Man D 2840 LE 301 Repair Manual
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Man D 2840 LE 301 Repair Manual

Marine diesel engines
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Summary of Contents for Man D 2840 LE 301

  • Page 3: Preface

    Only use fuels, lubricants etc. in accordance with MAN’s regulations. Otherwise the manufacturer’s liability for defects will not apply! For basic information on the fuels see the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”. You can find the approved products on the Internet at: −http://www.man-mn.com/ "...

  • Page 4: Instructions

    Flat seals / gaskets can be fitted properly only if the following points are observed: D Use only genuine MAN seals / gaskets D The sealing faces must be undamaged and clean D Do not use any sealing agent or adhesive −...
  • Page 5 Instruction Masking of fuel and lube oil pipe con- nections (for classified engines only) The unions of pressurised oil and fuel pipes are masked with a protective tape. If this tape is removed during a repair, the unions must be masked with protective tape again after- wards.

  • Page 6: Table Of Contents

    Contents Preface ................. Instructions .
  • Page 7 Service Data Engine D 2840 LE 301 ..............

  • Page 8: Engine Type Classification

    The system is explained below using the model type D 2840 LE 301 as an example: The “D” at the start of the type classification stands for “Diesel”...

  • Page 9: Safety Regulations

    Safety regulations General notes This summary is a compilation of the most important regulations. These are broken down into main sections which contain the information necessary for preventing injury to persons, damage to property and pollution. Additional information can be found in the operating instructions of the engine. Important: Should an accident occur despite all precautionary measures, particularly one involving contact with corrosive acid, penetration of fuel under the skin, scalding by hot oil, antifreeze splashing into the eyes etc.
  • Page 10 D If engine operation is disrupted, immediately determine the cause and have it remedied to prevent additional damage. 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 11 Safety regulations 3. Regulations designed to prevent pollution Engine oil and filter elements / cartridges, fuel / fuel filter D Hand old oil over to old oil disposal companies only. D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground. Caution: Risk of contamination of potable water.
  • Page 12 Safety regulations 4. Notes on safety in handling used engine oil ∗ Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin. Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous substances which have caused skin cancer in animal experiments.
  • Page 13 The precondition for this, however, is that the experts are familiar with the Repair Manual for the engine as well as the accompanying Operating Instructions and the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”.

  • Page 14: Troubleshooting Table

    Troubleshooting table Starter turns over engine only slowly or not at all Starter turns, engine does not start, engine does not start / difficult to start when cold Engine stalls (dies) during operation, no longer starts (starter turns), engine does not start / starts with difficulty when hot Sudden, temporary engine shutdown, engine does not reach full revs Engine only runs at idle speed, no throttle response Engine only runs at increased idle speed, no throttle response...
  • Page 15 Troubleshooting table Starter turns over engine only slowly or not at all Starter turns, engine does not start, engine does not start / difficult to start when cold Engine stalls (dies) during operation, no longer starts (starter turns), engine does not start / starts with difficulty when hot Sudden, temporary engine shutdown, engine does not reach full revs Engine only runs at idle speed, no throttle response Engine only runs at increased idle speed, no throttle response...
  • Page 16 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 17: General Notes On Engine Overhaul

    D Technically correct installation D Inspection if installation by authorised personnel D Regular maintenance as per maintenance plan D Choice and quality of lube oil, fuel and coolant in accordance with the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”...

  • Page 18: Commissioning After Engine Overhaul

    Commissioning after engine overhaul Pressurisation It is extremely important for internal combustion engines (following the completion of repair work, i.e. in their dry state) to be pressurised with lube oil before being recommissioned. This procedure can also be used for ascertaining damage and its causes. If engines are not pressurised, the risk of premature damage to bearing surfaces is very high because it takes a relatively long period of time for the lube oil drawn in from the oil pan via the oil pump to reach the individual bearings.
  • Page 19 Commissioning after engine overhaul Pressurising an engine affords the following advantages: D All engine parts are lubricated before engine startup; a lubricating film can be built up inside the bear- ings as early as after the first few rotations of the crankshaft, thereby preventing damage to the bearing races D Any loss of oil, be it the result of excessively large bearing play or leaks from the crankcase or from crankcase bores which may not be plugged, can be detected immediately.

  • Page 20: Engine Views D 2842 Le 301

    Engine views Engine views D 2842 LE 301...
  • Page 21 Engine views À Heat exchanger and coolant surge tank Á Coolant filler neck  Relief valve on coolant surge tank à Intercooler Ä Oil filler neck Å Crankcase breather Æ Air filter Ç Turbocharger È Exhaust manifold É Starter Oil pan Engine cranking device Alternator Coolant pump...

  • Page 22: Engine Lubrication Schedule

    Engine lubrication schedule À Oil line to crankshaft Å Oil pump with oil pressure relief valves Á High−pressure pump lubrication Æ Holes for conrod bearing lubrication  Lubricating oil lines to exhaust turbochargers Ç Oil drain screw à Oil return line from exhaust turbochargers È...
  • Page 23 Engine lubrication schedule À Lubricating oil lines to exhaust turbochargers Å Oil intake pipe Á Rocker arm lubrication Æ Oil pressure relief valves  Piston pin lubrication Ç Oil cooler à Spray nozzles for piston cooling and È Bypass valve cam lubrication É...

  • Page 24: Schematic Diagram Of Cooling System

    Schematic diagram of cooling system 10 11 À Sea water inlet Coolant filler neck Á Sea water pump Heat exchanger, engine coolant / sea water  Exhaust turbocharger, liquid−cooled Sea water outlet à Exhaust manifold, liquid−cooled Thermostat Ä Exhaust pipe, liquid−cooled Heater feed and return system Å...

  • Page 25: Fuel Diagram

    Fuel diagram À Injector Ä Tank Á Injection pump Å Fuel filter  Hand pump with prefilter Æ Fuel pump à Valve...

  • Page 26: Checking And Adjusting Start Of Fuel Delivery

    Checking and adjusting start of fuel delivery Checking start of delivery Figs. 1 and 2 For the purpose of checking the start-of-delivery setting, an “OT” (= TDC) mark and a scale from 10 ... 50_ before TDC are engraved on a disc Á fitted in front of the torsional vibration damper.
  • Page 27 Checking and adjusting start of fuel delivery Fig. 5 Remove plug from inspection hole in timing case cover. Fig. 6 Then rotate engine so that mark on pointer fitted to injection pump coincides with mark on pump hub. Read degrees on scale engraved on disc on tor- sional vibration damper.
  • Page 28 Checking and adjusting start of fuel delivery Fig. 9 Remove timing case cover. Note: Pipes are attached to the timing case cover. To facilitate reassembly, note down the positions of the brackets, pipe clamps, spacer sleeves etc. Fig. 10 Turn engine to specified angle for delivery start. Fig.

  • Page 29: Removing And Installing Injection Pump

    Removing and installing injection pump Removing injection pump Note: The subsequent reinstallation of the injection pump is rendered considerably easier if before its removal the engine has been turned to start of delivery. See page Fig. 1 Remove the charge-air elbow and the charge-air pipes leading to the turbocharger.
  • Page 30 Removing and installing injection pump Fig. 5 Remove container together with fuel hand pump too. Fig. 6 Remove all fuel connections from injection pump. Remove oil return line from crankcase. Caution: The lines contain fuel. Catch emerging fuel in a container. Fig.
  • Page 31 Removing and installing injection pump Fig. 9 Remove mounting bolts from injection pump. Take off injection pump. Note: Ensure meticulous cleanliness when work- ing on the injection pump. Prevent dirt and foreign matter from pene- trating into opened line connections. Installing injection pump Fig.
  • Page 32 Removing and installing injection pump Fig. 13 Fit injection pump in such a way that the mounting bolts can be screwed in by hand. Check distance between injection pump and crankcase. Fig. 14 Tighten mounting bolts to specified torque (see “Service Data”).

  • Page 33: Removing And Installing Fuel Injectors

    Removing and installing fuel injectors Removing fuel injectors Fig. 1 To facilitate removing the injection lines, remove the charge-air elbow and the charge-air pipes leading to the turbocharger. Fig. 2 Remove the injection lines from the injection nozzles and from the injection pump. Remove the fuel return lines.
  • Page 34 Removing and installing fuel injectors Fig. 5 Screw adapter on to nozzle holder. Screw on inertia extractor and knock out nozzle holder. Take sealing ring off the injection nozzle. Check and repair injector, see page 33. Installing fuel injectors Fig. 6 Insert new sealing ring, apply “Never Seeze”...

  • Page 35: 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, see page 34.
  • Page 36 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, inter- mediate washer, pressure pin, compression spring and shim.
  • Page 37 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 38: Fuel Prefilter

    Fuel prefilter Cleaning fuel pre-cleaner Fig. 1 and Fig. 2 D Unscrew the filter housing of the fuel prefilter Fig. 3 D Clean filter housing and strainer in clean diesel fuel and blow out with compressed air D Reassemble with a new seal D Screw on filter housing and tighten it to 10−12 Nm Fig.

  • Page 39: Removing And Attaching Fuel Filter, Exchanging Filter Cartridge

    Removing and attaching fuel filter, exchanging filter cartridge Removing and attaching fuel filter Fig. 1 Remove the fuel lines À. Remove the mounting bolts Á and take off fuel filter. Install in reverse order. The fuel lines are to be fit- ted with new sealing rings.
  • Page 40 Removing and attaching fuel filter, exchanging filter cartridge Venting fuel system Note: To bleed the fuel system switch on the “ignition” so that the EHAB will be open. Figs. 4 and 5 An arrow on the filter head indicates the direction of fuel flow.

  • Page 41: Draining And Filling Coolant

    Draining and filling coolant Draining coolant Danger: When draining hot coolant, there is a danger of scalding! Caution: Collect the drained coolant and dispose of it in accordance with regulations! Drain coolant as follows when cooling system has cooled down: D Briefly open cap À...
  • Page 42 Draining and filling coolant Fill / bleed the cooling system (only when engine has cooled down) The cooling system of the engine is to be filled with a mixture of drinking water from the mains and antifreeze based on ethylene glycol and / or anticorrosion additive. Caution: Use only approved fuels, lubricants etc.
  • Page 43 Draining and filling coolant Note: The turbocharger and the intercooler may not be bled when the coolant system is topped up. Danger: If, in an exceptional case, the coolant level has to be checked in an engine that has reached operating temperature, first carefully turn the cap Ä...

  • Page 44: Removing And Installing Thermostats

    Removing and installing thermostats D Drain off coolant, see page 39 Figs. 1 and 2 Loosen the mounting bolts of the cover. Loosen the mounting bolts of coolant manifold at the liquid-cooled exhaust pipe and take off both components together. Fig.

  • Page 45: Removing And Installing Coolant Pump

    Removing and installing coolant pump Removing coolant pump D Drain off coolant, see Page 39 D Remove heat exchanger, see page 52 D Remove the thermostats, see page 42 D Take off V−belt, see page 138 Note: If the coolant pump is to be disassembled later, remove V−belt pulley before remov- ing the coolant pump and pull off coolant pump hub with a stable three−arm puller.
  • Page 46 Removing and installing coolant pump Note: Exchange or repair coolant pump only if it has been found to be leaky. The design of the coolant pump mechanical cassette seal permits small amounts of coolant to pass through it. This coolant passing through results in a trace of drained coolant below the drain bore.

  • Page 47: Repairing Coolant Pump

    Repairing coolant pump Disassembling coolant pump The following special tool is needed to disas- semble and assemble the coolant pump: D Press D Additional tools to make yourself (special tool) Fig. 1 À Mechanical seal Á Pump bearing  Hub Ã...
  • Page 48 Repairing coolant pump Fig. 4 Pull impeller off the coolant pump bearing. Four M8 threaded bores are provided for this pur- pose. Fig. 5 Centre the pump housing on a suitable holder. Use suitable mandrel to press the coolant pump shaft with bearing out of the housing.
  • Page 49 Repairing coolant pump Figs. 8 and 9 Turn coolant pump housing over. Press in new mechanical seal with press-fitting sleeve (special tool) until it stops. Observe installation note for seal on page 49. Note: The seal can be exchanged even without removing the coolant pump shaft.
  • Page 50 Repairing coolant pump Figs. 12 and 13 Place on the new pump cover and use a suitable pressing die to press the cover into the housing. Fit coolant pump with new seal, see page 43.
  • Page 51 Fit the mechanical seal “wet”, i.e. when fitting, coat holding sleeve à and coolant pump shaft À with a mix- ture of 50% water and 50% cleaning spirit or 40% to 50% antifreeze as per MAN 324 and water. Other anti-skid agents must not be used.

  • Page 52: Cleaning Cooling System

    Cleaning cooling system Cleaning inside of cooling system Tests have shown that in many cases the poor condition of the coolant and / or the cooling system ac- counts for damage to the coolant pump seal. The poor condition of the cooling system is normally due to the use of unsuitable or no antifreeze or corrosion inhibitor or to defective caps for filler necks and service valves which are not punctually replaced.
  • Page 53 Cleaning cooling system Removing lime deposits in cooling system Proceed as follows: D Drain coolant D Fill the system with undiluted original pickling fluid (lithsolvent acid or engine pickling fluid RB-06). Keep the engine running for approx. 8 hours with this fluid in the system (also in normal operation) D Drain the pickling fluid and flush the system thoroughly with tap water D If necessary, refill the system with fresh pickling fluid and pickle the system for a further 8 hours D Drain the pickling fluid, fill the system with tap water, and run the engine at idle for 5 minutes to flush out...

  • Page 54: Removing And Installing Heat Exchanger

    Removing and installing heat exchanger D Drain off coolant, see page 39 Figs. 1 and 2 Unscrew all pipe connections to the heat ex- changer. Fig. 3 Unscrew the mounting bolts at the brackets. Fig. 4 Unscrew the mounting bolts on the front side of the engine.
  • Page 55 Removing and installing heat exchanger Fig. 5 Install the heat exchanger in reverse order. Tighten the mounting bolts with the prescribed torque. Fit pipe connections with new O-rings. Check the system for leaks. Fill coolant, see page 40...

  • Page 56: Removing And Installing Pipe Cluster For Heat Exchanger

    Removing and installing pipe cluster for heat exchanger Removing pipe cluster for heat ex- changer D Remove heat exchanger, see page 52 Fig. 1 In the installed condition the collar of the pipe cluster can be seen between the cover and the heat exchanger housing (arrow).
  • Page 57 Removing and installing pipe cluster for heat exchanger Fig. 5 Carefully knock pipe cluster out from the other end with a block of wood. Caution: The pipe cluster is bolted to the heat ex- changer! See Figs. 3 and 4. Figs.
  • Page 58 Removing and installing pipe cluster for heat exchanger Installing pipe cluster for heat ex- changer Figs. 8 and 9 The pipe cluster is installed in reverse order. When installing the pipe cluster, use new O-rings (total of 4 rings). Fig. 10 Push pipe cluster into heat exchanger housing.

  • Page 59: Checking And Repairing Pipe Cluster For Heat Exchanger

    Checking and repairing pipe cluster for heat exchanger D Remove pipe cluster, see page 54 Fig. 1 When the pipe cluster is removed, we recommend always checking the position of the deflectors (ar- rows) (the picture shows the pipe cluster for a D 2848 LE 403 engine).
  • Page 60 The area must also be free of grease. To effect the soldering, use soldering tin DIN 1707 − L − SN 50 PB SB (MAN no. 09.43007−0092), melting range 183_C−215_C and soldering fluid such as DEGUSSA Soltaflux K or similar products from other manufacturers.

  • Page 61: Cleaning Heat Exchanger Pipe Cluster

    Cleaning heat exchanger pipe cluster Internal cleaning of the pipe cluster in sea water heat exchangers Deposits may form on the sea water side of the pipe cluster in the heat exchanger, impairing the heat transition 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 62: Disassembling And Assembling Seawater Pump

    Disassembling and assembling seawater pump À Pump housing Ç Nut Á O-ring È Shaft  Tensioning nut É Bearing à Impeller Adjusting washer Ä Axial face seal Circlip Å Bearing housing Belt pulley Æ Leakage bore Bolt Disassembling seawater pump Remove belt pulley by undoing bolt .

  • Page 63: Changing Oil Filter

    Changing oil filter Caution: Old oil and used oil filters are hazardous waste. Observe safety instructions for the pre- vention of environmental damage. Fig. 1 Open oil drain plug and use container to catch oil that may emerge. Danger: Oil filter can and oil filter are filled with hot oil.

  • Page 64: Removing And Installing The Oil Cooler

    Removing and installing the oil cooler D Drain off coolant, see Page 39 D Drain engine oil, see page 64 Fig. 1 Remove the oil filter (WAF 17). Remove filter head seal. Fig. 2 Pipes that lead to the oil cooler housing cover or go over the cover and obstruct removal are to be unscrewed.
  • Page 65 Removing and installing the oil cooler Fig. 5 Remove oil cooler housing cover with fitted oil cooler. Figs. 6 and 7 Inspect the oil cooler for damage and replace if necessary. Fit oil cooler with new seals. Apply a thin bead of “Loctite 5900” sealing com- pound to the seal À.

  • Page 66: Removing And Installing, Repairing 2-Gear-Oil Pump

    Removing and installing, repairing 2-gear-oil pump Drain engine oil Fig. 1 Danger: The oil is hot, risk of scalding! Do not touch the oil drain plug with bare fingers. Oil is an environmental hazard. Handle it with care! Drain off engine oil from the oil pan and the oil filters.
  • Page 67 Removing and installing, repairing 2-gear-oil pump Fig. 5 Unscrew the mounting bolts of the pressure relief valve and oil pump. Take off overpressure valve and oil pump. The overpressure valve is encapsulated. Opening pressure, see “Service Data”. Note: Depending on the engine model and oil pan variant, various oil pump versions are possible.
  • Page 68 Removing and installing, repairing 2-gear-oil pump Checking the axial clearance of the pump wheels Fig. 9 Position dial gauge and push shaft up to the stop in one direction and set dial gauge to “0”. Push the shaft in the opposite direction and read off the needle deflection on the dial gauge.

  • Page 69: Removing And Installing, Repairing 3−Gear−Oil Pump

    Removing and installing, repairing 3−gear−oil pump Drain engine oil Fig. 1 Danger: The oil is hot, risk of scalding! Do not touch the oil drain plug with bare fingers. Oil is an environmental hazard. Handle it with care! Drain off engine oil from the oil pan and the oil filters.
  • Page 70 Removing and installing, repairing 3−gear−oil pump Repairing oil pump Fig. 5 Fit the oil pump in a vice (use protective jaws). Unscrew the upper oil pump cover. Fig. 6 Pull the driven oil pump wheel from the casing. Check the toothed wheels and pump casing for wear (see “Service Data”).
  • Page 71 Removing and installing, repairing 3−gear−oil pump Checking the axial clearance of the pump wheels Fig. 9 Position dial gauge and push shaft up to the stop in one direction and set dial gauge to “0”. Push the shaft in the opposite direction and read off the needle deflection on the dial gauge.
  • Page 72 Removing and installing, repairing 3−gear−oil pump Filling with engine oil Figs. 12 and 13 Caution: Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Overfilling will result in damage to the engine.

  • Page 73: Oil Injection Nozzle

    Oil injection nozzle Removing the oil injection nozzle D Drain off oil, see page 64 D Removing the oil pan, see page 64 Fig. 1 Unscrew the mounting bolts of the oil injection nozzle (arrow). Remove oil injection nozzle with valve. Check the oil injection nozzle valve Fig.
  • Page 74 Oil injection nozzle Fig. 5 The oil spray from each nozzle must reach the entry bore hole of the cooling duct in the piston crown À and cams Á without hindrance. Bent oil injection nozzles must on no account be repaired.

  • Page 75: Removing And Fitting Vibration Damper, Replacing Front Crankshaft Gasket

    Removing and fitting vibration damper, Replacing front crankshaft gasket Removing vibration damper D Turn engine to ignition “TDC”. This ensures that in subsequent assembly work the indicating dial will be in the correct position D Relax and remove V-belt; see page 138 Fig.
  • Page 76 Removing and fitting vibration damper, Replacing front crankshaft gasket Changing front crankshaft seal Fig. 5 Loosen the mounting bolts of the cover. Fig. 6 Remove the cover. Only replace the front crankshaft gasket as a com- plete unit, i.e. replace the bearing race and the radial shaft sealing ring.
  • Page 77 Removing and fitting vibration damper, Replacing front crankshaft gasket Fig. 9 A special too is required to fit the bearing race. Clean the inside of the bearing race and tail shaft. Coat the tail shaft with sealing compound “Antipor 46”. D Push race À...
  • Page 78 Removing and fitting vibration damper, Replacing front crankshaft gasket Fitting the vibration damper Fig. 13 Fit the hub and oil splash ring on the crankshaft. Fig. 14 Place vibration damper on two guide pins (M16x1.5). Ensure that the position of the graduated disc rela- tive to the crankshaft is correct! Tighten the mounting bolts.

  • Page 79: Removing And Installing Flywheel, Replacing Starter Gear Ring

    Removing and installing flywheel, Replacing starter gear ring Removing flywheel Fig. 1 Release the mounting bolts, securing the engine against rotating if necessary. Fig. 2 Unscrew two bolts opposite one another and re- place with two guide mandrels (special tool). Remove all the bolts.
  • Page 80 Removing and installing flywheel, Replacing starter gear ring Replacing starter ring gear Fig. 5 Remove the flywheel. Drill the starter motor toothed wheel and break with a chisel. Caution: In doing so, do not damage the flywheel. Fig. 6 Note: As the maximum axial run-out of the starter motor toothed wheel must not be exceeded, the axial run-out of the fly-...

  • Page 81: Replacing Crankshaft Seal (Flywheel End)

    Replacing crankshaft seal (flywheel end) Removing shaft sealing ring Fig. 1 Remove flywheel, see page 77. Prise out the seal using the special tool (Fig. 2) or a screwdriver. Fig. 2 Special tool for levering out the crankshaft seal. Fit shaft sealing ring Fig.

  • Page 82: Replacing The Bearing Race

    Replacing the bearing race Replacing bearing race Remove flywheel, see page 77. Fig. 1 If the shaft sealing ring on flywheel side is re- placed, it is also recommended to replace the bearing race of the flywheel. Pull off the bearing race to be exchanged using a puller (special tool).

  • Page 83: Crankshaft Seals

    Crankshaft seals General information on crankshaft seals As a general principle, the radial shaft sealing rings are made of polytetrafluorothylene (PTFE), otherwise known as Teflon. PTFE sealing rings differ from the elastomer sealing rings that used to be common in that they have a much wider, flat sealing lip that is not pretensioned by a coiled spring expander.

  • Page 84: Removing And Installing Intake Pipes

    Removing and installing intake pipes D Draining off coolant, see page 39 D Remove heat exchanger, see page 52 D Remove intercooler, see page 91 D Remove injection lines, see page 27 Note: When working with the intake system, take care to ensure that everything re- mains very clean to prevent foreign bodies from entering the engine.

  • Page 85: Removing And Installing Exhaust Pipe

    Removing and installing exhaust pipe Removing exhaust pipe D Draining off coolant, see page 39 D Remove turbocharger, see page 87 Fig. 1 Remove exhaust manifold. To remove the right−hand exhaust pipe, the oil fil- ter bowls must be removed, see page 61. Close up oil filter console to prevent dirt or foreign matter from getting into the lube oil circuit.
  • Page 86 Removing and installing exhaust pipe Fig. 5 Tighten the securing bolts with the prescribed tor- que. Tightening torque: 50 Nm Fig. 6 Bolt on the exhaust manifold in diagonal sequence. Tightening torque: 185 Nm...

  • Page 87: Turbocharger, Troubleshooting

    Turbocharger, troubleshooting Before replacing the turbocharger, carry out the following checks Turbochargers are frequently replaced if engine oil consumption is too high, power output too low or intake or exhaust gas noises appear to be abnormal. Subsequent inspections by the manufacturer of the supposedly defective parts frequently prove the turbo- chargers to be in working order.
  • Page 88 Turbocharger, troubleshooting If oil accumulates in charge-air pipes and intercooler The very design of the engine causes a small amount of oil to collect in the charge-air system in the form of oil mist − this is perfectly natural and desired. The oil mist is required to lubricate the intake valve seats.

  • Page 89: Removing And Installing Turbocharger

    Removing and installing turbocharger Removing turbocharger D Drain off coolant, see Page 39 Fig. 1 Remove the venting line and intake neck. Fig. 2 Remove the coolant lines. Fig. 3 Unscrew the oil supply line and oil return line. Fig. 4 Remove diffuser from exhaust manifold and turbo- charger.
  • Page 90 Removing and installing turbocharger Fig. 5 Release the four (self-locking) nuts (WAF 17) on the turbocharger flange. Take off turbocharger. Note: When placing the turbocharger to one side, ensure extreme cleanliness to pre- vent penetration of dirt and foreign bodies. Installing turbocharger Fig.

  • Page 91: Measuring Axial / Radial Clearance Of Turbocharger Shaft

    Measuring axial / radial clearance of turbocharger shaft D Remove turbocharger, see page 87 Fig. 1 Mark the turbine housing relative to the bearing housing and remove the turbine housing. Axial clearance Fig. 2 Arrange the dial gauge bracket with magnetic foot and dial gauge as shown in the illustration.

  • Page 92: Charge Pressure Control Valves

    Charge pressure control valves Fig. 1 The engines are equipped with charge pressure control valves (also know as waste gates, arrow). Their task is to limit the charge-air pressure to a precisely defined value. Fig. 2 The charge pressure control valves are mainten- ance-free.

  • Page 93: Removing And Installing Intercooler

    Removing and installing intercooler Removing intercooler D Remove heat exchanger, see page 52 Fig. 1 Remove the bolts from the flanges on the pipe connections. Fig. 2 Unscrew the charge-air manifold and charge air pipes. Fig. 3 Unscrew the mounting bolts at the venting line brackets.
  • Page 94 Removing and installing intercooler Fig. 5 Remove the boost pressure sensor. Fig. 6 Unscrew the mounting bolts of the intake mani- folds. Remove the intercooler with manifold. Danger: The intercooler is heavy. Use lifting gear or work with a helper. Install in reverse order.

  • Page 95: Removing And Installing Cylinder Head

    Removing and installing cylinder head Removing cylinder head D Drain coolant, see page 39 D Remove injection lines, see page 27 D Remove injectors, see page 31 Note: The intake and exhaust pipes need not be detached for removing the cylinder head. Fig.
  • Page 96 Removing and installing cylinder head Fig. 5 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. On engines recently manufactured Torx bolts are used for which an E20 − ½” wrench is required.
  • Page 97 Removing and installing cylinder head Installing cylinder head Fig. 8 Before installation clean and blow out threaded bores in crankcase. Clean sealing faces on cylinder head and crankcase. Lay new cylinder head gaskets in place in dry condition, ensuring that the holes match those in the crankcase, and place cylinder head on top.
  • Page 98 Removing and installing cylinder head Fig. 12 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 99 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 100: Setting Valve Clearance

    Fig. 3 D 2840 LE 301 Valves are in crossover in cylinder Set valves in the cylinder Fig. 4...
  • Page 101 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 “Service Data”) using screwdriver to prevent ad- justing screw from turning.

  • Page 102: Removing And Installing Rocker Arms

    Removing and installing rocker arms Fig. 1 Remove rocker arms, see page 93. Unclip circlip. Fig. 2 Take rocker arms off the rocker arm shaft. Note: If the rocker arm bearing bushes have to be exchanged, ready-to-install new or reconditioned rocker arms are to be used.

  • Page 103: Removing And Installing Valves

    Removing and installing valves Removing valves D Remove rocker arms. Take off cylinder head, see page 93. 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 104 Removing and installing valves Installing valves Fig. 4 Apply oil to valve stern and insert valves into valve guides. Note: Minor damage to the valve seat can be eliminated by lapping using valve lapping paste. New valves must always be lapped until an even valve seat has been achieved.
  • Page 105 Removing and installing valves Fig. 8 Insert discs and valve springs. The word ”TOP” facing upwards, the tight coils facing 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 106: Removing And Installing Valve Guides

    Removing and installing valve guides D For removing and installing cylinder head, see page 93 D For removing and installing valves, see page 101 Fig. 1 Press valve guide out of the combustion chamber side using pressing mandrel (special tool). Oil new valve guide and drive/press it into the cylinder head using pressing mandrel and spacer sleeve (special tool).

  • Page 107: 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 otherwise 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 replaced only together with the valve guides, i.e.
  • Page 108 Replacing valve seat insert Installing valve seat insert Fig. 4 Cool new valve seat insert down to approx. -200°C and insert it into the cylinder head (at an ambient temperature of approx. 20°C). Carry out check by driving it in until the stop is reached using pressing tool.

  • Page 109: Reworking Valve Seat

    Reworking valve seat Reworking valve seat (with Mira precision valve seat machining device) Fig. 1 1 Feed nut with mm scale 2 Guide ball 3 Jaccard lever 4 Lubricating nipple 5 Rotary head 6 Hex socket screw 7 Tool 8 Guide mandrel 9 Driving crank 10 Toggle switch 11 Handle...
  • Page 110 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. Fig.
  • Page 111 Reworking valve seat Fig. 8 Note: When dressing the valve seat inserts, remove as little material as possible from the seat face. The valve retrusion is to be used as ref- erence value. If the cylinder head interface is to be machined (max.

  • Page 112: Refacing Valves

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

  • Page 113: Checking Compression

    Checking compression D Check valve clearance and adjust, if necessary, see page 98 D Let engine warm up D Remove all fuel injectors, see page 31 D For compression guideline values, see publication “Service Data” Fig. 1 Start with 1st cylinder. Insert new seal, screw on test connection of compression recorder with union nut and tighten with pin spanner.

  • Page 114: Removing And Installing The Timing Case

    Removing and installing the timing case Removing timing case D Removing the starter motor, see page 133 D Remove crankcase breather D Remove the intercooler, see page 91 D Remove Fuel Service Centre, see page 37 D Remove sea water pump, see page 60 D If necessary, remove hydraulic pump D If necessary, remove engine bearer D Removing the flywheel, see page 77...
  • Page 115 Removing and installing the timing case Fig. 5 Remove the timing case. Fitting the timing case Fig. 6 Clean residues of seals from the seating surface on the crankcase. Stick the new seal on with a little grease. Guide timing case on to the alignment pins and bolt it into place.

  • Page 116: Removing And Installing Camshaft

    Removing and installing camshaft Removing camshaft D Draining off coolant, see page 39 D Removing the oil pan, see page 64 D Removing the starter motor, see page 133 D Removing the flywheel and timing case, see page 112 D Removing cylinder heads, see page 93 Note: The engine must be turned through 180_ in order to remove the camshaft.
  • Page 117 Removing and installing camshaft Replacing the camshaft bearings Fig. 3 Pull out the camshaft bearing bushes with the mounting tool (special tool). Press in the camshaft bearing bushes with mount- ing tool (special tool) until the are flush. In doing so, observe the correct position of the oil supply bore hole (arrow).
  • Page 118 Removing and installing camshaft Measuring the axial clearance of the camshaft Fig. 7 Remove screw plug or angle drive for tachometer from camshaft cover. Apply the sensor of the dial gauge to the front of the camshaft or driver for the revcounter. Set the dial gauge to “0”.

  • Page 119: Checking The Valve Timing

    Checking the valve timing Note: Unsynchronised valve timing can cause severe engine damage. For this reason, following engine faults that can cause twisting of the shrunk-on cam- shaft toothed wheel, the correct seating must be checked by checking the valve timing.

  • Page 120: Removing And Installing Crankshaft

    Removing and installing crankshaft Removing crankshaft D Remove the oil pan, see page 64 D Remove oil pump, see page 64 D Remove timing case, see page 112 D Remove front cover of crankshaft seal, see page 74 D Remove all pistons with connecting rods, see page 121 Fig.
  • Page 121 Removing and installing crankshaft Check the spread of the bearing bushes Fig. 5 Place the bearing shells together on a level sur- face. Measure and note down dimensions “A” and “B”. Spread dimension = A−B Installing crankshaft Figs. 6 and 7 Clean the oil ducts in the crankcase and in the crankshaft with dry compressed air.
  • Page 122 Removing and installing crankshaft Fig. 9 Caution: Removed bolts must be replaced. Screw in the crankshaft bearing cover bolts and tighten them. Pretightening: 80−90 Nm 1st angle tightening: 90_ 2nd angle tightening: 90_ Check that the crankshaft runs smoothly. Caution: Damaged bearing caps cannot be replaced on an individual basis.

  • Page 123: Removing And Installing Pistons With Conrods

    Removing and installing pistons with conrods Removing pistons with conrods D Removing oil pan, see page 64, 67 D Removing cylinder heads, see page 93 Fig. 1 Loosen and remove conrod bearing cover bolts. Fig. 2 Take off conrod bearing covers with bearing bushes;...
  • Page 124 Removing and installing pistons with conrods Installing pistons with conrods Note: If the pistons have to be replaced, it must be determined whether oversize pistons were fitted by measuring the pistons or re- ading off the dimension on the piston crown.
  • Page 125 Removing and installing pistons with conrods Fig. 9 Place the conrod bearing cover in position. Caution: The numbers on the connecting rod bear- ing cap and connecting rod big end must be on one side. Fig. 10 Screw in the conrod bearing bolts and tighten them in stages.

  • Page 126: Removing Pistons From Conrod And Fitting, Checking − Replacing Conrod

    Removing pistons from conrod and fitting, checking − replacing conrod Removing pistons from conrod and fit- ting Fig. 1 Remove pistons with conrods. Clamp the conrod in a vice using protective jaws. Disengage piston pin fastening. Fig. 2 Press out the gudgeon pin, in doing so, hold the piston.
  • Page 127 Removing pistons from conrod and fitting, checking − replacing conrod Fig. 5 Clean conrod. Inspect for external damage, re- place damaged conrods if necessary. Check parallel location of conrod and twisting of piston pin eye to bearing bush bore hole. In the case of deviations beyond the tolerance range, replace conrod.

  • Page 128: Removing And Installing Piston Rings

    Removing and installing piston rings Piston ring arrangement Fig. 1 1 Compression ring (keystone ring) 2 Compression ring (minute ring) 3 Oil control ring (bevelled ring) Removing piston rings Fig. 2 Remove pistons with conrods Fit conrod in a vice, use protective jaws. Set piston ring wrench to piston diameter.
  • Page 129 Removing and installing piston rings Installing piston rings Fig. 5 and Fig. 6 use the piston ring wrench to engage the piston rings in the relevant piston ring groove (TOP facing upwards). Checking piston ring axial clearance Fig. 7 Determine the piston ring clearance in each piston ring groove at various points using a feeler gauge.

  • Page 130: Replacing Cylinder Liners

    Replacing cylinder liners Removing cylinder liners Note: Observe oversizes for cylinder liner outside diameters and collar heights (see “Service data”). D Remove cylinder head, see page 93 D Remove piston, see page 121 Fig. 1 Special tool for removing the cylinder liners. Fig.
  • Page 131 Replacing cylinder liners Fig. 5 Set the cylinder liner down in an upright position. Remove the O-rings. Number cylinder liners in order of installation. Fig. 6 Remove the O-rings from the crankcase. Clean the seat for the cylinder liners in the crankcase.
  • Page 132 Replacing cylinder liners Installing cylinder liners Checking cylinder liner protrusion Fig. 7 Clean the basic bore and the cylinder liner. Insert the cylinder liner without O-rings into the crankcase, observing the marking (ensure that it is identical to the position prior to removal). Using the dial gauge and its holder, measure the cylinder liner protrusion at no less than 4 different points.
  • Page 133 Replacing cylinder liners Fig. 10 Insert new O-rings for the lower seal (144x4) dry into the crankcase. Fig. 11 Insert new O-rings for the upper seal (138x2) into the cylinder liner grooves. Do not overstretch the O-rings. Note: Do not use grease or sealing compounds of any type to install the cylinder liners and O-rings.

  • Page 134: Measuring Piston Protrusion

    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”. Fig. 2 Carefully slew dial gauge holder round, lifting the dial gauge tip as you do so.

  • Page 135: Removing And Installing Starter Motor

    Removing and installing starter motor Fig. 1 Disconnect the negative lead from the battery or, if fitted, switch off the battery master switch. Disconnect the connecting cable at terminal 31 (negative terminal, thick cable), connecting cable at terminal 30 (positive terminal, thick cable) and at terminal 50 from the starter motor.

  • Page 136: Removing And Attaching Alternator

    Removing and attaching alternator Removing alternator D Relax V-belt and take it off the alternator pulley, see page 138 D Disconnect earth cable from battery Fig. 1 Disconnect connectors B+ and B− from alternator. Disconnect connectors D+ and W (plug) from alter- nator.
  • Page 137 Removing and attaching alternator Alternator − 55 A at the heat exchanger and alternator 120 A Fig. 5 Remove mounting bolts À. Remove the alternator. Alternator − 55 A bottom right Fig. 6 Remove mounting bolts À. Remove the alternator. Fitting the alternator The alternator is fitted in reverse order to the removal procedure;...

  • Page 138: V-Belts

    V-belts Checking condition Fig. 1 Remove the V-belt guard. Fig. 2 D Check V-belts for cracks, oil, overheating and wear D Change damaged V-belts Checking tension Figs. 3 and 4 Use V-belt tension tester to check V-belt tension. D Lower indicator arm À into the scale D Position the tension tester on the belt at a point midway between two pulleys so that the edge of contact face Á...
  • Page 139 V-belts Reading of tension Tensioning forces according to the kg graduation on the tester Fig. 5 New installation Drive belt D Read off the tension at the point where the top When ser- width of the gauge arm (À in Fig. 3) intersects the vicing after After 10 scale...
  • Page 140 V-belts Tensioning and changing V-belts Alternator 120 A bottom left Fig. 6 D Remove mounting nut À D Turn setting bolt Á in clockwise direction until the tension of the V-belts is correct D Retighten mounting nut To change the V-belts turn the setting bolt anti− clockwise.
  • Page 141 V-belts 55 A alternator on heat exchanger and alterna- tor 120 A Fig. 10 D Remove mounting bolts À D Release lock-nut Á D Turn adjusting nut  until the V-belt is correctly tensioned D Retighten lock-nut and mounting bolts To change the V-belts, back off the adjusting nut and swing the alternator inwards.

  • Page 142: Removing And Installing Power Take-Off For Hydraulic Pump

    Removing and installing power take-off for hydraulic pump Removing power take-off for hydraulic pump D Remove crankcase breather D Remove Fuel Service Centre, see page 37 Fig. 1 Remove hydraulic pump or blind flange. Fig. 2 Oil and coolant lines, brackets for wiring harnesses etc.
  • Page 143 Removing and installing power take-off for hydraulic pump Fig. 5 Use ring spanner (special tool) to remove mount- ing bolt from drive gear. Caution: The bolt must not fall into the engine. Fig. 6 Take off drive gear and pull out bearing flange with drive shaft.

  • Page 144: Electronic Speed Control

    An electronic control system consists of three components: 1. Speed pickup In MAN engines the speed pickup Á, which works according to the induction principle, is located on the flywheel housing. It consists of a permanent magnet surrounded by a coil.
  • Page 145 Electronic speed control Electric control unit The GAC ESD 5221 electronic speed governor is used as an example here to give a general overview of the possibilities provided by this control system and to show what characteristic data can be set or altered. When installing and commissioning, please heed without fail the Operator’s Manual for the respective control unit model.
  • Page 146 Electronic speed control 1 LED display for electronic overspeed control 2 Output contacts “Overspeed” LED display for overspeed 3 Overspeed reset button: initial position of the relay contacts after overspeed signal has been sent. Resetting can also be effected by briefly interrupting the battery power supply 4 Overspeed test button, lowers the switching point by approx.

  • Page 147: Troubleshooting With Gac Governor

    Troubleshooting with GAC governor Fig. 1 The control unit is equipped with a terminal strip for the connections of the output and input signals. − Checking procedure: Engine does not BATTERY start. Fig. 2 Check battery voltage on control unit during starting procedure.
  • Page 148 Troubleshooting with GAC governor Fig. 5 ACTUATOR Check final controlling element. Remove both final controlling element cables from control unit and measure resistance. Correct value: 4,6 - 5 W If value deviates, check cabling and plug. If cabling and plug are in order, exchange final controlling element.

  • Page 149: Removing And Installing Speed Pickup

    Removing and installing speed pickup Fig. 1 The speed pickup is fitted to the bottom right-hand side of the flywheel housing. To remove it, disconnect cable from terminal, remove the mounting bolts from the retaining plate and take it off together with the speed pickup. Fig.
  • Page 150 Notes ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 151: Service Data

    Service Data...

  • Page 152: Engine D 2840 Le 301

    Specifications Engine D 2840 LE 301 Design ..........

  • Page 153: Engine D 2842 Le 301

    Specifications Engine D 2842 LE 301 Design ..........V 90_ 4−stroke diesel with turbocharger / intercooler and charge−air regulation (waste gate)Waste Gate) Number of cylinders...

  • Page 154: Crankcase

    Dimensions Service Data Limit values Crankcase standard size: 153,90−154,00 mm for liners with larger outer diameter: 0,5 and 1,0 mm: 154,40−154,50 mm Ø standard size: 145,80−145,84 mm for liners with larger outer diameter: Ø 0,5 mm: 146,30−146,34 mm 1,0 mm: 146,80−146,84 mm 9,97−9,99 mm standard size: 144,50−144,54 mm...

  • Page 155: Crankshaft

    Dimensions Service Data Limit values Crankshaft Crankshaft front end (opposite end to flywheel) 99,985−100,020 mm Standard size: 89.98−90.00 mm undersize −0.25: 89.73−89.75 mm undersize −0.50: 89.48−89.50 mm undersize −0,75: 89.23−89.25 mm undersize −1.00: 88,98−89,00 mm Standard size: 103.98−104.00 mm undersize −0.25: 103.73−103.75 mm undersize −0.50: 103.48−103.50 mm...
  • Page 156 Dimensions Service Data Limit values Crankshaft rear end (adjacent to flywheel) Max. permissible runout with crankshaft taken up in end bearings: D 2840 at bearing 3 0,06 mm at bearing 4 0,06 mm D 2842 at bearing 4 0,06 mm Standard size: 38.000−38.062 mm undersize −0.25:...
  • Page 157 Dimensions Service Data Limit values Thrust bearing Standard size: 37.74−37.81 mm undersize −0.25: 38.24−38.31 mm undersize −0.50: 38.24−38.31 mm undersize −0.75: 38.74−38.81 mm undersize −1.00: 38,74−38,81 mm Spread: 0,1−0,5 mm Marking: top / bottom standard size: 0164 / 0165 mm undersize −0.25: 0168 / 0169 mm undersize −0.50:...

  • Page 158: Flywheel And Starter Gear Ring

    Dimensions Service Data Limit values Flywheel and starter gear ring Ø Flywheel: 432,490−432,645 mm Internal gear ring Ø: 432,000−432 ,155 mm Interference: 0,335−0,645 mm Installation temperature: 200−230_C m = 60,554 kg (with gear ring) Ø J = 2,392 kgm Number of teeth: Z = 160, module 3 Matching gear: Starter pinion (Z = 9) Gear ratio: i = 17,78 Backlash:...

  • Page 159: Conrods

    Dimensions Service Data Limit values Conrods 46,055−46,065 mm Wear limit: 46,06 mm Bearing bore in measuring directions 1, 2 and 3 and in measuring planes a and b: 90,075−90,120 mm 8 mm 8 mm Edge condition: New conrod bearing in place, conrod as- sembled Conrod bearings Standard size:...

  • Page 160: Pistons

    Dimensions Service Data Limit values Pistons Compression height: 81,250−81,300 mm with undersize 0,2 mm: 81,050−81,100 mm 0,4 mm: 80,850−80,900 mm 0,6 mm: 80,650−80,700 mm Piston protrusion above crankcase top: 0,01−0,38 mm Ø 46,005−46,013 mm Piston bolt diameter: 45,994−46,000 mm Ø 127,835−127,875 mm Max.

  • Page 161: Cylinder Head

    Dimensions Service Data Limit values Cylinder head 12,000−12,018 mm Intake valve 12,000−12,018 mm Exhaust valve 17,1−17,5 mm Intake valve α = 60_ β α Exhaust valve β = 45_ a = 3,3−3,8 mm b = 3,3−3,8 mm Valve guide bore in cylinder head: Ø...

  • Page 162: Cylinder Head Bolts (6Kt- Oder Torx-Kopf)

    Dimensions Service Data Limit values Cylinder head bolts (6kt- oder Torx-Kopf) Length With each tightening, the bolts are deliberately stressed beyond the stretch limit and each tightening thus extends their length permanently. When the max. length has been reached, the bolt may no longer be used.

  • Page 163: Valve Gear

    Dimensions Service Data Limit values Valve gear Rocker arm bearing pedestal 24,967−24,980 mm Ø Kipphebel Rocker arm radial clearance: 0,025−0,054 Wear limit: 0,08 mm 25,005−25,021 mm Valve clearance Valve clearance (cold engine) Intake valve: 0,5 mm Exhaust valve: 0,5 mm...

  • Page 164: Camshaft

    Dimensions Service Data Limit values Camshaft Replace if there are traces of wear Camshaft axial clearance: 0,20−0,90 mm Wear limit: 1,5 mm Ø Ø 69,910−69,940 mm Backlash: Crankshaft wheel and camshaft wheel: 0,118 mm−0,242 mm Camshaft bearing 70,000−70,030 mm or 70,070−70,090 mm for bush 5 (V8), 6 (V10) or 7 (V12) = bush at timing case Valve tapped...

  • Page 165: Valve Timing

    Dimensions Service Data Limit values Valve timing 1 = engine direction of turn 2 = intake valve opens 24 ° before TDC 3 = exhaust valve closes 36 ° after TDC 4 = exhaust valve opens 63 ° before 5 = intake valve closes 27 ° after BDC 6 = Exhaust open for 270°...

  • Page 166: Engine Lubrication

    Dimensions Service Data Limit values Engine lubrication Valve opening pressures Bypass valve for oil filter 2,2−2,8 bar Overpressure valve on the oil pump 9−10 bar Pressure valve of the oil injection nozzles Opening pressure 1,66−1,9 bar Pressure at max. opening 1,3−1,6 bar Oil pump 3−gear oil pump...
  • Page 167 Dimensions Service Data Limit values Oil pump Oil pump wheel Gear width 43 mm Shaft: 21,930−21,940 mm Bore Ø in housing: 22,000−22,017 mm Ø Radial clearance 0,040−0,106 mm Press on force: 12200 N Housing depth: 43,000−43,039 mm Axial clearance: 0,050−0,128 mm 42,950−42,911 mm 11,5−11,7 mm Drive wheel with oil pump wheel...

  • Page 168: Cooling System

    Dimensions Service Data Limit values Cooling system Engine coolant pump gap: 0,7−0,8 mm Ø impeller: 149,5−150 mm Bearing seat in housing: 54,940−54,970 Ø of bearing: 54,981−54,994 mm Interference: 0,011−0,054 mm Bore for bearing shaft in impeller: 16,008−16,010 mm Ø of bearing shaft: 16,045 −16,056 mm Interference: 0,035−0,048 mm Bore in hub:...
  • Page 169 Dimensions Service Data Limit values Cover for heat exchanger Filler cap with safety valve: Safety valve with imprint 1.5 opens at 1.3 bar−1.7 bar above atmospheric pressure Valve cover: Working valve with imprint 1.0 opens at 0.85 bar−1.15 bar above atmospheric pressure and 0.02 bar −0.08 bar below atmospheric pressure Warning:...

  • Page 170: Fuel System

    280+8 bar Injection pump Bosch-In-line pump Governor Electronic speed governor (GAC) Start of delivery Model crank angle before TDC D 2840 LE 301 optimised consumption optimised NOX 1500 1/min, constant 14_$1_ 10_$1_ 1800 1/min, constant 15_$1_ 12_$1_ D 2842 LE 301...

  • Page 171: Starter Motor

    Dimensions Service Data Limit values Starter motor Manufacturer: Bosch Type: Operating method: splined shaft Starter motor pinion: Number of teeth: Z = 9 Module: Nominal power: 6,6 kW Nominal voltage: 24 V Power take-off for hydraulic pump Ø 52,000−52,046 mm Pin diameter: 29,959−29,980 mm Bearing bore: 30,020−30,041 mm Speed of power take−off:...

  • Page 172: Torque Guide Values

    Torque guide values Note: All screw connections whose purpose is not stated in the following table are to be tightened in accordance with the guide values in our company standard M 3059 (see page 173). Fit the bolts slightly oiled! Plugs DIN 908 M14x1.5, M16x1.5...
  • Page 173 Torque guide values Timing devices Adjusting segment to camshaft gear M10 ........90 Nm Adjusting segment to intermediate gear M10 .
  • Page 174 Torque guide values Starter / alternator Gear case to crankcase M10, 5 ..........80 Nm V−belt pulley on alternator M14x1,5 und M16x1,5 .
  • Page 175 Torque guide values Installation tightening torques according to company standard M 3059 Bolts / nuts with external or internal hexagon, head without collar or flange Thread size Property classes / tightening torques in Nm x pitch for 8.8 / 8 for 10.9 / 10 for 12.9 / 12 13,0...
  • Page 176 Torque guide values Retightening of the cylinder head bolts Engine cold or warm) The cylinder heads are fitted with cylinder−head bolts for rotation angle tightening. On new en- Zweiter Nachzug der Zylinder- gines, the cylinder−head bolts are retightened at kopfschrauben erledigt the factory after running in and marked by the sticker “First retightening of cylinder−head bolts ...”...
  • Page 177 Torque guide values Retightening the cylinder−head bolts following a repair (engine cold) Before inserting the cylinder−head bolts, apply Intake side / injection nozzle engine oil to the thread (not the threaded hole) and coat the seating surface of the bolt head with installation paste “Optimoly White T”.
  • Page 178 Torque guide values Reuse of used cylinder−head bolts Check Before used cylinder−head bolts are reused, they must be checked as follows: Length With each tightening, the bolts are deliberately L = shaft length stressed beyond the stretch limit and each tightening thus extends their length permanently.

  • Page 179: Special Tools

    Special tools...
  • Page 180 Special tools...
  • Page 181 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 182 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 183 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 184 Special tools 19.1 19.2 20.1 20.2 25.1 25.2 27.1 27.2...
  • Page 185 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 186 Special tools...
  • Page 187 Special tools Fig. no. Designation Item number Blocking pin 51.11112−0004 Light signal transmitter 80.99605−6002 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 188 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 189 Special tools Pressing mandrel for cap, dia. 50.1 mm Pressing mandrel for cap, dia. 62.1 mm 2843...
  • Page 190 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 191: Index

    ......D 2840 LE 301 ......
  • Page 192 Index Injection lines ......Starter motor ..... . . 133 , 169 Injection nozzles .

This manual is also suitable for:

D 2842 le 301

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