TABLE OF CONTENTS

Contents Chapter/page

Table showing allocation of engines ............................................................................................... 1.15 - 1a

Safety instructions .......... ................................................................................................................ 1.20 - 1
Index ............................... ................................................................................................................ 1.31 - 1
Description and distinguishing features........................................................................................... 1.40 - 1a
Engine illustrations ......... ................................................................................................................ 1.60 - 1a
Engine illustrations, longitudinal sections/cross-sections................................................................ 1.70 - 1a
Diagram of the engine lubrication system ....................................................................................... 1.71 - 1
Diagram of the coolant circuit with automatic gearbox.................................................................... 1.71 - 2
Diagram of the turbocharger system with intercooling .................................................................... 1.71 - 3
Diagram of the combined turbocharger system with intercooling ................................................... 1.71 - 4
Diagram of the fuel system.............................................................................................................. 1.71 - 5
Diagram of the flame start system................................................................................................... 1.71 - 6
Diagram showing the timing gears .................................................................................................. 1.71 - 7
Exhaust emissions and limit values on emissions........................................................................... 1.80 - 1
Table of malfunctions and their probable causes............................................................................ 1.90 - 1

In-line injection pump

Checking/setting the start of pumping, in version with pointer on the fuel injection
pump flange .................... ................................................................................................................ 2.11 - 1
Checking/setting the start of pumping, in version without pointer on the fuel injection
pump flange .................... ................................................................................................................ 2.11 - 3
Checking/setting the start of pumping, in-line injection pump with illuminated indicator ................ 2.12 - 1a
Removing and installing the in-line injection pump ......................................................................... 2.21 - 1
Removing and installing the in-line injection pump with illuminated indicator ................................. 2.22 - 1

Injector nozzles
Removing and installing the injector nozzles, 2-valve cylinder head ............................................. 2.30 - 1a
Removing and installing the injector nozzles, 4-valve cylinder head .............................................. 2.31 - 1a
Checking/repairing the injector nozzles........................................................................................... 2.32 - 1a

Flame start system

Removing, installing and repairing the flame start system.............................................................. 2.51 - 1

Cooling system
Filling the cooling system with coolant ............................................................................................ 3.11 - 1a
Coolant expansion tank, repair instructions .................................................................................... 3.11 - 2a
Allocation of filler and screw caps ................................................................................................... 3.12 - 1

Water pump/thermostat
Removing and installing the water pump ........................................................................................ 3.21 - 1
Repairing the water pump ............................................................................................................... 3.22 - 1
Removing and installing the thermostat .......................................................................................... 3.23 - 1

Fan
Fan types and locking devices ........................................................................................................ 3.31 - 1
Hydrostatically driven fan ................................................................................................................ 3.33 - 1

Lubrication system
Changing the oil filter ...... ................................................................................................................ 4.10 - 1
Removing and installing the heat exchanger .................................................................................. 4.20 - 1

RA - A 11 1.30 - 1a
 TABLE OF CONTENTS

Contents Chapter/page

Oil sump/oil pump/oil injector nozzles

Removing and installing the oil sump............................................................................................... 4.31 - 1
Removing, installing, dismantling and assembling the oil pump...................................................... 4.32 - 1
Removing and installing the oil injector nozzles .............................................................................. 4.33 - 1
Removing and installing the PCV valve (crankcase ventilation) ...................................................... 4.34 - 1

Crankcase
Replacing the cap in the crankcase ................................................................................................. 5.11 - 1

Flywheel
Removing and installing the clutch pilot bearing .............................................................................. 5.21 - 1
Removing, installing and repairing the flywheel ............................................................................... 5.22 - 1
Fitting a new flywheel ring gear........................................................................................................ 5.23 - 1

Crankshaft
Fitting a new crankshaft oil seal and front race................................................................................ 5.51 - 1a
Removing and installing the front housing cover ............................................................................. 5.52 - 1
Fitting a new (back) crankshaft oil seal on the flywheel end............................................................ 5.53 - 1
Removing and installing the timing chain housing; checking the camshaft end play ...................... 5.54 - 1a
Removing, installing, dismantling and assembling the mass compensation gearbox ..................... 5.55 - 1
Removing and installing the crankshaft ........................................................................................... 5.56 - 1

Piston/connecting rod
Removing and installing a piston with its connecting rod................................................................. 5.61 - 1a
Measuring piston protrusion............................................................................................................. 5.62 - 1
Fitting new piston rings.... ................................................................................................................ 5.63 - 1
Removing a piston from its connecting rod and fitting it back on..................................................... 5.64 - 1
Fitting a new big end bearing ........................................................................................................... 5.65 - 1a

Cylinder liners
Removing and installing cylinder liners / measuring protrusion ....................................................... 5.71 - 1

Intake/exhaust manifold
Removing and installing the intake manifold.................................................................................... 6.11 - 1
Removing and installing the exhaust manifold................................................................................. 6.21 - 1a

Turbocharger
Turbocharger, troubleshooting, checks before replacing................................................................. 6.31 - 1
Checking the boost pressure ........................................................................................................... 6.32 - 1
Turbocharger, removing and installing............................................................................................. 6.33 - 1
Note regarding the boost pressure regulating valve (waste gate) ................................................... 6.33 - 4
Measuring the end/radial play of the turbine/rotor shaft................................................................... 6.34 - 1

Rocker arm mechanism

Removing and installing the rocker arm mechanism, 2-valve cylinder head ................................... 7.11 - 1a
Dismantling/assembling the rocker arm mechanism, 2-valve cylinder head .................................. 7.12 - 1a
Removing and installing the rocker arm, 4-valve cylinder head ..................................................... 7.12 - 2a

1.30 - 2a RA - A 11
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Contents Chapter/page

Setting the valve clearance

Setting the valve clearance in 5-cylinder engines ........................................................................... 7.13 - 1a
Setting the valve clearance in 6-cylinder engines with 2-valve cylinder heads .............................. 7.13 - 2a
EVB = Exhaust Valve Brake for 2-valve cylinder heads ................................................................. 7.13 - 3a
Setting the valve clearance in 6-cylinder engines with 4-valve cylinder heads and EVB .............. 7.14 - 1a
Alternative valve setting method for D 2866.. and D 2876.. .......................................................... 7.15 - 1a

Cylinder head/control
Removing and installing the 2-valve cylinder head ......................................................................... 7.20 - 1a
Removing and installing the 4-valve cylinder head ........................................................................ 7.21 - 1a
Checking the cylinder head for cracks ............................................................................................ 7.22 - 1
Tightening and re-tightening the cylinder head bolts....................................................................... 7.23 - 1a
Checking the combustion pressure, 2-valve cylinder head............................................................. 7.24 - 1a
Checking the combustion pressure, 4-valve cylinder head............................................................. 7.24 - 2a

Valves
Removing and installing the valves, 2-valve cylinder head ............................................................ 7.30 - 1a
Removing and installing the valves, 4-valve cylinder head ............................................................ 7.31 - 1a
Removing and installing the valve guide ......................................................................................... 7.32 - 1
Turning the valve seats ................................................................................................................... 7.33 - 1
Regrinding the valves ...................................................................................................................... 7.34 - 1
Fitting a new valve seat ring ............................................................................................................ 7.35 - 1

Control/camshaft
Removing and installing the camshaft, fitting new camshaft bearings............................................ 7.51 - 1
Checking the valve timing................................................................................................................ 7.52 - 1a

Add-on units
Dismantling and repairing (assembling) the air compressor ........................................................... 8.11 - 1

V-belts
Checking the V-belt tension............................................................................................................. 8.41 - 1

Notes on installation ........................................................................................................................ 8.99 - 1

Technical Data
Table of contents ............................................................................................................................. 9.00 - 2a
Type designations, explanations ..................................................................................................... 9.11 - 1a
Characteristic data........................................................................................................................... 9.12 - 1a
Table of engine settings (type, power, start of pumping, nozzles, exhaust emissions test data) ... 9.13 - 1a
Checking and setting values used in chapters 2.11 to 8.99............................................................ 9.21 - 1a
Reference torques used in chapters 2.11 to 8.99 ........................................................................... 9.51 - 1a
Standard torque tightening values................................................................................................... 9.53 - 1a
Running in the engine...................................................................................................................... 9.61 - 1a

Special tools
Special tools used in chapters 2.11 to 8.99..................................................................................... 9.71 - 1
Do-it-yourself special tools .............................................................................................................. 9.73 - 1

RA - A 11 1.30 - 3a