D7D Engine Shop Manual For EC290&240

EC290B/240B Engine
(D7D)
Workshop manual
1
Specifi cati ons
General
Specifications, tightening torques ......................................... 4
Screw plugs ........................................................................ 4
Volvo standard tightening torques ........................................ 5
Engine .................................................................................. 6
Cylinder liner, piston ............................................................. 6
Valve mechanism ................................................................. 7
Engine timing gears, camshaft ............................................. 7
Crankshaft, connecting rod, flywheel .................................... 8
Fuel system .......................................................................... 9
Tools
General
Special tools ....................................................................... 10
Engine
General
Specifications, general ....................................................... 12
Description .......................................................................... 13
Engine overview ........................................................ 13
Engine, reconditioning ........................................................ 15
Turbocharger, removing ................................................... 16
Engine, installing in mechanic's trestle ............................. 17
Cable harness, removing .................................................. 17
Oil cooler and oil filter, removing ...................................... 19
Fuel feed pump, removing ................................................ 20
Coolant pump and thermostat housing, removing ............ 21
Oil trap, removing ............................................................. 22
Cylinder head, removing ................................................... 22
Pump element, removing .................................................. 26
Flywheel, removing ........................................................... 27
Front cover with oil pump, removing ................................. 28
Pistons and connecting rods, removing ............................ 31
Crankshaft, removing ....................................................... 32
Camshaft and valve tappets, removing ............................ 34
Camshaft bushings, checking ........................................... 34
Power take-off housing, removing .................................... 35
Pressure control valve, removing ..................................... 35
Cylinder liners, removing .................................................. 37
Cylinder block, checking ................................................... 38
Pistons, checking .............................................................. 39
Connecting rods, checking ............................................... 41
Crankshaft, checking ........................................................ 43
Oil cooler core, checking .................................................. 45
Front cover with oil pump, dismantling ............................. 46
Front cover with oil pump, assembling ............................. 47
Timing gear casing, replacing crankshaft oil seal ............. 47
Pressure control valve, installing ...................................... 48
2
Cylinder liners, checking ................................................... 49
Cylinder liners, installing ................................................... 50
Camshaft and valve tappets, checking ............................. 51
Camshaft, installing .......................................................... 51
Crankshaft, installing ........................................................ 53
Piston and connecting rod, assembling ............................ 56
Pistons and connecting rods, installing ............................ 57
Determining thickness of cylinder head gasket ................ 58
Timing gear casing, installing ........................................... 59
Front cover with oil pump, installing ................................. 60
Power take-off housing, installing ..................................... 64
Flywheel, installing ........................................................... 64
Cylinder head, installing ................................................... 65
Pump element, installing .................................................. 67
Injectors and fuel lines, installing ...................................... 68
Manifold, charge air pipe and valve cover, installing ........ 70
Oil trap, installing .............................................................. 71
Coolant pump and thermostat housing, installing ............. 72
Fuel feed pump, installing ................................................. 73
Oil cooler and oil filter, installing ....................................... 73
Cable harness, installing .................................................. 74
Valve adjustment .............................................................. 76
Engine, removing from mechanic's trestle ........................ 77
Turbocharger, installing .................................................... 78
Cylinder head
Cylinder head, reconditioning ............................................. 80
Dismantling ....................................................................... 80
Rocker arm retainer, checking .......................................... 83
Cylinder block
Specifications, tightening torques ....................................... 84
Screw plugs ...................................................................... 84
Cylinder liner, piston
Valve mechanism
Engine timing gears, camshaft
Crankshaft, connecting rod, flywheel
Starter ring gear, replacing ................................................. 89
Lubr icat ion a nd oil sy stem s

Oil cooler, engine
Leakage check ................................................................... 90
Fuel sy stem
Injectors
Injector, checking ................................................................ 92
3
General
Specifi catio ns
General
Specific ations, t ightening torques
Screw plugs
Fig. 1
4 35 N m (26 lbf ft)

6 95 N m (70 lbf ft)
7 65 N m (48 lbf ft)
8 35 N m (26 lbf ft)
13 35 N m (26 lbf ft)
17 29 N m (21 lbf ft)
21 9 N m (6.6 lbf ft)
4
Volvo standard tightening torques
The tightening torques in the following tables apply to bolts with
a tensile strength as shown below. The tables are to be consid-
ered as a general instruction for the tightening torque of nuts
and bolts when no other torque is stated.
OBS
! For flanged bolts type U6FS the values should be
increased by 10 %.
Nuts and bolts should be cleaned and lubricated with oil.
Threads Nm kgf m lbf f t

M6 10 2 1.0 0.2 7.4 1.5
M8 24 5 2.4 0.5 18 3.5
M10 48 10 4.8 1.0 35 7.4
M12 85 18 8.5 1.8 63 13.0
M14 140 25 14.0 2.5 103 18.0
M16 220 45 22.0 4.5 160 33.0
M20 430 85 43.0 8.5 320 63.0
M24 740 150 74.0 15.0 550 110.0

M6 12 2 1.2 0.2 9 1.5
M8 30 5 3.0 0.5 22 3.5
M10 60 10 6.0 1.0 44 7.5
M12 105 20 10.5 2.0 78 14.5
M14 175 30 17.5 3.0 130 22
M16 275 45 27.5 4.5 204 33
M20 540 90 54.0 9.0 400 66
M24 805 160 80.5 16.0 594 118

1/4" 9 2 0.9 0.2 6.6 1.5
5/16" 18 4 1.8 0.4 13 3.0
3/8" 33 8 3.3 0.8 24 5.9
7/16" 54 14 5.4 1.4 40 10
1/2" 80 20 8.0 2.0 59 15
9/16" 120 30 12.0 3.0 89 22
5/8" 170 40 17.0 4.0 130 30
3/4" 300 70 30.0 7.0 220 52
7/8" 485 115 48.5 11.5 360 85
1" 725 175 72.5 17.5 530 130
5
Engine
General
Designation Volvo D7D
Number of cylinders 6
Cylinder bore 108 +0.02 mm
(4.251 +0.0008 in)
Wear limit 108.1 mm (4.256 in)
Stroke 130 mm (5.118 in)
Displacement 7150 cm3 (436 in3)
Compression ratio 17.6
Compression pressure 30–38 bar (435–551 psi)
Order of injection 1-5-3-6-2-4
Max. torque
EC290B 940Nm(96 kgf.m)

EC240B 750Nm(76.5 kgf.m)
Direction of rotation Facing the flywheel, counter-

clockwise
Working cycle Four-stroke diesel

Combustion system Direct injection
Cylinderliner,piston
Cylinder liner
Number of seal rings per cylin- 3
der liner
Pis to n
Number of ring grooves 3
Piston pin, diameter 42 +0 / –0.006 mm
(1.653 +0 / –0.0002 in)
Pisto n r ings
Compression r ing s
Number of 2
Piston ring clearance in
grooves:
upper compression ring tapered
lower compression ring 0.17 mm (0.007 in)
Piston ring gap:
upper compression ring 0.8 mm (0.031 in)
Oil scraper r ing
Number of 1
Piston ring clearance in 0.10 mm (0.004 in)
grooves
Piston ring gap 1.5 mm
6
Valv e mechanism
Valves
Valve head diameter:
inlet 48.0 +- 0.1 mm
(1.8890 +- 0.004 in)
exhaust 42.0 +- 0.1 mm (3.9386 +-
0.0004 in)
Stem diameter:
inlet 8.98+- 0.015 mm
(0.354 +-0.0006 in)
exhaust 8.96 +- 0.015 mm
(0.150 +- 0.0006 in)
Valve head edge:
inlet 2.1 mm (0.083 in)
exhaust 1.8 mm (0.071 in)
Seat insert angle in cylinder
head:
inlet 30
exhaust 45
Distance valve head – under- 1.5 mm
side of cylinder head
Valve clearance, cold engine,
value when adjusting:
inlet 0.3 mm (0.012 in)
exhaust 0.5mm (0.020 in)
Valve seat inserts

Valve seat width:
inlet 2.8 mm (0.110 in)
Valve guides
Clearance, valve stem – guide
inlet max 0.10 mm (0.004 in)
exhaust max 0.13 mm (0.005 in)
Valve springs
Length, unloaded 64.7 +- 1.3 mm
(2.547 +- 0.051 in)
Engine timing gears,camshaft

Camshaft bear ings
Camshaft bearings, inside 65 +0.054 / –0 mm
diameter (2.559 +0.0021 / –0 in)
Tooth backlas h
Max. tooth backlash camshaft 0.031 +- 0.095 mm
gear – crankshaft gear (0.0.0012 +- 0.0037 in)
7
Crankshaft, connecting rod,flywheel
Crankshaft
Max. "throw" 0.07 mm (0.0028 in)
Main bearing journals

Diameter, standard 85.00 +0 / –0.02 mm
(3.346 +0 / –0.0008 in)
Each undersize 0.25 mm (0.010 in)
Limit for undersize 84.75 +0 / –0.02 mm
(3.337 +0 / –0.0008 in)
Max. out-of-round 0.01 mm (0.0004 in)
Width, standard 38.00 +0.06 / –0 mm
(1.496 +0.0024 / –0 in)
Each oversize 0.40 mm (0.016 in)
Limit for oversize 38.46 +0 / –0.2 mm
(1.514 +0 / –0.008 in)
Big-end bearing journals

(2.677 +0 / –0.0008 in)
(2.657 +0 / –0.0008 in)
Connecting rod
Marking of connecting rod and digit code
cap respectively
Small-end, bushing inside 42 +0.05 / –0 mm
diameter (1.654 +0.0020 / –0 in)
Small-end, bushing outside 45.5 +0.12 / –0 mm
diameter (1.791 +0.0047 / –0 in)
Hole diameter in connecting 45.5 +0.02 / –0 mm
rod (1.791 +0.0008 / –0 in)
Max. clearance bushing – con- 0.08 mm (0.0031 in)
necting rod
Big-end, inside diameter with 72.5 +0.05 / –0 mm
bearing cap installed (2.854 +0.0020 / –0 in)
Big-end, inside diameter with 68.036–68.076 mm (
bearing cap and bearing shells 2.6786–2.6802 in)
installed
Wear limit radial clearance big- 0.12 mm (0.0047 in)
end bearings
8
Parallelism (twist)
Measurement "a" max. 0.05 mm (0.020 in) per 100 mm (3.937
in) length.
Fig. 2
Straightness
Permissible tolerance A to B: 0.05 mm (0.020 in) per 100 mm
(3.937 in) length.
Fig. 3
Fuel syste m
Injector
Opening pressure 275 +8 bar (3989 +116 psi)
9
Tools
General
Special tools
The following special tool are used when working on the engine.
The tools may be ordered from Volvo CE Customer Support.
Fig. 4 Special tools

11 666 014 Jack
11 666 030 Pump
998 6485 Trestle
999 2000 Drift handle
999 3713 Puller bolt
999 3717 Quick nut
999 3722 Support
999 6400 Impact puller
999 6662 Pressure testing equipment
999 6685 Clamp for oil cooler
999 8007 Adapter
10
Fig. 5 Special tools
999 8671 Fixture

999 8672 Installation tool
999 8674 Adapter
999 8675 Puller plate
999 8678 Measuring tool
999 8679 Protractor
999 8681 Cranking tool
11
Engi ne
Engine
General
Specifications, general
General
Designation Volvo D7D
Number of cylinders 6
Cylinder bore 108 +0.02 mm
(4.251 +0.0008 in)
Stroke 130 mm (5.118 in)
Displacement 7150 cm3 (436 in3)
Compression ratio 17.6
Compression pressure 30–38 bar (435–551 psi)
Order of injection 1-5-3-6-2-4
Max. torque (@1400 rpm)
EC290B 940Nm(96 kgf.m)

EC240B 750Nm(76.5 kgf.m)
Direction of rotation Facing the flywheel, counter-

clockwise
Working cycle Four-stroke diesel

Combustion system Direct injection
12
Engine overview
Fuel filter Air heater

Oil filter
Alternator
Oil cooler
Injection pump Oil pan
Air inlet Turbo-charger
Coolant inlet
Starter
Oil drain v/v
13
Alternator Air cooler to intake
Turbo-charger to air cooler
Oil drain v/v
Oil refill Fuel filter Nameplate
Coolant outlet
Air inlet Turbo charger
14
Engine, reconditioning
Op nr
Verktyg:
11 666 014 Jack
11 666 030 Pump
999 2000 Drift handle
999 3713 Puller bolt
999 3717 Quick nut
999 3722 Support
999 6400 Impact puller
998 6485 Trestle
999 8007 Adapter
999 8671 Fixture
999 8674 Adapter
999 8675 Puller plate
999 8678 Measuring tool
999 8679 Protractor
999 8681 Gear wheel (Cranking tool)
Socket or spanner Torx E10
Socket Torx E12
Socket Torx E18
Socket Torx E20
Lifting eyes M10
Lifting sling
Thread tap M8 with turning bar
Indicator gauge with magnetic base
Dial test indicator with angled "base"
Dial test indicator for inside measurements (crankshaft)
Depth gauge
Piston ring pliers
Feeler gauge
Screw micrometer
Connecting rod tester
Drift 20 mm
Steel ruler
Torque wrench with open end grip
OBS! The number 1 cylinder is nearest to the flywheel.
15
Turbocharger, removing
1 Remove the oil supply and return pipes from the turbo-
charger. Install protective plugs in the connections on the
turbocharger.
Fig. 10
1 Return pipe
2 Oil supp ly pip e
2 Remove the attaching nuts and remove the turbocharger.
Fig. 11
3 Install protective plugs in the connections for oil return and

supply pipes and the manifold.
Fig. 12
1 Prot ect ive pl ug s
16
Engi ne, i nst all ing i n m echanic's tr estle
4 Install the engine fixture on the engine.
VIKTIGT! Use the supplied bolts. They are of a higher
strength than the standard bolts.
5 Lift the engine into position and bolt the engine fixture onto
the mechanic's trestle. The weight of the engine is approx.
700 kg (1543 lb) .
Fig. 13
1 999 8671
Cable har ness, removing

6 Remove the attaching plate for the ECU connector.
Fig. 14
1 Connector for ECU
7 Disconnect the connector from the coolant temperature

sensor. Take apart the connector for the induction tempera-
ture sensor. Disconnect the connector from the camshaft
speed sensor.
Fig. 15
1 Sensor, coolant temperature
2 Connector for induction temperature sensor
3 Sensor, camshaft speed
17
8 Disconnect the connector from the charge air pressure
sensor.
Fig. 16
1 Sensor, charge air pres sure
9 Disconnect the connectors from the sensors for fuel tem-

perature, oil pressure and crankshaft speed.
Fig. 17
1 Senso r, fu el t emp eratur e
2 Sensor, crankshaft speed
3 Senso r, oi l p ressu re
10 Disconnect the electrical leads from the pump elements.
Fig. 18
1 Elect rical leads
18
11 Remove the cable rail together with electrical leads.
Fig. 19 Oil cooler and oi l fi lt er, remov ing
12 Disconnect the hose from the fuel pipe. Disconnect the

hose from the connection nipple on the fuel feed pump.
13 Remove the fuel and lubricating oil filters. Install protecting
plugs.
Fig. 20
1 Hose to f uel pipe
2 Hose to f uel feed p um p
3 Fuel fil ter
4 Lubricatin g oi l f ilte r
14 Remove the attaching bolts and remove the oil cooler.
Fig. 21
19
15 Remove any gasket remnants. Install protective plugs, pro-
tect the opening with masking tape.
Fig. 22
1 Prot ect ive pl ug s
Fuel feed pump, r emov ing

16 Slacken the bolts retaining the fuel feed pump. Remove the
V-belt.
Fig. 23
1 Attachin g b olt
2 Tensio ning b olt
17 Remove the bolts and remove the fuel feed pump.
Fig. 24
20
Cool ant pum p and t herm ost at housi ng, remov ing
18 Remove the bolts and remove the coolant pump and the
intermediate housing.
Fig. 25
1 Coo lant pu mp
2 Interm ediate hous ing
3 Therm ostat hou sing
19 Remove gasket remnants and protect the openings with

masking tape.
Fig. 26
20 Remove the bolts and remove the thermostat housing.
Fig. 27
21
Oil trap, remo ving
21 Remove the bolts and remove the oil trap.
Fig. 28
Cylinder head, rem ov ing

22 Remove the valve cover.
Fig. 29
23 Remove the attaching bolts and lift away the charge air
pipe.
Fig. 30
1 Charge air pi pe
22
24 Remove the attaching bolts and remove the manifold.
Fig. 31
1 Manifol d
25 Remove the pipes between the pump elements and the

injectors. Discard the pipes. Disconnect the return hoses
from the injectors.
Fig. 32
1 Pipe
2 Return hose
26 Disconnect the return hose from the overflow valve.

Remove all hoses.
Fig. 33
1 Overflow valve
23
27 Mark the rocker arm retainers. Remove the rocker arm
retainers together with rocker arms and the push rods.
OBS
! Spring force.
Fig. 34
1 Roc ker arm retain er
2 Roc ker arm
3 Pus h r od
28 Remove the nozzle holders, use tools for Torx E10.
Fig. 35
1 Torx E10
2 Nozzle holder
24
29 Mark the injectors and pull them out. If necessary use an
impact puller with adapter.
Fig. 36
1 999 6400
2 999 8007
30 Remove the bolts using a Torx E18 socket.
Fig. 37
31 Connect a lifting sling to the lifting eyes and lift away the
cylinder head. The cylinder head weight is approx. 80 kg
(17 6 lb).
Fig. 38
1 Lifti ng sl ing
25
Pump el ement, remov ing
32 Remove the fuel pipe from the pump elements.
Fig. 39
1 Fuel pipe
33 Mark the pump elements. Slacken the attaching bolts

approx. 4 mm (0.16 in) and loosen the pump elements from
the block.
Fig. 40
34 Slacken the attaching bolts fully and remove them and the
pump elements.
OBS! Spring force. Make sure that the pump elements do
not jump up.
Fig. 41
26
35 Remove the roller tappets and the shims.
OBS
! The shims and the roller tappets must not be moved
from one pump element to another.
Fi
g. 42
Flywheel, r emov ing

36 Remove the oil dipstick.
37 Turn the engine in the mechanic's trestle so that the oil
sump comes uppermost. Remove the bolts and remove the
oil sump.
OBS
! The oil sump is glued to the cylinder block. Take care
when removing, so that the sump is not damaged. Use a
pinch-bar at therefore intended recesses.
The oil sump weight is approx. 40 kg (88 lb) .
Fi
g. 43
38 Turn the engine in the mechanic's trestle so that the fly-

wheel comes uppermost.
Fi
g. 44
27
39 Remove the cover washer.
Fi
g. 45
40 Install lifting eyes M10 and a lifting sling.

41 Lift away the flywheel.
The weight of the flywheel is approx. 40 kg (88 l b ).
Fi
g. 46
1 Lifting eyes M10
Front cov er wit h oi l pum p, remov ing

42 Turn the engine in the mechanic's trestle so that the front
end comes uppermost.
43 Remove the oil suction pipe together with bracket. Remove
the oil filler pipe.
44 Mark the position of the belt pulley together with the
toothed wheel and the two oscillation dampers with a felt-
tip pen or similar.
Fi
g. 47
1 Oil suction pipe
2 Bracket
3 Oil fil ler pi pe
28
45 Install the cranking tool. Use it as a counterhold when loos-
ening the attaching bolts in points 46 and 48.
Fig. 48
1 999 8681
46 Remove the attaching bolts and remove the outer oscilla-

tion damper.
Fig. 49
29
48 Remove the attaching bolts using a Torx E20 socket and lift
away the V-belt pulley.
Fig. 51
1 Torx E20
2 Toothed wheel
3 V-belt pully
49 Remove the attaching bolts and remove the cover together

with the oil pump.
Fig. 52
1 Oil pump
50 Remove the attaching bolts and remove the timing gear

casing.
Fig.53 Timing gear casing removed
30
Pistons and con nect ing rods, remov ing
51 Mark the connecting rod caps.
52 Remove the attaching bolts and remove the caps together
with bearing shells.
Fig. 54
53 Push out the pistons together with connecting rods. Take

care of the bearing shells.
Fig. 55
31
Crankshaf t, remov ing
54 Turn the engine in the mechanic's trestle so that the crank-
shaft comes uppermost.
55 Check that the camshaft and crankshaft gears are marked.
Fig. 56
1 Marking
56 Check that the big-end bearing caps are marked. Remove

the attaching bolts and remove the caps together with the
bearing shells.
Fig. 57
57 Remove the thrust washers by main bearing number 2 (the

thrust bearing journal).
The number 1 main bearing is nearest to the flywheel.
Fig. 58
1 Thrus t w ashers
32
58 Connect a lifting sling to the crankshaft and lift it away.
The crankshaft weight is approx. 75 kg (165 lb) .
Fig. 59
59 Remove all bearing shells and the thrust washers at main

bearing number 2. Mark the bearing shells, if they are to be
used again.
Fig. 60
1 Bearing sh ell
2 Thrus t w ashers
60 Remove the piston cooling nozzles.
Fig. 61
33
Camshaf t and valv e tappet s, remov ing
61 Pull out the camshaft.
OBS! Take care not to damage the camshaft bearings.
Fi
g. 62
62 Remove the valve tappets. Mark them if they are to be

used again
Fi
g. 63
Camshaf t bushings checking

63 Set the dial test indicator to 65 mm (2.559 in).
64 Check the inside measurements of the bushings at points
"a" and 2 and in planes "a" and "b" as shown in the figure.
Inside diameter:
65 +0.054 / –0 mm (2.559 +0.0021 / –0 in) .
Wear limit: 65.080 mm (2 .562 in) .
Fi
g. 64
Fi
g. 65
1 Angled dial test indi cator
34
65 Remove the camshaft bearing bushings, if these are to be
replaced.
Fig. 66
1 999 8695
Power take-off housing, remov ing

66 Disconnect the oil pipe from the cylinder block.
67 Remove the attaching bolts (sockets Torx E10 and E12)
and remove power take-off housing together with the oil
pipe.
Fig. 67
1 Attachin g b olt s
2 Oil pipe
Pressure co nt rol valve, remov in g

68 Tap the hole for the pressure control valve to M8 using an
M8 thread tap.
Fig. 68
1 Threa d t ap M8
35
69 Pull up the pressure control valve with an impact puller.
Fig. 69
1 999 8674 Adapter
2 999 6400 Impact puller
70 Remove the valve.
Fig. 70
36
Cylinder liners, removing
71 Turn the engine in the mechanic's trestle so that the cylin-
der liners come uppermost.
72 Install tools as shown in the figure. Align puller plate 999 8675
with the halves of the quick nut under the lower edge on the cylin-
der liner.
Fig. 71
1 11 666 014
2 11 666 030
3 999 3722
4 999 3713
5 999 8675
6 999 3717
73 Pump with the hydraulic pump. The liner should loosen

after approx. 15 mm (0.6 in).
Fig. 72
74 Remove the tools and lift out the cylinder liner.
Fig. 73
37
Cylinder block, checking
75 Check that the cylinder liner collar locations and the cylin-
der liner sealing surfaces are not damaged.
Fig. 74
1 Cylinder liner collar location
76 Check with a depth gauge the distance between the cylin-

der block face and the bottom of the cylinder liner collar
location. Measure in approx. eight different places for each
cylinder. The depth must be 8.92 + 0.03 mm (0.3512
+ 0.0012 in) .
VIK
TIGT! Is the depth greater, the cylinder block must be
discarded.
77 Remove all screw plugs from the end faces.
Fig. 75
1 Depth gauge
38
Pistons, checking
78 Remove the lock ring. Take out the piston pin.
79 Remove the piston rings using a pair of piston ring pliers.
Fig. 76
1 Piston ring pliers
80 Push down one piston ring at a time in the cylinder bore,

below the upper turning point, with the aid of a piston.
Make sure that the piston ring is positioned horizontally.
Check the piston ring gaps with a feeler gauge.
Wear limits:
Piston ring 1: 0.8 mm (0.031 in) .
81 Clean the piston ring grooves.
Fig. 77
1 Feeler gauge
39
82 If new piston rings are to be used, measure the piston ring
grooves using the new piston rings 2 and 3 together with a
feeler gauge.
Wear limits:
Fig. 78
Fig. 79
1 Tapered compression ring
2 Chamfered compression ring
3 Slotted oil control ring
The piston rings are marked "TOP"
83 Install the piston rings using a pair of piston ring pliers.

OBS! Displace the spring gap on the oil control ring 180 to
the ring gap.
Fig. 80
84 Measure the piston pin with a screw micrometer.

Outside diameter: 42 –
0.006 mm (1.6535 –0.0002 in).
Fig. 81
40
Connecting rods, checking
85 Check the small-end bearing bushing in the connecting
rods with a dial test indicator. Measure at points 1 and 2
and in the planes "a" and "b" according to the figure. The
bushings are to be installed in the connecting rods when
measuring.
Inside diameter:42 +0.05 / – 0 mm (1.6535 +0.0020 / –0 in).
Fig. 82
86 Check the clearance of the bearing bushings.

Permissible clearance is 0.08 mm (0.003 in) .
87 Replace bearing bushings when necessary.
Hole diameter in connecting rod: 45.5 +0.02 / –0 mm
(1.791 +0.0008 / –0 in).
Outside diameter of bushing:
45.5 +0.12 / –0 mm (1.791 +0.0008 / –0 in) .
Fig. 83
88 Press in the new bearing bushing until flush with the rod.
OBS! The lubricating oil hole in the bushing must align with
the connecting rod oil duct.
89 After the pressing in, precision ream the bushing to an
inside diameter of 42 +0.05 /–0 mm (1.654 + 0.0020 /
–0in) .
Fig. 84
1 999 8692
41
90 Check that the numbering on the bearing cap matches that
on the connecting rod. Check that the guide studs are cor-
rectly positioned.
91 Install the bearing cap and tighten the bolts.
Initial tightening torque: 30 N m (22 lbf ft) .
1st tightening angle: 60 .
2nd tightening angle: 60 .
92 Set the dial test indicator to 72.5 mm (2.854 in).
Fig. 85
93 Measure the inside diameter at points 1 and 2 and in

planes "a" and "b" according to the figure.
Diameter: 72.5 +0.05 /–0 mm (2.854 +0.0020 / –0in) .
Fig. 86
Fig. 87
94 Remove the bearing cap and install new bearing shells.

Re-install the bearing cap and tighten the bolts.
2nd tightening angle: 60 .
42
95 Set the dial test indicator. Measure the inside diameter of
the bearing shells at points 1 and 2 and in planes "a" and
"b" According to Fig. 86.
Inside diameter: 68.036–68.076 mm (2.6786–2.6802 in) .
There are two 0.25 mm (0.010 in) undersizes.
Limit for undersize: 67.536–67.576 mm (2.659–2.660 in) .
Wear limit:
Radial clearance for big-end bearings: 0.12 mm (0.0047
in) .
OBS! If the obtained values do not exceed the bearing tol-
erances by more than 0.015 mm (0.0006 in), the connect-
ing rod may be used again. If the limit value is exceeded,
replace the connecting rod with a new one.
96 Check the connecting rod without bearing shells in i con-
necting rod testing fixture as regards parallelism (twist).
Tolerance "a" = 0.05 mm (0.0020 in) per 100 mm (3.937 in)
length.
Straightness test:
Permissible tolerance A to B: 0.05 mm (0.0020 in) per 100
mm (3.937 in) length.
Fig. 88
97 Check the connecting rod as regards straightness.

Permissible tolerance A to B: "a" = 0.05 mm (0.0020 in)
per 100 mm (3.937 in) length.
Fig. 89
Crankshaft, checking
98 Place the crankshaft in a trestle with V-blocks.
Fig. 90
43
99 Measure the diameter of the big-end bearing journals at 1
and 2 and in the planes "a" and "b".
Bearing journal diameter: 85.00 +0 / – 0.1 mm (3.346 +0 / –
0.0039 in)
One 0.25 mm (0.010 in) undersize is available.
Limit for undersize:
84.75 +0 / – 0.02 mm (3.337 +0/ –0.0008 in)
Wear limit out-of-round: 0.01 mm (0.0004 in) .
Fig. 91
100 Measure the width of the thrust bearing journal. Use a dial
test indicator intended for inside measurements. Make a
note of the measurement, it will be needed when installing
the crankshaft.
Bearing journal width: 34.00 +0.04 mm (1.339 +0.0016 in)
Oversize: 0.40 mm 0.016 in)
Limit for oversize: 34.46 mm (1.357 in)
Fig. 92
101 Measure the diameter of the big-end bearing journals.

Bearing journal diameter:
68.00 + 0 / – 0.02 mm (2.677 +0 / –0.0008 in)
Two 0.25 mm (0.010 in) undersizes are available
Limit for undersize:
67.50 + 0 / – 0.02 mm (2.657 +0 / –0.0008 in)
Wear limit out-of-round: 0.01 mm (0.0004 in) .
Fig. 93
102 Rotate the crankshaft and measure throw.

Max. deviation: 0.07 mm (0.0028 in).
Fig. 94
44
Oil cooler core, checking
103 Remove the screw plug.
Fig. 95
104 Remove the flange head bolts (17 mm) retaining the oil
cooler.
105 Check that the oil cooler core is not damaged. If damage is
suspected, pressure test the cooler core, see Leakage
check, sid 90.
106 Replace all seal rings.
Fig. 96
107 Install oil cooler core in the housing.
Fig. 97
108 Install flange head bolts together with the washers. Tight-
ening torque 170 N m (125 lbf ft) .
109 Apply locking fluid to the screw plug threads. Install the
screw plug.
Tightening torque 80 N m (59 lbf ft) .
Fig. 98
45
Front cover with oil pump, dismantling
110 Knock out the crankshaft oil seal with a drift.
111 Secure the cover in a vice with soft jaws.
Fig. 99
112 Press down the compression spring with a 13 mm (0.5 in)

wide screwdriver.
Move the lock plate out sideways.
VIK
TIGT! Great spring force. Make sure that the lock plate
location is not damaged.
Remove the pressure control valve.
Fig. 100
113 Remove the oil pump cover. Check that the pump compo-
nents are not damaged. Replace damaged parts.
114 Tighten down the cover to a torque of

8–9N m (5.9–6.6lbf ft) .
46
Front cover with oil pump, assembling
115 Install the pressure control valve.
116 Press down the compression spring and install the lock
plate.
VIKTIGT! Great spring force. Make sure that the lock plate
is correctly located.
117 Lubricate the new crankshaft oil seal with oil and install it.
Fig. 103
1 999 2000
2 999 8673
Timing gear casing, replacing crankshaft oil seal
118 Knock out the crankshaft oil seal with a drift.
Fig. 104
119 Lubricate the new crankshaft oil seal with oil and install it.
Fig. 105
1 999 2000
2 999 8672
47
Pressure control valve, installing
120 Clean the seat for the pressure control valve.
121 Check that it is possible to press in the valve poppet.
122 Apply locking fluid to the sealing surface of the valve.
Fig. 106
123 Install the valve.
Fig. 107
124 Drive in the valve until it bottoms using a drift with a 20 mm

(0.79 in) diameter.
Fig. 108
48
Cylinder liners, checking
125 Check that the liner is free from cracks or other damage.
126 Measure the cylinder liner inside diameter. Measure at
three different depths according to the figure, both longitu-
dinally and across.
Diameter: 108 +0.02 mm (4.252 +0.0008 in).
Wear limit: 108.1 mm (4.256 in) .
Fig. 109
127 Measure the height of the cylinder liner collar. Measure in

several places around the liner.
Height: 9 –0.02 mm (0.354 –0.0008 in) .
Fig. 110
49
Cylinder liners, installing
128 Make sure that the cylinder liner location and the sealing
surface are clean.
129 Install new O-rings.
Fig. 111
1 O-rings
130 Lubricate the cylinder block and the cylinder liner with oil to
cover the area marked with an "x" in the figure.
Fig. 112
131 Install the cylinder liners in the cylinder block. Drive them
down as far as possible.
VIK
TIGT! Sealing compound must not be used.
Fig. 113
50
Camshaft and valve tappets, checking
Check that the contact face on the valve tappets against the
camshaft is convex or level. If the surface is concave, replace
the valve tappet(s).
If the valve tappet is worn across the contact surface, the tappet
must be discarded. "The ditch" indicates that the tappet has not
rotated. A dark stripe outermost on the contact surface indicates,
however, that the surface is not worn down.
It is the condition of the valve tappets which determines, if it
isnecessary to check the camshaft wear.
Check that the contact surfaces on the camshaft and the valve
tappets do not have large pitting damage. Pitting damage may
arise for different reasons. The damage consists of small metal
particles loosening from the hardened surface. Tappet and cam-
shaft with minor pitting damage may be used. Pitting type
Fig. 114 damage rarely become worse.
1 Steel ruler Check that the camshaft bearing races and cam lobes are not
abnormally worn. The cams may, for example, be worn obliquely
in an axial direction. If the damage is slight, it can be corrected
by honing.
Replace the camshaft, in case of major damage or wear. When
replacing a camshaft, all valve tappets must be replaced at the
same time.
Camshaft, installing
132 Replace bearing bushings when necessary.
OBS! The wider bushing (27 mm = 1.063 in) should be
positioned at the gear end.
Replace bearing bushings, if they are worn.
OBS! The lubricating oil holes must align with the oil ducts
in the bearing locations.
Fig. 115 Positioning bearing bushings
Fig. 116
1 Lubricating oil hole
51
133 Press in the bushing to the correct position.
Fig. 117
1 999 8695
134 Lightly lubricate the valve tappets with oil and install them.
Fig. 118
135 Install the camshaft.

OBS! Take care not to damage the bearing bushings.
Check that the camshaft can rotate freely.
Fig. 119
52
Crankshaft, installing
136 Install the piston cooling nozzles. Press them in as far as
possible.
Fig. 120
137 Install the bearing shells in the cylinder block and lubricate
them with oil.
Fig. 121
1 Bearing shell
138 Install the bearing shells in the bearing caps and lubricate
them with oil.
Fig. 122
53
139 Wipe the bearing cap for the thrust bearing and the thrust
washers provided with a locating lug until clean. Install the
thrust washers and measure the width.
140 Determine the axial clearance. The width of the crankshaft
bearing journal, see Crankshaft, checking, sid 43, less the
measured width of the bearing cap and the thrust washers
will result in the actual clearance.
Permissible end float: 0.10–0. 30 mm (0.004–0.
012 in) .
Fig. 123
141 Lift the crankshaft into position. Make sure that the marking
against the camshaft gear is correctly lined up.
Fig. 124
142 Oil and install the thrust washer halves without a locating
lug. Insert them under the crankshaft. Turn the surfaces
with oil grooves toward the thrust bearing surfaces on the
crankshaft.
Fig. 125
143 Attach the other thrust washers to the bearing cap using a
little grease. Turn the surfaces with oil grooves on the
washers toward the thrust bearing surfaces on the crank-
shaft.
Fig. 126
54
144 Lubricate the bearing caps with oil and install them accord-
ing to markings. No. 1 next to the flywheel end.
1st tightening angle: 60
2nd tightening angle:
VIKTIGT! The bolts must be replaced with new ones after
the third time the engine has been dismantled.
Fig. 127
145 Make sure that the thrust washers on the cap align with the
washers in the block.
Fig. 128
146 Install the indicator gauge together with magnetic base.

Prize with a pinch-bar and check the crankshaft end float.
Permissible clearance: 0.10–0.30 mm (0.004–0.012 in).
Fig. 129
1 Pinch-bar
2 Magnetic base
3 Dial test indicator
55
Piston and connecting rod, assembling
147 Install one of the lock rings in the groove in the piston.
VIK
TIGT! The ring gap on the spring ring should be turned
toward the piston crown.
Fig. 130
148 Install the connecting rod in the piston with the guide pins
toward the side on the piston which has a flywheel symbol.
Push in the piston pin.
Check that the connecting rod can be moved sideways on
the piston pin.
Fig. 131
1 Guide pin
56
Pistons and connecting rods, installing
149 Install the bearing shells on the connecting rods and lubri-
cate them with oil.
Fig. 132
150 Install the piston rings. Arrange the piston ring gaps dis-
placed at 60 from each other.
Fig. 133
151 Use a piston ring compressor and install the pistons

together with connecting rods from the cylinder head side.
The flywheel symbol must be turned toward the flywheel
end.
Fig. 134
1 999 8687
152 Lubricate the big-end bearing journals on the crankshaft.

Push the connecting rod against the bearing journal and
install the caps according to markings.
Install new bolts and tighten them down.
2nd tightening angle: 60
153 Check that the crankshaft can rotate freely.
Fig. 135
57
Determining thickness of cylinder head gasket
Cylinder head gaskets are marked with one, two or three holes
in one corner. The gaskets should be used according to the
table.
Number
Piston height of holes
0.28 up to 0.54 mm 1
(0.011 up to 0.021 in)
0.54 up to 0.64 mm 2
(0.021 up to 0.025 in)
0.64 up to 0.75 mm 3
(0.025 up to 0.030 in)
Fig. 136
1 Marking of cylinder head gasket
154 Install the protractor on the crankshaft. Use the short bolts
(M10x1, 30 mm (1.18 in) long).
Fig. 137
1 999 8679 Protractor
155 Position the measuring tool together with spacer washers

and dial test indicator on the cylinder block. Set the dial test
indicator to zero.
OBS! Place the spacer washers on the block, not on the
liner collar.
Fig. 138
1 999 8678
2 Dial test indicator
3 Spacer washers
58
156 Position the dial test indicator stylus at points indicated in
the figure. Crank the engine with the handles on the pro-
tractor to find the highest position. Read off the piston
height on the gauge.
Fig. 139 Checking points
Timing gear casing, installing

157 Remove gasket remnants from the timing gear casing and
the cylinder block.
158 Apply sealing compound to the timing gear casing sealing
surface.
159 Lightly oil the crankshaft oil seal.
Fig. 140
160 Install the timing gear casing without tightening down the
bolts. Position the casing in line with the sealing surface on
the oil sump.
161 Tighten down the bolts (apart from the two bolts where the
cranking tool is to be fastened).
Tightening torque: 21 N m (15 lbf ft) .
Fig. 141
59
Front cover with oil pump, installing
162 Install the cranking tool at the flywheel end.
163 Turn the engine in the mechanic's trestle so that the front
end comes uppermost.
164 Remove any gasket remnants from the casing and the cyl-
inder block.
Fig. 142
1 999 8681
165 Lightly oil the oil pump rotors.
Fig. 143
166 Attach the gasket to the casing with a little grease.
Fig. 144
167 Position the oil pump drive against the crankshaft.

OBS! Will only fit in one position.
Fig. 145
60
168 Install the casing together with the oil pump without tighten-
ing down the bolts. Align the casing with the oil sump seal-
ing surface.
169 Tighten down the bolts.
Fig. 146
170 Install the toothed wheel and the V-belt pulley and align the
guide sleeve and the guide pin.
Fig. 147
1 Guide sleeve
2 Guide pin
171 Tighten down the bolts (Torx E20), holding the shaft in posi-
tion with the cranking tool at the flywheel end.
2nd tightening angle: 60
Fig. 148
1 Torx 20 E
2 V-belt pulley
3 Toothed wheel
61
172 Check that the oscillation dampers are free from external
damage.
Install the inner oscillation damper and the spacer. Make
sure that the bolt holes align with the holes in the belt pul-
ley.
Fig. 149
1 Spacer
2 Oscillation damper
174 Install a new gasket at the connection for the oil suction
pipe in the front cover.
Fig. 151
1 Gasket
62
175 Install the oil suction pipe together with the bracket. Install
the oil filler pipe.
Fig. 152
1 Oil suction pipe
2 Bracket
3 Oil filler pipe
176 Fill the joints in the oil sump sealing surface with sealing
compound.
Fig. 153
178 Install the oil sump and tighten down the bolts.
OBS! There are bolts of two different lengths.
Tightening torque: 25 N m (18 lbf ft)
Fig. 155
63
Power take-off housing, installing
179 Install the power take-off housing. Apply locking fluid and
tighten down the bolts (socket Torx E10 and E12).
180 Install the oil pipe.
Fi g. 156
1 Attaching bolts
2 Oil pipe
Flywheel, installing
181 Turn the engine in the mechanic's trestle so that the fly-
wheel end comes uppermost.
182 Lift the flywheel into position.
Fi g. 157
1 Lifting eyes M10
183 Install the bolts and tighten them down. Use the cranking
tool and a ratchet handle to hold the shaft.
Initial tightening torque, 30–45 mm (1.18–1.77 in) long
bolts: 20–30 N m (15–2 2 lbf ft) .
Initial tightening torque, 50– 85 mm (1.97–3.35 in) long
bolts: 30–40 N m (22–30 lbf ft) .
2nd tightening angle, 30 mm (1.18 in) bolts: 30 .
2nd tightening angle, 35–85 mm (1.38–3.35 in) bolts: 60 .
Fig. 158
64
184 Install the cover washer.
185 Remove the cranking tool.
Fig. 159
186 Re-install the cover together with the O-ring.
Fig. 160
1 Cover
Cylinder head, installing
187 Lay the cylinder head gasket on the cylinder block with the
digits upward. Place the guide sleeves in the holes.
Fig. 161
1 Guide sleeves
188 Lift the cylinder head into position. Pay attention to the
guide sleeves.
Fig. 162
65
189 Lightly oil the bolts and install them. Tighten them down in
three stage, noting the sequence.
2nd stage: 134 N m (99 lbf ft) .
Final tightening: 90 .
Fig. 163
190 Install the push rods.
Fig. 164
191 Place the rocker arm retainers according to the markings.

Align them with the push rods and the valves and tighten
down the bolts.
192 Adjust the valve clearance, see Valve adjustment, sid 76.
Fig. 165
66
Pump element, installing
193 Install the roller tappets. Make sure that the correct tappet
comes in the correct place according to markings on the
pump elements.
Make sure that the guide on the tappet engages the groove
in the bore.
Fig. 166
1 Guide lug
194 Lower the washer into the tappet with the aid of a screw-
driver.
The washers are 2.4 mm (0.094 in) thick.
Fig. 167
195 Install the pump elements according markings. Crank the

engine, so that the camshaft ends up in a position to suite
each pump element before tightening down the bolts.
Tightening torque stage 1: 5 N m (3.7 lbf ft) .
Stage 2: 30 N m (22 lbf ft) .
Fig. 168
67
Injectors and fuel lines, installing
196 Attach a new copper washer to the injector with a little
grease.
Fig. 169
1 Washer
197 Install the injectors with the connection for return fuel
toward the exhaust side. Install the holders and screw in
the bolts loosely. Torx E10.
Fig. 170
1 Connection for return fuel
2 Bolt, Torx E10
3 Retainer
198 Install new delivery pipes. Tighten the bolts loosely.

VIK
TIGT! The delivery pipes must not be reshaped (bent).
199 Tighten down the spring anchorage attaching bolt.
Fig. 171
68
200 Tighten down the delivery pipe nuts.
Fig. 172
201 Install new return fuel lines. Use new clamps and rubber
grommets. Connect the lines to the injectors and the return
valve.
Fig. 173
1 Return fuel line
2 Rubber grommet
202 Install the fuel pipe on the pump elements. The thicker
gasket is to be placed between the pipe and the pump ele-
ment, the thinner between the pipe and the bolt head.
Fig. 174
1 Thin gasket
2 Fuel pipe
3 Thick gasket
Fig. 175
1 Fuel pipe
69
Manifold, charge air pipe and valve cover, installing
203 Install the manifold together with new gaskets. The gasket
flange should be facing the cylinder head.
Install and tighten down the nuts.
Fig. 176
1 Manifold
204 Install the charge air pipe together with new gaskets and
tighten down the bolts.
Tightening torque: 9 N m (6.6 lbf ft) .
Fig. 177
1 Charge air pipe
205 Place the gasket for the valve cover on the cylinder head.
Make sure that return fuel lines do not get pinched.
Install the valve cover and tighten down the bolts.
Fig. 178
70
Oil trap, installing
206 Install a new gasket in the oil trap groove.
Fig. 179
1 Gasket
207 Align the oil trap connection with the oil line.
Fig. 180
1 Oil line
208 Bolt down the oil trap against the valve cover.
Fig. 181
71
Coolant pump and thermostat housing, installing
209 Check that there is no noticeable play in the coolant pump.
210 Remove the protective tape. Install the coolant pump
together with a new gasket. Pull the bolts loosely.
Fig. 182
211 Lubricate the O-rings and install the intermediate housing.
Fig. 183
212 Install the thermostat housing. Use a new gasket.

213 Tighten down all bolts to the coolant pump, the intermedi-
ate housing and the thermostat housing.
Fig. 184
72
Fuel feed pump, installing
214 Install the fuel feed pump. Pull the bolts loosely.
Fig. 185
215 Install the V-belt on the belt pulleys. Tension the belt by
moving the fuel feed pump. At correct tension it should be
possible to depress the belt approx. 10 mm (0.40 in) at the
centre between the belt pulleys.
Tighten down the bolts.
Fig. 186
1 Attaching bolt
2 Tensioning bolt
Oil cooler and oil filter, installing

216 Remove protective plugs and masking tape. Install the oil
cooler together with a new gasket. Install the bolts and
tighten down.
217 Connect the hoses to the fuel feed pump and the fuel pipe.
218 Install new oil and fuel filters.
Fig. 187
73
Cable harness, installing
219 Install the rail together with the electrical leads. Make sure
that none of the electrical leads become pinched.
Fig. 188
220 Connect the electrical leads to the pump elements.

Fig. 189
1 Electrical leads
221 Connect the connectors to the sensors for fuel tempera-

ture, oil pressure and crankshaft speed.
Fig. 190
1 Sensor, fuel temperature
2 Sensor, crankshaft speed
3 Sensor, oil pressure
74
222 Connect the connector to the charge air temperature sensor.
Fig. 191
1 Sensor, charge air temperature
223 Connect the connector to the sensor for coolant tempera-

ture. Join the connector halves for the boost pressure
sensor. Connect the connector to the sensor for cam-
shaft speed.
Fig. 192
1 Sensor, coolant temperature
2 Connector for boost pressure sensor
3 Sensor, camshaft speed
75
Valve adjustment
224 Crank the engine until the valves on cylinder No. 1 overlap.
Overlapping means that the exhaust valve is about to
close, and inlet valve is about to open. In this position it
should not be possible to rotate any of the push rods for the
cylinder in question.
Fig. 193
Fig. 194
1. 3, 5. 7. 9, 11: exhaust valves
2. 4. 6, 8. 10. 12: inlet valves
225 Adjust the clearance for the valves marked black in the fig-
ure.
Inlet valve: 0.30 mm (0.012 in) .
Exhaust valve: 0.50 mm (0.020 in) .
OBS! The valve clearance should be increased by 0.1 mm
(0.004 in), when the cylinder head gasket has been
replaced. The valve clearance should be adjusted to
normal after 50 hours operation.
Fig. 195
226 Tighten down the lock nut to 20 N m (15 lbf ft) . Check the
adjustment again with the feeler gauge.
Fig. 196
76
227 Crank the engine one revolution. Adjust the clearance for
the valves marked black in the figure.
228 Install the valve cover together with a new gasket and
tighten down the bolts.
Tightening torque: 9 N m (6.6 lbf f t).
Fig. 197
Engine, removing from mechanic's trestle

229 Connect a lifting device to the engine lifting eyes.
The weight of the engine is approx. 700 kg (15 43 lb).
Fig. 198
230 Remove the bolts between the mechanic's trestle and the
engine fixture and lift away the engine.
231 Remove the engine fixture.
Fig. 199
1 Engine fixture
77
Turbocharger , inst all ing
232 Remove the protective plugs from the connections for the
return pipe, the pressure pipe and the manifold.
Fi g. 200
1 Protective plug
233 Install the turbocharger together with a new gasket and

tighten down the attaching nuts.
Fi g. 201
234 Install the pressure-oil pipe together with a new gasket.

Tighten down the bolts.
Fi g. 202
78
235 Install a new O-ring on the return pipe.
Fig. 203
236 Install the return pipe together with a new gasket. Tighten
down the bolts.
Tightening torque: 21 Nm (15 lbf ft) .
Fig. 204
237 Install the retaining yoke.
Fig. 205
79
Cylind er head
Cylinder head, reconditioning
Op nr 21168
Verktyg:
Valve spring compressor
Dial test indicator with magnetic base
Sliding calipers for depth measuring
Dismantling
1 Remove the lifting eyes, the temperature sensor, the fuel
connection and the plug. Install protective plugs in the
openings.
Fig. 206
1 Lifting eye
2 Plug
3 Fuel connection
4 Temperature sensor
2 Stand the cylinder head edgeways and secure with C-

clamps.
Fig. 207
3 Remove valve cotters, valve washers, valve springs and

valves.
Fig. 208
80
4 Remove the valve stem seals.
5 Clean the cylinder head and check that there is no dam-
age.
Fig. 209
1 Valve stem seal
6 Measure the valve clearance in the valve guides with a dial

test indicator.
Wear limits:
Inlet valve: 0.10mm (0.004in) .
Exhaust valve: 0.13mm (0.005in)
Fig. 210
7 Check the valves.

– Valve stem diameter standard:
Inlet valve: 8.98 +0/-0.015mm (0.354 +0/-0.0006in)
Exhaust valv e: 8.96 +0/-0.015mm (0.353 +0/-0.0006in)
– Thickness of valve head edge:
Wear limits:
Inlet valve: 2.1mm (0.083in) .
– Valve head diameter:
Inlet valve: 48.0 +0.1/-0.1 mm (1.890 +0.004/-0.004 in)
Exhaust valve: 48.0 +0.1/-0.1 mm (1.890 +0.004/-0.004 in)
Fig. 211
81
8 Check the valve seat inserts.
Wear limits:
Inlet valve: 2.8 mm (0.110in) .
Fig. 212 .
9 Measure the depth of the valves in the cylinder head (the

distance between the valve head centre and the cylinder
head face).
Wear limit: 1.5mm (0.059in) .
Fig. 213
10 Measure the length of the valve springs (unloaded).

Standard lengths: 64.7 +1.3/-1.3 mm (2.547 +0.051/-0.051 in)
Fig. 214
82
Rocker arm ret ainer , ch ecki ng
11 Remove the lock rings and remove the rocker arms. Check
that the shaft studs and the rocker arms are not damaged.
12 Check that the oil ducts are not blocked.
Fig. 215
83
Cylind er blo ck
Specifications, tightening torques
Screw plugs
Fig. 216
4 35 Nm (26 lbf ft)

6 95 Nm (70 lbf ft)
7 65 Nm (48 lbf ft)
8 35 Nm (26 lbf ft)
13 35 Nm (26 lbf ft)
17 29 Nm (21 lbf ft)
21 9 Nm (6.6 lbf ft)
84
Cylind er liner , pist on
Cylinder liner
Number of seal rings per cylin- 3
der liner
Piston
Number of ring grooves 3
Piston pin, diameter 42 +0 / –0.006 mm
(1.653 +0 / –0.0002 in)
Piston rings
Compression rings
Number of 2
Piston ring clearance in
grooves:
upper compression ring tapered
Piston ring gap:
upper compression ring 0.8 mm (0.031 in)
Oil scraper ring
Number of 1
Piston ring clearance in 0.10 mm (0.004 in)
grooves
Piston ring gap 1.5 mm
85
Valv e mecha nism
Valves
Valve head diameter:
inlet - 0.1 mm
48.0+
exhaust (1.890 +- 0.004 in)
- mm
42.0 + 0.1
- 0.004 in)
(1.653 +
Stem diameter:
inlet 8.98 –0.015 mm
exhaust (0.354 –0.0006 in)
8.96 – 0.015 mm
(0.353 – 0.0006 in)
Valve head edge:
inlet 2.1 mm (0.083 in)
Seat insert angle in cylinder
head: 30
inlet 45
exhaust
Distance valve head – under- 1.5 mm
side of cylinder head
Valve clearance, cold engine,
value when adjusting:
inlet 0.3 mm (0.012 in)
Valve seat inserts

Valve seat width:
inlet 2.8 mm (0.110 in)
Valve guides
Clearance, valve stem – guide
inlet max 0.10 mm (0.004 in)
exhaust max 0.13 mm (0.005 in)
Valve springs
Length, unloaded - 1.3 mm
64.7 +
- 0.051 in)
(2.547 +
86
Engin e tim ing gears, cam shaf t
Camshaft bearings
Camshaft bearings, inside 65 +0.054 / –0 mm
diameter (2.559 +0.0021 / –0 in)
Tooth backlash
Max. tooth backlash camshaft 0.031–0.095 mm
gear – crankshaft gear (0.0012–0.0037 in)
Cranksh aft, con nect ing rod, f ly wheel

Crankshaft
Max. "throw" 0.07 mm (0.003 in)
Main bearing journals

(3.346 +0 / –0.0008 in)
(3.337 +0 / –0.0008 in)
Width, standard 38.00 +0.06 / –0 mm
(1.496 +0.0024 / –0 in)
Each oversize 0.40 mm (0.016 in)
Limit for oversize 38.46 +0 / –0.2 mm
(1.514 +0 / –0.008 in)
Big-end bearing journals

(2.677 +0 / –0.0008 in)
(2.657 +0 / –0.0008 in)
87
Connecting rod
Marking of connecting rod and digital code
cap respectively
Small-end, bushing inside 42 +0.05 / –0 mm
diameter (1.654 +0.0020 / –0 in)
Small-end, bushing outside 45.5 +0.12 / –0 mm
diameter (1.791 +0.0047 / –0 in)
Hole diameter in connecting 45.5 +0.02 / –0 mm
rod (1.791 +0.0008 / –0 in)
Max. clearance bushing – con- 0.08 mm (0.003 in)
necting rod
Big-end, inside diameter with 72.5 +0.05 / –0 mm
bearing cap installed (2.854 +0.0020 / –0 in)
Big-end, inside diameter with 68.036–68.076 mm
bearing cap and bearing shells (2.6786–2.6802 in)
installed
Wear limit radial clearance big- 0.12 mm (0.0047 in)
end bearings
Parallelism (twist)
Measurement "a" max. 0.05 mm (0.020 in) per 100 mm (3.937
in) length.
Fig. 217
Straightness
Permissible tolerance A to B: 0.05 mm (0.020 in) per 100 mm
(3.937 in) length.
Fig. 218
88
Starter ring gear , replacin g
Op nr
Verktyg:
1 Heat the new starter ring gear to +210 C (410 F). If an

oven is used, begin work by heating the ring gear. If a weld-
ing torch is used, heat the ring gear just before installing.
2 Drill a 10 mm (0.40 in) hole between two gear teeth on the
old ring gear. Drill to a depth of 9 mm (0.35 in).
VIK
TIGT! Do not drill into the flywheel. Risk of imbalance.
g.
Fi 219
3 Secure the flywheel in a vice with soft jaws. Split the starter
ring gear at the drilled hole using a cold chisel.
g.
Fi 220
4 Install the starter ring gear. Make sure that it bottoms

against the flywheel flange. If necessary use a drift.
5 Allow the starter ring gear to cool.
g.
Fi 221
89
Lubrication and oil sys t s
Oil cooler, engine

Leakage check
Op nr
Verktyg:
999 6662 Pressure testing equipment
999 6685 Clamp for cooler
Plug M26x1.5 Part No. 942352
Spacer 30 mm (1.18 in) (e.g. a 10 mm socket)
When checking, the oil cooler core should be as dry as possible
internally, as remaining water may have a sealing effect on any
possible crack. Neither must water leak into the oil cooler core
during the check.
During the test avoid starting or stopping fan systems or letting
air in or out of the room, as the air pressure in the room may
then change and be misinterpreted a a leak.
The oil cooler core should, during the test, have the same tem-
perature as the surroundings. The oil cooler core must not be
repaired.
1 Install a clamp on he oil cooler core according to the figure.
Make sure a good seal is obtained.
2 Install a clamp at the other connection.
Fi g. 222
1 Plug
2 999 6685
3 Spacer
90
3 Connect the pressure testing equipment.
4 Immerse the oil cooler core in a bowl of water.
5 Set the air pressure to 100 kPa (14.5 psi). Check whether
any air bubbles rise from the oil cooler core.
Leave the pressure on for one minute. The pressure must
not drop during this time.
6 Increase the pressure to 500 kPa (73 psi). Leave the pres-
sure on for one minute. The pressure must not drop during
this time.
If the pressure drops during the check, there is a leak. Replace
the oil cooler core.
Fig. 223
1 999 6685
91
Fuel s yste m
Injectors
Injector
Opening pressure 275 +8 bar (3989 +116 psi)
Injector, checking
Op nr
Verktyg:
Testing equipment for injectors

I The utmost cleanliness must be observed when work-
ing with the testing of injectors. Only use clean testing oil
according to ISO 4113 or clean diesel fuel.
VARNING!
Fuel is forced out of the injector at very high pressure. If a jet of
fuel should hit an unprotected part of your body, the fuel may
penetrate the skin and possibly cause blood-positioning
1 Connect the injector to the testing equipment.

2 Make sure that the pressure gauge is connected. Slowly
push down the lever and read off the pressure gauge.
When the pressure gauge pointer stops or suddenly falls,
the opening pressure has been reached.
The opening pressure should be 27
Fig. 224
92
3 To adjust the opening pressure, unscrew the cap nut.
Fig. 225
4 Set the pressure by selecting suitable shims. A thicker

shims will result in a higher opening pressure.
5 Dry the nozzle and the nozzle holder with compressed air.
Press down the lever until the pressure gauge shows
approx. 20 bar (290 psi) below the earlier recorded opening
pressure.
6 Check that fuel does not drip from the injector during the
first 10 seconds.
7 If drops appear within 10 seconds, dismantle the injector
and clean. Assemble the injector and again check for
leaks. If drops still appear, discard the injector.
8 Disconnect the pressure gauge.
Fig. 226
1 Cap mut 9 Check the spray pattern and the sound the injector makes.
2 Inj ector nozzle It should make a buzzing sound when the lever is moved
3 Adapt er rapidly and at the same time show an evenly distributed
4 Thrus t pin spray pattern.
5 Com pr essi on sp rin g
6 Sh i m
The buzzing sound is different from a new and a used
injector. This is due to the wear at the needle seat area.
If no buzzing sound is audible, even though the injector has
been cleaned, discard the injector.
93

D7D Engine Shop Manual For EC290&240

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D7D Engine Shop Manual For EC290&240

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EC290B/240B Engine

Lubr icat ion a nd oil sy stem s

4 35 N m (26 lbf ft)

Threads Nm kgf m lbf f t

Threads Nm kgf m lbf f t

Threads Nm kgf m lbf f t

EC290B 940Nm(96 kgf.m)

Direction of rotation Facing the flywheel, counter-

Working cycle Four-stroke diesel

Valve seat inserts

Engine timing gears,camshaft

Main bearing journals

Big-end bearing journals

Fig. 4 Special tools

999 8671 Fixture

EC290B 940Nm(96 kgf.m)

Direction of rotation Facing the flywheel, counter-

Working cycle Four-stroke diesel

Fuel filter Air heater

Injection pump Oil pan

Air inlet Turbo-charger

Oil drain v/v

Turbo-charger to air cooler

Oil drain v/v

Oil refill Fuel filter Nameplate

Air inlet Turbo charger

2 Remove the attaching nuts and remove the turbocharger.

3 Install protective plugs in the connections for oil return and

Cable har ness, removing

7 Disconnect the connector from the coolant temperature

9 Disconnect the connectors from the sensors for fuel tem-

10 Disconnect the electrical leads from the pump elements.

Fig. 19 Oil cooler and oi l fi lt er, remov ing

12 Disconnect the hose from the fuel pipe. Disconnect the

14 Remove the attaching bolts and remove the oil cooler.

Fuel feed pump, r emov ing

17 Remove the bolts and remove the fuel feed pump.

19 Remove gasket remnants and protect the openings with

20 Remove the bolts and remove the thermostat housing.

Cylinder head, rem ov ing

25 Remove the pipes between the pump elements and the

26 Disconnect the return hose from the overflow valve.

28 Remove the nozzle holders, use tools for Torx E10.

30 Remove the bolts using a Torx E18 socket.

33 Mark the pump elements. Slacken the attaching bolts

Flywheel, r emov ing

38 Turn the engine in the mechanic's trestle so that the fly-

40 Install lifting eyes M10 and a lifting sling.

Front cov er wit h oi l pum p, remov ing

46 Remove the attaching bolts and remove the outer oscilla-

49 Remove the attaching bolts and remove the cover together

50 Remove the attaching bolts and remove the timing gear

Fig.53 Timing gear casing removed

53 Push out the pistons together with connecting rods. Take

56 Check that the big-end bearing caps are marked. Remove

57 Remove the thrust washers by main bearing number 2 (the

59 Remove all bearing shells and the thrust washers at main

60 Remove the piston cooling nozzles.

62 Remove the valve tappets. Mark them if they are to be

Camshaf t bushings checking

Power take-off housing, remov ing

Pressure co nt rol valve, remov in g

70 Remove the valve.