Repair Manual

For Industrial Diesel Engine

D2530 ME / MTE
D 2540 MTE / MLE
D 2840 ME / LE
D 2542 ME / MTE / MLE
D 2842 ME / LE
These instructions are intended to facilitate repair
of the engines listed herein.

This manual has been prepared for personnel ex-

perienced in the repair and maintenance of Diesel
engines.

Any repair of such components as injection pump,

alternator etc. should be left to our or the manu-
facturer's service department.

MASCHINENFABRIK AUGSBURG-NURNBERG
Aktiengesellschaft
Niirnberg Works
 TABLE OF CONTENTS

Chapter 1 Page

ALPHABETICAL INDEX
ENGINE VIEWS
LONGITUDINAL SECTION
CROSS SECTION
SCHEMATIC DIAGRAM OF LUBRICATION SYSTEM: ME-ENGINES
SCHEMATIC DIAGRAM OF LUBRICATION SYSTEM: MTEIMLE ENGINES
SCHEMATIC DIAGRAM OF FUEL SYSTEM
SCHEMATIC DIAGRAM OF FLAME STARTING DEVICE
SCHEMATIC DIAGRAM OF TIMING GEARS

Checking, controlling, adjusting

Checking compression
Checking drive belt tension
Adjusting valve clearance
Checkingladjusting start of delivery
I
Fuel system

Removing and installing fuel injection pump

Removing and installing fuel injection lines
Removing, repairing and installing fuel injectors
Removing, installing and repairing flame starting device
Removing and installing shut-down devices
Removing and installing speed governor
Removing and installing speed adjuster

Cooling System

Removing, repairing and installing water pump

D 2530 MEIMTE, D 2540 MTEIMLE, D 2542 ME, D 2840 ME, D 2842 ME
Removing, repairing and installing water pump D 2542 MTEIMLE
Removing, repairing and installing water pump for intercooler
Removing and installing surge tank and plenum tank
Removing and installing heat exchanger and thermostats
Removing and installing raw water pump
PTO for raw water pump
Removing and installing intercooler

Lubricating System

Replacing oil filter element

Removing and installing oil cooler
Removing and installing oil pan and oil drain
Removing and installing oil separating valve
Removing and installing oil spray jets
Removing and installing oil pump, relief valve
Disassembling and assembling oil pump

Flywheel, Crankshaft Seals

Removing, installing and repairing flywheel

Replacing starter gear ring
Replacing rear crankshaft seal (flywheel end)
Replacing front crankshaft seal and pilot bearing race
 TABLE OF CONTENTS

ltem Chapter 1 Page

Intake and Exhaust Systems

Removing and installing inlet bend and inlet manifold

Removing and installing exhaust manifold
Removing and installing turbocharger
Checking axial and radial play of turbinelrotor shaft

Cylinder Head

Removing and installing cylinder head

Removing and installing cylinder head, summary
Removing and installing valves
Removing and installing valve guides
Refacing valve seat
Replacing valve seat rings

Timing

Removing and installing timing case

Removing and installing camshaft
Replacing camshaft bearing
Checking valve timing

Crankshaft, Conrods, Pistons

Removing and installing crankshaft

Removthg and installing pistons with connecting rods
Replacing piston rings
Detaching and attaching piston on connecting rod, checking connecting rod
Removing and installing cylinder liners
Measuring piston protrusion

Compressor

Removing and installing compressor

Electrical Equipment, Monitoring Devices

Monitoring devices, instrument panel, tachometer

Removing and installing starter
Removing and installing alternator
Removing and installing preheater
Tension pulley for V-belt

General Instructions

lnstallation of flat gaskets

Technical Data

Specifications
Testing and adjusting values
Tightening torque guide values
Running-in engine
Special tools
 ALPHABETICAL INDEX

ltern Chapter 1 Page

Air compressor
Alternator

Camshaft
Compression, checking
Compressor
Crankcase vent
Crankshaft
Crankshaft seal (flywheel end)
Crankshaft seal (front)
Cylinder head
Cylinder liners

Engine barring device

Engine cross section
Engine longitudinal section
Engine lubrication (layout)
Engine timing gear (layout)
Engine views
Exhaust manifold

Flame starting device

Flywheel
Fuel injection lines
Fuel injectors
Fuel nozzles
Fuel pipes
Fuel pump
Fuel system (layout)
Fuel valves

Gaskets (installation instructions)

Governor (electronic)

Heat exchanger

Injection pump
l njectors
lntake manifold
l ntercooler
Lubrication (layout)

Nozzles

Oil cooler
Oil dipstick
Oil drain
Oil filter
Oil pan
Oil pressure monitor
Oil pump
Oil separating valve (crankcase vent)
Oil spray jet
Overvoltage protection
 ALPHABETICAL INDEX

ltern Chapter / Page

Preheater 4911
Piston pins 4211
Piston rings 4111
Piston protrusion 4411
Pistons 4011
Plenum tank 1311
PTO for raw water pump 1411

Raw water pump 1411

Reconditioned engines (notes) 4411
Regulator, alternator 4811
Relief valve 2111
Rocker arms 3111
Running-in instructions (reconditioned engines) 218

Shutdown device 911

Small end bushes 3911
Solenoid valve (flame starting device) 811
I Special tools 301 to 309
Specification (engine) 20 1
Speed adjuster (electric)
1111
Speed governor (electronic) 1011
Starter 4711
Starter gear ring 2411
Start inhibit relay 4711
Start of delivery 411
Surge tank 1311

Tachometer
Tappet bores N I
Technical data
Temperature monitor
Tensioning pulley, Vee belt
Testing and adjusting values
Thermostat
Tightening torques
Tightening torques (table)
' Timing case
Timing gear adjustment
Timing gear diagram
Tools
Turbocharger, checking axiallradial play
Turbocharger, removing and installing

Valve clearance
Valve guides
Valve retrusion
Valves
Valve seat insert
Valve timing, checking
Vee belts

Water pump
ENGINE VIEWS D 2540 ME, D 2 8 N ME
ENGINE VtEWS D 2542 ME, D 2842 ME
 ENGINE VIEWS D 15@ MTE

1 tandem fuel filter 7 torsional vibration damper

2 oil Fifter neck 8 tensioning pulley
3 turbocharger 9 water pump
4 starter 10 alternator
5 oil drain plug 1I oil cooler
8 oil dip stick 12 full flow oil filter
 ENGlNE VIEWS D 2540 MLE

intercooler 8 crankcase vent filter

exhaust gas turbocharger 9 injection pump
ail filler neck 10 fuel filter
starter 11 water pump
ail dip stick 12 oil drain plug
alternator 13 oilcooler
tensioning pulley 14 lubricating oil filter
ENGINE VIEWS D 2542 MTE
12 ENGINE VIEWS D 2842 LE
 ENGINE VIEWS D 2842 LE

1 Barer pump 8 Crankcase vent filter

9 Exhaust manifold, water-cooled

I 2 Fuel filter, ch8ngeover-type

3 Oif filler cap 10 Lube oil filter, changeover type

4 Starter 11 l ntercooler

5 Oil dipstick 12 Tensioning pulley

6 Alternator 1J Oil drain plug

7 Turbocharger 14 Oil cooler

Fig, 2

InsWFi rBew gsskdt m d mrrnect cawtpresion

pr@ssurereeertddr with union nut and special
wrench,
Screw GO~~FBBBEQII pr8ssur~record~ran connec-
tion with ths axlei~siorn, h r n engine with
stafier motor until needla d@fIecfi<anof com-
pression tester remeins ssaedy,

Renoare comprsaian recorder end connection.

In@all nozzle with ne* gsskgt and install in-
jector. Apply ,,Never SBBZ"t~ t h injector
~ eon-
tact points prior to inl;t81istion, Eighten union
nut to specify torque, Connect fuel injection
lines,
 Checking drive belt tension with ,,KRIKiTfl belt tension tester 2/1

Fig. 1

The life of the drive belt depends mainly on

correct belt tension, Far accurate measurement
of belt tension the ,,KRIKIT'"belt tension
tester can be used.

Fig. 2

Apply tension tester to belt a t a point midway

between two pulleys sa that edge of bearing
sunFace cantacts side of belt farrow). Before
testing, the indicator arm mu& be lowered into
the scale.
To check tension, uniformly depress push pad
below rubber loop perpendicular to belt upper
side until the spring underneath the push pad
can be heard ar felt to disengage.
Important: Pressing fu@herafter disengagement
of the spring would result in wrong readings.
Do not knack lesler before reading tension

Fig, 3

Read the tension value of the rested belt a t the

point where the Pop sudace of the indicator
arm intersects with the scale,

8pc;cified tension
Drive beit: width Tension in N (kgf)
new installation after 10 minutes when servicing after long
running time running time
450 (45) 400 (40)
500 (50) 450 (45)
700 (70) 600 (60)
700 (70) 600 (60)
 Adjuling valve ccla~anee 3/ 1

Fig, 1

Remove cylinder kasd covers

Fig. 2

Turn engine until pistan of cylinder being ad-

justed is ax igrgition WE>and rocket arms are
unloaded, "E"a valvas QI the synchranous cy-
linder will than be rocking,

10 cyl. Valves adjusted for cyl.

engines Valves are rocking in cyl.

12 cyl. Valves adju&ed for cyl,

engines Valves are rocking in cyl.

Fig. 3

Slide feeler gauge piate between valve stem and

rocker arm, Unscrew lock nut and turn adjusting
screw until feeler gauge can be moved with
tight resistance, Tighten lack nut. Recheck
play. Replace cylinder head covers.

Mate: Adjust: valves with engine in cold con-

dition only (rnax. coaling water temperature
5ooc ) .
Checking start OF delivary

Fig. 1

Tib check, ret~avegplug From tirning cam cover,

Fig. 2

1 pointer
2 TDG mark and xc~le
3 hexagon for turning engine by hand (32
rnm width alc flatsf
Turn crankshaft via hexagon (31 of turning
device until pointer and rnark on the injection
pump hub have rsechad the position in the in-
spection hole shown in Fig, 1, Sta@of delivery
has been correctly adjusted when winter (1)
is in line with the ang1e on ec&Ie f2f specified
for the engine type,

Adjusting (injection pump)

Fig. 3

Turn enginsl until pointer coincides with speci-

fied start of delivery. Remove timing ease
cover. Coosn screws of injection pump gear.
Turn injection pump h u b accordingly until the
line marks coincide and retighten grews. Re-
place timing case cover, Plug hole, Fig. 1.

Mate: If the spscified adjugmen%cannot be

obtained by turning the injection pump hub,
check injection pump for correct installation.
4/2 Gheckingl~djuging&;kart of delivery 4./2

Adjuging pointer on crank case

Fig, 4

After diassembly sdjusment of pointer f I ) ,

Fig, 2 becomes necesBry. For this purpom mt
flywheel $0 TDC mark. Align edge of pointer
with TDC point on scale. Secure painter in this
position.

Mote: Qn engines equipped with an electronic

speed governor the inspection hole is used to
fir the pickup in the proximity of the starter
ring gear, In his case first remove the mounting
plate complete wirh the pickup, Do not change
the position of the pickup in the mounting
plate,
 Removing and installing fuel injection pump 5/2

Fig. 5

Install injection pump with new o-ring and seal.

Make sure the line marks on the injection pump
hub and an the painter coincide,

Fig, 6

Install and tighten smuring screws to the speci-

fied torque in a criss-cross manner. Adjust and
check s t a g of delivery,

Fig. 7

Tighten union nuts of injection lines to speci-

fied torque. Gonn~ct fuel lines. Replace all
other pans that were removed,
 Removing and installing fuel injection lines

Removal

Fig. 1

Remove injection lines with open ring spanner

(08.08013-0500) from fuel injectors and
pressure connKtors of the injection pump and
remove in sets,
in the case of leakage-poof injection lines the
ovedlow lines mug first be removed.

Remove leakage lines from fuel injectors.

Fig. 2

Leak-proof injection lines

1 overFlowlines
2 float bowl
3 monitor {floating solenoid switch)
4 multiple connector
5 bleed pipe
6 leakoil connection

I f a leak occurs on leakage-proof injection lines

the leak oil flows through the overflow lines ( I f
into the float casing (2).Monitor (3) provides
alarm signals via connection (4) causing engine
shutdown. Monitor (3) cannot be repaired. In
case of a fault use new monitor. No fuel must
flow out at the vent line ( 5 ) . If fuel flows out
monitor (3) is defective.

Installation

Connect removed or new injection line. Note:

Make sure all parts are clean. install injection
i i r ~ e sfree from constraint. Tighten union nuts
t a specified torque. Connect leak oil line with
new gaskets, In the case of non-flameproof
linsx new leak oil hoses and new rubber caps
~Bnauldbe uslld a f er every repair.
 711 Rsmoving, repairing and in&@t liag fuel injectors ?/I

Fig, 1

Remove fuel injstztisfx linss snd leakoff tine,

Remove slskted twts (3) sf injectors (4) as
follows:
- Gfeen rece?;s3saf slsttsd nuts (3)to ensure
correct seat af wrench (21.
- Screw nut (1 1 fitlger-tight anto the fuel
injector threcld fadm nst lockf, N@t(11 prevents
slippage sf wreneE.5 (21 during removal.
- If nuts canoot be I s o ~ n e ddue to cor-
rosion apply penetrating oil swd loosen by
means af impact: wrench, if available,
Fig. 2

Secure inertia extrectar to fuel injector and

I
remove injector, Rgmove injector gasket.

Fig. 3

Check nozzle an teser for blowoff pressure

(discharge pressure), tightrsess and gray pattern.
Use pure tsst oil or pure Diesel fuel for testing.
Clean nozzle and check far wear before testing.
Test nozzle with asscrciated injector, Connect 1
nozzle to fuel pipe of tester.

1. Checking blowoff presure:

With the pressure geuge switch~d on slowly
depress the hand lever until the nozzle blows
the fuel out with a buzzing sound; take the
reading from the gauge (see ,,setting values").
If pressure is low in%G thicker and if pressure
is high thinner shims (7, Fig, 4).
Note: Shims are available in increments of 0.05
mm from 1 .Q to 1.95 mm,

2. Tightness:
Depress hand lever of Pester until the gauge
indicates a pressure abt. 20 bar below the speci-
f ied test pressure, The nozzle is tight if no drop
falls off the nozzle opening within 10 seconds.

3. Spray pattern:
With the pressure gauge switched off move lever
rapidly and check that a wlid jet is obtained.
The nozzle must produce a buzzing sound which
means that the needle moves freely and ensures
sufficient atomization under start conditions.
 Removing, repairing and installing fuel injectors

Figs, 4 and 5

Insert injector with downward directed nozzle

in holding fixture and clamp fixture in vice.
Remove union nut, injector, intermediate
washer, pressure pin, coil spring and shim.
Remove pipe cannection from device and pull
out rod-type filter.

Fig. 5

1 gasket
2 union nut
3 injector
4 intermediate washer
5 pressure pin
6 coil spring
7 shims

Fig, 6

Clean interior of" injector (1) with a stick of

weod and gasoline or Diesel fuel. Clean needle
(2) with a clean rag, Do not touch lapped faces
cf" nedtdls te prevent carrosion, Needle and
1-rarrzle are a a l g t i v e fit and must not be inter-
changed,
713 Removing, repairing and instatling fuel injectors 7/3

Fig. 7

Check cleaned parts for wear and damage and

replace if necessary; rfegreae new parts. Insert
clean rod-type filter in pipe connection. Insert
pipe cannection in holding fixture and install
shim and coil spring,

Fig. 8

Install pressure rod and intermediate washer.

Fig, Q

immerse nfxzzis and needle individually in fiite-

red Diesel fuel snd check for free movement.
When pulling the nwclle out of the nozzle on
third of its length and releasing it, it must drop
back onto its =st due to i t s own weight. Re-
intiirall nozzle, making sure That dowel pins
rwisler.

Fig, 10

Ingall union nut and tighten to specified torque

using the special wrench,
Check injector on tester,
 Removing, ingall ing end repairing f leme-stafling device 811

Fig, 1

Removing hearer plug.

Disconnect electric cable From heater plug.
Unscrew union nut of fuel line, Unscrew lock
nut of heater plug and remove heater plug.

Fig. 2
1
Disassembling healer plug: Using a screw driver
remove screw (If in fuel inlet (4). Remove filter
screen (2) and metering insert (3). Clean re-
m o v d paes in white spirit and check for wear/
damage, Replace damaged pa@$,l nstall metering
insert, f ifter screens and screw.
Installing heater plug: Screw locknut (5) on
heater plug fully upward. Screw plug fully in
against locknut and align with fuel line. Tighten
locknut 1/2 to 1 turn. Cannect fuel line and
make electric c a n n ~ t i a n(6).

Fig. 3

Chwking solenoid valve far tightness: Discon-

nect fuel line from heater plug, With the engine
running and at operating temperature no fuel
must be emitted,
Removing and installing salenoid valve: Pull
off electric mble from valve, Disconnect fuel
line to hearer plug, Remove valve. The valve
cannot be repaired. Replace defective valves.
Secure valve to bracket, Connwt fuel lines with
gaskets. Connect electric cable.
 911 Removing and insailing shut-down devices

Note: The shut-dawn devices differ in their circuitry and in operation.

Circuit:
af Open circuit (,,AS'". In this circuitry the shut-down solenoid is energized for engine shut-
dawn, As long as the engine is running, the power supply to the shutdown solenoid is
interrupted.
bf Closed circuit (,,RSF'), In this case the shutdown solenoid is energized as long as the engine
i s running, The engine is shut-down by spring force when the solenoid is deenergized.
Operation
Fig. l

af Shut-down device, type ,,RS" with linkage

operrJtian,
,,ASu type not shown.

Rernovet/installation
, Pde explanation required,

Adjustment (RS)
Adjust length of rod (2) so that a t the beginning
of the stroke of the solenaid, shut-down lever
f 1) reaches ,,stop" "sition. However, the shut-
down lever must got exert farce against the 1
,,%topw"mite siight play fapprox. 0.5 to 1 mm)
must be felt by hand. At the stroke end of the
solenaid the shut-down lever (1) must be in
,,operatian" "sition, The solenoid stroke end
must be recrehed under all cir~umstances
(audible hard click).
Tension sprint) (4) by displacing holder (3)
an rod (21 only sufficiently so that when speed
lever {ti) i s pressed agains ,,max, speed" stop,
shut-down lever (1) i s moved ts ,,stopu po-
sition by spring force,

Adjustment (AS)
Adjust length of rod ( 2 ) ,Fig. 1 so that at the
end of the stroke of the solenoid, shutdown
lever f I f reaches ,,~tap'~pasition. However, the
shut-dawn lever must nat exert; farce against
the ,,$%ope "mi% Slight play fapprox. 0.5 to
I mm) mum. be Ceit by hand. The solenoid
strake end must be reached under all circurn-
staness,
Tension spring (41 and holder (3) Etre not requir-
ed far this model.
,,RSU and ,,ASw': G o n n ~ rod
t end angle joints
making sure they are free From any constraint
and permit f r e ~motion,
912 Flemoving and insa lfiog shut-down devices 9f 2

Figs, 2 and 3

bf Shut-down device with Bowden Gable

aperation,

Removal

During removal make sure the key in pulley

f 3) does nat get lost,
InSaIlation

In$tall Bowden cabfe pulley (3) together with

the key, Ingall Bowden sheath (I) with grease
nipple on the side of adjusing sleeve (2).

Using adjusting sleeves 12) adjust Bowden cable

so that at %hebeginning of the stroke of the
mienaid pulley (3) reaches ,,stopw position.

Hawevax, the shut-dawn pulley must not exert

force @gains% tha ,,Sop" Qiimit. A slight play
(approx, 0.5 to 1 mrnf must be felt by hand.

At the srroke end of the salenoid the shut-

down pulley m u g be in ,,operationn position.
The solanoid stroks end must be reached under
all circumst@nces,(Audible hard click).

Adjustment {AS)

Adjurst: length of Bowden cable by means of ad-

juging sjesve (2) so that ax the end of the stroke
of' the salenoid the shut-down pulley (3) is in
,,stop" position, However, the shut-down pulley
must not exert farce against the ,,stopw limit.
A slight play (approx, 0.5 to 1 mm) must be
felt by hand.

The solenoid straka end must be reached under

all circumstances {audible hard click).
 Remove water pump, repair, ir?.;sall
D 2530 MEIWfEE,D 2540 RATE/MLE
O 2b49 ME, U 2848 ME, a 2M2 ME f D 2840 CE to 1800 rpm)

F igj, 1
Drwn crlrnlar-~t,Ratwve coalant lines, Depending
an enp$r?c tyys ra~trtovesurge tank with heat
@xchl;rngar ,efrtd hs&b exchanger tank or fan.
Rarsrov~ V bait, elbow, thermostat housing,
cfjulitrg wtBler wnnection and bypass inserts/
thermosrets, Remove V-belt: pulley.

Extract water pump hub using a puller. Remove

water pump screws and take off water pump.

Diassembly, repair

Fig. 3

Remove circlip from water pump body.

Fig, 4

Remove impstler From shaft using a suitable

mandrel,

Hots: The impeller mn also be extra&ed by

means OF a three-arm puller. This i%of advantage
when tha seal only has $0 be replamsf,
la2 Remove water pump, repilip, ipls;tsll 9 2/2
P 2530 MElMf E, D 2640 M"f"E/MLE
O 1542 ME, O 2840 ME, O 4842 ME f D 4W0 LE to 1800 rpm)

Wgtsr pump components

I hub
1 circlip
3 pump bearing
4 housing
& gasket
B seal {cassette seal)
f impeller

Qhxk all part for serviceable condition.

P P ~ Swater
S pump shaft with bearing into hous-
ing, Install circlip,
 Remove water pump, repair, install
D 2630 ME/MTE, D 2540 MTEIMLE
D 2542 ME, D 2840 ME, D 2842 ME ( D 2840 LE to 1800 rpm)

Fig. 8

apply e thin cost of liquid sealant (Teroian

367 Fluid) to fnechanical seal housing at (1)
aver i t s Ft411 ~Ircumference,

f i r t r &$round hausing, position the seal to-

gsther with plastic cap (2) on bearing shaft
(3and press in until the protruding edge is in
fail contact with the pump housing. Remove
plar;$ic cap (2). Thrus ring (3) forms part of
Ih@seal

1 mechanical seal
2 plastic cap
3 thrum ring
4 water pump housing
5 pressing toal
6 impeller
7 bearing shaft

Fig. 9

Press impeller onto shaft while observing gap

dimension, e.g. first press on impeller until
almost flush with the shaft. Check gap. Con-
tinue to press on impeller in steps until correct
gap dimension has been obtained. Reverse pump
hausing and press hub onto bearing shaft until
flush,

Clean sealing su~aces an water pump and

ersnk~il%~?, InStaIl water pump with new gasket.
Inaelf rhermastar or dummy thermostat with
n w O-rings and Fir cooling water connection.
Replace cooling water hags in all other parts
ther vvsre removsd,
 Remove water pump, repair, install
D 4542 MTEIMLE, D 2842 E
( D 2846 t E above 1800 rpm)

DraFtr csolr~~g water, Remave cooling water

tines, Nsfxwvs haat axchenger, fan, elbow, ther-
rmatsl housing I dummy thermostats, depen-
divrsj or1 ettgE19a rurodel. Remave belt pulley from
h~k),
w l l ~ k1~1~111p
r

Fig, 2

Refurova vv;$tsr pump hub with the water pump

%tillEfrstulted, if possible, Remove water pump
? ~ ~ r eand
w s taka off water pump.

&"dote: For disesembly and assembly of the

water purr.rp a Few %&is1 tools are required.
These taoEs can bs manufactured in accordance
with ttw Bdjmelgsl~ndrawings shown from page
$a8 anwarcis.

Fig, 3

1 hub
2 circlip
3 impeiier
4 cover
5 pump beeritgg
6 mecha~licelwa1

Remave the cover by driving a suitable punch

under cover (4) e t ths nacch. Remove impeller
(31 from the pufgll~bearing, For this purpose
the two Ma tsppings are provided. Should the
impeller hub remain on the pump bearing, pull
it off individually by means af a three arm
extractor. Prass aut mechanical seal,
 Remove watar pump, repair, inrjrall
D 2542 MTE/WlbE, D 4842 LE
( D 2848 LE absave 18(3&)rpml

Fig. 4
After ra8rtn)vtng 'bfle hub and the circlip, centre
t h purxrp
~ ~ P the
~ U K ~ B OM T ~ suppo~ering. Using a
%bjttebiia rrrrxertdrai press the water pump shaft
with G~t~rir.rg gut OJ the housing. Shaft and
baarrtsg me atx1:::~ptrulatedand Gan only be re-
:fa$ tr uniil,
f:~l,xc&~i

Agsembly, instaltation

Fig. 5

Centre the pump housing on the support ring

and press in the pump bearing. Use hollow
mandrel ta exert pressure on the bearing outer
race and not on the bearing shaft.

Fig. 6

Install circlip. Press pump hub onto bearing

shaft until flush while supporting opposite
shaft end.

Fig, 7

Apply a thin coat of liquid sealant (Terolan

3a7 Fluid) to mechanical seal housing a t ( I )
aver itti full circumference.

Turn around housing, pasitian the seal ragether

with pla~ticcap (21 an the bearing shaft and
pass in until else protruding sdge is in fuX1 can-
tact with ehs pump housing, Rsmave plagic
mp (2). Tlrrusle ring (3) forms par%of the?seal,
Note: Refar tat Fig, 8, pma 1213 far manufac-
turing dimsnsians Far pressing tool (61,
 Remove water pump, repair, install 1216
E4 2544 WITEIMtE, O 2842 LE
(D 2840 LE above 1800 rprn)

Elq, 8

Fir"s! pres~811 En~pelleruntil flush with the

bgaernp draft, Using the special tool (see page
3@31 press an enother 0.5 mm to obtain the
ewrect gap dimension between impeller and
plnfny h~uritrg. After inaallation check im-
plIer lor free and easy rotation. With the im-
peller correctly installed, dimension A (Fig. 3)
front the impeller back to the housing contact
surface musk be 7,05 to 7.10 mm, see also Fig.
40. Cksck with rule and depth gauge.

Fig, 9

Centre pump housing on support ring. Install

new pump cover,

Fig, 10

Align guide ring (2) with the two dowel pins

on the pump housing. Insert ring (1) in the guide
ring, Place flat stock (at least 10 mm thick) on
ring (Ifand press flat the rim of the pump
eover by means of a hand press.

Mount pump with new gasket on crankcase.

Replacs all removed parts,
 "1217 Removi~g,repairing and irrstgllirng wa2er pump for intercooler

Removal

Disconnwt cooling waQr hoses from water

pump connection. Releas and remove V-belt.
Remove V-belt pulley from the shaft. Remove
water pump from the bracket. Remove pump
caver,

Disassembly, repair, assembly

I
Fig. 2

Press shafr complete with impeller out of the

bearings.

Fig. 3

Place pump housing on hollow mandrel or open

vice and drive out lower ball bearing using a
drift. Remove spacer loosely inserted between
the bearings, Reverse pump housing and press
out second bearing; the mechanical seal will
also come out. The seal, however can be forced
out by means of a screw driver before pressing
out the bearing. Remove circlips, if required,
from the pump housing. 3

Fig. 4

Clean all pa@s and inspect for reuseability.

Impeller and shaft can only be supplied as an
assembly. Before inr;.talling the thrust: ring press
the shaft apprax. 5 to 8 mm aut of the impeller.
Press thrug ring with a new O-ring with the
slat above the locating pin into the impeller,
Fig, b

citelips, Prass in ball bearing

mttrked side facing inward.

lnsarl spacer into housing and press in second

ball bearing also with the marked side facing
inward, Fill offset sealing groove of nilosring
with multi-purpose grease and insert in housing.
Place splash ring with flat side facing upward
<antop.

Fig. 7

Press in mechanical seal until the protruding

edge is in full contact with the pump housing.
Manufacturing dimensions for assembly bush:
inner diameter .................. 47.5 mm
outer diameter .................. 54.5 mm
Length ........................ 60 mm

Fig. 8

tnseE spacer. Carefully insert impeller shaft to

avoid damage to the mechanical seal. To pro-
PeCE the thread at the shaft end, centre spacer
Bagtween the bearings in the housing by menas
af a suitable raund &ock from below (approx.
99.5 m m dia,). Slowly press in impeller shaft
ua"t2iI the two-section thrug ring in the impeller
shaft contacts the spacer f 14, Fig. 14 f .
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 Rernovirrg arsd in%aflingheat exchanger, 1J f l
thermostats and therr

Heat exchanger

Fig, 1

Drain cooling water. Remove coating water

lines and vent lines, Remove cover farraw)
and removl; O-ring. Remave connation cover
ftsr raw water lines.

fig. 2

Push through heat exchanger element. Clean

sealing surfaces (1 and 2). Install new gasket.
Replace heat exchanger element, if damaged.
Install new cover gasket. Secure cover. Also
secure cover (Fig. 1) after installing a new 0-
ring with a light coat of oil.

Fig, 3

Remove cooling water connection (arrow).

Fig. 4

Remove thermostat dummies (arrow) or therma-

stats. Replace O-rings. When installing the
thermostats make sure that the vent holes point
upward, Replace cooling water connection.
 Removing, disassembli~g~
asmmbling
raw water pump I kydratllic p

Removing and disassembling PTO

Fig, 1

Drain heat exchanger housing and hydraulic

lines and hydraulic oil tank. Remove suction
and supply pipes from pump. Remove flange
screws and take off pump.

Fig. 2

Remove nuts from studs. Remove bearing

flange, spacer and shims. Remove timing gear
case.

Fig. 3

More: For blocking the drive shaft we recom-

mend to use a spare coupling sleeve with a suit-
able piece of square section or flat material
welded to it so that the sleeve can be clamped
in a vice. The coupling sleeve should be a mini-
mum distance of 30 mm above the vice in order
not to damage the studs.

Fig. 4

AIign the riming gear case above the vice and

insert: the splined drive shaft end in the coupling
sleeve. Straighten deformed collar of nut and
remove nut fran shaft, Take off gear.
 Removing, ci isasmmbling, as$@n
rwv wgter pump

Fig, 5

Suppa& timing gear case on timber making sure

it cannot tilt, Prsss PTO out of timing gear case
using a piece of pipe (outer diameter = 90 mrnf.

Fig, 6

Support bearing housing on a bush. Press drive

shaft complete with ball bearing, inner spacer
and roller bearing inner race out of bearing
housing.

Fig. 7

Press roller bearing inner race, inner spacer and

ball bearing off the shaft. A suitable tool for this
operation is the coupling sleeve.

Assembling PTQ

Fig, 8

Fully press in ball bearing with split inner race.

Fit inner spacer. Press on roller bearing inner
race.
 Removing, disaswmblitsg, sg~mblingand in&;tialling P"T" for
raw water $dumpI hydrauli~p ~ m p

Fig. 9

Ins@@roller bearing with closed roller cage

facing dawnward in bearing housing and fully
press in,

Fig. 10

Insert spacer in bearing housing. Insert complete

drive shaft with movable parts lightly oiled.

Fig. 11

Press in assembled PTO in timing gear case.

Use new O-ring and apply thin coat of grease to
bearing seat in housing. Make sure not to da-
mage studs.

Fig. 12

Clamp drive shaft in vice, see Figs. 3 and 4.

Place drive gear in position. Screw on new
collar nut and tighten to specified torque.
Lock nut by caulking collar into recess of drive
gear.
4 414 Rern~ating,disassembling, asgemblli
raw water pump I hydrau

Installing PTQ

Fig. 13

tnstail timing gear case. First insert shimfs)

and then spacer into housing.

Fig. 12

Insert bearing flange with new O-ring lightly

coated with grease. Tighten nuts on studs to
the specified initial torque. Observe tightening
sequence (see diagram, page 2273.

Fig. 15

After initial tightening of the nuts a gap must

exist between the contact surfaces of the bear-
ing flange and the bearing housing. Check with
feeler gauge, see ,,testing and adjusting values"
page 224. If the gap is not correct select shim
thickness accordingly. Tighten nuts to speci-
fied final torque. Connect pump and pipes.
Prime water pump with water before connecting
the lines.
Note: With the engine shut off and if freezing
temperatures are expected the raw water pump
must be drained.
Fig. 1

D r ~ i nintercooler (arrow) and raw water pipes.

Remove water supply and return pipes from
intercoaler, hake off intercooler.

Fig. 2

Clean intercooler in accordance with the oper-

ating instructions for the engine. Remove top
and bottom cover ( I ) , if required, and replace
gaskets (2). Replace intercooler if the cooling
fins are damaged.
Install in reverse order.
4 812 Replacing oil filter element 16/1

Fig. 1

Note: Fig. 1 shows a twin lube oil filter without

changeover facility mounted on the engine. In
other cases, the oil filter can be mounted remote
from the engine, Oil filters with changeover
facility are also available.

Drain oil from filter bowls. Replace drain plugs

(arrow) with new seals. Loosen centre screw of
filter bowl.

Fig. 2

Remove filter bowl and clean internally. Replace

filter cartridge and install filter bowl with new
gaskets. Observe tightening torque for central
screw.
 Removing and installing oil cooler

Fig. 1

Drain engine oil and cooling water, Remove oil

filter. Remove filter head gasket,
Note: Fig. 1 shows an engine with a twin oil
cooler, Engine modets with one oil cooler are
not shown,

Fig. 2

Remove ail cooler housing cover with the oil

coolers mounted.
Wotc?: The oil coolers are secured by 10 screws
marked with an farrow). Loosen these screws
only aB@rremoval of the housing cover if the
oil coolers have to be replaced.

Fig. 3

Insp@zct oil cooler. Oil cooler, bypass lines and

the bypass valves contained therein (arrows)
can be replaced as the complete unit only. In-
stall ail cooler housing cover with oil coolers
%cured to it using a new gasket.

Fig. 4

Install oil filter with a new gasket. Fill in engine

oil and coolant,
 Removing and installing oil pan, oil dipstick, oil drain 1811

Fig. 1

Drain oil by means of handpump or by removing

drain plug in the bottom of the oil pan. Remove
handpump from bracket only if defective.
Wandpump and three-way cock (arrow) cannot
be repaired.

Fig. 2

Pull out oil dipstick. Remove screws around oil

pan. Take off oil pan and clean. Replace oiI pan
gasket. When reinstalling oil pan observe tight-
ening torques for screws. If the oil dipstick has
to be replaced follow instructions for Fig. 3.
 1911 Removing and installing oil separating valve (crankcase vent) 19/1

Figs. 1 and 2

The crankcase is provided with forced ventila-

tion. The air from the crankcase is drawn
through an oil separator valve and a pipe into
the intake manifold to the engine. The oil se-
parator valves are equipped with fatigue-
resistant diaphragms and are therefore mainte-
nance-free. On engines which have to be over-
hauled after an extended operation time due to
general wear the oil separating valves have to be
replaced. Fig, 1 shows the oil separating valve
with oil collecting space (1) and oil return pipe
(2);Fig. 2 shows the former version of the oil
separator valve.

Fig, 3

Loosen pipe clips and pull off oil separator valve

( e r r ~ w fwith O-ring from pipe connection in
crankcilse, Reinstall with new O-ring, hoses and
pipe clips,
 2611 Removing and indalling oil spray jets 2Ct/ 1

Fig. 1

Remove oil pan, Remove screws (If,spring

washer f2f, oil spray jet (3) and gasket (6).

Note: Do not remove hollow screw 141, seal

(5) and flange (7). if these parts must be re-
moved we recommend to mark the position of
flange (7) in the crankcase, Observe text for
Fig. 3.

Using a screw driver, check that the valve piston

is still held in contact Ciy spring force in the
spray jet body {3).

Fig. 2

Install oil spray jet with new gasket.

Fig. 3

Check for correct direction of oil jet. The jet

I from each nozzle must impinge directly on the
piston underside and reach two cams. Never
repair bend oil spray jets by bending.

In the case of turbocharged engines the pistons

are provided with an annular coolant duct.
When aligning the oil spray jet, make sure the
nozzle opening is directed accurately to the in-
let port: af the cooling duct.

Note: The diameters of the oil spray nozzles for

nr3lurally aspirated engines and turbocharged
engines differ; see ,,Testing and Adjusting 3
Values",
 Removing and in@@llirsg
sail pump, relief wlve

Fig. 1

Remove oil pan and screws 05 oil suction pipe.

Measure backlash between oil pump drive gear
and crankshaft gear. Obsewe specified value and
replace gears if necessary.

Fig, 2
Remove oil pump screws. Take off oil pump.
On engines with tandem pumps first remove the
second pump with connection sleeves and
circlips.

Fig. 3

The pressure relief valves are encapsulated. For

testing connect pressure gauge to oil passage
I with the engine cold; the pressure must lie be-
tween 9 and 10 bar for a short period.

Reinstall all removed parts in reverse order. Use

new gaskets. Observe tightening torques for
screws.
 Disassembling and assembling ail pump 221I

Fig. 1

Clamp oil pump in a vice (fitted with ~ P x

jaws). Remove screws from oil pump cover
and take off cover.

Fig. 2

Remove idler gear. Check gears and pump

housing for wear; see ,,Testing and Adjusting
Values".

Fig. 3

Remove oil pump drive gear by placing pump

on a suitable surface and pressing out the gear
with a mandrel.

For instalfation, position the pump such that the

g@aris in contact. Place drive gear on shaft and
pnss in until flush.
 Disassembling and assembling oil pump 22/2

Fig, 5

lnstall cover and tighten screws to the specified

torque. Rewark or replace covers, if heavily
worn!

Fig. 6

ranee of gear. Install complete

23/l Removing and insailing flywhc~lI gear ring

Fig. l

Loosen S G T ~ W Sarrest
; starter ring gear by apply-
ing a tool. Remove two screws and replace by
two guide pins. Remove all screws and take off
ffywheet, Clean and inspea flywheel. Hairline
cracks which do not run into the rim or screw
flange are permissible. Inspect flywheel with
clutch surface far score marks or burnt spots.
Remachine clutch surface if scores or burnt
spots are found; see ,,Testing and Adjusting
Values".

Fig. 2

Remove race by cutting through. Place new

bearing race in installation tool with outer
chamfered side first and heat to approx. 150°C.
Coat seat of race in flywheel with Omnifit
green 150 L and fully press in race. Then tho-
roughly dean and lubricate race with oil.

Fig. 3

Place flywheel on guide pins making sure pin

and hole (arrow) are in alignment. Bring fly-
wheel in position.

Fig. 4

Ceat flywheel screws with oil, screw in and

tighten to specified torque.

!I I Use new flywheel screws felasticated screws).

 Replacing sta@ergear ring 2411

Fig. 1

Remove flywheel.
Drill hole in starter gear ring and cut ring taking
care not to damage the flywheel.

Fig. 2

Heat new starter gear ring to max. 230% and

press on as far as it will go. Max. axial runout of
starter gear ring 0.5 mm.
25/1 Replacing rear ccnnkshaft seai [flywheel end) 2514

Fig. 1

Remove flywheel. Using a screwdriver , lift out

seal from timing case.

Fig. 2

The pressing mandrel consists of two parts. For

pressing in place guide ring of mandrel onto
crankshaft.

Fig. 3

Apply a thin coat of sealing compound to outer

surface of new seal and slide it over mandrel.
Apply thin coat of grease to sealing lip. When
placing the mandrel in position make sure the
hole in the mandrel (arrow) is in alignment with
the pin (arrow).

Fig. 4

Drive in seal until flush.

Install flywheel, observing the seal.
26/1 Replacing Front erankshafi sm d pilot bearing race =?@/I

Fig. 1

Loosen V-belt for water pump and al"cerator

and remove it, Remove engine turning device
farrow} and belt pulley.

Wgmove vibration damper and oil splash ring.

Fig. 2

Remove cover.
! !! The bottom of the cover is secured to the oil
pan.

Fig. 3

Push guide ring (3) and race (4), apply puller

(1) with screw (2) and pull off bearing race.

f nstallation

Fig. 4

Insert new bearing race with chamfered end on

outer diameter first in mandrel and heat both to
apprax. 150 to 200'6. Press bearing race onto
crankshaft until in contact with the drive in
mandrel. After installation clean bearing race
and caat with ail. The correct distance between
crankshafi front sdge and bearing race is ensured
only if modified mandrel 80.9961'74016 is
umd.
 Replacing froost cranksha& sal and pilot bearing race 26/2

Fig, t

Cover f 1 ) and shaft seal ( 2 ) are supplied for

r~placementas ritn assembled set only to ensure
~tisfactoryinstallatian.

Fig, Gi

Apply a thin coat of grease to cleaned crank-

case surface (do not use liquid sealing com-
pound) and place cover gasket on top. Apply
multi-purpose grease to seal lips. Push cover
over guide pins and carefully bring into contact.
Tighten cover screws to specified torque.

Fig. 7

Place oil splash ring in position. For correct

in&allation position, see also Figs. 513.

Fig. 8

I n%talf vibration damper. Observe tightening

tcarque for screws,
Replace V-belt pulley, engine turning device,
V-bells and all other parts,
2711 Removing and installing inlet bend and inlet manifold

Note: There are various types of inlet bends and inlet manifolds. In most cases, these parts are
sa arranged that instructionsfor removal and installation are not required. However, do not over-
look replacement of gaskets and damaged parts and observe the specified torques for screws.
(Test values, standard values).

Fig. 1

In the case of MLE engines remove intercooler

(arrow). Injection lines must be removed in all
case.

Fig. 2

Remove screws and take off intake manifolds.

Fig. 3

install intake manifold with new gaskets, Tight-

en screws to specified torque; see ,,Tightning
torque guide values" and standard table (page
229). Re-place all other removed parts.
 Removing and installing exhaust manifold 28/1

Fig. 1 (D 2542 MTE)

Remove screws and take off exhaust manifold.

Replace reusable or new exhaust manifold with
new gaskets. Observe specified tightening torque
for screws; see also Note for Fig. 3.

Fig. 2 (D 2542 MLE)

Remove uncooled exhaust manifolds consisting

of several sections. During reassembly replace
all gaskets. Insert connection piece a t splint
line (arrow). Tighten screws to specified torque;
see also Note for Fig. 3.

Fig. 3 (D 2542 MLE)

In the case of engines with water-cooled exhaust

manifold, drain cooling water. Disconnect
caoling water lines and vent lines a t exhaust
I
manifolds. Remove screws and take off exhaust
manifold.

The two section exhaust manifold should be

dimssembled only if the gasket (arrow) must be
replaced. In this case, the exhaust manifold must
be sa positioned that the flange sealing faces
lie in one plane (max. permissible uneveness
owr entire length 0.05 mm). Tighten nuts on
gzuds to 90 to 100 Nm.

Hare: Follaw recommendations given under

3U2,Fig. 6 far inmallation of exhaust manifold.
Observe tightening torque for screws.
2911 Rernovi~gamd in&allirsg turbocharger 2911

Fig. 1 (D 2542 MLE far marine prapulsionf

Remove air filter and guads.

Fig. 2 (D 2542 MTE for marine propulsion)

Remove lube oil lines (drain). Loosen clips of

intake manifold.

Fig. 3 (D 2542 MTE for marine propulsion)

Remove engine vent hoses from hose connec-

tions on intake manifolds and take off intake
manifolds. Loosen hose clip on intake mani-
folds. Remove turbine casing from exhaust
manifold and take off complete turbocharger.

During reinstallation replace gaskets, hoses and

hose clips, Observe tightening torques for
screws,
 3011 Checking axial and radial play of Purbinefmtor shaft

Checking axial play

Fig. 1
Remove turbocharger. Mark position of turbine
housing relative to bearing housing. Loosen
clamp on turbine housing and remove turbine
housing, Apply gauge holder with dial gauge
under preload to shaft end face of turbine as
shown, Press rotor shaft against dial gauge, read
and note value. Push rotor shaft in opposite
direction, read and note value. The difference
between both values is the axial play.
I!! Refer to technical data!
Replace turbocharger if play is exceeded, lnstall
turbine casing while observing marks. l nstall
clamp and tighten to specified torque.

Checking radial play

Radial play is measured on turbine end only

with a dial gauge or feeler gauge.

Fig. 2
Dial gauge: Remove turbocharger and detach
turbine housing, apply dial gauge stylus to up-
side, push turbine towards dial gauge, read and
note value. Push turbine in opposite direction,
read and note value. The difference between
both values is the radial play.
! !! Refer to technical data!
Install turbine housing while observing marks.
Install clamp and tighten to specified torque.

Fig. 3

Feeler gauge: Push turbine in one direction and

t measure gap between turbine housing and tur-
bine. Push turbine fully in opposite direction
and measure gap. The difference between both
gags is the radial play.

! !! Refer to technical data!

Measure a t two different points. Replace turbo-
charger if play is exceeded.

Hate: Radial play can be measured with feeler

gauge also while the turbocharger is installed.
 Removing and installing cylinder head 3111

Removal

Fig. 1

Remove inlet bend, inlet manifold and exhaust

manifold. Remove fuel injection lines and vent
pipe for cooling water circuit. Remove cylinder
head covers.

Fig. 2

Back off valve adjusting screws. Remove rocker

arm bracket. Remove push rods.

Fig. 3

Remove cylinder head screws in reverse order

of tightening.
The cylinder head screw under the injector can
either be removed by means of the special
wrench or with a box wrench after removal of
injector.
Lift off and deposit cylinder head so that the
protruding 'end of the injector will not be
damaged. Remove cylinder head gasket. Check
cylinder head sealing surface and cylinder block
for flatness using a straight edge.
Mot@: Remove cylinder heads only with engine
in cold condition to avoid distortion.

Fig. 4
Befare insallation clean and blow out tapped
hates in crankcase. Clean sealing surfaces on
cylinder head and crankcase. When grinding the
=@ling sudaces observe specified finish. Place
new cylinder head gasket in dry condition in
position abserving the hole pattern and mount
cyl inder head,
Male: Make sure rkst cylinder head gasket and
cylinder liner match up properly; s e ,,Te&ing
and AdjusCing Values", pwe 2 13.
31l 2 Removing and installing cylinder head

installation

Fig. 5

Two dowel sleeves per cylinder head are in-

serted in the crankcase top surface for locating
the cylinder heads.
5
Fig. 6

Install cylinder head screws after lubricating

with oil. Observe order of tightening and speci-
fied tightening method, see instructions on pages
32/1 and 32/2 and ,,Torque Guide Values".
Note: To avoid any distortion between cylinder
heads and manifolds we recommend to proceed
as follows:
- Place cylinder head gaskets in position
- Place cylinder heads in position. Screw in
cylinder head screws a few rotations.
- Secure steel ruler (80.99607.0044) with
ground surface on exhaust side using 6
M I 0 x 70 mm screws (06.01019.0095)
and 6 U-washers (10.5 mm). Tightening
torque for screws = 20 Nm (2 kpm).
- Tighten cylinder head screws as specified.
- Remove steel ruler. Install exhaust manifold
and inlet manifold.

Fig. 7

Inspect push rods for distortion. When inseaing

the push rods make sure they fit into the seat
of the valve tappet.
Place rocker arm bracket in position. Tighten
screws lightly and align rocker arms to valves.
Tighten screws to specified torque.

Fig. 8

Note: Before installing rocker arms (4) on

brackets in (1) coat contact surfaces (5 and 6)
with OPTIMOLY-PASTE-WHITE T.
31/3 Removing and ingalling cylinder head 31f3

Fig. Q

Install injection lines, Observe tightening tor-

ques. Adjust valve clearance.

Fig. 10

lnstall inlet manifold and exhaust manifold.

Install cylinder head cover with new gasket
in dry condition and tighten screws to specified
torque. lnstall cooling water pipe. Fill in cool-
ant.
 Removing and installing cylinder head

SUMMARY:

1. Tightening cylinder head screws (torquetightening method)

2. Retighteningcylinder head screws (torque-tighteningmetlhod)

3. Tightening cylinder head screws (angle-of-rotation method)

The sealing effect of the cylinder head gasket largely depends on whether the required preload
for the cylinder head screws is actually reached and maintained. Tests have shown that a con-
siderable amount of the tightening torque is absorbed by friction due to dry threads and bolt
head contact surfaces and is therefore not available for screw preloading. Therefore proceed as
follows:

1. Tightening

1.I Before installing the cylinder head screws apply engine oil (no lubricants containing
MoS2) to the thread (do not lubricate tapped hole) and to the screw head contact
surface.

1.2 To position the cylinder heads, tighten screws only lightly. Then tighten in specified
order and in steps to the specified torque. If during initial tightening some screws are
tightened excessively, cylinder head and gasket will be distorted and this distortion
cannot be compensated when tightening to the specified torque.

1.3 Use calibrated torque wrenches.

Permanently adjusted ,,snap-type" torque wrenches can also be used.

Calibration of the wrenches can be performed on calibration benches (tool manufac-

turers and dealers) or by applying weights to the lever arm. Calibration by comparison
of wrenches is not acceptable. Calibration must be repeated a t certain intervals (approx.
every 3 months) depending on use.

1.4 During final tightening the specified torque must be maintained at least 5 seconds (not
required in the case of snap-type torque wrenches). When using snap-type torque wren-
ches tighten screws gradually since otherwise the torque selected will not be fully
transferred to the screws.
1

2. Retightening

2.1 On new engines and reconditioned engines, the cylinder head screws are ret tightened t o
final torque after the test run in the Works. Consequently retightening is unnecessary.
A lable ,,do not retighten cylinder head screws" is attached to the engines for an ex-
tended period of time.

2.2 When repairs requiring the removal of one or more cylinder heads are carried out, the
cylinder head screws must be retightened under load not earlier than after one operat-
ing hour.

Retighten the cylinder screws with the engine in cold condition, e.g, crankcase hand-
warm or cooler.

Proceed as follows:
- Disconnect fuel injection lines from injectors
- Loosen cylinder head screws in specified order
- Apply oil to screw contact surface
- Tighten to specified torque

To make sure no screw has been overlooked recheck in specified order.

 32/2 Removing and installing cylinder head

3. Tightening cylinder head screws (angle-of-rotationmethod)

From the 4th quarter of 1983 onward, the cylinder head screws described in Sections 1 and 2
will gradually be replaced by screws suitable for the angle-of-rotationtightening method. Also in
this case, engine oil must be applied to the screw thread (not the tapped hole) and the head con-
tact face before installation, Tighten screws in the specified order, see ,,Torque Guide Values".
Retightening of the screws is not acceptable, also not after repairs.

3.1 Distinguishingfeatures

In the installed condition these screws can be

distinguished by a triangular symbol in the
screw head. In addition, the thread length of
90 to 93 mm considerably exceeds the thread
length of the screws used previously (34 to
36 mm). All engines supplied with these new
screws ex Works will be marked with a label
on one of the cylinder head covers.
I

3.2 Reusabiliw

After each application of the angle-of-rotation

tightening method as specified, the cylinder
head screws will be subjected to permanent
elongation. Re-use is only acceptable if the
screw length has not yet reached the follow-
ing maximum values.

Left-hand: screw suitable for angle-of-rotation

tightening method
Right-hand: screw suitable for torque tighten-
ing method

max. permissible length

after applying angle-of-
rotation tightening me-
thod

Moreover, the surface of the screws must be free from any defects. To prevent erroneous re-use,
all screws even with the slightest defects in the protective phosphate coating or rust or screws
which reach the max. permissible length after applying the angle-of-rotationtighten'
should be discarded. We recommend to destroy the threads of these screws using a
by ginding tomakg them unusable.

Note: Screws suitable for the angle-of-rotationtightening method can be used as required, e.g.
they can also be replaced individually.
 Removing and installing valves 3311

Fig. 1

Remove cylinder head.

Mount cylinder head o n valve fixture. Press
d o w n valve spring retainers w i t h f o r k and re-
move collets. Lift f o r k and remove valve spring
retainer, valve spring and washers.

Fig. 2

Note: Valve spring retainer and valve spring

can also be replaced w i t h the cylinder head in-
stalled. The piston must be i n TDC and the t o o l
shown must be used.
T u r n cylinder head. Remove valves and p u t
aside i n installed order o r mark the valves.

Fig. 3

Note: I n t h e case o f naturally aspirated engines,

first remove t h e valve stem seals.

Fig, 4

A change o f valve head height ,,H" is n o t accep-

table. Replace damaged valves.

Note: Valve head height ,,H" varies f r o m valve

to valve; see ,,Testing and Adjuaing Values",

4
 Removing and installing valves J3/2

Fig. 5

Machine valve seat o r replace.

Lubricate valve w i t h o i l and install m o u n t
cylinder head o n valve fixture. Insert valve
spring washers.

Fig. 6

Note: I n t h e case o f naturally aspirated engines

place installation sleeve f o r valve stem seab o n
the valve and install seal. Remove sleeve. Place
pressing bush i n position and press in seal,

Fig. 7

lnsert valve springs and replace damaged or

weak springs. The w o r d ,,TOPu facing upward
and tight coils facing downward. Install valve
spring retainers and collets.

Fig. 8

Measure valve retrusion. Refer t o specified

values. If necessary replace seat insert o r valve.
 Removing and installing valve guide 3411

Fig. 1

Knock o r press o u t valve guide.

Note: N 1 valve guides are n o longer available

for installation.

I Fig. 2
Lubricate new valve guide w i t h oil and press
o r drive into a cylinder head using a mandrel
and spacer sleeve. The valve seat must be
machined when replacing the valve guide.
 3511 Refacing valve seat (with Hunger valve seat tool) 35ll

Fig. 1

Insert pilot into valve guide and clamp in po-

sition. The collet collar (arrow) must contact
the valve guide.

Fig. 2

Clamp turning bit into tool side for the valve

seat angle (45' in illustration). Attach handle
so that the bit is pulled.
I

Fig. 3

Place head (1)on pilot and fully back off feed

screw (2) in clockwise direction. Position tip
of bit (3) to valve seat centre using quick adjust-
ment screw (4) after loosening coupling nut (5)
and place carefully in position on the valve
seat.
r
Slightly press drop pin (6) on the pilot and
clamp with screw (7).

Fig, 4

Mount head (I) without constraint and parallel

ta axis, back off tool bit with quick adjustment
screw (2) and lightly tighten coupling nut
(31.Adjust depth of cut 11 graduation = 1/10
mm) by turning knurled screw (4) anti-clockwise
and lack knurled screw with clamping screw
(5).Hold large knurled screw (6) and machine
valve seat by turning crank. Loosen mupling
nut, if necessary. Back of bit using quick adju&-
ment screw and repeat operation.
 Replacing valve seat rings 36/1

Fig. 1

Apply two short weld beads with arc welding

set on valve seat ring and extract ring by means
of internal puller. Clean ring contact surface
in cylinder head.

Fig. 2

Heat cylinder head to approx. 80°C in water

bath. Deep-freeze valve seat ring and insert
quickly into cylinder head. Drive in with
mandrel and hammer to ensure the ring is in
full contact with the cylinder head seat.
 Removing and installing timing case 3711

Fig. 1

Remove starter and flywheel. Remove lube oil

lines of turbocharger, lines from compressor,
raw water pump, bracket of oil drain pump
(arrows) etc., depending on the engine model.

Fig. 2

Remove timing case screws.

! I ! The timing case is screwed to the oil pan
at the bottom.

Fig. 3

Remove timing case, Inspect thrust washer on

camshaft (arrow); see ,,Testing and Adjusting
Values". Apply Omnifit Green to screws of
thrust washer and screw them in.

Fig. 4

Remove gasket residues from crankcase sealing

surface, lnstall new gasket using some grease to
hold it in position, if necessary. Place timing
case on dowel pins (arrows), press on and secure
with screws.
Observe specified torque values for screws.
Re-placeall other parts.
 Removing and installing camshi3ft, replacing camshaft bearing, 3811
checking valve tin

Fig. 1

Drain engine oil and coolant. Remove rocker

arm brackets and push rods. Remove flywheel,
timing case and oil pan. I f the camshaft bearings
have to be replaced too, cylinder heads, pistons
with connecting rods and crankshaft must also
be removed. Turn engine upside down so that
valve tappets do not obstruct camshaft removal.
Pull out camshaft, taking care not to damage
camshaft bearings. Inspect camshaft for wear
and damage.

Fig. 2

Remove valve tappets, inspect for wear and

replace, if necessary.
Valve tappets can only be removed after removal
of camshaft.
I!! Valve tappets, size N and N 1 may be in-
stalled in one and the same engine. N 1 tappets
are marked with a dot of red paint. Further
identification is given on the data plate (see
,,Crankshaft1').

Fig. 3

If the camshaft cover is removed, proceed as

follows during reinstallation:

1. Degrease bore and cover

2. Rework chamfer (detail x), if necessary.
3. Apply sealant (Wylomar) to bore and cover,
including chamfer.
4. Press in cover carefully without skewing.
5. Check for oil tightness.

Note: The plug of the cover is provided with

the gasket; replace if required.
 Removing and installing camshaft, replacing earnshaft bearing, 38/2
checking valve timing

Fig. 4

Remove camshaft bearing bushes with suitabte

mandrel and install new bushes. Make sure the
oil supply holes are in correct position.

Mote: Replacement camshaft bearing bushes

are supplied ready for installation. Reworking
is not necessary. Moreover, the last bearing (on
the side of the timing gear case) consists of a
bush with loose thrust ring. Insert thrust ring
with marked side facing the crankcase (coated
side facing outward).

Fig. 5

Measuring camshaft axial play with the timer

case removed.

Carefully introduce camshaft and exert force ta

take up clearance. Apply steel rule to face of
camshaft gear and measure gear projection
I x ) above the split line of the crankcasr; by
means of a depth gauge. Note measured value.

Fig. 6

Place rule on timer case and determine dimen-

sion (y) of thrust washer by means of depth
gauge. Add 0.5 mm to value determined fthick-
ness of gasket between crankcase and timing
case) and subtract recorded dimension {xf
to obtain camshaft axial play (y + 0.5 rnm x -
= 1,
If the play is not within the specified tolerance,
inspect thrust washer (on timing case) and cam-
shaft gear for wear.

Fig. 7

Measuring camshaft axial play with installed

timing case.

Press in camshaft with suitable lever until in

contact with the thrust washer (timing case),
 Removing and installing camshaft, replacing camshaft 3813
bearing, checking valve timing

Fig. 8

Remove plug or angle drive for tachometer from

camshaft cover. Apply stylus of dial gauge t o
camshaft face or driver dog for tachometer,

Fig. 9

Push camshaft fully forward towards dial gauge

stylus. The dial gauge reading equals the cam-
shaft axial play.

Replace all removed parts. Fill in engine oil and

coolant as specified. Check start of delivery and
adjust valve clearance.

CHECKING VALVE TIMING

Turning the shrink-fit camshaft drive gear may cause serious damage t o engine. Consequently,
when an engine condition existed which may have caused turning of the gear, e.g. resulting from
compressor failure, check for correct gear position by checking the valve timing.

Proceed as follows:

- Remove cylinder head cover from 1st cylinder

- Carefully adjust exhaust valve of this cylinder
- Turn engine until the valves of cylinder No. 1 are rocking
- Turn engine back to approx. 50' before TDC
- Then turn engine forward again t o 30' before TDC (observe graduations on flywheel)
- Apply dial gauge with approx. 10 mm preload on valve spring seat of exhaust valve in cylin-
der No. 1 and set t o ,On
- Turn engine through 180° in direction of rotation (exhaust valve fully closed)
- Read valve stroke on dial gauge

The following table contains the valve strokes which guarantee the correct position of the cam-
shaft gear and therefore correct timing.

Engine model Valve stroke

D 2530 ME, D 2542 ME, D 2842 ME ...................... . ................................................. 3,5 t o 4'4 mrn
D 2840 ME .................................................................................................................... 3,5 to 5,4 m n
D 2530 MTE, D 2540 MTE/MLE, D 2542 MTE/MLE, D 2840 LE, D 2842 LE ............. 4,5 to 5,rt mrn
 Removing and installing crankshaft

Fig. 1

Remove oil pan, oil pump, timing case, cylinder

heads and front cover of crankshaft seal. Re-
move screws of connecting rod bearing caps
and remove connecting rod with piston.

Fig. 2

Remove horizontal screws of crankshaft main

bearing caps.

Fig. 3

Remove screws of crankshaft main bearing

caps. Number bearing caps in order of installa-
tion and take them off. Matchmark bearing
shells with bearing caps (electric scriber) unless
already marked.

Fig. 4

Lift out crankshaft. Remove bearing shell halves

from crankcase. l nspect crankshaft and replace,
if necessary.
 Removing and installing crankshaft 39/2

Fig. 5

Clean oil passages in crankcase and crankshaft

with compressed air.
Thoroughly clean bearing shells and bearing
pins and install new bearing shells in crankcase2
if necessary. Observe repair stage.
Numbering of crankshaft main bearings:
1 = water pump side

Fig. 6

Apply thin coat of oil to the bearing shell,

bearing surfaces and place crankshaft in position
making sure the arrows of the crankshaft and
camshaft gear are correctly positioned.

Fig. 7

Install crankshaft main bearing caps with bear-

ing shells. Insert vertical bearing cap screws and
tighten t o specified torque. Tighten finally
with rotation angle gauge. lnsert horizontal
crankshaft main bearing cap screws and tighten
to specified torque.

!!! Use screws only once (elasticated screws),

Fig. 8

Check axial play of crankshaft. The axial play

depends on the thrust bearing. Mount dial
gauge holder with dial gauge to crankcase. Push
crankshaft in axial direction and read play on
dial gauge.
After installation, check crankshaft for free
rotation,
39/3 Removing and installing crankshaft 3913

Fig. 9

Measure connecting rod bearings. lnstall pistons

with connecting rods. Coat connecting rod
bearing shells with oil and pull connecting rods
onto the crank pins. Mount connecting rod
bearing caps with bearing shells (observing
position of mark - numbers must be on the
same side).
install screws and tighten in steps to specified
torque.

Fig. 10

Tighten finaily with rotation angle gauge.

Apply rotation angle gauge so, that the angle
hook contacts the casing. Tighten screws
through another 90°.

Fig. 11

There are different sizes, standard (N), standard I

(N I = 0.1 mm dimensional deviation) and
standard II (N II = 0.25 mm dimensional deviation)
for connecting rod and crankshaft bearings as
well as for tappet bores even in standard pro-
duction. To make sure this difference is observed
during repair work, data plates with an N I or
N I I box (arrow) are used. If N I or N Il parts
are installed in an engine, the following letters
will be stamped in the N I or N II box:

P = crankshaft; connecting rod bearing N I or 1

N II
t-1 = crankshaft; main bearing N I or N II
S = tapped bore N I (there is no N II)

Engines built before January 1976 have no N I

or N I I box on the data plate. In these instances
the sizes have to be determined by measurment.
 Removing and installing pistons with connecting rods

Fig. 1

Remove oil pan, oil pump suction pipe and

cylinder heads; remove screws from mnnect-
ing rod bearing caps and lift off caps with
bearing shells.

Fig. 2

Remove combustion deposits from cylinder

liner top edge (taking care not to damage liner
surface). Push out connecting rod with piston
in upward direction. Check pistons and piston
rings for damage. Replace piston if cracks are
found on edge of combustion chamber.

Fig. 3

Inspect bearing shells for wear and damage to

top layer. Measure spread. lnstall new bearing
shells, if necessary. When repairing the crank
pins, use bearing shells of the corresponding
repair stage.

Fig. 4

Install bearing shells into connecting rods and

connecting rod bearing caps (top coat must not
be damaged).
 Removing and installing pistons with connecting rods 4Q/2

Fig. 5

Lubricate cylinder liner and piston with oil.

Apply piston ring compression tool or sleeve
(piston ring gaps offset) and install piston with
connecting rod into "a cylinder liner (entrance
section on piston crown facing fuel injector),

I!! Take care not to damage oil spray jets during

installation. See ,,Oil spray jets", Fig. 4.

Fig. 6

Install connecting rod bearing caps (line up

figure in cap with figure on crankcase edge),
Tighten screws in steps to specified value..
Tighten finally by means of rotation angle
gauge.

Fig. 7

I!! Note: After proper application of the ro-

tation angle tightening method the connecting
rod bearing screws will be subjected to perma-
nent elongation. Re-use is only acceptable if
the shaft length
b
Screw length ,,L"
Mew condition after applying angle-of-
rotation tightening me-
thod 7
 Replacing piston rings 4111

Fig. 1

Remove piston with connecting rod. Clamp

connecting rod in a vice fitted with soft jaws.
Set piston ring pliers to 125 or 128 mm, respec-
tively.

Fig. 2

Remove piston rings. Clean piston ring grooves.

Be careful not to damage piston ring grooves,

Note: The oil scraper rings are bevelled-edge

spring-loaded oil rings.

Fig. 3

Check piston ring gaps. Observe specified

values. Install piston rings in piston using piston
ring pliers.
The ,,TOP" mark or the manufacturer's de-
signation must point upward. Adjust piston ring
gaps 120' offset on piston circumferenw.
The piston ring gaps must not be located above
the piston ring bores.

Fig. 4

Measure piston ring clearance in groove, In the

case of excessive clearance replace piston and
rings.

Mote: Pistons and piston rings for naturally

aspirated engines and supercharged engines
are different. Observe inspection and adjusting
values and instructions under ,,Oil spray jets".
 Detaching and attaching piston on connecting rod,
checking connecting rod

Fig. 1

Remove piston with connecting rod. Clamp

connecting rod in a vice using soft liners.
Remove piston pin circlips. Remove piston
pin. Take off piston.

Fig. 2

Install new big-end bearings. Install cap and

measure bearing bore.

Note: Small available. Re-

place connec defective.

Fig. 3

Clean connecting rod and inspect for ext~rnal

damage; scrap rod if defective. Check cannect-
ing rod for parallel bores and skewing of piston
pin bore relative to bearing shell bore. Replace
connecting rod if the two bores are not parallel
or skewed relative to each other. Place pistqn
on connecting rod (entrance section and long
fork arm on the same side). Insert piston pin.
Install circlips.
 Removing and installing cylinder liners

Fig. 1

Remove cylinder head and piston. Insert

cylinder liner puller into liner making sure not
to damage the oil jet.

Fig. 2

Place support on extraction screw and ingteil

nut. Hold extraction screw in position and
extract cylinder liner by tightening nut. Remave
puller and park cylinder liner upright. Remove
O-rings. Number cylinder liners in order of
installation.

Fig. 3

Before final installation of the liner check prs-

trusion over crankcase surface. Clean bore in
crankcase an liner for this purpose, Install
cylinder liner without O-rings in crankcase
and check protrusion of cylinder liner a t four
points using a dial gauge holder and dial gauge.

Fig. 4

Install new (green) O-rings in dry condition in

crankcase bottom. Install new (black) O-rings
in dry condition on cylinder liner top under
the collar.
Apply uniform coat of engine oil (do not
use brush) to cylinder liner in the area of the
upper and lower O-ring, including chamfer and
the lower O-rings in the crankcase.
Do not use grease or sealing compound of any
kind.

Note: Do not use nreen 0-rinas on the cvlinder

llar but &ly black b-rings
 Removing and ia&atfing cylinder liners

Fig. 5

Carefully insert cylinder liners by hand ta avoid

twisting or pushing the O-rings out af their
grooves. Place clean metal plate on liner and
exert uniform downward pressure unfit ths iiner
is seated in the crankcase recess.

r Fig. 6
Dieser Austa~lschmotorhat einbau-
Reconditioned engines can be fitted with (a3 fertigs und lskht wchs
mm oversize outside diameter cylinder liner$, Bundbuchsen
On these engines the locating features taking
up the liners in the crankcase are also e),5 mm
oversize. The standard O-rings far ~eaiiegPhe
cylinder liners can still be used. The sv@rsia@
liners are available as spare parts; abservg this
when replacing liners. The liner venisn is idm-
tified by the data plate on the eylindsr head
cover as shown on the right.

Translation of the plate, shown in the fig:

This exchange engine has ready to in$tatl,
easily replaceable shouldered cylinder l i ~ r @ r % ~
 Measuring piston protrusion

Fig. 1

Turn engine via hexagon 132 mm across flats)

(arrow) to move piston t o TDC.

Fig. 2

For engines where the turning device shown in

Fig. 1 is inaccessible, a turning gear is available
as a special attachment. With this special gear
the engine can be turned via the starter ring
gear (inspection hole for start of delivery adjust-
ment).

Fig. 3

Apply dial gauge in holder without contacting

the liner collar and measure piston protrusion
above cylinder head sealing surface. Specified
values must be maintained.

Fig. 4

NOTES FOR RECONDITIONED ENGINES

Selection of piston length for crankcases with

remachined sealing surfaces

On reconditioned engines the cylinder block

parting faces may be remachined. The machined
size is stamped in the face of the crankcase/
cylinder head parting surface behind the cylin-
der head in the crankcase. During assembly or
disassembly the following must be observed:
 Measuring piston protrusion

1. Depending on the repair stage, pistons which are undersize (see ,,Testing and Adjusting
Values") in respect of compression height X are used. The dimension is stamped into the
piston crown below a 3digit number (last three digits of the part number).

2. The pistons (piston crowns) must not be remachined, since they are har

3. After piston replacement measure compression height X; piston protrusion above crankcase
top must be within the specified values.
 Removing and installing compressor 45fl

Fig. 1
Disconnect coolant lines in suction as well as
discharge lines from compressor cylinder head.
I f a hydraulic pump is flange-mounted t o the
compressor instead of the cover, disconnect
pump oil lines. Close pump ports and lines with
protective caps.

Fig. 2

Disassembling
I
Remove cylinder head.

Fig. 3

Inspect inlet valve diaphragm. Replace ali or

cracked diaphragms.

Note: The water-cooled valve plate must not hii?

disassembled as effective sealing between a tr and
coolant spaces without special test equipment is
not ensured after assembly. Even small leaks
may result in considerable damage by water,
I f leakage is suspected replace complete valve
plate.
3

Fig. 4

Remove cover from compressor crankcase and

timer case cover.
 Disassembling and assembling compressar

Fig. 5

Note: In the case of a 2-cylinder Gompressar

the horizontal cylinder i s flange-mounted in-
stead of the side cover. Remove cylinder head
and valve plate as shown in Figs. 2 and 3.

Fig. 6

Remove screws of cylinder liner and carefully

pull off cylinder liner to ensure the piston rings
are not damaged. Remove piston rings. Remove
circlips of piston pin and remove piston pin.
Remove connecting rod bearing cap screws and
connecting rod.

Fig. 7

Introduce arresting device for compressor

erankshaft and secure in posit ion. Remove drive
gear with a special wrench.
 Disassembling and assembling compressor

Fig. 8

Press out compressor crankshaft and counter-

weights in upward direction using an assembly
tool and remove rear bearing flange. Extract
inner ball bearing.

Assembly

Fig. 9

Drive in rear ball bearing using a mandrel and

hammer. l nstall crankshaft.

Note: Apply a thin coat of assembly paste

,,Optimal White T'709.16012-0117) to the
running surfaces of the connecting rod bearing
shells of the crankshaft for the 2 cylinder com-
pressor.

Fig. 10

Install rear bearing flange with a new O-ring

(align oil passages in bearing flange and housing)
and bring in uniform contact with two screws.
Remove screws.

Fig. 11

Install arresting device. Install drive gear and

tighten securing screws to specified torque
using the special wrench. Remove arresting
device,
 Disassembling and assembling compressor 4514

Fig. 12

Piston and cylinder liners are available in

matched sets B, C , D in 0.01 mm increments.
Pistons and cylinders are marked as illustrated.
Only use parts with same pairing letter.

Fig. 13

Bring connecting rod in contact with crankshaft

and place bearing cap in position. Tighten screws
t o specified torque. Install pistons, piston pins
and pin circlips.

Fig. 14

Install cylinder liner with new gasket and

tighten in a criss-cross manner. Install side cover
and timing case cover with new gaskets.
 Disassembling and assembling 45/5

Fig. 15

Replace and install gasket between cylinder and

valve plate.

! ! I ,,OBEN/TOPfl must point towards valve

play; observe that different gaskets are used
for valve and aircooled valve plate.

Fig. 16

Install inlet valve (diaphragm) in valve plate

while observing centering pin.

! !! Diaphragm is dome-shaped. Check position

of diaphragm as follows:
Press diaphragm a t point A on valve plate and
put finger on point B. I f this causes a noise,
the diaphragm is inverted - turn round.

Place valve plate in position while observing

position of centering pins and diaphragm.

Fig. 17

Install cylinder head with new gasket (observ-

ing dowel pins) and tighten to specified torque.
lnstall cooling water pipes and suction and
delivery pipes.
 Monitoring devices, insrument panel 46f 1

Fig. 1

The engine can be equipped with one or two

coolant temperature monitors. The first moni-
tor is set for engine shutdown if the max, per-
missible operating temperature is exceeded,
The second monitor is set for a somewhat: lower
temperature and initiates a warning signal. The
switching values for each monitor are indicated
on the inner side of the cover. If damaged, uw
new devices. Adapt switching thresholds and
cable connections to previous ones.

Fig. 2

The engine can be equipped with one or two

oil pressure monitors. The first oil pressure
monitor is set for engine shutdown if the oil
pressure drops below the minimum permissible
operating pressure. The second oil pressure mo-
nitor is set for a somewhat higher oil pressure
and initiates a warning signal. The switching
values of each monitor are indicated on the
inner side of the cover. If damaged, use new
devices. Adapt switching thresholds and cable
connections to previous ones.

Fig. 3

Instrument panel types.

The instrument panels will be adapted to the
requirements and the space available.
 Removing and installing starter
start / inhibit / relay

Fig. 1

Before carrying out any work on the electrim1

system of engines equipped with an alternator
it is mandatory first to disconnect the battery
earth terminal. Reconnect as last operation.
Disconnect starter cable from enclosure or
solenoid switch.
Remove nuts (arrow) and take off starter.
Clean starter externally and inspect for damage,
Starter installation is in reverse order of removal;
connect cables correctly and observe torque
guide values.
After installation check starter for proper
function.

Fig. 2

The start inhibit relay prevents starter operation

as long as the flywheel is rotating. If a relay is
required and i t s location depend upon the
engine model. The relay cannot be repaired.
Replace, if defective.
 Removing and installing alternator,
regulator and ovewoltage protection

Fig. 1

Note: Alternators differ in their output (see

,,Test and Adjusting Values"). They also differ
with respect to mounting bracket and mounting
location on the engine; see spare parts catalogue.

Ovvervoltage protection ( 1) intercepts voltage

peaks (above 28 V) which make occur briefly
in the system to protect voltage regulator (2)
and alternator (3)from damage.

Removing and installing alternator.

Fig. 2 (installation front righthand, bottom)

Remove protective shields where provided.

Disconnect cables (disconnect battery mass
cable first! I!); loosen screws and clamping nuts
on the eye bolt. Remove V-belt. Remove screws
and take off alternator.
Remove alternator, if required.

Installation of alternator is in reverse order.

Tension V-belt as specified, Tighten screws to

specified torque.
 Removing and installing preheater

Fig. 1

Horizontally mounted heater shell.

Other mounting positions are also possible.
Before removal first disconnect cable from mul-
tiple connector. Open drain plug (arrow) and
collect coolant; remove coolant lines from
heater shell.
Remove complete heater shell. Screw out
emersion heater. Clean all parts. Replace defec-
tive parts. Reassembly is in reverse order. Refill
coolant.

Fig. 2

Select most favourable preheating temperature

for engine. To do so turn control switch until
the desired temperature on the scale aligns
with the mark on the shell.
 Removing and installing, disassembling and assembling
tensioning pulley

Fig. 1

Loosen nuts on studs and locknut on tensioning

screw. Remove tensioning screw and push ten-
sioning pulley fully in. Remove V-belt. Remove
nuts from studs and take off complete tension-
ing pulley. Remove V-belt pulley from bearing
shaft (the tensioning pulley has two M I 0 tapp-
ings for extractor screws). Remove circlip from
support and press out bearing. Replace damaged
parts.
Fully press in bearing and install circlip. Press
V-belt pulley onto bearing shaft until flush.

Note: When pressing in the bearing apply press-

ing tool to bearing outer race. For pressing the
V-belt pulley onto the shaft use a support
mandrel suiting the bearing shaft.

lnstall tensioning pulley and tighten V-belts

as specified.

Fig. 2

Note: Some tensioning pulley versions have a

pin (3) which at the side of cover ( I ) has a
longer end with a tapped hole taking up the
tensioning screw. I n such cases cover (11 is
identical with cover (2)and on both sides of the
bearings one bush (4) each is used.

Disassembling tensioning pulley.

Carefully drive out cover ( I and 2). Drive

through bearing pin (31. Remove bush (4)and
Nilos rings (5). Extract one deep groove ball
bearing (6) with internal puller, remove spacer
(71, circlip (8) and press out second bearing with
suitable tool applied to outer race. Clean, in-
spect and replace parts, if necessary.

Assembling tensioning pulley.

Inr;tall circlip 18) in tensioning pulley (9).Fully

pr~ssin ane bearing (6)with lettering facing
circlip againsl: circlip. Install spacer (71 and
fully press in second bearing with lettering
facing circlip.
 Removing and installing, disassembling and assembling
tensioning -pulley

!!! Different depths of circlip and spacer may

cause constraint when pressing in the bearings.
To avoid this press in second bearing simultan-
eously at inner and outer race. Fill off set groove
for Nilos rings (5) with multi-purpose grease.
Install individually into tensioning pulley. Insert
bearing pin (3). Slide on bush (4). lnstall covers
(1 and 2) and spread by applying a light blow
so that their rim is fully seated (tight) in the
notch of the tensioning pulley. Lock cover in
position with centre punch at 4 or 5 points
(arrow). Secure tensioning pulley in bracket.
Install V-belt and tension as specified. Fit belt
guard.
 Gaskets

INSTRUCTIONS FOR INSTALLATION OF GASKETS

To facilitate installation or for improved sealing, sealing compound or adhesive is frequently

applied to gaskets. When parts of materials having different coefficients of expansion are
assembled (e.g, aluminum and cast iron) the gasket may be displaced during operation resulting
form the so-called step or sewing machine effect causing leaks.

Example: The cover of the front crankshaft seal on engines of D 25 series. The use of sealing
compound or adhesive will cause the gasket gradually to move inward due to differences in ther-
mal expansion resulting in oil losses which may be attributed to the shaft seal.

For satisfactory installation of gaskets, proceed as follows:

- Use only original M.A.N. gaskets

- Sealing surfaces must be clean and free from damage
- Never use adhesives or sealing compounds - to facilitate installation apply some grease, if
necessary so that the gasket will adhere to the component. Uniformly tighten screws to
specified torque.
TECHNICAL DATA
 TECHNICAL DATA

Engine

Design V, 90'
Principle:
Cycles 4 stroke
Method: all D 25 . .ID 28 . . ME Engines ............................... Diesel method with direct fuel
injection into spherical com-
bustion chamber in centre of
piston (M-System, single hole nozzle)

Method: all D 28 . . LE-Engines ........................................... Diesel method with direct fuel

injection (four-hole nozzles)

Number of cylinders
D 2530 MEIMTE, D 2540 MTEIMLE, D 2840 ME 10
D 2542 MEIMTEIMLE, D 2842 ME, D 2842 LE 12

Compression ratio
D 2542 ME
D 2840 LE, D 2842 LE
All others

Borelstroke
D 2530 MEIMTE
D 2540 MTEIMLE, D 2542 MEIMTEIMLE
D 2840 MEILE, D 2842 MEILE

Firing order
10 cylinder engines
12 cylinder engines

Lubrication forced-feed lubrication

BY gear oil pumps
Filling capacity see Operating Instructions

Cooling system water cooling

BY impeller pump
Coolant temperature 80° to 90°C

Note: For output and torque values please refer to our sales programme.
 TESTING AND ADJUSTING VALUES

CRANKCASE

Case bore for liners

10 and 12-cylinder engines D 25.. with thick-wall liners

10 and 12-cylinder engines D 28..
Press fit. upper. standard size ........................................... 145.80 to 145.84 mm (dia. 145.8 H7)
.
oversize 0.5 mm ...................................... 146.30 to 146.34 mm (dia 146.3 H7)
oversize 1.0 mm ...................................... 146.80 to 146.84 mm (dia. 146.8 H7)
Press fit. lower. standard size ............................................ 144.50 to 144.54 mm (dia. 144.5 H7)
oversize 0.5 mm ...................................... 145.00 to 145.05 mm (dia. 145 H7)
oversize 1.0 mm ...................................... 145.50 to 145.55 mm (dia. 145.5 H7)

Flange diameter in engine block

standard size ........................................... 153.90 to 154.1 5 mm (dia. 153.9 H l 1)
oversize 0.5 I 1.0 mm ............................. 154.40 to 154.55 mm (dia. 154.4 H11)

10 and 12-cylinderengines D 25.. with standard size liners

Press fit. upper. standard size ............................................ 143.00 to 143.04 mm (dia. 143 H7)
oversize 0.5 mm ....................................... 143.50 to 143.54 mm (dia. 143.5 H7)
oversize 1.0 mm ....................................... 144.00 to 144.04 mm (dia. 144 H7)
Press fit. lower. standard size ............................................ 140.00 to 140.04 mm (dia. 140 H7)
oversize 0.5 mm ....................................... 140.50 to 140.54 mm (dia. 140.5 H7)
oversize 1.0 mm ...................................... 141.00 to 141.04 mm (dia. 141 H7)

Flange diameter in engine block

standard size ............................................ 152.10 to 152.35 mm (dia. 152.1 H11)
oversize 0.5 I 1.0 mm .............................. 152.60 to 152.85 mm (dia. 152.6 H I 1)

Depth of flange recess (for all liners) .......................................

Flange height (for all cylinder liners) ......................................

Liner outside diameter

10 and 12-cylinderengines D 25.. with thick-wall liners
10 and 12-cylinder engines D 28..
On flange standard size ........................................... 153.694 to 153.757 mm (dia. 153.8 f 8)
oversize 0.5 I 1.0 mm ............................. 154.300 to 154.257 rnm
On upper press fit
standard size .......................................... 145.761 to 145.786 mm (dia. 145.8 g 6)
oversize 0.5 mm ..................................... 146.261 to 146.286 mm (dia. 146.3 g 6)
oversize 1.0 mm ..................................... 146.761 to 146.786 mm (dia. 146.8 g 6)
On lower press fit
standard size ........................................... 144.432 to 144.457 mm (dia. 144.5 f 6)
oversize 0.5 mm ...................................... 144.932 to 144.957 mm (dia. 145 f 6)
.
oversize 1.0 mm ...................................... 145.432 to 145.457 mm (dia 145.5 f 6)

10 and 12-cylinder engines D 25.. with standard-size liners

On flange standard size ........................................... 151.894 to 151.957 mm (dia. 152 f 8)
oversize 0.5 I 1.0 mm ............................. 152.394 to 152.457 mm (dia 152.5 f 8) .
On upper press fit
standard size ........................................... 142.961 to 142.986 mm (dia. 143 g 6)
oversize 0.5 mm ...................................... 143.461 to 143.486 mm (dia. 143.5 g 6)
oversize 1.0 mm ...................................... 143.961 to 143.986 mm (dia. 144 g 6)
 TESTING AND ADJUSTING VALUES

On lower press fit

standard size ............................................
139.932 to 139.957 mm (dia. 140 f 6)
oversize 0.5 mm ...................................... 140.432 to 140.457 mm (dia. 140.5 f 6)
oversize 1.0 mm ...................................... 141.932 to 141.957 mm (dia. 141 f 6)
Clearance (for all liners)
on flange ................................................. 0.1 43 to 0.456 mm
on upper press fit .................................... 0.01 4 to 0.079 mm
on lower press fit .................................... 0.043 to 0.108 mm

Cylinder bore
D 25 .. engines .................................................................... 125.000 to 125.020 rnm
D 28 .. engines .................................................................... 127.090 to 128.010 mm

For all liners

Max. wear limit ...................................................................... 0.1 5 mm larger than basic size

Permissible conicity over cylinder length

in area a ............................................................................. 0.005 rnm
in area b ............................................................................. 0.008 mm
Liner protrusion above upper edge of crankcase
(measured at bearing surface for cylinder head gasket)
measured a t four points, liner without rubber O-rings ........ 0.04 to 0.08 mm

PISTONS

Piston diameter measured at right angle to piston boss

D 2530 ME
Mahle, measured 27 mm above bottom edge of piston ........
Alcan, measured 32.0 mm above bottom edge of piston .....

D 2530 MTE
Mahle, measured 16 mm above bottom edge of piston ....... 124.838 to 124.872 rnm

D 2540 MTEIMLE, D 2542 MTEIMLE

Mahle measured 16 mm above bottom edge of piston ........

D 2542 ME
Mahle, measured 16 mm above bottom edge of piston ....... 124.865 to 124.905 rnm

D 2840 ME, D 2842 ME

Mahle, measured 16 mm above bottom edge of piston ........
Alcan, measured 17 mm above bottom edge of piston ........
D 2840 LE, D 2842 LE
Mahle, measured 14 mm above piston bottom edge ...........
Alcan, measured 14.5 mm above piston bottem edge .........
206 TESTING AND ADJUSTING VALUES

Compression height, standard dimension (see page 4411, Fig. 4)

D 2542 ME, D 2840 ME, D 2842 ME ...................................... 86.250 to 86.300 mm
D 2530 MEIMTE, D 2540 MTEIMLE, D 2542 MTEIMLE ...... 92.250 to 92.300 mm
D 2840 LE, D 2842 LE ...........................................................81.250 to 81.300 mm
Compression height, undersize
D 2542 ME, D 2840 ME, D 2842 ME
undersize 0.2 mm ................................................................ 86.050 to 86.1 00 mm
undersize 0.4 mm ................................................................ 85.850 to 85.900 mm
undersize 0.6 mm .............................................................. 85.650 to 85.700 mm

D 2540 MTEIMLE
undersize 0.2 mm ................................................................ 92.050 to 92.1 00 mm

D 2530 MTEIMLE, D 2542 MTEIMLE

undersize 0.2 mm ................................................................ 92.050 to 92.1 00 mm
undersize 0.4 mm ................................................................ 91.850 to 91.900 mm
undersize 0.6 mm ................................................................ 91.650 to 91.700 mm
D 2840 LE, D 2842 LE
undersize 0.2 mm ................................................................ 81.050 to 81.100 mm
undersize 0.4 mm ................................................................ 80.850 to 80.900 mm
undersize 0.6 mm ................................................................ 80.650 to 80.700 mm
Bore for piston pins

D 2530 ME
Mahle ................................................................................. 46.003 to 46.009 mm
Alcan ................................................................................... 46.000 to 46.006 mm
All other engine models and piston makes ............................... 46.003 to 46.009 mm

Piston protrusion above crankcase top .................................... 0.01 to 0.38 mm

Max. difference in weight per engine piston set ....................... 50 g

Width of piston ring grooves

D 2530 ME
1st ring groove ................................................................... 3.080 to 3.100 mm
2nd ring groove ................................................................... 3.040 to 3.060 mm
3rd ring groove .................................................................... 5.020 to 5.040 mm

D 2530 MTE
1st ring groove ..................................................................... 2.685 to 2.715 mm
2nd and 3rd ring groove ....................................................... 3.040 to 3.060 mm
4th ring groove .................................................................... 5.020 to 5.040 mm

D 2540 MTEIMLE, D 2542 MTEIMLE

1st ring groove .................................................................... 3.185 to 3.215 mm
2ndand3rdringgroove ..................................................... 3.040to3.060mm
4th ring groove ................................................................... 5.020 to 5.040 mm

D 2542 ME
1st ring groove .................................................................... 2.685 to 2.71 5 mm
2nd ring groove ................................................................... 3.040 to 3.060 mm
3rd ring groove .................................................................... 5.020 to 5.040 mm
207 TESTING AND ADJUSTING VALUES

D 2840 ME, D 2842 ME

1st ring groove: Mahle ....................................................... 3.195 to 3.225 mm
Alcan ....................................................... 3.205 mm
2nd ring groove: Mahle and Alcan ...................................... 3.040 to 3.060 mm
3rd ring groove: Mahle and Alcan ...................................... 5.520 to 5.540 mm
. -

D 2840 LE, D 2842 LE

1st ring groove: Mahle ....................................................... 3.195 to 3.225 mm
Alcan ....................................................... 3.205 mm
2nd ring groove: Mahle and Alcan ...................................... 3.040 to 3.060 mm
3rd ring groove: Mahle and Alcan ...................................... 5.020 to 5.040 mm
Piston ring height / piston ring axial play / piston ring gap

1st ring
plain compr. ring: height ............................................ 2.978 to 2.990 mm
axial play ....................................... 0.090 to 0.1 22 mm
ring gap .......................................... 0.45 to 0.65 mm
2nd ring
taper face ring: height ............................................ 3.008 to 3.020 mm
. . .......................................
axial ~ l a v 0.020 to 0.052 mm
ring gap ........................................ 0.60 to 0.85 mm
3rd ring
bevel led ring: height ......................................... 4.978 to 4.990 mm
axial play ........................................ 0.030 to 0.062 mm
ring gap ........................................... 0.25 to 0.40 mm

D 2530 MTE
1st ring
keystone-type ring: height ......................................; . . 2.575 to 2.595 mm
axial play ........................................ 0.090 to 0.1 40 mm
ring gap ........................................... 0.45 to 0.65 mm
2nd ring
taper face scraper ring: height ......................................... 2.978 to 2.990 mm
axial play ........................................ 0.050 to 0.082 mm
ring gap: TevesIGoetze ................... 0.40 to 0.60 mm
Riken ............................... 0.40 to 0.65 mm
3rd ring
taper face ring: height .............................................. 2.978 to 2.990 mm
axial play ........................................ 0.050 to 0.082 mm
ring gap: TevesIGoetze .................... 0.45 to 0.65 mm
Riken ............................... 0.45 to 0.55 mm
4th ring
bevel led ring: height .............................................. 4.978 to 4.990 mm
, .........................................
axial .~ l a v 0.030 to 0.062 mm
ring gap ............................................ 0.25 to 0.40 mm

D 2540 MTEIMLE, D 2542 PATEIMLE

1s t ring
keystone-type ring: height .............................................. 3.075 to 3.095 mm
axial play ........................................ 0.090 to 0.1 40 mm
ring gap .......................................... 0.35 to 0.55 mm
2nd and 3rd ring
taper face ring: height ............................................. 2.978 to 2.990 mm
axial play ....................................... 0.050 to 0.082 mm
ring gap .......................................... 0.45 to 0.65 mm .
 TESTING AND ADJUSTING VALUES

4th ring
bevelled ring: height ...................................................... 4.978 to 4.990 mm
axial play ................................................ 0.030 to 0.062 mm
ring gap .................................................. 0.25 to 0.40 mm

1st ring
keystone-type ring: height .............................................. 2.575 to 2.595 mm
axial play ................................................ 0.090 to 0.1 40 mm
ring gap ................................................... 0.45 to 0.65 mm
2nd ring
taper face scraper ring: height ......................................... 2.978 to 2.990 mm
axial play ................................................. 0.050 to 0.082 mm
ring gap: TevesIGoetze ............................ 0.40 to 0.65 mm
Riken ....................................... 0.40 to 0.60 mm
3rd ring
bevelled ring: height ...................................................... 4.978 to 4.990 mm
axial play ................................................. 0.030 to 0.062 mm
ring gap .................................................... 0.25 to 0.40 mm

1st ring
keystone-type ring: height .............................................. 3.075 to 3.095 mm
axial play (Mahle-Kolben)............... 0.100 to 0.1 50 mm
axial play (Alcan-Kolben)................ 0.1 10 to 0.1 30 mm
ring gap ............................................ 0.45 to 0.70 mm
2nd ring
taper face ring: height .............................................. 2.978 to 2.990 mm
axial play ......................................... 0.050 to 0.082 mm
ring gap ............................................ 0.45 to 0.70 mm
3rd ring
bevelled ring: height ............................................... 5.478 to 5.490 mm
axial play .......................................... 0.030 to 0.062 mm
ring gap ............................................. 0.35 to 0.55 mm

1st ring
keystone-type ring: height .............................................. 3.075 to 3.095 mm
axial play (Mahle-Kolben) ............... 0.1 00 to 0.1 50 mm
axial play (Alcan-Kolben)................ 0.1 10 to 0.1 30 mm
ring gap ............................................ 0.35 to 0.55 mm
2nd ring
taper face ring: height .............................................. 2.978 to 2.990 mm
axial play ......................................... 0.050 to 0.082 mm
ring gap ............................................ 0.45 to 0.70 mm
3rd ring
bevelled ring: height ...............................................4.978 to 4.990 mm
axial play .......................................... 0.030 to 0.062 mm
ring gap ............................................. 0.25 to 0.40 mm

Piston ring wear limits (for all piston rings)

max. ring gap .................................... 1.5 mm

Piston pin diameter ................................................................... 45.994 to 46.000 mm

209 TESTING AND ADJUSTING VALUES
CONNECTING RODS
Piston pin bushing inside diameter .......................................... 46.055 to 46.065 mm
Piston pin radial play in connecting rod .................................. 0.055 to 0.071 mm
Conrod width at small end ...................................................... 35.341 to 35.380 mm (dia.35.5c 8)
Conrod crank pin width .......................................................... 71.000 to 71 .I20 mm (71 H 10)
Conrod axial play .................................................................... 0.240 to 0.438 mm
Conrod bearing radial play ...................................................... 0.058 to 0.1 24 mm
Bearing shell bore in connecting rod ....................................... 95.000 t o 95.022 mm (dia. 95 H 61
Spread of conrod bearing shells (new bearing shells only)
Glyco .................................................................................. 0.6 to 1.5 mm
Miba ................................................................................... 0.5 to 1.4 mm

Spread distance
Glyco ..................................................................................95.6 to 9.6.5 mm
Miba .................................................................................... 95.5to96.4mm

Bearing inside bore in installed condition

D 25. . M- and D 28. . LE-Engines
N ......................................................................................... 90.064 to 90.106 mm
N I .......................................................................................89.964 to 90.006 mm
Rep. 1 ................................................................................. 89.814 to 89.856 mm
Rep. 2 ................................................................................. 89.564 to 89.606 mm
Rep. 3 ................................................................................. 89.314 to 89.356 mm
Rep. 4 ................................................................................. 89.064 t o 89.106 mm
Wall thickness of connecting rod bearing shells
standard size ....................................................................... 2.463 to 2.473 mm
standard size 1 (0.10 mm oversize) ...................................... 2.51 3 to 2.523 mm
oversize 0.25 mm ................................................................ 2.588 to 2.598 mm
oversize 0.50 mm ................................................................ 2.71 3 to 2.723 mm
oversize 0.75 mm ................................................................ 2.838 to 2.848 mm
oversize 1.OO mm ................................................................ 2.963 to 2.973 mm

Bearing bore in installed condition

D 28. . M-Engines
Glyco
standard size .................................................................... 90.075 to 90.1 20 mm
standard size I .................................................................. 89.975 to 90.020 mm
Rep. 1 .............................................................................. 89.825 to 89.870 mm
Rep. 2 .............................................................................. 89.575 to 89.620 mm
Rep. 3 .............................................................................. 89.325 to 89.370 mm
Rep. 4 ..............................................................................89.075 to 89.1 20 mm
Miba
standard size .................................................................... 90.058 to 90.104 mm
standard size I ..................................................................89.958 to 90.004 mm
Rep. 1 .............................................................................. 89.808 to 89.854 mm
Rep. 2 .............................................................................. 89.558 to 89.604 mm
Rep. 3 ...........................................................................89.308 to 89.354 mm
Rep. 4 .............................................................................. 89.058 t o 89.104 mm

Thickness of connecting rod bearing shells

standard size
Glyco .............................................................................. 2.461 to 2.473 mm
Miba .................................................................................2.462 to 2.472 mm
standard size 1 (0.10 mm oversize)
Glyco ............................................................................... 2.510 to 2.522 mm
Miba ................................................................................ 2.512 to 2.522 mm
oversize 0.25 mm
Glyco ............................................................................... 2.585 to 2.597 mm
Miba ................................................................................2.587 t o 2.597 mm
 TESTING AND ADJUSTING VALUES

oversize 0.50 mm
Glyco .............................................................................. 2.710 to 2.722 mm
Miba ................................................................................ 2.712 to 2.722 mm
oversize 0.75 mm
Glyco ............................................................................... 2.835 to 2.847 mm
Miba ................................................................................. 2.837 to 2.847 mm
oversize 1.OO mm
Glyco ............................................................................... 2.960 to 2.972 mm
Miba ................................................................................ 2.962 to 2.972 mm

Max. difference in weight per conrod set ................................. 50 g

Bearing basic bore:

max. deviation of bore perpendicular to supporting surface . 0.035 mm
max. deviation of bore parallel to piston pin inside bore 0.02 mm .....

CRANKSHAFT
Case bore for main bearing ..................................................... 111.000 to 111.022 mm (dia. 111 H 6)
Permissible centre deviation (runout) ..................................... 0.03 mm
Fillet radius on crank pin ....................................................... 3.5 to 4.0 mm
Fillet radius on main bearing journals .................................... 3.5 t o 4.0 mm
Peak to valley depth of journals and crank pins ......................
P P
0. 002 to 0. 04 mm

Main bearing journal diameter

standard size ....................................................................... 103.98 to 104.00 mm
standard size 1 0.10 mm ..................................................... 103.88 to 103.90 mm
1st undersize 0.25 mm . (equalling N II)............................. 103.73 to 103.75 mm
2nd undersize 0.50 mm ...................................................... 103.48 to 103.50 mm
3rd undersize 0.75 mm ....................................................... 103.23 to 103.25 mm
4th undersize 1.OO mm ....................................................... 102.98 to 103.00 mm

Thrust bearing journal length

standard size ..................................................................... 38.000 to 38.062 mm
repair sizes 1 and 2 .............................................................. 38.500 to 38.562 mm
repair sizes 3 and 4 .............................................................. 39.000 to 39.062 mm

Crank pin diameter

standard size ....................................................................... 89.98 to 90.00 mm
standard size 1 0.1 0 mm ..................................................... 89.88 to 89.90 mm
1st undersize 0.25 mm (equalling N 11) ................................ 89.73 to 89.75 mm
2nd undersize 0.50 mm ....................................................... 89.48 to 89.50 mm
3rd undersize 0.75 mm ........................................................ 89.23 to 89.25 mm
4th undersize 1.00 mm ........................................................ 88.98 to 89.00 mm

Crank pins
max. permissible out-of-roundness....................................... 0.01 mm
max. permissible taper ....................................................... 0.005 mm

Max. permissible runout with crankshaft taken up in end bearings

10 cylinder engines
a t bearings 3 and 4 ........................................................... 0.06 mm
12 cylinder engines
a t bearing 4 ......................................................................
0.08 mm
21 1 TESTING AND ADJUSTING VALUES 21 1

Crank pin nominal diameter for front bearing race .................. 99.985 to 100.020 mm (dia. 100 j 7)
Inside diameter of bearing race ................................................ 99.907 to 99.942 mm (dia. 100 S 7)
Overlap ..................................................................................... 0.043to0.113mm

Thrust bearing shell width

standard size - standard I ................................................... 37.74 to 37.81 mm
oversize 0.25 and 0.50 mm ................................................. 38.24 to 38.31 mm
oversize 0.75 and 1 .OO mm ................................................. 38.74 to 38.61 mm

Axial play of crankshaft .......................................................... 0.190 to 0.322 mm

Wall thickness of main and thrust bearing.shells

D 2542 MTE, D 2542 MLE, D 2842 LE
standard size ....................................................................... 3.455 to 3.467 mm
standard size 1 (0.10 mm oversize) ....................................... 3.505 to 3.51 7 mm
standard size 0.25 mm ......................................................... 3.580 to 3.592 mm
standard size 0.50 mm ......................................................... 3.705 to 3.7 17 mm
standard size 0.75 mm ......................................................... 3.830 to 3.842 mm
standard size 1 .OO mm ......................................................... 3.955 to 3.967 mm

Bearing bore in installed condition

standard size ......................................................................... 104.066 to 104.1 12 mm
standard size I ....................................................................... 103.966 to 104.012 m m
repair stage 1 ........................................................................ 103.816 to 103.862 mm
repair stage 2 ........................................................................103.566 t o 103.612 mm
repair stage 3 .......................................................................
103.316 t o 103.362 mm
repair stage 4 ....................................................................... 103.066 to 103.112 mm

Main and thrust bearing radial play .......................................... 0.066 to 0.1 32 mm

Spread of main bearing shells ................................................... 0.3 to 1.2 mm
Spread of thrust bearing shells ................................................. 0.1 to 0.5 mm

Wall thickness of main and thrust bearing shells

D 2530 MEIMTE, D 2540 MTEIMLE, D 2542 ME, D 2840 ME, D 2840 LE
D 2842 ME
standard size
Glyco .............................................................................. 3.455 to 3.467 mm
Miba ................................................................................ 3.456 to 3.468 mm
standard size 1 0.10 mm oversize
Glyco ............................................................................. 3.505to3.517mm
Miba ............................................................................... 3.506 to 3.51 8 mm
oversize 0.25 mm
Glyco .............................................................................. 3.580 to 3.592 mm
Miba ............................................................................. 3.581 to 3.593 mm
oversize 0.50 mm
Glyco .............................................................................. 3.705 to 3.717 mm
Miba ................................................................................ 3.706 to 3.718 mm
oversize 0.75 mm
Glyco ............................................................................... 3.830 to 3.842 mm
Miba .................................................................................3831 to 3.843mm
oversize 1 .OO mm
Glyco ............................................................................... 3.955 to 3.967 mm
Miba ................................................................................. 3.956 to 3.968 mm
212 TESTING AND ADJUSTING VALUES

Bearing bore in installed condition

standard size
Glyco .............................................................................. 104.066to 104.112mm
Miba ................................................................................ 104.068to 104.114mm
standard size I
Glyco .............................................................................. 103.966 to 104.012 mm
Miba ............................................................................... 103.968 to 104.014 mm
repair stage 1
Glyco ...............................................................................103.816 to 103.862 mm
Miba ................................................................................. 103.818 to 103.864 mm
repair stage 2
Glyco ............................................................................... 103.566 to 103.612 mm
Miba .................................................................................103.568 to 103.614 mm
repair stage 3
Glyco ............................................................................... 103.316 t o 103.362 mm
Miba .................................................................................. 103.318 to 103.364 mm
repair stage 4
Glyco ................................................................................103.066 to 103.1 12 mm
Miba ..................................................................................103.068 t o 103.1 14 mm

Main and thrust bearing radial play

Glyco .....................................................................................0.066 to 0.1 32 mm
Miba ....................................................................................0.068to0.134mm

Spread of main bearing shells

Glyco .....................................................................................0.3 to 1.2 mm
Miba .....................................................................................0.5 to 1.4 mm
.
Spread of thrust bearing shells
Glyco .................................................................................. 0.1 to 0.5 mm
Miba .....................................................................................0.3 to 0.6 mm

FLYWHEEL

Diameter of starter gear ring spigot .......................................... 432.490 to 432.645 mm (dia. 432 u 9)
Starter gear ring, inside diameter ........................................ 432.000 to 432.1 55 mm (dia. 432 H)
Interferenax .............................................................................. 0.335 to 0.845 mm
Installation temperature ............................................................200 to 230 C

Max. permissible axial runout after installation:

flywheel, ZF transmission (fluid coupling) ........................... 0.3 mm
all others ..............................................................................0.5 mm

Wearing ring seat, diameter ....................................................... 114.980 t o 115.01 5 mm

Max. amount of stock that can be removed from clutch face

in remachining (only with Allison CL BT 750 transmission)
max..................................................................................... 2.0mm
dimension a, new .................................................................62 mm
.
213 TESTING AND ADJUSTING VALUES

CYLINDER HEADS AND VALVES

Thickness of cylinder head gasket

before installation approx. ...................................................1.6 to 1.7 mm
after installation ...................................................................1.163 to 1.297 mm
Cutout for combustion chamber in cylinder head gasket
10 and 12 cylinder engines D 28 ........................................ 144.5 to 145.0 mm dia.
10 and 12 cylinder engines D 25. . with
thick walled liners ............................................................ 144.5 to 145.0 mm dia.
10 and 1.2 cylinder engines D 25 . with .
standard liners ..................................................................141.0 to 141.5 mm dia.

Cylinder head height (observe specified recess dimensions

for injectors and valves)
standard ...............................................................................113.9 to 114.0 mm
minimum .............................................................................112.9 mm

Roughness height of cylinder head and crankcase mating

surfaces ................................................................................0.008to0.016 mm

Valve recess ..............................................................................

0.7 to 1.3. mm
Valve head diameter
intake, D 2530 ME, D 2542 ME, D 2840 ME, D 2842 ME ( * 57.85 to 58.15 mm
intake, D 2530 ME, D 2542 ME, D 2840 ME, D 2842 ME 56.85 to 57.15 mm
intake (all other) ................................................................... 57.85 to 58.1 5 mm
exhaust (all other) ................................................................. 50.9 to 51.1 mm

Valve head height

intake, D 2530 ME, D 2542 ME, D 2840 ME, D 2842 ME 3.2 to 3.3 mm
intake (all other) ................................................................... 3.4 to 3.5 mm
exhaust (all other) ................................................................. 3.0 to 3.1 mm

Valve seat insert bore in cylinder head

standard
intake ..............................................................................61.OO to 61.03 mm
exhaust ............................................................................53.00 to 53.03 mm
standard I
intake ..............................................................................61.20 to 61.23 mm
exhaust ............................................................................53.20 to 53.23 mm

Valve seat insert bore depth

N .........................................................................................12.5 to 12.6 mm
N I .......................................................................................12.7to 12.8 mm

Valve seat insert outside diameter

intake N ........................................................................61.10 to 61.1 1 mm
N I .....................................................................61.30 to 61-31 mm
exhaust N .......................................................................53.1 0 to 53.1 1 mm
N I ..................................................................... 53.30 to 53.31 mm

Valve seat angle

D 2530 ME, D 2542 ME, D 2840 ME, D 2842 ME
intake 1 exhaust ................................................................... 45'
all other
intake .................................................................................. 30'
exhaust ................................................................................ 45'
Valve stem diameter
intake .................................................................................. 11.969 to 11.980 mm
exhaust ............................................................................. 11.944 to 11.955 mm

( * = only installed up to engine number ... 3921 ... This valve is no longer available.
Replace by new valve.
214 TESTING AND ADJUSTING VALUES

Valve guide bore diameter (installed) ...................................... 12.000 to 12.018 mm

Valve radial clearance
intake .................................................................................. 0.020 to 0.049 mm
exhaust ................................................................................ 0.045 to 0.074 mm
Max. wear limit ........................................................................ 0.1 mm

Valve guide bore in cylinder head

N .......................................................................................... 18.000 to 18.018 mm (dia. 18 H 7)
N I ....................................................................................... 18.250 to 18.271 mm (dia. 18.25 H 7)

Valve guide outside diameter

N .......................................................................................... 18.028 to 18.046 mm (dia. 18 s7)
N I ........................................................................................ 18.285 to 18.306 mm (dia. 18.25 s 7)

lnterference
N ........................................................................................... 0.010 to 0.046 mm
N I ....................................................................................... 0.014 to 0.056 mm

Max. runout, valve guide relative to valve seat .......................... 0.04 mm

Valve guide protection above valve spring seat level ................. 17.1 to 17.5 mm

Valve lift (intake)

D2530ME, D2542ME, D2840ME, D2842ME .................. 14.11 mm
valve lift (intakelexhaust for all) .................................... 14.00 mm

Valve springs
Inner spring
free length, approx. ............................................................. 65.5 mm
spring force a t 46.3 mm ...................................................... 128 to 152 Nm
spring force a t 32.3 mm ...................................................... 255 to 294 Nm
Outer spring
free length, approx. ............................................................. 59 or 64 mm
spring force a t 46.8 mm ...................................................... 324 to 353 Nm
spring force at 32.8 mm ...................................................... 696 to 755 Nm

TIMING

Rocker arm bore .................................................................... 25.005 to 25.021 mm

Rocker arm bearing journal dia. .............................................. 24.967 to 24.980 mm (dia. 25 f 6)
Rocker arm radial play ............................................................ 0.025 to 0.054 mm
max. wear limit ................................................................... 0.08 mm

Max. runout of push rods ........................................................ 0.5 mm

Casing bore for valve tappets

N ......................................................................................... 20.000 to 20.021 mm (dia. 20 H 7)
N I ...................................................................................... 20.250 to 20.271 mm (dia. 20.25 H 7)

Valve tappet stem, outside diameter

N .......................................................................................... 19.944 to 19.965 mm
N I ....................................................................................... 20.194 to 20.215 mm

Valve tappet clearance .............................................................. 0.035 to 0.077 mm

215 TESTING AND ADJUSTING VALUES

Camshaft bush, inside diameter

70 cylinder engines
bearings 1 to 5 ..................................................................... 70.000 to 70.030 mm
bearing 6 ............................................................................70.070 to 70.090 mm
12 cylinder engines
bearings 1 to 6 .....................................................................70.000 to 70.030 mm
bearing 7 ..............................................................................70.070 to 70.090 mm

Camshaft diameter ...................................................................69.910 to 69.940 mm (dia. 70 e 7)

Camshaft radial runout
bearing 1 to 5 or 1 to 6 ........................................................ 0.060 to 0.120 mm
bearing 6 or 7 ....................................................................... 0.1 30 to 0.1 60 mm

Camshaft axial play ..................................................................0.20 to 0.90 mm

max. wear limit .................................................................... 1.5 mm

Thickness of thrust washer ...................................................... 5.95 to 6.00 mm

Backlash between
crankshaft gear and camshaft gear ....................................... 0.1 2 to 0.24 mm
intermediate gear and injection pump gear .......................... 0.10 to 0.34 mm

Valve clearance (adjust on cold engine)

intake .................................................................................. 0.25mm
exhaust ................................................................................ 0.40 mm

Timing, degree crankshaft angle

D 2530 ME
intake opens ....................................................................... 16O before TDC
intake closes ....................................................................... 50' after BDC
exhaust opens ................................................................... 44' before BDC
exhaust closes ..................................................................... 10' after TDC
D 2542 ME, D 2840 ME, D 2842
intake opens ........................................................................ 12' before TDC
intake closes ........................................................................ 48' after BDC
exhaust opens .....................................................................61' before BDC
exhaust closes ...................................................................... 11' after TDC
D 2530 MTE, D 2540 MTEIMLE, D 2542 MTEIMLE , D 2840 LE, D 2842 LE
intake opens ....................................................................... 24' before TDC
intake closes ........................................................................ 36' after BDC
exhaust opens ..................................................................... 63' before BDC
exhaust closes ...................................................................... 27' after TDC

Start of delivery ....................................................................... see Operating Instructions

CHECKING COMPRESSION PRESSURE

Good ....................................................................................... above 28 bar

Acceptable ............................................................................... 25 to 28 bar
Reconditioning necessary ......................................................... below 24 bar

Max. pressure difference ........................................................... 4 bar

216 TESTING AND ADJUSTING VALUES

ENGINE LUBRICATION

Valve opening pressures

bypass valve for full flow oil filter ....................................... 2.2 to 2.8 bar
short circuit valve in oil cooler ............................................ 4.5 to 5.5 bar
pressure relief valve on oil pump ......................................... 9 toid0 tjsr
pressure valve of oil jets
opening pressure ............................................................. 1.6 to 1.9 bar
closing pressure ............................................................... 1.3 t o 1.6 bar

Nozzle diameter of oil jets

D 2530 ME, D 2542 ME, D 2840 ME, D 2842 ME ............. 1.OO to 1.20 mm
and ................. 1.75to1.85mm
D 2530 MTE, D 2540 MTEIMLE, D 2542 MTEIMLE ........ 1.OO to 1.20 mm
and ................. 1.60 to 1.70 mm

Oil pumps

Standard version (one pump)

D 2530 MEIMTE, D 2540 MTEIMLE, D 2542 ME, D 2840 ME,

D 2842 ME, D 2840 LE
housing depth ...................................................................... 43.000 to 43.039 mm (43 H 8)
gear width ,a" ..................................................................... 42.91 1 to 42.950 mm (43 e 8)
gear axial play ..................................................................... 0.050 to 0.1 28 mm
shaft projection ,,x" ............................................................. 11.5 mm

pressing force ..................................................................... 15 500 N (1550 kgf)

shaft diameter ..................................................................... 21.93 to 21.94 mm
oil pump cover bore ............................................................ 22.000 to 22.021 mm (dia. 22 H 7)
radial clearance ................................................................... 0.060 t o 0.091 mm
bore in drive gear ................................................................. 21.870 to 21.885 mm
pressing force (drivegear onto shaft) ................................... 12000 N (1200 kgf)

Standard version (one pump)

D 2530 ME, D 2840 ME (up t o engine No. ... 4568 ....)

housing depth ...................................................................... 38.000 to 38.039 mm (38 H 8)
gear width ,a" .................................................................. 37.91 1 to 37.950 mm (38 e 8)
gear axial play .................................................................... 0.050 to 0.1 28 mm
217 TESTING AND ADJUSTING VALUES

shaft projection ,,xu ............................................................ 14.5 mm

pressing force .......................................
.............................. 10 000 N (1000 kgf)
shaft diameter ...................................................................... 17.930 to 17.940 mm
oil pump cover bore ............................................................. 18.000 to 18.018 mm (dia. 18 H 7)
radial clearance ..................................................................... 0.060 to 0.088 mm
bore in drive gear .................................................................. 17.885 to 17.900 mm
pressing force (drive gear onto shaft) .................................... 10 000 N (1000 kgf)

Tandem pumps
D 2530 MEIMTE, D 2540 MTEIMLE, D 2840 ME ,D 2840 LE
housing depth ..................................................................... 43.000 to 43.039.mm (43 H 8)
gear width ,,a" .................................................................... 42.91 1 to 42.950 mm (43 e 8)
gear axial play ..................................................................... 0.050 to 0.1 28 mm

shaft projection ,,xu ............................................................ 11.5 mm

shaft projection ,,y" ............................................................ 42.0 mm
pressing force ...................................................................... 15 500 N (1550 kgf
shaft projection in intermediate gear
(on side of circlip groove) .................................................. 61.0 mm
pressing force ....................................................................... 12 000 N (1200 kgf)
shaft diameter ...................................................................... 21.93 to 21.94 mm
bore in housing cover .......................................................... 22.000 to 22.021 mm (dia. 22 H 7)
radial play ............................................................................ 0.050 to 0.1 28 mm
bore in drive gear ................................................................. 21.870 to 21.885 mm
pressing force (drive gear on shaft) ...................................... 12 000 N (1200 kgf)

Tandem pumps
D 2542 MTEIMLE, D 2842 LE
housing depth ...................................................................... 28.000 to 28.033 mm (28 H 8)
gear width ,,a" ..................................................................... 27.927 to 27.960 mm (28 e 8)
gear axial play ...................................................................... 0.040 to 0.106 mm

. -.

t-t
218 TESTING AND ADJUSTING VALUES

shaft projection ,,x" ............................................................ 14.5 mm

shaft projection ,,y" ............................................................. 41.0 mm
pressing force .........;............................................................. 8200 N (820 kgf)
shaft1projection in intermediate gear (on side of
circl ip groove) ...................................................................... 54.0 mm
pressing force ....................................................................... 10 000 N (1000 kgf)
shaft diameter ...................................................................... 17.930 to 17.940 mm
bore in housing cover ........................................................... 18.000 to 18.018 mm (18 H 7)
radial clearance .................................................................... 0.060 to 0.088 mm
boreindrivegear ................................................................. 18.10to18.15mm
pressing force (drive gear onto shaft) ................................... 10 000 N (1000 kgf)

Delivery rate of oil pumps (with SAE 10 oil, a t 5 0 ' ~and p = 4 bar)

Oil pumps with 28 mm wide gears

a t n = 600 rpm .................................................................... 25 Ilmin
at n = 2440 rpm .................................................................. 113.5 Ilmin

Oil pumps with 38 mm wide gears

a t n = 600 rpm .................................................................... 33 Ilmin
at n = 2440 rpm .................................................................. 155 Ilmin

Oil pumps with 43 mm wide gears

a t n = 600 rpm .................................................................... 37 Ilmin
at n = 2440 rpm .................................................................. 175 Ilmin

COOLING SYSTEM

Water pump (engine)

D 2530 MEIMTE, D 2542 ME, D 2840 ME

impeller diameter ................................................................ 125 mm
gap between housing and impeller ...................................... 0,5 to 0,9 mm

D 2540 MTEIMLE, D 2842 ME (D 2840 LE to 1800 rpm)

impeller diameter .............................................................. 136 mm
gap between housing and impeller ....................................... 0,5 to 0,9 mm

D 2542 MTEIMLE (D 2840 LE above 1801 rpm)

impeller diameter ............................................................. 150 mm
gap between housing and impeller ....................................... 0.3 t o 0.6 mm

Bore for bearing shaft in impeller ............................................ 16.000 to 16.018 mm (dia. 16 H 7)

Diameter of bearing shaft ........................................................ 16.045 to 16.056 mm (dia. 16 x 6)
Interference ............................................................................. 0.027 t o 0.056 mm
Bearing seat in housing ............................................................ 54.940 to 54.970 rnm (dia. 55 R 7)
Bearing diameter ...................................................................... 54.981 to 55.000 mm (dia. 55 h 6)
Interference ............................................................................. 0.01 1 to 0.060 mm
H u b bore .................................................................................. 25.000 to 25.021 mm (dia. 25 H 7)
Diameter of bearing shaft ........................................................ 25.048 to 25.061 mm (dia. 25 u 6)
Interference ........................................................................... 0.027 to 0.061 mm

Water pump for intercooler

impeller diameter ................................................................ 114.8 mm
gap between impeller and housing ....................................... 0.4 mm
219 TESTING AND ADJUSTING VALUES 219
.

Bearing seat in housing ........................................................... 46.980 to 46.996 mm (dia. 47 M 6)

~

Ball bearing outer diameter ..................................................... 47.000 mm

Shaft diameter ........................................................................ 19.987 to 20.000 (dia. 20 h 6)

Ball bearing internal diameter .................................................. 20.000 mm

Thermostats
opening start ........................................................................ 7 9 ' ~

Compensation tank and heat exchanger

cover with relief valve
valve opens at ................................................................. 0.85 to 1.20 bar
pressure cap with valves
operating pressures
positive pressure ......................................................... 0.6 to 0.8 bar
negative pressure ........................................................ 0.1 bar

TURBOCHARGER

Manufacturer KKK

Type for D 2530 MTE

with watercooled exhaust manifold and constant speed
n=1500rpm ...................................................................... 3LEP-289A9.1
with non-cooled exhaust manifold and constant speed,
n = 1500 rprn and with watercooled exhaust manifold
and speed up to n = 1800 rpm ............................................ 3 LEP - 289 A 11.1
with non-cooled exhaust manifold and speeds up to
n = 1800 rprn and with watercooled exhaust manifold
and speeds with n = 1801 to 2300 rpm .............................. 3 LEP - 289 A 16.1

Type for D 2540 MTE

with watercooled exhaust manifold and speeds
upton=1800rpm ........................................................... K283264NC12.12
with uncooled exhaust manifold and speeds up t o
n = 1800 rprn and with watercooled exhaust manifold
and speeds of n = 1801 to 2300 rpm .................................. K 28 3264 NC 14.12
with non-cooled exhaust manifold and speeds of
n = 1801 to 2300 rpm ........................................................ K 28 3264 NC 19.1 2

Type for 2540 MLE

with watercooled exhaust manifold and speeds up to
n = 1500rpm ...................................................................... K 2 8 3264NC 12.12
with non-cooled exhaust manifold and speeds up to
n = 1800 rprn and with watercooled exhaust manifold
and speeds of 1500 to 2300 rpm ........................................ K 28 3264 NC 17.1 2
with non-cooled exhaust manifold and speeds above
n = 1801 to 2300 rpm ......................................................... K 28 3264 NC 19.12
Type for D 2542 MTE
with watercooled exhaust manifold and speeds up to
n = 1500 rpm ...................................................................... 4 LGZ 352 C 13.22
with watercooled exhaust manifold and speeds of
n = 1500 to 2300 rpm ........................................................ 4 LGZ 352 C 17.22
with non-cooled exhaust manifold and speeds up to
n = 1800 rpm ..................................................................... 4 LGZ 352 C 25.22
with non-cooled exhaust manifold and speeds of
n = 1801 to 2300 rpm ........................................................ 4 LGZ 352 C 27.22
220 TESTING AND ADJUSTING VALUES

Type for D 2542 MLE

with watercooled exhaust manifold and speeds up to
n = 1500 rpm ...................................................................... 4 LGZ 352 C 13.22
with watercooled exhaust manifold and speeds up to
n = 1800 rpm ................................................................... 4 LGZ 352 C 17.22
with nonqooled exhaust manifold and speeds up to
n = 1800 rprn and with watercooled exhaust manifold
and speeds up to n = 2300 rpm ........................................... 4 LGZ 352 C 21.22
with non-cooledexhaust manifold and speeds up to
n = 2300 rpm ...................................................................... 4 LGZ 352 C 25.22
Type for D 2840
with non-cooled exhaust and constant speed
n = 1500 llmin ........................................................... .......
K28-3467MOAl17.12
with non-cooled exhaust and constant or variable speed
. above 1500 rpm ................................................................ K 28-3467 MOAl22.12
with water-cooled exhaust manifold and constant or variable
.. speedupton= 1800rpm .................................................... K28-3467MOAl14.12
with water-cooled exhaust manifold and variable speed
above n = 1800 rpm ...........................................................K 28-3467 MOAl19.12
Type for D 2842 LE
with water-cooled exhaust manifold up to 2300 rpm .......... K 361-4067 MN0121.22

Axial play of impeller shaft for

3 LEP .................................................................................. max. 0.1 5 mm
K 28 .................................................................................... max. 0.1 6 mm
4 LGZ ................................................................................. max. 0.20 mm
K 361 ...................................................................................max. 0.1 56 mm
Radial play of impeller shaft for
3 LEP .................................................................................. max.0.65 mm
K 28 .................................................................................. max. 0.46 mm
4 LGZ ................................................................................. max. 0.65-mfl
K 361 ............................................ .................................... max. 0.63

FUEL SYSTEM (BOSCH) lnjectors

Type for D 2530 ME (single-hole nozzles) ............................. DLLA 288589
discharge pressure ................................................................ 175 + 8 bar
Type for D 2530 MTE (single-hole nozzles) ........................... DLLA 27S613
discharge pressure ................................................................ 175 + 8 bar
Type for D 2540 MTE, D 2542 MTE/M~E(single-holenozzles) DLLA 348876
discharge pressure ................................................................ 200 + 8 bar
Type for D 2540 MLE (single-hole nozzles)............................. DLLA 31S915
discharge pressure ................................................................ 220 + 8 bar
Type for D 2542 ME, D 2840 ME, D 2842 ME(single-hole) .... DLLA 34S837
discharge pressure ................................................................ 200 + 8 bar
Type for D 2840 LEI D 2842 LE (four-hole nozzles) with
constant speed n = 1500 rprn and constant or variable
speeds, n = 1800 rpm ...........................................................DLLA 136s 943
discharge pressure ............................................................... 220 + 8 bar
Type for D 2840 LEI D 2842 LE (four-hole nozzles) with
variable speeds, n = 2300 rpm ............................................. DLLA 136s 1002
discharge pressure ................................................................220 + 8 bar
221 TESTING AND ADJUSTING VALUES

Projection above cylinder head contact surface ....................... 1.5 to 2.0 mm

lnjector

Type for D 2540 M LE

f lame-proof design ............................................................... KDAL 80s 25
non-flame-proof design ........................................................ KDAL 80s 27

Type for all other engine models

flame-proof design ............................................................... KDAL 80s 20119
non-flame-proofdesign ....................................................... KDAL 80s 14114

Injection pump (Bosch)

in-line plunger-type injection pump, with tray attachment

Governor
Bosch (centrifugal governor) ................................................ variablespeed governor or
no-loadlmax. speed governor
Barber Colman ....................................................................
electronic speed governor

D 2530 ME
lnjection pump .................................................................. PElOA 95D 52015 L S2362
governor .............................................................................. RQV 750 AB
or
governor .............................................................................. RQV 250 .... 1250 AB 967 R

D 2530 MTE
injection pump .....................................................................
governor ...............................................................................
or
governor ..............................................................................
or
governor ..............................................................................
or
govenor ................................................................................ RQV 250 .... 1250 ABV 14767 D R
or
governor .............................................................................. RQV 250 ....
1150 ABV 15386
or
governor .............................................................................. RQV 250 .... 1250 ABV 15029

D 2540 MTE
injection pump .................................................................... PE10P110A52015 L S850
governor .............................................................................. RQ 750 PA 404-3
or
governor .............................................................................. RCV 250 .... 1150 PA 650
or
governor (dependenton charge-air pressure) ........................ RQV 250 .... 1150 PA 651

D 2540 MLE
injection pump .................................................................... PE 10P 120A 52015 L V15453
governor .............................................................................. RQ 750 PA 663-3
or
injection pump ..................................................................... PElOP 120A 52015 L S850
governor ............................................................................... RQV 250 .... 1150 PA 645
or
governor (dependent on charge-air pressure) ......................... RQV 250 .... 1150 PA 647
 TESTING AND ADJUSTING VALUES

D.2542 ME, D 2842 ME

injection pump ...................................................................
governor .............................................................................
or
governor .............................................................................. RQV 250 .... 1200 PA 644

D 2542 MTE
injection pump ....................................................................
governor ..............................................................................
or
injection pump ...................................................................
governor .............................................................................
or
injection pump ................................................................... PE12P 110A 520 L S839
governor ............................................................................. RQV 250 .... 1150 PA 353 R
or
governor .............................................................................

D 2542 MLE
injection pump ....................................................................
governor ..............................................................................
or
governor ..............................................................................
or
injection pump .................................................................... PE 12P 120A 520 L S836
governor ............................................................................. RQV 250 .... 1150 PA 353 R
or
injection pump ................................................................... PE12P 120A 520 L S ...
governor (dependent on charge-air pressure) ...................... RQV 250 .... 1150 PA 439 R

D 2840 ME
injection pump ................................................................... PE 1OA 95D 52015 L S 2604
governor ............................................................................. ROV 250 .... 1150 A6 1189 R
D 2840 LE
injection pump ...................................................................
governor .............................................................................
or
injection pump ...................................................................
governor .............................................................................

D 2842 LE
..
injection pump .................................................................
governor .............................................................................
or
governor .............................................................................
or
.. ..
governor ..................... ............. ...................................... RQV 250 .... 1150 PA V 17274
or
govenor ...............................................................................
223 TESTING AND ADJUSTING VALUES

Explanation of codes

. Injection pump, e.g. PE 10 A 95 D 520 / 5 L S2501 or

PE 12 P 120 A 520 LS836
PE ....................................................................................... pump with tray attachment
10 and 12 ............................................................................ number of cylinders
A and P: pump size, where .................................................. A = 8 mm plunger stroke
P = 10 mm plunger stroke
95, 110 and 120 .................................................................. plunger dia. in 1/10 mm
D ......................................................................................... change code letter
520 and 52015 .................................................................... assembly code (for identification
of installed position of camshaft,
governor, injection timing adjustor
and fuel lift pump)
direction of camshaft rotation:
L = left-hand
version code for pump size A:
...
S 2000 to = improved pump
design
serial number for pump size P

2. governor, e.g. RQ 750 A B 1015 R or

RQV 250 ... 1150 A B 1067 D R
no load / max. speed governor or
max. speed governor
RQV ................................................................................... variable speed governor
speed range
750 ................................................................................. max. speed governor
250 1 1150 ...................................................................... no load / max. speed governor
250 ... 1150 .................................................................... variable speed governor
A o r P ................................................................................. governor mounted to injection pump
size A or P
change code letter
A = 1st change
1015 and 1067 ................................................................... change code letter
D ........................................................................................ adjustment with spring
L or R ................................................................................ indicates on which side of pump
governor is mounted.
L = left-hand
R = right-hand

ELECTRIC SYSTEM

Starter, Bosch ......................................................................... solenoid-operated

voltage ................................................................................. 24 Volt
rating ................................................................................... 6.5 or 6.6 kW
Alternator ................................................................................ a.c. three-phase
voltage .................................................................................. 28 Volt
current ................................................................................ 27, 35, 55, 60, 85, 180 Ampere
Preheating ................................................................................ 2000 or 3000 W
(220 and 380 V)

AIR COMPRESSOR

Swept volume
singlecylinder air compressor .............................................. 300 cm3
two cylinder air compressor (per cylinder) ........................... 275 cm3
224 TESTING AND ADJUSTING VALUES

Cylinder bore (3 matching stages)

matching stage B .................................................................. 90.00 to 90.01 mm
matching stage C .................................................................. 90.01 to 90.02 mm
matching stage D .................................................................. 90.02 to 90.03 mm

Piston diameter (3 matching stages)

matching stage B
Alcan ............................................................................... 89.890 to 89.900 mm
KS.................................................................................... 89.910 to 89.920 mm
matching stage C
Alcan ............................................................................... 89.900 to 89.910 mm
KS .................................................................................... 89.920 to 89.930 mm
matching stage D
Alcan ................................................................................ 89.910 to 89.920 mm
KS .................................................................................... 89.930 to 89.940 mm
Piston ring groove width
1st, 2nd ring ....................................................................... 2.51 to 2.53 mm
3rd ring
Alcan .............................................................................. 4.01 to 4.03 mm
KS ................................................................................... 4.02 to 4.04 mm
Piston clearance
Alcan ................................................................................... 0.10to0.12mm
KS ........................................................................................0.08 to 0.10 mm
Piston recess from cylinder liner top
single-cylinder air compressor .............................................. 0.4 to 1.2 mm
two-cylinder air compressor ................................................. 1.9 to 2.7 mm
Connecting rod radial clearance ................................................ 0.027 to 0.073 mm

Backlash, air compressor / camshaft drive gear ......................... 0.08 to 0.19 mm

Piston pin bore ....................................................................... 20.003 to 20.008 mm
Piston pin diameter ................................................................. 19.994 to 20.000 mm
Piston pin bush, inside diameter ............................................... 20.020 to 20.033 mm (dia. 20 F 6)

Connecting rod wall thickness .................................................. 2.004 to 2.01 1 mm

Crank pin diameter ................................................................... 31959 to 31.975 mm (dia. 32 f 6)
Rear main bearing journal diameter ........................................ 29.959 to 29.980 mm (dia. 30 f 7)
Rear main bearing bushes, inside diameter ............................... 30.020 to 30.041 mm (dia. 30 F 7)

POWER TAKEOFF (raw water pump / hydraulic pump)

Speed ...................................................................................... 1.075 x engine speed

Bore in bearing housing .......................................................... 79.979 to 80.009 mrn (dia. 80 K7)
Bearing outer diameter ........................................................... 80.000 mm
Bearing inner diameter ............................................................ 40.000 mm
Bearing seat of drive shaft ....................................................... 39.995 to 40.01 1 mm (dia. 40 j 6)
Gap dimension (see chapter ,,power takeoff") ........................ 0.d to 0.2 mm
Outer diameter of bearing housing (fitting diameter a t flange). 92.071 to 92.093 mm (dia. 92 s 6)
Bore in timing case .................................................................. 92.000 to 92.035 mm (dia. 92 H 7)
lnterference ............................................................................. 0.036 to 0.093 mm
225 TIGHTENING TORQUE GUIDE VALUES 225

NOTE: All threaded fasteners the use of which i s not listed in the following table, must be tightened
to the guide values specified by M.A.N. Work Standard N 269.
Lightly oil screws before installation.

PLUGS

DIN 980
M 14x1.5M16x1.5 ......................................................... 8 0 N m ( 8kpm)
M 18 x 1.5 M 22 x 1.5 ......................................................... 100 Nm (10 kpm)
M 24x 1.5 M 2 6 x 1.5 ......................................................... 120 Nm (12 kpm)
M 30 x 1.5 .......................................................................... 150 Nm (15 kpm)
DIN 7604
A M l O x l M 1 2 x 1 . 5 ......................................................... 5 0 N m ( 5kpm)
AM 14 x 1.5 ......................................................................... 80 Nm ( 8 kpm)

CRANKCASE, CRANK SHAFT ASSEMBLY

Crankshaft bearing caps to crankcase

a
initial torque ....................................................................... 300 Nm ( 0 kpm)
rotation angle ...................................................................... 90 to 100
Crankshaft main bearing caps (side) ........................................ 80 Nm (8 kpm)
Cover to crankcase (crankshaft seal, front) .............................. 25 Nm (2.5 kpm)
Thrust washer to timing case .................................................... 40 Nm (4.0 kpm)
Timing case t o crankcase .......................................................... 25 Nm (2.5 kpm)
Counterweight to crankshaft
initial torque ........................................................................ 100 Nm (10 kpm)
rotation angle ....................................................................... 90 t o 100°
Hub to crankshaft .................................................................... 210 Nm (21 kpm)
Vibration damper to hub ......................................................... 60 Nm (6.0 kpm)
Flywheel/gear ring carrier to crankshaft ................................... 260 Nm (26.0 kpm)
Fan damper to crankshaft ........................................................ 22 Nm (2.2 kpm)
Connecting rod bearing caps
initial torque ....................................................................... 100 Nm (10 kpm)
rotation angle ..................................................................... 90 to 10oO

CYLINDER HEAD

Cylinder head to crankcase (torque tightening method)

initial torque (manually) 1st stepl2nd stepl3rd step ........... 10 - 50 - 100 Nm (1 - 5 - 10 kpm)
final torque (manually) ....................................................... 210 to 230 Nm (21 to 23 kpm)

Cylinder head to crankcase (angle of rotation method)

initial torque (manually) 1st step / 2nd step ........................ 80 Nm / 150 Nm
final torque (manually) 1st step / 2nd step .......................... 90' 1 90° to 100°
 TIGHTENING TORQUE GUIDE VALUES

Tightening order for cylinder head screws

Cylinder head cover to cylinder head ...................................... 22 Nm (2.2 kpm)

Rocker arm bracket to cylinder head ...................................... 65 Nm (6.5 kpm)
Locknut on valve adjusting screw ............................................ 50 Nm (5.0 kpm)

LUBRICATION SYSTEM

Oil pump to crankcase ............................................................ 22 Nm (2.2 kpm)

Oil pump cover ....................................................................... 22 Nm (2.2 kpm)
Oil cooler to oil filter head ..................................................... 22 Nm (2.2 kpm)
Filter bowl to oil filter head ................................................... 50 Nm (5 kpm)
Oil pan to crankcase ............................................................... 22 Nm (2.2 kpm)
Plug (oil drain plug) in oil pan'................................................ 80 Nm (8 kpm)
Oil jet to crankcase ................................................................. 70 Nm (7 kpm)

EXHAUST IINTAKE MANIFOLDS

Exhaust manifold to cylinder head (full shank) ..................... according to table

Exhaust manifold to cylinder head (elasticated screws) ......... 40 Nm (4.0 kpm)
Intake pipe to cylinder head .................................................. 22 Nm (2.2 kpm)

FUEL SYSTEM

Injection pump, fuel pipe to injection pump and injector ....... 15 to 25 Nm (1.5 to 2.5 kpm)
lnjection pump to crankcase .................................... ,.. ........... 45 Nm (4.5 kpm)
Nut for hub on injection pump camshaft (ME engines)............ 85 t o 100 Nm (8.5 to 10 kpm)
Nut for hub on injection pump camshaft (MTEIMLE engines) 100 to 110 Nm (10 to 11 kpm)
Drive gear on hub for injection pump ..................................... 35 Nm (3.5 kpm)
Fuelfilter .............................................................................. 80Nm(8kpm)
Pressure screw for injector ..................................................... 65 t o 75 Nm (6.5 t o 7.5 kpm)
227 TIGHTENING TORQUE GUIDE VALUES

STARTER / ALTERNATOR

Starter to timer case ............................................................... 80 Nm (8 kpm)

Alternator bracket to crankcase ............................................... 120 Nm (12 kpm)
V-belt pulley on alternator (thread M 14) ............................... 35 to 45 Nm (3.5 - 4.5 kpm)
V-belt pulley on alternator (thread M 20 and M 24) ................ 120 Nm (12 kpm)

TRANSMITTER

Oil pressure transmitter to crankcase ....................................... 80 Nm (8 kpm)

Temperature transmitter to crankcase ..................................... 20 Nm (2 kpm)

TIMING DEVICES

Adjusting segment t o camshaft gear ......................................... 50 Nm (5 kpm)

Adjusting segment to intermediate gear ................................... 50 Nm (5 kpm)

POWER TAKEOFFS (RAW WATER PUMP 1 HYDRAULIC PUMP)

Oil jet, oil supply to power takeoff ......................................... 80 Nm (8 kpm)

Nut (drive gear and flange) on PTO shaft
(punch lock after final tightening) ........................................... 300 Nm (30 kpm)
Bearing flange to bearing housing
initial torque ...................................................................... 10 Nm (1 kpm)
final torque .......................................................................... 25 Nm (2.5 kpm)

Tightening order for bearing flange nuts

 TIGHTENING TORQUE GUIDE VALUES

AIR COMPRESSOR

Drive gear t o air compressor crankshaft .................................. 360 Nm (36 kpm)

Drive gear to camshaft ............................................................ 65 Nm (6.5 kpm)
Mounting flange (on ball bearing) ........................................... 50 Nm (5 kpm)
Connecting rod bearing cap (air compressor) .......................... 30 Nm (3 kpm)
Cylinder liner to air compressor housing ................................. 40 Nm (4 kpm)
Air compressor cylinder head to cylinder liner ........................ 30 Nm (3 kpm)
Air compressor to crankcase .................................................... 30 Nm (3 kpm)
Threaded connection to cylinder head (air compressor) .......... 100 Nm (10 kpm)
Cover to air compressor housing .............................................. 25 Nm (2.5 kpm)
Cover (gear train) to air compressor ......................................... 25 Nm (2.5 kpm)
Threaded connection cooling water supply / drain, air
compressor .............................................................................. 80 Nm (8 kpm)

SUPERCHARGING

Screws for mounting strap

Compressor /turbine housing (4 L G Z ) .................................. 14 Nm (1.4 kpm)
Shaft nut (4 L G Z, K 361) ...................................................... 27 Nm (2.7 kpm)
Shaft nut (3 L E P) ....................................................................
12 Nm (1.2 kpm)
Shaft nut (K28) initial torque .................................................. 12 Nm (1.2 kpm)
final torque, angle of rotation ........................ 600
Screws in rear wall (K 28, 3L E P) ........................................... 8 Nm (0.8 kpm)
Screws for compressor housing (K 28, 3L E P) ........................ 7 Nm (0.7 kpm)
Screws for turbine housing (K 28, 3 L E P ) ............................ 20 Nm (2.0 kpm)
Nuts on exhaust inlet flange .................................................... 43 Nm (4.3 kpm)
Screws on flange of oil supply line ........................................... 43 Nm (4.3 kpm)
Screws on flanges of oil return line ........................................ 43 Nm (4.3 kpm)
Hose clip for charging system .................................................. 7 Nm (0.7 kpm)
Turbine housing with clamping strap (K 361) .......................... 10 Nm (1.0 kpm)
Compressor housing ( K 361) .................................................. 15 Nm (1.5 kpm)
 TIGHTENING TORQUE GUIDING VALUES

According to Works Standard N 269

Grade 8.8 10.9 12.9

Threads Nm Nm Nm

M 5 5.0 7.5 9.O

M 6 9.O 12.5 15.0

M 7 14.0 19.5 23.5

M 8 22.0 31.O 38.0

M 8x1.0

M 10

M l o x 1.0

M 12

M 12 x 1.5

M 14

M 14x1.5

M 16

M 1 6 x 1.5

M 18

M 1 8 x 1.5

M 20

M 20 x 1.5

M 22

M 2 2 x 1.5

M 24

M 2 4 x 1.5
 RUNNING-IN ENGINE

GENERAL:

Reconditioned engines must be run in. New parts, in particular liners, pistons, piston rings and
bearings will reach the necessary surface finish only after running in.

Running in of the engine should be on a dynamometer. If no test rig is available, the engine can
also be run-in in installed condition.

For running in a special running-in oil (initial operation oil) or standard engine oil (not heavy-
duty oil) should be used.

During running-in the cooling water temperature must be maintained within the most favourable
operating range from 65 to 75'~.

Before running-in make the following operations and checks:

1. Check oil level in engine, injection pump and governor.

2. Check level in cooling system and fuel tank.

3. Clean fuel and oil filters, replace filter elements.

4. Clean air filter and fill with engine oil.

5. Adjust injection pump, governor, injectors and start of de livery (see also Technical Data).

6. Clean fuel strainer of fuel lift pump.

7. Vent fuel system.

AFTER RUNNING-IN:

1. Drain running-in oil (also from oil filter) and fill in heavyduty oil.

2. Replace oil filter paper element.

RUNNING-IN

We recommend to operate new or reconditioned engines at not more than approx. 75 % load but
at varying speed during the first operating hours. Then gradually increase engine load to full load.