Service Information
Document Title: Function Group: Information Type: Date:
Engine, assembling 210 Service Information 11/1/2013
Profile:
Engine, D6E [GB]
Engine, assembling
Op nbr 210-078
6999004 Handle
6999030 Drift plate
6999038 Drift plate
9990144 Puller plate
88800317 Piston ring compressor
9992634 Counterhold
9998678 Measuring tool
9998681 Rotation tool
11668400 Installation tool
11668401 Installation tool
11668402 Installation tool
11668409 Pliers
Lifting eyes M10
Lifting sling
Thread tap M8 with handle
Dial test indicator with magnetic base
Dial indicator with angled base
Dial indicator for inside measurement (crankshaft)
Depth gauge
Piston ring pliers
Feeler gauge
Screw micrometer
Drift 20 mm
Steel ruler
Valve spring compressor
Puller
Sealing compound 11713514
Camshaft, installing
1. Replace bearing bushings when required.
NOTE!
The wider bushing shall be installed on the flywheel side.
The lubricating oil holes must be positioned according to the figure.
Figure 1
Figure 2
1. Lubricating oil holes
2. Press the bushing into the correct position, from the inside and out with 11668402 Installation tool
Figure 3
1. 11668402 Installation tool
Figure 4
1. Press sleeve 63 mm
2. Bearing bushing
3. Guide sleeve
Cylinder liner, installing
3. Make sure that the cylinder liner position and sealing surface are clean.
4. Install the cylinder liners in the engine block. Press them down as far as possible.
NOTICE
Do not use sealing compound.
Figure 5
Installing cylinder liner (principle illustration)
1. Pry bar
2. Cylinder head bolts
3. Spacer
4. 9990144 Puller plate
5. Check that the contact surface against the camshaft on the valve tappets is convex or flat. If the surface is concave,
replace the valve tappets.
If the valve tappet is worn across the contact surface, the tappet must be discarded. The "ditch" shows that the tappet
has not been rotating. A dark line outermost on the contact surface however, indicates that the surface is not worn
down.
It is the condition of the valve tappets that determines whether a check of the camshaft wear is necessary.
Check that the contact surfaces on the camshaft and the valve tappets do not have severe pitting damage. Pitting
damage may arise for varying reasons. The damage is caused by small bits of metal loosening from the hardened
surface. Tappets and camshaft with minor pitting damage may be used. Damage such as pitting usually does not get
any worse.
Check that the camshaft bearing races and cam profiles are not abnormally worn. The cams may, for example, be worn
obliquely in an axial direction. This can, if the damage is light, be adjusted by honing.
Figure 6
1. Steel ruler
6. Lightly lubricate the valve tappets with oil and install them
Figure 7
7. Install the piston cooling nozzles. Press them in as far as possible.
Figure 8
8. Turn the engine so that the tappets do not interfere with installation of the camshaft. Weight, camshaft: approx. 25 kg
(55 lbs).
NOTE!
Take care not to damage the bearing bushings.
Check that the camshaft can rotate freely.
Figure 9
Crankshaft, installing
9. Install the bearing shells in the cylinder block and lubricate them with oil.
Figure 10
1. Bearing shell
10. Lift the crankshaft into place. Weight, crankshaft: approx. 55 kg (121 lbs) Make sure that the marking against the
camshaft gear ends up in the right position. Use a marking pen to mark the extension of the markings.
Figure 11
Figure 12
Figure 13
1. Marking
1. Extension of marking
11. Install the bearing shells in the bearing caps and lubricate them with oil.
Figure 14
12. Wipe clean the bearing cap together with thrust bearing and thrust washers with pin. Install the thrust washers and
measure the width.
Figure 15
13. Determine axial run-out. Crankshaft pin's width, see Crankshaft, specifications, minus (-) the measured width of the
bearing cap and thrust washers give clearance in question.
Permitted axial run-out: see Crankshaft, specifications.
14. Lubricate and install the thrust washer halves which have no lug. Insert them into position under the crankshaft. Turn
the surfaces with oil grooves toward the thrust bearing surfaces on the crankshaft.
Figure 16
15. Attach the other thrust washers onto the bearing cap with a little grease. Turn the washers so that the surfaces with oil
grooves are facing toward the thrust bearing surfaces on the crankshaft
Figure 17
16. Lubricate the bearing caps with oil and install them according to the marking. No. 1 nearest the flywheel.
Make sure that the thrust washers on the cap fit correctly against the washers in the block.
Figure 18
17. Install the bearing caps.
Tightening torque: see Crankshaft, tightening torques.
NOTICE
The bolts should always be changed.
Figure 19
18. Install the dial indicator with magnetic base. Pry with a pry bar and check the crankshaft run-out.
Permitted clearance: see Crankshaft, specifications.
Figure 20
1. Pinch-bar
2. Magnetic base
3. Dial gauge
Pistons and connecting rods, installing
19. Install the bearing shells in the connecting rods and lubricate them with oil.
Figure 21
20. Use 88800317 Piston ring compressor and install the pistons with connecting rods. The flywheel symbol shall face the
flywheel side.
Figure 22
1. 88800317 Piston ring compressor
Figure 23
Flywheel marking
21. Lubricate the big-end bearing journals on the crankshaft with oil. Push the connecting rod against the bearing journal
and install the caps according to markings.
Install new bolts and tighten down. Tightening torque, see Crankshaft, tightening torques
NOTICE
The bolts should always be changed.
Figure 24
Frost plugs, changing
22. Remove the frost plugs using a suitable puller.
Figure 25 Figure 26
1. Puller 1. Puller
23. Install the frost plugs with 6999030 Drift plate, 6999038 Drift plate and 6999004 Handle.
Figure 27
1. 6999030 Drift plate or 6999038 Drift plate
2. 6999004 Handle
Front casing with oil pump
24. Drive out the crankshaft seal using a drift.
Figure 28
25. Remove the oil pump's cover. Check that the pump's components are free from damage. Replace the pump if the parts
are damaged.
Figure 29
1. Rotor
2. Cover
26. Clean the cover and the cylinder block from any gasket remnants.
27. Oil in the oil pump's rotors. Check that the pump's rotor turns easily.
Figure 30
28. Place the gasket on the engine block. Align it with the guide sleeve.
Figure 31
29. Install the cover. Make sure that the oil pump's drive fits against the crankshaft. Install the bolts without tightening
them.
Figure 32
30. Align the cover with the oil sump's sealing surface.
Figure 33
31. Tighten the cover's attaching bolts. Tightening torque, Engine, tighten torques.
32. Cut off the excess gasket for the cover.
Front crankshaft seal
33. Check the position of the wear groove on the crankshaft.
Figure 34
1. Wear groove
34. Install the guide (inner part of 11668400 Installation tool). Oil in the crankshaft seal and install it with the felt side facing
out.
Figure 35
1. Crankshaft oil seal
2. Guide
35. Install any spacer washers, press sleeve, the bearing and the nut. Use the number of washers required to prevent the
new crankshaft oil seal from ending up in the same position as the old one.
Figure 36
1. Washers
2. Press sleeve
3. Bearing
4. Nut
36. Screw the nut until stop. Check that the seal ends up in the correct position.
Timing gear casing
37. Remove any gasket remnants from the timing gear casing and the cylinder block.
38. Apply sealant on the timing gear casing's sealing face as shown.
Figure 37
Applying sealant
39. Install the timing gear casing without tightening the bolts. Place the casing in line with the oil sump's sealing face.
Tighten the bolts. Tightening torque, see Timing gear casing, tightening torques.
Rear crankshaft seal
40. Check the position of the wear groove on the crankshaft.
Figure 38
1. Wear groove
41. Install the guide (inner part of 11668401 Installation tool). Oil in the crankshaft seal and install it with the felt side facing
out on the guide.
Figure 39
1. Crankshaft oil seal
2. Guide, 11668401 Installation tool
42. Install any spacer washers, press sleeve, the bearing and the nut. Use the number of washers required to prevent the
new crankshaft oil seal from ending up in the same position as the old one.
Figure 40
1. Washers
2. Press sleeve
3. Bearing
4. Nut
43. Screw the nut until stop. Check that the seal ends up in the correct position.
Oil sump with suction pipe
44. Install a new gasket at the connection in the front cover for the oil suction pipe.
Figure 41
1. Gasket
45. Install the oil suction pipe
Figure 42
1. Oil suction pipe
46. Fill the joints between the casings and the engine block with sealant 11713514.
Figure 43
47. Install a new gasket. Install the oil sump. Tightening torque, see Oil sump, tightening torque
NOTE!
Longer bolts at the short sides
Figure 44
1. Longer bolts
Flywheel, installing
48. Turn the engine in the adjustable stand so that the flywheel comes upward.
Install 9998681 Rotation tool.
49. Install the flywheel housing. Tightening torque, see Flywheel, tightening torques
Weight flywheel housing:approx. 35 kg (77 lbs).
Figure 45
50. Lift the flywheel into place.Weight: approx. 55 kg (120 lbs).
Figure 46
51. Install and tighten the bolts for the flywheel. Use 9998681 Rotation tool as counterhold. Tightening torque, see
Flywheel, tightening torques.
NOTICE
The bolts should always be changed.
Figure 47
52. Install the cover washer.
NOTE!
Some versions do not have this washer.
Figure 48
53. Install the oil filter housing with new gaskets. Install the oil cooler.
Figure 49
1. Oil filter housing
2. Drain plug.
54. Fit the fuel filter bracket.
V-belt pulley and vibration damper
55. Install the guide sleeve and the guide pin on the crankshaft.
Figure 50
1. Guide pin
2. Guide sleeve
56. Install the tooth wheel and the V-belt pulley and align the guide sleeve and the guide pin.
Figure 51
1. Guide sleeve
2. Guide pin
57. Tighten the bolts. Use 9992634 Counterhold as counterhold. Tightening torque, see
Belt pulley/vibration damper, tightening torques.
NOTICE
The bolts should always be changed.
Figure 52
1. Torx E20
2. 9992634 Counterhold
3. V-belt pulley
4. Toothed wheel
58. Check that the vibration damper is free external damage. Replace the vibration damper if there is any leakage or
damage. Turn the engine so that the end with the V-belt pulley faces up. Install the vibration damper. Make sure that
the bolt holes line up with the holes in the belt pulley. Tighten the bolts acc. to
Belt pulley/vibration damper, tightening torques.
NOTICE
The bolts should always be changed.
Figure 53
Cylinder head gaskets are marked with one, two, or three holes in one of the corners. The gaskets shall be used for
different piston heights above the cylinder block's face.
Figure 54
1. Marking of cylinder head gasket
The pistons' height above the engine block shall be measured at two points on all pistons, see Pistons, specifications.
Cylinder head
Determining thickness of cylinder head gasket
59. Install 9998681 Rotation tool on the engine.
60. Install 9998678 Measuring tool together with spacer washers and dial indicator on the engine block. Set the dial
indicator to zero.
NOTE!
Place the spacer washers on the block — not on the liner's edge.
Figure 55
1. 9998678 Measuring tool
2. Dial gauge
3. Spacer washers
61. Place the dial indicator at measuring points as shown. Rotate the crankshaft with 9998681 Rotation tool to find the
highest value. Read off the piston height on the dial indicator.
Figure 56
62. Repeat the same measurement on all pistons. Note the highest value and use cylinder head gasket according to the
table Cylinder head, specifications.
Figure 57
Measuring points
63. Place the cylinder head gasket on the engine block. Install the guide sleeves in the holes.
NOTE!
The gasket is marked with a top marking
Figure 58
1. Guide sleeves
Figure 59
Top marking
64. Lift the cylinder head into place. Pay attention to the guide sleeves. Weight cylinder head:80 kg (176 lbs)
Figure 60
65. Install the push rods.
Figure 61
66. NOTICE
The bolts should always be changed.
Oil in the cylinder head bolts (M12) that run through the rocker arm holders. Install the rocker arm holders with bolts
acc. to marking. Align them with the push rods and valves, and tighten the M10 bolts. Tightening torque, see
Cylinder head, tightening torques.
Figure 62
Rocker arm device
1. Exhaust rocker arm
2. Rocker arm bridge
3. Inlet rocker arm
4. Push rods
67. NOTICE
The bolts should always be changed.
Oil in the remaining cylinder head bolts lightly and install them. Tighten down the cylinder head acc. to the diagram.
Tightening torque, see Cylinder head, tightening torques.
Figure 63
Tightening diagram, cylinder head
Injectors and fuel lines, installing
68. Install new O-rings and copper washers on the injectors.
Install the injectors together with attaching yoke. Tightening torque, see Tightening torque, fuel system.
69. Install the roller lifters with 11668409 Pliers.
Make sure that the guide on the lifter ends up in the groove in the cylinder block.
Figure 64
1. 11668409 Pliers
2. Roller tappet
70. Install new O-rings on the high-pressure pumps.
Install the high-pressure pumps. Tighten the attaching bolts crosswise. Rotate the crankshaft so that the roller lifter is in
its bottom position. Tightening torque, see Tightening torque, fuel system
Figure 65
71. Install the fuel control valve. Tightening torque, see Tightening torque, fuel system
72. Install the fuel rail. Tightening torque, see Tightening torque, fuel system.
73. Install new pressure lines on the injectors and the fuel rail, as well as to the fuel control valve. Tightening torque, see
Tightening torque, fuel system.
NOTE!
The pressure lines may not be reused.
74. Install new O-rings on the coolant pump. Install the coolant pump with new gasket. Install the thermostat housing.
For excavator engine version:
Install new O-rings on the coolant pump. Install the coolant pump and thermostat housing as a complete unit.
Figure 67
Excavator version
1. Coolant pump
2. Thermostat housing
Figure 66 3. Bracket for belt tensioner
Loader version
1. Coolant pump
2. Thermostat housing
3. Crankshaft position sensor SE2701
75. If the engine is of excavator version, install the bracket for the alternator.
76. Install the fuel feed pump.
For loader version:
Tighten the bolts by hand. The bolts are torqued when installing the V-belt.
Figure 68
Loader version
Figure 69
Excavator version
1. Fuel pump
2. Bracket for alternator
77. Install the V-belt on the belt pulleys.
For wheel loader engine version:
Tension the belt by moving the fuel feed pump. At correct tension it should be possible to press down the belt approx.
10 mm (0.394 in) in the middle between the pulleys. Tighten the bolts.
For excavator engine version:
Install the belt tensioner. Install the V-belt on the belt pulleys.
78. Install the fuel line (3) between the fuel feed pump and the filter housing (1). Install new copper washers.
Install the return fuel line (2).
Tightening torque: see Tightening torque, fuel system.
Figure 70
79. Install the bracket for the oil dipstick.
80. Install the oil filler pipe.
81. Install a new oil filter.
82. Adjust the valves according to Valves, adjusting
83. Install the protective moulding on the valve cover.
NOTE!
The protective moulding's profile is not symmetrical. The protective moulding shall be installed with its red-coloured
end forward, in the engine's direction.
Figure 71
1. Protective moulding
84. Install the gasket on the valve cover.
NOTE!
Make sure that the tab (1) on the gasket ends up in its groove.
Install the valve cover. Tightening torque, see Valve mechanism, tightening torques
Figure 72
85. Install a new gasket in the groove on the oil trap.
Align the oil trap connection with the oil line.
Tighten down the oil trap against the valve cover.
Tightening torque: see Oil trap, tightening torque.
86. Remove the engine from the work stand according to Engine, removing from work stand.
87. Install the temperature sensor and IEGR-solenoid. Tightening torque, see Valve mechanism, tightening torques.
Figure 73
1. Solenoid valve IEGR, MA2504
2. Coolant temperature sensor SE2606
88. Plug in the connectors for the coolant temperature sensor, boost pressure sensor, IEGR—solenoid and the speed
sensor.
Figure 74
1. Cable harness for boost pressure sensor SE2507
2. Cable harness for starter motor
3. Solenoid valve IEGR, MA2504
4. Coolant temperature sensor SE2606
89. Install the bracket for the central connector.
90. Install the bracket for the cable harness on the valve cover. Connect the electric connections for the injectors.
Clamp the cable harness.
Plug in connectors for:
E-ECU
Fuel control valve (FCV)
Oil pressure sensor SE2203
Fuel feed pressure sensor SE2301
Rail pressure sensor SE2309.
Figure 75
1. Central connector E-ECU
2. Fuel control valve (FCV)
3. Fuel feed pressure sensor SE2301
4. Pressure sensor rail SE2309
5. Connector for crankshaft speed sensor SE2701
6. Camshaft speed sensor SE2703
7. Connector for oil pressure sensor, SE2203
