Man D 2866 LE 401 Repair Manual
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Man D 2866 LE 401 Repair Manual

Marine diesel engines
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  • Page 2 We reserve the right to make technical modifications in the course of further development.  1999 MAN Nutzfahrzeuge Aktiengesellschaft Reprinting, copying or translation, even in the form of excerpts, is forbidden without the written permission of MAN. MAN expressly reserves all rights in accordance with the law on copyright. MTDA / 05.99 51.99493-8428...

  • Page 3: Table Of Contents

    Contents Page Safety instructions ............General information on the overhaul of engines .
  • Page 4 Contents Cylinder head Removing and installing cylinder head ........Setting valve clearance .

  • Page 5: General Information

    Safety instructions General information This brief overview summarises important instructions and is structured into areas of main concern in order to impart the knowledge necessary to prevent accidents involving injury to persons, damage to the engine or other property and harm to the environment. Additional notes are included in the operator’s manual for the engine.

  • Page 6: Safety Instructions

    Safety instructions D When checking the injection nozzles, do not hold your hands in the fuel jet. Do not in- hale fuel mist. D When working on the electrical system, unplug earth cable from battery first and recon- nect it last to avoid short-circuits. D Observe the manufacturer’s instructions for handling batteries.
  • Page 7 D In the event of operational faults immediately identy the cause and rectify to prevent more serious dam- age. D Always use genuine MAN parts only. Installation of ”equally” good parts from other suppliers may cause severe damage for which the workshop carrying out the work is responsible.
  • Page 8 Safety instructions 4. Instructions for handling used engine oil * Prolonged or repeated contact of any kind of engine oil with the skin causes the skin to degrease, which may result in dryness, irritation or inflammation. Old engine oil also contains hazardous substances which in animal experiments have caused skin cancer.

  • Page 9: General Information On The Overhaul Of Engines

    Regular interim inspections and overhauls frequently carried out on large engines (e.g. on those from MAN Augsburg) are generally not necessary on MAN Diesel engines from the MAN Nuremberg works.

  • Page 10: Trouble Shooting Table

    Trouble shooting table Faults and possible causes We recommend Repair work is to be considered complete only after the damage which has occurred and the possible causes have been eliminated. Ascertaining the causes of damage is frequently more difficult than eliminat- ing the damage caused.
  • Page 11 Trouble shooting table Fault Probable cause Remedy (This column is filled in only if the ”probable cause” gives no clue as to what must be done). Starter does not crank D Battery main switch in ”off” position the engine or only too D Batteries flat slowly D Crankgear blocks...
  • Page 12 Trouble shooting table Fault Probable cause Remedy (This column is filled in only if the ”probable cause” gives no clue as to what must be done). Engine speed variations D Too little fuel in fuel tank during operation D Air in fuel system D Fuel lines leaky D Fuel high-pressure part leaky D Injection nozzles defective, worn...
  • Page 13 Trouble shooting table Fault Probable cause Remedy (This column is filled in only if the ”probable cause” gives no clue as to what must be done). Coolant temperature D Coolant level too low too high, coolant loss D Air in coolant circuit D Proportion of anti-freeze / anticorrosion D See ”Fuels, Lubricants ...”...
  • Page 14 Trouble shooting table Fault Probable cause Remedy (This column is filled in only if the ”probable cause” gives no clue as to what must be done). Fuel consumption too D Constant full-load operation high D Speed resistance owing to incrustation of hull, shaft system and propeller with foreign matter D Poor efficiency of the drive system...
  • Page 15 Trouble shooting table Fault Probable cause Remedy (This column is filled in only if the ”probable cause” gives no clue as to what must be done). Vibrations, droning D Drive system not or inaccurately aligned noise, structure-borne D Unsuitable clutch sound D Unsuitable engine/gearbox mounts D Elastic mounts unequally loaded (height...
  • Page 16 Trouble shooting table Fault Probable cause Remedy (This column is filled in only if the ”probable cause” gives no clue as to what must be done). Starter D Battery insufficiently charged D Pinion does not turn D Terminals loose or oxidised, poor earth or turns too slowly connection D Terminals or carbon brushes have short-...

  • Page 17: Engine Views, D 2866 Le401

    Engine views, D 2866 LE401...
  • Page 18 Engine views, D 2866 LE401...
  • Page 19 Cross section of engine...
  • Page 20 Longitudinal section...

  • Page 21: Schematic Diagram Of Engine Lubrication System

    Schematic diagram of engine lubrication system 2033 1 Oil suction pipe 6 Bypass valve 2 Distributor pipe 7 Oil filter 3 Oil spray nozzle 8 Turbocharger 4 Oil pump 9 Oil cooler 5 Oil pressure relief valve 10 Injection pump...

  • Page 22: Schematic Diagram Of Fuel System

    Schematic diagram of fuel system 1 Fuel tank 6 Fuel injection pump 2 Fuel prefilter 7 Overflow valve 3 Fuel delivery pump 8 Fuel injector 4 Fuel filter 9 Suction pipe 5 Bleed screw 10 Return pipe...

  • Page 23: Schematic Diagram Of Cooling System

    Schematic diagram of cooling system 10 11 2583 1 Water pump housing with 9 Expansion tank integrated thermostat housing 10 Over/underpressure valve 2 Water pump impeller 11 Coolant filler neck 3 Engine oil cooler 12 Heating lead and return line 4 Crankcase 13 Measuring point for cooling water temperature 5 Exhaust manifold, liquid-cooled...

  • Page 24: Checking And Adjusting Start Of Fuel Delivery

    Checking and adjusting start of fuel delivery Checking start of delivery Fig. 1 For the purpose of checking the start-of-delivery setting, an ”OT” (= TDC) mark and a scale (2) from 10 ... 50_ before TDC are engraved on a disc fitted in front of the torsional vibration damper.
  • Page 25 Checking and adjusting start of fuel delivery Fig. 5 Remove screw plug (1) on governor housing. If fitted, take out blocking pin (2). If the pointer is exactly in the centre of the inspection hole, the pump plunger for cylinder no. 1 is at start of delivery.
  • Page 26 Checking and adjusting start of fuel delivery Fig. 8 The light signal transmitter KDEP 1601 (Fig.) is energized by its own power supply. 3393 b. Sleeve ø15 Fig. 9 ø12 ø9 If a light signal transmitter is not available, good measurement results can also be achieved with a plug-in sleeve.
  • Page 27 Checking and adjusting start of fuel delivery Adjusting start of delivery If the check according to method a) or b) should prove that the delivery start is not correct, proceed as follows: Fig. 10 Remove timing case cover (13mm). 3394 Fig.

  • Page 28: Removing And Installing Injection Pump

    Removing and installing injection pump Removing injection pump Fig. 1 Close cut–off valve from fuel tank to engine. Remove all fuel and air (LDA) connections from the injection pump and detach the injection lines. Caution: The lines contain fuel. Catch emerging fuel in a container. 3396 Fig.
  • Page 29 Removing and installing injection pump Installing injection pump Fig. 5 Important: If the injection pump is blocked the camshaft must on no account be loaded or turned be- cause parts of the blocking pin may break off and fall into the governor. Non-compliance with this may result in severe damage to the injection pump.
  • Page 30 Removing and installing injection pump Fig. 8 Insert the injection pump and tighten the mounting bolts. 3401 Fig. 9 Apply an initial torque of 5 Nm to all mounting bolts on the gear through the inspection hole. Two com- plete engine turns are necessary for this operation. Now tighten all mounting bolts to 30 Nm.

  • Page 31: Removing And Installing Fuel Injectors

    Removing and installing fuel injectors Removing fuel injectors Fig. 1 Remove leakage fuel return lines. 3402 Fig. 2 Remove injection lines. 3403 Fig. 3 Remove pressure screw from fuel injector using a pin spanner. 3378 Fig. 4 Bolt inertia puller on to fuel injector and knock out the injector.
  • Page 32 Removing and installing fuel injectors Fig. 5 Take out injector and injector seal. Check and repair injector. 3405 Installing fuel injectors Fig. 6 Apply ”Never Seeze” to contact areas of injector. Screw in injector with new seal. 3406 Fig. 7 Screw in injector with new seal.

  • Page 33: Checking And Repairing Fuel Injectors

    Checking and repairing fuel injectors Checking fuel injectors Fig. 1 The nozzle tester (manual test stand) is used to check the – opening pressure – tightness – spray pattern of the injection nozzle. Use pure testing oil or pure Diesel fuel for the test. Prior to testing, clean nozzle and check it for wear.
  • Page 34 Checking and repairing fuel injectors Disassembling fuel injectors Fig. 3 Insert injector assembly (the inlet orifice facing downwards) into the clamping device and hold in a vice. Remove union nut and take out nozzle body, intermediate washer, pressure pin, compression spring and shim.
  • Page 35 Checking and repairing fuel injectors Fig. 7 Dip nozzle body and nozzle needle separately into filtered Diesel fuel and check their gliding quality. When pulled out of the nozzle body by up to a third of its length the nozzle needle must sink back to its seat under its own weight when released.

  • Page 36: Cleaning Fuel Prefilter

    Cleaning fuel prefilter Fig. 1 Shut cut-off valve from fuel tank to engine. Remove round nut and take off filter housing with sieve. Use a bowl to catch fuel that may emerge. 3407 Fig. 2 Wash out filter housing and gauze filter in clean Diesel fuel and blow them out with compressed air.

  • Page 37: Changing Fuel Filter Cartridges

    Changing fuel filter cartridges Fig. 1 1 Disposable filter 2 Screw plug 3 Bleed screw 3590 Fig. 2 Use tape wrench to loosen filter cartridge and re- move cartridge by hand. Fit a new seal. Lightly coat seal on the filter cartridge with fuel. Screw on filter cartridge and firmly tighten it by hand.

  • Page 38: Draining And Filling With Coolant

    Draining and filling with coolant Draining coolant Drain coolant as follows when the engine is cold: Caution: Risk of scalding if hot coolant is drained! Drain coolant into a container and dispose of it in accordance with local regulations Fig. 1 Remove cap (arrow) from filler neck on the coolant 3412 expansion tank.
  • Page 39 Draining and filling with coolant Filling up with coolant Fig. 4 The engine’s cooling system is to be filled up with a mixture of potable tap water and antifreeze agent on ethylene glycol basis or anticorrosion agent. See publication ”Fuels, Lubricants, Coolants for Industrial and Marine Diesel Engines”.

  • Page 40: Removing And Installing Thermostat

    Removing and installing thermostat Fig. 1 D Drain coolant, see page 37 D Remove expansion tank, see page 45 Once the expansion tank has been removed the thermostats in the water pump housing are visible. 3428 Fig. 2 Take out thermostat. Check the function of the thermostat as follows.

  • Page 41: Removing And Installing Water Pump

    Removing and installing water pump D Take off V-belt, see page 118 D Drain coolant, see page 37 D Detach expansion tank, see page 45 D Take out thermostats, see page 39 Note: If the water pump is to be disassembled at a later date, remove V-belt pulley before the disassembly and pull off water pump hub with a stable three-arm puller.

  • Page 42: Repairing Water Pump

    Unclip the circlip from the water-pump housing. 3434 Fig. 3 Press impeller off the shaft, using a suitable man- drel. For this purpose align water–pump housing horizontally on a stable support. The picture shows an assembly device for this. If such a device is not available, use a support ring (special tool, see page 134).

  • Page 43: Repairing Water Pump

    Repairing water pump Assembling water pump Fig. 5 Press in water pump bearing. Use hollow mandrel to press on the outer bearing ring and not on the bearing shaft. For this purpose align water-pump housing hori- zontally on a stable support. 3437 Fig.
  • Page 44 Repairing water pump Fig. 8 Press impeller on to bearing shaft. For this purpose place water-pump bearing shaft on a stable support. The correct gap dimension (see ”Engineering S Data S Setting values”) is achieved if the outer face of the impeller is flush with the front face of the bearing shaft.
  • Page 45 Install mechanical seal while ”wet”, i.e. to install it, coat holding sleeve (1) and water pump shaft (2) with a mixture of either 50 % water and 50 % cleaning spirit or 35 % to 50 % antifreeze agent as per MAN 324 and water.

  • Page 46: Removing And Attaching Expansion Tank

    Removing and attaching expansion tank D Drain coolant, see page 37 Fig. 1 Remove hollow bolt from bleeder line. Remove coolant level sensor. 3424 Figs. 2 and 3 Remove the mounting bolts from the brackets of the expansion tank (13 mm and 19 mm). 3425 3426 Fig.

  • Page 47: Removing And Installing Heat Exchanger

    Removing and installing heat exchanger D Drain coolant, see page 37 Fig. 1 Remove mounting bolts from the coolant elbow between expansion tank and raw-water heat ex- changer (13 mm, 17 mm). 3440 Figs. 2 and 3 The raw-water connecting pipe from the intercooler is fastened to the heat exchanger by means of a plug connection.
  • Page 48 Removing and installing heat-exchanger pipe set D Remove raw-water heat exchanger, see page 46 Fig. 1 Match-mark the position of the covers relative to the heat-exchanger housing (arrow) and remove both covers (13 mm). 3443 Fig. 2 Take off cover. At the flywheel end of the heat exchanger the col- lar of the pipe cluster (arrow) is visible.

  • Page 49: Cleaning Heat Exchanger Pipe Set

    Cleaning heat exchanger pipe set Internal cleaning of the pipe set in raw water heat exchangers Deposits may form on the sea–water side of the pipe cluster in the heat exchanger, impairing the heat tran- sition to such an extent that the coolant heat can no longer be sufficiently conducted away. This is bound to cause an increase in the coolant temperature.

  • Page 50: Raw Water Pump

    Raw water pump Removing and installing raw-water pump Note: The raw–water pump shown in these pic- tures was used up to engine no..8120 999 ..From engine no..8121 001 ... onwards double pumps have been in use for improved cooling. However, the assembly steps are the same in principle.
  • Page 51 Raw water pump Changing impeller Fig. 1 Remove cover (8 mm). 3421 Fig. 2 The impeller can be removed only together with the cam. Note: The impeller will be destroyed if it is forcibly pulled out without the cam. To do this, remove the cap screw in the pump housing between the suction and the compression neck using a screwdriver.

  • Page 52: Changing Oil Filter

    Changing oil filter Fig. 1 Open oil drain plug on oil filter can (19 mm) and use container to catch oil that may emerge. Refit oil drain plug with new seal. 3447 Fig. 2 Remove mounting bolt of filter bowl (17 mm). 3448 Fig.

  • Page 53: Removing And Installing Oil Cooler

    Removing and installing oil cooler D Drain engine oil D Drain coolant, see page 37. D Remove oil filter, see page 51. Fig. 1 Remove hose clamp on the coolant outlet pipe leading from the oil cooler housing. Remove the mounting bolts from the oil cooler housing (17 mm).

  • Page 54: Removing And Installing Oil Pump

    Removing and installing oil pump Removing oil pump D Drain engine oil. Fig. 1 Remove oil pan (13 mm). Note: Various oil pan variants are possible. The picture shows a deep oil pan for inclinations of up to 30_. 3453 Figs.
  • Page 55 Removing and installing oil pump Fig. 5 Remove oil pump. Note: Depending on the engine model and oil pan variant, various oil pump versions are possible. In engines with tandem pumps, first remove the 2nd pump À with intermediate shaft Á, connection sleeves Â...
  • Page 56 Removing and installing oil pump Fig. 8 Remove oil pump drive gear. To do this, lay pump on suitable support and press off drive gear using a mandrel. Place drive gear on the shaft and press it into place. Thereby support opposite shaft end. Pres- sing force see ”Engineering S Data S Setting va- lues”.
  • Page 57 Removing and installing oil pump Installing oil pump Fig. 10 Before installing, check whether the oil pump(s) run(s) smoothly and then fit it/them free of tension (13 mm). 3588 Figs. 11 and 12 Fit the oil intake lines À with seals and the oil re- turn lines Á...

  • Page 58: Oil Spray Nozzle

    Oil spray nozzle Removing oil spray nozzle D Drain engine oil D Remove oil pan, see page 53 Fig. 1 Remove oil spray nozzle valve (arrow) and take out oil spray nozzle. Fig. 2 1 Oil spray nozzle valve 2 Oil spray nozzle 3462 Note: The oil spray nozzles are provided with two...

  • Page 59: Removing And Installing Vibration Damper, Changing Front Crankshaft Seal

    Removing and installing vibration damper, changing front crankshaft seal Removing vibration damper D Turn engine to TDC to facilitate the installation of the scale disc during the assembly. D Block the crankgear. D Release the tension and take off the V-belt(s). Figs.
  • Page 60 Removing and installing vibration damper, changing front crankshaft seal Changing front crankshaft seal Fig. 5 Remove cover (13 mm). Replace front crankshaft seal only as a complete unit, i.e. race and radial shaft seal. 3479 Fig. 6 To remove the race, a puller (special tool, see page 127, item 13) is necessary.
  • Page 61 Removing and installing vibration damper, changing front crankshaft seal Fig. 9 The adapter must contact the crankshaft free of play so that the correct pressing depth for the race is ensured. Pull in race using collar nut and pressing plate È and É...
  • Page 62 Removing and installing vibration damper, changing front crankshaft seal Installing vibration damper Fig. 12 Place vibration damper on two guide pins (M16 x 1.5). Ensure that the position of the graduated disc relative to the crankshaft is correct. 3584 Fig. 13 Tighten mounting bolts (24 mm) to specified torque.

  • Page 63: Removing And Installing Flywheel, Replacing Gear Ring

    Removing and installing flywheel, replacing gear ring Removing flywheel Fig. 1 Loosen mounting bolts (24 mm), securing the en- gine against turning if necessary. Note: Owing to the high initial torque a reinforced socket (for machine screws) in connection with a 1/2” tool is required. 3466 Fig.
  • Page 64 Removing and installing flywheel, replacing gear ring Fig. 5 Lightly oil new mounting bolts (elasticated bolts) , screw them in and tighten alternately on opposite sides of the ring gear to specified torque (see ”Engineering S Data S Setting values”). 3470 Changing starter gear ring Fig.

  • Page 65: Removing And Installing Crankshaft Seal (Flywheel End)

    Removing and installing crankshaft seal (flywheel end) D Remove flywheel, see page 62 Removing crankshaft seal Fig. 1 Use a screwdriver to prise seal out of the timing case. 3472 Installing crankshaft seal Fig. 2 Insert new shaft seal into the flywheel housing. Fig.

  • Page 66: Exchanging Bearing Race

    Do not damage flywheel. Do not use a chisel. Fig. 2 Insert the new bearing race into the pressing man- drel (special tool, see page 127 , item 14) so that for the subsequent assembly the internally cham- fered side faces the flywheel.

  • Page 67: Crankshaft Seals

    Crankshaft seals General remarks on crankshaft seals As a matter of fundamental principle only radial shaft seals made of polytetrafluor ethylene (PTFE), trade name Teflon, are used. PTFE seals can be easily distinguished from the former elastomer seals by their considerably wider and flat sealing lip which is no longer pre-loaded by means of a tubular spring.

  • Page 68: Removing And Installing Intake Manifold

    Removing and installing intake manifold D Drain coolant, see page 37 D Remove intercooler, see page 77 Note: When carrying out work on the intake sys- tem, ensure meticulous cleanliness to pre- vent dirt and foreign matter from penetrating into the system. Removing intake manifold Fig.
  • Page 69 Removing and installing exhaust manifold D Drain coolant, see page 37. D Remove turbocharger, see page 73. D Remove heat exchanger, see page 46. Removing exhaust manifold Fig. 1 Remove the mounting bolts from the exhaust pipe (17 mm). 3494 Fig.
  • Page 70 Removing and installing exhaust manifold Fig. 5 Fit exhaust pipe with new seals. 3498 Fig. 6 Tighten the mounting bolts to specified torque (see ”Engineering S Data S Setting values”). 3499...

  • Page 71: Turbocharger, Trouble Shooting

    Turbocharger, trouble shooting Before removing the turbocharger carry out the following checks Turbochargers are frequently exchanged if the oil consumption is too high, the output too low or the intake and/or exhaust gas noises appear to be abnormal. Subsequent inspections by the manufacturer of the sup- posedly defective parts frequently prove the turbochargers to be in order.
  • Page 72 Turbocharger, trouble shooting When there is unusual intake or exhaust noise – Check the intake and exhaust system in the area of the charger group. – Defective gaskets can lead you to think the turbocharger is defective. Replace them. – If there are still unusual noises, check the bearing clearance. –...

  • Page 73: Checking The Charge-Air Pressure

    Checking the charge-air pressure Why must the charge-air pressure be checked? Sufficient charge-air pressure is indispensable for full power output and clean combustion. Checking the charge-air pressure helps detect damage to the turbocharger, operating faults in the waste- gate and leaks in the intercooler and in the charge-air pipes. Extreme operating conditions (full-load operation and high air temperature) and the use of unsuitable en- gine oils (also see publication ”Fuels, Lubricants, Coolants for Industrial and Marine Diesel Engines”) may cause deposits on the compressor as well as in the intercooler, which results in a reduction in charge-air...

  • Page 74: Removing And Installing Turbocharger

    3503 Fig. 3 Remove the coolant supply line from the turbo- charger. 3504 Fig. 4 Remove the mounting bolts from the exhaust man- ifold (17 mm). Remove the coolant line between the turbine hous- ing and the exhaust manifold. 3505...
  • Page 75 Removing and installing turbocharger Fig. 5 Take off exhaust manifold. 3506 Fig. 6 Remove the four (self–locking) nuts from the turbo- charger flange (17 mm). Take off turbocharger. Note: Ensure meticulous cleanliness when putting the turbocharger aside to prevent dirt and foreign matter from penetrating into the inte- rior of the turbocharger.

  • Page 76: Checking Axial And Radial Play Of Turbocharger Rotor Shaft

    Checking axial and radial play of turbocharger rotor shaft D Remove turbocharger, see page 73 Fig. 1 Mark turbine housing relative to the bearing hous- ing and remove turbine housing. Axial play Fig. 2 Remove turbocharger. Mark turbine housing rela- tive to the bearing housing and remove turbine housing.

  • Page 77: Exchanging Waste Gate

    Exchanging waste gate Fig. 1 D 2866 LE4.. engines are equipped with waste gates (arrow). Their task is to limit the charge-air pressure to a precisely defined value. Manipulation or modification of the setting is not permitted. 3512 Fig. 2 The waste gates are maintenance-free.

  • Page 78: Removing And Installing Intercooler

    Removing and installing intercooler D Drain coolant from crankcase and intercooler, see page 37 Fig. 1 Remove the pipes from the fuel filter and detach the fuel filter. The coolant lines are fastened by means of plug connections. To remove them, unscrew pressure flange.
  • Page 79 Removing and installing intercooler Disassembling and cleaning intercooler Fig. 5 Remove charge-air elbow (13 mm). 3487 Fig. 6 Clean the fins on the intercooler of oil and resi- dues, using a steam jet cleaner. Do not damage the fins. 3489...

  • Page 80: Removing And Installing Cylinder Head

    Removing and installing cylinder head Removing cylinder head D Drain coolant, see page 37 Note: The intake and exhaust pipes need not be detached for removing the cylinder head. Fig. 1 Remove the injection nozzles, see page 30. Take off the cylinder head covers (13 mm). 3406 Fig.
  • Page 81 Removing and installing cylinder head Fig. 5 Take out push rods. 3516 Fig. 6 Remove cylinder head bolts in reverse order of tightening. Note: Use reinforced socket (screw–driving ma- chine) to loosen and tighten the cylinder head bolts. 3517 Fig. 7 Remove the mounting bolts from the intake and exhaust pipes for the respective cylinder head.
  • Page 82 20 Nm. If a steel ruler is not available, mount ex- haust manifold and tighten to 20 Nm. D Tighten cylinder head bolts as specified. D Remove steel ruler. D Tighten exhaust manifold and intake man- ifold to specified torque. 3522...
  • Page 83 Removing and installing cylinder head Fig. 13 Check push rods for distortion. When inserting the push rods ensure that they fit into the seat of the valve tappet. Put rocker arms and push rods in place. Screw in the mounting bolts without washers and tighten them slightly.
  • Page 84 Removing and installing cylinder head General notes: The sealing effect of the cylinder head gasket largely depends on whether the required initial tension for the cylinder head bolts is reached and maintained. Use calibrated torque wrenches to tighten the cylinder head bolts. When the specified final torque is applied it must be maintained for at least 5 seconds.

  • Page 85: Setting Valve Clearance

    Setting valve clearance Fig. 1 Remove cylinder head cover (13mm). 3389 Figs. 2 and 3 Use barring device to turn engine so that the pis- ton in the cylinder to be set is at TDC and the two valves are closed. At this point both inlet and ex- haust valves will be open i.e.
  • Page 86 Setting valve clearance Fig. 5 Push feeler gauge between valve stem and rocker arm. Loosen lock nut (17 mm) and turn adjusting screw with screwdriver until feeler gauge can be moved with slight resistance. Tighten lock nut to the specified torque (see ”Engineering S Data S Setting values”) using screw- driver to prevent adjusting screw from turning.

  • Page 87: Disassembling And Assembling Rocker Arms

    Disassembling and assembling rocker arms Fig. 1 Remove rocker arms. 3524 Fig. 2 Unclip circlip. 3525 Fig. 3 Take rocker arms off the rocker arm shaft. Note: If the rocker arm bearing bushes have to be exchanged, ready-to-install new or recondi- tioned rocker arms are to be used.

  • Page 88: Removing And Installing Valves

    Removing and installing valves D Remove rocker arms. Take off cylinder head see page 79. Removing valves Fig. 1 Screw valve assembly lever on to cylinder head. Note: Valve spring and valve spring retainer can also be replaced with the cylinder head installed.
  • Page 89 Removing and installing valves Installing valves Fig. 5 Apply oil to valve stern and insert valves into valve guides. Note: Minor damage to the valve seat can be elimi- nated by lapping using valve lapping paste. New valves must always be lapped until an even valve seat has been achieved.
  • Page 90 Removing and installing valves Fig. 9 Insert discs and valve springs. The word ”TOP” facing upwards, the tight coils fac- ing downwards. Replace damaged or weak springs. Fit valve discs and tapered elements. 1 Valve 2 Valve stem seal (on the inlet valve only) 3 Washer 4 Outer valve spring 5 Washer...

  • Page 91: Removing And Installing Valve Guides

    Removing and installing valve guides D For removing and installing cylinder head, see page 79 D For removing and installing valves, see page 87 Fig. 1 Press valve guide out of the combustion chamber side using pressing mandrel (special tool, see page 129, item 20).

  • Page 92: Replacing Valve Seat Insert

    Replacing valve seat insert Removing valve seat insert Note: If the valve seat inserts have to be changed it is necessary to change the valve guides too, as other- wise exact refacing of the valve seat inserts after the replacement cannot be guaranteed. For these reasons previously mentioned the tool for removing and installing valve guides and valve seat inserts was also designed in such a way that if this tool is used valve seat inserts can be re- placed only together with the valve guides, i.e.
  • Page 93 Replacing valve seat insert Installing valve seat insert Fig. 4 Heat cylinder head to approx. 80_C (175_F) in water bath. Cool new valve seat insert to approx. –200_C (–330_F) and insert it in the cylinder head. Carry out check by driving it in until the stop is reached using pressing tool.

  • Page 94: Reworking Valve Seat

    Select suitable guide mandrel, screw it in with a spanner (12 mm) and tighten it. Note: For extreme precision work the guide man- drel must fit snugly. Select and insert the tool with the corresponding seat width and the corresponding seat angle.
  • Page 95 Reworking valve seat Fig. 4 Release Jaccard lever, place magnetic flange flush on the clamping plate and set the height so that the tool does not contact the valve seat. Set toggle switch to position 1. Tighten the Jaccard lever. 3361 Fig.
  • Page 96 Reworking valve seat Fig. 8 Note: When dressing the valve seat inserts, re- move as little material as possible from the seat face. The valve retrusion is to be used as refer- ence value. If the cylinder head interface is to be machined (max.

  • Page 97: Refacing Valves

    Refacing valves Fig. 1 Apply abrasive paste to tapered area on the valve seat. Oil valve guide and insert valve. 3535 Fig. 2 Use valve refacer to reface valve seat by applying moderate axial pressure and describing a turning motion. Important: Keep valve stem and valve guide free of abrasive paste.

  • Page 98: Checking Compression

    Checking compression Fig. 1 D Check valve clearance and adjust, if necessary, see page 84 D Let engine warm up D Remove all fuel injectors, see page 30 D For compression guideline values, see publica- tion ”Engineering S Data S Setting values” Start with 1st cylinder (water pump end).

  • Page 99: Removing And Installing Timing Case

    Removing and installing timing case D Remove starter, see page 116 D Remove flywheel, see page 62 Fig. 1 Remove the mounting bolts (17 mm). The bottom of the timing case is bolted to the oil pan. 3536 Fig. 2 Take off the timing case.

  • Page 100: Removing And Installing Camshaft, Exchanging Camshaft Bearing

    Removing and installing camshaft, exchanging camshaft bearing Removing camshaft D Drain coolant, see page 37 D Remove oilpan, see page 53 D Remove starter, see page 116 D Remove flywheel and timing case, see page 98 D Remove the rocker arms and take out the push rods, see page 79 Note: For removing the camshaft the engine must...
  • Page 101 Removing and installing camshaft, exchanging camshaft bearing Exchanging the camshaft bearings Remove the cylinder heads, the pistons with the connecting rods and the crankshaft, before remov- ing camshaft bearings Fig. 5 Remove camshaft bearing bushes with suitable mandrel and drive in new bushes. Ensure that the oil supply bores are in correct position.

  • Page 102: Checking Valve Timing

    Checking valve timing Note: If the valve timing is incorrect, serious dam- age to the engine may result. For this rea- son, if faults occur in the engine which could lead to the shrunk-fitted camshaft gear turn- ing, check that the gear is correctly seated by checking the valve timing.

  • Page 103: Removing And Installing Crankshaft

    Removing and installing crankshaft Removing crankshaft D ,Remove oil pan and oil pump see page 53 D Remove timing case, see page 98 D Remove the front cover for sealing the crank- shaft and the cylinder heads, see page 79 Fig.
  • Page 104 Removing and installing crankshaft Checking spread of bearing shells Fig. 5 Position bearing shells together on flat surface. Measure and note down spread dimensions ”A” and ”B”. Spread dimension = A – B 2376 Installing crankshaft Fig. 6 Clean oil ducts in crankcase and in crankshaft with dry compressed air.
  • Page 105 Removing and installing crankshaft Checking axial play Fig. 9 The axial play of the crankshaft is determined by the centre crankshaft bearing (thrust bearing). 3550 Fig. 10 D Fit dial gauge holder with dial gauge to crank- case. D Move crankshaft in axial direction to and fro and read off play on dial gauge.

  • Page 106: Removing And Installing Piston With Connecting Rod

    Removing and installing piston with connecting rod Removing piston with connecting rod D Remove oil pan, oil suction pipe, see page 53 D Remove cylinder heads, see page 79 Fig. 1 Remove bolts from connecting rod bearing cap. 3724 Fig. 2 Take off connecting rod bearing caps with bearing shells, expediting the procedure by means of light strokes with a synthetic hammer if necessary.
  • Page 107 Removing and installing piston with connecting rod Installing piston with connecting rod Note: If the pistons must be changed, ascertain by measuring the pistons or reading the mea- surement on the top of the piston whether undersized pistons were installed. If this is the case, undersized pistons must be used.
  • Page 108 Removing and installing piston with connecting rod Fig. 9 Put connecting rod bearing caps in place. Important: The numbers on the connecting rod bearing cap and connecting rod big end must be on one side. 3560 Fig. 10 Screw in connecting rod bearing bolts and tighten them in stages to specified value.

  • Page 109: Detaching Piston From And Attaching To Connecting Rod

    Detaching piston from and attaching to connecting rod checking - changing connecting rod Detaching piston from and attaching to connecting rod Fig. 1 Remove piston with connecting rod. Clamp connecting rod in a vice using soft jaws. Remove gudgeon pin circlip. 3562 Fig.
  • Page 110 Removing piston from and attaching to connecting rod checking - changing connecting rod Fig. 5 Clean connecting rod and inspect for external damage; scrap any defective rods. Check connecting rod to see whether the piston pin bore is parallel or twisted relative to the bearing shell bore.

  • Page 111: Removing, Installing And Changing Piston Rings

    Removing, installing and changing piston rings Piston ring arrangement Fig. 1 1 Compression ring (double-sided keystone ring) 2 Compression ring (tapered compression ring) 3 Oil scraper ring (bevelled-edge ring) 2873 Removing piston rings Fig. 2 Remove piston with connecting rod. Clamp connecting rod in a vice using soft jaws.
  • Page 112 Removing, installing and changing piston rings Installing piston rings Figs. 5 and 6 Use piston ring pliers to place piston rings in the correct piston ring grooves (”TOP” mark facing up- wards). 2879 3729 Checking piston ring axial clearance Fig. 7 Use feeler gauge to ascertain the piston ring clear- ance at several points in each groove.

  • Page 113: Replacing Cylinder Liners

    Replacing cylinder liners Removing cylinder liners Note: Observe oversizes for cylinder liner outer diameters and collar heights (see ”Engineering S Data S Setting values”). D Remove cylinder head D Remove piston Fig. 1 3570 Mark cylinder liner position relative to engine so that it can be reinstalled in the same position if re- used.
  • Page 114 Replacing cylinder liners Checking cylinder liner protrusion Fig. 4 Clean basic bore and cylinder liner. Insert cylinder liner without O-rings into crankcase, observing the marking (ensure that it is identical with the position prior to removal). Measure cylinder liner protrusion at at least four different points, using gauge holder and gauge.
  • Page 115 Replacing cylinder liners Installing cylinder liners Fig. 6 Insert dry new O-rings for the lower seal (144x4) into the crankcase. Fig. 7 Insert new O-rings for the upper seal (138x2) into the grooves on the cylinder liner. Do not overstretch the O-rings. 3574 Fig.

  • Page 116: Measuring Piston Protrusion

    Measuring piston protrusion Fig. 1 Remove cylinder heads. Move piston to be measured to TDC. Apply dial gauge in holder to crankcase sealing face. Set dial gauge to - 0 -. 3577 Fig. 2 Carefully slew dial gauge holder round, lifting the dial gauge tip as you do so.

  • Page 117: Removing And Installing Starter

    Removing and installing starter Fig. 1 Disconnect minus cable from battery or switch off battery main switch if fitted. Disconnect cable from terminal 31 (minus terminal, thick cable), terminal 30 (plus terminal, thick cable) and terminal 50 from starter. Remove mounting nuts (19 mm). Note: A curved wrench is advantageous for the inner bolts (see Fig.).

  • Page 118: V-Belts

    V-belts Checking condition Fig. 1 D Check V-belts for cracks, oiling, overheating and wear. D Change damaged V-belts. 2642 Checking tension Figs. 2 and 3 Use belt tension indicator to check V-belt tension. D Lower the gauge arm À in the scale. D Position the tension indicator in the centre of the belt between the two pulleys so that the 2905...
  • Page 119 V-belts Tensioning V-belts Figs. 5 and 6 Remove the mounting bolts from both the alterna- tor and the tensioning device. 3386 3386 Fig. 7 D Loosen lock nut À D Turn adjusting nut Á until the V-belts are cor- rectly tensioned D Retighten lock nut and mounting bolts 3388...

  • Page 120: Coolant Level Probe

    Coolant level probe Monitoring the coolant level All engines are equipped with either one or two coolant level probes for monitoring the coolant level in the coolant expansion tank. This probe is of the capacitative type. The sensor and the evaluating electronics form a unit.
  • Page 121 Transmitters Checking the coolant temperature transmitter by measuring the resistance Ω Dip temperature sensor up to the lower edge of the hex section into a mixture of water and 30 % anti– freeze/anti–corrosion agent. The liquid must be circulated during this measurement. Check the temperature with a thermometer as the liquid is heated.
  • Page 122 Transmitters Checking the oil pressure transmitter by measuring the resistance Ω If the oil pressure transmitter is to be checked, the oil pressure must be measured with a second, indepen- dent instrument. Disconnect the gauge from the transmitter. Measure the resistance and compare it with the calibrated curves.
  • Page 123 Transmitters Checking the exhaust gas temperature transmitter by measuring the voltage If the exhaust gas temperature transmitter is to be checked, the exhaust gas temperature must be measu- red with a second, independent instrument. Disconnect the gauge from the transmitter. Measure the vol- tage and compare it with the calibrated curve (_F = 1.8_C + 32).

  • Page 124: Special Tools

    Special tools...

  • Page 125: Special Tools

    Special tools...
  • Page 126 Special tools Fig. no. Designation Item number Test connection for compression recorder 80.99607–0002 V-belt tension indicator 81.66814–6001 Valve gauge 80.99607–0076 Valve setting spanner 83.09195–0002 Spanner for nuts on injection lines (17 mm) 80.99603–0025 Socket spanner set for fuel injector 4-groove 80.99603–0049 4-groove with fixing screw 80.99603–0121...
  • Page 127 Special tools 12.2 12.1 14.1 15.6 15.7 15.4 15.3 15.1 15.3 15.5 15.1 15.2 18.1...
  • Page 128 Special tools Fig. no. Designation Item number Puller for water pump pulley 80.99601–0037 Pressing mandrel for cassette seal in conjunction with handle 14.1 80.99617–0091 Driving mandrel for seal in timing case consisting of: 12.1 Guide sleeve 80.99604–0068 12.2 Pressing plate in conjunction with handle 14.1 80.99604–0069 Puller for front crankshaft bearing race 80.99601–0076...
  • Page 129 Special tools 19.1 19.2 20.1 20.2 25.1 25.2 27.1 27.2...
  • Page 130 Special tools Fig. no. Designation Item number Sleeves for valve stem seal 19.1 Insert sleeve for valve stem seal 80.99616–0004 19.2 Pressing sleeve for valve stem seal 80.99604–0005 Pressing tool for valve guide 20.1 Pressing mandrel for valve guide 80.99617–0013 20.2 Pressing rings in conjunction with 20.1 80.99616–0003...
  • Page 131 Special tools...
  • Page 132 Special tools Fig. no. Designation Item number Valve assembly lever 80.99606–0031 Dial gauge holder for measuring valve retrusion and piston protrusion 90.99605–0172 Pressure gauge + accessories for charge-air pressure measurement 80.99605–0160...
  • Page 133 Special tools Fig. no. Designation Item number Measuring combination, consisting of: (1) Dial gauge 08.71000–1205 (2) Tracer pin for dial gauge 80.99605–0197 (3) Dial gauge holder 80.99605–0179 (4) Contact pin 80.99605–0180 (5) Dial gauge holder 80.99605–6006 (6) Dial gauge holder 80.99605–0172 Press–on measuring plate 80.99605–0195...
  • Page 134 Special tools Pressing mandrel for cap, dia. 50.1 mm Pressing mandrel for cap, dia. 62.1 mm 2843...
  • Page 135 Special tools Special tools for water pump repair for local manufacture (Material: steel as available) Support ring for pressing out the water pump bearing Ø 68 Ø 56...

  • Page 136: Index

    Index Bleeding fuel system Heat exchanger Cleaning Removing and installing Camshaft, Removing Heat exchanger pipe cluster Camshaft , Installing Camshaft bearings Charge–air pressure, Checking Impeller (raw water pump) Compression (checking) Injection nozzle (checking) Conrod, Checking Injection nozzles (repairing) Coolant Injection pump Draining Installing Filling...
  • Page 137 Index Piston V–belts 117–118 Detaching from conrod, Attaching to conrod Valve guides, Removing and Installing Valve recess Installing Valve seat, Reworking Removing Valve seat insert Piston protrusion Installing Piston ring axial play Removing Piston ring gap Valve timing Piston rings Valves Installing Installing...

This manual is also suitable for:

D 2866 le 402D 2866 le 403D 2876 le 403D 2866 le 405D 2876 le 301

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