This International Service Manual is a 108 page factory guide, published in 1973 (part number 1091624R2), for the Neuss built Basic Diesel Engines. It covers the naturally aspirated D-155, D-179, D-206, D-239, D-246, D-268, D-310, and D-358, plus the turbocharged DT-239, DT-358, and DT-402.
Written in English with a full text layer, it documents the complete engine from service diagnosis and specifications through the valve gear, camshaft, cylinder head, crankshaft, pistons, sleeves, and connecting rods. Fuel system coverage includes the VA and VE injection pumps, the nozzle holders, and timing.
Cooling, oil pump, water pump, and thermostat service are included, along with a full engine testing section, so a rebuilder or mechanic can work through an overhaul or a targeted repair on any engine in the family.
Other edition of this manual
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 4 | |
| Service Diagnosis | 9-14 | Work Safely - Follow Those Rules, Gaskets and Seals, Service Tools, Service Parts, Serial Numbers, Priming Lubricating System, Engine Run-In Schedule, Start |
| Specifications | 15-17 | Valves Sticking, Piston and Cylinder Sleeve Wear, Improper Fuel Pressure, Low Engine RPM, Low Fuel Pressure, High Fuel Pressure, Engine Runs Unevenly and Vibrates, Type |
| Longitudinal and Cross Section | 18-19 | Longitudinal Section of Engine, Illust. 3 Typical Dt-358 Engine, Cross Section of Engine, Illust. 4 Typical Dt-358 Engine, Valve Lever Springs, Removal and Disassembly, Cleaning |
| Valve Lever Assy | 20-22 | Valve Lever, Shaft, Valve Lever Springs, Removal, Disassembly, Reassembly |
| Camshaft and Idler Gear | 23-28 | General, Removal and Disassembly, Cleaning, Inspection and Repair, Procedure for Line Boring Camshaft Bushings, Camshaft Gear, Thrust Plate and Idler Gear |
| Cylinder Head Valves and Valve Guides | 29-40 | Idler Gear Carrier and Needle Bearings, Reassembly and Installation, General, Oversize Valve Seat Insert Counterbore Chart, Valve Timing, Valve Dimensional Chart |
| Manifolds | 41 | Intake Manifold, Exhaust Manifold, Turbocharger Installation, Air Hose, Fuel Lines, Gaskets |
| Fan - V-Belts | 42 | General, Cleaning, Inspection and Repair, Installation |
| Crankshaft Pulley and Vibration Damper | 43-44 | General, Removal and Disassembly, Cleaning, Inspection and Repair, Installation, Removal |
| Crankcase Front Cover and Plate | 45-46 | Reassembly and Installation, General, Removal and Disassembly |
| Crankcase | 47-50 | Cleaning, Inspection and Repair, Reassembly and Installation, Installation of the Front Oil Seal, Crankcase Front Cover in Place, General, Removal and Disassembly |
| Crankshaft | 51-64 | Grinding the Cutter, General, Hardening Processes, Straightening, Crankshaft Rear End Sealing Flange, Re-Hardening Processes for Nitrided Crankshafts |
| Pistons Cylinder Sleeves - Connecting Rods | 65-73 | General, Groove Diameter, Piston Versions, Piston Ring Gap, Piston Pin Dia, Removal and Disassembly, Checking Cylinder Sleeve Wear, Cleaning |
| Balancer (4-Cyl. Only) | 74-78 | General, Removal and Disassembly, Repair, Reassembly |
| Flywheel | 79-81 | Installation, Removal and Disassembly, Cleaning, Inspection and Repair |
| Oil Pump | 84-87 | Body Gears, Relief Valve, Idler Gear, Drive Gear, Crankshaft Pinion, Roller Bearing |
| Water Pump | 88-90 | Idler Gear Fastening with Self-Locking Nut, Idler Gear Shaft Replacement, General, Removal and Disassembly, Cleaning, Inspection and Repair, Reassembly |
| Thermostat and Coolant Manifold | 91-92 | Thermostat, Removal and Disassembly, Inspection and Repair |
| Injection Pump Ep/Va-Ve | 93-97 | Removal and Disassembly, Repair, Installation, General, A. Checking Static Timing, B. Removal, C. Installing and Timing the Pump to the Engine |
| Injection Nozzle Holder | 98 | Fuel Feed Pump, Installation, A. Flange Mounted Holder, B. Crab Mounted Holder |
| Timing Gear Train | 99-100 | Adjustment, Illust. 212, Illust. 212 Shows the Gear Train of a 6-Cyl.-Engine with Piston Number One on Compression TDC, Timing Chart for Injection Pump Gear Illust. 212 |
| Valve Lash Adjustment | 101-102 | Valve Lever, Feeler Gauge, Adjusting Screw, Lock Nut, Adjusting Valve Lash |
| Engine Testing | 103-108 | Valve Timing, Compression, Lubricating Oil Pressure, Air Cleaner Restriction, Boost Pressure, Crankcase Pressure Orificed Restrictor |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder-head cap screws with collar torque | 14+15 daNm (101+109 Lbf-ft) | p. 17 |
| Valve cover screws (sheet metal) torque | 0.5+0.7 daNm (3.6+5 Lbf-ft) | p. 17 |
| Valve cover screws (gray iron) torque | 1.5+1.7 daNm (11+12.3 Lbf-ft) | p. 17 |
| Nozzle holder stud nuts (flange mounted) torque | 1.3+1.8 daNm (9.4+13 Lbf-ft) | p. 17 |
| Nozzle union nut (nozzle holder) torque | 6-8 daNm (44-58 Lbf-ft) | p. 17 |
| Injection pump flange nut torque | 2.2+2.5 daNm (16+18 Lbf-ft) | p. 17 |
| Injection pump gear bolt (3 radial lines) torque | 2.2+2.5 daNm (16+18 Lbf-ft) | p. 17 |
| Fuel feed pump replacement | Install a new feed pump if the diaphragm is damaged or the operating mechanism is defective. | p. 97 |
| Oil pump idler gear end play | 0.0 - 0.05 mm (0.0 - .002 in.) | p. 84 |
| Oil pump drive gear end play | 0.10 mm (.004 in.) | p. 84 |
| Water pump bearing assembly replacement | Replace bearing assembly (1) Illust. 186 with a new one, if pump has been running rough and/or noisy. | p. 88 |
| Thermostat (5) opening temperature | 78 - 82°C (172 - 180 °F) | p. 91 |
