Man D2862 LE221 Repair Manual
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Man D2862 LE221 Repair Manual

Industrial diesel engines
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51.99598-8262
MAN Truck & Bus AG
Vogelweiherstraße 33
90441 Nürnberg
oder
Postfach 44 02 58
90441 Nürnberg
MAN Industrial Diesel Engines
3st edition
D2862 LE221
D2862 LE223
Copy deadline: 05.2015
Repair Manual
Reparaturanleitung AE6, 3. Ausgabe
MAN-Industriedieselmotoren
D2862 LE221
D2862 LE223
Printed in Germany
AE6
- Englisch -

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Summary of Contents for Man D2862 LE221

  • Page 1 MAN Industrial Diesel Engines D2862 LE221 D2862 LE223 Copy deadline: 05.2015 Repair Manual 3st edition 51.99598-8262 MAN Truck & Bus AG Reparaturanleitung AE6, 3. Ausgabe MAN-Industriedieselmotoren Vogelweiherstraße 33 90441 Nürnberg D2862 LE221 oder D2862 LE223 Postfach 44 02 58 - Englisch - 90441 Nürnberg...
  • Page 3 Repair Manual AE6 3st edition MAN Industrial Diesel Engines D2862 LE221 D2862 LE223 51.99598-8262...
  • Page 4 Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN Truck & Bus AG. All rights under the copyright law are strictly reserved by MAN Truck & Bus AG. If any changes are made without the written approval of MAN Truck & Bus AG then MAN Truck & Bus AG shall not be liable for any warranty or guarantee claims arising from damage and defects attributable to the unauthorised modication.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Content Chapter/Page Index Introduction ......................Safety instructions ........................ The engine .................. Model plate / model designation ....................Characteristic data ....................Engine description Engine electrics ....................Engine wiring harness ..............Removing, installing the engine wiring harness ..................... Engine control units ...............
  • Page 6 TABLE OF CONTENTS ................Removing, installing the guide roller ........................Alternator ................Removing, installing the alternator Common rail system ..................High-pressure lines and rails ............Removing, installing the high-pressure lines and rails ....................Injector with nozzle ..............Removing, installing injector with nozzle ..........
  • Page 7 TABLE OF CONTENTS Front timing gears/rear timing gears ..................... Front timing gears ................ Removing, installing front timing gears ...................... Rear timing gears ................. Removing, installing rear timing gears Engine lubrication ......................Oil modules ................Removing, installing oil modules ..............Dismantling and assembling the oil module ....................
  • Page 9 INDEX Catchword Page Camshaft Anti-rotation lock............................. 248 Insertion pin............................247 Roller tappet ............................248 Characteristic data............................17 Crank mechanism Lower connecting rod bearing ........................ 329 Piston pin..............................327 Piston pin bore ............................329 Crankshaft Axial play ..............................340 Connecting rod bearing journal ......................346 Crankcase lower section ........................
  • Page 10 INDEX Safety instructions ............................9 General information............................ 9 Technical data Alternator..............................99 Cylinder liner ............................368 Exhaust pipe............................205 Flywheel ..............................315 High-pressure pump..........................129 Oil injector nozzles ..........................279 Vibration damper ............................ 309 Timing gears Crankshaft gear............................259 Intermediate gear ........................... 259 Vibration damper Hub.................................

  • Page 11: Introduction

    Always wear protective gloves when changing oil (in units at operating temperature) in particular. – Do not open the coolant circuit unless the engine is cool. – The tool must be approved by MAN and be in good technical condition. Suspended loads –...
  • Page 12 INTRODUCTION Attachments and special bodies – Comply with the safety instructions and regulations issued by the body manufacturer in question if attachments or special bodies are tted. Working on high-pressure lines – Do not attempt to tighten or loosen pipe lines and hoses when they are under pressure (e.g. lubrication circuit, coolant circuit and hydraulic oil circuit).
  • Page 13 – Never run engines without coolant. – Apply a suitable information sign to units that are not ready to be operated. – Only use service products in accordance with MAN regulations, otherwise the manufacturer’s warranty will be rendered null and void.
  • Page 14 The obligations agreed in the delivery contract, the General Terms and Conditions of Business of MAN and the statutory regulations applicable at the time of the signing of the contract shall apply.
  • Page 15 – There is no danger to drivers and co-drivers wearing a pacemaker if the vehicle is used for its intended, i.e. approved, purpose. – There is no danger to operators wearing a pacemaker if units with MAN common rail engines are used for their intended, i.e. approved, purpose.
  • Page 16 Only use service products in accordance with MAN regulations, otherwise the manufacturer’s warranty will be rendered null and void. For basic information about the service products, see the publication entitled “Service Products for MAN Diesel Engines”. Details of approved products can be found online at: https://mmrepro.mn.man.de/bstwebapp/BSTServlet 6.
  • Page 17 INTRODUCTION – Oil pressure and oil consumption – Smoke emissions The following criteria have a major inuence on the engine service life: – Correct power setting for the application type – Correct installation – Approval of the installation by authorised personnel –...

  • Page 18: The Engine

    INTRODUCTION THE ENGINE Model plate / model designation Model plate (1) Engine type (2) Engine serial number Explanation of the engine no. (Engine identication number) Motor-Nr. / engine no. Classication terms (assignment) Model number after model code 0340 Day of assembly Assembly sequence (serial number on day of assembly) 1221 The last four digits of the engine no.

  • Page 19: Characteristic Data

    INTRODUCTION Characteristic data D2862 LE221 Designation Unit Figures Number of cylinders 12-cylinder/V 90° /arrangement Valves per cylinder 4 valves Engine weight, dry 1850 Injection system Common rail/EDC 7 Direction of rotation when Left looking towards ywheel Rated output to ISO 1585-88 kW/h.p.

  • Page 20: Engine Description

    INTRODUCTION Engine description D2862 LE221/ 223 front left view (1) Charge air manifold (2) Thermostat housing (3) Distributor (4) Turbocharger, right (5) Exhaust manifold (6) High-pressure pump (7) Exhaust manifold (8) Turbocharger, left (9) Starter (10) Oil sump (11) Oil lter...
  • Page 21 INTRODUCTION D2862 LE221/ 223 rear right view (1) Turbocharger, left (6) Oil sump (2) High-pressure pump (7) Fuel lter (3) Distributor (8) Flywheel (4) Charge air manifold (9) Flywheel housing (5) Turbocharger, right Engine, general The 12-cylinder engines described here are liquid-cooled 4-stroke diesel engines with turbocharger. The engines operated using the common rail high-pressure injection system in conjunction with EDC 7 (Electronic Diesel Control).
  • Page 22 INTRODUCTION The engine control units process the information received from the sensors and control the output signals which are sent to the actuators. The actuators convert the signals into mechanical variables. An actuator is, for example, the metering unit on the high-pressure pump. Crankcase The crankcase consists of the crankcase upper section and the crankcase lower section.
  • Page 23 INTRODUCTION Fuel system The fuel system consists of a low-pressure system and a high-pressure system. The low-pressure system includes the fuel lines, the hand pump and the fuel lters. The interface to the high-pressure system is the high-pressure pump. High-pressure system The high-pressure system consists of the ow-rate-controlled high-pressure pump with ange-mounted fuel pump and the rail with rail pressure sensor and pressure limiting valve.

  • Page 25: Engine Electrics

    ENGINE ELECTRICS ENGINE ELECTRICS (1) Engine control unit (slave) (3) Wiring harness (2) Engine control unit (master) AE6 3st edition...

  • Page 27: Engine Wiring Harness

    ENGINE ELECTRICS ENGINE WIRING HARNESS Removing, installing the engine wiring harness Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 (1) Engine wiring harness Technical data Electrical connection, terminal 85 relay ....................
  • Page 28 ENGINE ELECTRICS WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque • Final tightening must always be performed manually using a torque wrench WARNING Restricted operation due to incorrect entries in the fault memory •...

  • Page 29: Engine Control Units

    ENGINE ELECTRICS ENGINE CONTROL UNITS Removing, installing engine control units Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing the combination air lter holder, see 193 (1) Electrical connection (master) (4) Bracket for control units (2) Electrical connection (slave) (5) Engine control unit (master) (3) Engine control unit (slave)
  • Page 30 ENGINE ELECTRICS WARNING Electrical cable damage due to overtightening • Follow the operating instructions for the Cable tie pliers [2] WARNING Restricted operation due to incorrect entries in the fault memory • Before removing the engine control unit, read out and document the fault memory WARNING Danger of irreparable engine control unit damage •...
  • Page 31 ENGINE ELECTRICS Removing the engine control units Detaching the engine control unit (slave) Disconnecting the engine control unit (slave) electrical connections • Unscrew the mounting bolts (3) and remove with the bracket (1) • Remove the engine control unit (2) from the •...
  • Page 32 ENGINE ELECTRICS Installing the engine control units Detaching the engine control unit bracket Attaching the engine control unit bracket • Remove the compression springs (5) with spacer bushes (1) • Position the stop for control unit bracket (3) with • Remove the bracket (2) compression springs (4) •...
  • Page 33 ENGINE ELECTRICS Tightening sequence for engine control unit Connecting the engine control unit (slave) electrical connections • Beginning with 1, tighten the engine control unit in the sequence 1, 2, 3, 4, 5, 6, 7, 8 WARNING Danger of irreparable engine control Attaching the engine control unit (master) unit damage •...

  • Page 35: Engine Electrics

    ENGINE ELECTRICS ENGINE ELECTRICS Removing, installing the charge air pressure sensor EDC (1) Charge air pressure sensor Technical data Charge air pressure sensor mounting bolt....M6x16 ..............9 Nm Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 36 ENGINE ELECTRICS Removing the charge air pressure Installing the charge air pressure sensor sensor Installing the pressure sensor Disconnecting the electrical connection • Insert the pressure sensor (2) with a new O-ring • Disconnect the electrical connection (1) • Screw in the mounting bolts (1) and tighten them 9 Nm Removing the pressure sensor Connecting the electrical connection...

  • Page 37: Removing, Installing The Edc Fuel Temperature Sensor

    ENGINE ELECTRICS Removing, installing the EDC fuel temperature sensor (1) Fuel temperature sensor Technical data Fuel temperature sensor ........M16x1.5 ............47 Nm Service products Engine oil........see Maintenance Recommendations and Recommended Service Products Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 38 ENGINE ELECTRICS Removing the fuel temperature sensor Installing the fuel temperature sensor Disconnecting the electrical connection Installing the fuel temperature sensor • Disconnect the electrical connection (1) • Lightly apply clean Engine oil on the thread of the temperature sensor (1) Removing the fuel temperature sensor •...

  • Page 39: Removing, Installing The Edc Fuel Pressure Sensor

    ENGINE ELECTRICS Removing, installing the EDC fuel pressure sensor (1) Fuel pressure sensor Technical data Fuel pressure sensor ..........M18x1.5 ............47 Nm Service products Engine oil........see Maintenance Recommendations and Recommended Service Products Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 40 ENGINE ELECTRICS Removing the fuel pressure sensor Installing the fuel pressure sensor Disconnecting the electrical connection Installing the fuel pressure sensor • Disconnect the electrical connection (1) • Coat the fuel pressure sensor thread (1) with clean Engine oil Removing the fuel pressure sensor •...

  • Page 41: Removing, Installing The Engine Oil Pressure Sensor

    ENGINE ELECTRICS Removing, installing the engine oil pressure sensor (1) Oil pressure sensor Technical data Oil pressure sensor ..........M18x1.5 ............47 Nm Service products Engine oil........see Maintenance Recommendations and Recommended Service Products Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 42 ENGINE ELECTRICS Removing the oil pressure sensor Installing the oil pressure sensor Disconnecting the electrical connection Installing the oil pressure sensor • Disconnect the electrical connection (1) • Lightly apply clean Engine oil on the thread of the oil pressure sensor Removing the oil pressure sensor •...

  • Page 43: Removing, Installing The Crankshaft Speed Sensor

    ENGINE ELECTRICS Removing, installing the crankshaft speed sensor (1) Crankshaft speed sensor Technical data Crankshaft speed sensor mounting bolt ....M6x16 ..............8 Nm Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque •...
  • Page 44 ENGINE ELECTRICS Removing the crankshaft speed sensor Installing the crankshaft speed sensor Disconnecting the electrical connection Installing the engine speed sensor • Disconnect the electrical connection (1) • Insert the speed sensor (2) with a new O-ring • Screw in the mounting bolt (1) and tighten to 8 Nm Removing the engine speed sensor Connecting the electrical connection...

  • Page 45: Removing, Installing The Camshaft Speed Sensor

    ENGINE ELECTRICS Removing, installing the camshaft speed sensor (1) Camshaft speed sensor Technical data Camshaft speed sensor mounting bolt ....M6x16 ..............8 Nm Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque •...
  • Page 46 ENGINE ELECTRICS Removing the camshaft speed sensor Installing the camshaft speed sensor Disconnecting the electrical connection Installing the speed sensor • Disconnect the electrical connection (1) • Insert the speed sensor (1) with a new O-ring • Screw in the mounting bolt (2) and tighten to 8 Nm Removing the speed sensor Connecting the electrical connection...

  • Page 47: Removing, Installing The Coolant Temperature Sensor

    ENGINE ELECTRICS Removing, installing the coolant temperature sensor (1) Coolant temperature sensor Technical data Coolant temperature sensor ........M16x1.5 ............45 Nm Service products Engine oil........see Maintenance Recommendations and Recommended Service Products Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 48 ENGINE ELECTRICS Removing the coolant temperature Installing the coolant temperature sensor sensor Disconnecting the electrical connection Installing the temperature sensor • Disconnect the electrical connection (1) • Lightly apply clean Engine oil on the thread of the temperature sensor Removing the temperature sensor •...

  • Page 49: Removing, Installing The Engine Oil Temperature Sensor

    ENGINE ELECTRICS Removing, installing the engine oil temperature sensor (1) Engine oil temperature sensor Technical data Engine oil temperature sensor....... M16x1.5 ............45 Nm Service products Engine oil........see Maintenance Recommendations and Recommended Service Products Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 50 ENGINE ELECTRICS Removing the engine oil temperature Installing the engine oil temperature sensor sensor Disconnecting the electrical connection Installing the temperature sensor • Disconnect the electrical connection (1) • Lightly apply clean Engine oil on the thread of the temperature sensor Removing the temperature sensor •...

  • Page 51: Removing, Installing The Coolant Pressure Sensor

    ENGINE ELECTRICS Removing, installing the coolant pressure sensor (1) Coolant pressure sensor Technical data Coolant pressure sensor ........M18x1.5 ............47 Nm Service products Engine oil........see Maintenance Recommendations and Recommended Service Products Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 52 ENGINE ELECTRICS Removing the coolant pressure sensor Installing the coolant pressure sensor Disconnecting the electrical connection Installing the coolant pressure sensor • Disconnect the electrical connection (1) • Coat the coolant pressure sensor thread (2) with clean Engine oil Removing the coolant pressure sensor •...

  • Page 53: Removing, Installing The Engine Oil Pressure Sensor

    ENGINE ELECTRICS Removing, installing the engine oil pressure sensor (1) Oil pressure sensor Technical data Oil pressure sensor ..........M18x1.5 ............47 Nm Service products Engine oil........see Maintenance Recommendations and Recommended Service Products Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 54 ENGINE ELECTRICS Removing the oil pressure sensor Installing the oil pressure sensor Disconnecting the electrical connection Installing the oil pressure sensor • Disconnect the electrical connection (1) • Screw in the transition piece (3) with a new sealing ring (4) and then tighten it Removing the oil pressure sensor •...

  • Page 55: Cooling System

    COOLING SYSTEM COOLING SYSTEM (1) Coolant manifold (3) Moulded hose (2) Coolant pump (4) Ramfan AE6 3st edition...

  • Page 57: Cooling System

    COOLING SYSTEM COOLING SYSTEM Removing, installing the cooling system (1) Cooling system (2) Radiator strut Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque •...
  • Page 58 COOLING SYSTEM Removing the cooling system Detaching the right moulded hose Detaching the radiator struts • Unfasten hose clamps (1) and (3) • Remove the moulded hose (2) with hose clamps • Mark the installation position of the radiator struts (1) and (3) •...
  • Page 59 COOLING SYSTEM Detaching the left moulded hose Detaching the left protective grille • Unfasten hose clamps (1) and (3) • Unscrew the mounting nuts (3) • Remove the moulded hose (2) with hose clamps • Pull out the mounting bolts (2) and remove with (1) and (3) washers •...
  • Page 60 COOLING SYSTEM Installing the ramfan Attaching the protective grille holder Attaching the cooling system • Tighten the mounting bolts (1) • Position the cooling system (1) on the engine Attaching the left moulded hose Attaching the left protective grille • Pull on the moulded hose (2) with hose clamps (1) and (3) •...
  • Page 61 COOLING SYSTEM Attaching the right moulded hose • Pull on the moulded hose (2) with hose clamps (1) and (3) • Tighten the hose clamps (1) and (3) Attaching the right charge air hose • Position the charge air manifold (4) with a new O-ring (5) and hose clamp (6) •...

  • Page 63: Ramfan

    COOLING SYSTEM RAMFAN Removing, installing the ramfan Additional jobs – Removing, installing the cooling system, see 55 (1) Ramfan (2) Mounting bolt Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque •...
  • Page 64 COOLING SYSTEM Removing the ramfan Installing the ramfan Detaching the ramfan Attaching the ramfan • Unscrew the mounting bolts (2) • Position the ramfan (1) • Remove the ramfan (1) • Screw in and tighten the mounting bolts (2) AE6 3st edition...

  • Page 65: Intermediate Ange

    COOLING SYSTEM INTERMEDIATE FLANGE Removing, installing the intermediate ange Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 (1) Intermediate ange Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 66 COOLING SYSTEM Removing the intermediate ange Installing the intermediate ange Detaching the intermediate ange Attaching the intermediate ange • Unscrew the mounting bolts (2) • Position the intermediate ange (1) • Remove the intermediate ange (1) • Screw in and tighten the mounting bolts (2) AE6 3st edition...

  • Page 67: Coolant Pipes

    COOLING SYSTEM COOLANT PIPES Removing, installing coolant lines Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 – Removing, installing the engine wiring harness, see 25 –...
  • Page 68 COOLING SYSTEM Removing coolant pipes Detaching the left vent line Detaching the coolant line • Mark the installation position of the ring connector • Unfasten the holding clips (2) • Unscrew the hollow screw (1) and remove it with • Unscrew the union nuts (1) and (3) the ring connector (2) and sealing rings (3) •...
  • Page 69 COOLING SYSTEM Installing the coolant pipes Detaching the right vent line Installing the right vent line Note Hollow screws are restricted. Note Hollow screws are restricted. • Unscrew hollow screws (3) and hollow screw (2) • Remove the vent line (1) with the sealing rings (4) •...
  • Page 70 COOLING SYSTEM Attaching the left vent line • Position the ring connector (2) with new sealing rings (3) as marked • Screw in and tighten the hollow screw (1) Attaching the right vent line • Screw in the hollow screw connector (1) with a new sealing ring (3) and tighten •...

  • Page 71: Thermostat

    COOLING SYSTEM THERMOSTAT Removing, installing thermostats Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 – Removing, installing the engine wiring harness, see 25 –...
  • Page 72 COOLING SYSTEM Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque • Final tightening must always be performed manually using a torque wrench WARNING Thermostats with the incorrect opening temperature damage the engine •...
  • Page 73 COOLING SYSTEM Removing the thermostats Installing the thermostat Removing thermostats Attaching the thermostat housing lower section • Unscrew the mounting bolts (4) Note • Remove the thermostat housing upper section (3) O-rings are secured with Curil T sealing • Remove the thermostats (2) with sealing rings (5) compound to prevent them falling out or •...

  • Page 75: Coolant Pump Coolant Manifold

    COOLING SYSTEM COOLANT PUMP COOLANT MANIFOLD Removing, installing the coolant pump coolant manifold Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 – Removing, installing the fan V-belt, see 85 – Removing, installing the fan tensioning pulley, see 89 –...
  • Page 76 COOLING SYSTEM Removing the coolant pump coolant Detaching the coolant pump coolant manifold manifold Detaching the holders • Mark the installation position of the mounting bolt (4) • Unscrew the mounting bolt (4) • Mark the installation position of the mounting bolts •...
  • Page 77 COOLING SYSTEM Installing the coolant pump coolant Attaching the holder manifold Attaching the coolant pump coolant manifold • Position the holder (3) • Screw in and tighten the mounting bolts (1) and (2) as marked • Clean the sealing surfaces •...

  • Page 79: Coolant Pump

    COOLING SYSTEM COOLANT PUMP Removing, installing the coolant pump Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the fan V-belt, see 85 – Removing, installing the ramfan, see 61 – Removing, installing the intermediate ange, see 63 –...
  • Page 80 COOLING SYSTEM Removing the coolant pump Installing the coolant pump Detaching the coolant pump Installing the insert pipes • Mark the installation position of the mounting • Clean the sealing surfaces bolts (1) • Lightly apply Radiator antifreeze on the contact •...

  • Page 81: Add-On Units

    ADD-ON UNITS ADD-ON UNITS (1) Fan tensioning pulley (4) Poly-V-belt (2) Starter (5) V-belt pulley (3) Alternator (6) V-belt AE6 3st edition...

  • Page 83: Starter

    ADD-ON UNITS STARTER Removing, installing the starter Additional jobs – Disconnecting and connecting the battery, see Operator's Manual (1) Starter (2) Mounting bolt Technical data Mounting nut, terminal 30........M12..............25 Nm Mounting nut, terminal 31........M12..............25 Nm Mounting nut, terminal 50........M6 ..............4 Nm Mounting nut, terminal 85........
  • Page 84 ADD-ON UNITS Special tools Engine barring gear 80.99626-6009 • Cranking the engine in conjunction with: • Gear ratchet [4] Gear ratchet 80.99627-0001 • Cranking the engine in conjunction with: • Engine barring gear [84] AE6 3st edition...
  • Page 85 ADD-ON UNITS Removing the starter Installing the starter Detaching the starter Detaching the engine barring gear • Unscrew the mounting bolts (1) • Remove the Engine barring gear [3] (1) from the • Remove the starter (2) from the ywheel housing ywheel housing •...

  • Page 87: Fan V-Belt

    ADD-ON UNITS FAN V-BELT Removing, installing the fan V-belt Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 (1) Fan poly-V-belt Technical data Fan poly-V-belt mounting bolt ........ M12x1.5x100 .............20 Nm Poly-V-belt pulley mounting bolt ......M12x1x80-10.9 ..........117 Nm Fan poly-V-belt tension Section 1............................
  • Page 88 ADD-ON UNITS Special tools Frequency measuring instrument 80.99605-0296 • Measuring V-belt tension AE6 3st edition...
  • Page 89 ADD-ON UNITS Removing the fan poly-V-belt Detaching the poly-V-belt pulley Unscrewing the mounting bolt • Unscrew the mounting bolt (1) and remove with the washer (2) • Unscrew the mounting bolt (1) • Remove the poly-V-belt pulley (3) Detaching the poly-V-belt fan •...
  • Page 90 ADD-ON UNITS Installing the poly-V-belt Checking the poly-V-belt tension Attaching the poly-V-belt pulley • Check the belt tension with Frequency measuring instrument [5] • Position the poly-V-belt pulley (3) • Check the belt tension of section 1 (3), value • Screw in the mounting bolt (1) with washer (2) •...

  • Page 91: Fan Tensioning Pulley

    ADD-ON UNITS FAN TENSIONING PULLEY Removing, installing the fan tensioning pulley Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 – Removing, installing the fan V-belt, see 85 (1) Fan tensioning pulley Important information WARNING Component damage due to incorrectly tightened screw/bolt connections...
  • Page 92 ADD-ON UNITS Removing the fan tensioning pulley Installing the fan tensioning pulley Detaching the fan tensioning pulley Attaching the fan tensioning pulley • Detach the V-belt pulley (6) • Position the tensioning pulley carrier (2) • Unclip the circlip (5) •...

  • Page 93: Fan Carrier

    ADD-ON UNITS FAN CARRIER Removing, installing the fan carrier with fan bearing Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 – Removing, installing the fan V-belt, see 85 – Removing, installing the fan tensioning pulley, see 89 (1) Fan carrier (2) Holder Important information...
  • Page 94 ADD-ON UNITS Removing the fan carrier with fan Installing the fan carrier with fan bearing bearing Attaching the fan carrier with fan bearing Detaching the fan carrier with fan bearing • Position the fan carrier (1) • Unscrew the mounting bolts (2) and (4) •...

  • Page 95: Poly-V-Belt

    ADD-ON UNITS POLY-V-BELT Removing, installing the poly-V-belt Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 – Removing, installing the fan V-belt, see 85 (1) Poly-V-belt Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 96 ADD-ON UNITS Removing the poly-V-belt Installing the poly-V-belt Detaching the poly-V-belt Attaching the poly-V-belt CAUTION CAUTION The poly-V-belt tensioner is under The poly-V-belt tensioner is under spring tension spring tension • Hold the poly-V-belt tensioner steady • Hold the poly-V-belt tensioner steady to prevent it from springing back to prevent it from springing back unintentionally...

  • Page 97: Removing, Installing The Automatic Belt Tensioner

    ADD-ON UNITS Removing, installing the automatic belt tensioner Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 – Removing, installing the fan V-belt, see 85 – Removing, installing the poly-V-belt, see 93 (1) Automatic belt tensioner Technical data Mounting bolt ............
  • Page 98 ADD-ON UNITS Removing the automatic belt tensioner Installing the automatic belt tensioner Detaching the automatic belt tensioner Attaching the automatic belt tensioner • Unscrew the mounting bolt (2) • Position the automatic belt tensioner (1) • Remove the automatic belt tensioner (1) •...

  • Page 99: Removing, Installing The Guide Roller

    ADD-ON UNITS Removing, installing the guide roller Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 – Removing, installing the fan V-belt, see 85 – Removing, installing the poly-V-belt, see 93 – Removing, installing the automatic belt tensioner, see 95 (1) Guide roller Technical data...
  • Page 100 ADD-ON UNITS Removing the guide roller Installing the guide roller Detaching the guide roller Mounting the guide roller • Unscrew the mounting bolt (5) • Position the spacer bush (2) with guide roller (3) • Remove the washers (1) and (4) •...

  • Page 101: Alternator

    ADD-ON UNITS ALTERNATOR Removing, installing the alternator Additional jobs – Disconnecting and connecting the battery, see Operator's Manual – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 – Removing, installing the fan V-belt, see 85 –...
  • Page 102 ADD-ON UNITS Special tools Special spanner 80.99603-6029 • Removing, installing the poly-V-belt pulley in conjunction with: • Gripper [7] Gripper 08.06460-0002 • Removing, installing the poly-V-belt pulley Cable tie pliers 08.02960-0100 • Tightening and cutting off the cable ties AE6 3st edition...
  • Page 103 ADD-ON UNITS Removing the alternator Detaching the alternator Disconnecting the alternator electrical connection • Mark the installation position of the mounting bolts (8) and (9) • Unscrew the mounting bolts (8) • Unlock the compact plug (3) • Unscrew the mounting bolt (9) •...
  • Page 104 ADD-ON UNITS Installing the alternator Detaching the holder Attaching the poly-V-belt pulley • Unscrew the mounting bolts (1) • Remove the holder (2) • Push the poly-V-belt pulley (2) onto the alternator Unscrewing the poly-V-belt pulley mounting nut shaft • Lightly apply Loctite 2701 on the thread and contact surface of the new mounting nut (1)
  • Page 105 ADD-ON UNITS Attaching the holder Attaching the alternator • Position the holder (2) • Position the alternator (10) • Screw in and tighten the mounting bolts (1) • Position the insulating washers (1) and the bush Attaching the holder • Screw in the mounting bolt (3) and tighten it until nger-tight •...
  • Page 106 ADD-ON UNITS Connecting the alternator electrical connection • Route the alternator wiring harness (1) and secure it using cable ties • Tighten and cut off cable ties using the Cable tie pliers [8] • Screw on the terminal B+ mounting nut (2) and tighten it to 13 Nm •...

  • Page 107: Common Rail System

    COMMON RAIL SYSTEM COMMON RAIL SYSTEM (1) Fuel line (7) High-pressure pump, master (2) Leakage oil line, injectors (8) Collector (3) High-pressure lines (9) Leakage oil line, injectors (4) Distributor (10) High-pressure lines (5) Right rail (11) Left rail (6) High-pressure pump, slave AE6 3st edition...

  • Page 109: High-Pressure Lines And Rails

    COMMON RAIL SYSTEM HIGH-PRESSURE LINES AND RAILS Removing, installing the high-pressure lines and rails Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 –...
  • Page 110 • All work on components of the common rail system must be performed by specially trained personnel only • The engine must be stationary for at least 5 minutes before commencing work in order to enable depressurisation in the rail, or depressurisation must be checked by means of MAN-cats ® (desired value 0) •...
  • Page 111 COMMON RAIL SYSTEM [12] Protective sleeve Z 18 x 15 81.96002-0555 • Plugging the rail-pressure sensor • Plugging the pressure limiting valve [13] 81.96002-0518 • Sealing ring unions [14] Special spanner, size 17 80.99603-0309 • Detaching and attaching the high-pressure lines in conjunction with: •...
  • Page 112 COMMON RAIL SYSTEM Removing the high-pressure lines and Detaching the high-pressure line rails Detaching the high-pressure supply lines WARNING Danger of damage due to dirt ingress • Plug the component connections WARNING immediately using new, clean Danger of damage due to dirt ingress protective sleeves •...
  • Page 113 COMMON RAIL SYSTEM Removing the right pressure limiting valve Removing the right rail pressure sensor WARNING WARNING Component damage due to lack of Component damage due to lack of lubricant lubricant • Do not wash off the pressure limiting • Do not wash off the rail pressure sensor valve as the thread and biting edge are as the thread and biting edge are coated with lubricant...
  • Page 114 COMMON RAIL SYSTEM Installing the high-pressure lines and Removing the right rail rails Attaching the right rail Note The left rail is removed in the same way as the right rail Note The left rail is installed in the same way •...
  • Page 115 COMMON RAIL SYSTEM Installing the right rail pressure sensor Installing the right pressure limiting valve WARNING WARNING Component damage due to lack of Component damage due to lack of lubricant lubricant • Do not wash off the pressure limiting • Do not wash off the pressure limiting valve and rail pressure sensor as the valve and rail pressure sensor as the thread and biting edge are coated with...
  • Page 116 COMMON RAIL SYSTEM Attaching the high-pressure line Final tightening of high-pressure line • Remove the caps and plugs • Tighten the new high-pressure lines (1) to Final • Attach the high-pressure line (1), ensuring that it tightening 60° with Angle extension [15] is strain-free, using the Angle extension [15] Special spanner, size 17 [14]...

  • Page 117: Injector With Nozzle

    COMMON RAIL SYSTEM INJECTOR WITH NOZZLE Removing, installing injector with nozzle Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing the air lter, see 191 – Removing, installing the positive crankcase ventilation, see 355 – Removing, installing engine control units, see 27 –...
  • Page 118 • All work on components of the common rail system must be performed by specially trained personnel only • The engine must be stationary for at least 5 minutes before commencing work in order to enable depressurisation in the rail, or depressurisation must be checked by means of MAN-cats ® (desired value 0) •...
  • Page 119 COMMON RAIL SYSTEM WARNING Component damage due to reused bolts • Do not re-use a pressure ange mounting bolt, even if it has only been used once. Note In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is imprinted in the protective sleeves.
  • Page 120 COMMON RAIL SYSTEM [22] Plate 80.99602-0176 • Extracting the injector in conjunction with: • Extractor [21] • Support [23] • Hexagon collar nut [24] [23] Support 80.99602-0193 • Extracting the injector in conjunction with: • Extractor [21] • Plate [22] •...
  • Page 121 COMMON RAIL SYSTEM [30] Magnetic pick-up tool 80.99639-0009 • Removing the rail connection [31] Special spanner, size 17 80.99603-0309 • Detaching and attaching the high-pressure lines in conjunction with: • Angle extension [15] [32] Angle extension 08.06139-9025 • Detaching and attaching the high-pressure lines in conjunction with: •...
  • Page 122 COMMON RAIL SYSTEM Removing the injector with nozzle Removing the rail connection Detaching the high-pressure line • Unscrew the pressure screw (2) • Screw the Union nut [29] (1) onto the rail connection (2) and tighten WARNING • Unscrew the pressure screw (2) Danger of damage due to dirt ingress •...
  • Page 123 COMMON RAIL SYSTEM Removing the rocker arm mechanism Extracting the injector • Unscrew the mounting bolts (2) WARNING • Remove the rocker arm mechanism (4) Component damage due to incorrect • Mark the installation position of the valve removal of the injector bridges (3) •...
  • Page 124 • Fit a new O-ring (2) and new sealing ring (1) on the injector (3) • Thinly apply clean engine oil to MAN Standard 3277 on the O-ring (2) • Place the pressure ange (5) on the injector (3) •...
  • Page 125 COMMON RAIL SYSTEM Installing the rail connection Attaching the high-pressure line WARNING WARNING Danger of leaks in the common rail Component damage by incorrect system installation of pipe clamps • Ensure that the thinner tip engages in • Always install removed pipe clamps of the injector rail connection port the pipe set in the original position •...
  • Page 126 COMMON RAIL SYSTEM Final tightening of high-pressure line • Tighten the new high-pressure lines (1) to Final tightening 60° with Angle extension [32] Special spanner, size 17 [31] • Tighten the high-pressure lines (1) to Final tightening 30° with Angle extension [32] Special spanner, size 17 [31] if re-using •...

  • Page 127: Checking The Injector Seat, Rail And Leakage Oil Lines For Leaks

    • All work on components of the common-rail system must be performed by specially trained personnel only • The engine must be stationary for at least 5 minutes before commencing work in order to enable depressurisation in the rail, or depressurisation must be checked by means of MAN-cats ® (desired value 0) •...
  • Page 128 COMMON RAIL SYSTEM WARNING Danger of damage due to dirt ingress • Always detach only one fuel line • Close the component connections immediately using new, clean protective sleeves WARNING Residual fuel may run out during removal. Danger of environmental pollution. •...
  • Page 129 COMMON RAIL SYSTEM Installing the pressure loss tester Detaching the fuel line left leakage oil line – collector Detaching the right leakage oil line - collector fuel line • Unscrew the union nuts (1) and (3) • Remove the fuel line (2) •...
  • Page 130 COMMON RAIL SYSTEM Removing the pressure loss tester Detaching the pressure loss tester (right side) Detaching the pressure loss tester (left side) • Disconnect the Hand pump [35] (2) with the pressure gauge (1) from the Threaded • Disconnect the Hand pump [35] (2) with connection [37]...

  • Page 131: High-Pressure Pump/High-Pressure Pump Drive

    COMMON RAIL SYSTEM HIGH-PRESSURE PUMP/HIGH-PRESSURE PUMP DRIVE Removing, installing the high-pressure pump/high-pressure pump drive Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 –...
  • Page 132 • The engine must be stationary for at least 5 minutes before commencing work in order to enable depressurisation in the rail, or depressurisation must be checked by means of MAN-cats (desired value 0) • Ensure absolute cleanliness in all areas when carrying out all work.
  • Page 133 COMMON RAIL SYSTEM Special tools [40] Special spanner, size 17 80.99603-0309 • Detaching and attaching the high-pressure line in conjunction with: • Angle extension [41] [41] Angle extension 08.06139-9025 • Detaching and attaching the high-pressure line in conjunction with: • Special spanner, size 17 [40] [42] End plug...
  • Page 134 COMMON RAIL SYSTEM Removing the high-pressure pump Detaching the cover Detaching the high-pressure supply lines • Unscrew the mounting bolts (2) • Remove the cover (3) with the seal (1) • Mark the installation position of the pipe clamps • Clean the sealing surfaces (2) and (4) •...
  • Page 135 COMMON RAIL SYSTEM Installing the high-pressure pump Removing the master high-pressure pump Installing the master high-pressure pump • Disconnect the metering unit electrical connection • Remove the high-pressure pump (1) with drive • Clean the sealing surfaces housing (2) • Insert the high-pressure pump (1) and drive •...
  • Page 136 • Unscrew the oil ller plug (1) with sealing ring • 0.04 l Fill the high-pressure pump with clean engine oil to MAN Standard 3277 • Screw in the oil ller plug (1) with a new sealing ring and tighten to 18 Nm...

  • Page 137: Dismantling, Assembling The High-Pressure Pump/High-Pressure Pump Drive

    COMMON RAIL SYSTEM Dismantling, assembling the high-pressure pump/high-pressure pump drive Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 – Removing, installing the engine wiring harness, see 25 –...
  • Page 138 COMMON RAIL SYSTEM Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque • Final tightening must always be performed manually using a torque wrench Special tools [44] Protective sleeve Z 14 x 15...
  • Page 139 COMMON RAIL SYSTEM Removing the high-pressure pump Removing the drive gear Detaching the drive housing • Insert the drive shaft (4) with drive housing (2) into the driver sleeve (5) • Unscrew the mounting bolts (4) • Clamp the driver sleeve (5) in a vice with protective •...
  • Page 140 COMMON RAIL SYSTEM Removing the metering unit Removing the overow valve WARNING WARNING Danger of damage due to dirt ingress Danger of damage due to dirt ingress • Clean the components and blow them • Clean the components and blow them dry using compressed air dry using compressed air •...
  • Page 141 COMMON RAIL SYSTEM Installing the high-pressure pump Installing the metering unit Installing the overow valve Note When using micro-encapsulated bolts, WARNING the time between the tightening stages Danger of damage due to dirt ingress must not be longer than 2 minutes •...
  • Page 142 COMMON RAIL SYSTEM Installing the drive gear Attaching the drive housing • Insert the drive shaft (4) with drive housing (2) into • Insert the drive housing (3) with new O-rings (1) the driver sleeve (5) and (2) • Clamp the driver sleeve (5) in a vice with protective •...

  • Page 143: Fuel Lines

    COMMON RAIL SYSTEM FUEL LINES Removing, installing fuel lines Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 – Removing, installing the engine wiring harness, see 25 –...
  • Page 144 • The engine must be stationary for at least 5 minutes before commencing work in order to enable depressurisation in the rail, or depressurisation must be checked by means of MAN-cats (desired value 0) • Ensure absolute cleanliness in all areas when carrying out all work.
  • Page 145 COMMON RAIL SYSTEM [49] Protective sleeve Z 18x1.5 81.96002-0555 • Plugging the fuel line connections [50] Protective sleeve Z 16x8 81.96002-0513 • Plugging the fuel line connections [51] Protective sleeve Z 28x20 81.96002-0514 • Plugging the connection on the collector [52] 81.96002-0518 •...
  • Page 146 COMMON RAIL SYSTEM Removing the fuel lines Detaching the fuel line fuel lter – high-pressure pump Detaching the fuel return line • Unscrew the mounting bolt (3) • Mark the installation position of the mounting • Unscrew the union nuts (1) and (4) bolts (2) and (5) •...
  • Page 147 COMMON RAIL SYSTEM Detaching the fuel return line Detaching the fuel line high-pressure pump top – fuel lter • Unscrew the union nuts (1) and (3) • Unscrew the union nuts (1) and (3) • Remove the fuel line (2) •...
  • Page 148 COMMON RAIL SYSTEM Detaching the fuel line high-pressure pump top Detaching the fuel line high-pressure pump – hand pump bottom – collector • Unscrew the hollow screw (3) and remove it with • Unscrew the union nuts (1) and (3) the sealing ring •...
  • Page 149 COMMON RAIL SYSTEM Detaching the fuel line fuel lter – high-pressure Detaching the fuel line hand pump – pump bottom high-pressure pump bottom • Unscrew the union nuts (1) and (3) • Unscrew the union nuts (1) and (3) • Remove the fuel line (2) •...
  • Page 150 COMMON RAIL SYSTEM Detaching the fuel line left leakage oil line – Detaching the left leakage oil line collector • Unscrew the hollow screws (1) • Unscrew the union nuts (1) and (3) • Remove the leakage oil line (2) with the sealing •...
  • Page 151 COMMON RAIL SYSTEM Installing the fuel lines Detaching the collector Attaching the holder • Mark the installation position of the collector (2) • Unscrew the mounting nuts (1) and pull out the • Position the holder (1) with washers (3) mounting bolts (3) •...
  • Page 152 COMMON RAIL SYSTEM Attaching the distributor Attaching the right leakage oil line • Position the distributor (2) with holder (3) • Remove the protective sleeves • Screw in and tighten the mounting bolts (1) • Position the fuel line (2) so that it is strain-free •...
  • Page 153 COMMON RAIL SYSTEM Attaching the fuel line rail – collector Attaching the fuel line right rail – collector • Remove the end plugs and protective sleeves • Remove the end plugs and protective sleeves • Position the fuel line (2) with new sealing ring •...
  • Page 154 COMMON RAIL SYSTEM Attaching the fuel line high-pressure pump Attaching the fuel line – leakage oil line bottom – fuel lter • Remove the end plugs and protective sleeves • Remove the end plugs and protective sleeves • Position the fuel line (2) with new sealing ring •...
  • Page 155 COMMON RAIL SYSTEM Attaching the fuel line high-pressure pump top Attaching the fuel return line – hand pump • Remove the end plugs and protective sleeves • Remove the end plugs and protective sleeves • Position the fuel line (2) •...
  • Page 156 COMMON RAIL SYSTEM Attaching the fuel line fuel lter – high-pressure Attaching the fuel return line pump • Remove the end plugs and protective sleeves • Remove the end plugs and protective sleeves • Position the fuel line (1) • Position the fuel line (2) •...

  • Page 157: Fuel Lter

    • The engine must be stationary for at least 5 minutes before commencing work in order to enable depressurisation in the rail, or depressurisation must be checked by means of MAN-cats (desired value 0) • Ensure absolute cleanliness in all areas when carrying out all work.
  • Page 158 COMMON RAIL SYSTEM WARNING Residual fuel may run out during removal. Danger of environmental pollution. • Use a suitable fuel collecting container WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque •...
  • Page 159 COMMON RAIL SYSTEM Removing the fuel lter Detaching the fuel return line Detaching the fuel line gear pump – fuel lter • Unscrew the mounting nut (6) • Pull out the mounting bolt (1) • Unscrew the mounting nut (2) •...
  • Page 160 COMMON RAIL SYSTEM Installing the fuel lter Detaching the fuel lter holder Assembling the fuel lter • Unscrew the mounting bolts (2) and (3) • Remove the holders (1) and (4) • Remove protective sleeves and end plugs Dismantling the fuel lter •...
  • Page 161 COMMON RAIL SYSTEM Attaching the fuel lter Attaching the fuel line fuel lter – high-pressure pumps • Position the fuel lters (2), (3), (4) and (5) • Screw in and tighten the mounting bolts (1) • Remove protective sleeves and end plugs •...

  • Page 162: Dismantling, Assembling The Fuel Lter

    COMMON RAIL SYSTEM Dismantling, assembling the fuel lter Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 – Removing, installing the fuel lter, see 155 (1) Housing (3) O-ring (2) Fuel lter insert (4) Cover Technical data Cover.............................25 Nm...
  • Page 163 COMMON RAIL SYSTEM WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque • Final tightening must always be performed manually using a torque wrench Note In order to ensure that the correct protective sleeve is used, the designation (e.g.
  • Page 164 COMMON RAIL SYSTEM Dismantling the fuel lter Detaching the fuel lter insert Allowing the fuel lter cover to empty • Open the drain plug (1) and allow the fuel lter cover to empty • Tighten the drain plug (1) to 3 Nm Detaching the cover •...
  • Page 165 COMMON RAIL SYSTEM Assembling the fuel lter Attaching the cover Inserting the fuel lter insert • Fit the cover (3) with a new O-ring (2) and screw onto the housing (1) • Insert the new fuel lter insert (2) into the •...

  • Page 167: Hand Pump

    COMMON RAIL SYSTEM HAND PUMP Removing, installing the hand pump (1) Hand pump (2) Hand pump fuel line Important information WARNING Residual fuel may run out during removal. Danger of environmental pollution. • Use a suitable fuel collecting container WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 168 COMMON RAIL SYSTEM Special tools [58] End plug (GPN 330 L18) 81.96002-0556 • Plugging the fuel lines [59] Protective sleeve Z 28x20 81.96002-0514 • Plugging the connection on the collector AE6 3st edition...
  • Page 169 COMMON RAIL SYSTEM Removing the hand pump Installing the hand pump Detaching the hand pump fuel line Attaching the hand pump • Unscrew the mounting nut (2) • Position the hand pump (2) • Pull out the mounting bolt (1) •...

  • Page 170: Dismantling, Assembling The Hand Pump

    COMMON RAIL SYSTEM Dismantling, assembling the hand pump (1) Housing (3) Fuel pre-lter (2) O-ring (4) Cover Technical data Fuel pre-lter cover.........................10 Nm Hand fuel pump knurled nut ......................3 Nm Service products Fuel ..........see Maintenance Recommendations and Recommended Service Products Important information WARNING Residual fuel may run out during removal.
  • Page 171 COMMON RAIL SYSTEM Note A check valve is integrated in the hand pump to prevent the fuel from owing back. Special tools [60] End plug (GPN 330 L18) 81.96002-0556 • Plugging the fuel lines AE6 3st edition...
  • Page 172 COMMON RAIL SYSTEM Dismantling the hand pump Assembling the hand pump Dismantling the hand pump Installing the primary fuel lter • Unscrew the test connection (4) and remove it with • Clean the sealing surfaces sealing ring • Lightly apply clean Fuel on the new O-ring (2) •...

  • Page 173: Turbocharging

    TURBOCHARGING TURBOCHARGING (1) Insert pipe (6) Turbocharger, left (2) Intake manifold (7) Intake manifold (3) Turbocharger, right (8) Insert pipe (4) Charge air manifold (9) Charge air manifold (5) Charge air manifold AE6 3st edition...

  • Page 175: Turbocharger

    TURBOCHARGING TURBOCHARGER Removing, installing the turbocharger Additional jobs – Removing, installing the air lter, see 191 (1) Intake manifold (3) Turbocharger, left (2) Turbocharger, right (4) Intake manifold Technical data Mounting nuts, turbocharger........M10..............60 Nm Clamp............................15 Nm T-pin clamp ............................15 Nm Service products Engine oil........see Maintenance Recommendations and Recommended Service Products Important information...
  • Page 176 TURBOCHARGING Special tools [61] Torque wrench 08.06450-0003 • Tightening the turbocharger mounting nuts in conjunction with: • [62] Hose clamp pliers for jubilee clips 80.99625-0073 • Installing and removing the jubilee clips AE6 3st edition...
  • Page 177 TURBOCHARGING Removing the turbocharger Detaching the vent line Detaching the bellows hose • Remove the jubilee clip (3) with Hose clamp pliers for jubilee clips [62] • Loosen hose clamps (1) and (3) and push onto the • Pull the vent line hose (1) off the hose port (2) bellows hose (2) •...
  • Page 178 TURBOCHARGING Detaching the exhaust manifold Detaching the oil return line • Mark the installation position of the intake manifold • Unscrew the mounting bolts (3) • Loosen the hose clamp (5) with Hose clamp pliers • Unfasten the clamp (2) for jubilee clips [62] and push onto hose (4) •...
  • Page 179 TURBOCHARGING Installing the turbocharger Attaching the oil pressure line ange Attaching the turbocharger WARNING If no oil is added, the turbocharger • Clean the sealing surfaces will be damaged when the vehicle is • Position the turbocharger (1) with a new seal (4) started for the rst time •...
  • Page 180 TURBOCHARGING Attaching the oil pressure line Attaching the charge air manifold • Position the oil pressure line (2) • Clean the sealing surfaces • Screw on and tighten union nuts (1) and (3) • Insert a new O-ring (2) and guide band (1) into the charge air manifold (3) Attaching the exhaust manifold •...
  • Page 181 TURBOCHARGING Attaching the heat shield • Position the heat shield (2) • Screw in the mounting bolts (1), (3), (4) and (5) as marked with washers and tighten Attaching the bellows hose WARNING Danger of damage to property if the hose connection is leaking •...

  • Page 183: Charge Air Manifold

    TURBOCHARGING CHARGE AIR MANIFOLD Removing, installing the charge air manifold Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 – Removing, installing the engine wiring harness, see 25 –...
  • Page 184 TURBOCHARGING Removing the charge air manifold Detaching the charge air manifold Detaching the charge air manifold holder • Loosening the T-pin clamp (7) • Pull off the charge air manifold (5) and remove with • Unscrew the mounting bolt (2) and remove with T-pin clamp (7), O-rings (4), (6) and guide band (3) the washer (3) •...
  • Page 185 TURBOCHARGING Installing the charge air manifold Detaching the bracket Attaching the bracket • Unscrew the mounting bolts (2) • Remove the bracket (1) • Position the bracket (1) • Screw in the mounting bolts (2) and tighten until nger-tight Attaching the charge air manifold •...
  • Page 186 TURBOCHARGING Attaching the charge air manifold Attaching the charge air manifold holder • Clean the sealing surfaces • Position the holder (1) • Insert a new O-ring (1) and guide band (2) into the • Screw in and tighten the mounting bolts (4) charge air manifold inlet (9) •...

  • Page 187: Intake/Exhaust System

    INTAKE/EXHAUST SYSTEM INTAKE/EXHAUST SYSTEM (1) Air distribution pipe, right (4) Exhaust manifold heat shield (2) Combination air lter (5) Exhaust manifold (3) Combination air lter holder (6) Charge air manifold AE6 3st edition...

  • Page 189: Combination Air Lter

    INTAKE/EXHAUST SYSTEM COMBINATION AIR FILTER Removing, installing the combination air lter (1) Combination air lter right (3) Combination air lter left (2) Moulded hose right (4) Moulded hose left Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 190 INTAKE/EXHAUST SYSTEM Removing the combination air lter Detaching the right combination air lter Detaching the left moulded hose • Unscrew the mounting nuts (3) • Pull out the mounting bolts (2) • Unfasten hose clamps (1) and (3) • Remove the combination air lter (1) •...
  • Page 191 INTAKE/EXHAUST SYSTEM Installing the combination air lter Removing the air lter insert Attaching the holders • Removing the air lter insert (1) Detaching the rain cap • Insert and align holders (1) and (2) • Tighten holders (1) and (2) Attaching the rain cap •...
  • Page 192 INTAKE/EXHAUST SYSTEM Attaching the cap Attaching the left combination air lter • Position the cap (1) and clip it in • Position the combination air lter (1) • Insert the mounting bolts (3) Attaching the dust dump valve • Screw on and tighten the mounting nuts (2) Attaching the right moulded hose •...

  • Page 193: Air Lter

    INTAKE/EXHAUST SYSTEM AIR FILTER Removing, installing the air lter (1) Air lter Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque •...
  • Page 194 INTAKE/EXHAUST SYSTEM Removing the air lter Installing the air lter Detaching the left air lter Attaching the right air lter • Unfasten the hose clamp (1) • Position the air lter (1) with hose clamp (2) • Remove the air lter (2) with hose clamp (1) •...

  • Page 195: Combination Air Lter Holder

    INTAKE/EXHAUST SYSTEM COMBINATION AIR FILTER HOLDER Removing, installing the combination air lter holder Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 (1) Combination air lter holder (2) Combination air lter holder Important information WARNING Component damage due to incorrectly tightened screw/bolt connections...
  • Page 196 INTAKE/EXHAUST SYSTEM Removing the combination air lter Detaching the holder for the injector wiring holder harness Detach the vent line • Unscrew the mounting nuts (3) • Remove the injector wiring harness holder (1) with • Remove the jubilee clips (1) and (3) using the Hose spacer bush (2) clamp pliers for jubilee clips [63]...
  • Page 197 INTAKE/EXHAUST SYSTEM Installing the combination air lter Attaching the holder for the injector wiring holder harness Attaching the carrier • Position the injector wiring harness holder (1) with spacer bush (2) • Position the carrier (1) • Screw in and tighten the mounting nuts (3) •...
  • Page 198 INTAKE/EXHAUST SYSTEM Attach the vent line • Position the vent line (2) using the jubilee clips (1) and (3) • Attach the jubilee clips (1) and (3) using the Hose clamp pliers for jubilee clips [63] • Attach holding clips (4) and (5) •...

  • Page 199: Air Distribution Pipes

    INTAKE/EXHAUST SYSTEM AIR DISTRIBUTION PIPES Removing, installing air distribution pipes Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 – Removing, installing the engine wiring harness, see 25 –...
  • Page 200 INTAKE/EXHAUST SYSTEM Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque • Final tightening must always be performed manually using a torque wrench AE6 3st edition...
  • Page 201 INTAKE/EXHAUST SYSTEM Removing the left air distribution pipe Removing the charge air manifold Detaching the pressure sensor • Mark the installation position of the mounting bolts (3), (5) and (6) • Unscrew the mounting bolts (2) • Unscrew the mounting bolts (3) and (5) •...
  • Page 202 INTAKE/EXHAUST SYSTEM Installing the left air distribution pipe Removing the air distribution pipe Installing the air distribution pipe • Mark the installation position of the mounting bolts (1) and (2) • Clean the sealing surfaces • Remove the air distribution pipe (3) with seals (4) •...
  • Page 203 INTAKE/EXHAUST SYSTEM Installing the charge air manifold Attaching the pressure sensor • Clean the sealing surfaces • Clean the sealing surfaces • Fit the charge air manifold (1) with new seals (2) • Insert the pressure sensor (1) with a new O-ring and (4) and position it •...
  • Page 204 INTAKE/EXHAUST SYSTEM Removing the right air distribution pipe Removing the charge air manifold Detaching the pressure sensor • Mark the installation position of the mounting bolts (3), (5) and (6) • Unscrew the mounting bolts (2) • Unscrew the mounting bolts (3) and (5) •...
  • Page 205 INTAKE/EXHAUST SYSTEM Installing the right air distribution pipe Removing the right air distribution pipe Installing the right air distribution pipe • Mark the installation position of the mounting bolts (1) and (2) • Clean the sealing surfaces • Remove the air distribution pipe (3) with seals (4) •...
  • Page 206 INTAKE/EXHAUST SYSTEM Installing the charge air manifold Attaching the pressure sensor • Clean the sealing surfaces • Clean the sealing surfaces • Fit the charge air manifold (1) with new seals (2) • Insert the pressure sensor (1) with a new O-ring and (4) and position it •...

  • Page 207: Exhaust Pipes

    INTAKE/EXHAUST SYSTEM EXHAUST PIPES Removing, installing exhaust pipes Additional jobs – Removing, installing the turbocharger, see 173 (1) Cover plate (3) Cover plate (2) Cover plate (4) Exhaust pipe Technical data Mounting bolt, exhaust pipe ........M10x40-HWF ........ Initial torque 22 Nm Mounting bolt, exhaust pipe ........
  • Page 208 INTAKE/EXHAUST SYSTEM Removing exhaust pipes Detaching the cover plate holder Detaching the cover plate • Unscrew the mounting bolts (2) and remove with washers • Mark the installation position of the mounting bolts • Remove the holder (1) (1), (2), (3) and (5) •...
  • Page 209 INTAKE/EXHAUST SYSTEM Detaching the exhaust manifold Removing the connecting pieces • Unscrew the mounting nuts (3) and remove with • Pull off the exhaust pipe (3) bushes (2) • Remove connecting pieces (2) and (4) from the • Unscrew the mounting nuts (5) and remove with exhaust pipe (1) bushes (4) •...
  • Page 210 INTAKE/EXHAUST SYSTEM Installing exhaust pipes Attaching the exhaust manifold Installing connecting pieces • Clean the sealing surfaces • Position the exhaust manifold (6) with new seals • Clean the sealing surfaces (1) and (7) • Install new connecting pieces (2) and (4) in the •...
  • Page 211 INTAKE/EXHAUST SYSTEM Attaching the cover plate holder • Position the holder (1) • Screw in mounting bolts (2) with washers and tighten them • Repeat the same procedure for other holders Attaching the cover plate • Position the heat shield (1) •...
  • Page 213 CYLINDER HEAD CYLINDER HEAD (1) Cylinder head cover (2) Cylinder head AE6 3st edition...

  • Page 215: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD Removing, installing the cylinder head cover (1) Cylinder head cover Technical data Injector cable..........................1.8 Nm AE6 3st edition...
  • Page 216 CYLINDER HEAD Special tools [64] Torque screwdriver 08.06510-9024 • Installing the injector cable in conjunction with: • Adapter [65] • Socket, size 7 [66] [65] Adapter 08.06139-9029 • Installing the injector cable in conjunction with: • Torque screwdriver [64] • Socket, size 7 [66] [66] Socket, size 7...
  • Page 217 CYLINDER HEAD Removing the cylinder head cover Installing the cylinder head cover Detaching the cylinder head cover Putting on the seal • Clean the sealing surfaces • Unscrew the mounting bolts (1) • Remove the cylinder head cover (2) • Check the condition of the seal (1) and, if necessary, t a new one Removing the injector cable •...
  • Page 218 CYLINDER HEAD Attaching the cylinder head cover • Put on the cylinder head cover (2) • Screw in and tighten the mounting bolts (1) AE6 3st edition...

  • Page 219: Removing, Installing The Rocker Arm Mechanism

    CYLINDER HEAD Removing, installing the rocker arm mechanism Additional jobs – Removing, installing the turbocharger, see 173 – Removing, installing the cylinder head cover, see 213 – Checking and setting the valve clearance, see 238 (1) Push rods (4) Valve bridge, exhaust (2) Mounting bolts, rocker arm mechanism (5) Rocker arm mechanism (3) Valve bridge, intake...
  • Page 220 CYLINDER HEAD Removing the rocker arm mechanism Installing the rocker arm mechanism Removing the rocker arm mechanism Attaching the rocker arm mechanism • Unscrew the mounting bolts (2) • Thinly apply clean engine oil on the ball cups of • Remove the rocker arm mechanism (4) the push rods (1) •...

  • Page 221: Dismantling, Assembling The Rocker Arm Mechanism

    CYLINDER HEAD Dismantling, assembling the rocker arm mechanism Additional jobs – Removing, installing the turbocharger, see 173 – Removing, installing the cylinder head cover, see 213 – Removing, installing the rocker arm mechanism, see 217 – Checking and setting the valve clearance, see 238 (1) Circlip (7) Lock nut (2) Washer...
  • Page 222 CYLINDER HEAD Special tools [67] Dial gauge 08.71000-3217 • Checking the rocker arm radial play in conjunction with: • • AE6 3st edition...
  • Page 223 CYLINDER HEAD Dismantling the rocker arm mechanism Measuring the rocker arm shaft outside diameter Dismantling the rocker arm mechanism • Clean the rocker arm shaft (2) • Check the outside diameter of the rocker arm shaft • Detach the circlip (1) (2) using a micrometer (1) •...
  • Page 224 • Screw on the lock nut (1) Assembling the rocker arm mechanism • Thinly apply clean engine oil to MAN Standard 3277 on the rocker arm shaft (4) • Push on the rocker arm (3) as marked up to the stop •...

  • Page 225: Removing, Installing The Cylinder Head

    CYLINDER HEAD Removing, installing the cylinder head Additional jobs – Draining and topping up the coolant, see Operator's Manual – Removing, installing coolant lines, see 65 – Removing, installing the turbocharger, see 173 – Removing, installing the cylinder head cover, see 213 –...
  • Page 226 • All work on components of the common rail system must be performed by specially trained personnel only • The engine must be stationary for at least 5 minutes before commencing work in order to enable depressurisation in the rail, or depressurisation must be checked by means of MAN-cats ® (desired value 0) •...
  • Page 227 CYLINDER HEAD [70] Support 80.99606-0551 • Unscrewing and tightening the cylinder head bolts in conjunction with: • Socket, size 22 [68] • Torque multiplier i = 1 : 3.3 [69] • Torque angle gauge [71] • Holding device [72] • Cylinder head bolt [73] •...
  • Page 228 CYLINDER HEAD [74] Connecting pin 06.22729-0006 • Unscrewing and tightening the cylinder head bolts in conjunction with: • Socket, size 22 [68] • Torque multiplier i = 1 : 3.3 [69] • Support [70] • Torque angle gauge [71] • Holding device [72] •...
  • Page 229 CYLINDER HEAD [79] Dial gauge holder 80.99605-0172 • Checking the cylinder liner standout in conjunction with: • Dial gauge [80] • Measuring plate [81] • Hexagon shank bolt [82] • Washer [83] [80] Dial gauge 08.71000-3217 • Checking the cylinder liner standout in conjunction with: •...
  • Page 230 CYLINDER HEAD Removing the cylinder head Unscrewing sequence for cylinder head bolts Removing the crane hook lugs on the left and right • Unscrew the cylinder head bolts in the unscrewing sequence (1) to (6) Unscrewing the cylinder head bolts •...
  • Page 231 CYLINDER HEAD Installing the cylinder head Tightening sequence for cylinder head Checking the cylinder liner standout • Screw in the cylinder head bolts and tighten until nger-tight in the tightening sequence 1 to 6 • Place the Measuring plate [81] (2) on the cylinder liner Pre-tightening the cylinder head bolts...
  • Page 232 CYLINDER HEAD Final tightening of cylinder head bolts Note Note the torque multiplier ratio, i = 1 : 3.3. • Tighten the cylinder head bolts to 4th torque 90°, in the tightening sequence, with special tool (1) • Tighten the cylinder head bolts to 5th torque 90°, in the tightening sequence, with special tool (1)

  • Page 233: Removing, Installing The Valve Stem Seals

    CYLINDER HEAD Removing, installing the valve stem seals Additional jobs – Checking and setting the valve clearance, see 238 – Removing, installing the cylinder head cover, see 213 – Removing, installing the rocker arm mechanism, see 217 (1) Cylinder head (5) Valve (2) Valve spring (6) Valve stem seal...
  • Page 234 CYLINDER HEAD Special tools [84] Engine barring gear 80.99626-6009 • Cranking the engine in conjunction with: • Gear ratchet [85] [85] Gear ratchet 80.99627-0001 • Cranking the engine in conjunction with: • Engine barring gear [84] [86] Adapter 80.99606-0588 • Removing and installing the valve springs in conjunction with: •...
  • Page 235 CYLINDER HEAD [90] Holder 80.99613-0050 • Removing and installing the valve springs in conjunction with: • Adapter [86] • Holder [91] • Valve-spring compressor [89] • Extension [88] • Assembly device [87] [91] Holder 80.99613-0051 • Removing and installing the valve springs in conjunction with: •...
  • Page 236 CYLINDER HEAD Removing the valve stem seals Assembling the special tool Attaching the engine barring gear Note Retaining washer and Holder [91] have • Remove the cap with seal and TDC marking plate left-hand threads. from the ywheel housing • Attach the Engine barring gear [84] (1) on the •...
  • Page 237 CYLINDER HEAD Attaching the valve-spring compressor Removing the valve cotters WARNING CAUTION Injector damage Risk of injury due to springing back of • Spring compressor must not come into the valve springs contact with the injector • Ensure that the Holder [90] Holder [91] are seated correctly on...
  • Page 238 Note Mount the green valve stem seals on the intake side and the brown valve stem seals on the exhaust side • Thinly apply clean engine oil to MAN Standard 3277 on the Assembly sleeve [94] (4) and valve stem seal (3) •...
  • Page 239 CYLINDER HEAD Assembling the special tool Installing the valve cotters Note CAUTION Retaining washer and Holder [91] have Risk of injury due to springing back of left-hand threads. the valve springs • Ensure that the Holder [90] Holder [91] are seated correctly on •...

  • Page 240: Checking And Setting The Valve Clearance

    CYLINDER HEAD Checking and setting the valve clearance Additional jobs – Removing, installing the cylinder head cover, see 213 (1) Adjusting screw, exhaust valve (3) Valve bridge, intake valve (2) Adjusting screw, intake valve (4) Valve bridge, exhaust valve Technical data Intake valve clearance ........................
  • Page 241 CYLINDER HEAD Special tools [95] Engine barring gear 80.99626-6009 • Cranking the engine in conjunction with: • Gear ratchet [85] [96] Gear ratchet 80.99627-0001 • Cranking the engine in conjunction with: • Engine barring gear [84] [97] Valve wrench size 14 80.99603-6031 •...
  • Page 242 CYLINDER HEAD Checking and setting the valve Cranking the engine to the setting position clearance Detaching the cylinder head cover, cylinder 1 A = Rocker arms in overlap B = Rocker arms free for valve clearance setting • Unscrew the mounting bolts (2) •...
  • Page 243 CYLINDER HEAD Adjusting the intake valve clearance Setting the exhaust valve clearance • Unscrew the lock nut (4) • Unscrew the lock nut (4) • Unscrew the adjusting screw (5) until the (1) with • Unscrew the adjusting screw (5) until the (1) with (2) can be inserted between the ball socket (6) and (2) can be inserted between the ball socket (6) and the valve bridge (3)
  • Page 244 CYLINDER HEAD Detaching the engine barring gear • Remove the Engine barring gear [95] (1) from the ywheel housing • Attach the TDC marking plate • Attach the cap with new seal on the ywheel housing AE6 3st edition...

  • Page 245: Valve Timing

    VALVE TIMING VALVE TIMING (1) Rocker arm mechanism (4) Camshaft (2) Roller tappet (5) Push rod (3) Anti-rotation lock AE6 3st edition...

  • Page 247: Camshaft

    VALVE TIMING CAMSHAFT Removing, installing the camshaft / camshaft bearings Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 – Removing, installing the engine wiring harness, see 25 –...
  • Page 248 VALVE TIMING (1) Camshaft (4) Anti-rotation device (2) Camshaft gear (5) Roller tappet (3) Mounting bolt Camshaft technical data Anti-rotation lock..........................22 Nm Mounting bolt, oil injector nozzle......M14x20-10.9............120 Nm Axial play, camshaft ...................... 0.100 – 0.250 mm Radial play, camshaft.....................0.060 – 0.112 mm Important information WARNING Component damage due to incorrectly tightened screw/bolt connections...
  • Page 249 VALVE TIMING Removing the camshaft Removing the camshaft Detaching the camshaft gear • Push out the camshaft (1) towards the ywheel housing with Insertion pin [99] • Unscrew the mounting bolts (2) • Unscrew the Insertion pin [99] • Pull off the camshaft gear (1) over the alignment Unscrewing the anti-rotation device Detaching the axial shim •...
  • Page 250 VALVE TIMING Installing the camshaft Installing the camshaft Installing the roller tappetInstalling the roller tappet • Thinly apply clean engine oil to MAN Standard 3277 on the camshaft bearing • Screw the Insertion pin [99] into the camshaft (1) • Thinly apply clean engine oil on the roller tappet •...
  • Page 251 VALVE TIMING Mounting the camshaft gear • Position the camshaft gear (1) over the alignment • Screw in and tighten the mounting bolts (2) AE6 3st edition...

  • Page 253: Valve Timing

    VALVE TIMING VALVE TIMING Checking the valve timing Additional jobs – Removing, installing the cylinder head cover, see 213 – Checking and setting the valve clearance, see 238 (1) Intake valve, cylinder 1 Technical data Valve lift ..........................11.0 – 11.3 mm Important information WARNING Component damage due to incorrectly tightened screw/bolt connections...
  • Page 254 VALVE TIMING Special tools [100] Engine barring gear 80.99626-6009 • Cranking the engine in conjunction with: • Gear ratchet [101] [101] Gear ratchet 80.99627-0001 • Cranking the engine in conjunction with: • Engine barring gear [100] [102] Dial gauge holder 08.71082-0005 •...
  • Page 255 VALVE TIMING Checking the valve timing Checking the valve lift Detaching the cylinder head cover, cylinder 1 • Attach the Dial gauge [103] (1) with Dial gauge holder [102] (2) on the cylinder head • Unscrew the mounting bolts (2) •...

  • Page 257: Front Timing Gears/Rear Timing Gears

    FRONT TIMING GEARS/REAR TIMING GEARS FRONT TIMING GEARS/REAR TIMING GEARS Timing gears in the housing cover at the front (1) Crankshaft gear, coolant pump (2) Intermediate gear, crankshaft (split) (3) Intermediate gear pin (4) Mounting bolt (5) Crankshaft gear, oil pump AE6 3st edition...
  • Page 258 FRONT TIMING GEARS/REAR TIMING GEARS Timing gears in the ywheel housing (1) Crankshaft gear (3) Camshaft gear (2) Mounting bolt (4) Countershaft gear AE6 3st edition...

  • Page 259: Front Timing Gears

    FRONT TIMING GEARS/REAR TIMING GEARS FRONT TIMING GEARS Removing, installing front timing gears Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the ramfan, see 61 – Removing, installing the fan V-belt, see 85 – Removing, installing the intermediate ange, see 63 –...
  • Page 260 FRONT TIMING GEARS/REAR TIMING GEARS Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque • Final tightening must always be performed manually using a torque wrench Special tools [104] Aligning tool...
  • Page 261 FRONT TIMING GEARS/REAR TIMING GEARS Removing front timing gears Dismantling the intermediate gear Removing the coolant pump crankshaft gear • Mark the relative positions of the intermediate gear (2) and (5) • Screw in the Aligning tool [104] (1) and (3) •...
  • Page 262 • Put the intermediate gear (2) on the intermediate gear (5) as marked • Tighten the mounting bolts (1) and (6) • Thinly apply clean engine oil to MAN Standard 3277 on the intermediate gear pin (2) • Insert the intermediate gear pin (2) into the intermediate gear (3) •...
  • Page 263 FRONT TIMING GEARS/REAR TIMING GEARS Installing the coolant pump crankshaft gear • Push on the crankshaft gear (2) over Aligning tool [104] (1) and (3) as far as the stop • Unscrew the Aligning tool [104] (1) and (3) AE6 3st edition...

  • Page 265: Rear Timing Gears

    FRONT TIMING GEARS/REAR TIMING GEARS REAR TIMING GEARS Removing, installing rear timing gears Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 –...
  • Page 266 FRONT TIMING GEARS/REAR TIMING GEARS Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque • Final tightening must always be performed manually using a torque wrench Special tools [105] Aligning tool...
  • Page 267 FRONT TIMING GEARS/REAR TIMING GEARS Setting the crankshaft gear to the marks Removing the rear timing gears Fixing the crankshaft gear Removing the crankshaft gear • Fix the crankshaft gear (2) by screwing in the • Screw in the Aligning tool [105] (2) and (3) mounting bolts (1) and (3) •...
  • Page 268 FRONT TIMING GEARS/REAR TIMING GEARS Installing the rear timing gears Installing the crankshaft gear • Screw in the Aligning tool [105] (2) and (3) • Align the bore in the crankshaft gear (1) with the centring pin • Push the crankshaft gear (1) onto the crankshaft •...

  • Page 269: Engine Lubrication

    ENGINE LUBRICATION ENGINE LUBRICATION (1) Oil module, right (3) Oil sump (2) Oil module, left AE6 3st edition...

  • Page 271: Oil Modules

    ENGINE LUBRICATION OIL MODULES Removing, installing oil modules Additional jobs – Draining the coolant, see Operator's Manual – Draining the engine oil, see Operator's Manual – Removing, installing the cooling system, see 55 – Removing, installing the fan V-belt, see 85 –...
  • Page 272 WARNING Danger of engine damage due to insufcient oil supply • If an oil module is removed, the engine must be lled with engine oil to MAN Standard 3277 using the pressure application process before starting, . AE6 3st edition...
  • Page 273 ENGINE LUBRICATION Removing the oil module Detaching the left oil module Removing the left oil return line • Mark the installation position of the mounting bolts (1), (2), (7) and (8) • Release the fastening (1) • Unscrew the mounting bolts (1), (2), (7) and (8) •...
  • Page 274 ENGINE LUBRICATION Installing the oil module Right oil module removal instructions Installing the right oil module • Do not unscrew the oil cooler mounting bolts (1) to remove the oil module • Clean the sealing surfaces Detaching the right oil module •...
  • Page 275 ENGINE LUBRICATION Installing the right oil return line Tightening diagram for left oil module • Position the oil return lines (1) and (2) so that they • Tighten the mounting bolts (4) are strain-free • Unscrew the mounting bolts (4) 60° •...

  • Page 276: Dismantling And Assembling The Oil Module

    ENGINE LUBRICATION Dismantling and assembling the oil module Additional jobs – Draining the coolant, see Operator's Manual – Draining the engine oil, see Operator's Manual – Removing, installing the cooling system, see 55 – Removing, installing the fan V-belt, see 85 –...
  • Page 277 ENGINE LUBRICATION Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque • Final tightening must always be performed manually using a torque wrench WARNING Component damage caused by contamination •...
  • Page 278 ENGINE LUBRICATION Dismantling the oil module Removing the oil lter Removing the oil cooler WARNING Engine oil contamination WARNING • Always allow all of the engine oil to drain Component damage due to setting aside the oil module incorrectly • Unscrew the oil lter cover (1) 2-3 turns with the •...
  • Page 279 • Screw in the mounting bolts (1) as marked and • Pull the new O-ring (2) onto the oil lter cover (1) tighten them until nger-tight • Thinly apply clean engine oil to MAN Standard • Tighten the mounting bolts (1) 3277 on the O-ring (2) •...

  • Page 281: Oil Injector Nozzles

    ENGINE LUBRICATION OIL INJECTOR NOZZLES Removing, installing the oil injector nozzles Additional jobs – Removing, installing the oil sump, see 281 (1) Oil injector nozzle (2) Mounting bolt Technical data Mounting bolt ............M14x20-10.9............120 Nm Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 282 ENGINE LUBRICATION Removing the oil injector nozzle Installing the oil injector nozzle • Unscrew the mounting bolt (1) • Insert the oil injector nozzle (2) into the crankcase • Extract the oil injector nozzle (2) from the • Screw in the mounting bolt (1) and tighten to crankcase 120 Nm AE6 3st edition...

  • Page 283: Oil Sump

    ENGINE LUBRICATION OIL SUMP Removing, installing the oil sump Additional jobs – Draining and topping up the engine oil, see Operator's Manual (1) Fuse housing (3) Oil return line (2) Oil sump Technical data Oil drain plug............M26x1.5 ............80 Nm Important information WARNING Component damage caused by contamination...
  • Page 284 ENGINE LUBRICATION Removing the oil sump Detaching the manifold for the left oil suction line Detaching the left oil return line • Mark the mounting bolts (4) and (5) • Release the fastening (1) • Unscrew the mounting bolts (4) and (5) and then •...
  • Page 285 ENGINE LUBRICATION Installing the oil sump Detaching the holder for the housing Installing the oil sump • Unscrew the mounting bolts (2) • Remove the holder (1) • Clean the sealing surfaces Removing the oil sump • Position the oil sump (3) with a new seal (1) •...
  • Page 286 ENGINE LUBRICATION Attaching the manifold for the right oil suction Attaching the left oil return line line • Position the oil return lines (2) and (3) so that they • Clean the sealing surfaces are strain-free • Insert the new insert pipe (5) •...

  • Page 287: Dismantling, Assembling The Oil Sump

    ENGINE LUBRICATION Dismantling, assembling the oil sump Additional jobs – Removing, installing the oil sump, see 281 (1) Oil sump (4) Dipstick (2) Oil suction lines (5) Screw plug (3) Screw plug (6) Threaded connection Technical data Oil drain plug............M26x1.5 ............80 Nm Service products Loctite 648 ........................
  • Page 288 ENGINE LUBRICATION Dismantling the oil sump Removing the oil ller pipe Pull out the dipstick • Unscrew the mounting nut (2) • Unscrew the oil ller pipe (3) with sealing ring (1) • Pull the dipstick (1) out of the guide tube (2) Removing the oil suction lines Pulling out the guide tube •...
  • Page 289 ENGINE LUBRICATION Assembling the oil sump Dismantling the oil suction line Assembling the oil suction line • Remove the circlip (2) • Remove the screen plate (1) from the oil suction • Clean the screen plate (1) line • Insert the screen plate (1) into the oil suction line •...
  • Page 290 ENGINE LUBRICATION Installing the oil ller pipe Inserting the dipstick • Thinly coat the thread of the oil ller pipe (3) with • Insert the dipstick (1) in the guide tube (2) Loctite 648 • Screw in the oil ller pipe (3) with mounting nut (2) and new sealing ring (1) •...

  • Page 291: Oil Pumps

    ENGINE LUBRICATION OIL PUMPS Removing, installing oil pumps Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the fan V-belt, see 85 – Removing, installing the ramfan, see 61 – Removing, installing the intermediate ange, see 63 –...
  • Page 292 ENGINE LUBRICATION Axial play, rotor......................0.035 – 0.080 mm Mounting bolt, oil pump......... M6x40-10.9 ............15 Nm Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque •...
  • Page 293 ENGINE LUBRICATION Removing oil pumps Detaching the cover Detaching the manifold for the left oil suction line • Mark the installation position of the mounting bolts (3), (4), (5) and (6) • Unscrew the mounting bolts (3), (4), (5) and (6) •...
  • Page 294 ENGINE LUBRICATION Checking the oil pump Installing oil pumps Checking the ring gear axial play Installing oil pumps • Place the Dial gauge holder [107] (2) with Dial • Position the oil pumps (2) and (3) gauge [108] (1) on the oil pump •...
  • Page 295 ENGINE LUBRICATION Attaching the manifold for the right oil suction line • Clean the sealing surfaces • Insert the new insert pipe (5) • Position the manifold (2) with a new O-ring (1) • Screw in and tighten the mounting bolts (3) and (4) Attaching the manifold for the left oil suction line •...
  • Page 297 CRANKSHAFT OIL SEALS CRANKSHAFT OIL SEALS (1) Flywheel housing (3) Front crankshaft oil seal (2) Rear crankshaft oil seal (4) Cover AE6 3st edition...

  • Page 299: Crankshaft Oil Seals

    CRANKSHAFT OIL SEALS CRANKSHAFT OIL SEALS Removing, installing the front radial shaft seal Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the fan V-belt, see 85 – Removing, installing the ramfan, see 61 – Removing, installing the intermediate ange, see 63 –...
  • Page 300 CRANKSHAFT OIL SEALS Special tools [109] Impact extractor 80.99602-0016 • Extracting the radial shaft seal in conjunction with: • Extractor hook [110] [110] Extractor hook 80.99602-0175 • Extracting the radial shaft seal in conjunction with: • Impact extractor [109] [111] Aligning tool 80.99617-0020 •...
  • Page 301 CRANKSHAFT OIL SEALS Removing the front radial shaft seal Installing the front radial shaft seal • Assemble the Pressing plate [114] (3) with the WARNING Plug-on handle [112] (1) and Washer [113] Danger of component damage on the • Put the closed side of the radial shaft seal (4) onto cover the special tool •...

  • Page 302: Removing, Installing The Rear Radial Shaft Seal

    CRANKSHAFT OIL SEALS Removing, installing the rear radial shaft seal Additional jobs – Removing, installing the ywheel, see 315 (1) Flywheel housing (2) Rear radial shaft seal Important information WARNING Component damage due to inadequate positive locking of the crankshaft gear, because the front face of the crankshaft gear is shot-peened •...
  • Page 303 CRANKSHAFT OIL SEALS Special tools [115] Engine barring gear 80.99626-6009 • Blocking the engine [116] Impact extractor 80.99602-0016 • Extracting the crankshaft gear and radial shaft seal in conjunction with: • Extractor device [117] • Aligning tool [122] [117] Extractor device 80.99601-6033 •...
  • Page 304 CRANKSHAFT OIL SEALS [121] Press-in bush 80.99604-0340 • Installing the radial shaft seal in conjunction with: • Plug-on handle [118] • Washer [119] • Guide plate [120] • Aligning tool [122] [122] Aligning tool 80.99617-0220 • Removing, installing the ywheel •...
  • Page 305 CRANKSHAFT OIL SEALS Extracting the rear radial shaft seal Checking the valves for unobstructed movement, 1st cylinder Removing the cylinder head cover, cylinder 1 • Check the rocker arms (1) and (2) for the 1st • Unscrew the mounting bolts (2) cylinder for unobstructed movement •...
  • Page 306 CRANKSHAFT OIL SEALS Installing the rear radial shaft seal Mounting the special tool Installation position of crankshaft gear • Insert the Extractor device [117] (3) into the crankshaft gear (4) • Align the crankshaft gear so the marks (1) match •...
  • Page 307 CRANKSHAFT OIL SEALS Checking the crankshaft gear marks in relation Pressing in the radial shaft seal to the camshaft gear • Assemble the Press-in bush [121] (2) with the • Check the marks on the crankshaft gear (1) in Plug-on handle [118] (5) and Washer [119] relation to the camshaft gear (2)

  • Page 309: Crank Mechanism

    CRANK MECHANISM CRANK MECHANISM (1) Flywheel (3) Vibration damper (2) Pistons AE6 3st edition...

  • Page 311: Vibration Damper

    CRANK MECHANISM VIBRATION DAMPER Removing, installing the vibration damper Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the fan V-belt, see 85 – Removing, installing the ramfan, see 61 – Removing, installing the intermediate ange, see 63 –...
  • Page 312 CRANK MECHANISM Special tools [123] Aligning tool 80.99617-0020 • Removing, installing the vibration damper [124] Engine barring gear 80.99626-6009 • Cranking the engine in conjunction with: • Gear ratchet [125] [125] Gear ratchet 80.99627-0001 • Cranking the engine in conjunction with: •...
  • Page 313 CRANK MECHANISM Removing the vibration damper Pulling off the vibration damper Attaching the engine barring gear CAUTION Danger of injury due to heavy • Remove the cap with seal and TDC marking plate components and removal and from the ywheel housing installation position that is difcult •...
  • Page 314 CRANK MECHANISM Dismantling the vibration damper Assembling the vibration damper • Insert the hub (1) into the vibration damper (2) WARNING • Screw in and tighten the mounting bolts (3) Component damage due to putting the vibration damper aside incorrectly •...
  • Page 315 CRANK MECHANISM Installing the vibration damper Tightening the mounting bolts Putting on the vibration damper • Screw in the remaining mounting bolts (1) and (2) • Tighten all the mounting bolts to Initial torque 190 • Screw in the Aligning tool [123] (3) and (4) •...

  • Page 317: Flywheel

    CRANK MECHANISM FLYWHEEL Removing, installing the ywheel (1) Mounting bolt (2) Flywheel Technical data Mounting bolt ............M18x1.5x91-12.9 ......Initial torque 100 Nm Mounting bolt ............M18x1.5x91-12.9 ......Second tightening 90° Mounting bolt ............M18x1.5x91-12.9 ......Final tightening 90° Installation temperature for ywheel ring gear ................200-230°C Important information WARNING Component damage due to reused mounting bolts...
  • Page 318 CRANK MECHANISM Special tools [126] Aligning tool 80.99617-0220 • Detaching and attaching the ywheel [127] Socket, size 22 80.99612-0024 • Unscrewing and tightening the ywheel bolts in conjunction with: • Support [129] • Torque multiplier i = 1 : 3.3 [128] •...
  • Page 319 CRANK MECHANISM [130] Torque angle gauge 80.99607-0172 • Unscrewing and tightening the ywheel bolts in conjunction with: • Socket, size 22 [127] • Support [129] • Torque multiplier i = 1 : 3.3 [128] • Holding device [131] • Cylinder head bolt [133] •...
  • Page 320 CRANK MECHANISM [134] Connecting pin 06.22729-0006 • Unscrewing and tightening the ywheel bolts in conjunction with: • Socket, size 22 [127] • Support [129] • Torque multiplier i = 1 : 3.3 [128] • Torque angle gauge [130] • Holding device [131] •...
  • Page 321 CRANK MECHANISM Removing the ywheel Unscrewing the ywheel mounting bolts Assembling the special tool • Unscrew two opposite mounting bolts (1) and (2) • Insert the Torque multiplier i = 1 : 3.3 [128] (1) into Screwing in the aligning tools Support [129] •...
  • Page 322 CRANK MECHANISM Removing, installing the ywheel ring Pulling off the ywheel gear Spot-drilling the ywheel ring gear CAUTION Danger of injury due to heavy components WARNING • Use lifting gear to remove the ywheel Danger of injury from metal chips •...
  • Page 323 CRANK MECHANISM Installing the ywheel Screwing in the ywheel mounting bolts Putting on the ywheel • Screw in the remaining new mounting bolts (1) and CAUTION Tightening diagram Danger of injury due to heavy components • Use lifting gear to install the ywheel WARNING Component damage due to reused ywheel bolts...
  • Page 324 CRANK MECHANISM Tightening the ywheel mounting bolts Note Note the torque multiplier ratio, i = 1 : 3.3. • Tighten the mounting bolts (1) to Initial torque 100 Nm as per the tightening diagram • Tighten the mounting bolts (1) using the special tool (2) in conjunction with the Socket [132] •...

  • Page 325: Pistons And Connecting Rods

    CRANK MECHANISM PISTONS AND CONNECTING RODS Removing, installing a piston with its connecting rod Additional jobs – Removing, installing the turbocharger, see 173 – Removing, installing the oil sump, see 281 – Removing, installing the oil injector nozzles, see 279 –...
  • Page 326 CRANK MECHANISM Connecting rod radial play..................... 0.060 – 0.128 mm Connecting rod axial play....................0.240 – 0.438 mm Expansion............................ 2.0 mm Piston diameter D1 measured 13 mm above piston bottom edge............127.898 – 127.902 mm Piston ring (keystone ring) Piston ring (keystone ring)..................3.5 mm (nominal value) Piston ring width .......................
  • Page 327 CRANK MECHANISM Special tools [139] Feeler gauge 08.75310-0806 • Checking the piston ring axial play and ring gap [140] Dial gauge holder 80.99605-0172 • Checking the piston standout in conjunction with: • Dial gauge [142] [141] Piston ring pliers 83.09144-6090 •...
  • Page 328 CRANK MECHANISM Removing the pistons and connecting Removing the pistons rods Unscrewing the connecting rod bearing bolts • Mark the installation position and orientation of the piston (1) relative to the cylinder liner (2) • Pull the piston (1) with connecting rod out of the •...
  • Page 329 CRANK MECHANISM Detaching the pistons Measuring the pistons, piston rings and connecting rods Removing the piston pin Measuring the piston pins • Mark the relative positions of the piston (2), piston pin (4) and connecting rod (5) • Measure the piston pin (1) using a micrometer (2) •...
  • Page 330 CRANK MECHANISM Removing the piston rings Installing the piston rings • Set the Piston ring pliers [141] (1) to the piston WARNING diameter Component damage due to incorrect • Remove the piston rings (2) using the Piston ring installation of the piston rings pliers [141] •...
  • Page 331 CRANK MECHANISM Measuring the connecting rod bearings Measuring the piston pin bore Measuring the connecting rod bearing inside diameter • Use the internal calliper (2) and Dial gauge [142] (4) to check the piston pin bore (1) If the dimension of the piston pin bore (1) is out •...
  • Page 332 120° from one another and then thinly apply the direction of the arrow engine oil to MAN Standard 3277 on the piston (2) • Fit the piston (2) over the connecting rod (5) as and connecting rod bearing marked •...
  • Page 333 CRANK MECHANISM Installing the connecting rod bearing cap Tightening the connecting rod bearing shells • Turn the crankshaft to BDC to tighten the WARNING connecting rod bearing bolts (1) Crack surfaces are sensitive. The • Check the alignment of the connecting rod principle involved can cause chipping bearings.

  • Page 335: Crankshaft

    CRANK MECHANISM CRANKSHAFT Removing, installing the crankshaft Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 – Removing, installing the engine wiring harness, see 25 –...
  • Page 336 CRANK MECHANISM (1) Mounting bolt, crankcase lower section (7) Crankcase (2) Mounting bolt, crankcase lower section (8) Main bearing shell, crankcase (3) Mounting bolt, crankcase lower section (9) Crankshaft (4) Mounting bolt, crankcase lower section (10) Main bearing shell, crankcase lower (5) Crankcase lower section section (6) Sleeve...
  • Page 337 CRANK MECHANISM Glyco main bearing dimensions Wall thickness, main bearing, normal dimension............. 2.959 – 2.971 mm Wall thickness, main bearing, normal dimension II............3.084 – 3.096 mm Wall thickness, main bearing, repair level I..............3.209 – 3.221 mm Wall thickness, main bearing, repair level II ..............3.334 – 3.346 mm Expansion............................
  • Page 338 CRANK MECHANISM [151] Aligning tool 80.99617-0220 • Removing, installing the crankshaft in conjunction with: • Aligning tool [150] [152] Puller screw 80.99615-0039 (nicht • Removing the crankcase lower section freigegeben) • Aligning tool [150] [153] Eye-bolt 80.99606-0660 • Installing and removing the crankcase lower section [154] Three-arm puller...
  • Page 339 CRANK MECHANISM [157] Support 80.99606-0551 • Unscrewing and tightening the crankcase lower section mounting bolts in conjunction with: • Socket, size 22 [155] • Torque multiplier i = 1 : 3.3 [156] • Torque angle gauge [158] • Holding device [159] •...
  • Page 340 CRANK MECHANISM [161] Connecting pin 06.22729-0006 • Unscrewing and tightening the crankcase lower section mounting bolts in conjunction with: • Socket, size 22 [155] • Torque multiplier i = 1 : 3.3 [156] • Support [157] • Torque angle gauge [158] •...
  • Page 341 CRANK MECHANISM [164] Socket 80.99603-0327 • Unscrewing and tightening the crankcase lower section mounting bolts in conjunction with: • Socket, size 22 [155] • Torque multiplier i = 1 : 3.3 [156] • Support [157] • Torque angle gauge [158] •...
  • Page 342 CRANK MECHANISM Checking the crankshaft Checking the crankshaft radial play Checking the crankshaft axial play • Position the Dial gauge [146] (1) with the Dial gauge holder [147] (3) and Locating pin [148] • Position the Dial gauge [146] (1) with the Dial the crankshaft (2) with a preload gauge holder [147]...
  • Page 343 CRANK MECHANISM Removing the crankshaft Unscrewing the outer crankcase lower section mounting bolts Setting the timing gears to the mark • Align the marks on the crankshaft gear (1) and camshaft gear (2) with one another Unscrewing the crankcase lower section mounting bolts •...
  • Page 344 CRANK MECHANISM Assembling special tool 1 Unscrewing the inner crankcase lower section mounting bolts • Insert the Torque multiplier i = 1 : 3.3 [156] (1) into Support [157] • Attach the Holding device [159] (5) with the Cylinder head bolt [160] (4) and the Adapter [163] (3) on the...
  • Page 345 CRANK MECHANISM Detaching the crankcase lower section Removing the main bearing shells from the crankcase lower section CAUTION • Mark the installation position of the crankshaft Danger of injury due to heavy bearing shells (1) components • Remove the crankshaft baring shells (1) •...
  • Page 346 CRANK MECHANISM Screwing in the aligning tools Removing the crankshaft bearing shells from the crankcase • Screw in the Aligning tool [150] (1) at the front of • Mark the crankshaft bearing shells (1) to indicate the crankshaft correct assignment and installation position •...
  • Page 347 CRANK MECHANISM Checking the crankshaft and crankshaft Checking the crankshaft bearing shell inside bearings diameter Checking the crankshaft bearing shell expansion • Insert the crankshaft bearing shells into the crankcase and crankcase lower section (3) as marked • Put on the crankcase lower section (3) Note •...
  • Page 348 (1) using a micrometer (2) 10 items, V 12 engine has 14 items • Repeat the measurement for each main bearing • Thinly apply clean engine oil to MAN Standard journal 3277 on the main bearing shells (1) The dimensions of the crankshaft bearing journals •...
  • Page 349 • Screw in the Aligning tool [150] at the front of the crankshaft (1) • Thinly apply clean engine oil to MAN Standard • Screw in the Aligning tool [151] at the rear of the 3277 on the cleaned thrust washers (1) crankshaft (1) •...
  • Page 350 CRANK MECHANISM Installation instructions for crankcase lower Putting on the crankcase lower section section CAUTION Danger of injury due to heavy components • Lift off the crankcase lower section with support WARNING Component damage due to main bearing shells falling out •...
  • Page 351 • Tighten the mounting bolts 1 to 14 in the tightening sequence Tightening the outer mounting bolts • Thinly apply clean engine oil to MAN Standard 3277 on the contact surfaces and threads of the new mounting bolts (1) • Screw in the new outer mounting bolts (1) with washers (2) as marked •...
  • Page 352 If this is not the case, repeat the procedure for installing and removing the crankshaft. • Thinly apply clean engine oil to MAN Standard 3277 on the contact surfaces and threads of the new mounting bolts (1) •...
  • Page 353 CRANK MECHANISM Checking the crankshaft axial play Checking the crankshaft radial play • Position the Dial gauge [146] (1) with the Dial • Position the Dial gauge [146] (1) with the Dial gauge holder [147] (2) and Locating pin [148] gauge holder [147] (2) and Locating pin [148]...
  • Page 354 CRANK MECHANISM Crankshaft installation position • Align the marks on the crankshaft gear (1) and camshaft gear (2) with one another If the marks (1) and (2) do not match up, remove the crankshaft gear and install it again with the marks (1) aligned with the mark on the camshaft gear (2).
  • Page 355 CRANKCASE CRANKCASE (1) Right vent line (4) Engine mount (2) Left vent line (5) Cover (3) Flywheel housing AE6 3st edition...

  • Page 357: Positive Crankcase Ventilation

    CRANKCASE POSITIVE CRANKCASE VENTILATION Removing, installing the positive crankcase ventilation Additional jobs – Draining and topping up the coolant, see Operator's Manual (1) Vent line, right (2) Vent line, left Important information WARNING Component damage due to incorrectly tightened screw/bolt connections •...
  • Page 358 CRANKCASE Removing the positive crankcase Detaching the left oil return line ventilation Detaching the left positive crankcase ventilation • Release the fastening (1) • Detach the oil return lines (2) and (3) • Unscrew the mounting nuts (1) and remove with Detaching the right oil return line washers (2) •...
  • Page 359 CRANKCASE Installing the positive crankcase Attaching the right positive crankcase ventilation ventilation Attaching the left oil return line • Position the vent line (5) and pull on the hoses with jubilee clips (4) and (6) • Position the oil return lines (2) and (3) so that they •...

  • Page 361: Cover

    CRANKCASE COVER Removing, installing the cover Additional jobs – Removing, installing the cooling system, see 55 – Removing, installing the fan V-belt, see 85 – Removing, installing the ramfan, see 61 – Removing, installing the intermediate ange, see 63 – Removing, installing the fan tensioning pulley, see 89 –...
  • Page 362 CRANKCASE Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque • Final tightening must always be performed manually using a torque wrench Special tools [167] Aligning tool...
  • Page 363 CRANKCASE Detaching the cover Detaching the cover Removing coolant temperature sensors • Mark the installation position of the mounting bolts (2) and (5) • Unscrew the coolant temperature sensors (1) and • Unscrew the mounting bolts (2) and (5) (2) with sealing rings •...
  • Page 364 CRANKCASE Attaching the cover Attaching coolant temperature sensors Installing the oil pump crankshaft gear • Lightly apply clean Engine oil on the thread of the coolant temperature sensors (1) and (2) • Clean the contact surfaces of the crankshaft gear •...

  • Page 365: Flywheel Housing

    CRANKCASE FLYWHEEL HOUSING Removing, installing the ywheel housing Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 – Removing, installing the engine wiring harness, see 25 –...
  • Page 366 CRANKCASE Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque • Final tightening must always be performed manually using a torque wrench AE6 3st edition...
  • Page 367 CRANKCASE Removing the ywheel housing Dismantling the ywheel housing Detaching the ywheel housing • Unscrew the screw plug (2) and remove with sealing ring (3) • Unscrew the mounting bolts (5) CAUTION • Remove the cover (6) with the seal (7) Danger of injury due to heavy •...
  • Page 368 CRANKCASE Installing the ywheel housing Mounting the ywheel housing Assembling the ywheel housing CAUTION Danger of injury due to heavy • Clean the sealing surfaces components • Position the adjusting plate (4) • Use lifting gear to install the ywheel •...

  • Page 369: Cylinder Liner

    CRANKCASE CYLINDER LINER Removing, installing the cylinder liner Additional jobs – Removing, installing the combination air lter, see 187 – Removing, installing engine control units, see 27 – Removing, installing the combination air lter holder, see 193 – Removing, installing the engine wiring harness, see 25 –...
  • Page 370 CRANKCASE (1) Cylinder liner (2) Crankcase Cylinder liner standard Total height of cylinder liner ......................262.00 mm Outside diameter of cylinder liner at collar..............163.15 – 163.35 mm Outside diameter of cylinder liner stem ..............149.439 – 149.457 mm Collar height standard....................10.04 – 10.07 mm Cylinder liner inside diameter .................
  • Page 371 CRANKCASE Special tools [168] Extractor device 80.99601-6018 • Extracting the cylinder liner in conjunction with: • Extractor plate [169] [169] Extractor plate 80.99601-0187 • Extracting the cylinder liner in conjunction with: • Extractor device [168] [170] Dial gauge holder 80.99605-0172 •...
  • Page 372 CRANKCASE [174] Washer 06.15013-0417 • Checking the cylinder liner standout in conjunction with: • Dial gauge holder [170] • Dial gauge [171] • Measuring plate [172] • Bolt [173] [175] Depth gauge (electronic) 08.71195-9003 • Checking the cylinder liner seating AE6 3st edition...
  • Page 373 CRANKCASE Removing the cylinder liner Removing the sectional sealing rings Fitting the extractor device • Remove the sectional sealing rings (1) and (2) from the crankcase • Clean the cylinder liner seat and sectional sealing WARNING ring seats Component damage due to damaged •...
  • Page 374 Installing the cylinder liner • Check the seat (2) of the cylinder liner with Depth • Lightly apply clean engine oil to MAN Standard gauge (electronic) [175] 3277 on the new sectional sealing rings (1) and • Check the cylinder liner seat (2) at four...

  • Page 375: Engine Mount

    CRANKCASE ENGINE MOUNT Removing, installing engine mounts Additional jobs – Removing, installing the fuel lter, see 155 (1) Engine mount Important information WARNING Component damage due to incorrectly tightened screw/bolt connections • If impact wrenches are used, these may only be used for pretightening to max. 50% of the specied tightening torque •...
  • Page 376 CRANKCASE Removing engine mounts Installing engine mounts Detaching the left engine mount Attaching the right engine mount CAUTION CAUTION Danger of injury due to heavy Danger of injury due to heavy components components • Support the engine mount when • Support the engine mount when detaching it attaching it •...

  • Page 377: Technical Data

    TECHNICAL DATA Technical Data AE6 Stage 2 2st edition...
  • Page 378 TECHNICAL DATA AE6 Stage 2 2st edition...
  • Page 379 TECHNICAL DATA Technical Data Tightening Torques Important information User tip All bolted connections, the purpose of which is not stated in the following table, are to be tightened in accordance with the guideline values given in our Works Standard M 3059 (see page 384). Oil bolts lightly prior to assembly! Engine electrics Engine electrics...
  • Page 380 TECHNICAL DATA Alternator Mounting nut ........M16x1.5 .
  • Page 381 TECHNICAL DATA Common Rail System High-pressure lines and rails (common rail) High-pressure line (initial use) ..........initial torque 10 Nm High-pressure line (initial use) .
  • Page 382 TECHNICAL DATA High-pressure pump/high-pressure pump drive Mounting bolt, high-pressure pump ............60 Nm High-pressure line (initial use) .
  • Page 383 TECHNICAL DATA Cylinder head Cylinder head cover Cylinder head cover tightening diagram B = Exhaust end Observe the tightening sequence for the mounting bolts Rocker arm mechanism Mounting bolts, rocker arm mechanism ....M12x80-10.9 .
  • Page 384 TECHNICAL DATA Cylinder head Cylinder head bolts ....... . M18x2x246-10.9 .
  • Page 385 TECHNICAL DATA Engine lubrication Oil filter insert Oil filter cover ................45 Nm Support dome .
  • Page 386 TECHNICAL DATA Installation tightening torques according to Works 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 15.0...
  • Page 387 Components that are much weaker than standard parts must be tested separately Valid for: Valid for: -Hollow screws (DIN 7643 or similar) Screw-in fittings (DIN 390, MAN 200 or -Screw-in fittings (DIN 3901 / MAN 200, similar for cutting ring connection of a or similar for cutting ring connection of a...
  • Page 388 TECHNICAL DATA M45X1.5 190 Nm - - - - M48X1.5 190 Nm - - - - *) Tighten cutting ring connection User tip Bracing is possible when tightening and un­ doing the cutting ring connection. AE6 Stage 2 2st edition...
  • Page 389 TECHNICAL DATA Test and settings values Cooling system Thermostat Stroke at least 9.5 mm at 92 C 80.5-83.5 C Thermostat opening temperature ........... . Add-on units Starter Manufacturer: Mitsubishi...
  • Page 390 TECHNICAL DATA Cylinder head Rocker arm bracket Outside diameter, rocker arm bearing Ø 33.959-33.975 mm Rocker arm Inside diameter, rocker arm Ø 34.005-34.025 mm Radial play, rocker arm ............0.030 -0.066 mm Axial play .
  • Page 391 TECHNICAL DATA Cylinder liner protrusion ............0.025 - 0.100 mm Valve guide protrusion 18.1 - 18.5 mm...
  • Page 392 TECHNICAL DATA Valve recess Valve recess Intake valve: 0.090 - 0.390 mm Exhaust valve: 0.090 - 0.390 mm Nozzle projection: 2,73 - 3,58 mm AE6 Stage 2 2st edition...
  • Page 393 TECHNICAL DATA Valve clearance Valve clearance only to be set with engine in cold condition Intake valve ................0.50 mm Exhaust valve .
  • Page 394 TECHNICAL DATA Valve timing Camshaft Camshaft bearing bushing inside diameter Ø 80.000-80.061 mm Camshaft axial play: 0.100 - 0.200 mm Camshaft radial play: 0.030 - 0.066 mm Replace if signs of wear are present Valve timing Engine cranking device Intake valve opens 24° before TDC Exhaust valve closes 27°...
  • Page 395 TECHNICAL DATA Engine lubrication Oil pump Outer rotor (ring gear) Ring gear axial play: 0.040 - 0.090 mm Ring gear radial play: 0.122 - 0.194 mm Inner rotor (pinion) Pinion axial play: 0.035 - 0.080 mm Pinion radial play: 0.025 - 0.061 mm Gear width: 24 mm Gear axial play: 0.060 - 0.240 mm AE6 Stage 2 2st edition...
  • Page 396 TECHNICAL DATA Crank drive Flywheel Flywheel lateral runout ............. max.
  • Page 397 TECHNICAL DATA After accidental bolting of cracked conrods and conrod bearing covers that do not belong to­ gether, the parts must not be used again Conrod bearing Conrod bearing shell thickness: 2.480 - 2.495 Spread: max. 2.0 mm If traces of wear are present (traces of scoring, running layer damaged), replace both bearing shells Caution: note installation position (rod shell has...
  • Page 398 TECHNICAL DATA Piston Piston height, piston pin centre-piston crown: 78.95 - 79.05 mm Piston pin bore Ø 55.063 - 55.093 mm Piston pin diameter: Ø 54.994 - 55.000 mm Piston diameter D1 measured 13 mm above lower edge of piston: Ø...
  • Page 399 TECHNICAL DATA Piston rings 3.50 - 3.80 mm 1st ring - full keystone ring Piston ring height: 3.50 mm (nominal value) Piston ring width: 4.50 - 4.90 mm 2nd ring - tapered compression ring Piston ring height: 2.47 - 2.49 mm Piston ring width: 4.90 - 5.30 mm 3rd ring - double-bevelled ring Piston ring height: 3.47 - 3.49 mm...
  • Page 400 TECHNICAL DATA Crankshaft Conrod bearing journal: Ø 89.980 - 90.000 mm Standard size 1: Ø 89.970 - 89.900 mm Repair size 1: Ø 89.730 - 89.750 mm Repair size 2: Ø 89.480 - 89.500 mm Crankshaft bearing journal: Ø 99.975 - 99.995 mm Crankshaft bearing journal: Ø...
  • Page 401 TECHNICAL DATA Crankshaft bearing Crankshaft bearing shell wall thickness: 3.466 - 3.478 mm Standard size 1: 3.516 - 3.528 mm Repair size 1: 3.591 - 3.603 mm Repair size 2: 3.716 - 3.728 mm Inside diameter of crankshaft bearing shell in installed state: Ø...
  • Page 402 TECHNICAL DATA AE6 Stage 2 2st edition...
  • Page 403 Special tools Special tools AE6 Stage 2 2st edition...
  • Page 404 Special tools AE6 Stage 2 2st edition...
  • Page 405 Special tools Special tools Hexagon shank bolt 06.01499-0015 S Removing and installing the cylinder head S Removing and installing the cylinder liners Cheese-head screw 06.02191-0407 S Removing and installing the cylinder head S Removing and installing the flywheel S Removing and installing the crankshaft Eye-bolt 06.05110-0103 S Removing and installing the flywheel...
  • Page 406 Special tools Extension 08.06139-9025 S Removing and installing the high-pressure lines and rails S Dismantling and assembling the high-pressure pump/ high-pressure pump drive Adapter 08.06139-9029 S Removing and installing the injector with nozzle S Removing and installing the cylinder head cover [10] Socket size 7 08.06141-0700...
  • Page 407 Special tools [15] Dial gauge 08.71000-3217 S Dismantling and assembling the rocker arm mechanism S Removing and installing the cylinder head S Checking the valve timing S Removing and installing the oil pump S Removing and installing the piston and conrod S Removing and installing the crankshaft S Removing and installing the cylinder liners [16]...
  • Page 408 Special tools [22] Extractor 80.99601-6018 S Removing and installing the cylinder liner [23] Extractor 80.99601-6033 S Removing and installing the rear radial shaft seal [24] Impact extractor 80.99602-0016 S Removing and installing the front radial shaft seal S Removing and installing the rear radial shaft seal [25] Extractor hook 80.99602-0175...
  • Page 409 Special tools [29] Socket size 17 80.99603-0309 S Removing and installing the high-pressure lines and rails S Removing and installing the high-pressure pump drive [30] Socket size 36 80.99603-0325 S Removing and installing the oil module S Dismantling and assembling the oil module [31] Socket 80.99603-0327...
  • Page 410 Special tools [36] Feeler 80.99605-0197 S Removing and installing the rocker arm mechanism S Removing and installing the crankshaft [37] Measuring plate 80.99605-0289 S Removing and installing the cylinder head S Removing and installing the cylinder liners [38] Support 80.99606-0551 S Removing and installing the cylinder head S Removing and installing the flywheel S Removing and installing the crankshaft...
  • Page 411 Special tools [43] Thrust piece 80.99606-0655 S Removing and installing the injector with nozzle [44] Holder 80.99606-0641 S Removing and installing the cylinder head S Removing and installing the flywheel S Removing and installing the crankshaft [45] Eye-bolt 80.99606-0660 S Removing and installing the crankshaft [46] Guide plate 80.99606-0703...
  • Page 412 Special tools [51] Piston ring compressor pliers 80.99613-0040 S Removing and installing the piston and conrod [52] Holder 80.99613-0050 S Removing and installing the valve stem seals [53] Holder 80.99613-0051 S Removing and installing the valve stem seals [54] Valve spring compressor 80.99613-6000 S Removing and installing the valve stem seals [55]...
  • Page 413 Special tools [58] Detachable handle 80.99617-0187 S Removing and installing the front radial shaft seal S Removing and installing the rear radial shaft seal [59] Aligning tool 80.99617-0220 S Removing and installing the rear timing gears S Removing and installing the rear radial shaft seal S Removing and installing the flywheel S Removing and installing the crankshaft [60]...
  • Page 414 Special tools [65] Gear ratchet 80.99627-0001 S Removing and installing the starter S Removing and installing the valve stem seals S Checking and adjusting the valve clearance S Checking the valve timing S Removing and installing the vibration damper [66] Magnetic pickup 80.99639-0009 S Removing and installing the injector with nozzle...
  • Page 415 Special tools [72] Protective sleeve, injector nozzle 81.96002-0522 S Removing and installing the injector with nozzle [73] Injector inlet hole cap 81.96002-0523 S Removing and installing the injector with nozzle [74] End plug 81.96002-0541 S Removing and installing the injector with nozzle [75] Protective sleeve Z 18 x 15 81.96002-0555...
  • Page 416 Special tools [79] Special spanner 80.99603-6029 S Removing and installing the generator/alternator [80] Grip end 08.06460-0002 S Removing and installing the generator/alternator [81] Puller 80.99601-6022 S Removing and installing the injector with nozzle (common rail) [82] Protective sleeve Z 16 x 8 81.96002-0513 S Removing and installing the fuel lines [83]...
  • Page 417 Special tools [86] Valve adjustment spanner size 14 80.99603-6031 S Checking and adjusting the valve/valves [87] Hand pump 80.99620-0029 S Checking the high-pressure system for leaks [88] Adapter 80.99620-0033 S Checking the high-ressure system for leaks [89] Threaded connection 81.98130-0614 S Checking the high-pressure system for leaks AE6 Stage 2 2st edition...
  • Page 418 Special tools AE6 Stage 2 2st edition...
  • Page 420 MAN Truck & Bus AG Dachauer Str. 667 80995 München Postfach 500620 80976 München Germany A MAN Group company Printed in Germany 51.99598-8262...

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