D6E Assembly

Service Information Document Title: Engine, assembling

Function Group: 210

Information Type: Service Information

Date: 8/12/2016

Profile: D6E

Engine, assembling Showing Selected Profile Valid for serial numbers Model

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D6E Op nbr 210-078 Total procedure time (hr): 7.00 Tools: 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

Serial number stop

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. 2. 3.

Press sleeve 63 mm Bearing bushing 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. 2. 3. 4.

Pry bar Cylinder head bolts Spacer 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. 2. 3.

Pinch-bar Magnetic base 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

1.

Puller

Figure 26

1.

Puller

23. Install the frost plugs with 6999030 Drift plate, 6999038 Drift plate and 6999004 Handle.

Figure 27

1. 2.

6999030 Drift plate or 6999038 Drift plate 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. 2.

Rotor 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. 2.

Crankshaft oil seal 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. 2. 3. 4.

Washers Press sleeve Bearing 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. 2.

Crankshaft oil seal 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. 2. 3. 4.

Washers Press sleeve Bearing 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. 2.

Oil filter housing 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. 2.

Guide pin Guide sleeve

56. Install the tooth wheel and the V-belt pulley and align the guide sleeve and the guide pin.

Figure 51

1. 2.

Guide sleeve 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. 2. 3. 4.

Torx E20 9992634 Counterhold V-belt pulley 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. 2. 3.

9998678 Measuring tool Dial gauge 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. 2. 3. 4.

67.

Exhaust rocker arm Rocker arm bridge Inlet rocker arm Push rods

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 Fuel system, tightening torques. 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 Fuel system, tightening torques

Figure 65

71. Install the fuel control valve. Tightening torque, see Fuel system, tightening torques 72. Install the fuel rail. Tightening torque, see Fuel system, tightening torques. 73. Install new pressure lines on the injectors and the fuel rail, as well as to the fuel control valve. Tightening torque, see Fuel system, tightening torques. 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

Figure 66 Loader version 1. 2. 3.

1. 2. 3.

Coolant pump Thermostat housing Bracket for belt tensioner

Coolant pump Thermostat housing 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. 2.

Fuel pump 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 Fuel system, tightening torques.

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 redcoloured 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. 2.

Solenoid valve IEGR, MA2504 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. 2. 3. 4.

Cable harness for boost pressure sensor SE2507 Cable harness for starter motor Solenoid valve IEGR, MA2504 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. 2. 3. 4. 5. 6. 7.

Central connector E-ECU Fuel control valve (FCV) Fuel feed pressure sensor SE2301 Pressure sensor rail SE2309 Connector for crankshaft speed sensor SE2701 Camshaft speed sensor SE2703 Connector for oil pressure sensor, SE2203