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MAN Engines
A Division of MAN Truck & Bus
Repair Manual AE 4
2nd edition
51.99598-8250
1
PREFACE / PRINTER’S IMPRINT
PREFACE
This manual is intended to provide assistance in performing repairs correctly on vehicles and units and reects
the known technical situation appertaining at the copy deadline.
This publication assumes that persons who use it possess the requisite technical knowledge in handling
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always
correspond to the unit or peripherals in question, but this does not necessarily mean they are incorrect. In
such cases, plan and carry out the repair work in accordance with the sense of the instructions.
Repair work on complex add-on units should be entrusted to our customer service or to the customer service
of the manufacturing company. These units are mentioned specically in the text.
The repair jobs are divided up into sections and subsections. Each subsection starts with a page of jobs to
do in advance. The jobs to do in advance contain a summary of the main prerequisites for the repair section
in question. The detailed description of work can follow the jobs to do in advance.
Important instructions concerning technical safety and the safety of personnel are specically highlighted, as
indicated below.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in order to avoid
exposing people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in order to avoid
serious or irreparable damage to property.
Note
An explanatory note which is useful for understanding the working or operating procedure to be
performed.
Comply with general safety regulations when performing any repair work.
PRINTER’S IMPRINT
Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN
Truck & Bus AG. All rights under the copyright law are strictly reserved by MAN. If any changes are made
without the written approval of MAN Truck & Bus AG then Truck & Bus AG shall not be liable for any warranty or
guarantee claims arising from damage and defects attributable to the unauthorised modication. Furthermore,
MAN Truck & Bus AG shall not be liable for any damage resulting from the unapproved modication.
Satz: EPEGG
Druck: EPEGR
2 AE 4 2nd edition
TABLE OF CONTENTS
Content Chapter/Page
Index 7
Introduction
Troubleshooting chart
Engine electrics
Cooling system
Add-on units
Common-rail system
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TABLE OF CONTENTS
Removing and installing the high-pressure lines and rails ................................................. 163
Removing and installing the high-pressure lines and rails (classied variant) ......................... 174
Injectors ................................................................................................................. 191
Removing and installing the injectors .......................................................................... 191
Checking the injector seat, rail and leakage oil lines for leaks - D2862LE4.. ........................... 201
High-pressure pump/high-pressure pump drive ................................................................. 205
Removing and installing the high-pressure pump/high-pressure pump drive .......................... 205
Fuel lines ................................................................................................................ 213
Removing and installing the fuel lines ......................................................................... 213
Removing and installing the fuel lines (classied variant) .................................................. 224
Fuel lter ................................................................................................................ 239
Removing and installing the fuel lter .......................................................................... 239
Removing and installing the fuel lter (classied variant) .................................................. 245
Dismantling and assembling the fuel lter .................................................................... 250
Dismantling and assembling the fuel lter (classied variant) ............................................. 254
Hand pump ............................................................................................................. 259
Removing and installing the hand pump ...................................................................... 259
Removing and installing the hand pump (classied variant) ............................................... 263
Dismantling and assembling the hand pump ................................................................. 267
Turbocharging
Cylinder head
Valve timing
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TABLE OF CONTENTS
Engine lubrication
Crank mechanism
Crankcase
Special tools
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TABLE OF CONTENTS
Technical Data
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INDEX
Catchword Page
A
Add-on units
Starter..................................................................................................................................................... 144
Assembly instructions
Gaskets .................................................................................................................................................... 15
Pipelines................................................................................................................................................... 14
C
Camshaft
Anti-rotation device................................................................................................................................. 387
Camshaft gear........................................................................................................................................ 387
Countershaft gear................................................................................................................................... 386
Insertion pin............................................................................................................................................ 388
Roller tappet ........................................................................................................................................... 387
Characteristic data......................................................................................................................................... 19
Crankshaft
Axial play ................................................................................................................................................ 494
Connecting rod bearing journals ............................................................................................................ 501
Crankcase lower section ........................................................................................................................ 495
Crankshaft bearing shell......................................................................................................................... 499
Crankshaft gear...................................................................................................................................... 499
Marks...................................................................................................................................................... 507
Thrust washers....................................................................................................................................... 498
Crankshaft drive
Lower connecting rod bearing ................................................................................................................ 483
Piston pin................................................................................................................................................ 481
Piston pin bore ....................................................................................................................................... 483
Cylinder head
Final tightening ....................................................................................................................................... 367
Preliminary tightening............................................................................................................................. 367
Rocker arm mechanism ......................................................................................................................... 376
Tightening diagram................................................................................................................................. 367
Cylinder liner
Cylinder liner standout............................................................................................................................ 534
Sectional sealing rings ........................................................................................................................... 535
D
Drive gears
Crankshaft gear...................................................................................................................................... 397
Intermediate gear ................................................................................................................................... 397
E
Engine control unit
Removing the engine control unit............................................................................................................. 52
Removing the injector wiring harness ...................................................................................................... 52
Engine cover................................................................................................................................................ 516
Engine description ......................................................................................................................................... 22
Diagram of the cooling system ................................................................................................................. 30
Diagram of the engine lubrication system ................................................................................................ 28
Diagram of the engine timing system ....................................................................................................... 34
Diagram of the fuel system....................................................................................................................... 33
Engine housing
Cover...................................................................................................................................................... 520
Engine overhaul
General information.................................................................................................................................. 15
Pressure application process ................................................................................................................... 15
Engine timing, V12 engine
Checking the valve lift ............................................................................................................................ 392
Engine timing, V8 engine
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INDEX
H
Heat exchanger plate pack
Assembly instructions............................................................................................................................... 99
Loosening instructions.............................................................................................................................. 95
Pressure plate .......................................................................................................................................... 95
Tightening instructions.............................................................................................................................. 97
High-pressure pump
Fuel pump .............................................................................................................................................. 209
High-pressure line .................................................................................................................................. 207
Metering unit........................................................................................................................................... 209
High-pressure system
Extracting the injector............................................................................................................................. 197
Injector initial torque ............................................................................................................................... 199
Rail ......................................................................................................................................................... 182
Rail connection....................................................................................................................................... 196
Rail-pressure sensor and pressure limiting valve................................................................................... 182
M
Model plate .................................................................................................................................................... 18
N
Notes on installation
O-rings...................................................................................................................................................... 15
Notes on safety................................................................................................................................................ 9
General....................................................................................................................................................... 9
O
Oil cooler
Oil cooler ................................................................................................................................................ 419
Oil injector nozzles
Mounting bolt.......................................................................................................................................... 431
Oil module
Oil cooler ................................................................................................................................................ 429
Oil pump ...................................................................................................................................................... 439
Axial play ................................................................................................................................................ 440
Oil sump ...................................................................................................................................................... 434
Oil dipstick .............................................................................................................................................. 434
P
Performance overview................................................................................................................................... 20
T
Technical data
Alternator................................................................................................................................................ 149
Cylinder liner .......................................................................................................................................... 531
Flywheel ................................................................................................................................................. 469
High-pressure pump............................................................................................................................... 205
Oil injector nozzles ................................................................................................................................. 431
Vibration damper .................................................................................................................................... 457
Troubleshooting chart
Malfunctions ............................................................................................................................................. 39
V
Vibration damper
Hub......................................................................................................................................................... 466
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INTRODUCTION
INTRODUCTION
NOTES ON SAFETY
General
Working with engines and the necessary service products does not pose any problems provided the people
entrusted with operation, maintenance and repair have been trained accordingly and actively keep their minds
on the job.
Personnel in training or instruction or who are undergoing general education are not allowed to work on the
unit unless they are permanently supervised by an experienced person.
The following sections include summaries of important regulations listed according to major topics. The
intention is to provide the knowledge needed to avoid accidents which could lead to injury, damage and
environmental pollution. They represent only a small excerpt from the wide range of accident prevention
regulations and cannot replace these. It goes without saying that all other safety regulations must be
followed and that the corresponding action must be taken.
Additional direct references to danger are contained in the instructions at points where there is a potential
danger.
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin
contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes,
etc.
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INTRODUCTION
Suspended loads
– Do not lift heavy parts without assistance. Use suitable tools.
Procedure:
– Carefully attach individual parts and larger assemblies to lifting tackle prior to
exchanging them, in order to rule out any danger.
– Only use suitable lifting gear that is in perfect working order. Use lifting devices
with sufcient load-carrying capacity.
– Only ever use the crane hook eyelets provided for connecting the crane lifting
tackle when lifting the engine.
– No-one is allowed to stand under an engine suspended from a crane hook. Keep
all lifting tackle in good condition.
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INTRODUCTION
Electric welding
– Note the welding codes of practice.
– Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number
80.78010.0002) as described in the instructions accompanying the device.
– If this device is not available, disconnect the batteries and connect the positive cable
to the negative cable in order to make a conductive connection.
– Always earth the welding equipment as close as possible to the welding area. Do not
lay the cables to the welding equipment in parallel to electrical cables in the vehicle.
– Disconnect the control units.
Painting
– If paint spraying is to be carried out, do not expose the electronic components to
high temperatures (max. 95 °C) for more than brief periods; a time of up to 2 hours
is permissible at a maximum of 85 °C.
– Disconnect the batteries.
– Remove sensitive electrical components
– Screw connections of the high-pressure part of the injection system are not allowed
to be painted. Danger of dirt getting in during repair work.
General
– Engines are built exclusively for the application corresponding to the scope of supply – as dened by the
equipment manufacturer – (designated use):
– Designated use also includes compliance with the operating, maintenance and repair conditions specied
by the manufacturer. The engine is only allowed to be used, maintained and serviced by people who are
familiar with this work and have been informed about the dangers.
– Independent modications to the engine will result in the manufacturer’s liability for resulting damage being
rendered null and void.
Similarly, tampering with the injection and control system can affect the unit’s performance and exhaust-gas
characteristics. As a result, there is no longer any guarantee that statutory environmental protection
regulations will be complied with.
– If a fault occurs during operation, determine its cause immediately and correct the problem before the fault
can get any worse.
– Clean the units thoroughly before repairs. Ensure that no dirt, sand or foreign objects can get into the units
whilst carrying out repairs.
– Only use genuine spare parts. Fitting parts made by other companies can lead to severe damage, and the
workshop that did the work will be responsible for it. See the section entitled “Limited liability for accessories
and parts”.
– Never run a unit dry, in other words always make sure that it has been lled with oil before running it.
– Never run engines without coolant.
– Apply a suitable information sign to units that are not ready to be operated.
– Only use service products specied by MAN, otherwise the manufacturer warranty will be invalidated!
For general information about service products, refer to the publication entitled “Service products for MAN
diesel engines”.
Details of approved products can be found online at:
https://mmrepro.mn.man.de/bstwebapp/BSTServlet
– Do not ll engine/gear oil above the maximum level mark. Do not exceed the maximum permitted operational
tilt.
– Severe damage to the unit could result from failure to follow these regulations.
3. Limited liability
General
All of the data and information in this manual were compiled taking into account the applicable standards and
regulations, the state of the art, and our vast experience and knowledge.
12 AE 4 2nd edition
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The obligations agreed in the delivery contract, the General Terms and Conditions of Business of MAN and
the statutory regulations applicable at the time of the signing of the contract shall apply.
Accident prevention
A jet of fuel can cut through the skin. Risk of re due to fuel atomisation.
– Never undo the screwed connections on the fuel high-pressure side of the common-rail system whilst the
engine is running (injection line from the high-pressure pump to/on the rail and on the cylinder head to the
injector).
– Avoid standing near the running engine.
Whilst the engine is running, the lines are constantly carrying fuel under a pressure of up to 1800 bar.
– Before opening the screwed connections, wait for at least ve minutes so that the system can be
depressurised.
– Check depressurisation of the rail using MAN-cats if necessary.
Danger of injury!
– Do not touch the live parts at the injector electrical connection whilst the engine is running.
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INTRODUCTION
Cleanliness
Diesel-injection systems consist of precision engineered components that are subject to extreme loads. Due
to this high-precision technology, it is necessary to ensure the greatest possible cleanliness during all work
on the fuel system. Even dirt particles over 0.002 mm can cause component failure.
Before commencing work, you must therefore ensure the following measures without fail:
Manufacturer warranty
Only use service products specied by MAN, otherwise the manufacturer warranty will be invalidated!
For general information about service products, refer to the publication entitled “Service products for MAN
diesel engines”.
Assembly instructions
Mounting pipelines
Danger: Do not bend any kind of pipeline – Danger of breakage!
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INTRODUCTION
Mounting gaskets
Gaskets are often inserted with sealing compounds or adhesives in order to facilitate assembly or to offer a
better seal. Particularly if parts with different thermal coefcients of expansion are connected together (e.g.
aluminium and cast iron), this can lead to the seal migrating during operation and give rise to leaks.
Example: The cover of the front crankshaft oil seal. In this case, the use of a sealing compound or adhesive
causes the gasket to be pushed inwards over time due to the differences in thermal expansion. Oil leakage
occurs which may under certain circumstances be ascribed to the shaft seal.
Gaskets can only be tted correctly provided the following points are adhered to:
– Only use genuine MAN gaskets.
– Make sure the mating faces are undamaged and clean.
– Do not use adhesives or sealing compounds. If necessary, to facilitate installation, use a little grease to
stick the gasket to the part to be mounted.
– Tighten the bolts evenly to the specied tightening torque.
Installation of O-rings
– Only use genuine MAN O-rings.
– Make sure the mating faces are undamaged and clean.
– Coat O-rings with engine oil to MAN Standard 3277 when tting them.
Engine overhaul
In our judgement, it is not advisable to open an engine or perform a major overhaul if the engine has
good compression values and the following operating values have not changed signicantly since they were
measured and taken during the initial start-up:
– Charge pressure
– Exhaust temperature
– Coolant and lubricating oil temperature
– Oil pressure and oil consumption
– Smoke characteristics
The following criteria have a major inuence on the engine service life:
It is essential to ll engines with lubricating oil using the pressure application process in dry condition before
start-up following a repair. This process can also be used in the case of damage and cause assessments.
In all engines that have not undergone pressure application, the risk of premature bearing surface damage
is very high, since the lubricating oil drawn from the oil sump by the oil pump takes a relatively long time to
reach the individual bearing points.
Such preliminary damage may not lead to bearing failure immediately, but it can impair correct functioning of
the bearings and shorten the service life.
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INTRODUCTION
Schematic representation of the oil ow in engines which have not undergone pressure application
If the engine undergoes pressure application, the following benets are achieved:
– All engine parts are lubricated before starting, and a lm of lubricant can form in the bearing before the
crankshaft even starts turning. This prevents overlay damage.
– Unwanted oil loss – whether it be caused by excessive bearing clearance, leakages in the crankcase or
non-sealed bores in the crankcase – can be detected immediately. In this case, mount the engine on an
assembly trolley, remove the oil sump and install a suitable oil collecting container under the crankcase so
that the bearings are visible.
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Procedure:
During pressure application, the entire oil quantity is pressed into the engine oil circuit. The operating pressure
is used as the reference value for the press-in pressure. This is not allowed to be exceeded. The electrical
oil pump is connected to the engine oil circuit at the oil modules.
Connect the pressure hose for the electrical oil pump to the oil modules (1) and (2).
Press half of the entire oil quantity into the engine via the left oil module and the other half via the right oil
module, see Filling the engine with oil using the pressure application process, 416.
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INTRODUCTION
THE ENGINE
Model plate
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INTRODUCTION
Characteristic data
D 2868LE 433
D 2862LE 433
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INTRODUCTION
1 Performance overview
Unlimited number of operating hours per year, at full load 100% of the time
Up to 3000 operating hours per year, at full load 20% of the time, at 50% load on
average
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INTRODUCTION
Up to 1000 operating hours per year, at full load 20% of the time, at 50% load on
average
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Engine description
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Engine, general
The 8- and 12-cylinder diesel engines described here are liquid-cooled, 4-stroke diesel engines with 2-stage
exhaust turbocharger and intercooler. The engines operated using the common rail high-pressure injection
system in conjunction with EDC 7 (Electronic Diesel Control).
Crankcase
The crankcase consists of the crankcase upper section and the crankcase lower section. Both sections cast
from different special cast irons. The wet cylinder liners made from special, highly wear-resistant centrifugal
casting are exchangeable. The cylinder liners are sealed at the bottom using elastomer sealing rings. At the
rear of the crankcase, there is a ywheel housing. At the front of the crankcase, there is a housing cover.
The ywheel housing and housing cover are made of aluminium. The radial shaft seals are installed in the
housing cover and the ywheel housing.
Crankshaft
The crankshaft is forged in a die using high-quality, micro-alloyed steel. It has 6 or 10 mounted counterweights
to balance the masses. The crankshaft is mounted in ve or seven bearings in the crankcase. The crankshaft
journals and connecting rod bearing journals are mounted in ready-to-install three-component bearings. The
axial bearing is provided by thrust bearings in the last bearing seat at the ywheel end. The connecting rod
bearings are supplied with oil via a bore in the crankshaft bearing.
AE 4 2nd edition 25
INTRODUCTION
resulting from cracking results in a tooth engagement effect between the connecting rod bearing cap and the
connecting rod with a precise, non-interchangeable t and high lateral stability.
Pistons
3-ring steel pistons are used. The pistons have a cooling duct for relieving the thermal load. This area is
covered by exible metal containing a bore into which the oil jet from the oil injection nozzles is injected for
cooling. The ring set comprises one half keystone ring and taper-face ring each as compression rings as
well as a double-bevelled ring as oil scraper ring. The pistons can be removed from above together with the
connecting rods.
Camshaft
The camshaft is forged from steel and induction hardened. It is mounted in ve or seven bearings in the
crankcase. The camshaft is driven by timing gears that are installed in the ywheel housing.
Engine lubrication
The engine is lubricated by forced-feed lubrication for all bearing points. The engine oil lter and the oil cooler
are grouped together as an oil module. The oil level in the oil sump is measured using a dipstick.
Cooling system
The cooling circuit is a thermostat-controlled forced-circulation cooling system. The maintenance-free coolant
pump is installed on the end face in the housing cover and is driven by a separate gear set. The thermostats
are housed above in the two-section thermostat housing. The thermostats consist of an exchangeable insert
with expansion element.
The coolant pump is mounted at the rear left on the ywheel housing. It supplies coolant to the intercooler
and the heat exchanger.
Cylinder head
The D28 engine is equipped with a camshaft with overhead valves (OHV). Engines in series D28 are equipped
with individual cylinder heads made from special cast iron as well as shrink-tted valve seat rings and
pressed-in exchangeable valve guides. The valve guides have valve stem seals at all four valves. The
cylinder heads are secured with six high-strength external hexagon round bolts (cylinder head bolts). The
single-layer steel cylinder head gasket with elastomer elements has a specially designed combustion chamber
seal.
The intake air passes through the air lter to the low-pressure turbocharger (1st stage). The charge air
following precompression is intercooled as it passes through the low-pressure intercooler before passing
on to the high-pressure stage (2nd stage). Following the high-pressure stage, the charge air is once again
cooled in the high-pressure intercooler and then supplied to the engine.
Fuel system
The fuel system consists of a low-pressure system and a high-pressure system. The low-pressure system
includes the fuel lines, the hand pump and the fuel lters. The interface to the high-pressure system is the
high-pressure pump.
High-pressure system
The high-pressure system consists of the ow-rate-controlled high-pressure pump with ange-mounted fuel
pump and the rail with rail pressure sensor and pressure limiting valve. Solenoid valve-controlled injectors
with rail connections and high-pressure lines which meet the necessary requirements are also installed.
Injection pressure generation and fuel injection are separate in the high-pressure system. The injection
pressure is generated by the high-pressure pump, irrespective of the engine speed and the required injection
quantity. The injection quantity is available in the rail for injection via the injectors. The high-pressure pump
26 AE 4 2nd edition
INTRODUCTION
delivery quantity is controlled by a proportional valve. The injection point and the injection quantity are
calculated in the engine control unit and implemented by the solenoid valve-controlled injectors.
1 Pilot injection to improve combustion, reduce combustion noise and reduce peak combustion pressures.
2 Main injection to introduce the energy for the required engine power output.
Always ensure absolute cleanliness both in and around the working area whenever carrying out work on the
highly sensitive high-pressure system.
Injectors
The injectors are controlled by solenoid valve. They are arranged vertically in the cylinder head and clamped
with a pressure ange in the cylinder head.
Starter
The starter is a sliding-gear starter. When the starter is operated, the pre-engaged starter guides the pinion
into the ring gear by means of a starter solenoid. A relay is mounted in the starter for starter control.
Alternator
A compact, powerful, low-noise alternator is mounted for power generation. The alternator is equipped with
a multifunction controller. The voltage is controlled depending on the temperature, the battery charge level
and the current power consumption. The alternator is electrically insulated when mounted.
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Geartrain, front
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Charge-air diagram
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INTRODUCTION
Cylinder arrangement - V8
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INTRODUCTION
AE 4 2nd edition 37
TROUBLESHOOTING CHART
TROUBLESHOOTING CHART
Repairs can only be considered complete when both the problem that occurred and the possible causes
have been remedied. Finding out what caused a problem is often more difcult than remedying the problem
itself. We therefore recommend that, before “removing and dismantling”, you have the malfunction described
in detail. Then narrow down the probable causes by asking specic questions. Once this is done, use the
chart and your own experience to examine the probable causes one after the other and rectify the problem.
This method helps reduce repairs to acceptable levels and counteracts possible complaints regarding “rash”
exchange of parts and expensive labour time and downtime.
Note:
The following chart is designed to serve as a memory aid for experts, the aim being to ensure that no probable
causes are overlooked when troubleshooting. The specialist is expected to be very familiar with the Repair
Manual for the engine as well as the corresponding Operator's Manual and “Service products for MAN diesel
engines”.
AE 4 2nd edition 39
TROUBLESHOOTING CHART
Malfunction
EDC self-diagnosis or ashing code output
Starter does not crank engine or only cranks engine slowly
Starter turns, engine does not start, engine does not start/starts poorly when cold
Engine dies during operation, no longer starts (starter turns), engine does not start/starts
poorly when warm
Sudden and temporary engine standstill, engine does not get up to speed
Engine only runs at idling speed, cannot be accelerated
Engine runs at high idling speed, cannot be accelerated
Nominal speed considerably reduced (in no-load condition also)
Reduced power across the board
Irregular engine running, traction interruption
Idling speed unstable, engine “surges”, engine misring, knocking
in engine
Possible causes
x x x Flat batteries, loose or corroded battery cable connections,
discontinuity in circuit
x Crankshaft drive blocked
x x Starter solenoid switch sticking (clicking)/defective, cable connection
loose or defective
x Starter/start-locking relay defective (carbon brushes loose/worn, coil
defective, ground short)
x x Engine oil viscosity unsuitable, not suitable for ambient temperature,
lubricating oil grade not as specied
x Oil level in oil sump too high
x Engine cold
x Piston rings severely worn, broken
x Piston pins or crankshaft main bearings are loose
x x Incorrect valve clearance
x x Valves jamming
x x x Defective compression or more than 4 bar pressure differential
between the individual cylinders
x x Valve seats leaking
x x Increased power consumption due to defective auxiliary consumers
such as hydraulic pumps etc, PTO switched on
x x x x Air lter contaminated or clogged, charge air system leaking, air
supply/exhaust gas lines blocked/leaking
x x x x x x Low-pressure fuel system: tank, pre-lter, water trap defective
/blocked/mildew buildup, fuel unsuitable/heavily contaminated (with
parafn)
x x x x x x Low-pressure fuel system: Fuel lines leaking, broken, blocked
x x x x x x Low-pressure fuel system: Air in system (switch on ignition when
bleeding)
x x x x x x Low-pressure fuel system: Fuel pump, main lter
x x x High-pressure fuel system: Injectors defective/blocked/leaking/coked
40 AE 4 2nd edition
TROUBLESHOOTING CHART
Malfunction
EDC self-diagnosis or ashing code output
Starter does not crank engine or only cranks engine slowly
Starter turns, engine does not start, engine does not start/starts poorly when cold
Engine dies during operation, no longer starts (starter turns), engine does not start/starts
poorly when warm
Sudden and temporary engine standstill, engine does not get up to speed
Engine only runs at idling speed, cannot be accelerated
Engine runs at high idling speed, cannot be accelerated
Nominal speed considerably reduced (in no-load condition also)
Reduced power across the board
Irregular engine running, traction interruption
Idling speed unstable, engine “surges”, engine misring, knocking
in engine
Possible causes
x x High-pressure fuel system: Pressure lines - narrowing, cavitation,
leakage
x x x High-pressure fuel system: High-pressure pump worn
x x x x x x Pedal value sensor (shift lever signal) defective: Connection lines,
short-circuit, discontinuity
x x x x EDC speed sensor defective, line defect
x x EDC speed sensor polarity reversed
x x x x x x x EDC detects wrong speed (unwanted signal on speed sensor line)
x x EDC charge pressure sensor: Defective, incorrect, implausible with
atmospheric pressure sensor, line defect
x x Turbocharger leaking or defective
x x x x EDC coolant temperature sensor: Defective, line defect
x x x EDC charge air temperature sensor: Defective, line defect
x x Cooler contamination or cooling system failure (temperatures too
high)
x x x x x x x Voltage supply to EDC engine control unit interrupted or battery
voltage too low
x x x x EDC engine control unit defective (internal fault)
x Master-Slave control unit communication fault
x x x x x Incorrect EDC engine control unit (check MAN part numbers)
x After-run not completed
x Thermostat defective
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TROUBLESHOOTING CHART
Malfunction
Engine “shaking”
Unusual combustion noises
High smoke output: White smoke/blue smoke
High smoke output: Black smoke
Engine temperature too high (loss of coolant)
Excessive fuel consumption
Lubricating oil pressure too low
Lubricating oil pressure too high
Lubricating oil consumption too high
Engine too “loud”/manual gearbox
Possible causes
x x x Engine oil viscosity unsuitable, not suitable for ambient temperature,
lubricating oil grade not as specied
x x x Oil level in oil sump too high
x Oil level in oil sump too low, oil in the oil sump too thin (with
condensation or fuel)
x Engine temperature too high
x Oil lter blocked
x x Oil pressure gauge defective
x Safety valve in oil circuit defective (does not close, spring fatigue or
spring broken)
x x Severe bearing wear
x Oil pump gears severely worn
x Timing gears worn, excessive backlash
x x Engine cold
x x x Lubricating oil reaches the combustion chamber (piston rings worn,
piston rings broken) - valve stem guide worn - excess pressure in
crankcase (crankcase ventilation blocked)
x Safety valve in oil circuit defective (does not open), oil lines / oil ducts
blocked
x x Leaks in the lubrication oil circuit, particularly at turbocharger and oil
cooler
x x x x x x Piston rings severely worn, broken
x x Piston pins or crankshaft main bearings are loose
x x x x x x Valve stems severely worn, bent
x x x Incorrect valve clearance
x Valve seats leaking
x Increased power consumption due to defective auxiliary consumers
such as hydraulic pumps, fan etc., power take-off switched on
x x x Air lter contaminated or clogged, charge air system leaking, air
supply/exhaust gas lines blocked/leaking
42 AE 4 2nd edition
TROUBLESHOOTING CHART
Malfunction
Engine “shaking”
Unusual combustion noises
High smoke output: White smoke/blue smoke
High smoke output: Black smoke
Engine temperature too high (loss of coolant)
Excessive fuel consumption
Lubricating oil pressure too low
Lubricating oil pressure too high
Lubricating oil consumption too high
Engine too “loud”/manual gearbox
Possible causes
x x Low-pressure fuel system: Tank, pre-lter, water trap defective
/blocked/mildew buildup, fuel unsuitable/heavily contaminated (with
parafn)
x x Low-pressure fuel system: Fuel lines leaking, broken, blocked
x x Low-pressure fuel system: Air in system (switch on ignition when
bleeding)
x x Low-pressure fuel system: Fuel pump, main lter
x x x x x High-pressure fuel system: Injectors defective/blocked/leaking
/coked
x x High-pressure fuel system: Pressure lines - narrowing, cavitation,
leakage
x x x x High-pressure fuel system: High-pressure pump worn
x EDC speed sensor polarity reversed
x x x EDC detects wrong speed (unwanted signal on speed sensor line)
x EDC charge pressure sensor: Defective, incorrect, implausible with
atmospheric pressure sensor, line defect
x x x x Turbocharger leaking or defective
x Turbine and compressor wheel in turbocharger contaminated (not
running smoothly, imbalance)
x x x Intercooler leaking, defective
x x EDC coolant temperature sensor: Defective, line defect
x Cooler contamination or cooling system failure (temperatures too
high)
x Coolant level too low, air in coolant circuit
x Incorrect V-belt tension
x Coolant pump leaking, defective/thermostat defective, does not open
x Coolant lines leaking, blocked or twisted
x Coolant is getting into the combustion chamber (cylinder head/gasket
leaking)
x x x x Incorrect EDC engine control unit (check MAN part numbers)
x Thermostat defective
x Engine mounting worn
AE 4 2nd edition 43
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ENGINE ELECTRICS
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46 AE 4 2nd edition
ENGINE ELECTRICS
AE 4 2nd edition 47
ENGINE ELECTRICS
ENGINE ELECTRICS
Removing and installing the engine control units
Additional jobs
– Disconnecting and connecting the battery
Technical data
Mounting bolt, engine control unit .......................... M6x35-10.9 ....................................................... 11 Nm
Mounting bolt, terminal box ................................... M8x45-8.8 .........................................................14 Nm
Service products
Loctite 648 ........................................................................................................................ 04.10160-9164
AE 4 2nd edition 49
ENGINE ELECTRICS
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
CAUTION
Danger of injury due to sharp-edged protrusions on the cable ties
• Always use Cable tie pliers [1] to tighten and cut cable ties
WARNING
Electrical line damage due to overtightening
• Follow the Cable tie pliers [1] instructions
WARNING
Restricted operation due to defective entries in the fault memory
• Before removing the engine control unit, read out and document the fault memory
WARNING
Danger of irreparable engine control unit damage
• When installing the connectors, rst fully open the lock and then insert and lock the connectors
WARNING
Danger of irreparable plug connection damage
• Protect loosened plug connections and contacts against dirt ingress
WARNING
Danger of cable breakage
• Only secure the wiring harness at the previously marked attachment points
Note
Mark the attachment points before removing the engine wiring harness
Note
After a new engine control unit is tted, its parameters have to be reset.
After resetting the engine control unit parameters, read out the fault memory and delete as
necessary.
Special tools
50 AE 4 2nd edition
ENGINE ELECTRICS
AE 4 2nd edition 51
ENGINE ELECTRICS
• Fully unlock and pull off the connectors (3) and (4) • Unscrew the mounting bolts (1)
• Mark the installation position of the cable ties and • Remove the rail (2)
then disconnect the cable ties
• Expose the wiring harnesses Removing the engine control unit
• Swivel the injector wiring harness (1) with
grommet (2) to the side
52 AE 4 2nd edition
ENGINE ELECTRICS
WARNING
• Beginning with 1, tighten the engine control unit in Danger of irreparable engine control
the sequence 1, 2, 3, 4, 5, 6, 7, 8 unit damage
• When installing the connectors, rst
Installing the engine control unit fully open the lock and then insert and
lock the connectors
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54 AE 4 2nd edition
ENGINE ELECTRICS
AE 4 2nd edition 55
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56 AE 4 2nd edition
ENGINE ELECTRICS
(1) Sensor, fuel pressure upstream of (3) Sensor, exhaust gas temperature
high-pressure pump, Master upstream of turbocharger, right
(2) Sensor, coolant temperature (option) (4) Connector for water level sensor in fuel
pre-lter with water trap
Technical data
Injector cable.................................................................................................................................1.5 Nm
Service products
White T assembly paste..................................................................................................... 09.16012-0122
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Danger of irreparable engine control unit damage
Damage to the contacts
• When installing the connectors, rst fully open the lock and then insert and lock the connectors
WARNING
Cable break
• Only secure the wiring harness at the previously marked attachment points
AE 4 2nd edition 57
ENGINE ELECTRICS
Note
Mark the attachment points for the wiring harness on the engine.
Special tools
58 AE 4 2nd edition
ENGINE ELECTRICS
Removing the injector wiring harness Removing the injector wiring harness
WARNING
Danger of damage to the engine
• Unscrew the mounting bolts (2)
electrics/electronics
• Remove the cylinder head cover (1)
• Mark all electrical connections.
Removing the injector cable • Mark the attachment points for the
wiring harness on the engine.
WARNING
Danger of damage to the engine
electrics/electronics
• Mark all electrical connections.
• Mark the attachment points for the
wiring harness on the engine.
• Unscrew the mounting bolts (2)
• Mark the installation position of the injector cables • Remove the left injector wiring harness holder (1)
(1)
• Unscrew the mounting nuts from the injector
• Remove the injector cable (1) from the cable
passage in the gasket (2)
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ENGINE ELECTRICS
Removing the right injector wiring harness Installing the injector wiring harness
holder
Mounting the left injector wiring harness holder
60 AE 4 2nd edition
ENGINE ELECTRICS
WARNING WARNING
Danger of damage to the engine Component damage due to possible
electrics/electronics short-circuit
• Connect all electrical connections as • When tightening the mounting nuts,
marked make sure that the cable plugs do not
• Only fasten the wiring harness at the touch each other
previously marked attachment points
• Connect the injector cable to the injector as
• Position the injector wiring harness (1) and fasten marked
as marked • Screw on the mounting nuts with the Torque
• Secure the wiring harness (1) with cable ties as screwdriver [2] in conjunction with the Adapter [3]
marked and Socket, size 7 [4] and then tighten to 1.5 Nm
• Tighten and cut cable ties using the Cable tie • Thinly apply White T assembly paste on the cable
pliers [5] passage in the gasket (2)
• Insert the injector cable (1) into the cable passage
in the gasket (2)
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62 AE 4 2nd edition
ENGINE ELECTRICS
(1) Sensor, fuel pressure upstream of (3) Sensor, exhaust gas temperature
high-pressure pump, Master upstream of turbocharger, right
(2) Sensor, coolant temperature (option) (4) Connection, water level sensor in fuel
pre-lter with water trap
Technical data
Electrical connection, B+, alternator ...................... M8 ....................................................................14 Nm
Starter terminal 30-............................................... M12...................................................................25 Nm
Starter terminal 31-............................................... M12...................................................................25 Nm
Starter terminal 50-............................................... M6 ..................................................................... 4 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Danger of irreparable engine control unit damage
Damage to the contacts
• When installing the connectors, rst fully open the lock and then insert and lock the connectors
WARNING
Cable break
• Only secure the wiring harness at the previously marked attachment points
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ENGINE ELECTRICS
Note
Mark the attachment points for the wiring harness on the engine.
Special tools
64 AE 4 2nd edition
ENGINE ELECTRICS
WARNING
Danger of damage to the engine
electrics/electronics
WARNING • Mark all electrical connections.
Danger of damage to the engine • Mark the attachment points for the
electrics/electronics wiring harness on the engine.
• Mark all electrical connections.
• Mark the attachment points for the • Disconnect the cable ties
wiring harness on the engine. • Unlock the plug connection (1) and pull off the
connector
• Disconnect the cable ties • Unscrew the mounting nut (2) and remove the
• Unlock the left oil pressure plug connection (1) and cable (3)
pull off the connector • Unscrew the mounting nut (4)
• Remove the mounting bolt (7) and the washer (5)
• Remove the cable (6)
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ENGINE ELECTRICS
Disconnecting the oil pressure, oil temperature Disconnecting the charge-air and coolant plug
and coolant pressure plug connections connections
WARNING WARNING
Danger of damage to the engine Danger of damage to the engine
electrics/electronics electrics/electronics
• Mark all electrical connections. • Mark all electrical connections.
• Mark the attachment points for the • Mark the attachment points for the
wiring harness on the engine. wiring harness on the engine.
66 AE 4 2nd edition
ENGINE ELECTRICS
WARNING
WARNING Danger of damage to the engine
Danger of damage to the engine electrics/electronics
electrics/electronics • Mark all electrical connections.
• Mark all electrical connections. • Mark the attachment points for the
• Mark the attachment points for the wiring harness on the engine.
wiring harness on the engine.
• Disconnect the cable ties
• Disconnect the cable ties • Mark the installation position of the cables
• Unlock the suction vacuum plug connection (1) • Unscrew the mounting nut (3)
and pull off the connector • Remove the washer (2) and cable (3)
• Unlock the coolant temperature plug connection • Unscrew the mounting nut (10)
(2) (option) and pull off the connector • Remove the washer (11) and cable (12)
• Unlock the Slave metering unit plug connection (3) • Unscrew the mounting nut (6)
and pull off the connector • Remove the washer (5) and cable (4)
• Unlock the Master rail pressure plug connection • Unscrew the mounting nut (9)
(4) and pull off the connector • Remove the washer (8) and cable (7)
• Unlock the Slave rail pressure plug connection (5)
and pull off the connector
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ENGINE ELECTRICS
Disconnecting the exhaust gas and coolant Disconnecting the fuel pressure and
temperature plug connection temperature plug connection
WARNING WARNING
Danger of damage to the engine Danger of damage to the engine
electrics/electronics electrics/electronics
• Mark all electrical connections. • Mark all electrical connections.
• Mark the attachment points for the • Mark the attachment points for the
wiring harness on the engine. wiring harness on the engine.
68 AE 4 2nd edition
ENGINE ELECTRICS
Disconnecting the fuel pressure and metering Disconnecting the camshaft speed sensor plug
unit plug connection connection
WARNING WARNING
Danger of damage to the engine Danger of damage to the engine
electrics/electronics electrics/electronics
• Mark all electrical connections. • Mark all electrical connections.
• Mark the attachment points for the • Mark the attachment points for the
wiring harness on the engine. wiring harness on the engine.
WARNING
Danger of damage to the engine
electrics/electronics
WARNING • Mark all electrical connections.
Danger of damage to the engine • Mark the attachment points for the
electrics/electronics wiring harness on the engine.
• Mark all electrical connections.
• Mark the attachment points for the • Disconnect the cable ties
wiring harness on the engine. • Unlock the crankshaft speed sensor plug
connection (1) and pull off the connector
• Disconnect the cable ties
• Unlock the exhaust gas temperature plug
connection (1) and pull off the connector
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Removing the fuse protective caps Removing the engine wiring harness
70 AE 4 2nd edition
ENGINE ELECTRICS
Installing the engine wiring harness Mounting the plug connection X50 fastening
WARNING
• Position the holder (2) Danger of damage to the engine
• Screw in and tighten the mounting bolt (1) electrics/electronics
• Only secure the wiring harness at the
Fitting the engine wiring harness previously marked attachment points
WARNING
Danger of damage to the engine
electrics/electronics
• Only secure the wiring harness at the
previously marked attachment points
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ENGINE ELECTRICS
Mounting the fuse protective caps Connecting the camshaft speed sensor plug
connection
WARNING
Danger of damage to the engine WARNING
electrics/electronics Danger of damage to the engine
• Only fasten the wiring harness at the electrics/electronics
previously marked attachment points • Connect all electrical connections as
marked.
• Screw on and tighten the union nuts (2) • Only fasten the wiring harness at the
• Screw on and tighten the protective caps (1) previously marked attachment points
• Secure the wiring harness with cable ties as
marked • Position the connector (1) and lock the camshaft
• Tighten and cut cable ties using the Cable tie speed sensor plug connection
pliers [6] • Secure the wiring harness with cable ties as
marked
Connecting the crankshaft speed sensor plug • Tighten and cut cable ties using the Cable tie
connection pliers [6]
WARNING
Danger of damage to the engine
electrics/electronics
• Connect all electrical connections as
marked.
• Only fasten the wiring harness at the
previously marked attachment points
72 AE 4 2nd edition
ENGINE ELECTRICS
Connecting the exhaust gas temperature plug Connecting the fuel pressure and metering unit
connection plug connection
WARNING WARNING
Danger of damage to the engine Danger of damage to the engine
electrics/electronics electrics/electronics
• Connect all electrical connections as • Connect all electrical connections as
marked. marked.
• Only fasten the wiring harness at the • Only fasten the wiring harness at the
previously marked attachment points previously marked attachment points
• Position the connector (1) and lock the exhaust • Position the connector (1) and lock the plug
gas temperature sensor plug connection connection for the fuel pressure upstream of the
• Secure the wiring harness with cable ties as Master high-pressure pump
marked • Position the connector (1) and lock the plug
• Tighten and cut cable ties using the Cable tie connection for the Master metering unit (2)
pliers [6] • Secure the wiring harness with cable ties as
marked
• Tighten and cut cable ties using the Cable tie
pliers [6]
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Connecting the fuel pressure and temperature Connecting the exhaust gas and coolant
plug connection temperature plug connection
WARNING WARNING
Danger of damage to the engine Danger of damage to the engine
electrics/electronics electrics/electronics
• Connect all electrical connections as • Connect all electrical connections as
marked. marked.
• Only fasten the wiring harness at the • Only fasten the wiring harness at the
previously marked attachment points previously marked attachment points
• Position the connector (4) and lock the plug • Position the connector (1) and lock the exhaust
connection for the fuel pressure upstream of the gas temperature plug connection
Slave high-pressure pump • Position the connector (2) and lock the coolant
• Position the connector (3) and lock the fuel temperature plug connection (option)
temperature plug connection • Secure the wiring harness with cable ties as
• Position the connector (2) and lock the suction marked
side fuel pressure plug connection • Tighten and cut cable ties using the Cable tie
• Position the connector (1) and lock the return plug pliers [6]
connection
• Secure the wiring harness with cable ties as
marked
• Tighten and cut cable ties using the Cable tie
pliers [6]
74 AE 4 2nd edition
ENGINE ELECTRICS
WARNING WARNING
Danger of damage to the engine Danger of damage to the engine
electrics/electronics electrics/electronics
• Connect all electrical connections as • Connect all electrical connections as
marked. marked.
• Only fasten the wiring harness at the • Only fasten the wiring harness at the
previously marked attachment points previously marked attachment points
• Position the cable (7) as marked • Position the connector (1) and lock the suction
• Screw on the washer (2) with mounting nut (9) vacuum plug connection
• Tighten the mounting nut (9) to 25 Nm • Position the connector (2) and lock the coolant
• Position the cable (4) as marked temperature plug connection (option)
• Screw on the washer (5) with mounting nut (6) • Position the connector (3) and lock the Slave
• Tighten the mounting nut (6) to 25 Nm metering unit plug connection
• Position the cable (12) as marked • Position the connector (4) and lock the Master rail
• Screw on the washer (11) with mounting nut (10) pressure plug connection
• Tighten the mounting nut (10) to 4 Nm • Position the connector (5) and lock the Slave rail
• Position the cable (1) as marked pressure plug connection
• Screw on the washer (2) with mounting nut (3) • Secure the wiring harness with cable ties as
• Tighten the mounting nut (3) to 4 Nm marked
• Secure the wiring harness with cable ties as • Tighten and cut cable ties using the Cable tie
marked pliers [6]
• Tighten and cut cable ties using the Cable tie
pliers [6]
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ENGINE ELECTRICS
Connecting the charge-air and coolant plug Connecting the oil pressure, oil temperature and
connections coolant pressure plug connections
WARNING WARNING
Danger of damage to the engine Danger of damage to the engine
electrics/electronics electrics/electronics
• Connect all electrical connections as • Connect all electrical connections as
marked. marked.
• Only fasten the wiring harness at the • Only fasten the wiring harness at the
previously marked attachment points previously marked attachment points
• Position the connector (1) and lock the charge-air • Position the connector (1) and lock the oil pressure
pressure plug connection plug connection
• Position the connector (2) and lock the charge-air • Position the connector (2) and lock the coolant
temperature plug connection pressure plug connection
• Position the connector (3) and lock the coolant • Position the connector (3) and lock the oil
level plug connection temperature plug connection
• Position the connector (4) and lock the coolant • Secure the wiring harness with cable ties as
pressure plug connection marked
• Secure the wiring harness with cable ties as • Tighten and cut cable ties using the Cable tie
marked pliers [6]
• Tighten and cut cable ties using the Cable tie
pliers [6]
76 AE 4 2nd edition
ENGINE ELECTRICS
Connecting the alternator Connecting the left oil pressure plug connection
WARNING WARNING
Danger of damage to the engine Danger of damage to the engine
electrics/electronics electrics/electronics
• Connect all electrical connections as • Connect all electrical connections as
marked. marked.
• Only fasten the wiring harness at the • Only fasten the wiring harness at the
previously marked attachment points previously marked attachment points
WARNING • Position the connector (1) and lock the oil pressure
Danger of irreparable alternator plug connection
damage • Secure the wiring harness with cable ties as
Damage to the contacts marked
• Tighten and cut cable ties using the Cable tie
• When installing the connector, rst fully
pliers [6]
open the lock and then insert and lock
the connector
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78 AE 4 2nd edition
ENGINE ELECTRICS
Technical data
Sensor, fuel pressure upstream of high-pressure
pump (1) and (7)................................................... M18x1.5 ............................................................45 Nm
Sensor, coolant temperature (2) ............................ M16x1.5 ............................................................45 Nm
Sensor, exhaust gas temperature upstream of
turbocharger (3) and (5) ........................................ M14x1.5 ............................................................. 7 Nm
Screw-in tting ..................................................... M14x1.5 ............................................................25 Nm
Mounting bolt, sensor, crankshaft and camshaft
speed (6) and (4).................................................. M6 ..................................................................... 8 Nm
Sensor, fuel temperature (8).................................. M16x1.5 ............................................................45 Nm
Sensor, fuel pressure, suction side (9) ................... M14x1.5 ............................................................35 Nm
Sensor, fuel pressure, return (10) .......................... M14x1.5 ............................................................35 Nm
Sensor, oil pressure .............................................. M18x1.5 ............................................................45 Nm
Sensor, oil temperature......................................... M16x1.5 ............................................................45 Nm
Sensor, coolant pressure downstream of coolant
pump ................................................................... M18x1.5 ............................................................45 Nm
Sensor, coolant pressure in expansion tank ........... M14x1.5 ............................................................35 Nm
Sensor, coolant level............................................. M18x1.5 ............................................................22 Nm
Sensor, charge-air pressure .................................. M6 ..................................................................... 8 Nm
AE 4 2nd edition 79
ENGINE ELECTRICS
Important information
WARNING
The common-rail system can be damaged
• Plugs must not be re-used
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Residual oil may emerge during removal. Danger of environmental pollution.
• Use a suitable collecting tank
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
In order to ensure that the correct protective sleeve is used, the designation (e.g. Z14 x 15) is
imprinted in the protective sleeve. This is integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z14 x 15).
Special tools
80 AE 4 2nd edition
ENGINE ELECTRICS
Removing and installing the charge-air Installing the charge-air pressure sensor
sensors
Removing the expansion tank holder
AE 4 2nd edition 81
ENGINE ELECTRICS
Installing the charge-air temperature sensor Removing and installing the suction
vacuum sensor
Removing the suction vacuum sensor
82 AE 4 2nd edition
ENGINE ELECTRICS
Removing and installing the oil sensors Installing the left oil pressure sensor
AE 4 2nd edition 83
ENGINE ELECTRICS
Removing and installing the coolant Removing the coolant level sensor
sensors
Removing the coolant pressure sensor in the
expansion tank
CAUTION
Danger of burns
• Before unscrewing the sensor, unscrew
the cap with safety valve as far as
CAUTION the rst stop and carefully allow the
Danger of burns pressure in the coolant system to
• Before unscrewing the sensor, unscrew dissipate
the screw cap with safety valve as far
as the rst stop and carefully allow • Disconnect the electrical connection
the pressure in the coolant system to • Unscrew the sensor (1)
dissipate • Remove the sealing ring (2)
84 AE 4 2nd edition
ENGINE ELECTRICS
Removing the coolant pressure sensor Removing the coolant temperature sensor
downstream of the coolant pump (option)
CAUTION CAUTION
Danger of burns Danger of burns
• Before unscrewing the sensor, unscrew • Before unscrewing the sensor, unscrew
the cap with safety valve as far as the cap with safety valve as far as
the rst stop and carefully allow the the rst stop and carefully allow the
pressure in the coolant system to pressure in the coolant system to
dissipate dissipate
Note Note
Draining and topping up the coolant, see Draining and topping up the coolant, see
Operator's Manual Operator's Manual
Installing the coolant pressure sensor Installing the coolant temperature sensor
downstream of the coolant pump (option)
• Screw in the sensor (1) with a new sealing ring (2) • Screw in the sensor (1) with a new sealing ring (2)
• Tighten the sensor (1) to 45 Nm • Tighten the sensor (1) to 45 Nm
• Connect the electrical connection • Connect the electrical connection
• Fill with coolant • Fill with coolant
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ENGINE ELECTRICS
Removing the coolant temperature sensor Removing and installing the exhaust gas
(option) sensors
Removing the right exhaust gas temperature
sensor
CAUTION
Danger of burns
• Before unscrewing the sensor, unscrew • Disconnect the electrical connection
the cap with safety valve as far as • Unscrew the union nut (2)
the rst stop and carefully allow the • Remove the sensor (1)
pressure in the coolant system to • Unscrew the screw-in tting (3)
dissipate
Installing the right exhaust gas temperature
Note
sensor
Draining and topping up the coolant, see
Operator's Manual
86 AE 4 2nd edition
ENGINE ELECTRICS
Removing the left exhaust gas temperature Removing and installing the speed
sensor sensors
Removing the camshaft speed sensor
• Screw in the screw-in tting (3) and tighten to • Insert the sensor (1)
25 Nm • Screw in the mounting bolt (2) and tighten to 8 Nm
• Insert the sensor (1) and screw on the union nut
(2) • Connect the electrical connection
• Tighten the union nut (2) to 7 Nm
• Connect the electrical connection
AE 4 2nd edition 87
ENGINE ELECTRICS
Removing the crankshaft speed sensor Removing and installing the fuel
sensors
Removing the fuel pressure sensor upstream of
the Slave high-pressure pump
88 AE 4 2nd edition
ENGINE ELECTRICS
Removing the fuel temperature sensor Removing the fuel pressure sensor on the
suction side
AE 4 2nd edition 89
ENGINE ELECTRICS
Removing the return fuel pressure sensor Removing the fuel pressure sensor upstream of
the Master high-pressure pump
90 AE 4 2nd edition
COOLING SYSTEM
COOLING SYSTEM
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COOLING SYSTEM
92 AE 4 2nd edition
COOLING SYSTEM
HEAT EXCHANGER
Removing and mounting the heat exchanger
Additional jobs
– Draining the coolant, see Operator's Manual
– Removing and Installing the engine cover, see 515
– Assembly instructions for heat exchanger plates, see 99
Technical data
Mounting bolts (2)................................................. M16x80 ........................................ Final torque 180 Nm
Spacer bush (3)............................................................................................................................235 Nm
Centring bush (6)............................................................................................................................45 Nm
Mounting bolt (7) ............................................................................................................................15 Nm
Mounting bolt, sight glass...................................... M5x25-8.8 .......................................................... 5 Nm
Service products
White T assembly paste..................................................................................................... 09.16012-0117
AE 4 2nd edition 93
COOLING SYSTEM
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• Do not use impact wrenches to remove and install the heat exchanger plate pack.
• Always remove and install the heat exchanger plate pack manually.
WARNING
Component damage due to incorrectly assembled heat exchanger plate pack
• Assemble the heat exchanger plate pack in accordance with the assembly instructions
Special tools
94 AE 4 2nd edition
COOLING SYSTEM
AE 4 2nd edition 95
COOLING SYSTEM
Removing the spacer bushes Installing the heat exchanger plate pack
Installing the spacer bushes
96 AE 4 2nd edition
COOLING SYSTEM
• Thinly apply White T assembly paste on the thread • Unscrew the Assembly pin [10]
and the bolt head contact surface of mounting • Screw in the mounting bolts (1) and (3) with the
bolts (2) and (4) washers (2) and (4)
• Screw in the mounting bolts (2) and (4) with the • Tighten the mounting bolts (1) and (3) to 15 Nm
washers (3) and (5)
AE 4 2nd edition 97
COOLING SYSTEM
98 AE 4 2nd edition
COOLING SYSTEM
(1) Cooling plate type 4 faces pressure plate (5) Cooling plate type 2
(2) Cooling plate type 3 (6) Cooling plate type 1 faces expansion tank
(3) Cooling plate type 2 (7) Expansion tank
(4) Cooling plate type 3 (8) Pressure plate
Important information
WARNING
Component damage due to hardened gaskets
• Always replace gaskets as a set
AE 4 2nd edition 99
COOLING SYSTEM
Assembling the cooling plate pack Attaching gaskets to cooling plates type 3
(obtuse angle)
Attaching the gasket to cooling plate type 1
(obtuse angle)
WARNING
Component damage due to incorrect
WARNING gasket/cooling plate combination
Component damage due to incorrect • Only combine and assemble the gasket
gasket/cooling plate combination and cooling plate as illustrated
• Only combine and assemble the gasket
and cooling plate as illustrated • Attach the gasket (2) using the lugs on the cooling
plate (1)
• Attach the gasket (2) using the lugs on the cooling • Repeat the procedure for cooling plates type 3 see
plate (1) table 101
Attaching gaskets to cooling plates type 2 (acute Attaching the gasket to cooling plate type 4
angle) (acute angle)
WARNING WARNING
Component damage due to incorrect Component damage due to incorrect
gasket/cooling plate combination gasket/cooling plate combination
• Only combine and assemble the gasket • Only combine and assemble the gasket
and cooling plate as illustrated and cooling plate as illustrated
• Attach the gasket (2) using the lugs on the cooling • Attach the gasket (2) using the lugs on the cooling
plate (1) plate (1)
• Repeat the procedure for cooling plates type 2 see
table 101
Schematic diagram for assembling cooling Engine Type 1 Type 4 Type 2 Type 3
plates type 1 to type 4 type quantity quantity quantity quantity
D2868 1 1 10 10
LE423
D2868 1 1 13 13
LE433
D2862 1 1 15 15
LE423
D2862 1 1 20 20
LE433
Installing cooling plate type 2 Installing cooling plates type 2 and type 3
(1) Cooling plate type 1 • Repeat the “Installing cooling plates type 2 (1)” and
(2) Cooling plate type 2 “Installing cooling plates type 3” steps alternately
until the required number of cooling plates has
WARNING
been reached,
Component damage due to incorrectly
positioned cooling plates Engine type Total number Number of
• Only position the cooling plate as of cooling type 2 and
illustrated plates type 3 cooling
plates
• The gasket for cooling plate type 2 (2) faces the
expansion tank D2868 LE423 22 10
• Push cooling plate type 2 (2) onto cooling plate
D2868 LE433 28 13
type 1 (1)
D2862 LE423 32 15
Installing cooling plate type 3
D2862 LE433 42 20
Note
1st gasket has no nibs (2) on the sealing
lugs
Service products
Technical Vaseline ............................................................................................................. 09.15014-0001
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
• Unscrew the hollow screws (3) and (6) Removing the expansion tank
• Remove the sealing rings (1), (2), (4) and (5)
CAUTION
Danger of injury due to heavy
• Unscrew the hollow screws (1) and (5) components
• Remove the sealing rings (2), (4), (6) and (8) • Use lifting tackle for removal
• Remove the overow lines (3) and (7) WARNING
Danger of environmental pollution due
Removing the expansion tank holder
to emerging coolant
• Use a suitable tank to collect the
residual coolant that emerges
Note
An eye bolt can be screwed into the
thread (9) for removal.
The lifting tackle can be attached to the
eye bolt
Note
An eye bolt can be screwed into the
thread (9) for installation.
The lifting tackle can be attached to the
eye bolt
COOLANT MANIFOLD
Removing and installing the coolant manifold
Additional jobs
– Draining/topping up the coolant, see Operator's Manual
– Removing and installing the air lter, see 341
– Removing and installing the charge-air pipes, see 325
– Removing and installing the turbocharger (two-stage variant), see 301
Technical data
Temperature sensor.............................................. M16x1.5 ............................................................45 Nm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
Renolit Si 704 silicone grease ............................................................................................ 09.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Mounting the right coolant manifold-right Mounting the left coolant manifold-left exhaust
exhaust manifold manifold
• Thinly apply Renolit Si 704 silicone grease on the • Thinly apply Renolit Si 704 silicone grease on the
new O-ring (1) and new unscrewed conduit (4) new O-ring (4) and new unscrewed conduit (5)
• Position the unscrewed conduit (4) in the right • Position the unscrewed conduit (5) in the left
coolant manifold coolant manifold
• Position the coolant manifold (3) with O-ring (1) • Position the coolant manifold (3) with O-ring (4)
• Screw in and tighten the mounting bolts (2) • Screw in and tighten the mounting bolts (1) and (2)
THERMOSTATS
Removing and installing the thermostats
Additional jobs
– Draining/topping up the coolant, see Operator's Manual
– Removing the intercooler, 2nd stage, see 334
Technical data
Thermostat opening temperature...................................................................................................... 86 °C
Service products
Renolit Si 704 silicone grease ............................................................................................ 09.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
COOLANT PUMP
Removing and installing the coolant pump
Additional jobs
– Draining/topping up the coolant, see Operator's Manual
– Removing and mounting the expansion tank, see 105
Service products
Renolit Si 704 silicone grease ............................................................................................ 09.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
COOLANT MANIFOLD
Removing and Installing the coolant manifold
Technical data
Mounting bolt ....................................................... M8x20-8.8 .........................................................24 Nm
Mounting bolt ....................................................... M8x25-8.8 .........................................................24 Nm
Mounting bolt ....................................................... M8x45-8.8 .........................................................24 Nm
Mounting bolt, coolant manifold, collector............... M12x90-10.9......................................................75 Nm
Service products
Renolit Si 704 silicone grease ............................................................................................ 09.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Removing the coolant manifold Removing the coolant manifold upstream of the
intercooler, 2nd stage
Removing the coolant manifold upstream of the
intercooler, 1st stage, right
Removing the clamping piece Removing the coolant manifold upstream of the
intercooler, 1st stage, left
Removing the left charge-air manifold mounting Removing the charge-air manifold
• Unscrew the mounting bolts (1) and (2) • Unscrew the mounting bolts (4) whilst bracing the
• Remove the holder (3) nuts (9)
• Unscrew the mounting bolts (4) and (5) • Remove the charge-air manifold (5)
• Remove the holder (6) • Remove the unscrewed conduits (2) and (7)
• Remove the O-rings (1), (3), (6) and (8)
Removing the right charge-air manifold
mounting Removing the charge-air pipe fastening
• Unscrew the mounting bolts (1) and (6) • Unscrew the mounting bolts (1)
• Remove the holder (2) • Remove the holder (2)
• Unscrew the mounting bolts (4) and (5)
• Remove the holder (3) Removing the coolant manifold collector
Attaching the left charge-air manifold mounting Installing the coolant manifold upstream of the
intercooler, 1st stage, left
Mounting the clamping piece Installing the coolant manifold upstream of the
intercooler, 2nd stage
COOLANT PUMP
Removing and installing the coolant pump
Additional jobs
– Removing and Installing the coolant manifold, see 123
Service products
Renolit Si 704 silicone grease ............................................................................................ 09.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Technical data
Mounting bolt, drive gear....................................... M12x40-10.9.................................. Initial torque 40 Nm
Mounting bolt, drive gear....................................... M12x40-10.9........................................Final torque 45°
Mounting bolt, mounting ange........................................................................................................22 Nm
Mounting bolt, coolant manifold, pressure side ....... M8x25-8.8 .........................................................15 Nm
Mounting bolt, coolant manifold, pressure side ....... M8x75-10.9 .......................................................15 Nm
Mounting bolt, coolant manifold, suction side ......... M8x25-8.8 .........................................................15 Nm
Mounting bolt, cover, coolant pump ....................... M6x12 ................................................................ 7 Nm
Mounting bolt, cam ............................................... M8x25 ............................................................... 11 Nm
Service products
Technical Vaseline ............................................................................................................. 09.15014-0001
Loctite 5900 ...................................................................................................................... 04.10394-9292
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Unscrew the mounting bolts (3) • Unscrew the mounting bolts (3)
• Remove the pressure side coolant manifold (2) • Remove the cover (1) and the O-ring (2)
and the gasket (1)
• Clean the mating faces Removing the hub cover
• Pull off the impeller (1) with the Puller for • Remove the splash guard (1)
impeller [11] • Unclip the circlip (2) and remove it
• Screw the Puller for impeller [11] into the impeller • Remove the washer (3)
with the screw-in piece (2) • Remove the slide ring seal (4)
• Pull the impeller off the coolant pump by screwing
in the threaded spindle (3) Removing the coolant pump housing
• Insert the hub cover (1) into the impeller • Position the friction disc (4)
• Thinly apply Technical Vaseline on the hub cover • Push the drive gear (3) onto the drive shaft
(1) • Insert the washer (2)
• Screw in the mounting bolt (1)
Mounting the coolant pump cover • Brace the coolant pump on the drive gear (3) using
the Brace [12] (5)
• Tighten the mounting bolt (1) to Initial torque 40
Nm
• Tighten the mounting bolt (1) to Final torque 45°
ADD-ON UNITS
STARTER
Removing and installing the starter
Additional jobs
– Disconnecting and connecting the starter
(1) Starter
Technical data
Mounting bolt, starter ............................................ M12...................................................................75 Nm
Terminal 30 mounting nut...................................... M12...................................................................25 Nm
Mounting nut, terminal 31...................................... M12...................................................................25 Nm
Mounting nut, terminal 50...................................... M6 ..................................................................... 4 Nm
Mounting nut, terminal 30, on relay ........................ M6 ..................................................................... 4 Nm
Mounting nut, terminal 85, on relay ........................ M6 ..................................................................... 4 Nm
Mounting nut, terminal 31 and 50 .......................... M4 ...................................................................1.2 Nm
Number of starter pinion teeth .................................................................................................................9
Starter power ........................................................................................................................ 24 V/6.6 kW
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
• Unscrew the mounting bolts (2) • Insert the starter (1) into the ywheel housing
• Remove the starter (1) from the ywheel housing • Screw in new mounting bolts (2) and tighten them
• Crank the engine 360° and check the ywheel ring to 75 Nm
gear for wear
Replace the ywheel if the ywheel ring gear is worn.
POLY-V-BELT GUARD
Removing and installing the poly-V-belt guard
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
POLY-V-BELT
Removing and installing the poly-V-belt
(1) Poly-V-belt
(2) Poly-V-belt tensioner
CAUTION CAUTION
The poly-V-belt tensioner is under The poly-V-belt tensioner is under
spring tension spring tension
• Brace the poly-V-belt tensioner • Brace the poly-V-belt tensioner
to prevent it from springing back to prevent it from springing back
unintentionally unintentionally
• Turn the poly-V-belt tensioner (1) clockwise as far • Turn the poly-V-belt tensioner (1) clockwise as far
as the stop and hold it as the stop and hold it
• Remove the poly-V-belt (2) • Fit the poly-V-belt (2)
• Carefully slacken the poly-V-belt tensioner (1) • Carefully slacken the poly-V-belt tensioner (1)
ALTERNATOR
Removing and installing the alternator
Additional jobs
– Disconnecting and connecting the battery
– Removing and installing the poly-V-belt guard, see 145
– Removing and installing the poly-V-belt, see 147
Technical data
Mounting nut (2) ................................................... M16x1.5 ..........................................................100 Nm
Mounting nut, terminal B + .................................... M8 ....................................................................14 Nm
Mounting bolt, poly-V-belt tensioner .................................................................................................47 Nm
Mounting bolt, guide roller ..................................... M12x55-8.8 .......................................................60 Nm
Service products
Loctite 648 ........................................................................................................................ 04.10160-9164
Special tools
WARNING
• Position the guide roller (3) and bush (4)
Danger due to impermissible potential
• Screw in the mounting bolt (1) with washer (2)
on the crankcase
• Tighten the mounting bolt (1) to 60 Nm
• Only use undamaged insulating
washers and sleeves
WARNING CAUTION
Danger due to impermissible potential The poly-V-belt tensioner is under
on the crankcase spring tension
• Only use undamaged insulating • Brace the poly-V-belt tensioner
washers and sleeves to prevent it from springing back
unintentionally
• Position the holder (4) with insulating washers (3)
and (5) • Turn the poly-V-belt tensioner (1) clockwise as far
• Screw in the mounting bolt (7) with bush (6) as as the stop and hold it
marked • Fit the poly-V-belt (2)
• Insert the mounting bolt (1) with washer (2) as • Carefully slacken the poly-V-belt tensioner (1)
marked
• Screw the nut (8) onto the mounting bolt (1) and
tighten
• Tighten the mounting bolt (7)
• Tighten the mounting bolt (8), see see Installing
the alternator, 153 for step
WARNING
Danger of damage to the engine
electrics/electronics
• Connect all electrical connections as
marked.
• Only fasten the wiring harness at the
previously marked attachment points
WARNING
Danger of irreparable alternator
damage
Damage to the contacts
HYDRAULIC PUMP
Removing and installing the hydraulic pump
Technical data
Mounting bolt ...................................................... M12x100-10.9..................................................120 Nm
Axial play, drive shaft, power take-off, right...................................................................... 0.300 - 0.550 mm
Radial play, drive shaft, power take-off, right ................................................................... 0.020 - 0.054 mm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
Always use new O-rings, sealing rings and mounting bolts when converting the power take-offs.
Removing the hydraulic pump Removing the hydraulic pump power take-off
• Unscrew the mounting bolts (4) and (5) • Unscrew the mounting bolts (2) and (4)
• Remove the washers (3) and (6) • Remove the drive housing (3)
• Remove the hydraulic pump (2) with connecting • Remove the O-ring (5) from the drive housing (3)
sleeve (1) and O-ring • Remove the drive gear (1)
COMMON-RAIL SYSTEM
Technical data
High-pressure lines (initial use) ................................................................................... Initial torque 10 Nm
High-pressure lines (initial use) ....................................................................................Final tightening 60°
High-pressure lines (re-use) ........................................................................................ Initial torque 10 Nm
High-pressure lines (re-use) ..............................................................................................Final torque 30°
Hollow screw, leakage oil line ................................ M14x1.5 ............................................................25 Nm
Rail pressure sensor............................................. M18x1.5 ............................................................80 Nm
Pressure limiting valve .......................................... M20x1.5 ..........................................................100 Nm
Important information
WARNING
The common-rail system can be damaged
• All work on components of the common-rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats®
(desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Before working on the clean side of the fuel system, clean the engine and the engine compartment
(e.g. steam cleaner). The fuel system must be sealed during this process.
• Avoid any moisture whatsoever
• Always renew rail connections once they have been undone
• Do not reuse plugs for high-pressure lines, the rail or injectors, even if they have only been used
once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
WARNING
Danger of damage due to dirt ingress
• Always remove only one fuel line
• Plug the component connections immediately using new, clean protective sleeves
WARNING
Danger of damage due to leakage
• Check injector seat, rail and leakage oil lines for leaks after each installation
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the high-pressure lines and Detaching the high-pressure supply lines
rails
Removing the cover for the union nuts
WARNING
Component damage due to lack of
lubricant
• Do not wash off the new pressure
limiting valve as the thread and biting
edge are coated with lubricant
Removing the right rail pressure sensor Removing the left rail pressure sensor
WARNING WARNING
Component damage due to lack of Component damage due to lack of
lubricant lubricant
• Do not wash off the new rail pressure • Do not wash off the new rail pressure
sensor as the thread and biting edge sensor as the thread and biting edge
are coated with lubricant are coated with lubricant
• Unscrew the rail pressure sensor (1) • Unscrew the rail pressure sensor (1)
• Plug the rail pressure sensor with Protective • Plug the rail pressure sensor with Protective
sleeve Z 18 x 15 [18] and the thread in the rail sleeve Z 18 x 15 [18] and the thread in the rail
with End plug [17] with End plug [17]
Removing the left pressure limiting valve Removing the holder with rail on the right
• Unscrew the mounting bolts (2) and (4) • Unscrew the mounting bolts (2) and (3)
• Remove the rail (3) from the holder (1) • Remove the collector (1) from the rail
Removing the holder with rail on the left Detaching the left rail
• Unscrew the mounting bolts (1) and (2) • Unscrew the mounting bolts (1) and (2)
• Remove the holder with rail (3) • Remove the rail from the holder (3)
Installing the high-pressure lines and Installing the fuel return line for the left rail
rails
Attaching the left rail
Mounting the holder with rail on the right Installing the left pressure limiting valve
WARNING
Component damage due to lack of
lubricant
• Do not wash off the pressure limiting
valve and rail pressure sensor as the
thread and biting edge are coated with
lubricant
Installing the right pressure limiting valve Mounting the high-pressure line fastening points
• Remove the caps and plugs • Tighten the new high-pressure lines (1) to Final
• Attach the high-pressure line (1), ensuring that it tightening 60° with Angle extension [21] and
is strain-free, using the Angle extension [21] and Special spanner, size 17 [20]
Special spanner, size 17 [20] • Tighten the high-pressure lines (1) to Final torque
• Tighten the new high-pressure line (1) to Initial 30° with Angle extension [21] and Special spanner,
torque 10 Nm size 17 [20] if re-using
• Tighten the high-pressure line (1) to Initial • Repeat the same procedure for the other
torque 10 Nm if re-using high-pressure lines
• Repeat the same procedure for the other
high-pressure lines Mounting the cover for the union nuts
• Position the clamping piece as marked
• Screw in and tighten the mounting bolt
• Position and close the cover for the union nuts (1)
• Repeat the same procedure for all the
high-pressure lines
Removing and installing the high-pressure lines and rails (classied variant)
Additional jobs
– Removing and Installing the engine cover, see 515
– Removing and installing the intercooler, see 331
– Removing and Installing the coolant manifold, see 123
– Removing and installing the fuel lines, see 213
Technical data
High-pressure lines (initial use) ................................................................................... Initial torque 10 Nm
High-pressure lines (initial use) .........................................................................................Final torque 60°
High-pressure lines (re-use) ........................................................................................ Initial torque 10 Nm
High-pressure lines (re-use) ..............................................................................................Final torque 30°
Rail-pressure sensor............................................. M18x1.5 ............................................................80 Nm
Pressure-limiting valve.......................................... M20x1.5 ..........................................................100 Nm
Important information
WARNING
The common-rail system can be damaged
• All work on components of the common-rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats®
(desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Before working on the clean side of the fuel system, clean the engine and the engine compartment
(e.g. steam cleaner). The fuel system must be sealed during this process.
• Avoid any moisture whatsoever
• Always replace rail connections once they have been undone
• Do not reuse plugs for high-pressure lines, the rail or injectors, even if they have only been used
once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
WARNING
Danger of damage due to dirt ingress
• Always detach only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Danger of damage due to damaged high-pressure lines
• Before reinstallation, carefully check the high-pressure lines for damage and deformation to the
sealing cone
• Check high-pressure lines for crushing and deformation
• Renew damaged high-pressure lines
• Install high-pressure lines without tension
• Following installation, check the tightness of the lines with MAN-cats® PLV test
Special tools
Removing the high-pressure lines and Removing the right rail cover upper section
rails
Removing the cover for the union nuts
• Open up and remove the cover for the union nuts Removing the left rail cover upper section
(1)
• Repeat the same procedure for all the
high-pressure lines
Detaching the left rail high-pressure supply line Removing the pipe clamps
• Undo the union nuts for the high-pressure line (1) • Mark the installation position of the pipe clamps
with the Angle extension [27] and Special spanner, (1) and (2)
size 17 [26] • Remove the pipe clamps (1) and (2)
• Unscrew the union nuts for the high-pressure line
(1) save for 2 turns Detaching the cylinder 7 high-pressure line
• Unscrew the union nuts for the high-pressure line
(1)
• Remove the high-pressure line (1)
• Plug the high-pressure line with End plug [22]
and the connections with Protective sleeve
Z 14 x 15 [23]
Detaching the cylinder 1 high-pressure line Detaching the cylinder 2 and 3 high-pressure
lines
Detaching the cylinder 8 and 9 high-pressure Removing the cylinder 4 to 6 high-pressure lines
lines
Note
Note High-pressure lines can be removed as a
High-pressure lines can be removed as a set or individually
set or individually
• Remove pipe clamps (1) if required
• Remove pipe clamps (1) if required • Undo the union nuts for the high-pressure lines (2)
• Undo the union nuts for the high-pressure lines (2) with the Angle extension [27] and Special spanner,
with the Angle extension [27] and Special spanner, size 17 [26]
size 17 [26] • Unscrew the union nuts for the high-pressure lines
• Unscrew the union nuts for the high-pressure lines (2) save for 2 turns
(2) save for 2 turns • Unscrew the union nuts for the high-pressure lines
• Unscrew the union nuts for the high-pressure lines (2)
(2) • Remove the high-pressure lines (2)
• Remove the high-pressure lines (2) • Plug the high-pressure lines with End plug [22]
• Plug the high-pressure lines with End plug [22] and the connections with Protective sleeve
and the connections with Protective sleeve Z 14 x 15 [23]
Z 14 x 15 [23] • Mark the installation position of the pipe clamps
• Mark the installation position of the pipe clamp (1) (1)
• Unscrew the mounting bolt • Unscrew the mounting bolts
• Remove the pipe clamp • Remove the pipe clamps
Removing the cylinder 10 to 12 high-pressure Detaching the left rail return high-pressure line
lines
Removing the left rail Removing the right rail cover lower section
• Unscrew the mounting bolts (1) • Unscrew the mounting bolt (1) and remove it with
• Remove the rail (3) the sealing ring (3)
• Remove the O-ring (2) • Remove the rail cover lower section (2)
Removing the left rail cover lower section Removing the pressure-limiting valve
Removing the rail pressure sensor Installing the high-pressure lines and
rails
Installing the right rail pressure sensor
WARNING
Component damage due to lack of
lubricant
• Do not wash off the rail pressure sensor WARNING
as the thread and biting edge are Component damage due to lack of
coated with lubricant lubricant
• Do not wash off the pressure-limiting
Note valve and rail-pressure sensor as the
The left rail pressure sensor is removed thread and biting edge are coated with
in the same way as the right rail pressure lubricant
sensor
Note
• Unscrew the rail-pressure sensor (1) The left rail pressure sensor is installed
• Plug the rail pressure sensor with Protective in the same way as the right rail pressure
sleeve Z 18 x 15 [25] and the thread in the rail sensor
with End plug [24]
• Remove the caps and plugs
• Screw in the rail pressure sensor (1) and tighten it
to 80 Nm
Installing the right pressure limiting valve Installing the right rail
Attaching the right rail return high-pressure line Attaching the cylinder 10 to 12 high-pressure
lines
Attaching the cylinder 4 to 6 high-pressure lines Attaching the cylinder 8 and 9 high-pressure
lines
Note
High-pressure lines can be attached as a Note
set or individually High-pressure lines can be attached as a
set or individually
• Remove the caps and plugs
• Attach the high-pressure lines (2), ensuring that • Remove the caps and plugs
they are strain-free, using the Angle extension [21] • Attach the high-pressure lines (2), ensuring that
and Special spanner, size 17 [20] they are strain-free, using the Angle extension [21]
• Tighten the new high-pressure lines (2) to Initial and Special spanner, size 17 [20]
torque 10 Nm • Tighten the new high-pressure lines (2) to Initial
• Tighten the high-pressure lines (2) to Initial torque 10 Nm
torque 10 Nm if re-using • Tighten the high-pressure lines (2) to Initial
• Tighten the new high-pressure lines (2) to Final torque 10 Nm if re-using
torque 60° with Angle extension [21] and Special • Tighten the new high-pressure lines (2) to Final
spanner, size 17 [20] torque 60° with Angle extension [21] and Special
• Tighten the high-pressure lines (2) to Final torque spanner, size 17 [20]
30° with Angle extension [21] and Special spanner, • Tighten the high-pressure lines (2) to Final torque
size 17 [20] if re-using 30° with Angle extension [21] and Special spanner,
• Position the pipe clamps (1) as marked size 17 [20] if re-using
• Screw in and tighten the mounting bolts • Position the pipe clamps (1) as marked
• Screw in and tighten the mounting bolts
Attaching the cylinder 2 and 3 high-pressure Attaching the cylinder 1 high-pressure line
lines
Mounting the pipe clamps Attaching the left rail high-pressure supply line
• Attach the pipe clamps (1) and (2) as marked • Remove the caps and plugs
• Attach the high-pressure line (1), ensuring that it
Attaching the right rail high-pressure line is strain-free, using the Angle extension [21] and
Special spanner, size 17 [20]
• Tighten the new high-pressure line (1) to Initial
torque 10 Nm
• Tighten the high-pressure line (1) to Initial
torque 10 Nm if re-using
• Tighten the new high-pressure line (1) to Final
torque 60° using the Angle extension [21] and the
Special spanner, size 17 [20]
• Tighten the high-pressure line (1) to Final torque
30° with Angle extension [21] and Special spanner,
size 17 [20] if re-using
Mounting the left rail cover upper section Mounting the cover for the union nuts
• Position the rail cover upper section (1) • Position and close the cover for the union nuts (1)
• Screw in and tighten the mounting bolts (2) • Repeat the same procedure for all the
high-pressure lines
Mounting the right rail cover upper section
INJECTORS
Removing and installing the injectors
Additional jobs
– Removing and Installing the engine cover, see 515
– Removing and installing the intercooler, see 331
– Removing and Installing the coolant manifold, see 123
– Removing and installing the fuel lines, see 213
– Removing and installing the high-pressure lines and rails, see 163
Technical data
Pressure screw (9) ............................................... M24x1.5 ........................................ Initial torque 20 Nm
Pressure screw (9) ............................................... M24x1.5 ..............................................Final torque 60°
Mounting bolt ....................................................... M8x55-10.9 ..................................... Initial torque 2 Nm
Mounting bolt ....................................................... M8x55-10.9 ......................................2nd torque 25 Nm
Mounting bolt ....................................................... M8x55-10.9 .........................................Final torque 90°
Injector cable.................................................................................................................................1.5 Nm
Rocker arm mechanism mounting bolt ................... M12x80-10.9......................................................90 Nm
Mounting bolt, rocker arm mechanism ................... M12x80-10.9........................................Final torque 90°
Service products
White T assembly paste..................................................................................................... 09.16012-0122
Important information
WARNING
The common-rail system can be damaged
• All work on components of the common-rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats®
(desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Before working on the clean side of the fuel system, clean the engine and the engine compartment
(e.g. steam cleaner). The fuel system must be sealed during this process.
• Avoid any moisture whatsoever
• Always replace rail connections once they have been undone
• Do not reuse plugs for high-pressure lines, the rail or injectors, even if they have only been used
once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
WARNING
Danger of damage due to dirt ingress
• Always detach only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
Danger of damage due to leakage
• Check injector seat, rail and leakage oil lines for leaks after each installation
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Danger of damage to property
• Always allocate removed injectors to the corresponding cylinders
• Allocate new injectors to the corresponding cylinders using MAN-Cats®, see EDC system
description
WARNING
Danger of damage due to damaged high-pressure lines
• Before reinstallation, carefully check the high-pressure lines for damage and deformation to the
sealing cone
• Check high-pressure lines for crushing and deformation
• Replace damaged high-pressure lines
• Install high-pressure lines without tension
• Following installation, check the tightness of the lines with MAN-Cats® PLV test
WARNING
Component damage by incorrect installation of pipe clamps
• Always install removed pipe clamps of the pipe set in the original position
• Always reinstall all removed pipe clamps
• Tighten the pipe clamps to the specied tightening torque
WARNING
Component damage due to reused bolts
• Do not re-use a pressure ange mounting bolt, even if it has only been used once.
Note
In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is
imprinted in the protective sleeves. This is integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z 14 x 15).
Special tools
• Storing injectors
• Installing injectors
• Fit the gasket (1) • Fit the cylinder head cover (1)
• Screw in and tighten the mounting bolts (2)
Attaching the injector cable
WARNING
Component damage due to possible
short-circuit
• When tightening the mounting nuts,
make sure that the cable plugs do not
touch each other
Checking the injector seat, rail and leakage oil lines for leaks - D2862LE4..
(1) Leakage oil line (3) Fuel line, leakage oil line - collector
(2) Fuel line, leakage oil line - collector (4) Leakage oil line
Technical data
Pressurisation, drip test ......................................................................................................... 3.0 - 3.5 bar
Pressure drop .......................................................................................................... 0.1 bar in 10 minutes
Hollow screw........................................................ M14x1.5 ............................................................40 Nm
Important information
WARNING
The common-rail system can be damaged
• All work on components of the common-rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats®
(desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Before working on the clean side of the fuel system, clean the engine and the engine compartment
(e.g. steam cleaner). The fuel system must be sealed during this process.
• Avoid any moisture whatsoever
• Always replace rail connections once they have been undone
• Do not reuse plugs for high-pressure lines, the rail or injectors, even if they have only been used
once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
WARNING
Danger of damage due to dirt ingress
• Always detach only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Installing the pressure loss tester Detaching the fuel line left leakage oil line –
collector
Detaching the right leakage oil line - collector
fuel line
WARNING
Injectors can be damaged
WARNING • Pressurisation for leak test must not
Injectors can be damaged exceed 3.0 - 3.5 bar
• Pressurisation for leak test must not
exceed 3.0 - 3.5 bar • Remove the caps and plugs
• Mount the Adapter [45] (4) with the Threaded
• Remove the caps and plugs connection [46] (3) on the leakage oil line
• Mount the Adapter [45] (4) with the Threaded • Connect the Hand pump [44] (2) with the pressure
connection [46] (3) on the leakage oil line gauge (1) to the Threaded connection [46] (3)
• Connect the Hand pump [44] (2) with the pressure • Pressurise the Hand pump [44] (2) using
gauge (1) to the Threaded connection [46] (3) compressed air at 3.0 - 3.5 bar
• Pressurise the Hand pump [44] (2) using • Check the maximum permissible pressure loss on
compressed air at 3.0 - 3.5 bar the pressure gauge (1)
• Check the maximum permissible pressure loss on The desired pressure loss is max.
the pressure gauge (1) 0.1 bar in 10 minutes.
The desired pressure loss is max.
0.1 bar in 10 minutes.
If the fuel system is leaking, the affected parts
must be removed and then checked for damage or
If the fuel system is leaking, the affected parts contamination. Replace parts as necessary.
must be removed and then checked for damage or
contamination. Replace parts as necessary.
Removing the pressure loss tester Detaching the pressure loss tester (right side)
Technical data
Mounting bolts, high-pressure pump ................................................................................................60 Nm
High-pressure line (1) ........................................... M14x1.5 ........................................ Initial torque 10 Nm
High-pressure line (1) ........................................... M14x1.5 ..............................................Final torque 60°
High-pressure line re-use (1)................................. M14x1.5 ..............................................Final torque 30°
Oil ll quantity, high-pressure pump (2) and (3).................................................................................. 0.04 l
Oil ller plug ...................................................................................................................................18 Nm
Mounting bolt, drive gear....................................... M8x35-10.9 .......................................................30 Nm
Thrust washer mounting bolt ................................. M8x22-10.9 .......................................................30 Nm
Mounting bolts, fuel pump ..................................... M6x20 T30 ......................................................... 8 Nm
Mounting bolts, metering unit ................................ M5x20 T25 ...................................... Initial torque 3 Nm
Mounting bolts, metering unit ................................ M5x20 T25 .......................................Final torque 6 Nm
Important information
WARNING
The common-rail system can be damaged
• All work on components of the common-rail system must be performed by specially trained
personnel only.
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats (desired
value 0)
• Ensure absolute cleanliness in all areas when carrying out all work.
• Before working on the clean side of the fuel system, clean the engine and the engine compartment
(e.g. steam cleaner). The fuel system must be closed during this process.
• Avoid any moisture whatsoever
• Do not reuse plugs for the high-pressure lines, rail, injectors or fuel lines, even if they have only
been used once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
• Always detach only one fuel line and then immediately plug the fuel line connections and
component connections
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the Master drive housing Removing the Slave drive housing
• Mark the installation position of the mounting bolts • Unscrew the mounting bolts (4)
(4) • Remove the drive housing (3)
• Unscrew the mounting bolts (4) • Remove the O-rings (1) and (2)
• Remove the drive housing (3)
• Remove the O-rings (1) and (2) Removing the Slave follower sleeve
• Insert the drive shaft (4) with drive housing (2) into
WARNING
the follower sleeve (5)
Danger of damage due to dirt ingress
• Clamp the follower sleeve (5) in a vice with
• Clean the components and blow them
protective jaws
dry using compressed air
• Unscrew the mounting bolts (1) for the drive gear
(3)
• Unscrew the mounting bolts (2)
Removing the drive shaft • Extract the metering unit (1) by turning slightly to
the right/left
• Pull the drive shaft (1) out of the drive housing (2)
• Remove the drive gear (3)
WARNING
Danger of damage due to dirt ingress
• Clean the components and blow them
dry using compressed air
• Insert the drive shaft (4) with drive housing (2) into
the follower sleeve (5)
• Clamp the follower sleeve (5) in a vice with
protective jaws
• Screw in the mounting bolts (1) for the drive gear
Note (3) and tighten to 30 Nm
When using micro-encapsulated bolts,
Installing the thrust washer
the time between the tightening stages
must not be longer than 2 minutes
Installing the Slave follower sleeve Mounting the Master drive housing
• Attach the circlip (1) in the follower sleeve (2) • Insert the drive housing (3) with new O-rings (1)
• Insert the drive shaft into the follower sleeve (2) and (2)
• Screw in and tighten the mounting bolts (4) as
Mounting the Slave drive housing marked
Installing the Slave high-pressure pump Installing the Master high-pressure pump
• Insert the Slave high-pressure pump (1) with new • Insert the Master high-pressure pump (3) with new
O-rings (2) and (3) O-rings (1) and (2)
• Connect the metering unit electrical connection • Screw in new mounting bolts (4) and tighten them
to 60 Nm
• Connect the metering unit electrical connection
Screwing in the high-pressure pump mounting Filling the Master and Slave high-pressure pump
bolt
FUEL LINES
Removing and installing the fuel lines
(1) Fuel line, fuel lter - Master high-pressure (8) Fuel line, right leakage oil line return -
pump collector
(2) Fuel line, collector return - connecting (9) Leakage oil line, right
piece (10) Fuel line, Slave delivery pump -
(3) Fuel line, hand pump - Slave delivery connecting piece
pump (11) Fuel line, connecting piece - Slave
(4) Fuel line, Slave high-pressure pump return high-pressure pump
- collector (12) Fuel line, fuel lter - connecting piece
(5) Leakage oil line, left (13) Fuel line, connecting piece - fuel lter
(6) Fuel line, right rail return - collector (14) Fuel line, connecting piece - fuel lter
(7) Fuel line, left rail return - collector
Important information
WARNING
The common-rail system can be damaged
• All work on components of the common-rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats (desired
value 0)
• Ensure absolute cleanliness in all areas when carrying out all work.
• Before working on the clean side of the fuel system, clean the engine and the engine compartment
(e.g. steam cleaner). The fuel system must be sealed during this process.
• Avoid any moisture whatsoever
• Do not reuse plugs for the high-pressure lines, rail, injectors or fuel lines, even if they have only
been used once
• Always detach only one fuel line and then immediately plug the fuel line connections and
component connections
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the fuel lines Removing the fuel lter - high-pressure pump
fuel line
Removing the hand pump - Master delivery
pump fuel line
WARNING
Danger of damage to the engine
• Unscrew the union nuts (1) and (2) electrics/electronic control unit
• Remove the fuel line (3) • Mark all electrical connections.
• Plug the fuel line with End plug (GPN 330 • Mark the attachment points for the
L18) [56] and the connections with Protective wiring harness on the engine.
sleeve Z 18x1.5 [60]
Removing the delivery pump - fuel lter fuel line • Release the plug connection for the fuel pressure
upstream of the Master high-pressure pump (8)
and pull off the connector
• Unscrew the union nuts for the fuel line (7)
• Remove the fuel line (7)
• Unscrew the hollow screw (4) and remove the
sealing rings (1) and (3)
• Remove the connecting piece (2)
• Plug the fuel line with End plug (GPN 330
L18) [56] and the connections with Protective
sleeve Z 18x1.5 [60] and End plug [58]
• Unscrew the tting (6) and remove the sealing ring
(5)
• Plug the high-pressure pump with End plug [58]
Removing the collector return - connecting piece Removing the distributor - fuel lter fuel line
fuel line
Removing the hand pump - Slave delivery pump Removing the right leakage oil line - collector
fuel line fuel line
• Unscrew the hollow screw (1) • Unscrew the union nut (4)
• Unscrew the union nuts (3) • Unscrew the hollow screw (2) and remove the
• Remove the fuel line (2) sealing rings (1)
• Plug the fuel line with End plug (GPN 330 • Unscrew the clamp mounting bolt
L18) [56] and Protective sleeve Z 14x1.5 [54] • Remove the fuel line (3)
and the connections with Protective sleeve Z • Plug the fuel line with Cap [55] and End plug [58]
18x1.5 [60] and End plug [58] and the connections with End plug [58] and
Protective sleeve Z 14x1.5 [54]
Removing the Slave delivery pump - collector
fuel line Removing the right leakage oil line
• Unscrew the hollow screw (4) • Unscrew the hollow screws (1) and remove the
• Unscrew the hollow screw (2) and remove the sealing rings (3)
sealing rings (3) • Remove the leakage oil line (2)
• Remove the fuel line (1) • Plug the connections with End plug [58]
• Plug the fuel line with Cap [55] and Protective
sleeve Z 14x1.5 [54] and the connections with End
plug [58]
Removing the left leakage oil line - collector fuel Removing the right rail return - collector fuel line
line
Installing the fuel lines Installing the left leakage oil line - collector fuel
line
Installing the right rail return - collector fuel line
Installing the right leakage oil line - collector fuel Installing the hand pump - Slave delivery pump
line fuel line
Installing the distributor - fuel lter fuel line Installing the collector return - connecting piece
fuel line
Installing the fuel lter - delivery pump fuel line Installing the high-pressure pump return -
connecting piece fuel line
Installing the fuel lter - high-pressure pump fuel Installing the hand pump - Master delivery pump
line fuel line
Technical data
Temperature sensor.............................................. M16x1.5 ............................................................48 Nm
Pressure sensor ................................................... M14x1.5 ............................................................35 Nm
Pressure sensor .................................................. M14x1.5 ............................................................35 Nm
Pressure sensor ................................................... M18x1.5 ............................................................48 Nm
Temperature sensor.............................................. M14x1.5 ............................................................35 Nm
Pressure sensor ................................................... M14x1.5 ............................................................35 Nm
Important information
WARNING
The common-rail system can be damaged
• All work on components of the common-rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats (desired
value 0)
• Ensure absolute cleanliness in all areas when carrying out all work.
• Before working on the clean side of the fuel system, clean the engine and the engine compartment
(e.g. steam cleaner). The fuel system must be sealed during this process.
• Avoid any moisture whatsoever
• Do not reuse plugs for the high-pressure lines, rail, injectors or fuel lines, even if they have only
been used once
• Always detach only one fuel line and then immediately plug the fuel line connections and
component connections
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the fuel lines Detaching the connecting piece - left lter fuel
line
Detaching the connecting piece - return
connection fuel line
Detaching the rear FPPE - left lter fuel line Disconnecting the plug connections
• Unscrew the union nut (1) • Mark the installation position of the connectors (1),
• Remove the fuel line (2) (2), (3), (4) and (5)
• Plug the fuel line with End plug (GPN 330 • Pull off the connectors (1), (2), (3), (4) and (5)
L18) [56] and the connections with Protective
sleeve Z 18x1.5 [60] Removing the pressure sensor
• Mark the installation position of the temperature • Mark the installation position of the pressure
sensor (2) sensor (1)
• Unscrew the temperature sensor (2) and remove • Unscrew the pressure sensor (1) and remove it
with the sealing ring (1) with the sealing ring (2)
• Clean the mating faces • Clean the mating faces
• Plug the connection with End plug [58] • Plug the connection with End plug [58]
• Mark the installation position of the pressure • Mark the installation position of the pressure
sensor (2) sensor (2)
• Unscrew the pressure sensor (2) and remove it • Unscrew the pressure sensor (2) and remove it
with the sealing ring (1) with the sealing ring (1)
• Clean the mating faces • Clean the mating faces
• Plug the connection with End plug [57] • Plug the connection with End plug [58]
Removing the temperature sensor Detaching the return - connecting piece fuel line
• Mark the installation position of the temperature • Unscrew the union nuts (1) and (3)
sensor (1) • Remove the fuel line (2)
• Unscrew the temperature sensor (1) and remove • Plug the fuel line with End plug [59] and the
it with the sealing ring (2) connections with Protective sleeve Z 20x30 [62]
• Clean the mating faces
• Plug the connection with End plug [57]
Detaching the left rail - collector fuel line
Removing the holding clips
Detaching the distributor - front FPPE fuel line Detaching the connecting piece - front HDPPE
fuel line
Detaching the right leakage oil line - collector Detaching the left leakage oil line - collector fuel
fuel line line
• Unscrew the union nuts (1) and (3) • Unscrew the union nuts (2) and (3)
• Remove the fuel line (2) • Remove the fuel line (1)
• Plug the fuel line with End plug [57] and the • Plug the fuel line with End plug [57] and the
connections with Protective sleeve Z 16x1.5 [61] connections with Protective sleeve Z 16x1.5 [61]
Detaching the right rail - collector fuel line Removing the connecting piece
• Unscrew the union nuts (2) and (3) • Unscrew the mounting bolts (2)
• Remove the fuel line (1) • Remove the connecting piece (1)
• Plug the fuel line with End plug [57] and the
connections with Protective sleeve Z 16x1.5 [61]
Mounting the connecting piece Attaching the right leakage oil line - collector fuel
line
Attaching the front FPPE - distributor fuel line Attaching the return - connecting piece fuel line
• Remove the caps and plugs • Remove the caps and plugs
• Position the fuel line (3) • Position the fuel line (2)
• Screw on and tighten the union nuts (1) and (2) • Screw on and tighten the union nuts (1) and (3)
Attaching the distributor - front FPPE fuel line Mounting the holding clips
• Remove the caps and plugs • Position the holding clips (1) and (2) as marked
• Position the fuel line (2) • Attach the holding clips (1) and (2)
• Screw on and tighten the union nuts (1) and (3)
Installing the temperature sensor
Attaching the left rail - collector fuel line
Installing the pressure sensor Attaching the rear FPPE - left lter fuel line
FUEL FILTER
Removing and installing the fuel lter
Important information
WARNING
The common-rail system can be damaged
• All work on components of the common rail system must be performed by specially trained
personnel only
• Ensure absolute cleanliness in all areas when carrying out all work.
• Before working on the clean side of the fuel system, clean the engine and the engine compartment
(e.g. steam cleaner). The fuel system must be closed during this process.
• Avoid any moisture whatsoever
• Do not reuse plugs for the high-pressure lines, rail, injectors or fuel lines, even if they have only
been used once
• Always detach only one fuel line and then immediately plug the fuel line connections and
component connections
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the fuel lter Removing the fuel lter - high-pressure pump
fuel line
Removing the delivery pump - fuel lter fuel line
WARNING
• Unscrew the mounting bolt (2)
Danger of damage to the engine
• Remove the nut (4)
electrics/electronics
• Unscrew the screw connection (3)
• Mark all electrical connections.
• Unscrew the screw connection (1)
• Mark the attachment points for the
• Remove the fuel line (5)
wiring harness on the engine.
• Plug the fuel line with End plug (GPN 330
L18) [56] and Protective sleeve Z 14x1.5 [54]
• Unlock the plug connection for the fuel pressure
and the connections with Protective sleeve Z
upstream of the Master high-pressure pump (8)
18x1.5 [60] and End plug [58]
and pull off the connector
• Unscrew the union nuts for the fuel line (7)
• Remove the fuel line (7)
• Unscrew the hollow screw (4) and remove the
sealing rings (1) and (3)
• Remove the connecting piece (2)
• Plug the fuel line with End plug (GPN 330
L18) [56] and the connections with Protective
sleeve Z 18x1.5 [60] and End plug [58]
• Unscrew the tting (6) and remove the sealing ring
(5)
• Plug the high-pressure pump with End plug [58]
Removing the fuel lter - delivery pump fuel line Removing the fuel lter
• Unscrew the mounting bolt (4) • Unscrew the mounting bolts (1)
• Remove the nut (5) • Remove the washers (2)
• Unscrew the union nut (1) • Remove the fuel lter (3)
• Unscrew the screw connection (2) • The second fuel lter is removed in the same way
• Remove the fuel line (3)
• Plug the fuel line with End plug (GPN 330
L16) [65] and the connections with Protective
sleeve (Z16x8) [63]
Installing the fuel lter Installing the fuel lter - delivery pump fuel line
WARNING
Danger of damage to the engine
electrics/electronics
• Connect all electrical connections as
marked.
• Only fasten the wiring harness at the
previously marked attachment points
Important information
WARNING
The common-rail system can be damaged
• All work on components of the common rail system must be performed by specially trained
personnel only
• Ensure absolute cleanliness in all areas when carrying out all work.
• Before working on the clean side of the fuel system, clean the engine and the engine compartment
(e.g. steam cleaner). The fuel system must be closed during this process.
• Avoid any moisture whatsoever
• Do not reuse plugs for the high-pressure lines, rail, injectors or fuel lines, even if they have only
been used once
• Always detach only one fuel line and then immediately plug the fuel line connections and
component connections
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Detaching the holder for the fuel lter Installing the fuel lter
Detaching the holder for the fuel lter
Mounting the carrier for the fuel lter Attaching the fuel lter fuel line
• Position the carrier (1) • Remove the protective sleeves and end plugs
• Screw in and tighten the mounting bolts (2) • Screw on and tighten the union nuts (1)
Technical data
Cover (4)........................................................................................................................................20 Nm
Drain plug ....................................................................................................................................... 3 Nm
Important information
WARNING
The common-rail system can be damaged
• Do not reuse plugs for high-pressure lines, the rail or injectors, even if they have only been used
once
WARNING
The common-rail system can be damaged
• Always allow the fuel lter cover to empty completely in order to remove dirt and impurities before
changing the fuel lter
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
In order to ensure that the correct protective sleeve is used, the designation (e.g. Z14 x 15) is
imprinted in the protective sleeve. This is integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z14 x 15).
Special tools
• Open the drain plug (1) and allow the fuel lter
cover to empty
• Tighten the drain plug (1) to 3 Nm
• Screw the cover (3) with a new O-ring (2) onto the
housing (1)
• Insert the new fuel lter insert (2) into the housing • Tighten the cover (3) to 20 Nm using the Hexagon
(1) socket wrench, size 36 [68]
Technical data
Mounting bolt, cover ............................................. M114x50x10.9 ...................................................37 Nm
Important information
WARNING
The common-rail system can be damaged
• Do not reuse plugs for high-pressure lines, the rail or injectors, even if they have only been used
once
WARNING
The common-rail system can be damaged
• Always allow the fuel lter cover to empty completely in order to remove dirt and impurities before
changing the fuel lter
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
In order to ensure that the correct protective sleeve is used, the designation (e.g. Z14 x 15) is
imprinted in the protective sleeve. This is integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z14 x 15).
• Unscrew the screw plugs (1), (2), (3), (4), (5), (6)
and (7) and remove with the sealing rings
• Unscrew the wing screws (1) • Clean the mating faces
• Remove the cover (5) with the gasket (4)
• Remove the locking washers (3) Removing the distributor
• Pull out the wing screws (1) and remove with the
sealing rings (2)
• Clean the mating faces
HAND PUMP
Removing and installing the hand pump
Additional jobs
– Removing and installing the fuel lines, see 213
Technical data
Cover, fuel pre-lter (4) ...................................................................................................................10 Nm
Knurled nut, hand pump................................................................................................................... 3 Nm
Important information
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
In order to ensure that the correct protective sleeve is used, the designation (e.g. Z14 x 15) is
imprinted in the protective sleeve. This is integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z14 x 15).
Note
A check valve is integrated in the hand pump to prevent the fuel from owing back.
• Unscrew the mounting bolts (1) • Position the hand pump (2)
• Remove the hand pump (2) • Screw in the mounting bolts (1) and tighten them
• Insert the new fuel pre-lter (3) into the housing (1)
• Screw on the cover (4) with a new O-ring (2)
• Tighten the cover to 10 Nm
• Unscrew the cover (4)
• Pull the fuel pre-lter (3) off the housing (1)
• Remove the O-ring (2)
Important information
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
In order to ensure that the correct protective sleeve is used, the designation (e.g. Z14 x 15) is
imprinted in the protective sleeve. This is integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z14 x 15).
Note
A check valve is integrated in the hand pump to prevent the fuel from owing back.
Special tools
Technical data
Fuel pre-lter cover.........................................................................................................................10 Nm
Knurled nut, hand pump................................................................................................................... 3 Nm
Service products
Fuel ..........................................see Maintenance Recommendations and Recommended Service Products
Important information
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
In order to ensure that the correct protective sleeve is used, the designation (e.g. Z14 x 15) is
imprinted in the protective sleeve. This is integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z14 x 15).
Note
A check valve is integrated in the hand pump to prevent the fuel from owing back.
Special tools
• Mark the installation position of the WVE • Clean the mating faces
connection (1) • Thinly apply clean Fuel on the new O-ring (2)
• Unscrew the WVE connection (1) • Pull the new O-ring (2) onto the hand pump (1)
• Unscrew the hollow screw connector (2) and • Insert the fuel pre-lter (3)
remove it with sealing rings and ring union (3) • Screw on the cover (4) and tighten to 10 Nm
• Unscrew the plug (6)
• Unscrew the adapter tting (7) and remove it with Assembling the hand pump
the sealing ring
• Mark the installation position of the WVE
connection (5)
• Unscrew the WVE connection (5)
• Unscrew the threaded connection (4) and remove
with the sealing ring
• Plug the hand pump connections with End plug
(GPN 330 L18) [71]
• Clean the mating faces
TURBOCHARGING
(1) Turbocharger, 1st stage, right (4) Turbocharger, 2nd stage, left
(2) Turbocharger, 2nd stage, right (5) Turbocharger, 1st stage, left
(3) Exhaust manifold
Technical data
Hose clamp..................................................................................................................................... 5 Nm
Service products
Technical Vaseline .....................see Maintenance Recommendations and Recommended Service Products
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Removing the left adapter ange Removing the right adapter ange
• Mark the installation position of the mounting bolts • Mark the installation position of the mounting bolts
(1) and (7) (3) and (4)
• Unscrew and remove the mounting bolts (1) and • Unscrew and remove the mounting bolts (3) and
(7) (4)
• Pull out the adapter ange (2) and remove with the • Pull out the adapter ange (2) and remove with the
gaskets (3) and (6) gaskets (1) and (6)
• Pull out the unscrewed conduits (4) and remove • Pull out the unscrewed conduit (5) and remove the
the O-rings (5) O-rings
• Clean the mating faces • Clean the mating faces
• Insert the new O-rings (3) and (4) into the adapter • Position the coolant line (5) with hose clamps (1)
anges and (3)
• Position the exhaust manifold (5) • Mount the hose clamps (1) and (3) in the
• Screw in and tighten the mounting bolts (6) and installation position and tighten to 5 Nm
(7) as marked • Insert the mounting bolt (4)
• Screw on and tighten the mounting nuts (2) with • Screw on and tighten the mounting nut (2)
washers (1)
Technical data
Mounting bolt, adapter ange ................................ M10x60-10.9......................................................45 Nm
Mounting bolt, adapter ange ................................ M8 ....................................................................35 Nm
Clamp (2) and (5) ................................................. Ø170 .................................................................12 Nm
Hose clamp..................................................................................................................................... 5 Nm
Service products
Renolit Si 704 silicone grease ............................................................................................ 09.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
• Unscrew the hollow screw (1) and remove the • Unscrew the mounting bolts (1) and (4)
sealing rings (5) • Remove the adapter ange (2)
• Unscrew the hose tting (3) and remove the • Remove the gasket (3)
sealing rings (4) • Clean the mating faces
• Remove the coolant line (2)
Removing the right adapter ange
Removing the exhaust manifold
• Position the hose clamps (2) on the moulded hose • Thinly apply Renolit Si 704 silicone grease on the
(1) new O-rings (5) and (10) and the contact surfaces
• Position the moulded hose (1) with the hose • Insert a new O-ring (10) into the coolant manifold
clamps (2) (1)
• Tighten the hose clamps (2) to 5 Nm • Insert a new O-ring (5) into the coolant manifold
(4)
Mounting the left coolant manifold • Position the hose (3) with hose clamps (2) on the
coolant manifolds (1) and (4)
• Position the coolant manifolds (1) and (4) with the
hose (2)
• Position the retainer (7)
• Screw in the mounting bolt (6) and tighten to
35 Nm
• Position the retainer (9)
• Screw in the mounting bolt (8) and tighten to
35 Nm
• Tighten the hose clamps (2) and (4) to 5 Nm
(1) Control valve, charge pressure, left (5) Exhaust manifold, right
(2) Hose line, control valve, left (6) Temperature sensor
(3) Hose line, control valve, right (7) Control valve, charge pressure, right
(4) Exhaust manifold upstream of (8) Exhaust manifold upstream of
turbocharger, right turbocharger, left
Technical data
Temperature sensor.............................................. M16x1.5 ............................................................47 Nm
Service products
Technical Vaseline .....................see Maintenance Recommendations and Recommended Service Products
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Detaching the left hose line Removing the left shield (classied variant)
• Unscrew and remove the mounting bolt (4) • Unscrew and remove the mounting bolts (1)
• Undo the union nut (2) • Remove the shield (2)
• Unscrew the hollow screw (1) and remove it with
the sealing rings
• Remove the hose line (3)
Removing the left charge-pressure control valve Removing the left exhaust manifold
• Mark the installation position of the mounting bolts • Mark the mounting bolts (2), (6) and (7)
(3) and (4) • Unscrew and remove the mounting bolts (2)
• Unscrew the mounting bolts (3) and (4) and • Unscrew and remove the mounting bolts (6) and
remove with the holder (1) (7) with washers
• Remove the control valve (2) • Remove the exhaust manifold (5) with the coolant
line (4)
Removing the exhaust manifold upstream of the • Remove the O-rings (1), (3), (8) and (9)
turbocharger on the left • Clean the mating faces
• Unscrew and remove the mounting bolts (2) • Mark the mounting bolts (3) and (5)
• Undo the union nuts (3) and (4) • Unscrew and remove the mounting bolts (3) and
• Remove the hose line (1) (5)
• Remove the coolant manifold (2) with O-rings (1)
Removing the right shield (classied variant) and (4)
• Clean the mating faces
Mounting the exhaust manifold upstream of the Mounting the right charge-pressure control
turbocharger on the right valve
Mounting the left support Mounting the exhaust manifold upstream of the
turbocharger on the left
TURBOCHARGER
Removing and installing the turbocharger (one-stage variant)
Additional jobs
– Draining and topping up the coolant, see Operator's Manual
– Removing and installing the exhaust manifold (one-stage variant), see 273
– Removing and installing the air lter, see 341
– Removing and installing the intercooler, see 331
Technical data
Turbocharger mounting nuts ................................. M10...................................................................65 Nm
Hose clamp..................................................................................................................................... 5 Nm
Service products
Technical Vaseline .....................see Maintenance Recommendations and Recommended Service Products
Engine oil..................................see Maintenance Recommendations and Recommended Service Products
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Removing the turbocharger Detaching the left turbocharger oil pressure line
Detaching the left coolant line Removing the right charge-air manifold
• Unscrew the mounting bolts (3) and (4) • Undo the clamp (2)
• Remove the coolant line (1) with gaskets (2) and • Remove the charge-air manifold (4) with O-rings
(5) (1) and (3)
• Clean the mating faces • Clean the mating faces
• Loosen the hose clamp (3) and push onto the hose
CAUTION
• Unscrew the mounting bolts (1)
Danger of injury due to heavy
• Remove the coolant line (4) with gasket (2)
components
• Clean the mating faces
• Only lift the turbocharger with support
Filling the right turbocharger with oil Mounting the right charge-air manifold
CAUTION
Danger of injury due to heavy
components
• Only lift the turbocharger with support
Attaching the left coolant line Filling the left turbocharger with oil
(1) Oil pressure line, turbocharger, 1st stage, (8) Oil return line, turbocharger, 2nd stage, left
right (9) Turbocharger, 2nd stage, left
(2) Turbocharger, 1st stage, right (10) Lower housing section, turbocharger, 2nd
(3) Oil pressure line, turbocharger, 2nd stage, stage, left
right (11) Upper housing section, turbocharger, 2nd
(4) Coolant line, turbocharger, 1st stage, right stage, left
(5) Housing, turbocharger, 2nd stage, right (12) Oil pressure line, turbocharger, 2nd stage,
(6) Turbocharger, 2nd stage, right left
(7) Oil return line, turbocharger, 2nd stage, (13) Oil return line, turbocharger, 1st stage, left
right (14) Turbocharger, 1st stage, left
Technical data
Mounting nuts, turbocharger.................................. M10...................................................................65 Nm
Mounting bolts, turbocharger................................. M10x135HWF....................................................65 Nm
Mounting bolts, turbocharger................................. M10x145HWF....................................................65 Nm
Exhaust manifold mounting bolts ........................... M12x1.5 .......................................................... 110 Nm
Hose clamp..................................................................................................................................... 5 Nm
Service products
Renolit Si 704 silicone grease ............................................................................................ 04.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the left turbocharger Detaching the oil return line - turbocharger, 1st
stage, left
Detaching the oil pressure line - turbocharger,
2nd stage, left
• Unclip the jubilee clips (1) and (6) using the Hose
clamp pliers for jubilee clips [72]
• Unscrew the oil pressure line (5) screw connection • Unscrew the mounting bolt (5)
and remove the oil pressure line (5) • Remove the oil return line (3)
• Unscrew the ttings (4) and (6) • Remove the hoses (2) and (4)
• Unscrew the mounting bolts (3)
• Remove the ange (2) with the gasket (1)
• Clean the mating faces
Removing the left turbocharger bearing block Removing the assembly - turbocharger, 2nd
cooling stage, left
Installation position of the mounting bolts - Removing the left exhaust manifold
turbocharger, 2nd stage, left
Removing the left lower housing section Removing the right turbocharger
Detaching the oil pressure line - turbocharger,
2nd stage, right
Detaching the oil return line - turbocharger, 1st Detaching the coolant line
stage, right
• Unscrew the mounting bolts (2) • Unscrew the mounting bolts (3)
• Remove the coolant manifold (1) with O-ring (3) • Remove the coolant manifold (2)
• Remove the unscrewed conduit (4) • Remove the O-rings (1) and (4)
• Clean the mating faces • Remove the unscrewed conduit (5)
• Remove the O-ring (6)
Removing the right turbocharger bearing block • Clean the mating faces
cooling
Removing the exhaust manifold support
Removing the assembly - turbocharger, 2nd Installation position of the mounting bolts -
stage, right turbocharger, 2nd stage, right
Removing the right exhaust manifold Removing the right lower housing section
• Mark the position of the exhaust manifold (6) • Mark the installation position of the mounting bolts
relative to the turbocharger (1) (1) and (3)
• Unscrew the mounting bolts (5) • Unscrew the mounting bolts (1) and (3)
• Unscrew the nuts (4) • Unscrew the nut (2)
• Remove the exhaust manifold (6) with the gasket • Remove the lower housing section (5)
(2) • Remove the O-ring (4)
• Remove the O-ring (3) • Clean the mating faces
• Clean the mating faces
Removing the charge pressure control valve
Removing the unscrewed conduit
Installing the unscrewed conduit Mounting the turbocharger, 2nd stage, right
Mounting the right upper housing section Mounting the exhaust manifold support
• Thinly apply Renolit Si 704 silicone grease on the • Position the bracket (2)
new O-rings (4) and the unscrewed conduit (3) • Screw in the mounting bolts (1)
• Position the O-rings (4) and the unscrewed conduit • Screw in the mounting bolts (3)
(3) • Tighten the mounting bolts (1) and (3)
• Thinly apply Loctite 5900 on the mating face of the
upper housing section (1) Installing the right turbocharger bearing block
• Position the upper housing section (1) cooling
• Screw in and tighten the mounting bolts (2) as
marked
Mounting the coolant manifold Mounting the turbocharger, 1st stage, right
• Thinly apply Renolit Si 704 silicone grease on the • Position the turbocharger (1) with a new gasket (2)
new O-rings (1), (4) and (6) • Screw on the nuts (3) and tighten to 65 Nm
• Insert the O-rings (1), (4) and (6)
• Insert the unscrewed conduit (5) into the coolant Attaching the coolant line
manifold (2)
• Position the coolant manifold (2) with the
unscrewed conduit (5)
• Screw in and tighten the mounting bolts (3)
Attaching the oil return line - turbocharger, 2nd Filling the turbocharger with oil
stage, right
WARNING
• Position the oil return line (3) with hose (2) and (4)
Component damage when the engine
• Clip in the jubilee clips (1) and (5) using the Hose
is started for the rst time
clamp pliers for jubilee clips [72]
• Fill the turbocharger with clean engine
Attaching the oil return line - turbocharger, 1st oil before attaching the oil pressure
stage, right lines
• Use funnels (1) and (2) to ll clean Engine oil into
the oil feed holes on the turbochargers (3) and (4)
until the oil ducts of the turbochargers (1) and (2)
are full
• Position the oil return line (2) with a new gasket (1)
• Screw in the mounting bolts (8)
• Position the hose (7)
• Thinly apply Renolit Si 704 silicone grease on the
new O-ring (6)
• Position the oil return line (2) with O-ring (6)
• Screw in the mounting bolt (5)
• Clip in the jubilee clips (3) using the Hose clamp
pliers for jubilee clips [72]
• Tighten the mounting bolts (5) and (8)
Attaching the oil pressure line - turbocharger, Attaching the oil pressure line - turbocharger,
1st stage, right 2nd stage, right
WARNING WARNING
Component damage when the engine Component damage when the engine
is started for the rst time is started for the rst time
• Fill the turbocharger with clean engine • Fill the turbocharger with clean engine
oil to MAN Standard 3277 oil to MAN Standard 3277
• Pour clean engine oil to MAN Standard 3277 into • Pour clean engine oil to MAN Standard 3277 into
the oil pressure connection on the turbocharger the oil pressure connection on the turbocharger
using a funnel until the oil duct is full using a funnel until the oil duct is full
• Position the ange (1) with a new gasket (3) • Screw in the hollow screw (3) with new sealing
• Screw in the mounting bolts (2) rings (2) and ring union (4)
• Position the oil pressure line (4) and tting (5) • Position the oil pressure line (1)
• Screw on the oil pressure line (4) screw connection • Screw on the oil pressure line (1) screw connection
and tting (5) • Tighten the hollow screw (3)
• Tighten the mounting bolts (2) • Tighten the oil pressure line (1) screw connection
• Tighten the oil pressure line (4) screw connection
and tting (5)
Mounting the left exhaust manifold Mounting the turbocharger, 2nd stage, left
Mounting the left upper housing section Mounting the exhaust manifold support
Mounting the coolant manifold Mounting the turbocharger, 1st stage, left
• Thinly apply Renolit Si 704 silicone grease on the • Position the turbocharger (1) with a new gasket (2)
new O-rings (1), (3) and (5) • Screw on the nuts (3) and tighten to 65 Nm
• Insert the O-rings (1), (3) and (5)
• Insert the unscrewed conduit (4) into the coolant Attaching the coolant moulded hose -
manifold (2) turbocharger, 1st stage, left
• Position the coolant manifold (2) with the
unscrewed conduit (4)
• Screw in the mounting bolts (6) and tighten them
Attaching the oil return line - turbocharger, 2nd Filling the turbocharger with oil
stage, left
WARNING
• Position the oil return line (3) with hoses (2) and
Component damage when the engine
(4)
is started for the rst time
• Clip in the jubilee clips (1) and (6) using the Hose
• Fill the turbocharger with clean engine
clamp pliers for jubilee clips [72]
oil before attaching the oil pressure
• Screw in and tighten the mounting bolt (5)
lines
Attaching the oil return line - turbocharger, 1st
• Use funnels (1) and (2) to ll clean Engine oil into
stage, left
the oil feed holes on the turbochargers (3) and (4)
until the oil ducts of the turbochargers (1) and (2)
are full
• Position the oil return line (2) with a new gasket (1)
• Screw in the mounting bolts (6)
• Position the moulded hose (4)
• Clip in the jubilee clips (3) and (5) using the Hose
clamp pliers for jubilee clips [72]
• Tighten the mounting bolts (6)
Attaching the oil pressure line - turbocharger, Attaching the oil pressure line - turbocharger,
1st stage, left 2nd stage, left
WARNING WARNING
Component damage when the engine Component damage when the engine
is started for the rst time is started for the rst time
• Fill the turbocharger with clean engine • Fill the turbocharger with clean engine
oil to MAN Standard 3277 oil to MAN Standard 3277
• Pour clean engine oil to MAN Standard 3277 into • Pour clean engine oil to MAN Standard 3277 into
the oil pressure connection on the turbocharger the oil pressure connection on the turbocharger
using a funnel until the oil duct is full using a funnel until the oil duct is full
• Position the ange (2) with a new gasket (1) • Screw in the hollow screw (5) with new sealing
• Screw in the mounting bolts (3) rings (4) and ring union (3)
• Position the oil pressure line (5) with ttings (4) • Position the oil pressure line (2) with tting (1)
and (6) • Screw on the oil pressure line (2) screw connection
• Screw on the oil pressure line (5) screw connection and tting (1)
and ttings (4) and (6) • Tighten the hollow screw (5)
• Tighten the mounting bolts (3) • Tighten the oil pressure line (2) screw connection
• Tighten the oil pressure line (5) screw connection and tting (1)
and ttings (4) and (6)
CHARGE-AIR PIPES
Removing and installing the charge-air pipes
Additional jobs
– Removing and Installing the engine cover, see 515
Technical data
Clamp.................................................................. Ø 92 ................................................................... 7 Nm
Clamp.................................................................. Ø 108 ................................................................. 7 Nm
Clamp.................................................................. Ø 140 ................................................................. 7 Nm
Service products
Loctite 2701 ...................................................................................................................... 04.10160-9353
Renolit Si 704 silicone grease ............................................................................................ 04.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Removing the charge air pipes Removing the air ducting manifold
Removing the charge-air manifold, 2nd stage, Removing the charge-air manifold, 2nd stage,
left right
• Mark the installation position of the mounting bolts • Mark the installation position of the mounting bolts
(3) (3)
• Unscrew the mounting bolts (3) • Unscrew the mounting bolts (3)
• Remove the charge-air manifold (2) with O-ring (1) • Remove the charge-air manifold (2) with O-ring (1)
• Pull off the unscrewed conduit (5) • Pull off the unscrewed conduit (5)
• Remove the O-rings (4) and (6) • Remove the O-rings (4) and (6)
• Undo the clamp (9) • Undo the clamp (9)
• Remove the charge-air manifold (7) with O-ring (8) • Remove the charge-air manifold (7) with O-ring (8)
Removing the charge-air manifold, 1st stage,
right
Installing the charge air pipes Mounting the charge-air manifold, 2nd stage, left
Mounting the air ducting manifold Mounting the left air ducting manifold holder
• Thinly apply Renolit Si 704 silicone grease on the • Position the holder (3)
new O-rings (1), (3), (6) and (8) • Screw in and tighten the mounting bolts (1) and
• Insert the O-rings (1) and (3) into the air ducting (2) as marked
manifold (5) and intercooler hood • Position the holder (6)
• Insert the unscrewed conduit (2) into the air • Screw in and tighten the mounting bolts (4) and
ducting manifold (5) (5) as marked
• Insert the O-rings (6) and (8) into the air ducting
manifold (5) and charge-air manifold
• Insert the unscrewed conduit (7) into the air
ducting manifold (5)
• Position the air ducting manifold (5)
• Screw in and tighten the mounting bolts (4) with
the nut (9)
INTERCOOLER
Removing and installing the intercooler
Additional jobs
– Removing and Installing the coolant manifold, see 123
– Removing and installing the charge-air pipes, see 325
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the intercooler, 1st stage, left Removing the intercooler holder, 1st stage, left
Removing the intercooler, 1st stage, Removing the intercooler holder, 1st stage, right
right
Removing the intercooler
Installing the intercooler, 2nd stage Attaching the front intercooler mounting
Mounting the intercooler, 1st stage, right Tightening the intercooler holder mounting
bolts, 1st stage, right
Mounting the intercooler holder, 1st stage, right
Mounting the intercooler, 1st stage, left Tightening the intercooler holder mounting
bolts, 1st stage, left
Mounting the intercooler holder, 1st stage, left
(1) Right air distributor pipe (2) Left air distributor pipe
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Detaching the air distributor pipe Attaching the air distributor pipe
Detaching the left air distributor pipe Attaching the left air distributor pipe
• Mark the installation position of the mounting bolts • Position the air distributor pipe (5) with new
(1), (2) and (3) gaskets (6)
• Unscrew the mounting bolts (1), (2) and (3) • Position the holder (4)
• Remove the holder (4) • Screw in and tighten the mounting bolts (1), (2)
• Remove the air distributor pipe (5) with the gaskets and (3) as marked
(6)
• Clean the mating faces Attaching the right air distributor pipe
AIR FILTER
Removing and installing the air lter
Additional jobs
– Removing and installing the suction vacuum sensor, see 82
Technical data
Hose clamp (2), (7)............................................... Ø 160 ................................................................. 7 Nm
Clamp (4), (5)....................................................... Ø 163 ................................................................. 7 Nm
Service products
Renolit Si 704 silicone grease ............................................................................................ 04.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing and installing the air lter Installing the air lter
Removing the air lter Mounting the intake tting
• Undo the hose clamp (2) • Thinly apply Renolit Si 704 silicone grease on the
• Remove the air lter (1) with hose clamp (2) new O-rings (3)
• Insert the O-rings (3) into the intake tting (1)
Detaching the vent line • Position the intake tting (1)
• Position the clamp (2) and tighten it to 7 Nm
• Unclip the jubilee clips (1) and (3) using the Hose
clamp pliers for jubilee clips [74]
• Remove the moulded hose (2)
• Position the moulded hose (2)
Removing the intake tting • Position and clip in the jubilee clips (1) and (3)
using the Hose clamp pliers for jubilee clips [74]
• Position the air lter (1) with the hose clamp (2)
• Tighten the hose clamp (2) to 7 Nm
EXHAUST SYSTEM
Removing and installing the exhaust system
Additional jobs
– Removing and installing the air lter, see 341
– Draining and topping up the coolant, see Operator's Manual
– Removing and installing the turbocharger (two-stage variant), see 301
– Removing and installing the exhaust manifold (two-stage variant), see 278
Technical data
Mounting bolt ....................................................... M10x55 HWF.....................................................45 Nm
Mounting bolt ....................................................... M8x120 HFW.....................................................28 Nm
Service products
Renolit Si 704 silicone grease ............................................................................................ 04.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
• Unscrew the mounting bolts (4) • Position the exhaust pipe (2) with new gaskets (1)
• Remove the cover (3) with the gasket (2) and the • Screw in the mounting bolts (3) and tighten them
O-rings (1) to 45 Nm
Removing the inner exhaust pipes Installing the inner exhaust pipes
• Pull off the ange (1) • Position the inner exhaust pipe T-piece (2)
• Unscrew the mounting bolts (3) • Screw in the mounting bolts (3)
• Remove the inner exhaust pipes (2) and (4) • Repeat the steps for the remaining inner exhaust
pipe T-pieces (2)
Detaching the exhaust pipe • Position the inner exhaust pipe manifold (4)
• Screw in the mounting bolts (3)
• Insert the ange (1) into the exhaust pipe
• Tighten the mounting bolts (3) to 28 Nm
CYLINDER HEAD
CYLINDER HEAD
Removing and installing the rocker arm mechanism
Technical data
Mounting bolt, rocker arm mechanism (2) .............. M12x80-10.9......................................................90 Nm
Mounting bolt, rocker arm mechanism (2) .............. M12x80-10.9........................................Final torque 90°
Injector cable.................................................................................................................................1.5 Nm
Special tools
Removing the rocker arm mechanism Removing the rocker arm mechanism
WARNING
Component damage due to possible
WARNING short-circuit
Component damage due to incorrect • When tightening the mounting nuts,
tting of the valve bridges make sure that the cable plugs do not
• Document and mark the installation touch each other
position of the valve bridges (3)
• Connect the injector cable to the injector as
• Insert the push rods (4) marked
• Oil the ball cups of the push rods (4) • Screw on the mounting nuts with the Torque
• Oil the valve bridges (3) screwdriver [75] in conjunction with the
• Put on the valve bridges (3) as marked Adapter [76] and Socket, size 7 [77] and then
• Insert the rocker arm mechanism (1) into the push tighten to 1.5 Nm
rod cups and align • Thinly apply White T assembly paste on the cable
• Screw in new mounting bolts (2) and tighten them passage in the gasket (2)
to 90 Nm • Insert the injector cable (1) into the cable passage
• Tighten the mounting bolts (2) to Final torque 90° in the gasket (2)
• Fit the gasket (1) • Put on the cylinder head cover (1)
• Screw in the mounting bolts (2) and tighten them
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Dismantling the rocker arm mechanism Measuring the rocker arm shaft outside diameter
Measuring the rocker arm bearing inside If the outside diameter is out of tolerance, the rocker
diameter arm bracket must be replaced.
Technical data
Cylinder head bolts............................................... M18x2x246.................................... Initial torque 50 Nm
Cylinder head bolts............................................... M18x2x246.....................................2nd torque 150 Nm
Cylinder head bolts............................................... M18x2x246......................................3rd torque 300 Nm
Cylinder head bolts............................................... M18x2x246............................................ 4th torque 90°
Service products
White T assembly paste..................................................................................................... 09.16012-0122
Important information
WARNING
Component damage due to leaking cylinder head gasket
• Do not reuse old cylinder head bolts, even if they have only been used once
WARNING
The common-rail system can be damaged
• All work on components of the common-rail system must be performed by specially trained
personnel only.
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats®
(desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Always renew rail connections once they have been undone
• Do not reuse plugs for high-pressure lines, the rail or injectors, even if they have only been used
once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Note
Hollow screws are restricted.
Tightening sequence for cylinder head Final tightening of cylinder head bolts
Technical data
Mounting bolts, rocker arm mechanism.................. M12x80-10.9.................................. Initial torque 90 Nm
Mounting bolts, rocker arm mechanism.................. M12x80-10.9........................................Final torque 90°
Injector cable.................................................................................................................................1.5 Nm
Service products
White T assembly paste..................................................................................................... 09.16012-0122
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Unscrew the mounting bolts (2) • Screw the Adapter [97] (3) into the cylinder head
• Remove the rocker arm mechanism (1) (1)
• Pull out the push rods (4) • Screw the Assembly device [98] (2) into the
• Mark the installation position of the valve bridges Adapter [97] (3)
(3)
• Remove the valve bridges (3) Mounting the valve-spring compressor
WARNING
Injector damage
Note • Spring compressor must not come into
Retaining washer and Holder [102] have contact with the injector
left-hand threads.
• Position the Holder [101] (4) and Holder [102]
• Position the Holder [101] (5) and Holder [102] (3) (5) on the spring cap and tension by turning the
on the Valve-spring compressor [100] (1) and then threaded spindle (6)
screw on by turning the threaded spindle (4) • Hook the Valve-spring compressor [100] (2) in the
• Screw on the retaining washers (2) and (6) Assembly device [98] (3)
• Position the lever (8) on the Valve-spring • Place the Extension [99] (1) onto the Valve-spring
compressor [100] (1) and secure using the compressor [100] (2)
mounting bolt (7)
CAUTION
Risk of injury due to springing back of
the valve springs Note
• Ensure that the Holder [101] and Mount the green valve stem seals on the
Holder [102] are seated correctly on intake side and the brown valve stem
the spring cap seals on the exhaust side
• Do not remove the valve cotters from
the valve spring with your bare hands • Thinly apply clean engine oil to MAN Standard
3277 on the Mounting sleeve [105] (4) and the
• Push down the Valve-spring compressor [100] with valve stem seal (3)
Extension [99] (1) • Push the Mounting sleeve [105] (4) over the valve
• Remove the valve cotters (3) from the valve stem stem (5)
(4) with Magnetic pick-up tool [103] (2) • Insert the valve stem seal (3) into the Assembly
• Release the Valve-spring compressor [100] (1) device [104] (2) and tension it
• Remove the valve spring together with the washer • Push the Assembly device [104] (2) over the
and spring cap Mounting sleeve [105] (4)
• Repeat the same procedure for all the valves • Knock the valve stem seal (3) onto the valve stem
• Remove the special tool (5) using the impact weight (1)
• Remove the Assembly device [104] (2) and the
Removing the valve stem seals Mounting sleeve [105] (4)
Note CAUTION
Retaining washer and Holder [102] have Risk of injury due to springing back of
left-hand threads. the valve springs
• Ensure that the Holder [101] and
• Position the Holder [101] (5) and Holder [102] (3) Holder [102] are seated correctly on
on the Valve-spring compressor [100] (1) and then the spring cap
screw on by turning the threaded spindle (4) • Do not insert the valve cotters into the
• Screw on the retaining washers (2) and (6) valve spring with your bare hands
• Position the lever (8) on the Valve-spring
compressor [100] (1) and secure using the • Press the spring cap (4) down fully with
mounting bolt (7) Valve-spring compressor [100] (3) and
Extension [99] (2)
Mounting the valve-spring compressor • Insert the valve cotters (1)
• Carefully undo the Valve-spring compressor [100]
(3)
• Check the valve cotters (1) for correct seating and,
if necessary, repeat the procedure above
WARNING
Injector damage
• Spring compressor must not come into
contact with the injector
Note WARNING
Ensure that the oil bore in the valve bridge Component damage due to possible
is facing downwards short-circuit
• When tightening the mounting nuts,
• Thinly apply engine oil to MAN Standard 3277 on make sure that the cable plugs do not
the ball cups and balls of the push rods (4) touch each other
• Insert the push rods (4)
• Connect the injector cable to the injector as
• Put on the valve bridges (3) as marked
marked
• Fit the rocker arm mechanism (1) so that the rocker
• Screw on the mounting nuts with the Torque
arm balls lie in the push rod ball cups
screwdriver [106] in conjunction with the
• Screw in the new mounting bolts (2)
Adapter [107] and Socket, size 7 [108] and
• Tighten the new mounting bolts (2) to Initial torque
then tighten to 1.5 Nm
90 Nm
• Thinly apply White T assembly paste on the cable
• Tighten the mounting bolts (2) to Final torque 90°
passage in the gasket (2)
Fitting the gasket • Insert the injector cable (1) into the cable passage
in the gasket (2)
Technical data
Intake valve clearance ................................................................................................................ 0.50 mm
Exhaust valve clearance ............................................................................................................. 0.80 mm
Rocker arm adjusting screw lock nut................................................................................................45 Nm
Service products
White T assembly paste..................................................................................................... 09.16012-0122
Important information
WARNING
Engine damage caused by incorrectly set valves
• Do not adjust the valves unless the engine is cold
Special tools
Checking and setting the valve Cranking the engine to the setting position
clearance
Removing the cylinder head cover, cylinder 1
Setting the intake valve clearance Setting the exhaust valve clearance
• Undo the lock nut (4) • Undo the lock nut (4)
• Turn back the adjusting screw (5) until the Holding • Turn back the adjusting screw (5) until the Holding
xture [109] (1) with Feeler gauge leaf 0.5 [110] xture [109] (1) with Feeler gauge leaf 0.8 [111]
(2) can be inserted between the ball socket (6) (2) can be inserted between the ball socket (6)
and the valve bridge (3) and the valve bridge (3)
• Screw in the adjusting screw (5) until the Holding • Screw in the adjusting screw (5) until the Holding
xture [109] (1) with Feeler gauge leaf 0.5 [110] xture [109] (1) with Feeler gauge leaf 0.8 [111] (2)
(2) can be moved between the ball socket (6) and can be moved between the ball socket (6) and the
the valve bridge (3) with little resistance (suction) valve bridge (3) with little resistance (suction)
• Brace the adjusting screw (5) with the Valve • Brace the adjusting screw (5) with the Valve
adjusting spanner, size 14 [112] adjusting spanner, size 14 [112]
• Brace the adjusting screw (5) and tighten the lock • Brace the adjusting screw (5) and tighten the lock
nut (4) to 45 Nm nut (4) to 45 Nm
• Check the setting once more • Check the setting once more
Checking the exhaust valve clearance Mounting the cylinder head cover
• Insert the Holding xture [109] (1) with Feeler • Put on the cylinder head cover (1)
gauge leaf 0.8 [111] (2) between the valve bridge • Screw in the mounting bolts (2) and tighten them
(3) and the ball socket (4)
Adjust the valve clearance if the valve clearance is
not 0.80 mm
VALVE TIMING
CAMSHAFT
Removing and installing the camshaft/camshaft bearing
Additional jobs
– Removing and mounting the heat exchanger, see 93
– Removing and installing the coolant manifold, see 111
– Removing and installing the charge-air pipes, see 325
– Removing and installing the intercooler, see 331
– Removing and Installing the coolant manifold, see 123
– Removing and installing the coolant pump, see 131
– Removing and installing the starter, see 143
– Removing and installing the vibration damper, D2868 LE4xx, see 457
– Removing and installing the turbocharger (two-stage variant), see 301
– Removing and installing the injectors, see 191
– Removing and installing the air distributor pipes, see 339
– Removing and installing the ywheel, see 469
– Removing and installing the oil sump, see 433
– Removing and installing the oil pumps, see 437
– Removing and installing the oil injector nozzles, see 431
– Removing and installing the pistons and connecting rods, see 477
– Removing and installing the cylinder head, see 359
– Removing and installing the cover, see 519
– Removing and installing the ywheel housing, see 521
– Removing and installing the rear timing gears, see 401
– Removing and installing the front radial shaft seal, see 445
– Removing and installing the rear radial shaft seal, see 448
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
WARNING
Danger of damage to the roller tappets
or anti-rotation devices
• Ensure that the anti-rotation device
engages in the roller tappet recess
• Insert the oil injector nozzle (2) into the crankcase • Position the axial shim (1)
• Screw in new mounting bolt (1) and tighten to • Screw in and tighten the new mounting bolts (2)
120 Nm
Mounting the camshaft gear
Installing the camshaft
VALVE TIMING
Checking the valve timing
Additional jobs
– Removing and Installing the engine cover, see 515
– Checking and setting the valve clearance, see 377
Technical data
Valve lift, V8 ..........................................................................................................................2.7 - 3.7 mm
Valve lift, V12 .................................................................................................................... 10.0 - 10.6 mm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Service products
Loctite 270 ........................................................................................................................ 04.10160-9062
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Component damage due to inadequate positive locking of the crankshaft gear because the
front face of the crankshaft gear is shot-peened
• The crankshaft gear must be replaced every time after the crankshaft gear screw connection is
unscrewed
Note
The intermediate gear and pin do not have to be exchanged as a set.
They can also be replaced individually, depending on the degree of wear.
Note
The intermediate gear to the air compressor is split into two sections and preloaded (noise
damping).
Backlash cannot be measured here.
Special tools
Setting the crankshaft gear to the marks Removing the rear timing gears
Fixing the crankshaft gear Removing the crankshaft gear
• Fix the crankshaft gear (2) by screwing in the • Screw in the Aligning punch [118] (2) and (3)
mounting bolts (1) and (3) • Pull off the crankshaft gear (1)
Setting the crankshaft gear to the marks Removing the power take-off intermediate gear
• Crank the engine on the engine barring gear until • Extract the power take-off intermediate gear (1)
the mark (1) is aligned with the mark (2)
Mark (1) and mark (2) are aligned.
Installing the rear timing gears Checking the crankshaft gear mark
ENGINE LUBRICATION
OIL MODULES
Removing and installing the oil lter
Technical data
Mounting bolts, oil separator ................................. 6x20 .................................................................. 11 Nm
Oil lter cover .................................................................................................................................45 Nm
Support dome ................................................................................................................................25 Nm
Important information
WARNING
Danger of engine damage due to oil emulsion
• Drain all the coolant before removing the oil module, otherwise coolant will enter the oil sump
when the oil module is removed from the crankcase
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the oil lter and oil separator Removing the support dome
WARNING
Engine oil contamination
• Always allow all of the engine oil to drain
• Undo the oil lter cover (3) 2-3 turns with the
Socket, size 36 [119]
• Unscrew and remove the oil lter cover (3) with
Socket, size 36 [119] after approx. 1-2 minutes
• Remove the oil lter insert (1) from the oil lter
cover (3)
• Remove the O-ring (2)
• Clean the mating faces
Installing the oil lter and oil separator Installing the oil separator
• Pull the new O-ring (2) onto the oil lter cover (3)
• Thinly apply clean engine oil on the O-ring (3)
• Insert the new oil lter insert (1) into the oil lter
cover (3)
• Screw in the oil lter cover (3) using the Socket,
size 36 [119] and tighten it to 45 Nm 45 Nm
Important information
WARNING
Danger of engine damage due to oil emulsion
• Drain all the coolant before removing the oil module, otherwise coolant will enter the oil sump
when the oil module is removed from the crankcase
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Danger of engine damage due to insufcient oil supply
• If an oil module is removed, the engine must be lled with engine oil to MAN Standard 3277
using the pressure application process before starting, see Filling the engine with oil using the
pressure application process, 416.
Attaching the right oil return lines Mounting the left oil module
• Position the oil return lines (1) and (3) so that they • Insert new O-rings (5)
are free of strain • Insert the mounting bolts (1) and (7) into the oil
• Tighten the union nuts for the oil return lines (1) module (2) as marked
and (3) • Position a new gasket (4) and x using mounting
• Mount the fastening (1) bolts (1) and (7)
• Position the oil module (2) with gasket (4) and
Left oil module tightening diagram mounting bolts (1) and (7)
• Screw in the mounting bolts (3) and (6)
• Screw in the mounting bolts (1) and (7)
• Tighten the mounting bolts (3) and (6) and undo
60°
• Tighten the mounting bolts (1) and (7)
• Tighten the mounting bolts (3) and (6)
• Position the oil return lines (1) and (2) so that they
are free of strain
• Tighten the union nuts for the oil return lines (1)
and (2)
• Mount the fastening (3)
Filling the engine with oil using the pressure application process
Additional jobs
– Draining the engine oil, see Operator's Manual
(1) Filler hose, electric oil pump (2) Filler hose, electric oil pump
Fill quantities
Total oil ll quantity, V8 - 1200 ............................... Engine oil to MAN Standard 3277 .....................62 litres
Total oil ll quantity, V12 - 1800 ............................. Engine oil to MAN Standard 3277 .....................92 litres
Important information
WARNING
Component damage due to oil overlling
• Do not ll the engine oil beyond the max. notch on the oil dipstick
WARNING
Component damage due to oil
overlling
• Do not ll the engine oil beyond the
max. notch on the oil dipstick
Technical data
Mounting bolts...................................................... M6X65 ..............................................................28 Nm
Mounting bolts...................................................... M6X95 ..............................................................28 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Technical data
Screw plug .......................................................... M33x2 ...............................................................85 Nm
Screw plug .......................................................... M26x1,5 ............................................................85 Nm
Screw plug .......................................................... M18x1.5 ............................................................27 Nm
Pressure-relief valve ............................................ M27x1.5 ............................................................42 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
• Unscrew the ttings (1) and (2) with the sealing • Screw in the screw plug (1) with a new sealing ring
rings and tighten to 85 Nm
• Screw in the pressure-relief valve and tighten to
Unscrewing the screw plugs 42 Nm
• Unscrew the screw plugs (1), (2) and (3) with the
sealing rings
• Screw in and tighten the screw plug (1) with a new
Removing the pressure-relief valve sealing ring
• Screw in the screw plug (2) with a new sealing ring
and tighten to 27 Nm
• Screw in the screw plug (3) with a new sealing ring
and tighten to 85 Nm
Technical data
Filter bypass valve (1)........................................... Opening pressure ...................................... 1.9 -2.9 bar
Relief valve (3) ..................................................... M27x1.5 ............................................................45 Nm
Relief valve (3) ..................................................... Opening pressure ........................................... > 10 bar
Screw plug, return-ow check valve (4).................. M32x1.5 ............................................................80 Nm
Return-ow check valve (4) ................................... Opening pressure ............................................. 0.2 bar
Important information
WARNING
Danger of engine damage due to oil emulsion
• Drain all the coolant before removing the oil module, otherwise coolant will enter the oil sump
when the oil module is removed from the crankcase
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Danger of engine damage due to insufcient oil supply
• If an oil module is removed, the engine must be lled with engine oil to MAN Standard 3277
using the pressure application process before starting, see Filling the engine with oil using the
pressure application process, 416.
Technical data
Oil lter cover (4) ............................................................................................................................45 Nm
Support dome (3) ...........................................................................................................................25 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
WARNING
Engine oil contamination
WARNING • Always allow all of the engine oil to drain
Component damage due to setting
aside the oil module incorrectly • Undo the oil lter cover (1) 2-3 turns with the
• Set aside the oil module so as not to Socket, size 32 [120]
damage the oil cooler The engine oil then drains into the oil sump via the
drain valve
• Mark the installation position of the mounting • Unscrew and remove the oil lter cover (1) with
bolts (1) Socket, size 32 [120] after approx. 1-2 minutes
• Unscrew the mounting bolts (1) • Remove the oil lter insert (3) from the oil lter
• Remove the oil cooler (3) with the gaskets (2) cover (1)
• Clean the mating faces • Remove the O-ring (2)
Removing the oil separator
Technical data
Mounting bolt (2) .................................................. M14x20-10.9....................................................120 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
Replace the mounting bolts when exchanging the oil injector nozzle.
Removing the oil injector nozzle Installing the oil injector nozzle
• Unscrew the mounting bolt (1) • Insert the oil injector nozzle (2) into the crankcase
• Extract the oil injector nozzle (2) from the • Screw in new mounting bolt (1) and tighten to
crankcase 120 Nm
OIL SUMP
Removing and installing the oil sump
Additional jobs
– Draining and topping up the engine oil, see Operator's Manual
– Removing and installing the crankcase ventilation, see 511
– Removing and installing the engine control units, see 49
Technical data
Oil level sensor..................................................... M18x1.5 ............................................................25 Nm
Service products
Curil T............................................................................................................................... 04.90300-9030
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
• Unscrew the union nuts from the oil return lines (1)
• Unscrew the mounting bolts (3)
• Unscrew the mounting bolts (2) • Position the holder on the oil return lines (1)
• Remove the mounting nuts (4) and holder • Insert the mounting bolts (2) and screw on the
• Remove the oil return lines (1) mounting nuts (4)
• Insert the oil return lines (1) into the oil sump so
they are strain-free
• Screw on the union nuts for the oil return lines (1)
• Screw in the mounting bolts (3)
• Tighten the union nuts for the oil return lines (1)
• Tighten the mounting nuts (4)
• Tighten the mounting bolts (3)
Installing the oil sump Installing the oil measuring probe and oil
dipstick
OIL PUMPS
Removing and installing the oil pumps
Additional jobs
– Removing and mounting the heat exchanger, see 93
– Removing and installing the vibration damper, D2868 LE4xx, see 457
– Removing and installing the alternator, see 149
– Removing and installing the coolant pump, see 119
– Removing and installing the oil modules (variant B), see 424
Technical data
Backlash, ring gear - crankshaft gear.............................................................................. 0.060 - 0.240 mm
Axial play, ring gear ....................................................................................................... 0.040 - 0.090 mm
Axial play, rotor.............................................................................................................. 0.035 - 0.080 mm
Oil pump mounting bolt ......................................... M6x40-10.9 .......................................................15 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Put the Dial gauge holder [121] (2) with the Dial • Position the oil pumps (2) and (3)
gauge [122] (1) on the oil pump • Screw in the new mounting bolts (1) and (4) as
• Position the Dial gauge [122] (1) against the ring marked and then tighten them by hand
gear (3) with a preload • Tighten the mounting bolts (1) and (4) to 15 Nm
• Press the ring gear (3) towards the drive gear
• Zero the Dial gauge [122] (1) Mounting the cover
• Press the ring gear (2) towards the Dial
gauge [122] (1) and check the difference
The permissible axial play on the ring gear (3) is
0.040 - 0.090 mm.
Note
Mount the gasket with the textured side
facing the crankcase.
Important information
WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or grease before
installation.
• Clean the vibration dampers and installer sleeve before assembly
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the front radial shaft seal Installing the front radial shaft seal
Important information
WARNING
Component damage due to inadequate positive locking of the crankshaft gear because the
front face of the crankshaft gear is shot-peened
• The crankshaft gear must be replaced every time after the crankshaft gear screw connection is
unscrewed
WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or grease before
installation.
• Clean the crankshaft gear and installer sleeve before assembly
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Extracting the rear radial shaft seal Checking the valves for unobstructed
movement, 1st cylinder
Removing the cylinder head cover, cylinder 1
• Check the 1st cylinder rocker arms (1) and (2) for
• Unscrew the mounting bolts (2) unobstructed movement
• Remove the cylinder head cover (1) If the rocker arms (1) and (2) for the rst cylinder
cannot move unobstructed, crank the engine a
Attaching the engine barring gear further 360° at the hexagon prole of the engine
barring gear.
Mounting the special tool Installing the rear radial shaft seal
Installation position of crankshaft gear
WARNING
Component damage due to
insufciently tight t
• Replace the crankshaft gear every
time after the crankshaft gear/ywheel
screw connection is undone
• Screw the Hexagon bolt [129] (6) into the Extractor • Screw in the Aligning punch [136] (6) and (9)
device [131] (2) and press the crankshaft gear (3) • Align the alignment pin (3) for the crankshaft gear
off the crankshaft (1) with the bore in the crankshaft (2)
• Unscrew the ywheel bolts (5) and (8) • Put on the new crankshaft gear (1) and install
• Detach the Extractor device [131] (1) and remove using a soft hammer until the stop is reached
with the Bush [130] (4)
• Pull off the crankshaft gear (3) over the Aligning
punch [136] (4) and (7)
• Unscrew the Aligning punch [136] (4) and (7)
• Remove the radial shaft seal (2) from the
crankshaft gear (3)
Checking the crankshaft gear marks in relation Pressing in the radial shaft seal
to the camshaft gear
CRANK MECHANISM
VIBRATION DAMPER
Removing and installing the vibration damper, D2868 LE4xx
Additional jobs
– Removing and installing the poly-V-belt guard, see 145
– Removing and installing the poly-V-belt, see 147
Technical data
Mounting bolt (3) .................................................. M10x25-10.9......................................................65 Nm
Mounting bolt (7) .................................................. M16x1.5x117-10.9.........................Initial torque 190 Nm
Mounting bolt (7) .................................................. M16x1.5x117-10.9................................Final torque 90°
Mounting bolt (10) ................................................ M10x30-10.9......................................................65 Nm
Important information
WARNING
Component damage due to reused mounting bolts
• Replace vibration damper mounting bolts once they have been undone
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Remove the cover with the gasket and the TDC Pulling off the vibration damper
marking plate from the ywheel housing
• Clean the mating faces
• Mount and lock the Engine barring gear [139] (1)
CAUTION
Danger of injury due to heavy
components
• Use the lifting device or lift off with
• Unscrew the mounting bolts (1) support
• Remove the engine barring gear (2) with spacer
washer (3) • Unscrew the remaining mounting bolts (1)
• Pull off the vibration damper (2)
Unscrewing the mounting bolts • Unscrew the Aligning punch [141] (3) and (4)
• Insert the hub (1) and the graduated disc (2) into
WARNING
the vibration damper (3) as marked
Component damage due to putting the
• Screw in new mounting bolts (4) and tighten them
vibration damper aside incorrectly
to 65 Nm
• Do not lay the vibration damper down
on the discs
Technical data
Mounting bolt (3) .................................................. M10x25-10.9......................................................65 Nm
Mounting bolt (8) .................................................. M16x1.5x117-10.9.........................Initial torque 190 Nm
Mounting bolt (8) .................................................. M16x1.5x117-10.9................................Final torque 90°
Mounting bolt (11)................................................. M10x30-10.9......................................................65 Nm
Important information
WARNING
Component damage due to reused mounting bolts
• Replace vibration damper mounting bolts once they have been undone
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Remove the cover with the gasket and the TDC Pulling off the vibration damper
marking plate from the ywheel housing
• Clean the mating faces
• Mount and lock the Engine barring gear [139] (1)
CAUTION
Danger of injury due to heavy
components
• Use the lifting device or lift off with
• Unscrew the mounting bolts (1) and remove with support
the washers (2)
• Remove the engine barring gear (3) and vibration • Mark the position of the vibration damper (2) in
damper (4) relation to the crankshaft
• Unscrew the remaining mounting bolts (1)
Unscrewing the mounting bolts • Pull off the vibration damper (2)
• Unscrew the (3) and (4)
• Insert the hub (1) and the graduated disc (2) into
WARNING
the vibration damper (3) as marked
Component damage due to putting the
• Screw in new mounting bolts (3) and tighten them
vibration damper aside incorrectly
to 65 Nm
• Do not lay the vibration damper down
on the discs
FLYWHEEL
Removing and installing the ywheel
Additional jobs
– Removing and installing the speed sensors, see 87
– Removing and installing the rear radial shaft seal, see 448
Technical data
Mounting bolt (1) .................................................. M18x1.5x91-12.9 ..........................Initial torque 100 Nm
Mounting bolt (1) .................................................. M18x1.5x91-12.9 .................................. 2nd torque 90°
Mounting bolt (1) .................................................. M18x1.5x91-12.9 .................................Final torque 90°
Installation temperature, ywheel ring gear ................................................................................ 220-240℃
Important information
WARNING
Component damage due to reused mounting bolts
• Replace ywheel mounting bolts once they have been undone
WARNING
Component damage due to inadequate positive locking of the crankshaft gear because the
front face of the crankshaft gear is shot-peened
• The crankshaft gear must be replaced every time after the crankshaft gear screw connection is
unscrewed
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
• Insert the Torque multiplier i = 1 : 3.3 [147] (1) into Screwing in the aligning punches
the Support [148] (2)
• Mount the Holding device [150] (5) with the Pan
head screw [152] (4) and the Adapter [155] (3) on
the Support [148] (2)
• Put the Angle measuring disc [149] (9) on the
Torque multiplier i = 1 : 3.3 [147] (1)
• Put the Socket, size 22 [146] (8) on the Torque
multiplier i = 1 : 3.3 [147] (1) and secure with
the Connecting pin [153] (7) and the Rubber ring
42 mm [154] (6)
• Insert one Socket, E24 [156] each into the Holding
device [150] (5) and the Socket, size 22 [146] (8)
CAUTION
Danger of injury due to heavy
components
• Use lifting gear to remove the ywheel WARNING
Danger of injury from metal chips
• Screw the Eye-bolt [157] into the ywheel • Wear protective equipment
• Attach the lifting gear in the Eye-bolt [157]
WARNING
• Pull off the ywheel (3) over the Aligning
Flywheel damage due to imbalance
punch [145] (1) and (2)
• Take care not to damage the ywheel
• Detach the lifting gear
when spot-drilling the ywheel ring gear
• Renew the spot-drilled ywheel
Note
The chamfers on the teeth of the ywheel
ring gear must point away from the CAUTION
ywheel. Danger of injury due to heavy
components
• Heat the ywheel ring gear (1) to 220-240℃ • Use lifting gear to install the ywheel
• Put the ywheel ring gear (1) on the ywheel (2)
WARNING
and adjust as necessary
Component damage due to reused
ywheel bolts
• Fit new mounting bolts once they have
been undone
Screwing in the ywheel mounting bolts Tightening the ywheel mounting bolts
Technical data
Connecting rod bearing bolt (10) ........................... M14x1.5x66-10.9 ..........................Initial torque 100 Nm
Connecting rod bearing bolt (10) ........................... M14x1.5x66-10.9 ............................Final tightening 90°
Connecting rods
Connecting rod length, small end bush centre - connecting rod bearing centre................ 282.45 - 282.5 mm
Piston diameter
D1 measured 16 mm above lower edge of piston .....................................................127.770 - 127.800 mm
Piston height
Overall height.................................................................................................................115.4 - 115.6 mm
Piston height from middle of piston pin to piston crown / PH level 0 .................................. 78.95 - 79.05 mm
Piston
Piston standout measured from crankcase to piston ................................................... -0.361 to +0.080 mm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Crack surfaces are sensitive. The principle involved can cause chipping
• Exchange the connecting rod if the crack surfaces are damaged
• Protect crack surfaces against damage caused by hard and sharp objects
• To clean the crack surfaces on the connecting rods, always rinse them in clean cleaning agent
• After cleaning, use compressed air to blow-dry the crack surfaces
• Do not allow rinsed-out particles to enter the engine
Note
The piston diameter is always measured perpendicular to the piston pin bore.
Special tools
• Installing pistons
Removing the pistons and connecting Remove the connecting rod bearing cap
rods
Undoing the connecting rod bearing bolts
WARNING
Crack surfaces are sensitive. The
• Installation position and allocation of the principle involved can cause chipping
connecting rod bearing shell and connecting • Exchange the connecting rod if the
rod bearing crack surfaces are damaged
• Turn the crankshaft to BDC for unscrewing the • Protect crack surfaces against damage
connecting rod bearing bolts (1) caused by hard and sharp objects
• Unscrew the connecting rod bearing bolts (1) by • To clean the crack surfaces on the
one turn connecting rods, always rinse them in
clean cleaning agent
• After cleaning, use compressed air to
blow-dry the crack surfaces
• Do not allow rinsed-out particles to
enter the engine
WARNING
• Measure the piston pin (1) using a micrometer (2)
Crack surfaces are sensitive. The
If the dimension of the gudgeon pin (1) is out of
principle involved can cause chipping.
tolerance of 54.994 - 55.000 mm, t a new piston
• Exchange the connecting rod if the
with gudgeon pin (1).
crack surfaces are damaged
• Protect crack surfaces against damage Measuring the piston ring axial play
caused by hard and sharp objects
• To clean the crack surfaces on the
connecting rods, always rinse them in
clean cleaning agent
• After cleaning, use compressed air to
blow-dry the crack surfaces
• Do not allow rinsed-out particles to
enter the engine
Note
The axial play cannot be measured on the
keystone ring
Measuring the connecting rod bearings Measuring the piston pin bore
Installing the pistons and connecting Piston installation with piston ring compressor
rods pliers
WARNING
Component damage due to incorrect
Note piston installation position
There is an arrow on the piston crown. • Check the direction of the arrow on the
piston crown
Installing the connecting rod bearing cap Tightening the connecting rod bearing shells
CRANKSHAFT
Removing and installing the crankshaft
Additional jobs
– Removing and mounting the expansion tank, see 105
– Removing and installing the coolant manifold, see 111
– Removing and installing the charge-air pipes, see 325
– Removing and installing the starter, see 143
– Removing and installing the poly-V-belt guard, see 145
– Removing and installing the alternator, see 149
– Removing and installing the hydraulic pump, see 157
– Removing and installing the vibration damper, D2868 LE4xx, see 457
– Removing and installing the vibration damper, D2862 LE4xx, see 463
– Removing and installing the turbocharger (two-stage variant), see 301
– Removing and installing the exhaust system, see 345
– Removing and installing the injectors, see 191
– Removing and installing the high-pressure lines and rails, see 163
– Removing and installing the air distributor pipes, see 339
– Removing and installing the ywheel, see 469
– Removing and installing the oil sump, see 433
– Removing and installing the oil pumps, see 437
– Removing and installing the pistons and connecting rods, see 477
– Removing and installing the cylinder head, see 359
– Removing and installing the cover, see 519
– Removing and installing the ywheel housing, see 521
– Removing and installing the rear timing gears, see 401
– Removing and installing the front radial shaft seal, see 445
– Removing and installing the rear radial shaft seal, see 448
Technical data
Mounting bolts, crankcase lower section (4) ........... M8x35-10.9 .......................................................35 Nm
Mounting bolts, crankcase lower section ................ M8x50-10.9 .......................................................35 Nm
Mounting bolts, crankcase lower section (1) ........... M10x170-10.9....................................................65 Nm
Mounting bolts, crankcase lower section (2) and
(3) ....................................................................... M18x2x200...................................Initial torque 160 Nm
Mounting bolts, crankcase lower section (2) and
(3) ....................................................................... M18x2x200........................................... 2nd torque 90°
Mounting bolts, crankcase lower section (2) and
(3) ....................................................................... M18x2x200............................................ 3rd torque 90°
Crankshaft dimensions
Crankshaft journal, normal dimension ................................................................... Ø 111.966 - 111.988 mm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9272
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
If the axial play is out of tolerance, install suitable Check the crankshaft bearing journal outside
thrust washers, see Miba thrust washer dimensions, diameter, see Checking the main bearing journal,
489, see Glyco thrust washer dimensions, 489. 501.
Undoing the inner crankcase lower section Undoing the inner crankcase lower section
mounting bolts, V8 engine mounting bolts, V12 engine
• Mark the tightening sequence 1 to 20 for the • Mark the tightening sequence 1 to 28 for the
mounting bolts mounting bolts
• Undo the mounting bolts 1 to 20 using the special • Undo the mounting bolts 1 to 28 using the special
tool tool
• Unscrew the mounting bolts 1 to 20 • Unscrew the mounting bolts 1 to 28
• Dismantle the special tool • Dismantle the special tool
Removing the crankcase lower section Removing the main bearing shells from the
crankcase lower section
Screwing in the centring pins Removing the crankshaft bearing shells from the
crankcase
CAUTION
Danger of injury due to incorrect lifting
gear • Insert the Bush [173] (2) into the crankshaft gear
• Use separate lifting gear with equal (5)
length for each centring pin • Insert the Extractor device [174] (1) into the
WARNING crankshaft gear (5)
Component damage due to incorrect • Clamp the Extractor device [174] (1) at the
lifting gear clamping bolts
• Do not use any lifting gear or steel • Screw in the Aligning punch [170] (4) and (7)
cables with sharp edges to lift out the • Screw the Hexagon bolt [172] (6) into the Extractor
crankshaft device [174] (1)
• Press the crankshaft gear (5) off the crankshaft (3)
• Attach the lifting gear using the centring pins by screwing in the Hexagon bolt [172] (6)
• Lift out the crankshaft (1) • Pull off the crankshaft gear (5) over the Aligning
• Unscrew the Aligning punch [169] at the front punch [170] (4) and (7)
• Unscrew the Aligning punch [170] at the rear • Detach the Extractor device [174] (1) and remove
with the Bush [173] (2)
• Unscrew the Aligning punch [170] (4) and (7)
Checking the crankshaft and crankshaft Checking the crankshaft bearing shell inside
bearings diameter
Installation instructions for crankcase lower Tightening sequence for outer mounting bolts,
section V8 engine
Tightening sequence for inner mounting bolts, Tightening sequence for inner mounting bolts,
V8 engine V12 engine
• Tighten the mounting bolts 1 to 20 as per the • Tighten the mounting bolts 1 to 28 as per the
tightening sequence (1-20) tightening sequence (1-28)
Screwing in the crankcase lower section Checking the crankshaft axial play
mounting bolts
• Position the Dial gauge [165] (1) with the Dial • Align the marks on the crankshaft gear (1) and
gauge holder [166] (3) and Locating pin [167] on camshaft gear (2) with one another
the crankshaft (2) with a preload If the marks (1) and (2) do not match up, remove the
• Push the crankshaft (2) into the end position, crankshaft gear and install it again with the marks
towards the Dial gauge [165] (1) (1) aligned with the mark on the camshaft gear (2).
• Zero the Dial gauge [165] (1)
• Pull the crankshaft (2) in the opposite direction
The permissible radial play on the crankshaft (2) is
0.060 - 0.128 mm.
CRANKCASE
CRANKCASE VENTILATION
Removing and installing the crankcase ventilation
Additional jobs
– Draining and topping up the coolant, see Operator's Manual
– Removing and Installing the engine cover, see 515
– Removing and mounting the expansion tank, see 105
– Removing and installing the poly-V-belt, see 147
Service products
Renolit Si 704 silicone grease ............................................................................................ 09.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
Removing the crankcase ventilation Detaching the left oil return lines
• Position the oil return lines (1) and (2) so that they
are free of strain • Thinly apply Renolit Si 704 silicone grease on the
• Tighten the union nuts for the oil return lines (1) moulded hose contact surfaces
and (2) • Position the vent line (5) with the jubilee clips (1)
• Mount the fastening (3) and (2)
• Mount the jubilee clips (1) and (2) using the Hose
clamp pliers for jubilee clips [186]
• Position the bush (4) and then screw in and tighten
the mounting bolt (3)
ENGINE COVER
Removing and Installing the engine cover
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Removing the engine cover Removing the engine cover side section
Removing the rear engine cover attachment Mounting the engine cover
points
Mounting the engine cover centre piece (V12
only)
Installing the engine cover side section Mounting the rear engine cover
attachment points
COVER
Removing and installing the cover
Additional jobs
– Removing and installing the poly-V-belt guard, see 145
– Removing and installing the alternator, see 149
– Removing and mounting the expansion tank, see 105
– Removing and installing the coolant pump, see 119
– Removing and installing the vibration damper, D2868 LE4xx, see 457
– Removing and installing the vibration damper, D2862 LE4xx, see 463
– Removing and installing the crankcase ventilation, see 511
– Removing and installing the oil modules (variant B), see 424
– Removing and installing the front radial shaft seal, see 445
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
FLYWHEEL HOUSING
Removing and installing the ywheel housing
Additional jobs
– Removing and installing the charge-air pipes, see 325
– Removing and installing the coolant manifold, see 111
– Removing and Installing the coolant manifold, see 123
– Removing and installing the coolant pump, see 131
– Removing and installing the exhaust manifold (two-stage variant), see 278
– Removing and installing the turbocharger (two-stage variant), see 301
– Removing and installing the high-pressure pump/high-pressure pump drive, see 205
– Removing and installing the starter, see 143
– Removing and installing the ywheel, see 469
– Removing and installing the rear radial shaft seal, see 448
– Removing and installing the hydraulic pump, see 157
Technical data
Speed sensor, crankshaft...................................... M6x16 ................................................................ 8 Nm
Speed sensor, camshaft ....................................... M6x16 ................................................................ 8 Nm
Service products
Renolit Si 704 silicone grease ............................................................................................ 04.15014-0102
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Note
When retting the ywheel housing, always use new sealing rings, gaskets and mounting bolts.
Thoroughly clean the mating faces.
Removing the ywheel housing Detaching the oil return line - turbocharger, 2nd
stage, left
Removing the crankshaft speed sensor
• Unclip the jubilee clips (1) and (6) using the Hose
• Disconnect the electrical connection clamp pliers for jubilee clips [72]
• Unscrew the mounting bolt (1) • Unscrew the mounting bolt (5)
• Extract the speed sensor (2) • Remove the oil return line (3)
• Remove the hoses (2) and (4)
Removing the camshaft speed sensor
Detaching the oil return line - turbocharger, 1st
stage, right
Removing the left exhaust manifold support Removing the right engine mount
• Unscrew the mounting bolts (2) and (3) • Unscrew the mounting bolts (1)
• Remove the bracket (1) • Remove the engine mount (1) with the mounting
plate (2)
Removing the right exhaust manifold support
Removing the ywheel housing
Attaching the oil return line - turbocharger, 2nd Installing the camshaft speed sensor
stage, left
Technical data
Screw plugs ......................................................... M38x1.5 ..........................................................240 Nm
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
• Unscrew the mounting bolts (3) • Unscrew the screw plugs (1) and (2) with the
• Remove the cover (2) with gasket (1) sealing rings
• Clean the mating faces
CYLINDER LINER
Removing and installing the cylinder liner
Additional jobs
– Removing and installing the intercooler, see 331
– Removing and installing the coolant manifold, see 111
– Removing and installing the charge-air pipes, see 325
– Removing and installing the turbocharger (two-stage variant), see 301
– Removing and installing the exhaust system, see 345
– Removing and installing the injectors, see 191
– Removing and installing the oil sump, see 433
– Removing and installing the cylinder head, see 359
Technical data
Cylinder liner standout ................................................................................................... 0.035 - 0.085 mm
Depth of collar recess in crankcase .............................................................................. 9.985 - 10.015 mm
Service products
Engine oil..................................see Maintenance Recommendations and Recommended Service Products
Important information
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
Special tools
WARNING
• Place the Measuring plate [191] (2) on the cylinder Component damage due to damaged
liner or bent oil injector nozzles
• Screw in the Bolt [192] (4) with the Washer [193] • Insert Extractor device [187] without
and tighten to 40 Nm damaging the oil injector nozzle
• Place the Dial gauge holder [189] (5) with Dial
gauge [190] (3) on the Measuring plate [191] (2) • Mark the cylinder liners (1) to indicate their correct
• Place the dial gauge tip (1) on the crankcase assignment and installation position
• Zero the Dial gauge [190] (3) • Mount the Extractor plate [188] (1) on the Extractor
• Carefully place the dial gauge tip (1) on the device [187] (3)
cylinder liner and note the difference on the dial • Carefully push the Extractor device [187] (3) with
gauge folded Extractor plate [188] (1) into the cylinder
The permissible cylinder liner standout is 0.035 - liner (2)
0.085 mm.
Extracting the cylinder liner
If the cylinder liner standout is out of tolerance, t a
new cylinder liner/crankcase.
SPECIAL TOOLS
Technical data
Crankcase
Basic version: 163.50−163.60 mm
9.97−9.99 mm
Cylinder liner
Basic version: 10.04−10.07 mm
127.990−128.010
Wear limit:
0.15 mm under basic dimension
Crankshaft
111.5 mm
39.000−39.080 mm
Crankshaft
Main bearing
2.961−2.973 mm
Mounting bolts
Lower crankcase section
Loosened bolts must be replaced with new
ones.
Ø Flywheel: 432.490−432.645 mm
Overlap: 0.335−0.587 mm
Installation temperature: 200−230_C
Conrods
55.060−55.075 mm
Conrod bearings
2.480−2.495 mm
Spread: 2.0 mm
If traces of wear are present
(scoring, running surface damaged), replace
both bearing shells
Caution: note installed position (rod shell has
red marking on side)
Pistons
127.770−127.800 mm
55.060−55.080 mm
Piston pin diameter:
54.994−55.000 mm
2.965 − 2.995 mm
2.580−2.610 mm
3.530−3.560 mm
Piston rings
Cylinder head
18.100−18.500 mm
Exhaust valve:
Ø inner valve guide 9.015-9.030 mm
Intake valve:
Ø inner valve guide 9.015-9.030 mm
Outer spring
Length (L*) untensioned, approx. 62.62 mm
Spring force at L = 45.0 mm: 430-470 N
Spring force at L = 33.0 mm: 714-790 N
The lowest spring force is at the same time
the wear limit value.
Valve train
33.959-33.975 mm
Rocker arm
Rocker arm radial play: 0.030-0.066 mm
Rocker arm axial play: max. 0.51 mm
34.005-34.025 mm
Camshaft
79.910-79.940 mm
Camshaft bearing bushing inner diameter:
80.000-80.061 mm
Valve tappets
38.975-39.000 mm
Valve clearance
set when engine is cold
Intake valve: 0.5 mm
Exhaust valve: 0.8 mm
Valve timing
1 = Engine cranking direction
1 2 = Intake valve opens 24_ before TDC
2 TDC 3 3 = Exhaust valve closes 27_ after TDC
4 = Exhaust valve opens 63_ before BDC
5 = Intake valve closes 36_ after BDC
6 = Exhaust valve opening angle 270_
7 = Intake valve opening angle 240_
The degrees specified refer to the crankshaft
6 7 angle
BDC
Compression pressures
good above 16 bar
permitted 13-16 bar
repair required below 13 bar
Pressure difference (between the individual cylinders) max. 3 bar
Engine lubrication
Oil pump
Outer rotor
Axial play 0.04−0.09 mm
Radial play 0.122−0.194
Inner rotor
Axial play 0.035−0.080 mm
Radial play 0.025−0.061
Gear axial play: 0.060−0.240 mm
Gear width 24/30/34 mm
Cooling system
Thermostat
Opening begins at: 86_ C ("1.5_)
Full opening: 96_ C
at 9.5 mm valve lift
Starter motor
Manufacturer: Mitsubishi
Method of operation:
sliding gear
Starter pinion
no. of teeth: Z = 11
Module: 3.5
Alternator
Manufacturer: Bosch
Type: N1
Design: 1 pole, insulated
Method of operation:
3−phase
Rated voltage: 28.5 V
Maximum current: 120 A
Turbocharger
Manufacturer BorgWarner
Type D2868LE433 1st stage K3NS−089G84FN35A01JC
D2868LE433 2nd stage K2CS−082G87FN26A01CN
Type D2868LE433 1st stage K3NS−104G84GN35A01JC
D2868LE433 2nd stage K3CS−089G90FN32A01CN
Note:
All bolted connections, the purpose of which is not stated in the following table, are to be tigh-
tened in accordance with the guideline values given in our Works Standard M 3059 (see page
570). Oil bolts lightly prior to assembly!
Screw plugs
DIN 908
M14x1.5, M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
M18x1.5, M22x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
M24x1.5, M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
M30x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
DIN 7604
AM10x1, M12x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
AM14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Cylinder head
Camshaft
Lubrication system
Cooling system
Fuel system
Exhaust/intake manifold
Sensors
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