Man D2862 LE221, Repair Manual

Page: 118 / 420

COMMON RAIL SYSTEM
High-pressure lines (initial use) ....................................................................................Final tightening 60°
High-pressure lines (re-use) ........................................................................................ Initial torque 10 Nm
High-pressure lines (re-use) .........................................................................................Final tightening 30°
Pressure screw .................................................... M24x1.5 ........................................ Initial torque 10 Nm
Pressure screw .................................................... M24x1.5 ........................... Final tightening 20 Nm + 60°
Mounting bolt ....................................................... M8x55-10.9 ..................................... Initial torque 2 Nm
Mounting bolt ....................................................... M8x55-10.9 ...................... Final tightening 25 Nm + 90°
Injector cable.................................................................................................................................1.8 Nm
Mounting bolt, rocker arm mechanism ................... M12x80-10.9......................................................90 Nm
Mounting bolt, rocker arm mechanism ................... M12x80-10.9...................................Final tightening 90°
High-pressure line pipe clamp mounting screw.................................................................................. 5 Nm
Service products
White T assembly paste..................................................................................................... 09.16012-0122
Important information
WARNING
The common rail system can be damaged
• All work on components of the common rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats ®
(desired value 0)
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
• Always renew pressure-pipe connections once they have been unfastened
• Do not reuse plugs for high-pressure lines, injectors and the rail, even if they have only been
used once
• Follow the sequence described when tightening injectors, high-pressure lines and the rail
WARNING
Danger of damage due to dirt ingress
• Always detach only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
Danger of damage to property
• Always allocate removed injectors to the corresponding cylinders.
• Allocate new injectors to the corresponding cylinders using MAN-cats
® , see EDC system
description
WARNING
Component damage due to incorrectly tightened screw/bolt connections
• If impact wrenches are used, these may only be used for pretightening to max. 50% of the
specied tightening torque
• Final tightening must always be performed manually using a torque wrench
WARNING
Danger of damage due to damaged high-pressure lines
• Before reinstallation, carefully check the high-pressure lines for damage and deformation to the
sealing cone
• Check high-pressure lines for crushing and deformation
• Renew damaged high-pressure lines
• Install high-pressure lines without tension
• Following installation, check the tightness of the lines with MAN-cats
® PLV test
WARNING
Component damage by incorrect installation of pipe clamps
• Always install removed pipe clamps of the pipe set in the original position
• Always reinstall all removed pipe clamps
• Tighten the pipe clamps to the specied tightening torque
116 AE6 3st edition