Repair Manual D2862 LE Series

Repair Manual
MAN Marine Diesel Engines V8/V12
MAN Engines
A Division of MAN Truck & Bus
Repair Manual AE 4
2nd edition
MAN Marine Diesel Engines

non-classied and classied
V8 (D2868 LE4..)
V12 (D2862 LE4..)
51.99598-8250
1
PREFACE / PRINTER’S IMPRINT
PREFACE
This manual is intended to provide assistance in performing repairs correctly on vehicles and units and reects
the known technical situation appertaining at the copy deadline.
This publication assumes that persons who use it possess the requisite technical knowledge in handling
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always
correspond to the unit or peripherals in question, but this does not necessarily mean they are incorrect. In
such cases, plan and carry out the repair work in accordance with the sense of the instructions.
Repair work on complex add-on units should be entrusted to our customer service or to the customer service
of the manufacturing company. These units are mentioned specically in the text.
The repair jobs are divided up into sections and subsections. Each subsection starts with a page of jobs to
do in advance. The jobs to do in advance contain a summary of the main prerequisites for the repair section
in question. The detailed description of work can follow the jobs to do in advance.
Important instructions concerning technical safety and the safety of personnel are specically highlighted, as
indicated below.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in order to avoid
exposing people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in order to avoid
serious or irreparable damage to property.
Note
An explanatory note which is useful for understanding the working or operating procedure to be
performed.
Comply with general safety regulations when performing any repair work.
We reserve the right to make modications in the course of further development.
Best wishes from
MAN Truck & Bus AG
PRINTER’S IMPRINT
© 2011 MAN Truck & Bus AG
Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN
Truck & Bus AG. All rights under the copyright law are strictly reserved by MAN. If any changes are made
without the written approval of MAN Truck & Bus AG then Truck & Bus AG shall not be liable for any warranty or
guarantee claims arising from damage and defects attributable to the unauthorised modication. Furthermore,
MAN Truck & Bus AG shall not be liable for any damage resulting from the unapproved modication.
Redaktion: EPEGG, 01.2014
Satz: EPEGG
Druck: EPEGR
2 AE 4 2nd edition
TABLE OF CONTENTS
Content Chapter/Page
Index 7
Introduction
Notes on safety ........................................................................................................... 9

The engine ................................................................................................................ 18
Model plate/model designation .................................................................................... 18
Characteristic data .................................................................................................. 19
Engine description ................................................................................................... 22
Troubleshooting chart
Malfunctions and their probable causes ............................................................................. 39
Engine electrics
Engine electrics .......................................................................................................... 49

Removing and installing the engine control units .............................................................. 49
Removing and installing the injector wiring harness .......................................................... 56
Removing and installing the engine wiring harness ........................................................... 62
Removing and installing the sensors ............................................................................ 78
Cooling system
Heat exchanger .......................................................................................................... 93

Removing and mounting the heat exchanger .................................................................. 93
Assembly instructions for heat exchanger plates .............................................................. 99
Removing and mounting the expansion tank ..................................................................... 105
Removing and mounting the expansion tank ................................................................. 105
Coolant manifold ....................................................................................................... 111
Removing and installing the coolant manifold ................................................................ 111
Thermostats ............................................................................................................ 115
Removing and installing the thermostats ...................................................................... 115
Coolant pump .......................................................................................................... 119
Removing and installing the coolant pump ................................................................... 119
Coolant manifold ....................................................................................................... 123
Removing and Installing the coolant manifold ................................................................ 123
Coolant pump .......................................................................................................... 131
Removing and installing the coolant pump ................................................................... 131
Dismantling and assembling the coolant pump .............................................................. 133
Add-on units
Starter ................................................................................................................... 143

Removing and installing the starter ............................................................................ 143
Poly-V-belt guard ...................................................................................................... 145
Removing and installing the poly-V-belt guard ............................................................... 145
Poly-V-belt .............................................................................................................. 147
Removing and installing the poly-V-belt ....................................................................... 147
Alternator ................................................................................................................ 149
Removing and installing the alternator ........................................................................ 149
Hydraulic pump ........................................................................................................ 157
Removing and installing the hydraulic pump ................................................................. 157
Common-rail system
High-pressure lines and rails ........................................................................................ 163
AE 4 2nd edition 3
TABLE OF CONTENTS
Removing and installing the high-pressure lines and rails ................................................. 163
Removing and installing the high-pressure lines and rails (classied variant) ......................... 174
Injectors ................................................................................................................. 191
Removing and installing the injectors .......................................................................... 191
Checking the injector seat, rail and leakage oil lines for leaks - D2862LE4.. ........................... 201
High-pressure pump/high-pressure pump drive ................................................................. 205
Removing and installing the high-pressure pump/high-pressure pump drive .......................... 205
Fuel lines ................................................................................................................ 213
Removing and installing the fuel lines ......................................................................... 213
Removing and installing the fuel lines (classied variant) .................................................. 224
Fuel lter ................................................................................................................ 239
Removing and installing the fuel lter .......................................................................... 239
Removing and installing the fuel lter (classied variant) .................................................. 245
Dismantling and assembling the fuel lter .................................................................... 250
Dismantling and assembling the fuel lter (classied variant) ............................................. 254
Hand pump ............................................................................................................. 259
Removing and installing the hand pump ...................................................................... 259
Removing and installing the hand pump (classied variant) ............................................... 263
Dismantling and assembling the hand pump ................................................................. 267
Turbocharging
Exhaust manifold downstream of turbocharger .................................................................. 273

Removing and installing the exhaust manifold (one-stage variant) ...................................... 273
Removing and installing the exhaust manifold (two-stage variant) ....................................... 278
Exhaust manifold upstream of turbocharger ...................................................................... 283
Removing and installing the exhaust manifold upstream of the turbocharger (one-stage variant) . 283
Turbocharger ........................................................................................................... 293
Removing and installing the turbocharger (one-stage variant) ............................................ 293
Removing and installing the turbocharger (two-stage variant) ............................................ 301
Charge-air pipes ....................................................................................................... 325
Removing and installing the charge-air pipes ................................................................ 325
Intercooler ............................................................................................................... 331
Removing and installing the intercooler ....................................................................... 331
Air distributor pipe ..................................................................................................... 339
Removing and installing the air distributor pipes ............................................................ 339
Air lter .................................................................................................................. 341
Removing and installing the air lter ........................................................................... 341
Exhaust system ........................................................................................................ 345
Removing and installing the exhaust system ................................................................. 345
Cylinder head
Cylinder head .......................................................................................................... 351

Removing and installing the rocker arm mechanism ........................................................ 351
Dismantling and assembling the rocker arm mechanism .................................................. 355
Removing and installing the cylinder head .................................................................... 359
Removing and installing the valve stem seals ............................................................... 369
Checking and setting the valve clearance .................................................................... 377
Valve timing
Camshaft ................................................................................................................ 383

Removing and installing the camshaft/camshaft bearing .................................................. 383
Valve timing ............................................................................................................. 389
Checking the valve timing ........................................................................................ 389
Timing gears/drive gears
Front drive gears ....................................................................................................... 395
4 AE 4 2nd edition
TABLE OF CONTENTS
Removing and installing the front drive gears ................................................................ 395

Rear timing gears ...................................................................................................... 401
Removing and installing the rear timing gears ............................................................... 401
Engine lubrication
Oil modules ............................................................................................................. 407

Removing and installing the oil lter ........................................................................... 407
Removing and installing the oil modules (variant A) ........................................................ 411
Filling the engine with oil using the pressure application process ........................................ 416
Removing and installing the oil cooler (variant A) ........................................................... 418
Dismantling and assembling the oil module (variant A) .................................................... 420
Removing and installing the oil modules (variant B) ........................................................ 424
Dismantling and assembling the oil module (variant B) .................................................... 428
Oil injector nozzles .................................................................................................... 431
Removing and installing the oil injector nozzles ............................................................. 431
Oil sump ................................................................................................................. 433
Removing and installing the oil sump .......................................................................... 433
Oil pumps ............................................................................................................... 437
Removing and installing the oil pumps ........................................................................ 437
Crankshaft oil seals
Crankshaft oil seals ................................................................................................... 445

Removing and installing the front radial shaft seal .......................................................... 445
Removing and installing the rear radial shaft seal ........................................................... 448
Crank mechanism
Vibration damper ...................................................................................................... 457

Removing and installing the vibration damper, D2868 LE4xx ............................................. 457
Removing and installing the vibration damper, D2862 LE4xx ............................................. 463
Flywheel ................................................................................................................. 469
Removing and installing the ywheel .......................................................................... 469
Pistons and connecting rods ........................................................................................ 477
Removing and installing the pistons and connecting rods ................................................. 477
Crankshaft .............................................................................................................. 487
Removing and installing the crankshaft ....................................................................... 487
Crankcase
Crankcase ventilation ................................................................................................. 511

Removing and installing the crankcase ventilation .......................................................... 511
Engine cover ........................................................................................................... 515
Removing and Installing the engine cover .................................................................... 515
Cover .................................................................................................................... 519
Removing and installing the cover ............................................................................. 519
Flywheel housing ...................................................................................................... 521
Removing and installing the ywheel housing ............................................................... 521
Dismantling and assembling the ywheel housing .......................................................... 527
Cylinder liner ........................................................................................................... 531
Removing and installing the cylinder liner .................................................................... 531
Special tools
Overview of special tools ............................................................................................. 539

Special tools ........................................................................................................ 539
AE 4 2nd edition 5
TABLE OF CONTENTS
Technical Data
Technical Data 553
6 AE 4 2nd edition
INDEX
Catchword Page
A
Add-on units
Starter..................................................................................................................................................... 144
Assembly instructions
Gaskets .................................................................................................................................................... 15
Pipelines................................................................................................................................................... 14
C
Camshaft
Anti-rotation device................................................................................................................................. 387
Camshaft gear........................................................................................................................................ 387
Countershaft gear................................................................................................................................... 386
Insertion pin............................................................................................................................................ 388
Roller tappet ........................................................................................................................................... 387
Characteristic data......................................................................................................................................... 19
Crankshaft
Axial play ................................................................................................................................................ 494
Connecting rod bearing journals ............................................................................................................ 501
Crankcase lower section ........................................................................................................................ 495
Crankshaft bearing shell......................................................................................................................... 499
Crankshaft gear...................................................................................................................................... 499
Marks...................................................................................................................................................... 507
Thrust washers....................................................................................................................................... 498
Crankshaft drive
Lower connecting rod bearing ................................................................................................................ 483
Piston pin................................................................................................................................................ 481
Piston pin bore ....................................................................................................................................... 483
Cylinder head
Final tightening ....................................................................................................................................... 367
Preliminary tightening............................................................................................................................. 367
Rocker arm mechanism ......................................................................................................................... 376
Tightening diagram................................................................................................................................. 367
Cylinder liner
Cylinder liner standout............................................................................................................................ 534
Sectional sealing rings ........................................................................................................................... 535
D
Drive gears
Crankshaft gear...................................................................................................................................... 397
Intermediate gear ................................................................................................................................... 397
E
Engine control unit
Removing the engine control unit............................................................................................................. 52
Removing the injector wiring harness ...................................................................................................... 52
Engine cover................................................................................................................................................ 516
Engine description ......................................................................................................................................... 22
Diagram of the cooling system ................................................................................................................. 30
Diagram of the engine lubrication system ................................................................................................ 28
Diagram of the engine timing system ....................................................................................................... 34
Diagram of the fuel system....................................................................................................................... 33
Engine housing
Cover...................................................................................................................................................... 520
Engine overhaul
General information.................................................................................................................................. 15
Pressure application process ................................................................................................................... 15
Engine timing, V12 engine
Checking the valve lift ............................................................................................................................ 392
Engine timing, V8 engine
AE 4 2nd edition 7
INDEX
Checking the valve lift ............................................................................................................................ 391
H
Heat exchanger plate pack
Assembly instructions............................................................................................................................... 99
Loosening instructions.............................................................................................................................. 95
Pressure plate .......................................................................................................................................... 95
Tightening instructions.............................................................................................................................. 97
High-pressure pump
Fuel pump .............................................................................................................................................. 209
High-pressure line .................................................................................................................................. 207
Metering unit........................................................................................................................................... 209
High-pressure system
Extracting the injector............................................................................................................................. 197
Injector initial torque ............................................................................................................................... 199
Rail ......................................................................................................................................................... 182
Rail connection....................................................................................................................................... 196
Rail-pressure sensor and pressure limiting valve................................................................................... 182
M
Model plate .................................................................................................................................................... 18
N
Notes on installation
O-rings...................................................................................................................................................... 15
Notes on safety................................................................................................................................................ 9
General....................................................................................................................................................... 9
O
Oil cooler
Oil cooler ................................................................................................................................................ 419
Oil injector nozzles
Mounting bolt.......................................................................................................................................... 431
Oil module
Oil cooler ................................................................................................................................................ 429
Oil pump ...................................................................................................................................................... 439
Axial play ................................................................................................................................................ 440
Oil sump ...................................................................................................................................................... 434
Oil dipstick .............................................................................................................................................. 434
P
Performance overview................................................................................................................................... 20
T
Technical data
Alternator................................................................................................................................................ 149
Cylinder liner .......................................................................................................................................... 531
Flywheel ................................................................................................................................................. 469
High-pressure pump............................................................................................................................... 205
Oil injector nozzles ................................................................................................................................. 431
Vibration damper .................................................................................................................................... 457
Troubleshooting chart
Malfunctions ............................................................................................................................................. 39
V
Vibration damper
Hub......................................................................................................................................................... 466
8 AE 4 2nd edition
INTRODUCTION
INTRODUCTION
NOTES ON SAFETY
General
Working with engines and the necessary service products does not pose any problems provided the people
entrusted with operation, maintenance and repair have been trained accordingly and actively keep their minds
on the job.
Personnel in training or instruction or who are undergoing general education are not allowed to work on the
unit unless they are permanently supervised by an experienced person.
The following sections include summaries of important regulations listed according to major topics. The
intention is to provide the knowledge needed to avoid accidents which could lead to injury, damage and
environmental pollution. They represent only a small excerpt from the wide range of accident prevention
regulations and cannot replace these. It goes without saying that all other safety regulations must be
followed and that the corresponding action must be taken.
Additional direct references to danger are contained in the instructions at points where there is a potential
danger.
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin
contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes,
etc.
AE 4 2nd edition 9
INTRODUCTION
1. Regulations for preventing accidents leading to injury to personnel
Checking, setting and repair work
– Secure 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 technical personnel are allowed to perform inspection,
adjustment and repair work
– Switch off the battery master switch during assembly work.
– During maintenance and repair work, make certain that the engine cannot be started
inadvertently by unauthorised personnel.
– Only authorised personnel are permitted to start and operate the engine.
Operating the engine

– Only authorised personnel are permitted to start and operate the engine.
– Do not approach moving parts of a running engine too closely.
Do not wear baggy clothing.
– Ensure adequate ventilation if you are working in enclosed spaces.
– Do not touch units with your bare hands when they are at operating temperature.
Danger of burns!
Always wear protective gloves when changing oil (in units at operating temperature)
in particular.
– Do not open the coolant circuit unless the engine is cool.
– The tools must be approved by MAN and be in good technical condition.
Suspended loads
– Do not lift heavy parts without assistance. Use suitable tools.
Procedure:
– Carefully attach individual parts and larger assemblies to lifting tackle prior to
exchanging them, in order to rule out any danger.
– Only use suitable lifting gear that is in perfect working order. Use lifting devices
with sufcient load-carrying capacity.
– Only ever use the crane hook eyelets provided for connecting the crane lifting
tackle when lifting the engine.
– No-one is allowed to stand under an engine suspended from a crane hook. Keep
all lifting tackle in good condition.
Working on high-pressure lines

– Do not attempt to tighten or loosen pipe lines and hoses when they are under
pressure (e.g. lubrication circuit, coolant circuit and hydraulic oil circuit):
Fluid spraying out represents an injury hazard!
10 AE 4 2nd edition
INTRODUCTION
Work on the electrical system

– Make sure the batteries are rmly connected before starting the engine.
– Do no disconnect the batteries whilst the engine is running.
– Do not start the engine unless all the connections to the electronic control unit are in
place.
– Do not use a boost-charger to start the engine. Only render starting assistance with
separate batteries.
– The battery terminals must be disconnected for boost-charging the batteries. Comply
with the operating instructions for the boost-charger.
– Disconnect the batteries before starting electric welding work, and connect both
cables (+ and -) rmly together.
– Do not disconnect or connect the connections of the control unit unless the electrical
system is switched off.
– Take care when connecting the control unit to its electrical power supply.
Cross-polarity, e.g. caused by incorrect 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 are expecting them to be exposed to temperatures
in excess of 80 °C (e.g. drying oven).
– Only use suitable test cables for taking measurements on plug connections.
– Telephones and radios not connected to an external aerial can lead to malfunctions
in the on-board electronics and thereby impair the operational safety of the engine.
Caution! Battery acid is poisonous and corrosive!

– Comply with the manufacturer’s regulations.
– Wear appropriate protective clothing (gloves) when handling batteries.
Do not tilt batteries, acid may leak out.
– Measure voltage only using suitable measurement devices! The input resistance of
the measurement device must be at least 10 MΩ.
– The ignition must be switched off before the wiring harness plugs of the electronic
control units are disconnected or connected up!
Be careful as battery gases are explosive!

– Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after
the engine has been running for a long period and after charging the batteries with a
battery charger.
– Avoid short circuits caused by polarity reversal or by placing metal objects (spanners,
mole grips, etc.) on the battery terminals.
– Disconnect the batteries or recharge them every 4 weeks if the engine is not in use.
– When the batteries are disconnected this gas may be ignited by sparks produced by
other continuously operating consumers that have not been shut down. Ventilate the
battery box adequately before disconnecting the batteries!
AE 4 2nd edition 11
INTRODUCTION
Electric welding
– Note the welding codes of practice.
– Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number
80.78010.0002) as described in the instructions accompanying the device.
– If this device is not available, disconnect the batteries and connect the positive cable
to the negative cable in order to make a conductive connection.
– Always earth the welding equipment as close as possible to the welding area. Do not
lay the cables to the welding equipment in parallel to electrical cables in the vehicle.
– Disconnect the control units.
Painting
– If paint spraying is to be carried out, do not expose the electronic components to
high temperatures (max. 95 °C) for more than brief periods; a time of up to 2 hours
is permissible at a maximum of 85 °C.
– Disconnect the batteries.
– Remove sensitive electrical components
– Screw connections of the high-pressure part of the injection system are not allowed
to be painted. Danger of dirt getting in during repair work.
2. Notes on preventing damage and premature wear on units
General
– Engines are built exclusively for the application corresponding to the scope of supply – as dened by the
equipment manufacturer – (designated use):
– Designated use also includes compliance with the operating, maintenance and repair conditions specied
by 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 engine will result in the manufacturer’s liability for resulting damage being
rendered null and void.
Similarly, tampering with the injection and control system can affect the unit’s performance and exhaust-gas
characteristics. As a result, there is no longer any guarantee that statutory environmental protection
regulations will be complied with.
– If a fault occurs during operation, determine its cause immediately and correct the problem before the fault
can get any worse.
– Clean the units thoroughly before repairs. Ensure that no dirt, sand or foreign objects can get into the units
whilst carrying out repairs.
– Only use genuine spare parts. Fitting parts made by other companies can lead to severe damage, and the
workshop that did the work will be responsible for it. See the section entitled “Limited liability for accessories
and parts”.
– Never run a unit dry, in other words always make sure that it has been lled with oil before running it.
– Never run engines without coolant.
– Apply a suitable information sign to units that are not ready to be operated.
– Only use service products specied by MAN, otherwise the manufacturer warranty will be invalidated!
For general information about service products, refer to the publication entitled “Service products for MAN
diesel engines”.
Details of approved products can be found online at:
https://mmrepro.mn.man.de/bstwebapp/BSTServlet
– Do not ll engine/gear oil above the maximum level mark. Do not exceed the maximum permitted operational
tilt.
– Severe damage to the unit could result from failure to follow these regulations.
3. Limited liability
General
All of the data and information in this manual were compiled taking into account the applicable standards and
regulations, the state of the art, and our vast experience and knowledge.
MAN shall not be liable for any damaged resulting from:
– Failure to follow the instructions in this manual

– Non-intended use
12 AE 4 2nd edition
INTRODUCTION
– Use of non-trained personnel

– Unauthorised conversions
– Technical changes
– Use of non-approved spare parts and service products
The actual product delivered may differ from the descriptions and illustrations contained in this manual if the
product is a special version, when additional order options are selected or as a result of the latest technical
changes.
The obligations agreed in the delivery contract, the General Terms and Conditions of Business of MAN and
the statutory regulations applicable at the time of the signing of the contract shall apply.
Taking out of operation and storing

Temporary corrosion protection in accordance with MAN Works Standard M 3069 is required if an engine is
shut down for a relatively long time. The Works Standard can be obtained from our after-sales department at
the Nuremburg plant.
4. Regulations for avoiding injury and environmental contamination
Health protection precautions

– Avoid lengthy, excessive or repeated skin contact with used service uids, service products, thinners or
solvents.
– Protect your skin using a suitable skin protection agent or protective gloves.
– Do not use service uids, service products, thinners or solvents for cleaning your skin.
– Wash dirty skin thoroughly with soap and water.
– Special cleaning agents make it easier to clean dirty hands.
– Apply a greasy skin cream after cleaning your skin.
– Change out of clothing or shoes which have become soaked with oil.
– Never put oil-soaked rags into your clothing pockets.
Disposal of service uids and service products

– Please follow the instructions of your relevant local authority.
– When handling service products, make sure that no service uids leak onto the ground or into the drains
and watercourses.
– Collect different service products in separate containers and dispose of them accordingly.
– Use leak-tight containers when draining service products. Never use food or drinks containers, because
someone might drink the uid inadvertently.
– Before disposing of or recycling waste substances, check with your local environmental department
or recycling centre to ask what the correct method is. Incorrectly disposing of waste can damage the
environment.
Take care to dispose of used service products properly.
– Service products can damage groundwater quality –
5. Information for working on the common rail system
Accident prevention
A jet of fuel can cut through the skin. Risk of re due to fuel atomisation.
– Never undo the screwed connections on the fuel high-pressure side of the common-rail system whilst the
engine is running (injection line from the high-pressure pump to/on the rail and on the cylinder head to the
injector).
– Avoid standing near the running engine.
Whilst the engine is running, the lines are constantly carrying fuel under a pressure of up to 1800 bar.
– Before opening the screwed connections, wait for at least ve minutes so that the system can be
depressurised.
– Check depressurisation of the rail using MAN-cats if necessary.
Danger of injury!
– Do not touch the live parts at the injector electrical connection whilst the engine is running.
AE 4 2nd edition 13
INTRODUCTION
Special instructions for people with pacemakers

– Any changes made to the original engine cabling can result in the limit values specied in pacemaker safety
regulations being exceeded, e.g. non-twisted injector cables or installing the test box (contact box).
– People with pacemakers must stay at least 20 cm away from the running engine.
Cleanliness
Diesel-injection systems consist of precision engineered components that are subject to extreme loads. Due
to this high-precision technology, it is necessary to ensure the greatest possible cleanliness during all work
on the fuel system. Even dirt particles over 0.002 mm can cause component failure.
Before commencing work, you must therefore ensure the following measures without fail:
Danger of damage due to dirt ingress

– 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 closed during this process.
– Visually inspect the fuel system for leaks or damage.
– Do not spray the steam cleaner directly onto electrical components, or else afx covers.
– 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 repairs, brake and dynamometer tests, etc.).
– Avoid air movements (possible swirling up of dust due to starting of engines, the workshop
heating/ventilation system, due to draughts etc.).
– Clean and dry the area of the still closed fuel system using compressed air.
– Use a suitable extractor unit (industrial extractor unit) to remove loose dirt particles such as paint chippings
and insulating material.
– Areas of the engine compartment from which dirt particles could become detached must be covered with a
new, clean covering lm.
– Before removing any components, wash your hands and put on clean working clothes.
It is mandatory to comply with the following instructions during work:

– Using compressed air for cleaning is not allowed once the clean side of the fuel system has been opened.
– During assembly, remove loose dirt using a suitable extractor unit (industrial extractor unit).
– Only lint-free cleaning cloths are allowed to be used on the fuel system.
– Clean tools and equipment before starting work.
– Only use tools that show no signs of damage (cracked chrome coatings).
– Do not use materials such as cloths, cardboard or wood when removing and installing components as these
materials can produce particles and bres.
– If the undoing of connections causes the paint to chip (due to possible excess paint), carefully remove these
paint chippings before fully undoing the connection.
– All parts removed from the clean side of the fuel system must immediately have their apertures sealed
with suitable plugs.
– This sealing material must be packed to protect it from dust before it is used, and must be disposed of after
one use.
– Following this, the components must be carefully stored in a clean, sealed container.
– Never apply used cleaning or test uids to these components.
– New parts must not be removed from their original packaging until immediately before use.
– Work on removed components may only be carried out in a suitably equipped workplace.
– If removed parts are shipped, always use the new part's original packaging.
Manufacturer warranty
Only use service products specied by MAN, otherwise the manufacturer warranty will be invalidated!
For general information about service products, refer to the publication entitled “Service products for MAN
diesel engines”.
Details of approved products can be found online at: https://mmrepro.mn.man.de/bstwebapp/BSTServlet
Assembly instructions
Mounting pipelines
Danger: Do not bend any kind of pipeline – Danger of breakage!
14 AE 4 2nd edition
INTRODUCTION
Mounting gaskets
Gaskets are often inserted with sealing compounds or adhesives in order to facilitate assembly or to offer a
better seal. Particularly if parts with different thermal coefcients of expansion are connected together (e.g.
aluminium and cast iron), this can lead to the seal migrating during operation and give rise to leaks.
Example: The cover of the front crankshaft oil seal. In this case, the use of a sealing compound or adhesive
causes the gasket to be pushed inwards over time due to the differences in thermal expansion. Oil leakage
occurs which may under certain circumstances be ascribed to the shaft seal.
Gaskets can only be tted correctly provided the following points are adhered to:
– Only use genuine MAN gaskets.
– Make sure the mating faces are undamaged and clean.
– Do not use adhesives or sealing compounds. If necessary, to facilitate installation, use a little grease to
stick the gasket to the part to be mounted.
– Tighten the bolts evenly to the specied tightening torque.
Installation of O-rings
– Only use genuine MAN O-rings.
– Make sure the mating faces are undamaged and clean.
– Coat O-rings with engine oil to MAN Standard 3277 when tting them.
Engine overhaul
General information regarding engine overhauls

A range of very different factors affect the engine service life. It is therefore not possible to indicate the exact
number of operating hours before a major overhaul is due.
In our judgement, it is not advisable to open an engine or perform a major overhaul if the engine has
good compression values and the following operating values have not changed signicantly since they were
measured and taken during the initial start-up:
– Charge pressure
– Exhaust temperature
– Coolant and lubricating oil temperature
– Oil pressure and oil consumption
– Smoke characteristics
The 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 maintenance as per the maintenance schedule
– Selection and quality of lubricating oil, fuel and coolant as per the publication entitled “Service products for
MAN diesel engines”
Taking into operation following an engine overhaul

Pressure application process
It is essential to ll engines with lubricating oil using the pressure application process in dry condition before
start-up following a repair. This process can also be used in the case of damage and cause assessments.
In all engines that have not undergone pressure application, the risk of premature bearing surface damage
is very high, since the lubricating oil drawn from the oil sump by the oil pump takes a relatively long time to
reach the individual bearing points.
Such preliminary damage may not lead to bearing failure immediately, but it can impair correct functioning of
the bearings and shorten the service life.
AE 4 2nd edition 15
INTRODUCTION
Schematic representation of the oil ow in engines which have not undergone pressure application
If the engine undergoes pressure application, the following benets are achieved:
– All engine parts are lubricated before starting, and a lm of lubricant can form in the bearing before the
crankshaft even starts turning. This prevents overlay damage.
– Unwanted oil loss – whether it be caused by excessive bearing clearance, leakages in the crankcase or
non-sealed bores in the crankcase – can be detected immediately. In this case, mount the engine on an
assembly trolley, remove the oil sump and install a suitable oil collecting container under the crankcase so
that the bearings are visible.
16 AE 4 2nd edition
INTRODUCTION
Procedure:
During pressure application, the entire oil quantity is pressed into the engine oil circuit. The operating pressure
is used as the reference value for the press-in pressure. This is not allowed to be exceeded. The electrical
oil pump is connected to the engine oil circuit at the oil modules.
Connect the pressure hose for the electrical oil pump to the oil modules (1) and (2).
Press half of the entire oil quantity into the engine via the left oil module and the other half via the right oil
module, see Filling the engine with oil using the pressure application process, 416.
AE 4 2nd edition 17
INTRODUCTION
THE ENGINE
Model plate/model designation
Model plate
(1) Engine type (2) Engine serial number
Explanation of the engine no. (Engine identication number)
Engine no. Classication terms Example

(assignment)
710 Type number according to
type code
1234 Assembly day

567 Assembly sequence
(progression number on
assembly day)
8910 First day of plan period
Explanation of the model designation
Model Meaning Example

designation
D Fuel type Diesel

28 Identication number + 100 128 mm bore
6 Identication number for stroke 157 mm stroke (rounded 160 mm)
(rounded)
8 Number of cylinders 8 cylinders
L Turbocharging with turbocharging and intercooling
E Engine installation Auxiliary engine
433 Type identication 4 = Engine for marine applications
33 = Output / rpm / approval
18 AE 4 2nd edition
INTRODUCTION
Characteristic data
D 2868LE 433
Designation Unit Figures

Number of cylinders 8-cylinder/V 90°
/arrangement
Valves per cylinder 4 valves
Engine weight, dry kg approx. 1875
Injection system Common rail/EDC 7
Direction of rotation as viewed left
onto ywheel
Rated output to ISO 1585-88 kW/hp/rpm 882/1200 at 2300 rpm
/195 EEC at engine speed
Bore mm 128
Stroke mm 157
Swept volume cc 16,160
Firing sequence 1-5-7-2-6-3-4-8
Rated speed rpm 2300
Low idling speed rpm 600
Max. torque at engine speed Nm rpm 3662 at 2300
3800 at 1200-2100
D 2862LE 433
Designation Unit of measurement Data

Number of cylinders 12-cylinder/V 90°
/arrangement
Valves per cylinder 4 valves
Engine weight, dry kg approx. 2365
Injection system Common rail/EDC 7

Direction of rotation as viewed Left
onto ywheel
Rated output to ISO 1585-88 kW/hp/rpm 1324/1800 at 2300 rpm
/195 EEC at engine speed
Bore mm 128
Stroke mm 157
Swept volume cc 24,243
Firing sequence 1 - 12 - 2 - 11 - 3 - 10 - 6 - 7 - 5 - 8 - 4 - 9
Rated speed rpm 2300
Low idling speed rpm 600
Max. torque at engine speed Nm rpm 5497 at 2300
6020 at 1200-2100
AE 4 2nd edition 19
INTRODUCTION
1 Performance overview
1.1 Engines for heavy-duty operation
Unlimited number of operating hours per year, at full load 100% of the time
Engine type Engine output in kW / Rated speed in rpm Torque,

hp max. Nm / rpm
Engines with emissions status EPA Tier 3
D2868 LE424 441/ 600 1800 2630 / 1100-1600
D2862 LE434 551/ 750 1800 3290 / 1100- 1600
D2862 LE424 662/ 900 1800 3950 / 1000- 1600
D2862 LE444 735/ 1000 1800 4380 / 1100- 1600

Engines with emissions status IMO Tier 2
D2868 LE421 441/ 600 1800 2630 / 1100- 1600
D2862 LE421 662/ 900 1800 3955 / 1000- 1600
D2862 LE431 551/ 750 1800 3290 / 1000- 1600
1.2 Engines for medium-duty operation
Up to 4000 operating hours per year, at 60% load on average

hp max. Nm / rpm
D2868 LE425 588/ 800 2100 2945 / 1200- 1900
D2862 LE425 749/ 1019 2100 3780 / 1300- 1900
D2862 LE435 882/ 1200 2100 4450 / 1300- 1900

D2868 LE422 588/ 800 2100 2945 / 1200- 1900
D2862 LE422 749/ 1019 2100 3780 / 1300- 1900
D2862 LE432 882/ 1200 2100 4450 / 1300- 1900
1.3 Engines for medium-duty operation
Up to 3000 operating hours per year, at full load 20% of the time, at 50% load on
average

hp max. Nm / rpm
D2862 LE466 1029/ 1400 2100 5120 / 1300- 1900
D2862 LE463 1029/ 1400 2100 5120 / 1300- 1900
20 AE 4 2nd edition
INTRODUCTION
1.4 Engines for light-duty operation
Up to 1000 operating hours per year, at full load 20% of the time, at 50% load on
average

hp max. Nm / rpm
D2868 LE426 735/ 1000 2300 3350 / 1300- 2100
D2868 LE436 882/ 1200 2300 4010 / 1200- 2100
D2862 LE426 1140/ 1550 2300 5140 / 1300- 2100
D2862 LE446 1029/ 1400 2300 4670 / 1200- 2100
D2862 LE436 1324/ 1800 2300 6020 / 1200- 2100
D2862 LE456 1213/ 1650 2300 5520 / 1200- 2100

D2868 LE423 735/ 1000 2300 3350 / 1300- 2100
D2868 LE433 882/ 1200 2300 4010 / 1200- 2100
D2862 LE423 1140/ 1550 2300 5140 / 1300- 2100
D2862 LE443 1029/ 1400 2300 4670 / 1200- 2100
D2862 LE433 1324/ 1800 2300 6020 / 1200- 2100
D2862 LE453 1213/ 1650 2300 5520 / 1200- 2100
AE 4 2nd edition 21
INTRODUCTION
Engine description
D2868 LE433, front left view
(1) Heat exchanger

(2) Expansion tank
(3) Air lter
(4) Engine cover
(5) Intercooler, 1st stage, right
(6) Intercooler, 1st stage, left
(7) Engine terminal box
(8) Intercooler, 2nd stage
(9) Oil sump
(10) Alternator
(11) Oil module, left
(12) Engine barring gear
22 AE 4 2nd edition
INTRODUCTION
D2868 LE433, rear right view
(1) Fuel lter, left

(2) Oil module, right
(3) Turbocharger, 2nd stage, right
(4) Fuel lter, right
(5) Coolant pump
AE 4 2nd edition 23
INTRODUCTION
D2862 LE433, front left view
(1) Heat exchanger

(2) Expansion tank
(3) Air lter
(4) Engine cover
(7) Engine terminal box
(9) Oil sump
(10) Alternator
(12) Torsional vibration damper
24 AE 4 2nd edition
INTRODUCTION
D2862 LE433, rear right view
(1) Fuel lter, left (4) Fuel lter, right

(2) Oil module, right (5) Coolant pump
(3) Turbocharger, 2nd stage, right
Engine, general
The 8- and 12-cylinder diesel engines described here are liquid-cooled, 4-stroke diesel engines with 2-stage
exhaust turbocharger and intercooler. The engines operated using the common rail high-pressure injection
system in conjunction with EDC 7 (Electronic Diesel Control).
Crankcase
The crankcase consists of the crankcase upper section and the crankcase lower section. Both sections cast
from different special cast irons. The wet cylinder liners made from special, highly wear-resistant centrifugal
casting are exchangeable. The cylinder liners are sealed at the bottom using elastomer sealing rings. At the
rear of the crankcase, there is a ywheel housing. At the front of the crankcase, there is a housing cover.
The ywheel housing and housing cover are made of aluminium. The radial shaft seals are installed in the
housing cover and the ywheel housing.
Crankshaft
The crankshaft is forged in a die using high-quality, micro-alloyed steel. It has 6 or 10 mounted counterweights
to balance the masses. The crankshaft is mounted in ve or seven bearings in the crankcase. The crankshaft
journals and connecting rod bearing journals are mounted in ready-to-install three-component bearings. The
axial bearing is provided by thrust bearings in the last bearing seat at the ywheel end. The connecting rod
bearings are supplied with oil via a bore in the crankshaft bearing.
Connecting rods (cracked connecting rods)

The "cracked" connecting rods are precision forged in a die using quenched and tempered steel. The large
connecting rod eye is split diagonally by "cracking" the connecting rod bearing cap. The surface structure
AE 4 2nd edition 25
INTRODUCTION
resulting from cracking results in a tooth engagement effect between the connecting rod bearing cap and the
connecting rod with a precise, non-interchangeable t and 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 jet from the oil injection nozzles is injected for
cooling. The ring set comprises one half keystone ring and taper-face ring each as compression rings as
well as a double-bevelled ring as oil scraper ring. The pistons can be removed from above together with the
connecting rods.
Camshaft
The camshaft is forged from steel and induction hardened. It is mounted in ve or seven bearings in the
crankcase. The camshaft is driven by timing gears that are installed in the ywheel housing.
Engine lubrication
The engine is lubricated by forced-feed lubrication for all bearing points. The engine oil lter and the oil cooler
are grouped together as an oil module. The oil level in the oil sump is measured using a dipstick.
Cooling system
The cooling circuit is a thermostat-controlled forced-circulation cooling system. The maintenance-free coolant
pump is installed on the end face in the housing cover and is driven by a separate gear set. The thermostats
are housed above in the two-section thermostat housing. The thermostats consist of an exchangeable insert
with expansion element.
The coolant pump is mounted at the rear left on the ywheel housing. It supplies coolant to the intercooler
and the heat exchanger.
Cylinder head
The D28 engine is equipped with a camshaft with overhead valves (OHV). Engines in series D28 are equipped
with individual cylinder heads made from special cast iron as well as shrink-tted valve seat rings and
pressed-in exchangeable valve guides. The valve guides have valve stem seals at all four valves. The
cylinder heads are secured with six high-strength external hexagon round bolts (cylinder head bolts). The
single-layer steel cylinder head gasket with elastomer elements has a specially designed combustion chamber
seal.
Intake and exhaust system

The exhaust manifold is cooled by coolant and has dry exhaust pipes attached on the inside. It is fastened to
the cylinder head using heat-resistant bolts. The wastegate valve for the turbocharger for the high-pressure
stage (2nd stage) is mounted on the continuation of the exhaust manifold (connection housing) that is cooled
by coolant. From the high-pressure stage, the exhaust gases pass through a coolant-cooled manifold into the
turbocharger of the low-pressure stage (1st stage). The wastegate valve is directly controlled by the charge
air pressure. The turbocharger is lubricated by the main ow oil circuit of the engine, which supplies oil to the
oil pressure port on the turbochargers.
The intake air passes through the air lter to the low-pressure turbocharger (1st stage). The charge air
following precompression is intercooled as it passes through the low-pressure intercooler before passing
on to the high-pressure stage (2nd stage). Following the high-pressure stage, the charge air is once again
cooled in the high-pressure intercooler and then supplied to the engine.
Fuel system
The fuel system consists of a low-pressure system and a high-pressure system. The low-pressure system
includes the fuel lines, the hand pump and the fuel lters. The interface to the high-pressure system is the
high-pressure pump.
High-pressure system
The high-pressure system consists of the ow-rate-controlled high-pressure pump with ange-mounted fuel
pump and the rail with rail pressure sensor and pressure limiting valve. Solenoid valve-controlled injectors
with rail connections and high-pressure lines which meet the necessary requirements are also installed.
Injection pressure generation and fuel injection are separate in the high-pressure system. The injection
pressure is generated by the high-pressure pump, irrespective of the engine speed and the required injection
quantity. The injection quantity is available in the rail for injection via the injectors. The high-pressure pump
26 AE 4 2nd edition
INTRODUCTION
delivery quantity is controlled by a proportional valve. The injection point and the injection quantity are
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 combustion, reduce combustion noise and reduce peak combustion pressures.
2 Main injection to introduce the energy for the required engine power output.
Always ensure absolute cleanliness both in and around the working area whenever carrying out work on the
highly sensitive high-pressure system.
Injectors
The injectors are controlled by solenoid valve. They are arranged vertically in the cylinder head and clamped
with a pressure ange in the cylinder head.
Starter
The starter is a sliding-gear starter. When the starter is operated, the pre-engaged starter guides the pinion
into the ring gear by means of a starter solenoid. A relay is mounted in the starter for starter control.
Alternator
A compact, powerful, low-noise alternator is mounted for power generation. The alternator is equipped with
a multifunction controller. The voltage is controlled depending on the temperature, the battery charge level
and the current power consumption. The alternator is electrically insulated when mounted.
Diagram of the engine lubrication system
(1) Oil lter (4) Piston

(2) Oil cooler (5) Connecting rod
(3) Rocker arm (6) Main oil duct
AE 4 2nd edition 27
INTRODUCTION
(7) Camshaft (11) Oil pump

(8) High-pressure pump (12) Return-ow check valve
(9) Crankshaft (13) Pressure-relief valve
(10) Oil sump (14) Drain valve
Oil module diagram
(1) Oil lter

(2) Filter bypass valve
(3) Drain valve
(4) Pressure-relief valve
(5) Return-ow check valve
(6) Oil pump
(7) Oil return duct
(8) Main oil duct
(9) Oil cooler
28 AE 4 2nd edition
INTRODUCTION
Diagram of the cooling system – coolant circuit
(1) Heat exchanger

(2) Expansion tank
(3) Thermostat housing
(4) Coolant pump
AE 4 2nd edition 29
INTRODUCTION
(1) Heat exchanger

(2) Expansion tank
(3) Large coolant circuit
(4) Thermostat housing
(5) Thermostat
(6) Small (short-circuit) coolant circuit
(7) Coolant pump
30 AE 4 2nd edition
INTRODUCTION
Diagram of the cooling system – coolant circuit
(1) Heat exchanger

(2) Intercooler, 1st stage
(3) Return, heat exchanger, gear oil
(4) Feed, heat exchanger, gear oil
(5) Coolant inlet
(6) Intercooler, 1st stage
(7) Coolant pump
AE 4 2nd edition 31
INTRODUCTION
Diagram of the fuel system
(1) Leakage oil line, injectors

(2) High-pressure pump, Slave
(3) High-pressure pump, Master
(4) Fuel lter
(5) Hand pump
(6) Fuel pre-lter with water trap
(7) Fuel lter
(8) Injector
(9) Leakage oil line, injectors
(10) Rail
(11) Fuel distributor, return
32 AE 4 2nd edition
INTRODUCTION
Diagram of the engine timing system
(1) Coolant pump drive gear

(2) Countershaft gear
(3) Camshaft drive sprocket
(4) High-pressure pump drive gear
(5) Drive gear, power take-off
(6) Crankshaft gear
AE 4 2nd edition 33
INTRODUCTION
Geartrain, front
(1) Crankshaft gear 1

(2) Intermediate gear 1
(3) Coolant pump drive gear
(4) Intermediate gear 2
(5) Crankshaft gear 2 for oil pump
(6) Oil pump drive gear
34 AE 4 2nd edition
INTRODUCTION
Charge-air diagram
(1) Air lter, right

(2) Turbocharger, 1st stage, right
(4) Charge-air manifold
(6) Turbocharger, 2nd stage, left
(7) Turbocharger, 1st stage, left
(8) Air lter, left
(9) Air distribution pipe, left
(10) Air distribution pipe, right
AE 4 2nd edition 35
INTRODUCTION
Cylinder arrangement - V8
(1) Cylinder 1 (5) Cylinder 5

36 AE 4 2nd edition
INTRODUCTION
Cylinder arrangement - V12

AE 4 2nd edition 37
TROUBLESHOOTING CHART
MALFUNCTIONS AND THEIR PROBABLE CAUSES
We recommend the following:
Repairs can only be considered complete when both the problem that occurred and the possible causes
have been remedied. Finding out what caused a problem is often more difcult than remedying the problem
itself. We therefore recommend that, before “removing and dismantling”, you have the malfunction described
in detail. Then narrow down the probable causes by asking specic questions. Once this is done, use the
chart and your own experience to examine the probable causes one after the other and rectify the problem.
This method helps reduce repairs to acceptable levels and counteracts possible complaints regarding “rash”
exchange of parts and expensive labour time and downtime.
Note:
The following chart is designed to serve as a memory aid for experts, the aim being to ensure that no probable
causes are overlooked when troubleshooting. The specialist is expected to be very familiar with the Repair
Manual for the engine as well as the corresponding Operator's Manual and “Service products for MAN diesel
engines”.
AE 4 2nd edition 39
Troubleshooting chart - part 1, malfunctions 1-11
Malfunction
EDC self-diagnosis or ashing code output
Starter does not crank engine or only cranks engine slowly
Starter turns, engine does not start, engine does not start/starts poorly when cold
Engine dies during operation, no longer starts (starter turns), engine does not start/starts
poorly when warm
Sudden and temporary engine standstill, engine does not get up to speed
Engine only runs at idling speed, cannot be accelerated
Engine runs at high idling speed, cannot be accelerated
Nominal speed considerably reduced (in no-load condition also)
Reduced power across the board
Irregular engine running, traction interruption
Idling speed unstable, engine “surges”, engine misring, knocking
in engine
Possible causes
x x x Flat batteries, loose or corroded battery cable connections,
discontinuity in circuit
x Crankshaft drive blocked
x x Starter solenoid switch sticking (clicking)/defective, cable connection
loose or defective
x Starter/start-locking relay defective (carbon brushes loose/worn, coil
defective, ground short)
x x Engine oil viscosity unsuitable, not suitable for ambient temperature,
lubricating oil grade not as specied
x Oil level in oil sump too high
x Engine cold
x Piston rings severely worn, broken
x Piston pins or crankshaft main bearings are loose
x x Incorrect valve clearance
x x Valves jamming
x x x Defective compression or more than 4 bar pressure differential
between the individual cylinders
x x Valve seats leaking
x x Increased power consumption due to defective auxiliary consumers
such as hydraulic pumps etc, PTO switched on
x x x x Air lter contaminated or clogged, charge air system leaking, air
supply/exhaust gas lines blocked/leaking
x x x x x x Low-pressure fuel system: tank, pre-lter, water trap defective
/blocked/mildew buildup, fuel unsuitable/heavily contaminated (with
parafn)
x x x x x x Low-pressure fuel system: Fuel lines leaking, broken, blocked
x x x x x x Low-pressure fuel system: Air in system (switch on ignition when
bleeding)
x x x x x x Low-pressure fuel system: Fuel pump, main lter
x x x High-pressure fuel system: Injectors defective/blocked/leaking/coked
40 AE 4 2nd edition
Malfunction
EDC self-diagnosis or ashing code output
Starter does not crank engine or only cranks engine slowly
Starter turns, engine does not start, engine does not start/starts poorly when cold
Engine dies during operation, no longer starts (starter turns), engine does not start/starts
poorly when warm
Sudden and temporary engine standstill, engine does not get up to speed
Engine only runs at idling speed, cannot be accelerated
Engine runs at high idling speed, cannot be accelerated
Nominal speed considerably reduced (in no-load condition also)
Reduced power across the board
Irregular engine running, traction interruption
Idling speed unstable, engine “surges”, engine misring, knocking
in engine
Possible causes
x x High-pressure fuel system: Pressure lines - narrowing, cavitation,
leakage
x x x High-pressure fuel system: High-pressure pump worn
x x x x x x Pedal value sensor (shift lever signal) defective: Connection lines,
short-circuit, discontinuity
x x x x EDC speed sensor defective, line defect
x x EDC speed sensor polarity reversed
x x x x x x x EDC detects wrong speed (unwanted signal on speed sensor line)
x x EDC charge pressure sensor: Defective, incorrect, implausible with
atmospheric pressure sensor, line defect
x x Turbocharger leaking or defective
x x x x EDC coolant temperature sensor: Defective, line defect
x x x EDC charge air temperature sensor: Defective, line defect
x x Cooler contamination or cooling system failure (temperatures too
high)
x x x x x x x Voltage supply to EDC engine control unit interrupted or battery
voltage too low
x x x x EDC engine control unit defective (internal fault)
x Master-Slave control unit communication fault
x x x x x Incorrect EDC engine control unit (check MAN part numbers)
x After-run not completed
x Thermostat defective
AE 4 2nd edition 41
Troubleshooting chart - part 2, malfunctions 12-22
Malfunction
Engine “shaking”
Unusual combustion noises
High smoke output: White smoke/blue smoke
High smoke output: Black smoke
Engine temperature too high (loss of coolant)
Excessive fuel consumption
Lubricating oil pressure too low
Lubricating oil pressure too high
Lubricating oil consumption too high
Engine too “loud”/manual gearbox
Possible causes
x x x Engine oil viscosity unsuitable, not suitable for ambient temperature,
lubricating oil grade not as specied
x x x Oil level in oil sump too high
x Oil level in oil sump too low, oil in the oil sump too thin (with
condensation or fuel)
x Engine temperature too high
x Oil lter blocked
x x Oil pressure gauge defective
x Safety valve in oil circuit defective (does not close, spring fatigue or
spring broken)
x x Severe bearing wear
x Oil pump gears severely worn
x Timing gears worn, excessive backlash
x x Engine cold
x x x Lubricating oil reaches the combustion chamber (piston rings worn,
piston rings broken) - valve stem guide worn - excess pressure in
crankcase (crankcase ventilation blocked)
x Safety valve in oil circuit defective (does not open), oil lines / oil ducts
blocked
x x Leaks in the lubrication oil circuit, particularly at turbocharger and oil
cooler
x x x x x x Piston rings severely worn, broken
x x Piston pins or crankshaft main bearings are loose
x x x x x x Valve stems severely worn, bent
x x x Incorrect valve clearance
x Valve seats leaking
x Increased power consumption due to defective auxiliary consumers
such as hydraulic pumps, fan etc., power take-off switched on
x x x Air lter contaminated or clogged, charge air system leaking, air
supply/exhaust gas lines blocked/leaking
42 AE 4 2nd edition
Malfunction
Engine “shaking”
Unusual combustion noises
High smoke output: White smoke/blue smoke
High smoke output: Black smoke
Engine temperature too high (loss of coolant)
Excessive fuel consumption
Lubricating oil pressure too low
Lubricating oil pressure too high
Lubricating oil consumption too high
Engine too “loud”/manual gearbox
Possible causes
x x Low-pressure fuel system: Tank, pre-lter, water trap defective
/blocked/mildew buildup, fuel unsuitable/heavily contaminated (with
parafn)
x x Low-pressure fuel system: Fuel lines leaking, broken, blocked
x x Low-pressure fuel system: Air in system (switch on ignition when
bleeding)
x x Low-pressure fuel system: Fuel pump, main lter
x x x x x High-pressure fuel system: Injectors defective/blocked/leaking
/coked
x x High-pressure fuel system: Pressure lines - narrowing, cavitation,
leakage
x x x x High-pressure fuel system: High-pressure pump worn
x EDC speed sensor polarity reversed
x x x EDC detects wrong speed (unwanted signal on speed sensor line)
x EDC charge pressure sensor: Defective, incorrect, implausible with
atmospheric pressure sensor, line defect
x x x x Turbocharger leaking or defective
x Turbine and compressor wheel in turbocharger contaminated (not
running smoothly, imbalance)
x x x Intercooler leaking, defective
x x EDC coolant temperature sensor: Defective, line defect
x Cooler contamination or cooling system failure (temperatures too
high)
x Coolant level too low, air in coolant circuit
x Incorrect V-belt tension
x Coolant pump leaking, defective/thermostat defective, does not open
x Coolant lines leaking, blocked or twisted
x Coolant is getting into the combustion chamber (cylinder head/gasket
leaking)
x x x x Incorrect EDC engine control unit (check MAN part numbers)
x Thermostat defective
x Engine mounting worn
AE 4 2nd edition 43
ENGINE ELECTRICS
ENGINE ELECTRICS
(1) Wiring harness, engine

(2) Terminal box
(3) Wiring harness, injector
AE 4 2nd edition 45
ENGINE ELECTRICS
(1) Connector for water level sensor in fuel

pre-lter with water trap
46 AE 4 2nd edition
ENGINE ELECTRICS
(1) Connector X3 (6) Connector X51

(2) Connector X30 (7) Connector B, engine control unit, Slave
(3) Connector, vessel shaft speed for Marine (8) Connector C, engine control unit, Slave
Power Control (9) Connector A, engine control unit, Master
(4) Connector, connection, oil change pump (10) Connector C, engine control unit, Master
(5) Connector X1 (11) Connector B, engine control unit, Master
AE 4 2nd edition 47
ENGINE ELECTRICS
ENGINE ELECTRICS
Removing and installing the engine control units
Additional jobs
– Disconnecting and connecting the battery
(1) Cover (8) Engine control unit, Master

(2) Bush X50 (9) Connector A, engine control unit, Master
(3) Fuse (10) Terminal box
(4) Bush X51 (11) Holder
(5) Connector B, engine control unit, Slave (12) Terminal strip
(6) Connector C, injector wiring harness, (13) Injector wiring harness
Slave (14) Fuse
(7) Engine control unit, Slave
Technical data
Mounting bolt, engine control unit .......................... M6x35-10.9 ....................................................... 11 Nm
Mounting bolt, terminal box ................................... M8x45-8.8 .........................................................14 Nm
Service products
Loctite 648 ........................................................................................................................ 04.10160-9164
AE 4 2nd edition 49
ENGINE ELECTRICS
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 tightening torque
• Final tightening must always be performed manually using a torque wrench
CAUTION
Danger of injury due to sharp-edged protrusions on the cable ties
• Always use Cable tie pliers [1] to tighten and cut cable ties
WARNING
Electrical line damage due to overtightening
• Follow the Cable tie pliers [1] instructions
WARNING
Restricted operation due to defective entries in the fault memory
• Before removing the engine control unit, read out and document the fault memory
WARNING
Danger of irreparable engine control unit damage
• When installing the connectors, rst fully open the lock and then insert 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 wiring harness at the previously marked attachment points
Note
Mark the attachment points before removing the engine wiring harness
Note
After a new engine control unit is tted, its parameters have to be reset.
After resetting the engine control unit parameters, read out the fault memory and delete as
necessary.
Special tools
[1] Cable tie pliers 08.02960-0100
• Tightening and cutting the cable ties
50 AE 4 2nd edition
ENGINE ELECTRICS
Removing the engine control units Removing the bracket
Removing the terminal box
• Unscrew the mounting bolts (3) and remove with

the washers (4)
• Mark the installation position of the wiring • Remove the bracket (2) from the terminal box (1)
harnesses and cable ties • Remove the rubber mounts (5) and (6)
• Disconnect the cable ties
• Fully unlock and remove connector X50 (1) Removing the cover
• Fully unlock and remove connector X51 (2)
the washers (4)
• Remove the terminal box with bracket
Removing the terminal box holder
• Unscrew the mounting bolts (1)

• Remove the cover (2) and the gasket (3)
• Clean the mating faces

• Remove the holder (1)
AE 4 2nd edition 51
ENGINE ELECTRICS
Removing the injector wiring harness Removing the rail
• Fully unlock and pull off the connectors (3) and (4) • Unscrew the mounting bolts (1)
• Mark the installation position of the cable ties and • Remove the rail (2)
then disconnect the cable ties
• Expose the wiring harnesses Removing the engine control unit
• Swivel the injector wiring harness (1) with
grommet (2) to the side
Removing the wiring harness
• Mark the installation position of the engine control

units (2) and (3)
• Remove the Master engine control unit (2)
• Fully unlock and pull off the connectors (3), (4), (6) • Unscrew the mounting bolts (4)
and (7) • Remove the Slave engine control unit (3)
• Pull the terminal strip (2) off the rail
• Disconnect the electrical connection (1) cable tie
• Mark the installation position of the cable ties and
then disconnect
• Free the wiring harnesses
• Swivel the wiring harness (5) upwards
52 AE 4 2nd edition
ENGINE ELECTRICS
Installing the engine control units Installing the wiring harness
Tightening sequence for engine control unit
WARNING
• Beginning with 1, tighten the engine control unit in Danger of irreparable engine control
the sequence 1, 2, 3, 4, 5, 6, 7, 8 unit damage
• When installing the connectors, rst
Installing the engine control unit fully open the lock and then insert and
lock the connectors
• Insert the terminal strip (2) into the rail

• Connect the electrical connection (1)
• Insert and lock the connectors (3), (4), (6) and (7)
in the engine control units
• Route the wiring harnesses (5) as marked and
secure using cable ties
• Tighten and cut cable ties using the Cable tie
pliers [1]
• Insert the engine control units (2) and (3) as

marked
• Screw in new mounting bolts (1) and (4) and
tighten them to 11 Nm in the indicated tightening
sequence
Installing the rail
• Position the rail (2)

• Screw in and tighten the mounting bolts (1)
AE 4 2nd edition 53
ENGINE ELECTRICS
Removing the injector wiring harness Mounting the bracket
• Apply Loctite 648 on the thread of the new

WARNING
mounting bolts (3)
Danger of irreparable engine control
• Insert the rubber mount (6) into the bracket (2)
unit damage
• Position the bracket (2) on the terminal box (1)
• When installing the connectors, rst
• Screw in the mounting bolts (3) with washer (4)
fully open the lock and then insert and
and rubber mounts (5) and then tighten to 14 Nm
lock the connectors
Mounting the terminal box holder
• Insert and lock the connectors (3) and (4) in the
engine control units
• Insert the grommet (2) with the injector wiring
harness (1)
• Route the injector wiring harness (1) and secure it
using cable ties as marked
pliers [1]
Removing the cover
• Position the holder (1)

• Fit the cover (2) with the gasket (3)

54 AE 4 2nd edition
ENGINE ELECTRICS
Mounting the terminal box
• Position the terminal box

• Screw in and tighten the mounting bolts (3) with
washers (4)
• Insert and lock connector X50 (1)
• Insert and lock connector X51 (2)
• Route the wiring harnesses as marked and secure
using cable ties
pliers [1]
AE 4 2nd edition 55
ENGINE ELECTRICS
Removing and installing the injector wiring harness

Additional jobs
– Removing and installing the engine control units, see 49
(1) Sensor, coolant level

(2) Sensor, coolant pressure in expansion
tank
(3) Sensor, charge-air pressure
(4) Sensor, charge-air temperature
(5) Sensor, suction vacuum
(6) Connection, alternator
(7) Wiring harness, injectors
(8) Sensor, oil temperature
(9) Sensor, coolant pressure downstream of
coolant pump
(10) Sensor, oil pressure, right
56 AE 4 2nd edition
ENGINE ELECTRICS
(1) Sensor, fuel pressure upstream of (3) Sensor, exhaust gas temperature
high-pressure pump, Master upstream of turbocharger, right
(2) Sensor, coolant temperature (option) (4) Connector for water level sensor in fuel
Technical data
Injector cable.................................................................................................................................1.5 Nm
Service products
White T assembly paste..................................................................................................... 09.16012-0122
WARNING
WARNING
Damage to the contacts
WARNING
Cable break
AE 4 2nd edition 57
ENGINE ELECTRICS
Note
Mark the attachment points for the wiring harness on the engine.
Special tools
[2] Torque screwdriver 08.06510-9024
• Installing the injector cable in conjunction with:

• Socket, size 7 [4]
• Adapter [3]
[3] Adapter 08.06139-9029

• Torque screwdriver [2]
[4] Socket, size 7 08.06141-0700

• Adapter [3]
58 AE 4 2nd edition
ENGINE ELECTRICS
Removing the injector wiring harness Removing the injector wiring harness
Removing the cylinder head cover
WARNING
Danger of damage to the engine
electrics/electronics
• Remove the cylinder head cover (1)
• Mark all electrical connections.
Removing the injector cable • Mark the attachment points for the
wiring harness on the engine.
• Mark the installation position of the cable ties and

then disconnect
• Free and remove the injector wiring harness (1)
Removing the left injector wiring harness holder
WARNING
• Mark the attachment points for the
• Mark the installation position of the injector cables • Remove the left injector wiring harness holder (1)
(1)
• Unscrew the mounting nuts from the injector
• Remove the injector cable (1) from the cable
passage in the gasket (2)
AE 4 2nd edition 59
ENGINE ELECTRICS
Removing the right injector wiring harness Installing the injector wiring harness
holder
Mounting the left injector wiring harness holder

• Remove the left injector wiring harness holder (1) • Position the left injector wiring harness holder (1)
Mounting the right injector wiring harness

holder
• Position the right injector wiring harness holder (1)

60 AE 4 2nd edition
ENGINE ELECTRICS
Positioning the injector wiring harness Mounting the injector cable
WARNING WARNING
Danger of damage to the engine Component damage due to possible
electrics/electronics short-circuit
• Connect all electrical connections as • When tightening the mounting nuts,
marked make sure that the cable plugs do not
• Only fasten the wiring harness at the touch each other
previously marked attachment points
• Connect the injector cable to the injector as
• Position the injector wiring harness (1) and fasten marked
as marked • Screw on the mounting nuts with the Torque
• Secure the wiring harness (1) with cable ties as screwdriver [2] in conjunction with the Adapter [3]
marked and Socket, size 7 [4] and then tighten to 1.5 Nm
• Tighten and cut cable ties using the Cable tie • Thinly apply White T assembly paste on the cable
pliers [5] passage in the gasket (2)
• Insert the injector cable (1) into the cable passage
in the gasket (2)
Mounting the cylinder head cover
• Put on the cylinder head cover (1)

AE 4 2nd edition 61
ENGINE ELECTRICS
Removing and installing the engine wiring harness

Additional jobs
(1) Sensor, coolant level in expansion tank

tank
(6) Connection, alternator, B+
(7) Injector wiring harness
coolant pump
62 AE 4 2nd edition
ENGINE ELECTRICS
(1) Sensor, fuel pressure upstream of (3) Sensor, exhaust gas temperature
high-pressure pump, Master upstream of turbocharger, right
(2) Sensor, coolant temperature (option) (4) Connection, water level sensor in fuel
Technical data
Electrical connection, B+, alternator ...................... M8 ....................................................................14 Nm
Starter terminal 30-............................................... M12...................................................................25 Nm
Starter terminal 31-............................................... M12...................................................................25 Nm
Starter terminal 50-............................................... M6 ..................................................................... 4 Nm
WARNING
WARNING
WARNING
Cable break
AE 4 2nd edition 63
ENGINE ELECTRICS
Note
Mark the attachment points for the wiring harness on the engine.
Special tools
64 AE 4 2nd edition
ENGINE ELECTRICS
Removing the engine wiring harness Disconnecting the alternator
Disconnecting the left oil pressure plug

connection
WARNING
WARNING • Mark all electrical connections.
Danger of damage to the engine • Mark the attachment points for the
electrics/electronics wiring harness on the engine.
• Mark the attachment points for the • Disconnect the cable ties
wiring harness on the engine. • Unlock the plug connection (1) and pull off the
connector
• Disconnect the cable ties • Unscrew the mounting nut (2) and remove the
• Unlock the left oil pressure plug connection (1) and cable (3)
pull off the connector • Unscrew the mounting nut (4)
• Remove the mounting bolt (7) and the washer (5)
• Remove the cable (6)
AE 4 2nd edition 65
ENGINE ELECTRICS
Disconnecting the oil pressure, oil temperature Disconnecting the charge-air and coolant plug
and coolant pressure plug connections connections
WARNING WARNING
Danger of damage to the engine Danger of damage to the engine
electrics/electronics electrics/electronics
• Mark all electrical connections. • Mark all electrical connections.
• Mark the attachment points for the • Mark the attachment points for the
wiring harness on the engine. wiring harness on the engine.
• Disconnect the cable ties • Disconnect the cable ties

• Unlock the oil pressure plug connection (1) and • Unlock the charge-air pressure plug connection
pull off the connector (1) and pull off the connector
• Unlock the oil temperature plug connection (3) and • Unlock the charge-air temperature plug
pull off the connector connection (2) and pull off the connector
• Unlock the coolant pressure plug connection (2) • Unlock the coolant level plug connection (3) and
and pull off the connector pull off the connector
• Unlock the coolant pressure plug connection (4)
and pull off the connector
66 AE 4 2nd edition
ENGINE ELECTRICS
Disconnecting the upper engine plug Disconnecting the starter

connections
WARNING
WARNING Danger of damage to the engine
Danger of damage to the engine electrics/electronics
electrics/electronics • Mark all electrical connections.
• Mark all electrical connections. • Mark the attachment points for the
• Mark the attachment points for the wiring harness on the engine.
• Disconnect the cable ties • Mark the installation position of the cables
• Unlock the suction vacuum plug connection (1) • Unscrew the mounting nut (3)
and pull off the connector • Remove the washer (2) and cable (3)
• Unlock the coolant temperature plug connection • Unscrew the mounting nut (10)
(2) (option) and pull off the connector • Remove the washer (11) and cable (12)
• Unlock the Slave metering unit plug connection (3) • Unscrew the mounting nut (6)
and pull off the connector • Remove the washer (5) and cable (4)
• Unlock the Master rail pressure plug connection • Unscrew the mounting nut (9)
(4) and pull off the connector • Remove the washer (8) and cable (7)
• Unlock the Slave rail pressure plug connection (5)
AE 4 2nd edition 67
ENGINE ELECTRICS
Disconnecting the exhaust gas and coolant Disconnecting the fuel pressure and
temperature plug connection temperature plug connection
WARNING WARNING

• Unlock the exhaust gas temperature plug • Unlock the return fuel pressure plug connection
connection (1) and pull off the connector (1) and pull off the connector
• Unlock the coolant temperature plug connection • Unlock the suction side fuel pressure plug
(2) (option) and pull off the connector connection (2) and pull off the connector
• Unlock the fuel temperature plug connection (3)
• Unlock the plug connection for the fuel pressure
upstream of the Slave high-pressure pump (4) and
pull off the connector
68 AE 4 2nd edition
ENGINE ELECTRICS
Disconnecting the fuel pressure and metering Disconnecting the camshaft speed sensor plug
unit plug connection connection
WARNING WARNING

• Unlock the plug connection for the fuel pressure • Unlock the camshaft speed sensor plug
upstream of the Master high-pressure pump (1) connection (1) and pull off the connector
• Unlock the plug connection for the Master Disconnecting the crankshaft speed sensor plug
metering unit (2) and pull off the connector connection
Disconnecting the exhaust gas temperature plug

connection
WARNING
WARNING • Mark all electrical connections.
Danger of damage to the engine • Mark the attachment points for the
electrics/electronics wiring harness on the engine.
• Mark the attachment points for the • Disconnect the cable ties
wiring harness on the engine. • Unlock the crankshaft speed sensor plug
connection (1) and pull off the connector
• Unlock the exhaust gas temperature plug
connection (1) and pull off the connector
AE 4 2nd edition 69
ENGINE ELECTRICS
Removing the fuse protective caps Removing the engine wiring harness
• Unscrew the protective caps (1)

WARNING
• Unscrew the union nuts (2)
Removing the oil change pump plug connection electrics/electronics

• Free and remove the engine wiring harness (1)
Removing the rear engine wiring harness holder

• Swivel the plug connection (1) to the side
Removing the plug connection X50 fastening
• Unscrew the mounting bolt (1)


• Swivel the wiring harness (2) to the side
70 AE 4 2nd edition
ENGINE ELECTRICS
Installing the engine wiring harness Mounting the plug connection X50 fastening
Mounting the rear engine wiring harness holder
WARNING
• Position the holder (2) Danger of damage to the engine
• Screw in and tighten the mounting bolt (1) electrics/electronics
• Only secure the wiring harness at the
Fitting the engine wiring harness previously marked attachment points
• Position the wiring harness (2)

• Screw in and tighten the mounting bolt (1)
• Secure the wiring harness with cable ties as
marked
pliers [6]
Mounting the oil change pump plug connection
WARNING
• Fit the engine wiring harness (1) and secure it at

the marked attachment points
pliers [6] WARNING
• Only fasten the wiring harness at the
• Position the plug connection (1)

marked
pliers [6]
AE 4 2nd edition 71
ENGINE ELECTRICS
Mounting the fuse protective caps Connecting the camshaft speed sensor plug
connection
WARNING
Danger of damage to the engine WARNING
electrics/electronics Danger of damage to the engine
• Only fasten the wiring harness at the electrics/electronics
previously marked attachment points • Connect all electrical connections as
marked.
• Screw on and tighten the union nuts (2) • Only fasten the wiring harness at the
• Screw on and tighten the protective caps (1) previously marked attachment points
marked • Position the connector (1) and lock the camshaft
• Tighten and cut cable ties using the Cable tie speed sensor plug connection
pliers [6] • Secure the wiring harness with cable ties as
marked
Connecting the crankshaft speed sensor plug • Tighten and cut cable ties using the Cable tie
connection pliers [6]
WARNING
• Connect all electrical connections as
marked.
• Position the connector (1) and lock the crankshaft

speed sensor plug connection
marked
pliers [6]
72 AE 4 2nd edition
ENGINE ELECTRICS
Connecting the exhaust gas temperature plug Connecting the fuel pressure and metering unit
connection plug connection
WARNING WARNING
• Connect all electrical connections as • Connect all electrical connections as
marked. marked.
• Only fasten the wiring harness at the • Only fasten the wiring harness at the
previously marked attachment points previously marked attachment points
• Position the connector (1) and lock the exhaust • Position the connector (1) and lock the plug
gas temperature sensor plug connection connection for the fuel pressure upstream of the
• Secure the wiring harness with cable ties as Master high-pressure pump
marked • Position the connector (1) and lock the plug
• Tighten and cut cable ties using the Cable tie connection for the Master metering unit (2)
pliers [6] • Secure the wiring harness with cable ties as
marked
pliers [6]
AE 4 2nd edition 73
ENGINE ELECTRICS
Connecting the fuel pressure and temperature Connecting the exhaust gas and coolant
plug connection temperature plug connection
WARNING WARNING
marked. marked.
• Position the connector (4) and lock the plug • Position the connector (1) and lock the exhaust
connection for the fuel pressure upstream of the gas temperature plug connection
Slave high-pressure pump • Position the connector (2) and lock the coolant
• Position the connector (3) and lock the fuel temperature plug connection (option)
temperature plug connection • Secure the wiring harness with cable ties as
• Position the connector (2) and lock the suction marked
side fuel pressure plug connection • Tighten and cut cable ties using the Cable tie
• Position the connector (1) and lock the return plug pliers [6]
connection
marked
pliers [6]
74 AE 4 2nd edition
ENGINE ELECTRICS
Connecting the starter Connecting the upper engine plug connections
WARNING WARNING
marked. marked.
• Position the cable (7) as marked • Position the connector (1) and lock the suction
• Screw on the washer (2) with mounting nut (9) vacuum plug connection
• Tighten the mounting nut (9) to 25 Nm • Position the connector (2) and lock the coolant
• Position the cable (4) as marked temperature plug connection (option)
• Screw on the washer (5) with mounting nut (6) • Position the connector (3) and lock the Slave
• Tighten the mounting nut (6) to 25 Nm metering unit plug connection
• Position the cable (12) as marked • Position the connector (4) and lock the Master rail
• Screw on the washer (11) with mounting nut (10) pressure plug connection
• Tighten the mounting nut (10) to 4 Nm • Position the connector (5) and lock the Slave rail
• Position the cable (1) as marked pressure plug connection
• Screw on the washer (2) with mounting nut (3) • Secure the wiring harness with cable ties as
• Tighten the mounting nut (3) to 4 Nm marked
• Secure the wiring harness with cable ties as • Tighten and cut cable ties using the Cable tie
marked pliers [6]
pliers [6]
AE 4 2nd edition 75
ENGINE ELECTRICS
Connecting the charge-air and coolant plug Connecting the oil pressure, oil temperature and
connections coolant pressure plug connections
WARNING WARNING
marked. marked.
• Position the connector (1) and lock the charge-air • Position the connector (1) and lock the oil pressure
pressure plug connection plug connection
• Position the connector (2) and lock the charge-air • Position the connector (2) and lock the coolant
temperature plug connection pressure plug connection
• Position the connector (3) and lock the coolant • Position the connector (3) and lock the oil
level plug connection temperature plug connection
• Position the connector (4) and lock the coolant • Secure the wiring harness with cable ties as
pressure plug connection marked
• Secure the wiring harness with cable ties as • Tighten and cut cable ties using the Cable tie
marked pliers [6]
pliers [6]
76 AE 4 2nd edition
ENGINE ELECTRICS
Connecting the alternator Connecting the left oil pressure plug connection
WARNING WARNING
marked. marked.
WARNING • Position the connector (1) and lock the oil pressure
Danger of irreparable alternator plug connection
damage • Secure the wiring harness with cable ties as
Damage to the contacts marked
• When installing the connector, rst fully
pliers [6]
open the lock and then insert and lock
the connector
• Position the connector (1) and lock the plug

connection
• Position the cable (3) as marked
• Screw on the mounting nut (2)
• Tighten the mounting nut (2) to 14 Nm
• Insert the mounting bolt (7)
• Position the cable (6) as marked
• Screw on the washer (5) with mounting nut (4)
• Tighten the mounting nut (4)
marked
pliers [6]
AE 4 2nd edition 77
ENGINE ELECTRICS
Removing and installing the sensors

Additional jobs
– Removing and installing the engine wiring harness, see 62

tank
(3) Sensor, coolant level
(6) Sensor, coolant temperature (option)
(7) Sensor, oil pressure, left
coolant pump
78 AE 4 2nd edition
ENGINE ELECTRICS
(1) Sensor, fuel pressure upstream of (6) Sensor, crankshaft speed

high-pressure pump, Master (7) Sensor, fuel pressure upstream of Slave
(2) Sensor, coolant temperature (option) high-pressure pump
(3) Sensor, exhaust gas temperature (8) Sensor, fuel temperature
upstream of turbocharger, right (9) Sensor, fuel pressure, suction side
(4) Sensor, camshaft speed (10) Sensor, fuel pressure, return
(5) Sensor, exhaust gas temperature
upstream of turbocharger, left
Technical data
Sensor, fuel pressure upstream of high-pressure
pump (1) and (7)................................................... M18x1.5 ............................................................45 Nm
Sensor, coolant temperature (2) ............................ M16x1.5 ............................................................45 Nm
Sensor, exhaust gas temperature upstream of
turbocharger (3) and (5) ........................................ M14x1.5 ............................................................. 7 Nm
Screw-in tting ..................................................... M14x1.5 ............................................................25 Nm
Mounting bolt, sensor, crankshaft and camshaft
speed (6) and (4).................................................. M6 ..................................................................... 8 Nm
Sensor, fuel temperature (8).................................. M16x1.5 ............................................................45 Nm
Sensor, fuel pressure, suction side (9) ................... M14x1.5 ............................................................35 Nm
Sensor, fuel pressure, return (10) .......................... M14x1.5 ............................................................35 Nm
Sensor, oil pressure .............................................. M18x1.5 ............................................................45 Nm
Sensor, oil temperature......................................... M16x1.5 ............................................................45 Nm
Sensor, coolant pressure downstream of coolant
pump ................................................................... M18x1.5 ............................................................45 Nm
Sensor, coolant pressure in expansion tank ........... M14x1.5 ............................................................35 Nm
Sensor, coolant level............................................. M18x1.5 ............................................................22 Nm
Sensor, charge-air pressure .................................. M6 ..................................................................... 8 Nm
AE 4 2nd edition 79
ENGINE ELECTRICS
Sensor, charge-air temperature ............................. M16x1.5 ............................................................45 Nm

Sensor, suction vacuum ........................................ M14x1.5 ............................................................35 Nm
WARNING
The common-rail system can be damaged
• Plugs must not be re-used
• Ensure absolute cleanliness in all areas when carrying out all work
• Avoid any moisture whatsoever
WARNING
Residual fuel may run out during removal. Danger of environmental pollution.
• Use a suitable fuel collecting container
WARNING
Residual oil may emerge during removal. Danger of environmental pollution.
• Use a suitable collecting tank
WARNING
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 integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z14 x 15).
Special tools
[7] End plug (GPN 330 L14) 81.96002-0521
• Plugging the fuel sensor connection thread
[8] End plug (GPN 330 L16) 81.96002-0519
[9] End plug (GPN 330 L18) 81.96002-0556
80 AE 4 2nd edition
ENGINE ELECTRICS
Removing and installing the charge-air Installing the charge-air pressure sensor
sensors
Removing the expansion tank holder
• Insert the sensor (2)

• Screw in the mounting bolts (1) and tighten them
to 8 Nm
• Unscrew the mounting bolts (1) • Connect the electrical connection
Mounting the expansion tank holder
Removing the charge-air pressure sensor

• Disconnect the electrical connection • Screw in and tighten the mounting bolts (1)
• Remove the sensor (2) Removing the charge-air temperature sensor
• Disconnect the electrical connection

• Unscrew the sensor (1)
• Remove the sealing ring (2)
AE 4 2nd edition 81
ENGINE ELECTRICS
Installing the charge-air temperature sensor Removing and installing the suction
vacuum sensor
Removing the suction vacuum sensor
• Screw in the sensor (1) with a new sealing ring (2)

• Tighten the sensor (1) to 45 Nm
• Connect the electrical connection
• Unscrew the adapter (3)
Installing the suction vacuum sensor
• Screw in the adapter (3) with a new sealing ring

(4) and then tighten
82 AE 4 2nd edition
ENGINE ELECTRICS
Removing and installing the oil sensors Installing the left oil pressure sensor
Removing the right oil pressure sensor

• Disconnect the electrical connection • Connect the electrical connection
• Remove the sealing ring (2) Removing the oil temperature sensor
Installing the right oil pressure sensor

• Screw in the sensor (1) with a new sealing ring (2) • Remove the sealing ring (2)
• Connect the electrical connection Installing the oil temperature sensor
Removing the left oil pressure sensor

• Disconnect the electrical connection • Connect the electrical connection
AE 4 2nd edition 83
ENGINE ELECTRICS
Removing and installing the coolant Removing the coolant level sensor
sensors
Removing the coolant pressure sensor in the
expansion tank
CAUTION
Danger of burns
• Before unscrewing the sensor, unscrew
the cap with safety valve as far as
CAUTION the rst stop and carefully allow the
Danger of burns pressure in the coolant system to
• Before unscrewing the sensor, unscrew dissipate
the screw cap with safety valve as far
as the rst stop and carefully allow • Disconnect the electrical connection
the pressure in the coolant system to • Unscrew the sensor (1)
dissipate • Remove the sealing ring (2)
• Disconnect the electrical connection Installing the coolant level sensor

Installing the coolant pressure sensor in the

expansion tank


84 AE 4 2nd edition
ENGINE ELECTRICS
Removing the coolant pressure sensor Removing the coolant temperature sensor
downstream of the coolant pump (option)
CAUTION CAUTION
Danger of burns Danger of burns
• Before unscrewing the sensor, unscrew • Before unscrewing the sensor, unscrew
the cap with safety valve as far as the cap with safety valve as far as
the rst stop and carefully allow the the rst stop and carefully allow the
pressure in the coolant system to pressure in the coolant system to
dissipate dissipate
Note Note
Draining and topping up the coolant, see Draining and topping up the coolant, see
Operator's Manual Operator's Manual
• Disconnect the electrical connection • Disconnect the electrical connection

• Unscrew the sensor (1) • Unscrew the sensor (1)
• Remove the sealing ring (2) • Remove the sealing ring (2)
Installing the coolant pressure sensor Installing the coolant temperature sensor
downstream of the coolant pump (option)
• Screw in the sensor (1) with a new sealing ring (2) • Screw in the sensor (1) with a new sealing ring (2)
• Tighten the sensor (1) to 45 Nm • Tighten the sensor (1) to 45 Nm
• Connect the electrical connection • Connect the electrical connection
• Fill with coolant • Fill with coolant
AE 4 2nd edition 85
ENGINE ELECTRICS
Removing the coolant temperature sensor Removing and installing the exhaust gas
(option) sensors
Removing the right exhaust gas temperature
sensor
CAUTION
Danger of burns
• Before unscrewing the sensor, unscrew • Disconnect the electrical connection
the cap with safety valve as far as • Unscrew the union nut (2)
the rst stop and carefully allow the • Remove the sensor (1)
pressure in the coolant system to • Unscrew the screw-in tting (3)
dissipate
Installing the right exhaust gas temperature
Note
sensor
Draining and topping up the coolant, see
Operator's Manual

Installing the coolant temperature sensor

(option)
• Screw in the screw-in tting (3) and tighten to

25 Nm
• Insert the sensor (1) and screw on the union nut
(2)
• Tighten the union nut (2) to 7 Nm

• Fill with coolant
86 AE 4 2nd edition
ENGINE ELECTRICS
Removing the left exhaust gas temperature Removing and installing the speed
sensor sensors
Removing the camshaft speed sensor

• Unscrew the union nut (2)
• Remove the sensor (1) • Disconnect the electrical connection
• Unscrew the screw-in tting (3) • Unscrew the mounting bolt (2)
• Remove the sensor (1)
Installing the left exhaust gas temperature
sensor Installing the camshaft speed sensor
• Screw in the screw-in tting (3) and tighten to • Insert the sensor (1)
25 Nm • Screw in the mounting bolt (2) and tighten to 8 Nm
• Insert the sensor (1) and screw on the union nut
(2) • Connect the electrical connection
• Tighten the union nut (2) to 7 Nm
AE 4 2nd edition 87
ENGINE ELECTRICS
Removing the crankshaft speed sensor Removing and installing the fuel
sensors
Removing the fuel pressure sensor upstream of
the Slave high-pressure pump

• Remove the sensor (1)
Installing the crankshaft speed sensor • Disconnect the electrical connection

• Plug the connection thread
Installing the fuel pressure sensor upstream of

the Slave high-pressure pump
• Insert the sensor (1)

• Screw in the mounting bolt (2) and tighten to 8 Nm
• Remove the plug

88 AE 4 2nd edition
ENGINE ELECTRICS
Removing the fuel temperature sensor Removing the fuel pressure sensor on the
suction side

• Unscrew the sensor (1) • Disconnect the electrical connection
• Remove the sealing ring (2) • Unscrew the sensor (1)
• Plug the connection thread • Remove the sealing ring (2)
Installing the fuel temperature sensor
Installing the fuel pressure sensor on the suction
side
• Remove the plug

• Tighten the sensor (1) to 45 Nm • Remove the plug
• Connect the electrical connection • Screw in the sensor (1) with a new sealing ring (2)
AE 4 2nd edition 89
ENGINE ELECTRICS
Removing the return fuel pressure sensor Removing the fuel pressure sensor upstream of
the Master high-pressure pump

• Unscrew the sensor (1) • Disconnect the electrical connection
• Remove the sealing ring (2) • Unscrew the sensor (1)
• Plug the connection thread • Remove the sealing ring (2)
Installing the return fuel pressure sensor
Installing the fuel pressure sensor upstream of
the Master high-pressure pump
• Remove the plug

• Tighten the sensor (1) to 35 Nm • Remove the plug
• Connect the electrical connection • Screw in the sensor (1) with a new sealing ring (2)
90 AE 4 2nd edition
COOLING SYSTEM
COOLING SYSTEM
(1) Heat exchanger

(2) Coolant expansion tank
(3) Coolant manifold
AE 4 2nd edition 91
COOLING SYSTEM
(1) Coolant manifold (4) Coolant pump

(2) Thermostat housing (5) Coolant inlet
(3) Coolant outlet
92 AE 4 2nd edition
COOLING SYSTEM
HEAT EXCHANGER
Removing and mounting the heat exchanger
Additional jobs
– Draining the coolant, see Operator's Manual
– Removing and Installing the engine cover, see 515
– Assembly instructions for heat exchanger plates, see 99
(1) Pressure plate (5) Expansion tank

(2) Mounting bolt (6) Centring bush
(3) Spacer bush (7) Mounting bolt
(4) Heat exchanger plate pack
Technical data
Mounting bolts (2)................................................. M16x80 ........................................ Final torque 180 Nm
Spacer bush (3)............................................................................................................................235 Nm
Centring bush (6)............................................................................................................................45 Nm
Mounting bolt (7) ............................................................................................................................15 Nm
Mounting bolt, sight glass...................................... M5x25-8.8 .......................................................... 5 Nm
Service products
AE 4 2nd edition 93
COOLING SYSTEM
WARNING
• Do not use impact wrenches to remove and install the heat exchanger plate pack.
• Always remove and install the heat exchanger plate pack manually.
WARNING
Component damage due to incorrectly assembled heat exchanger plate pack
• Assemble the heat exchanger plate pack in accordance with the assembly instructions
Special tools
[10] Assembly pin 80.99617-0228
• Installing the heat exchanger plate pack
94 AE 4 2nd edition
COOLING SYSTEM
Removing the pressure plate Removing the pressure plate
Mounting the aligning punch
• Unscrew the mounting bolts (1) and (5) in

accordance with the loosening instructions for the
• Unscrew the mounting bolts (1) and (3) “Heat exchanger plate pack”
• Remove the washers (2) and (4) • Remove the washers (2) and (4)
• Screw in the Assembly pin [10] • Remove the pressure plate (3)
Loosening instructions for heat exchanger plate Removing the heat exchanger plates
pack
• Evenly undo each of the pressure plate mounting WARNING

bolts by 360° in the sequence 1-8 until the Risk of injury caused by sharp-edged
pressure plate is loose components
• Wear protective gloves when removing
and positioning the heat exchanger
plates
WARNING
Component damage due to damaged
heat exchanger plate pack
• Take care not to damage or deform the
plates in the heat exchanger plate pack
• Remove the heat exchanger plates (1)

AE 4 2nd edition 95
COOLING SYSTEM
Removing the spacer bushes Installing the heat exchanger plate pack
Installing the spacer bushes
• Mark the installation position of the centring

bushes (1) and (2)
• Mark the installation position of the spacer bushes • Screw in the centring bushes (1) and (2) as marked
(3) and (6) • Tighten the centring bushes (1) and (2) to 45 Nm
• Unscrew the centring bushes (1) and (2) • Screw in the spacer bushes (3) and (6) as marked
• Unscrew the spacer bushes (3) and (6) with washers (4) and (5)
• Remove the washers (4) and (5) • Tighten the spacer bushes (3) and (6) to 235 Nm
Mounting the heat exchanger plates

• Screw the Assembly pin [10] (2) and (5) into the
centring bushes (3) and (4)
• Position the heat exchanger plates (1) one by one
over the Assembly pin [10] on the heat exchanger,
see Assembly instructions for heat exchanger
plates, 99
96 AE 4 2nd edition
COOLING SYSTEM
Mounting the pressure plate Plugging the centring sleeves
• Thinly apply White T assembly paste on the thread • Unscrew the Assembly pin [10]
and the bolt head contact surface of mounting • Screw in the mounting bolts (1) and (3) with the
bolts (2) and (4) washers (2) and (4)
• Screw in the mounting bolts (2) and (4) with the • Tighten the mounting bolts (1) and (3) to 15 Nm
washers (3) and (5)
Tightening instructions for heat exchanger plate

pack
• Evenly tighten each of the pressure plate mounting

bolts by 360° in accordance with the tightening
instructions until the pressure plate is lying on the
spacer bolts
Tighten the pressure plate mounting bolts to Final
torque 180 Nm in the sequence 1-8
AE 4 2nd edition 97
COOLING SYSTEM
Removing and mounting the sight glass

Removing the sight glass

• Remove the cover (2)
• Remove the sight glass (3) and O-ring (4)
Mounting the sight glass
• Insert the O-ring (4) on the sight glass (3)

• Position the sight glass (3) with cover (2) on the
expansion tank
to 5 Nm
98 AE 4 2nd edition
COOLING SYSTEM
Assembly instructions for heat exchanger plates

Additional jobs
– Removing and mounting the heat exchanger, see 93
(1) Cooling plate type 4 faces pressure plate (5) Cooling plate type 2
(2) Cooling plate type 3 (6) Cooling plate type 1 faces expansion tank
(3) Cooling plate type 2 (7) Expansion tank
(4) Cooling plate type 3 (8) Pressure plate
WARNING
Component damage due to hardened gaskets
• Always replace gaskets as a set
AE 4 2nd edition 99
COOLING SYSTEM
Assembling the cooling plate pack Attaching gaskets to cooling plates type 3
(obtuse angle)
Attaching the gasket to cooling plate type 1
(obtuse angle)
WARNING
Component damage due to incorrect
WARNING gasket/cooling plate combination
Component damage due to incorrect • Only combine and assemble the gasket
gasket/cooling plate combination and cooling plate as illustrated
• Only combine and assemble the gasket
and cooling plate as illustrated • Attach the gasket (2) using the lugs on the cooling
plate (1)
• Attach the gasket (2) using the lugs on the cooling • Repeat the procedure for cooling plates type 3 see
plate (1) table 101
Attaching gaskets to cooling plates type 2 (acute Attaching the gasket to cooling plate type 4
angle) (acute angle)
WARNING WARNING
Component damage due to incorrect Component damage due to incorrect
gasket/cooling plate combination gasket/cooling plate combination
• Only combine and assemble the gasket • Only combine and assemble the gasket
and cooling plate as illustrated and cooling plate as illustrated
• Attach the gasket (2) using the lugs on the cooling • Attach the gasket (2) using the lugs on the cooling
plate (1) plate (1)
• Repeat the procedure for cooling plates type 2 see
table 101
100 AE 4 2nd edition

COOLING SYSTEM
Schematic diagram for assembling cooling Engine Type 1 Type 4 Type 2 Type 3
plates type 1 to type 4 type quantity quantity quantity quantity
D2868 1 1 10 10
LE423
D2868 1 1 13 13
LE433
D2862 1 1 15 15
LE423
D2862 1 1 20 20
LE433
Installing cooling plate type 1
(1) Cooling plate type 1

(2) Expansion tank
(2) Cooling plate type 2 WARNING
(3) Cooling plate type 3 Component damage due to incorrectly
(4) Cooling plate type 4 positioned cooling plates
• Only position the cooling plate as
WARNING illustrated
Component damage due to incorrectly
positioned cooling plates • The gasket for cooling plate type 1 (1) faces the
• Observe the assembly sequence for expansion tank (2)
coolant plates type 1 (1) to type 4 (4) • Push cooling plate type 1 (1) onto the expansion
in the next steps tank (2)
• Position coolant plate type 1 (1)

• Repeat the procedure for coolant plates type 2 (2)
and type 3 (3) according to the table and nish
with coolant plate type 4 (4)
AE 4 2nd edition 101

COOLING SYSTEM
Installing cooling plate type 2 Installing cooling plates type 2 and type 3
(1) Cooling plate type 1 • Repeat the “Installing cooling plates type 2 (1)” and
(2) Cooling plate type 2 “Installing cooling plates type 3” steps alternately
until the required number of cooling plates has
WARNING
been reached,
positioned cooling plates Engine type Total number Number of
• Only position the cooling plate as of cooling type 2 and
illustrated plates type 3 cooling
plates
• The gasket for cooling plate type 2 (2) faces the
expansion tank D2868 LE423 22 10
• Push cooling plate type 2 (2) onto cooling plate
D2868 LE433 28 13
type 1 (1)
D2862 LE423 32 15
D2862 LE433 42 20

WARNING
positioned cooling plates
• Only position the cooling plate as WARNING
illustrated Component damage due to incorrectly
positioned cooling plates
• The gasket for cooling plate type 3 (2) faces the • Only position the cooling plate as
expansion tank illustrated
type 2 (1) • The gasket for cooling plate type 4 (2) faces the
expansion tank
type 3 (1)

COOLING SYSTEM
Checking the position of the cooling plates
Note
1st gasket has no nibs (2) on the sealing
lugs
• Check whether the sealing lugs point alternately

left and right
• Check whether the nibs (2) on the sealing lugs
form a continuous formation
• Check the total number of cooling plates (1), see
table 102
• The nal plate (cooling plate type 4) can be
recognised by the rounded corners
If there are discrepancies, repeat the steps for
assembling the cooling plate pack.

COOLING SYSTEM
REMOVING AND MOUNTING THE EXPANSION TANK

Removing and mounting the expansion tank
Additional jobs
– Draining/topping up the coolant, see Operator's Manual
– Removing and installing the poly-V-belt guard, see 145
– Removing and installing the coolant sensors, see 84
(1) Expansion tank (4) Overow line

(2) Holder (5) Bracket
(3) Coolant vent line, cylinder head (6) Coolant manifold, coolant outlet
Service products
Technical Vaseline ............................................................................................................. 09.15014-0001
WARNING

COOLING SYSTEM
Removing the expansion tank Unscrewing the expansion tank
Detaching the cylinder head coolant vent line
• Unscrew the hollow screws (3) and (6) Removing the expansion tank
• Remove the sealing rings (1), (2), (4) and (5)
Detaching the overow line
CAUTION
Danger of injury due to heavy
• Unscrew the hollow screws (1) and (5) components
• Remove the sealing rings (2), (4), (6) and (8) • Use lifting tackle for removal
• Remove the overow lines (3) and (7) WARNING
Danger of environmental pollution due
Removing the expansion tank holder
to emerging coolant
• Use a suitable tank to collect the
residual coolant that emerges
Note
An eye bolt can be screwed into the
thread (9) for removal.
The lifting tackle can be attached to the
eye bolt
• Remove the expansion tank (1)

• Remove the unscrewed conduit with O-rings (2)
and (6)
• Remove the unscrewed conduit (4) with O-rings
(3) and (5)
• Remove the O-ring (7)
• Unscrew the mounting bolts (1), (2), (4) and (6) • Remove the O-ring (8)
• Remove the holders (3) and (5) • Clean the mating faces

COOLING SYSTEM
Detaching the unscrewed conduit Mounting the expansion tank

Mounting the bracket

• Remove the unscrewed conduit (1)
• Remove the O-ring (3) • Position the bracket (1)
• Clean the mating faces • Screw in the mounting bolts (2), (3), (4) and (5) as
marked
Removing the bracket • Tighten the mounting bolts (2), (3), (4) and (5)
Attaching the unscrewed conduit
• Mark the installation position of the mounting bolts

(2), (3), (4) and (5)
• Unscrew the mounting bolts (2), (3), (4) and (5) • Insert a new O-ring (3)
• Remove the bracket (1) • Thinly apply Technical Vaseline on the O-ring (3)
• Position the unscrewed conduit (1) on the
intercooler, 2nd stage
• Push the unscrewed conduit (1) into the
intercooler until the stop is reached
• Screw in the mounting bolt (2)
• Tighten the mounting bolt (2)

COOLING SYSTEM
Mounting the expansion tank Bolting on the expansion tank

CAUTION
Danger of injury due to heavy Mounting the expansion tank holders
components
• Use lifting tackle for installation
Note
Make sure the O-rings are correctly
seated.
Note
An eye bolt can be screwed into the
thread (9) for installation.
The lifting tackle can be attached to the
eye bolt
• Insert new O-rings (2) and (6)

• Thinly apply Technical Vaseline on the O-rings (2)
and (6)
• Insert new O-rings (3) and (5) • Position the holders (3) and (5)
• Thinly apply Technical Vaseline on the O-rings (3) • Screw in and tighten the mounting bolts (1), (2),
and (5) (4) and (6)
• Position the unscrewed conduits (4) on the
thermostat housing and press in Attaching the overow line
• Insert a new O-ring (7)
• Thinly apply Technical Vaseline on the O-ring (7)
• Insert a new O-ring (8)
• Thinly apply Technical Vaseline on the O-ring (8)
• Position and push on the expansion tank (1)
• Position the overow lines (3) and (7)

• Screw in the hollow screws (1) and (5) with new
sealing rings (2), (4), (6) and (8)
• Tighten the hollow screws (1) and (5)

COOLING SYSTEM
Attaching the cylinder head coolant vent line
• Screw in the hollow screws (3) and (6) with new

sealing rings (1), (2), (4) and (5)

COOLING SYSTEM
COOLANT MANIFOLD
Removing and installing the coolant manifold
Additional jobs
– Removing and installing the air lter, see 341
– Removing and installing the charge-air pipes, see 325
– Removing and installing the turbocharger (two-stage variant), see 301
(1) Coolant manifold, right coolant (3) Coolant manifold, left

manifold-unscrewed conduit (4) Coolant manifold, left coolant manifold-left
(2) Coolant manifold, right coolant exhaust manifold
manifold-right exhaust manifold
Technical data
Temperature sensor.............................................. M16x1.5 ............................................................45 Nm
Service products
Radiator antifreeze ............................................................................................................ 09.21001-0002
Renolit Si 704 silicone grease ............................................................................................ 09.15014-0102
WARNING

COOLING SYSTEM
Removing the coolant manifold Removing the right coolant manifold-right

exhaust manifold
Removing the left coolant manifold-left exhaust
manifold

• Remove the right coolant manifold (3)
• Unscrew the mounting bolts (1) and (2) • Remove the O-ring (1) and the unscrewed conduit
• Remove the left coolant manifold (3) (4)
• Remove the O-ring (4) and the unscrewed conduit • Clean the mating faces
(5)
• Clean the mating faces Coolant manifold, removing the right coolant
manifold-unscrewed conduit
Removing the left coolant manifold

• Mark the installation positions of the mounting • Remove the right coolant manifold (2)
bolts (2) and (8) • Remove the O-ring (3)
• Unscrew the mounting bolts (8) • Remove the O-rings (6) and (4) from the
• Remove the coolant manifold (7) unscrewed conduit (5)
• Remove the O-ring (6) • Clean the mating faces
• Remove the O-rings (4) and (5) from the
unscrewed conduit
• Remove the coolant manifold (1)
• Remove the O-rings (3)

COOLING SYSTEM
Removing the right coolant manifold Installing the coolant manifold

Mounting the right coolant manifold

(2) and (3)
• Unscrew the mounting bolts (2) and (3) • Thinly apply Renolit Si 704 silicone grease on the
• Remove the coolant manifold (1) new O-rings (4)
• Remove the O-rings (4) • Position the coolant manifold (1) with O-rings (4)
• Clean the mating faces on the crankcase
• Screw in and tighten the mounting bolts (2) and
(3) as marked
Coolant manifold, mounting the right coolant

manifold-unscrewed conduit
• Thinly apply Renolit Si 704 silicone grease on the

O-rings (3), (4) and (6)
• Position the unscrewed conduit (5) with O-ring
(3) in the coolant connection on the right exhaust
manifold
• Position the coolant manifold (2) with O-rings (3)
and (6)

COOLING SYSTEM
Mounting the right coolant manifold-right Mounting the left coolant manifold-left exhaust
exhaust manifold manifold
• Thinly apply Renolit Si 704 silicone grease on the • Thinly apply Renolit Si 704 silicone grease on the
new O-ring (1) and new unscrewed conduit (4) new O-ring (4) and new unscrewed conduit (5)
• Position the unscrewed conduit (4) in the right • Position the unscrewed conduit (5) in the left
coolant manifold coolant manifold
• Position the coolant manifold (3) with O-ring (1) • Position the coolant manifold (3) with O-ring (4)
• Screw in and tighten the mounting bolts (2) • Screw in and tighten the mounting bolts (1) and (2)
Mounting the left coolant manifold

new O-rings (3), (4), (5) and (6)
• Position the unscrewed conduit with O-ring (6) in
the coolant connection on the left exhaust manifold
and (6)
on the crankcase
• Screw in and tighten the mounting bolts (2) as
marked

COOLING SYSTEM
THERMOSTATS
Removing and installing the thermostats
Additional jobs
– Removing the intercooler, 2nd stage, see 334
(1) Thermostat housing upper section
Technical data
Thermostat opening temperature...................................................................................................... 86 °C
Service products
WARNING

COOLING SYSTEM
Removing the thermostats Removing the thermostat housing lower section
Removing the thermostat housing upper section

(3)
• Unscrew the mounting bolts (3) • Unscrew the mounting bolts (3)
• Remove the thermostat housing upper section (2) • Remove the thermostat housing lower section (2)
• Remove the gasket (1) • Remove the O-rings (1), (4), (5) and (6)
• Clean the mating faces of the thermostat housing • Clean the mating faces
upper section
Removing the thermostats
• Remove the thermostats (1)

COOLING SYSTEM
Installing the thermostat Mounting the thermostat housing upper section
Mounting the thermostat housing lower section
• Apply Renolit Si 704 silicone grease on the new

O-rings
• Thinly apply Renolit Si 704 silicone grease on the • Put on the thermostat housing upper section (2)
new O-rings (1), (4), (5) and (6) with a new gasket (1)
• Put on the thermostat housing (2) with new O-rings • Screw in the mounting bolts (3) and tighten them
(1), (4), (5) and (6)
marked
Installing the thermostats
• Apply Renolit Si 704 silicone grease on the

thermostat mating faces (1)
• Insert the thermostats (1) into the thermostat
housing

COOLING SYSTEM
COOLANT PUMP
Removing and installing the coolant pump
Additional jobs
– Removing and mounting the expansion tank, see 105
(1) Connection ange (3) Connection ange

(2) Coolant pump (4) Connection ange, coolant expansion tank
Service products
WARNING

COOLING SYSTEM
Removing the coolant pump Removing the unscrewed conduits
Removing the coolant expansion tank

connection ange
• Remove the O-rings (3) and (6)

• Remove the anges (2) and (5)
• Remove the unscrewed conduits (1) and (4)
• Unscrew the mounting bolts (1) • Clean the mating faces
• Remove the washers (2)
• Remove the connection ange (3)
Removing the coolant pump

(1), (4) and (5)
• Unscrew the mounting bolts (1), (4) and (5)
• Remove the coolant pump (2)

COOLING SYSTEM
Installing the coolant pump Mounting the coolant expansion tank

connection ange
Installing the unscrewed conduits

• Thinly apply Renolit Si 704 silicone grease on the new O-rings (4) and (5)
contact surfaces of the new unscrewed conduits • Position the connection ange (3)
(1) and (4) • Screw in and tighten new mounting bolts (1) with
• Insert the unscrewed conduits (1) and (4) into the washers (2)
coolant pump
• Put the connection anges (2) and (5) on the
unscrewed conduits (1) and (4)
new O-rings (3) and (6)
• Insert the O-rings (3) and (6) into the connection
anges (2) and (5)
Installing the coolant pump

new O-ring (3)
• Position the coolant pump (2) with a new O-ring
(3)
• Screw in and tighten the new mounting bolts (1),
(4) and (5) as marked

COOLING SYSTEM
COOLANT MANIFOLD
Removing and Installing the coolant manifold
(1) Coolant pump (4) Coolant manifold downstream of

(2) Coolant manifold, intercooler, 1st stage, intercooler, 1st stage, left
right (5) Coolant manifold, collector
(3) Coolant manifold, intercooler, 1st stage, (6) Coolant manifold, intercooler, 2nd stage
left
Technical data
Mounting bolt ....................................................... M8x20-8.8 .........................................................24 Nm
Mounting bolt, coolant manifold, collector............... M12x90-10.9......................................................75 Nm
Service products
WARNING

COOLING SYSTEM
Removing the coolant manifold Removing the coolant manifold upstream of the
Removing the coolant manifold upstream of the
intercooler, 1st stage, right

• Unscrew the mounting bolts (5) • Remove the O-rings (1) and (2)
• Remove the coolant manifold (1) • Clean the mating faces
• Remove the ange (3) and O-ring (4) Removing the coolant manifold upstream of the
• Clean the mating faces intercooler, 2nd stage
Removing the coolant manifold downstream of

the intercooler, 1st stage, right

• Unscrew the mounting bolts (1) • Clean the mating faces
• Remove the ange (2) and O-ring (3)

COOLING SYSTEM
Removing the clamping piece Removing the coolant manifold upstream of the
intercooler, 1st stage, left

• Remove the clamping piece (1) • Unscrew the mounting bolts (6)
Removing the return gearbox oil cooler coolant • Remove the O-rings (1) and (4)
manifold • Remove the ange (3) and O-ring (5)
Removing the coolant manifold downstream of

the intercooler, 1st stage, left


• Remove the ange (2) and O-ring (4)

COOLING SYSTEM
Removing the left charge-air manifold mounting Removing the charge-air manifold
• Unscrew the mounting bolts (1) and (2) • Unscrew the mounting bolts (4) whilst bracing the
• Remove the holder (3) nuts (9)
• Unscrew the mounting bolts (4) and (5) • Remove the charge-air manifold (5)
• Remove the holder (6) • Remove the unscrewed conduits (2) and (7)
• Remove the O-rings (1), (3), (6) and (8)
Removing the right charge-air manifold
mounting Removing the charge-air pipe fastening
• Unscrew the mounting bolts (1) and (6) • Unscrew the mounting bolts (1)
• Remove the holder (2) • Remove the holder (2)
• Unscrew the mounting bolts (4) and (5)
• Remove the holder (3) Removing the coolant manifold collector

• Remove the coolant manifold collector (3)

COOLING SYSTEM
Mounting the coolant manifold Mounting the charge-air manifold
Mounting the coolant manifold collector

new O-rings (1), (3), (6) and (8)
• Position the coolant manifold collector (3) • Position the unscrewed conduits (2) with O-rings
• Screw in the mounting bolts (1) with the holder (2) (3) in the charge-air manifold (5)
and tighten to 75 Nm • Position the O-rings (1) in the charge-air manifold
of the 2nd stage intercooler
Mounting the charge-air pipe fastening • Position the unscrewed conduits (7) with O-rings
(6) and (8) in the charge-air manifold (5)
• Position the charge-air manifold (5) with
unscrewed conduits
• Screw in and tighten the mounting bolts (4) whilst
bracing the nuts (9)
Attaching the right charge-air manifold

mounting


• Screw in the mounting bolts (4) and (5)and tighten
them
• Screw in and tighten the mounting bolts (1) and (6)

COOLING SYSTEM
Attaching the left charge-air manifold mounting Installing the coolant manifold upstream of the
intercooler, 1st stage, left

• Screw in and tighten the mounting bolts (4) and (5) • Thinly apply Renolit Si 704 silicone grease on the
• Position the holder (3) O-rings (1), (4) and (5)
• Screw in and tighten the mounting bolts (1) and (2) • Insert the O-rings (4) and (5) into the ange (3)
• Insert the O-ring (1) into the coolant pump
Installing the coolant manifold downstream of connection collector
the intercooler, 1st stage, left • Insert the coolant manifold (2) into the ange (3)
• Position the coolant manifold (2) and the ange (3)
• Screw in the mounting bolts (6) and tighten to
24 Nm
Installing the return gearbox oil cooler coolant

manifold

O-rings (3), (4) and (6)
• Insert the O-rings (3) and (4) into the ange (2)
• Insert the O-ring (6) into the coolant manifold
collector
• Insert the coolant manifold (1) into the ange (2)
• Position the coolant manifold (1) and the ange (2) • Thinly apply Renolit Si 704 silicone grease on the
• Screw in the mounting bolts (5) and tighten to new O-rings (1) and (3)
24 Nm • Insert the O-rings (1) and (3) on the coolant
manifold (2)
• Position the coolant manifold (2)

COOLING SYSTEM
Mounting the clamping piece Installing the coolant manifold upstream of the
• Position the clamping piece (1)

• Screw in the mounting bolt (2) and tighten to • Thinly apply Renolit Si 704 silicone grease on the
24 Nm new O-rings (1) and (2)
• Insert the O-rings (1) and (2) into the coolant
Installing the coolant manifold upstream of the manifold (3)
intercooler, 2nd stage • Position the coolant manifold (3)
24 Nm
Installing the coolant manifold downstream of

the intercooler, 1st stage, right

new O-ring (1)
• Insert the O-ring (3) into the coolant manifold
collector
• Insert the coolant manifold (1) into the coolant
manifold collector • Thinly apply Renolit Si 704 silicone grease on the
• Screw in and tighten the mounting bolt (2) O-rings (3), (4) and (6)
• Position the O-ring (6) in the coolant manifold
collector
24 Nm

COOLING SYSTEM
Installing the coolant manifold upstream of the

intercooler, 1st stage, right

O-rings (2), (4) and (6)
• Insert the O-ring (6) into the coolant pump
connection
24 Nm

COOLING SYSTEM
COOLANT PUMP
Removing and installing the coolant pump
Additional jobs
– Removing and Installing the coolant manifold, see 123
(1) Coolant pump
Service products
WARNING

COOLING SYSTEM
Removing the coolant pump Mounting the coolant pump

Removing the coolant pump

new O-ring (1)
• Unscrew the mounting bolts (3) • Position the coolant pump (1) with O-ring (2) on
• Remove the coolant pump (1) the ywheel housing
• Remove the O-ring (2) • Screw in the mounting bolts (3) and tighten them

COOLING SYSTEM
Dismantling and assembling the coolant pump

Additional jobs
– Removing and installing the coolant pump, see 131
(1) Drive gear (3) Coolant manifold, pressure side

(2) Mounting ange (4) Coolant manifold, suction side
Technical data
Mounting bolt, drive gear....................................... M12x40-10.9.................................. Initial torque 40 Nm
Mounting bolt, drive gear....................................... M12x40-10.9........................................Final torque 45°
Mounting bolt, mounting ange........................................................................................................22 Nm
Mounting bolt, coolant manifold, pressure side ....... M8x25-8.8 .........................................................15 Nm
Mounting bolt, coolant manifold, pressure side ....... M8x75-10.9 .......................................................15 Nm
Mounting bolt, coolant manifold, suction side ......... M8x25-8.8 .........................................................15 Nm
Mounting bolt, cover, coolant pump ....................... M6x12 ................................................................ 7 Nm
Mounting bolt, cam ............................................... M8x25 ............................................................... 11 Nm
Service products
Technical Vaseline ............................................................................................................. 09.15014-0001
Loctite 5900 ...................................................................................................................... 04.10394-9292
WARNING

COOLING SYSTEM
Special tools
[11] Puller for impeller 80.99601-6037
• Pulling off the coolant pump impeller
[12] Brace 80.99622-6002
• Bracing the coolant pump drive gear

COOLING SYSTEM
Dismantling the coolant pump Removing the drive gear
Removing the pressure side coolant manifold
• Brace the coolant pump on the drive gear (3) using

the Brace [12] (5)
• Unscrew the mounting bolts (3) • Unscrew the mounting bolt (1)
• Remove the pressure side coolant manifold (2) • Remove the washer (2)
and the gasket (1) • Remove the coolant pump from the drive gear (3)
• Clean the mating faces • Remove the friction disc (4)
Removing the suction side coolant manifold Removing the coolant pump cover
• Remove the pressure side coolant manifold (2) • Remove the cover (1) and the O-ring (2)
and the gasket (1)
• Clean the mating faces Removing the hub cover
• Remove the hub cover (1)

COOLING SYSTEM
Removing the impeller Removing the slide ring seal
• Pull off the impeller (1) with the Puller for • Remove the splash guard (1)
impeller [11] • Unclip the circlip (2) and remove it
• Screw the Puller for impeller [11] into the impeller • Remove the washer (3)
with the screw-in piece (2) • Remove the slide ring seal (4)
• Pull the impeller off the coolant pump by screwing
in the threaded spindle (3) Removing the coolant pump housing
Removing the cam

• Remove the washers (2)
• Unscrew the mounting bolts (1) and remove the • Remove the coolant pump housing (1)
cam (2)
• Clean the contact surfaces

COOLING SYSTEM
Assembling the coolant pump Installing the cam
Mounting the coolant pump housing
• Thinly apply Loctite 5900 on the contact surface

of the cam (2)
• Position the coolant pump housing (1) • Insert the cam (2)
• Screw in the mounting bolts (3) with washers (2) • Screw in the mounting bolts (1) and tighten them
• Tighten the mounting bolts (3) to 22 Nm to 11 Nm
Installing the slide ring seal Installing the impeller
• Insert the slide ring seal (4)

WARNING
• Insert the washer (3)
Component damage due to impeller
• Insert and clip in the circlip (2)
running dry
• Insert the splash guard (1)
• Moisten the impeller with Technical
Vaseline before installation
• Do not allow the coolant pump to run
dry
• Thinly apply Technical Vaseline on the impeller (1)

• Insert the impeller (1) into the coolant pump

COOLING SYSTEM
Inserting the hub cover Mounting the drive gear
• Insert the hub cover (1) into the impeller • Position the friction disc (4)
• Thinly apply Technical Vaseline on the hub cover • Push the drive gear (3) onto the drive shaft
(1) • Insert the washer (2)
Mounting the coolant pump cover • Brace the coolant pump on the drive gear (3) using
the Brace [12] (5)
• Tighten the mounting bolt (1) to Initial torque 40
Nm
• Tighten the mounting bolt (1) to Final torque 45°
Mounting the suction side coolant manifold
• Thinly apply Technical Vaseline on the new O-ring

(2)
• Position the O-ring (2) and cover (1) on the coolant
pump housing
to 7 Nm
• Position the pressure side coolant manifold (2) on
the coolant pump housing with a new gasket (1)
• Screw in the mounting bolts (3)
• Tighten the mounting bolts (3) to 15 Nm

COOLING SYSTEM
Mounting the pressure side coolant manifold
• Position the suction side coolant manifold (2) on

the coolant pump housing with a new gasket (1)

ADD-ON UNITS
ADD-ON UNITS
(1) Hydraulic pump

(2) Starter

ADD-ON UNITS
(1) Poly-V-belt cover (4) Guide roller

(2) Poly-V-belt (5) Alternator
(3) Poly-V-belt tensioner

ADD-ON UNITS
STARTER
Removing and installing the starter
Additional jobs
– Disconnecting and connecting the starter
(1) Starter
Technical data
Mounting bolt, starter ............................................ M12...................................................................75 Nm
Terminal 30 mounting nut...................................... M12...................................................................25 Nm
Mounting nut, terminal 31...................................... M12...................................................................25 Nm
Mounting nut, terminal 50...................................... M6 ..................................................................... 4 Nm
Mounting nut, terminal 30, on relay ........................ M6 ..................................................................... 4 Nm
Mounting nut, terminal 85, on relay ........................ M6 ..................................................................... 4 Nm
Mounting nut, terminal 31 and 50 .......................... M4 ...................................................................1.2 Nm
Number of starter pinion teeth .................................................................................................................9
Starter power ........................................................................................................................ 24 V/6.6 kW
WARNING
• If impact wrenches are used, these may only be used for pretightening to max. 50 % of the

ADD-ON UNITS
Removing the starter Installing the starter
• Unscrew the mounting bolts (2) • Insert the starter (1) into the ywheel housing
• Remove the starter (1) from the ywheel housing • Screw in new mounting bolts (2) and tighten them
• Crank the engine 360° and check the ywheel ring to 75 Nm
gear for wear
Replace the ywheel if the ywheel ring gear is worn.

ADD-ON UNITS
POLY-V-BELT GUARD
Removing and installing the poly-V-belt guard
(1) Poly-V-belt guard
WARNING

ADD-ON UNITS
Removing the poly-V-belt guard Installing the poly-V-belt guard

Installing the poly-V-belt guard mounting

(5) and (6)
• Unscrew the mounting bolts (5) and (6) • Position the holder (2) as marked
• Remove the washers (1) • Screw in and tighten the mounting bolt (1)
• Remove the nut (2) with washer (3) and bush (4) • Position the holder (4) as marked
• Remove the poly-V-belt guard • Screw in the mounting bolt (3) and tighten it
• Position the holder (6) as marked
Removing the poly-V-belt guard mounting • Screw in and tighten the mounting bolts (5)
Installing the poly-V-belt guard
• Mark the installation position of the holders (2), (4)

and (6)
• Unscrew the mounting bolt (1) • Position the poly-V-belt guard with bush (4)
• Remove the holder (2) • Screw in the mounting bolts (5) and (6) with
• Unscrew the mounting bolt (3) washers (1) as marked
• Remove the holder (4) • Screw the nut (2) with washer (3) onto the
• Unscrew the mounting bolts (5) mounting bolt (5) and tighten
• Remove the holder (6) • Tighten the mounting bolts (6)

ADD-ON UNITS
POLY-V-BELT
Removing and installing the poly-V-belt
(1) Poly-V-belt
(2) Poly-V-belt tensioner

ADD-ON UNITS
Removing the poly-V-belt Mounting the poly-V-belt

Removing the poly-V-belt Mounting the poly-V-belt
CAUTION CAUTION
The poly-V-belt tensioner is under The poly-V-belt tensioner is under
spring tension spring tension
• Brace the poly-V-belt tensioner • Brace the poly-V-belt tensioner
to prevent it from springing back to prevent it from springing back
unintentionally unintentionally
• Turn the poly-V-belt tensioner (1) clockwise as far • Turn the poly-V-belt tensioner (1) clockwise as far
as the stop and hold it as the stop and hold it
• Remove the poly-V-belt (2) • Fit the poly-V-belt (2)
• Carefully slacken the poly-V-belt tensioner (1) • Carefully slacken the poly-V-belt tensioner (1)

ADD-ON UNITS
ALTERNATOR
Removing and installing the alternator
Additional jobs
– Removing and installing the poly-V-belt, see 147
(1) Alternator (4) Poly-V-belt

(2) Connector (5) Poly-V-belt tensioner
(3) Guide roller
Technical data
Mounting nut (2) ................................................... M16x1.5 ..........................................................100 Nm
Mounting nut, terminal B + .................................... M8 ....................................................................14 Nm
Mounting bolt, poly-V-belt tensioner .................................................................................................47 Nm
Mounting bolt, guide roller ..................................... M12x55-8.8 .......................................................60 Nm
Service products
Loctite 648 ........................................................................................................................ 04.10160-9164

ADD-ON UNITS
Special tools
[13] Special spanner set, size 22 80.99603-6029
• Removing and mounting the poly-V-belt pulley in

conjunction with:
• Gripper [14]
[14] Gripper 08.06460-0002
• Removing and mounting the poly-V-belt pulley in

conjunction with:
• Special spanner set, size 22 [13]

ADD-ON UNITS
Removing the alternator Removing the upper alternator mounting
Disconnecting the electrical connection

(1) and (7)
WARNING • Unscrew the mounting bolt (1)
Danger of damage to the engine • Remove the washer (2) and nut (8)
electrics/electronics • Unscrew the mounting bolt (7)
• Mark all electrical connections. • Remove the bush (6), insulating washers (5) and
• Mark the attachment points for the (3) with holder (4)
Removing the alternator
• Unlock the plug connection (1) and pull off the
connector
• Unscrew the terminal B+ mounting nut
Removing the poly-V-belt pulley

(1) and (8)
• Remove the alternator (7)
• Remove the washer (4) and insulating washer (3)
• Unscrew the mounting nut with the Special • Remove the insulating sleeve
spanner set, size 22 [13] (1) in conjunction with • Remove the washer (5) and insulating washer (6)
the Gripper [14] • Unscrew the mounting bolt (1)
• Pull the poly-V-belt pulley (2) off the alternator • Remove the holder (2)
shaft

ADD-ON UNITS
Removing the bracket Removing and mounting the poly-V-belt

tensioner
Removing the poly-V-belt tensioner

• Remove the bracket

• Remove the poly-V-belt tensioner (2)
Mounting the poly-V-belt tensioner
• Position the poly-V-belt tensioner (2)

• Screw in the mounting bolt (1) and tighten to 47
Nm

ADD-ON UNITS
Removing and mounting the guide roller Installing the alternator

Removing the guide roller Mounting the bracket
• Unscrew the mounting bolt (1) • Position the bracket

• Remove the washer (2), guide roller (3) and bush • Screw in and tighten the mounting bolts (1)
(4)
Installing the alternator
Mounting the guide roller
WARNING
• Position the guide roller (3) and bush (4)
Danger due to impermissible potential
• Screw in the mounting bolt (1) with washer (2)
on the crankcase
• Tighten the mounting bolt (1) to 60 Nm
• Only use undamaged insulating
washers and sleeves

• Insert the insulating sleeve into the alternator (7)
• Position the washer (3) and insulating washer (4)
on the insulating sleeve
• Position the washer (5) and insulating washer (6)
on the insulating sleeve
• Insert the alternator (7) into the bracket
• Screw in the mounting bolt (8) as marked
Are the insulating washers (3) and (6) in the correct
position?
Repeat the work step if they are not.

ADD-ON UNITS
Installing the upper alternator mounting Mounting the poly-V-belt
WARNING CAUTION
Danger due to impermissible potential The poly-V-belt tensioner is under
on the crankcase spring tension
• Only use undamaged insulating • Brace the poly-V-belt tensioner
washers and sleeves to prevent it from springing back
unintentionally
• Position the holder (4) with insulating washers (3)
and (5) • Turn the poly-V-belt tensioner (1) clockwise as far
• Screw in the mounting bolt (7) with bush (6) as as the stop and hold it
marked • Fit the poly-V-belt (2)
• Insert the mounting bolt (1) with washer (2) as • Carefully slacken the poly-V-belt tensioner (1)
marked
• Screw the nut (8) onto the mounting bolt (1) and
tighten
• Tighten the mounting bolt (8), see see Installing
the alternator, 153 for step
Mounting the poly-V-belt pulley
• Put the poly-V-belt pulley (2) on the alternator shaft

• Thinly apply Loctite 648 on the thread and contact
surface of the new mounting nut (1)
• Tighten the mounting nut (1) to 100 Nm using the
Special spanner set, size 22 [13] in conjunction
with the Gripper [14]

ADD-ON UNITS
Connect the electrical connection
WARNING
marked.
WARNING
Danger of irreparable alternator
damage
• When installing the connector, rst fully

open the lock and then insert and lock
the connector

connection
• Position the cable as marked
• Screw on the terminal B+ mounting nut and tighten
it to 14 Nm

ADD-ON UNITS
HYDRAULIC PUMP
Removing and installing the hydraulic pump
(1) Hydraulic pump
Technical data
Mounting bolt ...................................................... M12x100-10.9..................................................120 Nm
Axial play, drive shaft, power take-off, right...................................................................... 0.300 - 0.550 mm
Radial play, drive shaft, power take-off, right ................................................................... 0.020 - 0.054 mm
WARNING
Note
Always use new O-rings, sealing rings and mounting bolts when converting the power take-offs.

ADD-ON UNITS
Removing the hydraulic pump Removing the hydraulic pump power take-off
• Unscrew the mounting bolts (4) and (5) • Unscrew the mounting bolts (2) and (4)
• Remove the washers (3) and (6) • Remove the drive housing (3)
• Remove the hydraulic pump (2) with connecting • Remove the O-ring (5) from the drive housing (3)
sleeve (1) and O-ring • Remove the drive gear (1)
Undoing the connecting piece
• Unscrew the connecting piece mounting bolts (1)
Removing the connecting piece holder


ADD-ON UNITS
Installing the hydraulic pump Securing the connecting piece
Installing the hydraulic pump power take-off
• Screw in and tighten the connecting piece

mounting bolts (1)
• Apply engine oil to MAN Standard 3277 on the
cleaned drive gear (1) Installing the hydraulic pump
• Insert the drive gear (1)
• Insert a new O-ring (5) into the drive housing (3)
O-ring (5)
• Position the drive housing (3)
• Screw in the new mounting bolts (2) and (4) and
tighten them to 120 Nm
Mounting the connecting piece holder

connecting sleeve (1)
new O-ring and insert on the hydraulic pump
• Position the hydraulic pump (2) with connecting
sleeve (1)
(5) with washers (3) and (6)


COMMON-RAIL SYSTEM
COMMON-RAIL SYSTEM
(1) Leakage oil line, injectors (7) Fuel lter, Master

(2) High-pressure pump, Slave (8) Injector
(3) High-pressure pump, Master (9) Leakage oil line, injectors
(4) Fuel lter, Slave (10) Rail
(5) Fuel pre-lter with hand pump (11) Fuel distributor, return
(6) Fuel pre-lter with water trap

COMMON-RAIL SYSTEM
HIGH-PRESSURE LINES AND RAILS

Removing and installing the high-pressure lines and rails
Additional jobs
– Removing and installing the intercooler, see 331
– Removing and installing the fuel lines, see 213
(1) Rail, right (Master) (3) Rail, left (Slave)

(2) High-pressure supply line (4) High-pressure line
Technical data
High-pressure lines (initial use) ................................................................................... Initial torque 10 Nm
High-pressure lines (initial use) ....................................................................................Final tightening 60°
High-pressure lines (re-use) ........................................................................................ Initial torque 10 Nm
High-pressure lines (re-use) ..............................................................................................Final torque 30°
Hollow screw, leakage oil line ................................ M14x1.5 ............................................................25 Nm
Rail pressure sensor............................................. M18x1.5 ............................................................80 Nm
Pressure limiting valve .......................................... M20x1.5 ..........................................................100 Nm

COMMON-RAIL SYSTEM
WARNING
• 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)
• 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.
• Always renew rail connections once they have been undone
• Do not reuse plugs for high-pressure 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
• Always remove only one fuel line
• Plug the component connections immediately using new, clean protective sleeves
WARNING
Danger of damage due to leakage
• Check injector seat, rail and leakage oil lines for leaks after each installation
WARNING
WARNING
Special tools
[15] End plug 81.96002-0521
• Plugging the high-pressure lines
[16] Protective sleeve Z 14 x 15 81.96002-0512
• Plugging the high-pressure line connections
[17] End plug 81.96002-0556
• Plugging the rail-pressure sensor bore in the rail

• Plugging the the pressure limiting valve bore in
the rail

COMMON-RAIL SYSTEM
• Plugging the rail-pressure sensor

• Plugging the pressure limiting valve
[19] Cap 81.96002-0518
• Sealing ring unions
[20] Special spanner, size 17 80.99603-0309
• Removing and mounting the high-pressure lines

in conjunction with:
• Angle extension [21]
[21] Angle extension 08.06139-9025
• Removing and mounting the high-pressure lines

• Special spanner, size 17 [20]

COMMON-RAIL SYSTEM
Removing the high-pressure lines and Detaching the high-pressure supply lines
rails
Removing the cover for the union nuts
• Undo the union nuts for the high-pressure line (1)

with the Angle extension [21] and Special spanner,
size 17 [20]
• Open up and remove the cover for the union nuts • Unscrew the union nuts for the high-pressure line
(1) (1) save for 2 turns
• Repeat the same procedure for all the • Unscrew the union nuts for the high-pressure line
high-pressure lines (1)
• Remove the high-pressure line (1)
Removing the Master high-pressure supply line • Plug the high-pressure line with End plug [15]
mounting and the connections with Protective sleeve
Z 14 x 15 [16]
• Repeat the same procedure for the second
high-pressure supply line
• Mark the installation position of the clamping

pieces (4) and (5)
• Remove the nut (3)
• Remove the clamping pieces (4) and (5)

COMMON-RAIL SYSTEM
Detaching the high-pressure line Removing the high-pressure line fastening

points

with the Angle extension [21] and Special spanner, • Mark the installation position of the holders (2),
size 17 [20] (4), (5), (7) and (9)
• Unscrew the union nuts for the high-pressure line • Mark the installation position of the mounting bolts
(1) save for 2 turns (1), (3), (6), (8) and (10)
• Unscrew the union nuts for the high-pressure line • Unscrew the mounting bolt (1)
(1) • Remove the holder (2)
• Remove the high-pressure line (1) • Unscrew the mounting bolt (3)
• Plug the high-pressure line (1) with End plug [15] • Remove the holder (4)
and the connections with Protective sleeve • Unscrew the mounting bolt (6)
Z 14 x 15 [16] • Remove the holder (5)
• Repeat the same procedure for the other • Unscrew the mounting bolt (8)
high-pressure lines • Remove the holder (7)
• Mark the installation position of the clamping piece • Unscrew the mounting bolt (10)
• Unscrewing the mounting bolt • Remove the holder (9)
• Remove the clamping piece
Removing the right pressure limiting valve
WARNING
Component damage due to lack of
lubricant
• Do not wash off the new pressure
limiting valve as the thread and biting
edge are coated with lubricant
• Unscrew the pressure limiting valve (1)

• Plug the pressure limiting valve with Protective
sleeve Z 18 x 15 [18] and the thread in the rail with
End plug [17]

COMMON-RAIL SYSTEM
Removing the right rail pressure sensor Removing the left rail pressure sensor
WARNING WARNING
Component damage due to lack of Component damage due to lack of
lubricant lubricant
• Do not wash off the new rail pressure • Do not wash off the new rail pressure
sensor as the thread and biting edge sensor as the thread and biting edge
are coated with lubricant are coated with lubricant
• Unscrew the rail pressure sensor (1) • Unscrew the rail pressure sensor (1)
• Plug the rail pressure sensor with Protective • Plug the rail pressure sensor with Protective
sleeve Z 18 x 15 [18] and the thread in the rail sleeve Z 18 x 15 [18] and the thread in the rail
with End plug [17] with End plug [17]
Removing the left pressure limiting valve Removing the holder with rail on the right

WARNING
• Remove the holder with rail (3)
lubricant
• Do not wash off the new pressure
limiting valve and new rail pressure
sensor as the thread and biting edge
are coated with lubricant

End plug [17]

COMMON-RAIL SYSTEM
Detaching the right rail Removing the collector
• Remove the rail (3) from the holder (1) • Remove the collector (1) from the rail
Removing the holder with rail on the left Detaching the left rail
• Remove the holder with rail (3) • Remove the rail from the holder (3)
Detaching the fuel return line from the left rail
• Unscrew the hollow screw (2)

• Unscrew the union nut
• Remove the fuel return line (1) from the left rail
• Plug the fuel return line (1) with Cap [19] and the
rail with End plug [15]

COMMON-RAIL SYSTEM
Installing the high-pressure lines and Installing the fuel return line for the left rail
rails
Attaching the left rail
• Remove the caps and plugs

• Position the fuel return line (1) on the left rail
• Screw in the hollow screw (3) with new sealing
• Position the rail on the holder (3) rings
• Screw in the mounting bolts (1) and (2) and tighten • Screw on and tighten the union nut
them to Initial torque 2 Nm • Tighten the hollow screw (3)
• Fully tighten the mounting bolts
Mounting the collector
Mounting the holder with rail on the left
• Position the collector (1) on the rail

• Screw in the mounting bolts (2) and (3) and tighten • Position the holder with rail (3)
them to Initial torque 2 Nm • Screw in and tighten the mounting bolts (1) and (2)
Attaching the right rail
• Position the rail (3) on the holder (1)


COMMON-RAIL SYSTEM
Mounting the holder with rail on the right Installing the left pressure limiting valve
• Position the holder with rail (3)

WARNING
Installing the left rail pressure sensor lubricant
• Do not wash off the pressure limiting
valve and rail pressure sensor as the
thread and biting edge are coated with
lubricant

• Screw in the pressure limiting valve (1) and tighten
to 100 Nm
Installing the right rail pressure sensor
WARNING
lubricant
lubricant

• Screw in the rail pressure sensor (1) and tighten it
WARNING
to 80 Nm
lubricant
• Do not wash off the pressure-limiting
valve and rail-pressure sensor as the
lubricant

to 80 Nm

COMMON-RAIL SYSTEM
Installing the right pressure limiting valve Mounting the high-pressure line fastening points

WARNING
lubricant
lubricant
• Remove the caps and plugs • Position the holder (9) as marked
• Screw in the pressure limiting valve (1) and tighten • Screw in and tighten the mounting bolt (10)
to 100 Nm
Attaching the high-pressure line
Installing the pressure limiting valve and rail
pressure sensor on the left
WARNING
lubricant
lubricant
• The pressure limiting valve and rail pressure

sensor on the left are installed in the same way
as the ones on the right

• Attach the high-pressure line (1), ensuring that it
is strain-free, using the Angle extension [21] and
Special spanner, size 17 [20]
• Tighten the new high-pressure line (1) to Initial
torque 10 Nm
• Tighten the high-pressure line (1) to Initial
torque 10 Nm if re-using
• Repeat the same procedure for the other
high-pressure lines
• Position the clamping piece as marked
• Screw in and tighten the mounting bolt

COMMON-RAIL SYSTEM
Attaching the high-pressure supply lines Final tightening of high-pressure line
• Remove the caps and plugs • Tighten the new high-pressure lines (1) to Final
• Attach the high-pressure line (1), ensuring that it tightening 60° with Angle extension [21] and
is strain-free, using the Angle extension [21] and Special spanner, size 17 [20]
Special spanner, size 17 [20] • Tighten the high-pressure lines (1) to Final torque
• Tighten the new high-pressure line (1) to Initial 30° with Angle extension [21] and Special spanner,
torque 10 Nm size 17 [20] if re-using
• Tighten the high-pressure line (1) to Initial • Repeat the same procedure for the other
torque 10 Nm if re-using high-pressure lines
• Repeat the same procedure for the other
high-pressure lines Mounting the cover for the union nuts
• Position the clamping piece as marked
• Screw in and tighten the mounting bolt
Attaching the Master high-pressure supply line

mounting
• Position and close the cover for the union nuts (1)
• Repeat the same procedure for all the
high-pressure lines
• Position the clamping pieces (4) and (5) as marked

• Insert the mounting bolt (1) and then screw on and
tighten the nut (3)

COMMON-RAIL SYSTEM
Removing and installing the high-pressure lines and rails (classied variant)
Additional jobs
(1) High-pressure line (5) High-pressure supply line, rail, left

(2) Rail, right (Master) (6) High-pressure lines
(3) High-pressure lines (7) Rail, left (Slave)
(4) High-pressure supply line, rail, right (8) High-pressure line
Technical data
High-pressure lines (initial use) ................................................................................... Initial torque 10 Nm
High-pressure lines (initial use) .........................................................................................Final torque 60°
High-pressure lines (re-use) ........................................................................................ Initial torque 10 Nm
High-pressure lines (re-use) ..............................................................................................Final torque 30°
Rail-pressure sensor............................................. M18x1.5 ............................................................80 Nm
Pressure-limiting valve.......................................... M20x1.5 ..........................................................100 Nm

COMMON-RAIL SYSTEM
WARNING
personnel only
(desired value 0)
• Always replace rail connections once they have been undone
once
connections
WARNING
• Always detach only one fuel line
• Close the component connections immediately using new, clean protective sleeves
WARNING
WARNING
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
Special tools
[22] End plug 81.96002-0521

COMMON-RAIL SYSTEM
[24] End plug 81.96002-0556

the rail

• Detaching and attaching the high-pressure lines



COMMON-RAIL SYSTEM
Removing the high-pressure lines and Removing the right rail cover upper section
rails
Removing the cover for the union nuts

• Remove the rail cover upper section (2)
• Open up and remove the cover for the union nuts Removing the left rail cover upper section
(1)
• Repeat the same procedure for all the
high-pressure lines
Removing the mounting plates

• Remove the rail cover upper section (1)
Removing the pipe clamps
• Mark the installation position of the mounting

plates (3) and (4)
• Remove the mounting plates (3) and (4)
• Mark the installation position of the pipe clamps

(1) and (2)
• Remove the pipe clamps (1) and (2)

COMMON-RAIL SYSTEM
Detaching the left rail high-pressure supply line Removing the pipe clamps
• Undo the union nuts for the high-pressure line (1) • Mark the installation position of the pipe clamps
with the Angle extension [27] and Special spanner, (1) and (2)
size 17 [26] • Remove the pipe clamps (1) and (2)
• Unscrew the union nuts for the high-pressure line
(1) save for 2 turns Detaching the cylinder 7 high-pressure line
(1)
• Plug the high-pressure line with End plug [22]
and the connections with Protective sleeve
Z 14 x 15 [23]
Detaching the right rail high-pressure line

size 17 [26]
(1) save for 2 turns
(1)
• Undo the union nuts for the high-pressure line (1) • Plug the high-pressure line with End plug [22]
with the Angle extension [27] and Special spanner, and the connections with Protective sleeve
size 17 [26] Z 14 x 15 [23]
(1)
Z 14 x 15 [23]

COMMON-RAIL SYSTEM
Detaching the cylinder 1 high-pressure line Detaching the cylinder 2 and 3 high-pressure
lines

with the Angle extension [27] and Special spanner, Note
size 17 [26] High-pressure lines can be removed as a
• Unscrew the union nuts for the high-pressure line set or individually
(1) • Remove pipe clamps (1) if required
• Remove the high-pressure line (1) • Undo the union nuts for the high-pressure lines (2)
• Plug the high-pressure line with End plug [22] with the Angle extension [27] and Special spanner,
and the connections with Protective sleeve size 17 [26]
Z 14 x 15 [23] • Unscrew the union nuts for the high-pressure lines
• Unscrew the union nuts for the high-pressure lines
(2)
• Remove the high-pressure lines (2)
• Plug the high-pressure lines with End plug [22]
Z 14 x 15 [23]
(1)
• Unscrew the mounting bolt
• Remove the pipe clamps

COMMON-RAIL SYSTEM
Detaching the cylinder 8 and 9 high-pressure Removing the cylinder 4 to 6 high-pressure lines
lines
Note
Note High-pressure lines can be removed as a
High-pressure lines can be removed as a set or individually
set or individually
• Remove pipe clamps (1) if required
• Remove pipe clamps (1) if required • Undo the union nuts for the high-pressure lines (2)
• Undo the union nuts for the high-pressure lines (2) with the Angle extension [27] and Special spanner,
with the Angle extension [27] and Special spanner, size 17 [26]
size 17 [26] • Unscrew the union nuts for the high-pressure lines
• Unscrew the union nuts for the high-pressure lines (2) save for 2 turns
(2) save for 2 turns • Unscrew the union nuts for the high-pressure lines
• Unscrew the union nuts for the high-pressure lines (2)
(2) • Remove the high-pressure lines (2)
• Remove the high-pressure lines (2) • Plug the high-pressure lines with End plug [22]
• Plug the high-pressure lines with End plug [22] and the connections with Protective sleeve
and the connections with Protective sleeve Z 14 x 15 [23]
Z 14 x 15 [23] • Mark the installation position of the pipe clamps
• Mark the installation position of the pipe clamp (1) (1)
• Unscrew the mounting bolt • Unscrew the mounting bolts
• Remove the pipe clamp • Remove the pipe clamps

COMMON-RAIL SYSTEM
Removing the cylinder 10 to 12 high-pressure Detaching the left rail return high-pressure line
lines

Note with the Angle extension [27] and Special spanner,
High-pressure lines can be removed as a size 17 [26]
set or individually • Unscrew the union nuts for the high-pressure line
• Remove pipe clamps (1) if required (1)
• Undo the union nuts for the high-pressure lines (2) • Remove the high-pressure line (1)
with the Angle extension [27] and Special spanner, • Plug the high-pressure line (1) with End plug [22]
size 17 [26] and the connections with Protective sleeve
• Unscrew the union nuts for the high-pressure lines Z 14 x 15 [23]
• Unscrew the union nuts for the high-pressure lines Detaching the right rail return high-pressure line
(2)
• Remove the high-pressure lines (2)
• Plug the high-pressure lines with End plug [22]
Z 14 x 15 [23]
(1)
• Unscrew the mounting bolts
• Remove the pipe clamps

size 17 [26]
(1)
• Plug the high-pressure line (1) with End plug [22]
Z 14 x 15 [23]

COMMON-RAIL SYSTEM
Removing the left rail Removing the right rail cover lower section
• Unscrew the mounting bolts (1) • Unscrew the mounting bolt (1) and remove it with
• Remove the rail (3) the sealing ring (3)
• Remove the O-ring (2) • Remove the rail cover lower section (2)
Removing the left rail cover lower section Removing the pressure-limiting valve
• Unscrew the mounting bolt (1) and remove it with

WARNING
the sealing ring (3)
• Remove the rail cover lower section (2)
lubricant
Removing the right rail • Do not wash off the pressure limiting
valve as the thread and biting edge are
coated with lubricant
Note
The left pressure limiting valve is
removed in the same way as the right
pressure limiting valve

• Remove the O-ring (2) from the pressure limiting
valve (1)
End plug [24]

• Remove the rail (1)

COMMON-RAIL SYSTEM
Removing the rail pressure sensor Installing the high-pressure lines and
rails
Installing the right rail pressure sensor
WARNING
lubricant
• Do not wash off the rail pressure sensor WARNING
as the thread and biting edge are Component damage due to lack of
coated with lubricant lubricant
Note valve and rail-pressure sensor as the
The left rail pressure sensor is removed thread and biting edge are coated with
in the same way as the right rail pressure lubricant
sensor
Note
• Unscrew the rail-pressure sensor (1) The left rail pressure sensor is installed
• Plug the rail pressure sensor with Protective in the same way as the right rail pressure
sleeve Z 18 x 15 [25] and the thread in the rail sensor
with End plug [24]
to 80 Nm

COMMON-RAIL SYSTEM
Installing the right pressure limiting valve Installing the right rail
• Fit a new O-ring (4)

WARNING
lubricant
valve and rail-pressure sensor as the Mounting the left rail cover lower section
lubricant
Note
The left pressure limiting valve is installed
in the same way as the right pressure
limiting valve

• Pull the new O-ring (2) onto the pressure limiting
valve (1)
• Screw in the pressure limiting valve (1) and tighten
to 100 Nm
Mounting the right rail cover lower section
• Position the rail cover lower section (2)

• Screw in the mounting bolt (1) with a new sealing
ring (3)
Installing the left rail
• Position the rail cover lower section (2)

• Screw in the mounting bolt (1) with a new sealing
ring (3)
• Fit a new O-ring (3)


COMMON-RAIL SYSTEM
Attaching the right rail return high-pressure line Attaching the cylinder 10 to 12 high-pressure
lines

• Attach the high-pressure line (1), ensuring that it Note
is strain-free, using the Angle extension [21] and High-pressure lines can be attached as a
Special spanner, size 17 [20] set or individually
torque 10 Nm
• Tighten the high-pressure line (1) to Initial • Remove the caps and plugs
torque 10 Nm if re-using • Attach the high-pressure lines (2), ensuring that
• Tighten the new high-pressure line (1) to Final they are strain-free, using the Angle extension [21]
torque 60° using the Angle extension [21] and the and Special spanner, size 17 [20]
Special spanner, size 17 [20] • Tighten the new high-pressure lines (2) to Initial
• Tighten the high-pressure line (1) to Final torque torque 10 Nm
30° with Angle extension [21] and Special spanner, • Tighten the high-pressure lines (2) to Initial
size 17 [20] if re-using torque 10 Nm if re-using
• Tighten the new high-pressure lines (2) to Final
Attaching the left rail return high-pressure line torque 60° with Angle extension [21] and Special
spanner, size 17 [20]
• Tighten the high-pressure lines (2) to Final torque
30° with Angle extension [21] and Special spanner,
size 17 [20] if re-using
• Position the pipe clamps (1) as marked
• Screw in and tighten the mounting bolts

torque 10 Nm
• Tighten the new high-pressure line (1) to Final
torque 60° using the Angle extension [21] and the
• Tighten the high-pressure line (1) to Final torque

COMMON-RAIL SYSTEM
Attaching the cylinder 4 to 6 high-pressure lines Attaching the cylinder 8 and 9 high-pressure
lines
Note
High-pressure lines can be attached as a Note
set or individually High-pressure lines can be attached as a
set or individually
• Attach the high-pressure lines (2), ensuring that • Remove the caps and plugs
they are strain-free, using the Angle extension [21] • Attach the high-pressure lines (2), ensuring that
and Special spanner, size 17 [20] they are strain-free, using the Angle extension [21]
• Tighten the new high-pressure lines (2) to Initial and Special spanner, size 17 [20]
torque 10 Nm • Tighten the new high-pressure lines (2) to Initial
• Tighten the high-pressure lines (2) to Initial torque 10 Nm
torque 10 Nm if re-using • Tighten the high-pressure lines (2) to Initial
• Tighten the new high-pressure lines (2) to Final torque 10 Nm if re-using
torque 60° with Angle extension [21] and Special • Tighten the new high-pressure lines (2) to Final
spanner, size 17 [20] torque 60° with Angle extension [21] and Special
• Tighten the high-pressure lines (2) to Final torque spanner, size 17 [20]
30° with Angle extension [21] and Special spanner, • Tighten the high-pressure lines (2) to Final torque
size 17 [20] if re-using 30° with Angle extension [21] and Special spanner,
• Position the pipe clamps (1) as marked size 17 [20] if re-using
• Screw in and tighten the mounting bolts • Position the pipe clamps (1) as marked

COMMON-RAIL SYSTEM
Attaching the cylinder 2 and 3 high-pressure Attaching the cylinder 1 high-pressure line
lines

Note • Attach the high-pressure line (1), ensuring that it
High-pressure lines can be attached as a is strain-free, using the Angle extension [21] and
set or individually Special spanner, size 17 [20]
torque 10 Nm
• Remove the caps and plugs • Tighten the high-pressure line (1) to Initial
• Attach the high-pressure lines (2), ensuring that torque 10 Nm if re-using
they are strain-free, using the Angle extension [21] • Tighten the new high-pressure line (1) to Final
and Special spanner, size 17 [20] torque 60° using the Angle extension [21] and the
• Tighten the new high-pressure lines (2) to Initial Special spanner, size 17 [20]
torque 10 Nm • Tighten the high-pressure line (1) to Final torque
• Tighten the high-pressure lines (2) to Initial 30° with Angle extension [21] and Special spanner,
torque 10 Nm if re-using size 17 [20] if re-using
• Tighten the new high-pressure lines (2) to Final
torque 60° with Angle extension [21] and Special Attaching the cylinder 7 high-pressure line
spanner, size 17 [20]
• Tighten the high-pressure lines (2) to Final torque
• Position the pipe clamps (1) as marked

torque 10 Nm

COMMON-RAIL SYSTEM
Mounting the pipe clamps Attaching the left rail high-pressure supply line
• Attach the pipe clamps (1) and (2) as marked • Remove the caps and plugs
Attaching the right rail high-pressure line is strain-free, using the Angle extension [21] and
torque 10 Nm
Mounting the pipe clamps

torque 10 Nm
size 17 [20] if re-using • Attach the pipe clamps (1) and (2) as marked

COMMON-RAIL SYSTEM
Mounting the left rail cover upper section Mounting the cover for the union nuts
• Position the rail cover upper section (1) • Position and close the cover for the union nuts (1)
• Screw in and tighten the mounting bolts (2) • Repeat the same procedure for all the
high-pressure lines
Mounting the right rail cover upper section
• Position the rail cover upper section (2)

Mounting the mounting plates
• Position the mounting plates (3) and (4) as marked


COMMON-RAIL SYSTEM
INJECTORS
Removing and installing the injectors
Additional jobs
– Removing and installing the high-pressure lines and rails, see 163
(1) Rocker arm mechanism (4) Injector

(2) Cylinder head cover (5) Pressure ange
(3) Gasket, cylinder head cover (6) Pressure screw
Technical data
Pressure screw (9) ............................................... M24x1.5 ........................................ Initial torque 20 Nm
Pressure screw (9) ............................................... M24x1.5 ..............................................Final torque 60°
Mounting bolt ....................................................... M8x55-10.9 ..................................... Initial torque 2 Nm
Mounting bolt ....................................................... M8x55-10.9 ......................................2nd torque 25 Nm
Mounting bolt ....................................................... M8x55-10.9 .........................................Final torque 90°
Rocker arm mechanism mounting bolt ................... M12x80-10.9......................................................90 Nm
Mounting bolt, rocker arm mechanism ................... M12x80-10.9........................................Final torque 90°
Service products

COMMON-RAIL SYSTEM
WARNING
personnel only
(desired value 0)
once
connections
WARNING
WARNING
Danger of damage due to leakage
• Check injector seat, rail and leakage oil lines for leaks after each installation
WARNING
WARNING
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
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
• Replace 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 reused bolts
• Do not re-use a pressure ange mounting bolt, even if it has only been used once.

COMMON-RAIL SYSTEM
Note
In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is
imprinted in the protective sleeves. This is integrated in the special tool designation (e.g. protective
sleeve, high-pressure line connection Z 14 x 15).
Special tools
[28] Storage sleeve 09.81020-1000
• Storing injectors
[29] End plug 81.96002-0520
• Plugging the cylinder head injector bore
[30] Injector nozzle protective sleeve 81.96002-0522
• Plugging the injector nozzle
[31] Injector feed bore cap 81.96002-0523
• Closing the injector feed bore
[32] End plug 81.96002-0541
• Plugging the bore for rail connections
[33] Extractor 80.99601-6022
• Extracting the injector in conjunction with:

• Plate [35]
• Support [36]
• Hexagon collar nut [37]
• Support [36]
• Knurled nut [34]
[34] Knurled nut 80.99602-0201

• Plate [35]
• Support [36]
• Extractor [33]

COMMON-RAIL SYSTEM
[35] Plate 80.99602-0176

• Extractor [33]
• Support [36]
[36] Support 80.99602-0193

• Extractor [33]
• Plate [35]
[37] Hexagon collar nut 06.11226-8306

• Extractor [33]
• Plate [35]
• Support [36]

• Adapter [39]
[39] Adapter 08.06139-9029

[40] Socket, size 7 08.06141-0700

• Adapter [39]
[41] Thrust piece 80.99606-0655
• Installing injectors

COMMON-RAIL SYSTEM
[42] Union nut 80.99603-0126
• Removing the rail connection
[43] Magnetic pick-up tool 80.99639-0009

COMMON-RAIL SYSTEM
Removing the injectors Removing the injector cable
• Mark the installation position of the injector cables

(1)
• Unscrew the mounting bolts (2) • Unscrew the mounting nuts from the injector
• Remove the cylinder head cover (1) • Remove the injector cable (1) from the cable
Removing the rail connection
Removing the gasket
• Undo the pressure screw (2)

• Screw the Union nut [42] (1) onto the rail • Remove the gasket (1)
connection (2) and tighten • Clean the mating faces
• Unscrew the pressure screw (2)
• Extract the rail connection from the cylinder head Unscrewing the pressure ange mounting bolt
with the Magnetic pick-up tool [43]
• Unscrew the Union nut [42] (1) and remove the
pressure screw (2)
• Plug the thread in the cylinder head with End
plug [32]

• Remove the spherical washer (2)

COMMON-RAIL SYSTEM
Removing the rocker arm mechanism Injector extraction instructions

WARNING
• Remove the rocker arm mechanism (4)
• Mark the installation position of the valve bridges
removal of the injector
(3)
• Always remove the relevant rail
• Remove the valve bridges (3)
connection (2) rst before removing
• Remove the push rods (1)
the injector (1)
Assembling the extractor tool for the injector • Always remove one injector only
Removing the injector
• Screw the Knurled nut [34] (3) onto the

Extractor [33] (6)
• Mount the Support [36] (1) and (5) with Hexagon WARNING
collar nut [37] (4) on the Plate [35] (2) Component damage due to incorrect
• Insert the Extractor [33] (6) into the Plate [35] (2) removal of the injector
• 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 [33] (3) in the groove of the
pressure ange (1) by turning the Knurled nut [34]
(4)
• Extract the injector with the pressure ange by
turning the Knurled nut [34] (4) at the Extractor [33]
• Remove the extractor tool (1)

COMMON-RAIL SYSTEM
Removing the sealing ring Installing the injectors

Inserting the injector
• Remove the pressure ange (5)

• Remove the O-ring (2) WARNING
• Plug the injector (3) with Injector nozzle protective Component damage due to dirty
sleeve [30] (6) and Injector feed bore cap [31] injector seat in the cylinder head
• Store the injector (3) in the Storage sleeve [28] • Check for cleanliness and to ensure
• Plug the injector bore in the cylinder head with End that there are no sealing rings on the
plug [29] (7) injector seat in the cylinder head.
Note
Always install the injector together with
the pressure ange.
It is not possible to install the pressure
ange afterwards.

• Align the bore for the rail connection port in the
injector (3) with the duct for the rail connection in
the cylinder head
• Fit a new O-ring (2) and new sealing ring (1) on
the injector (3)
• Lightly 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 pressure ange (5) into
the cylinder head
• Press the injector (3) fully into the cylinder head
with the Thrust piece [41] (4)

COMMON-RAIL SYSTEM
Installing the rocker arm mechanism Installing the rail connection
• Insert the push rods (1)

WARNING
• Put on the valve bridges (3) as marked
Danger of leaks in the common-rail
• Insert the rocker arm mechanism (4) in the push
system
rod cups and align
• Ensure that the thinner tip engages in
• Screw in new mounting bolts (2) and tighten to 90
the injector rail connection port
Nm
• Tighten the mounting bolts (2) to Final torque 90°
• Remove the protective sleeves
Injector initial torque • Insert the new rail connection (2) with the thin tip
facing the cylinder head
• Screw in the pressure screw (1) and tighten by
hand
• Tighten the pressure screw (1) to Initial torque 20
Nm
Injector/rail nal torque
• Screw in the new mounting bolt (1) with spherical

washer (2)
• Tighten the mounting bolt (1) to Initial torque 2 Nm
• Tighten the mounting bolt (2) to 2nd torque 25 Nm

• Tighten the mounting bolt (2) to Final torque 90°
• Tighten the pressure screw (1) to Final torque 60°
• Check the injector for leaks, see Checking the
injector seat, rail and leakage oil lines for leaks
- D2862LE4.., 201

COMMON-RAIL SYSTEM
Fitting the gasket Mounting the cylinder head cover
• Fit the gasket (1) • Fit the cylinder head cover (1)
Attaching the injector cable
WARNING
Component damage due to possible
short-circuit
• When tightening the mounting nuts,
make sure that the cable plugs do not
touch each other

marked
• Screw on the mounting nuts with the Torque
screwdriver [38] in conjunction with the
Adapter [39] and Socket, size 7 [40] and then
tighten to 1.5 Nm
• Lightly apply White T assembly paste on the cable
• Insert the injector cable (1) into the cable passage
in the gasket (2)

COMMON-RAIL SYSTEM
Checking the injector seat, rail and leakage oil lines for leaks - D2862LE4..
(1) Leakage oil line (3) Fuel line, leakage oil line - collector
(2) Fuel line, leakage oil line - collector (4) Leakage oil line
Technical data
Pressurisation, drip test ......................................................................................................... 3.0 - 3.5 bar
Pressure drop .......................................................................................................... 0.1 bar in 10 minutes
Hollow screw........................................................ M14x1.5 ............................................................40 Nm
WARNING
personnel only
(desired value 0)
once
connections

COMMON-RAIL SYSTEM
WARNING
WARNING
WARNING
Special tools
[44] Hand pump 80.99620-0029
• Checking the high-pressure pump for leaks in

conjunction with:
• Adapter [45]
• Threaded connection [46]
[45] Adapter 80.99620-0033
• Checking the high-pressure system for leaks
[46] Threaded connection 81.98130-0614
[47] End plug 81.96002-0519
• Female thread of union nuts
[48] Protective sleeve Z 16x1.5 81.96002-0513
• Plugging the fuel line connections

COMMON-RAIL SYSTEM
Installing the pressure loss tester Detaching the fuel line left leakage oil line –
collector
Detaching the right leakage oil line - collector
fuel line
• Unscrew the union nuts (1) and (3)

• Remove the fuel line (2)
• Unscrew the union nuts (1) and (3) • Plug the fuel line with End plug [47] and the
• Remove the fuel line (2) connections with Protective sleeve Z 16x1.5 [48]
• Plug the fuel line with End plug [47] and the
connections with Protective sleeve Z 16x1.5 [48] Mounting the pressure loss tester (left side)
Mounting the pressure loss tester (right side)
WARNING
Injectors can be damaged
WARNING • Pressurisation for leak test must not
Injectors can be damaged exceed 3.0 - 3.5 bar
• Pressurisation for leak test must not
exceed 3.0 - 3.5 bar • Remove the caps and plugs
• Mount the Adapter [45] (4) with the Threaded
• Remove the caps and plugs connection [46] (3) on the leakage oil line
• Mount the Adapter [45] (4) with the Threaded • Connect the Hand pump [44] (2) with the pressure
connection [46] (3) on the leakage oil line gauge (1) to the Threaded connection [46] (3)
• Connect the Hand pump [44] (2) with the pressure • Pressurise the Hand pump [44] (2) using
gauge (1) to the Threaded connection [46] (3) compressed air at 3.0 - 3.5 bar
• Pressurise the Hand pump [44] (2) using • Check the maximum permissible pressure loss on
compressed air at 3.0 - 3.5 bar the pressure gauge (1)
• Check the maximum permissible pressure loss on The desired pressure loss is max.
the pressure gauge (1) 0.1 bar in 10 minutes.
The desired pressure loss is max.
0.1 bar in 10 minutes.
If the fuel system is leaking, the affected parts
must be removed and then checked for damage or
If the fuel system is leaking, the affected parts contamination. Replace parts as necessary.
must be removed and then checked for damage or
contamination. Replace parts as necessary.

COMMON-RAIL SYSTEM
Removing the pressure loss tester Detaching the pressure loss tester (right side)
Detaching the pressure loss tester (left side)
• Disconnect the Hand pump [44] (2) with

the pressure gauge (1) from the Threaded
• Disconnect the Hand pump [44] (2) with connection [46] (3)
the pressure gauge (1) from the Threaded • Remove the Adapter [45] (4) with the Threaded
connection [46] (3) connection [46] (3)
• Remove the Adapter [45] (4) with the Threaded • Plug the fuel line with End plug [47] and the
connection [46] (3) connections with Protective sleeve Z 16x1.5 [48]
connections with Protective sleeve Z 16x1.5 [48] Attaching the right leakage oil line - collector fuel
line
Attaching the left leakage oil line – collector fuel
line

• Position the fuel line (2)
• Remove the caps and plugs • Screw on and tighten the union nuts (1) and (3)
• Screw on and tighten the union nuts (1) and (3)

COMMON-RAIL SYSTEM
HIGH-PRESSURE PUMP/HIGH-PRESSURE PUMP DRIVE

Removing and installing the high-pressure pump/high-pressure pump drive
Additional jobs
– Removing the intercooler, 1st stage, left, see 332
– Removing the intercooler, 1st stage, right, see 333
(1) High-pressure supply line (3) High-pressure pump, Slave

(2) High-pressure pump, Master
Technical data
Mounting bolts, high-pressure pump ................................................................................................60 Nm
High-pressure line (1) ........................................... M14x1.5 ........................................ Initial torque 10 Nm
High-pressure line (1) ........................................... M14x1.5 ..............................................Final torque 60°
High-pressure line re-use (1)................................. M14x1.5 ..............................................Final torque 30°
Oil ll quantity, high-pressure pump (2) and (3).................................................................................. 0.04 l
Oil ller plug ...................................................................................................................................18 Nm
Mounting bolt, drive gear....................................... M8x35-10.9 .......................................................30 Nm
Thrust washer mounting bolt ................................. M8x22-10.9 .......................................................30 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

COMMON-RAIL SYSTEM
WARNING
personnel only.
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.
(e.g. steam cleaner). The fuel system must be closed during this process.
• Do not reuse plugs for the high-pressure lines, rail, injectors or fuel lines, even if they have only
been used once
connections
• Always detach only one fuel line and then immediately plug the fuel line connections and
component connections
WARNING
WARNING
Special tools
• Detaching and attaching the high-pressure line in

conjunction with:
• Detaching and attaching the high-pressure line in

conjunction with:

COMMON-RAIL SYSTEM
Removing the high-pressure pump Removing the Master high-pressure pump
Detaching the high-pressure supply line
• Disconnect the metering unit electrical connection

• Mark the installation position of the clamping piece • Remove the Slave high-pressure pump (3)
(4) • Remove the O-rings (1) and (2)
• Unscrew the mounting bolt (1) • Clean the mating faces
• Remove the clamping plate (2) and clamping piece
(4) Removing the follower sleeve
• Detach the high-pressure supply lines (1) using
the Special spanner, size 17 [49] in conjunction
with the Angle extension [50]
Z 14 x 15 [16]
Unscrewing the high-pressure pump mounting

bolt
• Remove the follower sleeve (1)

• Unclip the circlip (2) and remove it

COMMON-RAIL SYSTEM
Removing the Master drive housing Removing the Slave drive housing
• Mark the installation position of the mounting bolts • Unscrew the mounting bolts (4)
(4) • Remove the drive housing (3)
• Unscrew the mounting bolts (4) • Remove the O-rings (1) and (2)
• Remove the drive housing (3)
• Remove the O-rings (1) and (2) Removing the Slave follower sleeve
Removing the Slave high-pressure pump
• Remove the follower sleeve (2)

• Unclip the circlip (1) and remove it
• Disconnect the metering unit electrical connection
• Remove the Slave high-pressure pump (1) Removing the thrust washer

• Remove the thrust washer (2) from the drive
housing (3)

COMMON-RAIL SYSTEM
Removing the drive gear Removing the metering unit
• Insert the drive shaft (4) with drive housing (2) into
WARNING
the follower sleeve (5)
• Clamp the follower sleeve (5) in a vice with
• Clean the components and blow them
protective jaws
dry using compressed air
• Unscrew the mounting bolts (1) for the drive gear
(3)
Removing the drive shaft • Extract the metering unit (1) by turning slightly to
the right/left
Removing the fuel pump
• Pull the drive shaft (1) out of the drive housing (2)
• Remove the drive gear (3)
WARNING
• Clean the components and blow them
dry using compressed air

• Pull out the fuel pump (1)
• Remove the coupling element (3) from the fuel
pump (1)

COMMON-RAIL SYSTEM
Installing the high-pressure pump Installing the drive shaft
Mounting the fuel pump
• Insert the drive gear (3)

• Insert the drive shaft (1) into the drive housing (2)
• Insert the coupling element (3) into the fuel pump
(1) Installing the drive gear
• Insert the fuel pump (1)
• Screw in new mounting bolts (2) and tighten them
to 8 Nm
Installing the metering unit
• Insert the drive shaft (4) with drive housing (2) into
the follower sleeve (5)
• Clamp the follower sleeve (5) in a vice with
protective jaws
• Screw in the mounting bolts (1) for the drive gear
Note (3) and tighten to 30 Nm
When using micro-encapsulated bolts,
Installing the thrust washer
the time between the tightening stages
must not be longer than 2 minutes
• Insert the metering unit (1)

• Tighten the mounting bolts (2) to Initial torque 3
Nm
• Tighten the mounting bolts (2) to Final torque 6
Nm
• Insert the thrust washer (2) into the drive housing

(3)

COMMON-RAIL SYSTEM
Installing the Slave follower sleeve Mounting the Master drive housing
• Attach the circlip (1) in the follower sleeve (2) • Insert the drive housing (3) with new O-rings (1)
• Insert the drive shaft into the follower sleeve (2) and (2)
Mounting the Slave drive housing marked
Installing the follower sleeve
• Insert the drive housing (3) with new O-rings (1)

and (2)
• Screw in new mounting bolts (4) and tighten them • Attach the circlip (2) in the follower sleeve (1)
to 60 Nm • Insert the drive shaft into the follower sleeve (2)
Installing the Slave high-pressure pump Installing the Master high-pressure pump
• Insert the Slave high-pressure pump (1) with new • Insert the Master high-pressure pump (3) with new
O-rings (2) and (3) O-rings (1) and (2)
• Connect the metering unit electrical connection • Screw in new mounting bolts (4) and tighten them
to 60 Nm
• Connect the metering unit electrical connection

COMMON-RAIL SYSTEM
Screwing in the high-pressure pump mounting Filling the Master and Slave high-pressure pump
bolt
• Unscrew the oil ller plug (1) with sealing ring

• Screw in new mounting bolt (1) and tighten to • Fill the high-pressure pump with 0.04 l of clean
60 Nm engine oil to MAN Standard 3277
• Screw in the oil ller plug (1) with a new sealing
Attaching the high-pressure supply line ring (2) and tighten to 18 Nm
• Remove the end plugs and protective sleeves

• Tighten the high-pressure line (3) to Initial torque
10 Nm using the Special spanner, size 17 [49] in
conjunction with the Angle extension [50]
• Position the clamping piece (4) and clamping plate
(2) as marked
• If using for the rst time, tighten the high-pressure
line (3) to Final torque 60° using the Special
spanner, size 17 [49] in conjunction with the Angle
extension [50]
• If re-using, tighten the high-pressure line (3) to
Final torque 30° using the Special spanner, size
17 [49] in conjunction with the Angle extension [50]

COMMON-RAIL SYSTEM
FUEL LINES
Removing and installing the fuel lines
(1) Fuel line, fuel lter - Master high-pressure (8) Fuel line, right leakage oil line return -
pump collector
(2) Fuel line, collector return - connecting (9) Leakage oil line, right
piece (10) Fuel line, Slave delivery pump -
(3) Fuel line, hand pump - Slave delivery connecting piece
pump (11) Fuel line, connecting piece - Slave
(4) Fuel line, Slave high-pressure pump return high-pressure pump
- collector (12) Fuel line, fuel lter - connecting piece
(5) Leakage oil line, left (13) Fuel line, connecting piece - fuel lter
(6) Fuel line, right rail return - collector (14) Fuel line, connecting piece - fuel lter
(7) Fuel line, left rail return - collector

COMMON-RAIL SYSTEM
WARNING
personnel only
value 0)
been used once
WARNING
WARNING
Special tools
[51] End plug (GPN 330 L18) 81.96002-0556
• Plugging the fuel lines
[52] End plug 81.96002-0521

COMMON-RAIL SYSTEM
[55] Cap 81.96002-0518
• Plugging ring unions

COMMON-RAIL SYSTEM
Removing the fuel lines Removing the fuel lter - high-pressure pump
fuel line
Removing the hand pump - Master delivery
pump fuel line
WARNING
• Unscrew the union nuts (1) and (2) electrics/electronic control unit
• Remove the fuel line (3) • Mark all electrical connections.
• Plug the fuel line with End plug (GPN 330 • Mark the attachment points for the
L18) [56] and the connections with Protective wiring harness on the engine.
sleeve Z 18x1.5 [60]
Removing the delivery pump - fuel lter fuel line • Release the plug connection for the fuel pressure
upstream of the Master high-pressure pump (8)
• Unscrew the union nuts for the fuel line (7)
• Unscrew the hollow screw (4) and remove the
sealing rings (1) and (3)
• Remove the connecting piece (2)
• Plug the fuel line with End plug (GPN 330
L18) [56] and the connections with Protective
sleeve Z 18x1.5 [60] and End plug [58]
• Unscrew the tting (6) and remove the sealing ring
(5)
• Plug the high-pressure pump with End plug [58]
Removing the high-pressure pump return -

connecting piece fuel line
• Unscrew the screw connection (3)
L18) [56] and Protective sleeve Z 14x1.5 [54]
and the connections with Protective sleeve Z
18x1.5 [60] and End plug [58]


COMMON-RAIL SYSTEM
Removing the collector return - connecting piece Removing the distributor - fuel lter fuel line
fuel line

• Unscrew the union nuts (1) and (3) • Unscrew the screw connection (2)
• Remove the fuel line (2) • Remove the fuel line (1)
• Plug the fuel line with End plug (GPN 330 • Plug the fuel line with End plug (GPN 330
L18) [56] and the connections with Protective L18) [56] and Protective sleeve Z 14x1.5 [54]
sleeve Z 18x1.5 [60] and the connections with Protective sleeve Z
18x1.5 [60] and End plug [58]
Removing the fuel lter - delivery pump fuel line
Removing the connecting piece - high-pressure
pump fuel line

• Unscrew the union nut (1) • Unscrew the hollow screw (2)
• Unscrew the screw connection (2) • Unscrew the union nuts (1)
• Plug the fuel line with End plug (GPN 330 • Plug the fuel line with End plug (GPN 330
L18) [56] and Protective sleeve Z 14x1.5 [54] L18) [56] and Protective sleeve Z 14x1.5 [54]
and the connections with Protective sleeve Z and the connections with Protective sleeve Z
18x1.5 [60] and End plug [58] 18x1.5 [60] and End plug [58]

COMMON-RAIL SYSTEM
Removing the hand pump - Slave delivery pump Removing the right leakage oil line - collector
fuel line fuel line
• Unscrew the hollow screw (1) • Unscrew the union nut (4)
• Unscrew the union nuts (3) • Unscrew the hollow screw (2) and remove the
• Remove the fuel line (2) sealing rings (1)
• Plug the fuel line with End plug (GPN 330 • Unscrew the clamp mounting bolt
L18) [56] and Protective sleeve Z 14x1.5 [54] • Remove the fuel line (3)
and the connections with Protective sleeve Z • Plug the fuel line with Cap [55] and End plug [58]
18x1.5 [60] and End plug [58] and the connections with End plug [58] and
Protective sleeve Z 14x1.5 [54]
Removing the Slave delivery pump - collector
fuel line Removing the right leakage oil line
• Unscrew the hollow screw (4) • Unscrew the hollow screws (1) and remove the
• Unscrew the hollow screw (2) and remove the sealing rings (3)
sealing rings (3) • Remove the leakage oil line (2)
• Remove the fuel line (1) • Plug the connections with End plug [58]
• Plug the fuel line with Cap [55] and Protective
sleeve Z 14x1.5 [54] and the connections with End
plug [58]

COMMON-RAIL SYSTEM
Removing the left leakage oil line - collector fuel Removing the right rail return - collector fuel line
line

• Unscrew the union nuts (1) and (3) sealing rings (3)
• Remove the fuel line (2) • Unscrew the hollow screw (1) and remove the
• Plug the fuel line with End plug (GPN 330 sealing rings (5)
L16) [65] and the connections with Protective • Remove the fuel line (4)
sleeve (Z16x8) [63] • Plug the fuel line with Cap [55] and the connections
with End plug [58]
Removing the left leakage oil line
• Unscrew the hollow screws (2) and remove the

sealing rings (1)
• Remove the leakage oil line (3)
• Plug the connections with End plug [58]

COMMON-RAIL SYSTEM
Installing the fuel lines Installing the left leakage oil line - collector fuel
line
Installing the right rail return - collector fuel line

• Remove the protective sleeves • Position the fuel line (2) so that it is strain-free
• Position the fuel line (4) so that it is strain-free • Screw on the union nuts (1) and (3)
• Screw in the hollow screw (2) with new sealing • Tighten the union nuts (1) and (3)
rings (3)
• Screw in the hollow screw (1) with new sealing Installing the right leakage oil line
rings (5)
Installing the left leakage oil line

• Position the fuel line (2) so that it is strain-free
• Screw in the hollow screws (1) with new sealing
rings (3)
• Remove the protective sleeves • Tighten the hollow screws (1)
• Screw in the hollow screws (2) with new sealing
rings (1)
• Tighten the hollow screws (2)

COMMON-RAIL SYSTEM
Installing the right leakage oil line - collector fuel Installing the hand pump - Slave delivery pump
line fuel line
• Remove the protective sleeves • Remove the protective sleeves

• Position the fuel line (3) so that it is strain-free • Position the fuel line (2) so that it is strain-free
• Screw on the union nut (4) • Screw on the union nut (3)
• Screw in the hollow screw (2) with new sealing • Screw in the hollow screw (1)
rings (1) • Tighten the hollow screws (1) and union nut (3)
• Screw in and tighten the clamp mounting bolt
• Tighten the hollow screws (1) and union nut (4) Installing the connecting piece - high-pressure
pump fuel line
Installing the Slave delivery pump - collector fuel
line

• Remove the protective sleeves • Screw on the union nut (1)
• Position the fuel line (1) so that it is strain-free • Screw in the hollow screw (2)
• Screw in the hollow screw (2) with new sealing • Tighten the hollow screw (2) and union nut (1)
rings (3)
• Screw in the hollow screw (4)

COMMON-RAIL SYSTEM
Installing the distributor - fuel lter fuel line Installing the collector return - connecting piece
fuel line

• Insert the fuel line (1) so that it is strain-free • Remove the protective sleeves
• Screw on the union nut (3) • Position the fuel line (2) so that it is strain-free
• Screw in the screw connection (2) • Screw on the union nuts (1) and (3)
• Tighten the union nut (3) and screw connection (2) • Tighten the union nuts (1) and (3)
Installing the fuel lter - delivery pump fuel line Installing the high-pressure pump return -
connecting piece fuel line

• Insert the fuel line (3) so that it is strain-free • Remove the protective sleeves
• Screw on the union nut (1) • Position the fuel line (2) so that it is strain-free
• Screw in the screw connection (2) • Screw on the union nuts (1) and (3)
• Tighten the union nut (1) and screw connection (2) • Tighten the union nuts (1) and (3)
• Screw on and tighten the nut (5)

COMMON-RAIL SYSTEM
Installing the fuel lter - high-pressure pump fuel Installing the hand pump - Master delivery pump
line fuel line
WARNING • Remove the protective sleeves

Danger of damage to the engine • Position the fuel line (3) so that it is strain-free
electrics/electronic control unit • Screw on the union nuts (1) and (2)
• Connect all electrical connections as • Tighten the union nuts (1) and (2)
marked.

• Screw in the tting (6) with a new sealing ring (5)
and then tighten
• Position the connecting piece (2) with new sealing
rings (1) and (3)
• Insert the fuel line (7) so that it is strain-free and
screw on the union nuts
• Tighten the hollow screw (4)
• Tighten the union nuts for the fuel line (7)
connection for the fuel pressure upstream of the
Master high-pressure pump
Installing the delivery pump - fuel lter fuel line

• Insert the fuel line (5) so that it is strain-free
• Screw in the union nut (3)
• Screw in the screw connection (1)

COMMON-RAIL SYSTEM
Removing and installing the fuel lines (classied variant)
(1) Connecting piece (4) Fuel line - fuel lter

(2) Fuel line, return connection (5) Fuel line, connecting piece - fuel lter
(3) Fuel line - fuel lter
Technical data
Pressure sensor ................................................... M14x1.5 ............................................................35 Nm
Pressure sensor .................................................. M14x1.5 ............................................................35 Nm

COMMON-RAIL SYSTEM
WARNING
personnel only
value 0)
been used once
WARNING
WARNING
Special tools
[56] End plug (GPN 330 L18) 81.96002-0556
[57] End plug 81.96002-0519
• Female thread of union nuts
[58] End plug 81.96002-0521
[59] End plug 81.96002-0679
• Plugging the fuel return line

COMMON-RAIL SYSTEM
[62] Protective sleeve Z 20x30 81.96002-0680

COMMON-RAIL SYSTEM
Removing the fuel lines Detaching the connecting piece - left lter fuel
line
Detaching the connecting piece - return
connection fuel line

• Unscrew the union nut (1) • Plug the fuel line with End plug (GPN 330
• Remove the fuel line (2) L18) [56] and the connections with Protective
• Plug the fuel line with End plug [59] and the sleeve Z 18x1.5 [60]
connections with Protective sleeve Z 20x30 [62]
Detaching the rear FPPE - left lter fuel line
Detaching the left lter - connecting piece fuel

line

• Unscrew the union nut (1) L18) [56] and the connections with Protective
• Remove the fuel line (2) sleeve Z 18x1.5 [60]

COMMON-RAIL SYSTEM
Detaching the rear FPPE - left lter fuel line Disconnecting the plug connections
• Unscrew the union nut (1) • Mark the installation position of the connectors (1),
• Remove the fuel line (2) (2), (3), (4) and (5)
• Plug the fuel line with End plug (GPN 330 • Pull off the connectors (1), (2), (3), (4) and (5)
sleeve Z 18x1.5 [60] Removing the pressure sensor
Detaching the rear HDPPE return - connecting

piece fuel line
• Mark the installation position of the pressure

sensor (2)
• Unscrew the pressure sensor (2) and remove it
• Unscrew the union nuts (1) and (3) with the sealing ring (1)
• Remove the fuel line (2) • Clean the mating faces
• Plug the fuel line with End plug (GPN 330 • Plug the connection with End plug [58]

COMMON-RAIL SYSTEM
Removing the temperature sensor Removing the pressure sensor
• Mark the installation position of the temperature • Mark the installation position of the pressure
sensor (2) sensor (1)
• Unscrew the temperature sensor (2) and remove • Unscrew the pressure sensor (1) and remove it
with the sealing ring (1) with the sealing ring (2)
• Clean the mating faces • Clean the mating faces
• Plug the connection with End plug [58] • Plug the connection with End plug [58]
Removing the pressure sensor Removing the pressure sensor
• Mark the installation position of the pressure • Mark the installation position of the pressure
sensor (2) sensor (2)
• Unscrew the pressure sensor (2) and remove it • Unscrew the pressure sensor (2) and remove it
with the sealing ring (1) with the sealing ring (1)
• Plug the connection with End plug [57] • Plug the connection with End plug [58]

COMMON-RAIL SYSTEM
Removing the temperature sensor Detaching the return - connecting piece fuel line
• Mark the installation position of the temperature • Unscrew the union nuts (1) and (3)
sensor (1) • Remove the fuel line (2)
• Unscrew the temperature sensor (1) and remove • Plug the fuel line with End plug [59] and the
it with the sealing ring (2) connections with Protective sleeve Z 20x30 [62]
• Plug the connection with End plug [57]
Detaching the left rail - collector fuel line
Removing the holding clips

• Mark the installation position of the holding clips • Remove the fuel line (2)
(1) and (2) • Plug the fuel line with End plug [57] and the
• Release the holding clips (1) and (2) connections with Protective sleeve Z 16x1.5 [61]

COMMON-RAIL SYSTEM
Detaching the distributor - front FPPE fuel line Detaching the connecting piece - front HDPPE
fuel line

• Remove the fuel line (2) • Unscrew the union nuts (1) and (3)
• Plug the fuel line with End plug (GPN 330 • Remove the fuel line (2)
L18) [56] and the connections with Protective • Plug the fuel line with End plug (GPN 330
sleeve Z 18x1.5 [60] L18) [56] and the connections with Protective
Detaching the front FPPE - distributor fuel line
Detaching the front HDPPE return fuel line

• Remove the fuel line (3) • Unscrew the union nuts (2) and (3)
• Plug the fuel line with End plug (GPN 330 • Remove the fuel line (1)
L18) [56] and the connections with Protective • Plug the fuel line with End plug (GPN 330
sleeve Z 18x1.5 [60] L18) [56] and the connections with Protective

COMMON-RAIL SYSTEM
Detaching the right leakage oil line - collector Detaching the left leakage oil line - collector fuel
fuel line line
• Unscrew the union nuts (1) and (3) • Unscrew the union nuts (2) and (3)
• Plug the fuel line with End plug [57] and the • Plug the fuel line with End plug [57] and the
connections with Protective sleeve Z 16x1.5 [61] connections with Protective sleeve Z 16x1.5 [61]
Detaching the right rail - collector fuel line Removing the connecting piece
• Unscrew the union nuts (2) and (3) • Unscrew the mounting bolts (2)
• Remove the fuel line (1) • Remove the connecting piece (1)
connections with Protective sleeve Z 16x1.5 [61]

COMMON-RAIL SYSTEM
Removing the adapter Installing the fuel lines

Mounting the holder
• Unscrew the mounting nuts (4) and pull out the

mounting bolts (3)
• Unscrew the mounting nuts (1) and remove with • Position the holder (1)
the washers (2) • Screw in and tighten the mounting bolts (2)
• Pull out the mounting bolts (5) with washers and
remove with adapter (7) and holder (6) Mounting the adapter
Removing the holder
• Position the adapter (7) and the holder (6)

• Insert the mounting bolts (5) with washers
• Unscrew the mounting bolts (2) • Screw on and tighten the mounting nuts (1) with
• Remove the holder (1) washers (2)
• Insert the mounting bolts (3)
• Screw on and tighten the mounting nuts (4)

COMMON-RAIL SYSTEM
Mounting the connecting piece Attaching the right leakage oil line - collector fuel
line
• Position the connecting piece (1)

• Screw in and tighten the mounting bolts (2) • Remove the caps and plugs
Attaching the left leakage oil line – collector fuel • Screw on and tighten the union nuts (1) and (3)
line
Attaching the front HDPPE return fuel line

• Position the fuel line (1) • Remove the caps and plugs
• Screw on and tighten the union nuts (2) and (3) • Position the fuel line (1)
Attaching the right rail - collector fuel line
Attaching the connecting piece - front HDPPE
fuel line

• Screw on and tighten the union nuts (2) and (3) • Remove the caps and plugs

COMMON-RAIL SYSTEM
Attaching the front FPPE - distributor fuel line Attaching the return - connecting piece fuel line
• Remove the caps and plugs • Remove the caps and plugs
• Position the fuel line (3) • Position the fuel line (2)
• Screw on and tighten the union nuts (1) and (2) • Screw on and tighten the union nuts (1) and (3)
Attaching the distributor - front FPPE fuel line Mounting the holding clips
• Remove the caps and plugs • Position the holding clips (1) and (2) as marked
• Position the fuel line (2) • Attach the holding clips (1) and (2)
Installing the temperature sensor
Attaching the left rail - collector fuel line
• Remove the plug

• Remove the caps and plugs • Clean the mating faces
• Position the fuel line (2) • Screw in the temperature sensor (1) with a new
• Screw on and tighten the union nuts (1) and (3) sealing ring (2) as marked
• Tighten the temperature sensor (1) to 48 Nm

COMMON-RAIL SYSTEM
Installing the pressure sensor Installing the pressure sensor
• Remove the plug • Remove the plug

• Screw in the pressure sensor (2) with a new • Screw in the pressure sensor (2) with a new
sealing ring (1) as marked sealing ring (1) as marked
• Tighten the pressure sensor (2) to 35 Nm • Tighten the pressure sensor (2) to 48 Nm
Installing the pressure sensor Installing the temperature sensor
• Remove the plug • Remove the plug

• Screw in the pressure sensor (1) with a new • Screw in the temperature sensor (2) with a new
sealing ring (2) as marked sealing ring (1) as marked
• Tighten the pressure sensor (1) to 35 Nm • Tighten the temperature sensor (2) to 35 Nm

COMMON-RAIL SYSTEM
Installing the pressure sensor Attaching the rear FPPE - left lter fuel line
• Remove the plug • Remove the caps and plugs

• Clean the mating faces • Position the fuel line (2)
• Screw in the pressure sensor (2) with a new • Screw on and tighten the union nut (1)
sealing ring (1) as marked
• Tighten the pressure sensor (2) to 35 Nm Attaching the rear FPPE - left lter fuel line
Connecting the plug connections

• Connect the connectors (1), (2), (3), (4) and (5) as • Screw on and tighten the union nut (1)
marked
Attaching the connecting piece - left lter fuel
Attaching the rear HDPPE return - connecting line
piece fuel line

• Remove the caps and plugs • Position the fuel line (2)
• Position the fuel line (2) • Screw on and tighten the union nut (1)

COMMON-RAIL SYSTEM
Attaching the left lter - connecting piece fuel

line

• Screw on and tighten the union nut (1)
Attaching the connecting piece - return

connection fuel line


COMMON-RAIL SYSTEM
FUEL FILTER
Removing and installing the fuel lter
(1) Mounting bolt (3) Fuel lter

(2) Washer
WARNING
• All work on components of the common rail system must be performed by specially trained
personnel only
been used once
WARNING

COMMON-RAIL SYSTEM
WARNING
Special tools
[63] Protective sleeve (Z16x8) 81.96002-0513
• Plugging the fuel lter connections
[64] Protective sleeve (GPN 695 BE10) 81.96002-0518
• Plugging the fuel line connection
[65] End plug (GPN 330 L16) 81.96002-0519

COMMON-RAIL SYSTEM
Removing the fuel lter Removing the fuel lter - high-pressure pump
fuel line
Removing the delivery pump - fuel lter fuel line
WARNING
L18) [56] and Protective sleeve Z 14x1.5 [54]
• Unlock the plug connection for the fuel pressure
and the connections with Protective sleeve Z
upstream of the Master high-pressure pump (8)
18x1.5 [60] and End plug [58]
• Unscrew the union nuts for the fuel line (7)
sealing rings (1) and (3)
• Remove the connecting piece (2)
sleeve Z 18x1.5 [60] and End plug [58]
• Unscrew the tting (6) and remove the sealing ring
(5)
• Plug the high-pressure pump with End plug [58]

COMMON-RAIL SYSTEM
Removing the fuel lter - delivery pump fuel line Removing the fuel lter
• Unscrew the mounting bolt (4) • Unscrew the mounting bolts (1)
• Remove the nut (5) • Remove the washers (2)
• Unscrew the union nut (1) • Remove the fuel lter (3)
• Unscrew the screw connection (2) • The second fuel lter is removed in the same way
sleeve (Z16x8) [63]
Removing the distributor - fuel lter fuel line

sleeve (Z16x8) [63]

COMMON-RAIL SYSTEM
Installing the fuel lter Installing the fuel lter - delivery pump fuel line
• Position the fuel lter (3) • Remove the protective sleeves

• Screw in and tighten the mounting bolts (1) with • Insert the fuel line (3) so that it is strain-free
washers (2) • Screw on the union nut (1)
• The second fuel lter is installed in the same way • Screw in the screw connection (2)
• Tighten the union nut (1) and screw connection (2)
Installing the distributor - fuel lter fuel line • Insert the mounting bolt (4)

• Screw on the union nut (3)
• Tighten the union nut (3) and screw connection (2)

COMMON-RAIL SYSTEM
Installing the fuel lter - high-pressure pump fuel

line
WARNING
marked.

• Screw in and tighten the tting (6) with a new
sealing ring (5)
• Position the connecting piece (2) with new sealing
rings (1) and (3)
• Insert the fuel line (7) so that it is strain-free and
screw on the union nuts
• Tighten the union nuts for the fuel line (7)
connection for the fuel pressure upstream of the
Master high-pressure pump
Installing the delivery pump - fuel lter fuel line

• Screw in the union nut (3)

COMMON-RAIL SYSTEM
Removing and installing the fuel lter (classied variant)
(1) Fuel lter
WARNING
• All work on components of the common rail system must be performed by specially trained
personnel only
been used once
WARNING
WARNING

COMMON-RAIL SYSTEM
Special tools
[66] End plug (GPN 330 L18) 81.96002-0556
[67] Protective sleeve (Z16x8) 81.96002-0513

COMMON-RAIL SYSTEM
Removing the fuel lter Detaching the fuel lter holder
Detaching the fuel lter fuel line

(1), (2) and (3)
• Undo the union nuts (1) • Unscrew the mounting nuts from the mounting
• Plug the fuel lines with End plug (GPN 330 bolts (1), (2) and (3)
L18) [66] and the connections with Protective • Remove the holder (4)
sleeve (Z16x8) [67]
Removing the carrier for the fuel lter
Removing the fuel lter

• Unscrew the mounting nut (4) • Remove the carrier (1)
• Pull out the mounting bolt (2) and remove with the
bush (3) Removing the retaining bracket for the fuel lter
• Unscrew and remove the mounting bolts (1)
• Remove the fuel lter (5)

• Remove the retaining bracket (2) with the bushes
(1)

COMMON-RAIL SYSTEM
Detaching the holder for the fuel lter Installing the fuel lter
Detaching the holder for the fuel lter
• Unscrew the mounting nut (8)

• Remove the angle bracket (9) with the mounting
bolt (10) • Position the holder (2) with the bush (1)
• Unscrew the mounting nut (6) and remove with the • Screw in and tighten the mounting bolt (3)
mounting bolt (5) • Position the holder (7), then screw in and tighten
• Unscrew the mounting bolt (4) and remove with the mounting bolt (4)
the holder (7) • Insert the mounting bolt (5), then screw on and
• Unscrew the mounting bolt (3) and remove with tighten the mounting nut (6)
the holder (2) and the bush (1) • Position the angle bracket (9) with the mounting
bolt (10)
• Screw on and tighten the mounting nut (8)
Mounting the retaining bracket for the fuel lter
• Position the retaining bracket (2) with the bushes

(1)

COMMON-RAIL SYSTEM
Mounting the carrier for the fuel lter Attaching the fuel lter fuel line
• Position the carrier (1) • Remove the protective sleeves and end plugs
• Screw in and tighten the mounting bolts (2) • Screw on and tighten the union nuts (1)
Mounting the fuel lter holder

• Insert the mounting bolts (1), (2) and (3) as marked
• Screw on and tighten the mounting nuts on the
mounting bolts (1), (2) and (3)
Mounting the fuel lter
• Position the fuel lter (5)

• Position the mounting bolt (2) with the bush (3)
• Tighten the mounting bolts (1)

COMMON-RAIL SYSTEM
Dismantling and assembling the fuel lter
(1) Housing (3) O-ring

(2) Fuel lter insert (4) Cover
Technical data
Cover (4)........................................................................................................................................20 Nm
Drain plug ....................................................................................................................................... 3 Nm
WARNING
once
WARNING
• Always allow the fuel lter cover to empty completely in order to remove dirt and impurities before
changing the fuel lter
WARNING
WARNING

COMMON-RAIL SYSTEM
Note
Special tools
[68] Hexagon socket wrench, size 36 80.99603-0385
• Removing and installing the fuel lter cover

COMMON-RAIL SYSTEM
Dismantling the fuel lter Removing the fuel lter insert
Allowing the fuel lter cover to empty
• Open the drain plug (1) and allow the fuel lter
cover to empty
• Tighten the drain plug (1) to 3 Nm
Removing the cover
• Remove the fuel lter insert (2) from the housing

(1)
• Unscrew the cover (3) from the housing (1) with

the Hexagon socket wrench, size 36 [68]

COMMON-RAIL SYSTEM
Assembling the fuel lter Removing the cover
Inserting the fuel lter insert
• Screw the cover (3) with a new O-ring (2) onto the
housing (1)
• Insert the new fuel lter insert (2) into the housing • Tighten the cover (3) to 20 Nm using the Hexagon
(1) socket wrench, size 36 [68]

COMMON-RAIL SYSTEM
Dismantling and assembling the fuel lter (classied variant)
(1) Fuel lter (11) Gasket

(2) Screw plug (12) Hexagon bolt
(3) Sealing ring (13) Hollow screw
(4) Wing screw (14) Ring connector
(5) Cover (15) Hollow screw
(6) Gasket (16) Threaded connection
(7) Locking washer (17) Hollow screw
(8) Cover (18) Distributor
(9) O-ring (19) Sealing ring
(10) Fuel lter insert
Technical data
Mounting bolt, cover ............................................. M114x50x10.9 ...................................................37 Nm
WARNING
once
WARNING
• Always allow the fuel lter cover to empty completely in order to remove dirt and impurities before
changing the fuel lter

COMMON-RAIL SYSTEM
WARNING
WARNING
Note

COMMON-RAIL SYSTEM
Dismantling the fuel lter Unscrewing the screw plugs
Removing the housing cover
• Unscrew the screw plugs (1), (2), (3), (4), (5), (6)
and (7) and remove with the sealing rings
• Unscrew the wing screws (1) • Clean the mating faces
• Remove the cover (5) with the gasket (4)
• Remove the locking washers (3) Removing the distributor
• Pull out the wing screws (1) and remove with the
sealing rings (2)
Removing the cover
• Mark the installation position of the ring connector

(5)
• Unscrew the hollow screw (7) and remove it with
the ring connector (5) and sealing rings (4) and (6)
• Unscrew the screw plug (8) and remove with the
• Unscrew the mounting bolt (1) and remove with sealing ring (9)
the sealing ring (2) • Unscrew the hollow screws (3) and (10) and
• Remove the O-ring (4) from the cover (5) remove with the sealing rings (11)
• Pull out the fuel lter (3) • Remove the distributor (2) with the sealing rings
• Clean the mating faces (1)

COMMON-RAIL SYSTEM
Removing the housing upper section Assembling the fuel lter

Assembling the distributor

• Remove the housing upper section (1) with the
sealing rings (2) • Clean the mating faces
• Clean the mating faces • Screw in and tighten the screw plugs (4) and (5)
with new sealing rings
Dismantling the distributor • Screw in and tighten the threaded connection (3)
with a new sealing ring
• Position the ring connector (2) with new sealing
rings as marked
• Screw in and tighten the hollow screw (1)
Mounting the housing upper section
• Mark the installation position of the ring connector

(2)
the ring connector (2) and sealing rings
• Unscrew the threaded connection (3) and remove
with the sealing ring
• Unscrew the screw plugs (4) and (5) and remove • Clean the mating faces
with the sealing rings • Position the housing upper section (1) with new
• Clean the mating faces sealing rings (2)
washers

COMMON-RAIL SYSTEM
Mounting the distributor Mounting the cover

• Position the distributor (2) with new sealing rings • Insert the new fuel lter (3)
(1) • Fit the new O-ring (4) on the cover (5)
• Screw in and tighten the hollow screws (3) and • Fit the cover (5)
(10) with new sealing rings (11) • Screw in the mounting bolt (1) with a new sealing
• Screw in and tighten the screw plug (8) with a new ring (2) and tighten to 37 Nm
sealing ring (9)
• Position the ring connector (5) with new sealing Mounting the housing cover
rings (6) as marked
• Screw in and tighten the hollow screw (7)
Screwing in the screw plugs

• Insert the wing screws (1) with new sealing rings
(2) into the cover (5)
• Mount the locking washers (3) on the wing screws
• Clean the mating faces (1)
• Screw in and tighten the screw plugs (1), (2), (3), • Put on the cover (5) with a new gasket (4)
(4), (5), (6) and (7) with new sealing rings • Screw in and tighten the wing screws (1)

COMMON-RAIL SYSTEM
HAND PUMP
Removing and installing the hand pump
Additional jobs
(1) Housing (3) Fuel pre-lter

(2) O-ring (4) Cover
Technical data
Cover, fuel pre-lter (4) ...................................................................................................................10 Nm
Knurled nut, hand pump................................................................................................................... 3 Nm
WARNING
WARNING

COMMON-RAIL SYSTEM
Note
Note
A check valve is integrated in the hand pump to prevent the fuel from owing back.

COMMON-RAIL SYSTEM
Removing the hand pump Installing the hand pump
• Unscrew the mounting bolts (1) • Position the hand pump (2)
• Remove the hand pump (2) • Screw in the mounting bolts (1) and tighten them

COMMON-RAIL SYSTEM
Dismantling and assembling the hand Assembling the hand pump

pump
Dismantling the hand pump
• Insert the new fuel pre-lter (3) into the housing (1)
• Screw on the cover (4) with a new O-ring (2)
• Tighten the cover to 10 Nm
• Unscrew the cover (4)
• Pull the fuel pre-lter (3) off the housing (1)

COMMON-RAIL SYSTEM
Removing and installing the hand pump (classied variant)
(1) Hand pump
WARNING
WARNING
Note
Note

COMMON-RAIL SYSTEM
Special tools
[69] End plug 81.96002-0556
• Plugging the hand pump connections

COMMON-RAIL SYSTEM
Removing the hand pump Detaching the hand pump
Detaching the fuel line
• Unscrew the mounting nuts (3)

• Pull out and remove the mounting bolts (1)
• Mark the installation position of the holding clips • Remove the hand pump (2)
(3) and (4)
• Remove the holding clips (3) and (4)
• Undo the union nuts (1) and (2)
connections with Protective sleeve Z 18 x 15 [70]
Detaching the fuel line
• Mark the installation position of the holding clips

(1) and (6)
• Unscrew the mounting nut (3) and remove the
mounting bolt (2)
• Unscrew the mounting nut (5) and remove the
mounting bolt (7)
• Undo the union nuts (4) and (8)
• Remove the fuel line
connections with Protective sleeve Z 18 x 15 [70]

COMMON-RAIL SYSTEM
Installing the hand pump Attaching the fuel line
Attaching the hand pump

• Position the hand pump (2) • Screw on and tighten the union nuts (1) and (2)
• Insert the mounting bolts (1) • Attach the holding clips (3) and (4) as marked
• Screw on and tighten the mounting nuts (3)
Attaching the fuel line

• Position the fuel line
• Install the holding clips (1) and (6) in the installation
position as marked

COMMON-RAIL SYSTEM
Dismantling and assembling the hand pump

Additional jobs
– Removing and installing the hand pump (classied variant), see 263
(1) Housing (3) Fuel pre-lter

(2) O-ring (4) Cover
Technical data
Fuel pre-lter cover.........................................................................................................................10 Nm
Knurled nut, hand pump................................................................................................................... 3 Nm
Service products
Fuel ..........................................see Maintenance Recommendations and Recommended Service Products
WARNING
WARNING

COMMON-RAIL SYSTEM
Note
Note
Special tools
[71] End plug (GPN 330 L18) 81.96002-0556

COMMON-RAIL SYSTEM
Dismantling the hand pump Assembling the hand pump

Dismantling the hand pump Installing the fuel pre-lter
• Mark the installation position of the WVE • Clean the mating faces
connection (1) • Thinly apply clean Fuel on the new O-ring (2)
• Unscrew the WVE connection (1) • Pull the new O-ring (2) onto the hand pump (1)
• Unscrew the hollow screw connector (2) and • Insert the fuel pre-lter (3)
remove it with sealing rings and ring union (3) • Screw on the cover (4) and tighten to 10 Nm
• Unscrew the plug (6)
• Unscrew the adapter tting (7) and remove it with Assembling the hand pump
the sealing ring
• Mark the installation position of the WVE
connection (5)
• Unscrew the WVE connection (5)
• Unscrew the threaded connection (4) and remove
with the sealing ring
• Plug the hand pump connections with End plug
(GPN 330 L18) [71]
Removing the fuel pre-lter
• Remove the end plug from the hand pump

• Screw in and tighten the threaded connection (4)
with a new sealing ring
• Screw on and tighten the WVE connection (5) as
marked
• Position the ring union (3) with new sealing rings
• Screw in and tighten the hollow screw connector
(2)
• Screw on and tighten the WVE connection (1) as
marked
• Unscrew the cover (4) • Screw in and tighten the adapter tting (7) with a
• Pull out the fuel pre-lter (3) new sealing ring
• Remove the O-ring (2) from the hand pump (1) • Screw on and tighten the plug (6)

TURBOCHARGING
TURBOCHARGING
(1) Turbocharger, 1st stage, right (4) Turbocharger, 2nd stage, left
(2) Turbocharger, 2nd stage, right (5) Turbocharger, 1st stage, left
(3) Exhaust manifold

TURBOCHARGING
EXHAUST MANIFOLD DOWNSTREAM OF TURBOCHARGER

Removing and installing the exhaust manifold (one-stage variant)
Additional jobs
– Draining and topping up the coolant, see Operator's Manual
(1) Exhaust manifold (2) Coolant line, return
Technical data
Hose clamp..................................................................................................................................... 5 Nm
Service products
Technical Vaseline .....................see Maintenance Recommendations and Recommended Service Products
WARNING

TURBOCHARGING
Removing the exhaust manifold Removing the exhaust manifold
Detaching the return coolant line
• Unscrew the mounting nuts (2) and remove with

the washers (1)
• Unscrew the mounting nut (2) and pull out the • Mark the installation position of the mounting bolts
mounting bolt (4) (6) and (7)
• Undo the hose clamps (1) and (3) • Unscrew and remove the mounting bolts (6) and
• Remove the coolant line (5) (7)
• Pull out and remove the exhaust manifold (5)
Detaching the return coolant line • Remove the O-rings (3) and (4)
Removing the left adapter ange
• Unscrew and remove the mounting bolt (2)

• Unscrew and remove the mounting bolt (4)
• Undo the hose clamp (1) • Mark the installation position of the holder (4)
• Remove the coolant line (3) • Unscrew the mounting nut (3) and remove with the
holder (4) and the bush (1)
• Unscrew the mounting nut (2)

TURBOCHARGING
Removing the left adapter ange Removing the right adapter ange
• Mark the installation position of the mounting bolts • Mark the installation position of the mounting bolts
(1) and (7) (3) and (4)
• Unscrew and remove the mounting bolts (1) and • Unscrew and remove the mounting bolts (3) and
(7) (4)
• Pull out the adapter ange (2) and remove with the • Pull out the adapter ange (2) and remove with the
gaskets (3) and (6) gaskets (1) and (6)
• Pull out the unscrewed conduits (4) and remove • Pull out the unscrewed conduit (5) and remove the
the O-rings (5) O-rings
Removing the right adapter ange mounting

nuts

TURBOCHARGING
Mounting the exhaust manifold Mounting the left adapter ange
Mounting the right adapter ange

• Thinly apply Technical Vaseline on the new O-rings
• Clean the mating faces (5) and t them on the unscrewed conduit (4)
• Thinly apply Technical Vaseline on the new O-rings • Insert the unscrewed conduit (4)
and t them on the unscrewed conduit (5) • Position the adapter ange (2) with new gaskets
• Insert the unscrewed conduit (5) (3) and (6)
• Position the adapter ange (2) with new gaskets • Screw in and tighten the mounting bolts (1) and
(1) and (6) (7) as marked
(4) as marked Mounting the left adapter ange
Mounting the right adapter ange mounting nuts
• Position the holder (4) with the bush (1) as marked

• Screw on and tighten the mounting nuts (1) • Screw on and tighten the mounting nut (2)

TURBOCHARGING
Mounting the exhaust manifold Attaching the return coolant line
• Insert the new O-rings (3) and (4) into the adapter • Position the coolant line (5) with hose clamps (1)
anges and (3)
• Position the exhaust manifold (5) • Mount the hose clamps (1) and (3) in the
• Screw in and tighten the mounting bolts (6) and installation position and tighten to 5 Nm
(7) as marked • Insert the mounting bolt (4)
• Screw on and tighten the mounting nuts (2) with • Screw on and tighten the mounting nut (2)
washers (1)
Attaching the return coolant line
• Position the coolant line (3) with the hose clamp

(1)
• Mount the hose clamp (1) in the installation
position and tighten to 5 Nm

TURBOCHARGING
Removing and installing the exhaust manifold (two-stage variant)

Additional jobs
(1) Intermediate ange (4) Clamping piece

(2) Prole clip (5) Clamp
(3) Exhaust manifold (6) Intermediate ange
Technical data
Mounting bolt, adapter ange ................................ M10x60-10.9......................................................45 Nm
Mounting bolt, adapter ange ................................ M8 ....................................................................35 Nm
Clamp (2) and (5) ................................................. Ø170 .................................................................12 Nm
Hose clamp..................................................................................................................................... 5 Nm
Service products
WARNING

TURBOCHARGING
Removing the exhaust manifold Detaching the hose
Removing the holder
• Undo the hose clamp (1)

• Pull off the hose (2)
• Remove the holders (1) and (4) Removing the left coolant manifold
Removing the coolant manifold
• Undo the hose clamps (1)

• Undo the hose clamps (2) • Remove the retainer (5)
• Unscrew the mounting bolt (6) • Remove the coolant manifold (3) with hose (2)
• Remove the retainer (7) • Remove the O-ring (4)
• Unscrew the mounting bolt (8) • Pull off the hose (2)
• Remove the retainer (9) • Clean the mating faces
• Remove the coolant manifolds (1) and (4) with
hose (3) Detaching the right moulded hose
• Remove the hose (3) with the hose clamps (2)
• Undo the hose clamps (2)

• Pull off the moulded hose (1)

TURBOCHARGING
Detaching the coolant line Removing the left adapter ange
• Unscrew the hollow screw (1) and remove the • Unscrew the mounting bolts (1) and (4)
sealing rings (5) • Remove the adapter ange (2)
• Unscrew the hose tting (3) and remove the • Remove the gasket (3)
sealing rings (4) • Clean the mating faces
• Remove the coolant line (2)
Removing the right adapter ange
Removing the exhaust manifold

• Unfasten the clamps (1) and (7) • Remove the adapter ange (3)
• Remove the exhaust manifold (3) • Remove the gasket (4)
• Remove the gaskets (2) and (6) • Clean the mating faces
• Pull off the clamping piece (5)

TURBOCHARGING
Mounting the exhaust manifold Mounting the exhaust manifold
Mounting the right adapter ange

new O-ring (4) and contact surface
• Position the adapter ange (3) with a new gasket • Insert a new O-ring (4) on the exhaust manifold
(4) • Position the clamping piece (5)
• Screw in the mounting bolts (1) and (2) • Position a new gasket (2) on the right adapter
• Tighten the mounting bolts (1) to 35 Nm using the ange
45 Nm and (2) • Position the exhaust manifold (3) with a new
gasket (6)
Mounting the left adapter ange • Mount the clamps (1) and (7) and tighten to 12 Nm
Attaching the coolant line
• Position the adapter ange (2) with a new gasket

(3)
• Screw in the mounting bolts (1) and (4)
• Tighten the mounting bolts (1) to 35 Nm using the • Position the coolant line (2) with new sealing rings
45 Nm and (4) (5) so that it is strain-free
• Screw in the hose tting (3) with new sealing rings
(4)
• Tighten the hose tting (3) and hollow screw (1)

TURBOCHARGING
Attaching the right moulded hose Mounting the coolant manifold
• Position the hose clamps (2) on the moulded hose • Thinly apply Renolit Si 704 silicone grease on the
(1) new O-rings (5) and (10) and the contact surfaces
• Position the moulded hose (1) with the hose • Insert a new O-ring (10) into the coolant manifold
clamps (2) (1)
• Tighten the hose clamps (2) to 5 Nm • Insert a new O-ring (5) into the coolant manifold
(4)
Mounting the left coolant manifold • Position the hose (3) with hose clamps (2) on the
coolant manifolds (1) and (4)
• Position the coolant manifolds (1) and (4) with the
hose (2)
• Position the retainer (7)
• Screw in the mounting bolt (6) and tighten to
35 Nm
• Position the retainer (9)
35 Nm
• Tighten the hose clamps (2) and (4) to 5 Nm
Attaching the hose
• Position the holders (1) and (4)

• Screw in mounting bolts (2) and (3) and tighten to
35 Nm
• Position the hose (2) with the hose clamp (1)

• Tighten the hose clamp (1) to 5 Nm

TURBOCHARGING
EXHAUST MANIFOLD UPSTREAM OF TURBOCHARGER

Removing and installing the exhaust manifold upstream of the turbocharger
(one-stage variant)
Additional jobs
– Removing and installing the exhaust manifold (one-stage variant), see 273
– Removing and installing the turbocharger (one-stage variant), see 293
(1) Control valve, charge pressure, left (5) Exhaust manifold, right
(2) Hose line, control valve, left (6) Temperature sensor
(3) Hose line, control valve, right (7) Control valve, charge pressure, right
(4) Exhaust manifold upstream of (8) Exhaust manifold upstream of
turbocharger, right turbocharger, left
Technical data
Service products

TURBOCHARGING
WARNING

TURBOCHARGING
Removing the exhaust manifold Removing the coolant manifold

upstream of the turbocharger
Removing the temperature sensor
• Mark the mounting bolts (4) and (5)

• Unscrew and remove the mounting bolts (4) and
(5)
• Unscrew the temperature sensor (2) and remove • Remove the coolant manifold (3) with unscrewed
it with the sealing ring (1) conduit (1) and O-ring (2)
Detaching the left hose line Removing the left shield (classied variant)
• Unscrew and remove the mounting bolt (4) • Unscrew and remove the mounting bolts (1)
• Undo the union nut (2) • Remove the shield (2)
the sealing rings
• Remove the hose line (3)

TURBOCHARGING
Removing the left charge-pressure control valve Removing the left exhaust manifold
• Mark the installation position of the mounting bolts • Mark the mounting bolts (2), (6) and (7)
(3) and (4) • Unscrew and remove the mounting bolts (2)
• Unscrew the mounting bolts (3) and (4) and • Unscrew and remove the mounting bolts (6) and
remove with the holder (1) (7) with washers
• Remove the control valve (2) • Remove the exhaust manifold (5) with the coolant
line (4)
Removing the exhaust manifold upstream of the • Remove the O-rings (1), (3), (8) and (9)
turbocharger on the left • Clean the mating faces
Removing the left support
• Mark the mounting bolts (2), (4) and (5)

• Unscrew and remove the mounting bolts (2), (4)
and (5) • Unscrew and remove the mounting bolts (2)
• Remove the exhaust manifold (1) with O-rings (3) • Remove the support (1)
and (6)

TURBOCHARGING
Detaching the right hose line Removing the coolant manifold
• Unscrew and remove the mounting bolts (2) • Mark the mounting bolts (3) and (5)
• Undo the union nuts (3) and (4) • Unscrew and remove the mounting bolts (3) and
• Remove the hose line (1) (5)
• Remove the coolant manifold (2) with O-rings (1)
Removing the right shield (classied variant) and (4)
Removing the exhaust manifold upstream of the

turbocharger on the right

• Remove the shield (2)
Removing the right charge-pressure control

valve • Mark the mounting bolts (2) and (4)
(4)
• Remove the exhaust manifold (1) with O-rings (3)
and (5)

the holder (1)
• Remove the control valve (2)

TURBOCHARGING
Removing the right exhaust manifold Mounting the exhaust manifold

upstream of the turbocharger
Mounting the right support
• Mark the mounting bolts (2), (3) and (7)

(7) with washers • Position the support (1)
• Remove the exhaust manifold (8) with the coolant • Screw in and tighten the mounting bolts (2)
line (9)
• Remove the O-rings (1), (4), (5) and (6) Mounting the right exhaust manifold
Removing the right support

(1), (4), (5) and (6)
• Unscrew and remove the mounting bolts (2) • Insert new O-rings (1), (4), (5) and (6)
• Remove the support (1) • Position the exhaust manifold (8) with the coolant
line (9)
(7) with washers as marked

TURBOCHARGING
Mounting the exhaust manifold upstream of the Mounting the right charge-pressure control
turbocharger on the right valve
• Clean the mating faces • Insert the control valve (2)

• Thinly apply Technical Vaseline on the new O-rings • Position the holder (1)
(3) and (5) • Screw in and tighten the mounting bolts (3)
• Position the exhaust manifold (1) with new O-rings
(3) and (5) Mounting the right shield
(4) as marked
Mounting the coolant manifold
• Position the shield (2)

Attaching the right hose line

(1) and (4)
• Position the coolant manifold (2) with new O-rings
(1) and (4)
(5) as marked
• Position the hose line (1)


TURBOCHARGING
Mounting the left support Mounting the exhaust manifold upstream of the
turbocharger on the left
• Position the support (1)

• Screw in and tighten the mounting bolts (2) • Clean the mating faces
Mounting the left exhaust manifold (3) and (6)
• Position the exhaust manifold (1) with new O-rings
(3) and (6)
• Screw in and tighten the mounting bolts (2), (4)
and (5) as marked
Mounting the left charge-pressure control valve

(1), (3), (8) and (9)
• Insert new O-rings (1), (3), (8) and (9)
• Position the exhaust manifold (5) with the coolant
line (4)
• Screw in and tighten the mounting bolts (6) and • Position the control valve (2)
(7) with washers as marked • Position the holder (1)
• Screw in and tighten the mounting bolts (2) • Screw in and tighten the mounting bolts (3) and
(4) as marked

TURBOCHARGING
Mounting the left shield Attaching the left hose line
• Position the shield (2) • Position the hose line (3)

• Screw in and tighten the mounting bolts (1) • Screw in the hollow screw (1) with new sealing
rings
Mounting the coolant manifold • Screw on and tighten the union nut (2)
Mounting the temperature sensor

• Thinly apply Technical Vaseline on the new O-ring
(2) and new unscrewed conduit (1)
• Position the coolant manifold (3) with a new
unscrewed conduit (1) and a new O-ring (2) • Clean the mating faces
• Screw in and tighten the mounting bolts (4) and • Screw in the temperature sensor (2) with a new
(5) as marked sealing ring (1) and tighten to 47 Nm

TURBOCHARGING
TURBOCHARGER
Removing and installing the turbocharger (one-stage variant)
Additional jobs
– Removing and installing the exhaust manifold (one-stage variant), see 273
(1) Turbocharger, left (2) Turbocharger, right
Technical data
Turbocharger mounting nuts ................................. M10...................................................................65 Nm
Hose clamp..................................................................................................................................... 5 Nm
Service products
Engine oil..................................see Maintenance Recommendations and Recommended Service Products
WARNING

TURBOCHARGING
Removing the turbocharger Detaching the left turbocharger oil pressure line
Removing the left charge-air manifold

• Undo the union nut (1)
• Undo the clamp (4) • Remove the oil pressure line (2) with the gasket
• Remove the charge-air manifold (2) with O-rings (4)
(1) and (3) • Clean the mating faces
Detaching the oil return line

• Unscrew and remove the mounting bolts (3) • Undo the hose clamps (5)
• Remove the coolant manifold (2) with O-rings (1) • Remove the oil return line (3) with the gasket (1)
and (4) • Remove the moulded hose (4)

TURBOCHARGING
Detaching the left coolant line Removing the right charge-air manifold
• Unscrew the mounting bolts (3) and (4) • Undo the clamp (2)
• Remove the coolant line (1) with gaskets (2) and • Remove the charge-air manifold (4) with O-rings
(5) (1) and (3)
Removing the left turbocharger Detaching the right coolant line
• Loosen the hose clamp (3) and push onto the hose
CAUTION
• Remove the coolant line (4) with gasket (2)
components
• Only lift the turbocharger with support
• Unscrew the nuts (3)

• Remove the turbocharger (1)
• Remove the gasket (2)

TURBOCHARGING
Detaching the oil return line Removing the right turbocharger
• Unscrew the mounting bolt (5) and remove with

CAUTION
the washer
components
• Pull off the oil return line (3) and remove with the
gasket (2) and the O-ring (4)
Detaching the oil pressure line ange • Remove the turbocharger (1)
Detaching the oil pressure line
• Undo the union nut (4)

• Remove the ange (2) with the gasket (3)
• Mark the installation position of the oil pressure
line (5)
• Detach the oil pressure line (5)
• Mark the installation position of the ring union (3)
• Unscrew the hollow screw (1)
• Remove the ring union (3) with the sealing rings
(2) and (4)

TURBOCHARGING
Installing the turbocharger Attaching the oil return line
Attaching the oil pressure line

• Thinly apply Technical Vaseline on a new O-ring
• Clean the mating faces (4) and t it on the oil return line (3)
• Position the ring union (3) with new sealing rings • Insert the oil return line (3) into the tting
(2) and (4) as marked • Position the oil return line (3) with a new gasket (2)
• Screw in and tighten the hollow screw (1) • Screw in and tighten the mounting bolts (1)
• Screw on and tighten the oil pressure line (5) as • Screw in and tighten the mounting bolt (5) with the
marked washer
Mounting the right turbocharger Attaching the right coolant line
CAUTION • Clean the mating faces

Danger of injury due to heavy • Position the coolant line (4) with a new gasket (2)
components • Screw in and tighten the mounting bolts (1)
• Only lift the turbocharger with support • Mount the hose clamp (3) in the installation
• Position the turbocharger (1) with a new gasket (3)
• Screw on the nuts (2) and tighten to 65 Nm

TURBOCHARGING
Filling the right turbocharger with oil Mounting the right charge-air manifold

WARNING
• Position the charge-air manifold (4) with the clamp
Component damage when the engine
(2) and new O-rings (1) and (3)
is started for the rst time
• Tighten the clamp (2)
• Fill the turbocharger with clean engine
oil before attaching the oil pressure Mounting the left turbocharger
lines
• Use a funnel (1) to pour clean Engine oil into the

oil feed hole on the turbocharger (2) until the oil
duct in the turbocharger (2) is full
Attaching the oil pressure line ange
CAUTION
components

• Clean the mating faces • Position the turbocharger (1) with a new gasket (2)
• Position the ange (2) with a new gasket (3) • Screw on the nuts (3) and tighten to 65 Nm

TURBOCHARGING
Attaching the left coolant line Filling the left turbocharger with oil

WARNING
• Position the coolant line (1) with new gaskets (2)
and (5)
Attaching the oil return line oil before attaching the oil pressure
lines
• Use a funnel (1) to pour clean Engine oil into the

oil feed hole on the turbocharger (2) until the oil
duct in the turbocharger (2) is full
Attaching the left turbocharger oil pressure line

• Position the moulded hose (4) and the oil return
line (3) with the hose clamps (5)
• Mount the hose clamps (5) in the installation
• Position the oil return line (3) with a new gasket (1)
• Screw in and tighten the mounting bolts (2) • Clean the mating faces
• Position the oil pressure line (2) with a new gasket
(4)

TURBOCHARGING

• Position the coolant manifold (2) with new O-rings
(1) and (4)
Mounting the left charge-air manifold

• Position the charge-air manifold (2) with new
O-rings (1) and (3)
• Tighten the clamp (4)

TURBOCHARGING
Removing and installing the turbocharger (two-stage variant)

Additional jobs
– Removing and installing the exhaust manifold (two-stage variant), see 278
(1) Oil pressure line, turbocharger, 1st stage, (8) Oil return line, turbocharger, 2nd stage, left
right (9) Turbocharger, 2nd stage, left
(2) Turbocharger, 1st stage, right (10) Lower housing section, turbocharger, 2nd
(3) Oil pressure line, turbocharger, 2nd stage, stage, left
right (11) Upper housing section, turbocharger, 2nd
(4) Coolant line, turbocharger, 1st stage, right stage, left
(5) Housing, turbocharger, 2nd stage, right (12) Oil pressure line, turbocharger, 2nd stage,
(6) Turbocharger, 2nd stage, right left
(7) Oil return line, turbocharger, 2nd stage, (13) Oil return line, turbocharger, 1st stage, left
right (14) Turbocharger, 1st stage, left
Technical data
Mounting nuts, turbocharger.................................. M10...................................................................65 Nm
Mounting bolts, turbocharger................................. M10x135HWF....................................................65 Nm
Mounting bolts, turbocharger................................. M10x145HWF....................................................65 Nm
Exhaust manifold mounting bolts ........................... M12x1.5 .......................................................... 110 Nm
Hose clamp..................................................................................................................................... 5 Nm
Service products

TURBOCHARGING
Loctite 5900 ...................................................................................................................... 04.10394-9292

Omnit green .................................................................................................................... 04.10394-9272
WARNING
Special tools
[72] Hose clamp pliers for jubilee clips 80.99625-0073
• Removing and installing jubilee clips

TURBOCHARGING
Removing the left turbocharger Detaching the oil return line - turbocharger, 1st
stage, left
Detaching the oil pressure line - turbocharger,
2nd stage, left

• Unclip the jubilee clips (3) and (5) using the Hose
• Unscrew the oil pressure line (2) screw connection clamp pliers for jubilee clips [72]
and remove the oil pressure line (2) • Remove the oil return line (2) with the gasket (1)
• Unscrew the tting (1) • Remove the moulded hose (4)
• Unscrew the hollow screw (5) and remove it with • Clean the mating faces
the sealing rings (4)
• Remove the ring union (3) Detaching the oil return line - turbocharger, 2nd
stage, left
1st stage, left
clamp pliers for jubilee clips [72]
• Unscrew the oil pressure line (5) screw connection • Unscrew the mounting bolt (5)
and remove the oil pressure line (5) • Remove the oil return line (3)
• Unscrew the ttings (4) and (6) • Remove the hoses (2) and (4)

TURBOCHARGING
Detaching the coolant moulded hose - Removing the coolant manifold

turbocharger, 1st stage, left

• Undo the hose clamps (2) bolts (1)
• Remove the moulded hose (1) with the hose • Unscrew the mounting bolts (1)
clamps (2) • Remove the coolant manifold (2) with O-ring (3)
Removing the turbocharger, 1st stage, left • Clean the mating faces

• Remove the gasket (2) • Unscrew the mounting bolts (6)
• Clean the mating faces • Remove the coolant manifold (2)

TURBOCHARGING
Removing the left turbocharger bearing block Removing the assembly - turbocharger, 2nd
cooling stage, left

CAUTION
bolts (2)
components
• Remove the coolant manifold (3) with the O-ring
• Only lift the assembly with support
(1)
• Remove the unscrewed conduit (5) with the
O-rings (4)
bolts (3)
Removing the exhaust manifold support • Remove the turbocharger assembly (2)
Removing the left upper housing section

• Remove the bracket (1)

bolts (1)
• Remove the upper housing section (1)
• Remove the O-rings (3), (4) and (6)

TURBOCHARGING
Installation position of the mounting bolts - Removing the left exhaust manifold
turbocharger, 2nd stage, left
• Mark the position of the exhaust manifold (1)

• Installation position of nut (1) relative to the turbocharger
• Installation position of mounting bolts (2) • Unscrew the mounting bolts (5)
Removing the turbocharger, 2nd stage, left • Remove the exhaust manifold (1) with the gasket
(4)
Removing the unscrewed conduit


(4)
• Unscrew the nut (3)
• Remove the gaskets (2) and (8)

TURBOCHARGING
Removing the left lower housing section Removing the right turbocharger
2nd stage, right

(2) and (4)
• Unscrew the nut (5) • Unscrew the oil pressure line (1) screw connection
• Remove the lower housing section (1) and remove the oil pressure line (1)
• Remove the O-ring (3) • Unscrew the hollow screw (3) and remove it with
• Clean the mating faces the sealing rings (2)
• Remove the ring union (4)
Removing the charge pressure control valve
1st stage, right
• Mark the installation position of the charge

pressure control valve (2)
• Unscrew the mounting bolts (1) • Unscrew the oil pressure line (4) screw connection
• Remove the charge pressure control valve (2) and remove the oil pressure line (4)
• Clean the mating faces • Unscrew the tting (5)

TURBOCHARGING
Detaching the oil return line - turbocharger, 1st Detaching the coolant line
stage, right

• Unscrew the mounting bolts (5) and (8) (3) and (4)
• Unclip the jubilee clips (3) using the Hose clamp • Unscrew the mounting bolts (3) and (4)
pliers for jubilee clips [72] • Remove the coolant line (2) with the O-ring (5)
• Remove the oil return lines (2) and (4) with the • Remove the gasket (1)
gasket (1) and the O-ring (6) • Clean the mating faces
• Remove the hose (7)
• Clean the mating faces Removing the turbocharger, 1st stage, right
Detaching the oil return line - turbocharger, 2nd

stage, right

• Unclip the jubilee clips (1) and (5) using the Hose • Clean the mating faces
• Remove the oil return line (3)
• Remove the hoses (2) and (4)

TURBOCHARGING
Removing the coolant manifold Removing the coolant manifold
• Remove the coolant manifold (1) with O-ring (3) • Remove the coolant manifold (2)
• Remove the unscrewed conduit (4) • Remove the O-rings (1) and (4)
• Clean the mating faces • Remove the unscrewed conduit (5)
Removing the right turbocharger bearing block • Clean the mating faces
cooling
Removing the exhaust manifold support

bolts (2) • Unscrew the mounting bolts (1) and (3)
• Unscrew the mounting bolts (2) • Remove the bracket (2)
• Remove the coolant manifold (2) with the O-ring
(1)
• Remove the unscrewed conduit (5) with the
O-rings (4)

TURBOCHARGING
Removing the assembly - turbocharger, 2nd Installation position of the mounting bolts -
stage, right turbocharger, 2nd stage, right
• Installation position of nut (1)

CAUTION
• Installation position of mounting bolts (2)
components Removing the turbocharger, 2nd stage, right

(3) and (5)
• Remove the turbocharger assembly (1)
Removing the right upper housing section

bolts (2)
• Remove the upper housing section (1)
• Remove the O-rings (4) • Mark the installation position of the mounting bolts
• Remove the unscrewed conduit (3) (7) and (8)
• Clean the mating faces • Unscrew the mounting bolts (7) and (8)
• Remove the gaskets (3) and (9)

TURBOCHARGING
Removing the right exhaust manifold Removing the right lower housing section
• Mark the position of the exhaust manifold (6) • Mark the installation position of the mounting bolts
relative to the turbocharger (1) (1) and (3)
• Unscrew the mounting bolts (5) • Unscrew the mounting bolts (1) and (3)
• Unscrew the nuts (4) • Unscrew the nut (2)
• Remove the exhaust manifold (6) with the gasket • Remove the lower housing section (5)
(2) • Remove the O-ring (4)
• Remove the O-ring (3) • Clean the mating faces
Removing the charge pressure control valve
Removing the unscrewed conduit
• Mark the installation position of the charge

• Remove the unscrewed conduit (1) pressure control valve (1)
• Remove the O-rings (2) • Unscrew the mounting bolts (2)
• Clean the mating faces • Remove the charge pressure control valve (1)

TURBOCHARGING
Installing the right turbocharger Checking the restrictors
Installing the charge pressure control valve
• Check whether the restrictors (1) are inserted and

xed
• Insert the charge pressure control valve (1) as Insert loose restrictors (1) after cleaning the contact
marked surface with Omnit green
Mounting the right exhaust manifold
Mounting the right lower housing section

• Thinly apply Loctite 5900 on the mating face of the new O-ring (3)
lower housing section (5) • Insert the O-ring (3)
• Thinly apply Renolit Si 704 silicone grease on the • Position the exhaust manifold (6) on the
new O-ring (4) turbocharger (1) with a new gasket (2) as marked
• Insert the O-ring (4) • Screw in the mounting bolts (5)
• Position the lower housing section (5) • Screw on the nuts (4)
• Screw in the mounting bolts (1) and (3) as marked • Tighten the mounting bolts (5) to 65 Nm and nuts
• Screw on and tighten the nut (2) (4) to 65 Nm
• Tighten the mounting bolts (1) and (3)

TURBOCHARGING
Installing the unscrewed conduit Mounting the turbocharger, 2nd stage, right

new O-rings (2)
• Position the O-rings (2) and the unscrewed conduit
(1)
Installation position of the mounting bolts -

turbocharger, 2nd stage, right

• Position the unscrewed conduit (4) with O-rings
(2) and (5)
• Position the turbocharger (1) with new gaskets (3)
and (9)
• Screw in the mounting bolts (7) and (8) as marked
• Screw on the nut (6)
• Installation position of nut (1) • Tighten the mounting bolts (7) and (8) to 65 Nm
• Installation position of mounting bolts (2) and the nut (3) to 65 Nm

TURBOCHARGING
Mounting the right upper housing section Mounting the exhaust manifold support
• Thinly apply Renolit Si 704 silicone grease on the • Position the bracket (2)
new O-rings (4) and the unscrewed conduit (3) • Screw in the mounting bolts (1)
• Position the O-rings (4) and the unscrewed conduit • Screw in the mounting bolts (3)
(3) • Tighten the mounting bolts (1) and (3)
• Thinly apply Loctite 5900 on the mating face of the
upper housing section (1) Installing the right turbocharger bearing block
• Position the upper housing section (1) cooling
marked
Mounting the assembly - turbocharger, 2nd

stage, right

(5)
• Insert the O-ring (1)
CAUTION • Position the coolant manifold (2) with the
Danger of injury due to heavy unscrewed conduit (5)
components • Screw in and tighten the mounting bolts (3) as
• Only lift the assembly with support marked

new O-rings (4)
• Insert the O-rings (4)
• Position the new gasket (2)
• Position the turbocharger assembly (1)
(5) as marked and then tighten to 110 Nm

TURBOCHARGING
Mounting the coolant manifold Mounting the turbocharger, 1st stage, right
• Thinly apply Renolit Si 704 silicone grease on the • Position the turbocharger (1) with a new gasket (2)
new O-rings (1), (4) and (6) • Screw on the nuts (3) and tighten to 65 Nm
• Insert the O-rings (1), (4) and (6)
• Insert the unscrewed conduit (5) into the coolant Attaching the coolant line
manifold (2)
• Position the coolant manifold (2) with the
unscrewed conduit (5)

new O-ring (5)
• Position the coolant line (2) with a new gasket (1)
(4) as marked
new O-ring (3) and the unscrewed conduit (4)
• Position the O-ring (3) and the unscrewed conduit
(4)

TURBOCHARGING
Attaching the oil return line - turbocharger, 2nd Filling the turbocharger with oil
stage, right
WARNING
• Position the oil return line (3) with hose (2) and (4)
• Clip in the jubilee clips (1) and (5) using the Hose
Attaching the oil return line - turbocharger, 1st oil before attaching the oil pressure
stage, right lines
• Use funnels (1) and (2) to ll clean Engine oil into
the oil feed holes on the turbochargers (3) and (4)
until the oil ducts of the turbochargers (1) and (2)
are full
• Position the hose (7)
new O-ring (6)
• Position the oil return line (2) with O-ring (6)
• Clip in the jubilee clips (3) using the Hose clamp
pliers for jubilee clips [72]

TURBOCHARGING
Attaching the oil pressure line - turbocharger, Attaching the oil pressure line - turbocharger,
1st stage, right 2nd stage, right
WARNING WARNING
Component damage when the engine Component damage when the engine
is started for the rst time is started for the rst time
• Fill the turbocharger with clean engine • Fill the turbocharger with clean engine
oil to MAN Standard 3277 oil to MAN Standard 3277
• Pour clean engine oil to MAN Standard 3277 into • Pour clean engine oil to MAN Standard 3277 into
the oil pressure connection on the turbocharger the oil pressure connection on the turbocharger
using a funnel until the oil duct is full using a funnel until the oil duct is full
• Position the ange (1) with a new gasket (3) • Screw in the hollow screw (3) with new sealing
• Screw in the mounting bolts (2) rings (2) and ring union (4)
• Position the oil pressure line (4) and tting (5) • Position the oil pressure line (1)
• Screw on the oil pressure line (4) screw connection • Screw on the oil pressure line (1) screw connection
and tting (5) • Tighten the hollow screw (3)
• Tighten the mounting bolts (2) • Tighten the oil pressure line (1) screw connection
• Tighten the oil pressure line (4) screw connection
and tting (5)

TURBOCHARGING
Installing the left turbocharger Checking the restrictors
Installing the charge pressure control valve
• Check whether the restrictors (1) are inserted and

xed
• Insert the charge pressure control valve (2) as Insert loose restrictors (1) after cleaning the contact
marked surface with Omnit green
Installing the unscrewed conduit
Mounting the left lower housing section

• Thinly apply Loctite 5900 on the mating face of the new O-rings (2)
lower housing section (1) • Position the O-rings (2) and the unscrewed conduit
• Thinly apply Renolit Si 704 silicone grease on the (1)
new O-ring (3)
• Position the lower housing section (1)

TURBOCHARGING
Mounting the left exhaust manifold Mounting the turbocharger, 2nd stage, left

new O-ring (3)
• Position the exhaust manifold (1) on the
turbocharger with a new gasket (4), as marked
• Screw on the nuts (2)
• Tighten the mounting bolts (5) to 65 Nm and nuts
(2) to 65 Nm
Installation position of the mounting bolts -

turbocharger, 2nd stage, left

• Position the unscrewed conduit (6) with O-rings
(5) and (7)
• Position the turbocharger (1) with new gaskets (2)
and (8)
• Screw in the mounting bolts (4) as marked
• Screw on the nut (3)
• Tighten the mounting bolts (4) to 65 Nm and the
nut (3) to 65 Nm
• Installation position of nut (1)

• Installation position of mounting bolts (2)

TURBOCHARGING
Mounting the left upper housing section Mounting the exhaust manifold support
• Position the bracket (1)

CAUTION
components
Installing the left turbocharger bearing block
• Thinly apply Renolit Si 704 silicone grease on cooling
the new O-rings (3), (4), (6) and the unscrewed
conduit (5)
• Position the O-rings (3), (4), (6) and the unscrewed
conduit (5)
• Thinly apply Loctite 5900 on the mating face of the
upper housing section (1)
• Position the upper housing section (1)
marked
Mounting the assembly - turbocharger, 2nd

stage, left

(5)
marked

• Insert the O-rings (1) and (4)
• Position the new gasket (5)
• Position the turbocharger assembly (2)
to 110 Nm

TURBOCHARGING
Mounting the coolant manifold Mounting the turbocharger, 1st stage, left
• Thinly apply Renolit Si 704 silicone grease on the • Position the turbocharger (1) with a new gasket (2)
new O-rings (1), (3) and (5) • Screw on the nuts (3) and tighten to 65 Nm
• Insert the O-rings (1), (3) and (5)
• Insert the unscrewed conduit (4) into the coolant Attaching the coolant moulded hose -
manifold (2) turbocharger, 1st stage, left
• Position the coolant moulded hose (1) with the

hose clamps (2)
• Tighten the hose clamps to 5 Nm

new O-ring (3) and the unscrewed conduit (4)
• Insert the O-ring (3) and the unscrewed conduit
(4)

TURBOCHARGING
Attaching the oil return line - turbocharger, 2nd Filling the turbocharger with oil
stage, left
WARNING
• Position the oil return line (3) with hoses (2) and
(4)
oil before attaching the oil pressure
lines
Attaching the oil return line - turbocharger, 1st
• Use funnels (1) and (2) to ll clean Engine oil into
stage, left
the oil feed holes on the turbochargers (3) and (4)
until the oil ducts of the turbochargers (1) and (2)
are full
• Position the moulded hose (4)

TURBOCHARGING
Attaching the oil pressure line - turbocharger, Attaching the oil pressure line - turbocharger,
1st stage, left 2nd stage, left
WARNING WARNING
Component damage when the engine Component damage when the engine
is started for the rst time is started for the rst time
• Fill the turbocharger with clean engine • Fill the turbocharger with clean engine
oil to MAN Standard 3277 oil to MAN Standard 3277
• Pour clean engine oil to MAN Standard 3277 into • Pour clean engine oil to MAN Standard 3277 into
the oil pressure connection on the turbocharger the oil pressure connection on the turbocharger
using a funnel until the oil duct is full using a funnel until the oil duct is full
• Position the ange (2) with a new gasket (1) • Screw in the hollow screw (5) with new sealing
• Screw in the mounting bolts (3) rings (4) and ring union (3)
• Position the oil pressure line (5) with ttings (4) • Position the oil pressure line (2) with tting (1)
and (6) • Screw on the oil pressure line (2) screw connection
• Screw on the oil pressure line (5) screw connection and tting (1)
and ttings (4) and (6) • Tighten the hollow screw (5)
• Tighten the mounting bolts (3) • Tighten the oil pressure line (2) screw connection
• Tighten the oil pressure line (5) screw connection and tting (1)
and ttings (4) and (6)

TURBOCHARGING
CHARGE-AIR PIPES
Removing and installing the charge-air pipes
Additional jobs
(1) Intercooler, 2nd stage (4) Intercooler, 1st stage, left

(2) Intercooler, 1st stage, right (5) Charge-air manifold
(3) Air ducting manifold
Technical data
Clamp.................................................................. Ø 92 ................................................................... 7 Nm
Clamp.................................................................. Ø 108 ................................................................. 7 Nm
Clamp.................................................................. Ø 140 ................................................................. 7 Nm
Service products
Loctite 2701 ...................................................................................................................... 04.10160-9353
WARNING

TURBOCHARGING
Removing the charge air pipes Removing the air ducting manifold
Removing the left air ducting manifold holder

• Remove the nuts (9)
• Mark the installation position of the mounting bolts • Remove the air ducting manifold (5)
(1) and (2) • Pull the unscrewed conduits (2) off the air ducting
• Unscrew the mounting bolts (1) and (2) manifold (5)
• Remove the holder (3) • Remove the O-rings (1) and (3)
• Mark the installation position of the mounting bolts • Pull the unscrewed conduits (7) off the air ducting
(4) and (5) manifold (5)
• Unscrew the mounting bolts (4) and (5) • Remove the O-rings (6) and (8)
Removing the charge-air manifold, 1st stage, left
Removing the right air ducting manifold holder
• Undo the clamp (2)

• Mark the installation position of the mounting bolts • Remove the charge-air manifold (6) with O-ring (1)
(1) and (6) • Pull off the unscrewed conduit (4)
• Unscrew the mounting bolts (1) and (6) • Remove the O-rings (3) and (5)
(4) and (5)

TURBOCHARGING
Removing the charge-air manifold, 2nd stage, Removing the charge-air manifold, 2nd stage,
left right
• Mark the installation position of the mounting bolts • Mark the installation position of the mounting bolts
(3) (3)
• Remove the charge-air manifold (2) with O-ring (1) • Remove the charge-air manifold (2) with O-ring (1)
• Pull off the unscrewed conduit (5) • Pull off the unscrewed conduit (5)
• Remove the O-rings (4) and (6) • Remove the O-rings (4) and (6)
• Undo the clamp (9) • Undo the clamp (9)
• Remove the charge-air manifold (7) with O-ring (8) • Remove the charge-air manifold (7) with O-ring (8)
Removing the charge-air manifold, 1st stage,
right

• Remove the charge-air manifold (4) with O-ring (3)
• Pull off the unscrewed conduit (6)

TURBOCHARGING
Installing the charge air pipes Mounting the charge-air manifold, 2nd stage, left
Mounting the charge-air manifold, 1st stage,

right

new O-rings (1), (4), (6) and (8)
• Position the charge-air manifold (2) with O-ring (1)
• Thinly apply Renolit Si 704 silicone grease on the • Screw in the mounting bolts (3) as marked
new O-rings (1), (3) and (5) • Insert the O-rings (4) and (6) into the charge-air
• Insert the O-rings (1) and (5) into the intercooler manifolds (2) and (7)
charge-air manifold (4) • Insert the unscrewed conduit (5) into the
• Insert the unscrewed conduit (6) into the charge-air manifold (2)
charge-air manifold (4) • Position the charge-air manifold (7) with clamp (9)
• Position the charge-air manifold (4) with O-ring (3) • Tighten the clamp (9) to 7 Nm
• Tighten the clamp (2) to 7 Nm • Tighten the mounting bolts (3)
Mounting the charge-air manifold, 2nd stage, Mounting the charge-air manifold, 1st stage, left
right

• Thinly apply Renolit Si 704 silicone grease on the new O-rings (1), (3) and (5)
new O-rings (1), (4), (6) and (8) • Insert the O-rings (3) and (5) into the charge-air
• Position the charge-air manifold (2) with O-ring (1) manifold (6) and intercooler
• Screw in the mounting bolts (3) as marked • Insert the unscrewed conduit (4) into the
• Insert the O-rings (4) and (6) into the charge-air charge-air manifold (6)
manifolds (2) and (7) • Position the charge-air manifold (6) with O-ring (1)
• Insert the unscrewed conduit (5) into the • Tighten the clamp (2) to 7 Nm
charge-air manifold (2)
• Position the charge-air manifold (7) with clamp (9)
• Tighten the clamp (9) to 7 Nm

TURBOCHARGING
Mounting the air ducting manifold Mounting the left air ducting manifold holder
• Thinly apply Renolit Si 704 silicone grease on the • Position the holder (3)
new O-rings (1), (3), (6) and (8) • Screw in and tighten the mounting bolts (1) and
• Insert the O-rings (1) and (3) into the air ducting (2) as marked
manifold (5) and intercooler hood • Position the holder (6)
• Insert the unscrewed conduit (2) into the air • Screw in and tighten the mounting bolts (4) and
ducting manifold (5) (5) as marked
• Insert the O-rings (6) and (8) into the air ducting
manifold (5) and charge-air manifold
• Insert the unscrewed conduit (7) into the air
ducting manifold (5)
• Position the air ducting manifold (5)
the nut (9)
Mounting the right air ducting manifold holder

(6) as marked
(5) as marked

TURBOCHARGING
INTERCOOLER
Removing and installing the intercooler
Additional jobs
(1) Intercooler, 2nd stage (4) Intercooler, 1st stage, left

(2) Intercooler, 1st stage, right (5) Charge-air manifold
(3) Air ducting manifold
WARNING
Special tools
[73] Eye-bolt 80.99606-0660
• Lifting off the intercooler

TURBOCHARGING
Removing the intercooler, 1st stage, left Removing the intercooler holder, 1st stage, left
Removing the intercooler

• Remove the bushes (1) and (6)
• Mark the installation position of the mounting bolts • Remove the holders (3) and (4)
(1), (4) and (5)
• Unscrew the mounting bolts (1), (4) and (5)
• Remove the bushes (2), (3) and (8)
Removing the intercooler, 1st stage, left

• Screw in the Eye-bolt [73] and lift off the intercooler
(3)

TURBOCHARGING
Removing the intercooler, 1st stage, Removing the intercooler holder, 1st stage, right
right

• Remove the holders (3) and (4)
(2) and (4)
Removing the intercooler, 1st stage, right
• Screw in the Eye-bolt [73] and lift off the intercooler

(1)

TURBOCHARGING
Removing the intercooler, 2nd stage Lifting off the intercooler
Removing the intercooler holder, 2nd stage
• Lift off the intercooler (2)

• Remove the holder (2) Removing the charge-air manifold
Removing the front intercooler mounting

(1), (4), (6) and (7)
• Unscrew the mounting bolts (1), (4), (6) and (7)
• Remove the charge-air manifolds (2) and (8)
• Mark the installation position of the mounting bolts • Remove the gaskets (3) and (5)
(1) • Clean the mating faces

• Screw in the Eye-bolt [73]

TURBOCHARGING
Installing the intercooler, 2nd stage Attaching the front intercooler mounting
Removing the charge-air manifold

marked
• Position the charge-air manifolds (2) and (8) with
new gaskets (3) and (5) Removing the intercooler holder, 2nd stage
• Screw in and tighten the mounting bolts (1), (4),
(6) and (7) as marked
Positioning the intercooler

• Insert the O-rings (1) and (3)
• Position the intercooler (2)
Mounting the intercooler

• Unscrew the Eye-bolt [73]

TURBOCHARGING
Mounting the intercooler, 1st stage, right Tightening the intercooler holder mounting
bolts, 1st stage, right
Mounting the intercooler holder, 1st stage, right

• Screw in the mounting bolts (1) and (5) with the
bushes (2) and (6)
Positioning the intercooler, 1st stage, right
• Position the intercooler (1) and unscrew the

Eye-bolt [73]
Mounting the intercooler, 1st stage, right

(4) as marked with bushes (1) and (3)

TURBOCHARGING
Mounting the intercooler, 1st stage, left Tightening the intercooler holder mounting
bolts, 1st stage, left
Mounting the intercooler holder, 1st stage, left

• Screw in the mounting bolts (2) and (5) with the
bushes (1) and (6)
Positioning the intercooler, 1st stage, left
• Position the intercooler (3) and unscrew the

Eye-bolt [73]
• Screw in and tighten the mounting bolts (1), (4)

and (5) as marked with bushes (2), (3) and (6)

TURBOCHARGING
AIR DISTRIBUTOR PIPE

Removing and installing the air distributor pipes
Additional jobs
(1) Right air distributor pipe (2) Left air distributor pipe
WARNING

TURBOCHARGING
Detaching the air distributor pipe Attaching the air distributor pipe
Detaching the left air distributor pipe Attaching the left air distributor pipe
• Mark the installation position of the mounting bolts • Position the air distributor pipe (5) with new
(1), (2) and (3) gaskets (6)
• Unscrew the mounting bolts (1), (2) and (3) • Position the holder (4)
• Remove the holder (4) • Screw in and tighten the mounting bolts (1), (2)
• Remove the air distributor pipe (5) with the gaskets and (3) as marked
(6)
• Clean the mating faces Attaching the right air distributor pipe
Detaching the right air distributor pipe
• Position the air distributor pipe (6) with new

gaskets (3)
• Mark the installation position of the mounting bolts • Position the holder
(1), (2), (4) and (5) • Screw in and tighten the mounting bolts (1), (2),
• Unscrew the mounting bolts (1), (2), (4) and (5) (4) and (5) as marked
• Remove the holder
• Remove the air distributor pipe (6) with the gaskets
(3)

TURBOCHARGING
AIR FILTER
Removing and installing the air lter
Additional jobs
– Removing and installing the suction vacuum sensor, see 82
(1) Air lter, right (5) Clamp

(2) Hose clamp (6) Intake tting
(3) Intake pipe (7) Hose clamp
(4) Clamp (8) Air lter, left
Technical data
Hose clamp (2), (7)............................................... Ø 160 ................................................................. 7 Nm
Clamp (4), (5)....................................................... Ø 163 ................................................................. 7 Nm
Service products
WARNING

TURBOCHARGING
Special tools
• Removing and installing the jubilee clips

TURBOCHARGING
Removing and installing the air lter Installing the air lter
Removing the air lter Mounting the intake tting
• Undo the hose clamp (2) • Thinly apply Renolit Si 704 silicone grease on the
• Remove the air lter (1) with hose clamp (2) new O-rings (3)
• Insert the O-rings (3) into the intake tting (1)
Detaching the vent line • Position the intake tting (1)
• Position the clamp (2) and tighten it to 7 Nm
Attaching the vent line
• Remove the moulded hose (2)
• Position the moulded hose (2)
Removing the intake tting • Position and clip in the jubilee clips (1) and (3)
using the Hose clamp pliers for jubilee clips [74]

• Remove the intake tting (1)

TURBOCHARGING
Mounting the air lter
• Position the air lter (1) with the hose clamp (2)
• Tighten the hose clamp (2) to 7 Nm

TURBOCHARGING
EXHAUST SYSTEM
Removing and installing the exhaust system
Additional jobs
(1) Exhaust pipe (6) Cover

(2) Flange (7) Mounting bolt
(3) Inner exhaust pipe, T-piece (8) Mounting bolt
(4) Gasket (9) Inner exhaust pipe, manifold
(5) O-ring (10) Mounting bolt
Technical data
Mounting bolt ....................................................... M10x55 HWF.....................................................45 Nm
Mounting bolt ....................................................... M8x120 HFW.....................................................28 Nm
Service products

TURBOCHARGING
WARNING

TURBOCHARGING
Removing the exhaust system Mounting the exhaust system

Removing the cover Attaching the exhaust pipe
• Unscrew the mounting bolts (4) • Position the exhaust pipe (2) with new gaskets (1)
• Remove the cover (3) with the gasket (2) and the • Screw in the mounting bolts (3) and tighten them
O-rings (1) to 45 Nm
Removing the inner exhaust pipes Installing the inner exhaust pipes
• Pull off the ange (1) • Position the inner exhaust pipe T-piece (2)
• Unscrew the mounting bolts (3) • Screw in the mounting bolts (3)
• Remove the inner exhaust pipes (2) and (4) • Repeat the steps for the remaining inner exhaust
pipe T-pieces (2)
Detaching the exhaust pipe • Position the inner exhaust pipe manifold (4)
• Insert the ange (1) into the exhaust pipe

• Remove the exhaust pipe (2) with the gaskets (1)

TURBOCHARGING
Mounting the cover

new O-rings (1)
• Insert the O-rings (1) into the exhaust pipe
• Position the cover (3) with the gasket (2)

CYLINDER HEAD
CYLINDER HEAD
(1) Push rods (6) Cylinder head

(2) Mounting bolt, rocker arm mechanism (7) Cylinder head bolt
(3) Intake valve rocker arm (8) Exhaust valve bridge
(4) Lock nut (9) Exhaust valve rocker arm
(5) Intake valve bridge

CYLINDER HEAD
CYLINDER HEAD
Removing and installing the rocker arm mechanism
(1) Push rods (4) Exhaust valve bridge

(2) Mounting bolts, rocker arm mechanism (5) Rocker arm mechanism
Technical data
Mounting bolt, rocker arm mechanism (2) .............. M12x80-10.9......................................................90 Nm
Mounting bolt, rocker arm mechanism (2) .............. M12x80-10.9........................................Final torque 90°

CYLINDER HEAD
Special tools

• Adapter [76]
[76] Adapter 08.06139-9029

[77] Socket, size 7 08.06141-0700

• Adapter [76]

CYLINDER HEAD
Removing the rocker arm mechanism Removing the rocker arm mechanism

• Remove the rocker arm mechanism (1)
• Unscrew the mounting bolts (2) • Mark the installation position of the valve bridges
• Remove the cylinder head cover (1) (3)
• Remove the valve bridges (3)
Removing the injector cable • Remove the push rods (4)

• Unscrew the mounting nuts from the injector
• Remove the injector cable (1) from the cable
Removing the gasket


CYLINDER HEAD
Installing the rocker arm mechanism Attaching the injector cable
Installing the rocker arm mechanism
WARNING
Component damage due to possible
WARNING short-circuit
Component damage due to incorrect • When tightening the mounting nuts,
tting of the valve bridges make sure that the cable plugs do not
• Document and mark the installation touch each other
position of the valve bridges (3)
• Insert the push rods (4) marked
• Oil the ball cups of the push rods (4) • Screw on the mounting nuts with the Torque
• Oil the valve bridges (3) screwdriver [75] in conjunction with the
• Put on the valve bridges (3) as marked Adapter [76] and Socket, size 7 [77] and then
• Insert the rocker arm mechanism (1) into the push tighten to 1.5 Nm
rod cups and align • Thinly apply White T assembly paste on the cable
• Screw in new mounting bolts (2) and tighten them passage in the gasket (2)
to 90 Nm • Insert the injector cable (1) into the cable passage
• Tighten the mounting bolts (2) to Final torque 90° in the gasket (2)
Fitting the gasket Mounting the cylinder head cover
• Fit the gasket (1) • Put on the cylinder head cover (1)

CYLINDER HEAD
Dismantling and assembling the rocker arm mechanism

Additional jobs
– Removing the rocker arm mechanism, see 353
– Installing the rocker arm mechanism, see 354
– Checking and setting the valve clearance, see 377
(1) Circlip (7) Lock nut

(2) Washer (8) Washer
(3) Rocker arm (9) Circlip
(4) Lock nut (10) Adjuster screw
(5) Rocker arm bracket (11) Adjuster screw
(6) Rocker arm
Rocker arm mechanism technical data

Radial play, rocker arms (3), (6)...................................................................................... 0.030 - 0.066 mm
Inside diameter, rocker arm bearing......................................................................... Ø 34.005 - 34.025 mm
Outside diameter, rocker arm shaft .......................................................................... Ø 33.959 - 33.975 mm
WARNING

CYLINDER HEAD
Special tools
[78] Dial gauge 08.71000-3217
• Checking the rocker arm radial play in conjunction

with:
• Dial gauge holder [79]
• Locating pin [80]
[79] Dial gauge holder 08.71082-0005

with:
• Dial gauge [78]
[80] Locating pin 80.99605-0197

with:
• Dial gauge [78]

CYLINDER HEAD
Dismantling the rocker arm mechanism Measuring the rocker arm shaft outside diameter
Dismantling the rocker arm mechanism
• Clean the rocker arm shaft (2)

• Check the outside diameter of the rocker arm shaft
• Detach the circlip (1) (2) using a micrometer (1)
• Remove the washer (2) • Repeat the procedure for the remaining rocker arm
• Mark the installation position of the rocker arm (3) shafts (2)
• Pull the rocker arm (3) off the rocker arm shaft (4) The permissible outside diameter of the rocker arm
• Repeat the procedure for the other rocker arms shaft (2) is Ø 33.959 - 33.975 mm.
Measuring the rocker arm bearing inside If the outside diameter is out of tolerance, the rocker
diameter arm bracket must be replaced.
• Clean the rocker arm (1) with bearing

• Use the Dial gauge [78] (3) and internal calliper (2)
to check the rocker arm bearing inside diameter
• Repeat the procedure for the remaining rocker
arms
The permitted rocker arm bearing inside diameter is
Ø 34.005 - 34.025 mm.
If the inside diameter is out of tolerance, t a new

rocker arm (1).

CYLINDER HEAD
Assembling the rocker arm mechanism

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
• Fit the washer (2)
• Attach a new circlip (1)
• Repeat the procedure for the other rocker arms

CYLINDER HEAD
Removing and installing the cylinder head

Additional jobs
– Removing and installing the exhaust system, see 345
– Removing and installing the air distributor pipes, see 339
– Removing and installing the rocker arm mechanism, see 351
– Removing and installing the injectors, see 191
(1) Push rods (6) Cylinder head

(2) Mounting bolt, rocker arm mechanism (7) Cylinder head bolt
(3) Rocker arm, intake valve (8) Exhaust valve bridge
(4) Lock nut (9) Rocker arm, exhaust valve
Technical data
Cylinder head bolts............................................... M18x2x246.................................... Initial torque 50 Nm
Cylinder head bolts............................................... M18x2x246.....................................2nd torque 150 Nm
Cylinder head bolts............................................... M18x2x246......................................3rd torque 300 Nm
Cylinder head bolts............................................... M18x2x246............................................ 4th torque 90°

CYLINDER HEAD
Cylinder head bolts............................................... M18x2x246............................................ 5th torque 90°

Cylinder head bolts............................................... M18x2x246..........................................Final torque 90°
Mounting bolt, rocker arm mechanism (2) .............. M12x40-10.9.................................. Initial torque 90 Nm
Mounting bolt, rocker arm mechanism (2) .............. M12x40-10.9........................................Final torque 90°
Cylinder liner standout ................................................................................................... 0.035 - 0.085 mm
Service products
WARNING
Component damage due to leaking cylinder head gasket
• Do not reuse old cylinder head bolts, even if they have only been used once
WARNING
personnel only.
(desired value 0)
• Always renew rail connections once they have been undone
once
connections
WARNING

CYLINDER HEAD
Special tools
[81] Socket, size 22 80.99612-0024
• Undoing and tightening the cylinder head bolts in

conjunction with:
• Torque multiplier i = 1 : 3.3 [82]
• Support [83]
• Angle measuring disc [84]
• Holding xture [85]
• Cylinder cap screw [86]
• Connecting pin [87]
• Rubber ring 42 mm [88]
• Adapter [89]
• Socket [90]
[82] Torque multiplier i = 1 : 3.3 80.99619-0006

conjunction with:
• Support [83]
• Adapter [89]
• Socket [90]
[83] Support 80.99606-0551

conjunction with:
• Adapter [89]
• Socket [90]
[84] Angle measuring disc 80.99607-0172

conjunction with:
• Support [83]
• Adapter [89]
• Socket [90]

CYLINDER HEAD
[85] Holding xture 80.99606-0641

conjunction with:
• Support [83]
• Adapter [89]
• Socket [90]
[86] Cylinder cap screw 06.02191-0407

conjunction with:
• Support [83]
• Adapter [89]
• Socket [90]
[87] Connecting pin 06.22729-0006

conjunction with:
• Support [83]
• Adapter [89]
• Socket [90]
[88] Rubber ring 42 mm 08.06142-9006

conjunction with:
• Support [83]
• Adapter [89]
• Socket [90]

CYLINDER HEAD
[89] Adapter 80.99606-0552

conjunction with:
• Support [83]
• Socket [90]
[90] Socket 80.99603-0327

conjunction with:
• Support [83]
• Adapter [89]
[91] Aligning bar 80.99606-0582
• Aligning cylinder heads
• Checking the cylinder liner standout in

conjunction with:
• Dial gauge [93]
• Measuring plate [94]
• Hexagon shank bolt [95]
• Washer [96]
[93] Dial gauge 08.71000-3217

conjunction with:
• Washer [96]
[94] Measuring plate 80.99605-0289

conjunction with:
• Dial gauge [93]
• Washer [96]

CYLINDER HEAD
[95] Hexagon shank bolt 06.01499-0015

conjunction with:
• Dial gauge [93]
• Washer [96]
[96] Washer 06.15013-0417

conjunction with:
• Dial gauge [93]

CYLINDER HEAD
Removing the cylinder head Assembling the special tool
Removing the crane hook lugs on the left and

right
• Insert the Torque multiplier i = 1 : 3.3 [82] (1) into

the Support [83] (2)
• Mount the Holding xture [85] (5) with the Cylinder
• Unscrew the mounting bolts (1) and (4) cap screw [86] (4) and the Adapter [89] (3) on the
• Remove the crane hook lugs (2) and (3) Support [83] (2)
• Put the Angle measuring disc [84] (9) on the
Removing the coolant vent line Torque multiplier i = 1 : 3.3 [82] (1)
• Put the Socket, size 22 [81] (8) on the Torque
multiplier i = 1 : 3.3 [82] (1) and secure with
the Connecting pin [87] (7) and the Rubber ring
42 mm [88] (6)
• Insert one Socket [90] each into the Holding
xture [85] (5) and the Socket, size 22 [81] (8)
Undoing sequence for cylinder head bolts
Note
Hollow screws are restricted.
• Unscrew the hollow screws (2) and (3) and remove

the sealing rings
• Remove the vent line (8) and ring union (1)
• Unscrew the hollow screws (4) and (6) and remove • Undo the cylinder head in the sequence indicated,
the sealing rings beginning with (6), (5), (4), (3), (2), (1)
• Remove the vent line (7) and ring union (5)

CYLINDER HEAD
Undoing the cylinder head bolts Installing the cylinder head

Checking the cylinder liner standout
• Fit the special tool (1) on the cylinder head bolt to

be undone
• Unscrew all cylinder head bolts in the sequence • Place the Measuring plate [94] (2) on the cylinder
indicated using the special tool (1) liner
• Screw in the Hexagon shank bolt [95] (4) with the
Removing the cylinder head Washer [96] and tighten
• Fit the Dial gauge holder [92] (5) on the Measuring
plate [94] (2) with Dial gauge [93] (3)
• Place the dial gauge tip (1) on the crankcase
• Zero the Dial gauge [93] (3)
• Carefully place the dial gauge tip (1) on the
cylinder liner and note the difference on the dial
gauge
The permissible cylinder liner standout is 0.035 -
0.085 mm.
If the cylinder liner standout is out of tolerance,

the cylinder liner/crankcase must be replaced, see
Checking the cylinder liner, 535.
Fitting the cylinder head

• Unscrew the cylinder head bolts (3)
• Remove the cylinder head (2)
• Remove the cylinder head gasket (1)
• Clean the tapped holes in the crankcase
• Place the new cylinder head gasket (1) over the

alignment pins
• Place the cylinder head (2) over the alignment pins
• Lightly apply White T assembly paste on the
contact surface of the new cylinder head bolts (1)
• Screw in the cylinder head bolts (3)

CYLINDER HEAD
Tightening sequence for cylinder head Final tightening of cylinder head bolts
• Tighten the cylinder head bolts in the tightening

Note
sequence 1 to 6
Note the torque multiplier ratio, i = 1 : 3.3.
Preliminary tightening of the cylinder head bolts
• Tighten the cylinder head bolts to 4th torque 90°,

in the correct sequence, with special tool (1)
• Tighten the cylinder head bolts to 5th torque 90°,
• Tighten the cylinder head bolts to Final torque 90°,
• Disassemble the special tool (1)
• Remove the Aligning bar [91] (2)
Attaching the coolant vent line
• Mount the Aligning bar [91] (2) on the exhaust side

of the cylinder heads
• Tighten the cylinder head bolts as per the
tightening sequence using a socket and a torque
wrench
• Tighten the cylinder head bolts (1) to Initial torque
50 Nm
• Tighten the cylinder head bolts (1) to 2nd torque
150 Nm
• Tighten the cylinder head bolts (1) to 3rd torque
300 Nm
Note
Hollow screws are restricted.
• Position the vent line (8) and ring union (1)

• Fit the hollow screws (2) and (3) with new sealing
rings, then screw in and tighten
• Position the vent line (7) and ring union (5)
• Fit the hollow screws (4) and (6) with new sealing
rings, then screw in and tighten

CYLINDER HEAD
Mounting the crane hook lugs on the left and

right
• Position the crane hook lugs (2) and (4)

• Screw in and tighten the new mounting bolts (1)
and (3)

CYLINDER HEAD
Removing and installing the valve stem seals

Additional jobs
(1) Cylinder head (5) Valve

(2) Valve spring (6) Valve stem seal
(3) Valve spring cap (7) Valve guide
(4) Valve cotters
Technical data
Mounting bolts, rocker arm mechanism.................. M12x80-10.9.................................. Initial torque 90 Nm
Mounting bolts, rocker arm mechanism.................. M12x80-10.9........................................Final torque 90°
Service products
WARNING

CYLINDER HEAD
Special tools
[97] Adapter 80.99606-0588
• Removing and installing the valve springs in

conjunction with:
• Holder [101]
• Holder [102]
• Valve-spring compressor [100]
• Extension [99]
• Assembly device [98]
[98] Assembly device 80.99606-6092

conjunction with:
• Adapter [97]
• Holder [101]
• Holder [102]
• Extension [99]
[99] Extension 80.99606-6094

conjunction with:
• Adapter [97]
• Holder [101]
• Holder [102]
[100] Valve-spring compressor 80.99613-6000

conjunction with:
• Adapter [97]
• Holder [102]
• Holder [101]
• Extension [99]
[101] Holder 80.99613-0050

conjunction with:
• Adapter [97]
• Holder [102]
• Extension [99]
[102] Holder 80.99613-0051

conjunction with:
• Adapter [97]
• Holder [101]
• Extension [99]

CYLINDER HEAD
• Removing the valve cotters in conjunction with:

• Adapter [97]
• Holder [101]
• Holder [102]
• Extension [99]
• Removing and installing the valve stem seal in

conjunction with:
• Mounting sleeve [105]
[105] Mounting sleeve 80.99606-0287
• Installing the valve stem seal in conjunction with:


• Adapter [107]
[107] Adapter 08.06139-9029

[108] Socket, size 7 08.06141-0700

• Adapter [107]

CYLINDER HEAD
Removing the valve stem seals Position of engine barring gear
• Crank the engine at the hexagon prole (1) of the

engine barring gear
• Remove the cylinder head cover (1) Cranking the engine to the setting position
Removing the injector cable
A Rocker arms in overlap

B Rocker arms free
• Unscrew the mounting nuts from the injector • Crank the engine in the engine's running direction
• Remove the injector cable (1) from the cable until the rocker arms are in overlap
passage in the gasket (2) • Remove and install the free valve stem seals as
per the table
Removing the gasket


CYLINDER HEAD
Removing the rocker arm mechanism Fitting the mounting device
• Unscrew the mounting bolts (2) • Screw the Adapter [97] (3) into the cylinder head
• Remove the rocker arm mechanism (1) (1)
• Pull out the push rods (4) • Screw the Assembly device [98] (2) into the
• Mark the installation position of the valve bridges Adapter [97] (3)
(3)
• Remove the valve bridges (3) Mounting the valve-spring compressor
Assembling the special tool
WARNING
Injector damage
Note • Spring compressor must not come into
Retaining washer and Holder [102] have contact with the injector
left-hand threads.
• Position the Holder [101] (4) and Holder [102]
• Position the Holder [101] (5) and Holder [102] (3) (5) on the spring cap and tension by turning the
on the Valve-spring compressor [100] (1) and then threaded spindle (6)
screw on by turning the threaded spindle (4) • Hook the Valve-spring compressor [100] (2) in the
• Screw on the retaining washers (2) and (6) Assembly device [98] (3)
• Position the lever (8) on the Valve-spring • Place the Extension [99] (1) onto the Valve-spring
compressor [100] (1) and secure using the compressor [100] (2)
mounting bolt (7)

CYLINDER HEAD
Removing the valve cotters Installing the valve stem seals

Installing the valve stem seals
CAUTION
Risk of injury due to springing back of
the valve springs Note
• Ensure that the Holder [101] and Mount the green valve stem seals on the
Holder [102] are seated correctly on intake side and the brown valve stem
the spring cap seals on the exhaust side
• Do not remove the valve cotters from
the valve spring with your bare hands • Thinly apply clean engine oil to MAN Standard
3277 on the Mounting sleeve [105] (4) and the
• Push down the Valve-spring compressor [100] with valve stem seal (3)
Extension [99] (1) • Push the Mounting sleeve [105] (4) over the valve
• Remove the valve cotters (3) from the valve stem stem (5)
(4) with Magnetic pick-up tool [103] (2) • Insert the valve stem seal (3) into the Assembly
• Release the Valve-spring compressor [100] (1) device [104] (2) and tension it
• Remove the valve spring together with the washer • Push the Assembly device [104] (2) over the
and spring cap Mounting sleeve [105] (4)
• Repeat the same procedure for all the valves • Knock the valve stem seal (3) onto the valve stem
• Remove the special tool (5) using the impact weight (1)
• Remove the Assembly device [104] (2) and the
Removing the valve stem seals Mounting sleeve [105] (4)
Installing the valve springs
• Push the Assembly device [104] (2) over the valve

stem seal (3)
• Clamp the Assembly device [104] (2) • Fit the washer, valve spring (2) and spring cap (1)
• Pull the valve stem seal (3) off the valve guide with over the valve stem
impact weight (1) • Repeat the same procedure for all the valves

CYLINDER HEAD
Assembling the special tool Installing the valve cotters
Note CAUTION
Retaining washer and Holder [102] have Risk of injury due to springing back of
left-hand threads. the valve springs
• Ensure that the Holder [101] and
• Position the Holder [101] (5) and Holder [102] (3) Holder [102] are seated correctly on
on the Valve-spring compressor [100] (1) and then the spring cap
screw on by turning the threaded spindle (4) • Do not insert the valve cotters into the
• Screw on the retaining washers (2) and (6) valve spring with your bare hands
• Position the lever (8) on the Valve-spring
compressor [100] (1) and secure using the • Press the spring cap (4) down fully with
mounting bolt (7) Valve-spring compressor [100] (3) and
Extension [99] (2)
Mounting the valve-spring compressor • Insert the valve cotters (1)
• Carefully undo the Valve-spring compressor [100]
(3)
• Check the valve cotters (1) for correct seating and,
if necessary, repeat the procedure above
WARNING
Injector damage
• Spring compressor must not come into
contact with the injector
• Screw the Adapter [97] (4) into the cylinder head

(8)
• Screw the Assembly device [98] (3) into the
Adapter [97] (4)
• Position the Holder [101] (5) and Holder [102]
(6) on the spring cap and tension by turning the
threaded spindle (6)
• Hook the Valve-spring compressor [100] (2) in the
Assembly device [98] (3)
• Place the Extension [99] (1) onto the Valve-spring
compressor [100] (2)

CYLINDER HEAD
Mounting the rocker arm mechanism Attaching the injector cable
Note WARNING
Ensure that the oil bore in the valve bridge Component damage due to possible
is facing downwards short-circuit
• When tightening the mounting nuts,
• Thinly apply engine oil to MAN Standard 3277 on make sure that the cable plugs do not
the ball cups and balls of the push rods (4) touch each other
• Insert the push rods (4)
• Put on the valve bridges (3) as marked
marked
• Fit the rocker arm mechanism (1) so that the rocker
• Screw on the mounting nuts with the Torque
arm balls lie in the push rod ball cups
screwdriver [106] in conjunction with the
• Screw in the new mounting bolts (2)
Adapter [107] and Socket, size 7 [108] and
• Tighten the new mounting bolts (2) to Initial torque
then tighten to 1.5 Nm
90 Nm
• Thinly apply White T assembly paste on the cable
Fitting the gasket • Insert the injector cable (1) into the cable passage
in the gasket (2)
• Fit the gasket (1)


CYLINDER HEAD
Checking and setting the valve clearance
(1) Exhaust valve adjusting screw (3) Intake valve bridge

(2) Intake valve adjusting screw (4) Exhaust valve bridge
Technical data
Intake valve clearance ................................................................................................................ 0.50 mm
Exhaust valve clearance ............................................................................................................. 0.80 mm
Rocker arm adjusting screw lock nut................................................................................................45 Nm
Service products
WARNING
Engine damage caused by incorrectly set valves
• Do not adjust the valves unless the engine is cold

CYLINDER HEAD
Special tools
[109] Holding xture 08.75300-0000
• Checking and adjusting the valve clearance in

conjunction with:
• Feeler gauge leaf 0.5 [110]
• Feeler gauge leaf 0.8 [111]
• Valve adjusting spanner, size 14 [112]
[110] Feeler gauge leaf 0.5 80.99607-0177

conjunction with:

conjunction with:
[112] Valve adjusting spanner, size 14 80.99603-6031
• Adjusting the valve clearance in conjunction with:

• Handle [113]
[113] Handle 08.06460-0003
• Adjusting the valve clearance in conjunction with:


CYLINDER HEAD
Checking and setting the valve Cranking the engine to the setting position
clearance
Removing the cylinder head cover, cylinder 1
A = Rocker arms in overlap

B = Rocker arms free for valve clearance
setting
• Remove the cylinder head cover (1) • Crank the engine until the rocker arms are in
overlap
Position of engine barring gear • Adjust the free rocker arms as indicated in the
table
Checking the intake valve clearance

engine barring gear
• Insert the Holding xture [109] (1) with Feeler

gauge leaf 0.5 [110] (2) between the valve bridge
(3) and the ball socket (4)
Adjust the valve clearance if the valve clearance is
not 0.50 mm

CYLINDER HEAD
Setting the intake valve clearance Setting the exhaust valve clearance
• Undo the lock nut (4) • Undo the lock nut (4)
• Turn back the adjusting screw (5) until the Holding • Turn back the adjusting screw (5) until the Holding
xture [109] (1) with Feeler gauge leaf 0.5 [110] xture [109] (1) with Feeler gauge leaf 0.8 [111]
(2) can be inserted between the ball socket (6) (2) can be inserted between the ball socket (6)
and the valve bridge (3) and the valve bridge (3)
• Screw in the adjusting screw (5) until the Holding • Screw in the adjusting screw (5) until the Holding
xture [109] (1) with Feeler gauge leaf 0.5 [110] xture [109] (1) with Feeler gauge leaf 0.8 [111] (2)
(2) can be moved between the ball socket (6) and can be moved between the ball socket (6) and the
the valve bridge (3) with little resistance (suction) valve bridge (3) with little resistance (suction)
• Brace the adjusting screw (5) with the Valve • Brace the adjusting screw (5) with the Valve
adjusting spanner, size 14 [112] adjusting spanner, size 14 [112]
• Brace the adjusting screw (5) and tighten the lock • Brace the adjusting screw (5) and tighten the lock
nut (4) to 45 Nm nut (4) to 45 Nm
• Check the setting once more • Check the setting once more
Checking the exhaust valve clearance Mounting the cylinder head cover
• Insert the Holding xture [109] (1) with Feeler • Put on the cylinder head cover (1)
gauge leaf 0.8 [111] (2) between the valve bridge • Screw in the mounting bolts (2) and tighten them
(3) and the ball socket (4)
Adjust the valve clearance if the valve clearance is
not 0.80 mm

VALVE TIMING
VALVE TIMING
(1) Rocker arm mechanism (4) Camshaft

(2) Roller tappet (5) Push rod
(3) Anti-rotation device

VALVE TIMING
CAMSHAFT
Removing and installing the camshaft/camshaft bearing
Additional jobs
– Removing and installing the coolant manifold, see 111
– Removing and installing the starter, see 143
– Removing and installing the vibration damper, D2868 LE4xx, see 457
– Removing and installing the ywheel, see 469
– Removing and installing the oil sump, see 433
– Removing and installing the oil pumps, see 437
– Removing and installing the oil injector nozzles, see 431
– Removing and installing the pistons and connecting rods, see 477
– Removing and installing the cylinder head, see 359
– Removing and installing the cover, see 519
– Removing and installing the ywheel housing, see 521
– Removing and installing the rear timing gears, see 401
– Removing and installing the front radial shaft seal, see 445
– Removing and installing the rear radial shaft seal, see 448
(1) Roller tappet (2) Camshaft gear

VALVE TIMING
(3) Mounting bolt (5) Anti-rotation device

(4) Countershaft gear (6) Camshaft
Camshaft technical data

Anti-rotation device (5)....................................................................................................................13 Nm
Mounting bolt, oil injector nozzle............................ M14x20-10.9....................................................120 Nm
Camshaft axial play (6) .................................................................................................. 0.100 - 0.250 mm
Radial play, camshaft (6)................................................................................................ 0.060 - 0.112 mm
WARNING
Special tools
[114] Insertion pin 80.99617-6009
• Removing and installing the camshaft

VALVE TIMING
Removing the camshaft Removing the camshaft
Removing the camshaft gear
• Push out the camshaft (1) towards the ywheel

housing with Insertion pin [114]
• Unscrew the mounting bolts (2) • Unscrew the Insertion pin [114]
• Pull off the camshaft gear (1) over the alignment
pin Removing the oil injector nozzles
Removing the axial shim

• Extract the oil injector nozzle (2) from the
• Unscrew the mounting bolts (2) crankcase
• Remove the axial shim (1)
Mounting the insert pin
• Screw the Insertion pin [114] (1) into the camshaft

VALVE TIMING
Unscrewing the anti-rotation device Dismantling the camshaft gear
• Clamp the camshaft gear (3) with countershaft

Note
gear (2) in a vice with protective jaws
Watch out for roller tappets falling out
when unscrewing the anti-rotation device
• Unclamp the camshaft gear (3) with countershaft
gear (2)
• Unscrew the anti-rotation devices (1) and (2) • Remove the countershaft gear (2) from the
camshaft gear (3)
Removing the roller tappet
• Extract the roller tappet (1) from the crankcase (2)

VALVE TIMING
Assembling the camshaft gear Installing the camshaft

Installing the roller tappet
• Put the countershaft gear (2) on the camshaft gear

(3)
• Clamp the camshaft gear (3) with countershaft • Thinly apply clean engine oil to MAN Standard
gear (2) in a vice with protective jaws 3277 on the roller tappet (1)
• Screw in and tighten the new mounting bolts (1) • Align the roller tappet (1) with the recess (2) facing
• Unclamp the camshaft gear (3) with countershaft the tapped hole for the anti-rotation device (3)
gear (2) • Insert the roller tappet (1) into the crankcase (2)
Screwing in the anti-rotation device
WARNING
Danger of damage to the roller tappets
or anti-rotation 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
13 Nm

VALVE TIMING
Installing the oil injector nozzles Mounting the axial shim
• Insert the oil injector nozzle (2) into the crankcase • Position the axial shim (1)
• Screw in new mounting bolt (1) and tighten to • Screw in and tighten the new mounting bolts (2)
120 Nm
Mounting the camshaft gear
Installing the camshaft
• Position the camshaft gear (1) over the alignment

• Thinly apply clean engine oil to MAN Standard pin
3277 on the camshaft bearing • Screw in and tighten the new mounting bolts (2)
• Screw the Insertion pin [114] into the camshaft (1)
• Push in the camshaft (1) carefully from the
ywheel side with the Insertion pin [114]
Removing the insertion pin
• Unscrew the Insertion pin [114] (1) from the

camshaft

VALVE TIMING
VALVE TIMING
Checking the valve timing
Additional jobs
(1) Intake valve, cylinder 1
Technical data
Valve lift, V8 ..........................................................................................................................2.7 - 3.7 mm
Valve lift, V12 .................................................................................................................... 10.0 - 10.6 mm
WARNING

VALVE TIMING
Special tools
• Checking the valve timing in conjunction with:

• Dial gauge [116]
[116] Dial gauge 08.71000-3217
• Checking the valve timing in conjunction with:


VALVE TIMING
Checking the valve timing Checking the valve lift, V8 engine
• Mount the Dial gauge [116] (1) with Dial gauge

holder [115] (2) on on the cylinder head for cylinder
• Unscrew the mounting bolts (2) 1
• Remove the cylinder head cover (1) • Place the measuring tip (3) of the Dial gauge [116]
• Clean the mating faces (1) on the valve disc for the intake valve (4)
Position of engine barring gear • Continue cranking the engine in the engine's
running direction until the dial gauge pointer stops
moving
In this position, the correct valve lift must be 2.7 - 3.7
mm.
If the valve lift is outside the tolerance of 2.7 - 3.7

mm, check the camshaft, transmission components
of the valve timing and timing gears and replace if
necessary.

engine barring gear until the cylinder 1 valves are
in overlap

VALVE TIMING
Checking the valve lift, V12 engine
• Mount the Dial gauge [116] (1) with Dial gauge

holder [115] (2) on the cylinder head
• Place the measuring tip (3) of the Dial gauge [116]
(1) on the valve disc for the intake valve (4)
• Continue cranking the engine in the engine’s
running direction until the dial gauge pointer stops
moving
In this position, the correct valve lift must be
10.0 - 10.6 mm.
If the valve lift is outside the tolerance of 10.0 - 10.6

mm, check the camshaft, transmission components
of the valve timing and timing gears and replace if
necessary.


TIMING GEARS/DRIVE GEARS

Drive gears in the housing cover at the front
(1) Coolant pump crankshaft gear

(2) Intermediate gear, crankshaft (split)
(3) Intermediate gear pin
(4) Mounting bolt
(5) Oil pump crankshaft gear

Timing gears in the ywheel housing
(1) Crankshaft gear (4) Drive gear, high-pressure pump

(2) Camshaft gear (5) Countershaft gear
(3) Mounting bolt (6) Power take-off drive gear

FRONT DRIVE GEARS

Removing and installing the front drive gears
Additional jobs
– Removing and installing the alternator, see 149
– Removing and installing the oil modules (variant B), see 424
(1) Coolant pump crankshaft gear (4) Mounting bolt

(2) Crankshaft intermediate gear (5) Oil pump crankshaft gear
(3) Intermediate gear pin
Service products
Loctite 270 ........................................................................................................................ 04.10160-9062
WARNING

Special tools
[117] Aligning punch 80.99617-0020
• Removing and installing the front crankshaft gear

Removing the front drive gears Dismantling the intermediate gear

Removing the coolant pump crankshaft gear
• Mark the relative positions of the intermediate

gears (1) and (5)
• Screw in the Aligning punch [117] (1) and (3) • Unscrew the mounting bolts (4)
• Pull off the crankshaft gear (2) • Remove the intermediate gear (5)
• Remove the pressure pieces (2)
Removing the intermediate gear • Remove the damping pieces (3)

• Pull off the intermediate gear (3) with the
intermediate gear pin (2)
Removing the oil pump crankshaft gear
• Pull off the crankshaft gear (1) over the Aligning

punch [117] (2) and (3)
• Clean the contact surfaces of the crankshaft gear
(1) and crankshaft

Assembling the intermediate gear Installing the front drive gears

Installing the oil pump crankshaft gear
• Insert the pressure pieces (2) into the intermediate

gear (1)
• Insert new damping pieces (3) into the • Push on the crankshaft gear (1) over the Aligning
intermediate gear (1) punch [117] (2) and (3) until the stop is reached
• Put the intermediate gear (5) onto the intermediate
gear (1) as marked Installing the intermediate gear
• Thinly apply Loctite 270 on the threads of the new
mounting bolts (4)

3277 on the intermediate gear pin (2)
• Insert the intermediate gear pin (2) into the
intermediate gear (3)
• Install the intermediate gear (3) in the crankcase
with the intermediate gear pin (2)

Installing the coolant pump crankshaft gear
• Push on the crankshaft gear (2) over the Aligning

punch [117] (1) and (3) until the stop is reached
• Unscrew the Aligning punch [117] (1) and (3)

REAR TIMING GEARS

Removing and installing the rear timing gears
Additional jobs
(1) Crankshaft gear (4) Drive gear, high-pressure pump

(2) Camshaft gear (5) Countershaft gear
(3) Mounting bolt (6) Drive gear, power take-off
WARNING
WARNING
Component damage due to inadequate positive locking of the crankshaft gear because the
front face of the crankshaft gear is shot-peened
• The crankshaft gear must be replaced every time after the crankshaft gear screw connection is
unscrewed

Note
The intermediate gear and pin do not have to be exchanged as a set.
They can also be replaced individually, depending on the degree of wear.
Note
The intermediate gear to the air compressor is split into two sections and preloaded (noise
damping).
Backlash cannot be measured here.
Special tools
[118] Aligning punch 80.99617-0220
• Installing the rear crankshaft gear

Setting the crankshaft gear to the marks Removing the rear timing gears
Fixing the crankshaft gear Removing the crankshaft gear
• Fix the crankshaft gear (2) by screwing in the • Screw in the Aligning punch [118] (2) and (3)
mounting bolts (1) and (3) • Pull off the crankshaft gear (1)
Setting the crankshaft gear to the marks Removing the power take-off intermediate gear
• Crank the engine on the engine barring gear until • Extract the power take-off intermediate gear (1)
the mark (1) is aligned with the mark (2)
Mark (1) and mark (2) are aligned.
Unscrewing the crankshaft gear mounting bolts

Installing the rear timing gears Checking the crankshaft gear mark
Positioning the power take-off intermediate gear
• Check the mark (1) and mark (2) match up

If the marks (1) and (2) do not match up, remove the
• Thinly apply clean engine oil to MAN Standard crankshaft gear and re-insert it at the mark.
3277 on the power take-off intermediate gear shaft
(1)
• Insert the intermediate gear (1)
Installing the crankshaft gear
• Screw in the Aligning punch [118] (2) and (3)

• Align the bore in the crankshaft gear (1) with the
centring pin
• Push the new crankshaft gear (1) onto the
crankshaft

ENGINE LUBRICATION
ENGINE LUBRICATION
(1) Oil module, right (3) Oil sump


ENGINE LUBRICATION
OIL MODULES
Removing and installing the oil lter
(1) Oil separator (4) O-ring

(2) O-ring (5) Oil lter
(3) Oil lter cover
Technical data
Mounting bolts, oil separator ................................. 6x20 .................................................................. 11 Nm
Oil lter cover .................................................................................................................................45 Nm
Support dome ................................................................................................................................25 Nm
WARNING
Danger of engine damage due to oil emulsion
• Drain all the coolant before removing the oil module, otherwise coolant will enter the oil sump
when the oil module is removed from the crankcase
WARNING

ENGINE LUBRICATION
Special tools
[119] Socket, size 36 80.99603-0325
• Removing and installing the oil lter cover

ENGINE LUBRICATION
Removing the oil lter and oil separator Removing the support dome
Removing the oil separator
• Unscrew the support dome (1)
• Unscrew the mounting bolts (2) Removing the drain valve

• Pull the oil separator (1) out of the oil module
Removing the oil lter
• Remove the drain valve (1)
WARNING
Engine oil contamination
• Always allow all of the engine oil to drain
• Undo the oil lter cover (3) 2-3 turns with the
Socket, size 36 [119]
• Unscrew and remove the oil lter cover (3) with
Socket, size 36 [119] after approx. 1-2 minutes
• Remove the oil lter insert (1) from the oil lter
cover (3)

ENGINE LUBRICATION
Installing the oil lter and oil separator Installing the oil separator
Installing the drain valve
• Insert new O-rings (3) and (4)

• Insert the oil separator (1) into the oil module and
• Insert the drain valve (1) align it
Installing the support dome to 11 Nm
• Screw in and tighten the support dome (1)
Installing the oil lter
• Pull the new O-ring (2) onto the oil lter cover (3)
• Thinly apply clean engine oil on the O-ring (3)
• Insert the new oil lter insert (1) into the oil lter
cover (3)
• Screw in the oil lter cover (3) using the Socket,
size 36 [119] and tighten it to 45 Nm 45 Nm

ENGINE LUBRICATION
Removing and installing the oil modules (variant A)

Additional jobs
– Draining the engine oil, see Operator's Manual
– Removing and installing the crankcase ventilation, see 511
(1) Oil module, right (3) Oil separator, left

(2) Oil separator, right (4) Oil module, left
WARNING
WARNING

ENGINE LUBRICATION
WARNING
Danger of engine damage due to insufcient oil supply
• If an oil module is removed, the engine must be lled with engine oil to MAN Standard 3277
using the pressure application process before starting, see Filling the engine with oil using the
pressure application process, 416.

ENGINE LUBRICATION
Removing the oil module Removing the left oil module
Detaching the left oil return lines

(1), (3), (6) and (7)
• Undo the fastening (3) • Unscrew the mounting bolts (1), (3), (6) and (7)
• Detach the oil return lines (1) and (2) • Remove the oil module (2) with gasket (4)
Left oil module removal instructions • Clean the mating faces
Detaching the right oil return lines
• Do not unscrew the oil cooler mounting bolts (1)

to remove the oil module
• Undo the fastening (2)
• Detach the oil return lines (1) and (3)
Right oil module removal instructions


ENGINE LUBRICATION
Removing the right oil module Installing the oil module

Tightening diagram for right oil module

(1), (3), (4) and (5)
• Unscrew the mounting bolts (1), (3), (4) and (5) • Tighten the mounting bolts (2)
• Remove the oil module (2) with the gasket (7) • Undo the mounting bolts (2) by 60°
• Remove the O-rings (6) • Tighten the mounting bolts (1)
• Clean the mating faces • Tighten the mounting bolts (2)
Mounting the right oil module
• Insert new O-rings (6)

• Insert the mounting bolts (3) and (4) into the oil
module (2) as marked
• Position a new gasket (7) and x using mounting
bolts (3) and (4)
• Position the oil module (2) with gasket (7) and
mounting bolts (3) and (4)
• Tighten the mounting bolts (1) and (5) and undo
60°

ENGINE LUBRICATION
Attaching the right oil return lines Mounting the left oil module
• Position the oil return lines (1) and (3) so that they • Insert new O-rings (5)
are free of strain • Insert the mounting bolts (1) and (7) into the oil
• Tighten the union nuts for the oil return lines (1) module (2) as marked
and (3) • Position a new gasket (4) and x using mounting
• Mount the fastening (1) bolts (1) and (7)
Left oil module tightening diagram mounting bolts (1) and (7)
• Tighten the mounting bolts (3) and (6) and undo
60°
Attaching the left oil return lines

• Undo the mounting bolts (1) by 60°
• Position the oil return lines (1) and (2) so that they
are free of strain
• Tighten the union nuts for the oil return lines (1)
and (2)
• Mount the fastening (3)

ENGINE LUBRICATION
Filling the engine with oil using the pressure application process
Additional jobs
(1) Filler hose, electric oil pump (2) Filler hose, electric oil pump
Fill quantities
Total oil ll quantity, V8 - 1200 ............................... Engine oil to MAN Standard 3277 .....................62 litres
Total oil ll quantity, V12 - 1800 ............................. Engine oil to MAN Standard 3277 .....................92 litres
WARNING
Component damage due to oil overlling
• Do not ll the engine oil beyond the max. notch on the oil dipstick

ENGINE LUBRICATION
Pressure application process for left oil

module
WARNING
Component damage due to oil
overlling
• Do not ll the engine oil beyond the
max. notch on the oil dipstick
• Unscrew the cap from the oil module connection

(1)
• Connect the electric oil pump's pressure hose (2)
to the oil module connection (1)
• Press half of the engine's total oil quantity into the
engine by pressing the "OIL IN" button (3)
• Detach the electric oil pump's pressure hose (2)
and then screw on and tighten the cap
Pressure application process for right oil

module
• Repeat the see Pressure application process for
left oil module, 417 procedure for the right oil
module

ENGINE LUBRICATION
Removing and installing the oil cooler (variant A)

Additional jobs
(1) Oil cooler (3) Mounting bolts, oil cooler

(2) Oil cooler (4) Mounting bolts, oil cooler
Technical data
Mounting bolts...................................................... M6X65 ..............................................................28 Nm
Mounting bolts...................................................... M6X95 ..............................................................28 Nm
WARNING

ENGINE LUBRICATION
Removing the oil cooler Installing the oil cooler

Removing the oil cooler Installing the oil cooler
• Insert the oil cooler (2) with new gaskets (1)

WARNING
Component damage due to putting the
and tighten them by hand
oil module aside incorrectly
• Tighten the mounting bolts (3) and (4) to 28 Nm
• Put the oil module aside so as not to
damage the oil cooler

(3) and (4)
• Remove the oil cooler (2) with the gaskets (1)

ENGINE LUBRICATION
Dismantling and assembling the oil module (variant A)

Additional jobs
(1) Oil separator

(2) Oil lter insert
(3) Support dome
(4) Oil lter cover
(5) Oil cooler
(6) Oil module

ENGINE LUBRICATION
(1) Filter bypass valve (3) Pressure-relief valve

(2) Drain valve (4) Oil return to oil sump
Technical data
Screw plug .......................................................... M33x2 ...............................................................85 Nm
Screw plug .......................................................... M26x1,5 ............................................................85 Nm
Screw plug .......................................................... M18x1.5 ............................................................27 Nm
Pressure-relief valve ............................................ M27x1.5 ............................................................42 Nm
WARNING

ENGINE LUBRICATION
Dismantling the oil module Assembling the oil module

Unscrewing the ttings Installing the pressure-relief valve
• Unscrew the ttings (1) and (2) with the sealing • Screw in the screw plug (1) with a new sealing ring
rings and tighten to 85 Nm
• Screw in the pressure-relief valve and tighten to
Unscrewing the screw plugs 42 Nm
• Unscrew the screw plugs (1), (2) and (3) with the
sealing rings
• Screw in and tighten the screw plug (1) with a new
Removing the pressure-relief valve sealing ring
• Screw in the screw plug (2) with a new sealing ring
and tighten to 27 Nm
• Screw in the screw plug (3) with a new sealing ring
• Unscrew the screw plug (1) with the sealing ring

• Unscrew the pressure relief valve (2)

ENGINE LUBRICATION
Screwing in the ttings
• Screw in and tighten the ttings (1) and (2) with

new sealing rings

ENGINE LUBRICATION
Removing and installing the oil modules (variant B)

Additional jobs
(1) Oil module, right

(2) Oil separator, right
(3) Oil separator, left
(5) Ventilation housing, left
(6) Ventilation housing, right

ENGINE LUBRICATION
(1) Filter bypass valve (4) Return-ow check valve

(2) Drain valve (5) Oil return to oil sump
(3) Relief valve
Technical data
Filter bypass valve (1)........................................... Opening pressure ...................................... 1.9 -2.9 bar
Relief valve (3) ..................................................... M27x1.5 ............................................................45 Nm
Relief valve (3) ..................................................... Opening pressure ........................................... > 10 bar
Screw plug, return-ow check valve (4).................. M32x1.5 ............................................................80 Nm
Return-ow check valve (4) ................................... Opening pressure ............................................. 0.2 bar
WARNING
WARNING
WARNING
Danger of engine damage due to insufcient oil supply
• If an oil module is removed, the engine must be lled with engine oil to MAN Standard 3277
using the pressure application process before starting, see Filling the engine with oil using the
pressure application process, 416.

ENGINE LUBRICATION
Removing the oil module Right oil module removal instructions
Left oil module removal instructions

to remove the oil module Removing the right oil module
Removing the left oil module

bolts (1)
• Mark the installation position of the mounting • Unscrew the mounting bolts (1) and (5)
bolts (1) • Remove the oil module (2) with the gasket (3)
• Unscrew the mounting bolts (1) and (3) • Remove the O-rings (4)
• Remove the oil module (2) with gasket (4) • Clean the mating faces

ENGINE LUBRICATION
Installing the oil module

Installing the left oil module

• Insert the mounting bolts (1) into the oil module (2)
as marked
bolts (1)
mounting bolts (1)
• Tighten the mounting bolts (3) and undo 60°
Installing the right oil module

• Insert the mounting bolts (1) into the oil module (2)
as marked
bolts (1)
mounting bolts (1)
• Tighten the mounting bolts (5) and undo 60°

ENGINE LUBRICATION
Dismantling and assembling the oil module (variant B)
(1) Oil separator (4) Oil lter cover

(2) Oil lter insert (5) Oil cooler
(3) Support dome (6) Oil module
Technical data
Oil lter cover (4) ............................................................................................................................45 Nm
Support dome (3) ...........................................................................................................................25 Nm
WARNING
Special tools
[120] Socket, size 32 80.99603-0326
• Removing and installing the oil lter cover

ENGINE LUBRICATION
Dismantling the oil module Removing the oil lter
Removing the oil cooler
WARNING
Engine oil contamination
WARNING • Always allow all of the engine oil to drain
Component damage due to setting
aside the oil module incorrectly • Undo the oil lter cover (1) 2-3 turns with the
• Set aside the oil module so as not to Socket, size 32 [120]
damage the oil cooler The engine oil then drains into the oil sump via the
drain valve
• Mark the installation position of the mounting • Unscrew and remove the oil lter cover (1) with
bolts (1) Socket, size 32 [120] after approx. 1-2 minutes
• Unscrew the mounting bolts (1) • Remove the oil lter insert (3) from the oil lter
• Remove the oil cooler (3) with the gaskets (2) cover (1)
• Clean the mating faces • Remove the O-ring (2)
Removing the oil separator

• Pull the oil separator (1) out of the oil module

ENGINE LUBRICATION
Assembling the oil module Installing the oil cooler
Installing the oil lter
• Insert the oil cooler (3) with new gaskets (2)

• Screw in the new mounting bolts (1) as marked
• Pull the new O-ring (2) onto the oil lter cover (1) and tighten them by hand
• Thinly apply clean engine oil to MAN Standard • Tighten the mounting bolts (1)
3277 on the O-ring (2)
• Insert the new oil lter insert (3) into the oil lter
cover (1)
• Screw in the oil lter cover (1) using the Socket,
size 32 [120] and tighten it to 45 Nm
Installing the oil separator
• Fit the new O-rings (3) and (4)

• Insert the oil separator (1) into the oil module

ENGINE LUBRICATION
OIL INJECTOR NOZZLES

Removing and installing the oil injector nozzles
Additional jobs
(1) Oil injector nozzle (2) Mounting bolt
Technical data
Mounting bolt (2) .................................................. M14x20-10.9....................................................120 Nm
WARNING
Note
Replace the mounting bolts when exchanging the oil injector nozzle.

ENGINE LUBRICATION
Removing the oil injector nozzle Installing the oil injector nozzle
• Unscrew the mounting bolt (1) • Insert the oil injector nozzle (2) into the crankcase
• Extract the oil injector nozzle (2) from the • Screw in new mounting bolt (1) and tighten to
crankcase 120 Nm

ENGINE LUBRICATION
OIL SUMP
Removing and installing the oil sump
Additional jobs
– Draining and topping up the engine oil, see Operator's Manual
– Removing and installing the engine control units, see 49
(1) Gasket (3) Oil sump

(2) Oil drain hose
Technical data
Oil level sensor..................................................... M18x1.5 ............................................................25 Nm
Service products
Curil T............................................................................................................................... 04.90300-9030
WARNING

ENGINE LUBRICATION
Removing the oil sump Removing the oil sump
Removing the oil level sensor and dipstick

• Remove the oil sump (2) with gasket (1)
• Unscrew the screw-in tting (1) with oil level • Clean the mating faces
sensor and remove the sealing ring (2)
• Pull out the oil dipstick Removing the oil suction pipes
• Remove the guide tube (4)
Removing the manifold for the oil suction line

• Unscrew the mounting bolts (4) and then remove
the holder (7) (V8 engine only), washers (5) and
nuts (6)
• Unscrew the mounting bolts (4) • Remove the oil suction pipes (2)
• Remove the manifold (3) with the unscrewed • Remove the O-rings (1) from the oil suction pipes
conduit (1) and O-ring (2) (2)

ENGINE LUBRICATION
Removing the oil return lines Installing the oil sump

Installing the oil return lines
• Unscrew the union nuts from the oil return lines (1)
• Unscrew the mounting bolts (2) • Position the holder on the oil return lines (1)
• Remove the mounting nuts (4) and holder • Insert the mounting bolts (2) and screw on the
• Remove the oil return lines (1) mounting nuts (4)
• Insert the oil return lines (1) into the oil sump so
they are strain-free
• Screw on the union nuts for the oil return lines (1)
• Tighten the union nuts for the oil return lines (1)
• Tighten the mounting nuts (4)
Installing the oil suction pipes
• Position new O-rings (1) on the oil suction pipes

(2)
• (V8 engine only)
Position the holder (7) on the oil suction pipes (2)
• Insert the mounting bolts (4) and screw on the
washers (5) with the nuts (6)
• Insert the oil suction pipes (2) into the oil sump so
they are strain-free
• Tighten the nuts (6)

ENGINE LUBRICATION
Installing the oil sump Installing the oil measuring probe and oil
dipstick
• Position the oil sump (2) with a new gasket (1)

• Screw in and tighten the new mounting bolts (3) • Position the guide tube (4) and screw on the union
nut (3)
Mounting the manifold for the oil suction line • Tighten the union nut (3) and push in the dipstick
until the stop is reached
• Screw in the screw-in tting (1) with the oil level
sensor and a new sealing ring (2) and then tighten
it to 25 Nm
• Thinly apply engine oil to MAN Standard 3277 on

the new O-rings (2)
• Position the manifold (3) with a new unscrewed
conduit (1) and a new O-ring (2)

ENGINE LUBRICATION
OIL PUMPS
Removing and installing the oil pumps
Additional jobs
(1) Oil pump (2) Oil pump
Technical data
Backlash, ring gear - crankshaft gear.............................................................................. 0.060 - 0.240 mm
Axial play, ring gear ....................................................................................................... 0.040 - 0.090 mm
Axial play, rotor.............................................................................................................. 0.035 - 0.080 mm
Oil pump mounting bolt ......................................... M6x40-10.9 .......................................................15 Nm
WARNING

ENGINE LUBRICATION
Special tools
• Checking the ring gear axial and radial play in

conjunction with:
[122] Dial gauge 08.71000-3217
• Checking the ring gear axial and radial play in

conjunction with:

ENGINE LUBRICATION
Removing the oil pumps Removing the oil pumps
Removing the manifold for the oil suction line

(1) and (4)
• Unscrew the mounting bolts (4) • Unscrew the mounting bolts (1) and (4)
• Remove the manifold (3) with the unscrewed • Remove the oil pumps (2) and (3)
conduit (1) and O-ring (2)
Removing the cover

bolts (3)
• Remove the cover (1) with gasket (2)

ENGINE LUBRICATION
Checking the oil pump Installing the oil pumps

Checking the ring gear axial play Installing the oil pumps
• Put the Dial gauge holder [121] (2) with the Dial • Position the oil pumps (2) and (3)
gauge [122] (1) on the oil pump • Screw in the new mounting bolts (1) and (4) as
• Position the Dial gauge [122] (1) against the ring marked and then tighten them by hand
gear (3) with a preload • Tighten the mounting bolts (1) and (4) to 15 Nm
• Press the ring gear (3) towards the drive gear
• Zero the Dial gauge [122] (1) Mounting the cover
• Press the ring gear (2) towards the Dial
gauge [122] (1) and check the difference
The permissible axial play on the ring gear (3) is
0.040 - 0.090 mm.
If the axial play is out of tolerance, t a new oil pump.
Checking the rotor axial play
Note
Mount the gasket with the textured side
facing the crankcase.
• Position the cover (1) with a new gasket (2)

and then tighten them
• Put the Dial gauge holder [121] (2) with the Dial
gauge [122] (1) on the oil pump
• Position the Dial gauge [122] (1) against the rotor
(3) with a preload
• Press the rotor (3) towards the drive gear
• Press the rotor (2) towards the Dial gauge [122]
(1) and check the difference
The permissible axial play on the rotor (3) is
0.035 - 0.080 mm.
If the axial play is out of tolerance, t a new oil pump.

ENGINE LUBRICATION
Mounting the manifold for the oil suction line

the new O-rings (2)

CRANKSHAFT OIL SEALS
(1) Front crankshaft oil seal (3) Flywheel housing

(2) Cover (4) Rear crankshaft oil seal


Removing and installing the front radial shaft seal
Additional jobs
(1) Front radial shaft seal (2) Cover
WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or grease before
installation.
• Clean the vibration dampers and installer sleeve before assembly
WARNING

Special tools
[123] Impact extractor 80.99602-0016
• Extracting the radial shaft seal in conjunction with:

• Extractor hook [124]
[124] Extractor hook 80.99602-0175
• Extracting the radial shaft seal in conjunction with:

• Impact extractor [123]
[125] Aligning punch 80.99617-0020
• Installing the radial shaft seal in conjunction with:

• Plug-on handle [126]
• Ring [127]
• Pressing plate [128]
[126] Plug-on handle 80.99617-0187

• Aligning punch [125]
• Ring [127]
[127] Ring 80.99617-0144

[128] Pressing plate 80.99604-0342

• Ring [127]

Removing the front radial shaft seal Installing the front radial shaft seal
• Assemble the Pressing plate [128] (3) with the

WARNING
Plug-on handle [126] (5) and the Ring [127] (4)
Danger of component damage on the
• Put the closed side of the radial shaft seal (1) on
cover
the special tool
• Ensure that the Extractor hook [124]
• Screw in the Aligning punch [125] (2)
does not hook in behind the cover
• Push the special tool onto the Aligning punch [125]
• Extract the radial shaft seal (1) using the Impact (2)
extractor [123] (3) and the Extractor hook [124] (2) • Press in the radial shaft seal (1) as far as the stop
using the special tool
• Remove the special tool

Removing and installing the rear radial shaft seal

Additional jobs
(1) Rear radial shaft seal (2) Flywheel housing
WARNING
unscrewed
WARNING
PTFE sealing rings are rendered unusable if they come into contact with oil or grease before
installation.
• Clean the crankshaft gear and installer sleeve before assembly
WARNING

Special tools
[129] Hexagon bolt 06.01499-0121
• Extracting the crankshaft gear and radial shaft

seal in conjunction with:
• Extractor device [131]
[130] Bush 80.99601-0259

• Hexagon bolt [129]
[131] Extractor device 80.99601-6033

[132] Plug-on handle 80.99617-0187

• Washer [133]
• Guide plate [134]
• Press-in bush [135]
[133] Washer 80.99617-0144

[134] Guide plate 80.99606-0703

• Washer [133]
[135] Press-in bush 80.99604-0340

• Washer [133]

[136] Aligning punch 80.99617-0220
• Removing and installing the ywheel

• Washer [133]
[137] Engine barring gear 80.99626-6009
• Cranking the engine in conjunction with:

• Gear ratchet [140]
[138] Gear ratchet 80.99627-0001

• Engine barring gear [139]

Extracting the rear radial shaft seal Checking the valves for unobstructed
movement, 1st cylinder
• Check the 1st cylinder rocker arms (1) and (2) for
• Unscrew the mounting bolts (2) unobstructed movement
• Remove the cylinder head cover (1) If the rocker arms (1) and (2) for the rst cylinder
cannot move unobstructed, crank the engine a
Attaching the engine barring gear further 360° at the hexagon prole of the engine
barring gear.
Mounting the cylinder head cover, cylinder 1
• Remove the cover with the gasket and the TDC

marking plate from the ywheel housing
• Crank the engine to TDC using the Engine barring • Put on the cylinder head cover (1)
gear [143] (1) • Screw in and tighten the mounting bolts (2)

Mounting the special tool Installing the rear radial shaft seal
Installation position of crankshaft gear
• Insert the Bush [130] (4) into the crankshaft gear

(5)
• Insert the Extractor device [131] (3) into the • Align the marks on the crankshaft gear (1) and the
crankshaft gear (5) mark on the camshaft gear (2) with one another
• Clamp the Extractor device [131] (3) at the
clamping bolts (2) Installing the crankshaft gear
• Screw the Hexagon bolt [129] (8) into the Extractor
device [131]
• Screw in two ywheel bolts (1) and (7) opposite
one another
Extracting the radial shaft seal
WARNING
Component damage due to
insufciently tight t
• Replace the crankshaft gear every
time after the crankshaft gear/ywheel
screw connection is undone
• Screw the Hexagon bolt [129] (6) into the Extractor • Screw in the Aligning punch [136] (6) and (9)
device [131] (2) and press the crankshaft gear (3) • Align the alignment pin (3) for the crankshaft gear
off the crankshaft (1) with the bore in the crankshaft (2)
• Unscrew the ywheel bolts (5) and (8) • Put on the new crankshaft gear (1) and install
• Detach the Extractor device [131] (1) and remove using a soft hammer until the stop is reached
with the Bush [130] (4)
• Pull off the crankshaft gear (3) over the Aligning
punch [136] (4) and (7)
• Remove the radial shaft seal (2) from the
crankshaft gear (3)

Checking the crankshaft gear marks in relation Pressing in the radial shaft seal
to the camshaft gear
• Assemble the Press-in bush [135] (2) with the

• Check the marks on the crankshaft gear (1) in Plug-on handle [132] (5) and the Washer [133] (3)
relation to the camshaft gear (2) • Push the special tool onto the Guide plate [134]
Marks (1) and (2) match up. over the Aligning punch [136] (1) and (4)
• Press in the radial shaft seal into the ywheel
If the marks (1) and (2) do not match up, remove the housing (6) with the special tool until the Pressing
crankshaft gear and install at the mark. Align the plate [128] (2) is in contact with the Guide
crankshaft with the alignment pin if necessary. plate [134]
• Remove the special tool
Preparing to install the radial shaft seal
Removing the engine barring gear
• Separate two opposite-facing discs from the

transport sleeve in each case • Remove the Engine barring gear [143] (1)
• Position the radial shaft seal (4) with supplied • Mount the TDC marking plate
transport sleeve at the Guide plate [134] (3) • Mount the cover on the ywheel housing with a
• Carefully push the radial shaft seal (4) onto the new gasket
Guide plate [134] (3)
• Push the Guide plate [134] (3) over the Aligning
punch [136] (1) and (2)
• Remove the transport sleeve

CRANK MECHANISM
CRANK MECHANISM
(1) Piston (4) Flywheel

(2) Cylinder liner (5) Crankshaft
(3) Crankcase (6) Vibration damper

CRANK MECHANISM
VIBRATION DAMPER
Removing and installing the vibration damper, D2868 LE4xx
Additional jobs
(1) Mounting bolt (5) Mounting bolt

(2) Vibration damper (6) Spacer washer
(3) Graduated disc (7) Engine barring gear
(4) Hub (8) Mounting bolt
Technical data
Mounting bolt (3) .................................................. M10x25-10.9......................................................65 Nm
Mounting bolt (7) .................................................. M16x1.5x117-10.9.........................Initial torque 190 Nm
Mounting bolt (7) .................................................. M16x1.5x117-10.9................................Final torque 90°
Mounting bolt (10) ................................................ M10x30-10.9......................................................65 Nm
WARNING
Component damage due to reused mounting bolts
• Replace vibration damper mounting bolts once they have been undone

CRANK MECHANISM
WARNING
Special tools

[140] Gear ratchet 80.99627-0001

[141] Aligning punch 80.99617-0020
• Removing and installing the vibration damper

CRANK MECHANISM
Removing the vibration damper Screwing in the aligning punches
Attaching the engine barring gear
• Remove the cover with the gasket and the TDC Pulling off the vibration damper
• Mount and lock the Engine barring gear [139] (1)
CAUTION
components
• Use the lifting device or lift off with
• Unscrew the mounting bolts (1) support
• Remove the engine barring gear (2) with spacer
washer (3) • Unscrew the remaining mounting bolts (1)
• Pull off the vibration damper (2)
Unscrewing the mounting bolts • Unscrew the Aligning punch [141] (3) and (4)
• Unscrew two opposite mounting bolts (1) and (2)

CRANK MECHANISM
Dismantling the vibration damper Assembling the vibration damper
• Insert the hub (1) and the graduated disc (2) into
WARNING
the vibration damper (3) as marked
vibration damper aside incorrectly
to 65 Nm
• Do not lay the vibration damper down
on the discs
• Mark the position of the components in relation to

each other
• Remove the hub (1) and scale disc (2) from the
vibration damper (3)

CRANK MECHANISM
Installing the vibration damper Tightening diagram
Positioning the vibration damper
• Tighten the mounting bolts in the sequence 1-8
Preliminary tightening of mounting bolts

CAUTION
components
• Use a lifting device or lift with support
Note
Check the oil module screw connection
before installation

• Position the vibration damper (2) as marked
• Screw in the new mounting bolts (1) and tighten
them by hand
Unscrewing the aligning punches
• Screw in the remaining new mounting bolts (1) and

(2)
• Tighten all the mounting bolts to Initial torque 190
Nm in accordance with the tightening diagram
• Tighten all the mounting bolts to Final torque 90°
using the special tool (1) in accordance with the
tightening diagram

CRANK MECHANISM
• Position the engine barring gear (2) with spacer

washer (3)
65 Nm
• Remove the Engine barring gear [139] (1)

• Mount the TDC marking plate
• Mount the cover on the ywheel housing with a
new gasket

CRANK MECHANISM
Removing and installing the vibration damper, D2862 LE4xx

Additional jobs
(1) Mounting bolt (6) Mounting bolt

(2) Vibration damper (7) Engine barring gear
(3) Graduated disc (8) Washer
(4) Hub (9) Mounting bolt
(5) Vibration damper
Technical data
Mounting bolt (3) .................................................. M10x25-10.9......................................................65 Nm
Mounting bolt (8) .................................................. M16x1.5x117-10.9.........................Initial torque 190 Nm
Mounting bolt (8) .................................................. M16x1.5x117-10.9................................Final torque 90°
Mounting bolt (11)................................................. M10x30-10.9......................................................65 Nm
WARNING
• Replace vibration damper mounting bolts once they have been undone
WARNING

CRANK MECHANISM
Special tools
[142] Aligning punch 80.99617-0020
• Removing and installing the vibration damper

[144] Gear ratchet 80.99627-0001


CRANK MECHANISM
Removing the vibration damper Screwing in the centring pins
• Screw in the (1) and (2)
• Remove the cover with the gasket and the TDC Pulling off the vibration damper
• Mount and lock the Engine barring gear [139] (1)
CAUTION
components
• Use the lifting device or lift off with
• Unscrew the mounting bolts (1) and remove with support
the washers (2)
• Remove the engine barring gear (3) and vibration • Mark the position of the vibration damper (2) in
damper (4) relation to the crankshaft
• Unscrew the remaining mounting bolts (1)
Unscrewing the mounting bolts • Pull off the vibration damper (2)
• Unscrew the (3) and (4)

CRANK MECHANISM
Dismantling the vibration damper Assembling the vibration damper
• Insert the hub (1) and the graduated disc (2) into
WARNING
the vibration damper (3) as marked
vibration damper aside incorrectly
to 65 Nm
• Do not lay the vibration damper down
on the discs
• Mark the position of the components in relation to

each other
• Remove the hub (1) and graduated disc (2) from
the vibration damper (3)

CRANK MECHANISM
Installing the vibration damper Tightening diagram
Positioning the vibration damper
Preliminary tightening of mounting bolts

CAUTION
components
• Use a lifting device or lift with support
Note
Check the oil module screw connection
before installation

• Position the vibration damper (2) as marked
• Screw in the new mounting bolts (1) and tighten
them by hand
Unscrewing the centring pins

(2)
• Tighten all the mounting bolts to Initial torque 190
Nm in accordance with the tightening diagram
• Tighten all the mounting bolts to Final torque 90°
using the special tool (1) in accordance with the
tightening diagram
• Unscrew the (1) and (2)
• Position the engine barring gear (3)

• Screw in the mounting bolt (1) with washers (2)

CRANK MECHANISM
• Remove the Engine barring gear [139] (1)

• Mount the TDC marking plate
• Mount the cover on the ywheel housing with a
new gasket

CRANK MECHANISM
FLYWHEEL
Removing and installing the ywheel
Additional jobs
– Removing and installing the speed sensors, see 87
(1) Mounting bolt (2) Flywheel
Technical data
Mounting bolt (1) .................................................. M18x1.5x91-12.9 ..........................Initial torque 100 Nm
Mounting bolt (1) .................................................. M18x1.5x91-12.9 .................................. 2nd torque 90°
Mounting bolt (1) .................................................. M18x1.5x91-12.9 .................................Final torque 90°
Installation temperature, ywheel ring gear ................................................................................ 220-240℃
WARNING
• Replace ywheel mounting bolts once they have been undone
WARNING
unscrewed

CRANK MECHANISM
WARNING
Special tools
[145] Aligning punch 80.99617-0220
• Removing and tting the ywheel
[146] Socket, size 22 80.99612-0024
• Undoing and tightening the ywheel bolts in

conjunction with:
• Support [148]
• Holding device [150]
• Pan head screw [152]
• Adapter [155]
• Socket [151]

conjunction with:
• Support [148]
• Adapter [155]
• Socket [151]
[148] Support 80.99606-0551

conjunction with:
• Adapter [155]
• Socket [151]

CRANK MECHANISM

conjunction with:
• Support [148]
• Adapter [155]
• Socket [151]
[150] Holding device 80.99606-0641

conjunction with:
• Support [148]
• Adapter [155]
• Socket [151]
[151] Socket 80.99603-0327

conjunction with:
• Support [148]
• Adapter [155]
• Socket [151]
[152] Pan head screw 06.02191-0407

conjunction with:
• Support [148]
• Adapter [155]
• Socket [151]

CRANK MECHANISM
[153] Connecting pin 06.22729-0006

conjunction with:
• Support [148]
• Adapter [155]
• Socket [151]
[154] Rubber ring 42 mm 08.06142-9006

conjunction with:
• Support [148]
• Adapter [155]
• Socket [151]
[155] Adapter 80.99606-0552

conjunction with:
• Support [148]
• Socket [151]
[156] Socket, E24 80.99603-0327
• Undoing and tightening the vibration damper

mounting bolts in conjunction with:
• Support [83]
• Adapter [155]
[157] Eye-bolt 06.05110-0103

CRANK MECHANISM
Removing the ywheel Unscrewing the ywheel mounting bolts
Assembling the special tool
• Insert the Torque multiplier i = 1 : 3.3 [147] (1) into Screwing in the aligning punches
• Mount the Holding device [150] (5) with the Pan
head screw [152] (4) and the Adapter [155] (3) on
Torque multiplier i = 1 : 3.3 [147] (1)
42 mm [154] (6)
• Insert one Socket, E24 [156] each into the Holding
device [150] (5) and the Socket, size 22 [146] (8)
Undoing the ywheel mounting bolts

• Unscrew the remaining mounting bolts
• Put the special tool (2) on the mounting bolt (1) to

be undone
• Undo the mounting bolts (1) using the special tool
(2) in conjunction with the Socket [151]

CRANK MECHANISM
Pulling off the ywheel Removing and installing the ywheel

ring gear
Drilling the ywheel ring gear
CAUTION
components
• Use lifting gear to remove the ywheel WARNING
Danger of injury from metal chips
• Screw the Eye-bolt [157] into the ywheel • Wear protective equipment
• Attach the lifting gear in the Eye-bolt [157]
WARNING
• Pull off the ywheel (3) over the Aligning
Flywheel damage due to imbalance
punch [145] (1) and (2)
• Take care not to damage the ywheel
• Detach the lifting gear
when spot-drilling the ywheel ring gear
• Renew the spot-drilled ywheel
• Spot-drill the ywheel ring gear (1) and use a chisel

to prise it open
• Remove the ywheel ring gear (1) from the
ywheel (2)
• Clean the contact surfaces of the ywheel ring
gear (1) on the ywheel (2) and check them for
damage

CRANK MECHANISM
Installing the ywheel ring gear Installing the ywheel

Fitting the ywheel
Note
The chamfers on the teeth of the ywheel
ring gear must point away from the CAUTION
ywheel. Danger of injury due to heavy
components
• Heat the ywheel ring gear (1) to 220-240℃ • Use lifting gear to install the ywheel
• Put the ywheel ring gear (1) on the ywheel (2)
WARNING
and adjust as necessary
Component damage due to reused
ywheel bolts
• Fit new mounting bolts once they have
been undone
• Attach the lifting gear in the Eye-bolt [157]

• Align the dowel hole in the ywheel (3) with the
crankshaft alignment pin
• Fit the ywheel (3) over the Aligning punch [145]
(1) and (2) using lifting gear
• Detach the lifting gear
• Unscrew the eye-bolt from the ywheel
Unscrewing the centring pins
• Screw in new ywheel mounting bolts until

nger-tight, with the exception of two mounting
bolts

CRANK MECHANISM
Screwing in the ywheel mounting bolts Tightening the ywheel mounting bolts

Note
(2) and tighten by hand
Note the torque multiplier ratio, i = 1 : 3.3.
Tightening diagram
• Tighten the mounting bolts (1) to Initial torque 100

Nm as per the tightening diagram
• Tighten the mounting bolts (1) using the special
tool (2) in conjunction with Socket [151]
• Tighten the mounting bolts (1) to 2nd torque 90°
as per the tightening diagram
as per the tightening diagram

CRANK MECHANISM
PISTONS AND CONNECTING RODS

Removing and installing the pistons and connecting rods
Additional jobs
(1) Double-bevelled ring (6) Piston

(2) Taper-face ring (7) Internal circlip
(3) Keystone ring (8) Connecting rod
(4) Internal circlip (9) Connecting rod bearing cap
(5) Piston pin (10) Connecting rod bearing bolt
Technical data
Connecting rod bearing bolt (10) ........................... M14x1.5x66-10.9 ..........................Initial torque 100 Nm
Connecting rod bearing bolt (10) ........................... M14x1.5x66-10.9 ............................Final tightening 90°
Connecting rods
Connecting rod length, small end bush centre - connecting rod bearing centre................ 282.45 - 282.5 mm

CRANK MECHANISM
Connecting rod bearing dimensions

Connecting rod bearing normal dimension .................................................................. 96.047 - 96.099 mm
Radial play, connecting rod ............................................................................................ 0.060 - 0.128 mm
Axial play, connecting rod............................................................................................... 0.240 - 0.438 mm
Spread......................................................................................................................................... 2.0 mm
Piston diameter
D1 measured 16 mm above lower edge of piston .....................................................127.770 - 127.800 mm
Piston ring (keystone ring)

Piston ring (keystone ring)..................................................................................... 3.5 mm (nominal value)
Piston ring width ................................................................................................................ 4.50 - 4.90 mm
Ring gap ........................................................................................................................... 0.40 - 0.55 mm
Piston ring (taper-face ring)

Piston ring height............................................................................................................... 2.47 - 2.49 mm
Axial play .......................................................................................................................... 0.09 - 0.18 mm
Ring gap ........................................................................................................................... 0.80 - 1.00 mm
Piston ring (double-bevelled ring)

Piston ring height............................................................................................................. 3.475 - 3.49 mm
Axial play ...................................................................................................................... 0.040 - 0.085 mm
Ring gap ........................................................................................................................... 0.25 - 0.45 mm
Piston height
Overall height.................................................................................................................115.4 - 115.6 mm
Piston height from middle of piston pin to piston crown / PH level 0 .................................. 78.95 - 79.05 mm
Piston pin/piston pin bore

Piston pin diameter.................................................................................................... 54.994 - 55.000 mm
Piston pin bore .......................................................................................................... 55.060 - 55.075 mm
Piston
Piston standout measured from crankcase to piston ................................................... -0.361 to +0.080 mm
WARNING
WARNING
Crack surfaces are sensitive. The principle involved can cause chipping
• Exchange the connecting rod if the crack surfaces are damaged
• Protect crack surfaces against damage caused by hard and sharp objects
• To clean the crack surfaces on the connecting rods, always rinse them in clean cleaning agent
• After cleaning, use compressed air to blow-dry the crack surfaces
• Do not allow rinsed-out particles to enter the engine
Note
The piston diameter is always measured perpendicular to the piston pin bore.

CRANK MECHANISM
Special tools
[158] Feeler gauge 08.75310-0806
• Checking the piston ring axial play and gap
• Checking the piston standout in conjunction with:

[160] Piston ring compressor pliers 83.09144-6090
• Removing and installing piston rings
[161] Dial gauge 08.71000-3217
• Checking the piston standout in conjunction with:

• Installing pistons
[163] Setting tool 80.99622-0052
• Positioning the bearing shell, cracked connecting

rod
[164] Depth gauge (electronic) 08.71195-9003
• Checking the piston ring insertion depth

CRANK MECHANISM
Removing the pistons and connecting Remove the connecting rod bearing cap
rods
Undoing the connecting rod bearing bolts
WARNING
Crack surfaces are sensitive. The
• Installation position and allocation of the principle involved can cause chipping
connecting rod bearing shell and connecting • Exchange the connecting rod if the
rod bearing crack surfaces are damaged
• Turn the crankshaft to BDC for unscrewing the • Protect crack surfaces against damage
connecting rod bearing bolts (1) caused by hard and sharp objects
• Unscrew the connecting rod bearing bolts (1) by • To clean the crack surfaces on the
one turn connecting rods, always rinse them in
clean cleaning agent
• After cleaning, use compressed air to
blow-dry the crack surfaces
• Do not allow rinsed-out particles to
enter the engine
• 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 bearing bolts (1)
• Remove the connecting rod bearing cap (2) and
big end bearing (3)
Removing the piston
• Mark the installation position and orientation of the

piston (1) relative to the cylinder liner (2)
• Pull the piston (1) with connecting rod out of the
cylinder liner (2)
• Remove the small end bearing from the
connecting rod

CRANK MECHANISM
Removing the piston Measuring the pistons, piston rings and

connecting rods
Removing the piston pin
Measuring the piston pins
WARNING
• Measure the piston pin (1) using a micrometer (2)
If the dimension of the gudgeon pin (1) is out of
principle involved can cause chipping.
tolerance of 54.994 - 55.000 mm, t a new piston
• Exchange the connecting rod if the
with gudgeon pin (1).
crack surfaces are damaged
• Protect crack surfaces against damage Measuring the piston ring axial play
caused by hard and sharp objects
• To clean the crack surfaces on the
connecting rods, always rinse them in
clean cleaning agent
• After cleaning, use compressed air to
blow-dry the crack surfaces
• Do not allow rinsed-out particles to
enter the engine
• Mark the relative positions of the piston (2), piston

pin (4) and connecting rod (5)
• Detach the internal circlips (1) and (3)
• Press the piston pin (4) out of the piston (2)
• Remove the piston (2)
Note
The axial play cannot be measured on the
keystone ring
• Measure the axial play between the

double-bevelled ring (3) and the piston (4)
at several points using the Feeler gauge [158] (1)
• Measure the axial play between the taper-face ring
(2) and the piston (4) at several points using the
Feeler gauge [158] (1)
The axial play on the double-bevelled ring (3) must
be 0.040 - 0.085 mm.
The axial play on the taper-face ring (2) must be

0.09 - 0.18 mm.
If the axial play is out of tolerance, replace the piston

with the piston rings.

CRANK MECHANISM
Removing the piston rings Installing the piston rings
• Set the Piston ring compressor pliers [160] (1) to

WARNING
the piston diameter
• Remove the piston rings (2) using the Piston ring
installation of the piston rings
compressor pliers [160] (1)
• Take care not to damage the jacket
• Carefully clean the piston ring grooves in the
surface of the piston when installing the
piston (3)
piston rings
Measuring the piston ring gap • Only install piston rings using correctly
set piston ring compressor pliers
Note
Install the joint of the double-bevelled
ring and the tube spring offset by 180°
in relation to one another.
• Set the Piston ring compressor pliers [160] (1) to

the piston diameter
• Insert the new piston rings (2) into the correct
piston ring grooves in the piston (3) using the
Piston ring compressor pliers [160] (1), ensuring
that the gaps are 120° offset
• Clean the piston rings

• Insert the piston ring (2) evenly deep into the
cylinder liner (1)
• Obtain the same depth for the piston ring (2) with
Depth gauge (electronic) [164]
• Measure the ring gap with the Feeler gauge [158]
The keystone ring gap must be 0.40 - 0.55 mm.
The taper-face ring gap must be 0.80 - 1.00 mm.
The double-bevelled ring gap must be 0.25 - 0.45

mm.
If the ring gaps are out of tolerance, the piston rings

must be replaced (as a set only, not individually).

CRANK MECHANISM
Measuring the connecting rod bearings Measuring the piston pin bore
Measuring the connecting rod bearing inside

diameter
• Use the internal calliper (1) and Dial gauge [161]

(3) to check the piston pin bore
If the dimension of the gudgeon pin hole is out
• Insert the cleaned upper connecting rod bearing of tolerance of 55.060 - 55.075 mm, t a new
shell into the cleaned connecting rod (1) connecting rod (2).
• Insert the cleaned lower connecting rod bearing
shell into the cleaned connecting rod bearing cap
(2)
• Insert the connecting rod bearing shell into the
corresponding connecting rod bearing cap (2)
according to the marking and pairing; position
using the Setting tool [163] if necessary
• Fit the connecting rod bearing cap (2) with inserted
connecting 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 bearing bolts and
tighten them to Initial torque 100 Nm
• Use the Dial gauge [161] (4) and internal calliper
(3) to check the connecting rod bearing inside
diameter
Connecting rod bearing inside diameter,
96.047 - 96.099 mm.
If the inside diameter is out of tolerance, t new

connecting rod bearing shells.

CRANK MECHANISM
Installing the pistons and connecting Piston installation with piston ring compressor
rods pliers
Installing the piston pins
WARNING
Note piston installation position
There is an arrow on the piston crown. • Check the direction of the arrow on the
piston crown
WARNING • Turn the crankshaft so that the connecting rod

Crack surfaces are sensitive. The bearing journal is located before the cylinder of
principle involved can cause chipping. the piston to be installed (2) (TDC)
• Exchange the connecting rod if the • Align the gaps in the piston rings so they are each
crack surfaces are damaged offset 120° from one another and then thinly apply
• Protect crack surfaces against damage engine oil to MAN Standard 3277 on the piston (2)
caused by hard and sharp objects and connecting rod bearing
• Insert the upper connecting rod bearing into the
• Attach a new circlip (3) in the groove in the piston connecting rod, positioning it using the Setting
(2) tool [163] if necessary
• Align the connecting rod (5) with the piston (2) so • Align the piston (2) so that the arrow on the piston
that the long connecting rod big end is pointing in crown is facing the centre of the engine
the direction of the arrow • Open the Piston ring compressor pliers [162] (1)
• Fit the piston (2) over the connecting rod (5) as and t over the piston (2)
marked • Clamp the Piston ring compressor pliers [162] (1)
• Thinly apply clean engine oil to MAN Standard • Push the piston (2) through the Piston ring
3277 on the piston pin (4) compressor pliers [162] (1) into the cylinder liner
• Push the piston pin (4) through the piston (2) and as marked
the connecting rod (5) as marked, ensuring that • Carefully push the piston (2) through the cylinder
the stop is reached liner until the connecting rod bearing is lying on
• Attach a new circlip (1) in the groove in the piston the crankshaft
(2)
• Check that the circlips (1) and (3) are seated
correctly
If the circlips (1) and (3) have not engaged correctly,
remove and re-attach the circlips (1) and (3),
ensuring that they are seated correctly.
If the connecting rod (5) is installed in the incorrect

position relative to the piston (2), repeat the
procedure.

CRANK MECHANISM
Installing the connecting rod bearing cap Tightening the connecting rod bearing shells
• Turn the crankshaft to BDC for tightening the

WARNING
connecting rod bearing bolts (1)
• Check the alignment of the connecting rod
principle involved can cause chipping.
bearings, remove the connecting rod bearing
• Exchange the connecting rod if the
shells and position the connecting rod bearings
crack surfaces are damaged
again with Setting tool [163], then t the connecting
• Protect crack surfaces against damage
rod bearings back on
caused by hard and sharp objects
• Tighten the new connecting rod bearing bolts (1)
to Initial torque 100 Nm
• Insert the connecting rod bearing shell (3) into
• Tighten the connecting rod bearing bolts (1) to
the corresponding connecting rod bearing cap (2)
Final tightening 90°
according to the marking and pairing; position
using the Setting tool [163] if necessary Measuring the piston standout
• Fit the connecting rod bearing cap (2) with
inserted connecting rod bearing shell (3) 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 new connecting rod bearing bolts (1)
and tighten them by hand
• Move the piston (2) to top dead centre

• Put the Dial gauge [161] (3) with the Dial gauge
holder [159] (4) on the crankcase (1)
• Locate the dial gauge tip (5) on the crankcase (1)
and zero the Dial gauge [161] (3)
• Locate the dial gauge tip (5) on the piston (2) and
read off the difference
The permissible piston standout is -0.361 to +0.080
mm.

CRANK MECHANISM
CRANKSHAFT
Removing and installing the crankshaft
Additional jobs
– Removing and installing the hydraulic pump, see 157
– Removing and installing the oil pumps, see 437
– Removing and installing the pistons and connecting rods, see 477
– Removing and installing the rear timing gears, see 401

CRANK MECHANISM
(1) Mounting bolt, crankcase lower section (7) Crankcase

(2) Mounting bolt, crankcase lower section (8) Main bearing shell, crankcase
(3) Mounting bolt, crankcase lower section (9) Crankshaft
(4) Mounting bolt, crankcase lower section (10) Main bearing shell, crankcase lower
(5) Crankcase lower section section
(6) Sleeve (11) Fitted sleeve
Technical data
Mounting bolts, crankcase lower section (4) ........... M8x35-10.9 .......................................................35 Nm
Mounting bolts, crankcase lower section ................ M8x50-10.9 .......................................................35 Nm
Mounting bolts, crankcase lower section (1) ........... M10x170-10.9....................................................65 Nm
Mounting bolts, crankcase lower section (2) and
(3) ....................................................................... M18x2x200...................................Initial torque 160 Nm
(3) ....................................................................... M18x2x200........................................... 2nd torque 90°
(3) ....................................................................... M18x2x200............................................ 3rd torque 90°
Crankshaft technical data

Axial play, crankshaft (1) ................................................................................................ 0.200 - 0.401 mm
Radial play, crankshaft (1).............................................................................................. 0.060 - 0.128 mm
Crankshaft dimensions
Crankshaft journal, normal dimension ................................................................... Ø 111.966 - 111.988 mm
Connecting rod bearing journal dimensions

Connecting rod bearing journal, normal dimension ................................................... Ø 95.966 - 95.988 mm

CRANK MECHANISM
Glyco main bearing dimensions

Wall thickness main bearing normal dimension ............................................................... 2.961 - 2.973 mm
Spread......................................................................................................................................... 2.0 mm
Main bearing Ø....................................................................................................... 112.036 - 112.126 mm
Glyco thrust washer dimensions

Thrust washer thickness, normal dimension .................................................................... 3.350 - 3.400 mm
Miba main bearing dimensions

Wall thickness main bearing normal dimension ............................................................... 2.961 - 2.973 mm
Spread......................................................................................................................................... 2.0 mm
Main bearing Ø....................................................................................................... 112.063 - 112.126 mm
Miba thrust washer dimensions

Thrust washer thickness, normal dimension .................................................................... 3.300 - 3.350 mm
Service products
Loctite 5900 ...................................................................................................................... 04.10394-9272
WARNING
Special tools
[165] Dial gauge 08.71000-3217
• Checking the crankshaft axial and radial play in

conjunction with:

conjunction with:
[167] Locating pin 80.99605-0197

conjunction with:
[168] Setting tool 80.99622-0052
• Positioning the bearing shell – cracked

connecting rod

CRANK MECHANISM
[169] Aligning punch 80.99617-0020
• Removing and installing the crankshaft in

conjunction with:
[170] Aligning punch 80.99617-0220
• Removing and installing the crankshaft in

conjunction with:
[171] Eye-bolt 80.99606-0660
• Removing and installing the crankcase lower

section
[172] Hexagon bolt 06.01499-0121

[173] Bush 80.99601-0259


[175] Socket, size 22 80.99612-0024
• Undoing and tightening the crankcase lower

section mounting bolts in conjunction with:
• Support [177]
• Adapter [183]
• Socket [184]

CRANK MECHANISM

• Support [177]
• Adapter [183]
• Socket [184]
[177] Support 80.99606-0551

• Adapter [183]
• Socket [184]

• Support [177]
• Adapter [183]
• Socket [184]
[179] Holding xture 80.99606-0641

• Support [177]

CRANK MECHANISM
[180] Pan head screw 06.02191-0407

• Support [177]
• Adapter [183]
• Socket [184]
[181] Connecting pin 06.22729-0006

• Support [177]
• Adapter [183]
• Socket [184]
[182] Rubber ring 42 mm 08.06142-9006

• Support [177]
• Adapter [183]
• Socket [184]
[183] Adapter 80.99606-0552

• Support [177]
• Socket [184]

CRANK MECHANISM
[184] Socket 80.99603-0327

• Support [177]
• Adapter [183]
[185] Holding xture 80.99606-0585

• Support [177]
• Adapter [183]

CRANK MECHANISM
Checking the crankshaft Checking the crankshaft radial play
Checking the crankshaft axial play
• Position the Dial gauge [165] (1) with the Dial

gauge holder [166] (3) and Locating pin [167] on
• Position the Dial gauge [165] (1) with the Dial the crankshaft (2) with a preload
gauge holder [166] (2) and Locating pin [167] on • Push the crankshaft (2) into the end position,
the crankshaft (3) with a preload towards the Dial gauge [165] (1)
• Push the crankshaft (3) horizontally into the end • Zero the Dial gauge [165] (1)
position towards the ywheel housing • Pull the crankshaft (2) in the opposite direction
• Zero the Dial gauge [165] (1) The permissible radial play on the crankshaft (2) is
• Pull the crankshaft (3) into the end position, 0.060 - 0.128 mm.
towards the Dial gauge [165] (1), and read off the
difference If the radial play is out of tolerance, check the outside
The permissible axial play on the crankshaft (3) is diameter of the crankshaft bearing journal and the
0.200 - 0.401 mm. inside diameter of the crankshaft bearing.
If the axial play is out of tolerance, install suitable Check the crankshaft bearing journal outside
thrust washers, see Miba thrust washer dimensions, diameter, see Checking the main bearing journal,
489, see Glyco thrust washer dimensions, 489. 501.
Check the crankshaft bearing inside diameter,

see Checking the crankshaft bearing shell inside
diameter, 500.

CRANK MECHANISM
Removing the crankshaft Undoing the outer crankcase lower section

mounting bolts, V8 engine
Setting the timing gears to the mark
• Align the marks on the crankshaft gear (1) and

camshaft gear (2) with one another
Unscrewing the crankcase lower section

mounting bolts
• Mark the tightening sequence 1 to 10 for the

mounting bolts
• Unscrew the mounting bolts 1 to 10 and remove
the washers

(1)

CRANK MECHANISM
Undoing the outer crankcase lower section Assembling special tool 1

mounting bolts, V12 engine

• Mount the Holding xture [179] (5) with the Pan
head screw [180] (4) and the Adapter [183] (3) on
42 mm [182] (6)
• Insert the Socket [184] into the Socket, size
22 [175] (8) and Holding xture [179] (5)
• Mark the tightening sequence for the 14 mounting

bolts
• Unscrew the mounting bolts 1 to 14 and remove
the washers

CRANK MECHANISM
Undoing the inner crankcase lower section Undoing the inner crankcase lower section
mounting bolts, V8 engine mounting bolts, V12 engine
• Mark the tightening sequence 1 to 20 for the • Mark the tightening sequence 1 to 28 for the
mounting bolts mounting bolts
• Undo the mounting bolts 1 to 20 using the special • Undo the mounting bolts 1 to 28 using the special
tool tool
• Unscrew the mounting bolts 1 to 20 • Unscrew the mounting bolts 1 to 28
• Dismantle the special tool • Dismantle the special tool

CRANK MECHANISM
Removing the crankcase lower section Removing the main bearing shells from the
crankcase lower section
CAUTION • Mark the installation position of the crankshaft

Danger of injury due to heavy bearing shells (1)
components • Remove the crankshaft baring shells (1)
• Lift off the crankcase lower section with • Check for completeness of the tted sleeves (2)
support for the V8 engine (10 pcs.) and the V12 engine
WARNING (14 pcs.)
Component damage due to main
bearing shells falling out Removing the thrust washers at the bottom
• Make sure the main bearing shells do
not fall out when lifting off the crankcase
lower section
• Screw the into the crankcase lower section at the

positions (1) V8 engine and (2) V12 engine
• Tighten the by hand
• Screw in the alternately, one turn at a time
• After this is done three times, the bolt head comes
into contact
Do not tighten the
• Lift off the crankcase lower section (5) in
conjunction with the Eye-bolt [171] (3) and
(4)
• Mark the installation position of the thrust washers
(1)
• Remove the thrust washers (1)

CRANK MECHANISM
Screwing in the centring pins Removing the crankshaft bearing shells from the
crankcase
• Screw in the Aligning punch [169] (1) at the front

of the crankshaft • Mark the crankshaft bearing shells (1) to indicate
• Screw in the Aligning punch [170] (2) at the rear correct assignment and installation position
of the crankshaft • Remove the crankshaft baring shells (1)
• Mark the installation position of the thrust washers
Lifting out the crankshaft (2)
• Remove the thrust washers (2)
Pulling off the crankshaft gear
CAUTION
Danger of injury due to incorrect lifting
gear • Insert the Bush [173] (2) into the crankshaft gear
• Use separate lifting gear with equal (5)
length for each centring pin • Insert the Extractor device [174] (1) into the
WARNING crankshaft gear (5)
Component damage due to incorrect • Clamp the Extractor device [174] (1) at the
lifting gear clamping bolts
• Do not use any lifting gear or steel • Screw in the Aligning punch [170] (4) and (7)
cables with sharp edges to lift out the • Screw the Hexagon bolt [172] (6) into the Extractor
crankshaft device [174] (1)
• Press the crankshaft gear (5) off the crankshaft (3)
• Attach the lifting gear using the centring pins by screwing in the Hexagon bolt [172] (6)
• Lift out the crankshaft (1) • Pull off the crankshaft gear (5) over the Aligning
• Unscrew the Aligning punch [169] at the front punch [170] (4) and (7)
• Unscrew the Aligning punch [170] at the rear • Detach the Extractor device [174] (1) and remove
with the Bush [173] (2)

CRANK MECHANISM
Checking the crankshaft and crankshaft Checking the crankshaft bearing shell inside
bearings diameter
Checking the crankshaft bearing shell

expansion
• Insert the crankshaft bearing shells into the

crankcase and lower crankcase section (3) as
marked
Note • Put on the crankcase lower section (3)
The difference between dimension A • Screw the old mounting bolts (4) into the lower
and dimension B is the spread of the crankcase section (3) and tighten to 65 Nm
crankshaft bearings. • Check the crankshaft bearing using the internal
calliper (2) in conjunction with the Dial gauge [165]
(1)
• Clean the bearing shells (2) and put them together
• Repeat the measurement on all the crankshaft
on a at surface as marked
bearings
• Check dimension A using a micrometer (1)
• Remove the crankcase lower section (3)
• Check dimension B using a micrometer (1)
If the crankshaft bearing dimensions are out of
If the maximum permissible expansion of 2.0 mm is
tolerance, see Glyco main bearing dimensions, 489
exceeded, new bearing shells must be tted.
or see Miba main bearing dimensions, 489, the main
bearing shells must be replaced.

CRANK MECHANISM
Checking the main bearing journal Installing the crankshaft

Inserting the main bearing shells into the
• Clean the main bearing journal of the crankshaft

(1)
• Measure the main bearing journal of the
crankshaft (1) using a micrometer (2) • Check for completeness of the tted sleeves (2)
• Repeat the measurement for each main bearing for the V8 engine (10 pcs.) and the V12 engine
journal (14 pcs.)
The dimensions of the crankshaft bearing • Thinly apply clean engine oil to MAN Standard
journals must be within the specied tolerances, 3277 on the main bearing shells (1)
Ø 111.966 - 111.988 mm. • Insert the main bearing shells (1) into the bearing
seats as marked and align with the Setting
Replace the crankshaft if the dimensions are out of tool [168]
tolerance
Inserting the main bearing shells into the
Checking the connecting rod bearing journals crankcase
• Clean the crankshaft (1) Note

• Measure the connecting rod bearing journal using Only install thrust washers with the same
a micrometer (2) wall thickness.
• Measure the connecting rod bearing journal at
several points
• Insert the cleaned main bearing shells (1) into the
• Repeat the measurement for each connecting rod
bearing seats on the crankcase (1) as marked and
bearing journal
align with the Setting tool [168]
• The permitted connecting rod bearing journal
diameter is Ø 95.966 - 95.988 mm
3277 on the main bearing shells (1)
Replace the crankshaft if the dimensions are out
• Determine the thrust washers (2) to be used, see
of tolerance
Checking the crankshaft axial play, 494
3277 on the cleaned thrust washers (2)
• Insert the thrust washers (2) into the nal bearing
seat as marked, with the oil grooves facing the
crankshaft

CRANK MECHANISM
Inserting the crankshaft Unscrewing the centring pins
• Unscrew the Aligning punch [169] (1) at the front

CAUTION
of the crankshaft
Danger of injury due to incorrect lifting
• Unscrew the Aligning punch [170] (2) at the rear
gear
of the crankshaft
• Use separate lifting gear with equal
length for each centring pin Installing the thrust washers at the bottom
WARNING
lifting gear
• Do not use any lifting gear or steel
cables with sharp edges to lift out the
crankshaft
WARNING
Component damage when inserting
the crankshaft
• Make sure that the crankshaft does not
collide with other components when
being installed
• Screw in the Aligning punch [169] at the front of

the crankshaft (1)
• Screw in the Aligning punch [170] at the rear of the
3277 on the cleaned thrust washers (1)
crankshaft (1)
• Put the thrust washers (1) onto the nal bearing
• Attach the lifting gear using the centring pins
seat as marked, with the oil grooves facing the
crankshaft
3277 on the main bearing journal of the crankshaft
(1)
• Insert the crankshaft (1) into the crankcase

CRANK MECHANISM
Installation instructions for crankcase lower Tightening sequence for outer mounting bolts,
section V8 engine
• Thinly apply Loctite 5900 (1) on the mating faces

of the crankcase lower section (2), as illustrated
Putting on the crankcase lower section
• Evenly tighten the mounting bolts (1) and (2)

alternately until the crankcase lower section
comes into contact
• Tighten the mounting bolts 1 to 10 as per the
tightening sequence (1-10)
CAUTION
components
• Lift off the crankcase lower section 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
• Check the bushings (4) for completeness (2 pcs.)

• Attach the lifting gear at the Eye-bolt [171] (3)
• Lift the crankcase lower section (2) onto the
crankcase
• Centre the crankcase lower section (2) using the
mounting bolts (1) when putting it on
• Remove the mounting bolts (1) and the
Eye-bolt [171] after putting on

CRANK MECHANISM
Tightening sequence for outer mounting bolts, Assembling special tool 1

V12 engine

• Mount the Holding xture [179] (5) with Pan head
screw [180] (4) and Adapter [183] (3) on the
Support [177] (2)
• Put the Socket, size 22 [175] on the Torque
multiplier i = 1 : 3.3 [176] (1) and secure
using Connecting pin [181] (7) and Rubber
ring 42 mm [182] (6)
• Insert the Socket [184] (8) into the Socket, size
22 [175] and Holding xture [179] (5)
• Evenly tighten the mounting bolts (1) and (2)

alternately until the crankcase lower section
comes into contact
• Tighten the mounting bolts 1 to 10 as per the
tightening sequence (1-14)
Tightening the outer mounting bolts

3277 on the contact surfaces and threads of the
new mounting bolts (1)
• Screw in the new outer mounting bolts (1) with
washers (2) as marked
• Tighten the outer mounting bolts (1) to 65 Nm as
per the tightening diagram

CRANK MECHANISM
Tightening sequence for inner mounting bolts, Tightening sequence for inner mounting bolts,
V8 engine V12 engine
• Tighten the mounting bolts 1 to 20 as per the • Tighten the mounting bolts 1 to 28 as per the
tightening sequence (1-20) tightening sequence (1-28)
Tightening the inner mounting bolts

3277 on the contact surfaces and threads of the
new mounting bolts (1)
• Screw in the new inner mounting bolts (1) as
marked
• Tighten the inner mounting bolts (1) to Initial torque
160 Nm as per the tightening diagram
• Tighten the inner mounting bolts (1) to 2nd torque
90° as per the tightening diagram
• Tighten the inner mounting bolts (1) to 3rd torque
90° as per the tightening diagram

CRANK MECHANISM
Screwing in the crankcase lower section Checking the crankshaft axial play
mounting bolts
• Position the Dial gauge [165] (1) with the Dial

• Screw in the mounting bolts (1) as marked and gauge holder [166] (2) and Locating pin [167] on
tighten them to 35 Nm the crankshaft (3) with a preload
• Push the crankshaft (3) horizontally into the end
Checking the crankshaft for unobstructed position towards the ywheel housing
movement • Zero the Dial gauge [165] (1)
• Pull the crankshaft (3) into the end position,
towards the Dial gauge [165] (1), and read off the
difference
The permissible axial play on the crankshaft (3) is
0.200 - 0.401 mm.
If the axial play is out of tolerance, install suitable

thrust washers, see Miba thrust washer dimensions,
489, see Glyco thrust washer dimensions, 489.
• Turn the crankshaft (1)

It must be easy to turn the crankshaft (1), and the
crankshaft must not touch other components.
If this is not the case, repeat the procedure for

removing and installing the crankshaft.

CRANK MECHANISM
Checking the crankshaft radial play Crankshaft installation position
• Position the Dial gauge [165] (1) with the Dial • Align the marks on the crankshaft gear (1) and
gauge holder [166] (3) and Locating pin [167] on camshaft gear (2) with one another
the crankshaft (2) with a preload If the marks (1) and (2) do not match up, remove the
• Push the crankshaft (2) into the end position, crankshaft gear and install it again with the marks
towards the Dial gauge [165] (1) (1) aligned with the mark on the camshaft gear (2).
• Pull the crankshaft (2) in the opposite direction
The permissible radial play on the crankshaft (2) is
0.060 - 0.128 mm.
If the radial play is out of tolerance, check the outside

diameter of the crankshaft bearing journal and the
inside diameter of the crankshaft bearing.
Check the crankshaft bearing journal outside

diameter, see Checking the main bearing journal,
501.
Check the crankshaft bearing inside diameter,

see Checking the crankshaft bearing shell inside
diameter, 500.
Installing the crankshaft gear
• Place the crankshaft gear (1) over the alignment

pin (2) as far as the stop on the crankshaft (3)

CRANKCASE
CRANKCASE
(1) Right vent line (8) Oil return line

(2) Left vent line (9) Oil return line, engine ventilation
(3) Flywheel housing (10) Cover
(4) Cylinder liner (11) Oil return line, engine ventilation
(5) Sealing ring (12) Oil return line
(6) Oil separator, left (13) Ventilation housing, right
(7) Ventilation housing, left (14) Oil separator, right

CRANKCASE
CRANKCASE VENTILATION
Removing and installing the crankcase ventilation
Additional jobs
(1) Right vent line (3) Left oil return line

(2) Left vent line (4) Right oil return line
Service products
WARNING

CRANKCASE
Special tools

CRANKCASE
Removing the crankcase ventilation Detaching the left oil return lines
Removing the left ventilation line

• Unscrew the mounting bolt (3) and remove the
bush (4) Detaching the right oil return lines
• Undo the jubilee clip (2) using the Hose clamp
pliers for jubilee clips [186] and push it onto the
moulded hose
moulded hose
• Remove the vent line (5)
Removing the right ventilation line

• Unscrew the mounting bolt (5) and remove the

bush (2)
moulded hose
• Undo the jubilee clips (1) using the Hose clamp
pliers for jubilee clips [186] and push them onto
the moulded hose
• Remove the vent line (4)

CRANKCASE
Installing the crankcase ventilation Installing the right vent line
Attaching the right oil return lines

moulded hose contact surfaces
• Position the oil return lines (1) and (3) so that they • Position the vent line (4) with the jubilee clips (1)
are free of strain and (3)
• Tighten the union nuts for the oil return lines (1) • Mount the jubilee clips (1) and (3) using the Hose
and (3) clamp pliers for jubilee clips [186]
• Mount the fastening (1) • Position the bush (2) and then screw in and tighten
the mounting bolt (5)
Attaching the left oil return lines
Installing the left vent line
• Position the oil return lines (1) and (2) so that they
are free of strain • Thinly apply Renolit Si 704 silicone grease on the
• Tighten the union nuts for the oil return lines (1) moulded hose contact surfaces
and (2) • Position the vent line (5) with the jubilee clips (1)
• Mount the fastening (3) and (2)
• Mount the jubilee clips (1) and (2) using the Hose
• Position the bush (4) and then screw in and tighten
the mounting bolt (3)

CRANKCASE
ENGINE COVER
Removing and Installing the engine cover
(1) Front engine cover (4) Rear engine cover

(2) Engine cover centre piece (V12 only) (5) Engine cover side section, left
(3) Engine cover side section, right
WARNING

CRANKCASE
Removing the engine cover Removing the engine cover side section
Removing the front engine cover

• Remove the mounting nuts (2) with the washers
• Unscrew the mounting nuts (2) (1)
• Remove the mounting nuts (2) with the washers • Remove the right engine cover side section (3)
(1) • Unscrew the mounting nuts (5)
• Remove the front engine cover (3) • Remove the mounting nuts (5) with the washers
(6)
Removing the rear engine cover • Remove the left engine cover side section (4)
Removing the engine cover side section

attachment points

• Remove the mounting nuts (2) with the washers
(1)
• Remove the rear engine cover (3) • Mark the installation position of the holders (4) and
(6)
• Mark the installation position of the rubber/metal
buffers (3) and (5)
• Unscrew and remove the mounting nut (2)
• Remove the rubber/metal buffer (3)

CRANKCASE
Removing the rear engine cover attachment Mounting the engine cover
points
Mounting the engine cover centre piece (V12
only)
• Mark the installation position of the holders (1) and

(9)
• Mark the installation position of the rubber/metal • Position the engine cover centre piece (3)
buffers (3) and (6) • Screw on and tighten the mounting nuts (2) with
• Unscrew and remove the mounting nut (4) washers (1)
• Unscrew the mounting bolt (2) Installing the rear engine cover attachment
• Remove the holder (1) and bush (10) points
• Remove the holder (9) and bush (8)
Removing the engine cover centre piece (V12

only)
• Position the bush (10) and holder (1) as marked

• Position the rubber/metal buffer (3) as marked
• Position the bush (8) and holder (9) as marked
• Unscrew the mounting nuts (2) • Screw on and tighten the mounting nut (7)
• Remove the mounting nuts (2) with the washers If the rear engine cover does not centre in the
(1) rubber/metal buffers (3) and (6) easily, repeat the
• Remove the engine cover centre piece (3) procedure and re-align the holders (1) and (9) with
the rubber/metal buffers (3) and (6).

CRANKCASE
Installing the engine cover side section Mounting the rear engine cover
attachment points
• Position the rear engine cover (3)

• Position the holder (4) as marked • Screw on and tighten the mounting nuts (2) with
• Screw in and tighten the mounting bolt (1) washers (1)
• Screw on and tighten the mounting nut (2) Mounting the front engine cover
If the side sections do not centre in the rubber/metal
buffers (3) and (5) easily, repeat the procedure and
re-align the holders (4) and (6) with the rubber/metal
buffers (3) and (5).
Mounting the engine cover side section
• Position the front engine cover (3)

• Screw on and tighten the mounting nuts (2) with
washers (1)
• Position the right engine cover side section (3)

washers (1)
• Position the left engine cover side section (4)
washers (6)

CRANKCASE
COVER
Removing and installing the cover
Additional jobs
(1) Cover (4) Mounting bolt

(2) Gasket (5) Mounting bolt
(3) O-ring
WARNING

CRANKCASE
Removing the cover Mounting the cover

Removing the manifold for the oil suction line Mounting the cover

Note
• Remove the manifold (3) with the unscrewed
conduit (1) and O-ring (2)

and then tighten them
Mounting the manifold for the oil suction line

(3)
• Remove the cover (1) with gasket (2)
the new O-rings (2)

CRANKCASE
FLYWHEEL HOUSING
Removing and installing the ywheel housing
Additional jobs
– Removing and installing the high-pressure pump/high-pressure pump drive, see 205
– Removing and installing the hydraulic pump, see 157
(1) Speed sensor, crankshaft (5) Flywheel housing

(2) Speed sensor, camshaft (6) Engine mount, left
(3) Support, exhaust manifold, right (7) Support, left
(4) Engine mount, right
Technical data
Speed sensor, crankshaft...................................... M6x16 ................................................................ 8 Nm
Speed sensor, camshaft ....................................... M6x16 ................................................................ 8 Nm
Service products

CRANKCASE
WARNING
Note
When retting the ywheel housing, always use new sealing rings, gaskets and mounting bolts.
Thoroughly clean the mating faces.

CRANKCASE
Removing the ywheel housing Detaching the oil return line - turbocharger, 2nd
stage, left
Removing the crankshaft speed sensor
• Disconnect the electrical connection clamp pliers for jubilee clips [72]
• Unscrew the mounting bolt (1) • Unscrew the mounting bolt (5)
• Extract the speed sensor (2) • Remove the oil return line (3)
• Remove the hoses (2) and (4)
Removing the camshaft speed sensor
Detaching the oil return line - turbocharger, 1st
stage, right

• Extract the speed sensor (2) • Unscrew the mounting bolts (5) and (8)
• Unclip the jubilee clips (3) using the Hose clamp
• Remove the oil return lines (2) and (4) with the
gasket (1) and the O-ring (6)
• Remove the hose (7)

CRANKCASE
Removing the left exhaust manifold support Removing the right engine mount
• Unscrew the mounting bolts (2) and (3) • Unscrew the mounting bolts (1)
• Remove the bracket (1) • Remove the engine mount (1) with the mounting
plate (2)
Removing the right exhaust manifold support
Removing the ywheel housing

• Remove the bracket (2)
CAUTION
Removing the left engine mount Danger of injury due to heavy
components
• Lift off the ywheel housing with support

(1)
• Remove the ywheel housing (2) and gasket (3)

• Remove the engine mount (3) with the mounting
plate (2)

CRANKCASE
Installing the ywheel housing Mounting the left engine mount
Mounting the ywheel housing
• Position the engine mount (3) with the mounting

plate (2)
CAUTION • Screw in and tighten the mounting bolts (1)
Mounting the right exhaust manifold support
components
• Lift on the ywheel housing with support
Note
• Position the ywheel housing (2) with a new gasket

(3)
marked
Mounting the right engine mount
• Position the bracket (2) so that it is strain-free

Mounting the left exhaust manifold support
• Position the engine mount (3) with the mounting

plate (2)
• Position the bracket (1) so that it is strain-free


CRANKCASE
Attaching the oil return line - turbocharger, 2nd Installing the camshaft speed sensor
stage, left
• Insert the speed sensor (1) with a new O-ring

• Position the oil return line (3) with hose (2) and (4) • Screw in the mounting bolt (2) and tighten to 8 Nm
clamp pliers for jubilee clips [72] • Connect the electrical connection
Installing the crankshaft speed sensor
Attaching the oil return line - turbocharger, 1st
stage, right
• Insert the speed sensor (1) with a new O-ring

• Screw in the mounting bolt (2) and tighten to 8 Nm
• Screw in the mounting bolts (8) • Connect the electrical connection
• Position the hose (7)
new O-ring (6)
• Position the oil return line (2) with O-ring (6)
• Clip in the jubilee clips (3) using the Hose clamp

CRANKCASE
Dismantling and assembling the ywheel housing

Additional jobs
(1) Screw plugs (4) Cap

(2) Screw tting (5) Screw plug
(3) Cover
Technical data
Screw plugs ......................................................... M38x1.5 ..........................................................240 Nm
WARNING

CRANKCASE
Dismantling the ywheel housing Dismantling the ywheel housing
Removing the cover
• Unscrew the ttings (1) and (2) with the sealing

rings
• Unscrew the mounting bolts (1) • Unscrew the screw plugs (3) and (4) with the
• Remove the cover (2) sealing rings
Removing the cap Unscrewing the screw plugs
• Unscrew the mounting bolts (3) • Unscrew the screw plugs (1) and (2) with the
• Remove the cover (2) with gasket (1) sealing rings
Removing the OT indicator adjuster

• Remove the adjuster (1)

CRANKCASE
Assembling the ywheel housing Installing the cap

• Screw in and tighten the screw plugs (1) and (2) • Screw in and tighten the mounting bolts (3)
with the sealing rings
Mounting the cover
Assembling the ywheel housing
• Position the cover (2)

• Screw in and tighten the ttings (1) and (2) with • Screw in and tighten the mounting bolts (1)
new sealing rings
• Fit screw plugs (3) and (4) with new sealing rings
Removing the OT indicator adjuster
• Position the adjuster (1)


CRANKCASE
CYLINDER LINER
Removing and installing the cylinder liner
Additional jobs
(1) Cylinder liner (2) Crankcase
Cylinder liner standard

Total height of cylinder liner ............................................................................................ 261.5 - 262.5 mm
Outside diameter of cylinder liner at collar................................................................... 163.15 - 163.35 mm
Outside diameter of cylinder liner stem ....................................................................149.439 - 149.457 mm
Collar height standard.................................................................................................... 10.04 - 10.07 mm
Cylinder liner inside diameter ..................................................................................... 131.99 - 132.01 mm
Technical data
Cylinder liner standout ................................................................................................... 0.035 - 0.085 mm
Depth of collar recess in crankcase .............................................................................. 9.985 - 10.015 mm
Service products

CRANKCASE
WARNING
Special tools
• Extracting the cylinder liner in conjunction with:

• Extractor plate [188]
[188] Extractor plate
• Extracting the cylinder liner in conjunction with:


conjunction with:
[190] Dial gauge 08.71000-3217

conjunction with:

conjunction with:
[192] Bolt 06.01499-0015

conjunction with:
• Washer [193]

CRANKCASE
[193] Washer 06.15013-0417

conjunction with:
• Bolt [192]
• Checking the cylinder liner seating

CRANKCASE
Removing the cylinder liner Fitting the extractor device
WARNING
• Place the Measuring plate [191] (2) on the cylinder Component damage due to damaged
liner or bent oil injector nozzles
• Screw in the Bolt [192] (4) with the Washer [193] • Insert Extractor device [187] without
and tighten to 40 Nm damaging the oil injector nozzle
• Place the Dial gauge holder [189] (5) with Dial
gauge [190] (3) on the Measuring plate [191] (2) • Mark the cylinder liners (1) to indicate their correct
• Place the dial gauge tip (1) on the crankcase assignment and installation position
• Zero the Dial gauge [190] (3) • Mount the Extractor plate [188] (1) on the Extractor
• Carefully place the dial gauge tip (1) on the device [187] (3)
cylinder liner and note the difference on the dial • Carefully push the Extractor device [187] (3) with
gauge folded Extractor plate [188] (1) into the cylinder
The permissible cylinder liner standout is 0.035 - liner (2)
0.085 mm.
Extracting the cylinder liner
If the cylinder liner standout is out of tolerance, t a
new cylinder liner/crankcase.
Checking the cylinder liner diameters
• Clamp the Extractor device [187] (1) with the

hexagon nut (2)
• Extract the cylinder liner (3) by screwing in the
hexagon nut (2)
• Use the Dial gauge [190] and the internal calliper
(1) to check the cylinder liner (2)
• Repeat the measurement several times at 120°
offset
• Repeat the measurement at four different heights
If the cylinder liner (2) has become oval, a new
cylinder liner must be tted.

CRANKCASE
Removing the sectional sealing rings Checking the cylinder liner

Checking the cylinder liner seat
• Remove the sectional sealing rings (1) and (2)

from the crankcase
• Clean the cylinder liner seat and sectional sealing • Check the cylinder liner seat with the Depth gauge
ring seats (electronic) [194] (1)
• Check the sectional sealing ring seats on the • Check the cylinder liner seat at four
cylinder liner for wear opposite-facing points
• Check the cylinder liners for porosity The permitted collar recess depth is 9.985 - 10.015
mm
If the seat depth is out of tolerance, the crankcase

must be replaced with the cylinder liners.

CRANKCASE
Installing the cylinder liner

Installing the cylinder liner
• Thinly apply clean Engine oil on the new sectional

sealing rings (1) and (2) and then insert them into
the sectional sealing ring seats (4)
• Thinly apply clean Engine oil in the outer lower
area of the cylinder liner (3) on the outside
• Insert the cylinder liner (3) into the crankcase as
marked, ensuring that the stop is reached
• Place the Measuring plate [191] (2) on the cylinder

liner
• Screw in the Bolt [192] (4) with the Washer [193]
• Put the Dial gauge holder [189] (5) with Dial
gauge [190] (3) on the Measuring plate [191] (2)
• Place the dial gauge tip (1) on the crankcase
• Carefully place the dial gauge tip (1) on the
cylinder liner and note the difference on the dial
gauge
The permissible cylinder liner standout is 0.035 -
0.085 mm.

SPECIAL TOOLS
SPECIAL TOOLS

SPECIAL TOOLS
OVERVIEW OF SPECIAL TOOLS

Special tools
[195] Assembly pin 80.99617-0228
• Installing the heat exchanger plate pack
[196] Puller for impeller 80.99601-6037
• Pulling off the coolant pump impeller
[197] Brace 80.99622-6002
• Holding the coolant pump drive gear steady
[198] Special spanner set (size 22) 80.99603-6029
• Removing and mounting the poly-V-belt pulley
[199] Gripper 08.06460-0002
• Removing and mounting the poly-V-belt pulley
[200] Storage sleeve 09.81020-1000
• Storing the injectors
[201] End plug 81.96002-0520
• Plugging the cylinder head injector bore

SPECIAL TOOLS
[202] Injector nozzle protective sleeve 81.96002-0522
• Plugging the injector nozzle
[203] Injector feed bore cap 81.96002-0523
• Plugging the injector feed bore
[204] End plug 81.96002-0541
• Plugging the bore for rail connections
[205] End plug 81.96002-0521
[207] Cap 81.96002-0518
• Plugging the fuel line hollow screw connections
[208] End plug 81.96002-0556

the rail


SPECIAL TOOLS
[210] Extractor 80.99601-6022
• Extracting the injector
[211] Knurled nut 80.99602-0201
[212] Plate 80.99602-0176
[213] Support 80.99602-0193
[214] Hexagon collar nut 06.11226-8306
• Installing the injector cable
[216] Adapter 08.06139-9029
[217] Socket, size 7 08.06141-0700

SPECIAL TOOLS
[218] Pressure piece 80.99606-0655
• Installing the injectors
[219] Union nut 80.99603-0126
• Detaching and attaching the high-pressure line
[222] End plug (GPN 330 L18) 81.96002-0556
[223] End plug 81.96002-0521
[224] Protective sleeve Z 18x1,5 81.96002-0555

SPECIAL TOOLS
[226] Cap 81.96002-0518
• Plugging the ring unions
[228] Eye-bolt 80.99606-0660
• Lifting the intercooler
[229] Socket, size 22 80.99612-0024
• Undoing and tightening the cylinder head bolts
[231] Support 80.99606-0551
[232] Torque angle gauge 80.99607-0172
[233] Holding device 80.99606-0641

SPECIAL TOOLS
[234] Pan head screw 06.02191-0407
[235] Connecting pin 06.22729-0006
[236] Rubber ring 42 mm 08.06142-9006
[237] Adapter 80.99606-0552
[238] Socket 80.99603-0327
[239] Aligning bar 80.99606-0582
• Aligning the cylinder heads
[240] Dial gauge 08.71000-3217
• Checking the cylinder liner standout
• Checking the rocker arm radial play

SPECIAL TOOLS
[242] Locating pin 80.99605-0197
• Checking the rocker arm radial play
[243] Adapter 80.99606-0588
• Removing and installing the valve springs
[245] Extension 80.99606-6094
[246] Valve-spring compressor 80.99613-6000
[247] Holder 80.99613-0050
[248] Holder 80.99613-0051
• Removing the valve cotters

SPECIAL TOOLS
• Removing and installing the valve stem seal
[251] Assembly sleeve 80.99606-0287
• Installing the valve stem seal
[252] Insertion pin 80.99617-6009
• Removing and installing the camshaft
[253] Holding device 08.75300-0000
• Checking and setting the valve clearance
[256] Valve wrench size 14 80.99603-6031
• Adjusting the valve clearance
• Cranking the engine

SPECIAL TOOLS
[258] Gear ratchet 80.99627-0001
• Cranking the engine
[259] Aligning punch 80.99617-0020
• Removing and installing the front crankshaft gear
[260] Aligning punch 80.99617-0220
• Installing the rear crankshaft gear
[261] Impact extractor 80.99602-0016
• Removing the radial shaft seal
[262] Extractor hook 80.99602-0175
• Extracting the radial shaft seal
[263] Plug-on handle 80.99617-0187
• Installing the radial shaft seal

seal
[265] Disc 80.99617-0144

SPECIAL TOOLS
[266] Pressing plate 80.99604-0342
[267] Press-in bush 80.99604-0340
[268] Socket E20 80.99612-0022

mounting bolts
[269] Socket E24 80.99603-0327

mounting bolts
[270] Feeler gauge 08.75310-0806
• Checking the piston ring axial play and ring gap
[271] Piston ring pliers 83.09144-6090
• Removing and installing piston rings
• Installing the piston
[273] Setting tool 80.99622-0052
• Positioning the bearing shell, cracked connecting

rod

SPECIAL TOOLS
• Checking the piston ring insertion depth
[275] Locating pin 80.99605-0197
• Checking the crankshaft axial and radial play
[276] Puller screw 80.99615-0039
• Removing the crankcase lower section
[277] Eye-bolt 80.99606-0660
• Installing and removing the crankcase lower

section
[278] Eye-bolt 06.05110-0103
[279] Three-armed puller 08.99605-9014
• Pulling off the crankshaft gear
[280] Socket 80.99603-0327

section mounting bolts
[281] Holding device 80.99606-0585

section mounting bolts

SPECIAL TOOLS
• Extracting the cylinder liner
[283] Extractor plate 80.99601-0187
• Extracting the cylinder liner
[286] Hexagon shank bolt 06.01499-0015
[287] Washer 06.15013-0417
[288] Hand pump 80.99620-0029

SPECIAL TOOLS
[289] Adapter 80.99620-0033
[290] Threaded connection 81.98130-0614

TECHNICAL DATA
Technical data
AE4 2nd edition 553

TECHNICAL DATA
Crankcase
Basic version: 163.50−163.60 mm
9.97−9.99 mm
Cylinder liner
127.990−128.010
Wear limit:
0.15 mm under basic dimension

Adm. liner projection:
0.035−0.085 mm
554 AE4 2nd edition

TECHNICAL DATA
Crankshaft
Crankshaft, front (opposite end to flywheel)

95.966−95.988 mm
111.5 mm
Crankshaft, rear (flywheel side)

3.350−3.400 mm
39.000−39.080 mm
max. axial play of crankshaft:

0.200−0.401 mm
AE4 2nd edition 555

TECHNICAL DATA
Crankshaft
Main bearing
2.961−2.973 mm
Inner bearing Ø when installed:

112.036−112.126 mm
Spread: 2.0 mm
Mounting bolts
Lower crankcase section
Loosened bolts must be replaced with new
ones.
556 AE4 2nd edition

TECHNICAL DATA
Flywheel and starter ring gear
Ø Flywheel: 432.490−432.645 mm
Internal Ø ring gear:

432.000−432.097 mm
Overlap: 0.335−0.587 mm
Installation temperature: 200−230_C
m = 37.65 kg (with ring gear)

J = 1.20 kgm2
No. of teeth: Z = 137, module 3.5

Mating gear: starter pinion (Z = 11)
AE4 2nd edition 557

TECHNICAL DATA
Conrods
55.060−55.075 mm
Bore for bearing shells in the conrod:

101.000−101.022 mm
Conrods which are discoloured at the big end
must not be reinstalled.
Bearing bore in the directions of measure-

ment 1, 2 and 3 and in the planes of measu-
rement a and b:
96.047−96.099 mm
Boundary condition:
New conrod bearing fitted,
conrod assembled
Conrod bearings
2.480−2.495 mm
Spread: 2.0 mm
If traces of wear are present
(scoring, running surface damaged), replace
both bearing shells
Caution: note installed position (rod shell has
red marking on side)
Conrod bearing bolts
Loosened bolts must always be replaced

with new ones.
558 AE4 2nd edition

TECHNICAL DATA
Pistons
Compression height: 78.95−79.05 mm
Piston protrusion from upper edge of crank

case: −0.361−0.080
127.770−127.800 mm
55.060−55.080 mm
Piston pin diameter:
54.994−55.000 mm
Piston ring grooves
2.965 − 2.995 mm
2.580−2.610 mm
3.530−3.560 mm
Piston rings
1st ring − Double−sided keystone ring:

height: 2.796−2.830 mm
2nd ring − Tapered compression ring:

height: 2.47−2.49 mm
3rd ring − D−Ring with sleeve spring:

height: 3.475−3.490 mm
Ring end clearance:

1st ring: 0.40−0.55 mm
2nd ring: 0.80−1.00 mm
3rd ring: 0.25−0.45 mm
AE4 2nd edition 559

TECHNICAL DATA
Cylinder head
18.100−18.500 mm
Exhaust valve:
Ø inner valve guide 9.015-9.030 mm
Ø bore in cylinder head for

valve guide: 15.000-15.018 mm
Outside diameter
of valve guide: 15.028-15.046 mm
Intake valve:
Ø inner valve guide 9.015-9.030 mm
Ø bore in cylinder head for

valve guide: 15.000-15.018 mm
Outside diameter
of valve guide: 15.028-15.046 mm
Intake valve ö = 60_

Exhaust valve b = 45_
Ø intake valve 8.930-8.944 mm

Valve recess: 0.09-0.39 mm
Ø exhaust valve 8.963-8.977 mm

Valve recess: 0.09-0.39 mm
Bore in the cylinder head - intake:

46.00-46.03 mm
External diameter of the valve seat insert:
46.052-46.068 mm
Bore in the cylinder head - exhaust:
44.00-44.03 mm
External diameter of the valve seat insert:
44.055-44.065 mm
560 AE4 2nd edition

TECHNICAL DATA
Cylinder head bolts

Loosened bolts must always be replaced
with new ones.
Valve springs outer
Outer spring
Length (L*) untensioned, approx. 62.62 mm
Spring force at L = 45.0 mm: 430-470 N
The lowest spring force is at the same time
the wear limit value.
Valve springs inner

Inner spring:
Length (L) unstressed, approx. 64.24 mm
The lowest spring force is at the same time
the wear limit value.
AE4 2nd edition 561

TECHNICAL DATA
Valve train
Rocker arm bracket
33.959-33.975 mm
Rocker arm
Rocker arm radial play: 0.030-0.066 mm
Rocker arm axial play: max. 0.51 mm
34.005-34.025 mm
Camshaft
79.910-79.940 mm
Camshaft bearing bushing inner diameter:
80.000-80.061 mm
Camshaft axial play: 0.10-0.20 mm

Camshaft radial play: 0.030-0.066 mm
Replace if signs of wear are present
Backlash:
Crankshaft gear and camshaft gear:
0.172 mm-0.278 mm
562 AE4 2nd edition

TECHNICAL DATA
Valve tappets
38.975-39.000 mm
Corresponding bore in crankcase:

39.025-39.050 mm
Replace if signs of wear are present
Valve clearance
set when engine is cold
Intake valve: 0.5 mm
Exhaust valve: 0.8 mm
Valve timing
1 = Engine cranking direction
1 2 = Intake valve opens 24_ before TDC
2 TDC 3 3 = Exhaust valve closes 27_ after TDC
4 = Exhaust valve opens 63_ before BDC
5 = Intake valve closes 36_ after BDC
6 = Exhaust valve opening angle 270_
7 = Intake valve opening angle 240_
The degrees specified refer to the crankshaft
6 7 angle
Valve lift for measuring procedure:

10.0-10.6 mm
4 10.0-10.6 mm
BDC
Compression pressures
good above 16 bar
permitted 13-16 bar
repair required below 13 bar
Pressure difference (between the individual cylinders) max. 3 bar
AE4 2nd edition 563

TECHNICAL DATA
Engine lubrication
Valve opening pressures

Bypass valve for oil filter 1.9−2.9 bar
Relief valve to oil module 7.8−10.0 bar
Spray hole diameter of the oil spray nozzles 2.80 mm
Oil pump
Outer rotor
Axial play 0.04−0.09 mm
Radial play 0.122−0.194
Inner rotor
Axial play 0.035−0.080 mm
Radial play 0.025−0.061
Gear axial play: 0.060−0.240 mm
Gear width 24/30/34 mm
Delivery capacity of the oil pump

The rpm figures relate to pump speeds
Delivery capacities are with SAE 20W/20 oil at 90 _C and 4
b-
a
r
Oil pressure at n = 3400 rpm (engine speed 2300 rpm)
Gear width 24 mm 167 ltr./min
564 AE4 2nd edition

TECHNICAL DATA
Cooling system
Thermostat
Opening begins at: 86_ C ("1.5_)
Full opening: 96_ C
at 9.5 mm valve lift
Cover for heat exchanger

Working valve opens at:
1.40−1.60 bar overpressure
0.02−0.12 bar vacuum
AE4 2nd edition 565

TECHNICAL DATA
Starter motor
Manufacturer: Mitsubishi
Method of operation:
sliding gear
Starter pinion
no. of teeth: Z = 11
Module: 3.5
Rated power: 7.0 kW

Rated voltage: 24 V
Alternator
Manufacturer: Bosch
Type: N1
Design: 1 pole, insulated
Method of operation:
3−phase
Rated voltage: 28.5 V
Maximum current: 120 A
Turbocharger
Manufacturer BorgWarner
Type D2868LE433 1st stage K3NS−089G84FN35A01JC
D2868LE433 2nd stage K2CS−082G87FN26A01CN
Type D2868LE433 1st stage K3NS−104G84GN35A01JC
D2868LE433 2nd stage K3CS−089G90FN32A01CN
566 AE4 2nd edition

TECHNICAL DATA
Torque guide values
Note:
All bolted connections, the purpose of which is not stated in the following table, are to be tigh-
tened in accordance with the guideline values given in our Works Standard M 3059 (see page
570). Oil bolts lightly prior to assembly!
Screw plugs
DIN 908
M14x1.5, M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
M18x1.5, M22x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
M24x1.5, M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
M30x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
DIN 7604
AM10x1, M12x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
AM14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Crankcase, crank assembly
Engine mount to crankcase M16, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Nm

Flywheel housing to crankcase M12, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
Timing case cover on timing case M8, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm
Lower crankcase section to crankcase M18x2 as per tightening instructions
Preliminary tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm
1st tightening angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2nd tightening angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Lower crankcase section to crankcase at side M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Vibration damper to crankshaft M16x1.5, 10.9
Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Vibration damper to hub 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Nm
Flywheel to crankshaft M18x1.5
1st tightening angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2nd tightening angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Conrod bearing cover M14x1.5
Cylinder head
Cylinder head bolts M18x2 as per tightening pattern

2nd tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
3rd tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm
4. Tightening angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5. Tightening angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Final tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Rocker arm mechanism on cylinder head M12−10.9
Lock nut, adjusting bolt, rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Camshaft
Anti−twist lock roller tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Nm
AE4 2nd edition 567

TECHNICAL DATA
Lubrication system
Oil filter cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm

Support dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Oil spray nozzle: flange on crankcase M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
Oil pump M6, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cooling system
Heat exchanger M16 as per tightening instructions

Preliminary tightening torque with even tightening of 360
2nd tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm
Spacer sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Nm
Centring bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Mounting bolt for inspection glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Mounting bolt for collector M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Coolant pump drive gear M12
Fuel system
Mounting bolts for high−pressure pump M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm

Mounting bolts for drive gear M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Mounting bolts for thrust plate M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Mounting bolt for metering unit M5x20 T25
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
Mounting bolt for fuel feed pump M6x20 T30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nm
Oil filler screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nm
Overflow valve on high−pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm
Mounting bolt for pressure flange M8x55
1st tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Pressure bolt for pressure pipe M24
High−pressure lines, first use
High−pressure lines, reused
Rail pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Pressure limiting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
Injector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Nm
Exhaust/intake manifold
Mounting bolt for turbocharger M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm

Mounting nut for turbocharger M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Exhaust manifold M12x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm
Exhaust pipe to cylinder head M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Inner exhaust pipe to exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm
568 AE4 2nd edition

TECHNICAL DATA
Sensors
Engine oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm

Engine oil temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Coolant pressure sensor to oil module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Coolant pressure sensor to expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Coolant level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
M6 mounting bolts for charge air pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nm
Charge air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Intake vacuum pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Exhaust temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Nm
Exhaust temperature sensor threaded sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
M6 mounting bolt for crankshaft rpm sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nm
M6 mounting bolt for camshaft rpm sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nm
Rail pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Fuel pressure sensor to hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Fuel pressure sensor to connector/fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Fuel pressure sensor to return line connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
AE4 2nd edition 569

TECHNICAL DATA
Installation tightening torques according to company standard M 3059
Bolts/nuts with flange
Thread size Strength class/tightening torques in Nm

x pitch
for 8.8 / 8 for 10.9 / 10 for 12.9 / 12
M5 6.0 9.0 10.0
M6 10.0 15.0 17.0
M8 24.0 35.0 41.0
M8x1 25.5 40.0 44.0
M10 45.0 65.0 76.0
M10x1.25 46.0 70.0 80.0
M10x1 49.0 75.0 84.0
M12 81.0 120.0 140.0
M12x1.5 85.0 125.0 146.0
M12x1.25 88.0 130.0 152.0
M14 128.0 190.0 221.0
M14x1.5 138.0 200.0 237.0
M16 200.0 285.0 334.0
M16x1.5 212.0 300.0 354.0
M18 279.0 395.0 464.0
M18x2 294.0 420.0 489.0
M18x1.5 309.0 440.0 515.0
M20 382.0 545.0 637.0
M20x2 400.0 570.0 667.0
M20x1.5 418.0 595.0 696.0
M22x2 558.0 795.0 930.0
M22x1.5 580.0 825.0 966.0
570 AE4 2nd edition

51.99598-8250
Printed in Germany
Subject to technical alterations in the interests of further development.
Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN.
All rights under the copyright law are strictly reserved by MAN.
MAN Truck & Bus AG

Vogelweiherstraße 33
90441 Nürnberg, Deutschland
man-engines@man.eu
www.man-engines.com
MAN Truck & Bus – a member of the MAN Group

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MAN Marine Diesel Engines V8/V12

MAN Marine Diesel Engines

We reserve the right to make modications in the course of further development.

Best wishes from

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© 2011 MAN Truck & Bus AG

Redaktion: EPEGG, 01.2014

Notes on safety ........................................................................................................... 9

Malfunctions and their probable causes ............................................................................. 39

Engine electrics .......................................................................................................... 49

Heat exchanger .......................................................................................................... 93

Starter ................................................................................................................... 143

High-pressure lines and rails ........................................................................................ 163

Exhaust manifold downstream of turbocharger .................................................................. 273

Cylinder head .......................................................................................................... 351

Camshaft ................................................................................................................ 383

Timing gears/drive gears

Front drive gears ....................................................................................................... 395

Removing and installing the front drive gears ................................................................ 395

Oil modules ............................................................................................................. 407

Crankshaft oil seals

Crankshaft oil seals ................................................................................................... 445

Vibration damper ...................................................................................................... 457

Crankcase ventilation ................................................................................................. 511

Overview of special tools ............................................................................................. 539

Technical Data 553

Checking the valve lift ............................................................................................................................ 391

1. Regulations for preventing accidents leading to injury to personnel

Checking, setting and repair work

– Secure units during their removal.

Operating the engine

Working on high-pressure lines

Work on the electrical system

Caution! Battery acid is poisonous and corrosive!

Be careful as battery gases are explosive!

2. Notes on preventing damage and premature wear on units

MAN shall not be liable for any damaged resulting from:

– Failure to follow the instructions in this manual

– Use of non-trained personnel

Taking out of operation and storing

4. Regulations for avoiding injury and environmental contamination

Health protection precautions

Disposal of service uids and service products

– Service products can damage groundwater quality –

5. Information for working on the common rail system

Special instructions for people with pacemakers

Danger of damage due to dirt ingress

Danger of damage due to dirt ingress

Details of approved products can be found online at: https://mmrepro.mn.man.de/bstwebapp/BSTServlet

General information regarding engine overhauls

– Correct power setting for the application type

Taking into operation following an engine overhaul

Model plate/model designation

(1) Engine type (2) Engine serial number

Explanation of the engine no. (Engine identication number)

Engine no. Classication terms Example

1234 Assembly day

Explanation of the model designation

Model Meaning Example

D Fuel type Diesel

Designation Unit Figures

Designation Unit of measurement Data

Injection system Common rail/EDC 7