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 Liebherr D 9306, D 9308, D 9406, D 9408 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 |
Liebherr D 9306, D 9308, D 9406, D 9408 Common Problems This Manual Covers
Liebherr D 9306, 9308, 9406, 9408 diesel engine showing low oil pressure on the gauge
Check the low oil pressure causes in the troubleshooting chart before tearing in. Remove and inspect the oil pressure relief valve and confirm it opens at 9 ± 1 bar, per page 59. If the valve checks good, inspect the crankshaft and bearings using the bearing section starting page 233.
Manual Section: Engine TroubleshootingCoolant mixing into the engine oil, found on the dipstick at a routine oil check
Check the coolant in oil entry in the troubleshooting chart on pages 189 to 191 to narrow down where the coolant gets in. Remove the cylinder head following the Cylinder Assembly section at page 193, inspect the head and valves on the bench, and pull every torque value from the torque specification pages before refitting.
Manual Section: Engine TroubleshootingBlue exhaust smoke and low compression readings on one or more cylinders
Test compression on every cylinder and compare each reading against 20 to 28 bar (18 to 26 bar on the D 9306 T/TI and D 9308 T/TI) from page 13. Check the blue exhaust causes in the troubleshooting chart, and adjust valve clearance before you retest so a tight valve does not skew the reading. If one cylinder stays low, remove the cylinder head following page 193.
Manual Section: Engine Compression CheckTurbocharger leaking oil with blue or black exhaust smoke and low power
Check the turbocharger malfunction chart before you blame the base engine, because it traces low power, black or blue exhaust and oil leakage back to the turbo. Remove the turbocharger following the section starting page 561, service or replace it, and test compression against 20 to 28 bar (18 to 26 bar on the D 9306 T/TI and D 9308 T/TI, page 13) to rule out the engine itself.
Manual Section: Turbocharger p. 561Fuel injector nozzle suspected on a cylinder with rough running and black exhaust smoke
Remove the injectors, then test and calibrate each one following the Fuel Injector Testing procedure, replacing any nozzle that fails. On the D 9406 TI-EA5 and D 9408 TI-EA4/EA5, set new condition injection pressure to 225 +8 bar per page 16 (300 +8 bar from 440 kW on the D 9408 and from 320 kW on the D 9406). Torque the nozzle union nut to 40 +10 Nm, page 77.
Manual Section: Fuel Injector TestingInjection pump delivery begin (FB) out of spec after the pump was removed and refitted
Check delivery begin (FB) with the Fuel Injection Pump Timing procedure and adjust it before the engine is fired. When refitting the pump, torque the locknut for the splined shaft on the injection pump to 150 +10 Nm, per page 77 (355 Nm on EA5 engines with the M24x1.5 pump, page 78). Bleed the fuel system following the Fuel Injection System section starting page 363.
Manual Section: Fuel Injection Pump TimingFrequently Asked Questions
What are the torque specifications for the cylinder-head bolts on Liebherr D 9306–D 9408 engines?
Per the torque table on page 76, pretorque the cylinder-head bolts to 30 Nm (22 ft-lbs), then tighten to 90 Nm (66 ft-lbs), then turn them in four further 60° stages (60 + 60 + 60 + 60 = 240°). p. 76
What are the replacement specifications for fuel filters and fuel-system seals on Liebherr D 9306–D 9408 engines?
Fuel pre-filters should be replaced every 1000 hours, or sooner if there is a drop in engine performance. Always replace seals, such as O-rings and gaskets, with new ones during any repair. p. 95
What is the correct valve clearance for the D 9306 T/TI engine?
The valve clearance for the D 9306 T/TI engine is 0.25 mm (0.0098 inch) for the inlet and 0.30 mm (0.0118 inch) for the exhaust, measured cold. p. 13
What is the required oil pressure relief valve setting for the D 9306 TB engine?
The oil pressure relief valve setting for the D 9306 TB engine is 9 ± 1 bar (116 - 145 PSI). p. 60
How do I bleed the fuel system on these engines?
Open the shut-off valve on the fuel tank and loosen the bleeder screw on the fuel filter. Actuate the hand pump until fuel free of air bubbles flows from the bleeder screw, then tighten it. Repeat this process at the injection pump overflow valve and finally at the fuel injection line union nuts on the injectors. p. 421
Will this Liebherr D 9306 Service Manual download right away?
Delivery is instant: a 664-page searchable PDF is yours the second checkout clears. Laptop, tablet, or phone, all fine.
Am I able to print pages from this Liebherr D 9306 manual?
Yes. Many buyers print one chapter at a time for their own shop and keep the rest on a tablet.
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