Pieces of old sealant must be completely removed to allow good resealing. Apply a 1.8 mm thick bead of sealant part number 888 661 (black) to the cover as illustrated. IMPORTANT! As the sealant starts to harden immediately on contact with air moisture, the parts should be assembled immediately after application (<3 min). 62 Screw in guide pins 885 686.Put on the crankcase ventilation cover. Take great care not to damage the silicone bead when fitting. Screw in the bolts, undo the locating pins and fit the remaining bolts. Tighten the bolts immediately to 10 Nm. NB! Excess sealant must not be wiped off. Wiping it off can cause leaks. 63 IMPORTANT! Clean the mating surfaces on the cylinder head and the intake manifold with methylated spirits and gasket scraper 885 516. Pieces of old sealant must be completely removed to allow good resealing. Apply a thin layer of sealant (red), part number 1161 059, to the intake manifold as illustrated. Use roller 885 511. Screw in locating pins 885 519 (2 off) into the cylinder block to facilitate assembly. Fit the intake manifold. Take care not to scrape off the sealant when fitting. 65 Fit the bracket for the return fuel cooler (1) and the port bracket (2) for the upper cover. Tighten the bolts, remove the locating pins and fit the remaining two bolts. Torque tighten the bolts to 25 Nm. NB! Do not forget the short bolts inside the intake manifold by the intercooler attachment flange and the bolt under the attaching lugs for the fuel filter bracket. IMPORTANT! Torque tightening must be done immediately after assembly. 66 Fit a new O-ring (1) onto the charge pressure/charge air temperature sensor (2) and fit it onto the intake manifold. Torque tighten the bolt to 10 Nm. Fit a new O-ring (1) and the oil pressure/oil temperature sensor (2). Tightening torque 30 Nm. 68 Fit the piston cooling valve (1), spring (2) and plug (3). Apply sealant (brown), part number 1161 370, to the plug thread. 69 (D4 only) Fit the elbow nipple and hose to the coolant drain on the cylinder block. Apply sealant (brown), part number 1161 370, to the nipple thread. Place the hose clamp as illustrated. Fit the drain cock to the cylinder block. Apply sealant (brown), part number 1161 370, to the drain cock thread. 71 Fit new O-rings for the heat exchanger/oil cooler water and oil passages. NB! The ”FRONT” mark on the elbow up to the cylinder head must be facing forward. 72 Suspend the heat exchanger/oil cooler from the lower studs (1) and fit the remaining bolts. Top picture shows D4, lower D6. Torque tighten nuts and bolts to 25 Nm. NB! Cover the connection to the oil filter to prevent dirt from entering. Fit the starter motor. Use a 14 mm sleeve and long extension bar. Torque tighten the bolts to 50 Nm. 74 Fit the port engine mounting bracket. Tightening torque: (1) M10: 50 Nm (2) M12: 80 Nm 75 Fit the sea water pump. NB! Bolt M8 x 40. Torque tighten the bolts to 25 Nm. Fit the circulation pump. Use a new gasket. NB! The gasket must be fitted dry. Fit a hexagon socket bolt (1) as illustrated. Torque tighten the bolts to 25 Nm. 77 Fit the oscillation damper (1) and crankshaft belt pulley (2). Tighten the bolts (3) in two stages. NB! New bolts must be used. Tightening torque: Stage 1 100 Nm Stage 2 45° (angle tightening) Use lock pin 885 504 as a counterhold. 78 Fit the studs to the exhaust manifold as illustrated if they have been removed. (Top picture shows D4, lower D6). Fit the exhaust manifold. Use new gaskets. Fit (and tighten) only the nuts/bolts illustrated at this time. Tightening torque 25 Nm. (Top picture shows D4, lower D6). 80 Fit the sealing ring in the thermostat housing. Turn the steel edge up and press in the sealing ring with drift 884 168. 81 Press down the thermostat (1) into the housing (2) and fit a new O-ring (3). Fit a new O-ring (4) in the exhaust manifold. Fit the unit onto the exhaust manifold. Torque tighten the bolts to 25 Nm. Fit the plug (5). Apply sealant (brown), part number 1161 370, to the thread. Fit the turbocharger. Put in place the new gasket. Turn the raised edge (1) around the exhaust manifold towards the turbocharger. Do not remove the tape from the gasket. NB! Use no sealant as this can cause leaks. Torque tighten the nuts (stainless) to 50 Nm. 83 Fit the oil feed hose to the turbocharger. Fit a new O-ring (1) to the nipple against the cylinder block. Use socket 885 500 to tighten the nipple to the cylinder block. Tightening torque 25 Nm. Torque tighten the bolts for the connection to the turbocharger to 25 Nm. 84 Connect the oil return pipe (1) from the turbocharger. Tighten the hose clamps. Torque tighten the bolts to the turbocharger to 25 Nm. Make sure the lock pins for the flywheel and camshafts have engaged. Place a new O-ring (1) on the spacer flange. Turn the gear so that the mark agrees with the spacer flange mark. Fit the high pressure pump/spacer flange onto the engine. Torque tighten the bolts to 25 Nm. 86 Remove the lock pins for the camshafts and the flywheel. Turn the crankshaft two revolutions (clockwise, seen from front). Check that all lock pins still can be fitted. Fit the plugs (1). Use new copper washers (2). 87 Fit the rail. Torque tighten the bolts (M8 x 40) to 25 Nm. Fit a new O-ring (1). Lubricate the injector with assembly compound, part number 3588346. Fit the caliper (2). Lower the injector (3). Fit bolt (4) (strength class 10.9) and spacer (5). NB! The bevelled side of the spacer is turned towards the caliper. Tightening torque: M8 bolt 30 Nm M9 bolt 40 Nm NB! Retightening must be done immediately by undoing the bolt and retightening it to 30 or 40 Nm. 89 Fit the delivery pipe between the rails and the injectors. Tighten the cap nuts by hand. Check that clamps (1 and 2) are parallel with the valve cover and adjust as necessary. Use socket 885 490 and a torque wrench to torque tighten the cap nuts. Tightening torque: (new pipe) 20 Nm (refitted or used pipe) 24 Nm NB! If a single delivery pipe is being changed, the clamp must be returned to its original position. D4 has double clamps (1) on the front pair of delivery pipes. 90 Fit the delivery pipe (1) between the high pressure pump and the rail. Use socket 885 490 and a torque wrench to torque tighten the cap nuts. Tightening torque: (new pipe) 20 Nm (refitted or used pipe) 24 Nm Do not forget to screw on the clamp (2). Torque tighten the clamp bolt to 10 Nm. Fit the return fuel block (1). Torque tighten the bolt to 25 Nm. 92 Fit new O-rings to the nipples on the return fuel line (1). Moisten the O-rings with diesel oil and fit the return fuel line. 93 Fit the air elbow pipe onto the turbocharger housing. Use a new O-ring (1) and torque tighten the bolts to 25 Nm. 94 IMPORTANT! Clean the mating surfaces on the intercooler and the connecting pipe with methylated spirits and gasket scraper 885 516. Pieces of old sealant must be completely removed to allow good resealing. Apply a 1.7 mm thick bead of sealant (black) part number 888 661 to the intercooler as illustrated. IMPORTANT! As the sealant starts to harden immediately on contact with air moisture, the parts should be assembled immediately after application (<3 min). 95 Fit the connecting pipe (1) and the bracket (2). Take great care not to damage the sealant bead when fitting. Torque tighten nuts and bolts immediately to 25 Nm. 96 IMPORTANT! Clean the mating surfaces on the intercooler and the intake manifold with methylated spirits and gasket scraper 885 516. Pieces of old sealant must be completely removed to allow good resealing. Apply a 1.7 mm thick bead of sealant (black) part number 888 661 to the intercooler as illustrated. IMPORTANT! As the sealant starts to harden immediately on contact with air moisture, the parts should be assembled immediately after application (<3 min). Fit the hose couplings (1) and (2) and hose clamps to the heat exchanger and turbocharger housing and lift in place the intercooler. Take great care not to damage the sealant bead when fitting. Torque tighten all bolts immediately. Tightening torque 25 Nm. Tighten the hose clamps. 98 (AQ engines only) Fit the bracket (1) to the sea water filter. Torque tighten the bolts to 25 Nm. 99 Fit the return fuel cooler with associated water hose to the sea water pump/sea water filter and heat exchanger. Turn the return fuel cooler so that the fuel connections are pointing straight up. Do not tighten the clamp (1) for the mounting bracket at this stage so that it is possible to mount the wiring for the charge pressure/charge air temperature sensor later. Fit the return fuel hoses (1) and (2) from the return fuel cooler to the rail and on to the return fuel block. Torque tighten the pressure retaining valve (3) to 30 Nm. 101 Fit the fuel filter bracket (1) and the bracket (2) for the oil dipstick. Torque tighten the bolts to 25 Nm. 102 Fit the return fuel hose (1) between the return fuel cooler’s front connection and the high pressure pump and the engine’s return fuel connection (2). Fit the fuel hose (1) between the fuel filter and the high pressure pump. Enter the hose inside the return fuel cooler. see illustration. Fit the clamp (2). 104 Lift down the enigne from the stand and remove the engine fixture. Fit the starboard engine mounting bracket. Tightening torque: (1) M10: 50 Nm (2) M12: 80 Nm Place the engine on a suitable engine rack. 105 Fit the control unit mounting bracket (1). Torque tighten the bolts to 50 Nm. Fit the control unit. Inspect and change the rubber cushions as necessary. 2 1 3 107 Mount the alternator on its lower attaching point. Make sure the insulating sleeves (1) are intact. Fasten the upper bracket (2) to the alternator. Do not forget the insulating washer (3). The alternator must be mounted so that it is insulated from the cylinder block. 108 Fit the circulation pump belt pulley. Turn the belt pulley so ”OUT” can be seen. Use a suitable screwdriver as a counterhold. Torque tighten the bolts to 25 Nm. 109(D4 only) Fit the multi V-belt idler gear (1). Torque tighten the centre bolt to 25 Nm. 110 (D4 only) Mount the multi V-belt while fitting the belt tension pulley (1). Screw in the tension pulley bolts fully but do not tighten. 111 (D6 only) Fit the two multi V-belt idler gears (1). Torque tighten the centre bolts to 25 Nm. Mount the multi V-belt while fitting the belt tension pulley (1). Screw in the tension pulley bolts fully but do not tighten. 113 Tension the belt by applying a torque of 70 Nm on the tensioning roller square fitting. Secure the tension pulley with the bolts (1) and (2). Torque tighten the bolts to 50 Nm. Undo the bolts (1) and (2) when warm and repeat the belt tensioning procedure. 114 Fit the cable harness. Start by fitting the starboard bracket (1) to the upper cover and clamp (2). Torque tighten the nuts/bolts to 25 Nm. Plug in the connector (3) to the temperature sensor. Plug in the connector (4) on the control unit. Press in the connector while raising the lock brace. Tighten the clamps (5) and (6). Fit the camshaft position sensor (1). Use a new O-ring. Torque tighten the bolt to 10 Nm (7.38 lbf ft). Plug in the connector if it has been unplugged. 116 Fit the cable harness (1) for the injectors. Plug in the connectors (2) and (3) on the control unit. Press in the connector while raising the lock brace. Tighten the clamp (4). 117 Plug in the connectors to the injectors (1). NB! Check the marking on the injector connectors. ”Cyl 1” is connected at the front. Tighten the clamps (2) and (3) to the valve cover. Plug in the connectors to the rail pressure sensor (1) and the fuel temperature sensor (2). 1 4 3 2 119 Connect the alternator cables. (1) red 16 mm2 (2) black 16 mm2 (3) red-blue 1.0 mm2 (4) yellow 0.75 mm2 120 Inser the cable harness under the starboard engine mounting and fit the clamps to the cable irons fitted earlier. Inser the cables for the port side components under the engine, between the oil sump and the flywheel housing. Fit the bracket (1) for the flywheel timing sensor cable. Torque tighten the bolt to 80 Nm. 122 Fit the flywheel timing sensor (1) to the flywheel housing with a new O-ring. Torque tighten the bolt to 10 Nm. 123 Fit clamps (1, 2 and 3) on the port side to the cable irons fitted earlier. Connect the starter motor cable terminals. (1) red 16 mm2 (2) red 2.5 mm2 (3) black 16 mm2 (4) black 2.5 mm2 (5) red-yellow 1.5 mm2 (6) yellow 0.75 mm2 125 Plug in the connector (1) to the high pressure pump. 126 Fit the intercooler support bracket (1). Tighten all bolts by hand until the bracket is resting against the intercooler and the flywheel housing before final tightening. Tightening torque 25 Nm. Fit the DC/DC unit (1). Torque tighten the bolts to 10 Nm. Plug in the connector (2) 128 Plug in the connector to the oil pressure/oil temperature sensor. 129 Insert the cable (1) for the charge pressure/charge air temperature sensor under/behind the return fuel cooler and plug in the connector to the sensor (not illustrated). Tighten the return fuel cooler’s front hose clamp (2). Make sure the hose clamp grips the cooler bracket (3) securely. Fit the oil filter, bypass oil filter and fuel filter. Moisten the rubber gaskets (fuel filter 2 off) with oil. Screw on the filters by hand until they make contact with the sealing surface. Then screw a further 3/4 turn, but no more. 131 Fit the monitor (1) for water in the fuel filter. Screw in the monitor until the gasket makes contact with the filter and then a further 1/4 to 1/2 turn. Plug in the connector (2) to the monitor. 132 Fit the bracket (1) and crankcase ventilation filter (2). Torque tighten the bolts to 25 Nm. Fit the hose (3) between the filter and the inner connection in the cylinder block. Fit the hose (4) on the outer connection (hose for changing oil). Clamp it to the bracket (1) with a cable tie. Fit the rubber bend (1), air filter housing (2) and the bracket (3) to the oil dipstick tube (at starboard placed oil dipstick). Torque tighten the bolts to 25 Nm. 134 Fit the hose (1) between the crankcase ventilation filter and the crankcase ventilation cover. Make sure the rubber grommet (2) is intact. Fit the hose (3) between the air filter housing and the crankcase ventilation filter. Fit the hose (4) between the crankcase ventilation cover and the camshaft gear cover. 135 Fit the expansion tank (1). Plug in the connector (2) to the coolant level sensor. Fit the air vent hose (3) from the exhaust pipe. Fit the air vent hose (1) from the turbocharger. Fit clamp (2) and clamp (3). Clamp (3) must only be fitted on D6. NB! Make sure the hose is run as illustrated. Incorrect hose locations can cause an air lock. 137 Fit the turbocharger support bracket (1). Torque tighten the bolts to 50 Nm. Fit the exhaust bend (2). 138 Fit the oil dipstick tube and the oil dipstick. Use new O-rings. If needed the dipstick can be mounted on the engines starboard side. Fit the rear engine cover (1). Tighten the bolts by hand. Fit the rubber dampers (2) and (3). 140 Fit the upper engine cover. Torque tighten the bolts to 10 Nm. Adjust the rear cover and torque tighten the bolts to 25 Nm. Tightening torques General tightening torgue values Nm Angel tightening M6 standard bolt 8.8 ......................................................... 10 – M8 standard bolt 8.8 ......................................................... 25 – M10 standard bolt 8.8 ....................................................... 50 – M12 standard bolt 8.8 ....................................................... 85 – M14 standard bolt 8.8 ....................................................... 140 – Note! Only torqued bolts can be re-installed Torqued and angle tightened/plastic limit tightened should not be re-installed. Special tightening torques Idler gear journal ............................................................... 25 – Main bearing bolts Stage 1 .......................................................................... 130 – Stage 2 .......................................................................... – 180° Flywheel housing M8 ................................................................................. 25 – M14 ............................................................................... 135 – Flywheel Stage 1 .......................................................................... 100 – Stage 2 .......................................................................... – 45° Big end bearing bolts Stage 1 .......................................................................... 65 – Stage 2 .......................................................................... – 90° Balance shaft housing assembly D4................................. Please refer to ”Tightening schedules” Ladderframe D6 25 – Oil pump ........................................................................... 25 – Oil sump ........................................................................... 25 – Cylinder head .................................................................... Please refer to ”Tightening schedules” Valve cover ...................................................................... Please refer to ”Tightening schedules” Camshaft gear .................................................................. 95 (left hand thread) Intake manifold ................................................................. 25 – Exhaust manifold .............................................................. 25 – Polygone hub, center bolt Stage 1 .......................................................................... 100 – Stage 2 .......................................................................... – 45° Vibration damper, fixing bolts Stage 1 .......................................................................... 100 – Stage 2 .......................................................................... – 45° Turbocharger, exhaust pipe flange .................................... 45 – Oil pressure pipe turbocharger, nippel against cylinderblock .............................................. 25 – Gear wheel, high pressure pump....................................... 105 – Caliper, injector M8 bolt Stage 1 .......................................................................... 30 – Stage 2 .......................................................................... 30 – M9 bolt Stage 1 .......................................................................... 40 – Stage 2 .......................................................................... 40 – Note. Undo the bolt for the caliper before doing the second stage. Delivery pipe (high pressuse pipe), fuel new ................................................................................ 20 – re-installed ..................................................................... 24 – Tightening schedules Cylinder head D4/D6 Nm Angle tightening Stage 1 ............................................................................. 30 – Stage 2 ............................................................................. 80 – Stage 3 ............................................................................. 150 – Stage 4 ............................................................................. – 180° Stage 5 ............................................................................. – 90° Valve cover D4/D6 Nm Angle tightening Stage 1 ............................................................................. 15 – Stage 2 ............................................................................. 25 – Balance shaft housing assembly D4 Nm Angle tightening Tightening torque .............................................................. 25 – 7742906 English 11-2003