Taking a Liebherr engine from bare crankcase back to running order is the job these 664 pages are written for: factory service manual ID No. 8717408, covering four D series diesel variants. Cylinder head removal and valve inspection, crankshaft and camshaft bearing replacement, injection pump removal, injector testing and turbocharger servicing each have a chapter in this Liebherr D 9408 service manual PDF, while the basic engine teardown walks the timing case, crankshaft and camshaft out and back in. A maintenance schedule, troubleshooting charts and torque tables come in the early chapters; the book closes on the measuring tools and fixtures your rebuild calls for. Set injector pop pressure to 225+8 bar on new nozzles and 217+8 bar in service; the oil filter bypass valve should open at 6 ±1 bar. Alone at the stand, there is nobody to ask. Bookmarked and text-searchable, the PDF is bought once and stays yours, holding every clearance and torque sequence before your engine goes back together.
What's Inside This Manual
| System | Pages | Key Topics |
|---|
| Technical Data | 9-92 | Engine Data, Fuel Injection System, Crank and Camshaft Drive, Lubrication System, Cooling System |
| Inspections. Checks and Adjustments | 93-192 | Maintenance Schedule, Air Filter Maintenance, Service Fluids |
| Cylinder Assembly | 193-232 | Cylinder Head Removal, Cylinder Head Disassembly, Valve Inspection |
| Crankcase, Crankshaft, Camshaft Inspection and Bearing Replacement | 233-252 | Crankcase Inspection, Crankshaft Inspection, Camshaft Inspection |
| Components - Front Section | 253-348 | Fan Drive Removal, Coolant Pump Removal |
| Components - Flywheel Section | 349-362 | Flywheel Removal, Flywheel Ring Gear, Crankshaft Seal Replacement |
| Fuel Injection System | 363-422 | Injection Pump Removal, Fuel Injector Testing, Bleeding Fuel System |
| Pumps / Add-On Components | 423-516 | Air Compressor Removal, Alternator Removal, Hydraulic Pump Removal |
| Disassembly / Assembly of Basic Engine | 517-560 | Timing Case Removal, Crankshaft Removal, Camshaft Removal |
| Turbocharger | 561-612 | Turbocharger Servicing, Turbocharger Removal |
| Special Tools | 613-664 | Measuring Tools, Installation Fixtures, Cylinder Head Tools |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| D 9408 TI-EA4 / TI-EA5 below 440 kW, D 9406 TI-EA5 below 320 kW |
| Injection pressure in new condition | 225+8 bar (3263-3379 PSI) | p. 16 |
| Injection pressure Operating press. | 217+8 bar (3147-3263 PSI) | p. 16 |
| D 9408 TI-EA4 |
| Injection pump drive side sub-group 7.15 Bushing diameter | 45+0.056 mm (1.7717-1.7739 inch) | p. 18 |
| D 9408 TI-EA4 (M20x1.5); EA5 M24x1.5 = 355 Nm |
| Locknut for splined shaft on injection pump torque | 150 +10 Nm (111 - 118 ft-lbs) | p. 77 |
| D 9408 TI-EA4, D 9406 TI-EA5, D 9408 TI-EA5 |
| Oil-Filter / Oil cooler By-pass valve opening pressure (2.4 mm spring wire) | 6 ±1 bar (73 - 102 PSI) | p. 64 |
| Compression pressure | 20 - 28 bar | p. 13 |
| All Models |
| Thermostats opening temperature | 71°C (160°F) and 80°C (176°F) | p. 70 |
| Battery fluid level | 10 to 15 mm above the plates | p. 101 |
| Minimum idle speed | 600 - 1000 RPM | p. 11 |
| Oil pressure relief valve opening pressure | 9 ± 1 bar | p. 59 |
| 55 A version (80 A version also listed) |
| Alternator 28V 55A | 28V 55A | p. 429 |
| coolant with corrosion inhibitor/antifreeze |
| Coolant change interval | 2 years | p. 109 |
