Specifications

Note: Since illustrations are used for several different variants, certain details may differ from the
variant in question. The essential information in the illustrations is, however, always correct.

General

Type designation Max power output Max. torque

1
At 2300 rpm (38 rps) At 1200–1700 rpm (20–28 rps)

D5F 215 219 kW (300 hp) 816 Nm

1
Net effect according to ISO 1585. Smoke requirements fulfilled according to ECE reg. 24 Federal
Register and Swedish requirements

Number of cylinders.....4

Cylinder bore.....108 mm

Stroke.....130 mm

Swept volume..... 1.190 dm³

Firing sequence.....1-3-4-2

Note: No. 1 cylinder is placed closest to the flywheel

Compression ratio.....17,3:1
Slow idling..... 750 rpm (10 rps)
Fast idling.....2650 rpm (44 rps)
Highest full load engine speed.....2300 rpm (38 rps)
Weight, engine..... 500 kg
Maximum length..... 757 mm
Maximum width..... 335 mm
Maximum height..... 778 mm

Engine
Engine block
Length..... 757 mm

Height, upper block face - crankshaft centre..... 345.5 mm

Height, lower block face - crankshaft centre..... 105 mm

Cylinder head

Type..... 4-cylinder

Length..... 586 mm

Width.....256 mm

Height.....110 mm

Cylinder head gasket, thickness.....1 hole = 1.15 mm. 2 holes = 1.25 mm

Cylinder head bolt

Quantity/cylinder head.....18

Thread size.....M15

Length.....134 or 170 mm respectively

Cylinder liner

Type.....Wet, exchangeable

+0.05
Height of sealing surface above block face.....0,10 /–0,0 mm

Number of sealing rings per cylinder liner.....2

Piston
Height above cylinder block face:
seal marked with a hole (t = 1.15 mm)..... 0.31–0.40 mm
gasket marked with two holes (t = 1.25 mm).....0.41 – 0.50 mm

Type.....Forged pistons

Number of slots.....3

Front marking.....Symbol facing the flywheel

Piston rings

Compression rings

Quantity.....2

Piston ring markings upwards

Specifications Wear tolerance

Piston ring clearance in grooves: 0.07 – 0.105 mm
Upper compression ring.....(trapezoidal form)
Lower compression ring

Piston ring gap measured in ring opening: 0.30 — 0.55 mm

Upper compression ring 1.50 – 2.00 mm
Lower compression ring

Maximum piston ring gap measured at ring opening: 35.5 mm

Upper compression ring 35.5 mm
Lower compression ring

Oil ring

Quantity.....1

Piston ring marking upwards

Specifications Wear tolerance

Piston ring clearance in grooves 0.03 — 0.075 mm

Piston ring gap measured in ring opening 0.30 — 0.60 mm

Maximum piston ring gap measured at ring opening 22.7 mm

Valve mechanism
Valves

Valve head, diameter

Inlet.....38.2 mm
Exhaust.....35.8 mm

Valve stem, diameter

+0
Inlet.....7,96 /–0,01 mm
+0
Exhaust.....7,95 /–0,01 mm

Valve seat angle (A):

Inlet.....60,0°
Exhaust.....45,0°

Seat angle in cylinder head (B):

Inlet.....30±0,5°
Exhaust.....45±1°

Specifications Wear tolerance

Measurement between valve head and cylinder head face: +0,25

Inlet.....1,25 /–0,1 mm
Exhaust.....1,25 +0,25
/–0,1 mm
Note: The valves must also be replaced when replacing the valve seats.
Valve clearances, cold engine, setting values:
Inlet.....75° (0.35 mm)
Exhaust..... 105° (0.45 mm)

Valve seats

Standard

Outer diameter (A)

Inlet.....39.31 mm
Exhaust.....36.81 mm

Height (B)
Inlet..... 7.5 mm
Exhaust..... 7.5 mm

Valve seat position

Standard

Diameter (C)
Inlet.....39.2 mm
Exhaust.....36.7 mm

Depth (D)
Inlet/Exhaust.....11.5 mm

Seat bottom radius (R)

Inlet/Exhaust.....max 0.5 mm

Valve guides

Length
Inlet/Exhaust.....145.85 mm

Inner diameter
Inlet/Exhaust.....8±0.1 mm

+0,2
Height above cylinder head spring surface.....23,4 /–0,0 mm

Specifications Wear tolerance

1
Clearance valve shaft guide: ±0.01 mm
Inlet.....0,02 ±0.01 mm
Exhaust.....0,03

1
The measurements are calculated for the measurement method described in the service literature,
see Group 214.

Rocker arms

Rocker arm spring.....max 38.8 mm

Valve springs

Inlet
Length, without load.....64.48 mm

Exhaust
Length, without load.....64.48 mm

Engine transmission
Timing gear
Gear

1. Drive gear, crankshaft

2. Drive gear, camshaft

3. Drive wheel, fuel feed pump

4. Drive gear, air compressor

Camshaft

Drives.....gear

Number of bearings..... 5

Note: Check values only, not for machining.

Diameter, bearing journals, standard.....77.10-77.15 mm
Undersize.....no
Valve lift
Inlet.....6.63±0.08 mm
Exhaust.....7.13±0.08 mm
Axial clearance.....0.1 — 0.6 mm

Camshaft bearings

Camshaft bearing thickness, standard.....2.0 mm

Oversize.....no
Crank mechanism
Crankshaft

Length..... 712.1 ±0.35 mm

1
Crankshaft axial clearance ..... 0.1–0.32 mm

Ovality of main bearing journals and big-end bearing journals.....Max 0.05 mm

Taper of main bearing journals and big-end bearing journals.....Max 0.008mm

1
The dimensions refer to oiled parts.

Main bearing journals

Diameter (Ø) standard.....85 mm

Undersize
0.25 mm.....84.75 mm
0.50 mm.....84.50 mm

Width axial bearing stub (A)

standard.....33.9 mm
Oversize
0.4 mm (axial bearing 0.2).....34.3 mm

Recess radius (R).....2.5±0.2 mm

Thrust washers (axial bearing)

Width (B) standard.....2.9 mm

Oversize
0.2 mm.....3.1 mm

Main bearing shells

Thickness (C) standard.....2.73 mm

Oversize
0.25 mm.....2.85 mm
0.50 mm.....2.98 mm

Run-out, main bearing.....max 0.1 mm

Main bearing journal

Diameter (Ø).....75 mm
Undersize
0.25 mm.....74.79-74.82 mm
0.50 mm.....74.54-74.58 mm

Width (A).....37.4±0.04 mm

Recess radius (R).....3.5±0.2 mm

Big-end bearing shells

Thickness (B) standard.....2.47 mm

Oversize
0.25 mm.....2.60 mm
0.50 mm.....2.72 mm

Diameter, bearing shell seating (C).....80-80.02 mm

Connecting rod

Length centre - centre (D)..... 712 ±0.35 mm

Piston bushing inside diameter (E).....45 mm

1
Axial clearance, connecting rod - crankshaft ..... 0.1–0.35 mm

1
Big-end bearing, run-out .....

Straightness, max deviation per 100 mm of measured length.....0.04 mm

Twist, max deviation per 100 mm of measured length.....0.04 mm

1
The dimensions refer to oiled parts.

Marking.....the arrow points to the flywheel.

Connecting rod and cap are marked as a

pair with a three-digit serial number (see
illustration).
Flywheel, fitted

Axial run-out (manual gearbox) measurement radius 150 mm.....max 0.20 mm

Number of teeth, starter motor crown wheel.....129

Lubrication and oil system

Oil

Oil change volume, see service information group 175.

Oil pressure

1: Oil pressure
2: Oil temperature

Operating speed (1300 rpm).....max 400 kPa

Operating speed (1800 rpm).....max 450 kPa

Operating speed (2300 rpm).....max 500 kPa

Slow idling (750 rpm).....min 180 kPa

Oil temperature

Cold engine, engine stopped.....ambient temperature

1
Warm engine, engine running (coolant temperature 75-95° C).....125° C

1
Up to 130°C at high loads.

Oil filter

Full flow filter.....1

Fuel system
Safety valve

Opening pressure, high pressure

Max pressure between.....1850-1950 bar

Opening pressure, low pressure

Inlet and exhaust system
Charge pressure

Euro5

Charge pressure

D5F 215: 102 kPa

1000 rpm..... 207 kPa
1200 rpm..... 245 kPa
1400 rpm..... 253 kPa
1600 rpm..... 267 kPa
1800 rpm..... 267 kPa
2000 rpm..... 255 kPa
2100 rpm

Actuator

Setting values:
200 kPa.....provides 4.1 mm link arm movement.
Max pressure..... 300 kPa

Boost air temperature indicator

Cold engine, engine switched off.....Ambient temperature

Warm engine, engine running (coolant temperature 75-95° C).....42° C above ambient
temperature

Heat retention function

Air pressure for exhaust shutter.....750 kPa

Heat retention activated

coolant temperature.....<65° C
engine load.....<350 Nm
ambient temperature.....<10° C

Heat retention deactivated

coolant temperature..... >70 °C
engine load..... >850 Nm
ambient temperature..... >12 °C

Engine brake

Brake type Braking power with unloaded Braking power with loaded
vehicle vehicle

2-position 0% 0%
lever 100% 100%

Exhaust back-pressure

EURO5: exhaust back pressure, max...... 24 kPa

Cooling system
Thermostat

Quantity.....1

Opening temperature..... 86 °C

Engine control system

Engine electronic control unit

Number of pins.....2 x 62

Generation..... EMS 2.2

Sensors

Coolant temperature sensor

Engine oil temperature sensor
Common rail sensor
Charge air temperature sensor
Charge pressure sensor
Check value.....1 V at 93.75 kPa

Camshaft sensor

Distance to camshaft.....1±0.5 mm

Flywheel sensor

Distance to flywheel.....1±0.5 mm

Tightening torques and order

Tightening torques Group 20

General tightening torques

M6 standard bolt 8.8.....10±1,5 Nm
M8 standard bolt 8.8.....24±4 Nm
M10 standard bolt 8.8.....48±8 Nm
M12 standard bolt 8.8.....85±15 Nm
M14 standard bolt 8.8.....140±25 Nm
M16 standard bolt 8.8.....190±35 Nm

Only torque-tightened bolts can be refitted.

Torque and angle tightened/yield limit tightened bolts

8.8.....shall not be reused
10.9.....can be refitted
12.9.....can be refitted

Note: Check bolts before refitting. Damaged bolts, i.e. cuts on underside, to be scrapped.

Tightening torques Group 21

Rear engine mounting, flywheel housing.....275±40 Nm

Main-bearing cap
Step 1.....50±8 Nm
Step 2.....60° Angle tightening
Step 3.....60° Angle tightening

Note: Use new screws.

Connecting rod cap
Step 1.....30±5 Nm
Step 2.....60° Angle tightening
Step 3.....60° Angle tightening

Note: Use new screws.

Flywheel

Note: Make sure the flange is dry and clean.

Note: Tighten the screws in the numerical order shown in the illustration.

Step 1.....30±5 Nm
Step 2.....60° Angle tightening
Step 3.....60° Angle tightening
Flywheel casing
Step 1: Tighten all M12 bolts.....110 Nm
Step 2: Tighten all M8 bolts.....30 Nm
Step 3: Tighten all M16 bolts.....260 Nm

Note: Apply sealing compound as illustrated.

Width.....2 mm
Oscillation damper
Step 1.....30±5 Nm
Step 2.....60° Angle tightening
Step 3.....60° Angle tightening

Note: Tighten the bolts in the numerical order shown in the illustration.
The oscillation damper bolts may not be reused.
Cover, crankshaft seal
Step 1: Tighten all bolts by hand.
Step 2: Tighten bolts 2 and 10 .....30 Nm
Step 3: Tighten the remaining bolts.....30 Nm
Note: Apply sealing compound as illustrated.

Width.....2 mm

Rocker cover.....8,5 Nm

Note: Tighten the screws in the numerical order shown in the illustration.
Cylinder head

Note: The cylinder head must be fitted according to the instructions, see 21124-1 2111-02-01-
01 Cylinder head, install group 21.

Step 1.....95±5 Nm
Step 2.....180°±10° Angle tightening

1
Lock nuts, valve adjusting screws (inlet).....20 Nm

1
Lock nut, valve adjusting screw (exhaust).....20 Nm

1
after contact
Rocker shaft.....21 Nm

Tightening torques Group 22

Oil sump.....30 Nm

Note: Tighten the screws in the numerical order shown in the illustration.

Note: Apply sealing compound as illustrated.

Width.....3.5 mm

Oil strainer.....30±5 Nm

Oil pump
Step 1.....15 Nm
Step 2.....30±3 Nm

Oil filter housing.....60±10 Nm

Oil cooler, securing screws.....22±2 Nm

Drain plug.....55 Nm

Piston cooling nozzle.....21±4 Nm

Tightening torques Group 23

Feed pump, securing screws
(1).....30 ±5 Nm

Fuel filter housing, securing screws

(2).....30 ±5 Nm

High-pressure pump, securing

screws (3)
Step 1.....10±1.5 Nm
Step 2.....50±8 Nm

Fuel distributor, securing screws

(4).....30 ±5 Nm

Hollow screw (5).....26±3 Nm

Hollow screw (6).....34 ±4 Nm

Hollow screw (7).....49±5 Nm

Hollow screw (8).....39±4 Nm

Hollow screw (9).....39±4 Nm

Hollow screw (10).....39±4 Nm

Hollow screw (11).....39±4 Nm

Hollow screw (12).....49±5 Nm

Cap nuts (13).....20±2 Nm

Sensor, common rail (14).....70±12

Nm

Sensor, common rail (15).....100±17

Nm

Casing, fuel filter (16).....25±2 Nm

Common rail
Fit the common rail by hand only
Step 1.....10±1,5 Nm
Step 2.....30±5 Nm
Step 3.....25±5 Nm
Step 4.....40±7 Nm

Note: Use new pressurised fuel delivery pipes and washers.

1 Fitting for cylinder head..... 80±5 Nm
Stage1 Yoke, injector.....4 Nm
Stage2 Cap nut, fuel supply pipe.....20 Nm
Stage3 Yoke, injector.....30±5 Nm
Stage 4 Cap nut, fuel supply pipe.....52 Nm
Tightening torques Group 25

Screws..... 20±20% Nm

Inlet pipe, tighten the screws in the correct order, from 1–8 .....30 Nm
Clamp..... 6 ±20%Nm

Pressure/temperature sensor, charge air.....7,5±1 Nm

Exhaust manifold:
Step 1.....Tighten bolts to contact (max 10 Nm)
Step 2.....Tighten bolts to contact (max 10 Nm)
Step 3.....40±4 Nm

Turbocharger
Exhaust manifold.....30±5 Nm

Note: Use new nuts.

Throttle housing..... 60±10 Nm

Oil pressure pipe..... 39±8 Nm

Coolant pipe..... 49±5 Nm

Tightening torques Group 26

Thermostat housing.....30±5 Nm

Coolant pump.....30±5 Nm

Coolant pump fixture for alternator.....85±15 Nm

Belt tensioner..... 65 Nmp