Man D2862 LE221, Repair Manual

Page: 132 / 420

COMMON RAIL SYSTEM
Oil ll quantity, high-pressure pump .................................................................................................. 0.04 l
Oil ller plug ...................................................................................................................................18 Nm
Mounting bolts, fuel pump ..................................... M6x20 T30 ......................................................... 8 Nm
Mounting bolts, metering unit ................................ M5x20 T25 ...................................... Initial torque 3 Nm
Mounting bolts, metering unit ................................ M5x20 T25 ....................................... Final torque 6 Nm
High-pressure line pipe clamp mounting screw.................................................................................. 5 Nm
Important information
WARNING
The common rail system can be damaged
• All work on components of the common rail system must be performed by specially trained
personnel only
• The engine must be stationary for at least 5 minutes before commencing work in order to enable
depressurisation in the rail, or depressurisation must be checked by means of MAN-cats (desired
value 0)
• Ensure absolute cleanliness in all areas when carrying out all work.
• Before working on the clean side of the fuel system, clean the engine and the engine compartment
(e.g. steam cleaner). The fuel system must be sealed during this process.
• Avoid any moisture whatsoever
• Do not reuse plugs for the high-pressure lines, rail, injectors or fuel lines, even if they have only
been used once
• Follow the sequence described when tightening injectors, high-pressure lines, the rail and rail
connections
• Always detach only one fuel line and then immediately plug the fuel line connections and
component connections
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
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
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
130 AE6 3st edition