A40 Common Rail In-Line Engines

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ADDITIONAL WIRING DIAGRAM5
-- --
-
WIRING DIAGRAM NO. 81.99192.2496
Trailer socket, 24V 7-pin sheet 1 of 1

Status: 07.1999
Legend
A Trailer socket, 24V 7-pin N
-
A1 00 Central electrical system
A302 Central computer 2
I GlOl Battery 2
1 X330 Socket N 24V
I XI540 Plug connection, frame I
1 XI586
I
Plug connection, connection, trailer socket 1
I
Note
Installation position of XI586 for semitrailer E8!
I
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- - - -
('I ZLfCY
- -
s ' z Tiair-
ADDITIONAL WIRING DIAGRAMS
-- - -- - - -- - - - -- - - - --- - --
WlRlNG DIAGRAM NO. 81.99192.2497
Trailer socket, 24V 7-pin + 4-pin sheet 1 of 1

Status: 07.1999
Legend
B Trailer socket, 24V 4-pin N
Central electrical system

Central computer 2
Battery 2
Socket N 24V
Trailer socket (reversing light and rear fog lamp)
Plug connection, frame I
Installation position of XI586 and XI587 for semitrailer E8!

- - -- -- --
Trailer socket, 24V 7-pin + C p i n and 12V 13-pin sheet 1 of 2

Status: 03.1999
Legend
B Trailer socket, 24V 4-pin

DC transformer, 24 1 12V
Central computer 2
Battery 2
Socket N 24V
Trailer socket (reversing light and rear fog lamp)
Trailer socket, 24V 7-pin + 4-pin and 12V 13-pin sheet 2 of 2

Status: 07.1999
Legend
A Trailer socket, 12V 13-pin
-
A 100 Central electrical system
A236 DC transformer, 24 / 12V
X740 Trailer socket 12V
- -- ---- -- - -- ----- --- -- -
Trailer socket, 24V 7-pin + 7-pin sheet 1 of 1

Status: 07.1999
Legend
B Trailer socket, 24V 7-pin S

Central computer 2
Battery 2
Socket S 24V
Socket N 24V
: E,"llation position of X I 586 and XI587 for semitrailer E8!

Lo
-
X
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F Z K 0 1 C *----
- -- -- -
- --- - - -- -- - ---

Status: 03.1999
Legend
B Trailer socket, 24V 7-pin S
-
A100 Central electrical system
A236 DC transformer, 24 1 12V
G l 01 Battery 2
X329 Socket S 24V
X330 Socket N 24V
X I 540 Plug connection, frame I
XI586 Plug connection, connection, trailer socket 1
X I 587 Plug connection, connection, trailer socket 2
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- - - - -
5' i
--- ---- -.- - -- ------ - -- -- -. -- --- - -- --
WRING DIAGRAM NO. 81.99192.2449

Status: 07.1999
Legend
A Trailer socket, 12V 13-pin
-
A236 DC transformer, 24 1 12V
X740 Trailer socket 12V
--- -- -- -- -
Trailer socket, 24V 7-pin and 12V 13-pin sheet 1 of 1

Status: 03.1999
Legend
B Trailer socket, 12V 13-pin

DC transformer, 24 1 12V
Central computer 2
Battery 2
Socket N 24V
Trailer socket 12V
-- - A - - -- - -
WRING DIAGRAM NO. 81.99192.1 534
Floodlights, cab roof (left) sheet 1 of 1

Status: 08.2001
Legend
A Floodlights

Central computer 2
Floodlight, left
Fuse, floodlights
Switch, floodlights
Plug connection, floodlight, left
Plug connection, floodlight in roof, left
Potential distributor, 21-pin, line 31000
I ADDITIONAL WIRING DIAGRAMS
. - p ~ - _ - _ _ - - _ _ - - . ~ - - --__ - ~
I, _-
i WIRING DIAGRAM NO. 81.99192.1356
I
) Floodlights, cab roof (left, right) sheet 1 of 1
I Status: 04.2001
) Legend
I A Floodlights
I

Central computer 2
Floodlight, right
Floodlight, left
Fuse, floodlights
Switch, floodlights
Plug connection, floodlight, left
Plug connection, floodlight in roof, left
Plug connection, floodlight in roof, right
Plug connection, floodlights
Potential distributor, 21-pin, line 31 000
-- - - -- -- -- - -- - -- - - --
Ashtray lighting, left sheet 1 of 1

Status: 12.2002
Legend
E l 77 Lighting, ashtray, left
X2541 Potential distributor, 21-pin, line 31000
~ - -~ ~ - - - ~- - - -- ~-
- -- - - - ~~ -- -
Ashtray lighting, right sheet 1 of 1

Status: 11.2002
Legend
El78 Lighting, ashtray, right
ASR check lamp sheet 1 of 1

Status: 04.2001
Legend
A ASR check lamp
-
A407 Instrumentation
HI40 Check lamp, ASR info.
1 For basic equipment, see wiring diagram for EBS

- --- --- - --- - --- - - --- - --
ASR slip threshold button sheet 1 of 1

Status: 11.2002
Legend
A ASR slip thresholds
-
A402 Control unit, EBS
S256 Button, ASR or ASRIESP slip threshold increase
- .- - - --
WlRlNG DIAGRAM NO. 81.99192.1685
Battery EMERGENCY OFF sheet 1 of 2

Status: 12.2003
Legend
A Battery EMERGENCY OFF

Central computer 2
Instrumentation
Fuse, alternator (terminal 15)
Check lamp, emergency off fault
Relay, EMERGENCY OFF, alternator
Switch, EMERGENCY OFF, cab, external
Switch, isolator switch, battery
Switch, EMERGENCY OFF, cab
8-diode cluster, battery isolator switch
Plug connection, auxiliary heater, battery master switch, electrical
Plug connection, enginelEDClgearbox II
Earthing point, cab, next to central electrical system
Crimped connector, line 59104
Plug connection, EMERGENCY OFF-alternator, terminal 15
Plug connection, EMERGENCY OFF, switch, external
Plug connection, auxiliary water heater - battery isolator switch
1 Auxiliary heater
I
I WIRING DIAGRAMS
I -- . - --- -- -- --
ADDITIONAL---
I
I WIRING DIAGRAM NO. 81.99192.1685
i Battery EMERGENCY OFF sheet 2 of 2

) Status: 10.2002
) Legend
A Battery EMERGENCY OFF
I -
) A100 Central electrical system
) A302 Central computer 2
) A317 Control unit, battery isolator switch, battery EMERGENCY OFF
I F128 Fuse, permanent load
) F243 Fuse, central on-board computer, continuous positive
J F522 Fuse line 30000
I F523 Fuse line 30000
) G I 00 Battery 1
)GI01 Battery2
1 MI00 Starter
J Q105 Isolator switch, battery +
J XI00 Ground connection, engine
I XI557 Plug connection, frame, left
! ~ 2 1 7 7 Plug connection, EMERGENCY OFF, switch, external
)X3437 Plug connection, frame, left II
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--- -- -- --- --- -- -- -- - -
--- -- -- - - --
Battery master switch, mechanical (left-hand drive vehicles) sheet 1 of 1

Status: -
Legend
A Battery master switch, mechanical

GI00 Battery 1
MI00 Starter
S149 Isolator switch, battery +
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- -- -- -- -- -- - - - -
-- -- ---- --
WIRING DIAGRAM NO. 81.991 92.2853
Controls, MMI controller sheet 1 of 1

Status: 02.2002
Legend
A MMI controller
-
A574 Controls, MMI
F412 Fuse, tachograph, instrumentation (terminal 30)
XI642 Earthing point, cab behind instrument panel
XI643 Solder connector line 58300
XI757 Solder connector line 16006
X3119 Plug connection, distributor, line 30009
--- - - -- - - - - -- -- - --
Control module, upper bunk sheet 1 of 1

Status: 08.2002
Legend
A Button, sliding roof, in control module
B Button, instrumentation, roof, white, in control module
C Button, window lifter, door, left, i n control module
D Button, window lifter, door, right, in control module
-
S813 Button, sliding roof, in control module
S824 Switch, interior lighting, in control module
S826 Button, window lifter, co-driver door, control module
S827 Button, window lifter, driver door, control module
X I 567 Plug connection, sliding roof
XI581 Plug connection, switch, interior lighting
X1733 Plug connection, switch, sliding roof
X3219 Plug connection, switch, control module
X3220 Plug connection, control module
X3221 Plug connection, control module
I ADDITIONAL WIRING DIAGRAMS
- -
) WIRING DIAGRAM NO. 81.99192.2854
i CAN databus, Highline (H-CAN), with instrumentationlMMl sheet 1 of 1

) Status: 05.2002
I
1 Legend
I
I A Instrumentation
B MMI controller
I -
) A100 Central electrical system
) A302 Central computer 2
) A407 lnstrumentation
( A574 Controls, MMI
~- ~
.--- ---
CAN databus, Highline (H-CAN), with instrumentationlMMllradiosheet 1 of 1

Status: 09.2000
Legend
A Instrumentation
6 MMI controller
C Radio
-
A148 Radiolcassette player
A407 lnstrumentation
A574 Controls, MMI
--- - - -- - - --- - -- - - --
WRING DIAGRAM NO. 81.99192.1546
CAN databus, Highline (H-CAN), with instrumentationlMMllradiolnavigation sheet 1 of 1

Status: 09.2001
Legend
A Instrumentation
B MMI controller
C Radio
D Truck-Gate
-
A1 48 Radiolcassette player
A574 Controls, MMI (man-machine interface menu)
A635 Truck-Gate
- -.. --- -- -- - - ---- -- --- - -- -- -- -- - - ---- --- -
CAN databus, instrumentation (I-CAN)ltachograph(FS-CAN)(standard) sheet 1 of 1

Status: 03.2000
Legend
A I-CANIFS-CAN

Central computer 2
Instrumentation
Tachograph
Fuse, instrument, tachograph (terminal 15)
Plug connection, tachograph
Earthing point, cab, next to central electrical system
Solder connector line 16006
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Electrical System
CAN Controller Area Network
Trucknology Generation A (TG-A)
Publication no.: System Description
MAN Nutzfahrzeuge Aktiengesellschaft Elektrische Anlage TG-A

Dachauer Str. 667 oder Postfach 50 06 20 Systembeschreibung T 51A1
80995 MLJNCHEN 80976 MUNCHEN - englisch -
Printed in Germany
Electrical System
CAN Controller Area Network

System Description T 51-A1
Trucknology Generation A (TG-A)

DIAGRAMS
Table of contents
Diagram titles Diagram no. Sectionlpage
Guide to using the diagrams 6.01 - 1

Diagram, instrumentation CAN databus (I-CAN)/ 81.99192.2377 6.20 - 2
tachograph CAN databus (FS-CAN)
Diagram, drive train CAN databus (T-CAN) 81.99192.2359 6.20 - 4
Diagram, drive train CAN databus (T-CAN) with 81.99192.2522 6.20 - 6
AS-TRONIC
ECAS
customer-specified module
ECASIAS-TRONIC
ECASIcustomer-specified module
lntarder or retarder
ECASIlntarder or retarder
ECASIlntarder or retarderlcustomer-specified
module
ECASIlntarder or retarder/AS-TRONIC
ECASIlntarder or retarder/AS-TRONICI
customer-specified module
lntarder or retarder1AS-TRONIC
lntarder or retarderlcustomer-specified module
AS-TRONIC/customer-specified module
Diagram, drive train CAN databus (T-CAN) with 81.991 92.2434 6.20 - 44
ECASIAS-TRONIC/customer-specified module
Diagram, drive train CAN databus (T-CAN) with 81.991 92.2435 6.20 - 48
Intarder or retarder1AS-TRONIC/customer-specified
module
Diagram, EDC electronic diesel control EDC MS6.1 81.99192.2351 6.20 - 52
Diagram, EDC electronic diesel control EDC MS6.1 81.99192.2427 6.20 - 58
with exhaust gas recirculation (EURO 3)
I DIAGRAMS
Identifier Installation position
Rear of vehicle
Engine
Gearbox
Front of vehicle
Bumper
Right-hand entry point
Left-hand entry point
Area of central electrical system
Control unit holder
Back wall of cab
Instrument panel
Mid-section
Steering colurnn/steering wheel
Pedal mechanism
Front wall inside left
Front wall inside right
Driver's seat
Co-driver's seat
Gearshift console
Battery box
B-pillar, driver's side
A-pillar, driver's side
B-pillar, co-driver's side
A-pillar, co-driver's side
Ceilinglroof
Front axle
Rear axle
Front frame sections
Rear frame section
Left-hand doors
Right-hand doors
Electrical component designation

consisting of code letter and serial number
Code letter: Component or component application code
Key to code letters:
Central electrical system/ECU/assembly P Displayiinstruments

Sensor Q Isolating relay with electronic system
Condenser R Resistor
Lighting S Switch
Fuse V Diodeldiode group
Power supply/pulse generator X Connection
Warning and check device Y Solenoid valve
Relaylcontrol unit Z Interference suppression filter
DIAGRAMS
Identifier Installation position

.-
@ .................................................................................................. Rear of vehicle

@ .................................................................................................. Engine
@ .................................................................................................. Gearbox
@ ................................................................................................. Front of vehicle
@ .................................................................................................. Bumper
@ ................................................................................................ Right-hand entry point
@ .................................................................................................. Left-hand entry point
@ .................................................................................................. Area of central electrical system
@ .................................................................................................. Control unit holder
@ .................................................................................................. Back wall of cab
@ .................................................................................................. Instrument panel
@ .................................................................................................. Mid-section
@ .................................................................................................. Steering columnlsteering wheel
-
..~ O .................................................................................................. Pedal mechanism
@ .................................................................................................. Front wall inside left
@ .................................................................................................. Front wall inside right
@ .................................................................................................. Driver's seat
@ .................................................................................................. Co-driver's seat
@ .................................................................................................. Gearshift console
@ .................................................................................................. Battery box
@ .................................................................................................. B-pillar, driver's side
@ .................................................................................................. A-pillar, driver's side
@ .................................................................................................. B-pillar, co-driver's side
@ .................................................................................................. A-pillar, co-driver's side
@ .................................................................................................. Ceilinglroof
@ ................................................................................................. Front axle
.................................................................................................. Rear axle
@ .................................................................................................. Front frame sections
@ .................................................................................................. Rear frame section
@ .................................................................................................. Left-hand doors
@ .................................................................................................. Right-hand doors
DIAGRAMS
Drive train CAN databus (T-CAN) with lntarder or retarder/

AS-TRONIC Codes for installation positions
Key @ Rear of vehicle @ Driver's seat

~ i a ~ r ano.
m81.99192.2524 sheet 1 of 1 6 Engine @ Co-driver's seat
Modification status: b
@ Gearbox @ Gearshift console
A = Vehicle management computer @ Front of vehicle @ Battery box
B = Electronic brake system @
- Bumper @ B-pillar, driver's side
C = lntarder @ Right-hand entry point @ A-pillar, driver's side
D = Central on-board computer
@ Left-hand entry point @ B-pillar, co-driver's side
E = Oil level sensor
F = AS-TRONIC @ Area of central electrical system @ A-pillar, co-driver's side
G = Electronically controlled air management @ Control unit holder @ Ceilinglroof
@ Back wall of cab @ Front axle
A1 00 (255) Central electrical system
@ Instrument panel @ Rear axle
A144 (451) Control unit, retarder
A302 (352) Central computer 2 @ Mid-section @ Front frame section
A31 1 (392) Oil level sensor with CAN databus @ Steering column/steering wheel @ Rear frame section
A330 (442) Control unit, AS-TRONIC (on gearbox) @ Pedal mechanism @ Left-hand doors
A402 (399) Control unit, EBS
A403 (339) Vehicle management computer @ Front ,wall inside left @ Right-hand doors
A409 (353) Control unit, ECAM @ Front wall inside right
X I 557 Plug connection, frame, left

X I 559 Plug connection, engine/EDC/gearbox IV
X2042 Plug connection, adaptation, AS-TRONIC
X2043 Plug connection, adaptation, AS-TRONIC
Note:
The pin assignment for control unit A144 shown on the diagram applies to
lntarder EST 48 only!
Pin assignment for Voith retarder: CAN High: XI13
CAN Low: XI11
1'14wI c l x L >
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L ' L LSi I
- - - - - - - - - - - - -<
h 0
Error list
Address Error Meaning

code
20 031 16 CAN data bus: EDC message EDC4, byte 0
20 03120 CAN data bus: EDC message EDC4, bytes 4 and 5
20 03121 CAN data bus: EDC message EDC4, byte 6
20 03125 CAN data bus: EDC message EDC5, bytes 2 and 3
Error list
Address Error Meaning

code
38 03230 Setpoint level control
38 03231 Leakage
List of addresses
Address Control unit

EBS
lntarder
Door module, driver's seat
Door module, co-driver's seat
EDC
AS Tronic
Vehicle management computer
Central on-board computer ZBR II
ECAS
Instrumentation
DIAGNOSIS
System structure, K-lines
All the control units testable using the MAN-cats diagnostic system are connected with diagnosis socket
X200 via a K-line. The diagnostic system stimulates a certain control unit via the K-line. The control unit
replies and digitally transfers the errors stored in the error memory via the K-line.
X200
ACC Adaptive cruise control GET Gearbox control unit

AIRBAG Control unit, airbag HZG Heating control
CD Instrument panel KLlMA Air-conditioning system
DPFIGDK Diesel partic. filterlcontr. diesel cat. KSM Customer-specified module
EBS Electronic brake system RET RetarderAntarder control
ECAM Electr. controlled air management TM Door module, driver side
ECASIEFR Electr. controlled air suspension TM 1 Door module, co-driver side
EDC Electronic diesel control ZBR II Central on-board computer with
FFR Vehicle management computer X200 Diagnosis socket
FSS Driver seat control unit
Electrical System
Key, Code Numbers
Line Numbers, Symbols, Diagnosis ...
Publication no.: Device List

2nd edition T 60
MAN Nutzfahrzeuge Aktiengesellschaft Elektrische Anlage Gerateliste

Dachauer Str. 667 oder Postfach 50 06 20 Gerateliste T 60 (2. Ausgabe)
80995 M~JNCHEN 80976 M~JNCHEN - englisch -
Printed in Germany
Electrical System
Device List T 60 (2nd edition)

Key, Code Numbers
Line Numbers, Symbols, Diagnosis ...
ELECTRICAL SYSTEM
Table of contents
Electrical system.......................................................................................................................... 0
Table of contents .......................................................................................................................... 0.11 .1
Abbreviations................................................................................................................................ 0.13 .1
General information...................................................................................................................... 1
Notes on safety ............................................................................................................................ 1.20 .1
Key to wiring diagrams ................................................................................................................ 2

Code letter A Control units .............................................................................................. 2.01 .1
Code letter B Sensors. pressure switches. pickups ..........................................................2.02 .1
Code letter C Condensers................................................................................................. 2.03 .1
Code letter E Lighting........................................................................................................ 2.05 .1
Code letter F Protective devices (fuses,...) ..................................................................... 2.06 .1
Code letter G Alternator, battery ........................................................................................ 2.07 .1
Code letter H Checking and warning devices.................................................................. 2.08 .1
Code letter K Relays ......................................................................................................... 2.1 1 .1
Code letter M Motors ......................................................................................................... 2.1 3 .1
Code letter N Amplifiers, controllers .................................................................................. 2.1 4 .1
Code letter P Gauges and instruments ............................................................................. 2.1 6 .1
Code letter Q Master switches ......................................................................................... 2.1 7 .1
Code letter R Resistors .................................................................................................... 2.1 8 .1
Code letter S Switches ................................................................................................... 2.1 9 .1
Code letter T Transformers, voltage dividers .................................................................. 2.20 .1
Code letter V Diodes ......................................................................................................... 2.22 .1
Code letter W Antennae, connection lines ......................................................................... 2.23 .1
Code letter X Terminals, plug connections, plug distributors ............................................ 2.24 .1
Code letter Y Solenoid valves ........................................................................................... 2.25 .1
Code letter Z Filters, diplexers .......................................................................................... 2.26 .1
Wiring diagram line numbers ................................................................................................ 3

04 Ignition system ................................................................................................................... 3.04 .1
05 Fuel system. supply .heating................................................................................................ 3.05 .1
13 Fire extinguisher system. fire suppression system ................................................................ 3.1 3 .1
14 Safety devices. emergency mode. emergency shut.off. intrinsically safe circuits ................. 3.14 .1
15 Voltage supply (terminal 15) .................................................................................................. 3.15 . 1
16 Monitoring devices. tachograph ...................................................................................... 3.16 .1
17 Bulbs. flame start system ...................................................................................................... 3.17 . 1
20 Washers and wipers .............................................................................................................. 3.20 .1
23 Air-conditioning system ......................................................................................................... 3.23 .1
24 Heating. auxiliary heaters. battery heating ............................................................................ 3.24 .1
25 Ventilation.............................................................................................................................. 3.25 .1
30 Voltage supply, positive ......................................................................................................... 3.30 .1
31 Voltage supply. negative ................................................................................................. 3.31 .1
32 Electric motors ....................................................................................................................... 3.32 .1
37 Ticket cancelling machine ................................................................................................. 3.37 .1
40 Gearbox ............................................................................................................................ 3.40 .1
43 Retarderlengine brake...................................................................................................... 3.43 .1
49 Turn indicators and hazard warning lights............................................................................. 3.49 .1
50 Starter control ........................................................................................................................ 3.50 .1
55 Masked lighting ..................................................................................................................... 3.55 .1
56 Headlight low beam. headlight high beam. fog lamps. rear fog lamps .................................. 3.56 .1
57 Park light ............................................................................................................................... 3.57 .1
58 Parking lights. sidelights. tail lights ........................................................................................ 3.58 .1
59 Alternator. power generation ................................................................................................. 3.59 .1
60 Engine. electronic engine management (EMS). electronic accelerator................................. 3.60 .1
61 Fan drive. coolant .................................................................................................................. 3.61 .1
62 Radio set ............................................................................................................................... 3.62 .1
ELECTRICAL SYSTEM
ABBREVIATIONS
FM Vehicle management
FMI Failure Mode ldentification
FMR Vehicle engine control
FOC Front Omnibus Chassis
FSCH Windscreen heating
FSG Artificial roadway equipment
FSH Window heating
FTW Driver's cab partition
FUNK Communications radio set
FZA Destination display
GDK Closed-loop diesel exhaust catalytic converter

GEN Generator
GET Transmission
GGVS Ordinance regulating the movement of dangerous goods by road
GND Ground (or earth)
GP Planetary gear group -transmission (post-shift group)
GS Transmission control
GV Pre-shift group - transmission (splitter group)
HA Rear axle
HBA Secondary braking system
HGB Maximum speed limit
HGS Hydraulic gearshift
HLUE Hydrostatic fan
HOC Heck Omnibus Chassis
HSS Highside switch
HST Main switch panel
HU Main examination
Hz Hertz (alternationslperiod per second)
HZA Halt sign facility
HZG Auxiliary engine speed pickup
IBEL Interior lamps

IBIS lntegrated vehicle information system
IC lntegrated Circuit
ID Identification
IMR lntegrated mechanical relay (start-up control)
INA Information display (e.g. control lamp)
IR Individual control (ABS)
IRM Modified individual control (ABS)
IS0 International Standardization Organization
IWZ Incremental angle-time measuring system
KBZ Combi-brake cylinder

KFH Fuel filter heating
KlTAS Kienzle Intelligent Tachograph-Sensor
KLI Air-conditioning unit
KNEEL Kneeling
KSM Customer-specific control module
KSW Customer option
KWP Key Word Protocol (protocol for diagnosis with MAN-cats)
LBH Air vessel

LCD Liquid Crystal Display
LDA Charge pressure-sensitivefull-load stop
LDF Charge pressure sensor
LDS Air suspension damping system
LED Light Emitting Diode
KEY TO WIRING DIAGRAMS
Code letter H Checking and warning devices
Check lamp, coolant level

Check lamp, stop, "central warning light"
Check lamp, oil pressure
Electric horn
Electric horn, Fiamm, low frequency
Steering pressure check
Air horn
Electric horn, Fiamm, high frequency
Steering oil check
Check, gearbox oil temperature
Check lamp, for S33.1 only
Check lamp, turn indicators, trailer
Check lamp, gearbox oil temperature
Buzzer, operating state
Electric horn, reverse gear
Check lamp, ABS fault
Check lamp, ASR control
Check lamp, ASR control, diagnosis
Check lamp, EDC
Check lamp, EMS, diagnosislwarning device
Check lamp, EMS, warning device
H95 Check lamp, 2nd alternator
H l 00 Charge check lamp
HlOl Check lamp, flame start system
H102 Signal horn
H103 Check, level deviation
H104 Check, door open
H105 Buzzer, frost warning, air-conditioning system
H106 Gong, PA system
H107 ABS, tractorltrailer
HI08 Check lamp, reservoir pressure
HI09 Check lamp, oil pressure
HllO Check lamp, coolant temperature
H111 Central warning light, STOP
HI12 Brake lamp, right
H113 Brake lamp, left
H114 Additional brake lamp, right top
H115 Additional brake lamp, left top
HI16 Check lamp, central lubrication system
HI17 Check lamp, parking brake
HI18 Check lamp, turn indicators, tractor
HI19 Check lamp, turn indicators, trailer
HI20 Turn indicator, front right
HI21 Turn indicator, front left
HI22 Turn indicator, rear right
HI23 Turn indicator, rear left
HI24 Turn indicator, side right
HI25 Turn indicator, side left
HI26 Turn indicator at rear, right top
HI27 Turn indicator at rear, left top
H128 Check lamp, undervoltage protection
H129 Check lamp, headlight high beam
H130 Check lamp, roof flaps
HI31 Check lamp, air-conditioning system
H132 Warning buzzer, emergency valve
H133 Check lamp, call steward
H134 Check lamp, toilet
H I 35 Check lamp, toilet
Check lamp, toilet waste tank fulllfresh water empty
Check lamp, ENGAGED

Check lamp, central locking
Check lamp, luggage compartment flap
Charge check lamp, alternator 2
Check lamp, air suspension, warning
Check lamp, ABS, tractor
Check lamp, central lubrication system
Check lamp, ASR info.
Check lamp, EDC Ielectronic accelerator
Check lamp, EMS (fault)
Horn 2
Check lamp, ECAS (fault)
Check lamp, ECASIEFR (fault)
Check lamp, ECAS (warning)
Check lamp, ECASIEFR (warning)
Check lamp, retarder
Warning buzzer, reverse gear for driver
Check lamp, pressure drop, gearbox
Warning buzzer, driver
Check lamp, tipper
Check lamp, cab lock
Check lamp, pressure drop, gearbox
Check lamp, ABS, trailer
Buzzer, reverse gear
Check lamp, ABS info., trailer
Check lamp, coolant level
Additional turn indicator, front left
Additional turn indicator, front right
Warning buzzer, intercom system
Check lamp, power steering
Air horn
Check lamp, hydraulic system
Check lamp, crane
Check lamp, converter-clutch unit
Check lamp, gearbox, oil temperature
Warning buzzer
Check lamp, power take-off
Check lamp, differential lock, rear axle
Check lamp, differential lock, front axle
Check lamp, differential lock, interaxle
Check lamp, off-road range
Check lamp, neutral position
Signal horn (two-tone)
Check lamp, emergency operation, outside, door 1+2
Masked brake lamp, left
Masked brake lamp, right
Check lamp, steering oil level indicator
Check lamp, priority vehicle light, right
Siren for anti-theft warning system
Check lamp, emergency release device
Check lamp, seat belt
Check lamp, tyre pressure control system
Check lamp, gearbox, status monitor
Check lamp, body (multi)
Check lamp, body (multi)
Warning buzzer, reverse gear, vehicle, outside
Check lamp, monitor, rear axle load
Check lamp, ENGAGED
Check lamp, combined mode
Check lamp, trailing axle, steering, fault
Check lamp, emergency valve warning, front
Check lamp, frequent-stop brake

Warning buzzer, differential lock, transverse, front axle
Check lamp, support system
Warning buzzer, door monitor, body
Check lamp, door monitor, body
Check lamp, 2nd priority vehicle light
High-volume horn, low
High-volume horn, high
Check lamp, cable winch
Check lamp, splitter group
Warning buzzer, differential lock, transverse, rear axle
Check lamp, gritter
Panel of check lamps for H I 80 and H I 81
Warning buzzer, engine and brake circuit monitoring
Check lamp, coolant temperature, 105 degrees
Check lamp, gearbox, oil pressure
Check lamp, gearbox, oil temperature
Check lamp, gearbox, oil level
Check lamp, axle lock-out, front axles
Check lamp, axle lock-out, rear axles
Panel of check lamps for H204 and H205
Check lamp, levelling
Panel of check lamps for H207
Warning buzzer, frequent-stop brake not applied
Check lamp, 5-axle steering, supply OK
Check lamp, 5-axle steering, rear axle, straight-ahead steering
Check lamp, system, central computer
Check lamp, alarm (red)
Check lamp, early warning (yellow)
Warning buzzer, instrument panel 1
Check lamp, customer's special request 1
Check lamp, servomotor fault
Warning buzzer, door closing warning, door 2
Check lamp, pram
Check lamp, door 3
Check lamp, door 4
Check lamp, door open
Check lamp, door closed
Check lamp, release
Check lamp, stop symbol system
Ceiling sign, bus stopping (front section)
Ceiling sign, bus stopping (tractor)
Warning buzzer, bell, departure
Check lamp, gas filter
Check lamp, engine fault
Check lamp, lift
Warning light, lift, outside, front
Warning light, lift, outside, rear
Warning light, lift, inside
Warning buzzer, lift
Check lamp, trailing axlelleading axle, steering, warning (yellow)
Check lamp, trailing axlelleading axle, steering, fault (red)
Diode, economy circuit

Diode, turn indicators, right
Diode, hazard warning lights
Diode, turn indicators, left
Diode, turn indicators, school bus readiness
Diode group, retarder operation (Verona circuit)
Diode group, retarder operation (Verona circuit)
Diode, voltage supply, body, multi
Diode group V100, V154
Diode, interior heating
Diode group V255, V365, V366, V367
Diode, "ON" at ignition
Diode, self-holding
Diode group, IBIS on
Diode, control suppression, ECAS
Diode, control suppression, ECAS
Diode group, control suppression, ECAS
Diode, retarder, reduction
Diode, retarder, reduction
Diode, door 1 open
Diode, door 2 open
Diode group V406, V407, V408
Diode group, cab lock, anti-theft warning system
Diode group, cab lock, anti-theft warning system
Diode, brake lamp, retarder
Diode, retarder, self-holding
Diode group, axle lock-out, hydropneumatic suspension
Diode, engine stop
Diode, taillift
Diode, headlight high beam
Diode, headlight low beam
Diode, frequent-stop brake
Diode, hillholder
Diode D+ (CNG)
Diode, mute, anti-theft warning system
Diode, rear distributor, anti-theft warning system
Diode, emergency valve warning, door 3
Diode, emergency valve warning, door 4
Diode, oil top-up, "WAKE-UP"
Diode, hazard warning lights, "WAKE-UP"
Diode, check, hydraulic system
Diode, fan motor, auxiliary heater
Diode, fan motor, air-conditioning system
Diode, power steering
Diode group, brakelparking brake
Diode group, stop request
Diode, disabled button
Diode group - PLM

Diode group- 2 x
Diode, power take-off IIPLM
Diode, ISG 1
Diode, power take-off IIIPLM
Diode, shut-off, roof duct blower, if door feed
Diode, "levelling"
Diode group, hillholder
Diode, circulating pump
Diode, thermostat switch
Double diode V320, V321
Diode, tipper lowering
Diode group, engine stop (CNG)
Diode group, engine stop (CNG)
Diode, roof ventilator
Diode, roof ventilator
Diode group for "NUMMEK axle"
Diode for "NUMMEK axle"
Diode for GDK
Diode group, "WAKE-UP"
Diode, intermediate speed governor
Diode for instrument panel, line 15002
Diode for instrument panel, line 58013
Diode, entry lighting
Diode, heating
Diode, ventilation
Diode, stop signal request, door 3
Diode, opening, pram, door 3
Diode, keep open, door 3
Diode group, pram, door 3
Diode, stop signal request, door 4
Diode, axle load monitor
Diode, check, axle monitor
Diode, disconnectable rear loading crane
Diode, turn indicator, left (middle)
Diode, turn indicator, right (middle)
Diode, turn indicator, left (rear, top)
Diode, turn indicator, right (rear, top)
Diode group, headlight high beamlheadlight low beam, driving school
Diode, flame start system
Diode, gearbox splitter and range-change groups
Diode, MANEX trailing axle

Diode group V121, V340, V427, ...
Diode, compressor
Diode group V175, ...
Diode, economy circuit
Diode group V431
Diode, stop request
Diode, CNG control
Diode, CNG control
Diode, relay, ignition system
Diode, relay, ignition system
Diode group, CNG
Diode, shut-off cylinder, CNG
Diode, exhaust flap, CNG
Diode, CNG control
Diode, driver light
Diode group, stop request
Diode, stop request, wheelchair
Diode, stop request, pram
Diode group, voltage supply
Diode on at ignition
Diode, door 2 open
Diode, enable
Diode, door 3 open
Diode, door 4 open
Diode, retarder
Diode, retarder
Diode, roof flaps open
Diode, roof flaps open
Diode group, auxiliary heater
Diode group, triple
Diode, oil level
Diode, dirty oil
Diode, auxiliary compressor
Diode, battery box heater
Diode, battery box heater
Diode group for V465, V466
Diode group V469, V470, V471, V ...
Diode, compressor relief valve
Diode group, masked light
Diode group, masked light
Diode group, slanted seat valve
Diode, slanted seat valve (front section)
Diode, slanted seat valve (tractor)
Diode, roof flap 3, rear, open
Diode, roof flap 3, rear, open
Diode, roof flap 3, front, open
Diode group, roof flap 3
Diode, heater control, continuous positive
Diode, heater control, ignition
Diode group, heater control
1
Plug connection, charging socket
Plug connection, seat heating, right
Plug connection, seat heating, left
Plug connection, storage locker lighting, right
Plug connection, sliding roof
Plug connection, storage locker lighting, top
Plug connection, storage locker lighting, left
Plug connection, storage locker lighting, right
Plug connection, refrigerator
Plug connection, cargo space lighting
Plug connection, bunk lighting, bottom
Plug connection, water pump, auxiliary heater
Plug connection, temperature sensor, retarder (water, oil)
Jumper, WAKE-UP, auxiliary heater
Isolating point, ramp
Plug connection, refuelling ECU, equipment board
Plug connection, refuelling ECU, equipment board
Plug connection, interior lighting
Plug connection, switch, interior lighting
Plug connection, main and wide-angle mirror, right
Plug connection, main and wide-angle mirror, left
Plug connection, kerb mirror, right
Plug connection, kerb mirror, left
Plug connection, interface, trailer socket 1
Plug connection, interface, trailer socket 2
Plug connection, side marker light
Plug connection, washer pump
Plug connection, line 43005
Plug connection, CAN databus for EDC
Plug connection, TS-CAN databus for ECAM
Jumper, throttle valve potentiometer, electronic accelerator, VDO
Plug connection, hydrostatic fan drive
Plug connection, gearbox oil temperature
Plug connection, tank sensor
Plug connection, kerb mirror heater, additional
Plug connection, voltage supply, EASY-SHIFT
Plug connection, working spotlights
Plug connection, rack, central wiring
Plug connection, rack, central wiring
Plug connection, axle steering, EMPL
Connector, tank data, preparation
Plug connection, switch in gearshift knob
Jumper, IBIS continuous positive
Jumper, ticket cancelling machine, continuous positive
Plug connection, automatic gearbox-engine brake, EDC
Plug connection, automatic gearbox-engine brake, EDC
Vehicle-isolating point 1
Vehicle-isolating point 2
Vehicle-isolating point, driver's area
Vehicle-isolating point, road speed governor
Isolating point, driver's area
Isolating point, road speed governor
Plug connection, trailer control module
Jumper for relay, air-conditioning system, front end
Plug connection, roof ventilator, right
Plug connection, roof ventilator, left
Plug connection, roof ventilator, right
Plug connection, roof ventilator, left
Distributor for line 15002
Distributor for line 31000

Distributor, line 70003
Connector, tank data
Connector, tank data loop, fuel
Connector, tank data loop, gearbox oil
Connector, tank data loop, coolant
Connector, tank data loop, fresh oil
Connector, tank data loops
Plug connection, R gear signal
Interface, components
Plug connection, retarder
Plug connection, equipment board (air-conditioning systemlheating), tractor
Plug connection, cab-ACC
Plug connection, masked tail lightlbrake lamp, right
Plug connection, engine stop, 3-pole
Plug connection, reversing buzzer
Plug connection, relay, winter service
Plug connection, relay, winter service, driver side
Plug connection, relay, winter service, co-driver side
Plug connection, relay, brake wear indicator without Autocheck
Plug connection, relay, brake wear indicator without Autocheck
Plug connection, relay, ABSIASR-2M Stage 112
Jumper on central electrical system, item 40
Socket, 12V, Pakistan
Plug connection, 3-pole, C 0 2 extinguisher system
Plug connection, temperature gauge, additional
Plug connection, gearbox, gear interlock
Plug connection, 3-pole, button, C 0 2 extinguisher system
Plug connection, interior lighting, line 30075
Plug connection, tunnel, ABSIASR-2M Stage Y2
Plug connection, tunnel, ABSIASRPM Stage Y2
Plug connection, 3-pole, trigger, C 0 2 extinguisher system
Plug connection, 1-pole, D+ relay, NCIKC alternator
Plug connection, 3-pole, gear lock-out device
Plug connection, 8-pole, ABS-valve, rear axle
Plug connection, ADM, cab-chassis
Plug connection, ADM, cab-chassis
Plug connection, ADM, distributor, line 40017
Plug connection, ADM, diagnosis
Plug connection, traffic light transmitter
Ultrasonic weld, driveline
Plug connection, switch, sliding roof
Plug connection, cab-co-driver door
Plug connection, cab-driver door
Plug connection, cab-co-driver door
Plug connection, cab-driver door
Plug connection, video monitor
Plug connection, loudspeakers, shielded
Plug connection, auxiliary battery
Line distributor 31009
. .
Plug connection, cab-frame, check, crane

Plug connection, distributor box, ground, crane
Potential distributor, 21-pole, line 31000
Potential distributor, 21-pole, K-line
Socket, cable winch control
Plug connection, pilot switch and solenoid valve, power take-off 1
Plug connection, equipment board, front
Plug connection, equipment board, rear
Plug connection, instrument panel 1
Plug connection, rear lights, top left
Plug connection, auxiliary brake switch
Plug connection, accelerator pedal sensor
Plug connection, front end-node
Plug connection, rear end-node
Plug connection, masked light, "follow-me light"
Plug connection, diagnosis, K-line, central computer (ZBRO)
Plug connection, cab, tyre pressure control system
Plug connection, receptacle, tyre pressure control system
Plug connection, tyre pressure control system, line 58314
Plug connection, voltage supply, vehicle management computer
Plug connection, voltage supply, EBS
Plug connection, voltage supply, ECAS
Plug connection, voltage supply, ECAM
Plug connection, vehicle management computer - main switchboard
Plug connection, EBS - main switchboard
Plug connection, ECAS - main switchboard
Plug connection, central on-board computer - main switchboard
Plug connection, distributor, line 30000
Chassis earth distributor, luminous bar, right
Chassis earth distributor, luminous bar, left
Relay socket K250, K609
Plug connection, cablroof (luminous bar)
Plug connection, proximity switch
Isolating point, ground connection, engine
Plug connection, adaptation, fuel pressure controller
Plug connection, equipment board, front for ECE36
Plug connection, equipment board, rear for ECE36
Plug connection, taillift
Line divider, line 5831 1
Line divider, line 58357
Plug connection, battery box, equipment board, rear
Plug connection, equipment board, central locking
Plug connection, resistor bank
Plug connection, glove compartment
Plug connection, control unit, airbag
I KEY TO WIRING DIAGRAMS
Code letter Y Solenoid valves
Solenoid valve
Solenoid valve, engine brake
Solenoid valve, differential lock, interaxle
Solenoid valve, differential lock
Control valve, spare wheel cover
Solenoid valve, overload, trailing axle
Solenoid valve, lowering, rear left, trailing axle
Solenoid valve, lowering, rear right, trailing axle
Solenoid valve, ABS, front right
Solenoid valve, ABS, rear right
Solenoid valve, lowering, front left
Solenoid valve, lowering, front right
Solenoid valve, raising
Solenoid valve, lowering, rear left
Solenoid valve, lowering, rear right
Solenoid valve, ABS, front left
Solenoid valve, ABS, rear left
Oil separator (Haldex)
Solenoid valve, ASR
Injection pump: Regulator, MS5-Stage 213, M(S)5-Stage 3
Solenoid valve, kneeling, front left
Solenoid valve, kneeling, front right
Solenoid valve, kneeling, rear left
Solenoid valve, kneeling, rear right
Solenoid valve, block, air suspension
Hand lever valve, retarder
Solenoid valve, lntarder
Solenoid valve, retarder, level 1
Solenoid valve, accumulator
Solenoid valve, retarder, reduction Y5
Solenoid valve, engine speed increase
Solenoid valve, retarder
Solenoid valve, retarder
Solenoid valve, accumulator
YlOO Solenoid valve, flame start system
YlOl Solenoid valve, white smoke reduction
Y102 Solenoid valve, engine stop, engine brake
Y103 Solenoid valve, road speed limiter
Y104 Solenoid valve, central lubrication pump
Y105 Solenoid valve, warm water, front left
Y106 Solenoid valve, warm water, front right
Y107 Solenoid valve, warm water, rear left
Y108 Solenoid valve, warm water, rear right
Y109 Solenoid valve, fresh air flap, roof
YllO Solenoid valve, recirculated air flap, roof
Ylll Pressure control valve, front left
Solenoid valve, warm water, roof
Pressure control valve, front right
Solenoid valve, freshlrecirculated air, front end
Pressure control valve, middle left
Solenoid valve, engine speed increase
Pressure control valve, middle right
Magnetic clutch, compressor
Pressure control valve, rear left
Solenoid valve, toilet flush
Solenoid valve, ABS, rear left
. .
Plug connection, cab-frame, check, crane

Plug connection, distributor box, ground, crane
Potential distributor, 21-pole, K-line
Socket, cable winch control
Plug connection, pilot switch and solenoid valve, power take-off 1
Plug connection, equipment board, front
Plug connection, equipment board, rear
Plug connection, rear lights, top left
Plug connection, auxiliary brake switch
Plug connection, accelerator pedal sensor
Plug connection, rear end-node
Plug connection, masked light, "follow-me light"
Plug connection, diagnosis, K-line, central computer (ZBRO)
Plug connection, cab, tyre pressure control system
Plug connection, receptacle, tyre pressure control system
Plug connection, tyre pressure control system, line 58314
Plug connection, voltage supply, vehicle management computer
Plug connection, voltage supply, EBS
Plug connection, voltage supply, ECAS
Plug connection, voltage supply, ECAM
Plug connection, vehicle management computer - main switchboard
Plug connection, EBS - main switchboard
Plug connection, ECAS - main switchboard
Plug connection, central on-board computer - main switchboard
Chassis earth distributor, luminous bar, right
Chassis earth distributor, luminous bar, left
Relay socket K250, K609
Plug connection, cablroof (luminous bar)
Plug connection, proximity switch
Isolating point, ground connection, engine
Plug connection, adaptation, fuel pressure controller
Plug connection, equipment board, front for ECE36
Plug connection, equipment board, rear for ECE36
Plug connection, taillift
Line divider, line 5831 1
Plug connection, battery box, equipment board, rear
Plug connection, equipment board, central locking
Plug connection, resistor bank
Plug connection, glove compartment
Plug connection, control unit, airbag
WIRING DIAGRAM LINE NUMBERS
I
155 Other lines
15512 Fuse - control unit, BUSE
15513 Fuse - supply, RACK, terminal 15
15514 Fuse - supply, proximity switch, starter interlock
15515 Fuse - supply, TRIVECTOR 18
15516 Supply, TRIVECTOR T8
15517 Supply, card
32 Electric motors
320 Supply (from fuses or master switch)

32001 Fuse F226 - control unit, gritter
321 Pickups, sensors, check lamps (incl. check lamp in diagnosis button)
Consumers
Button, sunblind - sunblind, right
Button, sunblind - sunblind, left or full-width
Button, sunblind - sunblind, right
Button, sunblind - sunblind, left or full-width
Switch - control unit, gritter
Fuse F228 - motor, gritter
Sunblind
Sunblind
Motor, gritter
Auxiliary button, sunblind, right, co-driver
Auxiliary button, sunblind, right, co-driver
Other lines
Control unit, fuse F227 - gritter
Fuse F227 - relay K310, gritter
Control unit, fuse F228
Switch, gritter
Pilot switch, flap, front-end "Klimator" heater
Pilot switch, flap, ECAS valves
Pilot switch, flap, battery compartment
Pilot switch, flap, silencer
Pilot switch, rear silencerlengine
Pilot switch, battery compartment (tractor)
Supply for camera
Limit switch, stowage compartment, right
~ ~
Ticket cancelling machine
Supply (from fuses or master switch)

Fuse, ticket cancelling machine continuous positive - shut-off relay
Shut-off relay - switch-on relay
Fuse, IBIS - shut-off relay
Shut-off relay - single fuses
Supply, IBIS
Electro-acoustic supply +
Destination displays +
Lighting, destination display
Supply, PA system
Voltage supply, loading recorder
lgnition positive, ticket cancelling machine 2 OFF
Continuous positive, ticket printer OFF
Destination lighting
lgnition positive, ticket printer
Supply, IBIS
Supply, diagnosis computer
Supply, on-board computer
Spare, destination
Spare, destination
Voltage supply, destination display
Switch, ticket cancelling machine
Supply, ignition, tyre pressure monitor, IVTM
Supply, ELA
Supply, terminal 15
Supply, terminal 15
Supply, terminal 15
Supply, terminal 15
Switching contact, relay, socket
Socket, 24V, switched
Voltage supply, inside display
Voltage supply, inside display
Monitor, electronic stability program, supply
Pickups sensors, check lamps (incl. check lamp in diagnosis button)

Switch, ticket printer
Consumers
Continuous positive for ticket cancelling machine
lgnition positive for ticket cancelling machine
Lighting, destination display via economy circuit
Lighting, destination display, when parking lights on
Paying console
Voltage supply, console - changeover relay
Voltage supply, control unit - changeover relay
Voltage supply, console, filtered
Ticket cancelling machine, batt+ switched
Ticket cancelling machine, ignition+ switched
Destination lighting
Destination display
Supply, passenger counting system
Supply, passenger counting system
Computer-controlled central guidance system, radio set
Computer-controlled central guidance system 1, supply
Computer-controlled central guidance system 2, supply
Computer-controlled central guidance system, self-holding
Spare line
Fuse F592,main switchboard - ceiling
Supply, ticket cancelling machine (can be deactivated)
Load shedding, destination system
Electronically controlled air suspension ECASIElectronic shock absorber control ESAC
Supply (from fuses or master switch)

Voltage supply + (30-ER) SG (ECAS)
Voltage supply - (15-ER) SG (ECAS)
Switch, loading and unloading (changeover, terminal 15lterminal 30)
Switch, trailing axle, raise (voltage supply +15-ER)
Relay, supply, terminal 30 (ECASIESAC)
Voltage supply, 5V
Voltage supply, terminal 15, axle lifting
Bellows pressure sensor, tractor
Pickups, sensors, check lamps (incl. check lamp in diagnosis button)

Check lamp, fault - ECAS
Check lamp, warning - ECAS
Position sensor, rear axle, left - ECAS
Position sensor, rear axle, right - ECAS
Position sensor, front axle - ECAS
Brake pressure sensor (ESAC)
Bellows pressure sensor, rear axle, right
Bellows pressure sensor, rear axle, left
Accelerator pedal sensor
Check lamp, trailing axlelleading axle, raisedlrelieved
Check lamp, starting-off aid
Activation, bypass, axle lock-out, hydropneumatic suspension
Activation, bypass, hydropneumatic suspension
Sensor, front axle, right, hydropneumatic suspension
Sensor, front axle, left, hydropneumatic suspension
Sensor, rear axle, right, hydropneumatic suspension
Sensor, rear axle, left, hydropneumatic suspension
Sensor 2, front, right, hydropneumatic suspension
Sensor 2, front, left, hydropneumatic suspension
Sensor 2, rear, right, hydropneumatic suspension
Sensor 2, rear, left, hydropneumatic suspension
Axle lock-out, rear axle
Axle lock-out, all axles
Level control, hydropneumatic suspension
Sensor, 3rd axle, left
Sensor, 3rd axle, right
Sensor, 4th axle, left
Sensor, 4th axle, right
Travel sensor, front axle, right
Position sensor, centre axle
Axle lock-out, axle 1
HR-load monitor
Door monitor, door 1
Activation, ISG, hydropneumatic suspension
Kneeling strip, control unit - door 1 (SZ)
Kneeling strip, control unit - door 1 (SZ)
Kneeling strip, door 1 - door 2 (SZ)
Kneeling strip, last door, terminator (SZ)
Kneeling strip, last door, terminator (SZ)
Check lamp, level 2
Check lamp, brake warning
Steering angle potentiometer
Control, trailing axle

Control, trailing axle or ECAS
Control, trailing axle or leading axle, trailer
Axle lock-out, hydropneumatic suspension, solenoid valve, axle 1
Axle lock-out, hydropneumatic suspension, solenoid valve, unlock
Supply, solenoid valves, ECAS
Other lines
Switch, lower, ECAS (= line, raise)
Switch, raise, ECAS (= line, lower)
Pressure switch, air reservoir, ECAS
Remote control, ECAS (cycle)
Remote control, ECAS (data)
Switch, level 112, ECAS
Pressure switch, ECAS, empty run
Pressure switch, ECAS, starting-off aid
Button, moving-off aid
Switch, trailing axlelleading axle, raiselrelieve
Starting-off aid, time relay
Level 112, ECAS
Remote control, hydropneumatic suspension
Relay, supply, terminal 30 (ECASIESAC)
Hydropneurnatic suspension, 5V, voltage supply for sensors, front left and right
Hydropneumatic suspension, 5V, voltage supply for sensors, rear left and right
Button, kneeling (kneeling lower)
Button, kneeling (kneeling raise)
ECAS, resistor bank
ECAS, resistor bank
ECAS, control suppression
Frequent-stop brake, kneeling
Bus-stop brake, kneeling
Vehicle lowered
Vehicle lowered
Check, vehicle lowered
ECAS signal, 15 kmlh
Button, lowering
Button, raising
Button, raising above ride height
Switch, manuallautomatic
Button, emergency raising
Standstill signal
Kneeling
CODE NUMBERS
Sensors, pressure switches, pickups
Temperature sensor
Pressure sensor
Tank sensor
Oil pressure sensor
Coolant temperature sensor, switching point 95 "C
Pressure switch, NC contact, 5.8 bar
Pressure switch, NO contact
Pulse generator
Pulse generator for tachograph (mechanical)
Water level probe
Boost pressure sensor, EDC
Pedal value sensor
Pressure switch, NC contact, 6.5 - 0.4 bar
Position sensor for ECAS
Temperature sensor
Loudspeakers, AL 120
Pressure switch, NO contact, 0.3 - 0.8 bar, Medium
Temperature sensor for fan control
Loudspeakers
Hand-held microphone with helix cable
Load sensor
Loudspeakerlmicrophone
Pressure switch, NO contact, 5.2 bar - 0.4 bar
Pressure switch, NO contact, 0.6 bar + 0.3 bar
Thermostat switch, TWL
Temperature switch, opening at 12 "C, closing at 4 "C
Position sensor (G74.2, bayonet 16S), Wabco
Pressure sensor
Combined highllow-pressure switch
Temperature sensor
Loudspeaker 452, oval, Blaupunkt
Temperature sensor for fan control
Loudspeaker, 50W
Loudspeaker, tweeter
Position sensor for ECAS
Pressure switch, NC contact, 5.8 bar
Pressure switch, NO contact, 5.2 bar
lnterior thermostat, Thermo 90
Coolant level probe
Map board light
Pressure transducer
Pressure sensor 0 - 10 bar
Loudspeaker with moulding
lnterior thermostat for auxiliary heater, Thermo
Pressure switch, NC contact, ECAS, empty run
Pressure switch, NO contact, 0.7 bar + 0.3 bar
Coolant level probe, 3020 VZ18lKZl
lnterior thermostat
Temperature sensor, interior thermostat
Pressure chamber loudspeaker
Pedal value sensor
Float switch, oil top-up
Pressure switch, NO contact, 0.4 bar
Hand-held microphone, cordless, Fredrich
Temperature sensor, inside, air-conditioning system
Temperature sensor, outside, air-conditioning system
CODE NUMBERS
Speed sensor
Auxiliary speed sensor
Boost pressure sensor, EDC
Air pressure sensor for emergency release device
Light scanner
Pressure switch
Coolant level probe
Loudspeaker with handsfree kit
Light scanner
Light scanner
Rotational speed sensor, ESP
Oil level probe
Temperature switch, fire detector
Coolant level probe
Pressure switch, low-pressure switch, G60
Pressure switch, high-pressure switch, G63
Pedal value sensor
Sensor, ACC distance sensor
Temperature sensor
Air pressure switch
Rectangular loudspeaker
Air pressure switch
Air pressure switch
Diaphragm pressure switch, NO contact
Pedal value sensor
Loudspeakers
Pressure switch, door panel
Lighting
5-element light, right (for new SR), see H I 02

5-element light, left (for new SR), see H I 03
Light with switch
Headlight, left, low beam and parking light
Headlight, right, low beam and parking light
Headlight, left, high beam
Headlight, right, high beam
Outline light, front
Outline light, rear
Fog lamps
Light
Reading light with gooseneck
Light
lnterior light
Light, halogen (spot)
Light
lnterior light, sleeping area
lnterior light
Entrance lighting
Licence plate light
Side marker light
Holder for festoon bulb (socket)
Glove compartment light
Socket
Bulb socket
Ceiling light
Licence plate light
"Follow me" light
Masked headlights
Priority vehicle light
DIAGNOSIS
Diagnosis socket
The SPN error codes can be read out from the error memory of various control units using MAN-cats II
(connection on diagnosis socket X200). The results are displayed on the MAN-cats display.
View of socket X200, line side
\ Arrow in the centre

points to Pin 1
Connector pin assignment
- TGA:
Diagnosis socket X200 Address
Pin Function Terminal Line number From CES pin
4 K-line 16202 Via X2544 to the control units

KWP 2000
9 Negative 31 31000 Earthing point, central
potential electrical system
X I 644 via X I 829
10 Voltage supply 30 30009 Via X I 535 to fuse F412 / 10A A211 1
11 Voltage supply 15 16000 Via X I 833 to fuse F376 / 10A F/3
12 Signal, alternator W 59101 Alternator G I 02 pin 1
- R021R03 and R071R08:
Diagnosis socket X200 Address
Pin Function Terminal Line number From CES pin
4 K-line 16202 Via X I 908 to the control units

KWP 2000
9 Negative 31 31000 Earthing point, central
potential electrical system (item 92)
10 Voltage supply 30 30009 Fuse F412 / 10A A211 1
11 Voltage supply 15 16000 Via X362 to fuse F/1
F376 / 10A
12 Signal, alternator W 59101 Alternator G I 02 pin 1
DIAGNOSIS
FFR 20 03233 CAN databus: Astronic message TSCl-TE, byte 4

FFR 20 03234 CAN databus: Astronic message TSCI-TE, byte 5
FFR 20 03235 CAN databus: EBS message TSC1-AE, byte 1
FFR 20 03236 CAN databus: EBS message TSC1-AE, byte 2 and 3
FFR 20 03239 CAN databus: ZBR message AUX-ZBRI, byte 1 and 2
FFR 20 03240 CAN databus: ZBR message AUX-ZBR1 , byte 3
FFR 20 03241 CAN databus: ZBR message AUX-ZBRl , byte 4
FFR 20 03242 CAN databus: ECAS message ECAS1, byte 6 to 8
DIAGNOSIS
take-off neutral switch indicates "Neutral"
activation valve is not activated

In-line engines
Publication No.: Repair Manual

81.99598-4322 3rd Edition A 13
MAN Nutzfahrzeuge Aktiengesellschaft Reparaturanleitung A 13 (3. Ausgabe)
Dachauer Str. 667 oder Postfach 50 06 20 Reihenrnotoren
80995 M~JNCHEN 80976 M ~ ~ N C H E N D 02 -1 D 08 -
- englisch -
Printed in Germany
ALLOCATION OF ENGINES TO VEHICLE SERIES / VEHICLE TYPES
Engines for trucks Series Vehicle type Chassis no.

(Trade name) Starting from:
D 0226 MKFII 70 ............................................. F 9 ....................... xx.170 ...................... WMA4..

D 0226 MKF ....................................................F 9 ....................... xx.192 ...................... WMA4..
D 0824 GF ...................................................... G 90 ....................xx.100 ...................... WVML..

D 0824 GF 01 ................................................ G 90 ....................xx.100 ...................... WVML..
D 0824 GF 02 .................................................G 90 ....................xx.100 ...................... WVML..
D 0824 GF 03 ....... Euro 1 .............................. G 90 ....................xx.100 ...................... WVML..
D 0226 MFl125 .............................................. G 90 ....................xx.150 ...................... WVML..

D 0826 GF 04 ....... Euro 1 .............................. G 90 ....................xx.150 ...................... WVML..
D 0826 GFA 04 ..... Euro 1 .............................. G 90 .................... xx.150 ...................... WVML..
D 0826 GF 03 ................................................ G 90 ....................xx.150 ...................... WVML..
D 0826 GFA 03 ..............................................G 90 .................... xx.150 ...................... WVML..
D 0826 GF 01 ................................................G 90 ....................xx. 150 ...................... WVML..
D 0826 GFA 01 ..............................................G 90 .................... xx. 150 ...................... WVML..
D 0826 GF ..................................................... G 90 ....................xx.150 ...................... WVML..
D 0826 GFA ................................................... G 90 .................... xx.150 ...................... WVML..
D 0824 FL 01 ....... Euro 1 .............................. L 2000 .................xx.103 ...................... WMAL..

D 0824 LFL 04 ..... Euro 2 .............................. L 2000 ................. xx.1 13 ...................... WMAL..
D 0824 LFL 08 ..... Euro 2 .............................. L 2000 .................xx.1 13 ...................... WMAL..
D 0824 LFL 07 ..... Euro 2 .............................. L 2000 .................xx.143 ...................... WMAL..
D 0824 LFL 01 ..... Euro 1 .............................. L 2000 .................xx.153 ...................... WMAL..
D 0824 LFL 05 ..... Euro 1 ..............................L 2000 ................. xx.153 ...................... WMAL..
D 0824 LFL 06 ..... Euro 2 .............................. L 2000 ................. xx.163 ...................... WMAL..
D 0824 LF 01 ....... Euro 1 .............................. M 90 .................... xx.152 ...................... WMAM..

D 0824 LF 03 ....... Euro 2 .............................. M 90 .................... xx.152 ...................... WMAM..
D 0824 LF 02 ....... Euro 2 .............................. M 90 .................... xx.162 ...................... WMAM..
D 0826 F 02 ...................................................M 90 ....................xx.152 ...................... WMAM..

D 0826 F 01 ................................................... M 90 .................... xx. 152 ...................... WMAM..
D 0826 F ........................................................M 90 .................... xx.152 ...................... WMAM..
D 0826 TF .......................................................M 90 .................... xx.1821192 ............... WMAM..
D 0826 LF 01 ...............................................M 90 .................... xx.192 ...................... WMAM..
D 0826 LF 05 ................................................. M 90 ....................xx.192 ...................... WMAM..
D 0826 LF 07 ....... Euro 1 .............................. M 90 ....................xx.192 ...................... WMAM..
D 0826 LFl217 ............................................... M 90 .................... xx.232 ...................... WMAM..
D 0826 LF 11 ....... Euro 2 .............................. M 90 .................... xx.222 ...................... WMAM..
D 0826 LF 13 ....... Euro 2 .............................. M 90 .................... xx.262 ...................... WMAM..
D 0826 LF 02 ................................................. M 90 .................... xx.232 ...................... WMAM..
D 0826 LF 06 ................................................M 90 .................... xx.232 ...................... WMAM..
D 0826 LF 08 ....... Euro 1 .............................. M 90 .................... xx.232 ...................... WMAM..
D 0826 LF ......................................................M 90 .................... xx.232 ...................... WMAM..
D 0826 LF 04 ....... Euro 1 .............................. M 90 .................... xx.272 ...................... WMAM..
DESCRIPTION AND DIFFERENTIATION CRITERIA
The A 13 Repair Manual describes series D 02.. / D 08.. engines.

This series has a modular configuration, i.e. larger or smaller engines with different power levels are built
using the same design principles and, wherever feasible, use the same components.
The most important shared features are twin cylinder heads and various add-on parts.
The vehicle engines currently available are 4 and 6-cylinder engines, naturally aspirated engines and su-
percharged engines, each with different cylinder bores for D 02.. and D 08.. as well as various combustion
processes.
1. Combustion process
There are three combustion processes.
1. The proven M-process in the D 02.. engines with direct injection through one-orifice nozzles into the
central spherical combustion chamber in the piston (example: D 0226 MF).
2. The new process (without M letter coding) in the D 08.. engines with direct injection through four-orifice
nozzles into the concave combustion chamber in the piston (example: D 0824 GF, D 0826 LF 01).
- Euro 1 engines have direct injection through five-orifice nozzles at an increased injection pressure of up
to 295 bar into the concave combustion chamber in the piston (example: D 0824 GF 03, D 0826 LF 04).
3. Electronically controlled diesel injection (EDC) for Euro 2 engines.
- Euro 2 engines have direct injection through eight-orifice nozzles at an increased injection pressure of up
to 320 bar into the concave combustion chamber in the piston (example: D 0824 LFL 04, D 0826 LFL 03).
The injector nozzle of the first cylinder is equipped with a needle movement sensor for this purpose.
EDC stands for electronic diesel control. The electronic engine management system directly compares
and monitors the actual values in relation to the stored nominal values. The values are continuously
brought into line with the specified optimum nominal values. The version used is adapted to the engine
type in each case.
The most significant difference between this and the M-engines is the combustion process. Otherwise, the
engines have largely identical configurations, meaning they are identical as far as repairs are concerned.
This applies unless there is an express reference to differences during the repair sequence or in the techni-
cal data.
2. Supercharging
There are four different supercharging methods.
In D 08.. engines:
1. Turbocharging (T):
The intake air required for the combustion process is precompressed by a turbocharger and fed into the
cylinders through the intake manifold. Example: D 0826 TF
2. Turbocharging with intercooling (L):
The intake air required for the combustion process is cooled to approx. 50 'C following precompression
and then fed into the cylinders. Example: D 0824 LFL
In D 02.. engines:
3. Turbocharging with resonance supercharging, without intercooling (C):
The intake air required for the combustion process is compressed in a resonance system
(tubes/chambers) for a second time following its initial precompression. Example: D 0226 MC
4. Combined supercharging with resonance system and intercooling (K):
Combination of the characteristics of L and C. Example: D 0226 MKF
3. Crankcaselcrankshaft drive
There are also differences between different crankcases:
- The older D 02.. engines have crankshaft main bearings and fitted bearings of normal thickness.
- The newer D 02.. engines (see 5.56 for information about engine numbers) have similar crankcases to
the D 08.. engines. The D 02.. engines are fitted with thick-walled bearings in order to compensate for
the differences in size, see 5.56 - 6.
- Series production D 02.. and D 08.. naturally aspirated engines are built without replaceable cylinder
liners.
CHANGESINEW FEATURES
Mounting instructions
The KSB function must be switched off before a fuel

injection pump with a cold-starting aid (KSB) is fitted.
This is because the start of pumping is moved to-
wards "early" by max. 5" when the KSB function is
switched on.
KSB function setting when the pump is delivered

- Use a suitable spanner (size 8) to brace clamping
piece @ and unscrew hexagon nut 0.
@ Adjustment lever
- Move clamping piece @ into the release groove

of the guide piece @ by turning it through 90".
- KSB relieved -
The fuel injection pump can now be fitted.
- Restore the preset early position after setting the

engine. Do this by moving and turning clamping
piece @.
- Use a suitable spanner (size 8) to brace the
clamping piece and tighten hexagon nut @) to
3.5 k 1 Nm.
OIL PUMP
Fittina the oil auma aear fT-k ?Mk4

Place the oil pump gear (with its inside taper free
from grease) onto the taper of the input shaft which
must also be free from grease.
Put on the washer, screw on the mounting nut and
tighten it to the specified tightening torque.
Fitting the timing chain housing, 5.54 - 3.
Installing the auxiliary oil pump
Position the auxiliary oil pumpa.

Insert mounting bolts @ and tighten them to the
specified tightening torque.
Use mounting bolts @ and clips to fix on the second
suction pipe @.
Screw the suction pipe with banjo bolt 0, new lock-
ing fastener @ and new sealing rings @ onto the
auxiliary oil pump.
Tighten the mounting bolts of the suction pipe to the
REMOVING AND INSTALLING THE PCV VALVE
Removing and installing the PCV valve

(crankcase ventilation)
PCV valves on engines being serviced after long

periods in service must be replaced due to general
wear and tear.
For example:
D 02.. engine .....................................................+
The seating of the PCV valve varies between the

different engine types.
a
Uncover PCV valve if necessary.
D 08.. engine with 3-cowl ventilation ...................-+
Release clamping bracket @ at the base of the PCV

valve.
Release clamping brackets @ on the air suction duct
at the top of the PCV valve.
Remove PCV valve a
and O-ring a.
Fit a new O-ring @.
Position PCV valve a
and line it up with the intake
line to the suction duct.
Position hose section @ and tighten hose clamps @.
Fasten clamping bracket @ at the base of the PCV
valve.
I FllTlNG A NEW BIG END BEARING
Checking the expansion of the bearing shells
Removing a piston with its connecting rod, 5.61
Lay out the bearing shells together on a flat surface.

Measure and note down expansion dimension "A".
Measure and note down dimension "B".
Expansion dimension = A - B
f
B
I
Technical data 9.21 - 5
Note: Use bearing shells of the appropriate repair

level when performing repairs on the crank pins.
Press new bearing shells into the connecting rod big

end and the connecting rod bearing cover.
Important
Note the installation position!
The rod shell has a red paint mark
on its side.
Do not damage the running-in coat-
ing! I
Lightly oil the bearing surfaces of the bearing shells.
Installing a piston with its connecting rod, 5.61 - 3.
Note regarding D 02.. engines: Previously, it was a requirement that new con-
necting rod bearing bolts (expansion bolts) always had to be fitted during a repair
because tightening these bolts permanently stretches them.
However, tests have shown that an expansion up to a shank length (L) of 61 mm
does not pose any problems.
Connecting rod bearing bolts 51.90020.0190 can be re-used provided their shaft
length does not exceed 61 mm.
The shank length of a new connecting rod bearing bolt is 59.5 to 60.5 mm.
I REMOVING AND INSTALLING OIL INJECTOR NOZZLES
Removing the oil injector nozzle
Note: The oil injector nozzles can also be removed

and installed without removing the crankshaft.
The crankshaft has been removed here in order to
give a better view. @
Unscrew oil pressure valve @ on oil injector nozzle

@ and remove it.
Remove the 011 injector nozzle together with the
valve.
Checking the oil injector nozzle valve
Use a small screwdriver to check whether the valve

spring is still pressing valve piston against the
valve seat. Fit a new oil injector nozzle valve if it is
not.
Note the opening pressure.
Installing the oil injector nozzle
Position the oil injector nozzle and make sure the

adjusting ball (arrow) on the oil injector nozzle body
is placed in the hole provided for it (arrow).
Screw in the oil pressure valve and tighten it to the

Check the spraying direction.

The jet of oil must reach the piston crown without
hindrance.
Never attempt to straighten out oil injector nozzles
which are bent.
I CHECKING THE VALVE TIMING
Checking the valve timing
Any twisting of the screwed-on camshaft drive sprocket can lead to serious engine damage.
Consequently, check the valve timing to ensure the camshaft drive sprocket is seated correctly after any
engine malfunction which could lead to twisting, e.g. failure of the air compressor.
Precondition: The tappets must not be bent!
Proceed as follows:
- Fit the engine barring gear onto the flywheel housing.
- Remove the valve covers.
- Set the valve clearance of the 1st cylinder correctly.
- Turn the engine to about 30" before TDC in the opposite direction to its direction of rotation.
- Place a dial gauge onto the inlet valve spring cap on the 1st cylinder with a slight preload. Zero the dial
gauge.
- Slowly turn the engine in its running direction and observe the needle on the dial gauge.
- The intake valve opens as soon as the needle deflects.

- Read off the degree scale on the flywheel and compare it with the timings on page 9.21 - 14.
Note: Fitting one dial gauge each on the intake and exhaust valve head of the 1st cylinder makes it possi-
ble to check all valve timings and the valve lift by turning the engine further.
Example:
Control diagram for D 0824 LFL
Values in degrees relate to the crankshaft an-

gle.
a Turning direction of the engine

@ Intake opens
@ Exhaust closes
@ Centre of intake cam
@ Exhaust opens
@ Intake closes
@ Centre of exhaust cam
@ Exhaust opening time
@ Intake opening time
Note: Valve clearance and timings of various

engines, see page 9.21 - 14.
REMOVING AND INSTALLING THE AIR COMPRESSOR IN D 02.. ENGINES
D 02.. engine
Removing the air compressor (with V-belt drive)
Release the tension on the V-belt at the tensioning

pulley and take off the V-belt.
Separate the suction and pressure connection at the
hose pieces.
Remove the coolant hoses on a water-cooled cylin-

der head (see picture).
Note: Disconnect the hydraulic pump at the air com-

pressor flange (arrows) if the vehicle has power
steering.
The lines can remain on the hydraulic pump.
Unscrew and remove the air compressor mounting

bolts and lift the air compressor off the bracket.
Remove the sealing rings for the pressurised oil
supply and oil return.
Removing the air compressor bracket
Unscrew and remove the mounting bolts.

Remove the bracket with the tensioning pulley.
Clean seal residue off the sealing surfaces.
Removing, fitting, dismantling and assembling the
tensioning pulley, 8.41
TABLE OF ENGINE SETTINGS
I
I EURO1 I EURO1 1 Emissions category
Start of pumping
Discharge pressure
21 6 51.1 01 02-0216 51.1 0102-0202
339 1 51.1 0101 -7339 1 51.1 01 01-7349 1 Jet bear. with nozzle
ULLH 33 S 119 I A /x !-J 322 1 DLLA 78 P 322 1 DLLA 134 P 180 1 Nozzle name
153 1 0 433 175 053 1 0 433 171 159 1 Manufacturer's no.
If25 700f 25 800530 Idling speed
40 2840 2600 Setting for inj. cut-off
- - I - - - - 1 2700 I speed min./max.
Idling speed *I -
Inj. cut-off Ispeed A1J
- 3105 min./max.
K-value A l
30 Fuel injection pump
- -
11103-7158 51.1 1103-7217 51.1 1103-7243 MAN no.:
RQV RQV Governor
1I4115512400 1181160/24( 1 I4115512400

EURO 1 EURO 2 EURO 2 I EUROl I Emissions category
4-1 8- 1 Start of pumping
2651250 27( 2701250 Discharge pressure
51.101 02-0202 51. 223 51.1 0102-ULZJ
DLLA 134 P 180 1 DSLA 154 P 492 1 DSLA 154 P 492 1 DLLA 134 P 180 1 Nozzle name
0 433 175 085 0 433 171 159 Manufacturer's no.
800f 30 800f30 Idling speed
2650 2600 Setting for inj. cut-off
27; 2750 2700 speed min./rnax.
80C 800+1 OC 800+ Idling speed AU
Lu-w 261, 3~;c;n 355n Inj. cut-off speed AU
2780 2770 min.1max.
-
1.4 0.7 - K-value AC -
2 F 1200.. PE. A320. PES 4P120A320 VE 4112 F 1200.. Fuel injection pump
51. 295 51.1 1103-7469 51.1 1103-7243 MAN no.:
RQ RQ RQV Governor
I TABLE OF ENGINE SElTINGS
114115512700 11011 5012700 kW1h.p.lrpm
- FAV 2 Emissions category-

art of p unping
~
10
51 . l u102-0199
51 .I 0101-7305
I 51. I u l u z - u z l /
51.1 0101 -7333
i s l .I ulu2-0217
51.10101-7333
1 51.10102-0216
51.1 0101-7339
1
scharge pressure
Nozzle
Jet bear. with nozzle
DLLA 140 P 175 DLLA 35 S 1190 DLLA 35 S 1190 DSLA 78 P 322 Nozzle name
i20 0 433 271 520 0 433 175 053 Manufacturer's no.
585f35 585k35 Idling speed
Setting for in~.cut-off
speed min./max.
1 31(
t 600+100
3105
Idling speed AU
Inj. cut-off !
min./max.
J
-
1.5 I~1 1.8 1.2 K-value Ab
VE 611 VE 611 1 F 1350.. Fuel injection pump
51 .I
1l u z - / 8 / 3 11lu3-/032 51.1 1103-7159 MAN no.:
RQV RQV RQV Governor
Replac Up to engine no. From engine no. Remark:
51 1 1 1u ~ - / t l b 3 6579000.. ...6579001 .... -
I %issions category-
art of pur
scharge Ipressure
I Nozzle
I Jet bear. with nozzle
DSLA78P322 1 nlLA140P175 1 DLLA35S1190 I DLLA35S1190 1 Nozzlename
33 171 154 1 0 433 271 520 1 0 433 271 520 1 Manufacturer's no.
585f 35 585k35 Idling speed
Setting for inj. cut-off
I f 4 n g speed AU
. cut-off !
n./max.
I VE 611 1 F 1350.. 1 VE 611 1 F 1350.. 1 Fuel injection pump

( 51.1 1103-7032 ( 51.1 1103-7157 I MAN no.:
RQV I RQV / RQV I RQ I Governor
Up to engine no. From engine no. Remark:
...6579000.... ...6579001....
RA-A13 9.13 - 9
I TABLE OF ENGINE SETTINGS
FAV E ( EURO 1 EURO 1 1 EURO 1 I Emissions category

14-1 tart of pumping
2651250 2651: ischarge pressure
51.1 0102-0202
51.10101-7349
DLLA 134 P 180 1 DLLA 134 P 180 1 Nozzle name
0 433 171 159 1 0 433 171 159 1 Manufacturer's no.
585f 35 1 585f35 1 Idling speed
Setting for inj. cut-off
speed min.1max.
!d AU -
j. cut-off speed A\
-
in./max.
2.3 .value A1 -
PES6MW1001321 Fuel injection pump
51.1 1103-7253 MAN no.:
RQV Governor
Replaced by Remark
- - -- d
162122012400 162122012400 191126012300 160121712200 kW/h.p.lrpm

EURC EUIRO 2 EURO 2 Emissions category
5- 1 after
lo ' 15-1 Start of pumping
2701250 2701250 2651250 Discharge pressure
51.1 0102-0223 51.1 0102-0223 51.1 01 02-0202 Nozzle
51.1 0100-7364 51.10101-7364 51.1 01 01-7349 Jet bear. with nozzle
DSLA ,LA 154 P 492 DLLA 134 P 180 Nozzle name
33 175 085 0 433 171 159 Manufacturer's no.
585f35 630f30 600f 50 585f35 Idling speed
2580 2500 Setting for inj. cut-off
2680 2560 speed min./max.
630530 600+ ling spee -
2520 2310 i. cut-off Ispeed A1J
2650 2530 m~n.lmax. -
1.18 2.5 K-value AC -
PES6P120A320.. PESGP120A320.. PES6H1101320.. PES6MW1001320 Fuel ~njectionpump
1 1103-7461 5 1.I1103-7482 51.1 1103-7022 MAN no.:
IV ------ RQV Governor
Wlth RQ (Idlingltop speed Silent engine Remark:
51.1 1103-7330 governor)
STANDARD TORQUE TIGHTENING VALUES
7.2 Tightening torques in accordance with the M 3059 works standard
Bolt connections for which no torques are specified. with the exception of those that are less important or
used for tacking purposes. should always be tightened using either the torque wrenches generally found in
workshops or precision bolt tighteners.
The actual torque values should not deviate from the specified values by more than +I 5%.
Notes on the use of the tables below
. In the case of property class pairings other than those specified. use the tightening torque of the
component with the lower property class (e.g. if the bolt hash a property class of 8.8 and the nut a
property class of 10. use the tightening torque given in the column headed 8.8).
- If you are fastening a component with a slot to one with a hole. tighten from the side with the hole.
Nutslbolts with an external or internal hexagon and a head without a collar or flange
Thread size Property classes in Nm

x pitch (boltlnut)
I SPECIAL TOOLS
Fig. no. Name MAN no. Sectionipage
[I] Dial gauge for setting the start of pumping ............................... 08.71000.1 205 2.1 1 .1
[I . 11 Extension for [I] ........................................................................ 08.71 075.0507 2.1 1 .1
[2] Adapter for [I] ........................................................................... 80.99605.6007 2.1 1 .1
[3] Special spanner (size 17) for injection pressure lines ............... 80.99603.0025 2.12 .3
[4] Illuminated indicator for setting the start of pumping ................. 80.99605.6002 2.21 . 1
[5] Locking pin for fuel injection pump camshaft ............................ 81.1 1523.0042 2.21 . 1
[5.1] New version, including Euro 2 ................................................... 80.99605.0217
[6] Socket for jet bearing forcing bolt D 02 .................................... 08.06141 .9062 2.31 - 1
[7] Grooved nut spanner for jet bearing forcing bolt D 08 ..

.Previous grooved nut spanner ................................................ 80.99603.0121
. New = 3 grooves, open for needle movement sensor ............ 80.99603.0240 2.31 .2
[8] Inertial puller for injector nozzles ............................................... 80.99602.0011 2.31 .1

4-
[8.1] Adapter for [8] .................................................................... 80.99602.0059
[9] Mounting device for injector nozzles ........................................ 80.99606.0008 2.32 - 2
[I 01 Socket for injector nozzle union screw connection ................... 80.99603.0024 2.32 - 3
[I 11 Puller for V-belt sheavelflange on water pump ......................... 83.09143.6060 3.22 .1
[I 21 Press-in bush for water pump cassette ring .............................. 80.9961 7.0091 3.22 .3
[13] Press-in bush for water pump bearing shaft ............................. 80.99635.0008 3.22 .4
[14] Press-in plate for water pump vane impeller ............................. 80.99614.001 6 3.22 .4
[I 51 Oil filter wrench ......................................................................... 80.99606.0343 4.10 .1
[I 61 Press-in device for oil pump shaft ............................................. 80.99604.0055 4.32 .3

Comprising:
Support liner .............................................................................. 80.99604.0056
Spacer bush .............................................................................. 80.99604.0057
SPECIAL TOOLS
SPECIAL TOOLS
Fig. no. Name MAN no. Sectionlpage

u
[I 71 Internal extractor for clutch pilot bearing ................................... 08.9961 5.1400
[I 81 Counter support for [I 71 ............................................................

08.9961 5.0005
[I91 Press-in pin for clutch pilot bearing ........................................ 80.99617.0059
[20] Extractor hook ........................................................................... 80.99602.0127
[21] Impact puller for [20] ................................................................. 80.99602.0016
[22] Handle for all press-in plates ................................................80.99617.0129
[23] Press-in plate for crankshaft sealing ring. front

.D 02....................................................................................... 80.99614.0033
. D 08....................................................................................... 80.99617.0073
[24] Press-in plate for crankshaft sealing ring. flywheel end ............ 80.99614.0032
[25] Torque angle gauge for bearing bolts ....................................... 80.99605.0010
[26] Piston ring clamp. universal .................................................... 80.99625.0001
1271 Slip-on sleeve 0 108 mm .......................................................... 83.09144.0057
[28] Engine barring gear ............................................................... 80.99626.6006

[28.1] Gear ratchet for [28]................................................................. 80.99627.0001
[29] Dial gauge holder ...................................................................... 80.99605.01 72
[30] Piston ring compressor pliers .................................................... 83.09144.6090
[31] Cylinder liner extractor device. complete .................................. 80.99602.0019
[32] Extractor plate 0 102 mm ........................................................ 80.99602.0097

0 107.8 mm ..................................................... 80.99602.0123
.
Note: There is a complete catalogue of MAN SPECIAL TOOLS
This catalogue contains all special tools that MAN supplies for maintenance and repairs to MAN
trucks. buses and engines . Order no . 81.99593.8062, order from the central spare parts
warehouse .
In-line Engines
D 02.J D 08..
Publication No.: Repair Manual

81.99593-4032 I st Supplement A 13 (3rd)
MAN Nutzfahrzeuge Aktiengesellschaft Reparaturanleitung A 13 (3. Ausgabe)

Dachauer Str. 667 oder Postfach 50 06 20 1. Nachtrag
80995 M ~ ~ N C H E N 80976 M~JNCHEN Reihenmotoren
D 02.J D 08..
- englisch -
Printed in Germany
1st Supplement
to the
Repair Manual A 13. 3rd Edition
Information on inserting this supplement into the existing manual.

Please use all the pages in this supplement to replace the corresponding pages in the
3rd edition of the Repair Manual A 13 or add them as new pages.
The page numbers are identified with the index letter "a" so you can subsequently
identify which pages have been exchanged.
Example: Previous page number: 1.20 .1, page number of replacement page: 1.20 .1a.
Exchange the following pages
1.00 .1 to 1.00 .3 ....................................deleted

Title page and 1.10 .2 .................................... by ............................................. T i t Page and 1.10 .2a
add ............................................ 1.15.la to 1.15.3a
1.30 .1 to 1.30 .3 .................................... by ............................................... 1.30 .1a to 1.30 .3a
2.11 - 1 to 2.11 - 3.................................... by ............................................2.11 - l a to 2.11 - 3 a
2.13.1 to 2.13.6 .................................... by .............................................. l a to 2.13. 10a
add ........................................ - l a to 2.15.4a
add ............................................ 6 . l a to 2.16.2a
5.1 1 .1 ................................................by ............................................. 5.11 .l a
5.52 .1 ................................................ by ............................................. 5.52 .l a
6.21 .1 to 6.21 .2 .................................... by ............................................6.21 .l a to 6.21 .2a
add ........................................ 6 . 2 .1a
6.33.1 to 6.33.2 .................................... by ...........................................- l a to 6.33.2a
add ............................................ - l a to 6.35.5a
7.13.1 to 7.13.2 .................................... by .......................................... 7.13. l a to 7.13.2a
add ............................................ 7.14. l a to 7.14.2a
add ............................................ - l a to 7.15.2a
7.23.1 to 7.23.5 .................................... by ..............................................- l a to 7.23.7a
7.51 .1 to 7.51 .4 .................................... by .............................................. 7.51 .l a to 7.51 .4a
8.13. 1 to 8.13.7 .................................... by ............................................. 8.13. l a to 8.13.7a
8.51 .1 ................................................by ............................................. 8.51 .1a to 8.51 .2a
9.00 .1 to 9.61 .1 = blue pages .............. by ..................... blue pages = 9.00 .1a to 9.61 .l a
9.71 .1 to 9.72 .2 = pink pages .............. by ..................... pink pages = 9.71 .1a to 9.72 .2a
ADJUSTING THE VALVE CLEARANCE I
Adjusting the valve clearance
Do not set the valves unless the engine is cold.

(Max. cooling water temperature 50 "C.)
Remove the valve covers.
IMPORTANT
Residual oil may leak out.
Treat used oil as hazardous waste.
Comply with the safety regulations for
preventing environmental pollution.
4-
i e engine barring gear [28] can be fitted on newer +

-
engine types.
Diagram of cylinder order and valve arrangement in

4-cyl. engines.
I Fan end
II Power output
6 Exhaust valve & Intake valve
Setting the valve clearance in 4-cylinder engines:

Turn over the engine until the rocker arm has moved
the cylinder to be set into the unloaded position.
The rocker arms of the synchronous cylinder are
then in overlap.
a
@
Rocker arm in overlap with cylinder:
Setting the valve clearance with cylinder:
Firing sequence: 1 - 3 - 4 - 2
Valve clearance (with the engine cold)

with D 02.. Intake................................... 0.20 mm
Outlet ................................... 0.35 mm
with D 08.. Intake/outlet ......................... 0.50 mm

SElTING THE EVB VALVE CLEARANCE
D 08.. engines with EVB
EVB = Exhaust Valve Brake
The system increases the braking effect of the engine through holding the
exhaust valves open by a gap during the engine braking procedure.
Check the valve clearance at the previously normal intervals and adjust it if
necessary.
Do not set the valves unless the engine is cold.
(Cooling water temperature below 50 "C.)
As far as the intake valve is concerned, there is no difference between

engines with EVB and those without EVB.
Set screw 1
@ Locknut 1
Tightening torque ...................50 Nm
@ Counter-holder
Tightening torque ................... 60 Nm +90°
@ Set screw 2
@ Locknut 2
Tightening torque ...................40 Nm
@ Depressurisation hole (oil drain)
@ Piston (cut open)
@ End of the valve stem
@ Rocker arm (cut open)
@ Pressurised oil hole (oil supply)
Checking the exhaust valve clearance

1. Set the piston of the cylinder to be checked to ignition TDC.
2. Turn adjuster screw 2 @ in the counter-holder back as far as possible without using force.
3. Push the rocker arm downwards - e.g. using a screwdriver - as often as required (at least 3 times) until
no more oil emerges from the depressurisation bore. (All the oil must be forced out of the piston space.)
4. lnsert a 0.55 mm valve feeler gauge between the piston @ and the end of the valve stem @.
If the 0.55 mm valve feeler gauge can be inserted, continue from the setting section.
Continue checking if the 0.55 mm valve feeler gauge cannot be inserted.
5. Insert a 0.50 mm valve feeler gauge between the piston @ and the end of the valve stem @.
If the 0.50 mm valve feeler gauge cannot be inserted, continue from the setting section.
Continue checking if the 0.50 mm valve feeler gauge can be inserted
6. Push a 0.35 mm valve feeler gauge between the piston and valve stem. Press down the rocker arm
using a screwdriver until the piston reaches the stop, thereby forcing all the oil out of the piston space.
7. Hold the tappet pressed down and screw in adjuster screw 2 @ until the valve feeler gauge is clamped.
8. Set a 0.35 mm valve clearance by loosening adjuster screw 2 @, but only so far as it is possible to pull
out the valve feeler gauge against moderate resistance. Tighten locknut 2 @ to 40 Nm.
9. Check: There must be play on the push rod.
TABLE OF ENGINE SElTINGS
n
*Tissions category
bef. TDC art of purnping
0 bar 50 bar ;charge 13ressure
t bear. with nozzle
51.1 0102-0202
DLLA 134 P 18( I L L I ~I la1 he
0 433 171 159 er's no.
ing speec
ing speec
. cut-off s
Z/OU m~n./rnax.
1.4 K-value AU
PES6MW1001320 I I VE 6112 F 1200.. Fuel injection pump -
51.1 1103-7022 51.1 1 ' 4N no. -
RQV RQV -
16" 20.5" bef. TDC 1 7" - l o bef. TDC / 14" - l o bef. TDC I 5" -lo bef. TDC I Start of pumping
2651250 bar 2651250 bar 263250 b: 2651250 bar Discharge pressure
51.1 0101-7349 51.1 0101-7349 51.1 0101-; 51.1 0101-7349 Jet bear. with nozzle
--
51.1 0102-0202 1 51.1 0102-0202 1 51.1 0102-0202 1 51.1 0102-0202 1 Nozzle

DLLA 134 P 180 DLLA 134 P 180 DLLA 134 P 180 DLLA 134 P 180 Nozzle nan
0 433 171 159 0 433 171 159 0 433 171 159 0 433 171 159 Manufactur-. - . .-.
585535 585 58553 ing speec3
600 -- ing speec -
252 2520 ] In]. cut-off speed AU
PES6MW1001321 1 VE 6112 F 1200.. I 1

PES6MW1001321 VE 611 2 F 1200.. I Fuel iniection pump
51.1 1103-7165 51.1 1103-7110 1 51.1 1103-7165 51.1 1103-7199 I MAN
I _
no.
DA
I 1 U RQ' I RQ RQV -
with RC with RQ
51.1111 51.1110:
-
9
sure
3r. with n
Idling :
-- 600+1O( 600+ ;peed AC
252C Inj. cut-off spee
276C min./m-...
- 1.O K-valuc3 AU
101321 N1001321 PESl 1201 6-Zyl. RP 43 Fuel injection PI
51.
- 51.1 1103-7559 51.1 1103-7529 MAN no.
RC
- - RQ EDC-MS5 Governor
wit,, ,,, wltn HU with RQ Remark:
51.1 1103-7267 51.1 1103-7301 51.1 1103-7558
* NBF = Needle movement sensor
1621220/2400 162122012400 162122012A00 162122012 kWlh.p.1rpm

Euro 2 Euro 2 Euro 1 Euro 1 Emlss~onscategory
- - %f. TDC bef. Tnr

lo '4' - l o be4 TnP Start of ~
, u m ~
gi n
>
27( bar 250 bar 651250 t: Discharge pres:sure

- -
51.1 0100-7 51.1010 0-7364 51 .I 0101-73L 1.101 01-7349 Jet bear, w~thnozzle
51.1 0102-0223 51.1 0102-0223 51.1 0102-0202 51.1 0102. Nozzle
DSLA 154 P 492 DSLA 154 P 492 DLLA 134 P 180 DLLA 134 Nozzle name
"33 175 085 0 433 175 085 0 433 171 159 0 4 3 3 171 133 Manufacturer's
)+30 630+30 5855 585f35 Idling speed
12100 - 630+100 6002100 6002100 - Idling speed AC
2530 254C Inj. cut-off spee
2730 - 273C ax.
1.O 1 .U 1.4 1 K-value HU
PES6P120A320.. PES6P1 6MW1001321 PES6MW1001321 Fuel injection PIumP
1 103-7331 51.1 1103-7384 MAN n
RQV RQ RQV Governor
with RQ )p speed with RQ (Idlingltop speed Remark:
51.1 1103-7332 governor)
Euro 1 Euro 1
" bef. TDC
17" +_I 18" -1" bef. 16" - l o bef. TDC 4" -'I" bef. TC
175 bar 190/175 ba 1901175 bar 2651250 bar
L
et bear. \ivith nozz
7
51 - lozzle
ULLH ULLH /U Y YZZ n i:<ar iuu I N O Z Z I ~name
8 ,
0 433 0 433 175 053 0 433 1' rrer's no.

700+2 700+25 700525 mng spet
Iling spet
~ j cut-off
. speed A
-
U
VE 411 0 F 1350.. I VE 411 0 F 2 F 1200 1 Fuel iniection ourno-
51.1 1 ' IAN no. -
RQV IUVt!I I I U I
5512400 1 18116012400 112400 kW1h p Irprn

-
Euro 1 Euro 2 turo L Emlss~onscategory
bef. TDC 3" -1" bc3f. TDC tart of pu
50 bar UIZSU ~a 2701250I bar lscnarge pressure
51.I 01 01- 7 3 4 9 1 3 6 4
'
51.1 0100-7364 7 / Jet bear. wlth nozzle

51.1 0102-0202 1 51 .I
0102-0223 1 51.1 0102-0223 1 I Nozzle
'ozzle na
la nu fact^~rer'sno.
lling spet
-
Iling spet -
~ j .cut-off speed A U
VE 411 2 F 1200..
51.11' !
PES 4P120A320.
51.1 1103-7295
PES 4P120A320
-I Fuel injection pump-
MAN no.
- -
RQ RQVK f Governor
-
TABLE OF ENGINE SElTINGS
188125512400 1621220/2400 kWlh.p./rprn

Euro 1 Euro 2 Emissions category
12.5"-1°bef.TDC1 5"-1°bef.TDC 1 1 1 Start of pumping
265/250 bar I 2651250 bar I 1 I Discharge pressure
51.1 0100-7377 1 51.1 0100-7377 1 I I Jet bear. with nozzle
51.1 0102-0202 1 51.1 0102-0202 1 1 1 Nozzle
DLLA 134 P 180 DLLA 134 P 180 Nozzle name
585+35 600Ifr30 Idling speed
600+100 600C100 Idling speed AU
Inj. cut-off speed AU
min./max.
PES6MW100/321 6-cyl. VE pump Fuel injection pump

51.1 1103-7491 51.1 1103-7535 MAN no.
RQV All-speed gov.
(RQV characteristic)
I Governor
Design acc. to
TEA-N I
Euro 2 Euro 2 Emissions category

0" k0.5" TDC 0" k0.5" TDC Start of pumping
330 bar I 330 bar 1 1 1 Discharse pressure
Jet bear. with nozzle
with NBF
--
5~51.10100-74261 5~51.10100-74261 I I Jet bear. with nozzle
6~51.10102-0254 6~51.10102-0254 Nozzle
DSLA 157 P 871 DSLA 157 P 871 Nozzle name
600f 30 600k30 Idling speed
1 I Idling speed AU
2520 2520 Inj. cut-off speed AU
2760 2760 min./max.
1.2 1.2 K-value AU
VP 44 I VP44 I 1 1 Fuel injection pump
51.1 1103-7590 1 I I 1 MAN no.
EDC-MS6.4 I
I
EDC-MS6.4 I I 1 Governor
Design acc. to Design acc. to Remark:
TEA-N TEA-N
* NBF = Needle movement sensor
RA-A13
TABLE OF ENGINE SElTlNGS
169123012600 140119012A00 i l o o i l 9012400 !30/2400 kW1h.p.lrpm

FAV 2 Emissions category
bef. TD( k0.5" bei 7" -1" bef. 16" k0.5" bef. TDC Start of pumping
0 bar ,1250 bar 2651250 b; 2651250 bar Discharge pressure
10101-72 -. t bear. w ith nozzle
10102-02 -.
)zzle
U L L A 1 3 4 Y ltl( -A 134 P ULLAIY~Y ltlu -. U L L P\ 1 3 4 Y itlu N O Z Z I ~name
-. 1171 159 M: 'er's no.

585+35 35 ldl~ngspeed --
I
600f100 600rt ing spee~ -
2520 . cut-off 5 J
n./max.
value AU
6112 F 1200.. -. PESGMW1001321 Fuel ~njectionpump
51.1110: -. 103-7035 MAN no.
RQ - Governor
with R( with RQ with RQ Remark:
51.1 11' 51.11103-7110 51.1 1103-7036
1691231 12171220 4011 901;

FAV 2 iuro 1
i Euro 1 nissions category
Y?
bef. TD( . TDC " bef. TC 3rt of purnping
0 bar >ar 50 bar Di!;charge Ixessure -
61 1 n101-7349 1I " I . 1 Jet bear. with nozzle
1 0102-02
DLLA 1 DLLA ~zzlenan
,er's no.
ing speec
cnn .I nn I cnnlinn
' 500+100 / 600+1nn
. cut-off 5
2760 n.1max.
2.5 2.3 2.3 K-value AU
PES6h 21 PESGMW1001321 VE 6/12 F 1200.. PES6 321 Fuel iniectic3n pump
iiin.3
51.1 1103-7240 c 4
51.1 1103 7"ni 51.1 1103-7219 MI
-
-. Gc
vith RQ with R Q Remark:
i1.11103-7199 51.1 1103-7218
An "JSTMENT VALUES
Piston (c
D 08..
Mahle, measured 22.7 mm above tli e bottorn edge o.f the pist1
Normal
. . dimension ................... ..........................................
~versizestage 0.5 mm ....................
I
4lcan, mt2asured above t tte bottorri edge of the piston @

Norrnal dime1 ......................................................................................
wersize stage 0.5
I'iston-in- cylinder clearanc~

. . . . . ............
h e a r 11m1t .............. ..............
Piston protrusion I 2p edge I~f crankc
Piston compression level

3 08..
Normal dime1ision .....
Undersize I
I
I
108.. supercharged*
Wan, measured 13 mm above the bottom e ie piston
Normal dimension ...................
1st oversize stage 0.5 mm ......
~-
Schmidt, measured 12 mm above the bottom edge of the ~ i s t IbLJI
Normal dime1
'iston-in-cylinder c;ladl dl lc;!

Wear limi ..............
Piston prc ~p edge of crankc
Piston compression level e>

3 08.., superchar~led
Normal dirnerision .....
Undersize II
3ore for gudgeon pin ........

3udgeon pin diameter .................... .............., ..............
'iston weight difference pe!r set in cme engirle, max. ,
Uote: I ne Manle plsron nas Deen replacea ~y Hican or scnrnlar plsrons.

Either Alcan or Schmidt pistons can be used.
REFERENCE TORQUES
I torque!;for ins1tallation to Works Stand;

..
With the exception of subordinate or tacking connections, screw connections without specially prescribed
tightening torques should always be tightened using standard workshop torque wrenches or precision nut
runners.
The torques applied should not differ from the specified tolerance values by more than k15°/0.
Notes about using the ta

- For strength pairings other than those glven, use the tlghtenlng torque tor the part In the lower strength
class (e.g. bolt in strength class 8.8, nut in strength clas: ,mined from
the 8.8 column).
- When tightening a part with a slot onto a part with a round nole, worK trom rne slae wltn tne round hole.
- Do not tighten Ripp bolts and n ilts onto :;lots.
- Wherever possible, alvvays w o,k~ on thc! side of the harcler material wheri tightening soft (:omponents
against hard ones. .. . .
- Always use washers to protect light alloy metal surfaces in conjunction with hexagon bolts and nuts.
- Do not tighten Ripp bolts and nuts on light alloy metals.
- Bolts with a collar or flanged head may only be tightened using rings spanners or sockets due to the low
h~i"h
t of the head flank-
Nominal assemt,ly tighte!ning torques MAfor screw connections with a smooth bearing surface
I
I Strength classes (bolt Inut) in Nm
Thread si; External or interrial hex,agon Collar or flange

x pitch smooth head
10.9110 .9/12 10.9110
MAN Nutzfahrzeuge Aktiengesellschaft
Dachauer Str. 667 or Postfach 50 06 20
80995 M~JNCHEN 80976 MUNCHEN
Repair Manual - A 13, 3rd Edition incl. 1st Supplement -
D 02.. / D 08.. In-Line Engines
- English -
Publication No. 81.99598-4322
Printed in Germany
Common-rail In-line Engines
Copy deadline: 12.2004
Repair Manual
81.99598-6282 I st edition A23
MAN Nutzfahrzeuge AG Reparaturanleitung 1423,
Dachauer Str. 667 Reihenmotoren Common Rail
80995 Miinchen D 0834 LF40
oder D 0834 LF41
Postfach 500620 D 0834 LF42
80995 Munchen - Englisch -
Printed in Germany
Repair Manual A23
1st edition
Common-rail In-line Engines

Special tools
Pressing off the impeller
Removing the coolant pump hub
Pressing out the coolant pump slide seal ring
Pressing in the coolant pump slide seal ring in

conjunction with:
Installer sleeve [6]
Pressing in the coolant pump slide seal ring in

conjunction with:
Plug-on handle, short [4]
Installer sleeve [6]
[GI Installer sleeve 80.99617-0191

,, /p\, Pressing in the coolant pump slide seal ring in
Q ,,,,,./ ,)
conjunction with:
Plug-on handle, short [4]
Disc [5]
[71 Feeler gauge 80.99607-6019
Pressing on the impeller

<----y
-:->-<-c
A,
-
1.
-\
/
Removing the air compressor I power steering Removing the air compressor
Pump
Removing the air compressor coolant lines
Remove the air compressor line

Unscrew the mounting bolts (2) from the support
block (7)
Unscrew the hollow screws (3) Unscrew the mounting bolts (1)
Remove the seals Pull the air compressor (6) out of the timing case
Remove the coolant lines (1) and (2) rearwards
Remove the O-rings (4) and (5) with driver plate
Removing the power steering pump
(3)
Remove the steering oil lines

Unscrew the mounting bolts (5)
Pull the power steering pump (4) off the air
compressor (1)
Remove the driver plate (2) and the O-ring (3)
ALTERNATOR
Removing and installing the alternator
Includes
- Disconnecting and connecting the battery, see Operator's Manual
- Removing and installing the fan, see 2-17
- Removing and installing the belt drive , see 3-49
(1) Alternator (4) Alternator mounting bolt

(2) Alternatorlbelt tensioner support (5) Alternator mounting bolt
(3) Alternator bracket
Technical data
Alternator mounting bolt. .......................................M I0x65-8.8 ...................................................... .45 Nm
Alternator mounting bolt (4). ..................................M I0x110-8.8 ......................................................45 Nm
Alternator mounting bolt (5) ................................... M12x40-8.8 ..................................................... 105 Nm
Poly-V-belt pulley collar nut ................................... M16x1.5 ............................................................80 Nm
Terminal B+ on alternator ...................................... M8 ....................................................................15 Nm
Alternator operating voltage .....................................................................................................2 8V
Alternator charging current (A) ........................................................ 35 Amps at 1800 rpm alternator speed
Alternator charging current (A) ........................................................ 80 Amps at 6000 rpm alternator speed
[241 Support 80.99602-0177
- ,-
(p7 Extracting the injector in conjunction with:
' p I,
Extractor device [22]
Support bridge [23]
/
*_ Support [25]
Hexagon nut [26]
Support [27]
[251 Support 80.99602-0199
i
/\ Extracting the injector in conjunction with:
.. c,,
/ . -
-?
/ Support bridge [23]
- Support [24]
Hexagon nut [26]
Support [27]
[261 Hexagon nut 06.11226-8306
Extracting the injector in conjunction with:
/'-=-,
[-
\.
b -1, ~ ~ g
.
Support bridge [23]
Support [24]
Support [25]
Support [27]
[271 Support 80.99602-0198
r2' Extracting the injector in conjunction with:

Support bridge [23]
Support [24]
Support [25]
Hexagon nut [26]
[281
fl Torque screwdriver
Installing the injector cable in conjunction with:

Adapter [29]
Socket, size 7 [30]
08.06510-9024
1291 Adapter 80.06139-9029
..;. 1 Installing the injector cable in conjunction with:

\* , k
,+' Torque screwdriver [28]
\ i Socket, size 7 [30]
1301 Socket, size 7 08.06141-0700
Installing the injector cable in conjunction with:

Torque screwdriver [28]
Adapter [29]
1311 Thrust piece 80.99606-0609
Installing injectors
[321 Hexagon wrench, size 17 80.99603-0309

/$J
,,i.,,''
,+,>-- Screwing on and unscrewing the high-pressure
line union nuts in conjunction with:
C<.\
/'--
{,
Angle extension 1331
?&>I
1331 Angle extension 08.06139-9025

-.,, ,'.'.
/
j+~.> 7,1, Screwing on and unscrewing the high-pressure
,/,' ), '$
d.-:
<\,Y
, ,--,.,
-<,.
line union nuts in conjunction with:
Hexagon wrench, size 17 1321
Installing the filter elements Installing the heating element
lnsert the heating element (3) with new sealing

ring (4) into the fuel service centre (1)
Screw in the mounting bolts (2) and tighten them
to 9 Nm
WARNING
The common-rail system can be
damaged
Dirt must not be allowed to reach the
clean side of the filter
Do not re-use used filter elements
lnsert a new fuel pre-filter (6)

Screw the cover (7) with new sealing ring (5) into
the housing (4)
Use Socket, size 19 [55] and a torque wrench to
tighten the cover (7) to 10 + 5 Nm
lnsert the new fuel filter element (3) into the cover
(1)
Screw the cover (1) with new sealing ring (2) into
the fuel service centre
Use Hexagon socket wrench, size 36 [54] and a
torque wrench to tighten the cover (1) to 20 + 5 Nm
FLAME START SYSTEM
Protective sleeves, flame start system
(1) Protective sleeve, flame start system line (4) Protective sleeve, hollow screw
81.96002-0516 connection 81.96002-0518
(2) Protective sleeve, flame start system line (5) Protective sleeve, hollow screw
81.96002-0516 connection 81.96002-0517
(3) End plug, hollow screw, fuel service centre (6) Protective sleeve, flame glow plug
81.96002-0520 81.96002-0511
Important information
WARNING
The common-rail system can be damaged
Do not reuse plugs for high-pressure lines, the pressure pipe or injectors, even if they have only
been used once
I p z d e r to ensure that the correct protective sleeve is used. the designation (e.g. Z14x15) is
imprinted in the protective sleeve. This is integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z14x15).
EGR MODULE
Removing and installing the EGR module
Includes
- Draining and topping up the coolant, see Repair Manual YAI
- Removing and installing the flame start system, see 4-95
- Removing and installing the charge air pipes, see 5-101
rnd0834LF421ca00
(1) Thermostat housing (5) EGR positioning cylinder

(2) EGR module gasket (6) EGR module connecting piece
(3) EGR module mounting bolt (7) EGR module
(4) EGR shut-off valve (8) Non-return valve housing
Technical data
EGR module mounting bolt (3) .............................. M8x55-8.8 ........................................................22 Nm
Non-return valve housing mounting bolt (8) ............ M8x60-8.8 .........................................................22 Nm
EGR module temperature sensor (7) .....................M16x1.5 ............................................................35 Nm
EGR shut-off valve mounting bolt (4) .....................M8x55-8.8 ......................................................27 Nm
EGR positioning cylinder mounting nut (5) ............. M8 ....................................................................22 Nm
Service products
Renolit Si 704 silicone grease ............................................................................................09.15014-0102
Checking the adjustment dimension for the EVB Setting the valve clearance
piston
Setting the intake valve clearance
-
i ST-
* Lightly push down the valve bridge (3)

Insert the Feeler gauge [80](2)(0.35mm leaf) Crank the engine to the setting position, see
between the adjusting screw (1)and the valve Cranking to engine to the setting position, 7-140
bridge (3) Undo the locknut (1)
If the adjustment dimension between the adjusting Turn the adjusting screw (2)back until the Feeler
screw (I)and the valve bridge (3)is not 0.35 mm , gauge [80](4)(0.50mm leaf) can be inserted
the adjustment dimension must be adjusted. between the rocker arm (3)and the valve bridge
(5)
Screw in the adjusting screw (2)until the feeler
gauge (4) can be moved between the rocker arm
(3)and the valve bridge (5)with little resistance
Hold the adjusting screw (2)steady and tighten
the locknut (1) to 40 Nm
Check the setting once more
Forcing the engine oil out of the valve bridge
a WARNING
Danger of incorrect valve clearance
It must be possible to fully push the EVB
piston into the valve bridge (1)
Undo the locknut (2)and turn it back a long way

Screw in the adjusting screw (3)for the valve
bridge (1)as far as the stop several times in order
to force the engine oil out of the EVB piston
VALVE TIMING
md0834LF42e00
lntermediate gear 2 (8) Camshaft gear mounting bolt

Oil pump drive gear (9) Camshaft gear
Oil pump drive gear mounting nut (10) lntermediate gear 1
lntermediate gear 2 mounting bolt (11) Timing case
Crankshaft gear (12) Camshaft
Crankshaft gear fixing bolt (13) Tappet
lntermediate gear 1 mounting bolt
TIMING GEARS
Removing and installing the timing gears
Includes
- Removing and installing the fan, see 2-17
- Removing and installing the belt drive , see 3-49
- Removing and installing the coolant pipes, see 2-19
- Removing and installing the coolant pump, see 2-27
- Removing and installing the thermostat with thermostat housing, see 2-23
- Removing and installing the power take-off, see 3-37
- Removing and installing the air compressor 1 power steering pump, see 3-39
- Removing and installing the vibration damper, see 10-185
- Removing and installing the timing case cover, see 11-231
(1) Intermediate gear 2 (4) Crankshaft gear

(2) Oil pump drive gear (5) Camshaft gear
(3) Intermediate gear 1
Technical data
Intermediate gear 1 Allen screw (3) ....................... M14x1.75~45-8.8 .............................................115 Nm
Intermediate gear 1 Allen screw (3) ....................... M14x1.75~60-8.8............................................. 115 Nm
Intermediate gear 1 Allen screw (3) .......................M8x35-8.8 .........................................................22 Nm
Intermediate gear 2 mounting bolt (1) ....................M8x35-8.8 .........................................................22 Nm
Camshaft gear mounting bolt (5) ...........................M I0~38~1.25-10,9 ............................................ .65 Nm
Oil pump drive gear mounting nut (2) .....................M12x1.5-6s .......................................................30 Nm
Installation play values

Intermediate gear 1, radial play ......................................................................................0.060 - 0.109 mm
Removing the oil injector nozzle Installing the oil injector nozzles
Inserting the oil injector nozzles
Unscrew the oil pressure valve

Remove the oil injector nozzle (1)
WARNING
Component damage due to incorrect
alignment of the oil injector nozzle
Line up the ball mark on the oil injector
nozzle exactly with the mark in the
crankcase
Place the oil injector nozzle (2) aligned with the

mark ( I ) in the crankcase
Place the corrugated washer on the oil pressure
valve and screw in by hand
Tightening the oil pressure valve
Check the oil injector nozzle ( 1 ) is correctly seated

and align it if necessary
Tighten the oil pressure valve to 40 Nm
11031 Force multiplier spanner i = 1 : 3,3 80.99619-0006
Tightening the flywheel bolts in conjunction with:

..\.
==-.-
a Socket, size 22 [I021
Support [I041
Torque angle gauge [ I 051
Holding device [ I 061
Cheese-head screw [ I 071
Connecting pin [I081
Rubber ring 42 mm [I091
Disc [I101
[ I 041 Support 80.99606-0551
-.
[zT,.
.,_
,,/
,,
,'
', , Tightening the flywheel bolts in conjunction with:

/..
./-, "' Socket, size 22 [ I 021
, Force multiplier spanner i = 1 : 3,3 [I031
,'
y7c
i,:,.A Torque angle gauge [ I 051
l .
Connecting pin [ I 081
Disc [ I 101
[lo51 Torque angle gauge 80.99607-0172
Tightening the flywheel bolts in conjunction with:

Socket, size 22 [I021
Support [I041
Force multiplier spanner i = 1 : 3.3 [I031
Disc [ I 101
[ I 061 Holding device 80.99606-0585
(;y.?\ Tightening the flywheel bolts in conjunction with:

--.A
Socket, size 22 [ I 021
i
; ,
\ ~ _ _.
~ Support [I041
Force multiplier spanner i = 1 : 3,3 [I031
Torque angle gauge [I051
Disc [ I 101
[ I 071 Cheese-head screw 06.02191-0407
,'
r',
d+.l Tightening the flywheel bolts in conjunction with:
.
...-. .-.,. Socket, size 22 [ I 021
',
\:,;-.
. Support [I041
' k.?<;?
Force multiplier spanner i = 1 : 3,3 [I031
Torque angle gauge [ I 051
Disc [ I 101
Removing the flywheel Unscrewing the flywheel mounting bolts
Assembling the special tool
/--,
Unscrewthe mounting bolts (1)for the flywheel (2)

md08361f1021
except for two bolts
Fit the Holding device [I061(5)with Cheese-head
screw [I071 (4)and Disc [I101 (3)on the Support Installing the guide pins
[I041(2)
Place the Torque angle gauge [I051(9) onto the
Force multiplier spanner i = 1 : 3,3[I031(1)
Place the Socket, size 22 [I021(7) onto the Force
multiplier spanner i = 1 : 3,3[I031(1)and secure
with the Connecting pin [I081(8)and Rubber ring
42 mm [I 091 (6)
Undoing the flywheel mounting bolts
Screw the Aligning tool [I011 (1)through the

flywheel into the crankshaft
Unscrew the remaining mounting bolts (2)
Pulling off the flywheel
Place the assembled special tool (1)onto the

flywheel bolt that is going to be unscrewed
Undo all the flywheel bolts
CAUTION
Danger of injury due to heavy
components
Use lifting gear to install the flywheel
Checking the piston setback in conjunction with:
Dial gauge holder [I131
Installing the piston
Installing the piston
[I 171 Setting tool 80.99622-0052
Positioning the bearing shell, cracked connecting

rod
[I281 Disc 80.99609-0033
Tightening the crankshaft bolts in conjunction
with:
Support [I221
Torque angle gauge [I231
Holding device [I241
Cheese-head screw [I 251
Force multiplier spanner i = 1 : 3,3[I211
Socket, size 22 [I201
[I 291 Setting tool 80.99622-0052
Positioning the bearing shell, cracked connecting
rod
[ I 351 Crossmember 80.99606-0298
Removing the rear crankshaft oil seal in

conjunction with:
Hook [I361
i Guide plate [I311
Threaded spindle [ I 321
Hexagon nut [ I 331
Thrust piece [ I 381
Disc [I341
[ I 361 Hook 80.99606-6013

,7'
,
' conjunction with:
/,,
c> / Crossmember [ I 351

Guide plate [I311
Cheese-head screw [I 371
Hexagon nut [I331
Thrust piece [ I 381
Disc [I341
[ I 371 Cheese-head screw 06.02191-2713
0 d
/
.
-
')l~
\' \
Removing the rear crankshaft o ~ lseal in
conjunction with:
Crossmember [ I 351
Hook [I361
Guide plate [I311
Hexagon nut [I331
Disc [ I 341
[A381 Thrust piece XX XMXX-XXXX

conjunction with:
Crossmember [ I 351
Hook [I361
Guide plate [ I 311
Hexagon nut [I331
Threaded splndle [ I 321
Disc [ I 341
Hexagon collar nut [I401
Common rail in-line engines
Copy deadline: 07.2003
Repair manual
81.99598-5772 2nd edition A 30
MAN Nutzfahrzeuge Aktiengesellschaft Reparaturanleitung A 30

Dachauer Str. 667 oder Postfach 50 06 20 Reihenmotoren Common Rail
80995 M~JNCHEN 80995 M~JNCHEN D 2876 LF12 / LF13
- englisch -
Printed in Germany
Repair manual for the A 30
2nd edition
Common rail in-line engines

FITTING AND REMOVING THE AIR COMPRESSOR
-
.~
Removing the air compressor Removing the air compressor
Removing the coolant pipes
Mark the positions of the individual mounting

md2876kaa14
bolts (1) and (4) and then remove them
Dismantle and remove coolant pipes (1), (2) and Undo the fixing nuts (3) and remove the
(3) from the compressor bracket (2)
Pull the air compressor off the crankcase and
studs
Removing the air intake pipe
Clean the contact surfaces
Removing the steering pump
Remove retaining clips from the air intake pipe

(2) with angular clamping pliers [771]
Unscrew the mounting screw from the pipe clip
(1) and remove the air intake pipe (2) Unscrew the mounting bolts (1) from the steering
Pump
Pull the steering pump out of the air compressor
Remove the drive washer (3) from the air
compressor
Remove the O-ring (2) from the steering pump
ASSEMBLING AND DISMANTLING THE AIR COMPRESSOR
This comprises
Fitting and removing the air compressor, page 39
(1) Connecting rod (12) Cylinder head gaskets

(2) Piston pin circlip (13) Circlip
(3) Piston pin (14) Inner bearing ring
(4) Piston with piston rings (15) Roller bearing
(5) Piston pin circlip (16) Circlip
(6) Gasket, underside of cylinder liner (17) Drive gear
(7) Mounting bolts, cylinder liner (18) Mounting bolt, drive gear
(8) Cylinder liners (19) End plate
(9) Cylinder head mounting bolts (20) Mounting bolts, end plate
(10) Cylinder heads (21) Crankshaft
(1 1) Flap valve (22) Air compressor housing
Technical data
Mounting bolt, cylinder liner (7)................................ M8x30-100 ........................................................... 40 Nm
Cylinder head bolts, first pre-tightening (9) ..............M8x100-10.9 .......................................................21 Nm
Cylinder head bolts, final tightening (9) ....................M8x100-10.9 ........................................................... 90"
Mounting bolt, drive gear (18) .................................. M I 8x1 5x65-10.9 .......................................... 360 + 3 Nrn
Mounting bolts, end plate (20) ................................. M8x25-8.8 ............................................................ 23 Nm
Con rod bearing bolts, preliminary tightening ..........M8x38-10.9 ......................................................... 10 Nm
Con rod bearing bolts, final tightening ..................... M8x38-10.9 ............................................................... 90"
Pressure relief valve ................................................ 2 6 . 5 ............................................................... 95 Nm
Screw-in fitting for air connections ...........................M26x1.5.............................................................. 80 Nrn
Special tools
Socket assembly SW22 80.99603-6029
in combination with:
handle [820]
Fitting and removing the poly-V-belt pulley
[780] Socket assembly SW24 80.99603-6030
@Q
handle [820]
[8201 Handle 08.06460-0002
socket assembly [775]
or socket assembly [780]

Extension
socket insert [I 851
Fitting and removing injector lines
Adapter
torque wrench [752]
socket [823]
Fitting the control cable
I Socket 1 08.06141-0700
torque wrench [752]
adapter [822]
I Fitting the control cable 1

1 Storage sleeve
Storing injector
Protective plug and sleeve set for injector system 81.96002-6002
Sealing injectors, rail and high-pressure lines
[8271 Protective plug and sleeve set for overflow oil line
Sealing overflow oil line
Protective plug and sleeve set for fuel lines
Sealing high-pressure pump, leak-off manifold

and filter
Cross-piece assembly with adjustable supports
Removing injectors
23 33, :i:"K
>'$st-.g.$
" '
q "1"' *,?:: ?;.+;L
P" Ct' -
2 C
,- fi;$
. . .
Fitting the fuel pre-filter element Fitting the heater element
Slide new fuel pre-filter element (3) into fuel Slide heater element (2) with new O-ring into fuel
service centre (4) service centre (3)
Screw in filter end cap with new O-ring and Position the mounting bolts (1) and tighten to
tighten to prescribed torque, see Technical prescribed torque, see Technical data, page 87
data, page 87
Removing the fuel pre-heater
Removing the heater element
md2876gcb12
Unscrew mounting bolts (1)

Pull heater element (2) out of fuel service
centre (3)
FITTING AND REMOVING THE FLAME START DEVICE
(1) Fuel pre-filter (5) Solenoid valve

(2) Hand-priming pump (6) Fuel line
(3) Fuel service centre (7) Flame glow plug
(4) Mounting bolts, solenoid valve
Technical data
Flame glow plug ....................................................... M32x1.5 ........................................................ max. 25 Nm
Mounting bolts, solenoid valve ................................. M6x12-8.8 .............................................................. 9 Nm
Fitting for solenoid valve .......................................... 1 0 x 1 .................................................................. 15 Nm
Electrical connection, flame glow plug ..................... M4 ......................................................................... 5 Nm
Line to glow plug ..................................................... 1 0 x 1................................................................... 10 Nrn
Attaching the fuel lines
Position fuel line (2) at fuel service centre without

strain
Screw banjo bolt (3)through fuel line (2) into
solenoid valve (1)and tighten to the prescribed
torque, see Technical data, page 93
Position fuel line (5) without strain at solenoid
valve (I) and flame glow plug, and tighten
Position mounting bolts (4) and tighten to
prescribed torque, see Technical data, page 93
Fitting the flame glow plug
Screw flame glow plug (1) into intake pipe

Align flame glow plug and attach fuel line
Tighten flame glow plug to prescribed torque,
see Technical data, page 93
Attach cable
FIlTING AND REMOVING THE CHARGE AIR PIPES
Charge air manifold to charge air cooler (6) Charge air manifold from turbocharger
Mounting bolts (7) O-ring
O-ring (8) Shaped clip
Charge air pipe (9) Turbocharger
O-ring (10) Oil filter module
Technical data
Mounting bolts (2) .................................................... 8 170-8.8 .......................................................... 23 Nm
Mounting bolts (2) ...................................................M8x40-8.8 ........................................................... 23 Nm
Shaped clip .............................................................. 8 .......................................................................... 7 Nm
assembly tool [68]
Fitting and removing the valve springs
80.99606-0588
assembly tool 1681
assembly tool [758]

Lifting out the valve keepers Assembling the cylinder head
Fitting the valves
After being forced off, the valve keepers (1) stay

inside the assembly tool (2) and are lifted off the
valve stem Note
The exhaust valves (2) have a larger
-
F
1 recess in the valve head and areg
re
irl in
Removing the valves I diameter.
Slide the exhaust valves (2) and intake valves (3)

into the valve guides of the cylinder head (1)
Attaching holder for valve lifter
Unscrew guide sleeve and remove valve spring

retainer (2) and valve spring (3) from valve
Remove special tool from cylinder head
Turn the cylinder head over and remove washers
and valves
4
The same procedure is used for all the valves. The CAUTION
base plate and guide sleeve must be transferred to Valve heads will be damaged if valve
each valve in turn keepers with one ring are used.
Only valves, valve keepers and valve

spring retainers with a three-ring retain-
ing collet may be fitted. The valve
spring retainers feature three visible
raised areas.
Clamp cylinder head (2) on assembly plate (1)

[651
Fix base plate with notched piece (4) from tool kit
[68] through the cylinder head into the assembly
plate (1) using a hexagon bolt (3)
Screw guide sleeve (5) for assembly tool into
base plate (4)
ASSEMBLING AND DISMANTLING THE OIL PUMP
This comprises
Draining and refilling engine oil, Maintenance Manual
Fitting and removing the oil sump, page 197
Fitting and removing the oil pump, page 189
(1) Mounting bolts, oil pump cover (6) Drive gear

(2) Oil pump cover (7) Mounting bolt, oil pump
(3) Oil pump gears (8) Pressure limiting valve (DBV)
(4) Oil pump housing (9) Mounting bolts (pressure limiting valve)
(5) Mounting bolts, oil pump cover
Technical data
Mounting bolts, oil pump cover (1) ........................... M8x55-8.8 ............................................................ 22 Nm
Cheese-head screws, oil pump cover (5) ................ M8x55-8.8 ........................................................... 22 Nm
Backlash, drive gear - oil pump drive gear ................................................................................ 0.5 + 0 / - 0.1
End float, oil pump gear ........................................................................................................ 0.050 - 0.128 mm
Special tools
[I461 Gauge holder base plate 80.99605-0172
dial gauge [595]
Measuring end float of oil pump gears
13641 Press pin 80.99617-0029
Forcing off the oil pump drive gear
[5951 Dial gauge 08.71 000-3217
gauge holder base plate [I 461
Measuring end float of oil pump gears

ASSEMBLING AND DISMANTLING THE OIL PUMP
Dismantling the oil pump Assembling the oil pump
Removing the oil pump cover Forcing the drive gear on
Unscrew mounting bolts (1) for oil pump cover Place oil pump housing (3) and oil pump gears
(2) from the oil pump housing (3) on spacer blocks (4)
Unscrew mounting bolts (4) through the bore in Force on drive gear (2) using a suitable press pin
the drive gear (5) (1) until the backlash is correct,
Remove oil pump cover see Technical data, page 191
Forcing off the drive gear Measuring the backlash
md2876bcc06
Place oil pump (5) on spacer blocks (4) • Place the gauge holder (1) [I 461 and dial gauge
Using a press pin (1) [364], force the oil pump (2) [595] on the oil pump gear (3)
gear (2) out of the drive gear (3) • Set the dial gauge to zero
a Place the tip of the dial gauge on the drive gear
(4) and measure the amount of backlash
between it and the oil pump gear (3),
see Technical data, page 191
Fitting the vent line for the air intake
Attach vent line (2) with union nut (1) on air

intake
Slide retaining clip ( 3 ) on to vent pipe using
angular clamping pliers [771]
Slide vent line on to connecting pipe for oil
separator (4) and fasten with a hose clip ( 3 )
Fitting the vent line to the flywheel casing
Slide retaining clip (2) on to vent pipe ( 3 ) using

angular clamping pliers [771]
Push vent pipe ( 3 )on to ventilation manifold and
fasten with retaining clip ( 2 )
Fit banjo bolt (4) into flywheel casing with new
seals
Tighten banjo bolt to the prescribed torque, see
Technical data, page 239
FITTING AND REMOVING THE FLYWHEEL CASING
This comprises
Fitting and removing the starting motor, page 53
Fitting and removing the flywheel, page 201
(1) Mounting bolts, flywheel casing (2) Flywheel casing
Technical data
Mounting bolts (washer head bolts) (1) ....................M10x54-12.9 ........................................................ 75 Nm
Mounting bolt, thrust washer ....................................M8x8.4-12. ......................................................... 40 Nm
Consumables
Thread-locking adhesive ................................................................................................................. Loctite 648
Important information
CAUTION
If the PTFE seal comes into contact with oil or grease before being fitted, it will be unusable.
Clean oil and grease from the crankshaft and fitting tools before assembly.
Special tools
[831 Extractor assembly 80.99601.6018
Extracting cylinder liner

&&1
,3
@J
[I461 Gauge holder base plate 80.99605.0172
dial gauge [595]
Measuring'cylinder liner protrusion
Measuring plate 80.99605.0195
measuring combination 11691
gauge holder base plate [I 461
Measuring cylinder liner protrusion

Trucknology Generation A (TGA)
Maintenance Manual
MAN Nutzfahrzeuge Aktiengesellschaft Wartungsanleitung WA 74 (3.)

Dachauer Str. 667 oder Postfach 50 06 20 Trucknology Generation A (TGA)
80995 M~JNCHEN 80976 M~JNCHEN
- Printed in Germany
Maintenance Manual
WA 74* (3.)
Trucknology Generation A (TGA)

ENGINE D 0836 LF, FOUR-VALVE - WITH EVB
CHECKING THE VALVE CLEARANCE (alternative method)

- Alternative method for adjusting valve clearance in D 0836 engines
This alternative method enables all valves to be checked and adjusted in just two crankshaft positions.
The method described here can be used as an alternative to the usual method already described.
Adjustment
Fit the engine barring gear on the flywheel housing
(+) (see page 1)
Turn the crankshaft until it reaches the nearest
TDC position so that either cylinder 1 or cylinder 6
is at ignition TDC
6 valves can be adjusted in this position
Then turn the engine 1 more revolution so it
reaches TDC again
The remaining 6 valves can now be adjusted
Cylinder 1 or cylinder 6 must be exactly

at the TDC mark.
If cylinder 6 is at ignition TDC (= cylinder 1 in

overlap), adjust:
0 Exhaust valves and a intake valves
k- Intake valves
6 Exhaust valves
If cylinder 1 is at ignition TDC (= cylinder 6 in

overlap), adjust:
a Exhaust valves and 0 intake valves

@ Intake valves
4
$ Exhaust valves
Remove the engine barring gear
Fit the cover on the flywheel housing.
ENGINE D2866 LF, D2876 LF, DO836 LF
CHANGING ENGINE OIL AND FllTlNG A NEW

FILTER
Park the vehicle on a flat, level surface

Switch off the ignition
Draining the oil (with engine at operating

temperature)
Note: A new oil filter is also fitted each time the

engine oil is changed.
When the oil is changed, you may notice that a

quantitv of used oil (0.3 litres when ECAS is at
normal-level and vehicle is parked on the flat)
remains in the oil sump overflow area. This is due to
the shape of the oil sump. The actual quantity
depends on how far the vehicle is lowered at the
rear.
If ECAS is fitted, you should raise the rear of the
vehicle as far as possible when changing the oil so
that all of the used oil can flow out.
Note: The vehicle must be standing on a flat,

level surface when the oil level is measured!
If necessary, switch ECAS (electronically
controlled air suspension) to the normal level,
see sections 3.00 and 3.1 013.1 1 "ECAS" in the
Operator's Manual
The engine oil level falls when the rear axle is
lowered and rises when the rear axle is raised.
Tilt the cab

Put an oil pan or similar underneath
Unscrew the oil drain plug @ at the oil sump
(example illustrated)
You must comply with the notes on

safety regarding the treatment of used oil
and the disposal of oil filter elements,
see section 0.50 "NOTES ON SAFETY
AND ENVIRONMENTAL PROTECTION"!
Drain the used oil from the oil sump drain hole
INTAKE SYSTEM
Checking the water drain valve

vvater araln valve O J IS iocatea upstream or tne air
filter at the lowest point of the crude air pipe.
Danger of engine damage!

Regularly clean and check the
functioning of water drain valve @ as
there may be water in the crude air pipe
when the drain valve is closed.
This causes water to be sucked in,
resulting in engine damage!
Use your hand to check the water drain valve @

for free passage
Clean the valve if it is blocked
POLY-V-BELTS
Push the tension~nqpullev Q downwards

Remove the poly-V-belt
Example illustrated for DO836 LF engine with air-

conditioning system
Poly-V-belt installation is a reversal of the removal

procedure.
BREATHER FOR SEMlLlFETlME OIL FlLL
BREATHER FOR SEMlLlFETlME OIL FlLL

The breather and the PA pipelines (PA = polyamide
(plastic), 6x1 M3230) with connection system 203
(VOSS) must be renewed when changing the oil in
the gearbox and/or driven axle.
INSTALLATION POSITION
Gearbox:
-Breather a below the air filter housing
Axle:
-Breather a above the driven axle
RENEWING
Removing
Mark the routing of the PA pipelines and the
position of the plastic fasteners
Remove all the fasteners @
Undo the mounting bolts @ on the breather
(illustrated example: axle)
Unscrew the connection system union screw @ on

the axle housing
BREATHER FOR SEMILIFETIME OIL FILL
Cut the new PA pipeline to the desired size

Only use a plastlc cutting shears (MAN no.
08.02350-9004) for cutting the pipeline to size. This
is the only tool that ensures the clean and
perpendicular cut that is necessary for successful
assembly. It is not necessary to rework the cut, e.g.
deburring on the inside and outside.
Mark the required connection insert depth

(19.5 mm) on the PA pipeline that is to be fitted
This enables an immediate visual check for ensuring
correct PA pipeline assembly.
-Do not heat the PA pipeline when

routing it under any circumstances!
-Keep the PA pipelines well away from
any sources of heat.
Route the PA pipeline so that it is free from kinks,

chafing and tension. Observe the marks made
whilst removing the components
Remove the connection system plastic cap
(assembly stopper) concerned @ from the gearbox
or axle breather
Press the clean PA pipeline (without paint residue
or similar) into the plug connection until the stop is
reached. You must overcome the resistance
provided by the round rings and the toothed ring
within the connection system.
Briefly pull back the PA pipeline so that the holding
edges running around the inside of the plug
connection engage in the PA pipeline jacket
Check the "insert depth" mark on the PA pipeline!
In the case of the gearbox, ensure that the PA

pipeline rises (+) in addition to checking that it is
free from kinks, chafing and tension!
BREATHER FOR SEMILIFETIME OIL FILL
h I - PA aiaelines must be fastened usina

plastic fasteners.
-When mounting the PA pipes, ensure
that the pipe fasteners prevent the PA
pipelines from turning.
-The maximum distance between the
fasteners is 500 to 800 mm.
-Do not freely "suspend" pipe
connections in PA pipelines!
Fit all the plastic fasteners a,observing the marks

made durinn removal
BRAKE TECHNICAL SAFETY
Rrake chaft hearinn nn wheel hrake sectinn

Lubricate the brake shaft bearings via the
lubricating nipple (+) using a grease gun
ENGINE BRAKE
Gap too small:

Increase torsion bar spring pretension.
To do this, place an object (e.g. pliers) between the

"closed" stop @ and the valve lever.
Close the valve by hand and, by feeling,
"overpress" the torsion bar spring against the stop.
I HEADLIGHTS
HEADLIGHTS
ADJUSTMENT
General information
The vehicle and the setting instrument must be
standing on a flat, level surface. Only check and
adjust the headlight settings when the vehicle is
unladen and the tyres have been inflated to the
specified pressure.
When adjusting the headlights, also refer to the
headlight setting plate (co-driver side) and the
"Headlight beam adjustment" table MAN
no. 81.25000-8358 (also see Operator's Manual).
Use the Torx 120 tool for all adjustment work.
Checking (general description)

- In the case of vehicles with manual headlight
beam adjustment, the adjuster must be in
position "0"(+), see Operator's Manual for setting.
- In the case of vehicles with automatic headlight
beam adjustment (LWR) and xenon headlights,
the adjustment feature must be deactivated using
MAN-Cats before adjusting the headlights
(position "0").
Checkingladjustment can be performed using an

optical setting instrument (see the operating
instructions provided by the manufacturer
concerned) or a white screen (wall) positioned 10 m
away and parallel to the front of the vehicle.
The following general description is based on a left-

hand drive vehicle with asymmetrical driving lights.
Key to diagrams:
Figure I = Headlight low beam
Figure II = Headlight high beam
H = Height of the middle of the headlight above the

ground in mm
h = Height of the separating line on the screen

(wall) above the ground in mm
e = H minus h
Setting (e) for vehicles with leaf suspension:
Headlight = see adhesive label inside the
right-hand door next to the type plate, indicated
in % ( l % = 100 mm, 1.5% = 150 mm,
2% = 200 mm, etc.)
Fog lamps = 400 mm
Setting (e) for vehicles with air suspension:
Headlights = 100 mm
Fog lamps = 200 mm
A = Headlight centre-to-centre distance

HEADLIGHTS
For asymmetrical headlight low beam (see

Figure I):
Side setting
The "kink" on the line where light meets dark should
be on the vertical which runs through the setting
cross.
Height setting
The point where light meets dark should touch the
separating line (height h) to the left of the lower
setting cross.
For headlight high beam (see Figure 11):

The high beam "hotspot" (centre) should be
positioned on the upper setting cross.
HEADLIGHTS
Adjusting main headlights

(Figure shows left main headlight)
Move the headlight adjuster (see operating
instructions provided by manufacturer concerned) to
the "basic headlight setting" as indicated on the
"Headlight beam adjustment" table (see Operator's
ManualIMAN no. 81.25000-8358).
- In the case of vehicles with manual headlight

beam adjustment, the adjuster must be in
position "0"(+),see Operator's Manual for setting.
- In the case of vehicles with automatic headlight
beam adjustment (LWR) and xenon headlights,
the adjustment feature must be deactivated using
MAN-Cats before adjusting the headlights
(position "0").
Always make sure the headlights are set to low

beam before adjusting. If the low beam setting is
correct, the high beam setting will be correct too.
Height setting - down

Turn the upper adjusting screw a anti-clockwise
One revolution moves the line where light meets
dark (LD line) in the headlight adjuster downwards
by 0.4" and to the right by 0.3".
Then perform a counter correction by turning the
lower adjusting screw @ clockwise
One revolution is equivalent to a counter correction
of 0.3".
- Adjustment by 0.4" downwards
Height setting - up
Turn the upper adjusting screw a clockwise
One revolution moves the line where light meets
dark (LD line) in the headlight adjuster upwards by
0.4" and to the right by 0.3".
Then perform a counter correction by turning the
lower adjusting screw @ anti-clockwise
One revolution is equivalent to a counter correction
of 0.3".
- Adjustment by 0.4" upwards
Side setting - to the left (leftlright side)

Turn the lower adjusting screw @ anti-clockwise/
clockwise
One revolution moves the headlight to the left by
0.3".
- Adjustment by 0.3" to the left
Side setting - to the right (leftlright side)

Turn the lower adjusting screw @ clockwiselanti-
clockwise
One revolution moves the headlight to the right by
0.3".
- Adjustment by 0.3" to the right
TYRES
SPARE WHEEL MOUNTING

Check that the spare wheel mounting nuts are
firmly seated
Risk of injury if cable is frayed!

Renew defective cables immediately
Check the hoist and spare wheel mounting

Check the winch cable @
Note: Do not oil or grease the winch cable, to

prevent excessive dirt build-up.
TIPPER SYSTEM
MEILLER THREE-WAY TIPPER SYSTEM
GENERAL INFORMATION
Danger of accidents!
- Observe the relevant national work
safety and accident prevention
regulations.
- Before tipping, ensure that there are no
bulk goods or freight on the loading
area.
- Only tip if the vehicle is standing on a
flat, level and stable surface.
- In the case of Caxle vehicles, the
steering must be in the straight-ahead
position to prevent damage to the
wheel nut caps when the "Bordmatik"
automatic unloading system wall is
fully folded down.
- Ensure that the insert pins are
correctly seated when tipping!
- No-one is allowed to stand in the tipper
or side wall operating area.
- The operator must observe the correct
tipping and lowering procedure and
not move away from the tipper valve
actuator so that immediate action can
be taken in an emergency.
- Standing or working beneath a non-
supported tipper body puts lives at risk
and is therefore prohibited!
- Always make sure that the safety
supports are attached so that they
cannot slip!
- Do not perform maintenance work
unless the engine is stopped.
- Do not increase the hydraulic system
operating pressure set by the
manufacturer.
- Follow environmental protection
guidelines!
- For further details, refer to the "TIPPER
OPERATION" section in the Operator's
Manual.
TIPPER SYSTEM
TIPPER BODY (examples illustrated)
LUBRICATING THE TIPPING BOOM

Oil the noise level reduction devices via the hole a
(2 x left, 2 x right)
Oil the bearing points of the fittings
Oil the bearing points of the rear wall latches
Oil the bearing points of the body supports
LUBRICATING THE AUTOMATIC SIDE WALL

LATCH
Lubricate the automatic side wall latches via
grease nipple (+)
LUBRICATING THE "BORDMATIK"AUTOMATIC

UNLOADING SYSTEM
Lubricate the low-maintenance side wall bearing
points regularly every 2 months using a silicone oil-
based grease (commercially available).
Use a fluorine/silicone oil-based high-temperature
grease (commercially available) if transporting bulk
goods with high temperatures (e.g. bitumen).
Lubricate the bearing points of the "Bordmatik"

automatic unloading system via lubricating
nipple (+)
Only operate the "Bordmatik"automatic

unloading system with the hydraulic
pump switched on!
CHECKING THE REAR WALL CATCH SETTING
Automatic claw-type lock

If correctly set, the automatic claw-type lock opens
the steel rear wall once the tipping angle reaches
approx. 5".
a
Check that setting = 2 mm, @ = 6 mm and angle
@ = 7", readjust on the linkage if necessary
There must be no play between the roller and the
cam (+); however, the rollers must still rotate
easily
Check the locking components for clearance and
ease of movement

A40 Common Rail In-Line Engines

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WIRING DIAGRAM NO. 81.99192.2496

Trailer socket, 24V 7-pin sheet 1 of 1

WlRlNG DIAGRAM NO. 81.99192.2497

Trailer socket, 24V 7-pin + 4-pin sheet 1 of 1

Central electrical system

Installation position of XI586 and XI587 for semitrailer E8!

WIRING DIAGRAM NO. 81.99192.2448

Trailer socket, 24V 7-pin + C p i n and 12V 13-pin sheet 1 of 2

Central electrical system

Trailer socket, 24V 7-pin + 4-pin and 12V 13-pin sheet 2 of 2

WIRING DIAGRAM NO. 81.99192.2498

Trailer socket, 24V 7-pin + 7-pin sheet 1 of 1

Central electrical system

: E,"llation position of X I 586 and XI587 for semitrailer E8!

WIRING DIAGRAM NO. 81.99192.2449

Trailer socket, 24V 7-pin + 7-pin and 12V 13-pin sheet 1 of 2

WRING DIAGRAM NO. 81.99192.2449

Trailer socket, 24V 7-pin + 7-pin and 12V 13-pin sheet 2 of 2

WIRING DIAGRAM NO. 81.99192.2447

Trailer socket, 24V 7-pin and 12V 13-pin sheet 1 of 1

Central electrical system

WRING DIAGRAM NO. 81.99192.1 534

Floodlights, cab roof (left) sheet 1 of 1

Central electrical system

Central electrical system

WIRING DIAGRAM NO. 85.99192.2059

Ashtray lighting, left sheet 1 of 1

WIRING DIAGRAM NO. 85.99192.2020

Ashtray lighting, right sheet 1 of 1

ASR check lamp sheet 1 of 1

1 For basic equipment, see wiring diagram for EBS

WIRING DIAGRAM NO. 85.99192.2021

ASR slip threshold button sheet 1 of 1

WlRlNG DIAGRAM NO. 81.99192.1685

Battery EMERGENCY OFF sheet 1 of 2

Central electrical system

i Battery EMERGENCY OFF sheet 2 of 2

WIRING DIAGRAM NO. 81.99192.2495

Battery master switch, mechanical (left-hand drive vehicles) sheet 1 of 1

A1 00 Central electrical system

WIRING DIAGRAM NO. 81.991 92.2853

Controls, MMI controller sheet 1 of 1

WIRING DIAGRAM NO. 81.99192.1664

Control module, upper bunk sheet 1 of 1

) WIRING DIAGRAM NO. 81.99192.2854

i CAN databus, Highline (H-CAN), with instrumentationlMMl sheet 1 of 1

WIRING DIAGRAM NO. 81.99192.2857

CAN databus, Highline (H-CAN), with instrumentationlMMllradiosheet 1 of 1

WRING DIAGRAM NO. 81.99192.1546

CAN databus, Highline (H-CAN), with instrumentationlMMllradiolnavigation sheet 1 of 1

WIRING DIAGRAM NO. 81.99192.2377

CAN databus, instrumentation (I-CAN)ltachograph(FS-CAN)(standard) sheet 1 of 1

Central electrical system

$ 1 ' 0 1ocs1 >- 1

Trucknology Generation A (TG-A)

Publication no.: System Description

MAN Nutzfahrzeuge Aktiengesellschaft Elektrische Anlage TG-A

CAN Controller Area Network

Trucknology Generation A (TG-A)

Diagram titles Diagram no. Sectionlpage

Guide to using the diagrams 6.01 - 1

Identifier Installation position