MAN Engine - Repair Manual - Model D2876LE201

Foreword
This Repair Manual is designed to facilitate proper repair of the engines listed here.
The pictures and associated descriptions show typical work that may not always be applicable to the en-
gine in hand, which nevertheless does not mean that they are not correct.
In such cases, the repair work is to be planned and carried out in a similar way.
It is compulsory that the engine be removed before performing any of the work described in this Repair
Manual.
The expert knowledge necessary for handling diesel engines was taken for granted when this publication
was compiled.
Note:
Only use fuel, coolants and lubricants in accordance with MAN regulations, otherwise the manu-
facturer’s warranty will not apply!
For basic information on the fuels see the publication “Fuels, Lubricants and Coolants for MAN
Diesel Engines”.
You can find the approved products on the Internet at:
−http://www.man-mn.com/ " Products & Solutions " E-Business−
Any repair of components such as injection pump, alternator etc. ought to be left to our or the manufac-
turer’s service department.
Best regards
MAN Nutzfahrzeuge Aktiengesellschaft
Nuremberg Plant
Since our products are in continuous development, we reserve the right to make technical modifications.
© 2005 MAN Nutzfahrzeuge Aktiengesellschaft
Reprinting, copying or translation, even of extracts, is not allowed without written permission from MAN.
All rights under the copyright law are strictly reserved by MAN.
MTDB Technical status: 04.2005 51.99598−8138
1
Instruction
Important instructions concerning technical safety and personal protection are, as shown below, especially
highlighted.
Danger:
This refers to working and operating procedures which must be complied with in order to rule out
the risk to persons.
Caution:
This refers to working and operating procedures which must be complied with in order to prevent
damage to or destruction of material.
Note:
Explanatory descriptions which help in understanding the relevant work or operating procedure to
be carried out.
Fitting flat seals / gaskets
Gaskets are frequently used with sealants or adhesives as an aid to assembly or to achieve a better seal.
Above all when parts with different levels of thermal expansion (e.g. aluminium and cast iron) are bonded,
this can mean that the gasket is shifted during operation by the so-called stitching or sewing machine effect
and leaks occur.
Example: The cap of the front crankshaft seal. If a sealing agent or an adhesive is used here the flat seal
will move inwards in the course of time as a result of the different expansion rates of the materials. Oil will
be lost, for which the shaft seal may be thought to be responsible.
Perfect assembly of gaskets can only be achieved if the following instructions are adhered to:
D Use only genuine MAN seals / gaskets.
D The sealing faces must be undamaged and clean.
D Do not use any sealing agent or adhesive − as an aid to fitting the seals a little grease can be used if
necessary so that the seal will stick to the part to be fitted.
D Tighten bolts evenly to the specified torque.
Assembly of round sealing rings

D Use only genuine MAN round sealing rings.
D The sealing faces must be undamaged and clean.
D Always wet round sealing rings with engine oil before fitting them.
2
Instruction
Masking of fuel and lube oil pipe con-

nections (for classified engines only)
The unions of pressurised oil and fuel pipes are
masked with a protective tape.
If this tape is removed during a repair, the unions
must be masked with protective tape again after-
wards.
The following pipes are affected:
− Oil supply pipe to turbochargers
− Fuel pipes between supply pump, filter and
injection pump
− Injection pipes protected against leaks 1
Fig. 1
A protective tape is wound around the unions. En-
sure that there is 50 % overlap on every pass.
Figs. 2−4
The unions to be masked must be clean and free
of oil and grease.
Do not apply the protective tape unless this is the
case
2
3
Contents
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General notes on engine overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Commissioning after engine overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine lubrication schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine views D 2876 LE 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel system schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fuel system
Checking and setting start of fuel delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removing and installing the injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removing and installing fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Checking and repairing fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Replacing the fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Venting fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cooling system
Draining coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removing and installing thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removing and installing the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassembling the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fan radiator for engine coolant and combustion air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cleaning cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Lubrication system
Servicing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removing and installing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removing and installing, repairing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removing and installing the oil spray nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Flywheel / Crankshaft seals

Removing and installing the vibration damper, replacing the front crankshaft seal . . . . . . . . . . . . . . . 51
Removing and installing the flywheel, replacing the starter gear ring . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Replacing the crankshaft seal (flywheel end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Replacing the bearing race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Crankshaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Intake- and exhaust system

Removing and installing the intake manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Servicing the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Removing and installing the exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Turbocharger, troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Checking charging pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Removing and installing the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Measuring the axial / radial clearance or the turbocharger shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cylinder head
Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Setting the valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Dismantling and assembling the rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Removing and installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Removing and installing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4
Contents
Cylinder head
Replacing valve seat insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Reworking valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Refacing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Valve timing
Removing and installing the timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Removing and installing the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Removing and installing camshaft bearing bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Checking the valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Crankgear, pistons
Removing and installing the crankcase yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Removing and installing the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Removing and installing pistons with conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Removing pistons from conrod and installing, checking − replacing conrod . . . . . . . . . . . . . . . . . . . . 107
Removing and installing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Replacing cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Measuring piston protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Attachments
Removing and installing the starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Servicing V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Electronic speed governor GAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Troubleshooting with GAC governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Removing and installing the speed pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Overspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Coolant level probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Service Data
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Flywheel and starter motor gear ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Speed pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Torque guide values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5
Safety regulations
General
Important safety regulations are summarized in this quick-reference overview and arranged by topic to ef-
fectively convey the knowledge necessary to avoid accidents causing injury, damage or environmental haz-
ard. Additional information can be found in the operating instructions of the engine.
Important:
Should an accident occur despite all precautionary measures, particularly one involving contact with corros-
ive acid, penetration of fuel under the skin, scalding by hot oil, antifreeze splashing into the eyes etc. you
must seek medical assistance immediately.
1. Regulations designed to prevent accidents with injury to persons
Checks, setting jobs and repair work must be carried out by authorised skilled personnel only.
D When carrying out maintenance and repair work, ensure that the engine cannot be
accidentally started from the bridge by unauthorised persons.
D The engine may only be started and operated by authorised personnel.
D When the engine is running, do not get too close to the rotating parts.
Wear tight-fitting working clothes.
D Do not touch hot engine with bare hands: Risk of burns.
ËË
D Keep area surrounding engine, ladders and stairways free of oil and grease. Accidents
caused by slipping can have serious consequences.
D Only work with tools which are in good condition. Worn spanners/wrenches slip: Danger
of injury.
D Persons must not stand under an engine suspended on a crane hook. Keep lifting gear
in order.
D Open the coolant circuit only when the engine has cooled down. If opening the coolant
circuit while the engine is hot is unavoidable, observe the instructions in the chapter
”Maintenance and care” in the Operator’s Manual.
D Do not tighten or undo pipes and hoses under pressure (lubricating oil circuit, coolant
circuit and any downstream hydraulic oil circuits).
The fluids which flow out can cause injury.
D When checking the injection nozzles, do not hold your hands in the fuel jet. Do not in-
hale fuel mist.
6
Safety regulations
D When working on the electrical system, first disconnect the earth cable of the battery
and reconnect this last to prevent short circuits.
D Follow the manufacturer’s instructions for handling batteries.

Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.
D When performing welding work, observe the “Notes for welders”.
2. Regulations designed to prevent damage to engine and premature wear
D The engine must be cleaned thoroughly prior to repair. Ensure that dirt, sand or foreign matter
will not get into the engine during repair work.
D If engine operation is disrupted, immediately determine the cause and have it remedied to prevent addi-
tional damage.
D Always use genuine MAN parts only.Installation of “equally” good parts from other suppliers may cause
severe damage for which the workshop carrying out the work is responsible.
D Never allow the engine to run dry, i.e. without lubricant or coolant.
Appropriate notices must be attached to engines that are not ready for operation.
D Use only MAN-approved service products (fuel, engine oil, anti-freeze and anti-corrosion agent). Pay
attention to cleanliness. Diesel fuel must be free of water.
D Do not fill engine oil beyond the max. notch on the dipstick. Do not exceed the maximum per-
missible tilt of the engine.
Serious damage to the engine may result if these instructions are not adhered to.
D Control and monitoring devices (charge control, oil pressure, coolant temperature) must be in perfect
working order.
D Observe the instructions for operating the alternator; see chapter “Maintenance and care” in the Oper-
ator’s Manual.
3. Regulations designed to prevent pollution
Engine oil and filter cartridges and elements, fuel / fuel filters
D Old oil must be passed on for recycling.
D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground.
Caution:
The drinking water supply could be contaminated.
D Filter elements are classed as dangerous waste and must be treated as such.
Coolant
D Treat undiluted corrosion protection agents and / or antifreeze as hazardous waste.
7
Safety regulations
D When disposing of used coolant, the regulations issued by the relevant local authorities must be ob-
served.
4. Notes on safety in handling used engine oil *
Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin. Drying, ir-
ritation or inflammation of the skin may therefore occur. Used engine oil also contains hazardous sub-
stances that have caused skin cancer in tests on animals. If the basic rules of hygiene and health and
safety at work are observed, health risks are not to the expected as a result of handling used engine oil.
Health precautions:
D Avoid prolonged or repeated skin contact with used engine oil.
D Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
D Clean skin which has been in contact with engine oil.
− Wash thoroughly with soap and water. A nail brush provides effective assistance here.
− Certain products make it easier to clean your hands.
− Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
D After washing apply a fatty skin cream to the skin.
D Change clothing and shoes that are soaked in oil.
D Do no put oily cloths in you pockets.
Ensure that used engine oil is disposed of in the appropriate manner.

− Engine oil is a substance that endangers the water supply −
For this reason do not let engine oil get into the ground, waterways, the drains or the sewers.
Violations are punishable.
Carefully collect and dispose of used engine oil. Information on collection points can be obtained from sales
personnel, the supplier or the local authorities.
∗ Based on “Information sheet for handling used engine oil”.
8
Fault table
Operating faults and possible causes
We recommend
A repair is only complete when both the damage that occurred and the possible causes have been elimin-
ated. Finding out the cause of damage is often more difficult than repairing the damage that occurred. We
therefore recommend that you obtain a precise description of the operating fault before removing and dis-
mantling components. Then use a process elimination (questions) to pinpoint the probable causes and in-
vestigate and eliminate these successively on the basis of the table and your own experience. This helps
to reduce repairs to the required scale and to counteract claims regarding “overeager” replacement of parts
and complaints about expensive work and down time.
Note:
The following list is conceived as an aid to memory for experts so that to causes of damage are overlooked
when dealing with faults. The precondition for this, however, is that the experts are familiar with the Repair
Manual for the engine as well as the accompanying Operating Instructions and the publication “Fuels, Lu-
bricants and Coolants for MAN Diesel Engines”.
9
Fault table
1. Starter turns over engine only slowly or not at all

2 Starter motor turns engine, engine does not start
3. Engine does not start while cold
4. Engine does not run smoothly, and stops
5. Speed fluctuations during operation
6. Slow, periodic fluctuation of speed (approx. 0.5−1 Hz)
7. Quick periodic fluctuation of speed (approx. 8−12 Hz)
8. Engine cannot be switched off
9. Performance unsatisfactory
10. Coolant temperature too high, coolant loss
11. Lubricating oil pressure varies / too low
12. Lubricating oil consumption too high
13. Fuel consumption too high
14. Black smoke
15. Blue smoke
16. White smoke
17. Engine knocks
Possible causes
x Battery main switch in “off” position
x Batteries flat
x Battery cable connections loose or corroded
x x x Battery voltage at control unit is too low, see page 122
x Starter electromagnetic switch sticking (clicks)
x Cable connection from ignition lock to starter electromagnetic switch is loose or interrupted
x Starter motor defective (carbon brushes loosened, coil damaged, ground fault)
x Starter interlock relay defective
x x Fuel tank empty
x x Fuel valve shut
x x x x x Air in fuel system
x x x x x Fuel lines leaky, ruptured, clogged
x x x x Fuel filter / prefilter clogged
x Fuel filter clogged with paraffin, see “Fuels, Lubricants...”
x Fuel temperature too high
x x x x x x Unsuitable fuel, see “Fuels, Lubricants...”
x Fuel is slow to ignite, see “Fuels, Lubricants...”
x x Suction height of fuel delivery pump (max. 1m) exceeded
x x Fuel delivery pump faulty
x x Air supply/exhaust gas pipes clogged
x x x x x x x Delivery start incorrect
x x x x Valve clearance not correct
x x x x x x Injectors defective, leaking, worn
x x Injector needle sticking
x x x x x Compression insufficient
x Inlet chamber pressure of injection pump too low
x x x Injection pump defective
x Excessive friction in power transmission “actuator-linkage-control rod”
x Force of actuator too low
x x Actuator does not move control rod, see page 123
x “Actuator-linkage-control rod” transmission stiff / blocked
x x Electro-hydraulic shut-off valve (EHAB) without current
x Setting of the D proportion too small, see description of control unit
x Setting of the D proportion too large, see description of control unit
x Resonance vibrations in the drive / clutch, reduce sensitivity; see description of control unit
x Control rod not in full-load position
x x Speed pickup signal is inadequate, see page 124
x Temperature in engine room too high, combustion air and fuel too hot
x x x Supply of combustion air insufficient, intake vacuum too high
Intake or exhaust manifold pipe leaky
x Charge-air pipes leaky
x Intercooler contaminated
10
Fault table
1. Starter turns over engine only slowly or not at all

2 Starter motor turns engine, engine does not start
3. Engine does not start while cold
4. Engine does not run smoothly, and stops
5. Speed fluctuations during operation
6. Slow, periodic fluctuation of speed (approx. 0.5−1 Hz)
7. Quick periodic fluctuation of speed (approx. 8−12 Hz)
8. Engine cannot be switched off
9. Performance unsatisfactory
10. Coolant temperature too high, coolant loss
11. Lubricating oil pressure varies / too low
12. Lubricating oil consumption too high
13. Fuel consumption too high
14. Black smoke
15. Blue smoke
16. White smoke
17. Engine knocks
Possible causes
x x Turbocharger contaminated or defective
x x Turbocharger wear
x Coolant level too low
x Proportion of anti-freeze / anticorrosion agent too high, see “Fuels, lubricants...”
x Cap with working valves on expansion tank defective, leaky
x Thermostat in closed position blocked
x Radiator heavily contaminated
x V-belt for water pump drive not correctly tensioned (slipping)
x Water pump leaky, defective (bearing damage)
x Coolant circuit clogged by foreign matter
x Temperature indicator defective
x x Oil viscosity unsuitable (viscosity too high), see “Fuels, Lubricants...”
x Oil viscosity unsuitable (viscosity too low), see “Fuels, Lubricants...”
x Lubricating oil quality does not satisfy regulations, see “Fuels, Lubricants...”
x Oil level in oil pan too low
x Oil level in oil pan too high
x Automatic oil refill system incorrectly adjusted
x Max. inclination exceeded
x Oil pump gears heavily worn
x Safety valve in oil circuit defective (does not shut, spring fatigued or broken)
x Safety valve in oil circuit defective (does not open)
x Oil pressure gauge defective
x x x Engine in cold running phase
x Leaks in lubricating oil circuit, particularly at turbocharger and oil cooler
x x Piston rings heavily worn
x Heavy bearing wear
x x Valve guides heavily worn
x Crankcase breather clogged (excess pressure in the crankcase)
x Cylinder head gasket leaky / burned through
x Crank gear blocked
x Mainly low-load operation
11
General notes on engine overhaul
The service life of an engine is influenced by very different factors. It is therefore not possible to specify
certain fixed numbers of operating hours for general overhauls.
In our view, it is not necessary to open up and engine or perform a general overhaul
as long as the engine has good compression values and the following operating values have not changed
significantly in relation to the values measured on commissioning the engine:
D Boost pressure
D Exhaust temperature
D Coolant and lubricant temperature
D Oil pressure and oil consumption
D Smoke emissions
The following criteria greatly influence the length of the engine service life:
D Correct power output setting according to the type of application
D Technically correct installation
D Inspection if installation by authorised personnel
D Regular maintenance in accordance with the maintenance schedule in the Service Booklet
D Choice and quality of lubricating oil, fuel and coolant
Note:
Only use coolants that comply with MAN regulations.
For basic information on the consumable materials, refer to the publication “Fuels, Lubricants
and Coolants for MAN Diesel Engines”. You can find the approved products on the Internet at:
−http://www.mn.man.de/index/mn_eng/motor/serviceproducts.htm−
12
Commissioning after engine overhaul
Pressurisation
It is extremely important for internal combustion engines (following the completion of repair work, i.e. in
their dry state) to be pressurised with lubricating oil before being recommissioned. This procedure can also
be used for ascertaining damage and its causes.
If engines are not pressurised, the risk of premature damage to bearing surfaces is very high because it
takes a relatively long period of time for the lubricating oil drawn in from the oil pan via the oil pump to
reach the individual bearings.
Such incipient damage need not necessarily lead to immediate bearing failure, but may impair the proper
functioning of the bearings and reduce their service lives.
Diagram of the oil flow with unpressurised engines
13
Commissioning after engine overhaul
Pressurising an engine affords the following advantages:

D All engine parts are lubricated before engine startup; a lubricating film can be built up inside the bear-
ings as early as after the first few rotations of the crankshaft, thereby preventing damage to the bearing
races.
D Any loss of oil, be it the result of excessively large bearing play or leaks from the crankcase or from
crankcase bores which may not be plugged, can be detected immediately. For this purpose, mount the
engine on an assembly dolly, remove the oil pan and install a suitable oil collector under the crankcase
in such a way that the bearings are visible
Performance of pressurisation:
At least 30% of the total oil quantity is forced from the pressurisation container into the engine oil circuit.
The operating pressure serves as the yardstick for the pressure to be forced in and must not be exceeded.
The pressurisation container is connected up to the engine oil circuit at the oil filter head screw plug).
14
Engine lubrication schedule
7
6
9 1
10
2 3 4
1
À Oil suction pipe Å Bypass valve

Á Distributor pipe Æ Oil filter
Â Oil spray nozzle Ç Turbocharger
Ã Oil pump È Oil cooler
Ä Oil pressure relief valve É Injection pump
15
Engine views D 2876 LE 201
2 3
8
1
10 9
11
14
13
12
16
Engine views D 2876 LE 201
À Fan
Á Combustion air pipe to intercooler
Â Combustion air pipe from intercooler
Ã Crankcase breather
Ä Electro-hydraulic shut-off (EHAB)
Å Fuel strainer
Æ Fuel filter
Ç Injection pump
È GAC governor
É Oil dipstick
11 Air filter
12 Oil drain plug
13 Oil filter
14 Turbocharger
17
Cooling system diagram
1 2 3 4 5 6 1
12 11 10
À Overflow and ventilation line Æ Filling line

Á Positive pressure / negative pressure valve Ç Thermostat
Â Coolant level in the expansion tank È Engine / crankcase
Ã Expansion tank É Coolant pump
Ä Fluid filler neck 11 Fan
Å Degassing system 12 Coolant radiator / charge air cooler
18
Fuel system schedule
10
À Injection pump Å Overflow valve

Á Fuel filter Æ Fuel lift pump
Â Electro-hydraulic shut-off (EHAB) Ç Return line
Ã Injector È Suction line
Ä Fuel strainer É Fuel tank
19
Checking and setting start of fuel delivery
Checking start of delivery

Fig. 1
In order to enable the engine to be rotated man-
ually during adjustments, there is a plate with a
central hexagon driver fitted to the front of the
crankshaft pulley.
Turn engine to ignition TDC.
On 6-cylinder engines, cylinder 1 is at ignition TDC
if the valves of cylinder 6 are in crossover. Carry
out check by taking off valve cover.
Fig. 2
The speed pickup is fitted to the bottom right−hand
side of the flywheel housing. Remove the mounting
bolts from the retaining plate and take off plate to-
gether with the speed pickup.
Note:
As an alternative engine cranking tool,
the standard ratchet, special tool, see
page 157, Item 1, can be fitted.
Figs. 3 and 4
The picture shows the graduated scale on the fly-
wheel and the counter-marking visible when the
holding plate of the speed pickup is removed.
Turn the engine to the prescribed start of delivery
(see “Service Data”, page 145).
Note:
If possible, only turn the engine in the
direction of rotation (viewed on flywheel,
anticlockwise).
If the engine is turned beyond start of de-
livery, turn it back a few degrees and re- 3
peat the procedure.
To avoid read-off errors, always look over the

notch on the flywheel housing vertically to the
centre of the flywheel.
The marking on the graduated scale must be on
the imaginary “notch-flywheel centre” line.
20
Fig. 5
Remove screw plug for inspection hole in mounting
flange of injection pump.
Fig. 6
The start of delivery is correctly adjusted when the
markings can be seen through the inspection hole
to be opposite the pointer and injection pump hub.
Note:
If necessary, use a torch to light up the
inspection hole.
If the inspection reveals that the start of delivery is

set incorrectly, proceed as follows:
Setting start of delivery

Fig. 7
Unscrew the banjo bolt that secures the crankcase
breather.
Fig. 8
Remove the timing case cover.
21
Fig. 9
Loosen all bolts fastening the drive gear to the in-
jection pump hub. Two complete engine revol-
utions are necessary for this.
Turn the injection pump camshaft at the drive
flange either to the left or right until the marking
reaches the position shown in Fig. 6.
9
Fig. 10
Tighten the mounting bolts between the drive gear
and drive flange in sequence first to 5 Nm and
then to 38 Nm.
Check start of delivery again.
Close timing case.
10
22
Removing and installing the injection pump
Removing the injection pump

D Close shutoff valve from tank to engine
Note:
The subsequent reinstallation of the injec-
tion pump is rendered considerably
easier if before its removal the engine
has been turned to start of delivery. See
chapter “Adjusting start of delivery” on
page 20.
Fig. 1
Remove all fuel lines from the injection pump.
Caution:
The lines contain fuel!
Catch escaping fuel in a suitable con-
tainer.
Fig. 2
Remove the injection lines.
2
Fig. 3
After removal of the injection lines, we recommend
fitting caps to the connections on the injection
nozzles and injection pump.
This prevents dirt from getting into the injection
system.
Caution:
Dirt in the injection system causes:
D nozzles to jam
D the injection-pump drive gear to break
3
Fig. 4
Remove holders from injection pump.
23
Fig. 5
Remove the mounting bolts from the injection
pump flange.
Note:
For reasons of space, the mounting bolt
between the injection pump and the
crankcase (hexagon M10 bolt with re-
duced head 13 mm) can be reached only
with a 3/8” socket and an extension.
Take off injection pump.

5
Note:
Ensure meticulous cleanliness when
working on the injection pump.
Prevent dirt and foreign matter from pen-
etrating into opened line connections.
Installing injection pump

Fig. 6
Check whether engine is at start of delivery.
Fig. 7
Check whether the injection pump is at start of de-
livery. To do this, remove the screw plug from in-
jection pump flange.
Fig. 8
The start of delivery is correctly adjusted when the
markings can be seen through the inspection hole
to be opposite the pointer and injection pump hub.
Note:
If necessary, use a torch to light up the
inspection hole.
24
Fig. 9
Release the mounting bolts on the injection pump
drive gear so that it can be turned in the elongated
holes.
Hold the injection pump camshaft in place while
turning the gear.
Fit a new O-ring (lightly oiled) on the injection
pump flange.
Fig. 10
Insert the injection pump and tighten the mounting
bolts.
Tightening torque: . . . . . . . . . . . . . . . . . . . . . . 75 Nm
10
Fig. 11
Apply an initial torque of 5 Nm to all mounting bolts
on the gear through the inspection hole. Two com-
plete engine revolutions are necessary for this.
Now tighten all mounting bolts to 38 Nm.
Check and if necessary set start of delivery (see
Page 20).
Screw plug into mounting flange of injection pump.
Fit the fuel and injection lines without tension.
Caution:
Comply with instructions for masking
unions on pressurised oil and fuel pipes 11
(see page 3).
25
Removing and installing fuel injectors
Removing fuel injectors

Fig. 1
Remove injection lines and leak-off oil lines.
Fig. 2
Remove pressure screw from nozzle holder using
a pin spanner.
Fig. 3
Bolt inertia puller (Special tool, see page 157,
item. 15) on to fuel injector and knock out the in-
jector.
Fig. 4
Take out injector and copper seal.
Check and repair injector.
26
Removing and installing fuel injectors
Installing fuel injectors

Fig. 5
Treat the contact points of the nozzle holder with
“Never Seeze”. Screw in the nozzle holder and
nozzle with a new sealing ring.
Fig. 6
Screw on union nut and tighten to specified torque.
Connect the injection and leak-off oil lines.
Tighten pressure pipes to injector and injection
pump with specified torque.
Tightening torque: . . . . . . . . . . . . . . . . 120−125 Nm
27
Checking and repairing fuel injectors
Checking fuel injectors

Fig. 1
The nozzle tester (hand tester) is used to check
the
− opening pressure (injection pressure),
− leak−tightness and
− spray pattern of each injection nozzle.
Use pure calibrating oil or pure diesel fuel for the
test.
Prior to testing, clean the nozzle and check it for
wear.
1
Fig. 2
8
Check the nozzle with its nozzle holder. Connect
the pressure line of the tester to the injection 7
nozzle inlet connection. 6
Danger: 5
The high injection pressure can cause seri-
ous injury. Do not place hands under the
jet spray.
Wear safety goggles. 4
1. Checking opening pressure:

Switch on the pressure gauge and slowly press
lever downwards until the nozzle emits a jet with a 3
light grating noise.
Read opening pressure from the pressure
gauge. In the event of a pressure deviation, insert
a different shim. At pressure that is too low, insert 2
thicker shims; at pressure that is too high, insert
thinner shims Æ. After a long service life, the pre−
tension of the pressure springs Å drops. Conse-
quently, the injection pressure drops slightly. When 1
2
repairing injection nozzles, always set the opening
pressure to the upper limit (+ 8 bar).
À Seal
Note: Á Nozzle tension nut
Shims are available in Â Injection nozzle
0.02 mm steps from 1.0 mm to 1.98 mm. Ã Intermediate washer
Ä Pressure pin
Å Compression spring
2. Checking tightness:
Æ Shim
Actuate hand lever. At a pressure of 20 bar below
Ç Circlip
the set opening pressure, not a single drop must
fall from the nozzle opening within 10 seconds.
3. Checking jet:
Switch off pressure gauge and carry out some
swift strokes. The nozzle must emit an audible
grating noise and/or a well−atomised jet.
Nozzles that satisfy these three requirements can
be reused.
28
Dismantling the fuel injector

Fig. 3
Insert injector assembly (the inlet orifice facing
downwards) into the clamping device and hold in a
vice. Remove union nut and take out nozzle body,
intermediate washer, pressure pin, compression
spring and shim. Take pressure pipe neck out of
holder.
Repairing fuel injector

Fig. 4
Clean the inside of the nozzle body À with a
wooden rod and petrol or diesel fuel. Clean the 1
nozzle needle Á with a clean cloth.
Note:
To prevent corrosion, do not touch lapped
faces of nozzle needle with your fingers.
2
The needle and injection nozzle are
matched to each other and must not be
interchanged.
4
Check cleaned parts for wear and damage, replac-

ing them if necessary. De-grease new parts.
Assembling fuel injector

Fig. 5
Insert pressure pipe neck into clamping device.
Insert shim and compression spring.
Fig. 6
Check intermediate piece for wear.
Insert pressure pin and intermediate washer.
29
Fig. 7
Dip nozzle body and nozzle needle separately into
filtered Diesel fuel and check their gliding quality.
When pulled out of the nozzle body by up to a third
of its length, the nozzle needle must sink back to
its seat under its own weight when released. Place
injection nozzle on top, ensuring that the asso-
ciated pins are correctly fitted.
Fig. 8
Screw on the nozzle tension nut and tighten with
the prescribed torque.
Check injector on the manual test stand.
Ensure that the sieve bar filter is correctly

seated in the injector body.
Fig. 9
A dislocated sieve bar filter throttles and prolongs 8
the injection and consequently causes poor per-
formance, high consumption and heavy smoke
formation in conjunction with heavy engine vibra-
tions.
For this reason, measure the rim offset of the
sieve bar filter in the nozzle holder inlet.
The sieve bar filter must not be pressed into the
nozzle holder farther than approx 5 mm.
In the event of larger rim offsets, the nozzle holder 1
is to be replaced. 9
30
Fuel prefilter
Cleaning fuel prefilter

D Close cut-off valve from fuel tank to engine.
Figs. 1 and 2
Undo the fastening bolts of the filter housing and
remove the housing.
Catch escaping fuel in a suitable container.
Fig. 3
Clean filter housing and strainer in clean diesel fuel
and blow out with compressed air
Reassemble fuel prefilter using new seal.
3
Fig. 4
Operate the plunger on the hand pump until the
overflow valve in the injection pump can be heard
to open
Check fuel pre-filter for leaks while engine is run-
ning.
Note:
When bleeding the fuel system switch on
the electromagnetic shut-off valve (EHAB)
without fail (ignition on), as otherwise fuel
cannot reach the injection pump suction
gallery / suction chamber.
Wiring diagram see page 125.
4
31
Servicing the fuel filter
Replacing the fuel filter cartridge

3
Fig. 1
À Disposable filter 2
Á Screw plug 3
Â Bleed screw
1
Fig. 2
Loosen the filter cartridge using the tape wrench,
unscrew it by hand and take it off.
Moisten the seal on the new filter cartridge with
fuel Screw on the filter cartridges and tighten them
vigourously by hand.
Venting fuel system

Fig. 3
Open the bleed screw on the fuel filter.
3
Fig. 4
Pump the hand primer until fuel emerges without
bubbles.
Close the bleed screw.
Check the system for leaks.
Note:
When bleeding the fuel system switch on
the electromagnetic shut-off valve (EHAB)
without fail (ignition on), as otherwise fuel
cannot reach the injection pump suction
gallery / suction chamber.
Wiring diagram see page 125.
4
32
Draining and filling coolant
Draining coolant
2
Drain coolant when the engine is cold as follows:
1
Danger:
When draining hot coolant, there is a
danger of scalding! Collect the drained
coolant and dispose of it in accordance
with regulations!
Fig. 1
Open the sealing cover on the filler neck À of the 1
expansion tank on the fan radiator for pressure
equalisation.
Caution:
If the cap with the working valves Á is
opened, there is the risk that it will not
close tightly again afterwards. The re-
quired overpressure is no longer set up in
the cooling system. Premature simmering
and loss of coolant result. To avoid dam-
age to the engine, this cover should as a
general rule only be opened in excep-
tional cases and then replaced by a new
one. 2
Fig. 2
A valve for draining the coolant is located at the
lower water tank of the radiator.
Fig. 3
Remove the cap.
Screw in adapter 51.98131−6002 supplied with the
radiator connecting parts.
3
Fig. 4
This opens the sealing cone of the drain valve and
the coolant is to be drained using a hose with
20 mm internal diameter.
33
Draining and filling coolant
Fig. 5
Note:
There is another drain screw in the cool-
ant manifold on the engine.
Filling coolant
Fig. 6
5
The cooling system of the engine is to be filled with
a mixture of drinking water from the mains and
antifreeze based on ethylene glycol and / or anti-
corrosion additive.
Note:
Only use coolants that comply with MAN
regulations.
For basic information on the consumable
materials, refer to the publication “Fuels,
Lubricants and Coolants for MAN Diesel
Engines”. You can find the approved
products on the Internet at:
−http://www.mn.man.de/index/mn_eng/
motor/serviceproducts.htm− 6
Fig. 7
Coolant must be filled only at the filling neck.
Do not add cold coolant to a warm engine.
Danger:
If in an exceptional case the coolant level
has to be checked in an engine that has
reached operating temperature, first care-
fully turn the cap with safety valve to the
first stop, let off pressure, then open
carefully.
7
34
Removing and installing thermostats
D Draining off coolant, see page 33

Fig. 1
Remove the filler coolant neck from coolant pump.
Fig. 2
Take out thermostat insert.
Check the function of the thermostat insert as fol-
lows.
D Suspend the thermostat in a bowl of water
D Heat up the water
D Use suitable thermometer to ascertain the
opening start and compare it with the set-point
value given in “Service Data”.
D Measure opening stroke if necessary.
Replace defective thermostats.
2
Fig. 3
Insert thermostat inserts (ball valve facing upwards
(“TOP”) with new O-ring seal and new seal.
Caution:
Never operate the engine without its ther-
mostats.
35
Removing and installing the coolant pump
D Draining coolant, see page 33

D Remove the thermostats, see page 35
Figs. 1 and 2
Remove the fan and fan hub.
Fig. 3
Take off the V-belt, see page 118.
Remove the mounting bolts from fan bracket and
take it off.
Fig. 4
Remove the mounting bolts from the coolant
pump.
(Torx screws with spanner size E12”).
36
Removing and installing the coolant pump
Fig. 5
Remove the mounting bolts from coolant elbow
and take off coolant pump.
Fig. 6
Clean the sealing faces on the coolant pump and
crankcase with a scraper and fine abrasive paper.
Stick the new gasket for the coolant pump housing
to the crankcase with grease. Fit the water pump.
Use new seals for the coolant elbow.
37
Repairing coolant pump
Disassembling the coolant pump

Fig. 1
Support the V-belt pulley with a disconnecting
blade, press the coolant pump shaft and the
coolant pump out of the pulley with a suitable
mandrel.
Fig. 2
Unclip the circlip from the coolant pump housing.
Fig. 3
Turn the coolant pump around and support the
housing.
Press the coolant pump shaft together with bearing
out of the impeller with a suitable mandrel.
Fig. 4
6
Coolant pump dismantled
À Hub 4 5
Á Circlip
Â Pump bearing
Ã Housing
Ä Mechanical seal 3
Å Impeller wheel 1 2
38
Reassembling coolant pump

Fig. 5
Press in coolant pump bearing.
Use a hollow mandrel to press on the outer bear-
ing ring and not on the bearing shaft.
In doing so, align the coolant pump housing hori-
zontally on a firm surface.
Fig. 6
Fit the circlip.
Fig. 7
Press in new mechanical seal with press-fitting
sleeve (special tool, see page 157, item 7) until it
stops.
Observe installation note for seal on page 41.
Note:
The seal can be replaced even without re-
moving the water pump shaft.
39
Fig. 8
Press the impeller wheel onto the bearing shaft.
In doing so, support the coolant pump bearing
shaft on a firm surface.
The correct gap dimension (see “Service Data”) is
achieved if the outer face of the impeller is flush
with the front face of the bearing shaft.
Check the gap dimension with the feeler gauge.
The impeller wheel must be easy to turn and must
not contact the water-pump housing.
Fig. 9
Turn the pump housing over and align it horizon-
tally on a suitable support. Press the hub on to the
bearing shaft so that it fits flush.
For this purpose, place the bearing shaft together
with the flush-fitting impeller on a stable surface.
Fig. 10
Check the smooth running of the coolant pump.
10
40
Installation note for mechanical seal

Fit the mechanical seal “wet”, i.e. when fitting, coat holding sleeve Ã and coolant pump shaft À with a mix-
ture of 50% water and 50% cleaning spirit or 40% to 50% antifreeze as per MAN 324 and water.
Other anti−skid agents must not be used.
Because the seal on collar Á is coated with sealing paint, no sealing paint needs to be applied if the locat-
ing bore in the coolant pump housing is in perfect condition.
If the bore shows even the slightest scoring or other minor damage, a sealing bead of Dirko-Transparent,
must be applied to collar Á.
Fit the seal with a plastic transportation cap onto shaft À and use installation tool to press it in until the tool
contacts the housing. Remove the plastic cap.
1 2 3 4
Note:
Tests have shown that most cases of damage to the coolant pump can be attributed to the use of
unsuitable coolants.
Only those anticorrosion and antifreeze agents expressly approved by MAN Nutzfahrzeuge AG
as per the MAN 324 standard (see brochure “Fuels, Lubricants and Coolants for MAN Diesel En-
gines”) will guarantee fault-free operation.
41
Fan radiator for engine coolant and combustion air
Fig. 1
1 2
For recooling the engine coolant and the com-
pressed combustion air a combination radiator is
required.
This radiator consists of the following components:
À Intercooler 3
Á Expansion tank
Â Radiator for engine coolant
Note:
For installing the cooling system
see assembly instructions 51.06000−8013.
1
1 2
Fig. 2
Combustion air pipes to and from intercooler.
À Combustion air pipe from intercooler
Á Combustion air pipe to intercooler
Figs. 3 and 4
1
Engine coolant lines from and to fan radiator.
À Engine coolant from engine to fan radiator
Á Engine coolant from fan radiator to engine
42
Cleaning cooling system
Cleaning the outside of the fan radiator

Extreme dirt deposits can clog the honeycombs so that the remaining surface no longer ensures sufficient
cooling. In such cases, the insects, dust etc. should be removed from the honeycomb system of the radi-
ator block and the radiator itself then cleaned with the cleansing agent HENKEL P3-begesol. This cleansing
agent is available from MAN in 10-kg cans under Part No. 09.21002−0164.
Procedure:
D Mix P3−begesol with water, ratio 1:1
D Using a spray gun, spray the mixture in as straight a jet as possible directly into the radiator fins
D Let the mixture work for 5 minutes
D Hose down the radiator with a straight jet of tap water directly from the front. In cases of stubborn dirt
deposits, remove the radiator and hose it down directly from behind. Do not use high-pressure cleaners
(steam sprayers may be used)
Henkel P3-begesol contains no toxic or corrosive substances and, if handled properly, may be used without
hesitation.
Cleaning inside the cooling system

Tests have shown that in many cases the poor condition of the coolant and / or the cooling system ac-
counts for damage to the coolant pump seal. The poor condition of the cooling system is normally due to
the use of unsuitable or no antifreeze or corrosion inhibitor or to defective caps for filler necks and service
valves which are not punctually replaced.
If the coolant pump of an engine develops leaks twice in short succession or the coolant is heavily contami-
nated (cloudy, brown, mechanically contaminated, grey or black signs of leakage on the coolant pump
housing, after the defect on the oil cooler), clean the cooling system prior to removing the faulty coolant
pump as follows:
a) Drain coolant
b) Open the thermostats positively (use bypass inserts) so that the entire cooling circuit is flushed immedi-
ately during the cleaning operation
c) Fill coolant circuit with a mixture of hot water (min. 50°C) and Henkel P 3 neutrasel 5265 detergent
(1.5% by volume) (−5266, −5225, Kluthe Hakopur 316), refer to Publication “Fuels, Lubricants ...”
d) Warm up the engine under load. After a temperature of 60°C is reached, run the engine for a further 15
minutes
e) Drain cleaning fluid
f) Repeat steps c) and d)
g) Flush the cooling circuit; to do so
h) Replace the drain plug with a drain plug with an 8 mm dia. bore
i) Fill the cooling circuit with hot water
k) Run the engine at idle for 30 minutes. At the same time, continuously replenish the water emerging from
the bore in the drain plug by adding fresh water at the filler neck
Only now should the coolant pump be repaired. On completion of repairs, fill the cooling system with cool-
ant, refer to publication “Fuels, Lubricants ...”.
Note:
Only sediments and suspended particles can be removed by this cleaning method. If rust and lime
deposits are detected, proceed in line with the instructions set out in the section below:
43
Cleaning cooling system
Removing lime deposits in cooling system
Proceed as follows:
D Drain coolant
D Fill the system with undiluted original pickling fluid (Engine pickling fluid RB-06). Keep the engine run-
ning for approx. 8 hours with this fluid in the system (also in normal operation)
D Drain the pickling fluid and flush the system thoroughly with tap water
D If necessary, refill the system with fresh pickling fluid and pickle the system for a further 8 hours
D Drain the pickling fluid, fill the system with tap water and run the engine at idle for 5 minutes to flush out
the system; then drain the water
D Fill the system with soda solution (1%). Drain the soda solution after running the engine at idle for 5 min-
utes, and flush with tap water until the discharging water runs clear
D Fill the cooling circuit with a mixture of drinking water and anti-freeze with at least 40% by volume, refer
to Publication “Fuels, Lubricants ...”
Filler caps and service valves of cooling system

The rubber seals on the filler caps and service valves (negative pressure and positive pressure valves) of
the cooling system are subject to natural ageing.
To prevent leaks in the cooling system together with the associated loss of pressure and its consequences,
including serious engine damage, replace the filler caps and service valves at the same time as changing
the coolant (every two years at the latest).
Waste water treatment

Drained and spent cleaning and pickling fluid should be brought up to a pH value of 7.5 to 8.5 with the aid
of caustic soda. Once the precipitation has settled to the bottom of the container, the clear fluid above can
be tipped into the sewer system. To be sure, it is advisable to consult the local authorities for more informa-
tion on waste water rules and restrictions. The sludge at the bottom must be taken to a special waste
dump.
Sources of supply for pickling fluids

Motor pickling fluid RB-06
Reincolor-Chemie GmbH
Werkstr. 21
D−90518 Altdorf
Tel.: (0 91 87) 97 03 0
44
Servicing the oil filter
Replacing the oil filter element
Caution:
Old oil and used oil filters are hazardous
waste. Observe safety instructions for the
prevention of environmental damage.
Fig. 1
Release oil filter cap with special tool (special tool,
see page 157, item 3) until sealing ring (item. À in
figure 2) is visible, wait approx. 2 minutes until the 1
oil has drained out of the filter bowl.
Danger:
Oil filter can and oil filter arefilled with hot
oil.Risk of burns and scalds! 1
Fig. 2
Pull out oil filter cap together with filter element
and catch escaping oil in a suitable container.
Replace sealing rings À, Á and Â.
3 2
2
Fig. 3
Install a new filter element.
Fig. 4
Danger:
The oil filter cap is made of plastic; do not
exceed the specified torque.
Screw in and tighten the oil filter cap together with

filter element.
Fill engine oil and check for leaks after a short en-
gine run.
Check oil level.
4
45
Removing and installing the oil cooler
D Drain engine oil

D Draining off coolant, see page 33
D Remove the oil filter element, see page 45
Figs. 1 and 2
Undo all the hexagon bolts (10 bolts, WAF 17) of
the oil cooler housing as well as the banjo bolt À of
the oil return line.
Caution: 1
Here, oil residues can escape.
Old oil is hazardous waste. 1
Observe safety instructions for the preven-
tion of environmental damage.
Note:
Do not undo the 4 Torx screws Á. They 2 2 2 2
hold the oil cooler in place.
Fig. 3
Remove the oil cooler housing together with the oil
cooler.
Only now should you undo the Torx screws Á
(Also refer to Fig. 2) and remove the oil cooler
from the housing.
2
2
3
Fig. 4
Check oil cooler for damage and replace if necess-
ary. Fit oil cooler with new gaskets.
Fit oil filter with new gasket.
Fill up with engine oil and coolant.
46
Removing and installing, repairing oil pump
Removing oil pump

D Drain engine oil
Fig. 1
Remove the oil pan.
Fig. 2
Unscrew the oil intake pipe.
Measure backlash between oil pump drive gear
and crankshaft gear and compare value with the
nominal value.
Replace worn gears.
Figs. 3 and 4
Unscrew the mounting bolts of the pressure relief
valve and oil pump.
The overpressure valve is encapsulated.
Opening pressure, see “Service Data”.
Take off oil pump.
47
Disassembling and assembling oil

pump
Fig. 5
Fit the oil pump in a vice (use protective jaws). Un-
screw the oil pump cover.
Figs. 6 and 7
Pull the driven oil pump wheels from the casing.
Check the gears and pump casing for wear (see
“Service Data”).
Fig. 8
Remove the oil pump drive gear. To do this, lay the
pump on a suitable surface and press off the drive
gear using a mandrel.
Place drive gear on the shaft and press it into
place. Use the other shaft end as support.
Press-on force, refer to “Service Data”.
48
Checking the axial clearance of the

pump gears
Fig. 9
Apply the dial gauge; bring the shaft in one direc-
tion to the stop and set the dial gauge to “0”.
Push the shaft in the opposite direction and read
off the needle deflection on the dial gauge.
Installing the oil pump

Fig. 10
Before installing, check whether the oil pump(s)
run(s) smoothly and then fit it / them free of ten-
sion
Fit the oil intake line with seal without tension.
Screw on the pressure-relief valve without seal.
Before fitting the oil pan, run the engine to check
that the crankshaft drive and oil pumps are running
smoothly and easily.
10
Fig. 11
Attach a new oil pan gasket with grease and screw
on the oil pan.
11
49
Removing and installing the oil spray nozzle
Removing the oil spray nozzle

D Drain engine oil
D Removing the oil pan, see page 47
Fig. 1
Unscrew the oil spray nozzle valve (arrow) and
remove with the oil spray nozzle.
Fig. 2
À Oil spray nozzle valve
Á Oil spray nozzle 2
Note:
The oil spray nozzle are provided with two
balls. When the oil spray nozzles are tigh-
tened at the factory the balls are pressed 1
into the crankcase where they make im-
pressions used as marker points for the
installation of oil spray nozzles in the event
of repair work.
2
Checking the oil spray nozzle valve

Fig. 3
Use a piece of wire to check whether the valve
piston is easy to move.
Opening pressure, see “Service Data”.
Installing the oil injection nozzle 3

Fig. 4
Screw in the oil spray nozzle together with the oil
spray nozzle valve.
The balls of the oil spray nozzle must be located in
the impressions provided for this purpose in the
crankcase. This will ensure that the oil spray
nozzle will be installed in the correct position.
Turn the engine. The crankshaft drive or pistons
must not collide with the oil injection nozzle.
Tighten the securing bolts with the prescribed
torque.
Tightening torque: . . . . . . . . . . . . . . . . . . . . . . 70 Nm 4
50
Removing and installing the vibration damper,
replacing the front crankshaft seal
Removing the vibration damper

D Block the crankshaft drive.
Fig. 1
Remove the fan and fan hub.
Relax and remove the V-belt; see page 118.
Fig. 2
Remove the mounting bolts from the front V-belt
pulley and take it off.
Fig. 3
Loosen the mounting bolts of the vibration damper.
Fig. 4
Carefully remove the vibration damper and alterna-
tor pulley.
Caution:
The vibration damper is sensitive to im-
pacts.
51
Replacing the front crankshaft seal

Fig. 5
Remove the cover.
Only replace the front crankshaft gasket as a com-
plete unit, i.e. replace the bearing race and the
radial shaft sealing ring.
Fig. 6
A stripping device (special tool, see page 157 ,
item 8) is required to remove the bearing race.
Fig. 7
Pull off the bearing race.
Fig. 8
1 2
A special tool, see page 159, item 17, is required
to fit the bearing race.
Clean the inside of the bearing race and tail shaft.
Coat the tail shaft with sealing compound
“Antipor 46”.
D Push race Æ and pressing sleeve Ç onto
adapter Â 7
D Tighten spindle À in adapter Â with nut Ã
D Bolt adapter Â to crankshaft.
8
6 5 4 3
52
Fig. 9
The adapter must lie free of clearance on the
crankshaft so that the right press-in depth of the
bearing race is ensured.
Pull the bearing race as far as it will go into the
press-in sleeve (Item 8 in Fig. 8) on the adapter
with collar nut and thrust washer (Items 9 and 10
in Fig. 8).
Fig. 10
To ensure perfect installation, the replacement
cover and shaft sealing ring are only delivered as a
complete unit.
So that it remains possible to mount the shaft seal-
ing ring, it must stay on the transport and installa-
tion sleeve until assembly.
10
Fig. 11
Fit cover with new seal.
11
Installing the vibration damper

Fig. 12
Position the vibration damper on two guide man-
drels (M16x1.5).
Tighten the mounting bolts with the prescribed
torque.
Tightening torque: . . . . . . . . . . . . . . . . . . . . 260 Nm
Screw on the cranking tool.
Caution:
Unblock the crankshaft drive! 12
53
Removing and installing the flywheel,
replacing the starter gear ring
Removing the flywheel

D Removing the speed pickup, see page 124
Fig. 1
Release the mounting bolts, securing the engine
against rotating if necessary.
Fig. 2
Remove the two bolts facing each other and re-
place them with two guide pins (special tool, item
12, see Page 157).
Remove all bolts.
Pull off flywheel with suitable lifting gear.
Danger:
The flywheel is heavy!
Use lifting gear.
Installing the flywheel

Fig. 3
Insert the guide pins.
Apply sealing agent “Antipor 46” to the inside of
the flywheel.
Place guide mandrels on the flywheel; in doing so,
pay attention to the assignment of the centring pin
(arrow) to the hole in the flywheel.
Push the flywheel on as far as it will go.
Fig. 4
Lightly oil the new mounting bolts (stress bolts),
screw them in and tighten in diagonal sequence to
specified torque.
Tightening torque:
Pretightening . . . . . . . . . . . . . . . . . . . . 100−110 Nm
1st rotation angle . . . . . . . . . . . . . . . . . . . . . 90−100_
2nd rotation angle . . . . . . . . . . . . . . . . . . . . 90−100_
54
Removing and installing the flywheel,
replacing the starter gear ring
Replacing the starter motor toothed

wheel
Fig. 5
Remove the flywheel.
Drill the starter motor toothed wheel and break
with a chisel.
Caution:
In doing so, do not damage the flywheel.
Fig. 6 5
Note:
As the maximum axial run-out of the
starter motor toothed wheel must not be
exceeded, the axial run-out of the flywheel
should be measured on the contact sur-
face of the starter motor toothed wheel
prior to shrinking on the starter motor
toothed wheel.
If the required value is exceeded, replace
the flywheel.
Engage the flywheel at the hub.

Apply the dial gauge to the contact surface of the 6
toothed wheel.
Turn the flywheel a few revolutions by hand and
observe the reaction of the dial gauge.
Fig. 7
Heat the new starter gear ring up to approx. 200°C
to 230°C and press on as far as it will go.
Danger:
The parts are hot. Risk of burns.
Wear protective gloves.
Check axial runout and compare with max. per-

missible value. 7
55
Replacing the crankshaft seal
(flywheel end)
Removing the crankshaft seal

D Removing the flywheel, see page 54
Fig. 1
Use the special tool (Fig. 2) or a screwdriver to
prise out the seal.
Fig. 2
Special tool for levering out the crankshaft seal.
Fit shaft sealing ring

Fig. 3
When fitting a new shaft seal, you should also re-
place the bearing race of the flywheel.
Insert the new shaft sealing ring into the flywheel
housing.
Use mandrel (special tool, see page 157, item 10)
to drive in a sealing ring until flush.
Refer to the comments and assembly instructions
on page 58.
56
Replacing the bearing race
Replacing the bearing race

Fig. 1
If the shaft sealing ring on flywheel side is re-
placed, it is also recommended to replace the
bearing race of the flywheel.
Use an extractor to remove the bearing race to be
replaced, see page 157, item 11.2).
Fig. 2
Insert the new bearing race in the drift (special
tool, see page 157, item 11) in such a way that the
inner bevelled side faces the flywheel when fitted
later.
Carefully warm up the drift with bearing race.
The installation temperature of the bearing race is
approx. 150_C.
Fig. 3
Press in the bearing race as far as it will go.
Fig. 4
Seal the gap between flywheel and bearing race
with “Antipor 46”.
57
Crankshaft seals
General notes on the crankshaft seals

As a general principle, the radial shaft sealing rings are made of polytetrafluorethylene (PTFE), otherwise
known as Teflon.
PTFE sealing rings differ from the elastomer sealing rings that used to be common in that they have a
much wider, flat sealing lip that is not pretensioned by a coiled spring expander.
The relatively large pretension of the sealing lip itself means that it curves inwards. This is why the PTFE
sealing ring is delivered on a transport sleeve. So that it remains possible to mount the sealing ring, it must
stay on this sleeve until assembly. This applies also because the sealing lip is very sensitive and the
smallest damage causes leaks.
The sealing lip and the bearing race of the flywheel must not be coated with oil or other lubricants.
On fitting the new sealing ring, always replace the bearing race alongside it.
Assembly instructions for crankshaft seals

D The PTFE sealing ring must be fitted absolutely free of oil and grease. Even the slightest traces of oil or
grease on the bearing race or sealing ring lead to leaks
D Clean oil, grease and corrosion protection agents from the bearing race before assembly. Commercially
available cleaners are permitted for this purpose.
D If the PTFE sealing ring is soiled with oil or grease, it is unusable. Cleaning is not permitted in this case
D The PTFE sealing ring must never be stored without the supplied transport sleeve. Even after only 1/2
hour of storage without the transport sleeve, it loses its initial tension and becomes unusable
58
Removing and installing the intake manifolds
Removing the intake manifold

D Remove the air filter
Note:
When working on the air intake system,
ensure meticulous cleanliness to prevent
penetration of dirt and foreign bodies.
Figs. 1 and 2
Remove the fuel filter and electro-hydraulic shut-off
(EHAB).
1
Caution:
The lines contain fuel!
Catch escaping fuel in a suitable con-
tainer.
Fig. 3
Undo the intake manifold mounting bolts and re-
move the intake manifold.
Installing the intake manifold

Fig. 4
Place the intake manifold in position with new
gaskets.
torque.
Ensure that the seals are correctly seated.
59
Servicing the air filter
Replacing the air filter cartridge

1
Fig. 1
D 2876 LE 2.. engines.. are equipped with Mann−
Piclon combination air filters.
À Air intake 2
Á Air outlet
Fig. 2
The air filters are equipped with maintenance indi-
cators which are triggered once the air filters have
reached a certain degree of contamination with the
ensuing loss of pressure.
The picture shows an electric maintenance switch
which is triggered at an intake vacuum of 50 mbar
and can trigger a monitor.
Fig. 3
To replace the filter cartridge, disengage and open
the clip.
Fig. 4
Take off the dust collector. 1 2
À Dust collector
Á Cover
Take cover off the dust collector and empty the
collector.
60
Servicing the air filter
Fig. 5
Undo the mounting bolts on the filter cartridge.
Fig. 6
Take out the contaminated filter cartridge, replace
it with new one or clean it.
Clean the sealing face of filter housing using a
moist cloth.
Fig. 7
Replace the safety cartridge after the fifth mainten-
ance service or every
2 years.
Caution:
Safety cartridges must not be cleaned.
The engine must not be operated with the
safety cartridge alone.
Fig. 8
Check hose connections for leaks.
61
Removing and installing the exhaust manifold
Removing the exhaust manifold

D Remove air filter.
D Removing the turbocharger, see page 67
Fig. 1
Remove anti−contact protection device and
bracket for air filter.
Fig. 2
Loosen the mounting bolts of the exhaust mani-
fold.
Fig. 3
Remove the exhaust manifold.
Installing exhaust manifold

Fig. 4
Place the exhaust manifold in position with new
gaskets.
62
Removing and installing the exhaust manifold
Fig. 5
torque.
Tightening torque:
Pretightening: . . . . . . . . . . . . . . . . . . . . . . 60−65 Nm
Angle tightening: . . . . . . . . . . . . . . . . . . . . . 90−100_
63
Turbocharger, troubleshooting
Before replacing the turbocharger, carry out the following checks

It is frequently the case that with excessive engine oil consumption, low power or abnormal intake and/or
exhaust noise the turbocharger is replaced.
When the allegedly defective part is then checked by the manufacturer, it is often determined that the
charger is OK.
To ensure in the future that only defective turbochargers are replaced, the following checks must be carried
out first:
In the case of excessive oil consumption

− Check the air filter for soiling
− Ensure sufficient engine room ventilation,
− Check whether the diameter of the intake line has been reduced (e.g. due to damage, soiling).
These factors give rise to increased oil consumption on account of the increased vacuum pressure at the
compressor inlet.
− Check the outside of the turbocharger for traces of oil.
Oil consumption caused directly by the charger depends on the bearing wear and leads relatively quickly to
mechanical damage.
In the case of unsatisfactory engine power

A requirement for a satisfactory level of engine power is setting in accordance with regulations
− of start of fuel delivery,
− and of the valve clearance
− the function of the actuator / transmission linkage (control rod on full load stop)
Also check the following:
− the compression pressure
− soiling of the air filters
− the charging pressure
− the pressure in the inlet chamber of the injection pump,
− the exhaust back pressure.
If the above checks fail to establish a possible cause, check the turbocharger for:
− coking in the turbine area, which impairs the movement of the wheel assembly
(can be eliminated by axial movement)
− coarse dirt in the compressor area
− damage caused by foreign objects
− scraping of the rotor disk on the casing.
In the case of coarse dirt, the compressor side must be cleaned and the bearing clearance checked.
Caution:
Do not damage the light-alloy compressor wheel.
64
Turbocharger, troubleshooting
In the case of abnormal intake and exhaust noise

− Check the intake and exhaust system in the area of the charge group.
Damaged gaskets lead to false diagnosis of a defective turbocharger; these must be replaced.
− If the abnormal noise is still present, replace the turbocharger.
Turbochargers in good working order do not make any excessive noise.
In the case of oil accumulation in charge-air lines and charge-air cooler

Slight oil accumulation due to oil spray in the charge-air system is a result of the design and is desirable.
The oil mist is required to lubricate the intake valve seats.
If more oil accumulates than is normal, i.e. to the extent that oil pockets develop e.g. in the lower air box of
the intercooler, this can lead to oil disintegration or uncontrolled engine racing when the oil is separated. In
such cases, remove the cause.
Possible causes:
− The engine is overfilled with oil.
− Check whether the correct dipstick and guide pipe combination is installed.
− Use of unsuitable engine oil (see brochure “Fluids and lubricants...”)
− Operation of the engine on non−permitted inclines
− Excessive crankcase pressure, e.g. due to defective oil separator valve (crankcase breather) or piston
ring wear
Compressor coking
This can occur when the charge−air temperature is permanently high, for example when the engine is con-
stantly run at full load.
Coking leads to a reduction in the charging pressure, but not to drops in power or poorer acceleration char-
acteristics.
Coking can lead to increased exhaust haze.
In the case of compressor coking:
− Remove the compressor housing without tilting it If it jams, the compressor wheel blades may get dam-
aged or bent and the resulting imbalance may destroy the turbocharger.
− Remove carbonisation in the compressor housing with a suitable cleaning agent
Danger:
Under no circumstances should cleaner be sprayed in while the engine is running
− ineffective
− danger of accident!
− In problem cases, use oil types that are less likely to lead to compressor carbonisation (see publication
“Fuels, Lubricants...”)
65
Checking charging pressure
Adequate charging pressure is a requirement for full power output and clean combustion.
Checking the charge−air pressure helps detect damage to the turbocharger, operating faults in the waste-
gate and leaks in the intercooler and in the charge-air pipes.
Extreme operating conditions (full-load operation and high air temperature) and the use of unsuitable en-
gine oils (also see publication “Fuels, Lubricants, Coolants for MAN Diesel Engines”) may cause deposits
on the compressor as well as in the intercooler, which results in a reduction in charge-air pressure.
Preconditions for the measurement

The delivery start and the valve clearance must be set as specified, and the engine must be at operating
temperature.
The right value for charging pressure

No generally applicable target value for charging pressure can be given, as the installation conditions exert
an influence.
The target value is the value determined on commissioning of the engine and reported in the commission-
ing log.
Special aspects of the measurement

Due to various atmospheric reference states during measurement and tolerances of the pressure gauges
used, deviations of max. $100 hPa ($100 mbar) are permitted.
Fig. 1
A measuring connection for checking the charge−
air pressure and the charge−air temperature is lo-
cated in the intake manifold behind the intercooler.
Remove the screw plug (M32x1.5).
Connect up pressure gauge (if necessary using a
suitable threaded pipe as adapter).
Fig. 2
Measure the charge-air pressure downstream of
the intercooler at nominal engine speed and full
load.
66
Removing and installing the turbocharger
Removing the turbocharger

Figs. 1 and 2
Remove the corrugated hose from between the air
filter and compressor and the charge-air pipe from
between the compressor and intercooler.
Detach the hose from the crankcase breather
Remove the air intake manifold of the compressor.
Figs. 3 and 4
Unscrew the oil supply and oil return lines.
67
Removing and installing the turbocharger
Fig. 5
Release the four (self-locking) nuts on the turbo-
charger flange.
Fig. 6
Take off turbocharger.
Note:
When placing the turbocharger to one
side, ensure extreme cleanliness to pre-
vent penetration of dirt and foreign bodies.
Installing the turbocharger

Fig. 7
The turbocharger is fitted in reverse order.
On assembly, new gaskets and new self-locking
nuts are to be used.
Before connecting the oil supply line, fill the bear-
ing housing with fresh engine oil.
Check all the connections for leaks and to ensure
they are not subjected to strain.
Caution:
Comply with instructions for masking 7
unions on pressurised oil and fuel pipes
(see page 3).
68
Measuring the axial / radial clearance or the turbocharger shaft
D Removing the turbocharger, see page 67

D Mark the turbine housing in relation to the bear-
ing housing and unscrew the turbine housing.
Axial clearance
Fig. 1
Position the dial gauge bracket with the dial gauge
as shown in the illustration. Apply the dial gauge
with initial tension on the face of the shaft end of
the turbine wheel.
Press the rotor shaft against the dial gauge, read 1
off and note the value. Press the rotor shaft in the
opposite direction, read off and note the value.
The difference between the values obtained is the
axial clearance. In the case of excessive clear-
ance, replace the turbocharger.
Radial clearance
Fig. 2
The radial clearance is measured only on the tur-
bine side with a dial gauge or feeler gauge.
Place the measuring tip of the dial gauge to the
side of the hub, press the turbine wheel to the dial
2
gauge, read off and note the value.
Press the turbine wheel in the opposite direction,
read off and note the value. The difference be-
tween the values obtained is the radial clearance.
Position the turbine housing to the marking; screw
on turbine housing.
69
Removing and installing the cylinder head
Removing the cylinder head

D Drain off coolant, see page 33
D Remove injectors, see page 26
Note:
To remove the cylinder head, the intake
and exhaust pipes do not need to be re-
moved.
Fig. 1
Unscrew the valve cover (Torx screws with
spanner size E12”).
1
Fig. 2
Remove the coolant bleed pipe.
Fig. 3
Turn back the valve setting screws.
Loosen the securing bolts of the rocker arm
bracket.
Fig. 4
Remove the rocker arm bracket.
Take out the tappet push rods.
70
Fig. 5
Unscrew the cylinder−head bolts in reverse order
to their tightening and remove the bolts. (Torx
screws with spanner size E20 - 1/2”).
Fig. 6
Loosen all bolts on the intake and exhaust mani-
folds.
This reduces the tension on the cylinder head and
it is easier to remove the head.
6
Fig. 7
Remove the cylinder head and cylinder head
gasket.
Note:
If all the cylinder heads of a bank are re-
moved during an engine overhaul, use a
straightedge to check the evenness of the
sealing surfaces of the cylinder head and
cylinder block.
Cylinder heads that are not flush can be
milled by 1 mm. Observe the prescribed
valve recess (see chapter “Service Data”).
Check the cylinder heads for cracks.
7
71
Installing the cylinder head

Fig. 8
Before fitting, clean and blow out the threaded
holes in the crankcase. Clean the sealing surfaces
on the cylinder head and on the crankcase.
Lay the new cylinder head seal in place, ensuring
that the hole patterns match up, and place the cyl-
inder head on top.
Fig. 9
Two adjusting sleeves are used to secure each
cylinder head (arrow).
Fig. 10
Check cylinder−head bolts for max. permitted
length (see “Service Data”). Removed bolts can be
reused if the max. permitted length is not ex-
ceeded.
Before inserting the cylinder-head bolts, apply en-
gine oil to the thread and coat the seating surface
of the bolt head with installation paste “Optimoly 9
White T”.
Fig. 11
Tighten the bolts according to the rotation angle
method. Observe the tightening sequence, pre-
scribed tightening method, instructions and notes
on cylinder−head bolts (see “Service Data”).
Note:
To avoid possible deformation between the
cylinder heads and exhaust pipes, we rec-
ommend the following procedure: 10
D Place the cylinder head gaskets and
cylinder heads in position
D Turn the head bolts a few thread turns.
D Secure steel ruler (special tool) with
ground face on the exhaust side;
tightening torque for mounting bolts:
20 Nm. If a straightedge is not avail-
able, mount the exhaust manifold and
tighten to 20 Nm.
D Tighten the cylinder-head bolts as pre-
scribed
D Unscrew the straightedge
D Tighten the exhaust pipe and intake
manifold with the prescribed torque.
11
72
Fig. 12
Check the tappet push rod for deformation. When
inserting the tappet push rods, ensure that they fit
in the socket of the valve tappet.
Fit the rocker arm mechanism. Insert the securing
bolts without washers and tighten slightly.
Align the rocker arms to the valves.
Tighten the securing bolts with the prescribed
torque.
Note:
Use only M10x70 securing bolts with prop-
erty class 10.9. 12
Fig. 13
Fit new gaskets between the cylinder head and
intake / exhaust pipe.
Tighten the mounting bolts of the charging mixture
distributing pipe and exhaust pipe with the pre-
scribed torque.
13
Fig. 14
Set the valve clearance. Fit the injectors.
Fit the cylinder head cover with a new gasket.
Fit coolant bleed line with new gaskets.
Top up coolant.
14
73
General notes
The sealing effect of the cylinder head seal depends mainly on whether the required initial tension of the
cylinder-head bolt is actually achieved and retained.
To tighten the cylinder-head bolts, use a calibrated torque wrench. The prescribed tightening torque must
be kept for at least 5 seconds for final tightening using a torque wrench. With “snapping” torque wrenches,
tighten the bolts slowly, as otherwise the set torque is not fully transferred to the bolts.
Observe the notes on the usability of cylinder-head bolts, tightening sequence, and prescribed tightening
method in the chapter “Service Data”.
Tightening
“Tightening” is the initial tightening of the newly fitted bolts that have not yet been tightened following a re-
pair - e.g. after replacement of the cylinder head seal. Tighten the cylinder-head bolts with the engine cold,
i.e. the crankcase is hand-warm or colder.
Before inserting the cylinder−head bolts, apply engine oil to the thread (not the threaded hole) and coat the
seating surface of the bolt head with installation paste “Optimoly White T”.
Do not use oils or oil additives containing MoS2.
In the case of unoiled bolts, a significant portion of the tightening torque is converted into friction and is thus
lost for the bolt pretensioning.
D To secure the cylinder head, only tighten the cylinder-head bolts slightly
D Align the cylinder heads by screwing on the straightedge (special tool).
If no straightedge is available, use the exhaust pipe or intake manifold.
D Tighten step by step in the right order and with the prescribed tightening torque and/or angle of rotation
Caution:
If individual bolts are tightened too much during preliminary tightening, the cylinder head is dis-
torted. The distortion can no longer be removed with continued tightening in accordance with re-
gulations!
74
Setting the valve clearance
Fig. 1
Unscrew the valve cover (Torx screws with
spanner size E12”).
Fig. 2 1
Crank the engine with the cranking tool so that the
piston in the cylinder to be set is at TDC and all the
valves are closed. This is the case when the
valves in the cylinder with the synchronous piston
overlap.
Fig. 3
Valves overlap in cylinder:
1 5 3 6 2 4
6 2 4 1 5 3
Adjust valves in cylinder: 2

Diagram of cylinder sequence and valve arrange-
ment
I Engine front end
II Flywheel side 1 2 3 4 5 6
I E A E A E A E A E A E A II
A Exhaust valve
E Inlet valve
3
Fig. 4
Push feeler gauge between valve stem and rocker
arm. Loosen the lock nut and turn the adjusting
screw with screwdriver until the feeler gauge can
be moved with slight resistance.
Tighten the locknut with the prescribed torque.
Using the screwdriver to prevent the adjusting
screw from turning. Check the clearance again.
Refit the cylinder head covers.
75
Dismantling and assembling the rocker arm mechanism
D Removing the rocker arm mechanism,

see page 70
Fig. 1
Disengage securing ring.
Fig. 2
Remove the rocker arm from the rocker shaft.
Note:
If the rocker arm bearing bushes need to
be replaced, new or replacement rocker
arms ready for fitting are to be used.
Fig. 3
When fitting the rocker arms À on the rocker 1 2
shafts or pedestals, the sliding surfaces Á and Â
are to be coated with Optimoly paste White T.
This applies to new parts and parts that have al-
ready run.
3
3 2
76
Removing and installing valves
Removing valves
D Removing the rocker arm mechanism, remov-
ing the cylinder head, see page 70
Fig. 1
Screw the valve fitting lever onto the cylinder head.
Note:
Valve springs and spring plates can also
be replaced with the cylinder head still
fitted. The relevant piston must be at
“TDC”; the valve fitting lever is required.
1
Fig. 2
Note:
If available in the workshop, the work oper-
ations described can also be performed on
a valve frame.
Use the valve fitting lever to press the spring

plates and springs downwards and use a magnet
to take out the conical parts. Raise the fitting lever
(caution: spring tension), swing away to the side.
Fig. 3
Remove valve plates, spring and washers. Un-
screw the valve fitting lever.
Turn around the cylinder head and pull out valves.
Installing valves
Fig. 4
Oil the valves at the shaft and insert in the valve
guide.
Note:
Slight damage to the valve seat can be re-
paired by lapping in using valve lapping
paste. New valves must always be lapped
in until an even valve seat is achieved. If
necessary, rework the valve seat insert.
4
77
Removing and installing valves
Fig. 5
À Valve 7
Á Washer 6
Â Outer valve spring
Ã Washer
Ä Inner valve spring 5
Å Spring retainer
Æ Tapered element 4
Fig. 6
D Insert valve spring washers
D Screw the valve fitting lever onto the cylinder
head.
D Use the assembly lever to press the valve
springs together and insert the valve tapers
Caution:
Ensure the correct seating of the valve
tapers, as valve tapers that jump out can
lead to major damage.
Measuring valve recess

Fig. 7
D Position the dial gauge with its holder on the
cylinder head
D Apply the dial gauge tip with pre-tension to the
cylinder head
D Set the dial gauge to “0”.
D Swing towards the valve plates and read off the
recess
78
Removing and installing valve guides
D Removing and installing cylinder head,

see page 70
D Removing and installing valves, see page 77
Fig. 1
Use the pressing mandrel to drive out the valve
guide from the combustion chamber side (special
tool, see page 161, item 38).
Oil the new valve guides and use the driving man-
drel and spacer sleeve (special to) to drive / press
them into the cylinder head.
1
Fig. 2
The only difference between the valve guides is
the length. 3
À Inlet = long guide 1 2
Á Outlet = short guide
Â Press-in depth (see “Service Data”).
The correct press-in depth is obtained by using the
spacer sleeve.
Then rework the valve guide to the target dimen-
sion.
2
Note:
When the valve guides have been re-
placed, the valve seats must also be re-
worked (see technical data and manufac-
turers’ instructions for valve seat lathes
found in individual workshops).
79
Replacing valve seat insert
Removing the valve seat insert
Note:
If the valve seat inserts are replaced, the valve guides must be replaced at the same time as other-
wise exact refacing of the valve seat inserts cannot be guaranteed.
For the above-mentioned reasons, the tool for removing and installing the valve guides and valve
seat inserts have been designed in such a way that, when this tool is used, the valve guides and
the valve seat inserts can be replaced only together or only the valve guides alone can be re-
placed.
Fig. 1
Use a valve seat machining tool (valve seat turning
tool) to cut a groove approx. 3−4 mm wide in the
valve seat insert.
Insert an internal puller into the cut groove and
tighten.
Fig. 2
Note:
To avoid damaging the cylinder head seal- 5
ing face, lay disc Á or similar item under
arms Â of the support. 4
3
Screw threaded spindle Ã into internal extractor À, 1
align arms Â of the support and pull out the valve 2
seat insert by turning nut Ä.
Clean the contact face of the seat insert in the cyl-
inder head.
2
Fig. 3
If a valve seat machining tool is not available, the
following procedure may be adopted:
D Apply two short welding beads on the valve
seat (arrow) using an arc welding set
D Pull out the valve seat insert
D Clean the contact face of the seat insert in the
cylinder head.
80
Replacing valve seat insert
Installing valve seat insert
Fig. 4
Chill the new valve seat insert down to approx.
200°C and insert in the cylinder head (approx.
20°C room temperature).
Carry out a check by driving it in as far as it will go
using a pressing tool.
Install the valve guides.
Note:
When the valve seat inserts are replaced,
the valve seats must also be refaced. 4
Note:
D After temperature equalization: machine the valve seats
D After machining: clean the cylinder head and check for leaks with a leak testing device
D If the cylinder head is excessively heated (above +200°C), the core hole covers (end covers)
lose their tightness and must be replaced
D To do this, clean core holes, blow out channels and press in new core hole covers with
“LOCTITE 648” and pressing mandrel
81
Reworking valve seat

(with Mira precision valve seat machining tool)
Fig. 1 1
À Driving crank
Á Toggle switch
2
Â Handle
Ã Lubricating nipple 16
Ä Mains connection
15 3
Å Magnetic flange with coil
Æ Guide pipe 14 4
Ç Slewing arm
13
È Guide mandrel 5
É Tool 12
11 Hex socket screw
12 Rotary head 11 6
13 Lubricating nipple
14 Jaccard lever 10
7
15 Guide ball
16 Feed nut with mm scale 9
8
1
Fig. 2
Select a suitable guide mandrel, screw it in and
tighten with a fork wrench.
Note:
For extreme precision work, the guide
mandrel must fit snugly.
Select and insert a forming cutter with the corre-

sponding seat width and corresponding seat angle.
Fig. 3
Adjust the forming cutter with a setting gauge and
tighten with the hexagon socket screw.
Insert the tool complete with guide mandrel in the
valve guide.
82
Fig. 4
Release the Jaccard lever, set the magnetic flange
down flat on the clamping plate and adjust the
height so that the forming cutter does not contact
the valve seat.
Set the toggle switch to position 1.
Tighten the Jaccard lever.
Fig. 5
Machine the valve seat by turning the driving crank
steadily in a clockwise direction and simulta-
neously operating the feed nut.
Caution:
During the machining process, turn the
crank vigourously and steadily but under
no circumstances against the direction of
turning as this may cause the carbide
cutting edge to break off.
Fig. 6
Once the valve seat has been cleanly machined,
reduce the working pressure of the forming cutter
by 2−3 turns without feed motion.
During these turns, turn the feed nut back 2−3
turns.
Press the toggle switch briefly to position 2 to lift
the magnetic field.
Now move the entire Mira tool upwards and insert
it in the next valve guide, repeating the centring
operation. 6
Use the same cutter settings for all the intake and
exhaust valve seats.
Fig. 7
Observe the specified seat angle.
83
Fig. 8
When reworking the valve seat inserts, remove as
little material as possible from the seat face.
The valve recess serves as the reference value.
Fig. 9
The valve seat insert must be replaced if, as a re-
sult of machining the cylinder head interface and
the valve seat insert, the theoretical valve seat is
too deep in the cylinder head or the seat face has
become too wide.
Ensure that the valve recess (X) is correct, see
“Service Data”.
x
9
84
Refacing valves
Fig. 1
Apply abrasive paste to the tapered area of the
valve seat.
Lubricate the valve guide and insert the valve.
Fig. 2
Use a valve grinder to reface the valve seat by ap-
plying moderate axial pressure and describing a
turning motion.
Note:
Keep the valve stem and the valve guide
free of abrasive paste.
Fig. 3
The valve seat must have a faultless, contained
grinding pattern.
The grinding pattern width is correct if the valve 1 2
seat insert is in order.
À Valve tapered area
Á Valve seat
3
Fig. 4
À Valve seat insert
Á Valve
Â Valve seat good
1 2 1 2
Ã Valve seat too wide
Note:
Valve seats which are too wide tend to
accumulate coking residues,
− valves start to leak −
Valve seats which are to narrow prevent 3 4
rapid dissipation of heat from the valve
plate to the cylinder head,
− valves burn −
4
85
Checking compression
D Checking and/or setting valve clearance,

see page 75
D Run engine up to normal operating temperature
D Remove all nozzle holders with nozzles,
see Page 26
D For compression guideline values, see “Service
Data”
Fig. 1
Starting at cylinder no. 1 (cooling pump side), fit a
new sealing ring and tighten down the compres-
sion recorder test connection using the union nut
and pin spanner.
1
Insert a test chart in the compression recorder for
diesel engines. Screw the compression recorder
onto the test connection.
Interrupt the power supply to the electro-hydraulic
shut-off valve (EHAB) by removing the fuse; see
circuit diagram on page 125).
Turn the engine over with the starter motor until
there is no longer any needle deflection shown by
the compression recorder.
Connect the compression recorder together with
the test connection to the next cylinder and check
all the cylinders as described above.
2
Fig. 2
Depending on the configuration of the compression
recording device, the engine can also be turned
directly from the compression recording device.
Here, the electric connections are to be made to
the starter motor magnet switch (Terminals 50 and
30).
Fig. 3
Compare the recorded values and remove the
compression recorder and test connection. Treat
the contact points of the nozzle holder with “Never 3
Seeze”.
Fig. 4
Screw in injector with a new sealing ring. Screw on
union nut and tighten to specified torque.
Tightening torque: . . . . . . . . . . . . . . . . 120−125 Nm
Connect up injection and overflow oil lines and re−
insert fuse of EHAB.
86
Removing and installing the timing case
Removing the timing case

D Removing the starter motor, see page 116
Fig. 1
Loosen the securing bolts of the timing case.
The bottom of the timing case is bolted to the oil
pan! Loosen the securing bolts of the oil pan.
Fig. 2
Remove the timing case. Take the gasket off the
timing case and fit a new one.
Fig. 3
Check the contact washer on the camshaft for
wear, in necessary fitting a new one.
Installing the timing case

Fig. 4
Stick the new gasket on with a little grease.
Fit the flywheel housing. In doing so, examine the
oil pan gasket; replace if necessary.
Slightly oil the threads and the contact faces of the
mounting bolts and tighten the bolts to the speci-
fied torque.
87
Removing and installing the camshaft
Removing the camshaft

D Drain off coolant, see page 33
D Removing the oil pan, see page 47
D Removing the starter motor, see page 116
D Removing the flywheel and timing case, see page 87
D Removing the rocker arm mechanisms and tappet push rods, see page 70
Note:
When removing the camshaft, the engine must be turned by 180_. To do so, the engine must be
placed on a dolly.
Fig. 1
Turn the engine round so that the valve tappets
are not in the way when the camshaft is being re-
moved.
Pull out the camshaft; do not damage the cam-
shaft bearings in doing so.
Check the camshaft for wear and damage; replace
if necessary.
In the case of damage to the camshaft or drive
toothed wheel, the entire unit (camshaft − toothed
wheel) must be replaced.
Fig. 2
Use a magnet to pull out the valve tappets, check
for wear, replace if required.
Valve tappets can only be removed when the cam-
shaft has been removed.
88
Removing and installing the camshaft
Installing camshaft
Fig. 3
Oil and insert the valve tappets.
Oil the camshaft bearing bushings.
Oil the camshaft and insert carefully.
Caution:
Do not damage the bearings.
Fig. 4
In doing so, note the marking of the crankshaft and
camshaft toothed wheel.
89
Removing and installing camshaft bearing bushes
Note:
The engine is equipped with 7 camshaft
bearings. Bearing no. 1 is located on the
counter-flywheel side.
Press out the camshaft bearing bush,

bearing 1
Fig. 1
Use the impact extractor, special tool, see
page 159, item 24, to pull out the bearing bush of 1
bearing 1 from the counter-flywheel side.
1 2 3
Fig. 2
Special tool for pressing out bearing bushes 2 to 6
from the mounting tool, see page 159, item 26.
À Shaft with groove and fixed stop
Á Double-sided guide bush
Â Press-out plate
Press out camshaft bearing bush of

bearings 2, 3 and 4
Fig. 3
Use the special tool, see Fig. 2, to pull out bear-
ings 2, 3 and 4 from the counter-flywheel side.
Place the guide bush Á on the shaft with groove,
ensuring that you have the correct bush side (the
sides have different diameters!).
The spring-loaded balls lock into the oil holes.
2
3
Fig. 4
Place the press-out plate Â from the other side of
the stop onto the shaft and insert in bearing
bush 2. 2 3
Here, insert the guide bush Á with the small diam-
eter in the bearing hole and let the spring-loaded
balls lock into the oil holes.
The groove of the shaft must face upwards.
90
Fig. 5
Use a soft hammer (plastic or copper) to knock out
camshaft bearing bushes 2, 3 and 4 in succession.
Press out the camshaft bearing bush,

bearing 7
Fig. 6
Use the impact extractor, special tool, see
page 159, item 24, to pull out the camshaft bearing
bush of bearing 7 from the flywheel side.
Fig. 7
Pull out the bearing bush.
Press out camshaft bearing bushes of bear-

ings 5 and 6
Fig. 8
2
Press out the bearing bushes of bearings 5 and 6
from the flywheel side.
Place the guide bush Á on the shaft with groove,
The spring−loaded balls lock into the oil holes.
91
Fig. 9
Place the press-out plate Â from the other side of
the stop onto the shaft and insert in bearing 3 2
bush 6.
Here, insert the guide bush Á with the larger diam-
The groove of the shaft must then face upwards.
Fig. 10
Use a soft hammer (plastic or copper) to knock out
bearing bushes 6 and 5 in succession.
10
92
Installing the camshaft bearing bushes

Fig. 11 2 1
Depending on the number of the camshaft bearing,
there are various press-in plates, see also special
tool, page 159, item 26, for pressing in the bearing
bushes
Á Striking weight for À
Â Double-sided guide bush
Ã Press-out plate for bearing bushes 2 to 6
Ä Press-in plate for bearing bush 1
3 4 5 6 7 8
Å Press-in plate for bearing bushes 2 to 4 11
Æ Press-in plate for bearing bushes 5 and 6
Ç Press-in plate for bearing bush 7
Press in the camshaft bearing bush, bearing 2

Figs. 12 and 13
Place the bearing bush on the press−in plate Å.
Caution:
D One oil hole of the bearing bush must 6
be fixed in place by the spring-loaded
ball.
D The other oil hole must be flush with
the recess of the press-in plate
D The bearing bush must be seated up to 12
the stop on the press-in plate
13
Fig. 14
Place the guide bush Â on the shaft with groove,
When the shaft is put in place, the groove must
face upwards so that the guide bush is fixed in
place by the correct oil holes.
3
14
93
Fig. 15
Place the press-in plate Å with fitted bearing bush
on the shaft.
The press-in plate is fixed in place by the groove
6
so that the oil holes line up after pressing in.
15
Fig. 16
Here, insert the guide bush Â with the small diam-
eter in the bearing hole and let the spring-loaded 3 6
Apply the press-in plate Å with fitted bearing bush.
16
Fig. 17
Use a soft hammer (plastic or copper) to drive
camshaft bearing bush 2 in as far as it will go.
17
Press in camshaft bearing bushes,

bearings 3 and 4 1 3 4 6
Fig. 18
Arrangement of special tools:
Å Press-in plate
Ã Press-out plate as additional guide
18
94
Fig. 19
From the counter-flywheel side,
insert the press-out plate Ã in bearing 2. 3 4 6
Insert the shaft with guide bush Â through
bearing 1, then through the press-out plate Ã
(bearing 2).
Here, insert the guide bush Â with the small diam-
Place the press-in plate Å with fitted bearing bush
on the shaft. 19
The press-in plate is fixed in place by the groove
so that the oil holes line up after pressing in.
Fig. 20
Use a soft hammer (plastic or copper) to drive the
bearing bush into bearing 3 as far as it will go.
To fit bearing 4, proceed in the same manner.
20
Press in the camshaft bearing bush, bearing 1

Figs. 21 and 22
Place the bearing bush on the press-in plate.
Note:
The bearing bush and press-in plate Ä
for bearing 1 are wider than for
bearings 2 to 6. 5
Caution:
D One oil hole of the bearing bush must 21
be fixed in place by the spring−loaded
ball.
D The bearing bush must be seated up to
22
95
Figs. 23 and 24
Arrangement of special tools: 1 5 4 6
Ä Press-in plate for bearing bush 1
Ã Press-out plate for bearing bushes 2 to 6 as
additional guide
Å Press-in plate for bearing bushes 2 to 4 as
additional guide
From the counter-flywheel side,insert the press−
out plate as guide in camshaft bearing 2.
Insert the press−in plate Å in bearing 3 , letting the
spring-loaded ball for fixing the position of the shaft 23
À lock into the oil hole.
Insert the shaft up to the stop into the press-in
plate (bearing 2) and press-out plate (bearing 3).
Caution:
Do not twist the fixing from the groove.
The groove must face upwards.
24
Fig. 25
Place the press-in plate with fitted bearing bush on
the shaft.
The oil holes are covered in that the press−in plate 2
is fixed in position by the groove of the shaft.
Drive in the bearing bush with striking weight Á.
25
Fig. 26
Check all the pressed-in bearing bushes for seat-
ing and free access to the oil holes.
Caution:
Check that the bearing hole matches up
to the oil hole in the housing.
Minimum cross section with
mandrel ∅ = 2.5 mm.
26
96
Installing camshaft bearing bushes, bearings 3

and 4 1
2
Fig. 27
Special tool for pressing out bearing bushes 5, 6
and 7 from the mounting tool, see page 159,
item 26.
Á Striking weight for À
Ã Press-out plate as additional guide
Æ Press-in plate for bearing bushes 5 and 6 7 8 4 3
Ç Press-in plate for bearing bush 7 27
Fig. 28
From the counter-flywheel side, press in bearing
3
bushes 5 and 6 as described for bearing bushes 2,
3, and 4.
Insert the guide bush Â with large diameter in
bearing 7.
28
Fig. 29
Use a soft hammer (plastic or copper) to drive
bearing bush 6 in as far as it will go.
To fit bearing 5, proceed in the same manner.
Press in the camshaft bearing bush, bearing 7 29
Fig. 30
From the flywheel side,insert the press-out plate
as guide in bearing 5.
Insert the press-in plate as guide in bearing 6, let-
ting the spring-loaded ball for fixing the position of
the shaft lock into the oil hole.
Insert the shaft up to the stop into the press-in
plate (bearing 6) and press-out plate (bearing 5).
Caution:
Do not twist the fixing from the groove.
The groove must face upwards.
30
97
Fig. 31
Place the bearing bush with edge on the press-in
plate.
Caution:
D One oil hole of the bearing bush must
be fixed in place by the spring-loaded
ball.
D The bearing bush must be seated up to
31
Fig. 32
The oil holes are covered in that the press-in plate 2
is fixed in position by the groove of the shaft.
Drive in the bearing bush with striking weight Á.
32
Fig. 33
Check all the pressed-in bearing bushes for seat-
ing and free access to the oil holes.
Caution:
Check that the bearing hole matches up
to the oil hole in the housing.
Minimum cross section with
mandrel ∅ = 2.5 mm.
33
98
Checking the valve timing
Note:
Unsynchronised valve timing can cause
severe engine damage. For this reason,
following engine faults that can cause
twisting of the shrunk-on camshaft toothed
wheel, the correct seating must be
checked by checking the valve timing.
This check is also recommended after the
camshaft is fitted.
Fig. 1 1
Remove the cylinder head cover from the 1st cylin-
der.
Carefully adjust the exhaust valve of this cylinder.
Fig. 2
Continue cranking the engine until the valves on
cylinder no. 1 overlap.
Crank the engine back to approx. 50_ before TDC,
then forwards to 30_ before TDC (observe the
graduated marking on the flywheel).
Fig. 3
Place the dial gauge with approx. 2 mm initial ten-
sion on the valve spring retainer of the exhaust
valve on cylinder no. 1 and set to “0”.
Crank engine in the direction of normal rotation
through 180_ (the exhaust valve is then fully
closed).
Read the stroke of the valve on the dial gauge.
The valve stroke must be between 5.6 and 6.6
mm.
99
Removing and installing the crankcase yoke
Removing the crankcase yoke

D Remove the oil pan (see page 47) and oil suc-
tion pipe
Fig. 1
Undo the crankcase yoke mounting bolts and take
off the yoke.
Danger:
The crankcase yoke is heavy.
If necessary, place the engine on a dolly, 1
turn it by 180_ and use lifting gear.
Installing crankcase yoke

Figs. 2 and 3
Position crankcase yoke and tighten mounting
bolts to specified torque.
Tightening torque:
À Initial torque: . . . . . . . . . . . . . . . . . . . . 20−25 Nm
Angle tightening: . . . . . . . . . . . . . . . . . 180−190_
Á 35 Nm
Â 22 Nm 2
Fit oil pan and other detachable components.
1
2 3
3 1
100
Removing and installing the crankshaft
Removing the crankshaft

D Remove the oil pan (see page 47) and oil pump
(see page 47)
D Remove the crankcase yoke, see page 100
D Remove the timing case, see page 87
D Remove the front cover of the seal for the
crankshaft and cylinder heads
Fig. 1
Remove the bolts from conrod bearing caps, take
out the conrods with pistons and arrange them in 1
order of installation.
Fig. 2
Gradually loosen the securing bolts of the crank-
shaft bearing cover from inside to out and un-
screw.
Remove the bearing cover and place to one side in
the order of installation.
Remove the bearing bush halves from the bearing
covers and place to one side assigned to the bear-
ing covers.
Fig. 3
Remove the lower half of the contact washers.
Fig. 4 3
Lift the crankshaft out of the crankcase with hemp

rope or a leather belt.
Important:
If a steel cable is used, the contact sur-
faces of the crankshaft bearing journals
could be destroyed.
Remove the bearing shells and the upper halves of

the contact washers from the crankcase. If they
have not yet been marked, mark the bearing shell
halves for the bearing covers.
Clean the parts and check for wear; replace if
necessary. 4
101
Check the spread of the bearing bushes

Fig. 5
Place the bearing bushes together on a level sur-
face. Measure and note down dimensions
“A” and “B”.
B
Spread dimension = A−B
Install the crankshaft

Fig. 6 A
Clean the oil ducts in the crankcase and in the 5
crankshaft with dry compressed air.
Thoroughly clean the bearing bushes and journals.
Insert the bearing bushes in the crankcase, ob-
serving the numbering.
Tack the upper halves of the contact washer to the
crankcase with a little grease.
Important:
If new bearing bushes are used, pay
attention to the corresponding repair
level.
Fig. 7
Oil the bearing surfaces of the bearing bushes and
insert the crankshaft.
In doing so, note the marking of the crankshaft and
camshaft toothed wheel.
Fig. 8
Check bearing cover bolts for max. permitted
length (see “Service Data”).
Removed bolts can be reused if the max. per-
mitted length is not exceeded.
Complete the bearing covers in the installation se-
quence with the associated bearing bushes. 7
Oil the contact surfaces of the bearing shells and
fit the bearing caps.
Insert the bearing cover bolts and gradually tighten
from the outside to the inside to the prescribed
torque value.
Tightening torque:
Pretightening: . . . . . . . . . . . . . . . . . . . . 300−330 Nm
Check that the crankshaft runs smoothly.
Important:
Damaged bearing covers cannot be re-
placed on an individual basis.
8
102
Checking axial clearance

Fig. 9
Note:
The crankshaft axial clearance is deter-
mined by the centre crankshaft bearing
(thrust bearing).
D Fit the dial gauge bracket with dial gauge to the

crankcase
D Apply the tip of the dial gauge to the crankshaft
D Move the crankshaft back and forth in axial
direction and read off the clearance from the 9
dial gauge
D If the permitted axial clearance is exceeded,
fully replace the main bearing bushes
Fig. 10
Measure conrod bearings, insert pistons with con-
rods. Coat the conrod bushes with oil and pull the
conrods to the journals.
Fit the conrod bearing cover with bearing bush (ob-
serve marking - numbers must be on the same
side).
Screw in new securing bolts and tighten them in 10
stages to the prescribed value.
Tightening torque:
Fit oil pan and other detachable components.
103
Removing and installing pistons with conrods
Removing pistons with conrods

D Remove the oil pan and oil intake pipe,
see page 47
D Removing the cylinder heads, see page 70
Fig. 1
Loosen and remove the conrod bearing cover
bolts.
Fig. 2
Take off conrod bearing covers with bearing
bushes.
Note:
Conrod bearing caps are matchmarked
with the conrod bearing ends; arrange
them in the corresponding order.
Fig. 3
Remove combustion residues (oil carbon) from top
cylinder edge.
Caution:
Do not damage the cylinder liners!
Press out the conrod with piston upwards.
Caution:
Do not damage the oil injection nozzles!
3
Fig. 4
Lay pistons with conrods and associated covers
aside; use deposit rack if available.
Perform visual check of piston and piston rings.
Note:
For remachined crankcase sealing sur-
faces, there are repair pistons with 0.2, 0.4
and 0.6 mm lower dimension in compres-
sion height (see “Service Data”).
104
Installing pistons with conrods
Note:
If the pistons have to be replaced, it must
be determined whether oversize pistons
were fitted by measuring the pistons or re-
ading off the dimension on the piston
crown.
If this is the case, oversize pistons are to
be used.
Fig. 5
5
Check bearing bushes for wear and damage.
Measure spread as in the case of main bearing
bushes.
if required, fit new bearing bushes.
In the case of repairs to the conrod journals, use
bearing bushes of the corresponding repair level.
Fig. 6
Insert the bearing bushes in the conrod or conrod
bearing cover.
Caution:
The rod shell has a red or yellow mark on
the side. 6
The running surface must not be damaged!

Apply a thin coat of oil to the conrod bushes.
Fig. 7
Apply a thin coat of oil to the cylinder walls and
pistons.
Adjust the piston ring joints by approx. 120° each.
Apply piston ring tightener (special tool, see page
159, item 29) and tighten piston rings.
Note:
The picture shows a piston ring wrench as
used in the Nuremberg plant. 7
This wrench cannot be supplied as a
special tool.
Fig. 8
Insert the piston so that the recess on the piston
skirt points to the oil spray nozzle.
Guide the conrod and push the piston on until it
contacts the conrod foot on the conrod journal.
Caution:
Do not damage the oil injection nozzles!
105
Fig. 9
Caution:
Before attachment of conrods and conrod
bearing covers, ensure that bearing
shells are flush with cracked surfaces.
Fig. 10
Fit the conrod bearing cover.
Caution:
The numbers on the conrod bearing
cover and on the conrod foot must be on
one side.
After inadvertent attachment of cracked
conrods and conrod bearing covers that
do not belong together, the parts must
not be reused!
10
Fig. 11
Screw in the conrod bolts and tighten them in
stages to the prescribed value.
Caution:
Conrod bearing bolts which have worked
loose must be replaced.
Tightening torque:
11
Fig. 12
Turn the engine slowly.
The conrods and oil injection nozzles (arrow) must
not collide or scuff.
12
106
Removing pistons from conrod and installing,
checking − replacing conrod
Removing pistons from conrod and in-

stalling
Fig. 1
Remove pistons with conrods
Fit conrod in a vice, use protective jaws.
Disengage piston pin fastening.
Fig. 2
Press out the gudgeon pin, in doing so, hold the
piston. Remove the piston and place to one side.
Measure conrod foot bore (base hole)

Fig. 3
Insert new conrod bearings and fit cover.
Tighten bolts according to regulation.
Measure bearing bore hole with an internal micro- 1 8 mm 8 mm
meter in measuring directions 1, 2 and 3 as well as
planes A and B.
Max. permitted values, see “Service Data”. In the 2
A B
case of deviations beyond the tolerance range, 3
replace conrod.
Fig. 4
Piston pin sockets are not available. In the case of
worn sockets, fit replacement conrods.
107
Removing pistons from conrod and installing,
checking − replacing conrod
Fig. 5
Clean conrod. Check for externally visible damage;
if necessary, scrap damaged rods.
dia. 0.02A
Check parallel location of conrod and twisting of
piston pin eye to bearing bush bore hole. In the
case of deviations beyond the tolerance range,
replace conrod.
Figs. 6 and 7
Place piston on the conrod.
Caution:
The recess for the oil injection nozzle in
the piston shaft (arrow) must lie on the
side of the short conrod foot.
Insert piston pin. Engage fastenings.

Installing the pistons, see page 105.
108
Removing and installing piston rings
Piston ring arrangement

Fig. 1
À Compression ring (double-sided keystone ring)
Á Compression ring (tapered compression ring)
Â Oil scraper ring (bevelled-edge ring) 1
Removing piston rings

Fig. 2
Remove the pistons with conrods
Fit conrod in a vice, use protective jaws.
Set piston ring wrench to piston diameter.
Fig. 3
Apply piston ring wrench to piston ring joint and
disengage the piston ring from the piston ring
grooves.
Note:
The coiled spring expanders mean that the
oil scraper ring has greater tangential ten-
sion.
Carefully clean the piston ring grooves using saw-

dust. Do not damage the piston ring grooves.
3
Checking the ring end clearance

Fig. 4
Insert the piston rings individually in the cylinders
and use a feeler gauge to determine the ring end
clearance.
If the ring end clearance is too great, replace the
piston rings.
Ring end clearance, see “Service Data”.
109
Removing and installing piston rings
Installing piston rings

Figs. 5 and 6
Use the piston ring wrench to engage the piston TOP
rings in the relevant piston ring groove (TOP facing
upwards).
Checking piston ring axial clearance

Fig. 7
Determine the piston ring clearance in each piston
ring groove at various points using a feeler gauge.
To do so, press the piston ring fully into the piston
ring groove at the point to be measured.
If the clearance determined is too great, replace
the pistons and piston rings.
Piston ring axial clearance, see “Service Data”.
110
Replacing cylinder liners
Removing cylinder liners
Note:
Observe oversizes for cylinder liner out-
side diameters and collar heights (see
“Service data”).
D Remove the cylinder head, see page 70

D Remove pistons, see page 104
Fig. 1
Special tool for removing the cylinder liners, see
page 161, item 31. 1
Fig. 2
Mark cylinder liner position relative to engine so
that it can be reinstalled in the same position if re-
used.
Insert cylinder liner extractor device into cylinder
liner, taking care not to damage the oil spray
nozzle.
Fig. 3
Put support on extractor spindle and tighten nut.
Hold extractor spindle in place and extract cylinder
liner by turning nut.
Fig. 4
Take off extractor device and take out cylinder
liner.
111
Fig. 5
Deposit cylinder liner upright. Number cylinder
liners in order of installation.
Take off O-rings.
Fig. 6
Remove the O-rings from the crankcase. Clean the
seat for the cylinder liners in the crankcase.
112
Checking cylinder liner protrusion

Fig. 7
Clean basic bore and cylinder liner.
Insert the cylinder liner without O-rings into the
crankcase, observing the marking (ensure that it is
identical to the position prior to removal).
Measure the cylinder liner protrusion at a minimum
of four different points, using gauge holder and
gauge.
Specified values see “Service Data”.
Note:
If available, use a measuring plate for the 7
measurement (special tool, see
page 163, item 39). Proceed as follows:
D Position press-on measuring plate with
turned collar facing the liner using 2 fit-
ting sleeves to centre plate.
D Fit press-on measuring plate with
4 bolts (own manufacture: collar bolt
51.90020−0270, length shortened to
90 mm) on the press-on measuring
plate in stages and crosswise to
40 Nm.
D Set dial gauge combination above
press-on plate to “0” under preload
relative to the crankcase. Measure cyl- 8
inder liner protrusion at least at four
points.
Fig. 8
Install shim if the protrusion is below the minimum
protrusion even at only one point.
The shim is placed under the cylinder liner collar.
However, it may be used only if after installation
the upper tolerance limit is not exceeded.
113
Installing cylinder liners

Fig. 9
Insert dry new O-rings for the lower seal (144x4)
into the crankcase.
Insert new O-rings for the upper seal (138x2) into
the grooves on the cylinder liner.
Do not overstretch the O-rings.
Note:
No grease or sealing agents of any kind
must be used for installing cylinder liners
and O−rings.
9
Fig. 10 and Fig. 11

Apply thin coat of engine oil to cylinder liner in the
area of the upper and lower O-ring.
Apply thin coat of engine oil to lower O-rings in the
crankcase.
Insert cylinder liners into crankcase and push them
down by hand.
Place clean metal plate on liner and exert uniform
downward pressure until the liner is seated in the
crankcase recess.
If a perceptible resistance can be felt in this oper- 10
ation, the O-rings are no longer in their proper
place.
Reposition O-rings and insert cylinder liner again.
Note:
Measure cylinder liner protrusion after
installation of cylinder liners using special
tool (see page 163, item 39), see
page 113 to ensure that the O-rings are
seated correctly.
11
114
Measuring piston protrusion
Measuring piston protrusion

Fig. 1
Remove the cylinder heads.
Turn the piston to be measured to TDC.
Apply the dial gauge bracket with dial gauge to the
crankcase gasket surface.
Set the dial gauge to “0”.
Fig. 2
Carefully swing the dial gauge bracket around
while raising the tip of the dial gauge.
Lower the tip of the dial gauge to the piston crown
and read off the excess piston protrusion.
115
Removing and installing the starter motor
Fig. 1
Disconnect the negative cable from the battery or,
if present, switch off the main battery switch.
Disconnect connecting cable at Terminal 31 (nega-
tive electrode, thick cable), connecting cable Ter-
minal 30 (positive electrode, thick cable) and Ter-
minal 50 from the starter motor.
Fig. 2
Loosen the securing nuts.
Note:
An angle spanner is an advantage for
accessing the inner screws (see illustra-
tion).
Remove the starter motor.

Check the starter pinion for wear and whether it
can move freely. If required, clean the pinion with a
brush dipped in fuel and grease it again.
2
Check the toothed flywheel ring for wear and damage.
Turn over engine by hand once, paying particular attention to the positions at which the engine finally stops;
i. e. when the engine is switched off it always stops in certain positions.
The starter pinion engages in these positions when the engine is started.
Replacing the starter motor toothed ring, see page 55.
The starter motor is installed in reverse order to its removal; when doing so, connect the cables correctly
and tighten the bolts as specified.
Connect the battery or turn on the battery master switch.
Check the function of the starter motor after installation.
116
Servicing V-belts
Checking condition
Fig. 1
D Check V-belts for cracks, oil, overheating and
wear
D Replace damaged V-belts
Checking tension
Figs. 2 and 3
1
Use the V−belt tension tester to check V−belt ten-
sion.
1
D Lower indicator arm À into the scale
D Position the tension gauge Á on the belt at a
point midway between two pulleys so that the
edge of contact face locates against the side of
the belt
D Slowly press the pad Â until the spring can be
heard to disengage. This will cause the indica-
2
tor to move upwards
If pressure is maintained after the spring has dis-
engaged, a false reading will be obtained! 2
Note:
Always measure the tension with the
V-belt cold.
With the V-belt at operating temperature,
the tension force rises by up to 10 kp
(10 kg on the device scale), which can
lead to an incorrect setting. 3
3
Reading of tension
Fig. 4 Tensioning forces according to the
kg graduation on the tester
D Read off the tension at the point where the top
of the gauge arm (À in Fig. 2) intersects the Drive belt New installation When serser-
scale width After 10 vicing after
D Before taking readings make ensure that the Installation min. run- long run-
indicator arm remains in its position ning time ning time
If the value measured deviates from the setting 2/3VX 90−100 70−80 60
value specified, the V−belt tension must be cor- 4 4/3VX 180−200 140−160 120
rected.
117
Servicing V-belts
Tightening and replacing V-belts for

driving alternators
Fig. 5
Loosen the securing bolts of the tension pulley.
Fig. 6
Tension with the V-belt adjusting nut.
Tensioning or replacing the V-belt to

the alternator drive
Fig. 7
Unscrew the mounting bolts of the alternator and
tensioning device.
Fig. 8
D Remove the counternut À
D Use adjusting nut Á to tension the V-belt
1
D Retighten lock-nut and fixing bolts
Retighten all the mounting bolts of the alternator
and tensioning device. 2
118
Electronic speed governor GAC
Basic design
An electronic speed governor system consists of three components:
1. Speed pickup
In MAN engines, the speed pickup À is located on the flywheel housing. It works according to the induction
principle It consists of a permanent magnet surrounded by a coil.
Depending on whether a tooth of the starter gear ring Á is before the magnet or not, the magnetic field
changes and induces in the coil an AC voltage which is proportional to the engine speed and serves as
input signal for the control unit.
2 1
2. Electronic control unit

The electronic control unit receives the signal (actual value) generated by the speed pickup and compares
it with a preset value (nominal value).
If the actual and the nominal values are identical, the electronic control unit will generate an output signal
with which the actuator will be activated.
3. Actuator
In GAC governors, for example, the actuator is a spring-loaded linear solenoid.
This solenoid is connected to the control rod of the injection pump and changes its position according to the
signal from the control unit. As a result, the injection quantity and, consequently, engine speed are con-
trolled.
119
The electric control unit

The GAC ESD 5221 electronic speed governor is used as an example here to give a general overview of
the possibilities provided by this control system and to show what characteristic data can be set or altered.
When installing and commissioning, please observe the Operator’s Manual for the respective speed gov-
ernor model.
1 3 4
2
8
9
10
11
+ 12
−
13
20
16 15 14
19
17
18
120
À LED display for electronic overspeed control

Á Output contacts “Overspeed” LED display for overspeed
Â Overspeed reset button: initial position of the relay contacts after overspeed signal has been sent. Re-
setting can also be effected by briefly interrupting the battery power supply.
Ã Overspeed test button, lowers the switching point by approx. 12%
Ä 25-step potentiometer: adjustment of the overspeed. Run the engine at nominal speed. Press the test
button, simultaneously turning it to the left, until the engine shuts down and the display lights up.
Å 25-step potentiometer: setting the nominal speed
Æ Setting the stability
Ç Setting the sensitivity
È Additional assistance for stability improvement. In the event of very slow pendulum motion,
set 10−20 mF capacitor from E3 to E2.
É This makes it possible to set the lower idling speed limit if “L” and “M” are connected.
11 Setting the P degree if “L” and “K” are connected.
12 Stabilised voltage 10 V for triggering additional modules.
13 Input for signals from synchroniser, load divider, smoke limiter etc.
14 Connect “G” and “H” only if a high P degree (10%) is required.
15 Operation at low idling speed if L and M are connected.
16 P degree operation if “K” and “L” are connected.
17 Speed precision setting (only required for remote control)
18 Battery
19 Pulse generator
20 Actuator
Caution:
Except in emergency cases, the engine must never be switched off by interrupting the cables for
the actuators, but only by interrupting the battery supply.
121
Troubleshooting with GAC governor
Fig. 1
The control unit is equipped with a terminal strip
for the connections of the output and input signals.
Checking procedure: Engine does not − +

start BATTERY
Fig. 2 E F
Check battery voltage on control unit during start-
ing procedure.
Min. value: 17 V direct current
Otherwise, replace battery or reduce voltage drop
in the supply line.
_
V
2
Figs. 3 and 4
Check speed pickup signal on control unit during PICK-UP
starting procedure.
Min. value: 0.8 V alternating current C D
Otherwise check distance “D” of speed pickup, if
necessary correcting it, see page 124.
If distance “D” is correct, but the voltage still too
low, disconnect the cable from terminals “C” and
“D” on the control unit and measure the resistance
between both cables.
~ V
Correct value: 150−200 W
If the value deviates, replace the speed pickup.
3
122
Troubleshooting with GAC governor
Fig. 5
Check actuator. ACTUATOR
Remove both actuator cables from control unit and
measure resistance.
A B
Correct value: 4.6−5 W
If the value deviates, check cabling and plug. If
the cabling and plug are in order, replace the
actuator.
W
5
Fig. 6
ACTUATOR
If resistance as per Fig. 5 is in order, connect both
cables to battery voltage. The actuator must then
switch to max. position. A B
If it does not, the transmission linkage to the injec-
tion pump control rod or the control rod itself is
blocked.
If the linkage is in order, replace the actuator.
6
Fig. 7
If the actuator element is in order, but still fails to ACTUATOR
move during the starting procedure, the output
voltage at the actuator terminals of the control unit
are to be checked during the starting procedure.
A B
Min. value: 17 V direct current
If no voltage is present, the control unit is defec-
tive.
Caution:
Before installing a new control unit, always _
check the cabling and the actuator circuit V
for short circuits.
7
123
Removing and installing the speed pickup
Fig. 1
The speed pickup is fitted to the bottom right−hand
side of the flywheel housing.
To remove it, disconnect cable from terminal, re-
move the mounting bolts from the retaining plate
and take it off together with the speed pickup.
Fig. 2
After the installation, distance “D” between the
speed pickup and the gear ring of the flywheel
must be checked and, if necessary, readjusted.
Fig. 3
To do so, proceed as follows:
D Loosen counter nut and unscrew the speed
pickup.
D Turn gear ring so that one tooth is in centre
position relative to the thread bore.
D Screw in speed pickup as far as it will go.
D Turn it back by one revolution and fit counter
nut.
124
Overspeed protection
If an electronic speed governor is used, an over-

speed protection independent of the governor must
be provided.
For this purpose, an electromagnetic shut-off valve
(EHAB) is installed in the fuel supply line to the
injection pump. If the governor fails, this valve will
shut off the fuel supply, thus preventing the engine
from revving up in an uncontrolled manner.
Proposal for the circuitry of an electromagnetic shut-off valve
15A
30
1
15 50
10A
EHAB
50
F 1 2 3
M E
2 3
À Starter lock
Á GAC control unit
Â GAC actuator
125
Coolant level probe
Monitoring the coolant level

All engines are equipped with either one or two coolant level probes for monitoring the coolant level in the
coolant expansion tank. This a capacitative probe. The sensor and the evaluating electronics form a unit.
If the coolant falls below the level monitored, a minus potential is sent to the signal output “S”.
This can activate a check lamp or a relay.
Checking the coolant level probe

The probe features an integrated checking function. As soon as voltage is applied to the probe, the signal
appears for approx. 2 seconds to signalise that the probe is ready for operation.
If this signal does not appear, the probe must be checked.
It is not possible to carry out a functional check by measuring the resistance (ohmmeter) because of the
internal transistors.
The check can be carried out with a water tank and a small test bulb (v 3 Watts).
Dip the probe into the water and apply a supply voltage of 24 V to the plus and minus leads. The output “S”
is to be connected to the plus lead via the test lamp. The test lamp does not come on.
If the probe is taken out of the water, the test lamp must come on after approx. 7 seconds.
If the lamp does not come on, the probe is defective and must be replaced.
max. 3 W 24 V
+
S S
− −
126
Service Data
127
Specifications
Engine
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in-line, vertical
Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-stroke-Diesel with turbocharger and in-
tercooler
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 : 1
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 mm
Engine capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 816 cm3
Direction of rotation viewed on flywheel . . . . . . . . . . . . . . . . . . . . anti clockwise
Power based on DIN ISO 8528
D 2876 LE 201
Genset variable prime power (PRP=Prime Power)
ICXN, 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 kW at 1500 rpm
ICXN, 1800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 kW at 1800 rpm
D 2876 LE 202
Genset continuous power (COP=Continuous Power)
ICXN, 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 kW at 1500 rpm
ICXN, 1800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 kW at 1800 rpm
D 2876 LE 203
Limited-time running power (LTP=Limited Time Running Power)
ICXN, 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 kW at 1500 rpm
ICXN, 1800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461 kW at 1800 rpm
Ratings according to DIN ISO 3046/1
Standard reference conditions: Air tem-
perature 298 K, air pressure 1000 mbar,
humidity 60%
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure circulation
forced feed lubrication by gear oil pump
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In main flow
Filling capacities
Flat oil sump
Oil capacity in oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . min. 24 ltr.
max. 30 ltr.
Oil change quantity (with filter) . . . . . . . . . . . . . . . . . . . . 33 ltr.
Deep oil sump
Oil capacity in oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . min. 34 ltr.
max. 40 ltr.
Oil change quantity (with filter) . . . . . . . . . . . . . . . . . . . . 43 ltr.
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid cooling
Coolant temperature D 2876 LE201 / 202
normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°C
temporarily allowed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95°C
Coolant temperature D 2876 LE203
normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100°C
temporarily allowed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105°C
128
Dimensions
Service Data
Limit values
Crankcase
Standard: 153.90−153.94 mm
for cylinder liners with 0.5 und 1.0 mm
larger outside Ø: 154.40−154.50 mm
Ø Standard: 145.80−145.84 mm
for cylinder liners with 0.5 mm larger
outside diameter: 146.30−146.34 mm
9.955−10.025 mm
Standard: 144.50−144.54 mm
Ø
Cylinder liner
Standard: 153.694−153.757 mm
with 0.5 and 1.0 mm larger outside Ø:
Ø 154.194−154.257 mm
Ø
Standard: 10.05−10.07 mm
with 0.5 mm more flange height:
10.55−10.57 mm
0,005 Standard: 145.761−145.786 mm

with 0.5 mm larger outside Ø:
146.261−146.286 mm
146.761−146.786 mm
Ø
127.990−128.010
Max. wear limit:
0.15 mm below base dimension
Standard: 144.432−144.457 mm
144.932−144.957 mm
with 1,0 mm larger outside Ø:
145.432−145.457 mm
Ø Liner protrusion above upper deck of
crankcase: 0.03−0.08 mm
129
Dimensions
Service Data
Limiting values
Crankshaft
Crankshaft, front (opposite side to flywheel)

99.985−100.020 mm
Standard size: 89.98−90.00 mm

undersize −0.25: 89.73−89.75 mm
undersize −0.50: 89.48−89.50 mm
undersize −0.75: 89.23−89.25 mm
Ø
undersize −1.00: 88,98−89,00 mm

Ø
undersize −0.25: 103.73−103.75 mm

undersize −0.50: 103.48−103.50 mm
undersize −0.75: 103.23−103.25 mm
undersize −1.00: 102.98−103.00 mm
Bearing race for crankshaft, front end

Inner diameter:
99.907−99.942 mm
Ø
Thrust bearing journal

undersize:
−0.25 and −0.50: 46.500−46.562 mm
−0,75 and −1,00: 47.000−47.062 mm
130
Dimensions
Service Data
Limiting values
Main bearing
Data for wall thickness and bearing
inner diameter also apply to the align-
ment bearing
undersize −0.25: 3.591−3.603 mm
undersize −0.50: 3.716−3.728 mm
undersize −0.75: 3.841−3.853 mm
undersize −1.00: 3.966−3.978 mm
Bearing bore in installed condition:

undersize −0.25: 103.810−103.856 mm
undersize −0.50: 103.560−103.606 mm
undersize −0.75: 103.310−103.356 mm
undersize −1.00: 103.060−103.106 mm
Spread: 0.3−1.2 mm
Marking: top / bottom
standard size: 0005 / 0055
undersize −0.25: 0011 / 0058
undersize −0.50: 0013 / 0059
undersize −0.75: 0015 / 0060
undersize −1.00: 0017 / 0061
Permissible axial clearance of crankshaft:

0.200−0.401 mm
Thrust bearing width (thrust washer):

Repair stage 1: 3.600−3.650 mm
Repair stage 2: 3.850−3.900 mm
38.961−39.000 mm
Mounting bolts for crankshaft bearing caps

Length During tightening the bolts are
intentionally stressed beyond the yield
point and therefore subjected to some
100 permanent elongation each time they are
tightened. When the bolt has reached its
maximum length, it must not be re-used.
new: 152.5−153 mm
max.: 154.5 mm
131
Dimensions
Service Data
Limiting values
Flywheel and starter motor gear ring
Ø Flywheel: 432.490−432.645 mm
Internal gear ring Ø:
432.000−432.155 mm
Interference: 0.335 − 0.645 mm
Installation temperature: 200−230_C
m= 65.1 kg (with starter gear)

J= 2.412 kgm2
Number of teeth: Z=160, module 3

Matching gear: Starter pinion (Z=9)
Backlash: 0.6−0.9 mm
132
Dimensions
Service Data
Limiting values
Conrods
50.055−50.065 mm
Ø
A
Ø 0.02
A
Conrods which are discoloured at the big
end must not be re-installed.
1 8 mm 8 mm Bearing bore in measuring directions 1, 2
and 3 and in measuring planes A and B:
90.044−90.086 mm
2
A B Pre-condition:
3
New conrod bearing in place,
conrod assembled
Conrod bearings
undersize −0.25: 2.593−2.603 mm
undersize −0.50: 2.718−2.728 mm
undersize −0.75: 2.843−2.853 mm
undersize −1.00: 2.968−2.978 mm
Spread: 0.5−46.065 mm
If signs of wear are present (scores, anti-
waer coating damaged), change both
bearing shells.
Important: Note installation position
(upper half bearing shell has red mark on
the side)
Connecting rod bolt
Removed conrod bearing bolts must be

replaced as a general principle.
133
Dimensions
Service Data
Limiting values
Pistons
Compression height: 79.20−79.25 mm

with undersize
0.2 mm: 79.00−79.05
0.4 mm: 78.80−78.85
0.6 mm: 78.60−78.65
Piston protrusion above deck of crank-
Ø case: 0.013−0.331
50.03−50.04 mm
Piston bolt diameter:
49.994−50.000 mm
Ø
127.885−127.895 mm
20
Piston weight difference per set in an

engine: max. 100g
Piston ring grooves

2,5
3.47−3.50 mm
3.05−3.07 mm
II
III
4.02−4.04 mm
Piston rings
2,5
I 1st ring − keystone ring

Height: 3.296−3.330 mm
II 2 nd ring − taper faced compression ring:

Height: 2.97−3.00 mm
Axial clearance:0.05−0.10 mm
III 3rd ring − bevelled ring
Height: 3.975−3.990 mm
Axial clearance:0.030−0.065 mm
Ring gap:
1st ring: 0.50−0.70 mm
2nd ring: 0.70−0.90 mm
3rd ring: 0.25−0.55 mm
134
Dimensions
Service Data
Limiting values
Cylinder head
Ø
12.000−12.018 mm
Ø
Intake valve: a = 60_

Exhaust valve: b = 45_
a b
a = 3.3−3.8 mm
b = 3.3−3.8 mm
A B
Ø
Valve guide bore in cylinder head:
Ø 18.000−18.018 mm
Valve guide outside diameter:
18.028−18.046 mm
Standard: 113.9−114 mm
Minimum: 112.9 mm
(observe specified dimensions for valve
recess)
Ø Bore in cylinder head:

Ø 53.00−53.03 mm
Valve seat insert outside diameter:
53.10−53.11 mm
Bore in cylinder head:
61.00−61.03 mm
Valve seat insert outside diameter:
61.10−61.11 mm
135
Dimensions
Service Data
Limiting values
Valves
Ø
Intake valve: 11.968−11.982 mm
Exhaust valve: 11.945−11.955 mm
Max. wear limit: max. 0.1 mm
Valve recess for intake and exhaust

valve: 0.7−1.3 mm
Valve springs
Inner spring:
Length (L) untensioned, approx. 65.5 mm
Spring force at L = 46.3 mm: 128−152 N
Spring force at L = 32.3 mm: 255−294 N
Outer spring:
Length (L*) untensioned, approx. 59 mm
Spring force at L* = 46.8 mm: 324−353 N
L* L
Spring force at L* = 32.8 mm: 696−755 N
136
Dimensions
Service Data
Limiting values
Valve train
Rocker bracket
24.967−24.980 mm
14
Rocker arm
Rocker arm radial clearance:
0.025−0.054 mm
Wear limit: 0.08 mm
25.005−25.021 mm
Camshaft
Change if signs of wear are present
Camshaft axial clearance: 0.20−0.90 mm

Wear limit: 1.5 mm
Ø
Ø
69.910−69.940 mm (Ø 70 e7)
Backlash:
Crankshaft gear and camshaft gear:
0.118 mm−0.242 mm
Camshaft bearings
70.00−70.03 mm diameter 70.070

Ø
70.070−70.090 mm for bearing 7

(last bearing on gear case side)
137
Dimensions
Service Data
Limiting values
Valve tappet
Ø
19.944−19.965 mm
Matching bore in crankcase:
20.000−20.021 mm
Valve clearance
set when engine is cold
Intake valve: 0.5 mm
Exhaust valve: 0.6 mm
Valve timing
1 1 = Engine direction of turn
2 TDC 2 = intake valve opens 23° before TDC
3 3 = exhaust valve closes 30° after TDC
4 = exhaust valve opens 60° before BDC
5 = intake valve closes 12° after BDC
6 = exhaust valve opening angle 270°
7 = intake valve opening angle 215°
6 The degrees specified refer to the crank-

7 shaft angle
5 BDC
Compression pressures
good above 28 bar
permitted 25−28 bar
repair required below 24 bar
Pressure difference (between the individual cylinders) max. 4 bar
Backlash
Crankshaft gear and camshaft gear 0.118−0.242 mm
Crankshaft gear and oil pump drive gear 0.099−0.451 mm
Oil pump gears 0.312−0.476 mm
138
Dimensions
Service Data
Grenzwerte
Engine lubrication
Valve opening pressures
Bypass valve for oil filter 2−3 bar
Overpressure valve on the oil pump 9−10 bar
Pressure valve of the oil injection nozzles
Opening pressure 1.3−1.5 bar
Closing pressure 1.9−2.1 bar
Spray hole diameter of the oil injection nozzles 2.8−2.9 mm
Oilpump
Two-gears oil pump with shallow oil pan

Oil pump gear
11.5−11.7 mm
42.911−42.950 mm (Ø 43 e8)
Housing depth:
43.000−43.039 mm (Ø 43 H8)
Axial clearance: 0.050−0.128 mm
Shaft: 21.930−21.940 mm
Ø
Bore Ø in housing:
22.000−22.021 mm (Ø 22 H7)
Drive gear with oil pump gear
Shaft: 21.930−21.940 mm
Ø
Bore in drive gear:

21.870−21.885 mm
Press on force: 12000 N
0,5 mm
Backlash:
Drive wheel and crankshaft wheel:
0.099−0.451 mm
139
Dimensions
Service Data
Grenzwerte
Three gears-oilpump with deep oil pan

Oil pump gear
14.5−14.7 mm
27.927−27.960 mm (Ø 28 e8)
Housing depth:
28.000−28.033 mm (28 H8)
Axial clearance: 0.040−0.106 mm
Shaft: 21.930−21.940 mm
Ø
Bore Ø in housing:
22.000−22.021 mm (Ø 22 H7)
Drive gear with oil pump gear
Shaft: 21.930−21.940 mm
Ø
Bore in drive gear:

21.870−21.885 mm
Press on force: 12000 N
0,5 mm
Backlash:
Drive wheel and crankshaft wheel:
0.099−0.451 mm
140
Dimensions
Service Data
Limiting values
Cooling system
Engine coolant pump
Gap: 0.5−0.9 mm
Ø impeller: 135−136 mm
Bore for bearing shaft in impeller:

16.006−16.024 mm
Ø of bearing shaft: 16.043−16.056 mm
Interference: 0.019−0.050 mm
Bearing seat in housing:

54.93−54.96 mm
Ø of bearing: 54.981−54.994 mm
Hub bore:
25.007−25.020 mm
Ø of bearing shaft: 25.048−25.061 mm
Thermostat
Opening begins at: 79_C ("2_)

Fully open: 94_C
25.4−25.8 mm
Lift at least 8 mm at 94_C
141
Dimensions
Service Data
Limiting values
Valve cover at expansion tank

Valve cover with working valve (small
cover) opens at 0.85 bar−1.15 bar above
atmospheric pressure, 0.02 bar−0.08 bar
below atmospheric pressure
Valve cover with safety valve (for filler
neck, large cover) opens at
1.3 bar−1.7 bar above atmospheric pres-
sure
142
Dimensions
Service Data
Limiting values
Turbocharger
Axial clearance
Axial clearance: max. 0.16 mm
Radial clearance
Radial clearance: max. 0.58 mm
143
Dimensions
Service Data
Limiting values
Fuel system
Injectors
Manufacturer Bosch
Type of injector DLLA 152 P 486
Number of holes 6
Opening pressure of injector
New nozzle holder: 340 + 10 bar
Used nozzle holder: 320 + 10 bar
Nozzle holder KDEL 82 P
Projection above cylinder head
Eliminate nozzle protrusion by using Cu

sealing rings of different thickness. These
sealings are available in thicknesses of
0.5 / 1.0 / 1.5 / 2.0 / 2.5 / 3.0 mm
2.25−3.24 mm
144
Dimensions
Service Data
Limiting values
Injection pumps and governors

D 2876 LE 201 / 202 / 203
In-line injection pump: PES 6 R120 / 700 LS1520
Governor GAC-governor ACE 275 HD−24
Start of delivery
Model Start of delivery −1° crank angle before
TDC (Constant speed = without timing
adjustment)
Industrial engines Auxiliary marine
engine
D 2876 LE 201
1500 rpm, constant 14° 16°
D 2876 LE 202
1500 rpm, constant 14° −
1800 rpm, constant 14° −
D 2876 LE 203
145
Dimensions
Service Data
Limiting values
Starter motor
Manufacturer: Bosch
Type: KB
Operating method: splined shaft
Starter motor pinion:

Number of teeth: Z=9
Module: 3
Nominal power: 5.4 kW

Nominal voltage: 24 V
Alternator
Manufacturer: Bosch
Type: NCB1
Design: 1 pole, insulated
Mode of operation: Threephase current
Voltage: 28 V
Max. current: 80 A
or
Manufacturer: Bosch
Type: NCB2
Design: 1 pole, insulated
Mode of operation: Threephase current
Voltage: 28 V
Max current: 110 A
V-belts
Change damaged V-belts (cracks, wear,
oil)
Measuring tension withtension tester
Tensioning forces according to

the kg graduation on the tester
New installation When
Drive belt
servicing
width After 10 after long
Installa-
min. run- running
tion
ning time time
2/3VX 90−100 80−90 60
4/3VX 180−200 140−160 120
146
Dimensions
Service Data
Limiting values
Speed pickup
Turn one tooth of gear ring in centre posi-

tion relative to the thread bore, screw in
speed pickup until it stops, turn it back by
one revolution and fit counter nut
147
Torque guide values
Note:
All screw connections whose purpose is not stated in the following table are to be tightened in
accordance with the guide values in our company standard M 3059 (see page 150). Fit the bolts
slightly oiled!
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
Crankcase, crankshaft drive
Gear case to crankcase M14, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Nm

Gear case to crankcase M10, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Inspection port cover to gear case M8, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Crankshaft bearing caps to crankcase M18x2
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300−330 Nm
Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100°
Vibration damper to crankshaft M16x1.5, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Nm
Flywheel to crankshaft M16x1.5
1st angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100°
2nd angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100°
Pleuellagerdeckel M14x1.5
Cylinder head
Tightening / retightening the cylinder-head bolts, see page 151.
Rocker arm bracket to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Nm
Locknut on valve adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
148
Torque guide values
Lubrication system
Oil pump to crankcase M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm

Cover oil pump M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Oil cooler to oil filter head M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Cover to oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Oil pan to crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Oil drain plug to oil pan M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Oil spray nozzle: Flange to crankcase M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Exhaust / intake manifold
Exhaust manifold to cylinder head M10

Intake pipe to cylinder head M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Fuel system
Injection pump drive gear M8, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Nm

Injection pump to crankcase M10, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Injector to cylinder head M28 x 1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120−125 Nm
Nozzle tensioning nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Pressure pipe to injection pump
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
rotation angle for first installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
rotation angle for assembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Starter
Starter to timing case M12x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
149
Torque guide values
Installation tightening torques according to company standard M 3059
Bolts / nuts with external or internal hexagon, head without collar or flange
Thread size x pitch Grade / Tightening torque in Nm

for 8.8 / 8 for 10.9 / 10 for 12.9 / 12
M4 2.5 4.0 4.5
M5 5.0 7.5 9.0
M6 9.0 13.0 15.0
M7 14.0 20.0 25.0
M8 22.0 30.0 35.0
M8x1 23.0 35.0 40.0
M10 45.0 65.0 75.0
M10x1.25 45.0 65.0 75.0
M10x1 50.0 70.0 85.0
M12 75.0 105.0 125.0
M12x1.5 75.0 110.0 130.0
M12x1.25 80.0 115.0 135.0
M14 115.0 170.0 200.0
M14x1.5 125.0 185.0 215.0
M16 180.0 260.0 310.0
M16x1.5 190.0 280.0 330.0
M18 260.0 370.0 430.0
M18x2 270.0 290.0 450.0
M18x1.5 290.0 410.0 480.0
M20 360.0 520.0 600.0
M20x2 380.0 540.0 630.0
M20x1.5 400.0 570.0 670.0
M22 490.0 700.0 820.0
M22x2 510.0 730.0 860.0
M22x1.5 540.0 770.0 900.0
M24 620.0 890.0 1040.0
M24x2 680.0 960.0 1130.0
M24x1.5 740.0 1030.0 1220.0
150
Torque guide values
Tightening the cylinder-head bolts on a new engine

(Engine cold or warm)
The cylinder heads are fitted with cylinder−head
bolts for rotation angle tightening. On new en- Erster Nachzug der Zylinder-
gines, the cylinder-head bolts are retightened at kopfschrauben erledigt
the factory after running in and marked by the
sticker “First retightening of cylinder-head
bolts ...” on a cylinder head cover. First retightening of cylinder-
head-bolts completed
After the first 400 hours of operation, tighten the

cylinder-head bolts 1 to 4 in the order specified in Spare part no. 51.97801−0211
the tightening schedule “1” by 90° (1/4 turn).
Intake side / injection nozzle

The two outer bolts (intake and exhaust side)
must not be retightened.
Note:
The cylinder-head bolts to be retigh-
tened must not be loosened; they are to 1 4
be tightened further from their current
position by 90° (1/4 turn).
3 2
Exhaust side
Remove the sticker “First retightening of the Tightening schedule “1”
cylinder-head bolts ...” and attach the sticker
“Second retightening of the cylinder−head
bolts ...” to verify the second retightening.
Zweiter Nachzug der Zylinder-
kopfschrauben erledigt
Second retightening of cylinder-

head-bolts completed
Spare part no. 51.97801−0212
151
Torque guide values
Tightening the cylinder-head bolts following a repair

(engine cold)
Before inserting the cylinder-head bolts, apply Intake side / injection nozzle
engine oil to the thread (not the threaded hole)
and coat the seating surface of the bolt head with
6
installation paste “Optimoly White T”. Do not use
oils or oil additives containing MoS2. The bolts
are to be tightened using the rotation angle
method according to tightening schedule “2” as
follows.
1 4
D 1st pretightening = to 10 Nm
D 2nd pretightening = to 80 Nm
D 3rd pretightening = to 150 Nm
D 4th pretightening = 90°
D Final tightening = 90°
Set the valve clearance.
3 2
5
Exhaust side
Tightening schedule “2”
Retightening the cylinder-head bolts following a repair

(Engine cold or warm)
After the first 10 to 20 hours of operation, following a repair, tighten the cylinder-head bolts in the order
specified in the tightening schedule “2” by 90° (1/4 turn).
The cylinder-head bolts to be retightened must not be loosened; they are to be tightened further from their
current position by 90° (1/4 turn).
Attach the sticker “First retightening of cylinder-head bolts ...” (remove sticker that might already be
attached).
After the first 400 hours of operation, following a repair, tighten cylinder−head bolts 1 to 4 in the order
specified in the tightening schedule “1” by another 90° (1/4 turn).
The two outer bolts (intake and exhaust side) must not be retightened.
Attach sticker “Second retightening of cylinder-head bolts ...”.
Note:
When the head has been removed, the cylinder head gasket must always be replaced.
152
Torque guide values
Reuse of used cylinder−head bolts
Check
Before used cylinder-head bolts are reused, they
must be checked as follows:
90+3
L
Length
During tightening the bolts are intentionally L = shaft length
stressed beyond the yield point and therefore
subjected to some permanent elongation each
time they are tightened. Shaft lengths L in the Largest permitted
case of new bolts dimension
109 mm 111 mm
Surface 144 mm 146 mm
The bolts must have a perfect surface, i.e. closed 168 mm 170 mm
phosphatisation and no rust stains.
Rusted or damaged bolts or bolts stretched be-
yond the maximum length are to be made unus-
able immediately − e.g. by hammering the thread
− and to be scrapped.
153
154
Special tools
Special tools
155
Special tools
1 2 3
4 5 6
7 8 9
10 11 11.1
10.2
10.1
11.2 12 13
14 15 16
156
Special tools
Fig. no. Designation Item code

1 Engine cranking tool 80.99626−6008
with standard ratchet 80.99627−0001
2 Wrench socket for cylinder head bolts (Torx) 08.06143−0215
3 Oil filter wrench 80.99606−0508
4 Valve gauge for valve setting 80.99607−6019
5 Valve setting key 80.99603−6007
6 Handle for valve setting wrench 80.06460−0003
7 Press-in mandrel for cassette sealing in conjunction with handle 11.1 80.99617−0191
8 Puller for front crankshaft bearing race 80.99601−0076
9 Rotation angle measuring device 80.99607−0134
10 Driving mandrel for seal in flywheel housing
consisting of:
10.1 Guide bush 80.99604−0068
10.2 Press plate in conjunction with handle 11.1 80.99604−0069
11 Driving mandrel for race on flywheel in conjunction with handle 11.1 80.99617−0017
11.1 Attachment handle for all press-in plates 80.99617−0129
11.2 Puller for bearing race on the flywheel 80.99601−6017
12 Guide pins for flywheel 80.99617−0020
13 Valve fitting lever 80.99606−0031
14 Test connection for compression recorder 80.99607−0002
15 Inertia extractor for fuel injectors 80.99602−0011
16 Clamping device for fuel injectors 80.99606−0008
157
Special tools
17 18
17.1
17.3
17.6 17.2
19
17.7 17.5
17.4
20 21 22
23 24 25
26 27
28 29 30
158
Special tools

17 Special tool for front crankshaft seal 80.99606−6011
Components:
17.1 Spindle 80.99606−0229
17.2 Extractor device 80.99606−0298
17.3 Adapter 80.99606−0264
17.4 Extractor hook 80.99606−6013
17.5 Press-in sleeve 80.99606−0300
17.6 Adapter 80.99606−0302
17.7 Application sleeve 80.99606−0301
18 Press-in mandrel for cap, dia. 50.2 mm 51.91606−0053
19 Press-in mandrel for cap, dia. 62.2 mm 51.91606−0045
20 Straightedge for cylinder heads 80.99605−0175
21 Guide pins for flywheel 80.99617−0020
22 Piston ring pliers 83.09144−6090
23 Inserting mandrel for camshaft 80.99617−6007
24 Extractor device for front and rear camshaft bearing bush 80.99606−6103
in conjunction with:
25 Impact extractor 80.99602−0016
26 Mounting tool for camshaft bearing bushes 80.99606−6099
27 Piston ring scuff band 80.99613−0035
28 Piston ring tensioning sleeve 83.09144-0187
29 Dial gauge holder 80.99605−0172
30 V-belt tension tester 80.99605−0279
159
Special tools
31 32
33 34 35
36 37 38
38.1
38.2
160
Special tools

31 Extractor apparatus for cylinder liners 80.99601−6018
32 Power wrench 1:3.3 / 242.5 − 800 Nm 80.99619−0006
33 Mounting tool for cylinder head bolts 80.99606−6100
34 19 mm socket for flywheel bolts in conjunction with item 32, 35 80.99603−0311
35 Brace in conjunction with item 32, 34 80.99606−0585
36 27 mm socket for main bearing bolts with item 32, 37 80.99603−0312
37 Brace in conjunction with item 32, 36 80.99606−0584
38 Pressing tool for valve guides
38.1 Press mandrel for valve guide 80.99617−0013
38.2 Press rings in conjunction with 38.1 80.99616−0003
161
Special tools
1
3
4
39
5
40
41
162
Special tools

39 Measuring combination for measuring the cylinder liner protrusion
consisting of:
À Dial gauge 08.71000−1205
Á Tracer pin for dial gauge 80.99605−0197
Â Dial gauge bracket 80.99605−0179
Ã Support pin 80.99605−0180
Ä Dial gauge bracket 80.99605−6006
Å Dial gauge bracket 80.99605−0172
40 Press-on measuring plate 80.99605−0195
41 Fitting sleeves 51.91701−0247
163
Special tools
Special tools for coolant pump repair for improvised manufacture

(material: steel, as available)
Support ring for pressing out coolant pump bearing
dia. 68
dia. 56
90
164
2,52
3
B−
2,52
Generator
E1
Alternator
W L 15 S
30
B+
1 2 3 4 5
Startanlage und
15
Stromversorgung
X1
162
min 16
2
50
Starter system and power supply

min 50
2
2,52
50
31
Anlasser
M
Starter
30
+
−
Batterie
Battery
1
Elektrohydraulische
a
Abstellvorrichtung EHAB
F
Electric hydraulic
shut down device
L
31
G
2,5 2
−
H
Stellglied
Regelgerät
T
Actuator
RK
Control unit
J
+
51.11610−7135 ESD 5550 CE
Engine control
Motorregelung
Plug A4
K
Stecker A4
15
D+
Drehzahlgeber
−
L
C
Speed sensor
162
+
M
D
50
P
N
V
31
Schaltgerät für
E2
Flammstartanlage Temperaturgeber
50 T
A4
Control unit for Temperature sensor

flame starter
81.25902−0497
Unmarked cables 1mm2

87 D+ 15
MV RK
Lieferumfangsvereinbarung
the agreed extend of delivery

Komponentenbeistellung nach
Components provided according to
Nicht bezeichnete Leitungen 1mm2

Verdrahtung nicht Lieferumfang MAN
Circuit diagram
Magnetventil
Solenoid valve
Flammstartanlage
Flame start system
Wiring not included in MAN’s extent of delivery
Last-Schaltgerät
125A
85
A5
Power switiching 62
unit Flammglühkerze
86 30
87
F1
81.25902−0415 Flame glow plug
62
Flammglühkerze
Flame glow plug
+
Kühlmittelniveausonde
−
Coolant level probe

S
165
Wartungsschalter,
Verbrennungsluft
Service switch,
combustion air
Öldruckgeber
Engine control
P
Oil pressure sensor

Motorüberwachung
Kühlmitteltemperaturgeber
T
Coolant temperature sensor

8138
Circuit diagram
166
Index
A Crankshaft seal
Aiir filter, Maintaining . . . . . . . . . . . . . . . . . . . . . . . 60 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Air filter cartridge, replacing . . . . . . . . . . . . . . . . . 60 Replacing at front . . . . . . . . . . . . . . . . . . . . . . . . 52
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Replacing at rear . . . . . . . . . . . . . . . . . . . . . . . . 56
Crankshaft seals, Assembly instructions . . . . . 58
B Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Bearing race on flywheel side, Replacing . . . . . 57 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
C
Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Checking protrusion . . . . . . . . . . . . . . . . . . . . . 113
Removing and installing . . . . . . . . . . . . . . 88–89
Removing and installing . . . . . . . . . . . . . 111–113
Camshaft bearings
Cylinder sequence − diagram . . . . . . . . . . . . . . . 75
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Cylnder liners, Protrusion . . . . . . . . . . . . . . . . . . 129
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Checking conrod . . . . . . . . . . . . . . . . . . . . . . . . . 107 E
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Electro−hydraulic shut−off valve . . . . . . . . . . . . 125
Compression pressure, Checking . . . . . . . . . . . . 86 Electronic engine speed control . . . . . . . . . . . . 119
Compression pressures . . . . . . . . . . . . . . . . . . . 138 Electronic speed governor
Conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . 133 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Coolant Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . 122
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Engine commissioning after overhaul . . . . . . . . 13
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . 139
Coolant level probe . . . . . . . . . . . . . . . . . . . . . . . 126 Engine overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Engine specifications . . . . . . . . . . . . . . . . . . . . . 128
Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mechanical seal . . . . . . . . . . . . . . . . . . . . . . . . . 41 Exhaust manifold, Removing and installing . . . . 62
Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removing and installing . . . . . . . . . . . . . . . . . . 36 F
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Combustion air / coolant . . . . . . . . . . . . . . . . . . 42 Removing and installing . . . . . . . . . . . . . . . . . . 54
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fuel filter cartridge, Replacing . . . . . . . . . . . . . . . 32
Fan radiator, outside cleaning . . . . . . . . . . . . . 43 Fuel prefilter, Cleaning . . . . . . . . . . . . . . . . . . . . . 31
Filler caps and service valves . . . . . . . . . . . . . 44 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Inside cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
removing lime deposits . . . . . . . . . . . . . . . . . . . 44 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . 102 , 129
Crankcase yoke, Installing and I
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 100–101 Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Removing and installing . . . . . . . . . . . . . . . . . . 23
Checking the axial clearance . . . . . . . . . . . . . 103 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removing and installing . . . . . . . . . . . . 101–103 Injectors
Crankshaft axial clearance . . . . . . . . . . . . . . . . . 131 assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Crankshaft bearing . . . . . . . . . . . . . . . . . . . . . . . 131 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Crankshaft bearing cover . . . . . . . . . . . . . . . . . . 101 Projection above cylinder head . . . . . . . . . . . 144
Removing and installing . . . . . . . . . . . . . . . . . . 26
167
Index
Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . 144 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Intake manifold, Removing and installing . . . . . 59 Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Removing and installing . . . . . . . . . . . . . . . . . 116
L Starter motor toothed wheel, Replacing . . . . . . . 55
Lubrication system, Schedule . . . . . . . . . . . . . . . 15
T
O TDC mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Oil cooler, removing and installing . . . . . . . . . . . 46 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Oil filter, Replacing the filter element . . . . . . . . . 45 Thermostats
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Disassembling and assembling . . . . . . . . . . . 48 Removing and installing . . . . . . . . . . . . . . . . . . 35
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Timing case, removing and installing . . . . . . . . . 87
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Torque guide values . . . . . . . . . . . . . . . . . 148–154
Oil spray nozzle, Removing and installing . . . . . 50 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Oil spray valve, Checking . . . . . . . . . . . . . . . . . . . 50 Axial and radial clearance . . . . . . . . . . . . . . . . . 69
Oil sump capacities . . . . . . . . . . . . . . . . . . . . . . . 128 Checking charging pressure . . . . . . . . . . . . . . . 66
Overspeed protection . . . . . . . . . . . . . . . . . . . . . 125 Removing and installing . . . . . . . . . . . . . . . . . . 67
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 64
P
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . 134–136 V
checking axial clearance . . . . . . . . . . . . . . . . . 110 V−belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Checking ring end clearance . . . . . . . . . . . . . 109 Checking tension . . . . . . . . . . . . . . . . . . 117–118
Removing and installing . . . . . . . . . . . . . . . . . 109 Tightening and replacing . . . . . . . . . . . . . . . . . 118
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134–136 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Measuring protrusion . . . . . . . . . . . . . . . . . . . . 115 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Removing from conrod and installing . . . . . . 107 Valve cover, expansion tank . . . . . . . . . . . . . . . 142
Pistons with conrods, Removing Valve guide, Removing and installing . . . . . . . . . 79
and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Valve recess . . . . . . . . . . . . . . . . . . . . . . . . . . 78 , 84
R Valve seat, Reworking . . . . . . . . . . . . . . . . . . . . . 82
Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Rocker arm mechanism, Valve seat insert, Removing and installing . . . . 80
Dismantling / assembling . . . . . . . . . . . . . . . . . . . 76 Valve tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
S Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . 6–11 Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Safety regulations Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Handling used engine oil . . . . . . . . . . . . . . . . . . . 8 Refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Preventing accidents with injury to persons . . . 6 Removing and installing . . . . . . . . . . . . . . . . . . 77
Preventing damage to engine and Vibration damper, Removing and installing . . . . 51
premature wear . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preventing environmental damage . . . . . . . . . . 7 W
Service Daten . . . . . . . . . . . . . . . . . . . . . . . 127–153 Waste water treatment . . . . . . . . . . . . . . . . . . . . . 44
Special tools . . . . . . . . . . . . . . . . . . . . . . . . 155–164
Speed pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Removing and installing . . . . . . . . . . . . . . . . . 124
Setting value . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Start of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . 145
168

MAN Engine - Repair Manual - Model D2876LE201

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What safety precautions are highlighted in the document?

What safety precautions are highlighted in the document?

What components does the document provide instructions for working on?

What components does the document provide instructions for working on?

Foreword

Fitting flat seals / gaskets

Assembly of round sealing rings

Masking of fuel and lube oil pipe con-

Flywheel / Crankshaft seals

Intake- and exhaust system

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

1. Regulations designed to prevent accidents with injury to persons

D Do not touch hot engine with bare hands: Risk of burns.

D Follow the manufacturer’s instructions for handling batteries.

D When performing welding work, observe the “Notes for welders”.

2. Regulations designed to prevent damage to engine and premature wear

3. Regulations designed to prevent pollution

4. Notes on safety in handling used engine oil *

Ensure that used engine oil is disposed of in the appropriate manner.

Operating faults and possible causes

1. Starter turns over engine only slowly or not at all

1. Starter turns over engine only slowly or not at all

Diagram of the oil flow with unpressurised engines

Pressurising an engine affords the following advantages:

À Oil suction pipe Å Bypass valve

Á Combustion air pipe to intercooler

Â Combustion air pipe from intercooler

Ä Electro-hydraulic shut-off (EHAB)

12 Oil drain plug

À Overflow and ventilation line Æ Filling line

À Injection pump Å Overflow valve

Checking start of delivery

To avoid read-off errors, always look over the

If the inspection reveals that the start of delivery is

Setting start of delivery

Removing the injection pump

Take off injection pump.

Installing injection pump

Removing fuel injectors

Installing fuel injectors

Checking fuel injectors

1. Checking opening pressure:

Dismantling the fuel injector

Repairing fuel injector

Check cleaned parts for wear and damage, replac-

Assembling fuel injector

Ensure that the sieve bar filter is correctly

Cleaning fuel prefilter

Replacing the fuel filter cartridge

Venting fuel system

D Draining off coolant, see page 33

D Draining coolant, see page 33

Disassembling the coolant pump

Reassembling coolant pump

Installation note for mechanical seal

Cleaning the outside of the fan radiator

Cleaning inside the cooling system

Removing lime deposits in cooling system