Man D2862 LE221 Repair Manual Download Page 381

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TECHNICAL DATA

379

AE6 Stage 2 2st edition

Common Rail System

High-pressure lines and rails (common rail)

High-pressure line (initial use)

initial torque 10 Nm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-pressure line (initial use)

final torque 60°



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-pressure line (reuse)

initial torque 10 Nm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-pressure line (reuse)

final torque 30



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rail pressure sensor

M18x1.5

80 Nm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure limiting valve

M20x1.5

100 Nm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting bolt, pipe clamps, high-pressure lines

5 Nm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injector with nozzle (common rail)

High-pressure line (initial use)

initial torque 10 Nm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-pressure line (initial use)

final torque 60°



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-pressure line (reuse)

initial torque 10 Nm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-pressure line (reuse)

final torque 30



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure screw, rail connection

M24x1.5

initial torque 10 Nm

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

Pressure screw, rail connection

M24x1.5

final torque 20 Nm + 60



. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . .

Mounting bolt, pressure flange

M8x55-10.9

initial torque 1.5 Nm

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

Mounting bolt, pressure flange

M8x55-10.9

final torque 25 Nm + 90



. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

Mounting nut,

cable lug nut M4

1.8 Nm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

Mounting bolt, pipe clamps, high-pressure lines

5 Nm

. . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injector installation sequence
1. Mounting bolt, pressure flange

M8x55-10.9

initial torque 1.5 Nm

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

2. Pressure screw, rail connection

M24x1.5

initial torque 10 Nm

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

3. Mounting bolt, pressure flange

M8x55-10.9

final torque 25 Nm + 90°

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

4. Pressure screw, rail connection

M24x1.5

final torque 20 Nm + 60°

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . .

5. Mounting nuts, injector cable

1.5 Nm

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for D2862 LE221

Page 1: ...adline 05 2015 Repair Manual 51 99598 8262 3st edition AE6 MAN Truck Bus AG Vogelweiherstra e 33 90441 N rnberg oder Postfach 44 02 58 90441 N rnberg Reparaturanleitung AE6 3 Ausgabe MAN Industriedies...

Page 2: ......

Page 3: ...Repair Manual AE6 3st edition MAN Industrial Diesel Engines D2862 LE221 D2862 LE223 51 99598 8262 1...

Page 4: ...relating to safety and accident prevention are specially highlighted in the text as follows CAUTION Type and source of danger Refers to working and operating procedures which must be followed exactly...

Page 5: ...ngine oil temperature sensor 47 Removing installing the coolant pressure sensor 49 Removing installing the engine oil pressure sensor 51 Cooling system Cooling system 55 Removing installing the coolin...

Page 6: ...nd pump 168 Turbocharging Turbocharger 173 Removing installing the turbocharger 173 Charge air manifold 181 Removing installing the charge air manifold 181 Intake exhaust system Combination air lter 1...

Page 7: ...7 Removing installing the front radial shaft seal 297 Removing installing the rear radial shaft seal 300 Crank mechanism Vibration damper 309 Removing installing the vibration damper 309 Flywheel 315...

Page 8: ......

Page 9: ...liner Cylinder liner standout 372 Sectional sealing rings 371 E Engine control unit Disconnecting the electrical connections 29 Removing the bracket 29 Removing the engine control unit 29 Engine descr...

Page 10: ...9 T Technical data Alternator 99 Cylinder liner 368 Exhaust pipe 205 Flywheel 315 High pressure pump 129 Oil injector nozzles 279 Vibration damper 309 Timing gears Crankshaft gear 259 Intermediate gea...

Page 11: ...ure units during their removal Keep units ladders stairs steps and the surrounding area free from oil and grease Accidents caused by slipping can have very serious consequences Only authorised technic...

Page 12: ...correct connection to the batteries can lead to irreparable damage to the control unit Tighten connections on the injection system to the prescribed tightening torques Remove the control units if you...

Page 13: ...y the manufacturer The engine is only allowed to be used maintained and serviced by people who are familiar with this work and have been informed about the dangers Independent modi cations to the engi...

Page 14: ...clean the skin Apply a greasy skin cream after cleaning your skin Service uids and service products Do not use any food or beverage containers for draining and storing service uids and service produc...

Page 15: ...rectly at electrical components Cover them if necessary Place the engine in a clean area in the workshop where there will be no work going on that could throw up dust grinding welding work brake repai...

Page 16: ...ith the application guideline in works standard MAN 222 when using micro encapsulated bolts Reuse of bolts and nuts Check bolt heads threads and nuts for wear and ease of movement renew if necessary O...

Page 17: ...he following criteria have a major in uence on the engine service life Correct power setting for the application type Correct installation Approval of the installation by authorised personnel Regular...

Page 18: ...f assembly 1221 The last four digits of the engine no Motor Nr are production and equipment speci c data What the model designation means Model designation Explanation Example D Fuel type Diesel 28 Id...

Page 19: ...0 6 7 5 8 4 9 Rated speed rpm 1800 Low idling speed rpm 600 Max torque at engine speed Nm rpm 4246 at 1800 D2862LE223 Designation Unit Figures Number of cylinders arrangement 12 cylinder V 90 Valves p...

Page 20: ...ostat housing 3 Distributor 4 Turbocharger right 5 Exhaust manifold 6 High pressure pump 7 Exhaust manifold 8 Turbocharger left 9 Starter 10 Oil sump 11 Oil lter 12 Alternator 13 Poly V belt 14 Oil mo...

Page 21: ...mon rail high pressure injection system in conjunction with EDC 7 Electronic Diesel Control Engine monitoring Two engine control units are tted A master and a slave Each engine control unit controls o...

Page 22: ...nd high lateral stability Pistons 3 ring steel pistons are used The pistons have a cooling duct for relieving the thermal load This area is covered by exible metal containing a bore into which the oil...

Page 23: ...calculated in the engine control unit and implemented by the solenoid valve controlled injectors The solenoid valve controlled injectors allow multiple injections 1 Pilot injection to improve combust...

Page 24: ......

Page 25: ...ENGINE ELECTRICS ENGINE ELECTRICS 1 Engine control unit slave 2 Engine control unit master 3 Wiring harness AE6 3st edition 23...

Page 26: ......

Page 27: ...1 Engine wiring harness Technical data Electrical connection terminal 85 relay 4 Nm Electrical connection terminal 50 relay 4 Nm Electrical connection B alternator 15 Nm Important information CAUTION...

Page 28: ...stall switches and sensors with new O rings or sealing rings After installing switches or sensors read out the fault memory and if necessary delete it WARNING Component damage caused by incorrect wiri...

Page 29: ...unit master Technical data Mounting bolt master M6x30 10 9 11 Nm Mounting bolt slave M6x30 10 9 11 Nm Important information WARNING Component damage due to incorrectly tightened screw bolt connection...

Page 30: ...and lock the connectors WARNING Danger of irreparable plug connection damage Protect loosened plug connections and contacts against dirt ingress WARNING Danger of cable breakage Only secure the wirin...

Page 31: ...e wiring harnesses and cable ties Fully unlock and pull off the connectors 1 2 and 3 Mark the installation position of the cable ties and then disconnect Expose the wiring harnesses Detaching the engi...

Page 32: ...engine control units Attaching the engine control unit bracket Position the stop for control unit bracket 3 with compression springs 4 Position the bracket 2 Position the compression springs 5 Insert...

Page 33: ...RNING Danger of irreparable engine control unit damage When installing the connectors rst fully open the lock and then insert and lock the connectors Insert and lock the connectors 1 2 and 3 in the en...

Page 34: ......

Page 35: ...hes 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 Restricted operation...

Page 36: ...essure sensor Unscrew and remove the mounting bolts 1 Pull out the pressure sensor 2 Installing the charge air pressure sensor Installing the pressure sensor Insert the pressure sensor 2 with a new O...

Page 37: ...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 W...

Page 38: ...remove the temperature sensor 1 with the sealing ring 2 Installing the fuel temperature sensor Installing the fuel temperature sensor Lightly apply clean Engine oil on the thread of the temperature s...

Page 39: ...nections 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 WARNI...

Page 40: ...ew and remove the fuel pressure sensor 1 with sealing ring 2 Installing the fuel pressure sensor Installing the fuel pressure sensor Coat the fuel pressure sensor thread 1 with clean Engine oil Screw...

Page 41: ...nections 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 WARNI...

Page 42: ...remove the oil pressure sensor 1 with the sealing ring 2 Installing the oil pressure sensor Installing the oil pressure sensor Lightly apply clean Engine oil on the thread of the oil pressure sensor...

Page 43: ...ese 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 Restricted operation due to incorrec...

Page 44: ...engine speed sensor Unscrew and remove the mounting bolt 1 Pull out the speed sensor 2 Installing the crankshaft speed sensor Installing the engine speed sensor Insert the speed sensor 2 with a new O...

Page 45: ...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 Restricted operation due to defective e...

Page 46: ...ng the speed sensor Unscrew and remove the mounting bolt 2 Pull out the speed sensor 1 Installing the camshaft speed sensor Installing the speed sensor Insert the speed sensor 1 with a new O ring Scre...

Page 47: ...olt 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 wrenc...

Page 48: ...d remove the temperature sensor 1 with the sealing ring 2 Installing the coolant temperature sensor Installing the temperature sensor Lightly apply clean Engine oil on the thread of the temperature se...

Page 49: ...ew 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 w...

Page 50: ...d remove the temperature sensor 2 with the sealing ring 1 Installing the engine oil temperature sensor Installing the temperature sensor Lightly apply clean Engine oil on the thread of the temperature...

Page 51: ...onnections 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 WAR...

Page 52: ...nd remove the coolant pressure sensor 2 with sealing ring 1 Installing the coolant pressure sensor Installing the coolant pressure sensor Coat the coolant pressure sensor thread 2 with clean Engine oi...

Page 53: ...nections 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 WARNI...

Page 54: ...move the transition piece 3 with the sealing ring 4 Installing the oil pressure sensor Installing the oil pressure sensor Screw in the transition piece 3 with a new sealing ring 4 and then tighten it...

Page 55: ...COOLING SYSTEM COOLING SYSTEM 1 Coolant manifold 2 Coolant pump 3 Moulded hose 4 Ramfan AE6 3st edition 53...

Page 56: ......

Page 57: ...Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only be used for pretightening to max 50 of the speci ed tighte...

Page 58: ...llows hose 2 with hose clamps 1 and 3 Unfasten the hose clamp 6 Remove the charge air manifold 4 with O ring 5 and hose clamp 6 Detaching the right moulded hose Unfasten hose clamps 1 and 3 Remove the...

Page 59: ...etaching the right protective grille Unscrew the mounting nuts 2 Pull out the mounting bolts 3 and remove with washers Remove the protective grille 1 Detaching the left protective grille Unscrew the m...

Page 60: ...ective grille 1 Insert the mounting bolts 3 with washers Screw on and tighten the mounting nuts 2 Attaching the protective grille holder Tighten the mounting bolts 1 Attaching the left moulded hose Pu...

Page 61: ...the right charge air hose Position the charge air manifold 4 with a new O ring 5 and hose clamp 6 Tighten the hose clamp 6 Position the bellows hose 2 with hose clamps 1 and 3 Tighten the hose clamps...

Page 62: ......

Page 63: ...n 2 Mounting bolt Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only be used for pretightening to max 50 of t...

Page 64: ...Removing the ramfan Detaching the ramfan Unscrew the mounting bolts 2 Remove the ramfan 1 Installing the ramfan Attaching the ramfan Position the ramfan 1 Screw in and tighten the mounting bolts 2 62...

Page 65: ...stalling the ramfan see 61 1 Intermediate ange Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only be used for...

Page 66: ...taching the intermediate ange Unscrew the mounting bolts 2 Remove the intermediate ange 1 Installing the intermediate ange Attaching the intermediate ange Position the intermediate ange 1 Screw in and...

Page 67: ...arness see 25 Removing installing the charge air manifold see 181 Removing installing the cooling system see 55 1 Coolant line right 2 Coolant line left 3 TV connecting piece Important information WAR...

Page 68: ...rew the WD connecting piece 2 Unscrew the hollow screw connector 1 and remove it with the sealing ring 3 Detaching the left vent line Mark the installation position of the ring connector 2 Unscrew the...

Page 69: ...e coolant pipes Installing the right vent line Note Hollow screws are restricted Position the vent line 1 with new sealing rings 4 Screw in and tighten the hollow screws 3 and hollow screw 2 Installin...

Page 70: ...he hollow screw 1 Attaching the right vent line Screw in the hollow screw connector 1 with a new sealing ring 3 and tighten Screw on the WD connecting piece 2 as marked and tighten Attaching the coola...

Page 71: ...the cooling system see 55 Removing installing the fan V belt see 85 Removing installing the ramfan see 61 Removing installing the intermediate ange see 63 Removing installing the fan tensioning pulle...

Page 72: ...ches 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 Thermostats with the...

Page 73: ...g the thermostat housing lower section Note O rings are secured with Curil T sealing compound to prevent them falling out or slipping Clean the sealing surfaces Apply a thin coat of Curil T sealing co...

Page 74: ......

Page 75: ...ensioning pulley see 89 Removing installing the fan carrier with fan bearing see 91 1 Coolant pump coolant manifold Service products Radiator antifreeze 09 21001 0002 Important information WARNING Com...

Page 76: ...he holder 3 Detaching the coolant line Unfasten the holding clips 2 Unscrew the union nuts 1 and 3 Remove the coolant line Detaching the coolant pump coolant manifold Mark the installation position of...

Page 77: ...s 2 Insert new insert pipes 2 Fit the coolant pump coolant manifold 1 with new O rings 3 and position it Screw in mounting bolt 4 as marked and tighten Attaching the coolant line Position the coolant...

Page 78: ......

Page 79: ...y see 89 Removing installing the fan carrier with fan bearing see 91 Removing installing the coolant pump coolant manifold see 73 1 Coolant pump Service products Radiator antifreeze 09 21001 0002 Impo...

Page 80: ...om the coolant pump Clean the sealing surfaces Installing the coolant pump Installing the insert pipes Clean the sealing surfaces Lightly apply Radiator antifreeze on the contact surfaces of the new i...

Page 81: ...ADD ON UNITS ADD ON UNITS 1 Fan tensioning pulley 2 Starter 3 Alternator 4 Poly V belt 5 V belt pulley 6 V belt AE6 3st edition 79...

Page 82: ......

Page 83: ...25 Nm Mounting nut terminal 50 M6 4 Nm Mounting nut terminal 85 M6 4 Nm Number of teeth on starter pinion 11 Starter power 24 V 7 KW Important information WARNING Component damage due to incorrectly t...

Page 84: ...pecial tools 3 Engine barring gear Cranking the engine in conjunction with Gear ratchet 4 80 99626 6009 4 Gear ratchet Cranking the engine in conjunction with Engine barring gear 84 80 99627 0001 82 A...

Page 85: ...barring gear 3 1 to the ywheel housing Turn the engine through 360 with Gear ratchet 4 and check the starter ring gear for wear Installing the starter Detaching the engine barring gear Remove the Eng...

Page 86: ......

Page 87: ...5x100 20 Nm Poly V belt pulley mounting bolt M12x1x80 10 9 117 Nm Fan poly V belt tension Section 1 225 Hz Section 2 220 Hz Important information WARNING Component damage due to incorrectly tightened...

Page 88: ...ADD ON UNITS Special tools 5 Frequency measuring instrument Measuring V belt tension 80 99605 0296 86 AE6 3st edition...

Page 89: ...ly V belt fan Unscrew the mounting bolts 2 Unscrew the mounting bolt 1 and carefully slacken the poly V belt tensioner Detaching the poly V belt fan Remove the poly V belt 1 Detaching the poly V belt...

Page 90: ...unting bolt 1 and tighten to 20 Nm Tighten the mounting bolts 2 Checking the poly V belt tension Check the belt tension with Frequency measuring instrument 5 1 Check the belt tension of section 1 3 va...

Page 91: ...ee 61 Removing installing the fan V belt see 85 1 Fan tensioning pulley Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used t...

Page 92: ...ng nuts 1 and pull out the mounting bolts 3 Remove the tensioning pulley carrier 2 Installing the fan tensioning pulley Attaching the fan tensioning pulley Position the tensioning pulley carrier 2 Ins...

Page 93: ...e fan V belt see 85 Removing installing the fan tensioning pulley see 89 1 Fan carrier 2 Holder Important information WARNING Component damage due to incorrectly tightened screw bolt connections If im...

Page 94: ...4 Remove the holder 3 Unscrew the mounting bolts 5 Remove the fan carrier 1 Installing the fan carrier with fan bearing Attaching the fan carrier with fan bearing Position the fan carrier 1 Screw in a...

Page 95: ...Removing installing the fan V belt see 85 1 Poly V belt Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only b...

Page 96: ...ar as the stop and hold it Remove the poly V belt 2 Carefully relieve the poly V belt tensioner 1 Installing the poly V belt Attaching the poly V belt CAUTION The poly V belt tensioner is under spring...

Page 97: ...installing the poly V belt see 93 1 Automatic belt tensioner Technical data Mounting bolt M10x70 10 9 47 Nm Important information WARNING Component damage due to incorrectly tightened screw bolt conn...

Page 98: ...ic belt tensioner Unscrew the mounting bolt 2 Remove the automatic belt tensioner 1 Installing the automatic belt tensioner Attaching the automatic belt tensioner Position the automatic belt tensioner...

Page 99: ...see 93 Removing installing the automatic belt tensioner see 95 1 Guide roller Technical data Mounting bolt M12x55 10 9 60 Nm Important information WARNING Component damage due to incorrectly tightened...

Page 100: ...unting bolt 5 Remove the washers 1 and 4 Remove the guide roller 3 with spacer bush 2 Installing the guide roller Mounting the guide roller Position the spacer bush 2 with guide roller 3 Position wash...

Page 101: ...n see 61 Removing installing the fan V belt see 85 Removing installing the intermediate ange see 63 Removing installing the poly V belt see 93 Removing installing the automatic belt tensioner see 95 R...

Page 102: ...moving installing the poly V belt pulley in conjunction with Gripper 7 80 99603 6029 7 Gripper Removing installing the poly V belt pulley 08 06460 0002 8 Cable tie pliers Tightening and cutting off th...

Page 103: ...ith washer Remove the bush 2 insulating sleeve 3 and insulating washer 4 Detaching the alternator Mark the installation position of the mounting bolts 8 and 9 Unscrew the mounting bolts 8 Unscrew the...

Page 104: ...g nut 1 Remove the poly V belt pulley 2 from the alternator shaft Installing the alternator Attaching the poly V belt pulley Push the poly V belt pulley 2 onto the alternator shaft Lightly apply Locti...

Page 105: ...the bush 2 Screw in the mounting bolt 3 and tighten it until nger tight Position the holder 7 with insulating washers 6 washers 5 and insulating sleeve 4 Screw in and tighten the mounting bolts 8 and...

Page 106: ...tion Route the alternator wiring harness 1 and secure it using cable ties Tighten and cut off cable ties using the Cable tie pliers 8 Screw on the terminal B mounting nut 2 and tighten it to 13 Nm Ins...

Page 107: ...Fuel line 2 Leakage oil line injectors 3 High pressure lines 4 Distributor 5 Right rail 6 High pressure pump slave 7 High pressure pump master 8 Collector 9 Leakage oil line injectors 10 High pressure...

Page 108: ......

Page 109: ...an see 61 Removing installing the fan V belt see 85 Removing installing the intermediate ange see 63 Removing installing the fan tensioning pulley see 89 Removing installing the fan carrier with fan b...

Page 110: ...sure lines the rail or injectors even if they have only been used once Follow the sequence described when tightening injectors high pressure lines the rail and rail connections WARNING Danger of damag...

Page 111: ...002 0555 13 Cap Sealing ring unions 81 96002 0518 14 Special spanner size 17 Detaching and attaching the high pressure lines in conjunction with Angle extension 15 80 99603 0309 15 Angle extension Det...

Page 112: ...9 and the connections with the Protective sleeve Z 14 x 15 10 Detaching the high pressure line WARNING Danger of damage due to dirt ingress Plug the component connections immediately using new clean...

Page 113: ...valve with Protective sleeve Z 18 x 15 12 and the thread in the rail with End plug 11 Removing the right rail pressure sensor WARNING Component damage due to lack of lubricant Do not wash off the rai...

Page 114: ...1 with holder 2 Installing the high pressure lines and rails Attaching the right rail Note The left rail is installed in the same way as the right rail Position the rail 1 with holder 2 Screw in and t...

Page 115: ...plugs Screw in the rail pressure sensor 1 and tighten it to 80 Nm Installing the right pressure limiting valve WARNING Component damage due to lack of lubricant Do not wash off the pressure limiting v...

Page 116: ...extension 41 in conjunction with the Special spanner size 17 40 Position the pipe clamps 2 and 4 as marked Tighten the pipe clamp mounting bolts to 5 Nm If using for the rst time tighten the high pres...

Page 117: ...ling system see 55 Removing installing the fan V belt see 85 Removing installing the ramfan see 61 Removing installing the intermediate ange see 63 Removing installing the fan tensioning pulley see 89...

Page 118: ...he 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 o...

Page 119: ...otective sleeve high pressure line connection Z 14 x 15 Special tools 16 Storage sleeve Storing injectors 09 81020 1000 17 End plug Plugging the cylinder head injector bore 81 96002 0520 18 Injector n...

Page 120: ...actor 21 Plate 22 Support 23 06 11226 8306 25 Torque screwdriver Installing the injector cable in conjunction with Adapter 26 Socket size 7 27 08 06510 9024 26 Adapter Installing the injector cable in...

Page 121: ...lines in conjunction with Angle extension 15 80 99603 0309 32 Angle extension Detaching and attaching the high pressure lines in conjunction with Special spanner size 17 14 08 06139 9025 33 End plug...

Page 122: ...2 turns Unscrew the union nuts for the high pressure line 1 Remove the high pressure line 1 Plug the high pressure line 1 with End plug 33 and the connections with Protective sleeve Z 14 x 15 34 Repe...

Page 123: ...Always remove the relevant rail connection before removing the injector Always remove one injector only Place the extractor tool 2 over the injector Clamp the Extractor 21 3 in the groove of the press...

Page 124: ...d Fit a new O ring 2 and new sealing ring 1 on the injector 3 Thinly apply clean engine oil to MAN Standard 3277 on the O ring 2 Place the pressure ange 5 on the injector 3 Insert the injector 3 and p...

Page 125: ...60 Attaching the high pressure line 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 r...

Page 126: ...ing 60 with Angle extension 32 and Special spanner size 17 31 Tighten the high pressure lines 1 to Final tightening 30 with Angle extension 32 and Special spanner size 17 31 if re using Repeat the sam...

Page 127: ...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 ca...

Page 128: ...sed 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 Special tools 35 Hand pump Checking th...

Page 129: ...is leaking the affected parts must be removed and then checked for damage or contamination Replace parts as necessary Detaching the fuel line left leakage oil line collector Unscrew the union nuts 1...

Page 130: ...collector fuel line Remove the caps and plugs Position the fuel line 2 Screw on and tighten the union nuts 1 and 3 Detaching the pressure loss tester right side Disconnect the Hand pump 35 2 with the...

Page 131: ...5 Removing installing the ramfan see 61 Removing installing the intermediate ange see 63 Removing installing the fan tensioning pulley see 89 Removing installing the fan carrier with fan bearing see 9...

Page 132: ...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 co...

Page 133: ...Angle extension 41 80 99603 0309 41 Angle extension Detaching and attaching the high pressure line in conjunction with Special spanner size 17 40 08 06139 9025 42 End plug Plugging the high pressure l...

Page 134: ...with the Protective sleeve Z 14 x 15 43 Removing the slave high pressure pump Disconnect the metering unit electrical connection Remove the driver sleeve 3 Unclip the circlip 4 and remove it Unscrew...

Page 135: ...ure pump Installing the master high pressure pump Clean the sealing surfaces Insert the high pressure pump 1 and drive housing 2 with new O rings 3 and 4 Connect the metering unit electrical connectio...

Page 136: ...torque 10 Nm using the Angle extension 41 in conjunction with the Special spanner size 17 40 Position the pipe clamps 2 and 4 as marked Screw in mounting bolts of the pipe clamps 2 and 4 and tighten...

Page 137: ...the ramfan see 61 Removing installing the intermediate ange see 63 Removing installing the fan tensioning pulley see 89 Removing installing the fan carrier with fan bearing see 91 Removing installing...

Page 138: ...es 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 Special tools 44 Protective sl...

Page 139: ...remove it Removing the thrust washer Unscrew the mounting bolts 1 Remove the thrust washer 2 from the drive housing 3 Removing the drive gear Insert the drive shaft 4 with drive housing 2 into the dr...

Page 140: ...dirt ingress Clean the components and blow them dry using compressed air Unscrew the mounting bolts 2 Pull out the fuel pump 1 Remove the coupling element 3 from the fuel pump 1 Removing the over ow...

Page 141: ...Insert the coupling element 3 into the fuel pump 1 Insert the fuel pump 1 Screw in the mounting bolts 2 and tighten them to 8 Nm Installing the metering unit Note When using micro encapsulated bolts...

Page 142: ...the drive gear 3 Installing the thrust washer Insert the thrust washer 2 into the drive housing 3 Screw in and tighten the mounting bolts 1 Installing the driver sleeve Attach the circlip 1 in the dr...

Page 143: ...g installing the intermediate ange see 63 Removing installing the fan tensioning pulley see 89 Removing installing the fan carrier with fan bearing see 91 Removing installing the coolant pump coolant...

Page 144: ...ne 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 th...

Page 145: ...fuel line connections 81 96002 0555 50 Protective sleeve Z 16x8 Plugging the fuel line connections 81 96002 0513 51 Protective sleeve Z 28x20 Plugging the connection on the collector 81 96002 0514 52...

Page 146: ...ne 2 with the End plug GPN 330 L18 46 Plug the connections with End plug GPN 330 L18 46 and Protective sleeve Z 28x20 51 Detaching the fuel line fuel lter high pressure pump Unscrew the mounting bolt...

Page 147: ...g the fuel line 3 with the End plug 47 Plug the connections with Protective sleeve Z 18x1 5 49 Detaching the fuel line high pressure pump top fuel lter Unscrew the union nuts 1 and 3 Remove the fuel l...

Page 148: ...ap 52 Plug the connections with End plug 48 and Protective sleeve Z 16x8 50 Detaching the fuel line high pressure pump bottom collector Unscrew the hollow screw 3 and remove it with the sealing ring U...

Page 149: ...ngs Plug the fuel line 2 with the Cap 52 Plug the connections with the End plug 48 Detaching the fuel line hand pump high pressure pump bottom Unscrew the union nuts 1 and 3 Remove the fuel line 2 Plu...

Page 150: ...he hollow screws 1 Remove the leakage oil line 2 with the sealing rings Plug the connections with End plug 48 Detaching the left leakage oil line Unscrew the hollow screws 1 Remove the leakage oil lin...

Page 151: ...olts 2 Remove the holder 1 with washers 3 Installing the fuel lines Attaching the holder Position the holder 1 with washers 3 Screw in and tighten the mounting bolts 2 Mounting the collector Position...

Page 152: ...the hollow screws 1 with new sealing rings Tighten the hollow screws 1 Attaching the right leakage oil line Remove the protective sleeves Position the fuel line 2 so that it is strain free Screw in th...

Page 153: ...mp bottom Remove the end plugs and protective sleeves Position the fuel line 2 Screw on and tighten union nuts 1 and 3 Attaching the fuel line right rail collector Remove the end plugs and protective...

Page 154: ...w screw 3 with a new sealing ring and screw in Screw on and tighten the union nut 2 Tighten the hollow screw 3 Attaching the fuel line leakage oil line Remove the end plugs and protective sleeves Posi...

Page 155: ...en union nuts 1 and 3 Attaching the fuel line drain lter Remove the end plugs and protective sleeves Position the fuel line 3 Screw on and tighten union nuts 1 and 2 Attaching the fuel return line Rem...

Page 156: ...Attaching the fuel line high pressure pump fuel lter Remove the end plugs and protective sleeves Position the fuel line 2 Screw on and tighten union nuts 3 and 4 Screw in and tighten the mounting bol...

Page 157: ...s 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...

Page 158: ...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 Special tools 53 End plug GPN 330 L18 Plugging the...

Page 159: ...igh pressure pumps Unscrew the union nuts 2 and 5 Remove the fuel line 4 Plug the fuel line 4 with the End plug GPN 330 L18 53 Plug the connection with Protective sleeve Z 28x20 56 Detaching the fuel...

Page 160: ...tributor connections with Protective sleeve Z 28x20 56 Repeat the same procedure for the other distributors Plug the fuel lter 4 with End plug 54 Installing the fuel lter Assembling the fuel lter Remo...

Page 161: ...he mounting nut 4 Insert the mounting bolt 1 Screw on and tighten the mounting nut 6 Attaching the fuel line fuel lter high pressure pumps Remove protective sleeves and end plugs Position the fuel lin...

Page 162: ...m Important information WARNING The common rail system can be damaged Do not reuse plugs for high pressure lines the rail or injectors even if they have only been used once WARNING The common rail sys...

Page 163: ...g must always be performed manually using a torque wrench Note In order to ensure that the correct protective sleeve is used the designation e g Z14 x 15 is imprinted in the protective sleeve This is...

Page 164: ...lug 1 and allow the fuel lter cover to empty Tighten the drain plug 1 to 3 Nm Detaching the cover Unscrew the cover 3 from the housing 1 with the Hexagon socket wrench size 36 57 Remove the O ring 2 D...

Page 165: ...g the fuel lter insert Insert the new fuel lter insert 2 into the housing 1 Attaching the cover Fit the cover 3 with a new O ring 2 and screw onto the housing 1 Tighten the cover 3 to 25 Nm using the...

Page 166: ......

Page 167: ...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 Note In order to ensure...

Page 168: ...COMMON RAIL SYSTEM Special tools 58 End plug GPN 330 L18 Plugging the fuel lines 81 96002 0556 59 Protective sleeve Z 28x20 Plugging the connection on the collector 81 96002 0514 166 AE6 3st edition...

Page 169: ...sleeve Z 28x20 59 Detaching the hand pump Unscrew the mounting nuts 3 Pull out the mounting bolts 1 Remove the hand pump 2 Installing the hand pump Attaching the hand pump Position the hand pump 2 In...

Page 170: ...a suitable fuel collecting container WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only be used for pretightening to max 50 of the...

Page 171: ...COMMON RAIL SYSTEM Note A check valve is integrated in the hand pump to prevent the fuel from owing back Special tools 60 End plug GPN 330 L18 Plugging the fuel lines 81 96002 0556 AE6 3st edition 169...

Page 172: ...hand pump 1 Clean the sealing surfaces Assembling the hand pump Installing the primary fuel lter Clean the sealing surfaces Lightly apply clean Fuel on the new O ring 2 Pull the new O ring 2 onto the...

Page 173: ...GING TURBOCHARGING 1 Insert pipe 2 Intake manifold 3 Turbocharger right 4 Charge air manifold 5 Charge air manifold 6 Turbocharger left 7 Intake manifold 8 Insert pipe 9 Charge air manifold AE6 3st ed...

Page 174: ......

Page 175: ...Nm Service products Engine oil see Maintenance Recommendations and Recommended Service Products Important information WARNING Component damage due to incorrectly tightened screw bolt connections If im...

Page 176: ...ial tools 61 Torque wrench Tightening the turbocharger mounting nuts in conjunction with 08 06450 0003 62 Hose clamp pliers for jubilee clips Installing and removing the jubilee clips 80 99625 0073 17...

Page 177: ...with washers Remove the heat shield 2 Detaching the vent line Remove the jubilee clip 3 with Hose clamp pliers for jubilee clips 62 Pull the vent line hose 1 off the hose port 2 Detaching the charge a...

Page 178: ...ng the oil pressure line ange Unscrew the mounting bolts 2 Remove the ange 1 with seal 3 Clean the sealing surfaces Detaching the oil return line Unscrew the mounting bolts 3 Loosen the hose clamp 5 w...

Page 179: ...with hose clamp 5 over the tting Screw in and tighten the mounting bolts 3 Install the hose clamp 5 with Hose clamp pliers for jubilee clips 62 in the installation position Attaching the oil pressure...

Page 180: ...with a new seal 1 Screw on and tighten the mounting nuts 3 Attaching the charge air manifold Clean the sealing surfaces Insert a new O ring 2 and guide band 1 into the charge air manifold 3 Put on th...

Page 181: ...washers and tighten Attaching the bellows hose WARNING Danger of damage to property if the hose connection is leaking Fit the hose clamp as close as possible to the bead Position the bellows hose 2 wi...

Page 182: ......

Page 183: ...oving installing the ramfan see 61 1 Bracket for charge air manifold 2 Insert pipe right 3 Charge air manifold 4 Charge air manifold 5 Insert pipe left 6 Charge air manifold Technical data T pin clamp...

Page 184: ...out the mounting bolt 3 Remove the holder 1 Detaching the charge air manifold Loosening the T pin clamp 7 Pull off the charge air manifold 5 and remove with T pin clamp 7 O rings 4 6 and guide band 3...

Page 185: ...acket 1 Installing the charge air manifold Attaching the bracket Position the bracket 1 Screw in the mounting bolts 2 and tighten until nger tight Attaching the charge air manifold Position the charge...

Page 186: ...6 and T pin clamp 7 Tighten the T pin clamp 7 with 15 Nm Repeat the procedure for the other charge air manifold Attaching the charge air manifold holder Position the holder 1 Insert the mounting bolt...

Page 187: ...HAUST SYSTEM INTAKE EXHAUST SYSTEM 1 Air distribution pipe right 2 Combination air lter 3 Combination air lter holder 4 Exhaust manifold heat shield 5 Exhaust manifold 6 Charge air manifold AE6 3st ed...

Page 188: ......

Page 189: ...ination air lter left 4 Moulded hose left Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only be used for pret...

Page 190: ...f the moulded hose 2 Detaching the left combination air lter Unscrew the mounting nuts 2 Pull out the mounting bolts 3 Remove the combination air lter 1 Detaching the right combination air lter Unscre...

Page 191: ...p 1 Detaching the holder Unscrew holders 1 and 2 Remove holders 1 and 2 Installing the combination air lter Attaching the holders Insert and align holders 1 and 2 Tighten holders 1 and 2 Attaching the...

Page 192: ...crew on and tighten the mounting nuts 3 Attaching the left combination air lter Position the combination air lter 1 Insert the mounting bolts 3 Screw on and tighten the mounting nuts 2 Attaching the r...

Page 193: ...rmation 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 Fi...

Page 194: ...p 1 Detaching the right air lter Unfasten the hose clamp 2 Remove the air lter 1 with hose clamp 2 Installing the air lter Attaching the right air lter Position the air lter 1 with hose clamp 2 Tighte...

Page 195: ...der 2 Combination air lter holder Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only be used for pretightenin...

Page 196: ...nd 3 from the corrugated pipe holders 2 and 4 Detaching the holder for the injector wiring harness Unscrew the mounting nuts 3 Remove the injector wiring harness holder 1 with spacer bush 2 Repeat the...

Page 197: ...ition the combination air lter holder 1 Screw in and tighten the mounting bolts 2 Repeat the procedure for the other holder Attaching the holder for the injector wiring harness Position the injector w...

Page 198: ...ne Position the vent line 2 using the jubilee clips 1 and 3 Attach the jubilee clips 1 and 3 using the Hose clamp pliers for jubilee clips 63 Attach holding clips 4 and 5 Repeat the same procedure for...

Page 199: ...he cooling system see 55 Removing installing the fan V belt see 85 Removing installing the ramfan see 61 Removing installing the intermediate ange see 63 Removing installing the fan tensioning pulley...

Page 200: ...amage 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...

Page 201: ...the holder 2 and washer 1 Removing the charge air manifold Mark the installation position of the mounting bolts 3 5 and 6 Unscrew the mounting bolts 3 and 5 Unscrew the mounting bolts 6 and remove wit...

Page 202: ...an the sealing surfaces Installing the left air distribution pipe Installing the air distribution pipe Clean the sealing surfaces Position the air distribution pipe 3 with new seals 4 Screw in the mou...

Page 203: ...as marked Screw in the mounting bolt 6 with washer as marked and tighten Screw on the mounting nut 7 with washer and tighten Attaching the holder Position the holder 2 with washer 1 Screw in and tight...

Page 204: ...lder 2 and washer 1 Removing the charge air manifold Mark the installation position of the mounting bolts 3 5 and 6 Unscrew the mounting bolts 3 and 5 Unscrew the mounting bolts 6 and remove with the...

Page 205: ...sealing surfaces Installing the right air distribution pipe Installing the right air distribution pipe Clean the sealing surfaces Position the air distribution pipe 3 with new seals 4 Screw in the mou...

Page 206: ...as marked Screw in the mounting bolt 6 with washer as marked and tighten Screw on the mounting nut 7 with washer and tighten Attaching the holder Position the holder 2 with washer 1 Screw in and tight...

Page 207: ...WF 2nd tightening 90 Mounting bolt exhaust pipe M10x40 HWF Final tightening 10 Mounting nuts turbocharger M10 60 Nm Important information WARNING Component damage due to incorrectly tightened screw bo...

Page 208: ...Detaching the cover plate Unscrew the mounting bolts 2 and 4 and remove with washers Remove the heat shield 1 Repeat the procedure for cover plate 3 Detaching the cover plate holder Unscrew the mounti...

Page 209: ...old 6 with seals 1 and 7 Clean the sealing surfaces Detaching the exhaust pipe Unscrew the mounting bolts 3 and remove them together with bushes 4 Remove the exhaust pipes 1 and 2 with seals 5 Clean t...

Page 210: ...th bushes 4 and tighten to Initial torque 22 Nm Tighten the mounting bolts 3 to 2nd tightening 90 Tighten the mounting bolts 3 to Final tightening 10 Attaching the exhaust manifold Clean the sealing s...

Page 211: ...the same procedure for other holders Attaching the cover plate Position the heat shield 1 Fit mounting bolts 2 and 4 with washers screw in and tighten Repeat the procedure for cover plate 3 Attaching...

Page 212: ......

Page 213: ...CYLINDER HEAD CYLINDER HEAD 1 Cylinder head cover 2 Cylinder head AE6 3st edition 211...

Page 214: ......

Page 215: ...CYLINDER HEAD CYLINDER HEAD Removing installing the cylinder head cover 1 Cylinder head cover Technical data Injector cable 1 8 Nm AE6 3st edition 213...

Page 216: ...with Adapter 65 Socket size 7 66 08 06510 9024 65 Adapter Installing the injector cable in conjunction with Torque screwdriver 64 Socket size 7 66 08 06139 9029 66 Socket size 7 Installing the injecto...

Page 217: ...ndition of the seal 1 and if necessary t a new one Put on the seal 1 Attaching the injector cable WARNING Component damage due to possible short circuit When tightening the mounting nuts make sure tha...

Page 218: ...CYLINDER HEAD Attaching the cylinder head cover Put on the cylinder head cover 2 Screw in and tighten the mounting bolts 1 216 AE6 3st edition...

Page 219: ...inder head cover see 213 Checking and setting the valve clearance see 238 1 Push rods 2 Mounting bolts rocker arm mechanism 3 Valve bridge intake 4 Valve bridge exhaust 5 Rocker arm mechanism Technica...

Page 220: ...er arm mechanism Attaching the rocker arm mechanism Thinly apply clean engine oil on the ball cups of the push rods 1 Thinly apply clean engine oil on the balls of the rocker arms Put on the rocker ar...

Page 221: ...m 7 Lock nut 8 Washer 9 Circlip 10 Adjusting screw 11 Adjusting screw Rocker arm mechanism technical data Radial play rocker arm 0 030 0 066 mm Inside diameter rocker arm bearing 34 005 34 025 mm Outs...

Page 222: ...CYLINDER HEAD Special tools 67 Dial gauge Checking the rocker arm radial play in conjunction with 08 71000 3217 220 AE6 3st edition...

Page 223: ...the procedure for the remaining rocker arms The permissible rocker arm bearing inside diameter is 34 005 34 025 mm If the inside diameter is out of tolerance t a new rocker arm 3 Measuring the rocker...

Page 224: ...he rocker arm 2 Screw on the lock nut 1 Assembling the rocker arm mechanism Thinly apply clean engine oil to MAN Standard 3277 on the rocker arm shaft 4 Push on the rocker arm 3 as marked up to the st...

Page 225: ...rods 2 Rocker arm mechanism mounting bolt 3 Intake valve rocker arm 4 Lock nut 5 Intake valve bridge 6 Cylinder head 7 Cylinder head bolt 8 Exhaust valve bridge 9 Exhaust valve rocker arm Technical d...

Page 226: ...ines the rail or the injectors even if they have only been used once Follow the sequence described when tightening injectors high pressure lines the rail and rail connections WARNING Component damage...

Page 227: ...g device 72 Cylinder head bolt 73 Connecting pin 74 Rubber ring 42 mm 75 Socket 77 80 99607 0172 72 Holding device Unscrewing and tightening the cylinder head bolts in conjunction with Socket size 22...

Page 228: ...ylinder head bolt 73 Connecting pin 74 Socket 77 08 06142 9006 76 Adapter Unscrewing and tightening the cylinder head bolts in conjunction with Socket size 22 68 Torque multiplier i 1 3 3 69 Support 7...

Page 229: ...r 83 08 71000 3217 81 Measuring plate Checking the cylinder liner standout in conjunction with Dial gauge holder 79 Dial gauge 80 Hexagon shank bolt 82 Washer 83 80 99605 0289 82 Hexagon shank bolt Ch...

Page 230: ...the Torque multiplier i 1 3 3 69 1 and secure with Connecting pin 74 7 and Rubber ring 42 mm 75 6 Insert one Socket 77 each into the Holding device 72 5 and the Socket size 22 68 8 Unscrewing sequence...

Page 231: ...der liner 372 Putting on the cylinder head Place the new cylinder head gasket 1 over the alignment pins Place the cylinder head 2 over the alignment pins Thinly apply White T assembly paste on the con...

Page 232: ...th torque 90 in the tightening sequence with special tool 1 Tighten the cylinder head bolts to Final tightening 90 in the tightening sequence with special tool 1 Disassemble the special tool 1 Remove...

Page 233: ...lve guide Technical data Mounting bolts rocker arm mechanism M12x80 10 9 Initial torque 90 Nm Mounting bolts rocker arm mechanism M12x80 10 9 Final tightening 90 Service products White T assembly past...

Page 234: ...sembly device 87 80 99606 0588 87 Assembly device Removing and installing the valve springs in conjunction with Adapter 86 Holder 90 Holder 91 Valve spring compressor 89 Extension 88 80 99606 6092 88...

Page 235: ...spring compressor 89 Extension 88 Assembly device 87 80 99613 0051 92 Magnetic pick up tool Removing the valve cotters in conjunction with Adapter 86 Holder 90 Holder 91 Valve spring compressor 89 Ex...

Page 236: ...s are in overlap Remove install the free valve stem seals as per the table Assembling the special tool Note Retaining washer and Holder 91 have left hand threads Position the Holder 90 5 and Holder 91...

Page 237: ...that the Holder 90 and Holder 91 are seated correctly on the spring cap Do not remove the valve cotters from the valve spring with your bare hands Push down the Valve spring compressor 89 with Extensi...

Page 238: ...eal 3 Push the Assembly sleeve 94 4 over the valve stem 5 Insert the valve stem seal 3 into the Assembly device 93 2 and clamp Push the Assembly device 93 2 over the Assembly sleeve 94 4 Knock the val...

Page 239: ...ing the threaded spindle 7 Hook the Valve spring compressor 89 2 in the Assembly device 87 3 Place the Extension 88 1 onto Valve spring compressor 89 2 Installing the valve cotters CAUTION Risk of inj...

Page 240: ...lve 3 Valve bridge intake valve 4 Valve bridge exhaust valve Technical data Intake valve clearance 0 50 mm Exhaust valve clearance 0 80 mm Rocker arm adjusting screw lock nut 45 Nm Service products Wh...

Page 241: ...26 6009 96 Gear ratchet Cranking the engine in conjunction with Engine barring gear 84 80 99627 0001 97 Valve wrench size 14 Setting the valve clearance in conjunction with Handle 98 80 99603 6031 98...

Page 242: ...h the Engine barring gear 95 1 on the ywheel housing Cranking the engine to the setting position A Rocker arms in overlap B Rocker arms free for valve clearance setting Crank the engine until the rock...

Page 243: ...rt the 1 with 2 between the valve bridge 3 and the ball socket 4 Adjust the valve clearance if the valve clearance is not 0 80 mm Setting the exhaust valve clearance Unscrew the lock nut 4 Unscrew the...

Page 244: ...NDER HEAD Detaching the engine barring gear Remove the Engine barring gear 95 1 from the ywheel housing Attach the TDC marking plate Attach the cap with new seal on the ywheel housing 242 AE6 3st edit...

Page 245: ...VALVE TIMING VALVE TIMING 1 Rocker arm mechanism 2 Roller tappet 3 Anti rotation lock 4 Camshaft 5 Push rod AE6 3st edition 243...

Page 246: ......

Page 247: ...Removing installing coolant lines see 65 Removing installing the poly V belt see 93 Removing installing the automatic belt tensioner see 95 Removing installing the guide roller see 97 Removing install...

Page 248: ...250 mm Radial play camshaft 0 060 0 112 mm Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only be used for pre...

Page 249: ...Remove the axial shim 1 Attaching the insertion pin Screw the Insertion pin 99 1 into the camshaft Removing the camshaft Push out the camshaft 1 towards the ywheel housing with Insertion pin 99 Unscr...

Page 250: ...devices Ensure that the anti rotation device engages in the roller tappet recess Screw in the new anti rotation devices 1 and 2 Tighten the anti rotation devices 1 and 2 to 22 Nm Installing the camsha...

Page 251: ...VALVE TIMING Mounting the camshaft gear Position the camshaft gear 1 over the alignment pin Screw in and tighten the mounting bolts 2 AE6 3st edition 249...

Page 252: ......

Page 253: ...1 Intake valve cylinder 1 Technical data Valve lift 11 0 11 3 mm Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these ma...

Page 254: ...6 6009 101 Gear ratchet Cranking the engine in conjunction with Engine barring gear 100 80 99627 0001 102 Dial gauge holder Checking the valve timing in conjunction with Dial gauge 103 08 71082 0005 1...

Page 255: ...the engine s running direction until it reaches 50 before TDC Turn the engine in the engine s running direction until it reaches 30 before TDC Checking the valve lift Attach the Dial gauge 103 1 with...

Page 256: ......

Page 257: ...RONT TIMING GEARS REAR TIMING GEARS Timing gears in the housing cover at the front 1 Crankshaft gear coolant pump 2 Intermediate gear crankshaft split 3 Intermediate gear pin 4 Mounting bolt 5 Cranksh...

Page 258: ...FRONT TIMING GEARS REAR TIMING GEARS Timing gears in the ywheel housing 1 Crankshaft gear 2 Mounting bolt 3 Camshaft gear 4 Countershaft gear 256 AE6 3st edition...

Page 259: ...stalling the coolant pump coolant manifold see 73 Removing installing the poly V belt see 93 Removing installing the automatic belt tensioner see 95 Removing installing the guide roller see 97 Removin...

Page 260: ...w 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 wr...

Page 261: ...ermediate gear pin 2 Removing the oil pump crankshaft gear Pull off the crankshaft gear 1 over the Aligning tool 104 2 and 3 Clean the contact surfaces of the crankshaft gear 1 and crankshaft Dismantl...

Page 262: ...into the intermediate gear 5 Put the intermediate gear 2 on the intermediate gear 5 as marked Tighten the mounting bolts 1 and 6 Installing the front timing gears Installing the oil pump crankshaft g...

Page 263: ...ING GEARS REAR TIMING GEARS Installing the coolant pump crankshaft gear Push on the crankshaft gear 2 over Aligning tool 104 1 and 3 as far as the stop Unscrew the Aligning tool 104 1 and 3 AE6 3st ed...

Page 264: ......

Page 265: ...see 181 Removing installing the cooling system see 55 Removing installing the fan V belt see 85 Removing installing the ramfan see 61 Removing installing fuel lines see 141 Removing installing the hi...

Page 266: ...ew 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 w...

Page 267: ...the crankshaft gear to the marks Crank the engine on the engine barring gear until the mark 1 is aligned with the mark 2 Mark 1 and mark 2 are aligned Unscrewing the crankshaft gear mounting bolts Uns...

Page 268: ...3 Align the bore in the crankshaft gear 1 with the centring pin Push the crankshaft gear 1 onto the crankshaft Unscrew the Aligning tool 105 2 and 3 Checking the crankshaft gear mark Check that the ma...

Page 269: ...ENGINE LUBRICATION ENGINE LUBRICATION 1 Oil module right 2 Oil module left 3 Oil sump AE6 3st edition 267...

Page 270: ......

Page 271: ...ing the fan V belt see 85 Removing installing the ramfan see 61 Removing installing the intermediate ange see 63 Removing installing the fan tensioning pulley see 89 Removing installing the fan carrie...

Page 272: ...ule otherwise coolant will enter the oil sump when the oil module is removed from the crankcase WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used...

Page 273: ...hing the left oil module Mark the installation position of the mounting bolts 1 2 7 and 8 Unscrew the mounting bolts 1 2 7 and 8 and remove Mark the installation position of the wiring harness holder...

Page 274: ...ith seal 1 Remove the O rings 7 Clean the sealing surfaces Installing the oil module Installing the right oil module Clean the sealing surfaces Insert new O rings 7 Position the oil module 2 with a ne...

Page 275: ...odule 6 with a new seal 3 Position the wiring harness holder with bush as marked Screw in the mounting bolts 1 2 7 and 8 as marked Tightening diagram for left oil module Tighten the mounting bolts 4 U...

Page 276: ...n see 61 Removing installing the intermediate ange see 63 Removing installing the fan tensioning pulley see 89 Removing installing the fan carrier with fan bearing see 91 Removing installing the coola...

Page 277: ...he speci ed tightening torque Final tightening must always be performed manually using a torque wrench WARNING Component damage caused by contamination Clean the components and sealing surfaces with s...

Page 278: ...he seals 2 Clean the sealing surfaces Removing the oil separator Unscrew the mounting bolts 2 Pull the oil separator 1 out of the oil module Remove the O rings 3 and 4 Removing the oil lter WARNING En...

Page 279: ...il lter cover 1 Screw in the oil lter cover 1 with Socket size 36 106 and tighten to 45 Nm Installing the oil separator Fit the new O rings 3 and 4 Insert the oil separator 1 into the oil module Screw...

Page 280: ......

Page 281: ...M14x20 10 9 120 Nm Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only be used for pretightening to max 50 of...

Page 282: ...nozzle Unscrew the mounting bolt 1 Extract the oil injector nozzle 2 from the crankcase Installing the oil injector nozzle Insert the oil injector nozzle 2 into the crankcase Screw in the mounting bol...

Page 283: ...onent damage caused by contamination Clean components and sealing surfaces before assembly using suitable means Protect the cleaned surfaces to prevent them getting dirty again WARNING Component damag...

Page 284: ...ld for the left oil suction line Mark the mounting bolts 4 and 5 Unscrew the mounting bolts 4 and 5 and then remove with the holder 6 and bush 7 Remove the manifold 3 with the O ring 1 Pull out the in...

Page 285: ...ts 2 Remove the oil sump 3 with seal 1 Clean the sealing surfaces Installing the oil sump Installing the oil sump Clean the sealing surfaces Position the oil sump 3 with a new seal 1 Screw in and tigh...

Page 286: ...ert pipe 2 Position the manifold 3 with a new O ring 1 Screw in and tighten the mounting bolts 4 and 5 with holder 6 and bush 7 as marked Attaching the left oil return line Position the oil return lin...

Page 287: ...tion Technical data Oil drain plug M26x1 5 80 Nm Service products Loctite 648 04 90300 9024 Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact...

Page 288: ...1 Removing the connecting piece Unscrew the Connecting piece 1 with sealing ring 2 Removing the oil ller pipe Unscrew the mounting nut 2 Unscrew the oil ller pipe 3 with sealing ring 1 Removing the o...

Page 289: ...ssembling the oil suction line Clean the screen plate 1 Insert the screen plate 1 into the oil suction line Installing the circlip 2 Installing oil suction lines Clean the sealing surfaces Insert new...

Page 290: ...t 2 and new sealing ring 1 Tighten the mounting nut 2 Installing connecting pieces Screw in the tting 1 with a new sealing ring 2 and then tighten Inserting the guide tube Push the guide tube 1 into t...

Page 291: ...ld see 73 Removing installing the coolant pump see 77 Removing installing the poly V belt see 93 Removing installing the automatic belt tensioner see 95 Removing installing the guide roller see 97 Rem...

Page 292: ...se 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 Special tools 107 Dial gauge holder Checking...

Page 293: ...for the right oil suction line Unscrew the mounting bolts 3 and 4 and remove Remove the manifold 2 with the O ring 1 Pull out the insert pipe 5 Clean the sealing surfaces Detaching the cover Mark the...

Page 294: ...oil pump Place the Dial gauge 108 1 against the rotor 3 with a preload Press the rotor 3 towards the drive gear Zero the Dial gauge 108 1 Press the rotor 3 towards the Dial gauge 108 1 and check the...

Page 295: ...the manifold 2 with a new O ring 1 Screw in and tighten the mounting bolts 3 and 4 Attaching the manifold for the left oil suction line Clean the sealing surfaces Insert the new insert pipe 2 Position...

Page 296: ......

Page 297: ...CRANKSHAFT OIL SEALS CRANKSHAFT OIL SEALS 1 Flywheel housing 2 Rear crankshaft oil seal 3 Front crankshaft oil seal 4 Cover AE6 3st edition 295...

Page 298: ......

Page 299: ...ling the cover see 359 Removing installing the front radial shaft seal see 297 1 Front radial shaft seal Important information WARNING PTFE sealing rings are rendered unusable if they come into contac...

Page 300: ...conjunction with Plug on handle 112 Washer 113 Pressing plate 114 80 99617 0020 112 Plug on handle Installing the radial shaft seal in conjunction with Aligning tool 111 Washer 113 Pressing plate 114...

Page 301: ...tor 109 3 and Extractor hook 110 2 Installing the front radial shaft seal Assemble the Pressing plate 114 3 with the Plug on handle 112 1 and Washer 113 2 Put the closed side of the radial shaft seal...

Page 302: ...gear must be renewed every time after the crankshaft gear screw connection is unscrewed WARNING PTFE sealing rings are rendered unusable if they come into contact with oil or grease before installatio...

Page 303: ...n with Impact extractor 116 Aligning tool 122 80 99601 6033 118 Plug on handle Installing the radial shaft seal in conjunction with Washer 119 Guide plate 120 Press in bush 121 Aligning tool 122 80 99...

Page 304: ...ning tool 122 80 99604 0340 122 Aligning tool Removing installing the ywheel Installing the radial shaft seal in conjunction with Plug on handle 118 Washer 119 Guide plate 120 Press in bush 121 Extrac...

Page 305: ...aces Mount and lock the Engine barring gear 115 1 Checking the valves for unobstructed movement 1st cylinder Check the rocker arms 1 and 2 for the 1st cylinder for unobstructed movement If the 1st cyl...

Page 306: ...s 5 Remove the radial shaft seal 3 from the crankshaft gear 4 Installing the rear radial shaft seal Installation position of crankshaft gear Align the crankshaft gear so the marks 1 match up with the...

Page 307: ...uide plate 120 3 Carefully push the radial shaft seal 4 onto the Guide plate 120 3 Push the Guide plate 120 3 over the Aligning tool 122 1 and 2 Remove the transport sleeve Pressing in the radial shaf...

Page 308: ......

Page 309: ...CRANK MECHANISM CRANK MECHANISM 1 Flywheel 2 Pistons 3 Vibration damper AE6 3st edition 307...

Page 310: ......

Page 311: ...ee 91 Removing installing the poly V belt see 93 Draining the coolant see Operator s Manual 1 Mounting bolt 2 Hub 3 Vibration damper 4 Mounting bolt Technical data Mounting bolt M16x1 5x117 10 9 Initi...

Page 312: ...installing the vibration damper 80 99617 0020 124 Engine barring gear Cranking the engine in conjunction with Gear ratchet 125 80 99626 6009 125 Gear ratchet Cranking the engine in conjunction with E...

Page 313: ...g bolts Unscrew two opposite mounting bolts 1 and 2 Screwing in the aligning tools Screw in the Aligning tool 123 1 and 2 Pulling off the vibration damper CAUTION Danger of injury due to heavy compone...

Page 314: ...bration damper aside incorrectly Do not lay the vibration damper down on the discs Unscrew the mounting bolts 3 Remove the hub 1 from the vibration damper 2 Assembling the vibration damper Insert the...

Page 315: ...ng the aligning tools Unscrew the Aligning tool 123 1 and 2 Tightening the mounting bolts Screw in the remaining mounting bolts 1 and 2 Tighten all the mounting bolts to Initial torque 190 Nm Tighten...

Page 316: ......

Page 317: ...new ywheel mounting bolts once they have been unscrewed WARNING Component damage due to inadequate positive locking of the crankshaft gear because the front face of the crankshaft gear is shot peened...

Page 318: ...0024 128 Torque multiplier i 1 3 3 Unscrewing and tightening the ywheel bolts in conjunction with Socket size 22 127 Support 129 Torque angle gauge 130 Holding device 131 Cylinder head bolt 133 Connec...

Page 319: ...head bolt 133 Connecting pin 134 Rubber ring 42 mm 135 Adapter 136 Socket 132 80 99606 0641 132 Socket Unscrewing and tightening the ywheel bolts in conjunction with Socket size 22 127 Support 129 To...

Page 320: ...lt 133 Connecting pin 134 Adapter 136 Socket 132 08 06142 9006 136 Adapter Unscrewing and tightening the cylinder head bolts in conjunction with Socket size 22 68 Torque multiplier i 1 3 3 69 Support...

Page 321: ...1 and secure using the Connecting pin 134 7 and Rubber ring 42 mm 135 6 Insert one Socket E24 137 each into the Holding device 131 5 and the Socket size 22 127 8 Unscrewing the ywheel mounting bolts...

Page 322: ...due to spot drilling of the ywheel Take care not to damage the ywheel when spot drilling the ywheel ring gear Fit a new spot drilled ywheel Spot drill the ywheel ring gear 1 and force it open Remove...

Page 323: ...ng ones have been unscrewed Align the dowel hole in the ywheel 3 with the crankshaft alignment pin Put on the ywheel 3 over the Aligning tool 126 1 and 2 Unscrewing the aligning tools Screw in the new...

Page 324: ...to Initial torque 100 Nm as per the tightening diagram Tighten the mounting bolts 1 using the special tool 2 in conjunction with the Socket 132 Tighten the mounting bolts 1 to Second tightening 90 as...

Page 325: ...e cylinder head see 223 Checking and setting the valve clearance see 238 1 Double bevelled ring 2 Taper face ring 3 Keystone ring 4 Internal circlip 5 Piston pin 6 Piston 7 Internal circlip 8 Connecti...

Page 326: ...ston pin diameter 54 994 55 000 mm Piston pin bore 55 063 55 093 mm Pistons Piston standout measured from crankcase to piston 0 361 to 0 080 mm Important information WARNING Component damage due to in...

Page 327: ...ring pliers Removing installing the piston rings 83 09144 6090 142 Dial gauge Checking the piston standout in conjunction with Dial gauge holder 140 08 71000 3217 143 Piston ring compressor pliers In...

Page 328: ...turn Detaching the connecting rod bearing cap Turn the crankshaft so that the connecting rod bearing journal is located before the cylinder of the piston to be removed TDC Unscrew the connecting rod b...

Page 329: ...tolerance 54 994 55 000 mm t a new piston with piston pin 1 Measuring the piston ring axial play Note The axial play cannot be measured on the keystone ring Measure the axial play between the double b...

Page 330: ...m The double bevelled ring gap must be 0 30 0 50 mm If the ring gaps are out of tolerance t new piston rings as a set only not individually Installing the piston rings WARNING Component damage due to...

Page 331: ...necting rod bearing shell onto the connecting rod as marked taking care not to damage the contact surfaces between the connecting rod bearing shell 2 and the connecting rod Screw in the connecting rod...

Page 332: ...at the procedure Piston installation with piston ring compressor pliers WARNING Component damage due to incorrect piston installation position Check the direction of the arrow on the piston crown Turn...

Page 333: ...the new connecting rod bearing bolts 1 and tighten them by hand Tightening the connecting rod bearing shells Turn the crankshaft to BDC to tighten the connecting rod bearing bolts 1 Check the alignme...

Page 334: ......

Page 335: ...emoving installing the automatic belt tensioner see 95 Removing installing the guide roller see 97 Removing installing the coolant pump see 77 Removing installing the vibration damper see 309 Removing...

Page 336: ...5 Nm Mounting bolts crankcase lower section M10x170 10 9 65 Nm Mounting bolts crankcase lower section M18x2x200 Initial torque 160 Nm Mounting bolts crankcase lower sectio n M18x2x200 2nd tightening 9...

Page 337: ...nly be used for pretightening to max 50 of the speci ed tightening torque Final tightening must always be performed manually using a torque wrench Special tools 146 Dial gauge Checking the crankshaft...

Page 338: ...ghtening the crankcase lower section mounting bolts in conjunction with Torque multiplier i 1 3 3 156 Support 157 Torque angle gauge 158 Holding device 159 Cylinder head bolt 160 Connecting pin 161 Ru...

Page 339: ...lt 160 Connecting pin 161 Rubber ring 42 mm 162 Adapter 163 Socket 164 Holding device 165 80 99607 0172 159 Holding device Unscrewing and tightening the crankcase lower section mounting bolts in conju...

Page 340: ...nd tightening the crankcase lower section mounting bolts in conjunction with Socket size 22 155 Torque multiplier i 1 3 3 156 Support 157 Torque angle gauge 158 Holding device 159 Cylinder head bolt 1...

Page 341: ...159 Cylinder head bolt 160 Connecting pin 161 Rubber ring 42 mm 162 Adapter 163 80 99603 0327 165 Holding device Unscrewing and tightening the crankcase lower section mounting bolts in conjunction wit...

Page 342: ...asher dimensions 335 Checking the crankshaft radial play Position the Dial gauge 146 1 with the Dial gauge holder 147 3 and Locating pin 148 on the crankshaft 2 with a preload Push the crankshaft 2 in...

Page 343: ...1 and camshaft gear 2 with one another Unscrewing the crankcase lower section mounting bolts Mark the installation position of the mounting bolts 1 Unscrew the mounting bolts 1 Unscrewing the outer c...

Page 344: ...o the Torque multiplier i 1 3 3 156 1 Put the Socket size 22 155 8 on the Torque multiplier i 1 3 3 156 1 and secure using the Connecting pin 161 7 and Rubber ring 42 mm 162 6 Insert the Socket 164 in...

Page 345: ...the Puller screw 152 alternately one turn at a time After this is done three times the Puller screw 152 bolt head comes into contact Do not tighten the Puller screw 152 Lift off the crankcase lower s...

Page 346: ...l cables with sharp edges to lift out the crankshaft Attach the lifting gear using the aligning tools Lift out the crankshaft 1 Unscrew the Aligning tool 150 at the front Unscrew the Aligning tool 151...

Page 347: ...shells must be tted Checking the crankshaft bearing shell inside diameter Insert the crankshaft bearing shells into the crankcase and crankcase lower section 3 as marked Put on the crankcase lower sec...

Page 348: ...olerance Installing the crankshaft Inserting the main bearing shells into the crankcase lower section Check none of the tted sleeves 2 are missing 10 items V 12 engine has 14 items Thinly apply clean...

Page 349: ...e front of the crankshaft 1 Screw in the Aligning tool 151 at the rear of the crankshaft 1 Attach the lifting gear using the aligning tools Thinly apply clean engine oil to MAN Standard 3277 on the ma...

Page 350: ...tion with support WARNING Component damage due to main bearing shells falling out Make sure the main bearing shells do not fall out when putting on the crankcase lower section Check the bushings 4 for...

Page 351: ...lts 1 with washers 2 as marked Tighten the outer mounting bolts 1 to 65 Nm as per the tightening diagram Assembling special tool 1 Insert the Torque multiplier i 1 3 3 156 1 into the Support 157 2 Att...

Page 352: ...0 Nm as per the tightening diagram Tighten the inner mounting bolts 1 to 2nd tightening 90 as per the tightening diagram Tighten the inner mounting bolts 1 to 3rd tightening 90 as per the tightening d...

Page 353: ...auge 146 1 with the Dial gauge holder 147 2 and Locating pin 148 on the crankshaft 3 with a preload Push the crankshaft 3 into the limit position towards Dial gauge 146 1 Zero the Dial gauge 146 1 Pul...

Page 354: ...n Align the marks on the crankshaft gear 1 and camshaft gear 2 with one another If the marks 1 and 2 do not match up remove the crankshaft gear and install it again with the marks 1 aligned with the m...

Page 355: ...CRANKCASE CRANKCASE 1 Right vent line 2 Left vent line 3 Flywheel housing 4 Engine mount 5 Cover AE6 3st edition 353...

Page 356: ......

Page 357: ...tant information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only be used for pretightening to max 50 of the speci ed tightening...

Page 358: ...move the vent line 5 Detaching the right positive crankcase ventilation Unscrew the mounting nuts 1 and remove with washers 2 Pull out the mounting bolts 3 Loosen the jubilee clips 4 and 6 using the H...

Page 359: ...3 Attaching the right positive crankcase ventilation Position the vent line 5 and pull on the hoses with jubilee clips 4 and 6 Insert the mounting bolts 3 Screw on the mounting nuts 1 with washers 2 a...

Page 360: ......

Page 361: ...nt pump coolant manifold see 73 Removing installing the coolant pump see 77 Removing installing the poly V belt see 93 Removing installing the automatic belt tensioner see 95 Removing installing the g...

Page 362: ...tions 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 Special...

Page 363: ...nting bolts 1 and 2 Detaching the cover Mark the installation position of the mounting bolts 2 and 5 Unscrew the mounting bolts 2 and 5 Remove the cover 1 with the seal 3 and O rings 4 Clean the seali...

Page 364: ...e Attach the seal with the screen printed side facing the crankcase Clean the sealing surfaces Remove the cover 1 with a new seal 3 and new O rings 5 Screw in and tighten the mounting bolts 2 and 6 as...

Page 365: ...the fan V belt see 85 Removing installing the ramfan see 61 Removing installing the intermediate ange see 63 Removing installing the fan tensioning pulley see 89 Removing installing the fan carrier wi...

Page 366: ...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 per...

Page 367: ...ywheel housing 2 with seal 4 Clean the sealing surfaces Dismantling the ywheel housing Unscrew the mounting bolts 5 Remove the crane hook 1 Unscrew the screw plugs 2 3 and 4 and remove with sealing r...

Page 368: ...embling the ywheel housing Clean the sealing surfaces Fit screw plugs 2 3 and 4 with new sealing rings and tighten Position the crane hook 1 Screw in and tighten the mounting bolts 5 Mounting the ywhe...

Page 369: ...lines see 65 Removing installing the poly V belt see 93 Removing installing the automatic belt tensioner see 95 Removing installing the guide roller see 97 Removing installing the coolant pump see 77...

Page 370: ...Cylinder liner inside diameter 127 990 128 001 mm Technical data Cylinder liner standout 0 035 0 085 mm Depth of collar recess in crankcase 9 850 10 150 mm Important information WARNING Component dam...

Page 371: ...conjunction with Dial gauge 171 Measuring plate 172 80 99605 0172 171 Dial gauge Checking the cylinder liner standout in conjunction with Dial gauge holder 170 Measuring plate 172 08 71000 3217 172 M...

Page 372: ...ng the cylinder liner standout in conjunction with Dial gauge holder 170 Dial gauge 171 Measuring plate 172 Bolt 173 06 15013 0417 175 Depth gauge electronic Checking the cylinder liner seating 08 711...

Page 373: ...actor device 168 3 Carefully push the Extractor device 168 3 with folded Extractor plate 169 1 into the cylinder liner 2 Extracting the cylinder liner Clamp the Extractor device 168 1 with the hexagon...

Page 374: ...Dial gauge holder 170 5 with Dial gauge 171 3 on Measuring plate 172 2 Place the dial gauge tip 1 on the crankcase Zero the Dial gauge 171 3 Carefully place the dial gauge tip 1 on the cylinder liner...

Page 375: ...Engine mount Important information WARNING Component damage due to incorrectly tightened screw bolt connections If impact wrenches are used these may only be used for pretightening to max 50 of the sp...

Page 376: ...etaching it Mark the installation position of the mounting bolts 2 and 3 Mark the installation position of the mounting bolts 2 and 3 and unscrew Remove the engine mount 1 Installing engine mounts Att...

Page 377: ...TECHNICAL DATA 375 AE6 Stage 2 2st edition Technical Data...

Page 378: ...TECHNICAL DATA 376 AE6 Stage 2 2st edition...

Page 379: ...eed sensor M 6x16 8 Nm Coolant temperature sensor M 16x1 5 45 Nm Engine oil temperature sensor M 16x1 5 45 Nm Coolant pressure sensor M 18x1 5 47 Nm Oil pressure sensor M 18x1 5 47 Nm Engine wiring ha...

Page 380: ...ng nut M16x1 5 95 Nm Mounting nut terminal B M8 13 Nm Starter No of teeth starter pinion 11 Starter output 7 kW at 24 V Mounting bolt terminal 30 M12 25 Nm Mounting bolt terminal 31 M12 25 Nm Mounting...

Page 381: ...igh pressure line reuse initial torque 10 Nm High pressure line reuse final torque 30 Pressure screw rail connection M24x1 5 initial torque 10 Nm Pressure screw rail connection M24x1 5 final torque 20...

Page 382: ...0 8 Nm Mounting bolt metering unit M5x20 T25 initial torque 3 Nm Mounting bolt metering unit M5x20 T25 final torque 6 Nm Dismantling and assembling the fuel filter Cover 25 Nm Drain plug 3 Nm Dismantl...

Page 383: ...der head cover Cylinder head cover tightening diagram B Exhaust end Observe the tightening sequence for the mounting bolts Rocker arm mechanism Mounting bolts rocker arm mechanism M12x80 10 9 90 Nm Mo...

Page 384: ...46 10 9 3rd torque 300 Nm Cylinder head bolts M18x2x246 10 9 4th torque 90 Cylinder head bolts M18x2x246 10 9 5th torque 90 Cylinder head bolts M18x2x246 10 9 final torque 90 Cylinder head tightening...

Page 385: ...bolt vibration damper M16x1 5x117 10 9 final torque 90 Flywheel Mounting bolt M18x1 5x91 12 9 initial torque 100 Nm Mounting bolt M18x1 5x91 12 9 2nd torque 90 Mounting bolt M18x1 5x91 12 9 final torq...

Page 386: ...30 0 35 0 M8x1 23 0 35 0 40 0 M10 45 0 65 0 75 0 M10x1 25 45 0 67 0 75 0 M10x1 50 0 70 0 85 0 M12 75 0 110 0 125 0 M12x1 5 75 0 115 0 130 0 M12x1 25 80 0 120 0 135 0 M14 115 0 175 0 200 0 M14x1 5 125...

Page 387: ...or similar Screw in fittings DIN 3901 MAN 200 or similar for cutting ring connection of a further pipeline Screw plugs with hexagon socket or hexagon head DIN 908 DIN 910 DIN 7604 or similar Hose fitt...

Page 388: ...TECHNICAL DATA 386 AE6 Stage 2 2st edition M45X1 5 190 Nm M48X1 5 190 Nm Tighten cutting ring connection User tip Bracing is possible when tightening and un doing the cutting ring connection...

Page 389: ...system Thermostat 1 Stroke at least 9 5 mm at 92 C Thermostat opening temperature 80 5 83 5 C Add on units Starter Manufacturer Mitsubishi Type 5004 24 C Operating method pre engaged starter Starter p...

Page 390: ...ker arm bearing 33 959 33 975 mm Rocker arm 1 Inside diameter rocker arm 34 005 34 025 mm Radial play rocker arm 0 030 0 066 mm Axial play max 0 51 mm Valve tappet 1 Inside diameter rocker arm 38 975...

Page 391: ...Inside diameter 9 000 9 015 mm Outside diameter 15 028 15 046 mm Bore in cylinder head for valve guide 15 000 15 018 mm Exhaust valve 45 Intake valve 60 Valves 1 Intake valve 8 970 9 040 mm 2 Exhaust...

Page 392: ...TECHNICAL DATA 390 AE6 Stage 2 2st edition Valve recess 1 Valve recess Intake valve 0 090 0 390 mm Exhaust valve 0 090 0 390 mm 1 Nozzle projection 2 73 3 58 mm...

Page 393: ...exhaust valve only 1 Length L untensioned approx 64 24 mm Spring force at L 38 mm 142 158 N Spring force at L 26 mm 213 239 N The lowest spring force is at the same time the wear limit value Outside v...

Page 394: ...Intake valve opening angle 204 Valve stroke with valve clearance Intake valve max 11 00 11 30 mm Exhaust valve max 11 00 11 30 mm TDC BDC 1 2 3 4 5 6 7 Timing gears Front engine control timing gears B...

Page 395: ...rication Oil pump 1 Outer rotor ring gear Ring gear axial play 0 040 0 090 mm Ring gear radial play 0 122 0 194 mm 2 Inner rotor pinion Pinion axial play 0 035 0 080 mm Pinion radial play 0 025 0 061...

Page 396: ...11 Conrod 1 Piston pin socket inside diameter 55 060 52 075 mm 2 Bore for bearing shells in conrod 101 000 101 022 mm Do not reinstall conrods that are discoloured and tarnished on the conrod big end...

Page 397: ...parts must not be used again Conrod bearing 1 Conrod bearing shell thickness 2 480 2 495 mm Spread max 2 0 mm If traces of wear are present traces of scoring running layer damaged replace both bearing...

Page 398: ...piston 127 898 127 918 mm D2 measured 46 5 mm above lower edge of piston 127 882 127 902 mm D3 measured 77 5 mm above lower edge of piston 127 850 127 870 mm D4 measured 92 mm above lower edge of pis...

Page 399: ...nominal value Piston ring width 4 50 4 90 mm 3 2nd ring tapered compression ring Piston ring height 2 47 2 49 mm Piston ring width 4 90 5 30 mm 4 3rd ring double bevelled ring Piston ring height 3 47...

Page 400: ...g journal 99 975 99 995 mm 3 Crankshaft bearing journal 103 980 104 000 mm Standard size 1 103 880 103 900 mm Repair size 1 103 730 103 750 mm Repair size 2 103 480 103 500 mm 1 Thickness of thrust wa...

Page 401: ...591 3 603 mm Repair size 2 3 716 3 728 mm 2 Inside diameter of crankshaft bearing shell in installed state 104 044 104 090 mm Standard size 1 104 144 104 190 mm Repair size 1 104 294 104 340 mm Repai...

Page 402: ...TECHNICAL DATA 400 AE6 Stage 2 2st edition...

Page 403: ...Special tools 401 AE6 Stage 2 2st edition Special tools...

Page 404: ...Special tools 402 AE6 Stage 2 2st edition...

Page 405: ...lling the flywheel 4 Hex nut M12 06 11226 8306 S Removing and installing the injector with nozzle 5 Washer 06 15013 0417 S Removing and installing the cylinder head S Removing and installing the cylin...

Page 406: ...0700 S Removing and installing the injector with nozzle S Removing and installing the cylinder head cover 11 Rubber ring 42 mm 08 06142 9006 S Removing and installing the cylinder head S Removing and...

Page 407: ...1082 0005 S Dismantling and assembling the rocker arm mechanism S Checking the valve timing S Removing and installing the crankshaft 17 Depth gauge electronic 08 71195 9003 S Removing and installing t...

Page 408: ...S Removing and installing the front radial shaft seal S Removing and installing the rear radial shaft seal 25 Extractor hook 80 99602 0175 S Removing and installing the front radial shaft seal 26 Pla...

Page 409: ...linder head S Removing and installing the flywheel S Removing and installing the crankshaft 32 Hexagon socket size 36 80 99603 0385 S Dismantling and assembling the fuel filter 33 Press in bushing 80...

Page 410: ...0551 S Removing and installing the cylinder head S Removing and installing the flywheel S Removing and installing the crankshaft 39 Adapter 80 99606 0552 S Removing and installing the cylinder head S...

Page 411: ...ing and installing the crankshaft 46 Guide plate 80 99606 0703 S Removing and installing the rear radial shaft seal 47 Assembly jig 80 99606 6088 S Removing and installing the valve stem seal 48 Assem...

Page 412: ...3 6000 S Removing and installing the valve stem seals 55 Forcing bolt 80 99615 0039 S Removing and installing the crankshaft 56 Aligning tool 80 99617 0020 S Removing and installing the front drive ge...

Page 413: ...ing the cylinder head S Removing and installing the flywheel S Removing and installing the crankshaft 62 Set tool 80 99622 0052 S Removing and installing the piston and conrod S Removing and installin...

Page 414: ...2 S Removing and installing the high pressure lines and rails S Dismantling and assembling the high pressure pump high pressure pump drive 68 Cap 81 96002 0518 S Removing and installing the high press...

Page 415: ...emoving and installing the high pressure lines and rails S Removing and installing the fuel lines S Removing and installing the fuel filter 76 End plug 81 96002 0556 S Removing and installing the high...

Page 416: ...lling the injector with nozzle common rail 82 Protective sleeve Z 16 x 8 81 96002 0513 S Removing and installing the fuel lines 83 Protective sleeve Z 28 x 20 81 96002 0514 S Removing and installing t...

Page 417: ...99603 6031 S Checking and adjusting the valve valves 87 Hand pump 80 99620 0029 S Checking the high pressure system for leaks 88 Adapter 80 99620 0033 S Checking the high ressure system for leaks 89...

Page 418: ...Special tools 416 AE6 Stage 2 2st edition...

Page 419: ......

Page 420: ...MAN Truck Bus AG Dachauer Str 667 80995 M nchen or Postfach 500620 80976 M nchen Germany A MAN Group company Printed in Germany 51 99598 8262...

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Man D2862 LE221, Repair Manual

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Summary of Contents for D2862 LE221

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