Engine training

course

D 0834/36.
Euro 3/4

Common Rail
EDC 7
Produced by
Plank/Schier
AT 01b MAN Service Academy Steyr
Status 06/2005
This document is intended to be used exclusively for
training and is not covered by the ongoing update and
amendment service.

2005 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, copying, publishing, editing, translating, microfilming and
storing and/or processing in electronic systems, including databases and
online services, is not permitted without the written permission of MAN.

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 CONTENTS

CONTENTS...................................................................................................3 EXHAUST VALVE BRAKE.......................................................................... 32

ENGINE SPECIFICATION.............................................................................5 EVB - SERVICE INFORMATION / EXHAUST BUTTERFLY VALVE
ASSOCIATION OF POWER UNITS WITH RANGES AND VEHICLE TYPES.6 UNCONTROLLED ...................................................................................... 32
EXPLANATION OF ENGINE CODE ..............................................................7 INLET MANIFOLD ...................................................................................... 32
ENGINE IDENTIFICATION NUMBER............................................................8 EXHAUST GAS RECIRCULATION ............................................................. 32
DESIGN AND PRINCIPLE OF OPERATION..................................................9 TURBOCHARGER...................................................................................... 32
ENGINE SPECIFICATIONS ........................................................................ 10 TWO-STAGE CONTROL VALVE ................................................................ 32
CRANKCASE .............................................................................................. 22 CHARGE PRESSURE CHARACTERISTIC................................................. 32
CYLINDER LINERS..................................................................................... 24 TURBOCHARGER...................................................................................... 32
CRANKSHAFT ............................................................................................ 26 PREVENTION OF ACCIDENTS - COMMON RAIL CLEANLINESS............. 32
CRANKSHAFT SEALING RINGS ................................................................ 28 COMMON RAIL SYSTEM WITH EDC 7 ENGINE CONTROL UNIT............. 32
TIMING GEAR HOUSING............................................................................ 30 LOW-PRESSURE SECTION....................................................................... 32
CONNECTING ROD.................................................................................... 32 HIGH-PRESSURE SECTION...................................................................... 32
PISTONS .................................................................................................... 32 CR HIGH-PRESSURE PUMP CP3.............................................................. 32
CAMSHAFT................................................................................................. 32 REMOVING/FITTING HIGH-PRESSURE PUMP ......................................... 32
VALVE TIMINGS ......................................................................................... 32 RAIL ........................................................................................................... 32
ENGINE TIMING ......................................................................................... 32 INJECTOR .................................................................................................. 32
ENGINE OIL CIRCULATION ....................................................................... 32 SPEED SENSORS ..................................................................................... 32
BELT DRIVE ............................................................................................... 32 MAN CATS 2 ENGINE DATA...................................................................... 32
CYLINDER HEAD........................................................................................ 32 ACCELERATION TEST .............................................................................. 32
CYLINDER HEAD FIXING ........................................................................... 32 COMPRESSION TEST ............................................................................... 32
CHECKING AND ADJUSTING VALVE CLEARANCES................................ 32 WATER PUMP............................................................................................ 32
TIGHTENING INJECTOR ON CYLINDER HEAD......................................... 32 COMPRESSOR .......................................................................................... 32
ROCKER MECHANISM............................................................................... 32 GLOW PLUG STARTING SYSTEM ............................................................ 32

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 ENGINE SPECIFICATION

New features of the Euro 4 engine compared with Euro 3 engines:

Engine D 036 .. Common Rail Injection system

Reinforced crankcase
Common Rail EDC 7
Reinforced crankshaft bearings
Pre-supply pump ZP 18
Cylinder head (channel feed)
Fuel-lubricated high-pressure pump CP 3
Connecting rod
Injection pipes / High-pressure pipes
Oil injection nozzles
Star-type fuel filter
Optional turbocharger (2-stage)
Injectors with two-part armatures and 8 hole-type nozzles
Enhanced exhaust gas recirculation
AGR blocking valve with stepless control
Exhaust gas retreatment system:
Engine oil for Euro 4 engine to MAN standard (M3477)

PM catalytic converter (with OBD sensors)

Additional silencers

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 ASSOCIATION OF POWER UNITS WITH RANGES AND VEHICLE TYPES

HGV / Bus engines Emissions class Vehicle type Trade designation Chassis No.

D 0834 LFL 40 Euro 3 TGL/M xx. 150 BHP (110KW) WMA

D 0834 LFL 41 Euro 3 TGL/M xx. 180 BHP (132KW) WMA

D 0834 LFL 42 Euro 3 TGL/M xx. 206 BHP (150KW) WMA

D 0836 LFL 40 Euro 3 TGL/M xx. 240 BHP (176KW) WMAH

D 0836 LFL 41 Euro 3 TGL/M xx. 280 BHP (206KW) WMAH

D 0836 LFL 44 Euro 3 T-GA, TGL/M xx. 326 BHP (240KW) WMAH

D 0836 LOH 41 Euro 3 BUS xx. 240 BHP (176KW) WMA

D 0836 LUH 41 Euro 3 BUS xx. 240 BHP (176KW) WMA

D 0836 LOH 40 Euro 3 BUS xx. 280 BHP (206KW) WMA

D 0836 LUH 40 Euro 3 BUS xx. 280 BHP (206KW) WMA

D 0834 LFL 50 Euro 4 TGL/M xx. 150 BHP (110KW) WMAH

D 0834 LFL 51 Euro 4 TGL/M xx. 180 BHP (132KW) WMAH

D 0834 LFL 52 Euro 4 TGL/M xx. 206 BHP (151KW) WMAH

D 0836 LFL 51 Euro 4 TGL/M xx. 240 BHP (176KW) WMAH

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 EXPLANATION OF ENGINE CODE

Engine nameplate Engine type designation

D 0836 LF 43

D Fuel type (diesel)

MAN - Werk Nürnberg 08 + 100 = Bore diameter e.g. 128 mm 
Typ D0836 LF44 3 3x10+100 is approximately equal to the stroke in mm = 125
Motor- Nr. / Engine-no. N I / N II 6 Number of cylinders 6 = 6 cylinders,
L Charging type (turbocharger with charge air cooling)
209 0062 5015 2 0 1 P1
F Engine orientation
OH Bus rear-mounted, vertical engine
UH Bus rear-mounted, horizontal engine
Block N I / N II 43 Engine variant, particularly important for technical data
and set-up values and procurement of spare parts
I Dimensional variation 0.10 mm
II Dimensional variation 0.25 mm
P Big end bearing journal
H Main bearing journal
S Camshaft mushroom tappet (S1 0.25 mm oversize)

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 ENGINE IDENTIFICATION NUMBER

Example: Engine number

A 209 Engine type code

B 0062 Assembly date
C 501 Order of assembly (progress number on day of assembly)
D 5 Overview of flywheel
E 2 Overview of injection pump/controller
F 0 Overview of air compressor
G 1 Special equipment such as engine-dependent auxiliary output drive

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 DESIGN AND PRINCIPLE OF OPERATION

The common rail engines are liquid-cooled, 4-stroke in-line engines In contrast to the other designs, the 240 kW / 326 BHP engine (LF44)
with exhaust gas turbocharger and air/air charge air cooling. has an external exhaust gas recirculation system. The exhaust gas
is cooled by means of a heat exchanger supplied with cooling water.
The engine's omega-shaped combustion chamber is located in the The amount of exhaust gas is determined by means of a non-return
centre of the piston and is supplied with fuel by a vertically arranged valve and a blocking valve pneumatically controlled by the engine
injector nozzle. characteristic.
The other engine variants such as the LOH/LUH have internal
exhaust gas recirculation, which is defined by the camshaft control
times.
.

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 ENGINE SPECIFICATIONS

D0836 LFL 41 Euro 3

K value (m –1) 1.3

Working principle 4-stroke turbodiesel with charge air cooler
CO (G/KWH) 0.410
Number of cylinders/Design 6/vertical in line
HC (g/KWh) 0.070
Combustion process 7-jet direct injection
NOX (G/KWH) 4.960
Direction of rotation viewed from flywheel end left
Idle speed 600 rpm ± 50
Number of valves per cylinder 4
Max. cut-off speed rpm ca. 2640
Bore/Stroke in mm 108/125
Valve clearance with engine cold IV 0.50/EV 0.50 mm
Capacity in litres 6.871
EVB clearance with engine cold 0.35 mm
Compression 18:1
Compression pressure 26 - 30 bar
Max. ignition pressure in bar 160
Permissible pressure diff. between ind. cylinders max. 4 bar
Rated power kW/BHP at speed rpm 206/280 at 2400
Coolant
Ignition sequence 1-5-3-6-2-4
Oil quantity min/max. 21/26 L
Position of cylinder 1 fan side
Fuel system Bosch Common Rail
Rated speed rpm 2400
Cold start capability with/without glow plug 15/-32°C
Max. torque Nm at rpm 1100 at 1200-1750
Weight (dry) 598 kg

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D0836 LFL 44 EURO 3

Working principle 4-stroke turbodiesel with charge air cooler K value (m –1) 1.2

Number of cylinders/Design 6/vertical in line CO (G/KWH) 0.560

Combustion process 7-jet direct injection HC (g/KWh) 0.060

Direction of rotation viewed from flywheel end left NOX (G/KWH) 4.090

Number of valves per cylinder 4 Idle speed 600 rpm ± 50

Bore/Stroke in mm 108/125 Max. cut-off speed rpm ca. 2640

Capacity in litres 6.871 Valve clearance with engine cold IV 0.50/EV 0.50 mm

Compression 18:1 EVB clearance with engine cold 0.35 mm

Max. ignition pressure in bar 160 Compression pressure 26 - 30 bar

Rated power kW/BHP at speed rpm 240/326 at 2400 Permissible pressure diff. between ind. cylinders max. 4 bar

Ignition sequence 1-5-3-6-2-4 Coolant

Position of cylinder 1 fan side Oil quantity min/max. 21/26 L

Rated speed rpm 2400 Fuel system Bosch Common Rail

Max. torque Nm at rpm 1200 Nm at 1200-1800 Cold start capability with/without glow plug –15/-32°C
Weight (dry) 618 kg

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D0836 LOH 41

K value (m –1)
Working principle 4-stroke turbodiesel with charge air cooler
CO (G/KWH)
Number of cylinders/Design 6/vertical in line
HC (g/KWh)
Combustion process 7-jet direct injection
NOX (G/KWH)
Direction of rotation viewed from flywheel end left
Idle speed 600 rpm ± 50
Number of valves per cylinder 4
Max. cut-off speed rpm ca. 2640
Bore/Stroke in mm 108/125
Valve clearance with engine cold IV 0.50/EV 0.50 mm
Capacity in litres 6.871
EVB clearance with engine cold 0.35 mm
Compression 18:1
Compression pressure 26 - 30 bar
Max. ignition pressure in bar 160
Permissible pressure diff. between ind. cylinders max. 4 bar
Rated power kW/BHP at speed rpm 176/240 at 2400
Coolant
Ignition sequence 1-5-3-6-2-4
Oil quantity min/max 21/26 L
Position of cylinder 1 fan side
Fuel system Bosch Common Rail
Rated speed rpm 2400
Cold start capability with/without glow plug down to –15/-32°C
Max. torque Nm at rpm 925 at 1200-1800
Weight (dry) ca. 595 kg

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D0836 LOH 40

Working principle 4-stroke turbodiesel with charge air cooler K value (m –1)

Number of cylinders/Design 6/vertical in line CO (G/KWH)

Combustion process 7-jet direct injection HC (g/KWh)

Direction of rotation viewed from flywheel end left NOX (G/KWH)

Number of valves per cylinder 4 Idle speed 600 rpm ± 50

Bore/Stroke in mm 108/125 Max. cut-off speed rpm ca. 2640

Capacity in litres 6.871 Valve clearance with engine cold IV 0.50/EV 0.50 mm

Compression 18:1 EVB clearance with engine cold 0.35 mm

Max. ignition pressure in bar 160 Compression pressure 26 - 30 bar

Rated power kW/BHP at speed rpm 206/280 at 2400 Permissible pressure diff. between ind. cylinders max. 4 bar

Ignition sequence 1-5-3-6-2-4 Coolant

Position of cylinder 1 fan side Oil quantity min/max. 21/26 L

Rated speed rpm 2400 Fuel system Bosch Common Rail

Max. torque Nm at rpm 1100 at 1200-1750 Cold start capability with/without glow plug down to –15/-32°C
Weight (dry) ca. 600 kg

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D0836 LUH 41

Working principle 4-stroke turbodiesel with charge air cooler K value (m –1)

Number of cylinders/Design 6/vertical in line CO (G/KWH)

Combustion process 7-jet direct injection HC (g/KWh)

Direction of rotation viewed from flywheel end left NOX (G/KWH)

Number of valves per cylinder 4 Idle speed 600 rpm ± 50

Bore/Stroke in mm 108/125 Max. cut-off speed rpm ca. 2640

Capacity in litres 6.871 Valve clearance with engine cold IV 0.50/EV 0.50 mm

Compression 18:1 EVB clearance with engine cold 0.35 mm

Max. ignition pressure in bar 160 Compression pressure 26 - 30 bar

Rated power kW/BHP at speed rpm 176/240 at 2400 Permissible pressure diff. between ind. cylinders max. 4 bar

Ignition sequence 1-5-3-6-2-4 Coolant

Position of cylinder 1 fan side Oil quantity min/max 21/26 L

Rated speed rpm 2400 Fuel system Bosch Common Rail

Max. torque Nm at rpm 925 at 1200-1800 Cold start capability with/without glow plug down to –15/-32°C
Weight (dry) ca. 640 kg

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D0836 LUH 40

Working principle 4-stroke turbodiesel with charge air cooler K value (m –1)

Number of cylinders/Design 6/vertical in line CO (G/KWH)

Combustion process 7-jet direct injection HC (g/KWh)

Direction of rotation viewed from flywheel end left NOX (G/KWH)

Number of valves per cylinder 4 Idle speed 600 rpm ± 50

Bore/Stroke in mm 108/125 Max. cut-off speed rpm ca. 2640

Capacity in litres 6.871 Valve clearance with engine cold IV 0.50/EV 0.50 mm

Compression 18:1 EVB clearance with engine cold 0.35 mm

Max. ignition pressure in bar 160 Compression pressure 26 - 30 bar

Rated power kW/BHP at speed rpm 206/280 at 2400 Permissible pressure diff. between ind. cylinders max. 4 bar

Ignition sequence 1-5-3-6-2-4 Coolant

Position of cylinder 1 fan side Oil quantity min/max. 21/26 L

Rated speed rpm 2400 Fuel system Bosch Common Rail

Max. torque Nm at rpm 1100 at 1200-1750 Cold start capability with/without glow plug down to –15/-32°C
Weight (dry) ca. 640 kg

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 CRANKCASE

The new crankcase is cast in one piece together with the cylinder Re-machining the crankcase sealing surfaces:
block from cast iron alloy. For all engines, three re-machining stages are intended for the
cylinder head joint face.
6 cooling water channels drilled between the cylinders guarantee
Normal dimension A = 321.97 - 322.01 mm 0.0 mm
excellent heat dissipation and a uniform temperature distribution at
Stage 1 = 321.77 - 321.80 mm - 0.2 mm
the surface of the cylinders.
Stage 2 = 321.57 - 321.60 mm - 0.4 mm
Stage 3 = 321.37 - 321.40 mm - 0.6 mm
High rigidity and lower noise emissions are achieved by providing
Surface roughness of crankcase sealing surface 16 m
appropriate ribs on the new aluminium intermediate plate.

The crankcase ventilation is designed as a closed system, i.e. the B Main bearing bolts 115 Nm + 90o+10° (do not reuse)
blow-by is fed back to the engine combustion via a valve with integral C Dry cylinder liner
oil mist separator. D Flywheel bolts 100 Nm + 90o+10°
(do not reuse)
The pistons run directly in the crankcase where optimum conditions
with regard to resistance to wear and oil consumption are achieved Note:
due to the ceramic honing of the cylinder surfaces. Version-dependent (with and without cylinder liners)

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 CYLINDER LINERS

1. Cylinder liners (slip fit) 2. Fitting clearances

"A" Normal size 111.490 - 111.535 mm Clearance between crankcase bore and liners
Rep. stage + 0.5 mm 111.995 - 112.035 mm Outside diameter (A-E) 0.01 - 0.03 mm
"B" Crankcase collar diameter 116.00 - 116.10 mm At the collar (B-F) 0.12 - 0.36 mm
"D" Collar depth 4.040 - 4.060 mm
"E" Normal size 111.475 - 111.490 mm 3. Liner projection
1st Rep. stage 111.975 – 111.990 mm
Check amount by which liner projects from crankcase, (measure at
"F" Collar diameter 115.470 – 115.880 mm
4 points with clock gauge)
"G" Inside diameter 108.000 – 108.022 mm
Wear 0.150 mm "D" Collar depth 4.04 - 4.06 mm
"H" Overall height 216.700 - 217.000 mm "C" Depth of collar recess 4.00 - 4.03 mm
"I" Collar projection 0.01 - 0.06 mm

Note: NOTE:
Do not use grease or engine oil when fitting the lining.
The collar must sit solidly on the seat. Clean before fitting! The liner
ONLY MOLYCODEPOWDER
collar must not bear against the outside diameter.

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 CRANKSHAFT

The crankshaft with the counterweights is drop-forged in one piece. Crankshaft journal diameter STD 76.81 - 77.00 mm
The main and big end bearing journals are induction hardened. Crankshaft - main bearing internal Ø STD 77.04 – 77.08 mm
They can be reground 4 times without re-hardening. The thrust Radial play 0.04 –0.10mm
bearing is situated between cylinders 3 and 4 in all cases . Crankshaft axial play 0.15 – 0.28 mm
determined by the axial thrust washers C fitted to the 4th main
A vibration damper is fixed to the front end of the crankshaft. This
bearing (one repair stage possible)
reduces the torsional amplitude and thus the loading on the
crankshaft due to rotational vibration.
A Flywheel angle bolt. 100 Nm + 90o
(Note different lengths! No WVW)
N1 and N2 designs
B Vibration damper (no WVW) 150 Nm + 90o
Even in serial production there are two sizes for big end and
D Main bearing spread (Miba) 0.60 – 1.60 mm
crankshaft bearings and for tappet bores. Colour marking is used for
(Glyco) 0.15 – 0.50 mm
any other machining stage; every other fitting stage must be
E V-belt pulley with vibration damper (vulcanised rubber insert)
indicated on the nameplate and on the crankshaft.
F Loctite 574TB sealant for crankshaft gear
N = Normal size
G Main bearing bolts 115 Nm + 90o
N1 = 0.1 mm dimensional variation
I Sealing rings (PTFE). Fit in dry condition only.
P = Crankshaft, big end bearing N1
X Fit axial discs with oil pockets facing the crankshaft
H = Crankshaft, main bearing N1
.
S = Tappet bore N1

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 CRANKSHAFT SEALING RINGS

Front crankshaft sealing ring F Rear crankshaft sealing ring (flywheel side)

Assembly A Preliminary assembly

Fit new crankshaft sealing ring 7 with transport sleeve to adapter Fit new crankshaft sealing ring 2 with transport sleeve to adapter 4
from special toolkit. from special toolkit.
Slide crankshaft sealing ring 7 onto adapter and remove transport Slide crankshaft sealing ring 1 onto adapter and remove transport
sleeve. sleeve.
Slide press-on sleeve 8 over adapter and screw to threaded spindle
9. B Fit crankshaft sealing ring
Press shaft sealing ring against front timing gear cover as far as the Slide press-on sleeve 5 over adapter and screw to threaded spindle
stop using the press-on sleeve. 6.
Press shaft sealing ring against flywheel cover as far as the stop
Press-on tool 80.99606-6030 using the press-on sleeve.
Extractor 80.99606.6011

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 D F

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 TIMING GEAR HOUSING

Removing timing gear cover

Remove fixing bolts from timing gear housing.
Remove timing gear cover fixing screws, Remove timing gear housing seal 1 from engine block.
remove timing gear cover, and remove front seal 3
from gear casing 4. Assembly is carried out in reverse order.

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 CONNECTING ROD

The connecting rods are precision drop-forged and separated at the Fitting dimensions
big end by CRACKING. The separation joint is produced by means
of fracturing (cracking). The small end is trapezoidal in shape. The Big end bearing journal (normal size) :.... 69.981 – 70.000 mm
Big end bearing spread C(Miba): ....................... 74.5 – 76.0 mm
topmost of the two connecting rod bearing shells is made of highly
Big end bearing radial play:............................ 0.026 – 0.088 mm
wear-resistant sputter bearing metal. Big end bearing axial play: ............................. 0.120 – 0.259 mm
Hole spacing: ....................................................... 196 0.02 mm
Measuring the connecting rod bearings Gudgeon pin bearing (internal) :.....42mm +0.050 + 0.066 mm
Connecting rod weight difference per engine set: max. 50g
The measuring instrument is used to measure the bearing hole for
the big end bearing shells in the fitted state in directions 1, 2 and 3 Tightening torque for connecting rod bolts:
and in measuring planes a and b. Md ....................................................... 50 Nm + 10 plus 90° +10°
Bearing shells with bearing holes within the tolerance limits can be
Connecting rod bolts M 11x1.5 x60 Torx E14
reused. If the dimensions are outside the tolerance limits, the Connecting rod bolts must not be reused
bearings must be replaced.
The connecting rod and the connecting rod cap are marked together
at the side next to the break point.
NOTE:
Note:
Top bearing shell is identified with TOP (B) or red coloured dot on the
Do not stand the connecting rod or the connecting rod cap on
side. (Hardened supporting shell).
the break point. Damage (change) to the joint can cause damage
to the connecting rod.

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 PISTONS

3-ring (cut back) pistons made from special cast aluminium are used A: Piston diameter: ................................ 107.791 – 107.800 mm
with a cast-in ring carrier for the top piston ring. The combustion area B: Measure piston diameter 17 mm above bottom of piston.
is slightly drawn in, stepped and omega-shaped. Valve pockets are C: Compression height (standard): ....................... 63.9 – 64 mm
provided on the crown of the piston on the inlet and exhaust sides. To D: Piston projection / crankcase edge: .......... 0.093 – 0.391 mm
relieve the thermal stress, the pistons for the D0836 LF44 engine are
manufactured with a cast-in cooling channel and cooled by means of a Piston ring height / end clearance
jet of oil from the oil spray nozzle.
E: Compression ring
The flow cross-section of the oil spray nozzles has been matched to double-sided trap. ring Height 4.00 mm
End clearance 0.30 to 0.55 mm
the new piston cooling channel. The oil spray nozzle is controlled by
means of a pressure control valve in order to ensure adequate piston F: Sealing ring
taper-faced ring Height 2.50 – 2.52 mm
cooling. End clearance 0.40 to 0.65 mm

G: Oil scraper ring

NOTE: bevelled ring Height 2.97 – 3.00 mm
Difference in piston weight per engine set max. 40 g. End clearance 0.30 to 0.60 mm

Note:
Rings: Engine D0836 LF44 (326 BHP) with cooling channel pistons
The sealing rings comprise a double-sided trapezoidal ring and a Engine D0836 LF41 (280 BHP) without cooling channel pistons
taper faced ring. The bevelled spring-loaded ring is used as an oil
scraper ring.

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 CAMSHAFT

The forged camshafts are arranged in the crankcase on the exhaust "1" Camshaft (external or internal exhaust gas recirculation
side. In the 6-cylinder engines, the camshaft is mounted in 7 lead- design)
bronze bushes. The camshafts for external and internal exhaust "2" Guide pin
gas recirculation differ from one another with respect to the different
"3" Thrust washer
valve timings.
"4" Camshaft gear with 7 reference marks for EDC ECU

The camshaft gear is designed with 7 reference marks, 2 of which "5" Collar screw, spectacle flange 23 Nm
are considerably closer together than the others. "7" Collar screw, camshaft gear 65 Nm
These are used by the EDC control unit to detect the first cylinder.

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Checking camshaft axial play
NOTE:
Check camshaft axial play with clock gauge. The notch 1 on the camshaft bearing bush must point to the fan side.
The oil holes 2 in bearings 1, 3, 5 must coincide with the oil feed
Camshaft axial play "C" .....................................0.14 – 0.27 mm holes in the housing. All other bearings are offset with respect to the
Thickness of axial thrust washer "A"..................4.83 – 4.86 mm holes (no oil feed).

Camshaft bushes  .................................. 51.000 – 51.030 mm

Camshaft bearing diameter ........................ 50.910 – 50.940 mm
Radial play ..................................................... 0.060 – 0.120 mm

"B" Camshaft flange bolts M10x38x1.25...........................65Nm

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 VALVE TIMINGS

The valve timings are checked with the specified valve clearance. "A": Valve timings: Engine D 0834 external exhaust gas
recirculation
"A": Valve timings: Engine D 0836 external exhaust gas Inlet opens D 0834 6° before TDC
recirculation Inlet closes D 0834 32° after BDC
Exhaust opens D 0834 63° before BDC
Inlet opens D 0836 18° before TDC Exhaust closes D 0834 13° after TDC
Inlet closes D 0836 32° after BDC
Exhaust opens D 0836 63° before BDC "B": Valve timings: Engine D 0834 internal exhaust gas
Exhaust closes D 0836 29° after TDC recirculation
Exhaust closes D 0834 59° after TDC
"B": Valve timings: Engine D 0836 internal exhaust gas Example: Timing diagram
1 Direction of engine rotation
recirculation
2 Inlet opens
3 Exhaust closes
Inlet opens D 0836 18° before TDC 4 Inlet opening time
Inlet closes D 0836 32° after BDC 5 Centre of inlet cam
Exhaust opens D 0836 63° before BDC 6 Exhaust opens
7 Exhaust closes
Exhaust closes D 0836 1° before TDC
8 Exhaust opening time
9 Centre of exhaust cam

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 ENGINE TIMING

On assembly, the mark on crankshaft gear "A" must coincide with Tightening torques:
the mark on crankshaft gear "B" identified by " -  - ". A Crankshaft gear..........................Z = 32 ..... 150 Nm + 90°
B Camshaft gear............................Z = 64 ................ 65 Nm
C Compressor drive gear...............Z = 27 ...........................
D Intermediate gear ....................... Z =40................115 Nm
E Intermediate gear .......................Z = 31 ................. 22Nm
F CR high-pressure pump .............Z = 24
G Oil pump drive gear .................... Z =18..................30 Nm
H Water pump fitting

Note:
Intermediate gear "D" is mounted with the VP 44 radial injection
pump as on engine D0834/36.

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 ENGINE OIL CIRCULATION

Forced feed lubrication: Engine oil pressure

The forced feed lubrication system feeds the crankshaft, big end and
Idle speed 600 rpm .......................................................> 1.0 bar
camshaft bearings. The valve drive, intermediate gear, air
Rated speed 2400 rpm..................................................> 4.0 bar
compressor and exhaust gas turbocharger are supplied with
lubricating oil.
The oil pressure must be checked when the engine is warm.
The gear oil pump sits in the spur gear housing. The gears are fitted
in the pump housing and in the spur gear housing. The oil pressure
"A" Oil pressure control valve
control valve sits in the main channel and serves to relieve the load
Opening pressure........................5.0 – 6.0 bar
on the oil pump after a cold start at low ambient temperatures.
The oil filter and plate oil cooler are physically combined in the oil
"B" Oil filter bypass valve
module. Recyclable paper filters enable the oil filter to be disposed of
Opening pressure........................2.5 ± 0.5 bar
in a maintenance friendly and environmentally friendly manner.
The piston crown is cooled by the valve-controlled oil spray nozzle,
"C" Oil filter bottom valve (drainage protection)
which sprays into the piston ring channel or onto the piston crown.
Opening pressure........................0.2 ± 0.1 bar

Engine oil M 3477 Euro 4 – M 3277 Euro 3 Oil pressure switch B 104:
The only engine oils that are approved are those, which have been Wire (0.75mm2) 60155 Pin 1 to EDC A40
tested to and comply with works standard M 3477/3277. Wire (0.75mm ) 2
60158 Pin 2 to EDC A37
2
Wire (0.75mm ) 60137 Pin 3 to EDC A20

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Oil pump:

1 FIXING NUT NOTE:

2 DRIVE GEAR Slide oil pump drive gear "4" (internal taper free from grease) onto
3 OIL PUMP GEAR grease-free taper of drive gear.
4 OIL PUMP GEAR Oil pump gears must not be fitted dry
5 OIL PUMP HOUSING (indicated by a note on gears 3/4)
6 FIXING BOLT M24X1.5 60NM
7 SEALING RING Tightening torques:
8 COMPRESSION SPRING Oil pump drive gear nut "1" M12x1.5..................................... 30 Nm
9 PISTON
10 INTERMEDIATE PLATE Checking the gap:
Gap = Housing depth minus Gear height
ENGINE OIL PRESSURE CONTROL VALVE: Measure gear height at different positions
WITH 9 PISTON - 8 SPRING 7 SEALING RING Measure housing depth:
Housing depth 25.000 – 25.033 mm

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Oil filter module

The oil module 6 combines the oil filter 4 and oil cooler in one Oil filter bypass valve ..............................................2.5 ± 0.5 bar
housing. The filter is designed as a recyclable paper filter. The Oil filter bottom valve (drainage protection).............0.2 ± 0.1 bar
heated engine oil is cooled in a heat exchanger 9 by approximately Oil return blocking valve............................................................ 7
0
15 C.
Tightening torque, filter cover 2.........................................25 Nm
Fixing bolts to engine ........................................................22 Nm
Oil pressure switch 5.........................................................50 Nm

Oil filter cover spanner 1 ..................................... 80.99606.0581

Oil module seal 8
Replace sealing rings 3/10 when changing filter

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Oil spray nozzle for piston crown cooling:

NOTE: Oil spray nozzle pressure valve:

Ensure that the adjusting ball in the body of the oil spray nozzle
locates in the hole provided. 1 Valve remains closed until.................................... 1.5 +– 0.1 bar
Valve fully open .................................................... 2.0 +– 0.1 bar
Bent oil spray nozzles must not be straightened!
2 Oil pressure valve begins to open .......................... 1.4 – 1.6 bar
Checking oil spray nozzles
3 Oil pressure valve fully open................................... 1.9 – 2.1 bar
Check whether the valve spring still pushes the valve piston onto the
valve seat, otherwise change oil spray nozzle valve. Tightening torques:
Oil spray nozzle pressure valve M12 ........................................ 40 Nm

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 BELT DRIVE

The V-belt is no longer driven from the belt pulley on the crankshaft A .........Left-hand threaded bolt M16x1.5x45-8.8LH 100 Nm+90°
vibration damper but via the belt drive shaft, which is connected to
B .........Belt pulley
the compressor drive gear. The belt drive (E) is connected to the
C .........Fixing bolt M10x35-8.8 45 Nm
compressor drive gear (D) by means of the cross-shaped disc (G)
and does not require adjustment. The belt pulley is fixed to the drive D .........Compressor gear
shaft by means of a screw (A) with a left-hand thread.
E..........Drive housing
The V-belt tensioner (1, 2) works automatically and needs no
F..........O-ring
adjustment. To loosen the belt, turn hexagonal bolt (1) anticlockwise
and remove belt. G .........Cross-shaped disc

H .........Belt tensioner for alternator and water pump

Note:
The central bolt (A) for the belt pulley (B) has a left-hand thread. I ...........Belt tensioner for optional extras, e.g. air-conditioning

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 CYLINDER HEAD

The channelling in the cylinder head of the D 0836 Euro 4 engine is "1" Height of cylinder head
different from that of the Euro 3 engine. In order to withstand the high Overall height "A"............................. 109.85 –110.15 mm
peak combustion pressures, the engines have just one continuous Minimum size.................................... 109.35 –110.05 mm
cylinder head for all cylinders.
"2" Valve seat angle
The cylinder head is made from cast iron alloy with cast-in inlet and Exhaust valve ................................................................ 90o
exhaust channels. The cylinder head is fixed with 4 equally Inlet valve .................................................................... 120o
distributed angle bolts per cylinder. (24 in total). The exhaust and
inlet valve seating rings are shrunk in place, and the valve guides are "3" Valve recess distance
pressed in. The valve star is slightly offset. Exhaust "A" .............................................. 0.60 – 0.90 mm
Inlet "B" .................................................... 0.30 – 0.60 mm
The sealing surface of the cylinder head "A" can be re-machined
(maximum 0.5 mm) "4" Valve guides
A thicker copper washer must then be used for the injector Exhaust valve guide recess .... 22.70 – 23.10 –-(-0.40 mm)
(51.98701.0093). Inlet valve guide recess ............20.70 – 21.10 –(-0.40 mm)

The core hole closures are fitted with Loctite 648.

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 CYLINDER HEAD FIXING

TIGHTENING/CHECKING CYLINDER HEAD BOLTS:

NOTE: Tightening torques and torsion angle:

Engine cylinder head bolts must not be reused once they have been
loosened. Tightening sequence following a repair:
When repairs are carried out, as a basic principle all cylinder head Align, and pre-tighten to 10 Nm
bolts M 14 x 2 (E18) must be replaced. 1st tightening stage 80 Nm
2nd tightening stage 150 Nm
NOTE: 3rd tightening stage 90°
The combustion chamber is sealed by means of multi-layer steel 4th tightening stage 90°
gaskets with enhanced sealing quality, and re-tightening is not 5th final tightening stage 90°
necessary.
Smear contact surface of the cylinder head bolts with Optimol White No further re-tightening of the cylinder head bolts is required.
T and oil the thread.

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 CHECKING AND ADJUSTING VALVE CLEARANCES

VALVE ADJUSTMENT:
IGNITION SEQUENCE: D 0834 1 - 3 – 4 – 2
IGNITION SEQUENCE: D 0836 1 - 5 – 3 – 6 – 2 – 4 1 Valve adjustment screw, inlet valve
2 Feeler gauge 0.50 mm
3 Valve bridge, inlet valve
Overlap = 624153
4 Valve bridge, exhaust valve
Adjustment = 153624 5 Adjusting nut, exhaust valve
6 Adjusting screw, exhaust valve
7 Adjusting screw EVB
 A Valve clearance, inlet valve 0.50 mm
8 Lock nut EVB
 B Valve clearance, exhaust valve 0.50 mm
9 Feeler gauge 0.35 mm
 C Clearance, rocker braking device 0.35 mm

Fixing bolt (cylinder head bolt) 9 Nm

Fixing bolt, bottom cable shaft M6x1 (8.8) 9 Nm
Lock nut, valve adjustment screw M10x1 (8.8) 40 Nm

The valve clearances are adjusted with the engine cold (T < 500)

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Removing an injector: Fitting an injector:
Note:
1 Do not remove the injector from the box until immediately
 Before removing the injector, always remove the appropriate before fitting.
pressure pipe support first. 2 Remove protective cover from injector hole in cylinder head.
 Only remove one injector at a time. 3 Always fit injector together with pressure flange.
 Remove injector with pressure flange and seal. (Pressure flange cannot be fitted retrospectively).
 Immediately seal injector hole in cylinder head with a 4 Fit new O-ring and new Cu gasket to injector.
protective cover. 5 Slide pressure flange onto injector.
 Immediately seal injector nozzle with a protective cover. 6 Fit injector together with gasket and pressure flange into
 Remove injector O-ring from above and place the injector in a cylinder head.
box for safe keeping. 7 Push injector with pressure flange completely into cylinder
head.
8 Align pressure pipe connection hole in injector channel
pressure pipe support in cylinder head.
Tighten fixing screw and spherical washer slightly to allow for
later adjustment.

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 TIGHTENING INJECTOR ON CYLINDER HEAD

1. High-pressure pipe Injector tightening procedure:

2. Connector
3. Sleeve nut
4. Leakage oil channel A Pre-tighten Allen screw to 2 Nm

5. Pressure pipe with filter and anti-rotation locking device B Pre-tighten pressure screw to 10 Nm

6. Copper washer C Tighten Allen screw finally to 30 Nm

7. O-ring D Tighten pressure screw finally to 55 Nm

8. Electrical connection E High-pressure pipe sleeve nut 10 Nm + 300

9. Injector F Tighten electrical connector to 1.5 Nm

10. Anti-rotation locking device for sword connector

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 ROCKER MECHANISM

1 Rocker, exhaust valve Technical data:

2 Valve adjustment screw Fixing bolts (cylinder head cover) 9 Nm
3 Thrust washer Retaining screw, rocker shaft (8) M8x50-8.8 22 Nm
4 Compression spring Fixing screw, rocker mechanism M8x85-8.8 22 Nm
5 Thrust washer
6 Valve adjustment screw
7 Rocker, inlet valve
8 Retaining screw, rocker shaft
9 Rocker shaft
10 Rocker block
11 Adjusting screw EVB

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