Repair Manual of MC11 Euro III Engine

REN.MC11.43/39/35/31.
01
The Repair Manual of MC11 Euro III Engine
SINOTRUK 53 Wuyingshanzhong Road

IMPORT & EXPORT CO., LTD Jinan, China, 250031
03.2014 MC11.43/39/35/31
1st Edition -E nglish-
R.EN.MC11.31/35/39/43.01
PREFACE
This manual provides assistance in performing repairs correctly on vehicles and units and re ects
the known technical situation appertaining at the copy deadline. Pictures and the corresponding
descriptions are typical one-time representations; they do not always correspond to the unit to be
repaired or its peripherals.
This publication assumes that persons who use it possess the requisite technical knowledge in
repairing vehicles and units.
The description of the bolt specification in this repair manual: M nominal diameter (×fine thread
pitch) ×length-performance grade, for example: M8×40-10.9 , nominal diameter is 8mm, standard pitch,
the length is 40mm, performance grade is 10.9. M8×0.75×40-8.8 means nominal diameter is 8mm, fine
thread pitch 0.75mm, length is 40mm, performance grade is 8.8.
In this repair manual, there are two codes for repair tools and fixture, for example : the Piston ring
compressor’s code : JD6805-0018 and 80.99602-0016， the former code is SINOTRUK tool code,the
latter is MAN tools code, it will be convenient for you to purchase the tools.
The repair jobs are divided up into sections and subsections. Each subsection starts with a page of
jobs to do in advance.The jobs to do in advance contain a summary of the main prerequisites for the
repair section in question. The detailed description of work can follow the jobs to do in advance.
Important instructions concerning technical safety and the safety of personnel are speci cally
highlighted, as indicated below.
CAUTION
Type and source of danger
Refers to working and operating procedures which must be followed exactly in order to
avoid exposing people to risk.
WARNING
Type and source of danger
Refers to working and operating procedures which must be followed exactly in order to
avoid serious or irreparable damage to property.
NOTE
An explanatory note which is useful for understanding the working or operating procedure
to be performed.
Comply with general safety regulations when performing any repair work.
This repair manual is edited by SINOTRUK marketing service group and translated by SINOTRUK
Import &Export company
Chief editor: Xiaodong Zhang
Chief auditor：Ailiang Jiang Defeng Zhong
Auditor ：Wenge Li Defeng Zhong
Editor ：Biao Yang Ping Zhu Zongyuan Zhang Bin Liu
Translator : Kai Wu Xuming Jiang
We reserve the right to make modifications in the course of further development.
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PREFACE................................................................................................................................................................... 1
INTRODUCTION....................................................................................................................................................... 1
SAFETY INSTRUCTIONS....................................................................................................................................... 1
ENGINE DESCRIPTION.......................................................................................................................................... 5
CHARACTERISTIC DATA........................................................................................................................................ 8
ENGINE ELECTRICS............................................................................................................................................. 11
ELECTRIC CONTROL UNIT（EDC）.................................................................................................................12
REMOVING AND INSTALLING THE ENGINE CONTROL UNIT...................................................................12
COOLING SYSTEM................................................................................................................................................15
FAN............................................................................................................................................................................ 16
REMOVING AND INSTALLING THE FAN......................................................................................................... 16
FAN DRIVE...............................................................................................................................................................18
REMOVING AND INSTALLING THE FAN DRIVE............................................................................................ 18
COOLANT MANIFOLD...........................................................................................................................................25
REMOVING AND INSTALLING THE COOLANT MANIFOLD........................................................................ 25
THERMOSTATS......................................................................................................................................................29
REMOVING AND INSTALLING THE THERMOSTATS................................................................................... 29
THERMOSTAT HOUSING.................................................................................................................................... 31
REMOVING AND INSTALLING THE THERMOSTAT HOUSING..................................................................31
COOLANT PUMP....................................................................................................................................................34
REMOVING AND INSTALLING THE COOLANT PUMP................................................................................. 34
DISTRIBUTOR HOUSING.....................................................................................................................................37
REMOVING AND INSTALLING THE DISTRIBUTOR HOUSING.................................................................. 37
MOUNTED COMPONENTS..................................................................................................................................39
AIR COMPRESSOR............................................................................................................................................... 40
REMOVING AND INSTALLING THE 1-CYLINDER AIR COMPRESSOR................................................... 40
STARTER................................................................................................................................................................. 46
REMOVING AND INSTALLING THE STARTER...............................................................................................46
BELT DRIVE............................................................................................................................................................. 49
REMOVING AND INSTALLING THE BELT DRIVE.......................................................................................... 49
ALTERNATORS....................................................................................................................................................... 53
REMOVING AND INSTALLING THE ALTERNATOR...................................................................................... 53
INTAKE/EXHAUST SYSTEM.................................................................................................................................59
EXHAUST MANIFOLD........................................................................................................................................... 61
REMOVING AND INSTALLING THE EXHAUST MANIFOLD........................................................................ 61
CHARGE-AIR PIPES..............................................................................................................................................64
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REMOVING AND INSTALLING THE CHARGE-AIR PIPES........................................................................... 64

CHARGER-AIR MANIFOLD.................................................................................................................................. 66
REMOVING AND INSTALLING THE CHARGE-AIR MANIFOLD.................................................................. 66
TURBOCHARGER..................................................................................................................................................68
REMOVING AND INSTALLING THE TURBOCHARGER............................................................................... 68
CYLINDER HEAD................................................................................................................................................... 73
REMOVING AND INSTALLING THE CYLINDER HEAD.................................................................................74
CHECKING AND SETTING THE VALVE CLEARANCE.................................................................................. 87
VALVE STEM SEALS.............................................................................................................................................94
REMOVING AND INSTALLING THE VALVE STEM SEALS.......................................................................... 94
VALVE TIMING......................................................................................................................................................106
CAMSHAFT/CAMSHAFT BEARING................................................................................................................. 107
REMOVING AND INSTALLING THE CAMSHAFT/CAMSHAFT BEARING.............................................. 107
VALVE TIMING......................................................................................................................................................123
CHECKING THE VALVE TIMING...................................................................................................................... 123
REAR TIMING GEARS........................................................................................................................................ 128
REMOVING AND INSTALLING THE REAR TIMING GEARS......................................................................128
COMMON-RAIL SYSTEM................................................................................................................................... 143
REMOVING AND INSTALLING THE INJECTORS AND PRESSURE PIPE............................................. 144
HIGH-PRESSURE PUMP/HIGH-PRESSURE PUMP DRIVE...................................................................... 158
REMOVING AND INSTALLING THE HIGH-PRESSURE PUMP/HIGH-PRESSURE PUMP DRIVE....158
DISMANTLING AND ASSEMBLING THE FUEL SERVICE CENTRE........................................................ 171
ENGINE LUBRICATION...................................................................................................................................... 176
OIL MODULE......................................................................................................................................................... 177
REMOVING AND INSTALLING THE OIL MODULE....................................................................................... 177
OIL SUMP AND OIL SUCTION PIPE................................................................................................................ 185
REMOVING AND INSTALLING THE OIL SUMP AND OIL SUCTION PIPE............................................. 185
OIL INJECTOR NOZZLES...................................................................................................................................187
REMOVING AND INSTALLING THE OIL INJECTOR NOZZLES................................................................187
OIL PUMP...............................................................................................................................................................189
REMOVING AND INSTALLING THE OIL PUMP............................................................................................ 189
CRANKSHAFT OIL SEALS.................................................................................................................................198
REMOVING AND INSTALLING THE FRONT CRANKSHAFT OIL SEAL...................................................198
REMOVING AND INSTALLING THE REAR CRANKSHAFT OIL SEAL.................................................... 204
ENGINE HOUSING.............................................................................................................................................. 208
FLYWHEEL HOUSING/TIMING CASE............................................................................................................. 209
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REMOVING AND INSTALLING THE FLYWHEEL HOUSING/TIMING CASE.......................................... 209

COVER....................................................................................................................................................................211
REMOVING AND INSTALLING THE COVER................................................................................................. 211
CYLINDER LINERS..............................................................................................................................................213
REMOVING AND INSTALLING THE CYLINDER LINERS........................................................................... 213
PISTONS AND CONNECTING RODS..............................................................................................................218
VIBRATION DAMPER.......................................................................................................................................... 219
REMOVING AND INSTALLING THE VIBRATION DAMPER........................................................................219
FLYWHEEL............................................................................................................................................................ 223
REMOVING AND INSTALLING THE FLYWHEEL.......................................................................................... 223
PISTONS AND CONNECTING RODS..............................................................................................................232
REMOVING AND INSTALLING THE PISTONS AND CONNECTING RODS............................................ 232
CRANKSHAFT.......................................................................................................................................................245
REMOVING AND INSTALLING THE CRANKSHAFT.................................................................................... 245
FRONT DRIVE GEARS....................................................................................................................................... 256
REMOVING AND INSTALLING THE FRONT DRIVE GEARS..................................................................... 256
TECHNICAL DATA................................................................................................................................................263
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INTRODUCTION
SAFETY INSTRUCTIONS
General
Only trained personnel are allowed to perform operating, maintenance and repair work on trucks,
buses and coaches
Additional references to danger are contained in the instructions at points where there is a potential
danger.
Accidents may happen in spite of all precautionary measures having been taken. In such an
eventuality, obtain immediate medical assistance from a doctor. This is particularly important if the
accident involves skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil,
antifreeze spraying into eyes, crushing of limbs etc.
Regulations for preventing accidents leading to injury to personnel
Checking, setting and repair work
– Secure units during their removal.
– Support the frame when working on the pneumatic or spring suspension system.
– Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.
– Only use tools that are in perfect condition.
– Only authorised technical personnel are entitled to perform checking, setting and repair work.
Operating the engine
– Only authorised personnel are permitted to start and operate an engine.
– Do not approach moving parts of a running engine too closely and do not wear baggy clothing. Use
an extractor system if working in enclosed spaces.
– Danger of burns when working on engines at operating temperature.
– Danger of scalding when opening the hot cooling circuit.
Suspended loads
– People are not allowed to stand below suspended loads.
– Only use suitable lifting and gear that is in perfect working order. Use lifting devices with suf cient
load-carrying capacity.
Working on high-pressure lines
– Do not attempt to tighten or loosen pipe lines and hoses when they are under pressure (e.g.
lubrication circuit, coolant circuit and hydraulic oil circuit):
Risk of injury due to pressurised fluids emerging!
Checking injector nozzles
– Wear suitable protective equipment.
– Do not hold any part of your body under the jet of fuel when checking the injector nozzles.
– Do not inhale fuel vapours. Ensure that there is adequate ventilation.
Working on the vehicle electrical system
– Do not disconnect batteries whilst the engine is running!
– Always disconnect batteries when working on the vehicle electronic system, central electrical system,
alternator and starter! When disconnecting batteries, remove the negative terminals first. When
connecting batteries, fit the positive terminals first.
– Always use suitable test lines and test adapters when measuring at plug connections!
– If temperatures of over 80°C are to be expected (e.g. in a drying oven after painting), switch the
battery master switch to "OFF" and then remove the control units (EDC).
Electric welding
– If this device is not available, disconnect the batteries and connect the positive cable to the negative
cable in order to make a firm conductive connection. Otherwise it will damage the engine electrical
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equipment, such as EDC,etc.

–After completing welding work, first switch off all the consumers and remove all jumpers (re-create
original state), then connect the batteries.
– Always earth the welding equipment as close as possible to the welding area. Do not lay the cables to
the welding equipment in parallel to electrical cables in the vehicle.
Working with the cab tilted
– Keep the tilting area in front of the cab clear.
– Keep out of the area between the cab and the chassis during the tilting process. This is a danger
area!
– Always tilt the cab past the tilting point and secure the cab using a support rod.
Notes on preventing damage and premature wear on units
General
– Units are only designed for their specified purpose - defined by the manufacturer (designated use):
Any other use is classified as not in accordance with the designated use. The manufacturer is not
liable for damage caused as a result of such other use. In the event of such other use, the user alone
bears the risk.
– Designated use also includes compliance with the operating, maintenance and repair conditions
specified by the manufacturer.
– The unit may only be used, maintained and repaired by persons who are familiar with it and are fully
aware of the risks.
– Arbitrary changes to the engine mean that the manufacturer is no longer responsible for any damage
incurred as a result of such changes.
– Similarly, tampering with the injection and control system can affect the unit's performance and
exhaust-gas characteristics. This means that compliance with the statutory environmental
requirements is no longer assured.
– If malfunctions occur, determine the cause and remedy the problem immediately.
– Clean units thoroughly before repairs, ensuring that all openings where dirt is not allowed to enter for
safety or functioning reasons are plugged.
– Never run a unit dry, in other words always make sure that it has been filled with oil before running it.
– Never run engines without coolant.
– Apply a suitable information sign to units that are not ready to be operated.
– Only use service products as per the SINOTRUK Recommended Service Products, otherwise the
manufacturer warranty will be invalidated.
– Comply with the specified maintenance intervals.
– Do not fill engine/gear oil above the maximum level mark. Do not exceed the maximum permitted
operational tilt.
– engine running angle shall not exceed the maximum allowable angle.
3.Limited liability for parts and accessories
Only use accessories and genuine SINOTRUK parts that have been expressly approved by
SINOTRUK for your SINOTRUK vehicle. SINOTRUK accepts no liability for any other products.
Regulations for avoiding injury and environmental contamination
Health protection precautions
Avoid prolonged, excessive or repeated skin contact with service products, excipients, thinners or
solvents. Protect your skin using a suitable skin protection agent or protective gloves.
Service products and excipients
Do not use food or drink containers for draining and storing service products or excipients.
Cleaning the filter insert
When blowing compressed air through the filter insert, make sure the filter dust is collected by a
vacuum or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear
suitable rubber gloves or use a skin barrier cream when washing out the insert, because cleaning
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agents have aggressive grease-dissolving characteristics.

Used engine/gear oil
Lengthy or repeated skin contact with any type of engine/gear oil removes grease from the skin. This
can cause dry skin, irritation or skin in flammation. In addition to these hazards, used engine oil
contains dangerous materials which can trigger dangerous skin diseases. Wear gloves, especially
when changing the oil.
Special information for working on the common-rail system
General
– A jet of fuel can cut through the skin. Risk of re due to fuel atomisation.
– Never undo the screwed connections on the fuel high-pressure side of the common-rail system whilst
the engine is running (high-pressure line from the high-pressure pump to/on the rail and on the
cylinder head to the injector). Whilst the engine is running, the lines are constantly carrying fuel under
a pressure of 1800 bar or more. Before the screw connections are opened, wait at least one minute
until depressurisation has occurred, using EOL to check the depressurisation on the rail as
necessary.
– Do not touch the live parts at the injector electrical connection whilst the engine is running.
Danger of damage due to dirt ingress
– Diesel-injection systems consist of precision engineered components that are subject to extreme
loads. Due to this high-precision technology, it is necessary to ensure the greatest possible
cleanliness during all work on the fuel system.
– Even dirt particles over 0.002 mm can cause component failure.
Before commencing work on the clean side
– Clean the engine and engine compartment with the fuel system closed. Do not use a powerful jet
when cleaning electrical components.
– Drive the vehicle into a clean area of the workshop where none of the work causes dust to be swirled
up (sanding, welding, brake repairs, brake checks, performance tests etc.).
– Avoid air movements (possible swirling up of dust due to starting of engines, the workshop
heating/ventilation system, due to draughts etc.).
– Clean and dry the area of the still closed fuel system using compressed air.
– Use a suitable extractor unit (industrial extractor unit) to remove loose dirt particles such as paint
chippings and insulating material.
– Areas of the engine compartment from which dirt particles could become detached, e.g. tilted cab,
engine compartment in bus motors, must be covered with a new, clean covering foil.
– Wash your hands before starting to strip down the system and wear a clean set of overalls.
After opening the clean side
– The use of compressed air for cleaning is not permitted.
– During assembly, remove loose dirt using a suitable extractor unit (industrial extractor unit).
– Only lint-free cleaning cloths are allowed to be used on the fuel system.
– Clean tools and equipment before commencing work.
– Only use tools that show no signs of damage (cracked chrome coatings).
– Do not use any materials such as cloths, cardboard or wood when removing and installing
components, because these can give off particles and fibres.
– If any paint flakes off when connections are loosened (e.g. if they have been painted over), these
paint flakes must be removed carefully before completing the unfastening of the screw connection.
– All parts removed from the clean side of the fuel system must immediately have their apertures
sealed with suitable plugs.
– This sealing material must be packed to protect it from dust before it is used, and must be disposed of
after one use.
– Following this, the components must be carefully stored in a clean, sealed container.
– Never apply used cleaning or test fluids to these components.
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– New parts must not be removed from their original packaging until immediately before use.
– Work on removed components may only be carried out in a suitably equipped workplace.
– If removed parts are shipped, always use the new parts original packaging.
It is mandatory to comply with the following additional instructions during work on bus engines:
– Before opening the clean-side fuel system:
Clean the parts of the engine around the rail connections, injection lines, rail and valve cover with
compressed air.
– Remove the valve cover and then clean the part of the engine around the rail connections, injection
lines and rail again.
– Only remove the rail connections completely once the injectors have been removed so that no dirt
can fall into the injectors from above.
– After removal, rinse out the injectors with a cleaning fluid, making sure that the high-pressure
connection hole is facing downwards.
5. Limp-home program for units with electronic control units
General information
The units have an electronic control system that monitors the unit as well as itself (self-diagnosis).
As soon as a malfunction occurs, the malfunction is evaluated and one of the following measures is
implemented automatically:
– Output of a fault message with fault code.
– Switchover to suitable default function for further operation, albeit with restrictions. The malfunctions
should be remedied immediately.
– If SINOTRUK EOL is used, the fault code is output directly.
6. Installation instructions
Installation of piping
– Mechanical deformation of piping is not permitted when performing installation work - risk of fracture!
Installation of gaskets
– Only use genuine SINOTRUK gaskets
– Make sure the surfaces to be sealed are undamaged and clean.
– Do not use adhesives or sealing compounds. If necessary, to facilitate installation, use a little grease
to stick the seal to the part to be mounted.
– Tighten the bolts evenly to the specified tightening torque.
Engine overhaul
– A range of very different factors affect the engine service life. It is therefore not possible to indicate
the exact number of operating hours or miles before a major overhaul is due.
– In our judgement, it is not advisable to open an engine or perform a major overhaul if the engine has
good compression values and the following operating values have not changed signi cantly since they
were measured and taken during the initial start-up:
– Charge pressure
– Exhaust temperature
– Coolant and lubricating oil temperature
– Oil pressure and oil consumption
– Smoke characteristics
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Engine description
Engine, general
MC11 engine technology adopts MAN D20 engine which is developed new design in 2004 from
MAN company, it keep improving the torque instead of the power idea, modular design, and it has few
fuel consumption, high reliability, excellent performance and light weight advantages, and it meets Euro
Ⅴ standard.
Crankcase
The crankcase uses vermicular graphite cast iron material and wet cylinder liner, sealed by two
rubber sealing rings in the bottom. Part of the cylinder wall of crank case is strengthened to adapt to the
higher ignition pressure. (More than 220bar) Symmetric crank case casting can reduce noise effectively.
Crankcase gas gets through the oil-gas separator to the atmosphere. In the rear, crank case constitutes
the whole sealing with flywheel, flywheel shell and oil seal.
The main bearing cap is broken up by manufacture process. Rough up section can supply high
lateral support, achieving accurate positioning and benefit to reduce the wearing of bearing bush and
produce its life.
The wet cylinder liners made from special, highly wear-resistant centrifugal casting are
exchangeable. The cylinder liners are sealed using elastomer sealing rings.
There are seven main bearing on the body with the same width. The thrust plates are located on
the both sides of the sixth main bearing.
Crankshaft
The crankshaft is forged in a die using high-quality, micro-alloyed steel. It has four cast counterweights
to balance the masses. The crankshaft is mounted in 7 bearings in the crankcase. The vibration
damper is mounted on the front end of the crankshaft, the whole structure has high strength and rigidity.
Connecting rod
The "cracked" connecting rods are precision forged in a die using quenched and tempered steel. The
large connecting rod eye is split diagonally by "cracking" the connecting rod bearing cap. The surface
structure resulting from cracking results in a tooth engagement effect between the connecting rod
bearing cap and the connecting rod with a precise, non-interchangeable fit and high lateral stability.
Piston
3-ring pistons made of special die-cast aluminium are used. They feature a cast ring carrier for the
uppermost piston ring. The pistons have a cast-in cooling duct for reducing the thermal load when the
output is high. They are cooled by an oil jet from the oil injector nozzles. The ring set comprises one
taper-face ring and one full keystone ring, each as compression rings, as well as one double-bevelled
slotted oil control ring with spiral-type expander as an oil scraper ring.
Cylinder head
The cylinder head using the overall overhead camshaft design, made of gray cast iron casting.
Integrated in the cylinder head on the intake manifold, and reduces the seal area. 4-valve cylinder head
intake and exhaust system, four valves per cylinder design allows the injector to a more uniform
distribution coefficient higher inflatable effectively reduce emissions. The cylinder head inlet and
exhaust ports located on both sides, by direct injection combustion system, inlet certain eddy.
Injector mounting bosses cast in the cylinder head, is very beneficial to improve the cooling of the fuel
injectors, and improve the reliability of the fuel injectors work.
The cylinder head is specially designed the independent waterways and oil Road, cylinder head gasket
no waterway and oil Road, cylinder liners to improve reliability. Cooling water lateral flow mode,
reasonable design, good cooling effect.
Camshaft
The camshaft is forged from steel and induction hardened. It is mounted in 7 camshaft bearing
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shells in the cylinder head. It is axially mounted in a centre bearing on the camshaft. It is driven by spur
gears on the flywheel side.
Engine lubrication
The engine is lubricated by forced-feed lubrication for all bearing points. The engine oil filter and
the oil cooler are grouped together as an oil module. The crankcase adopts whirlwind structure and no
extra service cost; the oil filter adopts metal-free structure , and can be burnt after replacement , it will
don’t pollute the environment and low maintenance cost.
Cooling system
The cooling circuit is a thermostat-controlled, forced-circulation cooling system with a
maintenance-free coolant pump that is driven by a poly-V-belt. The distributor housing accommodates
the coolant pump, the alternator and the refrigerant compressor. The connection for the heater feed is
also mounted on the distributor housing. The thermostats are exchangeable inserts with wax expansion
elements. Viscous fan clutches are used for all vehicle engines. The fan is driven by the crankshaft spur
gears (maintenance-free), and the fan diameter is Ф704mm/Ф750mm.
The expansion tank can release the vapour of the low-pressure part of the colling system to avoid
lock and refill cooling water. The pressure in expansion tank shall be kept at75+20 kpa.
Intake/exhaust system
The 3-section exhaust manifold is made of high temperature-resistant nodular cast iron and secured to
the cylinder head using heat-resistant bolts. The maintenance-free turbocharger is mounted on the
middle exhaust manifold. The exhaust manifold with fixed-installation engine-brake flap is installed after
the turbocharger. The turbocharger is lubricated by the engine oil circuit.
Fuel system
The fuel system consists of a low-pressure system and a high-pressure system. The low-pressure
system includes the fuel lines, the hand pump and the fuel service centre (KSC). The fuel service
centre comprises a pre-filter and a special micro-filter with water separation to ensure the degree of fuel
purity required by the common-rail system. The low-pressure system also includes a heating element
and the flame start system. The interface to the high-pressure system is the fuel pump.
The high-pressure system consists of the flow-rate-controlled high-pressure pump , high pressure
pump and the rail with rail pressure sensor and pressure limiting valve.
Injection pressure generation and fuel injection are separate in the high-pressure system. The injection
pressure is generated by the high-pressure pump, irrespective of the engine speed and the required
injection quantity. The high-pressure pump delivery quantity is controlled by a proportional valve. The
injection point and the injection quantity are calculated in the engine control unit (EDC) and
implemented by the solenoid valve-controlled injectors.
Engine brake system
Series MC11 engines are equipped with a non-controlled EVB as standard. The braking effect is
about 60 % greater than the one with a conventional exhaust brake system.The exhaust valve bridge
has a built-in hydraulic piston which is pressurised by the engine oil pressure and depressurised via a
balance hole. Above the valve bridge is a counter-holder whose pressure piece closes the balance hole
when the exhaust valve is closed. When the valve is opened, the balance hole is unplugged and the
engine oil pressure can be reduced upstream of the hydraulic piston. If the engine brake valve is closed
against the torsion spring by the servo cylinder, pressure waves build up in the exhaust manifold,
causing the exhaust valves to open briefly once again. In other words, the exhaust valve is opened brie
y once again each time it closes. The hydraulic piston, which is held under the engine oil pressure, is
pushed behind the briefly opening valve. However, the hydraulic piston can no longer move back as the
counter-holder closes the balance hole and the non-return valve closes the oil feed bore. The exhaust
valve therefore remains open with a gap during the compression stroke and the following expansion
stroke. The engine braking power increases.
Starter
The starter is electromagnetic control, gear drive, with friction plate one-way clutch structure
transfer torque continuous current motor. The rated power is 5.5kW
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Generator
The rated voltage of the alternator is 28V with transistor regulator. The alternator is in parallel
connection with battery, the engine speed is 4 times as the generator rotating speed.
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Characteristic data
MC11 series Euro III engine
Model
NO. Items Unit
MC11.43-30 MC11.39-30 MC11.35-30 MC11.31-30
1 Cylinder number 6
2 Cylinder diameter mm 120
3 Stoke mm 155
4 Valve number per cylinder 4
5 Total displacement L 10.518
6 Compression ratio 19:1
7 Maximum rated net power kW 316 287 257 228
8 Rated speed rpm 1900
9 Maximum torque Nm 2100 1900 1750 1550
10 Maximum torque speed rpm 1000～1400
11 minimum specific fuel g/kWh ≤186
12 Rated condition specific fuel g/kWh ≤210
13 Highest unloaded speed rpm 2150±50
14 Idling speed rpm 550±50
15 Firing order 1－5－3－6－2－4
16 Intake valve clearance (cold) mm 0.5±0.03
The exhaust valve clearance mm 0.8±0.03
17 EVB control clearance (cold) mm 0.6±0.03
18 Lubricating oil sump capacity L 40
Net quality (excluding
19 kg 975
post-processing part)
20 Crankshaft direction of rotation Clockwise (see from the free end)
The highest allow diesel engine
21 rpm 2400
braking speed
Cold start without intake
-20
22 preheating ℃
Cold start with intake -40
preheating
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MC11 Series Euro Ⅳ Engine

Model
NO. Items Unit
MC11.44-40 MC11.40-40 MC11.36-40 MC11.32-
40
1 Cylinder number 6
3 Stoke mm 155
9 Maximum torque N·m 2100 1900 1800 1600
minimum specific fuel

11 g/kW·h ≤186
consumption
Rated condition specific fuel
12 g/kW·h ≤210
consumption
13 Highest unloaded speed rpm 2150±50

Intake valve clearance (cold) mm 0.5±0.03
16
The exhaust valve clearance
mm 0.8±0.03
(cold)
17 EVB control clearance (cold) mm 0.6±0.03

19 kg 975

21 rpm 2400
braking speed
Cold start without intake
22 ℃ -20
preheating
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Cold start with intake preheating -40
MC11 EuroⅤ Engine

Model
NO. Items Unit
MC11.44-50 MC11.40-50 MC11.36-50 MC11.32-50
1 Cylinder number 6
3 Stoke mm 155
9 Maximum torque N·m 2100 1900 1800 1600
11 minimum specific fuel consumption g/kW·h ≤186
12 Rated condition specific fuel g/kW·h ≤210
13 consumption
Highest unloaded speed rpm 2150±50

Intake valve clearance (cold) mm 0.5±0.03
16
The exhaust valve clearance mm 0.8±0.03
17 EVB control(cold)
clearance (cold) mm 0.6±0.03

19 kg 975
21 rpm 2400
braking speed
Cold start without intake preheating -20
22 ℃
Cold start with intake preheating -40
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ENGINE ELECTRICS
1. Oil Pressure Sensor; 2. Air Intake Pressure/Temperature Sensor; 3. Water Temperature Sensor; 4. Camshaft sensor; 5.
Rotation Speed Sensor; 6. Comm on Rail Pressure Sensor; 7.Fuel Pressure Sensor
Technical data
name specification technical requirement
oil pressure sensor M18×15 45+5 Nm
Air Intake Pressure/Temperature Sensor M4×14 2~5 Nm
Water Temperature Sensor M16×15 45+5 Nm
Camshaft sensor M6×16 8-10 Nm
Rotation Speed Sensor M6×12 8-10 Nm
Common Rail Pressure Sensor M18×15 70 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specified tightening torque
• Final tightening must always be performed manually using a torque wrench
• WARNING
Restricted operation due to defective entries in the fault memory
• Before removing switches or sensors, read out and document the fault memory
• Always install switches and sensors with new O-rings or sealing rings
• After installing switches or sensors, read out the fault memory and, if necessary, delete it
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Electric Control Unit（EDC）

Removing and installing the engine control unit
electric control unit（EDC）

1.Bracket mounting bolt 2.EDC mounting bolt 3.electric control unit(EDC) 4.EDC brakcket
Technical data
name specification technical parameter
mounting bolt（2） M6×30-10.9 10±2Nm
bracket mounting bolt（1） M8×40-10.9 12-14Nm
Service products
Loctite 270
WARNING
WARNING
Restricted operation due to defective entries in the fault memory
After installing switches or sensors, read out the fault memory and, if necessary,
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Remove the EDC Remove the EDC bracket

Disconnect the EDC connector
·unscrew the mounting bolts（1）

·and rubber washer（2）remove the bracket（3）
·Take the belt（3）

·Fully unlock and pull off the connectors（1）and
（2）
Remove the EDC
·unscrew the mounting bolt（2）

·remove the EDC（1）
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Install the EDC Connecting the engine control unit electrical

Mounting the engine control unit bracket connections
·Lightly apply Loctite 270 on the threads of the

new mounting bolts (1)
Position the bracket (3) with rubber mounts (2)
• Screw in the mounting bolts (1) and tighten
them to 12-14 Nm
Mounting the engine control unit
WARNING
Danger of irreparable engine control
unit damage
• When installing the connectors, first
fully open the lock and then insert and
lock the connectors
·Insert and lock the connectors (1) and (2) in
the engine control unit
·Route the wiring harnesses and secure them
using cable ties (3)
·Position the engine control unit (1)

• Screw in the new mounting bolts (2) and tighten
in the specified sequence to 10±2 Nm
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COOLING SYSTEM
1 3
1.coolant manifold 2.coolant pipe 3.thermostat housing
1 2
1.water pump 2.distributor housing
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FAN
Removing and installing the fan
1. Fan clutch 2. Fan 3. Mounting bolt 4. Fan drive
Technical data
name specification technical data
Mounting bolt (3) M8×1.25 22 Nm
WARNING
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of
the specified tightening torque
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Removing the fan

Remove the fan
Installing the fan
Installing the fan clutch
• Unscrew the mounting bolt (1)

• Remove the fan (3) from the fan drive (2)
Removing the fan clutch • Insert the fan clutch (1) into the fan (3)
them to 22 Nm
Mounting the fan
• Unscrew the mounting bolts (2)

• Remove the fan clutch (1) forwards out of the
fan (3)
• Position the fan (3) on the fan drive (2)

• Screw in and tighten the new mounting bolts (1)
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FAN DRIVE
Removing and installing the fan drive
Additional jobs
- Removing and installing the fan，see 22
- Removing and installing the coolant manifold，see 31
- removing and installing the distributor housing，see 43
- Removing and installing the belt drive,，see 55
- Removing and installing the front crankshaft oil seal，see 59
- Removing and installing the cover，see 210
- Removing and installing the vibration damper，see 59
1. Mounting bolt 2. Fan drive 3. Fan hub 4. Mounting bolt (left-hand thread)
Technical data
item specification technical data
Initial torque 100 Nm
Mounting bolt (left-hand thread) (4) M16×55
turn 90°
Axial play on fan drive(2) 0.20 – 0.55 mm
Radial play on fan drive 0.035-0.076 mm
Radial play on fan drive 35.000 – 35.025 mm
Outside diameter of fan shaft 34.949 – 34.965 mm
Service products
LOCTITE 5900
Lubricating oil
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WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or
grease before installation.
• Clean the fan hub and installer sleeve before assembly
WARNING
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of
Special tools
instruction SINOTRUK
NO. picture MAN CODE
CODE
[1] Impact extractor JD6805-0018 80.99602-0016
• Extracting the radial shaft seal in
conjunction with:
• Extractor hook [2]
[2] Extractor hook JD6805-0019 80.99602-0137

• Extracting the radial shaft seal in
conjunction with:
• Impact extractor [1]
[3] Plug-on handle JD6805-0020 80.99617-0187

• Pressing in the radial shaft seal in
conjunction
with:
• Installer punch [5]
• Washer [4]
[4] Washer JD6805-0021 80.99617-0144
• Pressing in the radial shaft seal
[5] Installer punch JD6805-0022 80.99604-0289

• Pressing in the radial shaft seal
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[6] Engine barring gear JD6805-0023 80.99626-6008

• Blocking the engine
[7] Dial gauge JD6805-0024 08.71000-3217

• Checking the inside diameter of the
fan shaft
mount
• Checking the fan drive axial and
radial play in
conjunction with:
• Dial gauge holder [8]
• Locating pin [9]
[8] Dial gauge holder JD6805-0025 08.71082-0005
radial play
[9] Locating pin JD6805-0026 80.99605-0197

radial play
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Checking the fan drive

Checking the fan drive axial play Checking the fan drive radial play
• Mount the Dial gauge holder [8] (2) with the • Mount the Dial gauge holder [8] (2) with
Dial gauge [7] (1) and the Locating pin [9] the Dial gauge [7] (3) and the Locating pin
• Position the Locating pin [9] against the [9]
drive gear(3) with a preload • Position the Locating pin [9] against the
• Press the drive gear (3) towards the fan hub (1) with a preload
crankcase • Press the fan hub (1) horizontally to the left
• Zero the Dial gauge [7] (1) into the end position
Pull the drive gear (3) into the end position • Zero the Dial gauge [7] (3)
and read off the difference • Pull the fan hub (1) into the end position,
The permitted axial play is 0.20 - 0.55 mm. towards dial gauge [7] (3) and read off the
If the axial play is out of tolerance, fit a new fan difference
drive。 The permitted radial play is 0.035 - 0.076 mm..
If the radial play is out of tolerance, check the fan
shaft and fan shaft mounting.
Check the fan shaft outside diameter, see
Checking the fan shaft outside diameter,23
Check the inside diameter of the fan shaft mount,
see Checking the inside diameter of the fan shaft
mount, see 29
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Removing the fan drive

Attaching the engine barring gear Removing the fan drive radial shaft seal
• Remove the cap from the flywheel housing • Pull the radial shaft seal (2) out of the fan
• Mount and lock the Engine barring gear [6] drive (1) with Impact extractor [1] (4) and
(1) on the flywheel housing Extractor hook [2]
Removing the fan hub Removing the fan drive
• Fix the crankshaft gear (4) using the • Mark the installation position of the
mounting bolt(5) mounting bolts (1) and (2)
• Unscrew the mounting bolt (left-hand • Unscrew the mounting bolts (1) and (2)
thread) (1) • Remove the O-ring (4)
• Remove the fan hub (2) from the fan drive (3) • Remove the fan drive (3)
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Checking the fan drive

Dismantling the fan drive
Checking the fan shaft outside diameter
• Pull the fan shaft (2) out of the housing (1) Check the fan shaft outside diameter at bearing
Checking the inside diameter of the fan shaft surfaces (2) and (3) using a micrometer (1)
mount The permitted outside diameter of the bearing
surfaces (2) and (3) is Ø 34.949 - 34.965 mm.
If the outside diameter is out of tolerance, fit a
new fan shaft.
Assembling the fan drive
• Check the inside diameter of the mount (2)

at the front with the Dial gauge [7] (1) and
internal calliper (4)
• Repeat the same procedure for the mount at
the rear
The permitted inside diameter of the mount (2)
is Ø 35.000 - 35.025 mm in each case.
• Lightly apply clean engine oil on the bearing
If the inside diameter is out of tolerance, fit a points of the fan shaft (2)
new housing (3). • Insert the fan shaft (2) into the housing (1)
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Installing the fan drive Mounting the fan hub

Installing the fan drive
• Lightly apply Technical Vaseline on a new O-ring •• Insert the new fan hub (2) into the fan drive
(4) (3)
• Lightly apply Loctite 5900 (5) on the rst 10
• Fit the O-ring (4)
mm of the thread of the new mounting bolt
• Position the fan drive (3) (left-handed thread) (1), starting from the
• Screw in the new mounting bolts (1) and (2) as bolt head
marked • Screw in the mounting bolt (left-handed
thread) (1) and tighten it to Initial torque
• Tighten the mounting bolts (1) and (2) 100 Nm
Pressing in the radial shaft seal • Tighten the mounting bolt (left-handed thread)
(1) to Final torque 90°
Removing the engine barring gear
• Press the radial shaft seal (2) into the fan

drive
(1) until the stop is reached using the Plug-on
handle [3] (4), Washer [4] and Installer punch [5]
(3) • Remove the Engine barring gear [6] (1)
from the flywheel housing
• Mount the cap on the flywheel housing
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COOLANT MANIFOLD
Removing and installing the coolant manifold
1.O ring 2.coolant mainifold 3.mounting bolt 4.unscrewed conduit 5.unscrewed conduit 6.coolant mainfold
1. Technical data
Coolant temperature sensor M16×15 45-50Nm
2. Service products
Radiator antifreeze、Technical Vaseline
3. important information
WARNING
speci ed tightening torque
4. special tool
SINOTRUK
No. picture instruction MAN code
code
[10] Hose clamp pliers for jubilee clips JD6805-0028 08.99605-9003
•Detaching and attaching the air
compressor air intake pipe
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Removing the coolant manifold

Detaching the air intake pipe

• Pull the coolant manifold (2)
• Pull off the O-ring (5)
• Pull out the unscrewed conduit (3) and (4)
Removing the temperature sensor

• Undo the jubilee clip (3) using Hose clamp
pliers for jubilee clips [10]
• Repeat the procedure for the jubilee clip at
the turbocharger intake pipe
• Remove the air intake pipe (2)
• Detach the fastening clamps for the
moulded hose (6) at the cable harness
holder
pliers for jubilee clips [10] NOTE
• Pull the moulded hose (6) off the fitting (5) The temperature sensor can also be
removed and installed whilst the
coolant manifold is mounted.
• Unscrew the temperature sensor (1) with
sealing ring (2) from the coolant manifold (3)
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• Pull the coolant manifold(2) with o-ring (1)
• clean the seal surface
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Installing the coolant manifold Installing the coolant manifold

Installing the coolant manifold
• Position the coolant manifold (2) with a new

O-ring (1)
• Lightly apply Technical Vaseline on the
• Screw in and tighten the new mounting
bolts (3) contact surfaces of the new unscrewed
Installing the temperature sensor conduits (3) and (4)
• Insert the unscrewed conduits (3) and (4) into
the coolant manifold (2)
• Lightly apply Technical Vaseline on a new
O-ring (5) and fit it on the coolant manifold (2)
• Mount the coolant manifold (2)
• Screw in and tighten the new mounting bolts
(1)
• Lightly apply clean engine oil on the thread of

the temperature sensor (1)
• Screw the temperature sensor (1) with a new
sealing ring (2) into the coolant manifold (3) and
tighten to 45 Nm-50Nm.
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THERMOSTATS
Removing and installing the thermostats
1.mounting bolt 2.mounting bolt 3. Thermostat mainfold 4.thermostat
Technical data
item Technical data
Opening temperature of thermostat (5) 83°C
WARNING
Thermostats with the incorrect opening temperature damage the engine
• Always use thermostats with the specified opening temperature
WARNING
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Removing the thermostat Installing the thermostats

Removing the thermostat manifold Installing the thermostats
• Mark the installation position of the •Insert new seals (2) into the thermostat housing (3)
mounting bolts(4) and (5) • Insert the thermostats (1) with the ball valve or
• Unscrew the mounting bolts (4) and (5)
TOP mark facing upwards
• Remove the thermostat manifold (2) with
Mounting the thermostat manifold
holder (3)（the present type don’t have this
holder ）
• Remove the O-rings (1) from the
thermostats
• Clean the mating faces
Removing the thermostats
• Fit the new O-rings (1) on the thermostats

•Position the thermostat manifold (2) with holder
(3) on the thermostat housing
• Screw in the new mounting bolts (4) and (5) as
marked and then tighten them
• Remove the thermostats (1) with seals (2)

from
the thermostat housing (3)
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THERMOSTAT HOUSING
Removing and installing the thermostat housing
1. Additional jobs
-Removing and installing the thermostats，see 35
1. Thermostat housing 2.hose coupler 3.seal washer 4.washer 5.mounting bolt 6.O-ring
Service product
Technical Vaseline
WARNING
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Fitting new unscrewed conduits

Removing the thermostat housing
Unscrew the mounting bolts
• Unscrew the mounting bolt (1) from the • Pull the unscrewed conduits (2) and (3) out of the
distributor housing (2) thermostat housing (1)
Detaching the thermostat housing •Lightly apply Technical Vaseline on the contact
surfaces of the new unscrewed conduits (2) and
(3)
• Insert the unscrewed conduits (2) and (3) into
the thermostat housing (1)
• Detach the thermostat housing (1) with

unscrewed conduits
• Remove the gasket (3) from the distributor
housing (2)
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Installing the thermostat housing

Mounting the thermostat housing
• Position the thermostat housing (1) with a

new gasket (3) and new unscrewed
conduits at the distributor housing (2)
Screwing in the mounting bolt
•Screw the new mounting bolt (1) into the

distributor housing (2) and then tighten it
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COOLANT PUMP
Removing and installing the coolant pump
1.mounting bolt 2.mounting3.coolant pump4.washer5. Distributor housing 6. Poly-V-belt pulley7.Mounting bolt
WARNING
• If impact wrenches are used, these may only be used for pretightening to max.
50% of the specified tightening torque
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Removing the coolant pump Removing the poly-V-belt pulley

Undoing the mounting bolts

• Pull the poly-V-belt pulley (2) off the hub (3)
Removing the coolant pump
CAUTION
The poly-V-belt tensioner is
under spring tension
• Hold the poly-V-belt tensioner
steady to prevent it from
springing back unintentionally
• Undo the mounting bolts (2)

• Turn the poly-V-belt tensioner (1) clockwise as
far as the stop and hold it
• Remove the poly-V-belt (3)
• Carefully relieve the poly-V-belt tensioner (1)
• Mark the installation position of the mounting

bolts (1) and (4)
• Remove the coolant pump (2) with gasket (3)
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Installing the coolant pump

Mounting the coolant pump
• Insert the coolant pump (2) with a new gasket

CAUTION
(3) The poly-V-belt tensioner is
• Screw in the new mounting bolts (1) and (4) as under spring tension
marked and then tighten them • Hold the poly-V-belt tensioner
Mounting the poly-V-belt pulley steady to prevent it from
• Turn the poly-V-belt tensioner (1) clockwise
as far as the stop and hold it
• Fit the poly-V-belt (3)
• Tighten the mounting bolts (2)
• Position the poly-V-belt pulley (2) on the hub

(3)
• Screw in the new mounting bolts (1) and tighten
them by hand
Tightening the mounting bolts
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DISTRIBUTOR HOUSING
Removing and installing the distributor housing
1. Additional jobs
- Removing and installing the fan，see 22
- Removing and installing the belt drive，see 55
- Removing and installing the thermostats，see35
- Removing and installing the thermostat housing，see 37
- Removing and installing the coolant pump，see 40
1. Mounting bolt 2. Distributor housing 3. Mounting bolt 4. Mounting bolt
WARNING
• If impact wrenches are used, these may only be used for pretightening to
max. 50% of the specified tightening torque
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Removing the distributor housing Installing the distributor housing
• Mark the installation position of the • Position the distributor housing (3) with a new
mounting bolts (1) and (2) gasket
• Unscrew the mounting bolts (1) and (2) • Screw in the new mounting bolts (1) and (2) as
• Remove the distributor housing (3) with marked and then tighten them
gasket
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MOUNTED COMPONENTS
1、Starter；2、Air intake pipe；3、1-cylinder air compressor；4、Power steering pump 1； 7、Alternator poly-V-belt pulley；8、High-pressure
pump drive poly-V-belt pulley；9、Poly-V-belt tensioner；10、Refrigerant compressor；11、Poly-V-belt pulley；12、Moulded hose
1st Edition 39
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AIR COMPRESSOR
Removing and installing the 1-cylinder air compressor
1、Air intake pipe；2、Moulded hose；3、1-cylinder air compressor；4、Power steering pump
Technical data

Bulkhead fitting M16×15 30-35 Nm
Threaded connection M26×15 45 Nm
Service product
LOCTITE 5900
WARNING
1st Edition 40
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Special tool
NO. picture MAN code
code
[27] Hose clamp pliers for jubilee JD6805-0028 08.99605-9003
clips
• Removing and attaching the

air compressor air intake pipe
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Detaching the coolant lines

Removing the air compressor
Detaching the air intake pipe
• Unlock and remove the plug connection for

the coolant line (1) by pressing the spring
clips (2)
• Repeat the same procedure for the other
coolant line

pliers for jubilee clips [27] and push onto the
air intake pipe (2)
•Repeat the procedure for the jubilee clip at the
turbocharger intake pipe
• Remove the air intake pipe (2)
• Detach the fastening clamps for the moulded
hose(6) at the cable harness holder
pliers for jubilee clips [27] and push onto the
fitting (5)
• Pull the moulded hose (6) off the fitting (5)
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Removing the air compressor Removing the connection fittings
• Mark the installation position of the mounting

bolts (1) and (2)
• Remove the air compressor (3)
• Unscrew the bulkhead fittings for feed (2) and

return (3) and then remove with sealing rings
• Unscrew the threaded connection (1) and
remove it with the sealing ring
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Air compressor installation instructions

Installing the air compressor
Installing the connection fittings
• Lightly apply sealing compound Loctite 5900

(1)on the mating face as illustrated
Fitting the air compressor
•Screw in the bulkhead fittings for feed (2) and

return (3) with new sealing rings and then tighten
• Position the air compressor (3)
them to 30-35 Nm
• Screw in the new mounting bolts (1) and (2) as
• Screw in the threaded connection (1) with a
marked and then tighten them
new sealing ring and then tighten it to 45 Nm
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Attaching the coolant lines Attaching the air intake pipe
WARNING
Component damage due to loose
plug connection
• Check the coolant line plug
connections
for firm seating after securing
• If a plug connection is loose, undo it
by pressing the spring clips, then • Push the moulded hose (6) onto the fitting (5)
reinsert and secure it with jubilee clip (4)
• Attach the fastening clamps for the moulded
• Mount the plug connection for the coolant line (1)
hose (6) at the cable harness holder
• If necessary, undo the plug connection for the
• Install the jubilee clip (4) with Hose clamp pliers
coolant line (1) by pressing the spring clip (2), then
for jubilee clips [27]
reinsert and secure it
• Insert the air intake pipe (2) with jubilee clip (3)
• Repeat the same procedure for the other coolant
line
• Install the jubilee clip (3) with Hose clamp pliers
for jubilee clips [27]
• Repeat the procedure for the jubilee clip at the
turbocharger intake pipe
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STARTER
Removing and installing the starter
1、Mounting bolts；2、starter；3、Flywheel housing

Technical data
Item Specification Technical data
mounting bolt(1) M12×35-10.9 110Nm
Terminal 30 mounting nut M10 22 Nm
Number of starter pinion teeth 12
Starter power 5.5 kW，24 V
WARNING
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Special tools
NO picture instruction SINOTRUK MAN code
code
8
• Cranking the engine in
conjunction with:
• Gear ratchet [60]
[60] Gear ratchet JD6805-0038 80.99627-000

1
• Cranking the engine
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Removing the engine Installing the starter

Attaching the engine barring gear
barring gear
• Remove the sealing cap from the flywheel

housing/timing case
• Mount the Engine barring gear [59] (1) on
Remove the Engine barring gear [59] (1) the flywheel housing/timing case
from the flywheel housing/timing case Installing the starter
• Mount the sealing cap on the flywheel
housing/timing case
Removing the starter

Unscrew the mounting bolts (1)
• Crank the engine 360° using Engine barring

gear [59] and Gear ratchet [60] whilst
checking the starter ring gear for
damage. Fit a new starter ring gear if
necessary
Remove the starter (2) from the flywheel • Insert the starter (2) into the ywheel
housing/timing case housing /timing case
• Screw in new mounting bolts (1) and tighten
to 110 Nm
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BELT DRIVE
Removing and installing the belt drive
1、Poly-V-belt pulley；2、Mounting bolts；3、Poly-V-belt tensioner；4、Alternator poly-V-belt pulley；5、High-pressure

pump drive poly-V-belt pulley；6、Mounting bolt；7、Refrigerant compressor poly-V-belt pulley；
Technical data

mounting bolt (6) M10×70-10.9 42-52Nm
mounting (2) M12×55-10.9 50-70 Nm
WARNING
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Removing the poly-V-belt tensioner

Removing the belt drive
Removing the poly-V-belt

• Remove the poly-V-belt tensioner (2)
CAUTION
The poly-V-belt tensioner is under
spring tension
• Hold the poly-V-belt tensioner steady
to prevent it from springing back
unintentionally
Turn the poly-V-belt tensioner (1) clockwise as far
as the stop and hold it

Removing the reversing rollers
• Mark the installation position of the reversing

rollers (3) and spacer bushes (4)
• Remove the washers (2)
• Remove the reversing rollers (3) with spacer
bushes (4)
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Mounting the poly-V-belt

Installing the belt drive
Mounting the poly-V-belt tensioner
CAUTION
• Position the poly-V-belt tensioner (2) on the spring tension
distributor housing • Hold the poly-V-belt tensioner steady
• Screw in a new mounting bolt (1) and tighten it to prevent it from springing back
to 47 Nm unintentionally
Mounting the reversing rollers • Turn the poly-V-belt tensioner (1) clockwise as
far as the stop and hold it
• Fit the poly-V-belt (2)
• Position the reversing rollers (3) with spacer

bushes (4) as marked
• Position the washers (2)
• Screw in new mounting bolts (1) and tighten
them to 60 Nm
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ALTERNATORS
Removing and installing the alternator
1、Holder with thread；2、Holder on charge-air manifold；3、Alternator

4、Holder on high-pressure pump drive；5、Mounting bolt；6、Poly-V-belt pulley 7、Poly-V-belt pulley mounting nut；
Technical data

Poly-V-belt pulley mounting nut (7) M16 80-100Nm
Connection B+ M8 9-13Nm
Service product
LOCTITE 270
CAUTION
1st Edition 53
R.EN.MC11.31/35/39/43.01
Special tool
NO. picture MAN code
code
[61] Special spanner JD6805-0039 80.99603-60
29
• Removing and
installing the poly-V-belt
pulley in conjunction
with:
• Gripper [62]
[62] Gripper JD6805-0040 08.06460-00
02
• Removing and
installing the
poly-V-belt pulley
1st Edition 54
R.EN.MC11.31/35/39/43.01
Removing the holder from the high-pressure

Removing the alternator pump drive
Removing the poly-V-belt
• Unscrew the mounting nut (3) from the

CAUTION mounting bolt (1)
The poly-V-belt tensioner is under • Unscrew the mounting bolt (4) and remove the
spring tension holder (2)
• Hold the poly-V-belt tensioner Removing the upper holder
steady to prevent it from
1st Edition 55
R.EN.MC11.31/35/39/43.01
• Turn the poly-V-belt tensioner (1) clockwise as far

as the stop and hold it
Disconnecting the alternator electrical
connection
•• Unscrew the mounting nut (4)

• Remove the alternator
•Unscrew the mounting bolt (2) and remove the
upper holder (1)
• Release and pull off the compact connector (3)
• Disconnect the cable tie (2)
• Unscrew the terminal B+ mounting nut (1)
• Expose the alternator wiring harness
1st Edition 56
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Undoing the poly-V-belt pulley mounting nut

Installing the alternator
Mounting the poly-V-belt pulley
•Mount the Special spanner [61] (2) with Gripper

[62] (3) on the poly-V-belt pulley mounting nut
• Insert the splined spanner (1) into the alternator
shaft spline
• Hold the splined spanner (1) steady and undo the • Slide the poly-V-belt pulley (2) onto the alternator
mounting nut shaft (3)
Removing the poly-V-belt pulley • Lightly apply Loctite 270 on the thread and
contact surface of the new mounting nut
• Screw on the new mounting nut (1)
Tightening the poly-V-belt pulley mounting nut
• Unscrew the mounting nut (1)

• Remove the poly-V-belt pulley (2) from the
• Mount the Special spanner [61] (2) with
alternator shaft (3)
Gripper [62] (3) on the poly-V-belt pulley
mounting nut
• Insert the splined spanner (1) into the
alternator shaft spline
• Hold the splined spanner (1) steady and
tighten the mounting nut to 80-100 Nm
1st Edition 57
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Mounting the upper holder Connecting the electrical connections
• Route the alternator wiring harness

• Position the upper holder (1) and screw in the • Screw on the mounting nut (1) and tighten to
new mounting bolt (2) 9-13 Nm
• Insert the alternator into the holder • Insert and lock the compact connector (3)
•• Screw in the new mounting bolt (3) • Secure the alternator wiring harness using
• Screw on and tighten the new mounting nut (4) cableties (2)
• Tighten the mounting bolts (2) and (3) Mounting the poly-V-belt
Mounting the holder on the high-pressure
pump drive
CAUTION
spring tension
• Position the holder (2) and screw in the new • Hold the poly-V-belt tensioner
mounting bolt (4) steady to prevent it from
• Insert the new mounting bolt (1) and screw on springing back unintentionally
the new mounting nut (3) • Turn the poly-V-belt tensioner (1) clockwise as
• Tighten the mounting nut (3) whilst holding the far as the stop and hold it
mounting bolt (1) steady • Fit the poly-V-belt (2)
• Tighten the mounting bolt (4) • Carefully relieve the poly-V-belt tensioner (1)
1st Edition 58
R.EN.MC11.31/35/39/43.01
intake/exhaust system
1. Turbocharger 2. Gasket 3. Gasket 4. Mounting bolt 5. Gasket 6. Exhaust manifold 7. Mounting nut
8. Mounting nut 9. Oil pressure line
1st Edition 59
R.EN.MC11.31/35/39/43.01
1. Heat shields 2. Exhaust manifold rear 3. Exhaust manifold gasket 4. Exhaust manifold centre 5. Exhaust manifold front
1st Edition 60
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EXHAUST MANIFOLD
Removing and installing the exhaust manifold
Additional jobs
- Removing and installing the turbocharger，see 72
- Removing and installing the oil module，see 59
1. Mounting bolt 2. Exhaust manifold 3. Gasket 4. Cylinder head 5. Mounting bolt 6. Heat shield 7. Mounting bolt 8. Heat shiel
Technical data

mounting bolt（5） M10×50
mounting bolt（5） M10×50 Initial torque 60Nm
mounting bolt（1） M10×95 Final torque90°
mounting bolt（1） M10×95
WARNING
1st Edition 61
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Dismantling the exhaust manifold

Removing the exhaust
manifold
Removing the heat shields
·Pull exhaust manifold sections(1) and(3)

out of exhaust manifold section（2）
·Remove the multi-piece rings from
exhaust manifold sections(1) and (3)
• Unscrew the mounting bolts (2) • Clean the mating faces
• Remove the heat shields (1) and (3)
Removing the exhaust manifold
• Mark the installation position of the

mounting bolts (2) and (3)
• Remove the exhaust manifold (4) with
gaskets (1)
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Mounting the exhaust manifold

Installing the exhaust manifold
Assembling the exhaust manifold
• Position the gaskets (1) with the raised

section facing the exhaust manifold (4)
• Position the exhaust manifold (4)
• Insert new multi-piece rings into exhaust • Screw in the new mounting bolts (2) and (3)
manifold sections (1)and (3)，the gap of the as marked
four rings have 90°separately • Tighten the mounting bolts (2) and (3) to
·insert the exhaust manifold sections (1) Initial torque 60 Nm in the sequence
and(3) into section (2) indicated
Tightening sequence for exhaust • Tighten the mounting bolts (2) and (3) to
manifold Final torque 90° in the sequence indicated
Mounting the heat shields
• Tighten the exhaust manifold (1) in the

sequence A, B, C, D, E, F, starting with A • Position the heat shields (1) and (3)
bolts (2)
1st Edition 63
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CHARGE-AIR PIPES
Removing and installing the charge-air pipes
1. Mounting bolts 2. Holding bracket 3. Mounting bolt 4. Mounting nut 5. Charge-air pipe
6. Charge-air pipe 7. Charge-air manifold 8. Screw plug 9. Sealing ring 10. Mounting bolt
Technical data

Clamp for charge-air manifold (7) M6 10Nm
Service product
Technical Vaseline
WARNING
NOTE
All the charge-air pipes are available.
Removing and installing is the same in nature
1st Edition 64
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Removing the charge-air pipe Installing the charge-air pipe
• Unscrew the mounting bolts (1), (2) and • Position the charge-air manifold (4) with new
(7) clamp (5) on the turbocharger and align it with
• Detach the charge-air pipe (6) the charge-air pipe (6)
• Undo the clamp (5) • Lightly apply Technical Vaseline on a new O-ring
• Remove the charge-air manifold (4) with (3) and insert it into the charge-air manifold (4)
O-ring (3) • Insert the charge-air pipe (6)
• Screw in and tighten the new mounting bolt (2)
• Insert a new mounting bolt (7), then screw on and
tighten the new mounting nut
• Tighten the clamp (5) to 10 Nm
1st Edition 65
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CHARGER-AIR MANIFOLD
Removing and installing the charge-air manifold
Additional jobs
- Removing and installing the belt drive，see 55
Charge-air manifold
1. Flame glow plug（special configuration）2. solenoid valve 3. Mounting bolt 4.bracket
5. Mounting bolt 6. Mounting bolt 7. Mounting bolt 8. Charge pressure sensor 9. Mounting bolt
Service product
LOCTITE 5900
WARNING
1st Edition 66
R.EN.MC11.31/35/39/43.01
Removing the charge-air Installing the charge-air
manifold manifold
Removing the upper holder Mounting the charge-air manifold
·unscrew the mounting bolt（1）and（2）and

remove the bracket（3）
Removing the charge-air manifold
• Lightly apply Loctite 5900 on the mating face

• Position the charge-air manifold (2)
(1)
• Insert the charge-air sensor (4) with a new
O-ring
• Screw in and tighten the mounting bolts (5)
• Connect the electrical connection (3)
Mounting the upper holder
• Disconnect the electrical connection (3)

• Unscrew the mounting bolts (5) and remove
the charge-air sensor (4) ·Position the upper holder（3）
• Unscrew the mounting bolts (1) ·screw in the new mounting bolt（1）and（2）
• Remove the charge-air manifold (2) ·Tighten the mounting bolt（2）
• Clean the mating faces ·Tighten the mounting bolt（1）
1st Edition 67
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TURBOCHARGER
Removing and installing the turbocharger
Additional jobs
-Removing and installing the charge-air pipe，see 68
1.turbocharger 2.gasket 3. Oil return line 4. Mounting bolt 5.gasket 6. Exhaust manifold 8. Mounting nut 9. Oil pressure lin
Technical data

Mounting nut (8) M10 Initial torque 10Nm
Final torque 90°
Service product
Lithium base grease
WARNING
Component damage due to incorrectly tightened screw/bolt
connections
1st Edition 68
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Special tools
NO. picture instruction SINOTRUK code MAN code
[165] Ring spanner, size 15 i = JD6805-0083 80.99603-0323

1 : 1.22
•Unscrewing andscrewing
on the turbocharger
mounting nuts
[166] Tester JD6805-0168 80.99606-0399
•Checking the
engagement of
compressed-air plug
connections
1st Edition 69
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Removing the turbocharger

Detaching the compressed-air lines

• Unscrew the oil return line (2) at the screw
fitting
• Remove the seal (4) and sealing ring (1)
Removing the turbocharger
• Detach the compressed-air line (1)
• Detach the compressed-air line (2) from the
positioning cylinder (3)
Removing the exhaust manifold
• Unscrew the mounting nuts (1) using Ring

spanner, size 15 i = 1 : 1.22 [165]
• Remove the turbocharger (2) with seal (3)
·Unscrew the mounting nuts (3) Installing the turbocharger
• Remove the exhaust manifold (2) with gasket Fitting the turbocharger
from the turbocharger (1)
Detaching the oil pressure line
WARNING
Component damage due to
incorrect use of special tool.
• Detach the oil pressure line (1) • Fit the turbocharger (2) with a new
Detaching the oil return line seal (3) and position it·
1st Edition 70
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• Screw on the new mounting nuts (1) and use

Ring spanner, size 15 i = 1 : 1.22 [165] to Attaching the oil return line
tighten them to Initial torque 10 Nm
• Tighten the mounting nuts (1) to Final torque
90°
Turbocharger mounting nut, bottom right
• Screw the oil return line (2) with a new sealing

ring (1) into the crankcase
• Position the oil return line (2) with a new seal
(4)
(3)
WARNING • Tighten the union nut for the oil return line (2)
incorrect use of special tool
• Tighten the mounting nut to Initial torque 10

Nm using Ring spanner, size 15 i = 1 : 1.22
[165] (1) and torque wrench (2)
• Tighten the mounting nut to Final torque 90°
Turbocharger mounting nut, bottom left
WARNING
incorrect use of special tool
• Tighten the mounting nut to Initial torque 10
Nm using Ring spanner, size 15 i = 1 : 1.22
[165] (1) and torque wrench (2)
• Tighten the mounting nut to Final torque 90°
1st Edition 71
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Filling the turbocharger with oil Mounting the exhaust manifold
• Position the exhaust manifold (2) with a

new gasket on the turbocharger (1)
WARNING • Screw on and tighten the new mounting
If no oil is added, the nuts (3)
turbocharger will be damaged Attaching the compressed-air lines
when the vehicle is started for
the first time
• Fill the turbocharger with clean engine
oil before attaching the oil pressure line
• Use a funnel (1) to pour clean engine oil
into the oil feed neck on the turbocharger
(2) until the oil duct in the turbocharger (2)
is full
Attaching the oil pressure line
• Attach the compressed-air line (1)
• Screw a new union screw into the
positioning
cylinder (3) and then tighten it
• Engage the compressed-air line (2) and
check for firm seating with Tester [166]
• If the connector comes loose from the
union screw, repeat the work step
• Attach the oil pressure line (1)

• Tighten the union nuts for the oil pressure
line (1)
1st Edition 72
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CYLINDER HEAD
1.crankcase 2. Cylinder head gasket 3. Cylinder head 4. Mounting bolt 5. Cylinder head cover
1st Edition 73
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CYLINDER HEAD
Removing and installing the cylinder head
Additional jobs
- Removing and installing the engine control unit，see 18
- Removing and installing the thermostats，see 35
- Removing and installing the thermostat housing，see 37
- Removing and installing the exhaust manifold，see 65
- Removing and installing the charge-air pipe，see 68
- Removing and installing the turbocharger，see 72
- Checking and setting the valve clearance，see 90
- Removing and installing the injectors and pressure pipe，see 144
- Removing and installing the fuel service centre，see 170
- Removing and installing the oil module，see 59
1.crankcase 2.cylinder head gasket 3.cylinder head 4.mounting bolt 5.cylinder head cover
1st Edition 74
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Technical data

Cylinder head bolts M18×2×246-10.9 initial torque 10Nm
Cylinder head bolts M18×2×246-10.9 2nd torque 150Nm
Cylinder head bolts M18×2×246-10.9 3rd torque 300Nm
Cylinder head bolts M18×2×246-10.9 4th torque 90°
Cylinder head bolts M18×2×246-10.9 5th torque 90°
Cylinder head bolts M18×2×246-10.9 Final torque 90°
Rocker arm mechanism
M12×60-10.9 105+10Nm
mounting bolts
Mounting bolt（4） 10Nm
Cylinder liner protrusion 0.035-0.085mm
Service production
White T assembly paste——when reassembly the cylinder head, daub small White T assembly
paste on the bolt support surface of the cylinder head.
WARNING
Component damage due to leaking cylinder head gasket
• Do not reuse old cylinder head bolts, even if they have only been used once
WARNING
The common-rail system can be damaged
• All work on components of the common-rail system must be performed by specially
trained personnel only.
• The engine must be stationary for at least 5 minutes before commencing work in
order to enable depressurisation in the rail, or depressurisation must be checked by
means of EOL (desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Always renew rail connections once they have been undone
• Do not reuse plugs for high-pressure lines, the pressure pipe or injectors, even if they
have only been used once
• Follow the sequence described when tightening injectors, high-pressure lines, the pressure
pipe and rail connections
WARNING
• If impact wrenches are used, these may only be used for pretightening to max. 50%
of the specified tightening torque
1st Edition 75
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Special tools
NO. picture instruction SINOTRUK MAN CODE

CODE
[175] Torque multiplier i = 1 :
3,5
Undoing and tightening
the cylinder head bolts
in conjunction with:
• Support [176]
• Socket, size 22 [183]
• Socket [184]
JD6805-0084 80.99619-0007
• Angle measuring disc
[177]
• Holding fixture [178]
• Pan head screw [179]
• Connecting pin [180]
• Rubber ring 42 mm
[181]
• Washer [182]
[176] Support
Undoing and tightening JD6805-0085 80.99606-0551
[177] Angle measuring disc
the cylinder head bolts JD6805-0086 80.99607-0172
[178] Holding xture

JD6805-0087 80.99606-0641
[179] Pan head screw

•Undoing and tightening
1st Edition 76
R.EN.MC11.31/35/39/43.01

CODE
[180] Connecting pin
[181] Rubber ring 42 mm

JD6805-0090 08.06142-9006
[182] Washer
[183] Socket, size 22

•Undoing and tightening
[184] Socket
JD6805-0093 80.99603-0327
[185] Engine barring gear

conjunction with:
JD6805-0023 80.99626-6008
[186] Gear ratchet

JD6805-0038 80.99627-0001
1st Edition 77
R.EN.MC11.31/35/39/43.01

CODE
[187] Cross beam
Removing and
mounting the cylinder
head in JD6805-0094 80.99629-6008
conjunction with:
• Slinging chain [188]
• Load hook [189]
[188] Slinging chain
• Removing and
mounting the cylinder
JD6805-0095 80.99629-6009
head
[189] Load hook

Removing and
mounting the cylinder JD6805-0096 80.99629-0040
head
[190] Dial gauge holder

• Checking the cylinder
liner protrusion in
conjunction with:
• Dial gauge [191] JD6805-0024 08.71000-3217
• Measuring plate [192]
• Hexagon shank bolt
[193]
• Washer [194]
[191] Dial gauge
liner protrusion
JD6805-0024 08.71000-3217
[192] Measuring plate

liner standout
JD6805-0097 80.99605-0286
1st Edition 78
R.EN.MC11.31/35/39/43.01

CODE
[193] Hexagon shank bolt
liner standout
JD6805-0098 06.01499-0015
[194] Washer
liner standout
JD6805-0099 06.15013-0417
1st Edition 79
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Removing the cylinder head cover

Removing the cylinder head
Disconnecting the speed sensor electrical
connection
NOTE
The mounting bolts can only be
removed from the cylinder head cover
• Disconnect the electrical connection (1) with damping elements and spacer sleeves.
Removing the cable duct cover • Unscrew the mounting bolts (3)
• Remove the cylinder head cover (2) from the
cylinder head (1)
• Open the locking pin (2) a quarter turn

• Remove the cable duct cover (1)
Removing the cable duct holder
• Remove the cap from the flywheel
housing/timing case
• Mount the Engine barring gear [185] (1) on the
flywheel housing/timing case

• Place the cable duct holder (2) to one side with
the wiring harness and secure
1st Edition 80
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Turning the engine to the TDC mark Removing the valve bridges
• Turn the engine in the engine’s running direction NOTE

with the Engine barring gear [185] (1) and Gear The cylinder head can also be
ratchet [186] until the 1st cylinder is at the TDC removed whilst the valve bridges
mark (2) are installed, depending on the type of
Removing the rocker arm mechanism repairs involved.
• Mark the installation position of the valve
bridges (1) and (2)
• Remove the valve bridges (1) and (2)
Assembling the special tool
NOTE
The cylinder head can also be removed
whilst the rocker arm mechanism is
installed, depending on the type of repairs
involved. • Insert the Torque multiplier i = 1 : 3,5
• Unscrew the mounting bolts (5) [175] (1) into the Support [176] (2)
• Remove the EVB counter-holder (6) • Mount the Holding fixture [178] (5) on the
• Unscrew the mounting bolts (3) and (4) Support [176] (2) with Pan head screw
• Remove the rocker arm mechanism (2) with [179](4) and Washer [182] (3)
rocker arm bearing bracket (1) • Put the Angle measuring disc [177] (10)
on the Torque multiplier i = 1 : 3,5 [175]
(1)
• Put the Socket, size 22 [183] (8) on the
Torque multiplier i = 1 : 3,5 [175] (1) and
lock using Connecting pin [180] (9) and
Rubber ring 42 mm [181] (7)
• Insert the Socket [152] (6) into the
Socket, size 22 [151] (8)
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Undoing the cylinder head bolts
Removing the cylinder head
NOTE
Undo the cylinder head bolts from
the outside inwards.
• Fit the special tool (1) on the cylinder
head bolt to be undone
• Undo all the cylinder head bolts
using special tool(1) and wrench (2)
Unscrewing the cylinder head bolts • Attach the Load hook [189] (6) to the
cylinder head (4) and camshaft
• Attach the Slinging chain [188] (3) in the
Load hook [189] (6) and the Cross beam
[187] (5)
• Lift the cylinder head (4) down from the
crankcase (1) using lifting device
• Remove the cylinder head gasket (2)
• Clean the tapped holes for the cylinder
head bolts
• Unscrew the cylinder head bolts (1) • Remove the special tool
1st Edition 82
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liner/crankcase, siehe Removing and

Installing the cylinder head installing the cylinder liners, 212
Turning the camshaft to the TDC mark Mounting the cylinder head
• Turn the camshaft (3) so that the TDC

mark (1) is aligned with the cylinder head
face (2)
Checking the cylinder liner standout
• Attach the Load hook [189] (6) to the

cylinder head (4) and camshaft
• Attach the Slinging chain [188] (3) in the
Load hook [189] (6) and the Cross beam
[187] (5)
• Place the new cylinder head gasket (2)
on the guide pins in the crankcase (1)
• Place the Measuring plate [192] (2) on • Place the cylinder head (4) on the
the cylinder liner crankcase (1)
• Screw in the Hexagon shank bolt [193] (4) • Remove the special tool
with Washer [194] (5) and tighten
• Put the Dial gauge holder [190] (6) with
Dial gauge [191] (3) on the Measuring
plate [192] (2)
• Place the dial gauge tip (1) on the
crankcase
• Zero the Dial gauge [191] (3)
• Carefully place the dial gauge tip (1) on
the cylinder liner and note the difference
on the dial gauge
The permitted cylinder liner protrusion is
0.035 -0.085 mm.
If the cylinder liner protrusion is out of
tolerance, fit a new cylinder
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Tightening sequence for cylinder head contact surface of the new cylinder head
bolts (1)
• Screw in the cylinder head bolts (1) and
tighten them by hand
• Tighten the cylinder head bolts (1) to Initial
torque 10 Nm in the sequence indicated
• Tighten the cylinder head bolts (1) to 2nd
• Tighten the cylinder head bolts (1) to 3rd
Final tightening of cylinder head bolts
• Fit the special tool (1) on the cylinder head

A intake side bolt that requires tightening
B exhaust side • Use the special tool (1) and wrench (2) to
·Ttight the cylinder head bolts clockwise in tighten the cylinder head bolts to 4th torque
the sequence indicated (1 to 26) 90° in the sequence indicated
Screwing in the cylinder head bolts • Use the special tool (1) and wrench (2) to
tighten the cylinder head bolts to 5th torque
90° in the sequence indicated
• Use the special tool (1) and wrench (2) to
tighten the cylinder head bolts to Final
torque 90° in the sequence indicated
WARNING
leaking cylinder head gasket
• Do not reuse old cylinder head bolts,
even if they have only been used once
• Lightly apply White T assembly paste on the
1st Edition 84
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Checking the camshaft TDC mark Installing the rocker arm mechanism
• Check the TDC mark (1) on the camshaft • Place the rocker arm bearing bracket (1) on
(3) the cylinder head
The TDC mark (1) must be in line with the • Place the rocker arm mechanism (2) on the
cylinder head face (2). rocker arm bearing bracket (1)
If the marks are not in line, remove the • Screw in the mounting bolts (3) and (4)
camshaft (3) and re-insert at the mark. • Tighten the mounting bolt (4) to 105 Nm
Fitting the valve bridges • Tighten the mounting bolt (3) to 105 Nm
• Fit the EVB counter-holder (6)
Tightening sequence for cylinder head cover
NOTE
The valve bridge recesses must
always face towards the camshaft.
• Fit the valve bridges (1) and (2) as marked
A intake side B exhaust side

• Stick to the illustrated mounting bolt
tightening sequence 1 to 18 in the following
work step
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Mounting the cylinder head cover Mounting the cable duct cover
• Check the gasket in the cylinder head • Put on the cable duct cover (1)
cover (2) and, if necessary, fit a new one • Close the locking pin (2) a quarter turn
• clean the seal gasket and the groove Connecting the speed sensor electrical
before install the cylinder head cover, connection
notice the difference of the cylinder head
cover bolts, there are 8 bolts at the
exhaust side without rubber washers, the
rest 10 bolts have rubber washers.
• Fit the cylinder head cover (2) on the
cylinder head (1)
• Screw in the mounting bolts (3)
• Tighten the mounting bolts (3) to 10 Nm
in the sequence indicated
Mounting the cable duct hold
• Position the cable duct holder (2) with the

wiring harness free of tension and kinks
and so that it does not chafe ·• Remove the Engine barring gear [185]
• Screw in and tighten the mounting bolts (1) from the flywheel housing/timing
(1) case
• Mount the cap on the flywheel
housing/timing case
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Checking and setting the valve clearance
1. Exhaust valve adjusting screw 2. Lock nut 3. Intake valve adjusting screw 4. Lock nut 5. EVB counter-holder lock nut 6.
EVB adjusting screw
Technical data
Item Technical data

Intake valve clearance 0.5±0.03mm
Exhaust valve clearance 0.8±0.03mm
EVB counter-holder adjustment dimension 0.6±0.03mm
Lock nuts（2），
（4） 45Nm
EVB counter-holder lock nut（5） 45Nm
Cylinder head cover mounting bolts 10Nm
WARNING
Danger of reduced engine output or engine damage
• Always adjust the valve clearance whilst the engine is cold
1st Edition 87
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WARNING
Special tools

CODE
[195 Engine barring gear
] • Cranking the engine in
conjunction with: JD6805-002 80.99626-60
• Gear ratchet [196] 3 08
[196 Gear ratchet

] • Cranking the engine
JD6805-003 80.99627-00
8 01
[197 Holding device

] Checking and adjusting
the valve and EVB
clearance in conjunction
with:
• Feeler gauge leaf 0.5
[198]
• Feeler gauge leaf 0.6 JD6805-010 08.75300-00
[199] 0 00
• Feeler gauge leaf 0.8
[200]
•Valve adjusting
spanner, size 14 [201]
•Valve adjusting
spanner, size 21 [202]
• Torque wrench [203]
[198 Feeler gauge leaf 0.5
] • Checking and adjusting JD6805-010 80.99607-01
the valve clearance 1 77
1st Edition 88
R.EN.MC11.31/35/39/43.01

CODE
] • Checking and adjusting
JD6805-010 80.99607-01
the EVB clearance
2 78

] • Checking and adjusting
JD6805-010 80.99607-01
the valve clearance
3 79
[201 Valve adjusting spanner,

] size 14
• Adjusting the valve JD6805-010 80.99603-60
clearance 4 31
[202 Valve adjusting spanner,

] size 21
• Adjusting the EVB
JD6805-010 80.99603-60
clearance
5 32
[203 Torque wrench

] • Setting the valve and
EVB clearance JD6805-003 08.06450-00
6 06
1st Edition 89
R.EN.MC11.31/35/39/43.01

Checking and setting the valve
clearance
Removing the cable duct cover
Remove the sealing cap from the ywheel

housing /timing case
• Mount the Engine barring gear [195] (1) on
the flywheel housing/timing case
• Open the locking pin (2) a quarter turn Moving the engine to the adjusting
• Remove the cable duct cover (1) position
Removing the cylinder head cover
A Rocker arms in overlap

B Rocker arms free
• Crank the engine in the engine's running
direction using Engine barring gear [195] and
NOTE Gear ratchet [196] until the rocker arms are in
The mounting bolts can only be overlap
removed from the cylinder head • Adjust free rocker arms as per table
cover with damping elements and spacer
sleeves.
• Remove the cylinder head cover (2) from the
cylinder head (1)
1st Edition 90
R.EN.MC11.31/35/39/43.01
Checking the intake valve clearance Checking the exhaust valve clearance
• Insert the Holding device [197] (4) with • Push down the valve bridge (2) several
Feeler gauge leaf 0.5 [198] (2) between the times in order to force the engine oil out of
ball socket (1) and valve bridge (3) the EVB piston (5)
Adjust the valve clearance if the valve • Insert the Holding device [197] (3) with
clearance is not 0.5 mm. Feeler gauge leaf 0.8 [200] (4) between the
Adjusting the intake valve clearance ball socket (1) and valve bridge (2)
Adjust the valve clearance if the valve
clearance is not 0.8 mm.
Moving the EVB piston to the adjusting
position
• Undo the lock nut (2) and adjusting screw (1)

• Insert the Holding device [197] (5) with
Feeler gauge leaf 0.5 [198] (6) between the
ball socket (3) and valve bridge (4) WARNING
• Screw in the adjusting screw (1) until the Danger of incorrect valve
Feeler gauge leaf 0.5 [198] (6) can be moved clearance
between the ball socket (3) and the valve • It must be possible to fully push
bridge (4) with little resistance the EVB piston into the valve bridge
• Hold the adjusting screw (1) steady with • Undo the lock nut (2) and unscrew it several
Valve adjusting spanner, size 14 [201] turns
• Tighten the lock nut (2) to 45 Nm using • Screw in the adjusting screw (1) to press the
Torque wrench [203] valve bridge (3) downwards several times until
• Check the setting again and, if necessary, the stop is reached
repeat the setting procedure All the engine oil must escape from the EVB
piston(4).
1st Edition 91
R.EN.MC11.31/35/39/43.01
Adjusting the exhaust valve clearance Adjusting the clearance for the EVB piston
• Undo the lock nut (3)

• Screw in the adjusting screw (2) to press the NOTE
valve bridge (6) downwards as far as the The valve bridge must not move the
pressure point exhaust valve when the adjusting
• Block the valve bridge (6) in this position with screw is screwed in.
the adjusting screw (1) • Undo the lock nut (2)
• Insert the Holding device [197] with Feeler • Unscrew the adjusting screw (1) until the
gauge leaf 0.8 [200] (5) between the ball Holding device [197] (3) can be inserted with
socket (4) and valve bridge (6) Feeler gauge leaf 0.6 [199] (4)
• Unscrew the adjusting screw (2) until the • Screw in the adjusting screw (1) with Feeler
Feeler gauge leaf 0.8 [200] (5) can be moved gauge leaf 0.6 [199] (4) inserted until the valve
between the ball socket (4) and the valve bridge reaches the stop – this can be felt by a
bridge (6) with little resistance noticeable increase in force
• Hold the adjusting screw (2) steady with • Hold the adjusting screw (1) steady with Valve
Valve adjusting spanner, size 14 [201] adjusting spanner, size 21 [202]
• Tighten the lock nut (3) to 45 Nm using • Tighten the lock nut (2) to 45 Nm using Torque
Torque wrench [203] wrench [203]
• Check the setting again and, if necessary, • Check the setting again and, if necessary,
repeat the setting procedure repeat the setting procedure
Checking the adjustment dimension for Removing the engine barring gear
the EVB piston
• Lightly push down the valve bridge (1) • Remove the Engine barring gear [195] (1) from
• Insert the Holding device [165] (3) with the flywheel housing/timing case
Feeler gauge leaf 0.6 [167] (2) between the • Mount the sealing cap on the flywheel housing
counter-holder (4) and the valve bridge (1) /timing case
Adjust the EVB clearance if the adjustment
dimension is not 0.6 mm.
1st Edition 92
R.EN.MC11.31/35/39/43.01
Tightening sequence for cylinder head cover Mounting the cylinder head cover
• Check the gasket in the cylinder head cover (2)

and, if necessary, fit a new one
• clean the seal gasket and the groove before
install the cylinder head cover, notice the
difference of the cylinder head cover bolts, there
are 8 bolts at the exhaust side without rubber
washers, the rest 10 bolts have rubber washers.
• Fit the cylinder head cover (2) on the cylinder
head (1)
• Tighten the mounting bolts (3) to 10 Nm in the
sequence indicated
Mounting the cable duct cover
A Intake side
B Exhaust side
• Stick to the illustrated mounting bolt tightening
sequence 1 to 18 in the following work step
• Put on the cable duct cover (1)

• Close the locking pin (2) a quarter turn
1st Edition 93
R.EN.MC11.31/35/39/43.01
VALVE STEM SEALS
Removing and installing the valve stem seals
Additional jobs
- Checking and setting the valve clearance，see 90.
- Removing and installing the injectors and pressure pipe，see 144.
1.cylinder head 2.valve stem seal 3.valve spring 4.valve collet
Technical data
Item specification technical data

Cylinder head cover 10Nm
mounting bolts
Rocker arm bearing M12×60-10.9 105+10Nm
bracket pan head screws
WARNING
1st Edition 94
R.EN.MC11.31/35/39/43.01
Special tool

CODE
• Cranking the
engine in
conjunction with:
[205] Gear ratchet

• Cranking the
engine
JD6805-0038 80.99627-0001
[206] Valve-spring
compressor
• Removing and
installing the valve
springs in
conjunction with:
JD6805-0106 80.99613-6000
• Adapter [207]
• Holder [211]
• Holder [210]
• Extension [209]
• Assembly device
[208]
[207] Adapter
• Removing and
JD6805-0107 80.99613-0042
springs
[208] Adapter JD6805-0108 80.99606-6092

• Removing and
springs
[209] Extension JD6805-0109 80.99606-6094
1st Edition 95
R.EN.MC11.31/35/39/43.01

CODE
• Removing and
springs
[210] Holder JD6805-0110 80.99613-0052

Removing and
springs
[211] Holder JD6805-0111 80.99613-0053

• Removing and
springs
[212] Magnetic pick-up JD6805-0112 80.99639-0009

tool
• Removing the
valve cotters
• adaptor [207]
• holder [210]
• holder [211]
• Valve-spring
compressor 206]
• Extension [209]
• Adapter [208]
[213] Assembly device
• Removing and
stem seal
JD6805-0113 80.99606-6088
[214] Mounting sleeve JD6805-0114 80.99606-0287
1st Edition 96
R.EN.MC11.31/35/39/43.01

CODE
• Installing the valve
stem seal in
conjunction with:
• Assembly device
[213]
1st Edition 97
R.EN.MC11.31/35/39/43.01

Removing the valve stem seals

housing/timingcase
• Open the locking pin (2) a quarter turn • Mount the Engine barring gear [204] (1) on
• Remove the cable duct cover (1) the flywheel housing/timing case
Removing the cylinder head cover Moving the engine to the adjusting
position

NOTE B Rocker arms free
The mounting bolts can only be • Crank the engine in the engine's running
removed from the cylinder head direction using Engine barring gear [204] and
cover with damping elements and spacer Gear ratchet [205] until the rocker arms are in
sleeves overlap
• Unscrew the mounting bolts (3) • Remove and install the free valve stem seals
• Remove the cylinder head cover (2) from the as per the table
cylinder head (1)
1st Edition 98
R.EN.MC11.31/35/39/43.01

Removing the rocker arm
mechanism

• Remove the EVB counter-holder (6)
• Unscrew the mounting bolts (3) and (4) NOTE
• Remove the rocker arm mechanism (2) with Retaining washer and Holder [211]
rocker arm bearing bracket (1) have left-hand threads.
Removing the valve bridges • Position the Holder [210] (5) and Holder [211]
(3) on the Valve-spring compressor [206] (1)
and then screw on by turning the threaded
spindle (4)
• Screw on the retaining washers (2) and (6)
• Position the lever (8) on the Valve-spring
compressor [206] (1) and secure using the
mounting bolt (7)
• Mark the installation position of the valve

bridges (1) and (2)
• Remove the valve bridges (1) and (2)
1st Edition 99
R.EN.MC11.31/35/39/43.01
Mounting the valve-spring compressor
Fitting the mounting device
• Position the Holder [210] (4) and Holder [211]

on the spring cap and tension by turning the
• Screw the Adapter [207] (2) into the bearing threaded spindle (5)
bracket (1) • Hook the Valve-spring compressor [206] (2)
• Screw the Assembly device [208] (3) into the in the Assembly device [208] (3)
Adapter [207] (2) • Place the Extension [209] (1) onto the
Valve-spring compressor [206] (2)
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R.EN.MC11.31/35/39/43.01
• Pull the valve stem seal (1) off the valve

Removing the valve cotters guide with impact weight (3)
Installing the valve stem seals

Installing the valve stem seals
CAUTION
Risk of injury due to springing
back ofthe valve springs
• Ensure that the Holder [210] and
Holder [211] are seated correctly on
the spring cap
• Do not remove the valve cotters from
the valve spring with your bare hands
• Push down the Valve-spring compressor
[206] (1) with Extension [209]
• Remove the valve cotters (2) from the valve NOTE
stem (3) with Magnetic pick-up tool [212] The intake and exhaust valve stem
• Release the Valve-spring compressor [206] seals are different colours.
(1) Green valve stem seals are installed
• Remove the valve spring together with the at the intake valves.
washer and spring cap Brown valve stem seals are installed
• Repeat the same procedure for all the valves at the exhaust valves.
• Remove the special tool • Lightly apply clean engine oil on the
Removing the valve stem seals Mounting sleeve [214] (2) and valve stem seal
(3)
• Push the Mounting sleeve [214] (2) over the
valve stem (1)
• Insert the valve stem seal (3) into the
Assembly device [213] (4) and clamp
• Push the Assembly device [213] (4) over the
Mounting sleeve [214] (2)
• Knock the valve stem seal (3) onto the valve
stem (1) using impact weight (5)
• Remove the Assembly device [213] (4) and
• Push the Assembly device [213] (2) over the Mounting sleeve [214] (2)
valvestem seal (1)
• Clamp the Assembly device [213] (2) Mounting the assembly device
1st Edition 101

R.EN.MC11.31/35/39/43.01
• Screw the Adapter [207] (2) into the bearing • Position the Holder [210] (4) and Holder [211]
bracket (1) on the spring cap and tension by turning the
• Screw the Assembly device [208] (3) into the threaded spindle (5)
Adapter [207] (2) • Hook the Valve-spring compressor [206] (2)
in the Assembly device [208] (3)
• Place the Extension [209] (1) onto the
Valve-spring compressor [206] (2)
Mounting the valve-spring compressor Installing the valve springs
1st Edition 102

R.EN.MC11.31/35/39/43.01
Installing the valve cotters
CAUTION
Risk of injury due to springing
back of the valve springs
• Ensure that the Holder [210] and
Holder [211] are seated correctly on
the spring retainer
• Do not insert the valve cotters into the
valve spring with your bare hands
• Push down the Valve-spring compressor
• Insert the washer (3), valve spring (2) and [206] (1) with Extension [209]
spring cap (1) over the valve stem • Use a suitable tool to insert the valve cotters
• Repeat the same procedure for all the valves (2) so that the valve cotters (2) are seated in
the grooves of the valve stem (3)
• Release the Valve-spring compressor [206]
(1)
• Remove the special tool
Fitting the valve bridges
NOTE
The valve bridge recesses must
always face towards the camshaft.
Installing the rocker arm mechanism
1st Edition 103

R.EN.MC11.31/35/39/43.01
Tightening sequence for cylinder head

cover
• Place the rocker arm bearing bracket (1) on

the cylinder head
• Place the rocker arm mechanism (2) on the
rocker arm bearing bracket (1)
• Screw in the mounting bolts (3) and (4)
• Tighten the mounting bolt (4) to 105 Nm
A intake side
B exhaust side
• Stick to the illustrated mounting bolt
tightening sequence 1 to 18 in the following
work step
• Remove the Engine barring gear [204] (1)

from the flywheel housing/timing case
• Mount the cap on the flywheel housing/timing
case
1st Edition 104

R.EN.MC11.31/35/39/43.01
VALVE TIMING
Mounting the cylinder head cover
• Check the gasket in the cylinder head cover

(2) and, if necessary, fit a new one
• Clean the seal gasket and the groove before
difference of the cylinder head cover bolts,
there are 8 bolts at the exhaust side without
rubber washers, the rest 10 bolts have rubber
washers.
head (1)
• Tighten the mounting bolts (3) to 10 Nm in
the sequence indicated
1. Camshaft gear 2. Intermediate gear 3. Camshaft 4. Cylinder head 5. Camshaft bearing cap

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R.EN.MC11.31/35/39/43.01
CAMSHAFT/CAMSHAFT BEARING
Removing and installing the camshaft/camshaft bearing
Additional jobs
- Checking the valve timing，see 125.
1. Camshaft gear 2. Intermediate gear 3. Camshaft 4.cylinder head 5.camshaft bearing
Technical data

Camshaft gear mounting bolts（1） M8×30-10.9 Initial torque 15Nm
Mounting bolts, camshaft gear（1） M8×30-10.9 Turn angle 90°
Intermediate gear mounting bolts M8×30-10.9 30Nm
（2）
Cylinder head cover mounting 10Nm
bolts
Rocker arm mechanism mounting M12×60-10.9 105+10Nm
bolts
Camshaft axial play（3） 0.05-0.85mm
Camshaft bearings Ø 39.925 - 39.950mm
1st Edition 106

R.EN.MC11.31/35/39/43.01

Camshaft bearing depth 42.095-42.150 mm
Camshaft gear installation depth 9.000-9.100mm
（1）
the seventh Camshaft bearing 32.500-32.700mm
seat width
Camshaft bearing shell width 25.700-26.000mm
Rocker arm radial play 0.030-0.066mm
Rocker arm bearing inside Ø 32.005-32.025 mm
diameter
Rocker arm shaft outside diameter Ø 31.959-91.975 mm
Service products
Omnifit 200M
WARNING
50% of the speciFIed tightening torque
Special tool
NO. Picture Instruction SINOTRUK MAN CODE

CODE
[215] Dial gauge
• Checking the camshaft
axial and radial play
inconjunction with:
• Checking the rocker arm JD6805-0024 08.71000-3217
radial play in conjunction
with:
• Checking the rocker arm
radial play
[217] Locating pin JD6805-0026 80.99605-0197
1st Edition 107

R.EN.MC11.31/35/39/43.01

CODE
• Checking the rocker arm
radial play
[218] Depth gauge (electronic)
bearing depth JD6805-0032 08.71195-9003
gear installation depth
[219] Plug-on handle
• Knocking in the cap in
conjunction with:
• Pressing plate [220] JD6805-0020 80.99617-0187
[220] Pressing plate

• Knocking in the cap
JD6805-0115 80.99604-0301
[221] Engine barring gear

conjunction with:
JD6805-0116 80.9626-6008
[222] Gear ratchet

JD6805-0038 80.99627-0001
1st Edition 108

R.EN.MC11.31/35/39/43.01

Checking the rocker arm
• Remove the cap from the ywheel

housing/timing case
• Open the locking pin (2) a quarter turn • Mount the Engine barring gear [221] (1)
• Remove the cable duct cover (1) on the flywheel housing/timing case
Removing the cylinder head cover Moving the engine into the checking
position

B Rocker arms free
NOTE ·• Crank the engine in the engine's running
The mounting bolts can only be direction using Engine barring gear [221]
removed from the cylinder head and Gear ratchet [222] until the rocker
cover with damping elements and spacer arms are in overlap
sleeves. • Check free rocker arms as per table
• Remove the cylinder head cover (2) from
the cylinder head (1)
1st Edition 109

R.EN.MC11.31/35/39/43.01
Checking the rocker arm radial play

Removing the rocker arm
mechanism
• Mount the Dial gauge holder [216] (2)

with the Dial gauge [215] (3) and Locating
pin [217]
• Position the Locating pin [217] against • Unscrew the mounting bolts (5)
the rocker arm (1) with a preload • Remove the EVB counter-holder (6)
• Press the rocker arm (1) vertically • Unscrew the mounting bolts (3) and (4)
downwards to the end position • Remove the rocker arm mechanism (2)
• Zero the Dial gauge [215] (3) with rocker arm bearing bracket (1)
• Pull the rocker arm (1) upwards to the Removing the valve bridges
end position and read off the difference
• Repeat the procedure for the remaining
rocker arms
The permitted radial play on the rocker
arm (1) is 0.030 - 0.066 mm.
If the radial play is out of tolerance, check
the inside diameter of the rocker arm (1)
and the outside diameter of the rocker arm
shaft.
Check the inside diameter of the rocker
arm (1), see Checking the rocker arm • Mark the installation position of the valve
bearing inside diameter, 114. bridges (1) and (2)
Check the outside diameter of the rocker • Remove the valve bridges (1) and (2)
arm shaft, see Checking the rocker arm
shaft outside diameter, 114.
1st Edition 110

R.EN.MC11.31/35/39/43.01
Checking the rocker arm shaft outside

Dismantling the rocker arm diameter
mechanism
• Clean the rocker arm shaft (2)

• Check the outside diameter of the rocker
arm shaft (2) using a micrometer (1)
• Detach the circlip (4) • Repeat the procedure for the remaining
• Remove the washer (3) rocker arm shafts (2)
• Mark the installation position of the The permitted outside diameter of the rocker
rocker arm (1) arm shaft (2) is Ø 31.959 - 31.975 mm.
• Pull the rocker arm (1) off the rocker arm If the outside diameter is out of tolerance,
shaft (2) fit a new rocker arm shaft (2)
Checking the rocker arm bearing inside Unscrewing the adjusting screw
diameter
• Unscrew the lock nut (1)

• Clean the rocker arm (1) with bearing • Unscrew the adjusting screw (3) from
• Use the Dial gauge [215] (3) and internal the rocker arm (2)
calliper
(2) to check the rocker arm bearing inside
diameter
• Repeat the procedure for the remaining
rocker arms
The permitted rocker arm bearing inside
diameter is Ø 32.005 - 32.025 mm.
If the inside diameter is out of tolerance,
fit a new rocker arm (1).
1st Edition 111

R.EN.MC11.31/35/39/43.01
Unscrewing the EVB adjusting screw

Assembling the rocker arm
mechanism
Screwing in the adjusting screw
• Unscrew the lock nut (3)

• Unscrew the adjusting screw (1) from the
EVB counter-holder (2)
• Screw the adjusting screw (3) into the
rocker arm (2)
• Screw on the lock nut (1)
Screwing in the EVB adjusting screw
• Screw the adjusting screw (1) into the

EVB counter-holder (2)
• Screw on the lock nut (3)
1st Edition 112

R.EN.MC11.31/35/39/43.01
Assembling the rocker arm mechanism

Checking the camshaft
Checking the camshaft axial play
• Lightly apply clean engine oil on the

rocker arm shaft (2)
• Push the rocker arm (1) onto the rocker • Mount the Dial gauge holder [216] (2)
arm shaft (2) as marked with the Dial gauge [215] (1) and Locating
• Fit the washer (3) pin [217]
• Attach the circlip (4) • Position the Locating pin [217] against
the camshaft (3) with a preload
• Push the camshaft (3) horizontally into
the end position towards the flywheel
housing/timing case
• Pull the camshaft (3) into the end
position, towards Dial gauge [215] (1), and
read off the difference
The permitted axial play on the camshaft
(3) is 0.050- 0.850 mm.
If the axial play is out of tolerance, check
the camshaft bearing depth, the camshaft
gear installation depth and the width of
camshaft bearing seat 7.
Check the camshaft bearing depth, see
Checking the depth of camshaft bearing 7,
119.
Check the camshaft gear installation depth,
see Checking the camshaft gear
installation depth, 119.
Check the width of camshaft bearing seat
7, siehe Checking the width of camshaft
bearing seat 7, 119.
1st Edition 113

R.EN.MC11.31/35/39/43.01
Checking the camshaft radial play

Removing the camshaft
Turning the engine to the TDC mark

with Dial gauge [215] (2) and Locating pin • Turn the engine in the engine’s running
[217] direction with the Engine barring gear [221] (1)
• Position the Locating pin [217] against and Gear ratchet [222] until the 1st cylinder is at
the the TDC mark (2)
camshaft (3) with a preload Checking the camshaft TDC mark
• Press the camshaft (3) vertically
downwards to the end position
• Pull the camshaft (3) into the end
position, towards Dial gauge [215] (2), and
read off the difference
The permitted radial play on the camshaft
(3) is 0.024 - 0.090 mm.
If the radial play is out of tolerance, check
the inside diameter of the camshaft
bearing shells and the outside diameter of • Check the TDC mark (1) on the camshaft (3)
the camshaft bearing. The camshaft (3) TDC mark (1) must be in line
Check the inside diameter of the camshaft with the cylinder head face (2).
bearing shells, see Checking the camshaft If the marks are not in line, continue cranking
bearing shells,118. the engine by 360° in the engine's running
Check the outside diameter of the direction until the TDC mark on the flywheel is
camshaft bearing, see Checking the reached.
outside diameter of the camshaft bearing, Block the Engine barring gear [221].
119
1st Edition 114

R.EN.MC11.31/35/39/43.01
NOTE
• Mark the installation position of the bearing The difference between dimension A
cap (1) and dimension B is the spread of the
• Unscrew the mounting bolts (2) camshaft bearings.
• Mark the installation position of the camshaft • Clean the camshaft bearing shells (2) and put
bearing shells them together on a at surface as marked
• Remove the bearing cap (1) with the camshaft • Check dimension A using a micrometer (1)
bearing shells • Check dimension B using a micrometer (1)
• Remove the camshaft (3) with the camshaft The permitted spread of the camshaft bearing
bearing shells shells (2) is max. 1.00 mm.
Removing the camshaft gear If the spread is out of tolerance, fit new camshaft
bearing shells (2).
Checking the camshaft bearing shells
• Unscrew the mounting bolts (4) • Clean the bearing cap (1) and the camshaft
• Pull the pulse plate (3) and camshaft gear (2) bearing shells
off the camshaft (1) • Mount the bearing cap (1) on the cylinder head
(4) with the camshaft bearing shells, as marked
• Use the Dial gauge [215] (3) and internal
caliper (2) to check the inside diameter of the
camshaft bearing shells
The permitted inside diameter of the camshaft
bearing shells is Ø 39.974 - 40.015 mm.
If the inside diameter is out of tolerance, fit new
camshaft bearing shells.
Checking the outside diameter of the
Checking the camshaft bearing camshaft bearing
1st Edition 115

R.EN.MC11.31/35/39/43.01
• Clean the camshaft (3) • Clean the camshaft gear (2)

• Check the outside diameter of the camshaft • Check the installation depth of the camshaft
bearing (1) using a micrometer (2) gear (2) using the Depth gauge (electronic) [218]
• Repeat the procedure at the rest of the (1)
camshaft bearings The permitted installation depth of the camshaft
The permitted outside diameter of the camshaft gear (2) is 9.000 - 9.010 mm.
bearing (1) is Ø 39.925 - 39.950 mm. If the installation depth is out of tolerance, fit a
If the outside diameter is out of tolerance, fit a new camshaft gear (2).
new camshaft (3). Checking the width of camshaft bearing seat
Checking the depth of camshaft bearing 7 7
• Check the depth of camshaft bearing 7 (2)

using Depth gauge (electronic) [218] (1) • Clean camshaft bearing seat 7 (2)
The permitted depth of camshaft bearing 7 (2) is • Check the width of camshaft bearing seat 7 (2)
42.095 - 42.150 mm. using a micrometer (1)
If the depth is out of tolerance, fit a new The permitted width of camshaft bearing seat 7
(2) is 32.500 - 32.700 mm.
camshaft(3)
If the width is out of tolerance, fit a new cylinder
head
Checking the camshaft gear installation

depth
1st Edition 116

R.EN.MC11.31/35/39/43.01
intermediate gear
Removing the cap
• Remove the intermediate gear (1) with

intermediate gear pin (2) upwards out of the
cylinder head
• Knock in the cap (2) using a screwdriver (1) at • Pull the intermediate gear (1) off the
the lowest edge intermediate gear pin (2)
• Prise out the cap (2)
Unscrewing the intermediate gear mounting
bolts
• Unscrew the mounting bolts (2) from the

intermediate gear (1)
Removing the camshaft intermediate gear
1st Edition 117

R.EN.MC11.31/35/39/43.01
Installing the cap

Installing the camshaft
intermediate gear
Installing the camshaft intermediate gear
• Lightly apply Omnifit 200M on the contact

surfaces of the new cap (3)
• Assemble the Pressing plate [220] (1) and the
Plug-on handle [219] (2)
• Lightly apply clean engine oil on the • Knock in the cap (3) as far as the stop using
intermediate gear pin (2) the special tool
• Insert the intermediate gear pin (2) into the
Installing the camshaft
• Insert the intermediate gear (1) with Mounting the camshaft gear
intermediate gear pin (2) into the cylinder head
from above
Screwing in the intermediate gear mounting
bolts
• Align the camshaft gear (3) and pulse plate (4)

with the locating pin (2)
• Fit the camshaft gear (3) and the pulse plate
(4) on the camshaft (1)
• Align the intermediate gear (1) with • Screw in new mounting bolts (5) and tighten
intermediate gear pin with the bores in the them to Initial torque 15 Nm
cylinder head • Tighten the mounting bolts (5) to Final torque
• Screw in new mounting bolts (2) and tighten 90°
them to 30 Nm
1st Edition 118

R.EN.MC11.31/35/39/43.01
Installing the camshaft Tightening the camshaft bearing mounting

bolts
• Lightly apply clean engine oil on the lower

camshaft bearing shells • Tighten the mounting bolts (1)
• Insert the lower camshaft bearing shells as Releasing the engine barring gear
marked
• Insert the camshaft (5) so that the TDC mark
(1) is aligned with the cylinder head face (2)
• Lightly apply clean engine oil on the upper
camshaft bearing shells
• Insert the upper camshaft bearing shells into
the bearing cap (3) as marked
• Fit the bearing cap (3)
• Screw in the new mounting bolts (4) and
evenly tighten them by hand without twisting
the camshaft(5) • Release the Engine barring gear [221] (1)
Checking the engine timing
• Use the Gear ratchet [222] to crank the engine

720° in the engine's running direction until the
TDC mark (2) is reached
• Block the Engine barring gear [221] (1)
1st Edition 119

R.EN.MC11.31/35/39/43.01
Checking the camshaft TDC mark

mechanism
Fitting the valve bridges
• Check the TDC mark (1) on the camshaft (3)

The camshaft (3) TDC mark (1) must be in line
with the cylinder head face (2). NOTE
If the marks are not in line, remove the The valve bridge recesses must always
camshaft (3) and re-insert at the mark. face towards the camshaft.
Installing the rocker arm mechanism
• Place the rocker arm bearing bracket (1) on

the cylinder head
• Place the rocker arm mechanism (2) on the
rocker arm bearing bracket (1)
• Screw in the mounting bolts (3) and (4)

cover
Installing the rocker arm
1st Edition 120
R.EN.MC11.31/35/39/43.01

sequence indicated

A Intake side
B Exhaust side
• Stick to the illustrated mounting bolt tightening
sequence 1 to 18 in the following work step
Mounting the cylinder head cover

from the flywheel housing/timing case
• Mount the cap on the flywheel housing/timing
case

washers.
head (1)
1st Edition 121

R.EN.MC11.31/35/39/43.01
VALVE TIMING
Checking the valve timing
Additional jobs
– Checking and setting the valve clearance，see 90.
1.camshaft 2. Flywheel housing/timing case 3. Engine barring gear
Technical data
Item Technical data

Valve lift during measurement intake valve 10±0.2mm，exhaust valve12±0.2mm
Cylinder head cover mounting bolts 10Nm
WARNING
NOTE
The valve timing must be checked with the valve clearance set correctly
1st Edition 122

R.EN.MC11.31/35/39/43.01
Special tools

CODE
[223] Dial gauge JD6805-0024 08.71000-3217
• Checking the valve
timing in conjunction with:

timing
[225] Locating pin JD6805-0026 80.99605-0197

timing

conjunction with:
[227] Gear ratchet JD6805-0038 80.99627-0001

1st Edition 123

R.EN.MC11.31/35/39/43.01

Checking the valve timing

housing/timing case
• Open the locking pin (2) a quarter turn • Mount the Engine barring gear [226] (1) on
• Remove the cable duct cover (1) the flywheel housing/timing case
Removing the cylinder head cover Turning the engine to the TDC mark
• Turn the flywheel in the engine's running

NOTE direction with Engine barring gear [226] (1) and
The mounting bolts can only be Gear ratchet [227] until the TDC mark on the
removed from the cylinder head flywheel is lined up with the TDC mark (2)
cover with damping elements and spacer
sleeves. The 6th cylinder rocker arms must be in overlap.
• Unscrew the mounting bolts (3) If the 6th cylinder rocker arms are not in overlap,
• Remove the cylinder head cover (2) from turn the flywheel a further 360° until the TDC
the cylinder head (1)） mark is reached
Checking the valve lift
1st Edition 124

R.EN.MC11.31/35/39/43.01
cover
WARNING
A false reading will be obtained if the
engine is turned against the engine's
running direction
• Only turn the engine in the engine's
running direction A Intake side
• Place the Dial gauge [223] (4) with Locating B Exhaust side
pin [225] (2) and Dial gauge holder [224] (3) on • Stick to the illustrated mounting bolt
the 3rd cylinder intake valve disc tightening sequence 1 to 18 in the following
• Zero the Dial gauge [223] (4) work step
• Continue cranking the engine in the engine's Mounting the cylinder head cover
running direction until the dial gauge pointer
stops moving
In this position, the correct valve lift must be

11.30 -11.70 mm.
• Check the gasket in the cylinder head cover

(2) and, if necessary, fit a new one
washers.
head (1)
• Tighten the mounting bolts (3) to 10 Nm in
the sequence indicated
1st Edition 125

R.EN.MC11.31/35/39/43.01

• Remove the Engine barring gear [226] (1) from the

flywheel housing/timing case
• Mount the sealing cap on the flywheel housing
/timing case
1st Edition 126

R.EN.MC11.31/35/39/43.01
REAR TIMING GEARS
Removing and installing the rear timing gears
Additional jobs
- Removing and installing the engine control unit，see 18.
- Removing and installing the coolant manifold，see 31.
- Removing and installing the thermostats，see 35
- Removing and installing the thermostat housing，see 37.
- Removing and installing the starter，see 52.
- Removing and installing the exhaust manifold，see 65.
- Removing and installing the charge-air pipe，see 68.
- Removing and installing the turbocharger，sse 72.
- Removing and installing the cylinder head，see 77
- Checking the valve timing，see 125.
- Removing and installing the injectors and pressure pipe，see 144
- Removing and installing the oil module ,see 59
- Removing and installing the rear crankshaft oil seal，see 59
- Removing and installing the flywheel，see 222.
1. Rear crankshaft gear 2. Air compressor intermediate gear 3.mounting bolts 4. Large intermediate gear
5. Mounting bolt 6. Small intermediate gear
1st Edition 127

R.EN.MC11.31/35/39/43.01
Technical data

mounting bolts（5） M14×80-10.9 Initial torque 150Nm
mounting bolts（5） M14×80-10.9 Final torque 90°
mounting bolts（3） M12×55-10.9 115Nm
Small intermediate gear mounting bolts（6） M8×20-10.9 30Nm
Backlash, large intermediate gear（4）- rear crankshaft 0.052-0.176mm
gear（1）
Backlash, large intermediate gear （ 4 ） - small 0.052-0.176mm
intermediate gear（6）
Axial play, air compressor intermediate gear（2） 0.100-0.240mm
Height, air compressor intermediate gear（2） 25.900-26.000mm
Height, thrust washer, air compressor intermediate gear 4.800-5.000mm
（2）
Inside diameter, air compressor intermediate gear（2） Ø 60.00 - 60.03 mm
Outside diameter, air compressor intermediate gear pin Ø 59.921 - 59.940 mm
Height, air compressor intermediate gear pin 26.100-26.140mm
Axial play, large intermediate gear（4） 0.100-0.290mm
Radial play, large intermediate gear（4） 0.060-0.109mm
Height, large intermediate gear（4） 52.950-53.000mm
Inside diameter, large intermediate gear（4） Ø 80.000 - 80.030
mm
Outside diameter, large intermediate gear pin Ø 79.921 - 79.940
mm
Height, large intermediate gear pin 56.200-56.240mm
Axial play, small intermediate gear（6） 0.100-0.290mm
Radial play, small intermediate gear（6） 0.060-0.109mm
Height, small intermediate gear（6） 17.950-18.000mm
Inside diameter, small intermediate gear（6） Ø 60.000 - 60.030
mm
Outside diameter, small intermediate gear pin Ø 59.921 - 59.940
mm
Height, small intermediate gear pin 21.200-21.240mm
WARNING
50 % of thespecified tightening torque
1st Edition 128

R.EN.MC11.31/35/39/43.01
NOTE
The intermediate gear and pin do not have to be exchanged as a set.
They can also be replaced individually, depending on the degree of wear.
NOTE
The intermediate gear to the air compressor is split into two sections and preloaded (noise
damping).
Backlash cannot be measured here
Special tools

CODE
[233] Aligning punch JD6805-0117 80.99617-0020
• Installing the rear crankshaft
gear
[234] Aligning tool JD6805-0118 80.99617-0209

• Removing the air compressor
intermediate gear
[235] Dial gauge JD6805-0024 08.71000-3217

• Checking the inside diameter of
the intermediate gears
• Checking the backlash of the
intermediate gears in conjunction
with:
• Checking the axial and radial
play of the intermediate gears in
conjunction with:
• Checking the intermediate gear
backlash
[237] Locating pin JD6805-0026 80.99605-0197

backlash
1st Edition 129

R.EN.MC11.31/35/39/43.01
[238] Depth gauge (electronic) JD6805-0032 08.71195-9003

pin height
1st Edition 130

R.EN.MC11.31/35/39/43.01
If the backlash is out of tolerance, fit a new

Checking the timing gear backlash small intermediate gear (4) and large
Checking the crankshaft gear/large intermediate gear
intermediate gear backlash
Setting the crankshaft gear to the
marks
Fixing the crankshaft gear
• Mount the Dial gauge holder [236] (3) with the

Dial gauge [235] (2) and Locating pin [237]
• Position the Locating pin [237] against the large
intermediate gear (1) with a preload
• Check the backlash between the crankshaft • Fix the crankshaft gear (1) by screwing in the
gear (4) and the large intermediate gear (1) mounting bolts (2) and (3)
The permitted backlash is 0.052 - 0.176 mm. Setting the crankshaft gear to the marks
If the backlash is out of tolerance, fit a new
crankshaft gear (4) and large intermediate gear
(1).
Checking the small intermediate gear/large
intermediate gear backlash
• Crank the engine until the mark (1) is aligned

with the mark (2)
Mark (1) and mark (2) are aligned.
• Mount the Dial gauge holder [236] (2) with

Dial gauge [235] (1) and Locating pin [237] (3)
• Position the Locating pin [237] (3) against the
small intermediate gear (4) with a preload
• Check the backlash on the small intermediate
gear (4) The permitted backlash is 0.052 - 0.176
mm.
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R.EN.MC11.31/35/39/43.01
Unscrewing the crankshaft gear mounting

bolts
Removing the large
intermediate gear
Checking the axial play on the large
intermediate gear
• Release the crankshaft gear (1) by unscrewing

the mounting bolts (2) and (3)

the Dial gauge [235] (2) and Locating pin
[237]
• Position the Locating pin [237] against the
large intermediate gear (1) with a preload
• Push the large intermediate gear (1) into
the end position
• Pull the large intermediate gear (1) into the
The permitted axial play is 0.100 - 0.290
mm.
If the axial play is out of tolerance, check the
height of the large intermediate gear (1) and
large intermediate gear pin (4).
Check the height of the large intermediate
gear (1), see Checking the large
intermediate gear height, 133
Check the height of the large intermediate
gear pin (4), see Checking the large
intermediate gear pin height, 133
1st Edition 132

R.EN.MC11.31/35/39/43.01
Checking the large intermediate gear

height
Checking the radial play on the large
intermediate gear
• Clean the large intermediate gear (1)

• Unscrew the mounting bolts (1) • Check dimension A of the large
• Remove the large intermediate gear (3) intermediate gear (1)
with intermediate gear pin (2) The permitted dimension A is 52.950 -
53.000 mm.
If dimension A is out of tolerance, fit a new
large intermediate gear (1).
Checking the inside diameter of the
large intermediate gear

caliper (1) to check the inside diameter of
the large intermediate gear (3)
The permitted inside diameter is
Ø 80.000 - 80.035 mm.
If the inside diameter is out of tolerance, t
a new large intermediate gear (3).
1st Edition 133

R.EN.MC11.31/35/39/43.01
Checking the large intermediate gear pin

height
Removing the small
intermediate gear
Checking the axial play on the small
intermediate gear
• Clean the large intermediate gear pin (1)

• Check the height of the large intermediate
gear pin (1) with Depth gauge (electronic) • Mount the Dial gauge holder [236] (2) with
[238] (2) the Dial gauge [235] (1) and Locating pin
The permitted height is 56.200 - 56.240 mm. [237]
If the height is out of tolerance, fit a new large • Position the Locating pin [237] against the
intermediate gear pin (1). small intermediate gear (3) with a preload
Checking the outside diameter of the large • Push the small intermediate gear (3) into
intermediate gear pin the end position
• Pull the small intermediate gear (3) into
the end position and read off the difference
The permitted axial play is 0.100 - 0.290
mm.
height of the small intermediate gear (3) and
small intermediate gear pin.
Check the height of the small intermediate
gear (3), see Checking the small
• Check the outside diameter of the large intermediate gear height, 135.
intermediate gear pin (1) using a micrometer Check the height of the small
(2) intermediate gear pin, see Checking the
The permitted outside diameter is small intermediate gear pin height, 135.
Ø 79.921 - 79.940 mm.
If the outside diameter is out of tolerance,
fit a new large intermediate gear pin (1).
1st Edition 134

R.EN.MC11.31/35/39/43.01
Removing the small intermediate gear Checking the inside diameter of the
small intermediate gear
• Unscrew the mounting bolts (1) • Use the Dial gauge [235] (2) and internal
• Remove the small intermediate gear (3) caliper (1) to check the inside diameter of
with small intermediate gear pin (2) the small intermediate gear (3)
Checking the small intermediate gear The permitted inside diameter of the small
height intermediate gear (3) is Ø 60.000 - 60.030
mm.
If the inside diameter is out of tolerance, fit a
new small intermediate gear (3).
• Clean the small intermediate gear (1)

• Check dimension A of the small
The permitted dimension A is 17.000 -
17.500 mm.
small intermediate gear (1).
1st Edition 135

R.EN.MC11.31/35/39/43.01
Checking the small intermediate gear pin

height
Removing the crankshaft gear
• Press the crankshaft gear (2) off the

crankshaft (1) with lever (3)
• Clean the small intermediate gear pin (1)
• Check the height of the small intermediate
gear pin (1) with Depth gauge (electronic)
[238] (2)
The permitted height of the small
intermediate gear pin (1) is 21.200 - 21.240
mm.
If the height is out of tolerance, fit a new
small intermediate gear pin (1).
small intermediate gear pin
• Check the outside diameter of the small

intermediate gear pin (1) using a micrometer
(2)
The permitted outside diameter of the gear pin (1)
is Ø 59.921 - 59.940 mm.
If the outside diameter is out of tolerance, fit
a new small intermediate gear pin (1)
1st Edition 136

R.EN.MC11.31/35/39/43.01
Removing the air compressor Screwing in the aligning tool
intermediate gear
Checking the axial play on the air
compressor intermediate gear
• Unscrew one mounting bolt (1)

• Screw in the Aligning tool [234] (2)
• Unscrew the remaining mounting bolts (1)
from the air compressor intermediate gear pin
• Mount the Dial gauge holder [236] (1) with the (3)
Dial gauge [235] (3) and Locating pin [237] Removing the air compressor intermediate
• Position the Locating pin [237] against the air gear
compressor intermediate gear (2) with a
preload
• Push the air compressor intermediate gear (2)
into the end position
• Pull the air compressor intermediate gear (2)
into the end position and read off the difference
The permitted axial play is 0.100 - 0.190 mm.
height of the air compressor intermediate gear
(2) and intermediate gear pin.
Check the height of the air compressor WARNING
intermediate gear (2), see Checking the air The thrust washer can fall into the
compressor intermediate gear height, 137 oil sump
Check the height of the intermediate gear pin, • Before removing the intermediate
see Checking the air compressor intermediate gear, secure the thrust washer to prevent it
gear pin height, 138 from falling·
• Hold the thrust washer (2) steady behind the
air compressor intermediate gear (1)
• Unscrew the Aligning tool [234]
• Remove the air compressor intermediate gear
(1) with the thrust washer (2) and air
compressor intermediate gear pin (3)
1st Edition 137

R.EN.MC11.31/35/39/43.01
Checking the air compressor intermediate 60.03 mm.

gear height If the inside diameter is out of tolerance, fit a
new air compressor intermediate gear (3).
• Clean the air compressor intermediate gear (1)

and thrust washer (2)
• Check the height of the air compressor
intermediate gear (1) and the thickness of the
thrust washer (2)
The permitted dimension A is 25.900 - 26.000
mm.
If dimension A is out of tolerance, t a new air
compressor intermediate gear (1).
The permitted thickness of the thrust washer (2)
is 4.800 - 5.000 mm.
If the thickness is out of tolerance, fit a new
thrust washer (2).
Checking the inside diameter of the air
compressor intermediate gear
• Clean the air compressor intermediate gear

(3)
caliper (1) to check the inside diameter of the
air
compressor intermediate gear (3)
The permitted inside diameter of the air
compressor intermediate gear (3) is Ø 60.00 -
1st Edition 138

R.EN.MC11.31/35/39/43.01
Checking the air compressor intermediate

gear pin height
Installing the timing gears
Air compressor intermediate gear
installation instructions
• Clean the intermediate gear pin (1)

• Check the height of the intermediate gear pin Mount the split air compressor intermediate
(1) with Depth gauge (electronic) [238] (2). gear with the wider side (1) of the division
The permitted height of the intermediate gear facing the crankcase
pin (1) is 26.100-26.140mm. Air compressor intermediate gear rubber
If the height is out of tolerance, fit a new element faces the crankcase.
intermediate gear pin (1). Positioning the air compressor intermediate
Checking the outside diameter of the gear
intermediate gear pin
• Lightly apply clean engine oil on the air

• Check the outside diameter of the intermediate compressor intermediate gear pin (3)
gear pin (1) using a micrometer (2) • Insert the air compressor intermediate gear
The permitted outside diameter of the pin (3) into the air compressor intermediate
intermediate gear pin (1) is Ø 59.921 - 59.940 gear (1)
mm. • Place the thrust washer (2) on the air
If the outside diameter is out of tolerance, fit a compressor intermediate gear pin (3) with the
new intermediate gear pin (1). more heavily chamfered side facing the
crankcase
1st Edition 139

R.EN.MC11.31/35/39/43.01
Installing the air compressor intermediate Installing the crankshaft gear

gear
• Turn the crankshaft until the centring pin (4) is

perpendicular to the oil sump
• Insert the air compressor intermediate gear • Screw in the Aligning punch [233] (3) and (5)
with air compressor intermediate gear pin (3) • Align the crankshaft gear (1) with the centring
and thrust washer into the crankcase and pin (4)
secure using Aligning tool [234] (2) • Push the crankshaft gear (1) onto the
• Screw in the new mounting bolts (1) crankshaft
• Unscrew the Aligning tool [234] (2) • Unscrew the Aligning punch [233] (3) and (5)
• Screw in the remaining new mounting bolt (1) Installing the large intermediate gear
Installing the small intermediate gear
• Lightly apply clean engine oil on the large

intermediate gear pin (2)
• Lightly apply clean engine oil on the small • Insert the large intermediate gear pin (2) into
intermediate gear pin (2) the large intermediate gear (3)
• Fit the small intermediate gear (4) with the • Install the large intermediate gear (3) so that
contact surface (3) facing the small the markings on the large intermediate gear (3)
intermediate gear pin (2) and crankshaft gear are lined up, see Checking
• Insert the small intermediate gear (4) with the crankshaft gear mark, 140
small intermediate gear pin (2) into the • Screw in new mounting bolts (1) and tighten
crankcase them to Initial torque 105 Nm
• Screw in new mounting bolts (1) and tighten • Tighten the mounting bolts (1) to Final torque
them to 30 Nm
90°
1st Edition 140

R.EN.MC11.31/35/39/43.01
Checking the crankshaft gear mark
• Check that the mark (1) on the large

intermediate gear and the mark (2) on the
crankshaft gear are in line
If the marks (1) and (2) are not in line,
remove the large intermediate gear and
re-insert it at the mark
1st Edition 141

R.EN.MC11.31/35/39/43.01
COMMON-RAIL SYSTEM
1. Mounting nut 2. Injector wiring harness 3. Rail connection 4. Pressure screw 5. Fuel service centre holder 6. Fuel service centre
7. Fuel pump 8. High-pressure pump 9. Mounting bolt 10. High-pressure pump poly-V-belt pulley 11. Mounting bolt
12. High-pressure line 13. Cylinder head 14. Pressure flange 15. Mounting bolt 16. Injector
WARNING
• If impact wrenches are used, these may only be used for pretightening to max. 50
% of the specified tightening torque
1st Edition 142

R.EN.MC11.31/35/39/43.01
INJECTORS AND PRESSURE PIPE
Removing and installing the injectors and pressure pipe
Addition work
- Removing and installing the Engine control Unit，see 18.
1.mounting bolt 2.rail connection 3.cylinder head 4.pressure flange 5.pressure screw 6.injector 7.mounting nut
8. Injector wiring harness 9.pressure pipe 10.mounting bolt
Technical data

High-pressure line (initial use) Initial torque 10 Nm
High-pressure line (initial use) Final torque 60°
High-pressure line (re-use) Initial torque 10 Nm
High-pressure line (re-use) Final torque 30°
Mounting bolt (10) M8×50-10.9 tighten it with hands (about 1.5Nm)
Mounting bolt (10) M8×50-10.9 Final torque 35 Nm
Pressure screw (1) Initial torque 10 Nm
Pressure screw (1) Final torque 20 Nm 60°
1st Edition 143

R.EN.MC11.31/35/39/43.01

Mounting bolt (5) M8×50-10.9 Initial torque 1-2Nm
Mounting bolt (5) M8×50-10.9 Final torque 25 Nm + 90°
Mounting nut (7) Cable socket 1.8+0.25Nm
nut M4
Drip test pressurisation 4+0.5 bar
Pressure drop 0.1 bar in 10 minutes
Rail-pressure sensor M18×15 70±5Nm
Pressure limiting valve M18×15 100±5Nm
Injector wiring harness M6×16-10.9 15Nm
mounting bolts
Cylinder head cover 10Nm
mounting bolts
Service product
Technical Vaseline
WARNING
• All work on components of the common-rail system must be performed by specially
trained personnel only.
• The engine must be stationary for at least 5 minutes before commencing work in order
to enable depressurisation in the pressure pipe, or depressurisation must be checked by
means of EOL (desired value 0)
• Always renew rail connections once they have been undone
• Do not reuse plugs for high-pressure lines, the pressure pipe or injectors, even if they have only
been used once
• Follow the sequence described when tightening injectors, high-pressure lines, the pressure pipe
and rail connections
WARNING
• Always remove only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
• If impact wrenches are used, these may only be used for pretightening to max. 50% of
Special tools
1st Edition 144

R.EN.MC11.31/35/39/43.01
NO. Picture Instruction SINOTRUK CODE MAN CODE
[79] Adapter
• Removing the rail
JD6805-0053 80.99603-0173
connection
·Extractor device[80]
[80] Extractor device
• Removing the rail
JD6805-0054 80.99602-0011
connection

• Removing and
installing the
JD6805-0055 80.99603-0309
high-pressure lines
• Extension [83]
• Removing and
installing the
JD6805-0056 80.99603-0310
high-pressure line in
conjunction with:
• Extension [83]
[83] Extension
• Removing and
installing the JD6805-0057 08.06139-9025
high-pressure lines
[84] Puller
• Extracting injectors in
conjunction with:
• Plate [85] JD6805-0058 80.99601-6022
• Column 66 mm [86]
• Column 70 mm [87]
• Hexagon nut M12 [88]
[85] Plate
• Extracting the
injectors JD6805-0059 80.99602-0176
1st Edition 145

R.EN.MC11.31/35/39/43.01
[86] Column 66 mm
• Extracting the
injectors JD6805-0060 80.99602-0193
[87] Column 70 mm
• Extracting the
injectors JD6805-0061 80.99602-0194
[88] Hexagon nut M12

• Extracting the
JD6805-0062 06.11226-8306
injectors
[89] Torque screwdriver

• Attaching the injector
cable in conjunction
JD6805-0063 08.06510-9024
with:
• Adapter [90]
• Socket, size 7 [91]
[90] Adapter
• Mounting the injector
JD6805-0064 08.06139-9029
cable
[91] Socket, size 7

• Mounting the injector
cable JD6805-0065 08.06141-0700
[92] Pressure piece

• Installing injectors
JD6805-0066 80.99606-0609
[93] Pressure loss tester

• Checking the
high-pressure system
for leaks in conjunction JD6805-0067 80.99607-6027
with:
• Adapter [94]
• Threaded connection
1st Edition 146

R.EN.MC11.31/35/39/43.01
[95]
• Sealing ring with
elastomer sealing lip
[98]
• Hollow screw [96]
• Ring connector [97]
[94] Adapter
• Checking the
high-pressure system JD6805-0068 80.99620-0033
for leaks
[95] Threaded connection

• Checking the
high-pressure system JD6805-0069 81.98130-0614
for leaks
[96] Hollow screw

• Checking the
JD6805-0070 51.98150-0715
for leaks
[97] Ring connector

• Checking the
for leaks JD6805-0071 51.98103-0037
[98] Sealing ring with

elastomer sealing lip
• Checking the
JD6805-0072 06.56639-0017
for leaks
1st Edition 147

R.EN.MC11.31/35/39/43.01
Detaching the fuel return line

Removing the injectors and
pressure pipe
Disconnecting the rail pressure sensor
electrical connection
WARNING
Component damage due to fuel in the
combustion chamber
• Allow the return duct in the cylinder head
to empty before extracting the injectors
WARNING
Danger of environmental pollution
• Disconnect the electrical connection (1) • Collect any remaining fuel that emerges in a
Removing the dipstick holder suitable container
• Unscrew the hollow screw (1) and allow
the return duct to empty
• Unscrew the fuel line (2) from the LVE fitting (3))
• Unscrew the fuel line (4) from the LVE fitting (3)
• Unscrew the LVE fitting (3) from the ring
connector (6)
• Unscrew the hollow screw (5)
• Remove the ring connector (6) with sealing rings
Detaching the high-pressure line

• Fasten the holder (1) with dipstick at the
side

• Detach the high-pressure line (3) from the
high-pressure pump (4) and pressure pipe (1) with
Socket, size 19 [82] and Extension [83]
Detaching high-pressure lines
1st Edition 148

R.EN.MC11.31/35/39/43.01
pressure limiting valve
WARNING
Danger of damage due to dirt WARNING
ingress Component damage due to lack
• Always detach only one of lubricant
high-pressure line • Do not wash off the pressure
• Close the component connections limiting valve and rail pressure
immediately using new, clean protective sensor as the thread and lipped edge
sleeves are coated with lubricant
• Mark the installation position of the • Unscrew the pressure limiting valve (1)
high-pressure lines (2) • Unscrew the rail pressure sensor (2)
• Detach the high-pressure lines (2) with Socket, Removing the cable duct cover
size 17 [81] (1) and Extension [83] (3)
Detaching the pressure pipe
• Open the locking pin (2) a quarter turn

• Remove the cable duct cover (1)
• Remove the pressure pipe (1)
Unscrewing the rail pressure sensor and Removing the cylinder head cover
1st Edition 149

R.EN.MC11.31/35/39/43.01
• Unscrew the mounting bolts (3) • Undo the mounting nuts (2)
• Remove the cylinder head cover (2) from the • Remove the injector cable (1)
cylinder head (1) Removing the injector wiring harness
Removing the rail connection
• Carefully remove the injector wiring harness

• Unscrew the pressure screw (3) (4) from the camshaft bearing shells (1)
• Extract the rail connection (2) from the • Unscrew the mounting bolts (3)
cylinder head (1) with Adapter [79] and • Carefully extract the flange (2) from the
Extractor device [80] cylinder head
• Carefully extract the injector wiring harness (4)
through the bore
Removing the pressure flange mounting
bolt
• Unscrew the mounting bolt (2) and remove

withthe spherical washer (1)
Detaching the injector cable Assembling the special tool
1st Edition 150

R.EN.MC11.31/35/39/43.01
Installing the injectors and
pressure Pipe
Installing the injector
• Assemble the Plate [85] (4) with Column

66 mm [86] (1), Column 70 mm [87] (5) and
Hexagon nut M12 [88] (2)
• Insert the Puller [84] (3) into the Plate [85] (4) NOTE
Always install injectors together with
Extracting the injector
pressure flange. It is not possible to
install the pressure flange
afterwards.
• Remove the old sealing washers (5)
• Check to ensure that the bore in the cylinder
head is clean
• Do not remove the injector (2) from the
Injector storage sleeve [69] until immediately
before installation
• Remove the protective sleeves
WARNING • Slide the pressure flange (1) onto the injector
Component damage due to (2), ensuring that the fuel inlet opening (3) is
incorrect removal of the injector turned towards the rail connection mounting
• Always remove the relevant rail bore (4)
connection first before removing • Insert the injector (2) into the cylinder head
the injector with new O-ring (6) and new sealing washer
• Always remove one injector only (5)
• Put on the special tool (1) • Press the injector (2) fully into the cylinder
• Insert the Puller [84] into the groove for the head using Pressure piece [92]
pressure flange
• Clamp the clamping sleeve (5) with the
knurled nut (2)
• Extract the injector (4) from the cylinder head
by turning the knurled nut (3)
1st Edition 151

R.EN.MC11.31/35/39/43.01
Injector initial torque Injector final torque
• Tighten the injector pressure flange mounting

• Screw in the new mounting bolt (2) for the bolt (1) to Final torque 25 Nm + 90°
pressure flange with spherical washer (1) Rail connection final torque
• Tighten the mounting bolt (2) to Initial torque
1-2Nm
Installing the rail connection
• Tighten the pressure screw (1) to Final torque 20

Nm 60°
Installing the injector wiring harness
WARNING
Rail connections are pressed
together on the cone during
installation
• Do not re-use rail connections if they
have already been installed
• Slide the new rail connection (2) into the
cylinder head (1) so that the balls on the rail • Lightly apply Technical Vaseline on the new
connection (2) are located in the groove in the O-ring for the injector wiring harness (4)
cylinder head • Carefully insert the injector wiring harness (4)
• Screw in the pressure screw (3) and tighten to through the bore
Initial torque 10 Nm • Carefully insert the flange (2) into the cylinder
head
them to 15 Nm
• Carefully insert the injector wiring harness (4)
into the camshaft bearing shells (1)
1st Edition 152

R.EN.MC11.31/35/39/43.01
Mounting the injector cable Tightening sequence for cylinder head cover
WARNING
Component damage due to possible
short-circuit
• When tightening the mounting nuts,
make sure that the cable plugs do not
touch each other
• Assemble the special tool consisting of the
Socket, size 7 [91] (2), Adapter [90] and Torque A Intake side B Exhaust side
screwdriver [89] (3) • Stick to the illustrated mounting bolt tightening
• Tighten the injector cable mounting nuts (1) to sequence 1 to 18 in the following work step
1-2 Nm using the special tool Mounting the cylinder head cover

difference of the cylinder head cover bolts, there
are 8 bolts at the exhaust side without rubber
washers, the rest 10 bolts have rubber washers.
head (1)
sequence indicated
1st Edition 153

R.EN.MC11.31/35/39/43.01
Mounting the cable duct cover Attaching the pressure pipe
• Put on the cable duct cover (1) • Position the pressure pipe (1) on the cylinder
• Close the locking pin (2) a quarter turn head
Screwing in the rail pressure sensor and • Screw in new mounting bolts (2) and tighten
pressure limiting valve them to Initial torque 1.5 Nm
Attaching high-pressure lines
WARNING
Component damage due to lack of WARNING
lubricant Component damage due to
• Do not wash off the pressure limiting non-aligned high-pressure lines
valve and rail pressure sensor as the • After initial tightening, check the
thread and biting edge are coated with lubricant alignment of the high-pressure lines
• Screw in the new rail pressure sensor (2) and and, if necessary, re-align them
tighten it to 70±5 Nm • Attach the high-pressure lines (2) to the
• Screw in a new pressure limiting valve (1) and pressure pipe (3) and rail connection (1) as
tighten it to 100±5 Nm marked
• Tighten the high-pressure lines to Initial torque
10 Nm using the Socket, size 17 [81] and
Extension [83]
1st Edition 154

R.EN.MC11.31/35/39/43.01
Pressure pipe final torque Attaching the high-pressure line
• Tighten the mounting bolts (1) to Final torque • Attach the high-pressure line (3) to the
35 Nm high-pressure pump (4) and pressure pipe (1)
High-pressure line final torque • Tighten the high-pressure line (3) to Initial
torque 10 Nm with Socket, size 19 [82] and
Extension [83]
• Check that the high-pressure line (3) is seated
free of stress
• Screw in and tighten the new mounting bolt (2)
• If reusing, tighten the high-pressure line (3) to
Final torque 30° using Socket, size 19 [82] and
Extension [83]
• Tighten the high-pressure line (3) to Final
• If reusing, tighten the high-pressure lines (2) to torque 60° with Socket, size 19 [82] and
Final torque 30° using Socket, size 17 [81] (1) Extension [83]
and Extension [83] (3) Mounting the pressure loss tester
• Tighten the new high-pressure lines (2) to Final
torque 60° using Socket, size 17 [81] (1) and
Extension [83] (3)
• Screw the Ring connector [97] onto the cylinder

head with Hollow screw [96] and Sealing ring
with elastomer sealing lip [98]
• Mount the Adapter [94] (1) with Threaded
connection [95] (2) and Pressure loss tester [93]
(3) on the Ring connector [97]
1st Edition 155

R.EN.MC11.31/35/39/43.01
Checking the pressure loss Mounting the dipstick holder
WARNING • Position the holder (1) with the dipstick

Injectors can be damaged • Screw in and tighten the mounting bolts (2)
• Pressurisation for leak test must not Connecting the rail pressure sensor electrical
exceed 4 + 0.5 bar connection
• Pressurise the Pressure loss tester [93] using
compressed air at 4 + 0.5 bar
• Pull off the compressed-air connection (2)
• Check the maximum permitted pressure loss on
the pressure gauge (1)
The desired pressure loss is max. 0.1 bar in 10
minutes.
Attaching the fuel return line
• Position the ring connector (6) with new sealing

rings
• Screw in the hollow screw (5)
• Screw the LVE fitting (3) onto the ring
connector (6) and tighten it
• Screw the fuel line (2) onto the LVE fitting (3)
• Screw the fuel line (4) onto the LVE fitting (3)
• Screw in the hollow screw (1) with new sealing
rings and tighten
• Tighten the hollow screw (5)
• Tighten the union nuts for fuel lines (2) and (4)
1st Edition 156

R.EN.MC11.31/35/39/43.01
HIGH-PRESSURE PUMP/HIGH-PRESSURE PUMP DRIVE
Removing and installing the high-pressure pump/high-pressure
pump drive
- Additional jobs
- Removing and installing the alternator，see 58.
1. Fuel service centre 2. High-pressure pump 3. Oil filler neck 4. Mounting bolt 5. High-pressure pump poly-V-belt pulley 6.
Washer 7. Mounting bolt 8. High-pressure pump drive 9. High-pressure line 10. Fuel service centre holder
Technical data

Mounting bolts for high-pressure
M10×55-10.9 60-70Nm
pump (2)
Oil filler neck (3) M38×15 35Nm
Mounting bolts for high-pressure
M12×90-10.9 115Nm
pump drive (8)
High-pressure line (9) (initial use) Initial torque 10Nm
High-pressure line (9) (initial use) Final torque 60°
High-pressure line (9) (re-use) Initial torque 10Nm
High-pressure line (9) (re-use) Final torque 30°
Service product
Curil T
Loctite 590
1st Edition 157

R.EN.MC11.31/35/39/43.01
WARNING
• All work on components of the common-rail system must be performed by
specially trained personnel only.
• The engine must be stationary for at least 5 minutes before commencing
work in order to enable depressurisation in the pressure pipe, or
depressurisation must be checked by means of EOL (desired value 0)
• Do not reuse plugs for high-pressure lines, the pressure pipe or injectors, even if they
have only been used once.
WARNING
• Always remove only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or
grease before installation
• Clean the high-pressure pump drive and installer sleeve before assembly
WARNING
• If impact wrenches are used, these may only be used for pretightening to max. 50% of
• Final tightening must always be performed manually using a torque wrench.
Special tool
NO. Picture SINOTRUK MAN CODE

instruction
CODE
[103] Impact tool JD6805-0076 80.99606-6078
• Removing the
high-pressure pump in
conjunction with:
• Removing device [104]
[104] Removing device JD6805-0077 80.99601-6021
• Removing the
high-pressure pump
[105] Impact extractor JD6805-0018 80.99602-0016

• Extracting the radial
shaft seal in conjunction
with:
1st Edition 158

R.EN.MC11.31/35/39/43.01
• Hook [106]
[106] Hook JD6805-0019 80.99602-0137
• Extracting the radial
shaft seal
[107] Plug-on handle JD6805-0020 80.99617-0187

• Pressing in the radial
shaft seal in conjunction
with:
• Press-in plate [109]
• Washer [108]
[108] Washer JD6805-0021 80.99617-0144
shaft seal
[109] Press-in plate JD6805-0022 80.99604-0289

shaft seal
[110] Socket, size 27 JD6805-0078 08.06556-

• Removing and
installing the oil ller
neck
[111] Release tool, size 1 JD6805-0079 80.99606-0625

• Opening the
quick-release couplings
• Release handle [112]
[112] Release handle JD6805-0080 80.99606-0597

• Opening the
quick-release couplings
[113] Socket, size 19 JD6805-0056 80.99603-0310

• Removing and
installing the
high-pressure line in
conjunction with:
• Extension [114]
1st Edition 159

R.EN.MC11.31/35/39/43.01
[114] Extension JD6805-0057 08.06139-9025

• Removing and
installing the
high-pressure line
1st Edition 160

R.EN.MC11.31/35/39/43.01
Removing the high-pressure pump

Removing the high-pressure
pump
Unscrewing the oil filler neck
·• Unscrew the mounting bolts (2)

• Extract the high-pressure pump (2) from
the high-pressure pump drive (4)
• Remove the O-ring (1)
• Unscrew the oil filler neck using Socket, • Pull the driver (4) off the drive shaft
size 27 [110]
·Detaching the measurement unit connector

（2）unscrew the mounting bolt（3）
• Detach the high-pressure line (4) from the
high-pressure pump (5) and pressure pipe
(1) with Socket, size 19 [113] and Extension
[114]
1st Edition 161

R.EN.MC11.31/35/39/43.01
Mounting the special tools

Removing the high-pressure
pump
·Detaching the measurement unit connector

（2）unscrew the mounting bolt（3） • Remove the fuel service centre, see Removing
• Detach the high-pressure line (4) from the and installing the fuel service centre, 164
high-pressure pump (5) and pressure pipe • Unscrew the mounting bolts for the
(1) with Socket, size 19 [113] and Extension high-pressure pump (5)
[114] • Screw the threaded spindle (2) into the
plate (3) for the Removing device [104] (4)
with Impact tool [103] (1) until flush
• Mount the Removing device [104] (4) on
the high-pressure pump (5) using two bolts
·• Remove the high-pressure pump (3) from

the high-pressure pump drive by tapping
lightly using Impact tool [103] (1) and
Removing device [104](2)
1st Edition 162

R.EN.MC11.31/35/39/43.01
Removing the high-pressure pump drive

drive
Removing the poly-V-belt pulley
• Unscrew the mounting bolts (1) and remove

the high-pressure pump drive (2)
·Unscrew the mounting bolts（1）and（2）

·Remove the washer（3）
·Pull the poly-V-belt pulley （ 4 ） off the splined
shaft（5）
Removing the high-pressure pump drive
radial shaft seal
• Remove the radial shaft seal (3) using Impact

extractor [105] (2) and Hook [106] (1)
Installing the high-pressure

1st Edition 163
R.EN.MC11.31/35/39/43.01
pump drive
• Press the radial shaft seal (2) into the

high-pressure pump drive (1) using Plug-on
• Lightly apply sealing compound Loctite 5900 handle [107] (3) and Washer [108] as well as
(1) on the high-pressure pump drive mating Press-in plate [109] (4)
face as illustrated Mounting the poly-V-belt pulley
Mounting the high-pressure pump drive
NOTE
• Position the high-pressure pump drive (2) • Lightly apply Loctite 5900 on the
• Screw in new mounting bolts (1) and tighten teeth of the new poly-V-belt pulley (1)
them to 115 Nm • Position the washer (3) and screw in the new
mounting bolts (2)
• Push the poly-V-belt pulley (4) onto the
splined shaft (5) until the stop is reached
• Screw in and tighten the mounting bolt (1)
• Tighten the mounting bolts (2)
Pressing in the radial shaft seal
1st Edition 164

R.EN.MC11.31/35/39/43.01
Attaching the high-pressure line

Installing the high-pressure
pump
• Attach the high-pressure line (4) to the

high-pressure pump (5) and pressure pipe (1)
• Tighten the high-pressure line (1) to Initial
torque 10 Nm with Socket, size 19 [113] and
NOTE Extension [114]
If you use special tools to remove • Check that the high-pressure line (4) is
the high-pressure pump, ensure seated free of stress
installing the fuel service center • Screw in and tighten the new mounting bolt
before install the high-pressure pump. (3)
• Slide the driver (3) onto the drive shaft for the • Tighten the high-pressure line (4) to Final
high-pressure pump (2) torque 60° if using for the first time
• Lightly apply Technical Vaseline on a new • Tighten the high-pressure line (4) to Final
O-ring and fit it on the high-pressure pump (2)· torque 30° if re-using
• Screw in new mounting bolts (2) and tighten Connect the measurement unit connector
them to 60-70 Nm Screwing in the oil filler neck
• Mount the fuel service centre if necessary,
see Removing and installing the fuel service
centre, 164
• Lightly apply Curil T on the thread of the oil

filler neck (1)
• Screw in the oil filler neck (1) using the
Socket, size 27 [110] and tighten to 35 Nm
1st Edition 165

R.EN.MC11.31/35/39/43.01
WARNING
• Final tightening must always be performed manually using a torque wrench·
NOTE
Mark all plastic fuel lines to indicate correct assignment and installation position
before removing them.
Special tools
SINOTRUK
No. picture instruction MAN code
code
Release tool, size
·Opening the
quick-release
[142] couplings in JD6805-0079 80.99606-0625
conjunction with:
·Release handle
[143]
Release handle
·Opening the
[143] JD6805-0080 80.99606-0597
quick-release
couplings
1st Edition 166

R.EN.MC11.31/35/39/43.01
Detaching the fuel service centre –

Removing the fuel service high-pressure pump fuel lines
centre
Detaching the rail fuel return lines
·Detach the fuel lines (1) and (2) using the

Release tool, size 1 [142] and Release
handle [143]
Detaching the fuel service centre fuel
return ine
·Detach the fuel line（5）

·Unscrew the hollow screw（2）
·Detach the fuel line（3）
·Unscrew the hollow screw（4）and remove
the LVE fitting（1）
Detaching the fuel service centre – fuel
pump fuel lines
·Unscrew the mounting bolt for the holding
clip (1)
·Pull off the fuel line (2) using the Release
tool, size 1 [142] and Release handle [143]
Detaching the solenoid valve – fuel
service Centre fuel line
·Unscrew the union nut（1）

Detach the fuel lines (2) and (3) using the
Release tool, size 1 [142] and Release
handle [143]
·Unscrew the hollow screws (1) and (3) and

remove them with the sealing rings
Remove the fuel line (2)
Removing the fuel service centre
1st Edition 167

R.EN.MC11.31/35/39/43.01
Installing the fuel service
centre
Mounting the fuel service centre

• Remove the fuel service centre (3)
• Remove the holder (4)
• Position the holder (4)

bolts (1)
• Position the fuel service centre (3)
bolts (2)
Attaching the solenoid valve – fuel
service centre fuel line
• Position the fuel line (2)

• Screw in the hollow screw (3) with new
sealing rings
• Screw in the hollow screw (1) with new
sealing rings and tighten
• Tighten the hollow screw (3) to 15 Nm
1st Edition 168

R.EN.MC11.31/35/39/43.01
Attaching the fuel service centre fuel Attaching the fuel service centre – fuel
return line pump fuel lines
• Attach the fuel line (2) • Attach the fuel lines (2) and (3)
• Check that the fuel line (2) is seated • Check that the fuel lines (2) and (3) are
firmly. Pull off and re-attach using Release seated rmly. Pull off and re-attach using
tool, size 1 [142] and Release handle [143] Release tool, size 1 [142] and Release
if necessary handle [143] if necessary
• Screw in and tighten the new mounting • Screw on and tighten the union nut (1)
bolt for the holding clip (1) Detaching the rail fuel return lines
Attaching the fuel service centre –
high-pressure pump fuel lines
• Position the LVE fitting (1) and screw in

the hollow screw (4) with new sealing
• Attach the fuel lines (1) and (2) rings
• Check that the fuel lines (1) and (2) are • Screw the fuel line (3) onto the LVE fitting
seated rmly. Pull off and re-attach using (1)
Release tool, size 1 [142] and Release • Screw in the hollow screw (2) with new
handle [143] if necessary sealing rings and tighten
• Tighten the union nut for the fuel line (3)
• Tighten the hollow screw (4)
• Attach the fuel line (5) and tighten the
union nuts
1st Edition 169

R.EN.MC11.31/35/39/43.01
Dismantling and assembling the fuel service centre
Additional jobs
- Dismantling and assembling the fuel service centre，see in page 170.
(1) Fuel filter (2) Cover (3) Sealing ring (4) Housing (5) Pressure sensor (6) Water drain plug (7) Mounting bolt (8) Sealing ring (9)
Heating element (10) Hollow screw (11) Cover (12) Fuel pre-filter (13) Sealing ring (14) Housing (15) Hand pump (16) Mounting bolts
1st Edition 170

R.EN.MC11.31/35/39/43.01
Technical data
item standard torque

Pressure sensor（5） M18×15 45Nm
cover（11） 20+2.5Nm
cover（2） 25Nm
Eater drain plug（6） 3Nm
WARNING
Dirt can cause failure of the common-rail system
• Always allow the fuel service centre to empty before changing the fuel filter
• Only use fuel filters that are designated for common-rail systems and
marked as such
• Do not re-use used filter elements
WARNING
Final tightening must always be performed manually using a torque wrench
Special tools
SINOTRUK
No. Picture Intruction MAN CODE
CODE
Socket, size 36
• Removing and
[153] JD6805-0081 80.99603-0325
installing the fuel
lter cover
Socket, size 19
• Removing and
[154] JD6805-0082 08.06141-9061
installing the fuel
pre-filter cover
1st Edition 171

R.EN.MC11.31/35/39/43.01
Removing the pressure sensor

Dismantling the fuel service
centre
Allowing the fuel service centre to empty
• Unscrew the pressure sensor (1) with sealing

ring (2)
Removing the fuel filter
WARNING
Danger of environmental
pollution
• Collect any remaining fuel that
emerges in a suitable container • Undo the
cover (1) by approx. 2 - 3 turns using the
Socket, size 36 [153]
• Open the water drain plug (2) and allow the
fuel service centre to empty
• Re-tighten the water drain plug (2) to 3 Nm
Removing the heating element
• Unscrew the cover (1) with Socket, size 36

[153]
• Pull the cover (1) with fuel filter (3) out of the
fuel service centre housing
• Remove the sealing ring (2)
• Unscrew the cover (7) with Socket, size 19
[154]
• Unscrew the mounting bolts (2) • Pull the fuel pre-filter (6) out of the hand pump
• Pull the heating element (3) and sealing ring housing (4)
(4) out of the fuel service centre (1) • Remove the sealing ring (5)
1st Edition 172

R.EN.MC11.31/35/39/43.01
Removing the hand pump housing

Assembling the fuel service
centre
Mounting the hand pump housing
• Unscrew the mounting bolts (2) from the fuel

service centre (3)
• Remove the hand pump housing (1)）
·• Position the hand pump housing (1) on

the fuel service centre (3)
bolts (2)
1st Edition 173

R.EN.MC11.31/35/39/43.01
Installing the fuel filter Tightening the fuel filter cover
Tighten the fuel filter cover to 20 Nm using the

socket, size 36 [153] (1)
Installing the pressure sensor
• Moisten the new sealing ring (5) with clean

diesel fuel
• Fit the sealing ring (5) on the hand pump
housing (4) • Screw in the pressure sensor (1) with a new
• Insert a new fuel pre-filter (6) sealing ring (2)
• Screw on the cover (7) and tighten by hand • Tighten the pressure sensor (1) to 45 Nm
• Insert the new fuel filter (3) into the cover (1) Installing the heating element
• Moisten the new sealing ring (2) with clean
diesel fuel
• Screw in the cover (1) with sealing ring (2)
and tighten by hand
Tightening the fuel pre-filter cover
·• Insert the heating element (3) with new

sealingring (4) into the fuel service centre
(1)
Tighten the fuel filter cover to 10 Nm using the • Screw in and tighten the new mounting bolts
Socket, size 19 [154] (1) (2)
1st Edition 174

R.EN.MC11.31/35/39/43.01
ENGINE LUBRICATION
1. Oil sump 2. Oil suction pipe 3. Oil pump 4. Oil cooler 5. Oil module；
1st Edition 175

R.EN.MC11.31/35/39/43.01
OIL MODULE
Removing and installing the oil module
Additional jobs
- Removing and installing the charge-air pipe，see in page 68
1. Oil cooler 2. Gasket 3. Screw-in fitting 4. Vent line 5. Mounting bolt
6. Oil module 7. Screw-in fitting 8. Mounting bolt
Technical data
Item Standard Torque

Oil module screw plug（6） M38×15 80+10Nm
Screw-in fitting（3） M24×15 4Nm
Screw-in fitting（7） M24×15 4Nm
Pressure-relief valve M27×15 40+5Nm
Oil filter cover 40+10Nm
Oil cooler mounting bolts（1） M8×55-8.8 30-35Nm
Oil cooler mounting bolts（1） M8×80-8.8 30-35Nm
Service products
Radiator antifreeze loc-tite243

Li-PF2 multipurpose grease
1st Edition 176
R.EN.MC11.31/35/39/43.01
P80 lubricant
WARNING
Danger of engine damage due to oil emulsion
• Drain all the coolant before removing the oil module, otherwise coolant will
enter the oil sump when the oil module is removed from the crankcase
WARNING
Special tools
SINOTRUK
CODE
[239] Socket, size 32 JD6805-0119 80.99603-0326
• Removing and installing
the oil filter cover
[240] Hose clamp pliers for JD6805-0028 08.99605-9003

jubilee clips
• Detaching the air intake
pipe from the air
compressor
[241] Tester JD6805-0168 80.99606-0399
• Checking the
engagement of
compressed-air
push-in connections
1st Edition 177

R.EN.MC11.31/35/39/43.01
Detaching the oil module line

Removing the oil module
Removing the heat shield
• Remove the jubilee clips (2) using Hose

clamp pliers for jubilee clips [240]
• Pull off the oil separator vent line (1)
• Remove the heat shield (1) Draining the coolant
Detaching the vent line
• Unscrew the mounting bolt (1) WARNING

• Pull the vent line (3) off the screw-in Danger of engine damage due
fittings (2) and(4) to oil emulsion
• Unscrew the screw-in fittings (2) and (4) • Drain all the coolant before
Unscrewing the coolant pump removing the oil module,
mounting bolts otherwise coolant will enter the oil sump
when the oil module is removed from
the crankcase
• Unscrew the screw plug (3) with sealing
ring (2) from the oil module (1)
• Drain the coolant
• Unscrew the coolant pump mounting

bolts (1) and (2) from the oil module
1st Edition 178
R.EN.MC11.31/35/39/43.01
Oil module removal instructions Removing the oil cooler
WARNING
• To remove the oil module (1), do not putting the oil module aside
unscrew the oil cooler mounting bolts (2) incorrectly
and (3) • Put the oil module aside so as
Detaching the oil module not to damage the oil cooler
• Mark the installation position of the
mounting bolts(4)
• Remove the oil cooler (3) with gaskets (2)
from the oil module (1)
Removing the pressure-relief valve
•Mark the installation position of the

mounting bolts (4) and (5)
• Remove the oil module (1) with gasket (2)
from the crankcase (3)
• Unscrew the oil pressure-relief valve (2)

from the oil module (1)
1st Edition 179

R.EN.MC11.31/35/39/43.01
Removing the connecting manifold Removing the oil filter
• Remove the unscrewed conduits (5) from

theconnecting manifold (3)
• Remove the connecting manifold (3) with
gasket(1) from the oil module (2)
Removing the oil separator
• Unscrew the oil filter cover (1) from the oil

module (4) with the Socket, size 32 [239]
• Remove the O-ring (2) from the oil filter
cover (1)
• Remove the oil filter (3) from the oil filter
cover (1)

• Pull the oil separator (2) out of the oil
module
1st Edition 180
R.EN.MC11.31/35/39/43.01
Installing the oil separator

Assembling the oil module
Installing the oil filter
• Insert the oil separator (2) into the oil

module
Mounting the connecting manifold
• Fit the new O-ring (2) on the oil lter
cover (1) and lightly apply clean engine
oil
• Insert the new oil filter (3) into the oil filter
cover (1)
• Screw the oil filter cover (1) into the oil
module (4) with the Socket, size 32 [239]
and tighten to 45 Nm
• Position the connecting manifold (3) with a

new gasket (1) on the oil module (2)
bolts (4)
• Lightly apply Radiator antifreeze on the
contact surfaces of the new unscrewed
conduits (5) and insert into the connecting
manifold (2)
Installing the pressure-relief valve
1st Edition 181
R.EN.MC11.31/35/39/43.01
Installing the oil module
• Screw the pressure-relief valve (2) into the

oil module (1)
• Tighten the pressure-relief valve (2) to 45 WARNING
Nm Component damage caused by
Installing the oil cooler incorrect tightening sequence
• Follow the tightening sequence
described below, otherwise the distributor
housing may fracture
• Position the oil module (1) on the
crankcase (3) with a new gasket (2)
• Screw in the new mounting bolts (4) and (5)
as marked and then tighten them by hand
Screwing in the coolant pump mounting
bolts
• Insert the oil cooler (3) with new gaskets (2)
into the oil module (1)
• Screw in the new mounting bolts (4) as
markedand tighten them by hand
Tightening the oil cooler mounting bolts

bolts (1) and (2)
• Tighten the oil module mounting bolts
• Put the oil module (1) aside so as not to

damage the oil cooler
Installing the screw plug
Installing the oil module
1st Edition 182
R.EN.MC11.31/35/39/43.01
• Push the vent line (1) fully onto the oil

separator
Screw the screw plug (3) with a new sealing • Fit the jubilee clips (2) with the Hose clamp
ring (2) into the oil module (1) and tighten pliers for jubilee clips [240]
it to 80 Nm Mounting the heat shield
Installing the vent line
• Mount the heat shield (1)
• Lightly apply Loctite 242 on the thread of

the screw-in fitting (4)
• Screw the screw-in tting (4) into the
crankcase and tighten it to 4 Nm
• Lightly apply Loctite 242 on the thread of
the screw-in fitting (2)
• Screw the screw-in fitting (2) into the oil
module and tighten it to 4 Nm
• Fit the vent line (3)
• Screw in and tighten the mounting bolt (1)
Attaching the oil module line

1st Edition 183
R.EN.MC11.31/35/39/43.01
OIL SUMP AND OIL SUCTION PIPE
Removing and installing the oil sump and oil suction pipe
1. Crankcase 2.Spacer sleeve 3.Mounting bolt 4. Oil sump
5.Stiffening plate 6. Oil suction pipe
Service products
Technical Vaseline
WARNING
1st Edition 184

R.EN.MC11.31/35/39/43.01
Removing the oil sump and Installing the oil sump and oil
oil suction pipe suction pipe

Removing the oil sump Installing the oil suction pipe
• Unscrew the mounting bolts (2) ·• Lightly apply Technical Vaseline on a

• Remove the spacer sleeves (1) new O-ring (3)
• Remove the oil sump (3) with stiffening • Insert the O-ring (3) into the crankcase
plates (4) • Insert the oil suction pipe (2) into the
• Clean the mating faces crankcase
Removing the oil suction pipe • Screw in and tighten the new mounting
bolts (1)
Mounting the oil sump

• Pull the oil suction pipe (2) out of the
crankcase • Lightly apply Loctite 5900 on the mating
• Remove the O-ring (3) from the face
crankcase • Position the oil sump (3) with stiffening
plates (4)
• Screw in the new mounting bolts (2) with
spacer sleeves (1) and tighten by hand
• Tighten the mounting bolts (2) in the
sequence indicated
1st Edition 185

R.EN.MC11.31/35/39/43.01
OIL INJECTOR NOZZLES
Removing and installing the oil injector nozzles
Additional jobs
- Dismantling and assembling oil sump and oil suction pipe，see in page 59
1、Oil injector nozzle；2、Mounting bolt
Technical data

Mounting bolt（2） M6×12-10.9 15Nm
WARNING
1st Edition 186

R.EN.MC11.31/35/39/43.01
Removing the oil injector Installing the oil injector
nozzles nozzles
• Unscrew the mounting bolt (2) • Insert the oil injector nozzle (1) into the
• Extract the oil injector nozzle (1) from the crankcase (3)
crankcase (3) • Screw in and tighten the new mounting
bolt (2)
1st Edition 187

R.EN.MC11.31/35/39/43.01
OIL PUMP
Removing and installing the oil pump
Additional jobs
- Removing and installing the fan, see page 22.
- Removing and installing the fan drive see page 24
- Removing and installing the coolant manifold , see page 31.
- Removing and installing the thermostats, see page 32
- Removing and installing the thermostat housing, see 37.
- Removing and installing the belt drive, see 55.
- Removing and installing the distributor housing，see 43.
- Removing and installing the high-pressure pump/high-pressure pump drive，see158
- Removing and installing the front crankshaft oil seal, see59
- Removing and installing the cover,，see 59
-Removing and installing the vibration damper，see 59
1.Mounting bolt .2 Ring gear 3. Oil pump pinion 4. Mounting bolt 5. O-ring 6.Shaft
7. Bearing bush 8. Crankcase 9.Oil pump cover 10. Mounting bolt
Technical data

Item Technical data

1st Edition 188
R.EN.MC11.31/35/39/43.01
Ring gear（
（2）-crankshaft gear backlash 0.092-0.272mm
Axial play, ring gear（2） 0.030-0.093mm
Radial play, ring gear（2） 0.1-0.210mm
Outside diameter, bearing, ring gear（2） 96.853-96.888mm
Height of ring gear（2） 29.952-29.970mm
Outside diameter, shaft（6） 36.950-36.965mm
Height of oil pump pinion（3） 29.955-25.970mm
Inside diameter of oil pump pinion(3) 36.985-37.050mm
WARNING
The crankcase can be damaged if the oil pump is damaged
• Always ensure absolute cleanliness when assembling the oil pump
WARNING
Special tools
SINOTRUK
CODE
[242] Dial gauge
• Checking the backlash
• Checking the ring gear
JD6805-0024 08.71000-3217
axial and radial play in
conjunction with:
axial and radial play JD6805-0025 08.71082-0005
[244] Locating pin

JD6805-0026 80.99605-0197
1st Edition 189

R.EN.MC11.31/35/39/43.01
SINOTRUK
CODE
[245] Aligning punch
JD6805-0117 80.99617-0020
the front crankshaft gear
[246] Impact extractor

• Extracting the bearing
bush in conjunction with: JD6805-0018 80.99602-0016
• Adapter [248]
• Extractor device [247]
bush
JD6805-0120 80.99602-0300
[248] Adapter
bush JD6805-0121 80.99602-0207
[249] Drive-up tool

• Pressing in the bearing
bush JD6805-0122 80.99604-6038

• Checking the height of
the oil pump pinion JD6805-0032 08.71195-9003
• Checking the height of
the ring gear
1st Edition 190

R.EN.MC11.31/35/39/43.01
Checking the ring gear axial play

Checking the oil pump
Checking the crankshaft gear/ring gear
backlash

the Dial gauge [242] (3) and Locating pin
• Mount the Dial gauge holder [243] (2) with [244]
the Dial gauge [242] (1) and Locating pin • Position the Locating pin [244] against the
[244] ring gear (2) with a preload
• Position the Locating pin [244] against the • Press the ring gear (2) towards the
ring gear (3) with a preload crankcase
• Check the backlash between the • Zero the Dial gauge [242] (3)
crankshaft gear and the ring gear (3) • Pull the ring gear (2) towards the oil pump
The permitted backlash is 0.092 - 0.272 cover and read off the difference
mm. The permitted axial play on the ring gear (2)
If the backlash is out of tolerance, t a new is 0.020- 0.093 mm.
crankshaft gear and oil pump If the axial play is out of tolerance, fit a new
Removing the crankshaft gear oil pump.
Checking the ring gear radial play
• Screw in the Aligning punch [245] (3) and • Mount the Dial gauge holder [243] (3) with
(4) the Dial gauge [242] (1) and Locating pin
• Pull off the crankshaft gear (2) [244]
• Unscrew the Aligning punch [245] (3) and • Position the Locating pin [244] against the
(4) ring gear (2) with a preload
• Clean the contact surfaces of the • Push the ring gear (2) horizontally into the
crankshaft gear(2) and crankshaft (1) end position
1st Edition 191
R.EN.MC11.31/35/39/43.01
• Zero the Dial gauge [242] (1) Removing the oil pump pinion shaft
• Pull the ring gear (2) into the end position,
towards Dial gauge [242] (1), and read off
the difference the permitted radial play on
the ring gear (2) is 0.053- 0.210 mm.
If the radial play is out of tolerance, fit a new
oil pump.
Removing the oil pump

Removing the oil pump cover

• Remove the shaft (3) with O-ring (2) from
the crankcase (4)
Extracting the bearing bush

• Remove the oil pump cover (2) from the
crankcase(3)
Removing the oil pump
• Insert the Extractor device [247] (2) into

the bearing bush (4) and expand it
• Fit the hose clamp (3) over the Extractor
device [247] (2) and tighten it
• Mount the Adapter [248] (1)
• Screw the Impact extractor [246] into the
Adapter [248] (1)
• Extract the bearing bush (4) with the
• Remove the ring gear (1) and the oil pump Impact extractor [246]
pinion
(2) from the crankcase (3)
1st Edition 192

R.EN.MC11.31/35/39/43.01
. Checking the inside diameter of the oil

Checking the oil pump bearing pump pinion
ring gear bearing
• Clean the ring gear (1)

• Check the outside diameter of the ring
gear (1) using a micrometer (2) The
permitted outside diameter is 96.893 -
96.928 mm.
If the outside diameter is out of tolerance, fit
a new oil pump with bearing.
Checking the height of the ring gear
• Clean the oil pump pinion (2)
caliper to check the inside diameter of the
oil pump pinion (2)
The permitted inside diameter of the oil
pump pinion (2) is 36.990 - 37.085 mm.
If the inside diameter is out of tolerance, fit a
new oil pump with bearing.
• Clean the ring gear (2)

• Check the height of the ring gear (2) using
the Depth gauge (electronic) [250] (1)
29.970 mm.
If the dimension is out of tolerance, fit a new
oil pump with bearing
1st Edition 193

R.EN.MC11.31/35/39/43.01
Checking the height of the oil pump Checking the outside diameter of the shaft
pinion
• Clean the shaft (1)

• Check the outside diameter of the shaft (1)
using a micrometer (2)
The permitted outside diameter is 36.950 -
36.980 mm.
If the outside diameter is out of tolerance, fit a
new oil pump with bearing.
• Clean the oil pump pinion (2)

• Check the height of the oil pump pinion (2)
with Depth gauge (electronic) [250] (1)
29.970 mm.
If the dimension is out of tolerance, fit a new
oil pump with bearing.
1st Edition 194

R.EN.MC11.31/35/39/43.01
Installing the oil pump Fitting the guide plate

Screwing in the threaded spindle
• Insert the guide plate (2) with bearing bush

(1) so that the counter-holder (3) slides into
• Clean the threaded spindle (1) the oil pump bore (4)
• Clean the contact face of the threaded Pressing in the bearing bush
spindle (1) in the crankcase
• Screw in the threaded spindle (1) with the
Drive-up tool [249] and tighten
Preparing the installer
• Screw on the hexagon nut (1)

• Press in the bearing bush (3) by screwing on
the hexagon nut (1) until the stop is reached
• Align the recess on the bearing bush (2) with • Remove the Drive-up tool [249] (2)
the mark on the Drive-up tool [249] (1)
• Fit the bearing bush (2)
1st Edition 195

R.EN.MC11.31/35/39/43.01
Installing the oil pump pinion shaft

Mounting the oil pump cover
Note
A guide pin determines the shaft • Position the oil pump cover (2) on the
installation position crankcase (3)
• Lightly apply clean engine oil on the new • Screw in new mounting bolts (1) and tighten
O-ring (2) them to 15 Nm
• Fit the O-ring (2) on the shaft (3) Installing the crankshaft gear
• Insert the shaft (3) into the crankcase (4)
bolt(1)
Installing the oil pump
• Screw in the Aligning punch [245] (3) and (4)

• Put the crankshaft gear (2) on the crankshaft
(1), making sure that the stop is reached
• Lightly apply clean engine oil on the bearing • Unscrew the Aligning punch [245] (3) and(4)
surfaces of the ring gear (1) and oil pump
pinion (2)
• Insert the ring gear (1) into the crankcase (3)
• Slide the oil pump pinion (2) onto the shaft
so that the markings (4) are visible
1st Edition 196

R.EN.MC11.31/35/39/43.01
CRANKSHAFT OIL SEALS
Removing and installing the front crankshaft oil seal
Additional jobs
- Removing and installing the fan,，see 22.
- Removing and installing the vibration damper, see 59
1、Cover；2、Front crankshaft oil seal；
WARNING
PTFE sealing rings are rendered unusable if they come into contact with
oil or grease before installation.
• Clean the crankshaft and insertion tool before assembly
WARNING
1st Edition 197

R.EN.MC11.31/35/39/43.01
Special tools
SINOTRUK
CODE
[251] Crossmember
• Extracting the
crankshaft oil seal in
conjunction
with:
• Pressure plate [252]
JD6805-0123 80.99606-0298
• Hexagon nut [255]
• Hook [253]
• Screw spindle [256]
• Pan head screw
[257]
• Guide plate [258]
[252] Pressure plate
• Extracting the
crankshaft oil seal
JD6805-0124 80.99609-0038
[253] Hook
• Extracting the
JD6805-0125 80.99606-6013
crankshaft oil seal
[254] Press-in bush

• Pressing in the
conjunction
with:
• Hexagon nut [255]
• Screw spindle [256]
• Pan head screw JD6805-0126 80.99606-0659
[257]
• Guide plate [258]
• Washer [259]
• Hexagon collar nut
[260]
• Washer, 6 mm [261]
• Washer, 3 mm [262]
1st Edition 198
R.EN.MC11.31/35/39/43.01
SINOTRUK
CODE
[255] Hexagon nut
• Extracting the
crankshaft oil seal
JD6805-0127 06.11069-0064
• Pressing in the
crankshaft oil seal
[256] Screw spindle

• Extracting the
crankshaft oil seal JD6805-0128 80.99606-0299
• Pressing in the
crankshaft oil seal
• Extracting the
• Pressing in the
crankshaft oil seal
[258] Guide plate
• Extracting the
crankshaft oil seal
JD6805-0130 80.99606-0658
• Pressing in the
crankshaft oil seal
[259] Washer
• Pressing in the
crankshaft oil seal
JD6805-0131 06.15230-0609
[260] Hexagon collar nut

• Pressing in the
JD6805-0132 06.11222-0211
crankshaft oil seal
[261] Washer, 6 mm
• Pressing in the
1st Edition 199

R.EN.MC11.31/35/39/43.01
SINOTRUK
CODE
[262] Washer, 3 mm
• Pressing in the
[263] Depth gauge

(electronic)
• Determining the JD6805-0032 08.71195-9003
crankshaft oil seal
press-in depth
1st Edition 200

R.EN.MC11.31/35/39/43.01
Removing the front crankshaft Installing the front crankshaft
oil seal oil seal

Positioning the crankshaft oil seal
WARNING
The crankshaft oil seal can be
damaged
• Carefully separate the discs
from the transport sleeve using a suitable
tool
• Separate two opposite-facing discs from
the transport sleeve (3) in each case
• Mount the Guide plate [258] (3) on the • Mount the Guide plate [258] (4) on the
crankshaft with the Pressure plate [252] and crankshaft (1) with the Pan head screw
the Pan head screw [257] (1) [257]
• Screw the Screw spindle [256] (6) with the • Position the crankshaft oil seal (2) with
Hexagon nut [255] into the Crossmember transport sleeve (3) and push the
[251] (5) crankshaft oil seal (2) onto the Guide plate
• Screw the second Hexagon nut [255] onto [258] (4)
the screw spindle [256] (6) and secure using • Remove the transport sleeve (3)
the hexagon nut [255]
• Insert the Hook [253] (4) through the
Crossmember [251] (5) at between the
crankshaft oil seal (2) and the crankshaft
• Turn the Hook [253] (4) through 90° so
that the recess is facing outwards
• Hold the hexagon nut steady on the
Crossmember [251] (5)
• Extract the crankshaft oil seal (2) by
screwing in the Screw spindle [256] (6)
1st Edition 201

R.EN.MC11.31/35/39/43.01
Install the crankshaft oil seal
• Push the Press-in bush [254] (2) with

Washer, 3 mm [262] onto the Guide plate
[258]
• Screw the Hexagon collar nut [260] (3)
onto the Screw spindle [256] (4)
• Screw the Hexagon nut [255] onto the
Screw spindle [256] (4)
• Screw the second Hexagon nut [255]
onto the Screw spindle [256] (4) and
secure using the hexagon nut [255]
• Screw the Screw spindle [256] (4) into
the Guide plate [258] with the Washer
[259]
• Hold the Hexagon nut [255] steady on
the screw spindle [256] (4)
• Press in the crankshaft oil seal (1) by
screwing in the Hexagon collar nut [260] (3)
until the Press-in bush [254] (2) with
Washer, 3 mm [262] is at the Guide plate
[258]
1st Edition 202

R.EN.MC11.31/35/39/43.01
Removing and installing the rear crankshaft oil seal
Additional jobs
- Removing and installing the flywheel,see 222.
1、Crankshaft oil seal；2、flywheel；
Technical data
Installation temperature for race------------------------approx.120℃
Service products
Loctite Antipor 5900
WARNING
PTFE sealing rings are rendered unusable if they come into contact with
oil or grease beforeinstallation.
• Clean the crankshaft and insertion tool before assembly
WARNING
Special tools
1st Edition 203
R.EN.MC11.31/35/39/43.01
SINOTRUK
CODE
[264] Impact extractor
• Extracting the
crankshaft oil seal in JD6805-0018 80.99602-0016
conjunction with:
• Extractor hook [265]
[265] Extractor hook
• Extracting the
[266] Removing device

• Pulling off the race in
conjunction with: JD6805-0136 80.99601-0182
• Threaded spindle [267]
• Pressure plate [268]
[267] Threaded spindle
• Pulling off the race
JD6805-0137 80.99601-0156
[268] Pressure plate

• Pulling off the race
JD6805-0138 80.99601-0183
1st Edition 204

R.EN.MC11.31/35/39/43.01
SINOTRUK
CODE
• Pressing on the race in
conjunction with:
• Pressing plate [271]
• Washer [270]
• Installing the
JD6805-0020 80.99617-0187
conjunction
with:
• Washer [270]
• Guide bush [272]
• Pressing plate [273]
[270] Washer
• Pressing on the race
• Installing the
JD6805-0021 80.99617-0144
crankshaft oil seal

• Pressing on the race
JD6805-0139 80.99617-0017
[272] Guide bush

• Installing the

• Installing the
1st Edition 205

R.EN.MC11.31/35/39/43.01
Removing the rear crankshaft Installing the rear crankshaft
oil seal oil seal
• Extract the crankshaft oil seal (3) from • Push the Guide bush [272] (4) into the
the flywheel housing/timing case using crankshaft
Impact extractor [264] (1) and Extractor • Assemble the Pressing plate [273] (6) with
hook [265] (2) Plug-on handle [269] (1) and Washer [270]
(2)
• Put the closed side of the crankshaft oil
seal (3) onto the special tool
• Push the special tool onto the Guide bush
[272] (4)
• Press the crankshaft oil seal (3) into the
flywheel housing/timing case (5) until the
Pressing plate [273] (6) is at the Guide bush
[272] (4)
1st Edition 206

R.EN.MC11.31/35/39/43.01
ENGINE HOUSING
1. mounting bolt 2.Hub 3. O-rings 4. Cylinder liner 5. Flywheel housing/timing case
6. Cover 7. Vibration damper 8. Mounting bolt
1st Edition 207

R.EN.MC11.31/35/39/43.01
FLYWHEEL HOUSING/TIMING CASE
Removing and installing the flywheel housing/timing case
Additional jobs
-Removing and installing the starter，see 52
- Removing and installing the rear crankshaft oil seal，see 59
- Removing and installing the flywheel，see 222
1.Mounting bolt 2.flywheel housing/timing casing
Technical data
name standard Technical data

Flywheel mounting bolt（1） M10×30-10.9 65Nm
Flywheel mounting bolt（1） M10×40-10.9 65Nm
Flywheel mounting bolt（1） M16×1.5×55-10.9 280Nm
Service products
Loctite 5900
Imorotant information
WARNING
1st Edition 208

R.EN.MC11.31/35/39/43.01
Removing the flywheel Installing the flywheel
housing/timing case housing/timing case

Removing the flywheel housing/timing Installation instructions for flywheel
case housing/timing case
• Lightly apply sealing compound Loctite 5900

(1) on the mating face as illustrated
Installing the flywheel housing/timing
case
CAUTION
Danger of injury due to heavy
components
• Remove the flywheel housing/timing
case with support
• Remove the flywheel housing/timing case
(2)
CAUTION
components
• Mount the flywheel housing/timing case
with support
• Fit the flywheel housing/timing case (2) on
thecentring pins
(1)
1st Edition 209
R.EN.MC11.31/35/39/43.01
COVER
Removing and installing the cover
Additional jobs
- Removing and installing the fan,，see 22
- Removing and installing the thermostats,，see35.
- Removing and installing the thermostat housing,，see 37.
- Removing and installing the distributor housing,see 43.
- Removing and installing the belt drive,，see 55.
- Removing and installing the front crankshaft oil seal,，see59
- Removing and installing the vibration damper，see59
1.mounting bolt 2.front cover 3.gasket 4.fan drive 5.crankcase
Technical data

Service products
Loctite 5900
Technical Vaseline
Important infmortion
WARNING
1st Edition 210

R.EN.MC11.31/35/39/43.01
Removing the cover Installing the cover

Installation instructions for cover
·• Mark the installation position of the

mounting bolts (1) • Fit a new O-ring (2)
• Unscrew the mounting bolts (1) • Lightly apply Technical Vaseline on the
• Remove the cover (2) with gasket (3) O-ring (2)
from the crankcase • Lightly apply sealing compound Loctite
• Clean the mating faces 5900 (1) on the mating face as illustrated
Installing the cover·
• Position the cover (2) with a new gasket (3)

• Screw in the new mounting bolts (1) as
marked and tighten them by hand
• Tighten the mounting bolts (1)·
1st Edition 211

R.EN.MC11.31/35/39/43.01
CYLINDER LINERS
Removing and installing the cylinder liners
Additional jobs
- Removing and installing the engine control unit,，see 18 .
- Removing and installing the coolant manifold，see31.
- Removing and installing the alternator，see 58
- Removing and installing the exhaust manifold,，see 65.
- Removing and installing the charge-air pipe,，see 68
- Removing and installing the charge-air manifold，see 70 .
- Removing and installing the turbocharger,，see 72 .
- Removing and installing the cylinder head,，see 78 .
- Removing and installing the oil module,，see59
- Removing and installing the oil sump，see59
- Removing and installing the pistons and connecting rods,，see59
1.crankcase 2.O-rings 3.cylinder liner
1st Edition 212

R.EN.MC11.31/35/39/43.01
Technical data
Item Technical data

Cylinder liner protrusion 0.035-0.085mm
Seating depth of cylinder liner collar in crankcase 8.0±0.015mm
Bore at lower O-ring area Ø 139.500 - 139.540 mm
WARNING
Special tool
SINOTRUK
No. Picture Intruction MAN code
CODE
• Extracting the cylinder
liner in conjunction with:
JD6805-0169 80.99602-6035
• Extractor plate [331]
[331] Extractor plate

• Extracting the cylinder
JD6805-0170 80.99601-0217
liner
[332] Dial gauge

liner diameters
liner standout in
conjunction with:
JD6805-0024 08.71000-3217
• Dial gauge holder
[333]
• Measuring plate [334]
• Hexagon shank bolt
[335]
• Washer [336]
1st Edition 213

R.EN.MC11.31/35/39/43.01
SINOTRUK
No. Picture Intruction MAN code
CODE
liner standout JD6805-0147 80.99605-0172
[334] Measuring plate

[335] Hexagon shank bolt

[336] Washer
[337] Depth gauge

(electronic)
• Checking the cylinder JD6805-0032 08.71195-9003
liner seating
1st Edition 214

R.EN.MC11.31/35/39/43.01
Extracting the cylinder liner

Removing the cylinder liners
Checking the cylinder liner diameters
• Clamp the Extractor device [330] (3) with

the nut (2)
• Extract the cylinder liners (1) with the
• Use the Dial gauge [332] (2) and internal Extractor device [330] (3)
caliper (1) to check the cylinder liner (3) • Clean the cylinder liners (1)
• Repeat the measurement several times Removing the O-rings
at 120° offset
• Repeat the measurement at four different
heights If the cylinder liner (3) has become
oval, a new cylinder liner must be fitted.
Fitting the extractor device
• Remove the O-rings (2) from the crankcase

• Clean the cylinder liner seats (1) and
O-ring seats
WARNING
Danger of engine damage
caused by damaged oil
injector nozzles
• Take care not to damage the oil injector
nozzles when inserting the Extractor
plate [331]
• Mark the cylinder liners (1) to indicate
their correct assignment and installation
position
• Push the Extractor device [330] (3) with
folded Extractor plate [331] (2) into the
cylinder liner (1)
1st Edition 215

R.EN.MC11.31/35/39/43.01
liner protrusion is 0.035 -0.085 mm. If the

Installing the cylinder liners cylinder liner protrusion is out of tolerance,
Checking the cylinder liner seat fit a new cylinder liner/crankcase.
Installing the cylinder liner
• Check the cylinder liner seat with the • Lightly apply clean engine oil on the new
Depth gauge (electronic) [337] (1) O-rings (2) and insert them into the O-ring
• Check the cylinder liner seat at four seats in the crankcase
opposite-facing points the permitted seat • Lightly apply clean engine oil in the outer
depth is 8.0 ± 0.015 mm. lower area of the cylinder liner (1) on the
If the seat depth is out of tolerance, fit a outside
new crankcase. • Insert the cylinder liner (1) into the
Checking the cylinder liner protrusion crankcase as marked and push it in as far
as the stop
• Place the Measuring plate [334] (2) on

the cylinder liner
• Screw in and tighten the Hexagon shank
bolt [335] (4) with Washer [336] (5)
• Put the Dial gauge holder [333] (6) with
Dial gauge [332] (3) on the Measuring
plate [334] (2)
• Place the dial gauge tip (1) on the
crankcase
• Carefully place the dial gauge tip (1) on
the cylinder liner and note the difference
on the dial gauge the permitted cylinder
1st Edition 216
R.EN.MC11.31/35/39/43.01
PISTONS AND CONNECTING RODS
1..flywheel 2.crankshaft 3.connecting rod 4.bearing bush 5. Vibration damper 6.pistion
1st Edition 217

R.EN.MC11.31/35/39/43.01
Vibration damper
Removing and installing the vibration damper
Additional job
- Removing and installing the fan,，see 22.
1.mounting bolt 2.vibration damper 3.mountin bolt 4.washer
Technical data

Initial torque 150+10Nm
Mounting bolt（3） M16×85-10.9
Final torque 90+10°
Mounting bolt（1） M10×25-8.8 50-55Nm
WARNING
Component damage due to incorrectly tightened screw/bolt
connections
1st Edition 218

R.EN.MC11.31/35/39/43.01
Special tool
SINOTRUK
No Picture Instruction MAN CODE
CODE
[274] Engine barring gear J D6805-0023 80.99626-6008
• Blocking the engine

• Undoing and tightening
the vibration damper
mounting bolts
1st Edition 219

R.EN.MC11.31/35/39/43.01
Removing the washer

Removing the vibration
damper
Unscrew the mounting bolt（3）

·Removing the washer（1）from vibration
damper（2）

housing/timing case
• Mount and lock the Engine barring gear
[278] (1) on the flywheel housing/timing
case
Removing the vibration damper
• Unscrew the mounting bolts (3) with

Socket, size 14 [279]
• Remove the vibration damper (2) with
washer (1) from the crankshaft gear
1st Edition 220

R.EN.MC11.31/35/39/43.01

Installing the vibration damper
Install the washer

Insert the washer（1）into vibration dam（2） from the flywheel housing/timing case
Screew the mounting bolt（3）and tighten to • Mount the cap on the flywheel
50-55Nm housing/timing case
Mounting the vibration damper
• Fit the vibration damper (2) with the hub

(1)
• Screw in the new mounting bolts (3)
• Tighten the mounting bolts (3) to Initial
torque 155 Nm using the Socket, size 14
[279]
• Tighten the mounting bolts (3) to Final
torque 90° using the Socket, size 14 [279]
1st Edition 221

R.EN.MC11.31/35/39/43.01
FLYWHEEL
Removing and installing the flywheel
Additional jobs
- Removing and installing the rear crankshaft oil seal, see59
1.flywheel 2.mounting bolt 3.flywheel housing
Technical data

Mounting bolt（2） M16×1.5×81-12.9 Initial torque100+10Nm
Mounting bolt（2） M16×1.5×81-12.9 Final torque180°+10°
Flywheel ring gear installation 200-230℃
temperature
Flywheel bridge to friction surface Max.9.5mm
dimension (maximum dimension)
WARNING
1st Edition 222

R.EN.MC11.31/35/39/43.01
Special tool
SINOTRUK
CODE
[280] Aligning punch
• Removing and
installing the JD6805-0117 80.99617-0020
flywheel
[281] Dial gauge

• Checking the
flywheel lateral
run-out in
JD6805-0024 08.71000-3217
conjunction with:
[282]
• Checking the
flywheel lateral
JD6805-0025 08.71082-0005
runout
[283] Locating pin

• Checking the
JD6805-0026 80.99605-0197
flywheel lateral
runout
[284] Depth gauge
(electronic)
• Checking the
flywheel for wear in JD6805-0032 08.71195-9003
conjunction with:
• Measuring
attachment [285]
[285] Measuring
attachment
JD6805-0142 08.71109-0000
• Checking the
flywheel for wear
[286] Torque multiplier i =
1 : 3.5
• Undoing and JD6805-0084 80.99619-0007
tightening the
flywheel mounting
1st Edition 223

R.EN.MC11.31/35/39/43.01
SINOTRUK
CODE
bolts in conjunction
with:
• Support [287]
• Angle measuring
disc [288]
• Holding device
[289]
• Washer [290]
• Pan head
screw[291]
• Connecting pin
[292]
• Rubber ring, 42
mm [293]
• Socket, size 19
[294]·
[287] Support
• Undoing and
tightening the JD6805-0085 80.99606-0551
ywheel mounting
bolts
[288] Angle measuring
disc
• Undoing and
JD6805-0086 80.99607-0172
tightening the
flywheel mounting
bolts
[289] Holding device
• Undoing and
tightening the
JD6805-0143 80.99606-0553
flywheel mounting
bolts
[290] Washer
• Undoing and
flywheel mounting
bolts
1st Edition 224

R.EN.MC11.31/35/39/43.01
SINOTRUK
CODE
• Undoing and
flywheel mounting
bolts
[292] Connecting pin
• Undoing and
flywheel mounting
bolts
[293] Rubber ring, 42 mm
• Undoing and
tightening the
JD6805-0090 08.06142-9006
flywheel mounting
bolts

• Undoing and
flywheel mounting
bolts
• Pressing in the
clutch pilot bearing in
conjunction with:
JD6805-0020 80.99617-0187
• Thrust washer
[296]
• Pressing plate
[297]
[296] Thrust washer
• Pressing in the
clutch pilot bearing JD6805-0021 80.99617-0144

• Pressing in the
JD6805-0145 80.99604-0302
clutch pilot bearing
1st Edition 225

R.EN.MC11.31/35/39/43.01
Unscrewing the ywheel mounting bolts

Removing the flywheel
• Unscrew two opposite-facing mounting bolts

(1)
Screwing in the aligning punches·
• Insert the Torque multiplier i = 1 : 3.5
[286] (1) into the Support [287] (9)
• Mount the Holding device [289] (6) on the
Support [287] (9) with Pan head screw
[291] (8) and Washer [290] (7)
• Put the Angle measuring disc [288] (2)
on the torque multiplier i = 1 : 3.5 [286] (1)
• Put the Socket, size 19 [294] (3) on the
Torque multiplier i = 1 : 3.5 [286] (1) and
securing using the Connecting pin [292] (5)
and Rubber ring, 42 mm [293] (4) • Screw in the Aligning punch [280] (1) and
Undoing the flywheel mounting bolts (2)
• Unscrew the remaining mounting bolts
Pulling off the flywheel·
CAUTION
·• Place the special tool (1) onto the Danger of injury due to heav
mounting bolt that is going to be undone components
• Undo all the mounting bolts • Use lifting gear to remove the
flywheel
• Pull off the flywheel (1) over the
aligning punch [280] (2)
1st Edition 226
R.EN.MC11.31/35/39/43.01
Removing the clutch pilot bearing

Removing the flywheel ring
gear
·• Remove the clutch pilot bearing (2) from

the flywheel (1)
WARNING
spot-drilling of the flywheel
• Take care not to damage the
flywheel when spot-drilling the flywheel
ring gear
• Renew the spot-drilled flywheel
• Spot-drill the flywheel ring gear (2) with a
drill (3) and force it open
• Remove the flywheel ring gear (3) from
the flywheel (1)
• Clean the contact surfaces of the
flywheel ring gear (3) and flywheel (1)
and then check for damage
1st Edition 227

R.EN.MC11.31/35/39/43.01
Mounting the flywheel ring gear

Checking the flywheel
Checking the flywheel for wear
• Heat the flywheel ring gear (1) to 200 -

230 °C
• Fit the flywheel ring gear (1) so that the
chamfer (3) on the teeth is facing away • Clean the flywheel
from the flywheel (2) • Check the flywheel for cracks, fit a new
• Fit the flywheel ring gear (1) so that the flywheel if necessary
bores ofthe flywheel ring gear (1) and the • Check the friction surface (1) for burns
flywheel (2) are in line and traces of running in; fit a new flywheel
• Adjust the flywheel ring gear (1) as if necessary
necessary • Check the teeth (2) on the flywheel ring
gear for wear; fit a new flywheel ring gear
if necessary
Checking the dimension between the
flywheel bridge (flywheel with race only)
and the friction surface
• Check the dimension between the

flywheel bridge and the friction surface (1)
using the Depth gauge (electronic) [284]
(2) and Measuring attachment [285] (3)
The bridge dimension is allowed to be max.
7.0 mmafter working the flywheel.
If the bridge dimension is out of tolerance,
fit a new flywheel.·
1st Edition 228
R.EN.MC11.31/35/39/43.01
Fitting the flywheel

Installing the flywheel
Pressing in the clutch pilot bearing
CAUTION
components
• Use lifting gear to install the flywheel
• Line up the flywheel (1) with the
crankshaft gear dowel pin
• Fit the flywheel (1) over the Aligning
punch [280] (2)
Unscrewing the aligning punches
• Assemble the special tool consisting of

the Plug-on handle [295] (1), Thrust
washer [296] (2) and Pressing plate [297]
(3)
• Use the special tool to press the clutch
pilot bearing (4) into the flywheel (5) until
the stop is reached
• Screw in the new flywheel mounting bolts

• Unscrew the Aligning punch [280] (1)
and (2)
1st Edition 229

R.EN.MC11.31/35/39/43.01
Screwing in the flywheel mounting

PISTONS
bolts
AND CONNECTING RODS
Removing and installing the pistons and connecting rods
Additional jobs
- Removing and installing the engine control unit,see18
- Removing and installing the coolant manifold,see 31
- Removing and installing the exhaust manifold,see 65.
- Removing and installing the charge-air pipe, see 68.
- Removing and installing the turbocharger, see 72
- Removing and installing the cylinder head,see 78.
- Checking and setting the valve clearance,see 90
-• Removing
Screw in the
and
remaining
installingmounting
the fuel service
bolts centre,see 170
-(1)
Removing and installing the oil module, see59
-Tightening
Removing the
andmounting
installing the
bolts
oil sump (variant with holding pieces) and oil suction pipe,
see, see59
NOTE
Note the ratio of the torque
multiplier: i =1 : 3.5.
• Tighten the mounting bolts to Initial
torque 105 Nm using the special tool (1)
• Tighten the mounting bolts to Final
torque 180° using the special tool (1)
1.pistion 2.connecting rod 3.connecting rod bearing bolt 4. connecting rod bearingcap 5.pistion pin 6.circlip 7.pistion ring
8.bottom connecting rod bearing shell 9.top connecting rod bearing shell
1st Edition 230

R.EN.MC11.31/35/39/43.01
Technical data
item Specification Technical data
Initial torque100±10 Nm
Connecting rod bolt （3） M12×64-11.9
Final torque 90°+10°
Connecting rod axial play 0.130-0.330mm
Connecting rod radial play 0.044-0.106mm
Inside diameter of piston pin bushing Ø 52.060 - 52.065 mm
Connecting rod width 43.170-43.270mm
Connecting rod bearing shell bore in Ø 95.000 - 95.022 mm
connecting rod
Weight difference per set of connecting Max.50g
rods in an engine
Spread of connecting rod bearing shells Max.2.0mm
(8), (9)
Connecting rod bearing shells (8), (9) Ø 90.060 - 90.102 mm
normal dimension
Connecting rod bearing shells (8), (9) 2.468+0.010mm
normal dimension I
Piston ring gap (keystone ring) 0.40-0.55mm
Piston ring gap (taper-face ring) 0.9-1.1mm
Axial play 0.08-0.13mm
Piston ring gap (double-bevelled ring) 0.25-0.55mm
Axial play 0.03-0.07mm
Piston weight difference per set in one Max.60g
engine
Piston pin Ø 51.992 - 52.000 mm
Piston standout (crankcase - piston) 0.0235-0.3435mm
WARNING
Crack surfaces are sensitive. The principle involved can cause chipping
• Exchange the connecting rod if the crack surfaces are damaged
• Protect crack surfaces against damage caused by hard and sharp objects
• To clean the crack surfaces on the connecting rods, always rinse them in
clean cleaning agent
• After cleaning, use compressed air to blow-dry the crack surfaces
• Do not allow rinsed-out particles to enter the engine
WARNING
1st Edition 231

R.EN.MC11.31/35/39/43.01
NOTE
The piston diameter is always measured perpendicular to the piston pin bore.
Special tools
No. Picture SINOTRUK MAN code
Intruction
CODE
[308] Piston-ring pliers
piston rings JD6805-0034 83.09144-6090
[309] Feeler gauge

• Checking the piston ring
JD6805-0146 08.75310-0808
axial play and gap
[310] Dial gauge

• Checking the inside
diameter of the connecting
rod bearing shells and
piston pin bushing
• Checking the piston
standout in conjunction
JD6805-0024 08.71000-3217
with:
• Checking the connecting
rod axial and radial play
• Checking the piston
standout JD6805-0147 80.99605-0172

rod axial and radial play JD6805-0025 08.71082-0005
1st Edition 232

R.EN.MC11.31/35/39/43.01

Intruction
CODE
[313] Locating pin
JD6805-0026 80.99605-0197
rod axial and radial play

• Checking the piston ring
JD6805-0032 08.71195-9003
insertion depth
[315] Piston ring clamping

sleeve
JD6805-0148 80.99613-0038
• Installing the pistons
[316] Setting tool

• Aligning the connecting
JD6805-0149 80.99622-0052
rod bearing shells
1st Edition 233

R.EN.MC11.31/35/39/43.01
Checking the connecting rod radial

Checking the connecting rod play
Checking the connecting rod axial play

·• Mount the Dial gauge holder [312] (2) with the Dial gauge [310] (2) and Locating
with the Dial gauge [310] (1) and Locating pin [313] on the crankcase (3)
pin [313] on the crankcase (3) • Position the Locating pin [313] against
• Position the Locating pin [313] against the connecting rod (4) with a preload
the connecting rod (4) with a preload • Press the connecting rod (4) vertically
• Push the connecting rod (4) horizontally downwards to the end position
into the end position towards the ywheel • Zero the Dial gauge [310] (2)
housing/timing case • Pull the connecting rod (4) into the end
• Zero the Dial gauge [310] (1) position, towards Dial gauge [310] (2), and
• Pull the connecting rod (4) into the end read off the difference
position, towards Dial gauge [310] (1), and • Repeat the procedure for the remaining
read off the difference connecting rods The permitted radial play
• Repeat the procedure for the remaining on the connecting rod (4) is 0.060 - 0.122
connecting rods The permitted axial play mm.
on the connecting rod (4) is 0.130 - 0.330 If the radial play is out of tolerance, check
mm. the connecting rod bearing shells and
If the axial play is out of tolerance, check journals.
the width of the connecting rod (4), see Check the inside diameter of the
Checking the connecting rod width, 235. connecting rod bearing shells, see
Checking the connecting rod bearing
inside diameter, 238.
Check the outside diameter of the
connecting rod bearing journals, see
connecting rod bearing journal, 249.
1st Edition 234

R.EN.MC11.31/35/39/43.01
Removing the piston

Removing the pistons and
connecting rods
Removing the connecting rod bearing cap
·• Extract the piston (1) with connecting rod (2)

from the cylinder liner (4)
• Mark the connecting rod (2) and connecting
WARNING rod bearing shell (3) to indicate correct
Crack surfaces are sensitive. assignment and installation position
The principle involved can • Remove the connecting rod bearing shell (3)
cause chipping fromthe connecting rod (2)
• Exchange the connecting rod if Checking the piston pin diameter
the crack surfaces are damaged
• Protect crack surfaces against damage
caused by hard and sharp objects
• Mark the connecting rod bearing cap (3)
and connecting rod bearing shell (2) to
indicate correct assignment and installation
position
• Unscrew the connecting rod bearing bolts
(4)
• Remove the connecting rod bearing cap (3)
with connecting rod bearing shell (2) ·• Check the diameter of the piston pin (2)
• Push the piston and connecting rod (1) out using a micrometer (1)
in the direction of the cylinder head The permitted diameter of the piston pin (2) is
Ø 51.992 - 52.000 mm.
If the diameter is out of tolerance, t a new
piston with piston pin (2)
1st Edition 235

R.EN.MC11.31/35/39/43.01
Checking the piston ring axial play Checking the piston ring gap
NOTE
An axial play cannot be Note
measured on thekeystone ring. The ring gap is only allowed to
• Measure the axial play between the be checked if the cylinder liner
piston rings (2) and (3) and the piston (4) has the correct inside diameter,
using the Feeler gauge [309] (1)The otherwise a false ring gap
permitted double-bevelled ring (3) axial reading would be obtained. Check the
play is 0.03 - 0.07 mm. The permitted inside diameter of the cylinder liner, see
taper-face ring (2) axial play is 0.08 - 0.13 Removing and installing the cylinder liners,
mm. If the axial plays are out of tolerance, 539.
fit a new piston • Insert the piston ring (3) evenly deep into
(4) with piston rings (2), (3) and keystone the cylinder liner (1)
ring. • Check even insertion depth of the piston
Removing the piston rings ring (3) using Depth gauge (electronic)
[314]
• Repeat the check with various insertion
depths
• Use the Feeler gauge [309] (2) to check
the ring gap The permitted keystone ring
gap is 0.40 - 0.55 mm. The permitted
taper-face ring gap is 0.70 - 0.90 mm. The
permitted double-bevelled ring gap is 0.25
-0.55 mm.
• Piston-ring pliers [308] Set the (1) to the If the ring gaps are out of tolerance, fit new
piston diameter piston rings.
• Detach the piston rings (2) from the
piston (3) using the Piston-ring pliers [308]
(1)
• Carefully clean the piston ring grooves·
1st Edition 236

R.EN.MC11.31/35/39/43.01
Checking the connecting rod bearing

Checking the connecting inside diameter
rods and connecting rod
bearings
Correct matching of connecting rod
and connecting rod bearing cap
• Insert the upper connecting rod bearing

shell into the connecting rod (4)
• Insert the lower connecting rod bearing
shell into the connecting rod bearing cap
(1)
• Screw in the connecting rod bearing bolts
WARNING and tighten them to Initial torque 100 Nm
Component damage due to • Use the Dial gauge [310] (2) and internal
incorrect matching of caliper (3) to check the connecting rod
connecting rod and bearing inside diameter Connecting rod
connecting rod bearing cap bearing inside diameter, see Connecting
• Ensure that the connecting rod and rod bearing shell dimensions, 232. If the
the connecting rod bearing cap are inside diameter is out of tolerance, fit new
matched correctly connecting rod bearing shells.
• Check the pairing numbers (1) and (2) on Checking the piston pin bushing
the connecting rod (3) and the connecting
rod bearing cap (4)
• Use the internal calliper (3) and the Dial

gauge [310] (2) to check the piston pin
bushing inside diameter The permitted inside
diameter of the piston pin bushing (3) is Ø
52.055 - 52.065 mm. If the inside diameter
1st Edition 237
R.EN.MC11.31/35/39/43.01
is out of tolerance, fit a new Checking the connecting rod width

connecting rod (1).
• Check the width of the connecting rod (1)

• Remove the connecting rod bearing cap
43.270 mm.
connecting rod (1).
1st Edition 238

R.EN.MC11.31/35/39/43.01
engaged correctly, detach and re-attach the

Installing the pistons and circlips (2) and (4),
ensuring that they are seated correctly.
connecting rods
Installing the piston rings
• Piston-ring pliers [308] Set the (1) to the

piston diameter
• Use the Piston-ring pliers [308] (1) to insert
the piston rings (2) into the corresponding ring
groove in the piston (3), ensuring that the TOP
mark is facing the piston crown
Installing the piston pin
·• Attach a new retaining ring (2) in the groove

in the piston
• Fit the piston (1) over the connecting rod (3)
as marked
• Lightly apply clean engine oil on the piston
pin (5)
• Push the piston pin (5) through the piston (1)
and the connecting rod (3) as marked,
ensuring that the stop is reached
• Attach a new circlip (4) in the groove in the
piston
• Check that the circlips (2) and (4) are seated
correctly If the circlips (2) and (4) have not
1st Edition 239
R.EN.MC11.31/35/39/43.01
Installation instructions for connecting Piston installation with piston ring

rod bearing shells clamping sleeve
WARNING
Crack surfaces are NOTE
sensitive. The principle There is an installation arrow on
involved can cause the piston surface. This must
chipping point towards the coolant pump during
• Exchange the connecting installation.
rod if the crack surfaces are damaged • Move the crankshaft for the cylinder
• Protect crack surfaces against damage concerned to TDC
caused by hard and sharp objects • Line up the piston ring gaps at 120°
• Clean the contact surfaces of the offset to one another
connecting rod bearing shells in the • Lightly apply clean engine oil on the
connecting rod and connect rod bearing upper
cap connecting rod bearing shell
• Insert the lower connecting rod bearing • Insert the upper connecting rod bearing
shell into the connecting rod bearing cap shell into the connecting rod
so that the lug (1) engages in the recess • Lightly apply clean engine oil on the
(4) piston (1) and cylinder liner (3)
• Insert the upper connecting rod bearing • Put the Piston ring clamping sleeve [315]
shell into the connecting rod so that the (2) on the piston (1) and clamp
lug (2) engages in the recess (3) • Push the piston (1) with connecting rod
• With the Setting tool [316], align the into the cylinder liner (3) until the piston
connecting rod bearing shells in the has been pushed out of the Piston ring
connecting rod and connecting rod clamping sleeve [315] (2)
bearing cap • Push in the piston (1) until the connecting
rod with connecting rod bearing shell is
lying on the crankshaft
1st Edition 240

R.EN.MC11.31/35/39/43.01
Checking the connecting rod alignment Installing the connecting rod bearing
cap
WARNING
Crack surfaces are
sensitive. The principle WARNING
involved can cause Crack surfaces are
chipping sensitive. Theprinciple
• Exchange the connecting involved can cause
rod if the crack surfaces are damaged chipping
caused by hard and sharp objects • Exchange the connecting rod if thecrack
• Check the alignment of the connecting surfaces are damaged
rod bearing shell (2) in the connecting rod • Protect crack surfaces against damage
(1) and, if necessary, adjust with Setting caused by hard and sharp objects
tool [316] (3) • Check the alignment of the lower
connecting rodbearing shell (2) and, if
necessary, adjust withSetting tool [316]
lower
connecting rod bearing shell (2)
• Position the connecting rod bearing cap
(3) on theconnecting rod (1) as marked
• Screw in new connecting rod bolts (4)
and tightenthem to Initial torque 100 Nm
• Tighten the connecting rod bearing bolts
(4) toFinal torque 90°
1st Edition 241

R.EN.MC11.31/35/39/43.01
Checking the connecting rod clearance gauge holder [311] (1) and Locating pin
[313] (3) on the piston (2) and read off the
difference (piston standout) The permitted
piston standout is 0.3 mm (nominal
dimension).
• Check the connecting rod (1) for

clearance by moving in the engine's
longitudinal direction If the connecting rod
(1) is not free, check that the connecting
rod and connecting rod bearing cap are
correctly matched, see Correct matching
of connecting rod and connecting rod
bearing cap, 506. Check the connecting
rod bearing shells. If incorrect connecting
rod bearing shells are installed, new ones
must be fitted instead.Check the seating of
the connecting rod bearing shells in the
connecting rod and connecting rod
bearing cap and, if necessary, re-align the
connecting rod bearing, see Checking the
connecting rod alignment, 241.
Checking the piston standout
·• Move the piston (2) to top dead centre

• Mount the Dial gauge [310] (4) with Dial
gaugeholder [311] (1) and Locating pin
[313] (3) on the crankcase (5) with a
preload
• Fit the Dial gauge [310] (4) with Dial
1st Edition 242
R.EN.MC11.31/35/39/43.01
CRANKSHAFT
Removing and installing the crankshaft
Additional job
- Removing and installing the engine control unit,see 18
- Removing and installing the coolant manifold,see31
- Removing and installing the thermostats,see 35
- Removing and installing the thermostat housing,see 37
- Removing and installing the distributor housing，see 43.
- Removing and installing the starter,，see 52
- Removing and installing the belt drive,see 55
- Removing and installing the exhaust manifold,，see 65.
- Removing and installing the turbocharger,see 72.
- Removing and installing the cylinder head, 78.
- Checking and setting the valve clearance,see 90.
- Removing and installing the injectors and pressure pipes,see 144.
- Removing and installing the fuel service centre,see 170
- Removing and installing the front drive gears,see 59
- Removing and installing the rear timing gears,see 130
- Removing and installing the oil module,see 59
- Removing and installing the oil sump,see59
- Removing and installing the cover,see59
- Removing and installing the vibration damper,see59
- Removing and installing the pistons and connecting rods,see59
1.flywheel 2.crakshaft 3.connecting rod 4. Crankshaft bearing cap 5.pistion
1st Edition 243

R.EN.MC11.31/35/39/43.01
Technical data
Item Specification standard

Initial torque50Nm
Mounting bolt, crankshaft Second torque 150Nm
M18×160.5
bearing cap（4） third torque300（0/30）Nm
Final torque90°+10°
Axial play, crankshaft（2） 0.200-0.401mm
Crankshaft journal, centring, front
99.975-99.995mm
crankshaft gear
Crankshaft journal, normal
Ø 103.980 - 104.000 mm
dimension
Crankshaft journal, normal
Ø 104.044 - 104.090 mm
dimension I
Wall thickness of crankshaft
3.466+0.12mm
bearing shell, normal dimension
Crankshaft bearing spread Max.1.2mm
Connecting rod bearing journal,
Ø 89.980 - 90.000 mm
normal dimension
Thrust washer thickness, normal
3.350-3.400mm
dimension
Import information
WARNING
Crack surfaces are sensitive. The principle involved can cause chipping
• Exchange the connecting rod if the crack surfaces are damaged
• Protect crack surfaces against damage caused by hard and sharp objects
• To clean the crack surfaces on the connecting rods, always rinse them in
clean cleaning agent
• After cleaning, use compressed air to blow-dry the crack surfaces
• Do not allow rinsed-out particles to enter the engine
WARNING
max. 50% of thespecified tightening torque
1st Edition 244

R.EN.MC11.31/35/39/43.01
Special tools

Intruction
code
[317 Dial gauge
] • Checking the
crankshaft bearing
inside diameter
• Checking the
08.71000-321
crankshaft axial and JD6805-0024
7
radial play in
conjunction with:
[318]
[318 Dial gauge holder
] • Checking the
08.71082-000
crankshaft axial and JD6805-0025
5
radial play
[319 Locating pin

] • Checking the 80.99605-019
JD6805-0026
crankshaft axial and 7
radial play
[320 Torque multiplier i =
] 1 : 3.5
• Undoing and
tightening the
crankshaft bearing
cap mounting bolts in
conjunction with:
• Support [321]
• Angle measuring
80.99619-000
disc [322] JD6805-0084
7
• Column [323]
• Washer [324]
• Pan head screw
[325]
• Connecting pin [326]
• Rubber ring, 42 mm
[327]
• Socket, size 27
[328]
1st Edition 245
R.EN.MC11.31/35/39/43.01

Intruction
code
[321 Support
] • Undoing and
80.99606-055
tightening the JD6805-0085
1
crankshaft bearing
cap mounting bolts
[322 Angle measuring disc
] • Undoing and
80.99607-017
2
crankshaft bearing
cap mounting bolts
[323 Column
] • Undoing and
tightening the 80.99606-058
JD6805-0150
crankshaft bearing 4
cap mounting bolts
[324 Washer
] • Undoing and
80.99609-003
3
crankshaft bearing
cap mounting bolts
[325 Pan head screw
] • Undoing and
06.02191-040
7
crankshaft bearing
cap mounting bolts
[326 Connecting pin
] • Undoing and
06.22729-000
6
crankshaft bearing
cap mounting bolts
[327 Rubber ring, 42 mm
] • Undoing and
tightening the 08.06142-900
JD6805-0090
cap mounting bolts
1st Edition 246

R.EN.MC11.31/35/39/43.01

Intruction
code
[328 Socket, size 27
] • Undoing and
80.99603-031
2
crankshaft bearing
cap mounting bolts
[329 Setting tool
] • Aligning the 80.99622-005
JD6805-0149
shells
1st Edition 247

R.EN.MC11.31/35/39/43.01
Checking the crankshaft Removing the crankshaft

Checking the crankshaft axial play Assembling the special tool
·• Position the Dial gauge holder [318] (3) • Insert the Torque multiplier i = 1 : 3.5
with the Dial gauge [317] (2) and Locating [320] (1) into the Support [321] (9)
pin [319] on the crankshaft (1) with a • Mount the Column [323] (6) with the Pan
preload head screw [325] (8) and Washer [324] (7)
• Push the crankshaft (1) horizontally into on the Support [321] (9)
the end position towards the flywheel • Put the Angle measuring disc [322] (2)
housing/timing case on the Torque multiplier i = 1 : 3.5 [320] (1)
• Zero the Dial gauge [317] (2) • Put the Socket, size 27 [328] (3) on the
• Pull the crankshaft (1) into the end Torque multiplier i = 1 : 3.5 [320] (1) and
position, secure with the Connecting pin [326] (5)
towards Dial gauge [317] (2), and read off and Rubber ring,42 mm [327] (4)
the difference The permitted axial play on Undoing the crankshaft bearing cap
the crankshaft (1) is 0.200 - 0.401 mm. If mounting bolts
the axial play is out of tolerance, install
suitable thrust washers. Install suitable
thrust washers, see Thrust washer
dimensions, 244.
• Undo the bearing cap mounting bolts

using the special tool (1)
1st Edition 248

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Removing the crankshaft bearing cap assignment

axial washers • Unscrew the mounting bolts (3)
• Remove the bearing cap (2)
• Mark the crankshaft bearing shell (1) to
indicate its installation position and correct
assignment and then remove it
• Repeat the work step for bearing caps 2,
3, 4, 5, and 7
Removing the crankshaft
WARNING
Crack surfaces are
sensitive. Theprinciple
involved can cause
chipping
• Exchange the crankcase if the crack
surfaces on the bearing cap or bearing
seats are damaged
• Protect crack surfaces against damage CAUTION
caused by hard and sharp objects Danger of injury due to heavy
• Mark the bearing cap (4) to indicate its components
installation position and correct • Remove the crankshaft with
assignment support
• Unscrew the mounting bolts (1) WARNING
• Remove the bearing cap (4) with thrust Component damage due to
washers (2) and (3) unsuitable lifting gear
• Mark the crankshaft bearing shells to • Do not use steel cables or
indicate their installation position and other sharp-edged tools to lift
correct assignment and then remove them out the crankshaft
Removing the crankshaft bearing cap • Lift the crankshaft (3) out of the
crankcase (2)
• Mark the crankshaft bearing shells (1) to
indicate their installation position and
correct assignment and then remove them
from the crankcase (2)
·
• Mark the bearing cap (2) to indicate its

installation position and correct
1st Edition 249
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Checking the crankshaft bearing inside Checking the outside diameter of the
diameter connecting rod bearing journal
• Clean the crankshaft connecting rod

·• Insert the upper and lower crankshaft bearing journal (1)
bearing shell into the bearing seat as • Check the connecting rod bearing journal
marked using a micrometer (2)
• Fit the bearing cap (3) as marked • Repeat the check several times at 120°
• Screw in the mounting bolts for the offset Outside diameter of connecting rod
bearing cap (3) and tighten them to Initial bearing journal, see Connecting rod
torque 50 Nm bearing journal dimensions, 244. If the
• Use the internal calliper (2) and Dial outside diameter is out of tolerance, fit a
gauge [317] new crankshaft (1).
(1) to check the crankshaft bearing
• Repeat the check several times at 120°
offset
• Remove the bearing cap (3) again after
the check Inside diameter of the
crankshaft bearings see Crankshaft
bearing shell dimensions, 244. If the inside
diameter is out of tolerance, fit new
crankshaft bearing shells.
1st Edition 250

R.EN.MC11.31/35/39/43.01
Checking the crankshaft bearing

journal outside diameter
Installing the crankshaft
Installing the crankshaft
• Clean the crankshaft journal (1)

• Check the crankshaft journal using a WARNING
micrometer (2) Component damage due to
• Repeat the check several times at 120° unsuitable lifting gear
offset Crankshaft journal outside diameter, • Do not use steel cables or other
see Crankshaft dimensions, 244. If the sharp-edged tools to lift in the
outside diameter is out of tolerance, fit a crankshaft
new crankshaft (1). • Lightly apply clean engine oil on the crankshaft
bearing shells (1)
• Insert the crankshaft bearing shells (1) into the
bearing seats as marked and align with the
Setting tool [329]
• Insert the crankshaft (3) into the crankcase (2)
Installing the upper thrust washers
NOTE
Only thrust washers whose wall
thicknesses are the same, upper and
lower thrust washer, are allowed to be
used.
1st Edition 251

R.EN.MC11.31/35/39/43.01
• Determine the thrust washers (2) to be crankshaft and, if necessary, fit a new
used, see Checking the crankshaft axial crankshaft or crankshaft bearings.
play, 247. Installing the crankshaft bearing cap
thrust washers (2)
• Insert the thrust washers (2) at bearing
seat 6 with the oil grooves facing the
crankshaft (1)
• Insert the thrust washers (2) into the
bearing seat by pressing lightly
Installing the crankshaft bearing cap
axial washers
WARNING
Crack surfaces are
sensitive. The principle
involved can cause chipping
• Exchange the crankcase if the crack
surfaces on the bearing cap or crankcase
are damaged
caused by hard and sharp objects
• Lightly apply clean engine oil on the • Lightly apply clean engine oil on the
crankshaft bearing shell and thrust crankshaft bearing shell (1)
washers (1) and (2) • Insert the crankshaft bearing shell (1)
• Insert the crankshaft bearing shell into into the bearing cap (2) as marked and
the bearing cap (3) as marked and align align with the Setting tool [329]
with the Setting tool [329] • Fit the bearing cap (2)
• Insert the thrust washers (1) and (2) into • Lightly apply clean engine oil on the
the bearing cap (3) with the oil grooves contact surface for the heads of the new
facing the crankshaft mounting bolts (3)
• Fit the bearing cap (3) with thrust • Screw in the mounting bolts (3) and
washers (1) and (2) tighten them to Initial torque 50 Nm
• Screw in new mounting bolts (4) and • Tighten the mounting bolts (3) to 2nd
tighten to Initial torque 50 Nm torque 150 Nmm
• Tighten the mounting bolts (4) to 2nd
torque 150 Nm
• Check to ensure that the crankshaft
moves freely If the crankshaft cannot be
turned or only turned with difficulty,
remove the crankshaft with crankshaft
bearings.
Recheck the crankshaft bearings and the
1st Edition 252
R.EN.MC11.31/35/39/43.01
Tightening the crankshaft bearing cap Note

mounting bolts Note the ratio of the torque multiplier: i =
1 : 3.5.
• Tighten the mounting bolts to 3rd torque
315 Nm using the special tool (1)
• Tighten the mounting bolts to Final
torque 90° using the special tool (1)
1st Edition 253

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FRONT DRIVE GEARS
Removing and installing the front drive gears
Additional jobs
- Removing and installing the fan,see 22
- Removing and installing the fan drive,see 24.
- Removing and installing the coolant manifold,see 31
- Removing and installing the thermostats,see 35
- Removing and installing the thermostat housing,see 37
- Removing and installing the distributor housing,see 43
- Removing and installing the belt drive,see 55
- Removing and installing the high-pressure pump/high-pressure pump drive,see 158
- Removing and installing the front crankshaft oil seal,see59
- Removing and installing the cover,see59
- Removing and installing the vibration damper,see59
1. High-pressure pump drive intermediategear 2. Intermediate gear pin 3. Intermediate gear pin mounting bolt
4. Front crankshaft gear 5. Oil pump
1st Edition 254

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Special tools
Intermediate gear pin mounting bolt M12×50-10.9 110Nm
Backlash, camshaft gear (4) - high-pressure
0.057-0.183mm
pump drive intermediate gear (1)
Axial play, high-pressure pump drive
0.100-0.029mm
intermediate gear
Radial play, high-pressure pump drive
0.060-0.109mm
intermediate gear
Height, high-pressure pump drive
21.950-22.000mm
intermediate gear
Inside diameter, high-pressure pump drive
Ø 60.000 - 60.030 mm
intermediate gear
Outside diameter, intermediate gear pin Ø 59.921 - 59.940 mm
Height, intermediate gear pin 27.200-27.240mm
WARNING
NOTE
The intermediate gear and pin do not have to be exchanged as a set.
They can also be replaced individually, depending on the degree of wear.
Special tools
Intruction
code
[228] Aligning punch JD6805-0117 80.99617-0020
• Removing and
installing the front
crankshaft gear
[229] Dial gauge JD6805-0024 08.71000-3217
• Checking the
backlash in
conjunction with:
• Checking the
intermediate gear axial
play inconjunction with:
• Checking the
intermediate gear
radial play in
1st Edition 255

R.EN.MC11.31/35/39/43.01
conjunction with:
[230]
• Checking the
backlash
• Checking the axial
play on the
intermediate gear
• Checking the radial
play on the
intermediate gear
[231] Locating pin JD6805-0026 80.99605-0197
• Checking the
backlash
• Checking the axial
play on the
intermediate gear
• Checking the radial
play on the
intermediate gear
[232] Depth gauge JD6805-0032 08.71195-9003
(electronic)
• Checking the
height
1st Edition 256

R.EN.MC11.31/35/39/43.01
Checking the axial play on the high

Checking the front drive gears pressure pump drive intermediate gear
Fixing the crankshaft gear
·• Position the Dial gauge holder [230] (2)

• Screw in the Aligning punch [228] (1) and with Dial gauge [229] (3) and Locating pin
(3) [231] on the intermediate gear (1) with a
• Screw in and tighten the mounting bolt (2) preload
Checking the crankshaft gear/high • Push the intermediate gear (1) into the
pressure pump drive intermediate gear end position
backlash· • Zero the Dial gauge [229] (3)
• Pull the intermediate gear (1) into the
The permitted axial play on the
intermediate gear (1) is 0.100 - 0.290 mm.
If the axial play is out of tolerance, check
the height of the intermediate gear (1) and
intermediate gear pin.
Check the height of the intermediate gear
(1), see Checking the height of the
• Position the Dial gauge holder [230] (4) high-pressure pump drive intermediate
with Dial gauge [229] (3) and Locating pin gear, 258.
[231] on the intermediate gear (1) with a Check the height of the intermediate gear
preload pin, see Checking the intermediate gear
• Check the backlash between the pin height, 258..
crankshaft gear (2) and the intermediate
gear (1) The permitted backlash is 0.057 -
0.183 mm. If the backlash is out of tolerance,
fit a new crankshaft gear (2) and
intermediate gear (1).·
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Checking the radial play on the high

pressure pump drive intermediate gear
Removing the crankshaft gear
Unscrewing the mounting bolt
·• Position the Dial gauge holder [230] (1)

with Dial gauge [229] (2) and Locating pin
[231] on the intermediate gear (3) with a • Unscrew the mounting bolt (1)
preload Removing the crankshaft gear·
• Push the intermediate gear (3) into the
end
position, towards the crankshaft gear
• Pull the intermediate gear (3) into the
end position, towards Dial gauge [235] (2),
and read off the difference The permitted
radial play on the intermediate gear
(3) is 0.060 - 0.109 mm. If the radial play is
out of tolerance, check the intermediate
gear (3) and intermediate gear pin. • Pull off the crankshaft gear (2)
Check the inside diameter of the • Unscrew the Aligning punch [228] (3) and
intermediate gear (3), see Checking the (4)
inside diameter of the high-pressure pump • Clean the contact surfaces of the
drive intermediate gear, 258. crankshaft gear (2) and crankshaft (1)·
Check the outside diameter of the
intermediate gear pin, see Checking the
outside diameter of the intermediate gear
pin, 259.
1st Edition 258

R.EN.MC11.31/35/39/43.01
Checking the height of the

Removing the high-pressure high-pressure pump drive intermediate
gear·
pump drive intermediate gear
Removing the intermediate gear
• Clean the intermediate gear (1)

• Check dimension A of the intermediate
gear (1) Dimension A is allowed to be
• Unscrew the mounting bolts (2) 21.000 - 21.500 mm. If dimension A is out
• Pull off the intermediate gear (1) with the of tolerance, fit a new intermediate gear
intermediate gear pin (3) (1).
Checking the inside diameter of the height·
high pressure pump drive intermediate
gear
• Clean the intermediate gear (3) • Clean the intermediate gear pin (1)
• Use the Dial gauge [229] (2) and internal • Check the height of the intermediate
caliper (1) to check the inside diameter of gear pin (1) with Depth gauge (electronic)
the intermediate gear (3) The permitted [232] (2). The permitted height of the
inside diameter of the intermediate intermediate gear pin (1)is 27.200 - 27.240
gear (3) is Ø 60.000 - 60.030 mm. mm.
If the inside diameter is out of tolerance, If the height is out of tolerance, fit a new
fit a new intermediate gear (3). intermediate gear pin (1).
Checking the intermediate gear pin
1st Edition 259

R.EN.MC11.31/35/39/43.01
Installing the front drive
gears
Installing the intermediate gear
• Check the outside diameter of the

intermediate gear pin (1) using a
micrometer (2) The permitted outside
diameter of the intermediate gear pin (1) is
Ø 59.921 - 59.940 mm. If the outside
diameter is out of tolerance, fit a new
intermediate gear pin (1). • Lightly apply clean engine oil on the
Tightening the intermediate gear pin intermediategear pin (3)
mounting bolts • Insert the intermediate gear pin (3) into
the intermediate gear (1)
• Install the intermediate gear (1) in the
crankcase with the intermediate gear pin
(3)
• Screw in the new mounting bolts (2)
Installing the crankshaft gear
Tighten the mounting bolts (1) to 110 Nm
• Screw in the Aligning punch [228] (3) and

(4)
• Put the crankshaft gear (2) on the
crankshaft (1), making sure that the stop is
reached
• Unscrew the Aligning punch [228] (3)
and (4)
1st Edition 260

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TECHNICAL DATA
MC11 series diesel engine main bolt, nut, screw and pipe joint tightening torque and tighten angle summary
Tighteni
ng angle
Initial
Tightening
No. Item Thread Strength class tightening Remarks
torque Nm
Nm ∡
50 Bearing surface with a

1 Main bearing bolt M18×2 10.9 150 90°+10° little oil
300+30 Do not reuse
2 Crankcase locking bolt M22×1.5 80+5
Bearing surface with a
3 Connecting rod bolt M13×1.5 11.9 100±10 90°+10° little oil
Do not reuse
Shock absorber and
4 wheel hub connecting M10 8.8 50＋5
bolt
Shock absorber and
5 crankshaft connecting M16×1.5 10.9 150＋10 90°+10°
bolt
Bearing surface with a
180°＋
6 Flywheel bolt M16×1.5 12.9 100＋10 little oil
10°
Do not reuse
261
R.EN.MC11.31/35/39/43.01
The new cylinder head

bearing surface with a
little oil
10
If cylinder head
7 Cylinder head bolt M18×2 10.9 150 3×90°
bearing surface has
300
damage, brush a small
amount of White T
Do not reuse
8 Cylinder head screw M16×1.5 40
9 Rocker arm base screw M12 10.9 105＋10
10 Rocker arm adjusting nut M10×1 45
11 EVB clamp adjusting nut M14×1 45
12 Camshaft gear bolt M8 10.9 15 90°
Large intermediate gear
13 M14 10.9 150＋10 90°
shaft
14 Oil pan drain plug M22×1.5 80
15 Oil module plug M16×1.5 25+5
16 Oil module plug M33×2 80+10
17 Oil module plug M38×1.5 80+10
18 Pressure limiting valve M27×1.5 40+5
19 Oil filter M20 40+10
Oil and gas separator oil
20 M24×1.5 PA66-GF30 4±0.5 Loctite 243
return pipe
21 Filler pipe M38×1.5 PA6-GF30 35
22 Fan hub and fan shaft M16×1.5- 850-1000N/mm2 100 90°＋
262
R.EN.MC11.31/35/39/43.01
connection bolt LH 10°

23 Distribution shell plug M14×1.5 30
Short exhaust manifold Heat-resistant 90°＋
24 M10 60＋5
bolt bolt 10°
Long exhaust manifold Heat-resistant 90°＋
25 M10 60＋5
bolt bolt 10°
The supercharger 90°＋
26 M10 21CrMoV5-7 10+5
fastening nut 10°
1-2 90°＋
27 Fuel injector clamp bolt M8 10.9
25 10°
Fuel intake pipe clamp 10
28 M24×1.5 40Cr 60°
nut 20
Common rail pipe fixed
29 M8 10.9 35±5
bolt
1-6 cylinder
30 M14×1.5 10 60°
high-pressure tubing nut
Pump to common rail
31 M14×1.5 10 60°
high pressure fuel pipe
32 Injector wiring harness M4 1.8+0.25
ECU support retaining
33 M8 10.9 12-14
bolt
34 ECU fixed bolt M6 10.9 10±2
High pressure fuel pump
35 and the transmission M10 10.9 60-70
case connecting bolt
263
R.EN.MC11.31/35/39/43.01
36 Fuel filter cover SW39 25+5

37 Fuel prefilter cap SW19 10+5
Low pressure circuit
38 M14×1.5 30-35
screwing in type joint
Coolant temperature
39 M16×1.5 45-50
sensor
40 Speed sensor M6 10.9 8-10
Diesel engine front
41 M14 12.9 230
support
Air compressor screwing
42 in type through joint M16×1.5 30-35
NG12
Air compressor sleeve
43 M26×1.5 45-50
through joint
Automatic tension wheel
44 fastening countersunk M10 10.9 42-52
screw
45 Idler wheel fastening bolt M12 10.9 50-70
High pressure pump
46 M38×1.5 35
driving box filler pipe
Oil level gauge tube
47 M14×1.5 30
transition joint
MC11 series diesel engine main parts fit clearance summary

No. Item Fit value（mm）
1 The value of that piston bulge crankcase top face +0.0235～
264
R.EN.MC11.31/35/39/43.01
+0.3435
2 The value of that piston bulge cylinder sleeve top face -0.0615～+0.3085
3 The value of that cylinder sleeve bulge crankcase top face +0.035～+0.085
4 Crankshaft axial clearance 0.200～0.401
5 Main bearing radial clearance 0.044～0.110
6 Connecting rod bearing radial clearance 0.044～0.106
7 Connecting rod axial clearance 0.130～0.330
8 Connecting rod little head bushing and piston pin radial clearance 0.055～0.073
9 The piston pin and piston pin seat radial clearance 0.010～0.024
10 The piston and cylinder liner radial clearance Min 0.101
11 Intake and exhaust valve guide bulging value 16.1～16.5
12 Camshaft radial clearance 0.024～0.090
13 Camshaft axial clearance 0.05～0.85
14 Rocker arm radial clearance 0.030～0.066
15 Intake valve stem radial clearance 0.023～0.052
16 Exhaust valve stem radial clearance 0.036～0.065
17 Intake valve recess quantity 0.5～0.8
18 Exhaust valve recess quantity 0.5～0.8
19 Cold inlet valve clearance 0.47～0.53
20 Cold exhaust valve clearance 0.77～0.83
21 EVB clearance 0.57～0.63
22 The inlet valve maximum lift when valve clearance is 0.5 10
23 The inlet valve maximum lift when valve clearance is 0.8 12
24 Oil pump outer rotor axial clearance 0.030～0.093
25 Oil pump outer rotor radial clearance 0.10～0.210
265
R.EN.MC11.31/35/39/43.01
26 Oil pump inner rotor axial clearance 0.030～0.090

27 Oil pump inner rotor radial clearance 0.02～0.10
28 Water pump shell and pump impeller clearance 3.7～4.3
29 Inlet valve open before TDC 24CA
30 Inlet valve close after TDC 12CA
31 Exhaust valve open Before TDC60CA
32 Exhaust valve close after TDC 30CA
33 Firing order 1-5-3-6-2-4
34 Fan drive shaft axial clearance 0.2～0.55
35 Fan drive shaft radial clearance 0.035～0.076
36 The crankshaft rear gear and the back end middle gear backlash 0.052～0.176
37 Rear intermediate pinion and crankcase intermediate gear backlash 0.052～0.176
38 Crankcase intermediate gear and cylinder head intermediate gear backlash 0.052～0.232
39 Cylinder head intermediate gear and camshaft gear backlash 0.054～0.180
40 Rear crankshaft gear and air compressor intermediate gear backlash 0.051～0.177
41 Air compressor intermediate gear and air compressor gear backlash 0.051～0.177
42 Air compressor gear and steering booster gear backlash 0.050～0.244
43 Rear big middle gear and PTO gear backlash 0.051～0.177
44 Front crankshaft gear and front intermediate gear backlash 0.057～0.183
45 Front intermediate gear and high pressure fuel pump gear backlash 0.053～0.247
46 Front intermediate gear and fan gear backlash 0.054～0.246
47 Front crankshaft gear and oil pump outer rotor backlash 0.092～0.272
48 Rear intermediate gear assembly radial clearance 0.060～0.109
49 Rear intermediate gear assembly axial clearance 0.100～0.290
50 Crankcase intermediate gear and cylinder head intermediate gear radial clearance 0.06～0.109
266
R.EN.MC11.31/35/39/43.01
51 Crankcase intermediate gear axial clearance 0.100～0.290

52 Cylinder head intermediate gear axial clearance 0.200～0.390
53 Air compressor intermediate gear radial clearance 0.060～0.109
54 Air compressor intermediate gear axial clearance 0.100～0.240
55 Front intermediate gear radial clearance 0.060～0.109
56 Front intermediate gear axial clearance 0.100～0.290
57 High pressure fuel pump propeller shaft axial clearance 0.200～0.700
58 High pressure fuel pump propeller shaft radial clearance 0.035～0.076
59 Air compressor power takeoff shaft axial clearance 0.100～0.700
60 Air compressor power takeoff shaft radial clearance 0.040～0.100
61 Air compressor shaft axial clearance 0.100～0.400
62 Air compressor shaft radial clearance 0.0400～0.100
63 Injector bulge quantity 2.68～3.53
267
R.EN.MC11.31/35/39/43.01
MC11 series diesel engine gluing summary

Brand Color Function Application place
High pressure fuel pump drive shell and crankcase joint surface
Air compressor joint surface
Crankcase back surface
Air conditioning compressor joint surface
Loctite Between high pressure fuel pump pulley and the drive shaft
Gray Sealing
5900 Between fan hub and bolt
High pressure fuel pump drive shaft
Crankcase front surface
PTO intermediate gear assembly
Intercooler rear intake pipe and cylinder head joint surface
Loctite Oil and gas separator return line transition joint
Azure Locking
243 EVB exhaust gate bridge assembly bolt
Loctite
Red Sealing Generator pulley and drive shaft
2701
White T Abrasion When assembly cylinder head again, brush a small amount of White T
White
grease proof grease to the cylinder head bolt support surface.
Note: color may be different due to the different manufacturer.
268

Repair Manual of MC11 Euro III Engine

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Repair Manual of MC11 Euro III Engine

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REN.MC11.43/39/35/31.

The Repair Manual of MC11 Euro III Engine

SINOTRUK 53 Wuyingshanzhong Road

We reserve the right to make modifications in the course of further development.

REMOVING AND INSTALLING THE CHARGE-AIR PIPES........................................................................... 64

REMOVING AND INSTALLING THE FLYWHEEL HOUSING/TIMING CASE.......................................... 209

equipment, such as EDC,etc.

agents have aggressive grease-dissolving characteristics.

MC11 Series Euro Ⅳ Engine

10 Maximum torque speed rpm 1000～1400

minimum specific fuel

13 Highest unloaded speed rpm 2150±50

14 Idling speed rpm 550±50

18 Lubricating oil sump capacity L 40

The highest allow diesel engine

Cold start with intake preheating -40

MC11 EuroⅤ Engine

14 Idling speed rpm 550±50

15 Firing order 1－5－3－6－2－4

18 Lubricating oil sump capacity L 40

Net quality (excluding

Electric Control Unit（EDC）

electric control unit（EDC）

Remove the EDC Remove the EDC bracket

·unscrew the mounting bolts（1）

·Take the belt（3）

·unscrew the mounting bolt（2）

Install the EDC Connecting the engine control unit electrical

·Lightly apply Loctite 270 on the threads of the

·Position the engine control unit (1)

1.coolant manifold 2.coolant pipe 3.thermostat housing

1.water pump 2.distributor housing

1. Fan clutch 2. Fan 3. Mounting bolt 4. Fan drive

Removing the fan

• Unscrew the mounting bolt (1)

• Unscrew the mounting bolts (2)

• Position the fan (3) on the fan drive (2)

[2] Extractor hook JD6805-0019 80.99602-0137

[3] Plug-on handle JD6805-0020 80.99617-0187

[5] Installer punch JD6805-0022 80.99604-0289

[6] Engine barring gear JD6805-0023 80.99626-6008

[7] Dial gauge JD6805-0024 08.71000-3217

[9] Locating pin JD6805-0026 80.99605-0197

Checking the fan drive

Removing the fan drive

Checking the fan drive

• Check the inside diameter of the mount (2)

Installing the fan drive Mounting the fan hub

• Press the radial shaft seal (2) into the fan

Removing the coolant manifold

• Unscrew the mounting bolts (1)

• Unscrew the mounting bolts (1)

Removing the coolant manifold

• Unscrew the mounting bolts (3)

Installing the coolant manifold Installing the coolant manifold

• Position the coolant manifold (2) with a new

• Lightly apply clean engine oil on the thread of

1.mounting bolt 2.mounting bolt 3. Thermostat mainfold 4.thermostat

Removing the thermostat Installing the thermostats

• Fit the new O-rings (1) on the thermostats

• Remove the thermostats (1) with seals (2)

Fitting new unscrewed conduits

• Detach the thermostat housing (1) with

Installing the thermostat housing