Service Information

Document Title: Function Group: Information Type: Date:

Engine, assembling 210 Service Information 11/01/2025
Profile:
D8J

Engine, assembling
Valid for serial numbers
Model Production site Serial number start Serial number stop
D8J

Op nbr 210-078

Total procedure time (hr): 11.00

Tools:
9998678 Measuring tool
9998681 Rotation tool
11667130 Drift plate
11668406 Installation tool
11668409 Pliers
88830632 Spanner
88800129 Press tool
88830421 Installation tool
88830457 Installation tool
88830492 Installation tool
88840293 Piston ring compressor

Depth micrometer
Dial indicator
Dial indicator with magnetic stand
Drift 20 mm
Feeler gauge
Lifting eye M10, 2 pcs.
Lifting eye M12, 2 pcs.
Lifting eye M16, 2 pcs.
Piston ring pliers
Puller
Ratchet block 250 kg (551 lb)
Screw micrometer
Sealant 11713514
Shackle M12, 2 pcs.
Sling 1 m (39 in), 2 pcs.
Thread tap M8 with crank
Valve spring compressor
E-tool E-2009
This operation also includes required tools and times for applicable parts of the following operations:

 Engine, removing from work stand

 Cylinder head, installing

NOTE!
Since the images are reused for different engine versions, some parts may vary from the version in question. However, the
essential information in the images is always correct.
Cylinder liners, installing

1. Make sure that the cylinder liner position and sealing surface are clean.

2. Install new O-rings.

Figure 1

1. O-rings

3. Use oil to lube the engine block and cylinder liner in the area marked with X.

Figure 2

4. Install the cylinder liners in the engine block. Press them down as far as possible using 11667130 Drift plate and a
pry bar.

NOTICE
Do not use sealing compound.
 Figure 3

1. Pry bar
2. Cylinder head bolt
3. Spacer
4. 11667130 Drift plate

5. Install 9998678 Measuring tool with spacer washers and dial indicator on the engine block. Make sure that the
measuring surface is clean and reset the dial indicator against the engine block before measuring. Measure the
cylinder liner's height above the engine block in three places. Replace the cylinder liner if the measurement is
outside the tolerance, see Engine, specifications.
NOTE!
Place spacer washers on the engine block, not on the cylinder liner's edge.

Figure 4

1. 9998678 Measuring tool

2. Dial indicator
3. Spacer washers
4. 88800129 Press tool

Camshaft, installing

6. Check that the rollers on the valve lifters roll easily and that the valve lifters are not damaged.

7. Replace the camshaft bearings if they are worn.

NOTE!
The wider bushing shall be installed on the flywheel side.

The lubrication hole is slightly displaced from the middle.

NOTE!
The lubrication oil holes must line up with the oil channels in the bearing positions.

Figure 5
 Position of bearing bushings

Figure 6

1. Markings
2. Lubrication oil holes
3. Bearing bushing

8. Press the bearing bushings to correct position, from the inside and out, using 88830457 Installation tool.

Figure 7

1. Bearing bushing
2. Press sleeve 65 mm
3. 88830457 Installation tool

9. Install the camshaft.

Weight, camshaft: approx. 25 kg (55 lb)
 Check that the camshaft can rotate freely.
NOTE!
Work carefully to avoid damaging the bearing bushings.

Figure 8

Camshaft

Crankshaft, installing

10. Install the piston cooling nozzles. Install the main bearings in the engine block and lube them with oil.
NOTE!
Make sure that the anti-rotation lug and lubrication oil holes are installed correctly in the slot.

Figure 9

1. Piston cooling nozzle

2. Main bearing
3. Lubrication oil hole
4. Anti-rotation lug

11. Install two slings, 1 m (39.4 in), on the crankshaft. Connect a lifting device to the slings and lift the crankshaft into
place.
Weight, crankshaft: approx. 75 kg (165 lb)
Make sure that the marking against the camshaft gear ends up in correct position. Use a color marker to mark the
extension.
 Figure 10

Figure 11

1. Marking

12. Install the main bearings in the main bearing caps and lube them with oil.
NOTE!
Make sure that the anti-rotation lug is installed correctly in the slot.

Figure 12

1. Main bearing

13. Install the thrust bearings and measure the width.

 Figure 13

14. Determine the axial run-out (clearance). Crankshaft journal's width, see Engine, specifications, minus (-) the
measured width of the bearing cap and thrust washers gives the relevant run-out (clearance). For permitted axial
run-out (clearance), seeEngine, specifications.

15. Oil in and install the thrust bearings and move them into position under the crankshaft.
NOTE!
Turn the thrust bearings so that the surfaces with oil grooves faces the crankshaft's thrust bearing surfaces.

Figure 14

16. Fasten the thrust bearings on the main bearing cap with grease.
NOTE!
Turn the thrust bearings so that the surfaces with oil grooves faces the crankshaft's thrust bearing surfaces.

Figure 15

1. Thrust washer
2. Oil groove

17. Install the main bearing caps according to the marking that was made when removing, with number one closest to
 the flywheel. Make sure that the bearing caps end up facing the right way and that the thrust washers on the main
bearing caps fit against the thrust washers in the engine block.
Tighten the attaching bolts in pairs. Tightening torque, see Engine, tightening torques.

NOTICE
The bolts should always be changed.

Figure 16

18. Install a dial indicator with magnetic stand. Use a pry bar to check the crankshaft's axial run-out (clearance). For
permitted axial run-out (clearance), see Engine, specifications.

Figure 17

1. Magnetic stand
2. Dial indicator

Pistons and connecting rods, installing

19. Install the connecting rod (big-end) bearings on the connecting rods and lube them with oil.
 Figure 18

1. Connecting rod
2. Connecting rod (big-end) bearings
3. 88830421 Installation tool

20. Check the piston rings, replace if needed.

Figure 19
Piston rings, relative positions

1. Upper ring, opening

2. Second ring, opening
3. Third ring, opening
4. Fourth ring, opening

21. Use a piston ring compressor and install the pistons with connecting rods from the cylinder head side. The flywheel
symbol shall face the flywheel.
 Figure 20

1. 88840293 Piston ring compressor

22. Use oil to lubricate the connecting rods' bearing journals on the crankshaft. Press the connecting rod against the
bearing journal and install the bearing caps according to marking.
Install new attaching bolts and tighten them. Tightening torque, see Engine, tightening torques.

NOTICE
The bolts should always be changed.

NOTE!
The connecting rods are halved and can only be assembled in one way. Parts that belong together are marked with
the same number.

Figure 21

1. Numbering of connecting rods' halves

 Figure 22

1. Arrow toward the flywheel

2. Marking closest the flywheel

Figure 23

1. Bearing cap

Front casing with oil pump

23. Drive out the crankshaft seal with a suitable drift.

 Figure 24

1. Crankshaft seal

24. Remove the oil pump and check that the oil pump's parts are free from damage. Change the oil pump if the parts
are damaged.

Figure 25

1. Rotor

25. Lube the oil pump's rotor with oil and make sure that it turns easily.

26. Place the gasket on the engine block. Align it with the guide sleeve.

Figure 26

1. Gasket
2. Guide sleeve

27. Install the front casing with oil pump. Make sure that the oil pump's drive aligns with the drive shaft. Install the
attaching bolts loosely. Align the casing with the oil sump's sealing surface, recommendation is to use a steel ruler.
Tighten the attaching bolts for the casing. Tightening torque, see Engine, tightening torques.
 Figure 27

1. Front casing with oil pump

Front crankshaft seal, installing

28. Check the position of the wear groove on the crankshaft.

Figure 28

1. Wear groove

29. Install the guide (inner part of 11668406 Installation tool). Oil in and install the crankshaft seal with the felt side
facing out.
 Figure 29

1. Guide
2. Crankshaft seal

30. Install any spacer washers, the press sleeve, the bearing, and the nut. Use as many spacer washers as needed for the
new crankshaft seal to not end up in the same position as the old one. Tighten the nut until it stops. Check that the
crankshaft seal ends up in correct position.

Figure 30

1. Washers
2. Press sleeve
3. Bearing
4. Nut

Oil sump, installing

31. Install a new gasket on the oil suction pipe's connection to the front casing. Install the oil suction pipe. Tightening
torque, see Engine, tightening torques.
 Figure 31

1. Oil suction pipe

2. Connection, oil suction pipe

32. Fill the joints between the casings and the engine block with sealant 11713514.

33. Use a new gasket. Install the oil sump and tighten the bolts. Tighten the bolts from the middle and outwards,
alternating between sides. Tightening torque, see Engine, tightening torques. Plug in the oil level/oil temperature
sensor and install the clamps.

Figure 32

1. Oil sump
2. Oil level/oil temperature sensor

Timing gear casing, installing

34. Remove any gasket remains from the timing gear casing and engine block.

35. Tap away the crankshaft seal from the timing gear casing.
 Figure 33

1. Crankshaft seal

36. Brush liquid gasket on the timing gear casing's sealing surface. Install the timing gear casing. Install the attaching
bolts loosely. Align the timing gear casing with the oil sump's sealing surface, for example, use a steel ruler. Tighten
the attaching bolts. Tightening torque, see Engine, tightening torques.
NOTE!
The timing gear casing must be installed within 20 minutes of brushing on the sealant.

Figure 34
Applying sealant

Figure 35

1. Timing gear casing

Rear crankshaft seal, installing

37. Check the position of the wear groove on the crankshaft.

Figure 36

1. Wear groove

38. Install the guide (inner part of 88830492 Installation tool). Oil in and install the crankshaft seal with the felt side
facing out on the guide.

Figure 37

1. Guide
2. Crankshaft seal

39. Install any spacer washers, the press sleeve, the bearing, and the nut. Use as many spacer washers as needed for the
new crankshaft seal to not end up in the same position as the old one. Tighten the nut until it stops. Check that the
crankshaft seal ends up in correct position.
 Figure 38

1. Spacer washers
2. Press sleeve
3. Bearing
4. Nut

Figure 39

40. Install two lifting eyes M12 on the flywheel housing. Connect a lifting device to the lifting eyes and lift the flywheel
housing into place.
Weight, flywheel housing: approx. 28 kg (62 lb)
Install and tighten the bolts for the flywheel housing. Tightening torque, see Engine, tightening torques.
 Figure 40

1. Flywheel housing

41. Install two lifting eyes M16 on the flywheel. Connect a lifting device to the lifting eyes and lift the flywheel into
place.
Weight, flywheel: approx. 60 kg (132 lb)
Install and tighten the bolts for the flywheel. Tightening torque, see Engine, tightening torques.

Figure 41

1. Lifting eye
2. Flywheel

Cylinder head, installing

42. Install the valve lifters. Note the marking so that they end up in the same place as when dismantling.

Figure 42

1. Valve lifter

43. Install the cylinder head, see Cylinder head, installing.

44. Install the camshaft sensor and crankshaft sensor.

45. NOTE!
Only applies to D8H.
 Install the oil cooler and cover plate.

Figure 43
Oil cooler

46. NOTE!
Only applies to D8J.

Install the oil cooler and cover plate.

Figure 44

1. Cover plate
2. Fuel filter
3. Oil cooler

47. Install the bracket for the AC-compressor.

48. Install the vibration damper. Install the belt pulley. Tightening torque, see Engine, tightening torques.
 Figure 45

1. Belt pulley
2. Vibration damper

49. Install the thermostat housing.

Figure 46

1. Thermostat housing

50. Install the coolant pump.

51. Install the bracket for the fan bearing.

Figure 47

1. Bracket for fan bearing

52. Install the fan bearing with the centre bolt.

 Figure 48

1. Centre bolt
2. Fan bearing

53. Lock the fan bearing with a suitable tool and install the intermediate piece.

Figure 49

1. Intermediate piece

54. Install the belt tensioner.

Figure 50
 Belt tensioner

55. Install the bracket for the alternator. Install the alternator. Plug in the connectors for the alternator. Install the belt
for the alternator and remove the lock in the tensioner.

Figure 51

1. Alternator
2. Belt

Fuel pipes and fuel pumps, installing

56. Install the feed pump.

Figure 52

1. Feed pump

57. Install high pressure fuel pipes. Install the feed pipes from the fuel control valve (FCV) and return pipe. Tightening
torque, see Fuel system, tightening torques.
NOTE!
The high pressure fuel pipes may not be reused.
 Figure 53

58. NOTE!
Only applies to D8H.

Install the filter bracket. Connect the fuel lines for the filter bracket.

Figure 54

1. Filter bracket
2. Fuel lines

59. Install the oil trap for the crankcase ventilation. Install the tube for the oil dipstick with bracket and clamp.
 Figure 55

1. Oil trap for crankcase ventilation

2. Tube for oil dipstick

60. NOTE!
Only applies to D8H.

Install the control unit for spark plugs. Plug in the connector.

Figure 56

1. Control unit for spark plugs

2. Connector

61. NOTE!
Only applies to D8H.

Install fuel dosing unit A and B with attaching plate. Plug in the connectors.

Figure 57

1. Fuel dosing unit A

2. Fuel dosing unit B

62. Install the exhaust manifold. Use new gaskets. Tightening torque, see Inlet and exhaust system, tightening torques.
Weight, exhaust manifold: approx. 14 kg (31 lb)
 Figure 58

1. Exhaust manifold

63. Install the inlet pipe. Use new gaskets. Use a little grease to keep the gaskets in place.

Figure 59

1. Inlet pipe

64. Install the starter motor.

Weight, starter motor: approx. 10 kg (22 lb)
Install the heat shield plate.

Figure 60

1. Heat shield plate

2. Starter motor

65. Install the turbocharger. Use new gaskets. Tightening torque, see Inlet and exhaust system, tightening torques.
 Figure 61

1. Turbocharger
2. Bracket

66. NOTE!
Only applies to D8H.

Install the air line from the compressor loosely. Install the bracket for the burner loosely. Install the burner. Use a
new gasket. Tighten the air line and bracket for the burner.

Figure 62

1. Burner
2. Bracket
3. Air line

67. Plug in all connectors.

68. NOTE!
Only applies to D8H.

Connect the temperature sensor, fuel line, and air lines. Plug in the connectors. Install the clamps on the air line.
 Figure 63

1. Air line
2. Air line
3. Temperature sensor
4. Fuel line

69. Remove the engine from the work stand, see Engine, removing from work stand.