Man D 2866 LUE 602 Repair Manual Download

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Repairing engine water pump

D 2866 LUE 602

Fig. 5
Pull impeller off the pump bearing.
For this purpose four threaded bores M8 are provi-
ded.

Fig. 6
Align water pump housing on a suitable and stable
surface.

Use a suitable mandrel to press the water pump
shaft together with bearing out of the housing.
Shaft and bearing are encapsulated and replaced
as a single unit only.

Take off axial face seal.

Assembling water pump

Fig. 7

Press in water pump bearing.

Use a hollow mandrel to apply pressure to the bea-
ring outer ring but not to the bearing shaft.

Fit the circlip.

Fig. 8
Press V-belt pulley flush on to bearing shaft.

Summary of Contents for D 2866 LUE 602

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Page 3: ...xpert knowledge necessary for handling Diesel engines was taken for granted when this publication was compiled Any repair of components such as injection pump alternator etc ought to be left to our or the manufac turer s service department Yours faithfully MAN Nutzfahrzeuge Aktiengesellschaft Nuremberg Works We reserve the right to make technical modifications in the course of further development ...

Page 4: ...n parts with different rates of linear expansion under heat e g aluminium and cast iron and leaks may then 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 Flat...

Page 5: ...ng and installing engine water pump 41 Repairing engine water pump D 2866 LUE 602 43 Repairing coolant pump with high temperature and low temperature parts D 2866 LUE 605 48 Cleaning cooling system 55 Lubrication Changing the oil filter 57 Removing and installing the oil cooler 58 Removing and installing the oil pan 60 Removing and installing Repairing Oil Pump 62 Removing and Installing Oil Spray...

Page 6: ...ng pistons with conrods 112 Removing pistons from conrod and fitting checking replacing conrod 115 Removing and installing replacing piston rings 117 Replacing cylinder liners 119 Measuring piston protrusion 123 Attachments Removing and installing the starter motor 124 V belts 125 Pilot clutch D 2866 LUE 602 127 Service Data Engine 132 Crankcase 133 Cylinder liner 133 Crankshaft 134 Flywheel and s...

Page 7: ...E 602 605 D The D at the start of the type classification stands for diesel 28 The numbers 28 indicates that the power plant in question has a bore of 128 mm 6 The 6 means 160 mm stroke This figure is however only approximate for this model The actual stroke is 155 mm 6 The 6 indicates the number of cylinders 6 L This letter stands for charge air cooling German Ladeluftkühlung U The U stands for U...

Page 8: ...rised persons D The engine must be started and operated by authorised personnel only D When the engine is running do not get too close to revolving components Wear tight fitting working clothes D Do not touch hot engine with bare hands risk of burning yourself ËË D Keep engine vicinity ladder and steps free of oil and grease Accidents resulting from slipping may have serious consequences D Work on...

Page 9: ...uine 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 operate the engine while it is dry i e without lubricant or coolant Use a suitable label to mark engines not ready for operation D Only use operating materials fuel engine oil antifreeze and anticorrosion agents approved by MAN Ensu...

Page 10: ...th hazard if the basic safety and hygiene related regulations are observed Health and safety regulations D Avoid prolonged excessive or repeated contact of old engine oil with the skin D Use a suitable skin protection agent or wear protective gloves D Clean the skin that has been in contact with engine oil Wash yourself thoroughly with soap and water A nailbrush is an effective aid Special hand cl...

Page 11: ... relation to the values measured on commissioning the engine D Power D Exhaust temperature D Coolant and lubricant temperature D Oil pressure and oil consumption The following criteria greatly influence the length of the engine service life D Correct power setting in accordance with conditions of use D Technically correct installation D Inspection if installation by authorised personnel D Proper d...

Page 12: ...e 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 lube 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...

Page 13: ... 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 ope...

Page 14: ...Notes 12 ...

Page 15: ...he 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 wh...

Page 16: ...tarter starter interlock relay defective carbon brushes worked loose worn winding defective short to ground x x x x Engine oil viscosity unsuitable not suitable for ambient temperature lubricating oil quality does not correspond to specifications x x Oil level in sump too high x Oil level in sump too low oil in sump too thin mixed with condensate or fuel x Engine temperature too high x Oil filter ...

Page 17: ... x x x o Fuel high pressure system injection pump worn incorrectly set o x o o Fuel high pressure system injection pump constant pressure control valve re turn flow constrictor faulty x x x o x EHAB defective drive faulty o o o x o x x x Injection pump engine synchronisation start of delivery incorrect basic installa tion start of delivery set incorrectly x x x x o x o Injection pump controller st...

Page 18: ...ne speed control cannot be activated does not switch off engine revs too high 18 Fuel consumption too high 19 Lubricating oil pressure too low 20 Lubricating oil pressure too high 21 Lubricating oil consumption too high 22 Engine too loud mechanical noise Possible causes x Coolant level too low air in coolant circuit x V belt for water pump drive not tensioned correctly x Incorrect V belt tension ...

Page 19: ...Memoranda 17 ...

Page 20: ...Engine views 18 Engine views 3 4 2 1 7 6 5 8 11 10 9 ...

Page 21: ... Crankcase breather 3 Oil filter 4 Turbocharger 5 Flame starter sheathed element glow plug 6 Solenoid valve for flame starter 7 Electro hydraulic cutout EHAB only D 2866 LUE 602 8 Oil drain plugs 9 Pilot clutch 10 TDC mark 11 Water pump ...

Page 22: ...e for oilcooler 13 Oil suction pipe 4 Bore for injection pipe lubrication 14 Spray nozzles for piston cooling 5 injection pump 15 Bore for main bearing lubrication 6 Bore for oil cooler 16 Bore for thrust bearing 7 Bore for gudgeon pin lubrication 17 Oil pressure sensor 8 Oil pressure relief valve 18 Bore for camshaft bearing lubrication 9 Oil pump 19 Bypass valve 10 Oil suction pipe 20 Oil filter...

Page 23: ...602 3 4 3 1 2 5 6 7 8 9 10 11 1 Flame starter sheathed element glow plug 7 Hand pump 2 Soleniod valve 8 Fuel filter 3 Injection pump 9 Fuel supply from tank 4 Fuel return to tank 10 Fuel pre filter 5 Leak fuel 11 Electro hydraulic shut off EHAB 6 Fuel delivery pump ...

Page 24: ...system Schematic diagram D 2866 LUE 605 1 2 5 3 3 4 9 8 7 6 1 Flame starter sheathed element glow plug 6 Tank 2 Solenoid valve 7 Fuel pre filter 3 Injection pump 8 Hand pump 4 Fuel return to tank 9 Fuel Filter 5 Fuel delivery pump ...

Page 25: ... Diagram 23 10 9 8 7 6 5 4 1 3 2 1 Surge tank 6 Retarder oil cooler 2 Positive pressure negative pressure valve 7 Thermostat 3 Coolant filler neck 8 Water pump 4 Thermostat 9 Oil cooler 5 Radiator 10 Engine crankcase ...

Page 26: ...Engine management schedule 24 1 2 3 4 6 5 1 Oil pump impeller gear 4 Injection pump drive gear 2 Oil pump drive gear 5 Idler gear 3 Crankshaft gear 6 Camshaft gear ...

Page 27: ...re is another scale engraved on the flywheel which can be read through an inspection hole in the flywheel housing but access may be difficult The scale should be used for readjusting the pointer after the vibration damper has been re moved or replaced In other words before the vibration damper with the scale disc is installed the engine should be positioned at OT top dead centre by means of the sc...

Page 28: ...means of the following special tools 1 Light signal transmitter Fig 6 Push light signal transmitter into socket in gover nor housing Ensure that the lug fits in the groove Tighten the knurled nut by hand Turn engine by hand so that piston in cylinder no 1 in the compression stroke comes close to the start of delivery Lamp A comes on shortly before start of delivery is reached Fig 7 Slowly turn the...

Page 29: ...o be achieved with a plug in sleeve The sleeve is to be made of aluminium or steel Set engine to start of delivery as described above Insert the sleeve into the governor housing up to the stop The start of delivery is set exactly when the pointer for start of delivery is in the centre of the 3 mm bore in the sleeve ø9 ø15 ø12 ø11 ø3 29 13 15 30 ...

Page 30: ...r head cover from cylinder no 6 flywheel end When the values of this cylinder are in crossover the piston in cylinder no 1 is at ignition TDC Remove screw plug from governor housing see Fig 5 The delivery start pointer must be visible in the centre of the inspection hole Fit a socket wrench to the mounting bolts and turn the injection pump camshaft at the drive flange to the left or right until th...

Page 31: ...tch escaping fuel in a suitable contai ner Fig 3 Remove holders from injection pump Unscrew the mounting bolts from the injection pump flange Take off injection pump Note Ensure meticulous cleanliness when wor king on the injection pump Prevent dirt and foreign matter from pe netrating into opened line connections Installing injection pump Fig 4 Remove screw plug from governor housing If fitted ta...

Page 32: ...e Remove the mounting bolts from the injection pump drive gear so that it can be turned in the slots Hold the injection pump camshaft in place while turning the gear Fit a new O ring lightly oiled on the injection pump flange Fig 7 Insert the injection pump and tighten the mounting bolts to specified torque Fig 8 Provisionally tighten all the mounting bolts of the gear through the inspection hole ...

Page 33: ...uel injector using a pin spanner Fig 3 Screw adapter on to nozzle holder Screw on inertia extractor and knock out nozzle holder Take sealing ring off the injection nozzle Check and repair injector see page 33 Installing fuel injectors Fig 4 Insert new sealing ring apply Never Seeze to the contact points of the nozzle holder and insert nozzle holder with nozzle into cylinder head Screw on union nut...

Page 34: ...side of the pressure screw to the threaded portion of the pressure screw and to the nozzle holder see shaded area Fig 6 Fit fuel return line together with new sealing rings to the nozzle holders and tighten to specified tor que Screw the pressure lines to the nozzle holders and to the injection pump and tighten to specified tor que ...

Page 35: ...re deviation insert a differ ent shim If the pressure is too low insert thicker shims if it is too high insert thinner shims Æ The initial tension of the compression spring Å de creases if a high number of operating hours has been clocked up Consequently the injection pressure drops slightly When repairing injection nozzles always set the opening pressure to the upper limit Note Shims are availabl...

Page 36: ...and petrol or Diesel fuel Clean nozzle needle Á with a clean cloth Clean coked nozzle needle surface on lathe with a piece of wood not too hard dipped into oil Note To prevent corrosion do not touch lapped faces of nozzle needle with the fingers The needle and injection nozzle are matched to each other and must not be interchanged Check cleaned parts for wear and damage replac ing them if necessar...

Page 37: ...ghtening it to the specified torque see Service Data Check injector on the manual test stand Ensure that the edge type filter is correctly seated in the injector body Fig 9 A dislocated sieve bar filter À throttles and pro longs the injection and consequently causes poor performance high consumption and heavy smoke formation in conjunction with heavy engine vibra tions For this reason measure the ...

Page 38: ...jection pump can be heard to open D Screw in and tighten the hand pump plunger D Start the engine D Check the fuel prefilter for leaks Cleaning fuel pre cleaner D 2866 LUE 605 Strip the fuel pre cleaner D Remove filter housing À D Wash out filter housing À and gauze filter Á in clean Diesel fuel and blow them out with com pressed air D Reassemble with a new seal D Screw on filter housing and tight...

Page 39: ...as dange rous waste and must be disposed of ac cordingly Bleeding the fuel system Note To bleed the fuel system switch on the ignition so that the EHAB will be open An arrow on the filter head indicates the direction of fuel flow D Unscrew the vent screw of the first filter in the direction of flow by one or two turns D Actuate tappet of hand primer until fuel emer ges without bubbles D Screw in a...

Page 40: ...sheathed element glow plug with Hylo mar until it stops at the counter nut and align it with fuel line Connect up fuel line and electric connection Tighten counter nut Checking solenoid valve for leaks Remove fuel line from flame glow plug When the engine is running and hot no fuel must emerge Removing solenoid valve Fig 3 D Remove fuel lines D Remove electric connection from valve D Remove the tw...

Page 41: ... of drinking water from the mains and anti freeze based on ethylene glycol and or anticorrosion additive See Publication Fuels Lubricants and Coolants for MAN Diesel Engines Coolant must be poured in according to the vehicle manufacturer s filling specifications Do not pour any cold coolant into an engine which is still warm Ensure that the ratio of water to anti freeze is correct D Pour in coolan...

Page 42: ...as follows D Suspend the thermostat in a bowl of water D Heat up the water D Using a suitable thermometer ascertain the start of opening and compare it with the setpo int value in Service data D If necessary measure the opening stroke Replace defective thermostats Install thermostat inserts with ball valve facing up wards TOP with new O ring and new seal Caution Never let the enging run without th...

Page 43: ...water pump D Draining off coolant see page 39 D Remove the thermostats see page 40 Take V belt off see page 125 Fig 1 Remove V belt pulley Fig 2 Remove the mounting bolts from water pump and take off water pump Clean the sealing faces on water pump and engine housing ...

Page 44: ... permits small amounts of coolant to pass through it This coolant passing through results in a trace of drained coolant below the drain bore The water pump need not be exchanged or repaired because of this trace of permeating coolant For this reason before replacing or repairing a coolant pump ascertain D whether the cooling circuit shows visible and recurring signs of coolant loss if yes D whethe...

Page 45: ... 6 Hub 7 Circlip Remove water pump see page 41 Disassembling water pump Fig 2 Clamp the water pump in a vice use protective jaws Pull off V belt pulley with three arm puller Fig 3 Unclip the circlip from the coolant pump housing Fig 4 Knock out cover by driving a suitable mandrel un der it Fig 1 item 3 at notch arrow 1 2 3 4 5 6 7 ...

Page 46: ...ace Use a suitable mandrel to press the water pump shaft together with bearing out of the housing Shaft and bearing are encapsulated and replaced as a single unit only Take off axial face seal Assembling water pump Fig 7 Press in water pump bearing Use a hollow mandrel to apply pressure to the bea ring outer ring but not to the bearing shaft Fit the circlip Fig 8 Press V belt pulley flush on to be...

Page 47: ...al on page 47 Note The seal can be exchanged even without removing the water pump shaft Fig 10 Slowly press impeller on to bearing shaft to ensure correct gap Fig 11 For this purpose an inspection hole closed up with a screw plug M16x1 5 is provided on the bottom of the water pump housing 1 Impeller 2 Water pump housing Fig 12 Fit new pump cover and press it into housing using a suitable pressing ...

Page 48: ... special tools see chapter Special tools and proceed as follows D Align guide ring Á with the two dowel pins on the pump housing D Insert pressing ring À into guide ring D Place a flat steel min thickness 10 mm on the pressing ring D Press cover into housing using a press Attach water pump with new seal see page 41 2 1 ...

Page 49: ...te 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 antiseize 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 loca ting bore in the coolant pump housing i...

Page 50: ...coolant pump HT circuit 8 Mechanical seal 51 06520 0099 9 Counterring complete 51 06520 0100 10 Impeller for coolant pump LT circuit 11 Splash shield 12 Mechanical seal 51 06520 0096 13 Water pump bearing 14 Drive shaft for coolant pump 15 Circlip 16 Water pump seal 17 Grooved ball bearing 6003 18 Cap Disassembling water pump Fig 3 Removing the water pump see page 41 Clamp water pump in a vice use...

Page 51: ...ded bores M8 are provi ded Fig 7 Note Remove bolt from low temperature part Fig 1 item 5 Align water pump housing on a suitable and stable surface Use a suitable mandrel to press the water pump shaft together with bearing out of the housing Take off mechanical seal The high temperature part and the low tempera ture suction part are now separated Remove axial face seals and grooved ball bearing fro...

Page 52: ...n to bearing shaft Fig 10 Turn water pump housing over Press in new me chanical seal with press fitting sleeve special tool until it stops Observe installation note for seal on page 47 Fig 11 Press in counterring arrow with a suitable pres sing tool may be possible by hand Install mechanical seal while wet i e to install it coat holding sleeve and water pump shaft with a mixture of either 50 water...

Page 53: ...ve special tool until it stops Observe installation note for seal on page 47 Fig 14 Lay coolant pump gasket on pump housing Fig 15 Carefully fit low temperature suction part to high temperature pump housing To make assembly easier insert 2 pins in opposite sides of HT part see Fig 14 Do not use force hammer etc and note the 3 centring features see arrows in Fig 14 Screw in bolt Fig 1 item 1 Bolt L...

Page 54: ...ion using special tool Fig 17 Press in new mechanical seal pos 6 with press fitting sleeve special tool until it stops Observe installation note for seal on page 47 Fig 18 Slowly press impeller on to bearing shaft to ensure correct gap Fig 19 For this purpose an inspection hole closed up with a screw plug M16x1 5 is provided on the bottom of the water pump housing 1 Impeller 2 Water pump housing 2...

Page 55: ...1 If no suitable pressing tool is available you may use self made special tools see chapter Special tools and proceed as follows D Align guide ring Á with the two dowel pins on the pump housing D Insert pressing ring À into guide ring D Place a flat steel min thickness 10 mm on the pressing ring D Press cover into housing using a press Attach water pump with new seal see page 41 1 2 ...

Page 56: ...allation note for mechanical seal Install mechanical seal while wet i e to install it coat holding sleeve and water pump shaft with a mixture of either 50 water and 50 cleaning spirit or 40 to 50 antifreeze agent as per MAN 324 and water Other antiseize 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 loca ting bore in th...

Page 57: ...nti freezing agents and corrosion inhibitor or defect not early enough replaced covers for filler neck and working valves If twice in a short time the water pump of an engine develops leakes or the coolant is heavily contaminated dull brown mechanically contaminated grey or black signs of a leakage on the water pump casing after the defect on the oil cooler clean the cooling system prior to removi...

Page 58: ...e bottom edge as otherwise foaming will cause the pickling fluid to spill over Damaged tube bundles may develop leaks when dirt deposits are removed Filler caps and working valves of cooling system The rubber gaskets of the filler caps and working valves negative pressure and positive pressure valves of the cooling system are subject to natural aging To preclude leakages in the cooling system and ...

Page 59: ...sing and filter insert are filled with hot oil danger of burns and scalding Reinsert oil drain plug with new gasket Fig 2 Loosen the securing bolt of the filter cup Remove filter cup and clean inside Fig 3 Insert a new filter cartridge and reinstall the filter casing with new seals Observe tightening torque for securing screw Note To avoid twisting the gasket hold the fil ter cup while tightening ...

Page 60: ... that the oil does not overflow Danger The oil is hot risk of scalding Do not touch the oil drain plug with bare fingers Oil is an environmental hazard Handle it with care D Draining off coolant see page 39 D Remove oil filter see page 57 Fig 2 Unscrew the mounting bolts from the oil cooler housing Remove the oil cooler housing together with the oil cooler Fig 3 Remove the oil cooler from the hous...

Page 61: ... Fig 5 Take a new o ring for oil cooler housing Screw on oil cooler housing together with attached oil cooler Fig 6 Tighten the securing bolts with the prescribed tor que D Attach oil filter with new seals D Top up engine with oil D Top up coolant ...

Page 62: ... ensure that the oil does not overflow Danger The oil is hot risk of scalding Do not touch the oil drain plug with bare fingers Oil is an environmental hazard Handle it with care Fig 2 Remove EHAB crankcase breather and oil filler neck Remove engine loom Fig 3 Tighten the securing bolts of the oil pan Take off oil pan Caution Oil pans are heavy It is now supported only by the lower oil Fitting the...

Page 63: ...Removing and installing the oil pan 61 Fig 5 Fitting the EHAB crankcase breather and oil filler neck Refit oil drain plugs with new seals Fill up the engine oil Check oil level Check the oil pan for leaks ...

Page 64: ...ipes Measure backlash between oil pump drive gear and crankshaft gear and compare value with the nominal value Replace worn gears Fig 2 Remove pressuer relief valve Opening pressure see Service Data Fig 3 first remove the 2nd pump À with intermediate shaft Á connection sleeves Â and circlips Ã Fig 4 Remove 1st oil pump 1 2 3 3 4 4 ...

Page 65: ...nd pump housing for wear Fig 7 Remove the oil pump drive gear To do this lay the pump on a suitable surface and press off the drive gear with a mandrel To install place the drive gear on the shaft sup porting the opposite shaft end in the process Press on the drive wheel observing the prescribed gap see Service Data Fig 8 Fit the cover Tighten the securing bolts with the prescribed tor que Grind o...

Page 66: ...e Installing oil pump Fig 10 Before installing check whether the oil pumps runs smoothly and then fit them free of tension Fit oil suction line with seal in a tension free man ner Screw on pressure relief valve without seal Tighten the securing bolts with the prescribed tor que Fig 11 Before installing the oil pan crank the engine to check whether the crank gear and the oil pumps run unimpeded and...

Page 67: ...which are used as marker points for installing the nozzle in the event of repairs Checking oil spray nozzle valve Fig 3 Use a piece of wire to check whether the valve plunger is easy to move Opening pressure see Service Data Installing the oil spray nozzle Fig 4 Screw in the oil spray nozzle together with its valve The balls of the oil spray nozzle must be located in the impressions designated for...

Page 68: ...Memoranda 66 ...

Page 69: ...ank the engine to TDC This ensures that it is easier to fit the graduated disc during subse quent assembly work D Block the crankshaft drive D Relieve tension on the V belt and remove the belt D Remove the delivery start pointer Fig 2 Loosen the securing screws of the vibration dam per À Note Prior to removal mark the position of the vibration damper relative to the cranks haft This will ensure th...

Page 70: ... 3 Loosen the securing screws of the cover Fig 4 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 Replacing bearing race Fig 5 A stripping device special tool is required to re move the bearing race Fig 6 Pull off the bearing race ...

Page 71: ...Fig 8 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 Á on the adapter with collar nut and thrust washer Â and Ã in Fig 9 Note The bearing race can also be mounted when the cover is fitted Replacing radial shaft sealing ring Fig 9 To ensure perfect installati...

Page 72: ... of the scale disc relative to the cranks haft as you do so Tighten the securing bolts with the prescribed tor que Fig 12 Screw on delivery start indicator Tensioning V belt Fig 13 Therefore check whether the scale of degrees on the inspection hole cover of the flywheel housing and on the vibration damper indicate the same va lues If necessary readjust delivery start indicator ...

Page 73: ...ssembly clean all clutch parts see page 127 Push pre assembled clutch on to driver flange and fasten it with interior bolts Á 69 Nm Connect propshaft to clutch again and fit washer Â with bolts À 25 Nm Positions of individual parts are marked Comply with specified torques Caution Unblock the crankshaft drive 1 2 3 ...

Page 74: ...eel with suitable lifting gear Danger The flywheel is heavy Use lifting gear Fitting flywheel Fig 3 Insert the guide pins Coat the sealing face on the inside of the flywheel with Antipor 46 sealing compound Place the flywheel on the two guide mandrels in doing so observe the allocation of the centring pin arrow to the bore hole in the flywheel Push the flywheel on as far as it will go Fig 4 Lightl...

Page 75: ... contact surface of the starter motor toothed wheel prior to shrinking on the starter mo tor 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 toothed wheel Rotate the flywheel by hand through several re volutions and observe the needle deflection on the dial gauge Fig 7 Heat the new starter ring g...

Page 76: ...iver to prise out seal Fig 2 Special tool for prising out crankshaft seal Installing crankshaft seal Fig 3 When fitting a new shaft seal you should also ex change the bearing race of the flywheel Insert new shaft seal into flywheel housing Use mandrel special tool to drive in sealing ring until flush Observe the remarks and assembly instruction on page 76 ...

Page 77: ...hanged using a puller special tool Fig 2 Insert the new bearing race into the pressing man drel special tool so that for the subsequent as sembly the internally chamfered side faces the fly wheel Carefully heat the pressing mandrel with the bear ing race The installation temperature for the bearing race is about 150_C Fig 3 Press in bearing race until it stops Fig 4 Seal the gap between the flywhe...

Page 78: ...seals Even the slightest damage to the seal would result in leaks The sealing lip and the race of the flywheel must not be coated with oil or any other lubricants When installing a new seal always replace the race too Assembly instructions for crankshaft seals D The PTFE seal must be absolutely free of oil and grease when installed Even the slightest traces of oil on the race or the sealing ring c...

Page 79: ...w plug to sole noid valve and to temperature sensor Unscrew and remove fuel pipes to solenoid valve and sheathed element flame glow plug Fig 2 Remove connection to turbocharger Fig 3 Remove the mounting bolts on the intake manifold Remove the intake manifold Installing intake manifold Fig 4 Place the intake manifold in position with new gas kets Fit the mounting bolts Make sure the gaskets are cor...

Page 80: ...produ ced by MAN The exhaust gas pipe can be removed with the exhaust manifold attached Remove the heat shields Installing exhaust manifold Fig 2 Before fitting the exhaust manifold screw in 2 stud bolts as a guide Bolt guard plate and exhaust manifold together inserting new gaskets between guard plate and exhaust manifold bead must face guard plate Fig 3 Position the exhaust manifold with new gas...

Page 81: ...ment for a satisfactory level of engine power is setting in accordance with regulations start of fuel delivery and of the valve clearance speed adjustment pedal value The following must also be checked the compression pressure soiling of the air filters the intake system for reductions in diameter and leaks the exhaust system for damage and leaks If these checks do not lead to detection of a possi...

Page 82: ...n non permitted inclines Excessive crankcase pressure e g due to defective oil separator valve crankcase breather or piston ring wear Compressor coking At permanently high charge air temperatures e g constant full load operation Coking leads to a reduction in the charging pressure but not to drops in power or poorer acceleration cha racteristics Coking can lead to increased exhaust haze In the cas...

Page 83: ...rge air pressuer 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 commissio ning log Specific instructions during measurement Based on various atmospheric reference conditions during the measurements and on tolerances of the pressure g...

Page 84: ...r Fig 1 Detach bleed pipe leading to cylinder head cover of cylinder 6 À and oil return pipe Á from turbo charger Fig 2 Then detach the pipe to the crankcase breather Â and the oil pressure pipe Ã Fig 3 Remove bra ket for intake pipe Fig 4 Remove guard plates arrows 1 2 3 4 ...

Page 85: ...o dies Installing turbocharger Fig 6 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 bea ring housing with fresh engine oil Check all the connections for leaks and to ensure they are not subjected to strain Fig 7 Note Ensure that the clamping area of the hose is always behind the bead of the...

Page 86: ...ion read off and note the value The difference between the values obtained is the axial clearance If the play exceeds the permissible value ex change turbocharger Radial clearance The radial clearance is measured only on the tur bine side with a dial gauge or feeler gauge Fig 2 Dial gauge Place the measuring tip of the dial gauge to the side of the hub press the turbine wheel to the dial gauge rea...

Page 87: ... screws Loosen mounting bolts of rocker arm bracket Remove rocker arm bracket Disassembling and assembling rocker arms see page 90 Removing cylinder head D Drain coolant see page 39 D Remove injectors see page 31 D Removing intake manifold see page 77 D Removing exhaust manifold see page 78 Note To remove a cylinder head it is not ne cessary to detach the intake and exhaust pipes Fig 3 Take out pu...

Page 88: ...nd blow out threaded bores in crankcase Clean sealing faces on cylin der head and crankcase Lay new cylinder head gaskets in place in dry condition ensuring that the holes match those in the crankcase and place cylinder head on top Fig 7 Each cylinder head is located with two fitting sleeves Fig 8 Check whether the cylinder head bolts have the max permissible length Bolts that have been removed ma...

Page 89: ...ght ening torque for mounting bolts 20 Nm If a steel ruler is not available mount exhaust manifold and tighten to 20 Nm D Tighten cylinder head bolts as specified D Remove steel ruler Installing the rocker arms and push rods Fig 11 Check push rods for distortion When inserting the push rods ensure that they fit into the seat of the valve tappet Put rocker arms and push rods in place Tighten the mo...

Page 90: ...cylinder head gasket Tighten cylinder head bolts while the engine is cold i e the crankcase is warm to the touch or colder Before inserting the cylinder head bolts apply engine oil to the thread not to the threaded hole and Opti moly White T assembly paste to the contact faces of the bolt heads Do not use oil or oil additives containing MoS2 If the bolts are not oiled a significant amount of the t...

Page 91: ...ocker arms are relieved The valves of the synchronous cylinder are then in cross over Set valves in the cylinder 1 5 3 6 2 4 6 2 4 1 5 3 Valves are in cross over in cylinder Fig 3 I Vibation damper II Flywheel A Outlet valve E Intake valve Fig 4 D Push feeler gauge between valve stem and rocker arm D Loosen lock nut 17 mm and turn adjusting screw with screwdriver until feeler gauge can be moved wi...

Page 92: ...er arm from rocker shaft Note If the rocker arm bearing bushes need to be replaced new or exchange rocker arms ready for fitting are to be used Fig 3 On fitting the rocker arms À on the rocker 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 1 2 2 3 ...

Page 93: ...sing a magnet D Move assembly lever upwards Caution spring under tension risk of injury and away to one side Figs 3 and 4 D Take off the upper spring plate the valve springs and the washer D Turn cylinder head over Pull out inlet and ex haust valves and put them aside arranging or marking them in the sequence of installation D Turn cylinder head over again and pull off valve stem seal arrow D Chec...

Page 94: ...an even valve seat has been achieved Machine valve seat insert if necessary Turn cylinder head over and insert valve spring washers Screw off valve assembly lever Fig 6 Turn cylinder head over Place assembly sleeve for valve stem seals special tool on the respective valve Fig 7 Fit sealing ring Note Use new valve shaft seals only Fig 8 Take off insert sleeve Fit press in sleeve and press in seal ...

Page 95: ...ve cone pieces Use suitable tool to lightly knock back the valve springs to ensure that the valve cone pieces sit correctly Caution Ensure that the valve cone pieces sit cor rectly since valve cone pieces which jump out may cause considerable da mage Measuring valve recess Fig 11 D Place dial gauge holder and dial gauge on cylin der head D Apply gauge tip under preload to cylinder head D Set dial ...

Page 96: ...to the cylinder head using pressing mandrel and spacer sleeve special tool Fig 2 The valve guides vary only in length 1 Inlet 2 Exhaust 3 Press in depth see Service Data The correct press in depth is obtained by using the spacer sleeve Afterwards ream valve guide to specified dimension Note When the valve guides have been changed the valve seats too must be re worked see technical data and manufac...

Page 97: ... 1 Use a valve seat machining tool valve seat lathe to cut an approx 3 4 mm wide groove in the valve seat insert Insert internal puller À into the groove and tighten it Fig 2 Note To avoid damage to the cylinder head sealing face lay disc Á or similar item under the arms Â of the support Turn threaded spindle Ã into the internal puller À align the arms Â of the support and pull out valve seat inse...

Page 98: ...uides Note When the valve seat inserts have been changed the valve seats must be re worked Note D After temperature equalization machine valve seats D After machining clean cylinder head and check for leaks using leak testing device D f the cylinder head is excessively heated above 200_C 390_F the core hole covers end covers loose their tightness and must be exchanged D To do this clean core holes...

Page 99: ...pple 13 Mains connection 14 Magnetic flange with coil 15 Guide pipe 16 Slewing arm Fig 2 Select suitable guide mandrel screw it in with a spanner 12 mm and tighten it Note For extreme precision work the guide mandrel must fit snugly Select and insert the tool with the corresponding seat width and the corresponding seat angle Fig 3 Set the tool with a setting gauge and tighten it with the hex socke...

Page 100: ...vigorously and evenly but under no circumstances against the di rection of turning as otherwise the car bide cutting edge may break Fig 6 Once the valve seat has been expertly machined reduce the working pressure of the tool by 2 3 rev olutions without feed motion During these revolutions turn the feed nut 2 3 rev olutions back Press toggle switch briefly to position 2 to lift the magnetic field N...

Page 101: ...alve retrusion If new valves and seat inserts are used increase the depth of the seat bore in the cylinder head ac cording to the amount of material removed from the cylinder head interface Fig 9 The valve seat insert must be changed if as a re sult of the cylinder head interface and the valve seat insert having been machined the theoretical valve seat is too deep in the cylinder head or the seat ...

Page 102: ...asive paste Fig 3 The valve seat must have a faultless closed grind ing pattern Á The grinding pattern width is correct if the valve seat insert is in order 1 Valve tapered area 2 Valve seat Fig 4 1 Valve seat insert 2 Valve 3 Valve seat good 4 Valve seat too wide Note Valve seats which are too wide tend to accumulate coking residues valves become leaky Valve seats that are too small prevent rapid...

Page 103: ... of starter until the pointer of the compression recorder is not de flected any further Connect up compression recorder with test con nection to the next cylinder and check all cylinders as described above Fig 3 Depending on the compression recorder design the engine can also be started directly by the com pression recorder For this purpose the electrical connections on the starter electromagnetic...

Page 104: ...e Danger The gear case is heavy Use lifting gear Remove the timing case gasket and fit a new gas ket Clean contact face on timing case and crankcase of sealing residues Fig 3 Check the contact washer on the camshaft for wear in necessary fitting a new one Fitting the gear case Fig 4 Stick the new gasket on with a little grease Fit the flywheelhousing Check the oil pan gasket replacing if necessary...

Page 105: ...earings 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 suitable mandrel to push the valve tappet out of the guide check for wear if required renew Valve tappets can only be removed when the camshaft has been removed Replacing the camshaft bearing...

Page 106: ...ft bearings 104 Fitting the camshaft Fig 4 Oil and insert the valve tappets Oil the camshaft bearing bushings Oil the camshaft and insert carefully Caution Do not damage the bearings Fig 5 In doing so note the marking of the crankshaft and camshaft gear wheel ...

Page 107: ... the valve clearance of the 1st cylinder cor rectly Fig 2 Turn the engine using the barring gear until the valves of the 1st cylinder overlap Turn the engine back to approx 50_ before TDC then turn forwards to 30_ before TDC again Note the degree marking on the flywheel Fig 3 Place the dial gauge with approx 2 mm initial ten sion on the valve spring pocket of the outlet valve on the 1st cylinder a...

Page 108: ...m the crankshaft bearing caps in stages from the inside outwards and remove 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 bea ring covers Fig 3 Lift the crankshaft out of the crankcase with hemp rope or a leather belt Caution If a steel cable is used the contact surfa ces of t...

Page 109: ... 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 permit ted length is not exceeded Assemble the bearing caps with the associated bearing shells in accordance with the installations sequence Oi...

Page 110: ...tion and read off the clearance from the 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 the securing bolts and tight...

Page 111: ...rds and remove 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 bea ring covers Fig 3 Remove the lower half of the contact washers Fig 4 Lift the crankshaft out of the crankcase with hemp rope or a leather belt Caution If a steel cable is used the contact surfa ces of the cranksh...

Page 112: ...sponding 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 that the bearing cap bolts do not exceed the max permitted length see Service Data Removed bolts can be reused if the max permit ted length is not exceeded Assemble the bearing caps with the associated bearing she...

Page 113: ...ce from the 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 the securing bolts and tighten them in stages to the pres...

Page 114: ...s are numbered at the conrod foot place to one side ac cordingly arrage them in corresponding order Remove combustion residues oil carbon from top cylinder edge using a piece of hard wood Caution Do not damage the cylinder liners Fig 3 Press out the conrod with piston upwards Caution Do not damage the oil injection nozzles Fig 4 Place the piston with conrod beside the relevant conrod bearing cover...

Page 115: ... journals use bearing bush 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 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 Slide on t...

Page 116: ...ne side Fig 10 Screw in the conrod bolts and tighten them in sta ges to the prescribed value Final tightening according to rotation angle me thod tightening torques and reusability of bolts see Service Data Fig 11 Turn the engine slowly The conrods and oil injection nozzles arrow must not collide or scuff Refit in reverse sequence to the removal proce dure all parts previously removed ...

Page 117: ...n Remove piston and place to one side Measure conrod foot bore base hole Fig 3 Insert new conrod bearing and fit cover Tighten bolts according to regulation Measure the bearing bore with an inside microme ter in measuring directions 1 2 and 3 and in pla nes a and b Max permitted values see Service Data In the case of deviations beyond the tolerance range replace conrod Fig 4 Piston pin sockets are...

Page 118: ...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 Fig 6 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 Fitting pistons see page 113 A Diameter 0 02 A ...

Page 119: ...y the piston ring pliers to the piston ring joint and disengage the piston rings from the piston ring grooves Note The coiled spring expanders mean that the oil control ring has greater tangential tension Carefully clean the piston ring grooves using a piece of wood Do not damage the piston ring grooves Checking ring end clearance Fig 4 Insert the piston rings individually into the cylinder and us...

Page 120: ... facing upwards Checking piston ring axial clearance Fig 6 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 Replace the piston and piston rings if the clea rance determined is too large Piston ring axial clearance see Service Data ...

Page 121: ...moving the cylinder liners 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 Fit the support on the extractor spindle and screw on the nut Hold extractor spindle in place and extract cylinder liner by turning nut Fig 4 Tak...

Page 122: ...ng cylinder liners 120 Fig 5 Deposit cylinder liner upright Number cylinder li ners in order of installation Take off O rings Fig 6 Remove O rings from the crankcase Clean seat for cylinder liners in the crankcase ...

Page 123: ...rement special tool Position press on measuring plate with turned collar facing the liner using 2 fitting sleeves to centre plate Tighten 4 boltsimprovised collar bolt 51 90020 0270 length shortened to 90 mm n the press on measuring plate in stages and crosswise to 40 Nm Set dial gauge combination above press on plate to 0 under preload relative to the crankcase Measure cylinder liner protrusion a...

Page 124: ...l 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 opera tion 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 to ensure that the O rings are seated correctly Proceed sa fol...

Page 125: ...the piston to be measured to TDC Apply the dial gauge holder with dial gauge to the crankcase sealing face Set the dial gauge to 0 Fig 2 Carefully slew dial gauge holder round lifting the dial gauge tip as you do so Lower the tip of the dial gauge to the piston crown and read off the piston protrusion ...

Page 126: ... starter motor Check the starter motor pinion for wear and smooth running If required clean the pinion with a brush dipped in fuel and grease it again Check the toothed flywheel ring for wear and damage In doing so crank the engine once by hand and pay particular attention to points where the engine finally stops i e when the engine is switched off it always stops at certain points In this positio...

Page 127: ...ica tor to move upwards Maintaining pressure after the spring has disenga ged will result in a false reading Taking tension reading Fig 4 D Read of the tensioning force of the belt at the point where the top surface of the indicator arm À intersects with the scale D Before taking readings make ensure that the indicator arm remains in its position If the value measured deviates from the setting val...

Page 128: ...nging V belts Fig 5 D Loosen securing bolts À D Remove lock nut Á D Adjust nut Â until V belt have correct tension D Retighten the lock nut and mounting bolts To replace the V belts loosen lock nut Â and swing alternator inwards 1 3 2 ...

Page 129: ...limits are indicated in the table on page 128 Pilot clutch examination and maintenance general The clutch is dismantled in accordance with the corresponding dismantling guides After the clutch has been dismantled the friction disk and friction ring can be measured Refer to the table for the permissible wear The clutch element can be examined for any detachment and incipient cracks by extending it ...

Page 130: ...ter repairs is not smooth the clutch must be rebalanced with the limits contained in the assembly drawing Balancing All front mounted clutchs are balanced with a balance quality of Q 6 3 In the production of new parts in our company the parts are well below the permissible limits The wearing parts to be replaced in the event of a repair are rotationally symmetric and experience has proven that the...

Page 131: ... off This reading should be repeated after a 90 twisting of the drive D Measured values which are below the double value named in the table above the wear values for the friction disk and friction ring are OK and experience has shown that they do not lead to a marked change in the running smoothness D If the limit is reached or exceeded it is a good idea to replace the friction ring The replacemen...

Page 132: ...ques must be observed Place friction disk Á and friction ring Ã in the flange plate Å if re utilised the friction disk and the friction ring should be inserted dry Push on hub Â and clutch element Ä and bolt on with flange bolt connection 1 25 Nm Attach pilot clutch see page 71 1 2 4 5 6 3 ...

Page 133: ...131 Service Data ...

Page 134: ...1 967 cm3 Direction of rotation viewed on flywheel anti clockwise Firing order 1 5 3 6 2 4 Firing interval 120_ Power based on DIN ISO 3046 D 2866 LE 602 300 kW at 2100 rpm D 2866 LE 605 230 kW at 1500 rpm Lubrication Pressure circulation Filling capacities Oil capacity in oil sump min 24 ltr max 30 ltr Oil change quantity with filter 33 ltr Cooling Fluid cooling by impeller pump Coolant temperatu...

Page 135: ...cylinder liners with 1 0 mm larger outside Ø 145 50 145 54 mm Cylinder liner standard size 153 694 153 757 mm with 0 5 and 1 0 mm larger outside Ø 154 194 154 257 mm standard size 10 05 10 07 mm with 0 5 mm more flange height 10 55 10 57 mm Liner protrusion above upper deck of crancase 0 03 0 08 mm standard size 145 761 145 786 mm with 0 5 mm larger outside Ø 146 261 146 286 mm with 1 0 mm larger ...

Page 136: ...rsize 0 75 89 23 89 25 mm undersize 1 00 88 98 89 00 mm standard size 103 98 104 00 mm 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 Inner diameter 99 907 99 942 mm Thrust bearing journal standard size 46 000 46 062 mm undersize 0 25 and 0 50 46 500 46 562 mm 0 75 and 1 00 47 000 47 ...

Page 137: ...installed condition standard size 104 066 104 112 mm undersize 0 25 103 816 103 862 mm undersize 0 50 103 566 103 612 mm undersize 0 75 103 316 103 362 mm undersize 1 00 103 066 103 112 mm Spread 0 3 1 2 mm Marking top bottom standard size 0005 0006 undersize 0 25 0011 0012 undersize 0 50 0013 0014 undersize 0 75 0015 0016 undersize 1 00 0017 0018 max axial clearance of crankshaft 0 200 0 401 mm W...

Page 138: ...ywheel 432 490 432 645 mm Starter gear ring inside diameter 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 number of teeth Z 9 Backlash 0 6 0 9 mm Ø Ø ...

Page 139: ... 50 2 718 2 728 mm undersize 0 75 2 843 2 853 mm undersize 1 00 2 968 2 978 mm Spread 0 6 1 5 mm If signs of wear are present scores antiwaer coating damaged change both bearing shells Important note installation position upper half bearing shell has red mark on side Conrod bolts Length With each tightening the bolts are deliberately stressed beyond the stretch limit and each tightening thus exten...

Page 140: ...Piston weight difference per set in an engine max 100g Piston ring grooves 3 695 3 725 mm 3 040 3 060 mm 4 020 4 040 mm Piston rings 1st ring keystone ring Height 3 675 3 695 mm 2nd ring minute ring Height 2 978 2 990 mm Axial clearance 0 050 0 082 mm 3rd ring bevelled ring Height 3 975 3 990 mm Axial clearance 0 030 0 062 mm Ring gap 1st ring 0 50 0 70 mm Wear limit 1 00 mm 2nd ring 0 45 0 70 mm ...

Page 141: ...in cylinder head 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 Valve seat insert bore in cylinder head 53 00 53 03 mm Valve seat insert outside diameter 53 10 53 11 mm Valve seat insert bore in cylinder head 61 00 61 03 mm Valve seat insert outside diameter 61 10 61 11 mm ö Ø Ø b Ø Ø Ø Ø ...

Page 142: ...6 mm 51 90490 0024 new 108 5 109 mm max 111 mm Valve recess Intake valve 11 968 11 982 mm Exhaust valve 11 943 11 957 mm Max wear limit 0 1 mm below base dimension Do not reuse valves with damaged chro mium layer Valve recess for intake and exhaust valve 0 7 1 3 mm Valve springs Inner spring Free length L 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 ...

Page 143: ... 0 025 0 054 mm Wear limit 0 08 mm 25 005 25 021 mm Camshaft Replace if there are traces of wear Camshaft axial clearance 0 20 0 90 mm Wear limit 1 5 mm 69 91 69 94 mm Backlash Crankshaft wheel and camshaft wheel 0 128 mm 0 222 mm Camshaft bearing 70 000 70 030 mm diameter 70 070 70 090 mm for bearing 7 last bearing on gear case side 14 Ø Ø Ø ...

Page 144: ...60 before BDC 5 intake valve closes 12 after BDC 6 exhaust valve opening angle 270 7 intake valve opening angle 215 The degrees specified refer to the cranks haft angle Compression pressures good above 16 bar permitted 13 16 bar repair required below 13 bar Pressure difference between the individual cylinders max 3 bar Backlash Crankshaft wheel and camshaft wheel 0 128 0 252 mm Crankshaft wheel an...

Page 145: ...2 5 mm Two gears oil pump Oil pump wheel 14 5 mm 33 950 33 910 mm Housing depth 34 000 34 039 mm Axial clearance 0 040 0 106 mm Shaft 17 930 17 940 mm Bore Ø in housing 17 000 17 018 mm Drive wheel with oil pump wheel Shaft 17 930 17 940 mm Bore Ø in drive wheel 17 885 17 883 mm Press on force 10000 N Backlash between Drive wheel and crankshaft wheel 0 099 0 451 mm Delivery volume of oil pump at o...

Page 146: ...2 5 mm Two gears oil pump Oil pump wheel 11 5 11 7 mm 42 950 42 910 mm Housing depth 43 000 43 039 mm Axial clearance 0 040 0 106 mm Shaft 21 930 21 940 mm Bore Ø in housing 22 000 22 017 mm Drive wheel with oil pump wheel Shaft 21 930 21 940 mm Bore Ø in drive wheel 21 885 21 883 mm Press on force 12000 N Backlash between Drive wheel and crankshaft wheel 0 099 0 451 mm Delivery volume of oil pump...

Page 147: ...0 054 mm Coolant pump with high temperature and low temperature parts D 2866 LUE 605 gap 0 7 0 8 mm Ø impeller 120 mm Bearing seat in housing Ø 61 976 61 995 mm Ø of bearing 61 987 62 000 mm Interference 0 008 0 024 mm Bore for bearing shaft in impeller NT 17 992 18 010 mm Ø bearing shaft 18 045 18 056 mm Interference 0 035 0 064 mm Bore in hub belt pulley 23 007 23 020 mm Ø bearing shaft 23 048 2...

Page 148: ...Grenzwerte Service Daten Abmessungen 146 Turbocharger S3A 91H39GAVM 1 40CF6 Axial clearance Max axial clearance max 0 16 mm Radial clearance Max radial clearance 0 64 mm ...

Page 149: ...r Projection above cylinder head contact surfaces Adjust nozzle protrusion by using Cu sea ling rings of different thickness These sealing rings are available in thick nesses of 0 5 1 0 1 5 2 0 2 5 3 0 mm 2 42 3 25 mm Injectors KDEL 82 P 7 Injection pump In line injection pump with electromagne tic fuel volume regulator Governor Electronic Diesel Control EDC Type M S 5 Start of delivery Model cran...

Page 150: ...se to crankcase M10 12 9 75 Nm Stop disc to gear case M8 12 9 40 Nm Inspection port cover to gear case M8 8 8 10 Nm Crankshaft bearing cover to crankcase M18x2 Pretightening 300 330 Nm Angle tightening 90 100 Vibration damper to crankshaft M16x1 5 10 9 260 Nm Flywheel to crankshaft M16x1 5 Pretightening 100 110 Nm Angle tightening 90 100 Angle tightening final tightening 90 100 Conrod bearing cove...

Page 151: ...ter cup to oil filter head M12 12 9 50 Nm Oil pan to crankcase 22 Nm Oil drain plug to oil pan M26x1 5 80 Nm Oil injection nozzle Flange to crankcase M14x1 5 70 Nm Exhaust intake manifold Exhaust manifold to cylinder head M10 Pretightening 50 Nm Intake manifold to cylinder head M8 8 8 22 Nm Starter motor Starter motor to gear case M12x1 5 80 Nm ...

Page 152: ... 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 M...

Page 153: ...der head bolts D Rotation angle cylinder head bolts with hexagon head WAF 17 D Rotation angle cylinder head bolts with Torx head Torx WAF E20 Bolts to be fitted on repair Hexagon bolts can be replaced by Torx bolts if all the bolts of an engine are replaced Mixed use of hexagon and Torx bolts is not permitted ...

Page 154: ... outer bolts intake and exhaust side must not be retightened Note The cylinder head bolts to be retighte ned must not be loosened they are to be tightened further from their current position by 90 1 4 turn Remove the sticker First retightening of the cylinder head bolts and attach the sticker Second retightening of the cylinder head bolts to verify the second retightening First retightening of cyl...

Page 155: ... 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 F...

Page 156: ...each tighte ning thus extends their length permanently Surface The bolts must have a perfect surface i e closed phosphatisation and no rust stains Rusted or damaged bolts or bolts stretched be yond the maximum length are to be made unusa ble immediately e g by hammering the thread and to be scrapped 90 3 L L shaft length Shaft lengths L in the case of new bolts Largest permitted dimension 109 mm 1...

Page 157: ...155 Special tools ...

Page 158: ...Special tools 156 2 3 4 5 6 7 8 1 6 1 6 2 6 3 9 1 9 2 9 3 9 ...

Page 159: ...l injector 6 1 4 groove 80 99603 0049 6 2 4 groove with fixing screw 80 99603 0121 6 3 open 3 groove 80 99603 0038 7 Inertia puller for fuel injector 80 99602 0011 8 Clamping device for fuel injectors 80 99606 0008 9 Special spanner for cylinder head bolts 9 1 Special spanner for cylinder head bolts 80 99603 0069 9 2 Special spanner for cylinder head bolts 80 99603 0095 9 2 Special spanner for cyl...

Page 160: ...Special tools 158 10 11 16 14 14 1 12 13 18 18 1 12 1 12 2 15 5 15 4 15 1 15 1 15 2 15 3 15 3 15 6 15 7 15 17 ...

Page 161: ...0 99601 0076 14 Drift for bearing race on flywheel in conjunction with handle 14 1 80 99617 0017 14 1 Detachable handle for all press in plates 80 99617 0129 15 Special tool for front crankshaft gasket 80 99606 6011 Components 15 1 Spindle 80 99606 0229 15 2 Extractor device 80 99606 0298 15 3 Adapter 80 99606 0264 15 4 Extractor hook 80 99606 6013 15 5 Press in sleeve 80 99606 0300 15 6 Adapter 8...

Page 162: ...Special tools 160 21 22 25 25 2 24 25 1 26 27 1 27 2 27 20 1 19 2 19 1 20 2 19 20 23 28 ...

Page 163: ...g scuff band 80 99613 0035 22 Piston ring tensioning sleeve 80 99604 0134 23 Angle of rotation measuring device 80 99607 0134 24 Piston ring pliers 83 09144 6090 25 Cylinder liner extractor 80 99602 0019 25 1 Support for 25 80 99623 0003 25 2 Extractor plate 83 09143 0195 26 Cooling system tester 80 99607 0061 27 Thread cutter 27 1 Thread drill set M15x2 for cylinder head bolt threads 80 40001 000...

Page 164: ...Special tools 162 30 31 32 1 32 32 2 ...

Page 165: ... no Designation Item code 30 Dial gauge bracket 90 99605 0172 31 Valve fitting lever 80 99606 0031 32 Compression recorder 10 40 bar 80 99605 0164 32 1 Tachograph disc 100 pcs 80 99605 0165 32 2 Angle adapter 81 98110 0099 ...

Page 166: ... consisting of 1 Dial gauge 08 71000 1205 2 Tracing pin for dial gauge 80 99605 0197 3 Dial gauge bracket 80 99605 0179 4 Seating pin 80 99605 0180 5 Dial gauge bracket 80 99605 6006 6 Dial gauge bracket 80 99605 0172 34 Press on measuring plate 80 99605 0195 35 Adjusting sleeves 51 91701 0247 ...

Page 167: ...Special tools 165 Pressing mandel for cap dia Ø 62 1 mm Pressing mandel for cap dia Ø 50 1 mm ...

Page 168: ...Special tools 166 Special tools for water pump repair for local manufacture Material steel as available Support ring for pressing out the water pump bearing Ø 68 Ø 56 90 ...

Page 169: ...Special tools 167 Pressing ring for coolant pump cover Ø 153 8 154 2 Ø 137 50 60 Ø 134 Ø 168 Support ring for pressing out the water pump cover ...

Page 170: ...Notes 168 ...

Page 171: ... instructions 76 Cylinder head 85 139 Cylinder head General notes 88 Cylinder head bolts 86 Cylinder head covers 85 Cylinder head gaskets 86 Cylinder liners 119 121 Cylinder head bolts 140 D Dismantling the oil pump 63 Drain oil 58 E Engine lubrication 132 Engine overhaul 9 Engine specifications 132 Engine Timing Arrangement Diagram 24 Engine views 18 20 Engine water pump 41 43 Exhaust manifold 78...

Page 172: ...iagram of engine lubrication system 20 Service Data 131 155 Solenoid valve 38 Special tools 155 167 Start of delivery 25 27 147 Adjusting 28 Starter motor 124 Starter ring gear 73 T Thermostats 40 Torque guide values 148 154 Troubleshooting chart 14 16 Turbocharger 82 83 146 Turbocharger axial clearance 84 turbocharger radial clearance 84 Turbocharger troubleshooting 79 U Used engine oil 8 V V bel...

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Man D 2866 LUE 602, Repair Manual

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