Liebherr d944 (a7 04) diesel engine service repair manual

Repair manual
Diesel engine
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
Onwards of serial number 2014-03-0001 / 2014-04-0001
en

D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
LMB/1.3/Issue:04/2016/enD9xx_A7_04_Deckblatt.fm
copyright © Liebherr Machines Bulle SA 2015
Document identification
Order number: 11418471
Issued: 04/2016
Valid for: D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
Compiled by: LMB - Department ED5
Version: 1.3
Product identification
Manufacturer: Liebherr Machines Bulle SA
Type: D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
Serial number: 2014-03-0001 / 2014-04-0001
Address
Address: Liebherr Machines Bulle SA
45, rue de l‘Industrie
CH - 1630 Bulle
Repair manual
Diesel engine
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
Onwards of serial number 2014-03-0001 / 2014-04-0001
en

2 - 4
Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
LMB/1.3/Issue:04/2016/enD9xx_A7_04_Deckblatt.fm
Machine data
The following data must be supplemented upon obtaining your diesel engine.
This will also be helpful when ordering spare parts.
Details indicated with * are printed on the company nameplate of the diesel en-
gine.
Diesel engine identification number*:
. . . . . . . . . . . . . . . . . .
Diesel engine serial number*:
. . . . . . . . . . . . . . . . . .
Date of initial start-up:
. . / . . / . .

D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
LMB/1.3/Issue:04/2016/en00.Kapitel_Vorwort.fm
Preface
Target group
These repair instructions are written for fitters and workshop personnel of LIEBHERR dealers and LIEBHERR bran-
ches, whose task is to ensure that the diesel engines are ready to operate.
Contents
These repair instructions provide you with technical documents to hand, which you can use for removal and instal-
lation, dismantling and assembling, setting tasks and technical data for Liebherr diesel engines.
The operating instructions D934 A7-04 / D936 A7-04 / D944 A7-04 / D946 A7-04 are part of these repair instructions
and provide descriptions for maintenance and care.
Safety instructions
The accident prevention regulations and all generally recognised safety and occupational health regulations are to
be observed during all maintenance and repair work on Liebherr diesel engines. Observe the national regulations in
the country and place of use if necessary.
Furthermore, the safety instructions for diesel engines provided in the "Safety instructions" chapter must be obser-
ved.
Changes to the diesel engine
Unauthorised changes to the diesel engine void the liability of the manufacturer for any resulting property damage
or personal injury.
This applies particularly to tampering with the injection and control system, as these affect the diesel engine's per-
formance and exhaust emission characteristics. Compliance with statutory environmental requirements is no longer
assured if unauthorised changes are made.
Work instructions
A prerequisite for a proper repair is a proper and complete basic tool, as well as the required devices and special
tools.
Use only clean and undamaged tools.
Damaged tools must not be re-used; they must be replaced in good time.
Cleanliness and order contribute to safety at the workplace.
Clean the diesel engine, and connections and screw fittings at the start of the maintenance /
repair work to remove oil, fuel or care products. Do not use aggressive cleaning agents. Use lint-free cleaning rags.
Do not use any flammable liquids to clean the diesel engine.
Sealing materials (e.g. o-rings, seals etc.) are to be replaced.
Parts that are removed are to be checked for reusability and replaced if necessary.
Screw connections are to be tightened according to the standard torques if no specific torque and tensioning instruc-
tions are stated. These are included in the "Technical data" chapter.
Specific torques, tensioning instructions and instructions for mounting are included in the chapter "Technical data"
and in the respective work descriptions.

3 - 6
Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
LMB/1.3/Issue:04/2016/en00.Kapitel_Vorwort.fm
Spare parts
Only original LIEBHERR spare parts or spare parts purchased from LIEBHERR may be used to repair LIEBHERR
diesel engines.
LIEBHERR will cancel all possible obligations received by LIEBHERR and/or its dealers, such as guarantees, service
contracts etc., without advance notice if any parts other than original LIEBHERR parts or spare parts purchased from
LIEBHERR are used for maintenance and repairs.
All "Part information" in this manual, e.g. ID numbers, thread dimensions, dimensions, etc. are for information only;
spare parts may only be ordered using the spare parts catalogue that is part of the scope of delivery.
Lubricants and operating fluids
Only lubricants and operating fluids that are approved by LIEBHERR may be used to operate LIEBHERR diesel en-
gines.
LIEBHERR will cancel all possible obligations received by LIEBHERR and/or its dealers, such as guarantees, service
contracts etc., without advance notice if any lubricants or operating fluids other than those approved by LIEBHERR
are used.
Usage instructions
Chapter 1, "General information", provides you with an overview on the structure of this manual.
The manual describes multiple types and construction states. The information applies to the types specified in the
footer. This does not apply to specifications that are specific to types or serial numbers in the relevant descriptions.
Certain illustrations in this manual may depict details that differ from your diesel engine. The relevant work must then
be carried out in accordance with the work description provided.
Improvements that have been made to the diesel engines may result in changes that are not mentioned in this ma-
nual.
If you require further explanations or information, contact the LIEBHERR customer service and customer service
school departments.
The repair instructions are not subject to change. The repair instructions are revised according to the technical re-
quirements and their current version published.
The service information issued by Liebherr Machines Bulle is a supplement to the repair instructions after a version
of them is published.
These repair instructions are available in German, English and French.
Changes, conditions, copyright
Subject to changes to technical details of the diesel engines compared with the information and illustrations in this
manual without prior notice.
Warranty and liability conditions of the general terms and conditions of LIEBHERR are not extended by the preceding
information.
Information and illustrations in this manual may neither be reproduced, disseminated nor used for competitive pur-
poses. All copyright rights according to the law are expressly reserved.

Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
i - 7
Table of ContentsLMB/1.3/Issue:04/2016/enD9xx_A7_04_deIVZ.fm
1 General information.............................................................................................................................. 1-13
1.2 Important notes in this manual ...................................................................................................... 1-18
1.2.1 Identification of operational safety instructions................................................................ 1-18
1.2.2 Additional identifications.................................................................................................. 1-18
1.3 Safety instructions ......................................................................................................................... 1-19
1.3.1 General safety instructions.............................................................................................. 1-19
1.3.2 Preventing personal injuries............................................................................................ 1-20
1.3.3 Preventing property damage........................................................................................... 1-22
1.4 Safety instructions for working on the fuel and injection system ................................................... 1-24
1.5 Safety instructions for working on the exhaust after-treatment system (SCR system).................. 1-26
1.5.1 Reducing agent ............................................................................................................... 1-26
1.6 Engine diagrams and engine components .................................................................................... 1-28
1.7 Technical data ............................................................................................................................... 1-32
1.7.1 Engine, general ............................................................................................................... 1-32
1.7.2 Standard torques for screw connections......................................................................... 1-37
1.7.3 Standard torques for screw plugs and banjo screws....................................................... 1-39
1.7.4 Standard torques for metric screw fittings....................................................................... 1-40
1.7.5 Standard torques for imperial screw fittings .................................................................... 1-42
1.7.6 Standard torques for cutting ring screw fittings ............................................................... 1-44
1.7.7 Standard torques for triple-lock screw fittings ................................................................. 1-45
1.7.8 Standard torques for VSTI screw plugs........................................................................... 1-46
1.8 Special torques, tensioning instructions, instructions for mounting and installation instructions... 1-47
1.8.1 Cleaning and locking agents, greases ............................................................................ 1-47
1.8.2 Special torques for cylinder head engine control unit and valves ................................... 1-48
1.8.3 Special torques for the engine......................................................................................... 1-51
1.8.4 Special torques for fuel and injection system.................................................................. 1-55
1.8.5 Special torques for charge air and exhaust system ........................................................ 1-58
1.8.6 Special torques for the electrical system......................................................................... 1-66
1.8.7 Special torques for the lubrication system....................................................................... 1-70
1.8.8 Special torques for the auxiliary output, air compressor ................................................. 1-72

Table of Contents
i - 8
Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
LMB/1.3/Issue:04/2016/enD9xx_A7_04_deIVZ.fm
1.9 Fuel diagram.................................................................................................................................. 1-74
1.10 Lubricating oil diagram................................................................................................................... 1-75
1.11 Coolant diagram ............................................................................................................................ 1-76
1.11.1 Coolant diagram, general overview................................................................................. 1-76
1.11.2 Coolant circuit, engine..................................................................................................... 1-78
1.12 Assigning the channels in the crankcase and the cylinder head ................................................... 1-81
1.13 Transport device and fastening parts ............................................................................................ 1-82
1.13.1 Removing and installing the transport device and fastening parts .................................. 1-83
1.14 Tools .............................................................................................................................................. 1-84
1.14.1 Special tools .................................................................................................................... 1-84
2 Cylinder head, engine control unit and valves ................................................................................. 2-107
2.1 Removing and installing the cylinder head cover ........................................................................ 2-108
2.2 Removing and installing the rocker arm bracket and push rods.................................................. 2-109
2.3 Removing and installing the valve bridge (engines with and without ABS) ................................. 2-111
2.4 Removing and installing the cylinder head .................................................................................. 2-112
2.5 Removing and installing the injector sleeve................................................................................. 2-115
2.6 Removing and installing the valve stem seal, valve springs, valves............................................ 2-117
2.6.1 Remove ......................................................................................................................... 2-118
2.6.2 Installing ........................................................................................................................ 2-119
2.6.3 Removing and installing the valve stem seal without removing the cylinder head........ 2-120
2.7 Removing and installing the roller tappet (valve controller) ......................................................... 2-122
2.8 Removing and installing the camshaft ......................................................................................... 2-123
2.8.1 Remove ......................................................................................................................... 2-124
2.8.2 Installing ........................................................................................................................ 2-125
3 Driving gear .......................................................................................................................................... 3-127
3.1 Removing and installing the piston with crank and piston rings .................................................. 3-129
3.1.1 Overview........................................................................................................................ 3-129
3.1.2 A: Removing and installing the piston with crank from the engine ................................ 3-130
3.1.3 B: Removing and installing the piston rings................................................................... 3-136
3.1.4 C: Removing and installing the pistons ......................................................................... 3-138
3.2 Removing and installing the cylinder liner ................................................................................... 3-139
3.2.1 Checking the cylinder liners' projection ......................................................................... 3-141
3.3 Removing and installing the crankshaft attachments .................................................................. 3-143
3.4 Removing and installing the front crankshaft seal ....................................................................... 3-145

Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
i - 9
3.4.1 General instructions ...................................................................................................... 3-146
3.4.2 Remove......................................................................................................................... 3-146
3.4.3 Installing ........................................................................................................................ 3-147
3.5 Removing and installing the unit carrier ...................................................................................... 3-150
3.6 Removing and installing the flywheel .......................................................................................... 3-153
3.6.1 Remove......................................................................................................................... 3-156
3.6.2 Installing ........................................................................................................................ 3-158
3.6.3 Removing and installing the starting gear ring .............................................................. 3-160
3.7 Removing and installing the rear crankshaft seal........................................................................ 3-162
3.7.1 General instructions ...................................................................................................... 3-163
3.7.2 Remove......................................................................................................................... 3-163
3.7.3 Installing ........................................................................................................................ 3-164
3.8 Removing and installing the flywheel housing............................................................................. 3-167
3.9 Removing and installing the top right intermediate wheel ........................................................... 3-169
3.10 Removing and installing the top middle intermediate wheel........................................................ 3-170
3.11 Removing and installing the crankshaft....................................................................................... 3-171
3.11.1 Remove......................................................................................................................... 3-174
3.11.2 Installing ........................................................................................................................ 3-177
4 Fuel and injection system................................................................................................................... 4-181
4.1 Removing and installing the fuel lines ......................................................................................... 4-182
4.2 Removing and installing the injection lines.................................................................................. 4-184
4.2.1 Removing fuel lines....................................................................................................... 4-186
4.2.2 Installing fuel lines......................................................................................................... 4-187
4.3 Removing and installing the pressure pipe branch and injector .................................................. 4-190
4.3.1 Removing the pressure pipe branch and injector.......................................................... 4-192
4.3.2 Installing the pressure pipe branch and injector ........................................................... 4-193
4.4 Removing and installing the fuel fine filter with console .............................................................. 4-196
4.4.1 Installing and filling the fuel fine filter............................................................................. 4-197
4.5 Removing and installing the fuel high pressure pump................................................................. 4-199
4.5.1 Removing and installing the fuel pre-feed pump........................................................... 4-202
4.5.2 Removing and installing the suction throttle valve ........................................................ 4-203
4.6 Removing and installing the fuel high pressure pump drive ........................................................ 4-204
5 Belt drive .............................................................................................................................................. 5-205
5.1 Overview of belt drives ................................................................................................................ 5-206

Table of Contents
i - 10
Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
5.2 Removing and installing the belt drive cover ............................................................................... 5-207
5.3 Removing and installing the V-ribbed belt tensioning device ...................................................... 5-208
5.4 Removing and installing the V-ribbed belt deflection roller.......................................................... 5-209
5.5 Removing and installing belt drive II (air conditioning compressor variant II).............................. 5-210
5.6 Removing and installing belt drive III (fan drive).......................................................................... 5-211
6 Charge air and exhaust system......................................................................................................... 6-213
6.1 Removing and installing the air intake pipe ................................................................................. 6-215
6.2 Removing and installing the air intake attachment ...................................................................... 6-216
6.3 Removing and installing the clock valve ...................................................................................... 6-217
6.4 Removing and installing the connecting line (turbocharger - charge air cooler).......................... 6-218
6.4.1 Connecting line (turbocharger - charge air cooler) variant 1 ......................................... 6-218
6.5 Removing and installing the heat protection plate ....................................................................... 6-221
6.6 Removing and installing the exhaust pipe ................................................................................... 6-222
6.6.1 Dismantling and assembling the 6-cylinder exhaust pipe.............................................. 6-224
6.7 Removing and installing the exhaust branch ............................................................................... 6-225
6.8 Removing and installing the intake branch .................................................................................. 6-227
6.9 Removing and installing the turbocharger ................................................................................... 6-228
6.10 SCR exhaust after-treatment system........................................................................................... 6-231
6.10.1 SCR functional overview ............................................................................................... 6-231
6.10.2 SCR module .................................................................................................................. 6-233
6.10.3 Reducing agent pump ................................................................................................... 6-235
6.10.4 Heating system for reducing agent lines ....................................................................... 6-239
6.10.5 Air compressor .............................................................................................................. 6-240
6.10.6 Reducing agent extraction module................................................................................ 6-242
6.10.7 Mixing section, installing the injector and the high temperature sensor in the mixing
section ........................................................................................................................... 6-243
6.10.8 Sensor section............................................................................................................... 6-246
6.10.9 Removing and installing sensors................................................................................... 6-247
6.10.10 WABCO water valve...................................................................................................... 6-250
6.11 Troubleshooting in SCR system .................................................................................................. 6-252
7 Electrical system.................................................................................................................................. 7-253
7.1 Removing and installing the heating flange ................................................................................. 7-254
7.2 Removing and installing the alternator ........................................................................................ 7-256

Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
i - 11
7.3 Removing and installing the starter ............................................................................................. 7-258
7.4 Removing and installing sensors................................................................................................. 7-260
7.4.1 Instructions for mounting sensors ................................................................................. 7-261
7.5 Removing and installing the engine control unit .......................................................................... 7-262
7.5.1 Instructions for dismounting the engine control unit...................................................... 7-263
7.5.2 Instructions for mounting the engine control unit........................................................... 7-263
7.6 Replacing the cable harness ....................................................................................................... 7-264
7.6.1 Preparation.................................................................................................................... 7-264
7.6.2 Removing the cable harness......................................................................................... 7-264
7.6.3 Installing the cable harness........................................................................................... 7-265
8 Lubrication system.............................................................................................................................. 8-269
8.1 Replacing the oil filter .................................................................................................................. 8-270
8.2 Removing and installing the crankcase ventilation...................................................................... 8-271
8.3 Removing and installing the oil return line (crankcase ventilation).............................................. 8-273
8.4 Removing and installing the oil dipstick and guiding pipe ........................................................... 8-274
8.5 Removing and installing the oil filler neck.................................................................................... 8-275
8.6 Removing and installing the single-piece oil pan......................................................................... 8-276
8.7 Removing and installing the connecting piece (oil pan - crankcase)........................................... 8-280
8.8 Removing and installing the oil cooler housing with oil cooler..................................................... 8-281
8.8.1 Dismantling and assembling the oil cooler housing with oil cooler................................ 8-283
8.8.2 Removing and installing the cold start valve from/in the oil cooler housing. ................. 8-285
8.9 Removing and installing the oil pressure pump........................................................................... 8-287
8.10 Removing and installing the oil extraction pump (D936, D946)................................................... 8-289
8.10.1 Removing and installing the suction and feed lines for the oil extraction pump (D 936, D
946) ............................................................................................................................... 8-290
8.11 Removing and installing the locking pieces for the oil extraction pump (D 936, D 946).............. 8-291
8.12 Removing and installing the piston cooling injector..................................................................... 8-292
8.13 Removing and installing the end control valve ............................................................................ 8-294
9 Cooling system .................................................................................................................................... 9-295
9.1 Removing and installing the coolant ventilation line .................................................................... 9-296
9.2 Removing and installing the coolant pump.................................................................................. 9-297
9.3 Removing and installing the coolant manifold ............................................................................. 9-298
9.4 Removing and installing the thermostat housing and the thermostat.......................................... 9-299
10 Auxiliary output, air compressor and air conditioning compressor............................................. 10-301

4 - 12
Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
10.1 Overview of auxiliary outputs..................................................................................................... 10-302
10.2 Removing and installing auxiliary output 1 ................................................................................ 10-303
10.6 Removing and installing the air compressor.............................................................................. 10-310
10.7 Removing and installing the switchable auxiliary output on the flywheel housing ..................... 10-312
10.7.1 Remove ....................................................................................................................... 10-313
10.7.2 Installing ...................................................................................................................... 10-313
10.8 Dismantling the switchable auxiliary output for the spool repair kit ........................................... 10-314
10.9 Dismantling and assembling the switchable auxiliary output bearing housing .......................... 10-319
10.10 Installing and removing the air conditioning compressor, variant 1 ........................................... 10-321
10.11 Installing and removing the air conditioning compressor, variant 2 ........................................... 10-322
11 Appendix............................................................................................................................................. 11-323
11.1 Symbols in this manual.............................................................................................................. 11-324
11.2 Abbreviations used .................................................................................................................... 11-325

Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
i - 13
Table of ContentsLMB/1.3/Issue:04/2016/en01.Kapitel_Allg_Information.fm
1 General information
1.1 Structure of this manual................................................................................................................. 1-16
1.2 Important notes in this manual ...................................................................................................... 1-18
1.2.1 Identification of operational safety instructions................................................................ 1-18
1.2.2 Additional identifications.................................................................................................. 1-18
1.3 Safety instructions ......................................................................................................................... 1-19
1.4 Safety instructions for working on the fuel and injection system ................................................... 1-24
1.5 Safety instructions for working on the exhaust after-treatment system (SCR system).................. 1-26
Definition of terms ..................................................................................................... 1-26
1.5.1 Reducing agent ............................................................................................................... 1-26
1.6 Engine diagrams and engine components .................................................................................... 1-28
Flywheel side view .................................................................................................... 1-28
Unit carrier side view................................................................................................. 1-29
6-cylinder wheel drive view ....................................................................................... 1-30
4-cylinder wheel drive view ....................................................................................... 1-31
1.7 Technical data ............................................................................................................................... 1-32
1.7.1 Engine, general ............................................................................................................... 1-32
1.7.2 Standard torques for screw connections......................................................................... 1-37
1.7.3 Standard torques for screw plugs and banjo screws....................................................... 1-39
1.7.4 Standard torques for metric screw fittings....................................................................... 1-40
1.7.5 Standard torques for imperial screw fittings .................................................................... 1-42
1.7.6 Standard torques for cutting ring screw fittings ............................................................... 1-44
1.7.7 Standard torques for triple-lock screw fittings ................................................................. 1-45
1.7.8 Standard torques for VSTI screw plugs........................................................................... 1-46
1.8 Special torques, tensioning instructions, instructions for mounting and installation
instructions .................................................................................................................................... 1-47
1.8.1 Cleaning and locking agents, greases ............................................................................ 1-47

Table of Contents
i - 14
Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
LMB/1.3/Issue:04/2016/en01.Kapitel_Allg_Information.fm
1.8.2 Special torques for cylinder head engine control unit and valves.................................... 1-48
Tensioning instruction for rocker arm bracket ........................................................... 1-48
Installation and tensioning instruction for cylinder head............................................ 1-48
Tensioning instruction for injector sleeve .................................................................. 1-49
Tensioning instruction for camshaft gear .................................................................. 1-50
1.8.3 Special torques for the engine......................................................................................... 1-51
Tensioning instruction for crank ................................................................................ 1-51
Tensioning instruction for crankshaft attachments .................................................... 1-51
Tensioning instruction for unit carrier ........................................................................ 1-52
Tensioning instruction for flywheel ............................................................................ 1-52
Tensioning instruction for flywheel ............................................................................ 1-53
Tensioning instruction for flywheel housing............................................................... 1-53
Tensioning instruction for main bearing .................................................................... 1-54
1.8.4 Special torques for fuel and injection system .................................................................. 1-55
Tensioning instruction for injection lines.................................................................... 1-55
Installation and tensioning instruction for injector and pressure pipe branch............ 1-56
Tensioning instruction for fuel fine filter..................................................................... 1-57
Tensioning instruction for fuel high pressure pump................................................... 1-57
1.8.5 Special torques for charge air and exhaust system......................................................... 1-58
Tensioning instruction for exhaust pipe..................................................................... 1-58
Tensioning instruction for exhaust branch................................................................. 1-59
Tensioning instruction for turbocharger and flange on turbocharger......................... 1-59
Tensioning instruction for SCR catalytic converter.................................................... 1-60
Tensioning instruction for air compressor nut ........................................................... 1-60
Tensioning instruction for reducing agent extraction module .................................... 1-61
Tensioning instruction for SCR profile clip ................................................................ 1-62
Instructions for mounting high temperature sensor ................................................... 1-62
Instructions for mounting lambda NOx sensor .......................................................... 1-63
Instructions for mounting NH3 sensor ....................................................................... 1-63
Instructions for mounting outside temperature sensor .............................................. 1-64
Instructions for mounting humidity sensor................................................................. 1-64
1.8.6 Special torques for the electrical system......................................................................... 1-66
Tensioning instruction for heating flange................................................................... 1-66
Tensioning instruction for alternator electrical connection ........................................ 1-66
Tensioning instruction for starter individual operation ............................................... 1-66
Tensioning instruction for sensors............................................................................. 1-68
Tensioning instruction for engine control units attachment ....................................... 1-69
1.8.7 Special torques for the lubrication system....................................................................... 1-70
Tensioning instruction for oil cooler housing screws ................................................. 1-70
Cold start valve.......................................................................................................... 1-70
Tensioning instruction for valve................................................................................. 1-70
Tensioning instruction for cold start valve default setting.......................................... 1-70
Tensioning instruction for piston cooling injector....................................................... 1-71
1.8.8 Special torques for the auxiliary output, air compressor.................................................. 1-72

Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
i - 15
Table of ContentsLMB/1.3/Issue:04/2016/en01.Kapitel_Allg_Information.fm
Tensioning instruction for proximity switch switchable auxiliary output..................... 1-73
Tensioning instruction for M52x1.5 ring auxiliary output ........................................... 1-73
Tensioning instruction for M40x1.5 ring auxiliary output ........................................... 1-73
1.9 Fuel diagram.................................................................................................................................. 1-74
1.10 Lubricating oil diagram .................................................................................................................. 1-75
1.11 Coolant diagram ............................................................................................................................ 1-76
1.11.1 Coolant diagram, general overview................................................................................. 1-76
1.11.2 Coolant circuit, engine..................................................................................................... 1-78
Coolant circuit, unit carrier side view......................................................................... 1-79
Coolant circuit, cylinder head .................................................................................... 1-80
1.12 Assigning the channels in the crankcase and the cylinder head ................................................... 1-81
1.13 Transport device and fastening parts ............................................................................................ 1-82
1.13.1 Removing and installing the transport device and fastening parts.................................. 1-83
1.14 Tools.............................................................................................................................................. 1-84
1.14.1 Special tools.................................................................................................................... 1-84
Lifting traverse........................................................................................................... 1-84
Engine assembly stand ............................................................................................. 1-88
Lifting device for flywheels (SAE0, SAE1 and SAE2) ............................................... 1-93
Turning devices......................................................................................................... 1-95
Assembly bolt............................................................................................................ 1-99
Pivot bracket devices ................................................................................................ 1-99
Torx tools ................................................................................................................ 1-100
Removing and installing the cylinder liner............................................................... 1-101
Checking the cylinder liners' projection................................................................... 1-102
Removing and installing the unit carrier .................................................................. 1-102
Removing and installing the flywheel housing ........................................................ 1-102
Removing and installing the front crankshaft seal................................................... 1-103
Removing and installing the crankshaft .................................................................. 1-103
Removing and installing the piston with crank and piston rings.............................. 1-103
Removing and installing the piston rings................................................................. 1-103
Removing and installing the valve stem seal, valve springs, valves ....................... 1-104
Removing and installing the mass balancing shafts ............................................... 1-104
Removing and installing the camshaft .................................................................... 1-104
Removing and installing the injection line ............................................................... 1-104
Removing and installing the pressure pipe branch and injector.............................. 1-105
Removing and installing the injector sleeve ............................................................ 1-105
Removing and installing the flywheel ...................................................................... 1-105
Removing and installing the rear crankshaft seal ................................................... 1-105
Reducing agent pump ............................................................................................. 1-106
Auxiliary outputs...................................................................................................... 1-106
LIDIA ....................................................................................................................... 1-106

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General information
1 - 16
Repair manual
Structure of this manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
1.1 Structure of this manual
The work descriptions in this manual are structured as follows:
There are two types of work descriptions:
1. Short work description (A)
This includes elements (1) to (4) above and elements (5) to (9) if the work process requires it.
You can identify this type by the key (4) containing a "Work instructions" table column (A).
The work process is described in the overview illustration. Work instructions are provided if necessary. Different sym-
bols are used to differentiate between installation instructions, removal or disassembly instructions, and assembly
instructions.
The following pages provide an explanation of the symbols.
2. Detailed work description (B)
This also includes elements (1) to (4), elements (5) to (9) if the work process requires it, and also element (10) with
text and illustrations.
You can identify this type by the key (4) not containing a "Work instructions" table column (B).
Please read the entire work description through to the end of the chapter as this is the only way to ensure you receive
all of the required information.
Different symbols are used in the illustrations and text in this manual.
The following pages provide an explanation of the symbols.
1 Chapter header
2 Previous tasks with information on the chapter
number and page number
3 Overview illustration with specification of where
the applicable assemblies are on the diesel en-
gines and all part of the assembly
4 Key for the overview illustration with working in-
structions, safety instructions, special tools,
tightening torques, lubricants, etc.
5 Special tools table
6 Lubricants table
7 Tensioning instruction table
8 Technical data table
9 Detailed work description with text and illustra-
tions

Repair manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
Structure of this manual
1 - 17
General informationLMB/1.3/Issue:04/2016/en01.Kapitel_Allg_Information.fm
140398

General information
1 - 18
Repair manual
Important notes in this manual
D934 A7-04 / D936 A7-04
D944 A7-04 / D946 A7-04
1.2 Important notes in this manual
1.2.1 Identification of operational safety instructions
The warning sign always appears in connection with the signal words
DANGER
WARNING
CAUTION
1.2.2 Additional identifications
_5
This is the warning sign. It warns of possible risk of injury. Comply with all measures that are identified with
warning signs in order to avoid injuries and death.
_5
DANGER Identifies an immediately dangerous situation that will result in death or serious bo-
dily injuries if it is not prevented.
_6
WARNING Identifies a dangerous situation that could result in death or serious bodily injuries
if it is not prevented.
_7
CAUTION Identifies a dangerous situation that could result in minor or moderate bodily injuries
if it is not prevented.
ATTENTION Identifies a dangerous situation that could result in property damage if it is not pre-
vented.
9
Note Identifies useful information and tips.

Liebherr d944 (a7 04) diesel engine service repair manual

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