Cylinder Liners and Pistons, Replace

Volvo Trucks North
Service Bulletin
America
Greensboro, NC USA
Trucks
Date Group No. Release Page
This service bulletin replaces bulletin 200-322 dated 1.2017 200 322 12 1(47)
5.2016.
Specifications
D11
Specifications
Contents:
• “General”, page 2
• “Engine”, page 4
• “Valve Mechanism”, page 8
• “Engine Timing Gears”, page 11
• “Lubricating and Oil System”, page 12
• “Fuel System”, page 14
• “Inlet and Exhaust System”, page 15
• “Cooling System”, page 17
• “Engine Control System”, page 19
• “Tightening Torques and Patterns”, page 20
• “Engine Lubricants and Sealants”, page 47
Note: Illustrations are used for several different variants. Some details may therefore differ
from the variant you are working on. The essential information in the illustrations is,
however, always correct.
PV776-89278271
USA138177701 English
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 1.2017 200 322 12 2(47)
General
Weights and Dimensions
Engine type In-line direct injection diesel

Number of cylinders 6
Displacement 11L
Compression ratio 16.0:1
Cylinder bore and stroke 123 x 152 mm (4.84 x 5.98 inches)
Emissions level US07: 2.5g NOx; 0.1g Pt maximum
US2010 and US2014: 0.2 g/hp-hr NOx maximum
Fuel system Dual solenoid electronic injector
Valve actuation Single overhead camshaft, four valves per cylinder
Aspiration Variable geometry turbocharger with sliding nozzle ring
Cylinder and piston type Wet Sleeve; one-piece steel piston
Electronic control Volvo VECTRO electronic management system
Emission controls US07: Cooled EGR; Diesel Particulate Filter (DPF)
US2010 and US2014: Cooled EGR; Diesel Particulate Filter
(DPF); Selective Catalytic Reduction (SCR)
Governed rpm 2100 rpm
Power ratings 325–405 hp
Torque ratings 1695-1966 Nm (1250–1450 lb-ft)
Weight (dry) Approximately 1,034 kg (2280 lbs.)

Firing order 1-5-3-6-2-4
Fasteners and threads Metric
Flywheel housing (standard) Aluminum
Total length 1364 mm (53.7 inches)
Total width 810 mm (31.9 inches)
Total height 1113 mm (43.8 inches)
Component Features and Materials
Item Description
Air compressor Flange mounted, oil lubricated, water cooled
Camshaft Induction hardened, gear driven:
US2007-US2016: Solid camshaft, machined from solid bar
stock;
US2017: Assembled camshaft, lobes pressfit and mechani-
cally locked onto hollow tube
Coolant conditioner Spin-on type, disposable
Connecting rods Forged steel, cracked cap design
Crankshaft Drop forged steel, induction hardened, seven main bearings
Item Description
Cylinder block In-line six cylinder, nodular iron, machined with bearing caps,
stiffener plate, timing gear mounting plate, guide dowels for
cylinder head; wet replaceable cylinder sleeves
Cylinder head One-piece cast iron alloy; overhead camshaft, four valves
per cylinder, injectors; cast iron valve guides and oil seals;
seat materials are iron based alloy for exhaust seats and co-
balt based alloy inlet seats; valve alignment 12 degrees from
perpendicular; copper or stainless steel injector sleeves; in-
tegral fuel passages and thermostat housing; guide slots for
installation on block
Valve cover 16 spring tension screws
Cylinder liner Wet Sleeve; replaceable; with EDPM rubber and Viton seals
Cylinder head — Valve springs Single springs on inlet and double springs on exhaust
Cylinder head — Valve guides Cast iron, replaceable; with oil seals
Cylinder head gasket One-piece steel stamping; elastomer seals added; one-time
bosses to aid in head installation
Cylinder head bolts M16 (26)
Timing gear cover (rear of cylinder head) Die-cast aluminum, elastomer seals
Flywheel housing Die-cast aluminum
Fuel filters One 30-micron primary, one 5–micron secondary
Fuel injection Six individually programmed injectors: EMS module con-
trolled; common fuel gallery in head; constant supply pres-
sure; over-pressure return
Fuel supply pump Gear type pump integral with power steering pump; idler gear
driven
Lubrication system Crankshaft gear driven oil pump; system integrated with
block and head; serves camshaft, rocker arm shaft, pistons,
crankshaft, air compressor, turbocharger, EGR valve; three
filters, two full flow, one bypass; oil level and temperature
sensor in oil pan; distribution crossover housing at bottom of
block; holds pump pressure tube, strainer and pressure relief
valve
Main bearing caps Nodular iron; machined with block; No. 7 mounts oil pump;
numbered for reassembly; sleeve guides for screws; thrust
washers at No. 4 main bearing journal
Exhaust manifold Three-piece, six port
Pistons One-piece steel; three ring grooves
Piston rings — Compression Two: one trapezoidal cross section, one rectangular cross
section
Piston rings — Oil One: garter spring type; scraping
Oil filters Two 40-micron full flow, one 5-micron bypass;
Filter capacity, two full flow:
• 4.0–4.5 liters (4.2–4.8 quarts)

Oil pan Steel; 18 spring tension screws
Sump capacity:
Item Description
• 25 liters (26.4 quarts) minimum
• 30 liters (31.7 quarts) maximum

Thermostat Sleeve type: 82°C (180°F)
Thermostat housing Integrated in cylinder head
Turbocharger Variable geometry type: exhaust driven; fixed vanes; sliding
ring nozzle; infinitely variable volume; oil and water cooled
Valve lifters Roller followers
Valve seat inserts Pressed in head; replaceable
Vibration damper Internal fluid-filled ring
Coolant pump Centrifugal rotor impeller; belt driven
Engine
Fits and Limits
Camshaft
Journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.97–70.00 mm (2.7547–2.7559 inches)
Inlet valve lobe nominal lift . . . . . . . . . . . . . . . . . . . . . . US2007: 13.1 mm (0.516 inch); US2010-US2017: 12.9 mm (0.51 inch)
Exhaust valve lobe nominal lift (with engine brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 mm (0.53 inch)
Camshaft end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.24 mm (0.0094 inch) maximum
Connecting Rod
Connecting rod journal-to-bearing clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.102 mm (0.004 inch) maximum
Side clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 inch) maximum
Length between centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 mm (8.8583 inches)
Twist within 100 mm (3.937 inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 inch) maximum
Bend within 100 mm (3.937 inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.0024 inch) maximum
Crankshaft
End play (lubricated parts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 inch)
Crankpin journal OD (inspection only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 mm (3.4646 inches)
Main journal OD (inspection only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 mm (4.2520 inches)
Journal out-of-round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 mm (0.0004 inch) maximum
Journal taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 inch) maximum
Runout at No. 4 journal (crankshaft supported at No. 1 and No. 7 journals) . . . . . . . . . . . . . . 0.15 mm (0.0059 inch) maximum
Main journal-to-bearing clearance (lubricated parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11 mm (0.0043 inch) maximum
Wear Value:
Crankshaft axial clearance 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070-0.320 mm (0.0028-0.0126 inch)
1 The measurements refer to lubricated components.

Cylinder Block
Deck flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm (0.0157 inch) maximum
Main bearing bore in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 mm (4.449 inches)
Cylinder sleeve height (sealing surface above block deck) . . . . . . . . . . . . . . . . . . . . . . . . 0.14–0.21 mm (0.0055–0.0083 inch)
Cylinder Head
well as the ability to correctly adjust timing gear backlash.
CAUTION Do not grind injector sleeves.
Do not machine the cylinder head. Machining changes

the extension of the injector and upsets injector timing as
Overall height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm (5.315 inches)

Valve guide height above spring face (inlet). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 ± 0.5 mm (0.965 ± 0.020 inch)
Valve guide height above spring face (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5 ± 0.5 mm (0.650 ± 0.020 inch)
Valve seat insert face angle (inlet/exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 degrees
Cylinder head valve seat insert counterbore diameter (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.654 inches)
Cylinder head valve seat insert counterbore diameter (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.575 inches)
Valve seat insert diameter (inlet, press fit in head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.654 inches)
Valve seat insert diameter (exhaust, press fit in head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.575 inches)
Valve seat height (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 mm (0.2874 inch)
Valve seat height (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 mm (0.252 inch)
Cylinder head valve seat counterbore depth inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 mm (0.4528 inch)
Cylinder head valve seat counterbore depth exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 mm (0.3898 inch)
Cylinder Head Bolt

Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Thread size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16
Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 mm (7.874 inches)
Cylinder Liner
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet, replaceable
Total height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249.55 mm (9.825 inches)
Cylinder liner protrusion (sealing surface above block deck) . . . . . . . . . . . . . . . . . . . . . . . 0.14–0.21 mm (0.0055–0.0083 inch)
Sealing rings per cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three: two lower, one upper
Piston
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pendulum rod
Number of ring grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Three
Front marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Arrow pointing forward
Piston (wrist) pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 mm (2.126 inches)
Piston above cylinder deck (at TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15–0.65 mm (0.0059–0.0256 inch)
Piston Rings
T2019958
Compression Rings
Upper ring end gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40–0.55 mm (0.0157–0.0217 inch)
Upper ring end gap — Wear tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 mm (0.0138–0.0354 inch) maximum
Lower ring end gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0–1.2 mm (0.0394–0.0472 inch)
Lower ring end gap — Wear tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 mm (0.0512 inch) maximum
Ring groove clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Upper: 0.07 mm (0.0027 inch)
Lower: 0.09–0.13 mm (0.0035–0.0051 inch)
Oil Ring
Oil ring end gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35–0.75 mm (0.0138–0.0295 inch)
Oil ring end gap — Wear tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.0394 inch) maximum
Ring groove clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05–0.10 mm (0.002–0.0039 inch)
Valve Mechanism
Valves
T2023980
A. Valve Face-to-Deck
Valve face-to-deck (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 1 mm (0.043 inch) minimum
Valve face-to-deck (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.95 mm (0.077 inch) maximum
Valve face-to-deck (exhaust). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm (0.016 inch) minimum
Valve face-to-deck (exhaust). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 mm (0.049 inch) maximum
Valve stem diameter (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.961-7.975 mm (0.3134-0.3140 inch)
Valve stem diameter (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.948-7.962 mm (0.3129-0.3135 inch)
Note: Do not grind or resurface valves. Grinding valves can

cause valve failure due to removal of hard facing.
Note: Grinding or resurfacing valve seats is not

recommended.
Valve Adjustment
Inlet valve adjustment, cold engine (at scheduled intervals). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 inch)
Inlet valve adjustment, cold engine (acceptable range for interim checks) . . . . . . . . . . . . . . 0.15–0.25 mm (0.006–0.010 inch)
Exhaust valve adjustment (without engine brake), cold engine (at scheduled intervals) . . . . . . . . . . . . . . . 0.8 mm (0.032 inch)
Exhaust valve adjustment (without engine brake),
cold engine (acceptable range for interim checks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75–0.85 mm (0.030–0.033 inch)
Exhaust valve adjustment (with engine brake), cold engine (at scheduled intervals) . . . 2.0 mm (0.079 inch); EURO 3,4,5: 1.6
mm (0.063 inch)
Exhaust valve adjustment (with engine brake), cold engine (interim checks) . . . . . . . . . . . . 1.95–2.05 mm (0.077–0.081 inch)
Exhaust valve adjustment (with engine brake), cold engine (interim checks) . . EURO 3,4,5: 1.55-1.65 mm (0.061-0.065 inch)
Valve Seat Inserts
T2014128
A — Insert outer diameter (inlet, press fit in head). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.654 inches)

A — Insert outer diameter (exhaust, press fit in head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.575 inches)
B — Insert height (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 mm (0.2874 inch)
B — Insert height (exhaust). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 mm (0.2913 inch)
Valve seat angle (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 degrees
Valve Seat Insert Counterbore in Cylinder Head
T2012872
C — Insert counterbore diameter (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.654 inches)

C — Insert counterbore diameter (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.575 inches)
D — Insert counterbore depth (inlet). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 mm (0.4528 inch)
D — Insert counterbore depth (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 mm (0.3898 inch)
R — Insert counterbore bottom radius . . . . . . . . . . . . . . . . . . 0.2 mm (0.0079 inch) minimum; 0.8 mm (0.0314 inch) maximum
Valve Guides
Valve guide length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.35 mm (3.281 inches)
Inner diameter (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 + 0.035 / +0.020 mm (0.315 + 0.001 +0.0008 inch)
Inner diameter (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 + 0.035 / +0.020 mm (0.315 + 0.001 +0.0008 inch)
Height above cylinder head spring surface (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 ± 0.5 mm (0.965 ± 0.020 inch)
Height above cylinder head spring surface (exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5 ± 0.5 mm (0.650 ± 0.020 inch)
Valve stem-to-guide clearance (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm (0.0157 inch) maximum
Valve Springs
Outer spring free length (approximate). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.0–74.0 mm (2.87–2.91 inches)
Outer spring length under 590 N (133 lbf) Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 mm (2.28 inches)
Outer spring length under 1150 N (259 lbf) Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 mm (1.77 inches)
Outer spring length (coils solid). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.57 inches)
Inner spring free length (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.0–71.0 mm (2.75–2.80 inches)
Inner spring length under 328 N (74 lbf) Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 mm (2.12 inches)
Inner spring length under 630 N (142 lbf) Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 mm (1.61 inches)
Inner spring length (coils solid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 mm (1.46 inches)
Rocker Arms
Bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.0039 inch) maximum
Rocker arm roller clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.0039 inch) maximum
Engine Timing Gears

Timing Gears
T2019433
Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Number of Teeth

1. Drive gear, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2. Idler gear, outer and inner drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer: 72, Inner: 56
3. Idler gear, adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4. Drive gear, camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5. Idler gear, power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6. Drive gear, power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7. Drive gear, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8. Drive gear, lubricating oil pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9. Engine power take-off (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Idler gear to camshaft gear backlash (adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05–0.17 mm (0.0020–0.0067 inch)
Idler gear axle (diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.097–99.99 mm (3.9358–3.9366 inches)
Idler gear bushing (diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.036–100.05 mm (3.934–3.9389 inches)
Idler gear axle-to-bushing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.0019 inch)
All Idler drive and idler gear, backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05–0.17 mm (0.0020–0.0067 inch)
Lubricating and Oil System

Oil
For oil change volume, specification and maintenance inter-
vals, refer to Service Information, Function Group 175.
Oil Pressure
RPM Minimum Oil Pressure
Idle 140 kPa (20 psi)
1200-1300 275 kPa (40 psi)
2000 or above 325 kPa (47 psi)
Oil Pressure, Rocker Arm Shaft

Engine brake not activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 kPa (14.5 psi)
Engine brake, activated (900-2300 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 kPa (29.0 psi) minimum
Oil Temperature
At operating temperature, engine running (coolant temperature 75-95°C (167-203°F) . . . . . . . . . . . . . . 90-117°C (194-243°F)
Full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to 128°C (262°F)
Lubricating Oil Pump

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear driven
Oil Filter
Full flow filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bypass filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Oil Filter Housing Valves
W2005248
Item Spring Free Length Spring Length Under Load

1. Control valve, oil cooler (bypass) 69 mm (2.717 inches) Load: 13–15 N (2.92–3.37 lbf)
Length: 40 mm (1.575 inches)
2. Safety valve marking, lubrication oil pump
N/A N/A
— violet
3. Reduction valve marking — blue N/A N/A
4. Control valve, piston cooling (balancing) 122 mm (4.803 inches) Load: 95 N (21.36 lbf)
5. Opening valve, piston cooling 122 mm (4.803 inches) Load: 95 N (21.36 lbf)
6. Overflow valve, full flow filter 69 mm (2.717 inches) Load: 13–15 N (2.92–3.37 lbf)
7. Overflow valve, bypass filter 69 mm (2.717 inches) Load: 13–15 N (2.92–3.37 lbf)
Fuel System
Fuel Pump Pressure
600 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 kPa (14.5 psi) minimum
1200 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 kPa (43.5 psi) minimum
Full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 kPa (43.5 psi) minimum
Overflow Valve
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300–550 kPa (43.5–79.8 psi)
Injectors
To adjust the rocker arm pre-tension for injectors:
W2005262
Tighten the rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . obtain zero clearance

Tighten the rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . additional 4 flats (2/3 turn) clockwise
Inlet and Exhaust System

Variable Geometry Turbocharger
Turbine rotor shaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051–0.152 mm (0.002–0.006 inch) maximum
Turbine rotor shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.381–0.533 mm (0.015–0.021 inch) maximum
Inlet Manifold Air Temperature Sensor

Cold engine, engine off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient temperature
Warm engine, engine running with
coolant temperature at 75–95°C (167–203°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40°C (104°F) above ambient temperature
Compression Brake Activation

To Become Activated
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greater than 950 rpm
Vehicle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than 5 km/h (3.0 mph)
Engine oil temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than 55°C (131°F)
Inlet manifold pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 173.7 kPa (25.19 psi)
To Become Deactivated
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 900 rpm
Vehicle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 5 km/h (3.1 mph)
Engine oil temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 55°C (131°F)
Inlet manifold pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greater than 198.7 kPa (28.82 psi)
Compression Brake Switch

Braking Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compression Brake
50%. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On
100%. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On
Cruise mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auto On/Off
Compression Brake, Cruise Mode

To Become Activated
Engine speed (The value must be increased by
300 rpm for the first five activations) . . . . . . . . . . . . . . . . . . . . Greater than 1000 rpm — Oil temperature 55–70°C (131–158°F)
Vehicle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than 8 km/h (5 mph)
Engine oil temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than 55°C (131°F)
Inlet manifold pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 2 bars (29 psi)
To Become Deactivated
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 1000 rpm
Vehicle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 8 km/h (5 mph)
Engine oil temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 55°C (131°F)
Inlet manifold pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greater than 2.5 bars (36 psi)
Exhaust Back Pressure

Exhaust back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 kPa (2.175 psi) maximum
Cooling System
General
Pressure valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi)
Thermostat
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Opening temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F)
Coolant
For cooling system volumes, coolant requirements and
maintenance intervals, refer to Service Information Function
Group 18.
Fan On/Off
Activated System Conditions Fan Engagement
Coolant temperature 100°C (212°F) Activated
Coolant temperature 96°C (205°F) Deactivated
Inlet manifold temperature 85°C (185°F) Activated
Inlet manifold temperature 80°C (176°F) Deactivated
Engine (ECM) temperature Greater than 100°C (212°F) Activated
Engine (ECM) temperature Less than 95°C (203°F) Deactivated
AC system Greater than 20 bar (290 psi) Activated
E-Viscous Fan
Activated System Conditions Fan Engagement
Coolant temperature 96°C (205°F) Variable fan speed activation
ECM temperature Greater than 100°C (212°F) 1200 rpm
Less than 95°C (203°F) Deactivated
Inlet manifold air temperature Greater than 70°C (150°F) 1200 rpm
Greater than half of maximum engine 7 second delay after engine brake
torque activated
AC compressor clutch activated Engine speed greater than 1500 rpm 1200 rpm
Ambient temperature greater than 40°C
(104°F)
Vehicle speed less than 45 km/h (28
mph)
AC compressor clutch activated Engine speed greater than 1200 rpm 1000 rpm
Ambient temperature greater than 30°C
(86°F)
mph)
AC compressor clutch activated Ambient temperature greater than 35°C 1200 rpm
(95°F)
mph)
AC compressor clutch activated Ambient temperature greater than 20°C 600 rpm
(68°F)
mph)
AC compressor clutch activated Refrigerant pressure greater than 20 Full engagement
bar (300 psi)
Engine Control System

Engine ECM
Number of pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 x 62
Sensors
Note: Sensors vary by engine. Use tech tool for component function and sensor values
checks.
Inlet Manifold Pressure Sensor

Check values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 – 1.30 volts at 1001 kPa (14.5 psi)
1 Normal atmospheric pressure at sea level.
Camshaft Sensor
Distance to toothed gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 ± 0.4 mm (0.04 ± 0.02 in)
Flywheel Sensor
Distance to flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 ± 0.5 mm (0.06 ± 0.02 in)
Tightening Torques and Patterns

Engine Component Torque Specifications (Critical Fasteners)
Note: All components are to be clean and free from foreign applied to the torque wrench settings (readings) in order to
material or corrosion. Assemblies are to be made using suit- obtain accurate fastener torque values.
able tools and procedures so that no permanent damage
will occur as a result of the assembly.
Threads, washers under the head of the screw and the
CAUTION
washer face of the nuts should be lubricated with clean en-
Repeated tightening of fasteners and threaded compo-
gine oil unless otherwise specified.
nents reduces their capacity to function adequately. The
The following listed fasteners require the use of a calibrated
following table describes the various items and the limits
manual torque wrench. If an adaptor is required in combina-
of their reusability. Failure to conform to these limits can
tion with a torque wrench, a correction factor must be
result in severe component damage.
Fasteners Examples Reusable Limit Reuse Recommendations

Highly loaded screws (phosphat- Cylinder head 1 time use Apply engine oil on threads and
ing plus oil) Cylinder block under screw head.
Injector clamp Mark bolt head with an
Camshaft bearing housing indentation.
Transmission Dry mounting for new screws
Flywheel (delivered with oil pre-applied
and anti-rust treatment for spare
parts).
If a part is replaced, e.g., cylin-
der head, also replace the
screws.
Highly loaded screws (phosphat- Connecting rods 5 times Apply clean engine oil.
ing plus oil)
Special screws (specific shape) Oil pan and valve cover No limit No limit if no cracks, corrosion or
damage to the flat surfaces.
Stainless steel/bronze studs and Turbocharger Not reusable If turbocharger, exhaust mani-
flange locknuts (Spiralock) Exhaust manifold fold or EGR valve studs or nuts
EGR valve are loosened, they must be
replaced.
Prevailing torque feature screws Piston cooling nozzles Not reusable
(Dri-lock Plastic or Tuflock) Timing gear plate
Standard screws Property class 8.8 Do not reuse Torque and angle tightened or
yield limit tightened bolts.
Standard screws Property class 10.9 No limit No limit if no cracks, corrosion or
Property class 12.9 damage to the flat surfaces.
V-nipple with taper threads With locking fluid pre-applied Not reusable Before fitting the new nipple,
clean the hole with a nipple tap
and apply sealant on the nipple
thread, or use a new coated
nipple.
Taper plugs or nipples With sealer fluid pre-applied Not reusable Before fitting the new nipple,
clean the hole with a nipple tap
and apply sealant on the nipple
thread, or use a new coated
nipple.
Tightening Torques Function Group 20

Standard Bolts, Property Class 8.8
General Tightening Torques

M6 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1 Nm (7 ± 1 ft-lb)
M8 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
M10 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
M12 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
M14 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 25 Nm (103 ± 18 ft-lb)
M16 standard bolt 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 ± 35 Nm (140 ± 26 ft-lb)
Torque/Angle Tightened or Yield Limit Bolts
Note: Only torque-tightened bolts can be reused.

Torque and angle tightened or yield limit tightened bolts:
8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .one time use only, do not reuse
10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reusable
12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . reusable
Note: Check bolts before reusing. Bolts showing damage, for example cut marks on the underside or damage to the flats,
should be discarded.
W2005482
Front engine bracket to engine bracket:

Step 1. Hand start all screws.
Step 2. Tighten one of the screws (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Step 3. Tighten screws (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 ± 45 Nm (203 ± 33 ft-lb)
Step 4. Tighten screws (1, 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 ± 45 Nm (203 ± 33 ft-lb)
Front engine mounting, cushion to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 25 Nm (103 ± 18 ft-lb)
Front engine mounting, cushion to crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
Rear engine mounting, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 ± 45 Nm (221 ± 33 ft-lb)
Rear engine mounting, rear engine pad (M20 Bolts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 ± 90 Nm (398 ± 66 ft-lb)
Rear engine pad, frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 ± 30 Nm (148 ± 22 ft-lb)
Crankshaft main bearing cap:

Step 1. Torque tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 ± 20 Nm (111 ± 15 ft-lb)
Step 2. Angle tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 ± 5 degrees
Connecting rod cap:
Step 1. Torque tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ± 3 Nm (22 ± 2 ft-lb)
Piston cooling nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 3 Nm (18 ± 2 ft-lb)
Note: The nozzle fastener has a patch lock feature that requires this fastener to be replaced when removed.
Engine stiffening frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 ± 5 Nm (48 ± 4 ft-lb)
Note: Tightening sequence — Start at the front and crosshatch rearward.
T2019438
Timing gear plate:

Apply a 2 mm (5/64-inch) bead of sealant to the cylinder block and cylinder head as shown.
Note: Attach the component within 20 minutes of applying the sealant.
T2019466
Timing gear plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ± 4 Nm (21 ± 3 ft-lb)

Note: Tighten the bolts in the order shown.
W2080377
Loosen any bolts used to pull the cylinder head into place.
Tighten the bolts in the order indicated on each timing gear.
(A) Crankshaft gear (2 bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
(B) Intermediate gear hub (6 bolts)
(C) Intermediate adjustable gear hub (5 bolts)
(D) Camshaft gear and damper (6 bolts)
Step 2. Angle tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 5 degrees
W2006046
W2005494
Flywheel housing:
Tighten all M14, M12 and M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Tighten all M14 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 15 Nm (103 ± 11 ft-lb)
Tighten all M12 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
Note: Apply sealant as shown in the top illustration. Tighten the bolts in the order shown.
W2005549
Timing gear cover:

Note: Apply a 2 mm (5/64-inch) bead of sealant to the timing gear cover following the pattern shown.
T2019512
Timing gear cover:

Step 1. Install bolts (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand tighten
Step 2. Align cover flush with points (A) and install bolts (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand tighten
Step 3. Tighten all bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Note: Alignment tool required.
T2019434
Flywheel:
Note: Make sure the crankshaft flange is dry and clean.

Step 2. Angle tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 ± 10 degrees
T2019437
T2020547
Front crankshaft seal cover:

Step 1. Tighten all bolts by hand.
Step 2. Tighten bolts (2) and (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Step 3. Tighten the remaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Note: Apply a 2 mm (5/64-inch) bead of sealant following the pattern shown.
W2005495
Crankshaft vibration damper:

Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ± 4 Nm (30 ± 3 ft-lb)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 10 Nm (66 ± 7 ft-lb)
Note: Tighten the bolts in two steps following the order shown.
The crankshaft vibration damper property class 8.8 bolts are one time use only and should be replaced when removed.
T2019471
Cylinder head sealant:

Note: Apply a 2 mm (5/64-inch) bead of sealant to the rear of the cylinder head following the pattern shown.

W2118356
Cylinder head tightening sequence:

Note: The cylinder head must be installed according to instructions. Refer to Cylinder Head Installation, Function Group 21.
Step 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 ± 5 Nm (74 ± 4 ft-lb)

Step 2. (Angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 ± 5 degrees
Step 3. (Angle tightening) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 5 degrees
Cylinder head plugs:
M10x1.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 4 Nm (15 ± 3 ft-lb)
M10x1.00, coated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 2 Nm (7.5 ± 1.5 ft-lb)
M14x1.5, coated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ± 3 Nm (22 ± 2 ft-lb)
W2005499
W2005500
Bearing cap, camshaft/rocker arm shaft:

Note: Tighten bolts in numbered steps to ensure that the rocker arm shaft is installed without bending or distortion.
Step 1. Tighten bolts 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18 ± 2 ft-lb)

Step 2. Tighten bolts 11, 9 and 13 incrementally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 5 Nm (66 ± 4 ft-lb)
Step 3. Tighten bolts 8, 10, 12 and 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 5 Nm (44 ± 4 ft-lb)
Step 4. Completely loosen bolts 11, 9 and 13
Step 5. Tighten bolts 11, 9 and 13 incrementally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 5 Nm (44 ± 4 ft-lb)
Step 6. Angle tighten bolts 1–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 ± 5 degrees
Step 7. Angle tighten bolts 8–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 ± 5 degrees
Locknut, valve adjustment screw, inlet, exhaust (without engine brake) . . . . . . . . . . . . . . . . . . . . . . . . . 38 ± 4 Nm (28 ± 3 ft-lb)
or, angle tighten after contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 5 degrees
Shim retainer bolt (exhaust bridge), engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ± 4 Nm (28 ± 3 ft-lb)
or, angle tighten after contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ± 15 degrees
Locknut, injector adjustment screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ± 4 Nm (38 ± 3 ft-lb)
Engine brake control valve or rocker shaft oil supply (non engine brake) . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
W2005496
Valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)

Note: If the valve cover is replaced, a new Engine Certification Label must be printed with tech tool and affixed to the new
valve cover.
W2006014
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)

Valve housing (block oil crossover). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Oil cooler, retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ± 5 Nm (26 ± 4 ft-lb)
Note: Use crisscross tightening pattern.
W2006008
Oil cooler cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)

W2006009
Oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 5 Nm (18 ± 4 ft-lb)
Oil plug, longitudinal oil channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ± 5 Nm (36 ± 4 ft-lb)
Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ± 5 Nm (22 ± 4 ft-lb)
W2005572
Oil pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)

Drain plug, oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 5 Nm (44 ± 4 ft-lb)
Note: The hex head plug must not be installed with a copper washer. Use only the appropriate steel washer.
W2005567
Fill tube adapter, oil pan (nut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (60 ft-lb)

Note: Maintain a minimum clearance of 38 mm (1.5 in) from the oil pan to the oil pan fill tube adapter.
W2005568
1 Front Engine Support

2 Engine Support Bolt
3 Oil Pan Fill Tube Adapter
4 Oil Fill Hose
5 Oil Pan
6 Oil Dipstick
Note: The 38 mm (1.5 in) clearance should be maintained to provide room between the front engine support bolt and the oil
fill tube adapter flange of approximately 3 mm (1/8 in).
Oil pan fill adapter screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Oil dipstick attaching screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1 Nm (7.5 ± 0.7 ft-lb)
T2022208
Retainer, injector:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (15 ft-lb)
Step 2 Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 ±5 degrees
Step 3 Loosen until the torque is 10–15 Nm (7–11 ft-lb).
Step 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 ft-lb)
Step 5 Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 ±5 degrees
T2022967
Locknut, injector adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ± 4 Nm (38 ± 3 ft-lb)

Tandem pump (power steering pump) mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)

Note: Torque all mounting nuts to specification twice.
Fuel pump (mounted on power steering pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Nm (6 ft-lb)
Fuel filter housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Fuel filter (pre, main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ± 3 Nm (13 ± 2 ft-lb)
Fuel line fittings:

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ±3 Nm (13 ±2 ft-lb)
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ±4 Nm (20.5 ±3 ft-lb)
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ±4 Nm (22 ±3 ft-lb)
D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ±5 Nm (26 ±4 ft-lb)
E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ±5 Nm (29.5 ±4 ft-lb)
F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ±5 Nm (35 ±4 ft-lb)
W2005926
Aftertreatment hydrocarbon doser, fuel supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ± 0.5 Nm (135 ± 5 in-lb)

W2006010
Inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)

Note: Tighten the inlet manifold bolts in the order shown.
Note: Use a new seal ring when installing the inlet manifold.
Inlet manifold plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ±3 Nm (15 ±2 ft-lb)
Inlet air preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)
Air pressure/temperature sensor, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ±1 Nm (7 ±1 ft-lb)
T2022740
Exhaust manifold:
Step 1: Tighten bolts 1 through 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10 Nm (4 - 7 ft-lb)
Step 2: Tighten bolts 1 through 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ± 4 Nm (30 ± 3 ft-lb)
Step 3: Tighten bolts 1 through 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ± 4 Nm (38 ± 3 ft-lb)
Note: Tighten the exhaust manifold bolts following the numbered sequence.
Exhaust gas recirculation (EGR):

EGR valve mounting bolts:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ±4 Nm (15 ±3 ft-lb)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ±8 Nm (35 ±6 ft-lb)
Note: Tighten the bolts diagonally.
EGR hot pipe clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Nm (50 in-lb)

EGR cooler mounting screws and locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ±2 Nm (9 ±1.5 ft-lb)
EGR cooler draincock mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ±3 Nm (11 ±2 ft-lb)
EGR cooler draincock valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ±0.5 Nm (27 ±4 in-lb)
EGR cold pipe V-clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ±2 Nm (7 ±1 ft-lb)
Mixing chamber inlet tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ±4 Nm (18 ±3 ft-lb)
W2111111
EGR spring hose clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (90 in-lb)
W2111112
EGR worm-gear hose clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ±0.5 Nm (40 ±4 in-lb)

Turbocharger:
Turbocharger mounting screws and nuts:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ±4 Nm (15 ±3 ft-lb)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ±8 Nm (35 ±6 ft-lb)
Note: Tighten diagonally.
Charge air cooler V-clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 ± 1 Nm (62 ± 9 in-lb)

Diffuser V-clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ± 2 Nm (9 ± 1.5 ft-lb)
Turbocharger oil supply and return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Turbocharger coolant supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 5 Nm (35 ± 4 ft-lb)
Turbocharger coolant return:
Hollow screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 5 Nm (35 ± 4 ft-lb)
Fitting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 6 Nm (44 ± 5 ft-lb)
Actuator coolant supply and return:
At turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ± 3 Nm (9 ± 2 ft-lb)
At block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 5 Nm (35 ± 4 ft-lb)
Closed crankcase ventilation (CCV):
Mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Hose clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ± 0.6 Nm (35 ± 5 in-lb)
Diesel Particulate Filter (DPF):

Compact (under cab):
Lower mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Mounting strap fastener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ± 4 Nm (20 ± 3 ft-lb)
Vertical (back of cab):
Mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
Mounting strap fastener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ± 1 Nm (17 ± 1 ft-lb)
Exhaust V-band clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ± 2 Nm (62 ± 18 in-lb)
Aftertreatment hydrocarbon doser fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 ± 2 Nm (53 ± 18 in-lb)
DPF V-band clamp:
Step 1 -Tighten to specification listed below.
Step 2 – Using a plastic hammer, firmly tap around the clamp in 4 places in sequence shown.
W2103266
Step 3 – Retighten to specification listed below.
• 2007 – 2009: 15 ± 1 Nm (132 ± 9 in-lb)

• 2010 – 2016: 20 ± 1 Nm (177 ± 9 in-lb)

Note: Years listed above are vehicle build dates, not model years.
Selective Catalytic Reduction (SCR):
Mounting nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Nm (200 ft-lb)
Cage fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Nm (50 ft-lb)
Heat shield fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Exhaust V-band clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ± 2 Nm (62 ± 18 in-lb)
V-band clamps (DPF to SCR pipe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ± 0.5 Nm (60 ± 5 in-lb)
Diesel Exhaust Fluid (DEF) tank:
DEF pump screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
ACM bracket screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
ACM mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Solenoid valve mounting bracket screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ± 0.5 Nm (27 ± 4 in-lb)
Tank cover screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Tank bracket to bracket screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Tank bracket to tank screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Frame rail mounting bracket to tank bracket fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
Frame rail mounting bracket to frame fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ± 25 Nm (103 ± 18 ft-lb)
Diesel Exhaust Fluid (DEF) Pump
Filter cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.5 ± 2.5 Nm (16.5 ± 2 ft-lb)
Coolant connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 ± 0.5 Nm (50 ± 5 in-lb)
Inlet connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ± 0.5 Nm (35 ± 5 in-lb)
Backflow connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ± 0.5 Nm (40 ± 5 in-lb)
Outlet connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ± 0.5 Nm (35 ± 5 in-lb)
Note: When a connector is replaced, a new O-ring must be used.
Aftertreatment hydrocarbon doser (previous version):
Doser:
Mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ± 0.5 Nm (125 ± 4.5 in-lb)
Fuel line fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ± 0.5 Nm (135 ± 5 in-lb)
Cooling lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 5 Nm (35 ± 4 ft-lb)
Two-way check valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm (18 ft-lb)
Air line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 ft-lb)
Shut-off Valve:
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 ± 3 Nm (120 ± 24 in-lb)
Fuel line fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Function Group 23
Aftertreatment hydrocarbon doser (new version)
Doser:
Mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ± 0.5 Nm (125 ± 4.5 in-lb)
Air/Fuel line fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ± 2 Nm (135 ± 18 in-lb)
M10 clamp socket screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ± 4 Nm (21 ± 3 ft-lb)
Connection joint between left and right fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ± 2 Nm (135 ± 18 in-lb)
Aftertreatment hydrocarbon dosing module:
Air/Fuel line fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ± 2 Nm (135 ± 18 in-lb)
Fuel line from housing to module fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum 18 ± 3 Nm (13 ± 2 ft-lb)
W2005979
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)

Coolant pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
W2006012
Coolant pump housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)

W2031416
Front, side cover, thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm (21 ft-lb)

Drive belt tensioner idler support
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 ± 45 Nm (203 ± 33 ft-lb)
Drive belt tensioner, idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Fan hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Viscous fan drive:
Drive-to-hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Hub-to-bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Upper radiator hose clamp:
Screw-type band clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (45 in-lb)
Screw-type band clamp with spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (90 in-lb)
Sensor and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specification

Note: Sensors vary by engine.
Flywheel position/speed, top of flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 ± 2 Nm (6 ± 1 ft-lb)
Camshaft position, timing gear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 ± 2 Nm (6 ± 1 ft-lb)
Turbocharger speed, top middle of turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 ± 2 Nm (75 ± 18 in-lb)
Turbocharger discharge temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ± 4.5 Nm (33 ± 3 ft-lb)
Oil level/temperature, inside sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1 Nm (89 ± 9 in-lb)
Oil pressure, oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ± 5 Nm (22 ± 4 ft-lb)
Coolant level, surge tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plug-in
Coolant temperature, front right side cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ± 3 Nm (16 ± 2 ft-lb)
Fuel pressure, fuel filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18.5 ± 2 ft-lb)
Aftertreatment hydrocarbon doser fuel pressure, behind fuel filter housing . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18.5 ± 2 ft-lb)
Crankcase pressure, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18.5 ± 2 ft-lb)
Charge air temperature and pressure, mixing chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1 Nm (89 ± 9 in-lb)
Humidity, fresh air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ± 3 Nm (20 ± 2 ft-lb)
Charge air temperature, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ± 1 Nm (89 ± 9 in-lb)
EGR temperature, EGR venturi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ± 4.5 Nm (33 ± 3 ft-lb)
EGR differential pressure, intake manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 3 Nm (15 ± 2 ft-lb)
Piston cooling jet pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 3 Nm (18.5 ± 2 ft-lb)
DPF temperature, DPF inlet, catalyst, outlet modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ± 4.5 Nm (33 ± 3 ft-lb)
DPF differential pressure, DPF inlet, catalyst, outlet modules:
Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ± 1 Nm (53 ± 9 in-lb)
Fitting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3 ± 2.7 Nm (12 ± 2 ft-lb)
NOx sensor, exhaust pipe after DPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ± 10 Nm (37 ± 7 ft-lb)
NOx sensor, exhaust pipe after SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ± 10 Nm (37 ± 7 ft-lb)
NOx module, frame bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)

Starter motor mounting nuts:
M10 nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Starter cables (Bat+, E-):
M12 nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ± 5 Nm (18± 4 ft-lb)
Starter control wire:
M6 nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ± 1 Nm (35 ± 9 in-lb)
Alternator:
Mounting bracket, tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ± 8 Nm (35 ± 6 ft-lb)
Pad mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65.5 ± 7.5 Nm (48 ± 5.5 ft-lb)
Pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.5 ± 6.5 Nm (75 ± 5 ft-lb)
Battery terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5 ± 0.25 Nm (57.5 ± 2.5 in-lb)
Ground terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 ± 0.5 Nm (55 ± 5 in-lb)
I, R terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 ± 0.5 Nm (20 ± 5 in-lb)
AC refrigerant compressor mounting bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 Nm (18 ± 3 ft-lb)
Wiring harness conduit to block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 3 Nm (18 ± 2 ft-lb)
Wiring harness conduit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ± 0.5 Nm (31 ± 4.4 in-lb)
Cable channel cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ± 0.5 Nm (31 ± 4.4 in-lb)

Air compressor mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ± 15 Nm (63 ± 11 ft-lb)
Air compressor out connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 ± 20 Nm (96 ± 15 ft-lb)
Air compressor gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 ± 20 Nm (200 ± 15 ft-lb)
Air compressor oil line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ± 2.5 Nm (12 ± 2 ft-lb)
Engine Lubricants and Sealants

Use only the following recommended sealing compounds Note: All genuine cylinder head gaskets are pre-coated and
and lubricants. do not require any type of sealing compound. When instal-
ling new gaskets, clean and degrease gasket sealing surfa-
ces to avoid leaks.
Location Sealant or Lubricant

Cup plugs/threaded plugs Loctite® 277 or equivalent/Teflon® thread sealer
Cylinder liner seat 1161231 sealant
Oil filter seal Clean engine oil
Holding metal parts in place Petroleum jelly
Valve stems and guides Clean engine oil
Engine front cover/flywheel housing/timing gear cover 3092340 sealant

Engine parts, fasteners and washers Clean engine oil
Exhaust manifold studs High temperature 1161929 anti-seize
Oil cooler assembly O-ring Clean engine oil
Oil cooler cover Permatex 85409 or equivalent gasket dressing
O-rings, coolant, EPDM Clean coolant, or Dow Corning® 55
O-rings (except as noted) Dow Corning® 55 O-ring lubricant
Threaded sensors Sealing compound on threads
Turbocharger mounting nuts 1161929 anti-seize

Cylinder Liners and Pistons, Replace

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Volvo Trucks North

• “Valve Mechanism”, page 8

• “Engine Timing Gears”, page 11

• “Lubricating and Oil System”, page 12

• “Fuel System”, page 14

• “Inlet and Exhaust System”, page 15

• “Cooling System”, page 17

• “Engine Control System”, page 19

• “Tightening Torques and Patterns”, page 20

• “Engine Lubricants and Sealants”, page 47

Engine type In-line direct injection diesel

Weight (dry) Approximately 1,034 kg (2280 lbs.)

Component Features and Materials

• 4.0–4.5 liters (4.2–4.8 quarts)

• 25 liters (26.4 quarts) minimum

• 30 liters (31.7 quarts) maximum

Coolant pump Centrifugal rotor impeller; belt driven

1 The measurements refer to lubricated components.

Do not machine the cylinder head. Machining changes

Overall height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm (5.315 inches)

Cylinder Head Bolt

Note: Do not grind or resurface valves. Grinding valves can

Note: Grinding or resurfacing valve seats is not

Valve Seat Inserts

A — Insert outer diameter (inlet, press fit in head). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.654 inches)

Valve Seat Insert Counterbore in Cylinder Head

C — Insert counterbore diameter (inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.654 inches)

Engine Timing Gears

Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Number of Teeth

Lubricating and Oil System

Oil Pressure, Rocker Arm Shaft

Lubricating Oil Pump

Oil Filter Housing Valves

Item Spring Free Length Spring Length Under Load

Tighten the rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . obtain zero clearance

Inlet and Exhaust System

Inlet Manifold Air Temperature Sensor

Compression Brake Activation

Compression Brake Switch

Compression Brake, Cruise Mode

Exhaust Back Pressure

Engine Control System

Inlet Manifold Pressure Sensor

1 Normal atmospheric pressure at sea level.

Tightening Torques and Patterns

Fasteners Examples Reusable Limit Reuse Recommendations

Tightening Torques Function Group 20

General Tightening Torques

Torque/Angle Tightened or Yield Limit Bolts

Note: Only torque-tightened bolts can be reused.

Tightening Torques Function Group 21

Front engine bracket to engine bracket:

Crankshaft main bearing cap:

Timing gear plate:

Timing gear plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ± 4 Nm (21 ± 3 ft-lb)

Timing gear cover:

Note: Attach the component within 20 minutes of applying the sealant.

Timing gear cover:

Note: Tighten the bolts in the order shown.

Step 1. Torque tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 5 Nm (44 ± 4 ft-lb)

Front crankshaft seal cover:

Crankshaft vibration damper:

Cylinder head sealant:

Note: Attach the component within 20 minutes of applying the sealant.