CLAAS Forage Harvesters D2862 LE131-138 MAN Industrial Diesel Engines Repair Manual - PDF DOWNLOAD

Repair Manual

MAN Industrial Diesel Engines D2862 LE131-138 MAN Engines

A Division of MAN Truck & Bus

Repair Manual 1st edition

MAN Industrial Diesel Engines

D2862 LE131-138

51.99598-8364 Version 993.1

Editorial and publishing information MAN Truck & Bus Vogelweiherstrasse 33 90441 Nuremberg Telephone +49 911 / 420-1745 Fax +49 911 / 420-1932 Engine-Documentation@man.eu www.man-engines.com 06/2015 © 2015 MAN Truck & Bus Subject to change without prior notice. Not to be reprinted, duplicated by any means whatsoever or translated – in whole or in part – without the prior written approval of MAN Truck & Bus AG. All rights deriving from copyright law are expressly reserved by MAN.

51.99598-8364

Index of contents Repair Manual

1 2

3 3.1 3.1.1

3.1.2 3.2 3.2.1 3.3 3.3.1 3.3.2 4 4.1 4.1.1

4.1.2

4.1.3 4.2 4.2.1

4.2.2

Preface ....................................................................................................................................

7 1.1 Preface ...............................................................................................................................

7 Safety instructions .................................................................................................................

9 2.1 Explanation of icons ...........................................................................................................

9 2.2 General ...............................................................................................................................

9 2.3 Requirements of personnel ................................................................................................ 10 2.4 Regulations to prevent accidents with personal injury ....................................................... 10 2.5 Regulations for avoiding injury and environmental contamination ....................................

12 2.6 Liability limitations for replacement parts and accessories ...............................................

12 2.7 Guidelines for preventing damage and premature wear on the engine ............................. 13 2.8 Limp-home program for engines with an electronic control unit .......................................

13 2.9 Information for working on the common rail system .......................................................... 14 2.10 Handling DEF ...................................................................................................................

15 2.11 Engine overhaul ................................................................................................................ 15 2.12 Assembly information ....................................................................................................... 16 Engine electrical system ........................................................................................................ 17 Switch, cable harness, sensors ............................................................................................

17 Cable harnesses, plug connector, vertical ........................................................................... 17 3.1.1.1 Removing/installing the charge pressure sensor .........................................................

17 3.1.1.2 Removing/installing the EDC fuel temperature sensor ................................................

19 3.1.1.3 Removing/installing the pressure sensor .....................................................................

21 3.1.1.4 Removing/installing the rail pressure sensor/transmitter (common rail) .....................

24 3.1.1.5 Removing/installing the oil pressure sensor (left) ......................................................... 28 3.1.1.6 Removing/installing the oil pressure sensor (right) ....................................................... 30 3.1.1.7 Removing/installing the engine oil temperature sensor ............................................... 33 3.1.1.8 Removing/installing the coolant temperature sensor ................................................... 36 3.1.1.9 Removing/installing the crankshaft speed sensor .......................................................

39 3.1.1.10 Removing/installing the camshaft speed sensor .......................................................

42 Other electrical devices ......................................................................................................... 45 3.1.2.1 Removing/installing EDC control unit (Electronic Diesel Control) ................................

45 Measurement and display devices, sensors ........................................................................ 50 Temperature and diameter ....................................................................................................

50 Electric machines, devices .................................................................................................... 51 Three-phase alternator .......................................................................................................... 51 3.3.1.1 Removing/installing the alternator ................................................................................ 51 Starter motor ..........................................................................................................................

56 3.3.2.1 Removing/installing the starter/starter motor .............................................................. 56 Engine ...................................................................................................................................... 61 Cooling system (water cooling) ............................................................................................. 61 Coolant line ............................................................................................................................. 61 4.1.1.1 Removing/installing the coolant pump coolant manifold ............................................. 61 4.1.1.2 Removing/installing the air compressor coolant line ...................................................

63 4.1.1.3 Removing/installing the coolant manifold on the engine block (left) ............................ 67 4.1.1.4 Removing/installing the coolant manifold on the engine block (right) .........................

70 4.1.1.5 Removing/installing the coolant line for the heater supply ..........................................

74 4.1.1.6 Removing/installing the coolant line on the cylinder head (left) ................................... 76 4.1.1.7 Removing/installing the coolant line on the cylinder head (right) ................................. 79 Coolant temperature control, thermostat ............................................................................ 83 4.1.2.1 Removing/installing the thermostat housing coolant manifold ................................... 83 4.1.2.2 Removing/installing the thermostat housing ............................................................... 85 4.1.2.3 Removing/installing the thermostat insert .................................................................... 89 Coolant pump components ................................................................................................... 94 4.1.3.1 Removing/installing the coolant pump ......................................................................... 94 Exhaust, intake manifold, air filter ........................................................................................ 97 Intake pipe, intake manifold components ............................................................................ 97 4.2.1.1 Removing/installing the charge-air manifold/air distributor pipe ................................

97 4.2.1.2 Removing/installing the intake manifold/air distributor pipe (left) ................................ 100 4.2.1.3 Removing/installing the intake manifold/air distributor pipe (right) .............................. 103 Exhaust manifold components ............................................................................................. 107

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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Index of contents

4.3 4.3.1 4.3.2

4.3.3 4.3.4 4.4 4.4.1 4.5 4.5.1

4.5.2 4.5.3 4.5.4 4.5.5 4.6 4.6.1

4.6.2 4.6.3 4.6.4

4.6.5

4.2.2.1 Removing/installing the turbocharger exhaust pipe connector (left) ...........................

4.2.2.2 Removing/installing the turbocharger exhaust pipe connector (right) .........................

4.2.2.3 Removing/installing the exhaust manifold (left) ............................................................

4.2.2.4 Removing/installing the exhaust manifold (right) .........................................................

4.2.2.5 Dismantling/assembling the exhaust manifold ............................................................

Engine control .........................................................................................................................

Valve / valves ...........................................................................................................................

4.3.1.1 Checking/adjusting valve/valves ..................................................................................

4.3.1.2 Removing/installing the valve stem seals ....................................................................

Rocker arm components .......................................................................................................

4.3.2.1 Checking the rocker arm ..............................................................................................

4.3.2.2 Removing/installing the rocker arm mechanism ..........................................................

4.3.2.3 Dismantling/assembling the rocker arm mechanism ...................................................

4.3.2.4 Checking the rocker arm bracket .................................................................................

Camshaft components ...........................................................................................................

4.3.3.1 Removing/installing the camshaft ................................................................................

Camshaft drive ........................................................................................................................

4.3.4.1 Checking the valve timing ...........................................................................................

4.3.4.2 Removing/installing the camshaft gear ........................................................................

Cylinder head ..........................................................................................................................

4.4.1 Removing/installing the cylinder head ............................................................................

Cylinder head cover components .........................................................................................

4.4.1.1 Removing/installing the cylinder head cover ...............................................................

Engine lubrication, automatic clean oil replenisher ............................................................

Oil filter ....................................................................................................................................

4.5.1.1 Removing/installing the oil filter insert .........................................................................

4.5.1.2 Removing/installing the oil module (left) ......................................................................

4.5.1.3 Removing/installing the oil module (right) ....................................................................

4.5.1.4 Dismantling/assembling the oil module .......................................................................

Oil cooler .................................................................................................................................

4.5.2.1 Removing/installing the heat exchanger/engine oil cooler ..........................................

Oil pipe, intake basket, oil screen .........................................................................................

4.5.3.1 Removing/installing the oil pump suction line manifold ...............................................

4.5.3.2 Removing/installing the oil pump suction line/intake pipe ...........................................

Oil intake and return pump ....................................................................................................

4.5.4.1 Removing/installing the oil pump ................................................................................

Oil sump and automatic clean oil replenisher .....................................................................

4.5.5.1 Removing/installing the oil sump ................................................................................

4.5.5.2 Dismantling/assembling the oil sump ..........................................................................

Crankshaft drive .....................................................................................................................

V-belt drive ..............................................................................................................................

4.6.1.1 Removing/installing the alternator V-belt .....................................................................

4.6.1.2 Removing/installing the automatic belt tensioner ........................................................

4.6.1.3 Removing/installing the ribbed V-belt guide roller .......................................................

Vibration damper components ..............................................................................................

4.6.2.1 Removing/installing the vibration damper ....................................................................

Flywheel components ............................................................................................................

4.6.3.1 Removing/installing the flywheel ..................................................................................

4.6.3.2 Removing/installing flywheel ring gear .........................................................................

Crankshaft components, engine barring gear .....................................................................

4.6.4.1 Mounting/removing the engine cranking unit ...............................................................

4.6.4.2 Coolant pump crankshaft gear .....................................................................................

4.6.4.3 Removing/installing the coolant pump intermediate gear ............................................

4.6.4.4 Dismantling/assembling the coolant pump intermediate gear .....................................

4.6.4.5 Removing/installing the crankshaft gear (front) ............................................................

4.6.4.6 Removing/installing the crankshaft gear (rear) .............................................................

4.6.4.7 Removing/installing the crankshaft ..............................................................................

4.6.4.8 Checking the crankshaft ..............................................................................................

Piston components ................................................................................................................

4.6.5.1 Checking the piston protrusion ....................................................................................

4.6.5.2 Removing/installing the piston with connecting rod ....................................................

4.6.5.3 Dismantling and assembling the piston with connecting rod ......................................

4.6.5.4 Checking the piston with connecting rod ....................................................................

107 108 110 112 114 117 117 117 122 129 129 131 133 135 137 137 142 142 144 147 147 155 155 159 159 159 161 165 169 176 176 178 178 179 182 182 185 185 188 191 191 191 192 194 197 197 201 201 207 210 210 211 213 215 217 219 220 237 241 241 242 248 250

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Index of contents 4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6

4.8 4.8.1 4.8.2 5 5.1 5.1.1

5.1.2

5.2 5.2.1

5.2.2 5.3 5.3.1

5.3.2 5.4 5.4.1 5.4.2 6 6.1

Engine housing .......................................................................................................................

Front plate and timing case components ............................................................................

4.7.1.1 Removing/installing the end cover ...............................................................................

Flywheel housing, engine flange ...........................................................................................

4.7.2.1 Removing/installing the flywheel housing ....................................................................

4.7.2.2 Dismantling/assembling the flywheel housing .............................................................

Housing sealing components ................................................................................................

4.7.3.1 Removing/installing the rear crankshaft radial shaft seal .............................................

4.7.3.2 Removing/installing the front crankshaft radial shaft seal ...........................................

Cylinder liners .........................................................................................................................

4.7.4.1 Removing/installing the cylinder liner ..........................................................................

Piston spray cooling ...............................................................................................................

4.7.5.1 Removing/installing the oil nozzle ................................................................................

Vent with filter and oil filler neck ...........................................................................................

4.7.6.1 Removing/installing the crankcase ventilation (left) .....................................................

4.7.6.2 Removing/installing the crankcase ventilation (right) ...................................................

4.7.6.3 Removing/installing the crankcase ventilation oil separator (left) ................................

4.7.6.4 Removing/installing the crankcase ventilation oil separator (right) ..............................

Turbocharging .........................................................................................................................

Intake manifold .......................................................................................................................

4.8.1.1 Intake fitting, left turbocharger .....................................................................................

4.8.1.2 Intake fitting, right turbocharger ...................................................................................

Exhaust turbine, oil pipe ........................................................................................................

4.8.2.1 Removing/installing the turbocharger (left) ..................................................................

4.8.2.2 Removing/installing the turbocharger (right) ................................................................

Fuel / exhaust system ............................................................................................................

Fuel system components .......................................................................................................

Fuel filter .................................................................................................................................

5.1.1.1 Removing/installing the fuel filter insert .......................................................................

5.1.1.2 Removing/installing the fuel service center .................................................................

5.1.1.3 Dismantling/assembling the fuel service center ...........................................................

Fuel lines .................................................................................................................................

5.1.2.1 Removing/installing the fuel line ...................................................................................

5.1.2.2 Removing/installing the fuel return line (left) ................................................................

5.1.2.3 Removing/installing the fuel return line (right) ..............................................................

Injection nozzle .......................................................................................................................

Pressure line, injector nozzle components ..........................................................................

5.2.1.1 Removing/installing the pump - rail CR pressure line ..................................................

5.2.1.2 Removing/installing the injection pressure line (left) ....................................................

5.2.1.3 Removing/installing the injection pressure line (right) ..................................................

5.2.1.4 Removing/installing the rail (left) ..................................................................................

5.2.1.5 Removing/installing the rail (right) ................................................................................

5.2.1.6 Removing/installing the common rail pressure-limiting valve ......................................

Injector nozzle components ..................................................................................................

5.2.2.1 Removing/installing the injector with nozzle (common rail) .........................................

Injection pump (actuation) .....................................................................................................

Injection pump, check valve ..................................................................................................

5.3.1.1 Removing/installing the high pressure pump (front) .....................................................

5.3.1.2 Removing/installing the high pressure pump (rear) ......................................................

5.3.1.3 Dismantling/assembling the high-pressure pump .......................................................

5.3.1.4 Removing/installing the high-pressure pump drive housing ........................................

5.3.1.5 Dismantling and assembling the high-pressure pump drive housing .........................

Control unit console ...............................................................................................................

5.3.2.1 Removing/installing the cooling plate/console for the control unit (EDC) ....................

Engine attachments ...............................................................................................................

Alternator attachment components .....................................................................................

5.4.1.1 Removing/installing the alternator bracket ..................................................................

Engine suspension .................................................................................................................

5.4.2.1 Removing/installing the crane lifting eye / engine lifting eye .......................................

Air compressor, pressure control valve ................................................................................

Air compressor, line ...............................................................................................................

6.1.1 Removing/installing the air compressor (single cylinder) ................................................

6.1.2 Dismantling/assembling air compressor (single cylinder) ...............................................

257 257 257 259 259 260 265 265 269 273 273 278 278 280 280 281 283 285 288 288 288 289 293 293 298 307 307 307 307 310 313 320 320 331 335 340 340 340 345 350 355 359 363 367 367 376 376 376 379 383 390 392 398 398 401 401 401 403 403 407 407 407 411

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5

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Index of contents

7 7.1 8 8.1 9 9.1

6.1.3 Removing/installing the air compressor cap ...................................................................

Power take-off ........................................................................................................................

Engine-dependent power take-off components .................................................................

7.1.1 Removing/installing the PTO cover .................................................................................

Hydraulic power steering components, engine suspension ..............................................

Engine suspension .................................................................................................................

8.1.1 Removing/installing the engine bracket (left) ..................................................................

8.1.2 Removing/installing the engine bracket (right) ................................................................

Hydraulics, air-conditioning system working devices ........................................................

Air-conditioning ......................................................................................................................

9.1.1 Removing/installing the refrigerant compressor .............................................................

Indexes .....................................................................................................................................

Special tools .............................................................................................................................

422 425 425 425 427 427 427 428 431 431 431 435 435

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

1 Preface 1.1 Preface Preface This repair manual is intended to provide assistance in performing repairs correctly on vehicles and units.

The technical details were correct at the time of going to press.

This publication assumes that persons who use it possess the requisite technical knowledge in handling vehicles and units.

Pictures and the corresponding descriptions are typical snapshots; they do not always correspond to the unit in question or its peripherals, but this does not necessarily mean they are incorrect. In cases such as these, plan and execute the repair measures accordingly.

Repair work on complex attachment units should be entrusted to our customer service or to the customer service of the manufacturing company. These units are mentioned specifically in the text.

The repair jobs are divided up into sections and subsections. Each subsection starts with a page of jobs to do in advance. The jobs to do in advance contain a summary of the main prerequisites for the repair section in question. A detailed description of work can follow the jobs to do in advance.

Important instructions concerning technical safety and the safety of personnel are specifically highlighted, as indicated below.

DANGER ... describes an imminently hazardous situation that will lead to serious or fatal injuries if it is not avoided.

For this reason: •

WARNING ... describes a potentially hazardous situation that could lead to serious or fatal injuries if it is not avoided.

For this reason: •

CAUTION ... describes a potentially hazardous situation that could lead to minor or slight injuries if it is not avoided.

For this reason: •

NOTICE ... describes a potentially hazardous situation that could lead to material damage if it is not avoided.

For this reason: • Comply with general safety regulations when performing any repair work.

Subject to technical alterations.

Yours faithfully, MAN Truck & Bus AG

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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1 Preface

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

2 Safety instructions 2.1 Explanation of icons Warnings Warnings in this guide are identified by icons. The information has been introduced with signal words that express the extent of risk or danger.

Follow the instructions in all cases and proceed with care in order to prevent accidents, personal injury and material damage.

DANGER Describes an immediate dangerous situation that will lead to severe injuries or death if it is not avoided.

For this reason: •

WARNING Describes a potentially dangerous situation that may lead to severe injuries or death if it is not avoided.

For this reason: •

CAUTION Describes a potentially dangerous situation that may lead to minor or moderate injuries if it is not avoided.

For this reason: •

NOTE Describes a potentially dangerous situation that may lead to damage to property if it is not avoided.

For this reason: •

Tips and Recommendations Tip for users Tips and recommendations as well as information for efficient and trouble-free operation.

ENVIRONMENTAL NOTE Tips on conduct for environmental protection.

General information • This symbol indicates a listing at the first level. ►This symbol displays an action or series of actions.

1 This symbol displays the position of a graphic in the text.

[1] This symbol displays the position of a special tool in the text.

2.2 General Only personnel with the proper training are permitted to perform maintenance or repair work on the engine.

The present manual must be read and understood carefully and completely.

The instructions refer to an engine in a removed¹ and dry² condition.

The safety regulations of the overall system must also be observed when working on the installed engine.

These are not included in the present manual.

The engine must be located on a suitable device, e.g. the assembly device of MAN Truck & Bus AG. Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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2 Safety instructions The assembly device can be obtained from a contact of MAN Truck & Bus AG. The following sections include summaries of important regulations, listed according to major topics. The intention is to provide the knowledge needed to avoid accidents which could lead to injury, damage and environmental pollution. Please note that these are merely brief extracts taken from various accident prevention regulations and cannot replace them. Naturally, all other safety regulations must be observed and the appropriate measures taken.

Additional direct references to danger are contained in the instructions at points where there is a potential danger.

Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality, obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes, crushing of limbs, etc. ¹The engine is located on a suitable assembly device. ²There are no fluids (e.g. lubricant, coolant) in the engine

2.3 Requirements of personnel Qualifications • each trained person has been instructed by qualified personnel about the tasks assigned to him/her and the potential dangers of working on an engine.

• Qualified personnel, by virtue of their professional training, knowledge and experience, as well as of their knowledge of the relevant provisions, are capable of undertaking the tasks assigned to them.

The personnel must be briefed and trained regularly. The training must be recorded for better tracking of the training.

MAN Truck & Bus regularly provides product and application training. These training sessions can provide the necessary expertise.

Contact information for the MAN Engine Academy. k http://www.engines.man.eu/global/de/ueber-man-engines/man-engine-academy/Themen.html

2.4 Regulations to prevent accidents with personal injury During inspection, adjustment and repair work • Secure units during their removal.

• Keep assemblies, ladders, steps, walkways and their surrounding areas free of oil and grease.

Accidents due to slipping may cause severe injuries.

• Checking, adjusting and repair measures may only be performed by authorized specialist personnel.

• The main battery switch must be switched off during installation work.

• When performing maintenance and repair work, ensure that the engine cannot be started inadvertently by unauthorized persons.

• Only authorized personnel are allowed to start and operate the engine.

• Do not use any tools that are not in perfect condition.

Operating the engine • • • •

Only authorized personnel are allowed to start and operate the engine.

Do not get too close to rotating parts when the engine is running. Wear close-fitting work clothes.

Ensure that there is adequate ventilation in enclosed spaces.

Do not touch equipment at operating temperature with bare hands. Risk of burns! Do not work with bare hands, especially when performing an oil change (units at operating temperature).

• Open the coolant circuit only after the engine has cooled.

• The tool must be approved by MAN and in good technical condition.

Suspended loads • Do not lift heavy parts with physical strength. Use suitable means.

Procedure: Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

2 Safety instructions • Carefully secure single components and component groups to the lifting equipment so that there is no danger.

• Only use suitable and serviceable lifting equipment and lifting gear with a sufficient load rating.

• Only lift the engine from the provided lifting eyes using the crane lifting gear.

• Persons are not allowed to stand below an engine hanging from a crane hook. Keep the lifting gear in order.

Bodies and special bodies • Comply with the safety instructions and regulations issued by the body manufacturer in question if bodies or special bodies are fitted.

Working on high-pressure lines • Do not attempt to tighten, loosen or open pipes and hoses (e.g. in the lubrication circuit, coolant circuit and hydraulic oil circuit) whilst they are pressurized: Risk of injury from escaping liquids!

Work on the electrical system • • • • • • • • • • • •

Only start units when the batteries are properly connected.

Do not disconnect batteries whilst the engine is running.

Only start units when they are completely connected to the electronic control system.

Do not use a quick-charger to start the unit. Use only separate batteries as a starting aid.

The battery terminals must be removed to quick-charge the batteries.

Observe the quick-charger's Operating Instructions.

For arc welding work, the batteries must be disconnected and both cables (+ and -) firmly connected with each other.

The connections of the control units may only be disconnected/connected when the electrical system is switched off.

Reversal of the control-unit supply-voltage polarity (e.g. if batteries are connected with the polarity reversed) can cause irreparable damage to the control units.

Screw on the connections on the injection system using the prescribed tightening torques.

At expected temperatures above 80 °C (e.g. in a drying oven), the control units must be removed.

Use only matching test lines for measurements at plug connectors.

Telephones and radios that are not connected with an outside aerial can lead to a vehicle electronics malfunction. This represents a threat to the operational safety of the unit.

Important: battery gases are explosive!

• Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after the engine has been running for an extended period or after charging the batteries with a battery charger.

• Avoid short circuits caused by polarity reversal or by placing metal objects (spanners, pliers, etc.) on the battery terminals.

• Disconnect the batteries of disabled engines or recharge them every 4 weeks.

• When the batteries are disconnected, gas may be ignited by sparks produced by other continuously operating consumers that are not shut down. Before disconnecting, ventilate the battery box sufficiently!

Caution! Battery acid is poisonous and corrosive.

• Please observe the manufacturer's specifications.

• Wear suitable protective clothing (gloves) when handling batteries. Do not tip or tilt batteries as acid may emerge.

• Only measure voltage with suitable measuring devices! The input resistance of the measurement device must be at least 10 MΩ.

• Disconnect or connect the cable harness connectors of electronic control units only when the ignition is switched off.

Electric welding • Please observe the welding instructions.

• Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN part number 80.78010.0002) as described in the instructions accompanying the device Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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2 Safety instructions • If this device is not available, disconnect the batteries and firmly connect the positive lead to the negative lead so that a conductive circuit is created.

• Always place the ground of the welding equipment as close as possible to the welding location. Do not lay welding equipment cable in parallel to the electrical cables in the vehicle.

• When carrying out welding tasks in the immediate vicinity of control units, the plug connectors must be disconnected. In doing so, observe the instructions and regulations contained in the section EDC Control Units.

Painting • If paint spraying is to be carried out, do not expose the electronic components to high temperatures (max. 95 °C) for more than brief periods; a time of up to 2 hours is permissible at a maximum of 85 °C. • Disconnect the batteries.

• Remove sensitive electrical components.

• Painting of bolt connections in the high-pressure section of the injection system is not permitted. Risk of dirt ingress in the event of repairs

Work on plastic tubes – risk of damage and fire • Plastic tubes must not be subject to mechanical or thermal load.

2.5 Regulations for avoiding injury and environmental contamination Preventative measures to protect your health • Avoid extended, excessive or repeated skin contact with service products, process materials, diluting agents and solvents.

• Protect the skin using a suitable skin protection agent or protective gloves.

• Do not use service products, auxiliary substances, thinners or solvents to clean the skin.

• Wash contaminated skin thoroughly with soap and water.

• Special cleaning agents make it easier to clean dirty hands.

• Apply a greasy skin cream after cleaning skin.

• Change out of clothing or shoes which have become soaked with oil.

• Never put oil-soaked rags into your clothing pockets.

Coolant Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority when disposing of used coolant (mixture of antifreeze and water).

Cleaning the cooling circuit Do not pour cleaning fluids and rinsing water down the drain when this practice is restricted by specific local regulations. However, the cleaning fluid and rinsing water must, in all cases, be passed through an oil separator with a sludge trap.

Cleaning the filter insert When blowing compressed air through the filter insert, make sure the filter dust is collected by an extractor system, or is blown into a dust collection bag. Otherwise, use a respiratory protection mask.

Wear suitable rubber gloves or use a skin barrier cream when washing out the element, because cleaning agents have aggressive grease-dissolving characteristics.

Engine oil, transmission oil, filter cartridges, inserts and box-type filters, desiccant cartridges Filter inserts, cartridges and box-type filters (oil and fuel filters, desiccant cartridges for the air dryer) are classified as hazardous waste materials. Please observe instructions issued by the relevant local authority on the disposal of the parts mentioned above.

Used engine oil and transmission oil Lengthy or repeated skin contact with any type of engine oil or transmission oil removes grease from the skin. This can cause dry skin, irritation or skin inflammation. In addition to these hazards, used engine oil contains dangerous materials which can trigger dangerous skin diseases. It is particularly important to wear gloves during an oil change.

2.6 Liability limitations for replacement parts and accessories Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

2 Safety instructions General All information and instructions in this manual have been compiled taking into consideration the applicable standards and regulations, the state-of-the-art technology as well as our knowledge and experience acquired over a period of several years.

MAN does not assume any liability for damage caused as a result of: • • • • • •

Non-observance of this manual Use that is not in accordance with specifications Use of untrained personnel Unauthorized alterations Technical changes Use of non-approved spare parts and service products

In case of special designs, the actual scope of supply, the use of additional ordering options or on account of the latest technical modifications may vary from the explanations and illustrations described here.

The obligations agreed upon in the delivery agreement and the General Terms and Conditions of Business of MAN Truck & Bus shall apply in addition to the statutory regulations valid at the time of the conclusion of the contract.

2.7 Guidelines for preventing damage and premature wear on the engine General • The engine is built exclusively for the application corresponding to the scope of supply -as defined by the equipment manufacturer- (designated use).

• The intended use also includes compliance with the operating and maintenance conditions defined by the manufacturer. The engine must only be used, maintained and repaired by personnel who are acquainted with it and have been instructed about any potential dangers.

• The manufacturer does not assume any liability for damage resulting from unauthorised modifications to the engine.

Manipulation of the injection and control system may also affect the performance and exhaust-gas values of the unit. Compliance with legal environmental regulations would then no longer be guaranteed.

• If malfunctions occur, determine the cause and remedy the problem immediately so that no serious damage occurs.

• Clean the engine thoroughly before repairing. Ensure that no dirt, sand or foreign objects get into the unit during repair work.

• Only use original spare parts. Installation of parts of by other manufacturers can sometimes cause major damage, for which the workshop carrying out the repair bears the responsibility. Follow the instructions in the section on Limitation on Liability for Accessories and Parts.

• Never run an engine dry, i.e. always make sure that it has been filled with lubricating oil before running it.

• Never run engines that have not been filled with coolant beforehand.

• Use a suitable information sign to clearly indicate units that are not ready to be operated.

• Use service products only in accordance with MAN regulations; otherwise the manufacturer's warranty is rendered void.

For basic information concerning service products, see the publication "Service Products for MAN Diesel Engines".

You can find approved products on the Internet at: k https://my.man-mn.com/portal/irj/asp • Do not replenish engine oil/transmission oil above the max. mark. Do not exceed the maximum permitted operational tilt.

• Non-observance can result in serious damage to the engine.

2.8 Limp-home program for engines with an electronic control unit General information Engines have an electronic control system that monitors the engine as well as itself (self-diagnosis).

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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2 Safety instructions As soon as there is a malfunction, the malfunction is evaluated and one of the following measures is initiated: • Output of a fault message with a diagnostic memory entry.

• Changeover to suitable, yet limited operation. Have malfunctions rectified immediately by MAN Customer Service.

• If MAN-cats® is used, the diagnostic memory entry is output directly.

2.9 Information for working on the common rail system General • A jet of fuel can penetrate the skin. Atomised fuel represents a fire hazard.

• Never loosen the bolt connection on the fuel high-pressure side of the common rail system when the engine is running (high-pressure line from the high-pressure pump to the rail, at the rail and on the cylinder head to the fuel injector). Whilst the engine is running, the lines are constantly carrying fuel under a pressure of 1600 bar or more. Wait for at least one minute before undoing bolt connections to allow the pressure to drop. MAN-cats® must be used to check that the system is depressurized at the rail.

• Do not remain in the vicinity of the engine when it is running.

Information for individuals with pacemakers • Any changes made to the original engine cabling can result in the limit values specified in pacemaker safety regulations being exceeded, e.g. non-twisted injector cables or installing the test box (bushing box).

• There is no danger to the driver or any passengers with pacemakers, in approved operation.

• Vehicle operators with heart pacemakers are not at risk from systems with MAN Common Rail engines, in approved operation.

• The product, in its original condition, complies with all the currently known limit values for heart pacemakers.

Special information for people with pacemakers • Any changes made to the original engine cabling can result in the limit values specified in pacemaker safety regulations being exceeded, e.g. non-twisted injector cables or installing the test box (bushing box).

• Wearers of pacemakers must remain a minimum of 20 cm from the running engine.

Risk of damage due to ingress of dirt • The components of the diesel fuel-injection system consist of high-precision parts that are subjected to extreme loads. Owing to this high level of precision engineering, strict rules of cleanliness must be followed when working on the fuel system.

• Even particles of dirt as small as 0.002 mm can cause component failure.

• The engine and engine compartment must be cleaned (steam cleaned) before work is performed on the clean side of the fuel system. The fuel system must be closed when cleaning takes place.

• Perform a visual inspection for leaks or damage to the fuel system.

• Do not aim jet of steam cleaner at electrical components, or fit covers to protect them.

• Place the engine in a clean area of the workshop where none of the work causes dust to be swirled up (sanding, welding, brake repairs, brake checks, performance tests etc.).

• Avoid air movements (possible swirling up of dust due to starting of engines, the workshop heating / ventilation system, due to draughts etc.).

• The area of the still closed fuel system must be cleaned and dried by means of compressed air.

• Use a suitable extractor unit (industrial extractor unit) to remove loose dirt particles such as paint chippings and insulating material.

• Use a new and clean cover in areas of the engine compartment where dirt particles can become loose.

• Before starting disassembly, wash your hands and put on a clean working overall.

• After the clean-side fuel system has been opened, it is not permitted to use compressed air for cleaning.

• Only lint-free cleaning cloths are allowed to be used on the fuel system.

• Clean tools and working equipment before starting work.

• Only tools that show no sign of damage (e.g. cracked chromium plating) must be used.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

2 Safety instructions • Materials such as cloths, cardboard or wood must not be used when removing and fitting components, as particles and fibres may become detached from such materials.

• If paint flakes should be produced when loosening connections (e.g. due to painting over the connections), these must be carefully removed before the bolt connection is finally undone.

• All removed components on the clean side of the fuel system must be plugged immediately at their connection openings using suitable caps.

• These sealing parts must remain packaged dust-tight until use and must be disposed of after being used once.

• The components must then be stored carefully in a clean, closed container.

• Never expose these components to used cleaning or testing fluids.

• New parts must only be taken out of the original packaging immediately before use.

• Work on removed components must be performed only at a work place equipped for this purpose.

• If removed parts are shipped, always use the original packaging of the new part.

2.10 Handling DEF DEF is a 32.5% urea solution that is used for NOx reduction in the SCR catalytic converter. The DEF used must conform with standard ISO 22241. Observe the DEF safety data sheets.

In the event of contact with DEF, immediately take suitable measures: • Eye contact: Immediately rinse the entire eye with clean water continuously for at least 15 minutes.

Prior to that, the eye should be checked for contact lenses. If the eye has a contact lens, please remove it first. Seek medical attention immediately in the event of physical symptoms.

• Skin contact: Wash areas concerned thoroughly with soap and water. Seek medical attention immediately in the event of physical symptoms.

• If swallowed: Do not induce vomiting. Seek immediate medical assistance.

• Contaminated clothing: Immediately change clothes and wash any areas on skin that have come into contact thoroughly with soap and water.

When opening components containing DEF, small amounts of ammonia fumes can escape. Do not inhale the ammonia fumes. Ammonia fumes are especially irritating to the eyes, mucous membranes and skin. The working area should be well-ventilated.

DEF has a corrosive effect on many materials. Clean components concerned thoroughly with water or a suitable cleaning agent.

Unintended release of DEF: • Small amounts: Absorb with liquid-binding material. Dispose of binding agent in the correct manner.

• Prevent large amounts from entering water drain facilities or the ground. If large amounts cannot be intercepted, the local authorities must be notified.

The storage temperature of DEF should not exceed 25°C. Storage should take place in well-ventilated and liquid-tight locations.

2.11 Engine overhaul General information on performing an engine overhaul A range of very different factors affect the engine service life. It is therefore not possible to indicate the exact number of operating hours before a major overhaul is due.

We are of the opinion that opening an engine or performing a general overhaul is not required, as long as the engine has good compression values and the following operating values do not deviate considerably from those determined at start-up.

• • • • •

Charging pressure Exhaust gas temperature Coolant and lubricating oil temperatures Oil pressure and oil consumption Smoke behavior

The following criteria have considerable influence on the engine's service life: • Correct performance setting according to deployment • Correct installation Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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2 Safety instructions • Approval of the installation by authorised personnel • Regular maintenance according to the maintenance schedule • For the selection and quality of lubricating oil, fuel and coolant, please see the publication "Service products for MAN diesel engines"

2.12 Assembly information Assembly information Fitting nuts and bolts • Lightly lubricate nuts and bolts on the threading and the contact surface of the bolt head.

• Refer to the reference values in works standard M 3059 for screw connections without specially prescribed tightening torques

Installation of micro-encapsulated bolts • Comply with the application guidelines in works standard MAN 222 when using micro-encapsulated bolts.

Reuse of bolts and nuts • Check bolt heads, threads and nuts for wear and ease of movement, replace if necessary • Only reuse bolts and nuts if they are not worn!

Installing pipe assemblies Danger: Pipes of all kinds may not be bent! - Danger of breakage!

Mounting gaskets • Only use MAN genuine gaskets • Make sure that the areas to be sealed are undamaged and clean.

• Do not use adhesives or sealing compounds. If necessary, to facilitate installation, use a little grease to stick the gasket to the part to be mounted.

• Tighten bolts evenly to prescribed tightening torque.

Mounting O-rings • Only use MAN genuine O-rings.

• Make sure that the areas to be sealed are undamaged and clean.

• Generally apply engine oil on O-rings as per MAN Standard 3277 for installation.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors 3.1.1

Cable harnesses, plug connector, vertical

3.1.1.1 Removing/installing the charge pressure sensor

key

1 Charge pressure sensor 2 Mounting bolt 3 Charge-pressure sensor electrical connection

Technical data Tightening torques Charging pressure sensor mounting bolt on air M6 x 16 - 10.9................................. ................ 8 +2 Nm manifold...................................................................

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Restricted operation due to incorrect entries in the diagnostic memory.

• Before removing switches or sensors, read out and document the fault memory.

• Always install switches and sensors with new O-rings or seals.

• After installing switches or sensors, read out the fault memory and delete it, if necessary.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors Special tools 1

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing the charging pressure sensor Disconnecting the charging pressure sensor electrical connection ►Free the cable ►Unlock and remove electrical connection 1 by pressing the spring shackle

Removing the charging pressure sensor ►Unscrew the mounting bolts 1 ►Pull the charging pressure sensor 2 out ►Remove the O-ring from the charge pressure sensor 2 ►Clean the sealing surfaces

Installing the charging pressure sensor Installing the charging pressure sensor ►Fit the new O-ring on the charge pressure sensor 2 ►Insert the charging pressure sensor 2 ►Screw in and tighten the mounting bolts 1 Charging pressure M6 x 16 - 10.9 ..... 8 +2 Nm sensor mounting bolt ...................... on air manifold.............

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors

Connecting the charging pressure sensor electrical connection ►Restore the electrical connection 1, pushing until the spring shackle engages ►Check that the electrical connection has engaged by pulling carefully, re-fit it if necessary ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [1]

3.1.1.2 Removing/installing the EDC fuel temperature sensor

key

1 Fuel temperature sensor 2 Connect the electrical connection for the fuel temperature sensor

Technical data Tightening torques Fuel temperature sensor.......................... M16 x 1.5.............................................. ........................ 45 +5 Nm

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Restricted operation due to incorrect entries in the diagnostic memory.

• Before removing switches or sensors, read out and document the fault memory • Always install switches and sensors with new O-rings or sealing rings.

• After installing switches or sensors, read out the fault memory and, if necessary, delete it Special tools 1

End plug Quantity 1

81.96002-0556

2

Protective sleeve Quantity 1

81.96002-0555

3

Cable tie pliers Quantity 1

08.02960-0100

4

Plug housing wrench Quantity 1

80.99603-0418

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors

Removing the temperature sensor Disconnecting the temperature sensor electrical connection ►Free the cable ►Open the bayonet catch 1 using the wrench for plug housing [4] ►Remove the connector 1 from the pressure sensor 2

Removing the temperature sensor ►Unscrew the temperature sensor 1 and remove with the sealing ring 2 ►Close off the temperature sensor 1 with the protective sleeve [2] ►Use the end plug [1] to seal the connections ►Clean the sealing surfaces

Installing the temperature sensor Installing the temperature sensor ►Remove the protective sleeve and end plug ►Screw in and tighten the temperature sensor 1 with a new sealing ring 2 Fuel temperature M16 x 1.5...... ....... 45 +5 Nm sensor......................

Connecting the temperature sensor electrical connection ►Attach the electrical connection 1 to the pressure sensor 2 ►Close the bayonet catch 1 using the wrench for the plug housing [4] ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [3]

3.1.1.3 Removing/installing the pressure sensor Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors

key

1 Connect the electrical connection for the fuel pressure sensor 2 Fuel pressure sensor

Technical data Tightening torques Pressure sensor.................................. M18x1.5............................................. ................................ 45 +5 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Restricted operation due to incorrect entries in the diagnostic memory • Before removing switches or sensors, read out and document the fault memory.

• Always install switches and sensors with new O-rings or seals.

• After installing switches or sensors, read out the fault memory and delete it, if necessary.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors Special tools 1

End plug Quantity 1 GPN 330 L 18, closing the hole of the rail pressure sensor and the pressure-limiting valve in the pressure pipe in the common rail system

81.96002-0556

2

Protective sleeve Quantity 1 Z18 x 15, closing the pressure-limiting valve and the rail pressure sensor in the common rail system

81.96002-0555

3

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

4

Plug housing wrench Quantity 1 Disconnecting electrical plug connectors with bayonet catch

80.99603-0418

Removing the fuel pressure sensor Disconnecting the pressure sensor electrical connection ►Free the cable ►Open the bayonet catch 1 using the wrench for plug housing [4] ►Remove the connector 1 from the pressure sensor 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors

Removing the fuel pressure sensor ►Unscrew the pressure sensor 1 and remove with the sealing ring 2 ►Close off the pressure sensor 1 with the protective sleeve [2] ►Use the end plug [1] to seal the connections

Installing the fuel pressure sensor Installing the fuel pressure sensor ►Remove the protective sleeve [2] and end plug [1] ►Screw in and tighten the pressure sensor 1 with a new sealing ring 2 Pressure sensor. M18x1.5............ ......... 45 +5 Nm

Connecting the electrical connection for the pressure sensor ►Attach the electrical connection 1 to the pressure sensor 2 ►Close the bayonet catch 1 using the wrench for the plug housing [4] ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [3]

3.1.1.4 Removing/installing the rail pressure sensor/transmitter (common rail)

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors

key

1 Rail pressure sensor

Technical data Tightening torques Rail pressure sensor......................................M18x1.5.......................................... .............................. 80 Nm Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or check depressurization using a MAN-cats (desired value 0).

• The common rail system must be depressurized before starting work.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components will be damaged.

For this reason: • Work on the common rail system must be performed by specially trained personnel only.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Incorrectly tightened bolted connections cause component damage.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

Tip for users Installation of the left rail pressure sensor is the same as that of the right rail pressure sensor.

Special tools 1

Protective sleeve Quantity 1 Z18 x 15, closing the pressure-limiting valve and the rail pressure sensor in the common rail system

81.96002-0555

2

End plug Quantity 1 GPN 330 L 18, closing the hole of the rail pressure sensor and the pressure-limiting valve in the pressure pipe in the common rail system

81.96002-0556

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors Cable tie pliers Quantity 1 Tightening and cutting the cable ties

3

08.02960-0100

Removing the rail pressure sensor Disconnecting the rail pressure sensor electrical connection ►Free the cable ►Unlock and remove electrical connection of the rail pressure sensor 1 by pressing the spring shackle

Removing the rail pressure sensor

NOTICE Risk of material damage due to lack of lubricant Components are damaged by a lack of lubricant For this reason: • Do not clean the pressure-limiting valve and rail pressure sensor as the thread and biting edge are coated with lubricant.

Tip for users Removal of the left rail pressure sensor is the same as that of the right rail pressure sensor. ►Unscrew the rail pressure sensor 1 ►Close the rail pressure sensor with protective sleeve Z18 x 15 [1] and the thread in the pressure pipe with an end plug [2]

Installing the rail pressure sensor Installing the rail pressure sensor

NOTICE Risk of material damage due to lack of lubricant Components are damaged by a lack of lubricant.

For this reason: • Do not clean the pressure-limiting valve and rail pressure sensor as the thread and biting edge are coated with lubricant.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors Tip for users Installation of the left rail pressure sensor is the same as that of the right rail pressure sensor. ►Remove the cap and plug ►Screw on and tighten the rail pressure sensor 1 Rail pressure M18x1.5............ ......... 80 Nm sensor.....................

Connecting the rail pressure sensor electrical connection ►Restore the electrical connection 1, pushing until the spring shackle engages ►Check that the electrical connection has engaged by pulling carefully, re-fit it if necessary ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [3]

3.1.1.5 Removing/installing the oil pressure sensor (left)

key

1 Oil pressure sensor

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors Technical data Tightening torques Oil pressure sensor..................................... M18x1.5........................................ ............................. 45 +5 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Restricted operation due to incorrect entries in the diagnostic memory • Before removing switches or sensors, read out and document the fault memory.

• Always install switches and sensors with new O-rings or seals.

• After installing switches or sensors, read out the fault memory and delete it, if necessary.

Special tools 1

Plug housing wrench Quantity 1 Disconnecting electrical plug connectors with bayonet catch

80.99603-0418

2

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing the oil pressure sensor Disconnecting the oil pressure sensor electrical connection ►Mark the installation position of the cable ties ►Disconnect the cable ties ►Free the cable ►Open the bayonet catch 1 using the wrench for plug housing [1] ►Disconnect the electrical connection 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors

Removing the oil pressure sensor ►Unscrew the pressure sensor 2 and remove with the sealing ring 1 ►Clean the sealing surfaces

Installing the oil pressure sensor Installing the oil pressure sensor ►Screw in pressure sensor 2 with new sealing ring 1 and tighten Oil pressure M18x1.5........... ........ 45 +5 Nm sensor...................

Connecting the oil pressure sensor electrical connection ►Put the electrical connection 1 on the oil pressure sensor ►Close the bayonet catch 1 using the wrench for the plug housing [1] ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [2].

3.1.1.6 Removing/installing the oil pressure sensor (right)

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors

key

1 Oil pressure sensor

Technical data Tightening torques Oil pressure sensor..................................... M18x1.5........................................ ............................. 45 +5 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Restricted operation due to incorrect entries in the diagnostic memory • Before removing switches or sensors, read out and document the fault memory.

• Always install switches and sensors with new O-rings or seals.

• After installing switches or sensors, read out the fault memory and delete it, if necessary.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors Special tools 1

Plug housing wrench Quantity 1 Disconnecting electrical plug connectors with bayonet catch

80.99603-0418

2

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing the oil pressure sensor Disconnecting the oil pressure sensor electrical connection ►Mark the installation position of the cable ties ►Disconnect the cable ties ►Free the cable ►Open the bayonet catch 1 using the wrench for plug housing [1] ►Disconnect the electrical connection 1

Removing the oil pressure sensor ►Unscrew the pressure sensor 2 and remove with the sealing ring 1 ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors

Installing the oil pressure sensor Installing the oil pressure sensor ►Screw in and tighten the pressure sensor 2 with a new sealing ring 1 Oil pressure M18x1.5........... ........ 45 +5 Nm sensor...................

Connecting the oil pressure sensor electrical connection ►Put the electrical connection 1 on the oil pressure sensor ►Close the bayonet catch 1 using the wrench for the plug housing [1] ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [2].

3.1.1.7 Removing/installing the engine oil temperature sensor

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors

key

1 Engine oil temperature sensor

Technical data Tightening torques Engine oil temperature sensor....................... M16 x 1.5.......................................... ...................... 45 +5 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Restricted operation due to incorrect entries in the diagnostic memory • Before removing switches or sensors, read out and document the fault memory.

• Always install switches and sensors with new O-rings or seals.

• After installing switches or sensors, read out the fault memory and delete it, if necessary.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors Special tools 1

Plug housing wrench Quantity 1 Disconnecting electrical plug connectors with bayonet catch

80.99603-0418

2

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing the engine oil temperature sensor Disconnecting the engine oil temperature sensor electrical connection ►Free the cable ►Open the bayonet catch 1 using the wrench for plug housing [1] ►Disconnect the electrical connection 1

Removing the engine oil temperature sensor ►Unscrew the engine oil temperature sensor 1 and remove with the sealing ring 2 ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors

Installing the engine oil temperature sensor Installing the engine oil temperature sensor ►Screw in and tighten the engine oil temperature sensor 1 with a new sealing ring 2 Engine oil M16 x 1.5..... ...... 45 +5 Nm temperature sensor...

Connecting the engine oil temperature sensor electrical connection ►Attach the electrical connection 1 to the engine oil temperature sensor ►Close the bayonet catch 1 using the wrench for the plug housing [1] ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [2].

3.1.1.8 Removing/installing the coolant temperature sensor

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors

key

1 Coolant temperature sensor

Technical data Tightening torques Coolant temperature sensor.................... M16 x 1.5.............................................. ........................ 45 +5 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Restricted operation due to incorrect entries in the diagnostic memory.

• Before removing switches or sensors, read out and document the fault memory • Always install switches and sensors with new O-rings or sealing rings.

• After installing switches or sensors, read out the fault memory and, if necessary, delete it

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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3 Engine electrical system 3.1 Switch, cable harness, sensors Special tools 1

Plug housing wrench Quantity 1 Disconnecting electrical plug connectors with bayonet catch

80.99603-0418

2

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing the temperature sensor Disconnecting the temperature sensor electrical connection ►Free the cable ►Open the bayonet catch 1 using the wrench for plug housing [1] ►Disconnect the electrical connection 1

Removing the temperature sensor ►Unscrew the temperature sensor 1 and remove with the sealing ring 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors

Installing the temperature sensor Installing the temperature sensor ►Screw in and tighten the connector 1 with a new sealing ring 2 Coolant temperature M16 x 1.5...... ....... 45 +5 Nm sensor......................

Connecting the temperature sensor electrical connection ►Attach the electrical connection 1 to the temperature sensor ►Close the bayonet catch 1 using the wrench for the plug housing [1] ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [2].

3.1.1.9 Removing/installing the crankshaft speed sensor

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

39

40

3 Engine electrical system 3.1 Switch, cable harness, sensors

key

1 Speed sensor

Technical data Tightening torques Mounting bolt, crankshaft speed sensor on M6 x 16 - 10.9................................. ................ 8 +2 Nm flywheel housing.......................................................

Service products Lubricant P-80 ..................................................................................................................... 09.15014-0031 Important information

CAUTION Risk of injury from sharp edges Sharp ends on the cable ties if wrong tool is used.

For this reason: • Only tighten and trim cable ties using the cable tie pliers [1]

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Restricted operation due to incorrect entries in the diagnostic memory Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors • Before removing switches or sensors, read out and document the fault memory.

• Always install switches and sensors with new O-rings or seals.

• After installing switches or sensors, read out the fault memory and delete it, if necessary.

Special tools 1

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing the crankshaft speed sensor Disconnecting the electrical connection to the speed sensor ►Disconnect the cable ties ►Unlock and remove electrical connection 1 by pressing the spring shackle

Removing the speed sensor ►Unscrew the mounting bolt 1 ►Remove the speed sensor 2 ►Remove the speed sensor O-ring ►Clean the sealing surfaces

Installing the crankshaft speed sensor Installing the speed sensor ►Apply a thin layer of installation lubricant P80 to the new O-ring and install O-ring on speed sensor 2 ►Insert the speed sensor 2 ►Screw in and tighten the mounting bolt 1 Mounting bolt, M6 x 16 - 10.9 ..... 8 +2 Nm crankshaft speed ...................... sensor on flywheel housing.........................

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

41

42

3 Engine electrical system 3.1 Switch, cable harness, sensors

Connecting the speed sensor electrical connection ►Restore the electrical connection 1, pushing until the spring shackle engages ►Check that the electrical connection has engaged by pulling carefully, re-fit it if necessary ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [1].

3.1.1.10 Removing/installing the camshaft speed sensor

key

1 Camshaft speed sensor

Technical data Tightening torques Camshaft speed sensor mounting bolt on flywheel M6 x 16 - 10.9................................. ................ 8 +2 Nm housing....................................................................

Service products Lubricant P-80 ..................................................................................................................... 09.15014-0031

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors Important information

CAUTION Risk of injury from sharp edges Sharp ends on the cable ties if wrong tool is used.

For this reason: • Only tighten and trim cable ties using the cable tie pliers [1]

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Restricted operation due to incorrect entries in the diagnostic memory.

• Before removing switches or sensors, read out and document the fault memory.

• Always install switches and sensors with new O-rings or seals.

• After installing switches or sensors, read out the fault memory and delete it, if necessary.

Special tools 1

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing the camshaft speed sensor Disconnecting the electrical connection to the speed sensor ►Disconnect the cable ties ►Unlock and remove electrical connection 1 by pressing the spring shackle

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

43

44

3 Engine electrical system 3.1 Switch, cable harness, sensors

Removing the speed sensor ►Unscrew the mounting bolt 2 ►Pull out the speed sensor 1 ►Remove the O-ring from the speed sensor ►Clean the sealing surfaces

Installing the camshaft speed sensor Installing the speed sensor ►Apply a thin layer of installation lubricant P80 to the new O-ring and install O-ring on speed sensor 1 ►Insert the speed sensor 1 ►Screw in and tighten the mounting bolt 2 Camshaft speed M6 x 16 - 10.9 ..... 8 +2 Nm sensor mounting bolt ...................... on flywheel housing.....

Connecting the speed sensor electrical connection ►Restore the electrical connection 1, pushing until the spring shackle engages ►Check that the electrical connection has engaged by pulling carefully, re-fit it if necessary ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [1].

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors 3.1.2

Other electrical devices

3.1.2.1 Removing/installing EDC control unit (Electronic Diesel Control)

key

1 Slave engine control unit 2 Master engine control unit

Technical data Tightening torques Master engine control unit mounting M6 x 25 - 10.9.......................... 1st torque........................ 1.5 ±0.5 Nm bolt....................................................

Master engine control unit mounting M6 x 25 - 10.9.......................... Final tightening............... bolt....................................................

10 ±2 Nm

Slave engine control unit mounting M6 x 25 - 10.9.......................... 1st torque........................ 1.5 ±0.5 Nm bolt....................................................

Slave engine control unit mounting M6 x 25 - 10.9.......................... Final tightening............... bolt....................................................

10 ±2 Nm

Important information

CAUTION Risk of injury from sharp edges Sharp ends on the cable ties if wrong tool is used.

For this reason: • Only tighten and trim cable ties using the cable tie pliers [1].

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

45

46

3 Engine electrical system 3.1 Switch, cable harness, sensors

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of material damage due to incorrect installation Electrical cable damage due to over-tightening.

For this reason: • Follow the cable tie pliers [1] instructions for use.

NOTICE Risk of material damage due to short circuit Components of the electrical system will get damaged.

For this reason: • Switch off the main battery switch.

• Disconnect the ground cable from the battery.

NOTICE Risk of material damage if cable harness incorrectly laid Components will be damaged.

For this reason: • Record the cable harness run and the mark installation position.

• Mark the installation position, type of fastening and the position of the cable fasteners.

Tip for users After installation of the engine the engine control unit must be re-parametrized and the diagnostic memory deleted.

Tip for users Before removal, mark the installation position of the cables, plugs and cable ties. When installing, route and secure the cables, plugs and cable ties as marked without tension, kinks or chafing.

Special tools 1

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors

Removing the engine control unit Disconnecting the electrical connection for the slave engine control unit ►Mark the installation position of wiring harnesses and cable ties ►Disconnect the cable ties ►Completely unlock and remove plugs 1, 2, 3 and 4 ►Free the cable harnesses

Disconnecting the electrical connection for the master engine control unit ►Mark the installation position of wiring harnesses and cable ties ►Disconnect the cable ties ►Completely unlock and remove plugs 1, 2 , 3 and 4 ►Free the cable harnesses

Removing the slave engine control unit ►Unscrew the mounting bolts 2 ►Remove the engine control unit 1 from the bracket

Removing the master engine control unit ►Unscrew the mounting bolts 2 ►Remove the engine control unit 1 from the bracket

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

47

48

3 Engine electrical system 3.1 Switch, cable harness, sensors

Installing the engine control unit Tightening sequence for engine control unit Follow the tightening sequence 1 through 8 given in the following step for the mounting bolts

Installing the master engine control unit ►Position the engine control unit 1 ►Screw in the mounting bolts 2 and tighten them to the 1st torque in accordance with the tightening sequence.

Master engine M6 x 25 - 1st Torque control unit10.9.......... ................ mounting bolt.....

1.5 Nm ±0.5

►Tighten the mounting bolts 2 to the final torque in accordance with the tightening sequence Master engine M6 x 25 - Final control unit10.9......... tightening..... mounting bolt....

10 Nm ±2

Installing the slave engine control unit ►Position the engine control unit 1 ►Screw in the mounting bolts 2 and tighten them to the 1st torque in accordance with the tightening sequence.

Slave engine M6 x 25 - 1st Torque control unit10.9.......... ................ mounting bolt.....

1.5 Nm ±0.5

►Tighten the mounting bolts 2 to the final torque in accordance with the tightening sequence Slave engine M6 x 25 - Final control unit10.9......... tightening..... mounting bolt....

10 Nm ±2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.1 Switch, cable harness, sensors

Attaching the electrical connection for the master engine control unit

NOTICE Risk of damage to components caused by incorrect locking Irreparable damages to the engine control module.

For this reason: • When installing the plug, first open the plug lock completely and then insert and lock the plug connector. ►Insert and lock the plugs 1, 2, 3 and 4 into the engine control unit ►Route the cable harnesses and secure using cable ties ►Tighten and trim the cable ties using the cable tie pliers [1].

Attaching the electrical connection for the slave engine control unit

NOTICE Risk of damage to components caused by incorrect locking Irreparable damages to the engine control module.

For this reason: • When installing the plug, first open the plug lock completely and then insert and lock the plug connector. ►Insert and lock the plugs 1, 2, 3 and 4 into the engine control unit ►Route the cable harnesses and secure using cable ties ►Tighten and trim the cable ties using the cable tie pliers [1].

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

49

50

3 Engine electrical system 3.2 Measurement and display devices, sensors 3.2.1

Temperature and diameter

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.3 Electric machines, devices 3.3.1

Three-phase alternator

3.3.1.1 Removing/installing the alternator Preparations

key

►Removing/installing the alternator V-belt, Page 191

1 Mounting bolt 2 Three-phase alternator

Technical data Tightening torques Mounting nut, ribbed V-belt disc.......................... M16 x 1.5................................... .................... 95 +13 Nm Service products Loctite 2701 ........................................................................................................................ 04.10160-9353 Important information

CAUTION Risk of injury from sharp edges Sharp ends on the cable ties if wrong tool is used.

For this reason: • Only tighten and trim cable ties using the cable tie pliers [3]

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

51

52

3 Engine electrical system 3.3 Electric machines, devices

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of material damage due to incorrect installation Electrical cable damage due to over-tightening.

For this reason: • Follow the cable tie pliers [3] instructions for use.

NOTICE Risk of material damage due to short circuit Components of the electrical system will get damaged.

For this reason: • Switch off the main battery switch.

• Disconnect the ground cable from the battery.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In cases such as these, plan and execute the instructions from the repair manual accordingly Special tools 1

Special wrench kit Quantity 1 Attaching and detaching ribbed V-belt disc (alternator) in conjunction with 08.06460-0002

80.99603-6029

Special wrench kit insert Quantity 1

80.99603-0317

Multi-tooth screwdriver insert Quantity 1

80.99603-0318

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.3 Electric machines, devices 2

Handle Quantity 1 Attaching and detaching ribbed V-belt disc (alternator) in conjunction with 80.99603-6029

08.06460-0002

3

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing the alternator Disconnecting the alternator electrical connection ►Disconnect the electrical connections 1 and 2

Removing the alternator ►Unscrew the mounting bolts 1 ►Remove the alternator 2 from the bracket 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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54

3 Engine electrical system 3.3 Electric machines, devices

Loosen the ribbed V-belt disc mounting nut ►Put the special wrench [1] 2 with handle [2] 3 on the ribbed V-belt disc mounting nut ►Insert the multiple-tooth key 1 into the alternator shaft teething ►Brace the multiple-tooth key 1 and loosen the mounting nut

Removing the ribbed V-belt disc ►Unscrew the mounting nut 1 ►Remove the ribbed V-belt disc 2 and fan wheel 3 from the alternator shaft 4

Installing the alternator Attaching the ribbed V-belt disc ►Slide the fan wheel 3 and ribbed V-belt disc 2 onto the alternator shaft 4 ►Thinly apply Loctite 2701 on the thread and contact area of the mounting nut 1 ►Screw on the mounting nut 1

Tightening the ribbed V-belt disc mounting nut ►Put the special wrench [1] 2 with handle [2] 3 on the ribbed V-belt disc mounting nut ►Insert the multiple-tooth key 1 into the alternator shaft teething ►Brace the multiple-tooth key 1 and tighten the mounting nut Mounting nut, ribbed M16 x 1.5.... ...... 95 +13 Nm V-belt disc.................

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.3 Electric machines, devices

Attaching the alternator ►Position the alternator 2 on the bracket 3 ►Screw in and tighten the mounting bolts 1

Connecting the alternator electrical connection ►Connect the electrical connections 1 and 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

55

56

3 Engine electrical system 3.3 Electric machines, devices 3.3.2

Starter motor

3.3.2.1 Removing/installing the starter/starter motor

key

1 Starter motor 2 Mounting bolt

Technical data Tightening torques Terminal 30 mounting nut........................................ M12........................................ ............................. 25 Nm Terminal 31 mounting nut........................................ M12........................................ ............................. 25 Nm Terminal 50 mounting nut........................................ M6.......................................... ............................. 4 Nm Terminal 85 mounting nut........................................ M6.......................................... ............................. 4 Nm Test values and settings Number of starter pinion teeth.........................................

11 ........................................................................................................

Starter power......................................... 7.0 kW at 24 V ........................................................................................................

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.3 Electric machines, devices Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of material damage due to short circuit Components of the electrical system will get damaged.

For this reason: • Switch off the main battery switch.

• Disconnect the ground cable from the battery.

Special tools 1

Engine cranking unit Quantity 1 Crank the engine in conjunction with 80.99627-0001

80.99626-6008

2

Gear ratchet Quantity 1 Crank the engine 1/2" in conjunction with 80.99626-6008

80.99627-0001

Removing the starter motor Disconnecting the starter motor electrical connection ►Remove the protective caps 2 ►Remove the mounting nuts from terminal 50 and terminal 85 ►Free the cable harness 1 ►Loosen the mounting nut 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

57

58

3 Engine electrical system 3.3 Electric machines, devices

Removing starter motor ►Unscrew the mounting bolts 2 ►Take the starter motor 1 out of the flywheel housing

Attaching the engine cranking unit ►Remove the cap with seal and TDC marking plate from the flywheel housing ►Attach engine cranking unit [1] 1 to flywheel housing ►Crank the engine 360° using the gear ratchet [2] and check the flywheel ring gear for wear

Installing the starter motor Removing the engine cranking unit ►Remove engine cranking unit [1] 1 to flywheel housing ►Attach the TDC marking plate ►Attach the cap on the flywheel housing with a new seal

Attaching the starter motor ►Insert the starter motor 1 into the flywheel housing ►Screw in and tighten the mounting bolts 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

3 Engine electrical system 3.3 Electric machines, devices

Connecting the starter motor electrical connection ►Screw on the mounting nut 3 and tighten it Terminal 30........... M12x1............... ........... 25 Nm Terminal 31........... M12x1............... ........... 25 Nm ►Connect the cable harness 1 ►Screw the mounting nuts on terminal 50 and terminal 85 Terminal 50...........M6 x 1.................. ........... 4 Nm Terminal 85...........M6 x 1.................. ........... 4 Nm ►Attach the protective caps 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

59

60

3 Engine electrical system 3.3 Electric machines, devices

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling) 4.1.1

Coolant line

4.1.1.1 Removing/installing the coolant pump coolant manifold

key

1 Coolant manifold inlet

Service products Radiator antifreeze ..................................

For more information see the MAN service product database.

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on radiator antifreeze see the MAN service product database. k https://my.man-mn.com/portal/irj/asp/

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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62

4 Engine 4.1 Cooling system (water cooling)

Removing the coolant pump coolant manifold Detaching the coolant connector ►Unscrew the mounting bolts 3 ►Remove the coolant connector 2 with O-ring 1 ►Clean the sealing surfaces

Removing the blind flange ►Unscrew the mounting bolts 3 ►Remove the blind flange 2 with O-ring 1 ►Clean the sealing surfaces

Removing the coolant manifold inlet ►Unscrew the mounting bolts 4 ►Remove the coolant manifold inlet 1 with O-ring 3 ►Pull out the coupling pipe 2 ►Clean the sealing surfaces

Dismantling the coolant manifold inlet ►Unscrew the hose piece 1 with the sealing ring 2 ►Unscrew the hose piece 4 with the sealing ring 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Installing the coolant pump coolant manifold Assembling the coolant manifold inlet ►Screw in and tighten the hose piece 4 with a new sealing ring 3 ►Screw in and tighten the hose piece 1 with a new sealing ring 2

Attaching the coolant manifold inlet ►Clean the sealing surfaces ►Apply a thin layer of radiator antifreeze on the coupling pipe 2 and O-ring 3 ►Install the coupling pipe 2 ►Position the coolant manifold inlet 1 with new O-ring 3 ►Screw in and tighten the mounting bolts 4

Attaching the blind flange ►Clean the sealing surfaces ►Apply a thin layer of radiator antifreeze on the new O-ring 1 ►Position the blind flange 2 with a new O-ring 1 ►Screw in and tighten the mounting bolts 3

Attaching the coolant connector ►Clean the sealing surfaces ►Apply a thin layer of radiator antifreeze on the new O-ring 1 ►Position the coolant connector 2 with a new Oring 1 ►Screw in and tighten the mounting bolts 3

4.1.1.2 Removing/installing the air compressor coolant line Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

63

64

4 Engine 4.1 Cooling system (water cooling)

key

1 Intake hose 2 Coolant return line

3 Coolant feed line 4 Oil pressure line

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Removing the air compressor coolant line Detaching the intake hose ►Mark the retaining clamp installation position ►Unscrew mounting bolt 3 and remove it with the washer ►Pull out the mounting bolt 5 with the washer ►Undo hose clamps 1 and 4 and push onto hose 2 ►Pull off the hose 2

Removing the oil pressure lines ►Loosen the retaining nuts 1 and 3 ►Remove the oil pressure line 2

Detaching coolant feed lines ►Loosen the retaining nuts 1 and 3 ►Detach the coolant feed lines 2

Removing the dual clamps ►Mark the installation position of the dual clamp on the coolant return line 1 ►Unscrew the mounting nut 6 ►Pull out the mounting bolt 2 and remove the cover plates 3 and 5 ►Open the dual clamp 4 and remove it ►Repeat the procedure for the remaining dual clamps

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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66

4 Engine 4.1 Cooling system (water cooling)

Detaching the coolant return line ►Loosen the retaining nuts 1 and 3 ►Remove the coolant return line 2.

Installing the air compressor coolant line Attaching the coolant return line ►Position the coolant return line 2 ►Screw on and tighten retaining nuts 1 and 3

Attaching the dual clamps ►Place the dual clamp 1 on the coolant return line at the marked position and close ►Position the cover plates 3 and 5 ►Insert the mounting bolt 2 and screw the mounting nut 6 on and tighten ►Repeat the procedure for the remaining dual clamps

Attaching coolant feed lines ►Attach the coolant feed lines 2 ►Screw on and tighten retaining nuts 1 and 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Attaching the oil return lines ►Position the oil pressure line 2 with the WV connector ►Screw on and tighten retaining nuts 1 and 3

Attaching the intake hose ►Position the intake hose 2 with new hose clamps 1 and 4 ►Push the intake hose 2 onto the pipe bend ►Tighten the hose clamps 1 and 4 at the installation position ►Place the retaining clamp in the installation position ►Insert the mounting bolt 5 with washer, then screw on the mounting nut 3 with washer and tighten

4.1.1.3 Removing/installing the coolant manifold on the engine block (left) Preparations ►Removing/installing the coolant temperature sensor, Page 36

►Removing/installing the air compressor coolant line, Page 63

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

67

68

4 Engine 4.1 Cooling system (water cooling)

key

1 Coolant manifold

Service products Radiator antifreeze ...................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Incorrectly tightened bolted connections cause component damage.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on radiator antifreeze see the MAN service product database. k https://my.man-mn.com/portal/irj/asp/

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Removing the coolant manifold on the engine block Detaching the coolant line from the left coolant manifold ►Loosen the retaining nuts 2 ►Remove the coolant line 1 ►Unscrew the hollow screw 3 with the sealing ring ►Remove the coolant line 4

Detaching the coolant line ►Loosen the retaining nuts 2 ►Remove the coolant line 1 with new sealing ring from the coolant manifold 3

Detaching the coolant manifold ►Unscrew the mounting bolts 1 ►Remove the coolant manifold 2 with O-rings 3 ►Clean the sealing surfaces

Installing the coolant manifold on the engine block Mounting the coolant manifold ►Clean the sealing surfaces ►Apply a thin layer of radiator antifreeze on the new O-rings 3 ►Insert the new O-rings 3 in the coolant manifold 2 ►Position the coolant manifold 2 ►Screw in and tighten the mounting bolts 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

69

70

4 Engine 4.1 Cooling system (water cooling)

Attaching the coolant line ►Place coolant line 1 with new sealing ring on the coolant manifold 3 ►Screw the retaining nut 2 on and then tighten

Attaching the coolant line to the left coolant manifold ►Attach the coolant line 4 with new sealing ring ►Screw on the retaining nut 1 ►Screw in and tighten the hollow screw 3 with the new sealing ring ►Tighten the retaining nut 1

4.1.1.4 Removing/installing the coolant manifold on the engine block (right) Preparations ►Removing/installing the coolant line for the heater supply, Page 74

►Removing/installing the air compressor coolant line, Page 63

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

key

1 Coolant manifold

Service products Radiator antifreeze ...................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Incorrectly tightened bolted connections cause component damage.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on radiator antifreeze see the MAN service product database. k https://my.man-mn.com/portal/irj/asp/

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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72

4 Engine 4.1 Cooling system (water cooling)

Removing the coolant manifold on the engine block Detaching the coolant line from the right coolant manifold ►Loosen the retaining nuts 1 and 2 ►Remove the coolant line 3

Detaching the coolant line from the left coolant manifold ►Loosen the retaining nuts 1 ►Unscrew the hollow screw 3 with the sealing ring 2 ►Remove the coolant line 4

Detaching the coolant line ►Loosen the retaining nuts 2 ►Remove the coolant line 1 with union ring and sealing ring 3

Detaching the coolant manifold ►Unscrew the mounting bolts 1 ►Remove the coolant manifold 2 with O-rings 3 ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Dismantling the coolant manifold ►Unscrew the transition flange 1 and remove it with the ring piece 4 and sealing rings ►Unscrew the hollow screw 2 and remove it with the ring union 3 and sealing rings

Installing the coolant manifold on the engine block Assembling the coolant manifold ►Screw in hollow screw 2 with the ring union 3 and new sealing rings and tighten by hand ►Screw in transition flange 1 with the ring piece 4 and new sealing rings and tighten by hand

Mounting the coolant manifold ►Clean the sealing surfaces ►Apply a thin layer of radiator antifreeze on the new O-rings 3 ►Insert the new O-rings 3 in the coolant manifold 2 ►Position the coolant manifold 2 ►Screw in and tighten the mounting bolts 1

Attaching the coolant line ►Place coolant line 1 with new sealing ring on the coolant manifold 3 ►Screw the retaining nut 2 on and then tighten

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

73

74

4 Engine 4.1 Cooling system (water cooling)

Attaching the coolant line to the left coolant manifold ►Attach the coolant line 4 with new sealing ring ►Screw on the retaining nut 1 ►Screw in and tighten the hollow screw 3 with the new sealing ring ►Tighten the retaining nut 1

Attaching the coolant line from the right coolant manifold ►Position the coolant line 3 ►Screw on and tighten retaining nuts 1 and 2 ►Tighten the hollow screw

4.1.1.5 Removing/installing the coolant line for the heater supply

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

key

1 Coolant line for heater supply

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Incorrectly tightened bolted connections cause component damage.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Removing the coolant line for the heater supply Disconnecting the retaining clamps ►Unscrew the mounting nut 1, with washer ►Pull out the mounting bolt 2 with the washer

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

75

76

4 Engine 4.1 Cooling system (water cooling)

Detaching the coolant line for the heater supply ►Unscrew the mounting nuts 4 ►Remove the mounting bolts 2 ►Unscrew the mounting nut 5 ►Pull out the mounting bolt 1 and remove along with the bushing 6 ►Loosen the coolant line retaining nut 3 ►Remove the coolant line 3

Installing the coolant line for the heater supply Attaching the coolant line for the heater supply ►Position the coolant line 3 ►Screw on the coolant line retaining nut 3 ►Position the bushing 6 ►Insert the mounting bolt 1 and screw the mounting nut 5 on and tighten ►Insert the mounting bolts 2 and screw the mounting nuts 4 in and tighten ►Tighten the coolant line retaining nut 3

Attaching the retaining clamps ►Install the mounting bolt 2 with washers ►Screw on and tighten the mounting nut 1 with washer

4.1.1.6 Removing/installing the coolant line on the cylinder head (left)

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

key

1 Coolant line 2 Left coolant line

3 Coolant line 4 Coolant line

Technical data Tightening torques Hollow screw, coolant line on cylinder head......................M14x1.5.............................. ...................... 42 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Incorrectly tightened bolted connections cause component damage.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

77

78

4 Engine 4.1 Cooling system (water cooling)

Removing the coolant lines Detaching the coolant line ►Unscrew retaining nuts 1 and 2 ►Remove the coolant line 3

Detaching the coolant line ►Unscrew the retaining nuts 1 and 3 ►Remove the coolant line 2

Detaching the coolant line ►Unscrew the mounting bolt 2 and remove along with the bushing 5 ►Unscrew the retaining nuts 4 and 6 ►Remove the coolant line 3 ►Unscrew on the TVE connector 1

Removing the left coolant line Tip for users Hollow screws are restricted. ►Unscrew the hollow screw connector 5 and the hollow screws 4 and remove along with the sealing rings ►Unscrew the hollow screw 2 and remove it with the ring union 1 and sealing rings ►Remove the coolant line 3 with the seals

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Installing coolant lines Attaching the coolant line Tip for users Hollow screws are restricted. ►Attach the coolant line 3 with new seals ►Screw in and tighten hollow screw connector 5 and hollow screws 4 Hollow screw, coolant M14x1.5......... ....... 42 Nm line on cylinder head..... ►Position the ring union 1 with new sealing rings ►Screw in and tighten the hollow bolt 2

Attaching the coolant line ►Screw on the TVE connector 1 ►Position the coolant line 3 ►Screw on and tighten retaining nuts 4 and 6 ►Position the bushing 5, screw in and tighten the mounting bolt 2 ►Tighten the TVE connector 1

Attaching the coolant line ►Position the coolant line 2 ►Screw on and tighten retaining nuts 1 and 3

Attaching the coolant line ►Position the coolant line 3 ►Screw on and tighten retaining nuts 1 and 2

4.1.1.7 Removing/installing the coolant line on the cylinder head (right) Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

79

80

4 Engine 4.1 Cooling system (water cooling)

key

1 Coolant line 2 Right coolant line

3 Coolant line 4 Coolant line

Technical data Tightening torques Hollow screw, coolant line on cylinder head............................................ M14x1.5.............................. 42 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Incorrectly tightened bolted connections cause component damage.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Removing the coolant lines Detaching the coolant line ►Unscrew the retaining nuts 1 and 3 ►Remove the coolant line 2

Detaching the coolant line ►Unscrew the mounting bolt 4 and remove along with the bushing 6 ►Unscrew the retaining nuts 2 and 5 ►Remove the coolant line 3 ►Unscrew the WVE connector 1

Detaching the coolant line ►Loosen the retaining nut on the cooling line 2 ►Remove the coolant line 2 ►Unscrew the TVE connector 1

Detaching the coolant line Tip for users Hollow screws are restricted. ►Unscrew the hollow screw connector 1 and the hollow screws 3 and remove along with the sealing rings ►Unscrew the hollow screw 5 and remove it with the ring union 4 and sealing rings ►Remove the coolant line 2 with the seals

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

81

82

4 Engine 4.1 Cooling system (water cooling)

Installing coolant lines Attaching the coolant line Tip for users Hollow screws are restricted. ►Attach the coolant line 2 with new seals ►Screw in and tighten hollow screw connector 1 and hollow screws 3 Hollow screw, coolant M14x1.5......... ....... 42 Nm line on cylinder head..... ►Position the ring union 4 with new sealing rings ►Screw in and tighten the hollow screw 5

Attaching the coolant line ►Screw on the TVE connector 1 ►Position the coolant line 2 ►Screw on and then tighten the fuel line retaining nut 2

Attaching the coolant line ►Screw on the WVE connector 1 ►Position the coolant line 3 ►Screw on and tighten retaining nuts 2 and 5 ►Position the bushing 6, screw in and tighten the mounting bolt 4 ►Tighten the WVE connection 1

Attaching the coolant line ►Position the coolant line 2 ►Screw on and tighten retaining nuts 1 and 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling) 4.1.2

Coolant temperature control, thermostat

4.1.2.1 Removing/installing the thermostat housing coolant manifold

key

1 Blind flange 2 Coolant manifold outlet

Service products Radiator antifreeze ...................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on radiator antifreeze see the MAN service product database. k https://my.man-mn.com/portal/irj/asp/

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

83

84

4 Engine 4.1 Cooling system (water cooling) Special tools 1

Cable tie pliers Quantity 1

08.02960-0100

Removing the thermostat housing coolant manifold Detaching the thermostat housing coolant manifold ►Mark the installation position of the cable ties ►Disconnect the cable ties ►Unscrew the mounting bolts 4 and remove with the bracket 3 ►Remove the coolant manifold 2 with O-ring 1 ►Clean the sealing surface

Detaching the blind flange on thermostat housing ►Unscrew the mounting bolts 1 ►Remove the blind flange 2 with O-ring 3 ►Clean the sealing surface

Installing the coolant manifold Attaching the flange to the thermostat housing ►Clean the sealing surfaces ►Apply a thin layer of radiator antifreeze on the new O-ring 3 ►Position the blind flange 2 with the new O-ring 3 on the thermostat housing ►Screw in and tighten the mounting bolts 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Attaching thermostat housing coolant manifold ►Clean the sealing surfaces ►Apply a thin layer of radiator antifreeze on the new O-ring 1 ►Position the coolant manifold 2 with the new Oring 1 on the thermostat housing ►Screw in and tighten the mounting bolts 4 with bracket 3 ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [1].

4.1.2.2 Removing/installing the thermostat housing Preparations ►Removing/installing the fuel line, Page 320 ►Removing/installing the charge-air manifold/air distributor pipe , Page 97

key

►Removing/installing the coolant pump coolant manifold, Page 61 ►Removing/installing the thermostat housing coolant manifold , Page 83

1 Thermostat housing upper section 2 Thermostat housing lower section

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

85

86

4 Engine 4.1 Cooling system (water cooling) Service products Radiator antifreeze ...................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on radiator antifreeze see the MAN service product database. k https://my.man-mn.com/portal/irj/asp/

Removing the thermostat housing Removing the bracket ►Unscrew the mounting bolts 1 ►Remove the bracket 2

Detaching the coolant line ►Loosen the retaining nuts 1 ►Remove the coolant line 2

Detaching the coolant line ►Loosen the retaining nut on the WVE connector 1 ►Remove the coolant return line 2 from the thermostat housing

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Detaching coolant lines ►Unscrew the mounting bolt 5 and remove along with the bushing 7 ►Unscrew the mounting nut 3 ►Remove the mounting bolt 1 together with the bushing 2 ►Loosen the retaining nuts 6 and 8 ►Remove the coolant line 4 ►Clean the sealing surfaces

Removing the thermostat housing upper section ►Mark the installation position of mounting bolts 1 and 2 ►Remove the mounting bolts 1 and 2 ►Detach the thermostat housing 3 ►Clean the sealing surfaces

Detaching the GE connectors ►Unscrew the GE connectors 1 and 2 and remove them along with the sealing rings ►Clean the sealing surfaces

Removing the thermostat housing lower section ►Unscrew the mounting bolts 1 ►Remove thermostat housing lower section 2 ►Remove the O-rings 3 and 4 ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

87

88

4 Engine 4.1 Cooling system (water cooling)

Installing the thermostat housing Attaching thermostat housing lower section ►Clean the sealing surfaces ►Apply a thin layer of radiator antifreeze on the new O-rings 3 and 4 ►Insert the new O-rings 3 and 4 into the thermostat housing lower section 2 ►Position the thermostat housing lower section 2 ►Screw in and tighten the mounting bolts 1

Attaching the GE connectors ►Clean the sealing surfaces ►Screw in and tighten the GE connectors 1 and 2 with new sealing rings

Attaching the thermostat housing upper section ►Clean the sealing surfaces ►Place a new thermostat housing 3 on the thermostat housing lower section ►Screw the mounting bolts 1 and 2 in as marked and tighten

Attaching the coolant lines ►Clean the sealing surfaces ►Position the coolant line 4 ►Screw on and tighten retaining nuts 6 and 8 ►Position the bushing 2 and screw in the mounting bolt 1 ►Screw on the mounting nut 3 and tighten it ►Position the bushing 7, screw in and tighten the mounting bolt 5

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Attaching the coolant line ►Place the coolant line 2 on the thermostat housing ►Screw on and tighten the retaining nut on the WVE connector 1

Attaching the coolant line ►Position the coolant line 2 ►Screw on and tighten the retaining nuts 1

Mounting the bracket ►Position the bracket 2 ►Screw in and tighten the mounting bolts 1

4.1.2.3 Removing/installing the thermostat insert Preparations

►Removing/installing the thermostat housing , Page 85

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

89

90

4 Engine 4.1 Cooling system (water cooling)

key

1 Thermostat housing 2 Sealing ring 3 Thermostat insert

Technical data Test values and settings Thermostat opening temperature................................................................................................... 82 ±1.5 °C Important information

NOTICE Thermostats with the incorrect opening temperature may damage the engine For this reason: • Always use thermostats with the specified opening temperature.

NOTICE Risk of damage to components due to contaminants For this reason: • Clean components and sealing surfaces before assembly by suitable means.

• Protect cleaned surfaces from re-contamination.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling) Special tools 1

Extraction tool Quantity 1 Removing/installing the sealing rings on the thermostat insert in conjunction with 80.99613-0027

80.99602-6042

2

Thrust spindle Quantity 1 For tightening the differential lock

80.99613-0027

3

Plug-on handle Quantity 1 1. Removing/installing the sealing rings on the thermostat insert, D3876 in conjunction with 80.99616-0147, 80.99604-0440, 80.99604-0441 2.

Pressing the sealing ring into the front of the crankcase, D2868 / 62 in conjunction with 80.99604-0342

80.99617-0237

4

Pressing tool Quantity 1 Ø67.5 x 68.5 journal 1 Ø57.5 x 8.5 journal 2 Ø44,85 x 50 in conjunction with 80.99604-0467 , 08.99615-2700 , 80.99602-0207 , 80.99602-0016

80.99604-0440

5

Guide bush Quantity 1 Ø73 x 38 journal Ø67.5 x 8 bore Ø45 in conjunction with 80.99604-0467 , 08.99615-2700 , 80.99602-0207 , 80.99602-0016

80.99604-0441

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

91

92

4 Engine 4.1 Cooling system (water cooling) 6

Washer Quantity 1 Removing/installing the sealing ring 51.06904-0038 in

80.99616-0147

the thermostat insert in conjunction with 80.99617-0237, 80.99604-0440, 80.99604-0441

Removing the thermostat insert Removing the thermostats ►Remove the thermostat 2 from the distributor housing 1

Removing the sealing rings ►Assemble the extraction tool [1] 3 and thrust spindle [2] 4 ►Insert extractor [1] 3 into the thermostat housing 1 and spread it until it rests against the sealing ring 2 firmly ►Pull the sealing ring 2 out of the thermostat housing 1 ►Repeat this procedure for all sealing rings ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Installing the thermostat insert Installing the seal ►Clean the sealing surfaces ►Assemble the press-in tool 6 consisting of pressing tool [4] 1, guide bushing [5] 2, washer [6] 3 and handle [3] 4 ►Position a new sealing ring 7 on the press-in tool 6 ►Attach press-in tool 6 with new sealing ring 7 to the thermostat housing 5 and press in the new sealing ring 7 until the washer [6] 3 is resting on the guide bushing [5] 2 ►Repeat this procedure for all sealing rings

Installing the thermostats ►Insert the thermostats 2 in the distributor housing 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

93

94

4 Engine 4.1 Cooling system (water cooling) 4.1.3

Coolant pump components

4.1.3.1 Removing/installing the coolant pump

key

1 Coolant pump

Service products Radiator antifreeze ...................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.1 Cooling system (water cooling)

Removing the coolant pump Removing the bracket with cable harness ►Mark the installation position of the cable harness 3 ►Unscrew the mounting bolts 1 and 6 and remove them with the washers 2 and 5 ►Move the cable harness 3 together with the bracket 4 out of the way

Detaching the coolant pump ►Mark the installation position of mounting bolts 1 and 6 ►Remove the mounting bolts 3 and 4 ►Remove the mounting bolts 1 and 6 ►Remove the O-ring 5 from the coolant pump 2 ►Clean the sealing surfaces

Removing the coupling pipes ►Remove O-rings 1 and 6 ►Remove flanges 2 and 5 ►Remove coupling pipes 3 and 4 from the coolant pump ►Clean the sealing surfaces

Installing the coolant pump Installing the coupling pipes ►Clean the sealing surfaces ►Apply a thin layer of radiator antifreeze to the contact surfaces of the new coupling pipes 3 and 4 ►Insert coupling pipes 3 and 4 into the coolant pump ►Position flanges 2 and 5 on coupling pipes 3 and 4 ►Apply a thin layer of radiator antifreeze on the new O-rings 1 and 6 ►Insert the new O-rings 1 and 6

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

95

96

4 Engine 4.1 Cooling system (water cooling)

Attaching the coolant pump ►Clean the sealing surfaces ►Insert new O-ring 5 in the groove in the coolant pump 2 ►Attach the coolant pump 2 ►Screw the mounting bolts 1 and 6 in as marked and tighten ►Screw in and tighten the mounting bolts 3 and 4

Attaching the bracket with cable harness ►Install the bracket 4 with cable harness 3 at the installation position ►Screw in and tighten the mounting bolts 1 and 6 with washers 2 and 6

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.2 Exhaust, intake manifold, air filter 4.2.1

Intake pipe, intake manifold components

4.2.1.1 Removing/installing the charge-air manifold/air distributor pipe Preparations ►Removing/installing the charge pressure sensor, Page 17

key

►Removing/installing the thermostat housing coolant manifold , Page 83

1 Charge-air pipe 2 Charge-air manifold

Technical data Tightening torques Clamp ring..........................................M8x70............................................... .................................. 12 ±1 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components may be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

97

98

4 Engine 4.2 Exhaust, intake manifold, air filter

Removing charge-air pipe Detaching information sign ►Unscrew the mounting bolts 2 ►Remove the information sign 1

Undoing the fuel lines ►Unscrew the mounting bolts 1 and 2 and remove them with the washers ►Unscrew the mounting bolts 3 and 4 and release the fuel lines

Removing the charge-air pipe ►Mark the installation position of mounting bolts 2 and 4 ►Remove the mounting bolts 2 and 4 ►Remove the charge-air pipe 1 with seals 3 ►Clean the sealing surfaces

Dismantling the charge-air pipe ►Mark the installation position of the charge-air manifold 5 ►Undo the clamp ring 4 ►Remove the charge-air manifold 5 with O-ring 6 and clamp ring 4 ►Undo the clamp ring 2 ►Remove the cap 1 with O-ring 3 and clamp ring 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.2 Exhaust, intake manifold, air filter

Installing the charge-air pipe Assembling the charge-air pipe

NOTICE Risk of material damage to components due to leaking hose clips or clamp ring connections For this reason: • Adjust the seat of the hose clips or clamp rings by knocking gently with a rubber hammer.

• Tighten the hose clips or clamp rings again using a torque wrench. ►Insert new O-ring 3 in the groove ►Attach the cap 1 with clamp ring 2 ►Tighten the profile clamp 2 Clamp ring........ M8x70.............. ........... 12 ±1 Nm ►Insert new O-ring 6 in the groove ►Attach the charge-air manifold 5 with clamp ring 4 as marked ►Tighten the profile clamp 4 Clamp ring........ M8x70.............. ........... 12 ±1 Nm

Attaching the charge-air pipe ►Clean the sealing surfaces ►Position the charge-air pipe 1 with new seals 3 ►Screw the mounting bolts 2 and 4 in as marked and tighten

Attaching the fuel lines ►Position the fuel lines ►Screw in and tighten the mounting bolts 3 and 4 ►Screw the mounting bolts 1 and 2 in with washers and then tighten

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

99

100

4 Engine 4.2 Exhaust, intake manifold, air filter

Attaching the information sign ►Position the information sign 1 ►Screw in and tighten the mounting bolts 2

4.2.1.2 Removing/installing the intake manifold/air distributor pipe (left) Additional measures ►Removing/installing the charge-air manifold/air distributor pipe , Page 97 ►Removing/installing the fuel service center , Page 310

key

►Removing/installing the rail (left), Page 355 ►Removing/installing the injection pressure line (left), Page 345

1 Fuel line bracket 2 Cable harness

►Removing/installing the fuel return line (left), Page 331 ►Removing/installing the coolant line on the cylinder head (left), Page 76

4 Cable harness bracket 5 Fuel line bracket

3 Left air distributor pipe

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.2 Exhaust, intake manifold, air filter Important information

CAUTION Risk of injury from sharp edges Sharp ends on the cable ties if wrong tool is used.

For this reason: • Only tighten and trim cable ties using the cable tie pliers [1].

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Special tools 1

Cable tie pliers Quantity 1

08.02960-0100

Removing the left air distributor pipe Expose the cable harness ►Mark the installation position of the cable harness 1 ►Mark the installation position of the cable ties and the attachment points. ►Disconnect the cable ties ►Open and secure the cable harness in position 1

Removing the fuel line bracket ►Unscrew the mounting bolt 7 with washer 8 ►Unscrew the mounting bolt 3 ►Remove the bracket 1 with the bushing 2 ►Remove the mounting bolts 4 and 6 ►Remove the bracket 5

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

101

102

4 Engine 4.2 Exhaust, intake manifold, air filter

Removing cable harness bracket ►Unscrew the mounting bolts 4 with washers 3 ►Remove the bracket 1 from the air distributor pipe 2

Detaching the air distributor pipe ►Mark the installation position of mounting bolts 1 and 3 ►Remove the mounting bolts 1 and 3 ►Remove the air distributor pipe 2 with seals 4 ►Clean the sealing surfaces

Installing the left air distributor pipe Mounting the air distributor pipe ►Clean the sealing surfaces ►Position the air distributor pipe 2 with new seals 4 ►Screw the mounting bolts 1 and 3 in as marked and tighten

Attaching the cable harness bracket ►Position the bracket 1 on the air distributor pipe 2 ►Screw in and tighten the mounting bolts 4 with washers 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.2 Exhaust, intake manifold, air filter

Attaching the fuel line bracket ►Position the bracket 5 ►Screw in and tighten the mounting bolts 4 and 6 ►Position the bracket 1 with the bush 2 ►Screw in and tighten the mounting bolts 3 ►Screw in and tighten the mounting bolt 7 with washer 8

Fastening the cable harness ►Check the cable harness 1 for damage, replace if necessary ►Attach the cable harness 1 at the installation position ►Attach the cable harness 1 in the marked positions with cable ties ►Tighten and trim the cable ties using the cable tie pliers [1].

4.2.1.3 Removing/installing the intake manifold/air distributor pipe (right) Additional measures ►Removing/installing the charge-air manifold/air distributor pipe , Page 97 ►Removing/installing the fuel service center , Page 310 ►Removing/installing the rail (right), Page 359

►Removing/installing the injection pressure line (right), Page 350 ►Removing/installing the fuel return line (right), Page 335 ►Removing/installing the coolant line on the cylinder head (right), Page 79

►Removing/installing the coolant line for the heater supply, Page 74

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

103

104

4 Engine 4.2 Exhaust, intake manifold, air filter

key

1 Right air distributor pipe

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Removing the right air distributor pipe Removing the bracket ►Mark the installation position of mounting bolts 2 and 4 ►Remove the mounting bolts 2 and 4 ►Remove the bracket 1 with washer 3 and bushing 5

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.2 Exhaust, intake manifold, air filter

Detaching the air distributor pipe ►Mark the installation position of mounting bolts 2 and 4 ►Remove the mounting bolts 2 and 4 ►Remove the air distributor pipe 3 with seals 1 ►Clean the sealing surfaces

Dismantling the air distributor pipe ►Unscrew screw plugs 1 and 2 and remove them along with the seals

Installing the right air distributor pipe Assembling the air distributor pipe ►Screw in and tighten new plugs 1 and 2 with new seals

Mounting the air distributor pipe ►Clean the sealing surfaces ►Position the air distributor pipe 3 with new seals 1 ►Screw the mounting bolts 2 and 4 in as marked and tighten

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

105

106

4 Engine 4.2 Exhaust, intake manifold, air filter

Mounting the bracket ►Position the bracket 1 with washer 3 and bushing 5 ►Screw the mounting bolts 2 and 4 in as marked and tighten

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.2 Exhaust, intake manifold, air filter 4.2.2

Exhaust manifold components

4.2.2.1 Removing/installing the turbocharger exhaust pipe connector (left) Preparations

key

►Removing/installing the turbocharger (left), Page 293

1 Exhaust pipe connector 2 Mounting nut 3 Spacer bush

Technical data Tightening torques Mounting nut......................... M10-HWF............................... 1. Torque........................................

25 +5 Nm

Mounting nut......................... M10-HWF............................... Final tightening............................... 60 +10 ° Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components may be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

107

108

4 Engine 4.2 Exhaust, intake manifold, air filter

Removing the turbocharger exhaust pipe connector Detaching the exhaust pipe connector ►Unscrew mounting nuts 4 and remove along with spacer bushings 3 ►Lift the exhaust pipe connector 2 and seal 1 off the stud bolts 5 on the exhaust manifold 6 ►Clean the sealing surfaces

Installing the turbocharger exhaust pipe connector Attaching the exhaust pipe connector ►Clean the sealing surfaces ►Slide the exhaust pipe connector 2 and seal 1 over the stud bolts 5 on the exhaust manifold 6 ►Screw on and tighten the mounting bolts 4 with spacer bushings 3 Mounting nut M10-HWF 1. Torque........ ................

25 +5 Nm

Mounting nut M10-HWF Final tightening ................ .......................

60 ° +10

4.2.2.2 Removing/installing the turbocharger exhaust pipe connector (right) Preparations

►Removing/installing the turbocharger (right), Page 298

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.2 Exhaust, intake manifold, air filter

key

1 Spacer bush 2 Mounting nut 3 Exhaust pipe connector

Technical data Tightening torques Mounting nut......................... M10-HWF............................... 1. Torque........................................

25 +5 Nm

Mounting nut......................... M10-HWF............................... Final tightening............................... 60 +10 ° Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components may be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

109

110

4 Engine 4.2 Exhaust, intake manifold, air filter

Removing the turbocharger exhaust pipe connector Detaching the exhaust pipe connector ►Unscrew mounting nuts 4 and remove along with spacer bushings 5 ►Lift the exhaust pipe connector 3 and seal 2 off the stud bolts 1 on the exhaust manifold 6 ►Clean the sealing surfaces

Installing the turbocharger exhaust pipe connector Attaching the exhaust pipe connector ►Clean the sealing surfaces ►Slide the exhaust pipe connector 3 and seal 2 over the stud bolts 1 on the exhaust manifold 6 ►Screw on and tighten the mounting bolts 4 with spacer bushings 5 Mounting nut M10-HWF 1. Torque........ ................

25 +5 Nm

Mounting nut M10-HWF Final tightening ................ .......................

60 ° +10

4.2.2.3 Removing/installing the exhaust manifold (left) Preparations ►Intake fitting, left turbocharger, Page 288

►Removing/installing the turbocharger (left), Page 293

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.2 Exhaust, intake manifold, air filter

key

1 Front exhaust pipe 2 Rear exhaust pipe

Technical data Tightening torques Exhaust pipe mounting bolt on cylinder head, M10x40-HWF............... 1. Torque........................ front.................................................................

20 +5 Nm

Exhaust pipe mounting bolt on cylinder head, M10x40-HWF............... Final tightening............... 90 +10 ° front.................................................................

Exhaust pipe connector mounting bolt on M10x40-HWF............... 1. Torque........................ cylinder head, rear...........................................

20 +5 Nm

Exhaust pipe connector mounting bolt on M10x40-HWF............... Final tightening............... 90 +10 ° cylinder head, rear...........................................

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

111

112

4 Engine 4.2 Exhaust, intake manifold, air filter

Removing the left exhaust manifold Detaching the exhaust manifold

NOTICE Component damage due to incorrect disassembly Exhaust manifold can be damaged.

For this reason: • Only remove the exhaust manifold in the assembled state • Dismantle the exhaust manifold only in the event of a leak ▸ Dismantling/assembling the exhaust manifold, Page 114 ►Unscrew the mounting bolts 4 and remove along with the bushings 5 ►Remove the front exhaust pipe 2 and rear exhaust pipes 3 together with the seals 1 ►Clean the sealing surfaces

Installing the left exhaust manifold Attaching the exhaust pipe ►Clean the sealing surfaces ►Position the front exhaust pipe 2 and rear exhaust pipes 3 together with the seals 1 ►Screw in and tighten the mounting bolts 4 with the bushings 5 Exhaust pipe M10x40- 1. Torque.... mounting bolt HWF.......... on cylinder head, front........

Exhaust pipe M10x40- Final mounting bolt HWF.......... tightening... on cylinder head, front........

Exhaust pipe M10x40- 1. Torque.... mounting bolt HWF.......... on cylinder head, rear.........

Exhaust pipe M10x40- Final mounting bolt HWF.......... tightening... on cylinder head, rear.........

20 Nm +5

90 ° +10

20 Nm +5

90 ° +10

4.2.2.4 Removing/installing the exhaust manifold (right) Preparations ►Removing/installing the turbocharger (right), Page 298

►Intake fitting, right turbocharger, Page 289

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.2 Exhaust, intake manifold, air filter

key

1 Front exhaust pipe 2 Rear exhaust pipe

Technical data Tightening torques Exhaust pipe mounting bolt on cylinder M10x40-HWF................ 1. Torque......................... head, front.....................................................

20 +5 Nm

Exhaust pipe mounting bolt on cylinder M10x40-HWF................ Final tightening................ 90 +10 ° head, front.....................................................

Exhaust pipe mounting bolt on cylinder M10x40-HWF................ 1. Torque......................... head, rear......................................................

20 +5 Nm

Exhaust pipe mounting bolt on cylinder M10x40-HWF................ Final tightening................ 90 +10 ° head, rear......................................................

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

113

114

4 Engine 4.2 Exhaust, intake manifold, air filter

Removing the right exhaust manifold Detaching the exhaust manifold

NOTICE Component damage due to incorrect disassembly Exhaust manifold can be damaged.

For this reason: • Only remove the exhaust manifold in the assembled state • Dismantle the exhaust manifold only in the event of a leak ▸ Dismantling/assembling the exhaust manifold, Page 114 ►Unscrew the mounting bolts 3 and remove along with the bushings 2 ►Remove the exhaust pipe 4 and exhaust pipe connector 5 with the seals 1 ►Clean the sealing surfaces

Installing the right exhaust manifold Attaching the exhaust pipe ►Clean the sealing surfaces ►Position the exhaust pipe 4 and exhaust pipe connector 5 with the new seals 1 ►Screw in and tighten the mounting bolts 3 with the bushings 2 Exhaust pipe M10x40- 1. Torque.... mounting bolt HWF.......... on cylinder head, front........

Exhaust pipe M10x40- Final mounting bolt HWF.......... tightening... on cylinder head, front........

Exhaust pipe M10x40- 1. Torque.... mounting bolt HWF.......... on cylinder head, rear.........

Exhaust pipe M10x40- Final mounting bolt HWF.......... tightening... on cylinder head, rear.........

20 Nm +5

90 ° +10

20 Nm +5

90 ° +10

4.2.2.5 Dismantling/assembling the exhaust manifold Preparations ►Removing/installing the exhaust manifold (right), Page 112

►Removing/installing the exhaust manifold (right), Page 112

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.2 Exhaust, intake manifold, air filter

key

1 Rear exhaust manifold 2 Front exhaust manifold

Service products Heat-resistant paste ............................................................................................................ 09.16012-0129 Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of damage to components by contaminants For this reason: • Clean components and sealing surfaces before assembly by suitable means.

• Protect cleaned surfaces from re-contamination.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

115

116

4 Engine 4.2 Exhaust, intake manifold, air filter

NOTICE Component damage due to incorrect installation Damaged sealing surfaces result in leaks For this reason: • Check the cylinder liners for damage • Do not use strike with metal tools to insert the connecting pieces into the hole.

• The sealing geometry and surface coating in particular must not be damaged.

• Replace an exhaust manifold with damaged sealing surfaces.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

Tip for users The dismantling/assembling procedures for the left and right exhaust manifolds are essentially identical.

Dismantling the exhaust manifold ►Pull the exhaust manifold 1 out of the exhaust manifold 3 ►Unscrew the connecting pieces 2 and 4 from the exhaust manifold ►Clean the sealing surfaces

Assembling the exhaust manifold

NOTICE Component damage due to incorrect installation Damaged sealing surfaces result in leaks For this reason: • Check the cylinder liners for damage • Do not use strike with metal tools to insert the connecting pieces into the hole.

• The sealing geometry and surface coating in particular must not be damaged.

• Replace an exhaust manifold with damaged sealing surfaces. ►Clean the sealing surfaces ►Apply high-temperature grease to the outside of new connecting pieces 2 and 4 ►Insert the new connecting pieces 2 and 4 into the exhaust pipe 1 as far as possible ►Position the exhaust manifold 3 on the exhaust manifold 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control 4.3.1

Valve / valves

4.3.1.1 Checking/adjusting valve/valves

key

1 Exhaust valve adjusting screw 2 Intake valve adjusting screw

3 Valve bridge, intake valve 4 Valve bridge, exhaust valve

Technical data Tightening torques Intake valve clearance....................................................................................... ............................... 0.50 mm Exhaust valve clearance.................................................... ............................... ............................... 0.80 mm Lock nut for rocker arm adjusting screw........................... ............................... ...............................

45 Nm

Service products White T assembly paste ...................................................................................................... 09.16012-0122 Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

117

118

4 Engine 4.3 Engine control

NOTICE Risk of material damage from incorrectly adjusted valves Reduced engine output or damage to engine.

For this reason: • Adjust the valve clearance only when the engine is cold.

Tip for users The values for valve clearance for the intake and exhaust valves are the same for engines with and without EVB. The testing and adjustment process should be carried out in the same way for engines without EVB. Special tools 1

Engine cranking unit Quantity 1 Cranking the engine in conj. with 80.99626-0017 • Cranking the engine in conjunction with: • Gear ratchet [2]

80.99626-6009

2

Gear ratchet Quantity 1 Crank the engine 1/2" in conjunction with 80.99626-6008

80.99627-0001

3

Feeler gage holding device Quantity 1 Holding the feeler gage • Checking and adjusting the valve clearance in conjunction with: • Feeler gage blade 0.5 [4] • Feeler gage blade 0.8 [5] • Valve wrench size 14 [6]

08.75300-0000

4

Feeler gage blade 0.50 Quantity 1 Feeler gage blade 0.50 • Checking and adjusting the valve clearance in conjunction with: • Holding device [3] • Valve wrench size 14 [6]

80.99607-0177

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control 5

Feeler gage blade 0.8 Quantity 1 Feeler gage blade 0.8

80.99607-0179

• Checking and adjusting the valve clearance in conjunction with: • Holding device [3] • Valve wrench size 14 [6] 6

Valve adjustment spanner size 14 Quantity 1 size 14 Adjust the valve clearance in conjunction with 08.06460-0003

Valve adjustment wrench insert Quantity 1

7

Handle Quantity 1 Detachable handle 9 x 12 - 150 mm Adjust the valve clearance

80.99603-6031

80.99603-0337

08.06460-0003

Checking and adjusting the valve clearance Removing cylinder head cover from cylinder 1 ►Unscrew the mounting bolts 1 ►Remove the cylinder head cover 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

119

120

4 Engine 4.3 Engine control

Attaching the engine cranking unit ►Remove the cap with seal and TDC marking plate from the flywheel housing ►Attach engine cranking unit [1] 1 to flywheel housing

Turning the engine to the adjustment position A = Rocker arms in overlapping position B = Rocker arms free for valve clearance adjustment ►Crank the engine until the rocker arms are in overlap ►Adjust the free rocker arms in accordance with the table

Checking the intake valve clearance ►Insert the holding device [3] 3 with feeler gage blade 0.5 [4] 4 between the valve bridge 1 and the ball cup 2 The valve clearance must be adjusted if it is not 0.50 mm

Adjusting the intake valve clearance ►Loosen the lock nut 3 ►Turn the adjusting screw 2 back until the holding device [3] 5 with feeler gage leaf 0.5 [4] 6 can be inserted between the ball socket 4 and the valve bridge 1 ►Screw in the adjusting screw 2 until the holding device [3] 5 with the feeler gage leaf 0.5 [4] 6 can be moved between the ball socket 4 and the valve bridge 1 with little resistance (inlet) ►Brace the adjusting screw 2 using the size 14 valve wrench [6] ►Brace the adjusting screw 2 and tighten the lock nut 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control Lock nut for rocker arm ......... ......... 45 Nm adjusting screw........................ ►Recheck the setting

Checking the exhaust valve clearance ►Insert the holding device [3] 3 with feeler gage blade 0.8 [5] 4 between the valve bridge 1 and the ball cup 2 The valve clearance must be adjusted if it is not 0.80 mm

Adjusting the exhaust valve clearance ►Loosen the lock nut 3 ►Turn the adjusting screw 2 back until the holding device [3] 6 with feeler gage leaf 0.8 [5] 6 can be inserted between the ball socket 4 and the valve bridge 1 ►Screw in the adjusting screw 2 until the holding device [3] 5 with the feeler gage leaf 0.8 [5] 6 can be moved between the ball socket 4 and the valve bridge 1 with little resistance (inlet) ►Brace the adjusting screw 2 using the size 14 valve wrench [6] ►Brace the adjusting screw 2 and tighten the lock nut 3 ►Recheck the setting

Attaching the cylinder head cover ►Install the cylinder head cover 2 ►Screw in and tighten the mounting bolts 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

121

122

4 Engine 4.3 Engine control

Removing the engine cranking unit ►Remove engine cranking unit [1] 1 to flywheel housing ►Attach the TDC marking plate ►Attach the cap on the flywheel housing with a new seal

4.3.1.2 Removing/installing the valve stem seals Preparations ►Checking/adjusting valve/ valves, Page 117

key

►Removing/installing the cylinder head cover, Page 155

1 Cylinder head 2 Valve spring

4 Valve keys 5 Valve

3 Valve spring retainer

6 Valve stem seal

►Removing/installing the rocker arm mechanism, Page 131

7 Valve guide

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control Service products White T assembly paste ...................................................................................................... 09.16012-0122 Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on engine oil see the MAN service product database. k http://portal.mn-man.biz/sapportal/irj/asp/login?NavigationTarget=navurl:// 18086d7745d3b567b2da029972a5ee34 Special tools 1

Intermediate piece Quantity 1 Intermediate piece • Removing and installing the valve springs in conjunction with: • Bracket [7] • Bracket [8] • Valve-spring compressor [6] • Extension [5] • Assembly device [4]

80.99606-0588

2

Fixing bracket Quantity 1 Fixing bracket • Removing and installing the valve springs in conjunction with: • Intermediate piece [3] • Bracket [7] • Bracket [8] • Valve-spring compressor [6] • Extension [5]

80.99606-6092

3

Extension Quantity 1 In conjunction with 80.99606-6094 • Removing and installing the valve springs in conjunction with: • Intermediate piece [3] • Bracket [7] • Bracket [8] • Valve-spring compressor [6] • Assembly device [4]

80.99606-6094

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

123

124

4 Engine 4.3 Engine control 4

Valve spring compressor Quantity 1 Removing and installing the valve springs in conjunction with 80.99613-0041, 80.99613-0052, 80.99613-0053, 80.99606-6094, 80.99606-6092

80.99613-6000

5

Bracket, short Quantity 1 • Removing and installing the valve springs in conjunction with: • Intermediate piece [3] • Bracket [8] • Valve spring compressor [6] • Extension [5] • Assembly device [4]

80.99613-0050

6

Bracket, short LH Quantity 1 • Removing and installing the valve springs in conjunction with: • Intermediate piece [3] • Bracket [7] • Valve spring compressor [6] • Extension [5] • Assembly device [4]

80.99613-0051

7

Magnetic lifter Quantity 1 Magnetic lifter • Removing the valve keys in conjunction with: • Intermediate piece [3] • Bracket [7] • Bracket [8] • Valve spring compressor [6] • Extension [5] • Assembly device [4]

80.99639-0009

8

Assembly and removal device Quantity 1 Assembly and removal device for the valve stem seal • Installing and removing the valve stem seal in conjunction with: • Sleeve [11]

80.99606-6088

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control Assembly sleeve Quantity 1 Sleeve

9

80.99606-0287

• Installing the valve stem seal in conjunction with: • Assembly device [10]

Removing the valve stem seals Turning the engine to the adjustment position A Rocker arms in overlapping position B Rocker arms free ►Mounting/removing the engine cranking unit, Page 210 ►Crank the engine in the engine's running direction until the rocker arms are in the overlapping position ►Removing and installing free valve stem seals as per table

Assembling the special tool Tip for users The lock washer and bracket [8] have left-hand threads. ►Position the bracket [5] 6 and bracket [6] 4 on the valve spring compressor [4] 2 and screw on by turning the threaded spindle 5 ►Screw on the lock washers 3 and 7 ►Position the lever 1 on the valve spring compressor [4] 2 and secure with the mounting bolt 8

Attaching the assembly device ►Screw the intermediate piece [1] 3 into the cylinder head 1 ►Screw the assembly device [2] 2 into the intermediate piece [1] 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

125

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4 Engine 4.3 Engine control

Attaching the valve spring compressor ►Position the bracket [5] 4 and bracket [6] 5 on the spring disc and tension by turning the threaded spindle 6 ►Hook the valve-spring compressor [4] 2 into the assembly device [2] 3 ►Put the extension [3] 1 onto the valve spring compressor [4] 2

Removing the valve keys CAUTION Risk of injury due to springing back of valve springs For this reason: • The bracket [5] and bracket [6] must be seated correctly on the spring disc.

• Do not remove the valve keys from the valve spring by hand; use the magnetic lifter [7]. ►Push the valve spring compressor [4] down using the extension [3] 1 ►Remove the valve keys 3 from the valve stem 4 using the magnetic lifter [7] 2 ►Slacken the valve spring compressor [4] 1 ►Remove the valve spring together with the washer and spring disc ►Repeat this procedure for all of the valves ►Remove the special tool

Removing the valve stem seals ►Push the assembly device [8] 2 over the valve stem seal 3 ►Clamp the assembly device [8] 2 ►Pull the valve stem seal 3 off the valve guide with the impact weight 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control

Installing the valve stem seals Installing the valve stem seals Tip for users Mount the green valve stem seals on the intake side, the brown valve stem seals on the exhaust side ►Apply a thin layer of clean engine oil on the sleeve [9] 4 and valve stem seal 3 as per MAN standard 3277 ►Push the assembly sleeve [9] 4 over the valve stem 5 ►Insert the valve stem seal 3 into the assembly device [8] 2 and tension ►Push the assembly device [8] 2 over the assembly sleeve [9] 4 ►Knock the valve stem seal 3 onto the valve stem 5 using the impact weight 1 ►Remove the assembly device [8] 2 and the assembly sleeve [9] 4

Installing the valve springs ►Place the washer, outer valve spring 2, inner valve spring 1 and spring disc 3 over the exhaust valve stem ►Place the washer, valve spring 5 and spring disc 4 over the intake valve stem ►Repeat this procedure for all of the valves

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

127

128

4 Engine 4.3 Engine control

Assembling the special tool Tip for users The lock washer and bracket [8] have left-hand threads. ►Position the bracket [5] 6 and bracket [6] 4 on the valve spring compressor [4] 2 and screw on by turning the threaded spindle 5 ►Screw on the lock washers 3 and 7 ►Position the lever 1 on the valve spring compressor [4] 2 and secure with the mounting bolt 8

Attaching the valve spring compressor ►Screw in the intermediate piece [1] 4 ►Screw the assembly device [2] 3 into the intermediate piece [1] 4 ►Position the bracket [5] 5 and bracket [6] 6 on the spring disc and tension by turning the threaded spindle 7 ►Hook the valve-spring compressor [4] 2 into the assembly device [2] 3 ►Put the extension [3] 1 onto the valve spring compressor [4] 2

Installing the valve keys CAUTION Risk of injury due to springing back of valve springs For this reason: • The bracket [5] and bracket [6] must be seated correctly on the spring disc.

• Do not remove the valve keys from the valve spring by hand; use the magnetic lifter [7]. ►Push down the spring disc 4 using the valve spring compressor [4] 3 and extension [3] 2 ►Insert the valve keys 1 ►Loosen the valve spring compressor [4] 3 carefully ►Check that the valve keys 1 are seated properly; if necessary, repeat the procedure

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control 4.3.2

Rocker arm components

4.3.2.1 Checking the rocker arm Preparations

key

►Removing/installing the cylinder head cover, Page 155

1 Exhaust valve 2 Rocker arm bracket 3 Intake valve

Technical data Test values and settings Rocker arm radial play...................................................... ..............................

0.030 - 0.066 mm

Rocker arm bearing inner diameter................................................................. Diameter 34.005 - 34.025 mm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

129

130

4 Engine 4.3 Engine control Special tools 1

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71000-3217

2

Dial gage holder Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71082-0005

3

Measuring tip Quantity 1 Adjusting the pre-loading of the EGR adjusting cylinder within the intake / exhaust system in conjunction with 08.71082-0005, 80.71000-3217

80.99605-0197

Checking the rocker arm Moving the engine into the checking position A = rocker arms overlapping B = rocker arms free ►Mounting/removing the engine cranking unit, Page 210 ►Crank the engine in the engine's running direction using the engine cranking unit and gear ratchet until the relevant rocker arms overlap ►Check free rocker arm according to the table

Checking the rocker arm Measuring the internal diameter of the rocker arm bearing ►Clean the rocker arm 3 with the bearing ►Check the internal diameter of the rocker arm bearing using a dial gage [1] 1 and an internal touch probe 2 ►Repeat the procedure for the remaining rocker arms The permissible inner diameter of the rocker arm bearings is 34.005 - 34.025 mm.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control

Checking the rocker arm radial play ►Attach the dial gage holder [2] 4 incl. dial gage [1] 3 and measuring tip [3] 2 ►Attach the measuring tip [3] 2 of the dial gage [1] 3 with pre-load on the rocker arm 1 ►Push the rocker arm 1 vertically down to the end position ►Zero the dial gage [1] 3 ►Mount the dial gage holder [2] 4 with the dial gage [1] 3 ►Pull the rocker arm 1 upwards to the end position and read off the difference ►Repeat the same procedure for all the rocker arms Permitted radial play of the rocker arm 1 Rocker arm radial play... ............ 0.030 - 0.066 mm If the radial play is outside the tolerance, replace relevant components of the rocker arm mount

4.3.2.2 Removing/installing the rocker arm mechanism Preparations ►Removing/installing the cylinder head cover, Page 155

►Checking/adjusting valve/ valves, Page 117

key Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

131

132

4 Engine 4.3 Engine control 1 Adjusting screw 2 Adjusting screw

3 Valve bridge, intake 4 Valve bridge, exhaust

Technical data Tightening torques Mounting bolt for rocker arm mechanism on M12x80-10.9.................. 1. Torque........................ 90 Nm cylinder head........................................................

Mounting bolt for rocker arm mechanism on M12x80-10.9.................. Final tightening............... 90 ° cylinder head........................................................

Service products Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on engine oil see the MAN service product database. k http://portal.mn-man.biz/sapportal/irj/asp/login?NavigationTarget=navurl:// 18086d7745d3b567b2da029972a5ee34

Removing the rocker arm mechanism Removing the rocker arm mechanism ►Unscrew the mounting bolts 2 ►Remove the rocker arm mechanism 4 ►Identify the installation position of the valve bridges 3 ►Remove the valve bridges 3 ►Remove the push rods 1

Installing the rocker arm mechanism Attaching the rocker arm mechanism ►Apply a thin layer of clean engine oil to the ball cups of the push rods 1 ►Apply a thin layer of clean engine oil to the balls of the rocker arms ►Position the rocker arm mechanism 4 so that the balls of the rocker arms rest in the ball cups of the push rods 1 ►Oil the valve bridges 3 ►Install the valve bridges 3 as marked ►Screw in and tighten new mounting bolts 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control Mounting bolts M12x80-10.9. 1. Torque... 90 Nm for rocker arm mechanism on cylinder head.....

Mounting bolts M12x80-10.9. Final 90 ° for rocker arm tightening.. mechanism on cylinder head.....

4.3.2.3 Dismantling/assembling the rocker arm mechanism Preparations

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►Removing/installing the rocker arm mechanism, Page 131

1 Locking ring 2 Washer 3 Rocker arm 4 Lock nut 5 Rocker arm bracket

Service products Engine oil ..................................................

6 Rocker arm 7 Lock nut 8 Washer

11 Adjusting screw

9 Locking ring 10 Adjusting screw

For more information see the MAN service product database

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

133

134

4 Engine 4.3 Engine control Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on engine oil see the MAN service product database. k http://portal.mn-man.biz/sapportal/irj/asp/login?NavigationTarget=navurl:// 18086d7745d3b567b2da029972a5ee34

Dismantling the rocker arm mechanism Dismantling the rocker arm mechanism ►Detach the locking ring 1 ►Remove the washer 2 ►Mark the installation position of the rocker arm 3 ►Pull the rocker arm 3 off the rocker arm shaft 4 ►Repeat the same procedure for the other rocker arms

Unscrewing the adjusting screw ►Unscrew the lock nut 1 ►Unscrew the adjusting screw 3 from the rocker arm 2

Assembling the rocker arm mechanism Screwing the adjusting screw in ►Screw the adjusting screw 3 in the rocker arm 2 ►Screw the lock nut 1 in

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control

Assembling the rocker arm mechanism ►Apply a thin coat of clean engine oil to the rocker arm shaft 4 as per MAN Standard 3277 ►Push on the rocker arm 3 as marked ►Fit the washer 2 ►Fit a new locking ring 1 ►Repeat the same procedure for the other rocker arms

4.3.2.4 Checking the rocker arm bracket Preparations ►Removing/installing the rocker arm mechanism, Page 131

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►Dismantling/assembling the rocker arm mechanism, Page 133

1 Rocker arm bearing bracket

Technical data Test values and settings Rocker arm shaft outer diameter........................................ ............................ Diameter 33.959 - 33.975 mm

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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136

4 Engine 4.3 Engine control Special tools 1

Micrometer Quantity 1 Measurement range 25 - 50 mm

08.71200-9002

Measuring the rocker arm shaft Measuring the rocker arm shaft external diameter ►Clean the rocker arm shaft 1 ►Check the external diameter of the rocker arm shaft 1 using a micrometer 2 [1] ►Repeat the procedure for the remaining rocker arm shafts 1 Permitted outside diameter of the rocker arm shaft 2 Rocker arm shaft ........ Diameter 33.959 - mm outer diameter............

33.975 If the external diameter is out of tolerance, the rocker arm bracket must be replaced.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control 4.3.3

Camshaft components

4.3.3.1 Removing/installing the camshaft Preparations ►Removing/installing the oil module (left), Page 161 ►Removing/installing the oil module (right), Page 165 ►Removing/installing the coolant pump, Page 94 ►Removing/installing the end cover, Page 257 ►Removing/installing the rail (right), Page 359

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1 Roller plunger 2 Camshaft

►Removing/installing the rail (left), Page 355 ►Removing/installing the intake manifold/air distributor pipe (right), Page 103 ►Removing/installing the intake manifold/air distributor pipe (left), Page 100 ►Removing/installing the exhaust manifold (right), Page 112

►Removing/installing the exhaust manifold (left), Page 110 ►Removing/installing the cylinder head, Page 147 ►Removing/installing the flywheel, Page 201 ►Removing/installing the flywheel housing, Page 259 ►Removing/installing the oil sump , Page 185

4 Mounting bolt 5 Anti-turning device

3 Camshaft gear Technical data Tightening torques Anti-turning device, roller plunger................. ............................................. ......................

13 Nm

Oil nozzle mounting bolt on crankcase..........M14x20-10.9........................ ......................

120 Nm

Camshaft axial play....................................... ............................................. ...................... 0.100 - 0.250 mm Camshaft radial play...................................... ............................................. ...................... 0.060 - 0.112 mm

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

137

138

4 Engine 4.3 Engine control Service products Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on engine oil see the MAN service product database. k http://portal.mn-man.biz/sapportal/irj/asp/login?NavigationTarget=navurl:// 18086d7745d3b567b2da029972a5ee34 Special tools 1

Guide pin Quantity 1 Guide pin • Removing and installing the camshaft

80.99617-6009

Removing the camshaft Detaching the axial shim ►Unscrew the mounting bolts 2 ►Remove the axial shim 1

Attaching the guide pin ►Screw the guide pin [1] 1 into the camshaft

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control

Removing the camshaft ►Push out the camshaft 1 in the direction of the flywheel housing using the guide pin [1] ►Unscrew the guide pin [1]

Removing the oil nozzles ►Unscrew the mounting bolt 1 ►Pull the oil nozzle 2 out of the crankcase

Unscrewing the anti-turning device ►Remove anti-turning devices 1 and 2

Removing the roller plunger ►Pull the roller plunger 1 out of the crankcase 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

139

140

4 Engine 4.3 Engine control

Installing the camshaft Installing the roller plunger ►Apply a thin coat of clean engine oil to the roller plunger 1 as per MAN Standard 3277 ►Align the recess 2 of the roller plunger 1 with the threaded hole of the anti-turning device 3 ►Insert the roller plunger 1 in the crankcase 2

Screwing in the anti-turning device

NOTICE Risk of damage to roller plungers or antiturning devices Ensure that the anti-turning device engages in the recess of the roller plunger For this reason: • Screw in new anti-turning devices 1 and 2 • Tighten anti-turning devices 1 and 2 Anti-turning device, roller ........... ........... 13 Nm plunger................................

Installing the oil nozzles ►Insert the oil nozzle 2 into the crankcase ►Screw in and tighten new mounting bolt 1 Oil nozzle mounting M14x20-10.9...... ..... 120 Nm bolt on crankcase....

Installing the camshaft ►Apply a thin layer of clean engine oil on the camshaft bearing as per MAN Standard 3277 ►Screw the guide pin [1] into the camshaft 1 ►Carefully insert the camshaft 1 from the flywheel side using the guide pin [1]

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control

Detaching the guide pin ►Unscrew the guide pin [1] 1 from the camshaft

Attaching the axial shim ►Attach axial shim 1 ►Screw in and tighten new mounting bolts 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

141

142

4 Engine 4.3 Engine control 4.3.4

Camshaft drive

4.3.4.1 Checking the valve timing

key

1 Cylinder 1 inlet valve

Technical data Tightening torques Valve lift................................................... ....................................... ....................................... 10.0 - 10.6 mm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control Special tools 1

Engine cranking unit Quantity 1 Cranking the engine in conj. with 80.99626-0017

80.99626-6009

• Cranking the engine in conjunction with: • Gear ratchet [2]

2

Gear ratchet Quantity 1 Crank the engine 1/2" in conjunction with 80.99626-6008

80.99627-0001

3

Dial gage holder Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71082-0005

4

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71000-3217

Checking the valve timing Removing cylinder head cover from cylinder 1 ►Unscrew the mounting bolts 2 ►Remove the cylinder head cover 1 ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

143

144

4 Engine 4.3 Engine control

Attaching the engine cranking unit ►Remove the cap with seal and TDC marking plate from the flywheel housing ►Clean the sealing surfaces ►Attach engine cranking unit [1] 1 to flywheel housing ►Crank the engine with the engine cranking unit [1] 1 and gear ratchet [2] in the running direction of the engine, until valves cut over the 1st cylinder ►Check the TDC mark on the flywheel; set directly to TDC if necessary ►Set engine to 50° before TDC against the engine's running direction ►Set engine to 30° before TDC in the engine's running direction

Checking the valve lift ►Attach the dial gage [4] 1 incl dial gage holder [3] 2 onto the cylinder head ►Place the measuring tip 3 of the dial gage [4] 1 on the inlet valve disc 4 ►Zero the dial gage [4] 1 ►Continue cranking the engine in the engine's running direction until the dial gage pointer stops moving In this position, the proper valve lift must be 10.0 - 10.6 mm.

If the valve lift is outside the tolerance range of 10.0 - 10.6 mm, check the camshaft, transmission parts of the valve control, and timing gears; replace if necessary.

Attaching the cylinder head cover ►Check the seal; replace if necessary ►Install the cylinder head cover 1 ►Screw in and tighten the mounting bolts 2

4.3.4.2 Removing/installing the camshaft gear Preparations ►Removing/installing the flywheel, Page 201

►Removing/installing the flywheel housing, Page 259

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.3 Engine control

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1 Mounting bolt 2 Camshaft gear

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Removing the camshaft gear Detaching the camshaft gear ►Unscrew the mounting bolts 2 ►Lift the camshaft gear 1 off the alignment pin

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

145

146

4 Engine 4.3 Engine control

Dismantling the camshaft gear ►Clamp the camshaft gear 3 with idler gear 2 in a vice with protective jaws ►Unscrew the mounting bolts 1 ►Unclamp the camshaft gear 3 with idler gear 2 ►Remove the idler gear 2 from the camshaft gear 3 ►Remove the pin 4

Installing the camshaft gear Assembling the camshaft gear ►Insert the pin 4 ►Place the idler gear 2 on the camshaft gear 3 ►Clamp the camshaft gear 3 with idler gear 2 in a vice with protective jaws ►Screw in and tighten new mounting bolts 1 ►Unclamp the camshaft gear 3 with idler gear 2

Attaching the camshaft gear ►Place the camshaft gear 1 on the alignment pin ►Screw in and tighten new mounting bolts 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.4 Cylinder head

4.4.1 Removing/installing the cylinder head Preparations ►Draining/topping up the coolant; see Operating Instructions ►Removing/installing the coolant line on the cylinder head (right), Page 79 ►Removing/installing the coolant line on the cylinder head (left), Page 76 ►Removing/installing the fuel return line (right), Page 335 ►Removing/installing the fuel return line (left), Page 331 ►Removing/installing the turbocharger (left), Page 293

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►Removing/installing the turbocharger (right), Page 298 ►Removing/installing the rocker arm mechanism, Page 131 ►Removing/installing the injection pressure line (right), Page 350 ►Removing/installing the injection pressure line (left), Page 345 ►Removing/installing the injector with nozzle (common rail), Page 367 ►Checking/adjusting valve/ valves, Page 117

►Removing/installing the cylinder head cover, Page 155 ►Removing/installing the intake manifold/air distributor pipe (right), Page 103 ►Removing/installing the intake manifold/air distributor pipe (left), Page 100 ►Removing/installing the exhaust manifold (right), Page 112 ►Removing/installing the exhaust manifold (right), Page 112

1 Cylinder head

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

147

148

4 Engine 4.4 Cylinder head Technical data Tightening torques Cylinder head mounting bolts on M18 x 2 x 246................................. 1. Torque........................ crankcase......................................

50 Nm

Cylinder head mounting bolts on M18 x 2 x 246................................. 2. Torque........................ crankcase......................................

150 Nm

Cylinder head mounting bolts on M18 x 2 x 246................................. 3. Torque........................ crankcase......................................

300 Nm

Cylinder head mounting bolts on M18 x 2 x 246................................. 4. Torque........................ crankcase......................................

90 °

Cylinder head mounting bolts on M18 x 2 x 246................................. 5. Torque........................ crankcase......................................

90 °

Cylinder head mounting bolts on M18 x 2 x 246................................. Final tightening.............. crankcase......................................

90 °

Lifting eye mounting bolt............... M12x45-10.9.................................. 1. Torque........................ 20 +10 Nm Lifting eye mounting bolt............... M12x45-10.9.................................. Final tightening.............. 90 +10 ° Service products White T assembly paste ...................................................................................................... 09.16012-0122 Important information

NOTICE Risk of material damage to components if bolts are reused Once used, cylinder head bolts do not ensure a safe seal between the cylinder head and the crankcase.

For this reason: • Do not reuse cylinder head bolts

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Special tools 1

Socket Quantity 1 Loosening and tightening the size 22 cylinder head bolts

80.99612-0024

2

Power amplifier Quantity 1 i=1:3.3 / up to 800 Nm 1 loosening the cylinder head bolts and tightening 1 in conjunction with 80.99606-0551, 80.99607-0172, 80.99606-0553, 06.02191-0407, 06.22729-0006, 06.56331-3274, 80.99606-0552, 80.99612-0023, 80.99612-0024 2 undoing and tightening the flywheel screws in the crank gear

80.99619-0006

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.4 Cylinder head 3

Support Quantity 1 Loosening and tightening the cylinder head bolts

80.99606-0551

4

Angle gage Quantity 1 Loosening and tightening the cylinder head bolts

80.99607-0172

5

Column Quantity 1 Support • Loosening and tightening the cylinder head bolts in conjunction with: • Socket wrench insert size 22 [1] • Power amplifier wrench i = 1 : 3,3 [2] • Support [3] • Angle gage [4] • Stud bolt [6] • Connecting pin [7] • Rubber ring 42 mm [8] • Guide adapter [9] • Socket wrench insert [10]

80.99606-0641

6

Stud bolt Quantity 1 M8 x 20 - 10.9 - MAN 183-PHR Loosening and tightening the cylinder head bolts

06.02191-0407

7

Connecting pin Quantity 1 5.5 x 35 for 3/4" inserts, loosening and tightening the cylinder head bolts

06.22729-0006

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

149

150

4 Engine 4.4 Cylinder head 8

Rubber ring Quantity 1 42 mm rubber ring for 3/4" inserts

08.06142-9006

9

Guide adapter Quantity 1 Component of 80.99606-6101 support for power amplifier, loosening and tightening the cylinder head bolts

80.99606-0552

10

Socket Quantity 1 • Loosening and tightening the cylinder head bolts in conjunction with: • Socket wrench insert size 22 [1] • Power amplifier wrench i = 1 : 3.3 [2] • Support [3] • Angle gage [4] • Holder [5] • Stud bolt [6] • Connecting pin [7] • Rubber ring 42 mm [8] • Guide adapter [9]

80.99603-0327

11

Alignment strip Quantity 1 Alignment device • Aligning cylinder heads

80.99606-0582

12

Dial gage holder base plate 80.99605-0172 Quantity 1 Dial gage holder base plate Checking the cylinder liner protrusion in conjunction with: • Dial gage [13] • Measuring plate [14] • Hex set screw [15] • Washer [16]

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.4 Cylinder head 13

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder in the intake / exhaust system

08.71000-3217

14

Measuring plate Quantity 1 Measuring plate • Checking the cylinder liner protrusion in conjunction with: • Dial gage Holder [12] • Dial gage [13] • Hex set screw[15] • Washer [16]

80.99605-0289

15

Hex set screw Quantity 1 Hex set screw • Checking the cylinder liner protrusion in conjunction with: • Dial gage Holder [12] • Dial gage [13] • Measuring plate [14] • Washer [16]

06.01499-0015

16

Washer Quantity 1 Washer Component of 80.99606-6101 support for power amplifier • Checking the cylinder liner protrusion in conjunction with: • Dial gage Holder [12] • Dial gage [13] • Measuring plate [14] • Hexagonal shanks screw [15]

80.99609-0033

Removing the cylinder head Removing the left and right lifting eyes ►Remove the mounting bolts 1 and 4 ►Remove the lifting eyes 2 and 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

151

152

4 Engine 4.4 Cylinder head

Assembling the special tool ►Power amplifier wrench width i =1: Insert 3.3 [2] 1 into the support [3] 2 ►Attaching the holder [5] 5 with stud bolt [6] 3 and guide adapter [9] 4 to the support [3] 2 ►Angle gage [4] 9 on power amplifier wrench i = 1 : 3.3 [2] 1 ►Fit the socket wrench size 22 [1] 8 on the power amplifier wrench i = 1 : 3.3 [2] 1 and secure with connecting pin [7] 7 and 42 mm rubber ring [8] 6 ►Insert one socket wrench insert [10] each into the holder [5] 5 and into the socket wrench insert size 22 [1] 8

Loosening sequence for cylinder head bolts ►Loosen cylinder head bolts according to the loosening sequence 1 through 6

Loosening the cylinder head bolts ►Fit the special tool 1 on the cylinder head bolt to be loosened ►Loosen all cylinder head bolts with the special tool 1 according to the loosening sequence

Removing the cylinder head ►Unscrew the cylinder head bolts 3 ►Remove the cylinder head 2 ►Remove the cylinder head gasket 1 ►Clean the sealing surfaces ►Clean the threaded holes in the crankcase

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.4 Cylinder head

Installing the cylinder head Checking the cylinder liner protrusion ►Place the measuring plate [14] 1 on the cylinder liner ►Screw in and tighten the hex set screw [15] 4 with washer [16] ►Put the dial gage holder [12] 2 with the dial gage [13] 3 onto the measuring plate [14] 1 ►Place the dial gage tip 5 on the crankcase ►Zero the dial gage [13] 3 ►Carefully place the dial gage tip 5 on the cylinder liner and read off the difference The permissible cylinder liner protrusion is 0.035 0.085 mm.

If the cylinder liner protrusion is out of tolerance, install a new cylinder liner/crankcase. ▸ Removing/installing the cylinder liner , Page 273

Positioning the cylinder head ►Place the new cylinder head gasket 1 over the alignment pins ►Place the cylinder head 2 over the alignment pins ►Apply a thin layer of White T assembly paste to the contact surface of the new cylinder head bolts 1 ►Screw in the cylinder head bolts 3

Tightening sequence for cylinder head ►Tighten the cylinder head bolts according to the tightening sequence 1 through 6

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

153

154

4 Engine 4.4 Cylinder head

Initial torquing of cylinder head bolts ►Attach an alignment strip [11] 2 to the cylinder heads on the exhaust side ►Tighten the cylinder head bolts 1 using a socket wrench insert and a torque wrench according to the tightening sequence ►Tighten the cylinder head bolts 1 Cylinder head M18 x 2 x 1. Torque.. mounting bolts on 246............. crankcase.............

50 Nm

Cylinder head M18 x 2 x 2. Torque.. 150 Nm mounting bolts on 246............. crankcase.............

Cylinder head M18 x 2 x 3. Torque.. 300 Nm mounting bolts on 246............. crankcase.............

Final tightening of cylinder head bolts Tip for users Note the power amplifier wrench multiplication ratio i = 1 : 3.3. ►Tighten the cylinder head bolts using the special tool 1 according to the tightening sequence Cylinder head M18 x 2 x 4. Torque....... 90 ° mounting bolts on 246............. crankcase.............

Cylinder head M18 x 2 x 5. Torque....... 90 ° mounting bolts on 246............. crankcase.............

Cylinder head M18 x 2 x Final 90 ° mounting bolts on 246............. tightening...... crankcase.............

Attaching the left and right lifting eyes ►Position the lifting eyes 2 and 3 ►Screw in and tighten new mounting bolts 1 and 4 Lifting eye M12x45-10.9.. 1. Torque.... mounting bolt..............

20 Nm +10

Lifting eye M12x45-10.9.. Final mounting tightening... bolt..............

90 ° +10

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.4 Cylinder head 4.4.1

Cylinder head cover components

4.4.1.1 Removing/installing the cylinder head cover

key

1 Cylinder head cover

Technical data Tightening torques Injector cable mounting nut....................................................................... .............................. 1.5 ±0.25 Nm Important information

NOTICE Risk of material damage from improperly tightened threaded connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed tightening.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

155

156

4 Engine 4.4 Cylinder head Special tools 1

Torque screwdriver Quantity 1 Range 40 - 200 cNm suitable interchangeable bits 6 mm

08.06510-9024

2

Adapter Quantity 1 1/4" mount the injector cable

08.06139-9029

3

Socket Quantity 1 SW 7 mount the injector cable

08.06141-0700

Removing the cylinder head cover Dismantling the cylinder head cover ►Unscrew the mounting bolts 1 ►Remove the cylinder head cover 2

Removing the injector cables ►Mark the installation position of the injector cable 1 ►Unscrew the mounting nuts from the injector ►Remove the injector cable 1 from the cable conduit of the seal 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.4 Cylinder head

Removing the seal ►Remove the seal 1 ►Clean the sealing surfaces

Installing the cylinder head cover Fitting the seal ►Clean the sealing surfaces ►Check the condition of the seal 1, replace if necessary ►Fit the seal 1

Attaching the injector cables

NOTICE Risk of material damage due to incorrect installation Risk of short circuit due to cable lugs touching.

For this reason: • Cable lugs must not come into contact after assembly ►Connect the injector cable to the injector as marked ►Screw on the mounting nuts with torque screwdriver [1] in conjunction with adapter [2] and socket wrench insert size 7 [3] and tighten Injector cable ......... ......... 1.5 ±0.25 Nm mounting nut................ ►Thinly apply White T assembly paste on the cable conduit of the seal 2 ►Insert the injector cable 1 into the cable conduit of the seal 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

157

158

4 Engine 4.4 Cylinder head

Tightening sequence for cylinder head cover ►Tighten the mounting bolts according to tightening sequence 1 to 3

Attaching cylinder head cover ►Fit the cylinder head cover 2 ►Screw in and tighten the mounting bolts 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher 4.5.1

Oil filter

4.5.1.1 Removing/installing the oil filter insert

key

1 Oil filter cover

Technical data Tightening torques Oil filter cover........................................................................................... .................................... 40 +10 Nm Service products Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

ENVIRONMENTAL WARNING Use a suitable container to collect any discharging engine oil.

Literature reference For information on engine oil see the MAN service product database.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

159

160

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher k http://portal.mn-man.biz/sapportal/irj/asp/login?NavigationTarget=navurl:// 18086d7745d3b567b2da029972a5ee34 Special tools 1

Socket Quantity 1 Size 36, 3/8", removing and installing the cover of the fuel pre-filter of the common rail system

80.99603-0325

2

Torque wrench Quantity 1 Torque wrench 6-50 Nm square drive 3/8" square for insertion tool 9x12 adjust to valve clearance, tighten the lock nut of the adjusting screw

08.06450-0006

3

Ratchet insert Quantity 1 Size 1 3/8", square

08.06455-0001

4

Handle Quantity 1 Detachable handle 9 X 12 - 400 mm

08.06460-0001

Removing the oil filter insert Removing the oil filter insert ►With 2-3 revolutions, detach the oil filter cover 3 with the handle [4], ratchet insert [3] and socket wrench insert SW 36 [1] ►Pull the O-ring 2 off the oil filter cover 3 ►Pull the oil filter insert 1 out of the oil filter cover 3 ►Measure and note the length of the old oil filter insert 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

NOTICE Risk of engine damage due to unsuitable components For this reason: • Measure and note the length of the old oil filter insert • The old and new oil filter inserts must be the same length.

Installing the oil filter insert Installing the oil filter insert ►Fit a new O-ring 2 on the oil filter cover 3 ►Apply a thin coat of clean engine oil to the Oring 2 as per MAN Standard 3277 ►Insert the new oil filter insert 1 into the oil filter cover 3 ►Screw in the oil filter cover 3 with a torque wrench [2], ratchet insert [3] and socket wrench insert SW 36 [1] and tighten it Oil filter cover......................... ............. 40 +10 Nm

4.5.1.2 Removing/installing the oil module (left) Preparations ►Removing/installing the alternator V-belt, Page 191

►Removing/installing the coolant pump, Page 94

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

key

1 Cable harness bracket 2 Left oil module 3 Oil return lines

Service products Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

ENVIRONMENTAL WARNING Use a suitable container to collect any discharging engine oil.

Literature reference For information on engine oil see the MAN service product database. k https://portal.mn-man.biz/sapportal/irj/asp

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher Special tools 1

Hose clip pliers Quantity 1 Hose clamp pliers, angled version

80.99625-0073

• Installing/removing spring band clamps

Removing the oil module Detaching the molded hose ►Undo the spring band clamps 1 using the hose clamp pliers for spring band clamps [1] and push onto the molded hose 2 ►Detach the molded hose 2 and remove with the spring band clamps 1

Removing the left oil return line ►Unscrew the fasteners 3 and 5 ►Loosen the retaining nut on the WVE connector 2 ►Unscrew the oil return line retaining nuts 1 and 3 ►Remove the oil return lines 1 and 3

Removing cable harness bracket ►Mark the installation position of mounting bolts 5, 6, 7 and 8 ►Remove the mounting bolts 6 , 7 and 8 ►Screw in the mounting bolt 5, incl. washer ►Remove the bracket 3 with bushings 1 and 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Removal instructions for left oil module ►Do not unscrew the oil cooler mounting bolts 1 to remove the oil module

Removing the left oil module ►Mark the installation position of mounting bolts 3, 4, 6 , 7 and 8 ►Remove mounting bolts 3, 4, 6 and 7 ►Unscrew the mounting bolt 8 with washer 9 ►Remove the oil module 1 incl. seal 2 ►Remove the O-rings 5 ►Clean the sealing surfaces

Installing the left oil module Attaching the left oil module ►Clean the sealing surfaces ►Insert the new O-rings 5 ►Attach the oil module 1 incl. a new seal 2 ►Screw in mounting bolts 3, 4, 6 and 7 as marked ►Screw in the mounting bolt 8 with washer 9 as marked

Attaching the left bracket ►Position the bracket 3 with bushings 1 and 2 ►Screw in the mounting bolt 5 incl. washer as marked ►Screw in the mounting bolts 6, 7 and 8 as marked

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Tightening sequence for left oil module ►Tighten the mounting bolts 4 ►Loosen mounting bolts 4 60° ►Tighten the mounting bolts 1, 2, 3 and 5 ►Tighten the mounting bolts 4

Attaching the left oil return line ►Position the oil return lines 1 and 3 ►Screw on the oil return line retaining nuts 1 and 3 ►Screw the retaining nut on the WVE connector 2 ►Tighten the oil return line retaining nuts 1 , 3 and the WVE connector 2 ►Install the fasteners 3 and 5 at the installation position

Attaching the left molded hose ►Position the molded hose 2 with the spring band clamps 1 ►Mount the spring band clamps 1 using the hose clamp pliers for spring band clamps [1]

4.5.1.3 Removing/installing the oil module (right) Preparations ►Removing/installing the alternator V-belt, Page 191

►Removing/installing the coolant pump, Page 94

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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166

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

key

1 Right oil module 2 Oil return lines

Service products Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

ENVIRONMENTAL WARNING Use a suitable container to collect any discharging engine oil.

Literature reference For information on engine oil see the MAN service product database. k https://portal.mn-man.biz/sapportal/irj/asp

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher Special tools 1

Hose clip pliers Quantity 1 Hose clamp pliers, angled version

80.99625-0073

• Installing/removing spring band clamps

Removing the oil module Detaching the molded hose ►Undo the spring band clamps 1 using the hose clamp pliers for spring band clamps [1] and push onto the molded hose 2 ►Detach the molded hose 2 and remove with the spring band clamps 1

Removing the right oil return line ►Unscrew the fasteners 3 and 4 ►Loosen the retaining nut on the WVE connector 1 ►Unscrew the oil return line retaining nuts 2 and 5 ►Remove the oil return lines 2 and 5

Removing cable harness bracket ►Unscrew the mounting bolts 3 and remove with the bushing 1 and bracket 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Removal instructions for right oil module ►Do not unscrew the oil cooler mounting bolts 1 to remove the oil module

Removing the right oil module ►Mark the installation position of mounting bolts 3, 4, 5, 6 , 7 and 8 ►Remove the mounting bolts 3, 5, 6, 7 and 8 ►Unscrew the mounting bolt 4, with washer ►Remove the oil module 2 incl. seal 1 ►Remove the O-rings 9 ►Clean the sealing surfaces

Installing the oil module Attaching the right oil module ►Clean the sealing surfaces ►Insert the new O-rings 9 ►Position the oil module 2 incl. seal 1 ►Screw in the mounting bolt 4 with washer as marked ►Screw in the mounting bolts 3, 5 , 6, 7 and 8 as marked

Attaching the cable harness bracket ►Position the bracket 2 with the bush 1 ►Screw in and tighten the mounting bolts 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Tightening sequence for right oil module ►Tighten the mounting bolt 4 ►Loosen mounting bolts 4 60° ►Tighten the mounting bolts 2 , 1, 5 and 3 ►Tighten the mounting bolts 4

Attaching right oil return line ►Position the oil return lines 2 and 5 ►Screw on the oil return line retaining nuts 2 and 5 ►Screw the retaining nut on the WVE connector 1 ►Tighten the oil return line retaining nuts 1 , 3 and the WVE connector 2 ►Install the fasteners 3 and 4 at the installation position

Attaching the molded hose ►Position the molded hose 2 with the spring band clamps 1 ►Mount the spring band clamps 1 using the hose clamp pliers for spring band clamps [1]

4.5.1.4 Dismantling/assembling the oil module Preparations ►Removing/installing the oil module (left), Page 161

►Removing/installing the oil module (right), Page 165

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

key

1 Oil filter cover 2 O-ring 3 Engine oil filter insert 4 Support tube 5 Drain valve 6 Seal

7 Oil cooler 8 Screw plug 9 Screw plug 10 Pressure-relief valve 11 Screw plug

13 Mounting bolt 14 Oil module housing 15 O-ring 16 Oil separator 17 Mounting bolt

12 Mounting bolt

Technical data Tightening torques Oil filter cover........................................... .......................................................... ............................. 40 +10 Nm Support tube............................................ .......................................................... .............................

25 Nm

Pressure-relief valve................................. M27x1.5............................................ ............................. 40 +5 Nm Oil cooler mounting bolt...........................M8x65-T45....................................... ............................. 25 +5 Nm Oil cooler mounting bolt...........................M8x95-T45....................................... ............................. 25 +5 Nm Screw plug............................................... M14x1.5............................................ ............................. 25 +5 Nm Screw plug............................................... M18x1.5............................................ ............................. 25 +5 Nm Screw plug............................................... M26x1.5............................................ ............................. 80 +8 Nm Screw plug............................................... M33x2............................................... ............................. 80 +10 Nm Mounting bolt........................................... M6 x 50............................................. ............................. 12 -2 Nm Test values and settings Pressure relief valve opening pressure..................................................... .................................... 10 +2.2 bar

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher Service products Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage due to oil emulsion Coolant may enter the oil sump from the crankcase when removing the oil module.

For this reason: • Drain all of the coolant before removing the oil module.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of damage to components by contaminants Components will be damaged.

For this reason: • Clean components and sealing surfaces before assembly by suitable means.

• Protect cleaned surfaces from re-contamination.

Tip for users Dismantling/assembling the left and right oil modules is identical in principle.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants. In such cases, plan and execute the repair work accordingly.

Special tools 1

Handle Quantity 1

08.06460-0001

2

Torque wrench Quantity 1

08.06450-0006

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher 3

Ratchet insert Quantity 1

08.06455-0001

4

Socket Quantity 1 Size 36, 3/8", removing and installing the cover of the fuel pre-filter of the common rail system

80.99603-0325

Dismantling the oil module Removing the oil cooler

NOTICE Risk of material damage if the oil module is placed down incorrectly Components will be damaged.

For this reason: • Put the oil module aside so as not to damage the oil cooler ►Mark the installation position of mounting bolts 4 and 5 ►Remove the mounting bolts 4 and 5 ►Remove the oil cooler 2, incl. the seals 1 and 3 ►Clean the sealing surfaces

Removing the oil separator ►Screw in the mounting bolt 1, incl. washer ►Extract the oil separator 2 from the oil module ►Remove the O-rings 3 and 4

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Removing the oil filter

NOTICE Risk of material damage due to engine oil contamination Components will be damaged.

For this reason: • Always allow engine oil to drain completely ►Unscrew the oil filter cover 1 using the handle [1], ratchet insert [3] and socket wrench insert size 32 [4] ►After approx. 1-2 minutes, unscrew the oil filter cover 1 with the socket wrench insert size 36 [1] and remove it ►Remove the oil filter insert 3 from the oil filter cover 1 ►Extract the support tube 4 from the oil module ►Remove the O-ring 2

Removing the drain valve ►Remove the drain valve 1 from the oil module housing 2

Removing the pressure relief valve ►Unscrew the threaded plug 3 with the sealing ring 2 ►Unscrew the pressure relief valve 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Unscrewing the screw plugs ►Unscrew screw plugs 1, 2 , 3 and 4 incl. seals

Assembling the oil module Screwing the screw plugs in ►Screw in and tighten the threaded plugs 1, 2 ,3 and 4 with new sealing rings Threaded plug 1.....M18x1.5.......... ........ 25 +5 Nm Threaded plugs 2, M26x1.5.......... ........ 80 +8 Nm 3.............................

Threaded plug 4.....M14x1.5.......... ........ 25 +5 Nm

Installing the pressure-relief valve ►Screw in and tighten the pressure relief valve 1 Pressure-relief M27x1.5........... ........ 40 +5 Nm valve....................... ►Screw the screw plug 3 in with a new sealing ring 2 and then tighten Screw plug........ M33x2............... ........... 80 +10 Nm

Installing the drain valve ►Place the drain valve 1 in the oil module housing 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Removing the oil filter ►Screw the support tube 4 into the oil module and tighten it Support tube.............. ................ ................ 25 Nm ►Fit a new O-ring 2 on the oil filter cover 1 ►Apply a thin layer of clean engine oil to the Oring 2 ►Insert the new oil filter insert 3 into the oil filter cover 1 ►Screw in the oil filter cover 1 with a torque wrench [2], ratchet insert [3] and socket wrench insert size 32 [4] and tighten it Oil filter cover on the oil ......... ......... 40 +10 Nm module.................................

Installing the oil separator ►Fit new O-rings 3 and 4 onto the oil separator 2 ►Insert the oil separator 2 ►Screw the mounting bolts 1 in with washers and then tighten Mounting bolt.......M6 x 50............. ......... 12 -2 Nm

Installing the oil cooler ►Clean the sealing surfaces ►Install oil cooler 2 with new seals 1 and 3 in the oil module ►Screw the mounting bolts 4 and 5 in as marked and tighten Oil cooler mounting M8x65-T45...... ....... 25 +5 Nm bolt..........................

Oil cooler mounting M8x95-T45...... ....... 25 +5 Nm bolt..........................

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher 4.5.2

Oil cooler

4.5.2.1 Removing/installing the heat exchanger/engine oil cooler Preparations ►Removing/installing the oil module (left), Page 161

key

1 Mounting bolt 2 Oil cooler

►Removing/installing the oil module (right), Page 165

3 Seal 4 Oil module

5 Mounting bolt 6 Mounting bolt

Technical data Tightening torques Mounting bolts for heat exchanger on oil module...........M6 x 65................................ .................. 25 +5 Nm Mounting bolts for heat exchanger on oil module...........M6 x 95................................ .................. 25 +5 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Removing the oil cooler Removing the oil cooler

NOTICE Risk of material damage if the oil module is placed down incorrectly Components will be damaged.

For this reason: • Put the oil module aside so as not to damage the oil cooler ►Mark the installation position of mounting bolts 1, 4 and 5 ►Remove the mounting bolts 1, 4 and 5 ►Remove the oil cooler 2 incl. the seals 3 ►Clean the sealing surfaces

Installing the oil cooler Installing the oil cooler ►Insert the oil cooler 2 with new seals 3 ►Screw in the mounting bolts 1, 4 and 5 as marked and tighten by hand ►Tighten the mounting bolts 1, 4 and 5 Mounting bolts for heat M6 x 65.... ..... 25 +5 Nm exchanger on oil module Mounting bolts for heat M6 x 95.... ..... 25 +5 Nm exchanger on oil module

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher 4.5.3

Oil pipe, intake basket, oil screen

4.5.3.1 Removing/installing the oil pump suction line manifold

key

1 Oil pump suction line manifold

Service products Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on engine oil see the MAN service product database. k https://portal.mn-man.biz/sapportal/irj/asp

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Removing the manifold for the oil suction line Removing the manifold for left oil suction line ►Unscrew the mounting bolts 3 ►Remove manifold 2 with O-ring 1 ►Pull the coupling pipe 4 out ►Clean the sealing surfaces

Removing the manifold for right oil suction line ►Unscrew the mounting bolts 3 ►Remove manifold 2 with O-ring 1 ►Pull the coupling pipe 4 out ►Clean the sealing surfaces

Installing the manifold for the oil suction line Attaching the manifold for the right oil suction line ►Clean the sealing surfaces ►Apply a thin layer of clean engine oil to the new O-ring 1 and new coupling pipe 4 ►Insert the new coupling pipe 4 ►Attach the manifold 2 with new O-ring 1 ►Screw in and tighten the mounting bolts 3

Attaching the manifold for left oil suction line ►Clean the sealing surfaces ►Apply a thin layer of clean engine oil to the new O-ring 1 and new coupling pipe 4 ►Insert the new coupling pipe 4 ►Attach the manifold 2 with new O-ring 1 ►Screw in and tighten the mounting bolts 3

4.5.3.2 Removing/installing the oil pump suction line/intake pipe Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher Preparations

key

►Removing/installing the oil sump , Page 185

1 Suction lines

Service products Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on engine oil see the MAN service product database. k https://my.man-mn.com/portal/irj/asp/

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Removing the oil suction lines Removing the oil suction lines ►Unscrew mounting bolts 2 and 4 with washers ►Tighten the oil suction lines 3 and 5 ►Remove the O-rings 1 and 6 from the oil suction lines 3 and 5 ►Clean the sealing surfaces

Dismantling the oil suction line ►Remove the retaining ring 2 ►Remove the strainer 1 from the oil suction line ►Clean the strainer 1

Installing the oil suction lines Assembling the oil suction line ►Clean the strainer 1 ►Insert the strainer 1 into the oil suction line ►Install the retaining ring 2

Installing the oil suction line ►Clean the sealing surfaces ►Apply a thin layer of engine oil on the new Orings 1 and 6 ►Install the new O-rings 1 and 6 on the oil suction lines 3 and 5 ►Insert the oil suction lines 3 and 5 as far as possible ►Screw the mounting bolts 2 and 4 in with washers and then tighten

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher 4.5.4

Oil intake and return pump

4.5.4.1 Removing/installing the oil pump Preparations

key

►Removing/installing the end cover, Page 257

1 Oil pump 2 Oil pump

Technical data Tightening torques Oil pump mounting bolt on end cover.................. M6 x 40 - 10.9...................................... ................. 15 Nm Test values and settings Ring gear - crankshaft gear backlash................................................................................. 0.060 - 0.240 mm Ring gear axial play............................................................................................................. 0.040 - 0.090 mm Axial play of rotor................................................................................................................ 0.035 - 0.080 mm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher Special tools 1

Dial gage holder base plate Quantity 1 Dial gage holder base plate

80.99605-0172

• Checking the ring gear axial and radial play in conjunction with: • Dial gage [2]

2

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder in the intake / exhaust system

08.71000-3217

Removing the oil pumps Removing the oil pumps ►Mark the installation position of mounting bolts 1 and 4 ►Remove the mounting bolts 1 and 4 ►Remove oil pumps 2 and 3

Checking the oil pump Checking the ring gear axial play ►Put the dial gage holder [1] 2 with the dial gage [2] 1 onto the oil pump ►Position the pre-loaded dial gage [2] 1 onto the ring gear 3 ►Press the ring gear 3 towards the drive wheel ►Zero the dial gage [2] 1 ►Push the ring gear 3 towards the dial gage [2] 1 and read off the difference The permissible axial play on the ring gear 3 is 0.040 - 0.090 mm.

If the axial play is out of tolerance, the oil pump must be replaced.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Checking the axial play of the rotor ►Put the dial gage holder [1] 2 with the dial gage [2] 1 onto the oil pump ►Position the pre-loaded dial gage [2] 1 onto the rotor 3 ►Press the rotor 3 towards the drive wheel ►Zero the dial gage [2] 1 ►Push the rotor 3 towards the dial gage [2] 1 and read off the difference The permissible axial play of the rotor 3 is 0.035 0.080 mm.

If the axial play is out of tolerance, the oil pump must be replaced.

Installing the oil pumps Installing the oil pumps ►Attach oil pumps 2 and 3 ►Screw in new mounting bolts 1 and 4 as marked and tighten by hand ►Tighten the mounting bolts 1 and 4 Oil pump mounting M6 x 40 - 10.9. ...... 15 Nm bolt on end cover.........

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher 4.5.5

Oil sump and automatic clean oil replenisher

4.5.5.1 Removing/installing the oil sump Preparations

key

►Removing/installing the oil pump suction line manifold, Page 178

1 Oil sump

Technical data Tightening torques Oil sump mounting bolt..................................... M8x55-10.9.................................... .......................... 35 Nm Oil sump mounting bolt..................................... M8x65-10.9.................................... .......................... 35 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

NOTICE Component damage due to contamination Components will be damaged.

For this reason: • Clean components and sealing surfaces before assembly by suitable means.

• Protect cleaned surfaces from re-contamination.

ENVIRONMENTAL WARNING Use a suitable container to collect any discharging engine oil.

Literature reference For information on engine oil see the MAN service product database. k https://my.man-mn.com/portal/irj/asp/

Removing the oil sump Removing the left oil return line ENVIRONMENTAL WARNING Use a suitable container to collect any discharging engine oil. ►Undo the fastener 3 ►Remove the oil return lines 1 and 2

Removing the right oil return line ENVIRONMENTAL WARNING Use a suitable container to collect any discharging engine oil. ►Unscrew the mounting bolts 3 ►Remove the oil return lines 1 and 2

Removing the fuel line for emptying the KSC ►Mark the installation position of mounting bolts 3 and 4 ►Remove the mounting bolts 3 and 4 ►Unscrew and remove the swivel fitting 1 with the sealing ring ►Remove the fuel line 2 ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Removing the oil sump ►Unscrew and remove the mounting bolts 3 ►Remove oil sump 2 incl. seal 1 ►Clean the sealing surfaces

Installing the oil sump Mounting the oil sump ►Clean the sealing surfaces ►Attach oil sump 2 with new seal 1 ►Screw in and tighten the mounting bolts 3 Oil sump mounting M8x55-10.9......... ....... 35 Nm bolt..........................

Oil sump mounting M8x65-10.9......... ....... 35 Nm bolt..........................

Attaching the fuel line for emptying the KSC ►Clean the sealing surfaces ►Position the fuel line 2 ►Screw in and tighten the swivel fitting 1 with the new seal ►Screw the mounting bolts 3 and 4 in as marked and tighten

Attaching right oil return line ►Attach the oil return lines 1 and 2 ►Screw in and tighten the mounting bolts 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Attaching the left oil return line ►Attach the oil return lines 1 and 2 ►Install the fastener 3

4.5.5.2 Dismantling/assembling the oil sump Preparations

key

►Removing/installing the oil sump , Page 185

1 Oil sump

Technical data Tightening torques Screw plug on oil sump.......................................... M26x1.5................................... ......................... 105 Nm Screw plug on oil sump.......................................... M24x1.5................................... .........................

95 Nm

Drain valve on oil sump.......................................... M26x1.5................................... ......................... 105 Nm

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Dismantling the oil sump Remove the blind flanges and plugs ►Unscrew and remove the plugs 1, 2 , 4, 6 and 8 with the sealing rings ►Unscrew and remove the drain valve 9 with the sealing ring ►Unscrew the mounting bolts in the blind flange 3 ►Remove the blind flange 3 with the seal ►Unscrew the mounting bolts in the blind flange 5 ►Remove the blind flange 5 with the seal ►Unscrew the mounting bolts in the blind flange 7 ►Remove the blind flange 7 with the seal ►Clean the sealing surfaces

Removing the oil return line Tip for users Removal of the left oil return line is the same as that of the right oil return line. ►Loosen the mounting bolts 3 ►Unscrew the oil return lines 1 and 2 ►Unscrew the oil return lines 1 and 2 and remove them along with the sealing rings Repeat this procedure for the return lines on the right

Removing the oil return line bracket Tip for users Removal of the left oil return line bracket is the same as that of the right oil return line bracket. ►Unscrew the mounting bolt 3 and remove along with the washer and retaining clamp 4 ►Unscrew the mounting bolt 2 ►Remove the bracket 1 Repeat this procedure for the return lines on the right

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

189

190

4 Engine 4.5 Engine lubrication, automatic clean oil replenisher

Assembling the oil sump Installing the oil return line bracket Tip for users Installation of the left oil return line bracket is the same as that of the right oil return line bracket. ►Position the bracket 1 ►Screw in and tighten the mounting bolt 2 ►Position the retaining clamp 4 and screw in the mounting bolts 3 with washers and tighten by hand

Installing the oil return line Tip for users Installation of the left oil return lines is the same as that of the right oil return lines. ►Place new sealing rings on the oil return lines 1 and 2 ►Place the oil return lines 1 and 2 with the new sealing rings in the oil sump and retaining clamps ►Tighten the mounting bolts 3 Repeat this procedure for the return lines on the right

Attach the blind flanges and plugs ►Clean the sealing surfaces ►Attach the blind flange 7 with a new seal ►Screw in and tighten the blind flange mounting bolts 7 ►Attach the blind flange 5 with a new seal ►Screw in and tighten the blind flange mounting bolts 5 ►Attach the blind flange 3 with a new seal ►Screw in and tighten the blind flange mounting bolts 3 ►Screw in and tighten the drain valve 9 with a new sealing ring Drain valve on oil M26x1.5........... ........ 105 Nm sump....................... ►Screw in and tighten the threaded plugs 1, 2, 4, 6 and 8 with new sealing rings Screw plug on oil M26x1.5.......... ........ 105 Nm sump........................

Screw plug on oil M24x1.5.......... ........ sump........................

95 Nm

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive 4.6.1

V-belt drive

4.6.1.1 Removing/installing the alternator V-belt

key

1 Ribbed V-belt 2 Deflection pulley 3 Automatic belt tensioner

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The belt drive for engines with a refrigerant compressor is shown here. The removal and installation procedures for the ribbed V-belt on engines without a refrigerant compressor are essentially identical.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

191

192

4 Engine 4.6 Crankshaft drive

Removing the V-belt/ribbed V-belt from the alternator Removing the ribbed V-belt CAUTION Risk of injury from spring tension The belt tensioner can spring back.

For this reason: • Secure the belt tensioner to prevent it from springing back unintentionally. ►Turn the V-belt tensioner 1 clockwise until it contacts the limit stop and hold it in this position ►Remove the ribbed V-belt 2 ►Carefully slacken the ribbed V-belt tensioner 1

Installing the V-belt/ribbed V-belt on the alternator Fit the ribbed V-belt CAUTION Risk of injury from spring tension The belt tensioner can spring back.

For this reason: • Secure the belt tensioner to prevent it from springing back inadvertently ►Turn the V-belt tensioner 1 clockwise until it contacts the limit stop and tension it in this position ►Fit the ribbed V-belt 2 ►Carefully release tension on the belt tensioner 1

4.6.1.2 Removing/installing the automatic belt tensioner

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

key

1 Belt tensioner 2 Mounting bolt

Technical data Tightening torques Mounting bolt for belt tensioner on distributor ................ M10 x 70 - 10.9.............................. 47 ±5 Nm housing...................................................................

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components may be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

193

194

4 Engine 4.6 Crankshaft drive

Removing the automatic belt tensioner Removing the belt tensioner ►Unscrew the mounting bolt 2 ►Remove the belt tensioner 1

Installing the automatic belt tensioner Attaching the belt tensioner Tip for users New belt tensioners tensioned and secured with a split pin ►Position the belt tensioner 1 on the alternator bracket ►Screw in and tighten the mounting bolt 2 Mounting bolt for belt ..... M10 x 70 47 ±5 Nm tensioner on 10.9............... alternator bracket.......

4.6.1.3 Removing/installing the ribbed V-belt guide roller

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

key

1 Mounting bolt 2 Deflection pulley

Technical data Tightening torques Guide roller mounting bolt..............................M12x60-8.8.................................. ........................ 60 ±10 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

195

196

4 Engine 4.6 Crankshaft drive Special tools 1

Torque wrench Quantity 1

08.06450-0006

2

Ratchet insert Quantity 1

08.06455-0002

Removing the idler pulley Detaching the idler pulley ►Unscrew the mounting bolt 4 and remove along with the washer 3 ►Remove the idler pulley 2 with the bushing 1

Installing the idler pulley Attaching the idler pulley ►Position the idler pulley 2 with the bushing 1 ►Screw in the mounting bolt 4 with washers 3 and tighten with a torque wrench [1] and ratchet insert [2] Guide roller M12x60-8.8....... ..... 60 ±10 Nm mounting bolt......

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive 4.6.2

Vibration damper components

4.6.2.1 Removing/installing the vibration damper

key

1 Vibration damper 2 Hub 3 Mounting bolt

Technical data Tightening torques Hub on crankshaft............... M16 x 1.5x 117 - 10.9......................... 1. Torque............................ 185 +10 Nm Hub on crankshaft............... M16 x 1.5x 117 - 10.9......................... Final tightening..................

90 +10 °

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque • Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

197

198

4 Engine 4.6 Crankshaft drive Special tools Centering pin Quantity 1 Guide mandrels

1

80.99617-0020

Removing vibration damper Undo the mounting bolts ►Unscrew two opposing mounting bolts 1 and 2

Screwing in the centering pins ►Screw the centering pins [1] 1 and 2 in

Extracting the vibration damper CAUTION Danger of injury due to heavy components For this reason: • Detach the vibration damper with assistance. ►Remove the remaining mounting bolts 1 ►Pull off the vibration damper 2 ►Unscrew the centering pins [1] 3 and 4

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Dismantling the vibration damper

NOTICE Risk of material damage if the vibration damper is set down incorrectly For this reason: • Do not lay the vibration damper down on the discs ►Unscrew the mounting bolts 3 ►Remove the hub 1 from the vibration damper 2

Assembling the vibration damper ►Insert the hub 1 into the vibration damper 2 ►Screw in and tighten new mounting bolts 3

Installing the vibration damper Fitting the vibration damper ►Screw the centering pins [1] 3 and 4 in ►Put on the vibration damper 2 ►Screw the mounting bolts 1 in and tighten by hand

Unscrewing the centering pins ►Unscrew the centering pins [1] 1 and 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

199

200

4 Engine 4.6 Crankshaft drive

Tightening the mounting bolts ►Screw in and tighten the remaining mounting bolts 1 and 2 Mounting bolt, M16 x 1.5x 1. Torque..... vibration 117 - 10.9 damper to crankshaft.........

185 Nm +10

Mounting bolt, M16 x 1.5x Final vibration 117 - 10.9 tightening.... damper to crankshaft.........

90 ° +10

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive 4.6.3

Flywheel components

4.6.3.1 Removing/installing the flywheel

key

1 Flywheel 2 Mounting bolt

Technical data Tightening torques Flywheel mounting bolts on M18x1.5x91-12.9..................... 1. Torque............................. 100 Nm crankshaft............................................

Flywheel mounting bolts on M18x1.5x91-12.9..................... 2. Torque............................. crankshaft............................................

90 °

Flywheel mounting bolts on M18x1.5x91-12.9..................... Final tightening.................... 90 ° crankshaft............................................

Important information

NOTICE Risk of material damage to components if bolts are reused For this reason: • Do not reuse flywheel mounting bolts.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

201

202

4 Engine 4.6 Crankshaft drive

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of material damage due to insufficient form fit of the crankshaft gear because the crankshaft gear's face is blasted For this reason: • The crankshaft gear must be replaced each time the crankshaft gear screw is loosened.

Special tools 1

Centering pin Quantity 2 Ø18.8 x 145 external thread M18x1.5 x 18 external hexagon size 10 x 9 • Detaching and attaching the flywheel

80.99617-0220

2

Socket Quantity 1 Loosening and tightening the size 22 cylinder head bolts

80.99612-0024

3

Power amplifier 80.99619-0006 Quantity 1 i=1:3.3 / up to 800 Nm 1 loosening the cylinder head bolts and tightening 1 in conjunction with 80.99606-0551, 80.99607-0172, 80.99606-0553, 06.02191-0407, 06.22729-0006, 06.56331-3274, 80.99606-0552, 80.99612-0023, 80.99612-0024 2 loosening and tightening the flywheel screws in the crank gear

4

Support Quantity 1 Loosening and tightening the cylinder head bolts

80.99606-0551

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive 5

Angle gage Quantity 1 Loosening and tightening the cylinder head bolts

80.99607-0172

6

Column Quantity 1 Support • Loosening and tightening the flywheel bolts in conjunction with: • Socket wrench insert size 22 [2] • Support [4] • Power amplifier wrench i = 1 : 3.3 [3] • Angle gage [5] • Stud bolt [8] • Connecting pin [9] • Rubber ring 42 mm [10] • Adapter [11] • Socket wrench insert [7]

80.99606-0641

7

Socket Quantity 1 Socket wrench insert E24 x size 22 • Loosening and tightening the flywheel bolts in conjunction with: • Socket wrench insert size 22 [2] • Support [4] • Power amplifier wrench i = 1 : 3.3 [3] • Angle gage [5] • Stud bolt [8] • Connecting pin [9] • Rubber ring 42 mm [10] • Adapter [11] • Holder [6] • Socket wrench insert [7]

80.99603-0327

8

Stud bolt Quantity 1 M8 x 20 - 10.9 - MAN 183-PHR Loosening and tightening the cylinder head bolts

06.02191-0407

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

203

204

4 Engine 4.6 Crankshaft drive 9

Connecting pin Quantity 1 5.5 x 35 for 3/4" inserts, loosening and tightening the cylinder head bolts

06.22729-0006

10

Rubber ring Quantity 1 42 mm rubber ring for 3/4" inserts

08.06142-9006

11

Guide adapter Quantity 1 Component of 80.99606-6101 support for power amplifier, loosening and tightening the cylinder head bolts

80.99606-0552

12

Socket Quantity 1 Socket wrench insert E24 x size 22 • Loosening and tightening the vibration damper mounting bolts in conjunction with: • Socket wrench insert size 22 [2] • Power amplifier wrench i = 1 : 3.3 [3] • Support [4] • Angle gage [5] • Holder [6] • Stud bolt [8] • Connecting pin [9] • Rubber ring 42 mm [10] • Adapter [11]

80.99603-0327

13

Eye-bolt Quantity 1 M12-C35 • Removing/installing the flywheel

06.05110-0103

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Removing the flywheel Assembling the special tool ►Power amplifier wrench width i =1: Insert 3.3 [3] 1 into the support [4] 2 ►Attach the support [6] 5 with stud bolt [8] 3 and adapter [11] 4 to the support [4] 2 ►Place angle gage [5] 9 on power amplifier wrench i = 1 : 3.3 [3] 1 ►Fit the socket wrench size 22 [2] 8 on the power amplifier wrench i = 1 : 3.3 [3] 1 and secure with connecting pin [9] 7 and 42 mm rubber ring [10] 6 ►Insert one socket wrench insert E24 [12] each into the holder [6] 5 and into the socket wrench insert size 22 [2] 8

Loosening the flywheel mounting bolts ►Place the special tool 2 onto each mounting bolt 1 that is going to be loosened ►Loosen the mounting bolts 1 using the special tool 2 in conjunction with the socket wrench insert [7]

Unscrewing the flywheel mounting bolts ►Unscrew two opposing mounting bolts 1 and 2

Screwing in the centering pins ►Screw the centering pins [1] 1 and 2 in

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

205

206

4 Engine 4.6 Crankshaft drive

Removing the flywheel CAUTION Danger of injury due to heavy components For this reason: • Use lifting gear to remove the flywheel ►Remove the remaining mounting bolts 3 ►Screw eye bolt [13] into the flywheel ►Hook the lifting gear onto the lifting eye-bolt [13] ►Remove the flywheel 4 over the centering pins [1] 1 and 2 ►Detach the lifting gear ►Check the flywheel ring gear for wear and fit a new one if necessary ►Removing/installing flywheel ring gear, Page 207

Installing the flywheel Fitting the flywheel CAUTION Danger of injury due to heavy components For this reason: • Use lifting gear to install the flywheel

NOTICE Risk of material damage to components if bolts are reused For this reason: • Do not reuse flywheel mounting bolts. ►Align the locating hole in the flywheel 4 with the crankshaft alignment pin ►Push the flywheel 4 over the centering pins [1] 1 and 2 ►Screw in new flywheel mounting bolts 3

Unscrewing the centering pins ►Unscrew the centering pins [1] 1 and 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Screwing in the flywheel mounting bolts ►Screw the remaining new mounting bolts 1 and 2 in

Tightening sequence ►Tighten the mounting bolts according to sequence 1-10

Tightening the flywheel mounting bolts Tip for users Be aware of the power amplifier wrench multiplication ratio i = 1 : 3.3. ►Tighten the mounting bolts 1 using the special tool 2 in conjunction with the socket wrench insert [7] ►Tighten the mounting bolts 1 in the specified sequence Flywheel M18x1.5x91-12.9 1. Torque.. 100 Nm mounting bolts on crankshaft...

Flywheel M18x1.5x91-12.9 2. Torque.. 90 ° mounting bolts on crankshaft...

Flywheel M18x1.5x91-12.9 Final 90 ° mounting tightening. bolts on crankshaft...

4.6.3.2 Removing/installing flywheel ring gear Preparations

►Removing/installing the flywheel, Page 201

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

207

208

4 Engine 4.6 Crankshaft drive

key

1 Flywheel 2 Flywheel ring gear

Technical data Test values and settings Installation temperature, flywheel ring gear................................................................................... 200-300 °C Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Removing the flywheel ring gear Detaching the flywheel ring gear CAUTION Risk of injury from chippings For this reason: • Wear personal protective equipment

NOTICE Risk of material damage due to spot-drilling of the flywheel For this reason: • Take care not to damage the flywheel when spot-drilling the flywheel ring gear • Fit a new spot-drilled flywheel ►Spot-drill the starter ring gear 1 and force it open ►Remove the starter ring gear 1 from the flywheel 2 ►Clean the contact surfaces of the starter ring gear 1 and the flywheel 2 and check for damage

Installing the starter ring gear Attaching the starter ring gear ►Heat the starter ring gear 1 to 200 - 230 °C ►Fit the starter ring gear 1 so that the chamfer on the teeth is facing away from the flywheel ►Fit the starter ring gear 1 so that the holes of the starter ring gear 1 and the flywheel 2 are in line ►Adjust the flywheel ring gear 1 if necessary

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

209

210

4 Engine 4.6 Crankshaft drive 4.6.4

Crankshaft components, engine barring gear

4.6.4.1 Mounting/removing the engine cranking unit

key

1 Spacer plates 2 Engine cranking unit

3 Mounting bolt 4 Flywheel housing

Important information

NOTICE Risk of material damage due to incorrectly tightened threaded connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed final tightening.

• Final tightening must always be performed manually using a torque wrench.

Special tools 1

Engine cranking unit Quantity 1 Cranking the engine in conj. with 80.99626-0017 • Crank the engine in conjunction with: • Gear ratchet [2]

80.99626-6009

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive 2

Gear ratchet Quantity 1 Crank the engine 1/2" in conjunction with 80.99626-6008

80.99627-0001

Attach the engine cranking unit Attach the engine cranking unit ►Remove the cap with seal and TDC marking plate from the flywheel housing ►Mount the engine cranking unit [1] 1, together with the spacer plates 2, on the flywheel housing ►Crank the engine 360° using the gear ratchet [2] and check the flywheel ring gear for wear

Removing engine cranking unit Removing engine cranking unit ►Remove the engine cranking unit [1] 1, together with the spacer plates 2, from the flywheel housing ►Attach the TDC marking plate ►Attach the cap on the flywheel housing with a new seal

4.6.4.2 Coolant pump crankshaft gear Preparations ►Removing/installing the thermostat housing coolant manifold , Page 83 ►Removing/installing the coolant pump coolant manifold, Page 61 ►Removing/installing the coolant pump, Page 94

►Removing/installing the oil module (left), Page 161 ►Removing/installing the oil module (right), Page 165 ►Removing/installing the alternator V-belt, Page 191 ►Removing/installing the alternator, Page 51

►Removing/installing the refrigerant compressor, Page 431 ►Removing/installing the vibration damper, Page 197 ►Removing/installing the end cover, Page 257

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

211

212

4 Engine 4.6 Crankshaft drive

key

1 Crankshaft gear

Important information

NOTICE Risk of component damage due to incorrectly tightened bolted connections For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed final torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

Special tools 1

Centering mandrel Quantity 1 Set consists of two units Ø18.8 x 145 external thread M18x1.5 x 18 external hex SW10 x 9 for removing/installing front crankshaft

80.99617-0020

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Removing the front crankshaft gear Detaching the front crankshaft gear ►Screw in the centering mandrels [1] 1 and 3 ►Pull off the crankshaft gear 2

Installing the front crankshaft gear Attaching the front crankshaft gear ►Fit the crankshaft gear 2 over the centering mandrel [1] 1 and 3 until it stops ►Unscrew the centering mandrels [1] 1 and 3

4.6.4.3 Removing/installing the coolant pump intermediate gear Preparations

►Coolant pump crankshaft gear, Page 211

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

213

214

4 Engine 4.6 Crankshaft drive

key

1 Coolant pump intermediate gear

Service products Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on engine oil see the MAN service product database. k http://portal.mn-man.biz/sapportal/irj/asp/login?NavigationTarget=navurl:// 18086d7745d3b567b2da029972a5ee34

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Removing the intermediate gear Removing the intermediate gear ►Remove the damping element 2 ►Unscrew the mounting bolts 1 ►Remove intermediate gear 4 incl. the intermediate gear bolts 3 and contact washer 5

Installing the intermediate gear Attaching the intermediate gear ►Apply a thin layer of clean engine oil to the intermediate gear 3 as per MAN Standard 3277 ►Insert the intermediate gear pin 3 into the intermediate gear 4 ►Install the intermediate gear 4 in the crankcase with the intermediate gear pin 3 and thrust washer 5 ►Screw in and tighten the mounting bolts 1 ►Fit the damping element 2 to the mounting bolts 1

4.6.4.4 Dismantling/assembling the coolant pump intermediate gear Preparations

►Removing/installing the coolant pump intermediate gear, Page 213

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

215

216

4 Engine 4.6 Crankshaft drive

key

1 Mounting bolt 2 Coolant pump intermediate gear 3 Thrust elements

4 Damping elements 5 Thrust elements

6 Coolant pump intermediate gear 7 Mounting bolt

Service products Loctite 270 .......................................................................................................................... 04.10160-9062 Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Dismantling the coolant pump intermediate gear Dismantling the coolant pump intermediate gear ►Mark the relative positions of intermediate gears 1 and 5 ►Unscrew the mounting bolts 7 ►Remove the intermediate gear 1 ►Remove the thrust elements 2 ►Remove the damping elements 3 ►Unscrew the mounting bolts 6 ►Remove the thrust elements 4

Assembling the coolant pump intermediate gear Assembling the coolant pump intermediate gear ►Insert the thrust elements 4 in the intermediate gear 5 ►Apply Loctite 270 to the thread of the new mounting bolts 6 ►Screw the mounting bolts 6 in ►Insert the thrust elements 2 in the intermediate gear 1 ►Apply a thin layer of Loctite 270 to the thread of the new mounting bolts 7 ►Screw the mounting bolts 7 in ►Insert the new damping elements 3 in the intermediate gear 5 ►Position the intermediate gear 1 as marked on the intermediate gear 5 ►Tighten the mounting bolts 6 and 7

4.6.4.5 Removing/installing the crankshaft gear (front) Preparations ►Removing/installing the coolant pump intermediate gear, Page 213

►Coolant pump crankshaft gear, Page 211

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

217

218

4 Engine 4.6 Crankshaft drive

key

1 Oil pump gear

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Special tools 1

Centering pin Quantity 1 Guide pin • Removing/installing the oil pump gear

80.99617-0020

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Removing the oil pump gear Detaching the oil pump gear ►Screw in the centering pins [1] 2 and 3 ►Pull off the oil pump gear 1 over the centering pins [1] 2 and 3 ►Clean the contact surfaces of the oil pump gear 1 and crankshaft

Installing the oil pump gear Attaching the oil pump gear ►Clean the contact surfaces of the oil pump gear 1 and crankshaft ►Push the oil pump gear 1 over the centering pins [1] 2 and 3 until it stops ►Unscrew the centering pins [1] 2 and 3

4.6.4.6 Removing/installing the crankshaft gear (rear)

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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220

4 Engine 4.6 Crankshaft drive

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1 Crankshaft gear

Important information

NOTICE Risk of component damage due to insufficient engagement Insufficient engagement of the crankshaft gear.

For this reason: • The crankshaft gear must be replaced each time the crankshaft gear screw is loosened.

Removing/installing the crankshaft gear (rear) Installing the crankshaft gear ►To remove rear radial shaft seal 1 and crankshaft gear 2, see: ►Removing/installing the rear crankshaft radial shaft seal ▸ Removing/installing the rear crankshaft radial shaft seal, Page 265

4.6.4.7 Removing/installing the crankshaft Preparations Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive ►Removing/installing the charge-air manifold/air distributor pipe , Page 97 ►Removing/installing the end cover, Page 257 ►Removing/installing the intake manifold/air distributor pipe (right), Page 103 ►Removing/installing the intake manifold/air distributor pipe (left), Page 100

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►Removing/installing the exhaust manifold (right), Page 112 ►Removing/installing the exhaust manifold (left), Page 110 ►Removing/installing the cylinder head, Page 147 ►Removing/installing the flywheel, Page 201

►Removing/installing the flywheel housing, Page 259 ►Removing/installing the oil sump , Page 185 ►Removing/installing the piston with connecting rod, Page 242

1 Crankshaft 2 Crankcase lower section 3 Crankcase

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive Technical data Tightening torques Crankcase lower section mounting bolts M8x35 - 10.9......................... ................................... on crankcase...............................................

35 Nm

Crankcase lower section mounting bolts M8x50 - 10.9......................... ................................... on crankcase...............................................

35 Nm

Crankcase lower section mounting bolts M10x165-10.9....................... ................................... on crankcase...............................................

65 Nm

Crankcase lower section mounting bolts M18x2x200........................... 1. Torque.................... 160 +5 Nm on crankcase...............................................

Crankcase lower section mounting bolts M18x2x200........................... 2. Torque.................... 90 +10 ° on crankcase...............................................

Crankcase lower section mounting bolts M18x2x200........................... Final tightening.......... 90 +10 ° on crankcase...............................................

Test values and settings Crankshaft Technical Data.................................................... .........................

Crankshaft axial play............................................................... .........................

0.200 - 0.401 mm

Crankshaft radial play.............................................................. .........................

0.060 - 0.128 mm

Crankshaft measurements.............................................................................

Standard dimensions of the crankshaft bearing journal...................................

Diameter 111.966 - mm 111.988

Measurements of connecting rod bearing journal............. .........................

Standard dimensions of the connecting rod bearing journal............................

Diameter 95.966 - mm 95.988

Measurements of Glyco main bearing................................. .........................

Main bearing Ø standard dimension.................................................................

112.036 - 112.126 mm

Measurements of Glyco main bearing................................. .........................

Wall thickness of main bearing, standard dimension.............. .........................

2.959 - 2.971 mm

Wall thickness of main bearing standard dimension II............ .........................

3.084 - 3.096 mm

Wall thickness main bearing repair stage I.............................. .........................

3.209 - 3.221 mm

Wall thickness main bearing repair stage II............................. .........................

3.334 - 3.346 mm

Inclination..........................................................................................................

2.0 mm

Measurements of Glyco contact washers........................... .........................

Standard thickness of contact washers.................................. .........................

3.350 - 3.400 mm

Service products Loctite 5900 ........................................................................................................................ 04.10394-9272 Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of material damage to components if bolts are reused For this reason: • Do not reuse crankshaft bearing cap mounting bolts Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive Tip for users The repair manual describes the repair method for one engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants. In cases such as these, plan and execute the instructions from the repair manual accordingly Literature reference For information on engine oil see the MAN service product database. k https://my.man-mn.com/portal/irj/asp/ Special tools 1

Dial gage Quantity 1 Adjusting the pre-loading of the EGR adjusting cylinder within the intake / exhaust system

08.71000-3217

2

Dial gage holder Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71082-0005

3

Measuring tip Quantity 1 Adjusting the pre-loading of the EGR adjusting cylinder within the intake / exhaust system in conjunction with 08.71082-0005, 80.71000-3217

80.99605-0197

4

Settling tool Quantity 1 Setting tool • Positioning the bearing shell on a cracked connecting rod

80.99622-0052

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive 5

Centering pin Quantity 1 Guide mandrels

80.99617-0020

6

Centering pin Quantity 1 Ø18.8 x 145 external thread M18x1,5 x 18 external hex SW10 x 9 • Removing/installing the crankshaft in conjunction with: • Centering pin [5]

80.99617-0220

7

Lifting bolt Quantity 1 Ø16 x 112.7 external thread M20x2 x 14 hex SW20 • Removing the crankcase lower section • Centering pin [5]

80.99615-0039

8

Eye-bolt Quantity 2 Removing and attaching the cylinder head

80.99606-0660

9

Power amplifier Quantity 1

80.99619-0007

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive 10

Brace Quantity 1

80.99622-6037

11

Angle gage Quantity 1 Loosening and tightening the cylinder head bolts

80.99607-0172

12

Connecting pin Quantity 1 5.5 x 35 for 3/4" inserts, loosening and tightening the cylinder head bolts

06.22729-0006

13

Rubber ring Quantity 1 42 mm rubber ring for 3/4" inserts

08.06142-9006

14

Socket Quantity 2 Loosening and tightening the size 22 cylinder head bolts

80.99612-0024

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive 15

Socket Quantity 2

80.99603-0327

16

Ratchet insert Quantity 1

08.06455-0003

17

Handle Quantity 1

08.06460-0003

18

Torque wrench Quantity 1

08.06450-0011

Checking the crankshaft Checking the crankshaft axial play ►Fit dial gage [1] 1 with dial gage holder [2] 3 and tracer pin [3] with pre-load to the crankshaft 2 ►Press the crankshaft 3 horizontally into the end position towards the flywheel housing ►Zero the dial gage [1] 1 ►Pull the crankshaft 3 to the end position towards the dial gage [1] 1 and read off the difference The permissible axial play of the crankshaft 3 is 0.200 - 0.401 mm.

If the axial play is outside the tolerance, fit corresponding contact washers, see Glyco Contact Washer Measurements.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Checking radial play of crankshaft ►Fit dial gage [1] 2 with dial gage holder [2] 3 and tracer pin [3] with pre-load to the crankshaft 1 ►Press the crankshaft 1 into the end position towards the dial gage [1] 2 ►Zero the dial gage [1] 2 ►Pull crankshaft 1 in the opposite direction ► The permissible radial play of the crankshaft 1 is 0.060 - 0.128 mm.

If the radial play is outside the tolerance, check the external diameter of the crankshaft bearing journal and internal diameter of the crankshaft bearing.

Check the external diameter of the crankshaft bearing journal, see Checking the Main Bearing Journal. ►Check the internal diameter of the crankshaft bearing, see Checking the Internal Diameter of the Crankshaft Bearing Shells.

Removing the crankshaft Placing the timing gears on the mark ►Align marks of crankshaft wheel 1 and camshaft wheel 2 to each other.

Removing the crankcase lower section mounting bolts ►Mark the installation position of the mounting bolts 1 and 2 ►Remove the mounting bolts 1 and 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive

Removing the crankcase lower section mounting bolts ►Mark the installation position of the mounting bolts 1 ►Unscrew the mounting bolts 1

Loosening the crankcase lower section mounting bolts ►Unscrew the mounting bolts 1 through 14 and remove them with the washers

Assembling the special tool ►Insert power amplifier i = 1 : 3.3 [9] 1 into the brace [10] 2 ►Place angle gage [11] 11 on power amplifier wrench i = 1: 3.5 [9] 1 ►Place socket wrench insert size 22 [14] 10 on power amplifier wrench i = 1: 3.5 [9] 1 and secure with connecting pin [12] 9 and 42 mm rubber ring [13] 8 ►Place socket wrench insert size 22 [14] 3 on brace [10] 2 and secure with connecting pin [12] 6 and 42 mm rubber ring [13] 4 ►Insert the socket wrench insert [15] 5 and [16] 7 into the size 22 socket [14] 3 and [14] 10

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Positioning the power amplifier wrench ►Fit the special tool 1 onto the mounting bolts to be loosened 2 ►Insert the handle [17] 3 and ratchet [16] into the special tool 1

Loosening the crankcase lower section internal mounting bolts ►Loosen mounting bolts 1 through 28 with the special tool ►Remove mounting bolts 1 through 28 ►Disassemble the special tool

Removing the crankcase lower section CAUTION Danger of injury due to heavy components For this reason: • Lift crankcase lower section with support

NOTICE Risk of material damage due to main bearing shells falling out For this reason: • When taking off the crankcase lower section, be aware of falling main bearing shells ►Screw the jacking screws [7] 1 into the crankcase housing lower section at positions 1 ►Tighten jacking screw [7] hand-tight Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive ►Screw in jacking screws [7] alternately by a single turn ►After three runs, the head of the jacking screw [7] comes to rest, do not tighten the jacking screw [7] ►Lift the crankcase lower section in conjunction with the eye-bolt [8] 2 ►Clean the sealing surfaces

Removing the main bearing shell from the crankcase lower section ►Mark the installation position of the crankshaft bearing shells 1 ►Remove the crankshaft bearing shells 1

Removing the lower contact washers ►Mark the installation position of the contact washers 1 ►Remove the contact washers 1

Screwing in the centering pins ►Screw the front centering pin [5] 1 into the crankshaft ►Screw the rear centering pin [6] 2 into the crankshaft

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Lifting out the crankshaft CAUTION Risk of injury due to incorrect lifting gear For this reason: • Use separate lifting gear of equal length for each centering pin

NOTICE Risk of material damage due to incorrect lifting gear For this reason: • Do not use any sharp-edge lifting gear or steel cables to remove the crankshaft ►Hook the lifting gear above centering pins ►Lift out the crankshaft 1 ►Unscrew the front centering pin [5] ►Unscrew the rear centering pin [6] ►Mark crankshaft bearing shells 2 according to their installation position and assignment ►Remove the crankshaft bearing shells 2

Removing the upper contact washers ►Mark the installation position of the contact washers 2 ►Remove the upper contact washers 1 from bearing seat 7

Installing the crankshaft Inserting the main bearing shells into the crankcase lower section ►Apply a thin coat of clean engine oil to the main bearing shells 1 as per MAN Standard 3277 ►Insert main-bearing shells 1 into the bearing seats as marked and align with setting tool [4]

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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Inserting the crankshaft CAUTION Risk of injury due to incorrect lifting gear For this reason: • Use separate lifting gear of equal length for each centering pin

NOTICE Risk of material damage due to incorrect lifting gear For this reason: • Do not use any sharp-edge lifting gear or steel cables to remove the crankshaft

NOTICE Risk of material damage when inserting the crankshaft For this reason: • Crankshaft must not collide with other components during installation ►Apply a thin coat of clean engine oil to the main bearing shells 2 as per MAN Standard 3277 ►Insert main-bearing shells 2 into the bearing seat as marked and align ►Screw the front centering pin [5] into the crankshaft 1 ►Screw the rear centering pin [6] into the crankshaft 1 ►Hook the lifting gear above centering pins ►Apply a thin coat of clean engine oil to the crankshaft main bearing journal 1 as per MAN Standard 3277 ►Place the crankshaft 1 in the crankcase ►Align the main bearing shells 2 with the setting tool [4]

Unscrewing the centering pins ►Unscrew the front centering pin [5] 1 from the crankshaft ►Unscrew the rear centering pin [6] 2 from the crankshaft

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Installing the upper contact washers Tip for users Only contact washers with identical wall thicknesses may be fitted. ►Apply a thin coat of clean engine oil to the cleaned contact washers 1 as per MAN Standard 3277 ►Pressing gently, twist the contact washers 1 with oil grooves facing the crankshaft 2 into the bearing seat as marked.

Fitting the lower contact washers ►Apply a thin coat of clean engine oil to the cleaned contact washers 1 as per MAN Standard 3277 ►Position contact washers 1 with oil grooves facing the crankshaft as marked onto the last bearing seat

Installation instructions for the crankcase lower section ►Apply a thin coat of Loctite 5900 to the sealing surfaces of the crankcase lower section 1 as illustrated

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive

Positioning the crankcase lower section CAUTION Danger of injury due to heavy components For this reason: • Lift crankcase lower section with support

NOTICE Risk of material damage due to main bearing shells falling out For this reason: • When positioning the crankcase lower section, be aware of falling main bearing shells ►Check the completeness of the sleeves 4 (2 units) ►Check the completeness of the fitting sleeves 2 (14 units) ►Hook the lifting gear onto the eye-bolt [8] ►Lift the crankcase lower section 1 onto the crankcase 3 ►Center the crankcase lower section 1 via the fitting sleeves 2 when positioning ►Remove the eye-bolt [8] after positioning

Tightening the external mounting bolts ►Apply a thin coat of clean engine oil to the contact surfaces and threads of the new mounting bolts 1 as per MAN Standard 3277 ►Screw in the new external mounting bolts incl. washers 1 according to the identification ►Tighten the external mounting bolts 1 according to tightening sequence Crankcase lower M10x165-10.9..... .... 65 Nm section mounting bolts on crankcase....

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Tightening sequence of the external mounting bolts ►Tighten the mounting bolts 1 and 2 uniformly on opposite sides until the crankcase lower section comes to rest. ►Tighten the mounting bolts 1 through 14 in the correct tightening sequence

Assembling the special tool ►Insert power amplifier i = 1 : 3.3 [9] 1 into the brace [10] 2 ►Place angle gage [11] 11 on power amplifier wrench i = 1: 3.5 [9] 1 ►Place socket wrench insert size 22 [14] 10 on power amplifier wrench i = 1: 3.5 [9] 1 and secure with connecting pin [12] 9 and 42 mm rubber ring [13] 8 ►Place socket wrench insert size 22 [14] 3 on brace [10] 2 and secure with connecting pin [12] 6 and 42 mm rubber ring [13] 4 ►Insert the socket wrench insert [15] 5 and [15] 7 into the size 22 socket [14] 3 and [14] 10

Tightening the internal mounting bolts ►Fit the special tool 1 onto the mounting bolts to be loosened 2 ►Apply a thin coat of clean engine oil to the contact surfaces and threads of the new mounting bolts 1 as per MAN Standard 3277 ►Screw in the new internal mounting bolts 2 as marked ►Tighten the internal mounting bolts 2 according to tightening sequence ►Insert the torque wrench [18] and the ratchet insert [16] into the special tool 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive Crankcase lower M18x2x200.. 1. Torque section .............. mounting bolts on crankcase.....

160 Nm +5

►Insert the handle [17] 3 and ratchet [16] into the special tool 1 Crankcase M18x2x200.. 2. Torque.... lower section mounting bolts on crankcase.....

90 ° +10

Crankcase M18x2x200.. Final lower section tightening... mounting bolts on crankcase.....

90 ° +10

Internal mounting bolts tightening sequence ►Tighten the mounting bolts 1 through 28 in the specified sequence (1-28)

Screwing in the crankcase lower section mounting bolts ►Screw the mounting bolts 1 in as marked and tighten Crankcase lower M8x35 - 10.9.. ...... 35 Nm section mounting bolts on crankcase.................

Crankcase lower M8x50 - 10.9.. ...... 35 Nm section mounting bolts on crankcase.................

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Checking the freedom of movement of the crankshaft ►Turn the crankshaft 1 The crankshaft 1 must turn freely and must not contact other components.

If this is not the case, repeat the steps for fitting and removing the crankshaft.

Checking the crankshaft axial play ►Fit dial gage [1] 1 with dial gage holder [2] 3 and tracer pin [3] with pre-load to the crankshaft 2 ►Press the crankshaft 3 horizontally into the end position towards the flywheel housing ►Zero the dial gage [1] 1 ►Pull the crankshaft 2 into the end position towards the dial gage [1] 1 and read off the difference The permissible axial play of the crankshaft 2 is 0.200 - 0.401 mm.

If the axial play is outside the tolerance, fit corresponding contact washers.

Standard thickness of ......... 3.350 - 3.400 mm contact washers...............

Checking radial play of crankshaft ►Fit dial gage [1] 2 with dial gage holder [2] 3 and tracer pin [3] with pre-load to the crankshaft 1 ►Press the crankshaft 1 into the end position towards the dial gage [1] 2 ►Zero the dial gage [1] 2 ►Pull crankshaft 1 in the opposite direction The permissible radial play of the crankshaft 1 is 0.060 - 0.128 mm.

If the radial play is outside the tolerance, check the external diameter of the crankshaft bearing journal and internal diameter of the crankshaft bearing.

Check the external diameter of the crankshaft bearing journal.

Standard dimensions of ...... the crankshaft bearing journal..............................

Diameter mm 111.966 111.988

Check the internal diameter of the crankshaft bearing, see Checking the Internal Diameter of the Crankshaft Bearing Shells.

4.6.4.8 Checking the crankshaft Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive Preparations

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►Removing/installing the crankshaft, Page 220

1 Top of the crankshaft bearing shell 1 Crankshaft 1 Bottom of the crankshaft bearing shell

Technical data Test values and settings Crankshaft measurements.................................................... ........................

Standard dimensions of the crankshaft bearing journal...................................

Diameter 111.966 - mm 111.988

Measurements of connecting rod bearing journal.............. ........................

Standard dimensions of the connecting rod bearing journal... ........................

ø 95.966 - 95.988 mm mm

Measurements of Glyco main bearing..........................................................

Main bearing Ø standard dimension........................................ ........................

112.036 - 112.126 mm

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

NOTICE Risk of material damage to components if bolts are reused For this reason: • Do not reuse crankshaft bearing cap mounting bolts Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In cases such as these, plan and execute the instructions from the repair manual accordingly Special tools 1

Dial gage Quantity 1 Check the inner diameter of the crankshaft bearing

08.71000-3217

2

Micrometer Quantity 1

08.71200-9005

Checking the crankshaft Check the crankshaft bearing spread Tip for users The difference between dimensions A and B gives the bearing spread. ►Clean the crankshaft bearing shells 2 and place them together on a flat surface as marked ►Check dimension A using a micrometer 1 ►Check dimension B using a micrometer 1 The permissible max. spread of the crankshaft bearing is max.

2 mm.

The crankshaft bearing shells must be replaced if the spread is outside the tolerance.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive

Checking the inner diameter of the crankshaft bearing ►Insert the upper and lower crankshaft bearing shell as marked in bearing seat ►Position the crankcase lower section 2 ►Screw in and tighten the mounting bolts 3 for the crankcase lower section 2 Crankcase lower M10x165-10.9...... .... 65 Nm section mounting bolts on crankcase... ►Check the crankshaft bearing with an internal touch probe 1 in connection with a dial gage [1] 4 ►Repeat measurement on all crankcase bearings ►Detach the crankcase lower section 2 ►If the measurements of the crankcase bearings are outside the tolerance dimensions, see Measurements of Main Bearing Glyco, the main bearing shells must be replaced.

Checking the outer diameter of the connecting rod bearing journals ►Clean the connecting rod bearing journal 2 ►Check the connecting rod bearing journal using a micrometer 1 ►Repeat the test procedure several times displaced by 120° See the connecting rod bearing shell dimensions for the outer diameter of the connecting rod bearing journal The crankshaft 2 must be replaced if the outer diameter is outside the tolerance.

Checking the outer diameter of the crankshaft bearing journal ►Clean the crankshaft bearing journal and crankshaft 2 ►Check the crankshaft bearing journal using a micrometer 1 ►Repeat the test procedure several times displaced by 120° See the crankshaft dimensions for the outer diameter of the crankshaft bearing journal The crankshaft 2 must be replaced if the outer diameter is outside the tolerance.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive 4.6.5

Piston components

4.6.5.1 Checking the piston protrusion Preparations

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►Removing/installing the piston with connecting rod, Page 242

1 Piston

Technical data Test values and settings Piston.............................................................................................................................

Piston protrusion, measured from crankcase to piston............. .................................... -0.361 to +0.080 mm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive Special tools 1

Dial gage holder base plate Quantity 1 Dial gage holder base plate

80.99605-0172

• Checking the cylinder liner protrusion in conjunction with: • Dial gage [2]

2

Dial gage Quantity 1 Measuring piston protrusion

08.71000-3217

Measuring piston protrusion Measuring piston protrusion ►Set piston 1 to top dead center ►Place dial gage [2] 2 incl. dial gage holder [1] 3 on the crankcase 5 ►Place dial gage tip 4 on the crankcase 5 and set the dial gage [2] 2 to zero ►Place the dial gage tip 4 on the piston 1 and read out the difference The permissible piston protrusion is -0.361 to +0.080 mm.

4.6.5.2 Removing/installing the piston with connecting rod Preparations ►Removing/installing the cylinder head, Page 147

►Removing/installing the oil sump , Page 185

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

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1 Doublebeveled ring 2 Taper-face ring 3 Keystone ring 4 Internal locking ring

5 Piston pin 6 Piston 7 Internal locking ring 8 Connecting rod

9 Connecting rod bearing cap 10 Connecting rod bearing bolt

Technical data Tightening torques Connecting rod bearing bolt............ M14x1.5x66-10.9....................... 1. Torque............................... 100 Nm Connecting rod bearing bolt............ M14x1.5x66-10.9....................... Final tightening...................... 90 ° Service products Engine oil ..................................................

For more information see the MAN service product database

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive Important information

NOTICE Risk of material damage due to incorrect handling Crack surfaces may be damaged.

For this reason: • The connecting rod must be replaced if the crack surfaces on the connecting rod are damaged.

• Protect crack surfaces from damage by hard or sharp objects.

• To clean the crack surfaces on the connecting rods, only rinse them with clean cleaning agent.

• Use compressed air to blow-dry the crack surfaces after cleaning.

• Do not allow any particles that are rinsed out to get into the engine.

NOTICE Risk of material damage to components if bolts are reused Components will be damaged.

For this reason: • Do not reuse old connecting rod bearing bolts.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Always measure the piston diameter transverse to the piston pin hole.

Literature reference For information on engine oil see the MAN service product database. k http://portal.mn-man.biz/sapportal/irj/asp/login?NavigationTarget=navurl:// 18086d7745d3b567b2da029972a5ee34 Special tools 1

Piston ring pliers Quantity 1 Removing and installing the piston rings, replaced with 80.99625-0167

83.09144-6090

2

Piston ring clamping pliers Quantity 1 Piston ring clamping pliers • Installing the piston

80.99613-0040

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive 3

Settling tool Quantity 1 Setting tool

80.99622-0052

• Positioning the bearing shell on a cracked connecting rod

Removing the piston and connecting rod Loosening the connecting rod bearing bolts ►Mark the installation position and assignment of the connecting rod bearing shells and connecting rod bearings ►To loosen the connecting rod bearing bolts 1, turn the crankshaft to bottom dead center ►Loosen the connecting rod bearing bolts 1 by one rotation

Remove the connecting rod bearing cap ►Turn the crankshaft so that the connecting rod bearing journal is in front of the cylinder of the piston to be removed (TDC) ►Unscrew the connecting rod bearing bolts 1 ►Remove the connecting rod bearing cap 2 and lower connecting rod bearing 3

Removing the piston ►Mark the installation position and location of the piston 1 in relation to the cylinder liner 2 ►Extract the piston 1 with connecting rod from the cylinder liner 2 ►Remove the upper connecting-rod bearing from the connecting rod

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive

Removing the piston rings ►Set the piston ring pliers [1] 1 to the piston diameter ►Remove the piston rings 2 with the piston ring pliers [1] 1 ►Carefully clean the piston ring grooves of the piston 3

Installing the piston and connecting rod Installing the piston rings

NOTICE Risk of material damage due to incorrect handling Piston rings break.

For this reason: • Install the piston rings using properly adjusted piston ring pliers Tip for users Install so that the gap of the double-beveled ring and that of the tube spring are offset to one another by 180°. ►Set the piston ring pliers [1] 1 to the piston diameter ►Using piston ring pliers [1] 1, insert new piston rings 2 into the corresponding groove in the piston 3, with the ring gaps offset to one another by 120°. ▸ Dismantling and assembling the piston with connecting rod, Page 248

Piston installation with piston ring clamping pliers

NOTICE Risk of material damage from incorrect installation position of the piston For this reason: • Observe the direction of the arrow on the piston crown. ►Turn the crankshaft so that the connecting rod bearing journal is in front of the cylinder of the piston 2 that is to be installed (TDC) ►Line up the piston ring gaps at 120° offset to one another and thinly apply clean engine oil on the piston 2 and connecting-rod bearing as per MAN standard 3277

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive ►Insert the upper connecting rod bearing into the connecting rod; position with setting tool [3] if necessary ►Align the piston 2 so that the arrow on the piston crown is pointing to the center of the engine ►Open the piston ring clamping pliers [1] 1 and place over the piston 2 ►Clamp the piston ring clamping pliers [1] 1 ►Insert the piston 2 through the piston ring clamping pliers [2] 1 into the cylinder liner as marked ►Carefully push the piston 2 through the cylinder liner until the connecting-rod bearing is lying on the crankshaft

Installing the connecting rod bearing cap

NOTICE Risk of material damage due to incorrect handling Crack surfaces may be damaged.

For this reason: • The connecting rod must be replaced if the crack surfaces on the connecting rod are damaged.

• Protect crack surfaces from damage by hard or sharp objects.

• To clean the crack surfaces on the connecting rods, only rinse them with clean cleaning agent.

• Use compressed air to blow-dry the crack surfaces after cleaning.

• Do not allow any particles that are rinsed out to get into the engine. ►Insert the connecting-rod bearing shell 3 into the corresponding connecting-rod bearing cap 2 in accordance with mark and assignment, and position with setting tool [3] as necessary ►Fit the connecting-rod bearing cap 2 with the positioned connecting-rod bearing shell 3 on the connecting rod as marked. Ensure that the contact areas between the connecting-rod bearing shell 3 and the connecting rod are not damaged ►Screw in the new connecting rod bearing bolts 1 and tighten by hand

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive

Tightening the connecting rod bearing shells ►To tighten the connecting rod bearing bolts 1, turn the crankshaft to bottom dead center ►Check connecting rod alignment, if necessary remove the connecting rod bearing shells and position the connecting rod bearing again with the setting tool [3], then reattach the connecting rod bearing ►Tighten the new connecting-rod bearing bolts 1 Connecting M14x1.5x66-10.9. 1.

100 Nm rod bearing Torque.. bolts...............

Connecting M14x1.5x66-10.9. Final 90 ° rod bearing tightening.. bolts...............

4.6.5.3 Dismantling and assembling the piston with connecting rod Preparations

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►Removing/installing the piston with connecting rod, Page 242

1 Internal locking ring 2 Piston

4 Internal locking ring 5 Connecting rod

3 Piston pin

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive Technical data Test values and settings Piston pin/piston pin hole...................................................... .......................................

Piston pin diameter.................................................................. ....................................... 54.994 - 55.000 mm Piston pin hole................................................................................................................. 55.063 - 55.093 mm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Special tools 1

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71000-3217

Dismantling the piston Dismantling the piston ►Mark the relative positions of the piston 2 , piston pin 4 and connecting rod 5 ►Detach inside locking ring 1 and 3 ►Press the piston pin 4 out of the piston 2 ►Remove the piston 2

Measuring the piston pin Measuring the piston pin ►Measure the piston pin 1 using a micrometer 2 If the dimensions of the piston pin 1 lie outside the tolerance limits of 54.994 - 55.000 mm, the piston must be replaced with the piston pin 1 .

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive

Measuring the piston pin hole ►Use the inside caliper 2 and the dial gage [1] 4 to check the piston pin hole 1 If the dimensions of the piston pin hole 1 lie outside the tolerance limits of 55.063 - 55.093 mm, the piston connecting rod 3 must be replaced.

Assembling the piston Assembling the piston Tip for users There is an arrow on the piston crown. ►Insert a new locking ring 3 in the groove in the piston 2 ►Align the connecting rod 5 with the piston 2 so that the long end of the connecting rod points in the direction of the arrow ►Fit the piston 2 over the connecting rod 5 as marked ►Apply a thin layer of clean engine oil to the piston pin 4 as per MAN Standard 3277 ►Push the piston pin 4 through the piston 2 and the connecting rod 5 in accordance with its marking until it stops ►Insert a new locking ring 1 in the groove in the piston 2 ►Check that the locking rings 1 and 3 are seated correctly If the locking rings 1 and 3 have not engaged correctly, remove and re-attach the locking rings 1 and 3, ensuring that they are seated correctly.

If the installation position of the connecting rod 5 is not correct in relation to the piston 2, repeat the step.

4.6.5.4 Checking the piston with connecting rod Preparations ►Removing/installing the piston with connecting rod, Page 242

►Dismantling and assembling the piston with connecting rod, Page 248

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

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1 Piston rings 2 Piston

4 Locking ring 5 Piston pin

3 Connecting rod Technical data Tightening torques Connecting rod bearing bolt........... M14x1.5x66-10.9...................... 1. Torque......................... 100 +10 Nm Connecting rod bearing bolt........... M14x1.5x66-10.9...................... 2. Torque.........................

90 +10 °

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

251

252

4 Engine 4.6 Crankshaft drive Test values and settings Piston ring (keystone ring)...................................................... .................................

Piston ring (keystone ring)...........................................................................................

3.5 mm

Piston ring width........................................................................ .................................

4.50 - 4.90 mm

Gap clearance............................................................................ .................................

0.45 - 0.55 mm

Piston ring (taper faced ring).................................................. .................................

Piston ring height....................................................................... .................................

2.47 - 2.49 mm

Piston ring width........................................................................ .................................

4.90 - 5.30 mm

Axial play.................................................................................... .................................

0.09 - 0.18 mm

Gap clearance............................................................................ .................................

1.10 - 1.30 mm

Piston ring (double-beveled ring)........................................... .................................

Piston ring height....................................................................... .................................

3.475 - 3.49 mm

Piston ring width........................................................................ .................................

3.30 - 3.70 mm

Axial play.................................................................................... .................................

0.040 - 0.085 mm

Gap clearance............................................................................ .................................

0.30 - 0.50 mm

Connecting Rod Bearing Dimensions.................................... .................................

Connecting-rod bearing, normal dimension.............................. .................................

96.047 - 96.099 mm

Connecting rod radial play......................................................... .................................

0.060 - 0.128 mm

Connecting rod axial play.......................................................... .................................

0.240 - 0.438 mm

Spread of connecting-rod bearing shells....................................................................

max. 2.0 mm

Connecting rod..........................................................................................................

Connecting rod width..................................................................................................

36.841 - 36.880 mm

Middle connecting rod length of middle piston pin bushing – ................................. middle connecting road bearing................................................

282.45 - 282.5 mm

Piston diameter........................................................................ .................................

D1 measured 24 mm above lower edge of piston..................... ................................. 127.926 - 127.930 mm Piston height..............................................................................................................

Overall height............................................................................. .................................

114.8 - 115.2 mm

Piston height from center of piston pin to piston crown - PH ................................. level 0.........................................................................................

78.95 - 79.05 mm

Important information

NOTICE Risk of material damage due to incorrect handling Crack surfaces may be damaged.

For this reason: • The connecting rod must be replaced if the cracked surfaces on the connecting rod are damaged.

• Protect cracked surfaces from damage by hard or sharp objects.

• To clean the cracked surfaces on the connecting rods, only rinse them with clean cleaning agent.

• Use compressed air to blow-dry the cracked surfaces after cleaning.

• Do not allow rinsed-out particles to enter the engine.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Always measure the piston diameter transverse to the piston pin hole.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive Special tools 1

Feeler gage Quantity 1 Feeler gage

08.75310-0806

• Checking the axial play and ring gap of the piston rings

2

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71000-3217

3

Depth gage Quantity 1 Check the dimensions of the impeller to the coolant pump housing

08.71195-9003

4

Settling tool Quantity 1 Setting tool • Positioning the bearing shell on a cracked connecting rod

80.99622-0052

5

Dial gage holder Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71082-0005

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive

Checking the piston with connecting rod Measuring the axial play of the connecting rod ►Attach the dial gage holder [5] 1 with the dial gage [2] 4 to the crankcase 2 ►Position the tracer pin of the dial gage [2] 4 against the connecting rod 3 with a pre-load ►Push the connecting rod 3 horizontally into the end position towards the flywheel housing/ timing case ►Zero the dial gage [2] 4 ►Pull the connecting rod 3 to the end position towards the dial gage [2] 4 and read off the difference ►Repeat the procedure for the remaining connecting rods The permitted axial play on the connecting rod 3 is Connecting rod axial play .......... 0.240 - 0.438 mm If the axial play is out of tolerance, check the width of the connecting rod 3

Correct matching of connecting rod and connecting rod bearing cap

NOTICE Risk of material damage due to incorrect matching of connecting rod and connectingrod bearing cap Components will be damaged.

For this reason: • Ensure that the connecting rod and the connecting rod bearing cap are matched correctly ►Check the pairing numbers 1 and 4 on the connecting rod 2 and the connecting-rod bearing cap 3

Checking the connecting rod width ►Checking the connecting rod width 1 ►Remove the connecting rod bearing cap The permitted dimension A is Connecting rod width............. 36.841 - 36.880 mm If dimension A is out of tolerance, fit a new connecting rod 1.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.6 Crankshaft drive

Measuring the radial play of the connecting rod ►Attach the dial gage holder [5] 2 with the dial gage [2] 3 to the crankcase 1 ►Position the tracer pin of the dial gage [2] 3 against the connecting rod 4 with a pre-load ►Push the connecting rod 4 vertically down to the end position ►Zero the dial gage [2] 3 ►Pull the connecting rod 4 to the end position towards the dial gage [2] 3 and read off the difference ►Repeat the procedure for the remaining connecting rods The permitted radial play on the connecting rod 4 is Connecting rod axial play .......... 0.240 - 0.438 mm If the radial play is outside the tolerance, check the connecting rod bearing shells and journals.

Measuring the connecting rod Measuring the connecting-rod bearing internal diameter ►Insert the cleaned upper connecting-rod bearing shell into the cleaned connecting rod 1 ►Insert the cleaned lower connecting-rod bearing shell into the cleaned connecting-rod bearing cap 2 ►Insert the connecting-rod bearing shell into the corresponding connecting-rod bearing cap 2 in accordance with mark and assignment and position with setting tool [4] as necessary ►Fit the connecting-rod bearing cap 2 with the positioned connecting-rod bearing shell on the connecting rod as marked. Ensure that the contact areas between the connecting-rod bearing shell 2 and the connecting rod are not damaged ►Screw in the connecting-rod bearing bolts and tighten them Connecting M14x1.5x66-10.9 1. Torque. 100 Nm rod bearing bolt..............

Connecting M14x1.5x66-10.9 Final 90 ° rod bearing tightening +10 bolt.............. ►Check the inner diameter of the connecting rod bearings using a dial gage [2] 3 and an internal touch probe 4 Connecting-rod bearing internal diameter, 96.047 96.099 mm.

The connecting rod bearing shells must be replaced if the inner diameter is outside the tolerance.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.6 Crankshaft drive

Checking the connecting rod bearing shell spread Tip for users The difference between dimension A and B gives the connecting-rod bearing shell inclination angle. ►Clean the connecting-rod bearing shells 2 and place them together on a flat surface as marked ►Check dimension A using a micrometer 1 ►Check dimension B using a micrometer 1 Permitted inclination angle of ....... max. 2.0 mm the connecting-rod bearing shells...........................................

If the inclination angle is out of tolerance, fit new connecting-rod bearing shells 2.

Measuring the axial play of the piston rings Tip for users The axial play cannot be measured on the keystone ring ►Measure the axial play between the doublebeveled ring 2 and the piston 3 at several points using the feeler gage [1] 4 ►Measure the axial play between the taper face ring 1 and the piston 3 at several points using the feeler gage [1] 4 The axial play of the double-beveled ring 2 must be between 0.040 - 0.085 mm.

The axial play of the taper face ring 1 must be between 0.09 - 0.18 mm.

If the axial play is out of tolerance, install a new piston with piston rings.

<b>Measuring the piston ring gap</b> ►Clean the piston rings ►Insert the piston ring 2 to a uniform depth in the cylinder liner 1 ►Even the height of the piston ring 2 using an electronic depth gage [3] ►Measure the ring gap with a feeler gage [1] 3 The ring gap of the keystone ring must be between 0.45 - 0.55 mm.

The ring gap of the taper face ring must be between 1.10 - 1.30 mm.

The ring gap of the double-beveled ring must be between 0.30 - 0.50 mm.

If the ring gaps are out of tolerance, the piston rings must be replaced (as a set only).

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing 4.7.1

Front plate and timing case components

4.7.1.1 Removing/installing the end cover Preparations ►Removing/installing the alternator V-belt, Page 191 ►Removing/installing the automatic belt tensioner, Page 192 ►Removing/installing the alternator, Page 51 ►Removing/installing the alternator bracket, Page 401

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►Removing/installing the refrigerant compressor, Page 431 ►Removing/installing the engine oil temperature sensor, Page 33 ►Removing/installing the coolant pump, Page 94 ►Removing/installing the oil module (left), Page 161

►Removing/installing the oil module (right), Page 165 ►Removing/installing the vibration damper, Page 197 ►Removing/installing the front crankshaft radial shaft seal, Page 269 ►Removing/installing the oil pump suction line manifold, Page 178

1 Cover

Service products Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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258

4 Engine 4.7 Engine housing

ENVIRONMENTAL WARNING Use a suitable container to collect any discharging engine oil.

Literature reference For information on engine oil see the MAN service product database. k https://my.man-mn.com/portal/irj/asp/

Removing the cover Cover removal instructions ►To remove the cover, do not unscrew the screw plugs 1

Detaching the cover ►Mark the installation position of mounting bolts 1, 4, 5, 6, 7 and 8 ►Remove the mounting bolts 1 , 4, 5, 6, 7 and 8 ►Remove the cover 2 with the seal 3 ►Clean the sealing surfaces

Installing the cover Attaching the cover Tip for users Attach the seal with the screen-printed side facing the crankcase. ►Clean the sealing surfaces ►Position the cover 2 with a new gasket 3 ►Screw in and tighten mounting bolts 1, 4, 5, 6, 7 and 8 as marked

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing 4.7.2

Flywheel housing, engine flange

4.7.2.1 Removing/installing the flywheel housing Preparations ►Removing/installing the PTO cover, Page 425 ►Removing/installing the air compressor (single cylinder), Page 407 ►Removing/installing the starter/starter motor , Page 56 ►Removing/installing the flywheel, Page 201

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►Removing/installing the fuel line, Page 320 ►Removing/installing the high pressure pump (rear), Page 379 ►Removing/installing the high pressure pump (front), Page 376

►Removing/installing the highpressure pump drive housing, Page 390 ►Removing/installing the crankshaft gear (rear), Page 219 ►Removing/installing the rear crankshaft radial shaft seal, Page 265

1 Flywheel housing

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

259

260

4 Engine 4.7 Engine housing

Removing the flywheel housing Detaching the flywheel housing CAUTION Danger of injury due to heavy components Heavy weights over 25 kg can pose a health hazard.

For this reason: • Use lifting gear to remove and install heavy components (>25 kg).

• Observe accident prevention regulations.

• Request assistance with removing and installing heavy components, if necessary. ►Mark the installation position of mounting bolts 4 and 5 ►Remove the mounting bolts 4 and 5 ►Lift the flywheel housing 1 with the seal 2 off the fitted sleeves 3 ►Clean the sealing surfaces

Installing the flywheel housing Attach flywheel housing CAUTION Danger of injury due to heavy components Heavy weights over 25 kg can pose a health hazard.

For this reason: • Use lifting gear to remove and install heavy components (>25 kg).

• Observe accident prevention regulations.

• Request assistance with removing and installing heavy components, if necessary. ►Clean the sealing surfaces ►Position the flywheel housing 1 incl. new seal 2 over the fitting sleeves 3 ►Screw the mounting bolts 4 and 5 in as marked and tighten by hand ►Tighten mounting bolts 4 and 5 crosswise

4.7.2.2 Dismantling/assembling the flywheel housing Preparations

►Removing/installing the flywheel housing, Page 259

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing

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1 Flywheel housing 2 Screw plug

4 Cap 5 Screw plug

3 Cover Technical data Tightening torques Screw plug on flywheel housing.................... M38 x 1,5....................................... ..................... 225 +15 Nm Screw plug on flywheel housing.................... M26 x 1.5....................................... ..................... 100 +10 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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262

4 Engine 4.7 Engine housing

Dismantling the flywheel housing Unscrewing the screw plugs ►Unscrew screw plugs 1 and 2 and remove them along with the seals

Unscrewing the screw plugs ►Unscrew screw plugs 1 and 2 and remove them along with the seals

Detaching the cover ►Unscrew and remove the mounting bolts 2 ►Remove the cover 1

Removing the cap ►Unscrew the mounting bolts 3 and remove them with the washers ►Remove the cap 2 incl. seal 1 ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing

Removing the TDC adjustment plate ►Unscrew the mounting bolts 2 and remove them with the washers ►Remove the TDC adjustment plate 1

Assembling the flywheel housing Attaching the TDC adjustment plate ►Attach the TDC adjustment plate 1 ►Screw the mounting bolts 2 in with washers and then tighten

Attaching the cap ►Clean the sealing surfaces ►Attach the cap 2 incl. seal 1 ►Screw the mounting bolts 3 in with washers and then tighten

Attaching the cover ►Attach the cover 1 ►Screw in and tighten the mounting bolts 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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264

4 Engine 4.7 Engine housing

Screwing the screw plugs in ►Screw in and tighten new plugs 1 and 2 with new seals Screw plugs on M38 x 1,5..... ...... flywheel housing....

225 Nm +15

Screwing the screw plugs in ►Screw in and tighten new plugs 1 and 2 with new seals Screw plugs on M26 x 1.5..... ...... flywheel housing....

100 Nm +10

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing 4.7.3

Housing sealing components

4.7.3.1 Removing/installing the rear crankshaft radial shaft seal Additional measures ►Removing/installing the flywheel, Page 201

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►Mounting/removing the engine cranking unit, Page 210

►Removing/installing the cylinder head cover, Page 155

1 Flywheel housing 2 Rear radial shaft seal

Important information

NOTICE Risk of component damage due to improper handling PTFE seals may start to leak.

For this reason: • Clean the crankshaft and fitting tool prior to assembly

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque • Final tightening must always be performed manually using a torque wrench

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.7 Engine housing

NOTICE Risk of component damage due to insufficient engagement of the crankshaft gear because the crankshaft gear's face is blasted Insufficient engagement of the crankshaft gear For this reason: • The crankshaft gear must be replaced each time the crankshaft gear screw is loosened.

Special tools 1

Engine cranking unit Quantity 1 Cranking the engine in conj. with 80.99626-0017 • Locking the engine

80.99626-6009

2

Slide hammer puller Quantity 1 Slide hammer puller • Extracting the crankshaft gear and radial shaft seal in conjunction with: • Extractor tool [3] • Centering pin [8]

80.99602-0016

3

Puller Quantity 1 Extractor tool • Extracting the crankshaft gear and radial shaft seal in conjunction with: • Slide hammer puller [2] • Centering pin [8]

80.99601-6033

4

Plug-on handle Quantity 1 Pressing in the axial face seal of the coolant pump

80.99617-0187

5

Thrust washer Quantity 1 Pressing in the axial face seal of the coolant pump

80.99617-0144

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing 6

Guide plate Quantity 1 Ø139 x 50 attachment Ø62 x 20 bore Ø45

80.99606-0703

Installing the radial shaft seal in conjunction with: • Detachable handle [4] • Washer [5] • Press-in bushing [7] • Centering pin [8]

7

Press-in bush Quantity 1 Ø163 x 62 inside Ø139.2 x 32.25 Ø21.5 Ø19 (2x) • Installing the radial shaft seal in conjunction with: • Detachable handle [4] • Washer [5] • Guide plate [6] • Centering pin [8]

80.99604-0340

8

Centering pin Quantity 1 Ø18.8 x 145 external thread M18x1,5 x 18 external hex size 10 x 9 • Removing/installing the flywheel • Installing the radial shaft seal in conjunction with: • Detachable handle [4] • Washer [5] • Guide plate [6] • Press-in bushing [7] • Extracting the crankshaft gear and radial shaft seal in conjunction with: • Slide hammer puller [2] • Extractor [3]

80.99617-0220

Extracting the rear radial shaft seal Valve ease of movement Checking the 1st cylinder ▸ Mounting/removing the engine cranking unit, Page 210 ►Attaching the engine cranking unit ►Dismantling the cylinder head cover ►Rocker arm 1 and 2 ease of movement Checking the 1st cylinder If the rocker arms 1 and 2 of the first cylinder are not accessible, crank the engine a further 360° with the engine cranking unit. ►Removing engine cranking unit ►Attach the cylinder head cover

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

267

268

4 Engine 4.7 Engine housing

Attaching the special tool ►Insert the extractor tool [3] 3 into the crankshaft gear 4 ►Clamp the extractor tool [3] 3 on the tensioning bolts 2 ►Screw in two flywheel bolts 1 and 5 opposite one another

Removing the radial shaft seal ►Screw the slide hammer puller [2] 1 into the extractor tool [3] 2 ►Pull out the crankshaft gear 4 using the slide hammer puller [2] 1 ►Unscrew the flywheel bolts 5 ►Remove the radial shaft seal 3 from the crankshaft gear 4

Installing the rear radial shaft seal Crankshaft gear installation position ►Align the crankshaft gear with the markings 1 to the marking 2 of the camshaft gear

Installing the crankshaft gear

NOTICE Risk of component damage due to insufficient engagement Insufficient engagement of the crankshaft gear For this reason: • The crankshaft gear must be replaced each time the crankshaft gear screw is loosened. ►Align the alignment pin 2 of the crankshaft gear 1 with the bore in the crankshaft 3 ►Position the crankshaft gear 1 and install using a soft hammer until it stops

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing

Checking the markings of the crankshaft gear and the camshaft gear ►Check the markings of the crankshaft gear 1 and the camshaft gear 2 Markings 1 and 2 coincide.

If markings 1 and 2 do not coincide, remove the crankshaft gear and install it on the marking; if necessary, align the crankshaft with the alignment pin.

Installation preparation for radial shaft seal ►Separate two opposite discs each from the transport sleeve ►Position the radial shaft seal 3 with the supplied transport sleeve on the guide plate [6] 2 ►Push the radial shaft seal 3 carefully onto the guide plate [6] 2 ►Push the guide plate [6] 2 over the centering pin [8] 1 and 4 ►Remove the transport sleeve

Pressing in the radial shaft seal ►Assemble the press-in bush [7] with the detachable handle [4] 5 and washer [5] 3 ►Push the special tool over the centering pin [8] 1 and 4 onto the guide plate [6] 2 ►Using the special tool, press the radial shaft seal into the flywheel housing 6 until the press-in bush [7] is in contact with the guide plate [6] 2 ►Remove the special tool

4.7.3.2 Removing/installing the front crankshaft radial shaft seal Preparations

►Removing/installing the vibration damper, Page 197

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

269

270

4 Engine 4.7 Engine housing

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1 Front crankshaft radial shaft seal

Important information

NOTICE Risk of material damage due to incorrect handling PTFE seals may start to leak.

For this reason: • Clean the crankshaft and fitting tool before assembly.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing Special tools 1

Slide hammer puller Quantity 1 Slide hammer puller

80.99602-0016

• Extracting the radial shaft seal in conjunction with: • Extractor hook [2]

2

Extractor hook Quantity 1 Extractor hook for removing the shaft seal Extracting the radial shaft seal in conjunction with: • Slide hammer puller [1]

80.99602-0175

3

Centering pin Quantity 1 Guide mandrels

80.99617-0020

4

Plug-on handle Quantity 1 Pressing in the axial face seal of the coolant pump

80.99617-0187

5

Thrust washer Quantity 1 Pressing in the axial face seal of the coolant pump

80.99617-0144

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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272

4 Engine 4.7 Engine housing Pressure plate Quantity 1 Ø145 x 38 attachment Ø110 x 12 bore Ø50 x 8 Ø20.1 Ø17 (2x) Installing the radial shaft seal in conjunction with: • Centering pin [3] • Detachable handle [4] • Washer [5]

6

80.99604-0342

Removing the front radial shaft seal

NOTICE Risk of component damage on the cover For this reason: • Ensure that the extractor hook [2] does not become hooked behind the cover ►Extract the radial shaft seal 3 with the slide hammer puller [1] 1 and the extractor hook [2] 2

Installing the front radial shaft seal ►Assemble the pressure plate [6] 3 with the detachable handle [4] 1 and washer [5] 5 ►Place the closed side of the radial shaft seal 4 on the special tool ►Screw in the centering pins [3] 2 ►Push the special tool onto the centering pins [3] 2 ►Press in the radial shaft seal 4 with the special tool until it stops ►Remove the special tool

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing 4.7.4

Cylinder liners

4.7.4.1 Removing/installing the cylinder liner Preparations ►Removing/installing the cylinder head, Page 147

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►Removing/installing the piston with connecting rod, Page 242

1 Crankcase 2 Cylinder liner

Technical data Tightening torques Bolt [6], measuring plate on cylinder head........................................ ......................... ......................... 40 Nm Test values and settings Standard cylinder liner............................................................................................

Cylinder liner, overall height..................................................... .................................

261.50 - 262.50 mm

Cylinder liner, outside diameter at collar.................................. .................................

163.15 - 163.35 mm

Cylinder liner, outside diameter, stem...................................... ................................. 149.439 - 149.457 mm Standard collar height.............................................................. .................................

10.04 - 10.07 mm

Internal diameter of cylinder liner............................................. ................................. 127.990 - 128.0010 mm Cylinder liner protrusion........................................................... .................................

0.025 - 0.100 mm

Depth of collar recess in crankcase......................................... .................................

9.850 - 10.150 mm

Service products Engine oil ..................................................

For more information see the MAN service product database

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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274

4 Engine 4.7 Engine housing Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

ENVIRONMENTAL WARNING Use a suitable container to collect any discharging engine oil.

Literature reference For information on engine oil see the MAN service product database. k http://portal.mn-man.biz/sapportal/irj/asp/login?NavigationTarget=navurl:// 18086d7745d3b567b2da029972a5ee34 Special tools 1

Puller Quantity 1 Extracting cylinder liners • Extracting cylinder liner in conjunction with: • Extractor plate [2]

80.99601-6018

2

Extractor plate Quantity 1 Extractor plate for D = 128 mm • Extracting the cylinder liner in conjunction with: • Extractor tool [1]

80.99601-0187

3

Dial gage holder base plate Quantity 1 Dial gage holder base plate • Checking the cylinder liner protrusion in conjunction with: • Gage holder [4] • Dial gage [5]

80.99605-0172

4

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71000-3217

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing Measuring plate Quantity 1 Measuring plate

5

80.99605-0289

• Checking the cylinder liner protrusion in conjunction with: • Dial gage holder [3] • Dial gage [4]

6

Hex set screw Quantity 1 Hex set screw • Checking the cylinder liner protrusion in conjunction with: • Dial gage holder [3] • Dial gage [4] • Measuring plate [5] • Washer [7]

06.01499-0015

7

Washer Quantity 1 Washer • Checking the cylinder liner protrusion in conjunction with: • Dial gage holder [3] • Dial gage [4] • Measuring plate [5] • Bolt [6]

06.15013-0417

8

Depth gage Quantity 1 Check the dimensions of the impeller to the coolant pump housing

08.71195-9003

Removing the cylinder liner Mounting the extractor tool

NOTICE Risk of component damage caused by damaged or deformed oil nozzles For this reason: • Insert the extractor tool [1] without damaging the oil nozzle ►If reusing the cylinder liner 1, mark the installation orientation and installation position ►Attach the extractor plate [2] 3 to the extractor tool [1] 2 ►Carefully insert the extractor tool [1] 2 with folded extractor plate [2] [31]] into the cylinder liner 1 Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.7 Engine housing

Extracting the cylinder liner ►Clamp the extractor tool [1] 1 with a hex nut 2 ►Extract the cylinder liner 3 by screwing in the hex nut 2

Removing profile seals ►Remove profile seals 1 and 2 from the crankcase ►Clean the cylinder liner seat and profile seal seats ►Check the profile seal seats on the cylinder liner for signs of wear ►Check the cylinder liners for pore formation

Checking the cylinder liner Checking the cylinder liner seat ►Using an (electronic) depth gage [8] 1, check the seat 2 of the cylinder liner ►Check the seat 2 of the cylinder liner at four points situated opposite one another The permissible depth of the collar recess is 9.850 - 10.150 mm If the collar recess depth is out of tolerance, the crankcase incl. the cylinder liners must be replaced.

Measuring the cylinder liner protrusion ►Place the measuring plate [5] 1 on the cylinder liner ►Screw in and tighten the bolt [6] 4 with washer [7] Bolt [6], measuring plate on ......... ......... 40 Nm cylinder head............................ ►Put the dial gage holder [3] 2 with the dial gage [4] 3 onto the measuring plate [5] 1 ►Place the dial gage tip 5 on the crankcase ►Zero the dial gage [4] 3 ►Carefully place the dial gage tip 5 on the cylinder liner and read off the difference

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing The permissible cylinder liner protrusion is 0.025 0.100 mm.

If the cylinder liner protrusion is out of tolerance, install a new cylinder liner/crankcase.

Installing the cylinder liner Installing the cylinder liner ►Apply a thin layer of clean engine oil on the new profiled seals 1 and 2 as per MAN standard 3277 and insert them into the profiled seal seats 4 ►Insert the cylinder liner 3 into the crankcase as marked and push it in until it stops

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.7 Engine housing 4.7.5

Piston spray cooling

4.7.5.1 Removing/installing the oil nozzle Preparations

key

►Removing/installing the oil sump , Page 185

1 Oil nozzle 2 Mounting bolt

Technical data Tightening torques Oil nozzle mounting bolt on crankcase..................M14x20-10.9........................... .................... 115 +10 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users Replace the mounting bolts and spring washers when replacing the oil nozzle.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing

Removing the oil nozzle Removing the oil nozzle ►Unscrew the mounting bolt 1 ►Pull the oil nozzle 2 out of the crankcase

Installing the oil nozzle Installing the oil nozzle ►Insert the oil nozzle 2 into the crankcase ►Screw in and tighten new mounting bolt 1 Oil nozzle M14x20-10.9..... .... mounting bolt on crankcase..............

115 Nm +10

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

279

280

4 Engine 4.7 Engine housing 4.7.6

Vent with filter and oil filler neck

4.7.6.1 Removing/installing the crankcase ventilation (left)

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1 Left crankcase ventilation

Service products Silicone grease, Renolit Si 704 ............................................................................................ 09.15014-0102 Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing Special tools 1

Hose clip pliers Quantity 1 Hose clamp pliers, angled version

80.99625-0073

• Installing/removing spring band clamps

Removing the left crankcase ventilation Detaching the crankcase on the left ►Unscrew the mounting nuts 5 ►Unscrew the mounting bolts 3 and remove them with the washers ►Undo the spring band clamp 1 using the hose clamp pliers for spring band clamps [1] and push onto the molded hose ►Undo the spring band clamp 4 using the hose clamp pliers for spring band clamps [1] and push onto the molded hose ►Remove the bleed line 2

Installing the left crankcase ventilation Attaching the left crankcase ventilation ►Apply a thin layer of silicone grease Renolit Si 704 to the contact areas of the molded hoses ►Position the bleed line 2 with spring band clamps 1 and 4 ►Attach the spring band clamps 1 and 4 using the hose clamp pliers for spring band clamps [1] ►Install the mounting bolts 3 with washers ►Screw on and tighten the mounting nuts 5

4.7.6.2 Removing/installing the crankcase ventilation (right)

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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282

4 Engine 4.7 Engine housing

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1 Crankcase ventilation, right

Service products Silicone grease, Renolit Si 704 ............................................................................................ 09.15014-0102 Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Special tools 1

Hose clip pliers Quantity 1 Hose clamp pliers, angled version • Installing/removing spring band clamps

80.99625-0073

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing

Removing the right crankcase ventilation Detaching the crankcase on the right ►Unscrew the mounting nuts 5 ►Unscrew the mounting bolts 3 and remove them with the washers ►Undo the spring band clamp 1 using the hose clamp pliers for spring band clamps [1] and push onto the molded hose ►Undo the spring band clamp 4 using the hose clamp pliers for spring band clamps [1] and push onto the molded hose ►Remove the bleed line 2

Installing the right crankcase ventilation Attaching the right crankcase ventilation ►Apply a thin layer of silicone grease Renolit Si 704 to the contact areas of the molded hoses ►Position the bleed line 2 with spring band clamps 1 and 4 ►Attach the spring band clamps 1 and 4 using the hose clamp pliers for spring band clamps [1] ►Install the mounting bolts 3 with washers ►Screw on and tighten the mounting nuts 5

4.7.6.3 Removing/installing the crankcase ventilation oil separator (left) Preparations

►Removing/installing the crankcase ventilation (left), Page 280

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.7 Engine housing

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1 Left oil separator

Technical data Tightening torques Mounting bolts for the oil separator on the oil module...........M6 x 20............................. ................ 13 -2 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing

Removing the left oil separator ►Mark the installation position of the oil separator 2 ►Unscrew the mounting bolts 3 with washers 4 ►Remove the oil separator cover 2 ►Remove the O-ring 5 from the oil separator cover 2 ►Extract the breather filter 6 from the oil module 7 ►Remove the O-rings 8 and 1 from the breather filter 6 ►Clean the sealing surfaces

Installing the left oil separator ►Clean the sealing surfaces ►Fit new O-rings 8 and 1 onto the breather filter 6 ►Insert the breather filter 6 into the oil module 7 ►Fit a new O-ring 5 onto the oil separator cover 2 ►Insert the oil separator cover 2 into the oil module 7 as marked and align ►Screw in and tighten the mounting bolts 3 with washers 4 Mounting bolts for the oil M6 x 20... ..... 13 -2 Nm separator on the oil module...............................

4.7.6.4 Removing/installing the crankcase ventilation oil separator (right) Preparations

►Removing/installing the crankcase ventilation (right), Page 281

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.7 Engine housing

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1 Right oil separator

Technical data Tightening torques Mounting bolts for the oil separator on the oil module...........M6 x 20............................. ................ 13 -2 Nm Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.7 Engine housing

Removing the right oil separator ►Mark the installation position of the oil separator 3 ►Unscrew the mounting bolts 2 with washers 1 ►Remove the oil separator cover 3 ►Remove the O-ring 5 from the oil separator cover 3 ►Extract the breather filter 6 from the oil module 8 ►Remove the O-rings 7 and 4 from the breather filter 6 ►Clean the sealing surfaces

Installing the right oil separator ►Clean the sealing surfaces ►Fit new O-rings 7 and 4 onto the breather filter 6 ►Insert the breather filter 6 into the oil module 8 ►Fit a new O-ring 5 onto the oil separator cover 3 ►Insert the oil separator cover 3 into the oil module 8 as marked and align ►Screw in and tighten the mounting bolts 2 with washers 1 Mounting bolts for the oil M6 x 20... ..... 13 -2 Nm separator on the oil module...............................

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.8 Turbocharging 4.8.1

Intake manifold

4.8.1.1 Intake fitting, left turbocharger Preparations

key

►Removing/installing the crankcase ventilation (left), Page 280

1 Intake manifold 2 Screw plug

4 Mounting bolt 5 Threaded union

3 Mounting nut Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.8 Turbocharging

Removing the intake fitting Removing the threaded union ►Unscrew and remove the threaded union 4 with the sealing ring 3 ►Unscrew the screw plug 2 and remove with the sealing ring 1

Removing the intake fitting ►Mark the installation position of the intake fitting 1 ►Loosen the mounting bolts 3 ►Remove the threaded union 1 from the turbocharger ►Remove the O-ring 2 from the intake fitting 1 ►Clean the sealing surfaces

Attaching the intake fitting Installing the intake fitting ►Clean the sealing surfaces ►Insert a new O-ring 2 into the intake fitting 1 ►Position the intake fitting 1 as marked on the turbocharger ►Tighten the mounting bolts 3

Attaching the threaded union ►Screw the screw plug 2 in with a new sealing ring 1 and then tighten ►Screw the threaded union 4 in with a new sealing ring 3 and then tighten

4.8.1.2 Intake fitting, right turbocharger Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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290

4 Engine 4.8 Turbocharging Preparations

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►Removing/installing the crankcase ventilation (right), Page 281

1 Hose 2 Hose clamp

4 Hex nut 5 Pipe elbow

3 Intake fitting Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.8 Turbocharging

Removing the intake fitting Removing the hose ►Undo hose clamp 2 and push onto hose 1 ►Pull the hose 1 off the pipe elbow

Removing the pipe elbow ►Mark the installation position of the pipe elbow 1 ►Loosen the hex nut 2 ►Unscrew and remove the pipe elbow 1 with hex nut 2 and sealing ring 3

Removing the threaded union ►Unscrew and remove the threaded union 2 with the sealing ring 1

Removing the intake fitting ►Mark the installation position of the intake fitting 1 ►Loosen the mounting bolts 3 ►Remove the intake fitting 2 from the turbocharger 4 ►Remove the O-ring 1 from the intake fitting 2 ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.8 Turbocharging

Installing the intake fitting Installing the intake fitting ►Clean the sealing surfaces ►Insert a new O-ring 1 into the intake fitting 2 ►Position the intake fitting 2 as marked on the turbocharger 4 ►Tighten the mounting bolts 3

Attaching the threaded union ►Screw the threaded union 2 in with a new sealing ring 1 and then tighten

Attaching the pipe elbow ►Screw on the pipe elbow 1 with hex nut 2 and sealing ring 3 as marked ►Tighten the hex nut 2

Attaching the hose ►Push the hose 1 with hose clamp 2 onto the pipe elbow ►Tighten the hose clamp 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.8 Turbocharging 4.8.2

Exhaust turbine, oil pipe

4.8.2.1 Removing/installing the turbocharger (left) Preparations ►Removing/installing the crankcase ventilation (left), Page 280

key

►Intake fitting, left turbocharger, Page 288

1 Exhaust-gas turbocharger 2 Clamp ring 3 Exhaust-gas turbocharger

Technical data Tightening torques Mounting nut, turbocharger on exhaust pipe M10............................. 1. Torque........................... connector.......................................................

25 +5 Nm

Mounting nut, turbocharger on exhaust pipe M10............................. Final tightening.................. 60 +10 ° connector.......................................................

Clamp ring......................................................M6 x 50....................... ..........................................

Service products Engine oil .................................................

6 ±1 Nm

For more information see the MAN service product database.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.8 Turbocharging Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference For information on engine oil see the MAN service product database. k https://my.man-mn.com/portal/irj/asp/ Special tools 1

Box wrench size 15, bent Quantity 1 Box wrench size 15; i = 1 1.22 • Tightening turbocharger mounting nuts in conjunction with: • Torque wrench [2]

80.99603-0323

2

Torque wrench Quantity 1 Torque wrench 80 - 400 Nm / 14 x 18 Square drive ¾" square for socket tool 14x18 • Tightening the turbocharger mounting nuts in conjunction with: • Box wrench size 15 i =1 : 1.22 [1]

08.06450-0003

Removing the left turbocharger Detaching the oil pressure line ►Unscrew mounting nut 7 and remove along with washer 2 ►Unscrew the mounting bolt 3 from the retaining clamp 4 ►Loosen the retaining nuts on the oil pressure line 1 ►Remove the oil pressure line 1 ►Unscrew and remove the connector 6 with the sealing ring

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.8 Turbocharging

Removing the hose line ►Unscrew the mounting bolt 1 and remove along with the bushing 5 ►Undo hose clamps 3 and 6 and push onto hose 2 ►Remove hose 2 from connection 7 and turbocharger 4

Removing the oil return line bracket ►Unscrew the mounting bolt 1 and remove along with the washer 2 ►Remove the bracket 4 from the oil return line 3

Removing the left oil return line ►Unscrew the mounting bolts 5 ►Pull the oil return line 3 out of the connector ►Remove the oil return line 3 with seal 1 from the turbocharger 2 ►Remove the O-ring 4 from the oil return line 3 ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.8 Turbocharging

Removing the turbocharger ►Unscrew the mounting nuts 4 from the stud bolts 6 and remove with the spacer sleeves 3 ►Remove the turbocharger 1 and seal 2 from the exhaust pipe connector 5 ►Clean the sealing surfaces

Detaching the charge air connector ►Undo the clamp ring 2 ►Remove the charge air connector 1 from the turbocharger 3

Installing the right turbocharger Attaching the charge air connector

NOTICE Risk of material damage to components due to leaking hose clips or clamp ring connections For this reason: • Adjust the seat of the hose clips or clamp rings by knocking gently with a rubber hammer.

• Tighten the hose clips or clamp rings again using a torque wrench. ►Place charge air connector 1 incl. clamp ring 2 on the turbocharger 3 ►Tighten the profile clamp 2 Clamp ring..........M6 x 50.................. ............ 6 ±1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.8 Turbocharging

Installing the left turbocharger Installing the exhaust gas turbocharger ►Clean the sealing surfaces ►Place a new seal 2 on the exhaust pipe connector 5 ►Position the turbocharger 1 over the stud bolts 6 ►Screw the mounting bolts 4 with spacer bushings 3 on the stud bolts 6 ►Tighten the mounting nuts 4 with a torque wrench [2] and box wrench [1] Mounting nut, M10... 1. Torque..... 25 +5 Nm turbocharger on exhaust pipe connector...............

Mounting nut, M10... Final turbocharger on tightening.... exhaust pipe connector...............

60 ° +10

Attaching the left oil return line ►Clean the sealing surfaces ►Fit the new O-ring 4 on the oil return line 3 ►Push the oil return line 3 into the connector ►Place the oil return line 3 with a new seal 1 on the turbocharger 2 ►Screw in and tighten the mounting bolts 5

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.8 Turbocharging

Attaching the oil return line bracket ►Position the bracket 4 on the oil return line 3 ►Screw in and tighten the mounting bolt 1 with washer 2

Filling the turbocharger with oil

NOTICE Risk of material damage from incorrect handling of the turbocharger If it is not filled with oil, the turbocharger will be damaged when started for the first time.

For this reason: • Fill the turbocharger with clean engine oil before the oil pressure lines are attached. ►Using a funnel 1, pour clean engine oil into the oil inlet connector on the turbocharger 2 until the oil channel in the turbocharger 2 is full

Attaching the hose line ►Push the hose 2 with hose clamps 3 and 6 onto the connection 7 and turbocharger 4 ►Tighten the hose clamps 3 and 6. ►Screw in and tighten the mounting bolt 1 with bush 5

Attaching the oil pressure line ►Screw in and tighten the connector 6 with a new sealing ring 5 ►Position the oil pressure line 1 ►Screw on and tighten the fuel line retaining nuts 2 ►Insert the mounting bolt 3 into the retaining clamp 4 ►Screw on and tighten the mounting nut 7 with washer 2

4.8.2.2 Removing/installing the turbocharger (right) Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.8 Turbocharging Preparations ►Removing/installing the crankcase ventilation (right), Page 281

key

►Intake fitting, right turbocharger, Page 289

1 Hose 2 Hose 3 Right turbocharger

Technical data Tightening torques Mounting nut, turbocharger on exhaust pipe M10............................. 1. Torque........................... connector.......................................................

25 +5 Nm

Mounting nut, turbocharger on exhaust pipe M10............................. Final tightening.................. 60 +10 ° connector.......................................................

Clamp ring......................................................M6 x 50....................... ..........................................

6 ±1 Nm

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

299

300

4 Engine 4.8 Turbocharging Literature reference For information on engine oil see the MAN service product database. k https://portal.mn-man.biz/sapportal/irj/asp/login?NavigationTarget=navurl:// 18086d7745d3b567b2da029972a5ee34 Special tools 1

Box wrench size 15, bent Quantity 1 Box wrench size 15; i = 1 1.22

80.99603-0323

• Tightening turbocharger mounting nuts in conjunction with: • Torque wrench [2]

2

Torque wrench Quantity 1 Torque wrench 80 - 400 Nm / 14 x 18 Square drive ¾" square for socket tool 14x18 • Tightening the turbocharger mounting nuts in conjunction with: • Box wrench size 15 i = 1.22 [1]

08.06450-0003

Removing the right turbocharger Removing the hose bracket ►Remove the hose brackets 1, 2 and 3

Removing the hose line ►Undo hose clamps 2 and 5 and push onto hose 1 ►Remove hose 1 from connection 3 and turbocharger 4

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.8 Turbocharging

Detaching the oil pressure line ►Unscrew the retaining nuts 1 and 3 ►Remove the oil pressure line 2 ►Unscrew the connector 4 and remove with the sealing ring 5

Removing the oil return line bracket ►Unscrew the mounting bolt 4 and remove along with the washer 3 ►Remove the bracket 2 from the oil return line 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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4 Engine 4.8 Turbocharging

Detaching the oil return line ►Unscrew the mounting bolts 3 ►Pull the oil return line 6 out of the connector ►Remove the oil return line 6 with seal 2 from the turbocharger 1 ►Remove the O-ring 5 from the oil return line 6 ►Clean the sealing surfaces

Removing the turbocharger ►Unscrew the mounting nuts 5 from the stud bolts 3 and remove with the spacer sleeves 6 ►Remove the turbocharger 1 with seal 2 from the exhaust pipe connector 4 ►Clean the sealing surfaces

Detaching the charge air connector ►Undo the clamp ring 2 ►Remove the charge air connector 1 from the turbocharger 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.8 Turbocharging

Installing the right turbocharger Attaching the charge air connector

NOTICE Risk of material damage to components due to leaking hose clips or clamp ring connections For this reason: • Adjust the seat of the hose clips or clamp rings by knocking gently with a rubber hammer.

• Tighten the hose clips or clamp rings again using a torque wrench. ►Place charge air connector 1 incl. clamp ring 2 on the turbocharger 3 ►Tighten the profile clamp 2 Clamp ring........ M6 x 50............... .......... 6 ±1 Nm

Installing the exhaust gas turbocharger ►Clean the sealing surfaces ►Place a new seal 2 on the exhaust pipe connector 4 ►Position the turbocharger 1 over the stud bolts 3 ►Screw the mounting bolts 5 with spacer bushings 6 on the stud bolts 3 ►Tighten the mounting nuts 5 with a torque wrench [2] and box wrench [1] Mounting nut, M10... 1. Torque..... 25 +5 Nm turbocharger on exhaust pipe connector...............

Mounting nut, M10... Final turbocharger on tightening.... exhaust pipe connector...............

60 ° +10

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

303

304

4 Engine 4.8 Turbocharging

Attaching the oil return line ►Clean the sealing surfaces ►Fit the new O-ring 5 on the oil return line 6 ►Push the oil return line 6 into the connector 4 ►Place the oil return line 6 with a new seal 2 on the turbocharger 1 ►Screw in and tighten the mounting bolts 3

Attaching the oil return line bracket ►Position the bracket 2 on the oil return line 1 ►Screw in and tighten the mounting bolt 4 with washer 3

Filling the turbocharger with oil

NOTICE Risk of material damage from incorrect handling of the turbocharger If it is not filled with oil, the turbocharger will be damaged when started for the first time.

For this reason: • Fill the turbocharger with clean engine oil before the oil pressure lines are attached. ►Using a funnel 1, pour clean engine oil into the oil supply line on the turbocharger 2 until the oil channel in the turbocharger 2 is full

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

4 Engine 4.8 Turbocharging

Attaching the oil pressure line ►Screw in and tighten the connector 4 with a new sealing ring 5 ►Position the oil pressure line 2 ►Screw on and tighten retaining nuts 1 and 3

Attaching the hose line ►Push the hose 1 with hose clamps 2 and 5 onto the connection 3 and turbocharger 4 ►Tighten the hose clamps 2 and 5.

Attaching the hose bracket ►Attach the hose brackets 1, 2 and 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

305

306

4 Engine 4.8 Turbocharging

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components 5.1.1

Fuel filter

5.1.1.1 Removing/installing the fuel filter insert

key

1 Fuel filter cover on housing

Technical data Tightening torques Fuel filter cover on housing................................................. ............................. ............................. 20 +5 Nm Service products Diesel fuel ..........................

see Maintenance Recommendations and Recommended Service Products

Important information

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always allow the fuel service center to empty before changing the fuel filter • Only use fuel filters that are designated for common-rail systems and marked as such.

• Used filter elements should not be reinstalled.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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308

5 Fuel / exhaust system 5.1 Fuel system components

NOTICE Risk of material damage from incorrectly tightened bolted connections Incorrectly tightened bolted connections cause component damage.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of damage to components by contaminants For this reason: • Clean components and sealing surfaces before assembly by suitable means • Protect cleaned surfaces from re-contamination.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Literature reference For information on diesel fuel see the MAN service product database. k https://portal.mn-man.biz/sapportal/irj/asp Special tools 1

Socket Quantity 1

80.99603-0325

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Removing the fuel filter insert Allow the Fuel Service Center (KSC) to empty ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container. ►Undo the cover 1 using a size 36 socket [1] with approx 2 to 3 revolutions ►Place a suitable container under the plug 3 ►Remove the plugs 3 ►Open the drain valve 2 and allow the KSC to drain into the prepared container ►Close the drain valve 2. ►Installed the plug 3

Removing the fuel filter ►Unscrew the cover 1 using the size 36 socket [1] ►Remove the cover 1 with the fuel filter insert 3 from the KSC housing 4 ►Remove the fuel filter 3 from the cover 1 ►Remove the O-ring 2 ►Clean the sealing surfaces

Installing the fuel filter insert Installing the fuel filter ►Clean the sealing surfaces ►Apply a thin layer of clean fuel to the new O-ring 2 ►Fit the new O-ring 2 on the cover 1 ►Insert the new fuel filter 3 into the cover 1 ►Screw on the cover 1 and tighten by hand

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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5 Fuel / exhaust system 5.1 Fuel system components

Tightening the fuel filter cover ►Tighten the fuel filter cover 2 with socket wrench insert size 36 [1] 1 Fuel filter cover on .......... .......... 20 +5 Nm housing.............................

5.1.1.2 Removing/installing the fuel service center Preparations ►Drain fuel, see: ►Removing/installing the fuel filter insert, Page 307

key

1 Fuel filter housing 2 Cover

►Removing/installing the thermostat housing , Page 85 ►Removing/installing the pressure sensor, Page 21

3 Mounting bolt 4 Ring union

►Removing/installing the fuel line, Page 320

5 Bracket 6 Fuel line

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or depressurization must be checked by means of MAN-cats® (desired value 0).

• The common rail system must be depressurized before starting work.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line • Close off the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of component damage from leaks The ingress of dirt and moisture in the lines and connections can cause damage to the components and lead to malfunctions.

For this reason: • Lines and connections should always be sealed after they have been opened.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

ENVIRONMENTAL WARNING Collect any remaining fuel that escapes in a suitable container.

Special tools 1

End plug Quantity 2

81.96002-0521

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

311

312

5 Fuel / exhaust system 5.1 Fuel system components 2

Protective sleeve Quantity 2

81.96002-0555

Removing the fuel service center Removing the fuel service center ►Loosen the retaining nut on the WV connector 4 ►Unscrew the mounting bolts 1 ►Remove the fuel service center 2 ►Close off the WV connector 4 with an end plug [1] ►Close off the connection with protective sleeves Z18 x 15 [2]

Removing the fuel line ►Loosen the retaining nuts on the fuel line 2 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connection with protective sleeves Z18 x 15 [2]

Removing the fuel service center bracket ►Remove the mounting bolts 1, 3 and 4 ►Remove the bracket 5 with the bushings 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Installing the fuel service center Attaching the fuel service center bracket ►Position the bracket 5 with the bushings 2 ►Screw in and tighten mounting bolts 1, 3 and 4

Attaching the fuel line ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw the retaining nut 2 on hand-tight

Mounting the fuel service center ►Remove end plugs and protective sleeves ►Place the fuel service center 2 on the bracket 3 ►Screw the fuel line retaining nuts 4 on and tighten by hand ►Screw in and tighten the mounting bolts 1 ►Tighten the fuel line retaining nuts 4

5.1.1.3 Dismantling/assembling the fuel service center Preparations

►Removing/installing the fuel service center , Page 310

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

313

314

5 Fuel / exhaust system 5.1 Fuel system components

key

1 Fuel filter cover 2 Support dome

5 O-ring for cover 6 Fuel filter

3 Support dome 4 Fuel filter cover

7 O-ring for support dome

8 O-ring for support dome 9 Filter housing 10 Fuel filter 11 O-ring for cover

Technical data Tightening torques Cover................................................ ................................................ ................................................ 20 +5 Nm Service products Diesel fuel ................................................

For more information see the MAN service product database.

Important information

NOTICE Danger of damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always allow the fuel service center to empty before changing the fuel filter • Use fuel filters intended and labeled for common rail systems.

• Used filter elements should not be reinstalled.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Literature reference For information on fuel see the MAN service product database. k https://portal.mn-man.biz/sapportal/irj/asp Special tools 1

Socket Quantity 1

80.99603-0325

2

Torque wrench Quantity 1

08.06450-0006

3

Ratchet insert Quantity 1

08.06455-0001

4

Protective sleeve Quantity 11

81.96002-0555

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

315

316

5 Fuel / exhaust system 5.1 Fuel system components 5

End plug Quantity 8

81.96002-0521

6

End plug Quantity 2

81.96002-0520

7

End plug Quantity 1

81.96002-0519

Dismantling the fuel service center Removing the ring union ►Unscrew the hollow screw 2 and remove it with the ring union 1 and sealing rings ►Unscrew the transition flange 9 with the sealing ring ►Close off the ring union 1 with a protective sleeve [4] and the connection with an end plug [6] ►Unscrew the hollow screw 3 and remove it with the ring union 4 and seals ►Unscrew the transition flange 5 with the sealing ring ►Close off the ring union 4 with a protective sleeve [4] and the connection with an end plug [6] ►Unscrew the hollow screw 7 and remove it with the ring union 6 and seal ►Close off the ring union 6 with a protective sleeve [4] and the connection with an end plug [5] ►Unscrew the GE connection 8 with the sealing ring ►Close off the GE connection 8 with a protective sleeve [4] and the connection with an end plug [5]

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Removing the ring union ►Unscrew the threaded plug 1 with the sealing ring and close off with an end plug [7] ►Unscrew the hollow screw 2 and remove it with the ring union 13 and seals ►Close off the ring union 13 with a protective sleeve [4] and the connection with an end plug [5] ►Unscrew the hollow screw 4 and remove it with the ring unions 3 , 5 and seals ►Close off the ring unions 3 and 5 with a protective sleeve [4] and the connections with an end plug [5] ►Unscrew the GE connection 6 with the sealing ring ►Close off the GE connection 6 with a protective sleeve [4] and the connection with an end plug [7] ►Remove the DW swivel fitting 7 and close off with an end plug [7] ►Unscrew the transition flange 8 with the sealing ring ►Close off the connections with end plugs [5] ►Unscrew the hollow screw 10 and remove it with the ring union 9 and seals ►Close off the ring union 9 and hollow screw 10 with a protective sleeve [4] and the connection with an end plug [5] ►Unscrew the hollow screw 11 and remove it with the ring union 12 and seals ►Close off the ring union 12 and hollow screw 11 with a protective sleeve [4] and the connection with an end plug [5]

Removing the fuel filter ►Unscrew the cover 1 using the size 36 socket [1] ►Remove the cover 1 with the fuel filter insert 3 from the housing ►Unscrew the fuel filter insert 3 from the cover 1 ►Remove the O-ring 2 ►Repeat this procedure for the second fuel filter insert

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

317

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5 Fuel / exhaust system 5.1 Fuel system components

Removing the support dome ►Remove the support dome 1 with the O-ring 2 from the housing ►Repeat this procedure for the second support dome

Assembling the fuel service center Installing the support dome ►Insert the support dome 1 with the O-ring 2 into the housing ►Repeat this procedure for the second support dome

Installing the fuel filter ►Insert the new fuel filter 3 into the cover 1 ►Thinly apply clean diesel fuel on the new O-ring 2 ►Screw in the cover 1 with the O-ring 2 and tighten by hand ►Repeat this procedure for the second fuel filter insert

Tightening the fuel filter cover ►Assemble the special tool 2 consisting of a torque wrench [2], ratchet insert [3] and a socket wrench insert [1] ►Tighten the cover 1 with the special tool 2 Cover.................. .................. .................. 20 +5 Nm ►Repeat this procedure for the second cover

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Attaching the ring union ►Remove the protective sleeves and end plugs ►Position the ring union 12 with new sealing rings, and screw in and tighten the hollow screw 11 ►Screw in the ring union 9 with new sealing rings, and screw in and tighten the hollow screw 10 ►Screw the transition flange 8 in with a new sealing ring and then tighten ►Screw in and tighten the DW swivel fitting 7 ►Screw the GE union 6 in with a new sealing ring and then tighten ►Position the ring unions 3 and 5 with new sealing rings, and screw in and tighten the hollow screw 4 ►Position the ring union 13 with new sealing rings, and screw in and tighten the hollow screw 2 ►Screw in the screw plug 1 with the new seal and tighten it

Attaching the ring union ►Remove the protective sleeves and end plugs ►Screw in and tighten the GE connection 8 with a new sealing ring ►Position the ring union 6 with new sealing rings, and screw in and tighten the hollow screw 7 ►Screw the transition flange 5 in with a new sealing ring and then tighten ►Position the ring union 4 with new sealing rings, and screw in and tighten the hollow screw 3 ►Screw the transition flange 9 in with a new sealing ring and then tighten ►Position the ring union 1 with new sealing rings, and screw in and tighten the hollow screw 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

319

320

5 Fuel / exhaust system 5.1 Fuel system components 5.1.2

Fuel lines

5.1.2.1 Removing/installing the fuel line Preparations ►Drain fuel, see: ►Removing/installing the fuel filter insert, Page 307

key

1 Fuel line, return KSC 2 Fuel line FPPE VO- KSC 3 Fuel line, right leak oil line KSC 4 Fuel line, return HDPPE rear

►Removing/installing the EDC fuel temperature sensor, Page 19

5 Fuel line, filter HDPPE rear 6 Fuel line, FPPE rear KSC 7 Fuel line, return HPPE front 8 Fuel line, KSC - HDPPE front

►Removing/installing the pressure sensor, Page 21

9 Fuel line, left leak oil line KSC 10 Fuel line, connection FPPE rear 11 Fuel line, connection FPPE front

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or check depressurization using a MAN-cats (desired value 0).

• The common rail system must be depressurized before starting work.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Literature reference For information on diesel fuel see the MAN service product database. k https://portal.mn-man.biz/sapportal/irj/asp Special tools 1

End plug Quantity 22

81.96002-0556

2

Protective sleeve Quantity 21

81.96002-0555

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

321

322

5 Fuel / exhaust system 5.1 Fuel system components 3

End plug Quantity 4

81.96002-0519

4

Protective sleeve Quantity 4

81.96002-0513

Removing the fuel lines Removing the fuel line, left leak oil line ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connections with protective sleeves Z18 x 15 [2]

Removing the dual clamps ►Mark the installation position of the dual clamps 6 ►Unscrew the mounting nut 5 ►Pull out the mounting bolt 1 and remove the cover plates 2 and 4 ►Open the dual clamp 3 and remove it ►Repeat the procedure for the remaining dual clamps 6

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Removing the information sign for the fuel connection ►Unscrew the mounting bolts 3 and remove the information sign 4 ►Loosen the mounting bolts 1 with washers 2 and loosen the retaining clamps 5

Removing the fuel line, FPPE rear - KSC ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connections with protective sleeves Z18 x 15 [2]

Removing the fuel line connector - KSC ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connections with protective sleeves Z18 x 15 [2]

Removing the fuel line connection - FPPE rear ►Loosen the fuel line retaining nut 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connection with protective sleeves Z18 x 15 [2]

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

323

324

5 Fuel / exhaust system 5.1 Fuel system components

Removing the fuel line connection, FPPE front ►Loosen the fuel line retaining nut 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connection with protective sleeves Z18 x 15 [2]

Removing the fuel line KSC - HDPPE rear ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connections with protective sleeves Z18 x 15 [2]

Removing the fuel line, return HDPPE front KSC ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connections with protective sleeves Z18 x 15 [2]

Removing the fuel line KSC - HDPPE front ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connections with protective sleeves Z18 x 15 [2]

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Removing the fuel line, return HDPPE rear KSC ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connections with protective sleeves Z18 x 15 [2]

Removing the connector ►Unscrew the mounting bolts 1 and remove the connector 2 from the bracket 3

Removing the fuel line, right leak oil line - KSC ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connections with protective sleeves Z18 x 15 [2]

Removing the fuel line, return KSC ►Loosen the fuel line retaining nut 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Use the end plug [1] to seal the connections

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

325

326

5 Fuel / exhaust system 5.1 Fuel system components

Removing the fuel line, return rail right - KSC ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [3] ►Close off the connections with protective sleeves Z18 x 15 [4]

Removing the bracket for the fuel line ►Remove the mounting bolts 1 and 2 ►Remove the bracket 3

Removing the fuel line, return rail left - KSC ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [3] ►Close off the connections with protective sleeves Z18 x 15 [4]

Removing the fuel line, FPPE front - KSC ►Loosen the retaining nuts on the fuel line 1 ►Remove the fuel line 1 and close off with an end plug [1] ►Close off the connections with protective sleeves Z18 x 15 [2]

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Installing the fuel line Attaching the fuel line, FPPE front - KSC ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw the fuel line retaining nuts 1 on and then tighten

Attaching the fuel line, return rail left - KSC ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw the fuel line retaining nuts 1 on and then tighten

Attaching the bracket for the fuel line ►Position the bracket 3 ►Screw in and tighten the mounting bolts 1 and 2

Attaching the fuel line, return rail right - KSC ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw the fuel line retaining nuts 1 on and then tighten

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

327

328

5 Fuel / exhaust system 5.1 Fuel system components

Attaching the fuel line, return KSC ►Remove the end plug ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

Attaching the fuel line, right leak oil line - KSC ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

Attaching the connector ►Place connector 2 on the bracket 3 ►Screw in and tighten the mounting bolts 1

Attaching the fuel line, return HDPPE rear - KSC ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Attaching the fuel line KSC - HDPPE front ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

Attaching the fuel line, return HDPPE front KSC ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

Attaching the fuel line KSC - HDPPE rear ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

Attaching the fuel line connection, FPPE front ►Remove the end plug and protective sleeve ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

329

330

5 Fuel / exhaust system 5.1 Fuel system components

Attaching the fuel line connection - FPPE rear ►Remove the end plug and protective sleeve ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

Attaching the fuel line connector - KSC ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

Attaching the fuel line, FPPE rear - KSC ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

Attaching the information sign for the fuel connection ►Place the retaining clamps 5 in the installation position ►Screw in and tighten the mounting bolts 1 with washers 2 ►Position the information sign 4, screw in and tighten the mounting bolts 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Attaching the dual clamps ►Place the dual clamp 3 on the fuel lines as illustrated and close ►Position the cover plates 2 and 4 ►Insert the mounting bolt 1 and screw the mounting nut 5 on and tighten ►Repeat the procedure for the remaining dual clamps 6

Attaching the fuel line, left leak oil line ►Remove end plugs and protective sleeves ►Position the fuel line 1 ►Screw on and then tighten the fuel line retaining nut 1

5.1.2.2 Removing/installing the fuel return line (left) Preparations

►Removing/installing the coolant line on the cylinder head (right), Page 79

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

331

332

5 Fuel / exhaust system 5.1 Fuel system components

key

1 Leak-oil pipe 2 Hollow screw

3 Fuel line, right leak oil line - KSC 4 Bracket, injector cable harness

Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or check depressurization using a MAN-cats (desired value 0).

• The common rail system must be depressurized before starting work.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Protective sleeve Quantity 3 Protective sleeve GPN 200 Z16 x 8

81.96002-0513

2

End plug Quantity 11 GPN 330L16, closing the hole of the pressure pipe socket in the common rail system

81.96002-0519

3

End plug Quantity 6 Closing the high-pressure lines and the bore of the air distributor pipe of GPN 330L14 in the common rail system

81.96002-0521

4

Cap Quantity 2 GPN 695 BE 10, closing the hollow screw connections in the common rail system

81.96002-0518

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

333

334

5 Fuel / exhaust system 5.1 Fuel system components

Removing the fuel return line Removing the injector cable harness bracket ►Unscrew mounting nuts 5 and remove the nuts 2 along with washers 3 ►Unscrew the mounting bolts 1 ►Remove the bracket 4 with the bushings 6

Removing the fuel line ►Loosen the retaining nuts 1 ►Remove the fuel line 2 and close off with an end plug [2] ►Close the connections with protective sleeves [1]

Detaching fuel return line ►Unscrew the hollow screws 2 and remove together with the sealing rings ►Remove the fuel return line 1 with the sealing rings ►Close off the fuel return line 1 with the end plug [2] and caps [4] ►Use the end plug [3] to seal the collections

Installing the fuel return line Attaching the fuel return line ►Remove end plugs and caps ►Attach the fuel return line 1 with new sealing rings ►Screw in the hollow screws 2 with new sealing rings and then tighten

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Attaching the fuel line ►Remove end plugs and protective sleeves ►Position the fuel line 2 ►Screw on and tighten the retaining nuts 1

Attaching the injector cable harness bracket ►Position the bracket 4 with the bushings 6 ►Screw in and tighten the mounting bolts 1 ►Insert the mounting bolts 2 with washers 3 and screw the mounting nuts 5 in and tighten

5.1.2.3 Removing/installing the fuel return line (right) Preparations

►Removing/installing the coolant line on the cylinder head (left), Page 76

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

335

336

5 Fuel / exhaust system 5.1 Fuel system components

key

1 Hollow screw 2 Leak-oil pipe

3 Fuel line, left leak oil line - KSC 4 Dual clamp

Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or check depressurization using a MAN-cats (desired value 0).

• The common rail system must be depressurized before starting work.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Protective sleeve Quantity 2 Protective sleeve GPN 200 Z16 x 8

81.96002-0513

2

End plug Quantity 10 GPN 330L16, closing the hole of the pressure pipe socket in the common rail system

81.96002-0519

3

End plug Quantity 6 Closing the high-pressure lines and the bore of the air distributor pipe of GPN 330L14 in the common rail system

81.96002-0521

4

Cap Quantity 2 GPN 695 BE 10, closing the hollow screw connections in the common rail system

81.96002-0518

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

337

338

5 Fuel / exhaust system 5.1 Fuel system components

Installing the fuel return line Removing the injector cable harness bracket ►Unscrew mounting nuts 6 and remove the nuts 2 along with washers 1 ►Unscrew the mounting bolts 3 ►Remove the bracket 4 with the bushings 5

Removing the dual clamp ►Mark the installation position of the dual clamp 3 ►Unscrew mounting nut 5 and remove along with cover plate 4 ►Pull out the mounting bolts 1 and remove together with the brackets 2 ►Open the dual clamp 3 and remove it

Removing the fuel line ►Loosen the retaining nuts 2 ►Remove the fuel line 1 and close off with an end plug [2] ►Close the connections with protective sleeves [1]

Detaching fuel return line ►Unscrew the hollow screws 2 and remove together with the sealing rings ►Remove the fuel return line 1 with the sealing rings ►Close off the fuel return line 1 with the end plug [2] and caps [4] ►Use the end plug [3] to seal the collections

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.1 Fuel system components

Installing the fuel return line Attaching the fuel return line ►Remove end plugs and caps ►Attach the fuel return line 1 with new sealing rings ►Screw in the hollow screws 2 with new sealing rings and then tighten

Attaching the fuel line ►Remove the protective sleeves and end plugs ►Position the fuel line 1 ►Screw on and tighten the retaining nuts 2

Attaching the dual clamp ►Place the dual clamp 3 at the marked position and close ►Position the cover plates 2 and screw in the mounting bolt 1 ►Position the cover plate 4, attach and tighten the mounting nut 5

Attaching the injector cable harness bracket ►Position the bracket 4 with the bushings 5 ►Screw in and tighten the mounting bolts 3 ►Insert the mounting bolts 2 with washers 1 and screw the mounting nuts 6 in and tighten

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

339

340

5 Fuel / exhaust system 5.2 Injection nozzle 5.2.1

Pressure line, injector nozzle components

5.2.1.1 Removing/installing the pump - rail CR pressure line Preparations

key

►Removing/installing the fuel line, Page 320

1 High-pressure lines 2 Union nut 3 Pipe clamp

Technical data Tightening torques High-pressure lines (initial use)................................................. 1. Torque............................................ 10 Nm High-pressure lines (initial use)................................................. Final tightening.................................. 60 ° High-pressure lines (reuse)............................... ........................ 1. Torque............................................ 10 Nm High-pressure lines (reuse)............................... ........................ Final tightening.................................. 30 ° Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • Before you work on the engine, the engine must be stationary for at least 5 minutes to depressurize the pressure pipe, or check depressurization using a MAN-cats® (desired value 0).

• The common rail system must be depressurized before starting work.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

CAUTION Risk of injury from sharp edges Sharp ends on the cable ties if wrong tool is used.

For this reason: • Only tighten and trim cable ties using the cable tie pliers [12].

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components of the common rail system may be damaged.

For this reason: • Work on the common rail system must be performed by specially trained personnel only.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z14 x 15) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Protective sleeve Quantity 4

81.96002-0512

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

341

342

5 Fuel / exhaust system 5.2 Injection nozzle 2

End plug Quantity 4

81.96002-0521

3

Special wrench, size 19 Quantity 1 Fuel line assembly, universally applicable, all engines

80.99603-0310

4

Angle extension 08.06139-9025 Quantity 1 3/8" x 150 mm, removing and installing the high-pressure lines of the common rail system

5

Ratchet insert Quantity 1 Size 1 3/8", square

08.06455-0001

6

Handle Quantity 1 Attaching and detaching ribbed V-belt disc (alternator) in conjunction with 80.99603-6029

08.06460-0002

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle Torque wrench Quantity 1 Torque wrench 6-50 Nm square drive 3/8" square for insertion tool 9x12 adjust to valve clearance, tighten the lock nut of the adjusting screw

7

08.06450-0006

Removing the pump - rail CR pressure line Detaching pipe clamps ►Mark the installation position of pipe clamps 2 and 5 ►Loosen the mounting bolts 1 and remove the pipe clamp 5 ►Unscrew the mounting nuts 4 ►Remove the mounting bolts 3 and detach the pipe clamp 2

Removing the HDPPE - rear rail pressure line ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container. ►Assemble the special tool, consisting of a handle [6], ratchet insert [5], angle extension [4] and special wrench (size 19) [3] ►Loosen retaining nuts 1 with the special tool ►Remove the fuel lines 2 and close off with end plugs [2] ►Close off the connections with protective sleeves Z14 x 15 [1]

Removing the HDPPE - front rail pressure line ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container. ►Assemble the special tool, consisting of a handle [6], ratchet insert [5], angle extension [4] and special wrench (size 19) [3] ►Loosen retaining nuts 1 with the special tool ►Remove the fuel lines 2 and close off with end plugs [2] ►Close off the connections with protective sleeves Z14 x 15 [1]

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

343

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5 Fuel / exhaust system 5.2 Injection nozzle

Removing the bracket ►Unscrew the mounting nut 3 ►Remove the mounting bolts 1 and detach the bracket 2

Installing the pump - rail CR pressure line Mounting the bracket ►Position the bracket 2 and screw in the mounting bolts 1 ►Screw on the mounting nut 3 and tighten it

Attaching the HDPPE - front rail pressure line ►Remove the protective sleeves and end plugs ►Position the fuel lines 2 and screw on retaining nuts 1 ►Using the torque wrench [7], ratchet insert [5], angle extension [4] and special wrench (size 19) [3], tighten retaining nuts 1 to 1st torque.

High-pressure lines ........ 1. Torque.......... 10 Nm (reuse)........................

High-pressure lines ........ 1. Torque.......... 10 Nm (initial use)..................

Attaching the HDPPE - rear rail pressure line ►Remove the protective sleeves and end plugs ►Position the fuel lines 2 and screw on retaining nuts 1 ►Using the torque wrench [7], ratchet insert [5], angle extension [4] and special wrench (size 19) [3], tighten retaining nuts 1 to 1st torque.

High-pressure lines ........ 1. Torque.......... 10 Nm (reuse)........................

High-pressure lines ........ 1. Torque.......... 10 Nm (initial use)..................

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

Attaching the pipe clamps ►Place the pipe clamps 2 in the installation position ►Insert mounting bolts 3 and screw on mounting nuts 4 ►Place the pipe clamp 5 in the installation position ►Screw the mounting bolt 1 in

High-pressure line, final tightening ►Using the torque wrench [7], ratchet insert [5], angle extension [4] and special wrench (size 19) [3], tighten retaining nuts 2 to the final torque High-pressure lines ........ Final tightening..... 30 ° (reuse).......................

High-pressure lines ........ Final tightening..... 60 ° (initial use)................. ►Tighten the pipe clamps on the fuel lines 1

5.2.1.2 Removing/installing the injection pressure line (left) Preparations

►Removing/installing the fuel line, Page 320

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

345

346

5 Fuel / exhaust system 5.2 Injection nozzle

key

1 High-pressure lines 2 Union nuts 3 Pipe clamps

Technical data Tightening torques High-pressure lines (initial use).............................................................. 1. Torque.............................. 10 Nm High-pressure lines (initial use).............................................................. Final tightening..................... 60 ° High-pressure lines (reuses)............................ ...................................... 1. Torque.............................. 10 Nm High-pressure lines (reuses)............................ ...................................... Final tightening..................... 30 ° Rail mounting bolts on air distributor pipe...... M8x50-8.8..................... ............................................. 25 Nm Rail mounting bolts on air distributor pipe...... M8x60-8.8..................... ............................................. 25 Nm Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or depressurization must be checked by means of MAN-cats® (desired value 0).

• The common rail system must be depressurized before starting work.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components of the common rail system may be damaged.

For this reason: • Work on the common rail system must be performed by specially trained personnel only.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

NOTICE Risk of injury due to leaks Fuel may escape from leaking high-pressure lines at high pressure.

For this reason: • Carefully inspect the high-pressure lines for damage and deformation of the sealing cone before reinstallation.

• Check the high-pressure lines for crushing and deformation.

• Replace damaged high-pressure lines.

• Fit the high-pressure lines so they are free of tension.

• After fitting, check the lines for leaks using MAN-cats® DBV Test.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Protective sleeve Quantity 12 Closing the connection of the pressure line to the pressure pipe and the connection of the pressure line to the high-pressure pump of Z14 x 15 in the common rail system

81.96002-0512

2

End plug Quantity 12 Closing the high-pressure lines and the bore of the air distributor pipe of GPN 330L14 in the common rail system

81.96002-0521

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

347

348

5 Fuel / exhaust system 5.2 Injection nozzle 3

Special wrench, size 19 Quantity 1 Fuel line assembly, universally applicable, all engines

4

Angle extension 08.06139-9025 Quantity 1 3/8" x 150 mm, removing and installing the high-pressure lines of the common rail system

5

Ratchet insert Quantity 1 Size 1 3/8", square

08.06455-0001

6

Handle Quantity 1 Attaching and detaching ribbed V-belt disc (alternator) in conjunction with 80.99603-6029

08.06460-0002

7

Torque wrench Quantity 1 Torque wrench 6-50 Nm square drive 3/8" square for insertion tool 9x12 adjust to valve clearance, tighten the lock nut of the adjusting screw

08.06450-0006

80.99603-0310

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

Removing the injection pressure line Removing cable harness bracket ►Unscrew the mounting bolt 4 ►Unscrew mounting bolts 3 and 7 with washers ►Remove the bracket for cable harness 1 ►Loosen the fasteners 5 and 6 in the bracket 2 ►Remove the bracket 2

Removing the injection pressure line Undoing the high-pressure line ENVIRONMENTAL WARNING Collect any remaining fuel that escapes in a suitable container. ►Assemble the special tool, consisting of a handle [6], ratchet insert [5], angle extension [4] and a socket (size 19) [3] ►Unscrew the retaining nuts of the high-pressure line set 1 and 2 using the special tool ►Loosen the rail mounting bolts 3 and tighten by hand

Detaching the high-pressure lines ►Remove the high-pressure line set from cylinders 7 to 9 1 and close off with end plugs [2] ►Close off the connections in the rail and pressure pipe connector using protective sleeves [1] ►Repeat the work step for the high-pressure line set on cylinders 10 to 12

Installing the high-pressure lines Positioning the high-pressure lines ►Remove the protective sleeves [1] from the connections in the rail and pressure pipe connector ►Remove the end plugs from the high-pressure line set for cylinders 7 to 9 1 ►Position the high-pressure line set for cylinders 7 to 9 1 and then screw on the retaining nuts and tighten by hand ►Repeat the work step for the high-pressure line set on cylinders 10 to 12

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

349

350

5 Fuel / exhaust system 5.2 Injection nozzle

Attaching the high-pressure lines ►Assemble the special tool consisting of torque wrench [7], ratchet insert [5], angle extension [4] and socket wrench insert (size 19) [3] ►Using the special tool, tighten the retaining nuts of the high-pressure line set 1 and 2 to the 1st torque.

Union nut, high....... 1. Torque........ 10 Nm pressure line (initial use)...............................

Union nut, high....... 1. Torque........ 10 Nm pressure line (reuse)...... ►Check that the high-pressure line sets 1 and 2 are seated free from stress and, if necessary, realign ►Tighten the rail mounting bolts 3 to the final torque Rail mounting bolts on M8x50-8.8....... ...... 25 Nm air distributor pipe........

Rail mounting bolts on M8x60-8.8....... ...... 25 Nm air distributor pipe........

Final tightening of high-pressure line ►Assemble the special tool consisting of torque wrench [7], ratchet insert [5], angle extension [4] and socket wrench insert (size 19) [3] ►Using the special tool, tighten the retaining nuts 1 of the high-pressure line sets 2 to the final torque.

Union nut, high-pressure ....... 1. Torque......... 60 ° line (initial use).................

Union nut, high-pressure ....... 1. Torque......... 30 ° line (reuse).......................

Attaching the cable harness bracket ►Position the bracket 2 ►Install the fasteners 5 and 6 in the bracket 2 ►Install the bracket for cable harness 1 ►Screw the mounting bolts 3 and 7 in with washers and then tighten ►Screw in and tighten the mounting bolts 4

5.2.1.3 Removing/installing the injection pressure line (right) Preparations

►Removing/installing the fuel line, Page 320

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

key

1 High-pressure lines 2 Bracket for intake pipe

3 Union nuts 4 Pipe clamps

Technical data Tightening torques High-pressure lines (initial use).............................................................. 1. Torque.............................. 10 Nm High-pressure lines (initial use).............................................................. Final tightening..................... 60 ° High-pressure lines (reuses)............................ ...................................... 1. Torque.............................. 10 Nm High-pressure lines (reuses)............................ ...................................... Final tightening..................... 30 ° Rail mounting bolts on air distributor pipe...... M8x50-8.8..................... ............................................. 25 Nm Rail mounting bolts on air distributor pipe...... M8x60-8.8..................... ............................................. 25 Nm Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or depressurization must be checked by means of MAN-cats® (desired value 0).

• The common rail system must be depressurized before starting work.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

351

352

5 Fuel / exhaust system 5.2 Injection nozzle

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components of the common rail system may be damaged.

For this reason: • Work on the common rail system must be performed by specially trained personnel only.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

NOTICE Risk of injury due to leaks Fuel may escape from leaking high-pressure lines at high pressure.

For this reason: • Carefully inspect the high-pressure lines for damage and deformation of the sealing cone before reinstallation.

• Check the high-pressure lines for crushing and deformation.

• Replace damaged high-pressure lines.

• Fit the high-pressure lines so they are free of tension.

• After fitting, check the lines for leaks using MAN-cats® DBV Test.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Protective sleeve Quantity 12 Closing the connection of the pressure line to the pressure pipe and the connection of the pressure line to the high-pressure pump of Z14 x 15 in the common rail system

81.96002-0512

2

End plug Quantity 12 Closing the high-pressure lines and the bore of the air distributor pipe of GPN 330L14 in the common rail system

81.96002-0521

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle 3

Special wrench, size 19 Quantity 1 Fuel line assembly, universally applicable, all engines

4

Angle extension 08.06139-9025 Quantity 1 3/8" x 150 mm, removing and installing the high-pressure lines of the common rail system

5

Ratchet insert Quantity 1 Size 1 3/8", square

08.06455-0001

6

Handle Quantity 1 Attaching and detaching ribbed V-belt disc (alternator) in conjunction with 80.99603-6029

08.06460-0002

7

Torque wrench Quantity 1 Torque wrench 6-50 Nm square drive 3/8" square for insertion tool 9x12 adjust to valve clearance, tighten the lock nut of the adjusting screw

08.06450-0006

80.99603-0310

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

353

354

5 Fuel / exhaust system 5.2 Injection nozzle

Removing the injection pressure line Removing the bracket for the intake pipe ►Mark the installation position of mounting bolts 3 and 4 ►Remove the mounting bolts 3 and 4 ►Remove the bracket 2 with bushing 5 and washer 1

Undoing the high-pressure line ENVIRONMENTAL WARNING Collect any remaining fuel that escapes in a suitable container. ►Assemble the special tool, consisting of a handle [6], ratchet insert [5], angle extension [4] and a socket (size 19) [3] ►Unscrew the retaining nuts of the high-pressure line set 1 and 2 using the special tool ►Loosen the rail mounting bolts 3 and tighten by hand

Detaching the high-pressure lines ►Remove the high-pressure line set from cylinders 1 to 3 1 and close off with end plugs [2] ►Close off the connections in the rail and pressure pipe connector using protective sleeves [1] ►Repeat the work step for the high-pressure line set on cylinders 4 to 6

Installing the high-pressure lines Positioning the high-pressure lines ►Remove the protective sleeves [1] from the connections in the rail and pressure pipe connector ►Remove the end plugs from the high-pressure line set for cylinders 1 to 3 1 ►Position the high-pressure line set for cylinders 1 to 3 1 and then screw on the retaining nuts and tighten by hand ►Repeat the work step for the high-pressure line set on cylinders 4 to 6

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

Attaching the high-pressure lines ►Assemble the special tool consisting of torque wrench [7], ratchet insert [5], angle extension [4] and socket wrench insert (size 19) [3] ►Using the special tool, tighten the retaining nuts of the high-pressure line set 1 and 2 to the 1st torque.

Union nut, high....... 1. Torque........ 10 Nm pressure line (initial use)...............................

Union nut, high....... 1. Torque........ 10 Nm pressure line (reuse)...... ►Check that the high-pressure line sets 1 and 2 are seated free from stress and, if necessary, realign ►Tighten the rail mounting bolts 3 to the final torque Rail mounting M8x50-8.8... Final 25 Nm bolts on air tightening.... distributor pipe...

Rail mounting M8x60-8.8... Final 25 Nm bolts on air tightening.... distributor pipe...

Final tightening of high-pressure line ►Assemble the special tool consisting of torque wrench [7], ratchet insert [5], angle extension [4] and socket wrench insert (size 19) [3] ►Using the special tool, tighten the retaining nuts 1 of the high-pressure line sets 2 to the final torque.

Union nut, high....... Final tightening... 60 ° pressure line (initial use)...............................

Union nut, high....... Final tightening... 30 ° pressure line (reuse).....

Attaching the bracket for the intake pipe ►Position the bracket 2 with bushing 5 and washer 1 ►Screw the mounting bolts 3 and 4 in as marked and tighten

5.2.1.4 Removing/installing the rail (left) Additional measures

►Removing/installing the injection pressure line (left), Page 345

►Removing/installing the pump - rail CR pressure line, Page 340

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

355

356

5 Fuel / exhaust system 5.2 Injection nozzle

key

1 Mounting bolt 2 Bracket

3 Fuel line, rail 4 Pressure pipe (rail)

Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or depressurization must be checked by means of MAN-cats® (desired value 0).

• The common rail system must be depressurized before starting work.

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components of the common rail system may be damaged.

For this reason: • Work on the common rail system may only be carried out by specially trained personnel.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Protective sleeve Quantity 1 Protective sleeve GPN 200 Z16 x 8

81.96002-0513

2

End plug Quantity 1 GPN 330L16, closing the hole of the pressure pipe socket in the common rail system

81.96002-0519

3

Cap Quantity 1 GPN 695 BE 10, closing the hollow screw connections in the common rail system

81.96002-0518

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

357

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5 Fuel / exhaust system 5.2 Injection nozzle

Removing the rail Disconnecting the rail pressure sensor electrical connection ►Unlock and unplug the plug connector 1 by pressing the spring shackle 2

Detaching the fuel line from the rail to the collector ►Mark the mounting bolts 2 and 3 ►Remove mounting bolts 2 and 3 ►Remove the rail pressure pipe 1 together with the bracket 4

Removing the ring union ►Mark the installation position of the ring union 3 ►Unscrew the hollow screw 2 and remove it with the sealing rings and ring union 3 ►Close the ring union 3 with protective sleeve Z16 x 8 [1] and a cap [3] ►Close off the rail 1 connection with an end plug [2]

Installing the rail Attaching the ring union ►Remove the end plug [2], protective sleeve Z16 x 8 [1] and cap [3] ►Position the ring union 3 with new seals on the rail 1 as marked ►Screw in and tighten the hollow bolt 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

Attaching the fuel line from the rail to the collector ►Attach the rail pressure pipe 1 together with the bracket 4 ►Screw the mounting bolts 2 and 3 in as marked and tighten by hand For final tightening of rail mounting bolts 2 and 3 on the air distributor pipe, see Removing/installing the injection pressure lines ▸ Removing/installing the injection pressure line (right), Page 350

Connecting the rail pressure sensor electrical connection ►Plug the electrical plug connector 1 in, pressing until the spring shackle 2 engages ►Carefully pull on the electrical plug connector 1 and check that it is locked in place (the electrical plug connector must not come loose) If the electrical plug connector 1 comes loose, unplug the electrical plug connector 1 and attach it again.

5.2.1.5 Removing/installing the rail (right) Additional measures ►Removing/installing the injection pressure line (right), Page 350

►Removing/installing the pump - rail CR pressure line, Page 340

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

359

360

5 Fuel / exhaust system 5.2 Injection nozzle

key

1 Mounting bolt 2 Pressure pipe (rail)

3 Fuel line, rail 4 Pipe clamp

Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or depressurization must be checked by means of MAN-cats® (desired value 0).

• The common rail system must be depressurized before starting work.

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components of the common rail system may be damaged.

For this reason: • Work on the common rail system may only be carried out by specially trained personnel.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants. In cases such as these, plan and execute the instructions from the repair manual accordingly

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Protective sleeve Quantity 1 Protective sleeve GPN 200 Z16 x 8

81.96002-0513

2

End plug Quantity 1 GPN 330L16, closing the hole of the pressure pipe socket in the common rail system

81.96002-0519

3

Cap Quantity 1

81.96002-0518

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

361

362

5 Fuel / exhaust system 5.2 Injection nozzle

Removing the rail Disconnecting the rail pressure sensor electrical connection ►Unlock and unplug the plug connector 1 by pressing the spring shackle 2

Removing the rail ►Mark the installation position of brackets 2 and 3 ►Mark the installation position of mounting bolts 4 and 5 ►Remove the mounting bolts 4 and 5 ►Remove the rail 1 with brackets 2 and 3

Removing the ring union ►Mark the installation position of the ring union 3 ►Unscrew the hollow screw 2 and remove it with the sealing rings and ring union 3 ►Close the ring union 3 with protective sleeve Z16 x 8 [1] and a cap [3] ►Close off the rail 1 connection with an end plug [2]

Installing the rail Installing the ring union ►Remove the end plug [2], protective sleeve Z16 x 8 [1] and cap [3] ►Position the ring union 3 with new seals on the rail 1 as marked ►Screw in and tighten the hollow bolt 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

Attaching the rail ►Attach the rail 1 with brackets 2 and 3 ►Screw the mounting bolts 4 and 5 in as marked and tighten by hand For final tightening of rail mounting bolts 4 and 5 on the air distributor pipe, see Removing/installing the injection pressure lines ▸ Removing/installing the injection pressure line (right), Page 350

Connecting the rail pressure sensor electrical connection ►Plug the electrical plug connector 1 in, pressing until the spring shackle 2 engages ►Carefully pull on the electrical plug connector 1 and check that it is locked in place (the electrical plug connector must not come loose) If the electrical plug connector 1 comes loose, unplug the electrical plug connector 1 and attach it again.

5.2.1.6 Removing/installing the common rail pressure-limiting valve

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

363

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5 Fuel / exhaust system 5.2 Injection nozzle

key

1 Pressure-limiting valve

Technical data Tightening torques Pressure-limiting valve.................................. M20x1.5......................................... ............................. 100 Nm Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or check depressurization using a MAN-cats (desired value 0).

• The common rail system must be depressurized before starting work.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components of the common rail system may be damaged.

For this reason: • Work on the common rail system must be performed by specially trained personnel only.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Incorrectly tightened bolted connections cause component damage.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

Tip for users Installation of the left pressure-limiting valve is the same as that of the right pressure-limiting valve.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Protective sleeve Quantity 1 Z18 x 15, closing the pressure-limiting valve and the rail pressure sensor in the common rail system

81.96002-0555

2

End plug Quantity 1 GPN 330 L 18, closing the hole of the rail pressure sensor and the pressure-limiting valve in the pressure pipe in the common rail system

81.96002-0556

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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5 Fuel / exhaust system 5.2 Injection nozzle

Removing the pressure-limiting valve Removing the pressure-limiting valve

NOTICE Risk of material damage due to lack of lubricant Components are damaged by a lack of lubricant.

For this reason: • Do not clean the pressure-limiting valve and rail pressure sensor as the thread and biting edge are coated with lubricant.

Tip for users Removal of the left pressure-limiting valve is the same as that of the right pressure-limiting valve. ►Unscrew the pressure-limiting valve 1 ►Remove the O-ring 2 from the pressure-limiting valve 1 ►Close off the pressure-limiting valve with protective sleeves Z18 x 15 [1]

Installing the pressure-limiting valve Attaching the pressure-limiting valve

NOTICE Risk of material damage due to lack of lubricant Components are damaged by a lack of lubricant.

For this reason: • Do not clean the pressure-limiting valve and rail pressure sensor as the thread and biting edge are coated with lubricant.

Tip for users Installation of the left pressure-limiting valve is the same as that of the right pressure-limiting valve. ►Remove the caps and plugs ►Fit a new O-ring 2 onto the pressure-limiting valve 1 ►Screw the pressure-limiting valve 1 in and tighten Pressure-limiting M20x1.5........... ........ 100 Nm valve.......................

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle 5.2.2

Injector nozzle components

5.2.2.1 Removing/installing the injector with nozzle (common rail) Additional measures ►Removing/installing the cylinder head cover, Page 155

key

1 Injector 2 Mounting bolt

►Removing/installing the injection pressure line (right), Page 350

►Removing/installing the injection pressure line (left), Page 345

4 Pressure pipe connector 5 Pressure screw

3 Pressure flange Technical data Tightening torques Pressure screw, pressure pipe to cylinder M24x1.5........................... 1. Torque............................. 10 Nm head................................................................

Pressure screw, pressure pipe to cylinder M24x1.5........................... 2. Torque............................. 20 Nm head................................................................

Pressure screw, pressure pipe to cylinder M24x1.5........................... Final tightening................... 60 ° head................................................................

Mounting bolt, pressure flange on cylinder M8x55-10.9..................... 1. Torque............................. head................................................................

2 Nm

Mounting bolt, pressure flange on cylinder M8x55-10.9..................... 2. Torque............................. 25 Nm head................................................................

Mounting bolt, pressure flange on cylinder M8x55-10.9..................... Final tightening................... 90 ° head................................................................

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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5 Fuel / exhaust system 5.2 Injection nozzle Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or check depressurization using a MAN-cats® (desired value 0).

• The common rail system must be depressurized before starting work.

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components of the common rail system may be damaged.

For this reason: • Work on the common rail system may only be carried out by specially trained personnel.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of material damage from incorrect removal and installation Reduced functionality due to incorrect installation of injectors.

For this reason: • Always allocate removed injectors to the correct cylinders • Allocate new injectors to the correct cylinders using MAN-cats®. For a description see EDC system description.

NOTICE Risk of material damage due to incorrect installation Missing pipe clamps result in component damage on high-pressure lines.

For this reason: • Always mount wiring harness pipe clamps that have been undone in their original positions • Always refit all of the pipe clamps removed.

• Tighten the pipe clamps to the specified torque.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

NOTICE Risk of injury due to leaks Fuel may escape from leaking high-pressure lines at high pressure.

For this reason: • Carefully inspect the high-pressure lines for damage and deformation of the sealing cone before reinstallation.

• Check the high-pressure lines for crushing and deformation.

• Replace damaged high-pressure lines.

• Fit the high-pressure lines so they are free of tension.

• After fitting, check the lines for leaks using MAN-cats® DBV Test.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 15) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Storage sleeve Quantity 12 Keep the injector in a safe place.

09.81020-1000

2

End plug Quantity 12 330L28 Plugging the injector bore on the cylinder head

81.96002-0520

3

Protective sleeve Quantity 12 Plugging the injector nozzle

81.96002-0522

4

Protective sleeve Quantity 12 B43 Plugging the injector feed bore

81.96002-0523

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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5 Fuel / exhaust system 5.2 Injection nozzle 5

Plug Quantity 12 Plug for threaded holes in the pressure pipe connection

81.96002-0541

• Closing the hole for pressure pipe connection

6

Pressure shim Quantity 12 Ø29 x 65 bore Ø24.5 35 deep • Installing injectors

80.99606-0655

7

Protective sleeve Quantity 12 Closing the connection of the pressure line to the pressure pipe and the connection of the pressure line to the high-pressure pump of Z14 x 15 in the common rail system

81.96002-0512

8

Extractor tool Quantity 1 Removing the pressure pipe socket in the common rail system

80.99602-0011

9

Injector extractor Quantity 1 Pulling out the injector in the common rail system in conjunction with 80.99601-0275, 80.99615-0069, 80.99602-0011

80.99601-6058

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle 10

Threaded adapter Quantity 1 Removing the pressure pipe connector in the common rail system in conjunction with 80.99602-0011

80.99615-0064

Removing the injector with nozzle (common rail) Removing the pressure pipe connector ►Unscrew and remove the pressure screw 1 ►Close off the pressure pipe connector with the protective sleeve [7] 2

Assembling the removal tool for the pressure pipe ►Screw the threaded adapter [10] 1 into the extractor tool [8] 2

Removing the pressure pipe connector ►Remove the protective sleeve [7] ►Extract the pressure pipe connector 2 from the cylinder head 1 using the threaded adapter [10] and the extractor tool [8] ►Close off the hole in the cylinder head 1 with the plug [5] ►Detach extractor tool

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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5 Fuel / exhaust system 5.2 Injection nozzle

Unscrewing the pressure flange mounting bolt ►Unscrew the mounting bolt 2 ►Remove the spherical washer 1

Assembling the extractor tool for the injector ►Screw the injector extractor [9] 1 into the extractor tool [8] 2

Extracting the injector

NOTICE Risk of component damage due to incorrect removal and installation Reduced functionality due to incorrect installation of injectors.

For this reason: • Always allocate removed injectors to the correct cylinders • Allocate new injectors to the correct cylinders using MAN-cats®. For a description see EDC system description. ►Place extractor tool 1 over injector ►Place the extractor [9] 1 in the groove on the pressure flange 2 and tension by turning the knurled nut ►Carefully drive out the injector with the pressure flange 1 using the extractor [9] 2 ►Detach the extractor tool 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle

Remove the sealing ring ►Remove the pressure flange 2 ►Remove the sealing ring 4 ►Remove the O-ring 3 ►Close off the injector 1 with the injector nozzle protective sleeve [3] and the injector inlet cap [4] ►Store the injector 1 in a storage sleeve [1] ►Close the injector inlet in the cylinder head using an end plug [2]

Installing the injector with nozzle Read the IQA code (only if replacing the injector) ►Read off the IQA code (arrow) 2 on the new injector 1 and make a note of it. After the work is finished, the IQA code must be programmed into the EDC 17 control unit using MAN-cats®.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

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5 Fuel / exhaust system 5.2 Injection nozzle

Installing the injector Inserting the injector

NOTICE Risk of damage due to contaminated injector seat in the cylinder head For this reason: • Check for cleanliness and whether there are no seals on the injector seat in the cylinder head Tip for users Always install the injectors together with the pressure flange. It is not possible to install the pressure flange afterwards. ►Remove the caps and plugs ►Align the hole for the pressure pipe connector in the injector 1 with the pressure pipe channel in the cylinder head ►Put a new O-ring 3 and a new seal 4 on the injector 1 ►Apply a thin coat of clean engine oil to the Oring 3 as per MAN Standard 3277 ►Put the pressure flange 2 on the injector 1 ►Insert the injector 1 and pressure flange 2 into the cylinder head ►Press the injector 1 completely into the cylinder head with the pressure shim [6]

Injector 1. Torque ►Screw in the new mounting bolt 2 with spherical washer 1 ►Tighten the mounting bolt 2 Mounting bolt, M8x55-10.9.... 1. Torque.. 2 Nm pressure flange on cylinder head..

Installing the pressure pipe connector

NOTICE Risk of material damage to components if pressure pipe sockets are reused The cone of the pressure pipe sockets is compressed during installation.

For this reason: • Do not reuse pressure pipe connectors once they have been installed. ►Remove the plug and protective sleeve ►Insert the new pressure pipe connector 2 with the thin tip facing the cylinder head 1 ►Tighten the pressure screw 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.2 Injection nozzle Pressure screw, ...... 1. Torque....... 10 Nm pressure pipe to cylinder head.................

Injector final tightening ►Tighten the injector pressure flange mounting bolt 1 Mounting bolt, M8x55-10.9... 2. Torque..... 25 Nm pressure flange on cylinder head.................

Mounting bolt, M8x55-10.9... Final 90 ° pressure flange tightening.... on cylinder head.................

Pressure pipe final tightening ►Tighten the pressure screw 1 Pressure screw, ...... 2. Torque........... 20 Nm pressure pipe to cylinder head..............

Pressure screw, ...... Final tightening. 60 ° pressure pipe to cylinder head..............

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

375

376

5 Fuel / exhaust system 5.3 Injection pump (actuation) 5.3.1

Injection pump, check valve

5.3.1.1 Removing/installing the high pressure pump (front) Preparations ►Removing/installing the fuel line, Page 320

key

►Removing/installing the pump - rail CR pressure line, Page 340

1 Dual clamp 2 High-pressure pump, front

4 Fuel supply pump 5 Coolant line

3 Proportional valve Technical data Tightening torques Mounting bolt, high-pressure pump on front drive M10x50-10.9...................... ................ 60 +10 Nm housing.............................................................................

Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or depressurization must be checked by means of MAN-cats® (desired value 0).

• The common rail system must be depressurized before starting work.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation)

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components of the common rail system may be damaged.

For this reason: • Work on the common rail system may only be carried out by specially trained personnel.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of injury due to leaks Fuel may escape from leaking high-pressure lines at high pressure.

For this reason: • Carefully inspect the high-pressure lines for damage and deformation of the sealing cone before reinstallation.

• Check the high-pressure lines for crushing and deformation.

• Replace damaged high-pressure lines.

• Fit the high-pressure lines so they are free of tension.

• After fitting, check the lines for leaks using MAN-cats® DBV Test.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 5) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Locking ring pliers Quantity 1 Locking ring pliers

08.04046-9000

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

377

378

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Removing the front high-pressure pump Disconnecting the metering unit electrical connection ►Unlock and unplug the electrical connection 1 by pressing the spring shackle 2

Detaching the air compressor return line ►Mark the installation position of the dual clamp 4 ►Unscrew mounting nut 5 and remove along with cover plate 3 ►Pull the mounting bolt 1 out of the dual clamp 4 and remove together with the cover plate 2 ►Open the dual clamp 4 and remove it ►Loosen the retaining nuts 6 and 8 ►Remove the coolant line 7

Removing the slave high-pressure pump ►Unscrew the mounting bolts 4 ►Remove the slave high-pressure pump 1 ►Remove the O-rings 2 and 3 ►Clean the sealing surfaces

Removing the driver sleeve ►Remove the driver sleeve 2 ►Detach the locking ring 1 with the locking ring pliers [1] and remove

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Installing the front high-pressure pump Installing the driver sleeve ►Attach the locking ring 1 to the driver sleeve 1 with locking ring pliers [2] ►Insert the drive shaft into the driver sleeve 2

Installing the slave high-pressure pump ►Insert the slave high-pressure pump 1 with new O-rings 2 and 3 ►Screw in and tighten the mounting bolts 4 Mounting bolt, high- M10x50-10.9.... ... pressure pump on front drive housing..

60 Nm +10

Attaching the air compressor return line ►Position the coolant line 7 ►Screw on and tighten retaining nuts 6 and 8 ►Place the dual clamp 4 at the marked position and close ►Position the cover plate 2 on the dual clamp 4 and insert the mounting bolt 1 ►Position the cover plate 3, attach and tighten the mounting nut 5

Attaching the metering unit electrical connection ►Connect and secure the electrical connection 2 to the metering unit 1

5.3.1.2 Removing/installing the high pressure pump (rear) Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

379

380

5 Fuel / exhaust system 5.3 Injection pump (actuation) Preparations ►Removing/installing the fuel line, Page 320

key

►Removing/installing the pump - rail CR pressure line, Page 340

1 High-pressure pump 2 Proportional valve

3 Mounting bolt 4 Fuel supply pump

Technical data Tightening torques Mounting bolt, high-pressure pump on drive housing for rear M10x50-10.9................. ............. 60 +10 Nm high-pressure pump.................................................................

Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or check depressurization using a MAN-cats (desired value 0).

• The common rail system must be depressurized before starting work.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation)

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components of the common rail system may be damaged.

For this reason: • Work on the common rail system must be performed by specially trained personnel only.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

NOTICE Risk of injury due to leaks Fuel may escape from leaking high-pressure lines at high pressure.

For this reason: • Carefully inspect the high-pressure lines for damage and deformation of the sealing cone before reinstallation.

• Check the high-pressure lines for crushing and deformation.

• Replace damaged high-pressure lines.

• Fit the high-pressure lines so they are free of tension.

• After fitting, check the lines for leaks using MAN-cats® DBV Test.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 5) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Locking ring pliers Quantity 1 Locking ring pliers

08.04046-9000

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

381

382

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Removing the rear high-pressure pump Disconnecting the metering unit electrical connection ►Unlock and unplug the electrical connection 2 by pressing the spring shackle 1

Removing the master high-pressure pump ►Unscrew the mounting bolts 3 ►Remove the slave high-pressure pump 2 ►Remove the O-rings 1 and 4 ►Clean the sealing surfaces

Removing the driver sleeve ►Remove the driver sleeve 1 ►Detach the locking ring 2 with the locking ring pliers [1] and remove

Installing the rear high-pressure pump Installing the driver sleeve ►Attach the locking ring 2 to the driver sleeve 1 with locking ring pliers [1] ►Insert the drive shaft into the driver sleeve 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Installing the master high-pressure pump ►Insert the master high-pressure pump 2 with new O-rings 1 and 4 ►Screw in and tighten the mounting bolts 3 Mounting bolt, high- M10x50-10.9... ... pressure pump on drive housing for rear high-pressure pump..

60 Nm +10

Attaching the metering unit electrical connection ►Connect and secure the electrical connection 1 to the metering unit 2

5.3.1.3 Dismantling/assembling the high-pressure pump Preparations ►Removing/installing the high pressure pump (rear), Page 379

►Removing/installing the high pressure pump (front), Page 376

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

383

384

5 Fuel / exhaust system 5.3 Injection pump (actuation)

key

1 High-pressure pump 2 Proportional valve

3 Fuel supply pump 4 Radial shaft seal

Technical data Tightening torques Overflow valve on high-pressure pump.............. M14x1.5.............................. ................................... 20 Nm Mounting bolt, proportional valve on highM5x20 T25-6.3.................... 1. Torque.................... pressure pump....................................................

3 Nm

Mounting bolt, proportional valve on highM5x20 T25-6.3.................... Final tightening........... 6 Nm pressure pump....................................................

Mounting bolt, fuel supply pump on highM6 x 20 T30 - 6.3................ ................................... pressure pump....................................................

8 Nm

Important information

CAUTION Risk of injury from common rail system Residual pressure in the common rail system may cause injury.

For this reason: • The engine must be stationary for at least 5 minutes before starting work on the engine to depressurize the pressure pipe, or check depressurization using a MAN-cats (desired value 0).

• The common rail system must be depressurized before starting work.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation)

NOTICE Risk of material damage due to incorrectly performed work on the common rail system Components of the common rail system may be damaged.

For this reason: • Work on the common rail system must be performed by specially trained personnel only.

• Ensure absolute cleanliness when working on the system.

• Avoid moisture.

• Replace pressure pipe sockets that have been undone.

• Replace plugs for the high-pressure lines, the pressure pipe and injectors, even if they have only been used once.

• Observe the proper tightening sequence for injectors, high-pressure lines, the pressure pipe and the pressure pipe socket.

NOTICE Risk of material damage due to dirt ingress The ingress of dirt can damage the common rail system.

For this reason: • Always detach only one fuel line.

• Close the component connections immediately using new, clean protective sleeves.

NOTICE Risk of material damage from incorrectly tightened bolted connections Incorrectly tightened bolted connections cause component damage.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users In order to ensure that the correct protective sleeve is used, the designation (e.g. Z 14 x 5) is stamped on it.

ENVIRONMENTAL WARNING Collect any fuel that escapes in a suitable container.

Special tools 1

Protective sleeve Quantity 1 Closing the connection of the pressure line to the pressure pipe and the connection of the pressure line to the high-pressure pump of Z14 x 15 in the common rail system

81.96002-0512

2

End plug Quantity 1 Closing the high-pressure lines and the bore of the air distributor pipe of GPN 330L14 in the common rail system

81.96002-0521

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

385

386

5 Fuel / exhaust system 5.3 Injection pump (actuation) 3

Extractor Quantity 1 Extractor

80.99601-6041

4

Guide sleeve Quantity 1 Guide sleeve

80.99604-0374

5

Pressing sleeve Quantity 1 Pressing sleeve

80.99604-0375

6

Internal six-lobe profile bit TX25 Quantity 1 Size = Torx profile TX25 Holding device ¼" entire length 25

08.06527-1007

7

Internal six-lobe profile bit TX30 Quantity 1 Size = Torx profile TX30 Holding device ¼" entire length 25

08.06527-1009

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation) 8

Extension Quantity 1 Extension for screwdriver bits

08.06564-9000

9

Ratchet insert Quantity 1 Ratchet insert for 5/16" - 9 x 12 bits

08.06410-9072

10

Torque wrench Quantity 1 Torque wrench 6-50 Nm square drive 3/8" square for insertion tool 9x12 adjust to valve clearance, tighten the lock nut of the adjusting screw

08.06450-0006

Dismantling the high-pressure pump Removing the radial shaft seal ►Insert extractor [3] 2 into radial shaft seal 3 and turn in until it engages ►Extract the radial shaft seal 3 by screwing in the threaded spindle 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

387

388

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Removing the proportional valve ►Clean the high-pressure pump and blow it dry using compressed air ►Mark the installation position of the proportional valve 1 ►Unscrew the mounting bolts 2 ►Extract the metering unit 1 by turning it slightly to the right/left

Removing the fuel supply pump ►Unscrew the mounting bolts 3 ►Pull the fuel supply pump 4 out ►Remove the coupling element 1 and the O-ring 2 from the fuel pump 4 ►Close off the fuel supply pump 4 with a protective sleeve Z14 x 15 [1]

Removing the overflow valve ►Unscrew the overflow valve 1 and remove with the seal 3 ►Close off the overflow valve 1 with a protective sleeve Z14 x 15 [1] ►Remove the O-ring 2 from the overflow valve 1 ►Close the hole with an end plug [2]

Assembling the high-pressure pump Installing the overflow valve ►Remove end plugs and protective sleeves ►Fit the new O-ring 2 on the overflow valve 1 ►Screw in and tighten the overflow valve 1 with a new sealing ring 3 Overflow valve on M14x1.5......... ....... 20 Nm high-pressure pump.....

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Installing the fuel supply pump ►Insert the coupling element 1 and the new Oring 2 into the fuel pump 4 ►Insert the fuel supply pump 4 ►Assemble the special tool, consisting of the torque wrench [10], ratchet insert [9], extension [8] and screwdriver bit size TX 30 [7] ►Screw in the mounting bolts 3 ►Tighten mounting bolts 3 with the special tool Mounting bolt, fuel M6 x 20 T30 - ..... 8 Nm supply pump on high- 6.3................... pressure pump...............

Installing the proportional valve Tip for users If using micro-encapsulated bolts, the time between the tightening stages must not exceed 2 minutes. ►Insert metering unit 1 with a slight right/left turn into the high-pressure pump ►Align the proportional valve 1 as marked ►Assemble the special tool, consisting of the torque wrench [10], ratchet insert [9], extension [8] and screwdriver bit size TX 25 [6] ►Screw in the mounting bolts 2 ►Tighten mounting bolts 2 to 1st torque Mounting bolt, M5x20 1. Torque.. 3 Nm proportional valve on T25-6.3...... high-pressure pump.. ►Tighten the mounting bolts 2 to final torque Mounting bolt, M5x20 Final 6 Nm proportional valve T25-6.3.... tightening.... on high-pressure pump.......................

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

389

390

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Installing the radial shaft sealing ring ►Place guide sleeve [4] 2 on drive shaft ►Put the closed side of the new radial shaft seal 3 on the guide sleeve [4] 2 ►Place the press-in bushing [5] 1 onto the radial shaft seal 3 over the guide sleeve [4] 2 ►Press in the radial shaft seal 3 until it engages

5.3.1.4 Removing/installing the high-pressure pump drive housing Preparations ►Removing/installing the fuel line, Page 320 ►Removing/installing the pump - rail CR pressure line, Page 340

►Removing/installing the high pressure pump (rear), Page 379 ►Removing/installing the high pressure pump (front), Page 376

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation)

key

1 Drive housing 2 Rear drive housing

3 Mounting bolt 4 Screw plug

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants. In such cases, plan and execute the repair work accordingly.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

391

392

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Removing the high-pressure pump drive housing Removing the rear high-pressure pump drive housing ►Mark the installation position of mounting bolts 4 and 5 ►Remove the mounting bolts 4 and 5 ►Remove the rear drive housing 1 with the Orings 2 and 3 ►Clean the sealing surfaces

Removing the front high-pressure pump drive housing ►Extract the drive housing 1 and remove with the O-rings 2 and 3 ►Clean the sealing surfaces

Installing the high-pressure pump drive housing Installing the rear high-pressure pump drive housing ►Clean the sealing surfaces ►Fit the new O-ring 2 on the drive housing 1 ►Install the drive housing 1 with a new O-ring 3

Removing the rear high-pressure pump drive housing ►Clean the sealing surfaces ►Fit the new O-ring 3 on the drive housing 1 ►Install the drive housing 1 with a new O-ring 2 ►Screw the mounting bolts 4 and 5 in as marked and tighten

5.3.1.5 Dismantling and assembling the high-pressure pump drive housing Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation) Preparations

key

►Removing/installing the highpressure pump drive housing, Page 390

1 Drive housing 2 Rear drive housing 3 Drive shaft

Service products Omnifit N703-A2 ................................................................................................................. 04.90300-9009 Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Incorrectly tightened bolted connections cause component damage.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

393

394

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Dismantling the high-pressure pump drive housing Removing the screw plug ►Unscrew the screw plug 1 from the drive housing 2 and remove it with the sealing ring ►Clean the sealing surfaces

Removing the thrust washer ►Unscrew the mounting bolts 1 ►Remove the thrust washer 2

Removing the drive gear ►Insert the drive shaft 4 with the drive housing 2 in the driver sleeve 5 ►Clamp the driver sleeve 5 in a vice with protective jaws ►Unscrew the mounting bolts 1 from the drive wheel 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Removing the drive shaft ►Extract the drive shaft 1 from the drive housing 2 ►Remove the drive wheel 3

Unscrewing the screw plugs ►Unscrew and remove the plug 1 with the sealing ring ►Unscrew and remove the plug 2 with the sealing ring

Removing the screw plug ►Unscrew the plug 1

Assembling the high-pressure pump drive housing Inserting the screw plug ►Apply a thin layer of Omnifit N703-A2 on the plug 1 ►Screw in the plug 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

395

396

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Screwing the screw plugs in ►Screw in the screw plug 2 with the new seal and tighten it ►Screw in the screw plug 1 with the new seal and tighten it

Installing the drive shaft ►Insert the drive wheel 3 ►Insert the drive shaft 1 into the drive housing 2

Installing the drive gear ►Insert the drive shaft 4 with the drive housing 2 in the driver sleeve 5 ►Clamp the driver sleeve 5 in a vice with protective jaws ►Screw the mounting bolts 1 into the drive wheel 3 and tighten

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Installing the thrust washer ►Insert the thrust washer 2 into the drive housing ►Screw in and tighten the mounting bolts 1

Inserting the screw plug ►Screw the plug 1 with a sealing ring into the drive housing 2 and then tighten it

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

397

398

5 Fuel / exhaust system 5.3 Injection pump (actuation) 5.3.2

Control unit console

5.3.2.1 Removing/installing the cooling plate/console for the control unit (EDC) Preparations

key

►Removing/installing EDC control unit (Electronic Diesel Control), Page 45

1 Console for control units 2 Interface connector bracket

Service products Loctite 270 .......................................................................................................................... 04.10160-9353 Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.3 Injection pump (actuation) Special tools 1

Cable tie pliers Quantity 1

08.02960-0100

Removing the console for the control units Detaching the interface connector bracket ►Mark the installation position of the cable ties ►Disconnect the cable ties ►Unscrew the mounting bolts 2 and remove along with the bushings 3 ►Open and secure the interface connector bracket 1 with cable harness

Detaching the console for the control units ►Mark the installation position of mounting bolts 5 and 6 ►Remove the mounting bolts 5 and 6 ►Remove the console 1 with rubber bearings 3, 4 and bushings 2, 7

Installing the console for the control units Attaching the console for the control units ►Apply a thin layer of Loctite 270 to the threads of the new mounting bolts 5 and 6 ►Position the console 1 with rubber bearings 3 , 4 and bushings 2 , 7 ►Screw the mounting bolts 5 and 6 in as marked and tighten

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

399

400

5 Fuel / exhaust system 5.3 Injection pump (actuation)

Attaching the interface connector bracket ►Check the cable harness for damage, replace if necessary ►Position the interface connector bracket 1 with bushings 3 and cable harness in the installation position ►Screw in and tighten the mounting bolts 2 ►Fasten the cable harness with cable ties at the marked positions ►Tighten and trim the cable ties using the cable tie pliers [1]

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.4 Engine attachments 5.4.1

Alternator attachment components

5.4.1.1 Removing/installing the alternator bracket Preparations ►Removing/installing the refrigerant compressor, Page 431

key

►Removing/installing the alternator, Page 51 ►Removing/installing the automatic belt tensioner, Page 192

►Removing/installing the alternator V-belt, Page 191

1 Alternator bracket 2 Mounting bolt 3 Mounting bolt

Important information

NOTICE Risk of damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

401

402

5 Fuel / exhaust system 5.4 Engine attachments

Removing the three-phase alternator bracket Removing the bracket ►Remove the mounting bolts 2 and 3 ►Remove the bracket 1 ►Remove the mounting bolts 4 and 5 ►Remove the bracket 6

Detaching the three-phase alternator bracket ►Unscrew the mounting bolts 2 ►Unscrew the mounting bolts 3 ►Remove the bracket 1

Installing the three-phase alternator bracket Attaching the three-phase alternator bracket ►Position the bracket 1 ►Screw in and tighten the mounting bolts 2 ►Screw in and tighten the mounting bolts 3

Mounting the bracket ►Position the bracket 6 ►Screw in and tighten the mounting bolts 4 and 5 ►Position the bracket 1 ►Screw in and tighten the mounting bolts 2 and 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.4 Engine attachments 5.4.2

Engine suspension

5.4.2.1 Removing/installing the crane lifting eye / engine lifting eye

key

1 Crane lifting eye, front 2 Attaching the rear crane lifting eye

Technical data Tightening torques Lifting eye mounting bolt................ M12x45-10.9........................ 1. Torque................................. 20 +10 Nm Lifting eye mounting bolt................ M12x45-10.9........................ Final tightening....................... 90 +10 ° Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

403

404

5 Fuel / exhaust system 5.4 Engine attachments

Removing the lifting eyes Detaching the front lifting eyes ►Unscrew the mounting bolts 2 ►Remove the lifting eye 1 ►Unscrew the mounting bolts 4 ►Remove the lifting eye 3

Removing the rear crane lifting eye mounting bolt ►Unscrew the mounting bolt 2 and remove along with the washer 1

Removing the bracket ►Unscrew mounting nut 3 ►Tighten the mounting bolts 1 ►Remove the bracket 2

Removing the rear lifting eye ►Mark the installation position of mounting bolts 2 and 3 ►Remove the mounting bolts 2 and 3 ►Remove the lifting eye 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

5 Fuel / exhaust system 5.4 Engine attachments

Installing the lifting eyes Attaching the rear lifting eye ►Attach the lifting eye 1 ►Screw in mounting bolts 2 and 3 as marked and tighten

Mounting the bracket ►Position the bracket 2 ►Insert the mounting bolt 1 ►Screw on the mounting nut 3 and tighten it

Attaching the rear crane lifting eye mounting bolt ►Screw in and tighten the mounting bolt 2 with washer 1

Attaching the front lifting eyes ►Attach the lifting eye 1 ►Screw in and tighten the mounting bolts 2 Lifting eye M12x45-10.9.. 1. Torque.... mounting bolt..............

20 Nm +10

Lifting eye M12x45-10.9.. Final mounting tightening... bolt..............

90 ° +10

►Attach the lifting eye 3 ►Screw in and tighten the mounting bolts 4

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

405

406

5 Fuel / exhaust system 5.4 Engine attachments Lifting eye M12x45-10.9.. 1. Torque.... mounting bolt..............

20 Nm +10

Lifting eye M12x45-10.9.. Final mounting tightening... bolt..............

90 ° +10

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

6 Air compressor, pressure control valve 6.1 Air compressor, line

6.1.1 Removing/installing the air compressor (single cylinder)

key

1 Air compressor 2 Coolant return line

3 Coolant feed line 4 Oil pressure line

Technical data Tightening torques Pressure-relief valve.................................... M26x1.5........................................... ............................... 80 Nm GE connection............................................. M26x1.5........................................... ............................... 80 Nm Service products Installation lubricant P-80 ................................................................................................... 09.15014-0031 Important information

NOTICE Risk of damage to components due to contaminants For this reason: • Clean components and sealing surfaces before assembly by suitable means • Protect cleaned surfaces from re-contamination

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

407

408

6 Air compressor, pressure control valve 6.1 Air compressor, line

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

Removing the 1-cylinder air compressor Detaching the intake hose ►Mark the retaining clamp installation position ►Unscrew and remove the mounting nut 3 with washer ►Pull out the mounting bolt 5 with the washer ►Undo hose clamps 1 and 4 and push onto hose 2 ►Pull off the hose 2

Removing the intake manifold ►Mark the intake manifold installation position ►Loosen the hex nut on the intake manifold 1 ►Unscrew the intake manifold 1

Removing the oil pressure lines ►Loosen the retaining nuts 1 and 3 ►Remove the oil pressure line 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

6 Air compressor, pressure control valve 6.1 Air compressor, line

Detaching coolant feed lines ►Loosen the retaining nuts 1 and 3 ►Detach the coolant feed lines 2

Detaching the coolant return lines ►Mark the installation position of the dual clamps ►Remove the dual clamps ►Loosen the retaining nut on the WV connector 1 ►Remove the coolant return line 2 from the air compressor

Detaching the air compressor CAUTION Danger of injury due to heavy components For this reason: • Remove the air compressor with support ►Unscrew and remove the mounting bolts 1 with washers ►Remove the air compressor 2 ►Remove the O-ring 3 from the air compressor 2 ►Clean the sealing surfaces

Installing the 1-cylinder air compressor Attaching the air compressor CAUTION Danger of injury due to heavy components For this reason: • Install the air compressor with support ►Clean the sealing surfaces ►Apply a thin layer of installation lubricant P80 to the new O-ring 3 ►Insert new O-ring 3 in the groove in the air compressor 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

409

410

6 Air compressor, pressure control valve 6.1 Air compressor, line ►Attach the air compressor 2 ►Screw the mounting bolts 1 in with washers and then tighten

Attaching the coolant return lines ►Position the coolant return lines 2 ►Screw on and then tighten the retaining nut on the WV connector 1 ►Install the dual clamps as marked

Attaching coolant feed lines ►Attach the coolant feed lines 2 ►Screw on and tighten retaining nuts 1 and 3

Attaching the oil return lines ►Position the oil pressure line 2 with the WV connector ►Screw on and tighten retaining nuts 1 and 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

6 Air compressor, pressure control valve 6.1 Air compressor, line

Attaching the intake manifold ►Align and screw on the intake manifold 1 with the hex nut as marked ►Tighten the hex nut

Attaching the intake hose ►Position the intake hose 2 with new hose clamps 1 and 4 ►Push the intake hose 2 onto the pipe bend ►Tighten the hose clamps 1 and 4 at the installation position ►Place the retaining clamp in the installation position ►Insert the mounting bolt 5 with washer, then screw on the mounting nut 3 with washer and tighten

6.1.2 Dismantling/assembling air compressor (single cylinder) Preparations

►Removing/installing the air compressor (single cylinder), Page 407

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

411

412

6 Air compressor, pressure control valve 6.1 Air compressor, line

key

1 Piston sealing rings 2 Piston

11 Pressure-relief valve 12 Stud bolt

21 GE connection 22 Blind flange

3 Piston pin 4 Locking ring

13 GE connection 14 Screw plug

23 Bearing flange 24 O-ring

5 Mounting bolt 6 GE connection 7 Connecting rod 8 Connecting rod bearing cap 9 Mounting bolt 10 GE connection

15 Air compressor cylinder head cover 16 Screw plug 17 Screw plug 18 Seal 19 Cylinder head 20 Seal

25 Crankshaft 26 Air compressor housing 27 Locking ring 28 Cylindrical roller bearing 29 Crankshaft drive wheel 30 Mounting bolt

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

6 Air compressor, pressure control valve 6.1 Air compressor, line Technical data Tightening torques Connecting rod mounting bolts............ M8x38................................... 1. Torque...........................

10 Nm

Connecting rod mounting bolts............ M8x38................................... Final tightening.................

90 °

Cylinder head mounting bolt.................M8x172-10.9......................... 1. Torque...........................

30 +3 Nm

Cylinder head mounting bolt.................M8x172-10.9......................... 2. Torque........................... 90 -5+10 ° Cylinder head mounting bolt.................M8x172-10.9......................... Final tightening................. 90 -5+10 ° Cylinder head bleed screw................... .............................................. .......................................... 10 ±1 Nm Cylinder head bleed screw................... .............................................. .......................................... 90 +10-5 ° Air compressor drive wheel mounting M18x1.5x50........................... .......................................... 360 +30 Nm bolt........................................................

Blind flange mounting bolt.................... M10x35 - 8.8......................... 1. Torque...........................

10 Nm

Blind flange mounting bolt.................... M10x35 - 8.8......................... Final tightening.................

90 °

Pressure relief valve on air compressor M26x1.5................................ ..........................................

80 Nm

Service products Loctite 5900 ........................................................................................................................ 04.10394-9272 Engine oil ..................................................

For more information see the MAN service product database

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Literature reference The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

Special tools 1

Disassembly device Quantity 1

80.99606-6118

2

Piston ring pliers Quantity 1

80.99625-0167

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

413

414

6 Air compressor, pressure control valve 6.1 Air compressor, line 3

Piston ring clamping strap Quantity 1

80.99613-0035

4

Ratchet insert Quantity 1

08.06455-0002

5

Torque wrench Quantity 1

08.06450-0006

6

Ratchet insert Quantity 1

08.06455-0020

7

Torque wrench Quantity 1

08.06450-0011

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

6 Air compressor, pressure control valve 6.1 Air compressor, line 8

Handle Quantity 1

08.06460-0002

9

Locking ring pliers Quantity 1

08.04046-9000

Dismantling the air compressor Removing the pressure relief valve ►Unscrew and remove the pressure relief valve 1 with the sealing ring 2

Removing the air compressor connections ►Unscrew and remove the GE connections 1 , 4 , 5 and 6 with the sealing rings ►Unscrew screw plugs 2 and 3 and remove them along with the sealing rings

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

415

416

6 Air compressor, pressure control valve 6.1 Air compressor, line

Removing the blind flange ►Unscrew the mounting bolts 2 ►Remove the blind flange 1 ►Clean the sealing surfaces

Attaching the disassembly device ►Place the disassembly device 1 on the air compressor ►Screw in and tighten the mounting bolts 2 ►Clamp the disassembly device [1] 1 in a vice

Detaching the drive wheel ►Unscrew the mounting bolt 1 ►Remove the drive wheel 2

Removing the cylinder head cover ►Unscrew the mounting bolts 1 ►Remove the cylinder head cover 2 together with the gasket 3 ►Clean the sealing surfaces

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

6 Air compressor, pressure control valve 6.1 Air compressor, line

Removing the cylinder head ►Remove the cylinder head 1 ►Remove the seal 2 ►Clean the sealing surfaces

Removing the piston ►Mark the relative positions of the piston 3 , piston pin 2 and connecting rod ►Detach locking rings 1 and 4 ►Press the piston pin 2 out of the piston 3 ►Remove the piston 3 from the connecting rod ►Clean the sealing surfaces

Removing the piston rings ►Mark the installation position of the piston rings 3 ►Set the piston ring pliers [2] to the piston diameter ►Remove the piston rings 3 with the piston ring pliers [2] 1 ►Carefully clean the piston ring grooves of the piston 2 ►Clean the sealing surfaces

Removing the connecting rod ►Unscrew the mounting bolts 1 ►Separate the connecting rod 2 from the connecting rod bearing cap 4 by means of the cylinder pins 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

417

418

6 Air compressor, pressure control valve 6.1 Air compressor, line

Removing the disassembly device ►Unscrew the mounting bolts 2 ►Remove the disassembly device 1

Removing the bearing flange ►Mark the bearing flange installation position ►Remove the bearing flange 2 from the air compressor housing ►Remove the O-ring 1 from the bearing flange 2 ►Clean the sealing surfaces

Removing the crankshaft ►Pull the crankshaft 4 out of the cylindrical roller bearings 2 ►Extract the crankshaft 4 from the air compressor housing 1 ►Expand and remove the locking ring 3 from the air compressor housing 1 with the locking ring pliers [9] ►Remove the cylindrical roller bearings 2 from the air compressor housing 1

Assembling the air compressor Attaching the crankshaft ►Insert the cylindrical roller bearings 2 into the air compressor housing 1 ►Place the locking ring 3 in the groove of the air compressor housing 1 with the locking ring pliers [9] ►Thread the crankshaft 4 into the air compressor housing 1 ►Insert the crankshaft 4 into the cylindrical roller bearings 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

6 Air compressor, pressure control valve 6.1 Air compressor, line

Attaching the bearing flange ►Clean the sealing surfaces ►Apply a thin layer of clean engine oil to the bearing flange ►Fit a new O-ring 1 on the bearing flange 2 ►Insert the bearing flange 2 into the air compressor housing in alignment with the marking

Attaching the disassembly device ►Rotate the crankshaft to the installation position ►Place the disassembly device 1 on the air compressor ►Screw in and tighten the mounting bolts 2 ►Clamp the disassembly device [1] 1 in a vice

Attaching the connecting rod ►Apply a thin layer of clean engine oil to the connecting rod 2 and connecting rod bearing cap 4 ►Place the connecting rod 2 on the connecting rod bearing 4 by means of the cylindrical pins 3 ►Screw in and tighten the mounting bolts 1 Connecting rod M8x38..... 1. Torque........ 10 Nm mounting bolts.....

Connecting rod M8x38..... Final 90 ° mounting bolts..... tightening.......

Attaching the piston rings ►Carefully clean the piston ring grooves of the piston 2 ►Set the piston ring pliers [2] 1 to the piston diameter ►Using the piston ring pliers [2] 1 install the piston rings 3 on the piston 2 with the TOP marking facing the piston crown in accordance with the marking

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

419

420

6 Air compressor, pressure control valve 6.1 Air compressor, line

Attaching the piston with piston rings ►Apply a thin layer of clean engine oil to the piston 2 and cylinder running surface ►Place and tighten the piston ring clamping strap [3] on the piston 2 the with the piston rings 1 ►Push the piston 2 into the cylinder liner 3 until the piston 2 is pushed out of the piston ring clamping strap [3]

Attaching the cylinder head with pistons ►Clean the sealing surfaces ►Place a new seal 4 on the air compressor housing ►Insert a new locking ring 2 in the groove in the piston 3 ►Fit the piston 3 with the cylinder liner 1 over the connecting rod as marked ►Apply a thin layer of clean engine oil to the piston pin 6 ►Push the piston pin 6 through the piston 3 and the connecting rod in accordance with the marking until it stops ►Insert a new locking ring 5 in the groove in the piston 3 ►Check that the locking rings 2 and 5 are seated correctly If the locking rings 2 and 5 have not engaged correctly, remove and re-attach the locking rings 2 and 5 , ensuring that they are seated correctly. ►Push the cylinder liner 1 over the piston 3 to the seal 4

Attaching the cylinder head cover ►Clean the sealing surfaces ►Position the cylinder head cover 2 with a new gasket 3 ►Screw in mounting bolts 1 and tighten by hand

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

6 Air compressor, pressure control valve 6.1 Air compressor, line

Cylinder head cover mounting bolt tightening sequence ►Tighten the mounting bolts 1 through 4 in the correct tightening sequence Cylinder M8x172-10.9.. 1. Torque.... 30 +3 Nm head mounting bolt...............

Cylinder M8x172-10.9.. 2. Torque.... head mounting bolt...............

Cylinder M8x172-10.9.. Final head tightening... mounting bolt...............

90 ° +10

-5

90 ° +10

-5

►Loosen the cylinder head bleed screw 5 ►Screw in and tighten the cylinder head bleed screw 5 Cylinder head bleed ........... ........... 10 ±1 Nm screw..............................

Cylinder head bleed ........... ........... 90 +10-5 ° screw..............................

Attaching the drive wheel ►Position the drive wheel 2 ►Screw in and tighten the mounting bolt 1 Air compressor M18x1.5x50..... .... 360 +30 Nm drive wheel mounting bolt..........

Removing the disassembly device ►Unscrew the mounting bolts 2 ►Remove the disassembly device 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

421

422

6 Air compressor, pressure control valve 6.1 Air compressor, line

Attaching the blind flange ►Clean the sealing surfaces ►Apply a thin layer of Loctite 5900 to the blind flange 1 ►Position the blind flange 1 ►Screw in and tighten the mounting bolts 2 Blind flange M10x35 - 8.8 1. Torque....... 10 Nm mounting bolt.. .....................

Blind flange M10x35 - 8.8 Final 90 ° mounting bolt.. ..................... tightening......

Installing the air compressor connections ►Screw in and tighten the GE connections 1, 4 , 5 and 6 with new sealing rings ►Screw in and tighten new plugs 2 and 3 with new seals

Attaching the pressure relief valve ►Screw in and tighten the pressure relief valve 1 with a new sealing ring 2 Pressure relief valve on M26x1.5........ ...... 80 Nm air compressor...............

6.1.3 Removing/installing the air compressor cap Preparations ►Removing/installing the air compressor (single cylinder), Page 407

►Removing/installing the air compressor coolant line, Page 63

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

6 Air compressor, pressure control valve 6.1 Air compressor, line

key

1 Mounting bolt 2 Cap

Service products Loctite N703-A2 DK 300 ml ................................................................................................ 04.10394-9272 Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants. In such cases, plan and execute the repair work accordingly.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

423

424

6 Air compressor, pressure control valve 6.1 Air compressor, line

Removing the air compressor cap Removing the air compressor cap ►Unscrew the mounting bolts 1 ►Remove the cap 2 ►Clean the sealing surfaces

Installing the air compressor cap Installation instructions for cap

NOTICE Component damage due to leaking flywheel housing/timing case For this reason: • The mating face must be free of grease.

• Bead of sealing agent must be continuous and not wider than 1 mm • Check that the sealing bead is continuous. ►Apply a thin layer of Loctite N703-A2 sealant 1 to the sealing surface as shown

Installing the air compressor cap ►Clean the sealing surfaces ►Put the cap 2 on ►Screw in and tighten the mounting bolts 1

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

7 Power take-off 7.1 Engine-dependent power take-off components

7.1.1 Removing/installing the PTO cover

key

1 PTO cover 2 Mounting bolts

Service products Installation lubricant P-80 ................................................................................................... 09.15014-0031 Important information

NOTICE Risk of damage to components by contaminants For this reason: • Clean components and sealing surfaces before assembly by suitable means.

• Protect cleaned surfaces from re-contamination.

NOTICE Risk of component damage due to incorrectly tightened bolted connections For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque • Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

425

426

7 Power take-off 7.1 Engine-dependent power take-off components In such cases, plan and execute the repair work accordingly.

Removing the PTO cover Detaching the PTO cover ►Unscrew the mounting bolts 4 ►Remove the PTO cover 3 from the flywheel housing/timing case 1 ►Remove the O-rings 2 and 5 from the PTO cover 4 ►Clean the sealing surfaces

Installing the PTO cover Attaching the PTO cover ►Clean the sealing surfaces ►Apply a thin layer of P80 installation lubricant to the new O-rings 2 and 5 ►Fit the new O-ring 2 on the PTO cover ►Insert new O-ring 5 in the groove in the PTO cover ►Attach the PTO cover 3 ►Screw in and tighten the mounting bolts 4

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

8 Hydraulic power steering components, engine suspension 8.1 Engine suspension

8.1.1 Removing/installing the engine bracket (left)

key

1 Mounting bolt 2 Left engine bracket

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

427

428

8 Hydraulic power steering components, engine suspension 8.1 Engine suspension

Removing the left engine bracket Detaching the engine bracket ►Unscrew the mounting bolts 3 and remove with the washer 2 ►Remove the engine bracket 1

Installing the left engine bracket Attaching the engine bracket ►Position the engine bracket 1 ►Screw in and tighten the mounting bolts 3 with washers 2

8.1.2 Removing/installing the engine bracket (right)

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

8 Hydraulic power steering components, engine suspension 8.1 Engine suspension

key

1 Right engine bracket

Important information

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50% of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

429

430

8 Hydraulic power steering components, engine suspension 8.1 Engine suspension

Removing the right engine bracket Detaching the engine bracket ►Unscrew the mounting bolts 2 and remove with the washer 3 ►Remove the engine bracket 1

Installing the right engine bracket Attaching the engine bracket ►Position the engine bracket 1 ►Screw in and tighten the mounting bolts 2 with washers 3

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

9 Hydraulics, air-conditioning system working devices 9.1 Air-conditioning

9.1.1 Removing/installing the refrigerant compressor Preparations

key

►Removing/installing the alternator V-belt, Page 191

1 Refrigerant compressor 2 Refrigerant compressor electrical connection

Important information

CAUTION Risk of injury due to chemical substances Health hazard from refrigerant and refrigeration oil.

For this reason: • Do not let refrigerant and refrigeration oil come into contact with the skin

CAUTION Risk of injury from sharp edges Sharp ends on the cable ties if wrong tool is used.

For this reason: • Only tighten and trim cable ties using cable tie pliers.

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

431

432

9 Hydraulics, air-conditioning system working devices 9.1 Air-conditioning

NOTICE Risk of material damage due to incorrect installation Electrical cable damage due to over-tightening.

For this reason: • Follow the instructions for use of the cable tie pliers.

NOTICE Risk of material damage from incorrectly tightened bolted connections Components will be damaged.

For this reason: • Only use an impact screwdriver to tighten to max. 50 % of the prescribed torque.

• Final tightening must always be performed manually using a torque wrench.

Tip for users The repair manual describes the repair method of an engine variant as an example.

Pictures and the corresponding descriptions do not always correspond to the engine being repaired as it was not possible to take into account all engine variants.

In such cases, plan and execute the repair work accordingly.

ENVIRONMENTAL WARNING Dispose of refrigerant and refrigeration oil in the correct manner.

Special tools 1

Cable tie pliers Quantity 1

08.02960-0100

Removing the refrigerant compressor Disconnecting the refrigerant compressor electrical connection ►Mark the installation position of the cable ties ►Disconnect the cable ties ►Unlock and unplug the electrical connection 1 by pressing the spring latch 2

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

9 Hydraulics, air-conditioning system working devices 9.1 Air-conditioning

Removing the refrigerant compressor Tip for users The intake connection is marked with an S. The pressure connection is marked with a D. ►Unscrew the mounting nuts 3 ►Remove the mounting bolts 1 ►Remove the refrigerant compressor 2 from the bracket 4

Installing the refrigerant compressor ►Position the refrigerant compressor 2 on the bracket 4 ►Insert the mounting bolts 1 ►Screw on the mounting nut 3 and tighten it

Connecting the refrigerant compressor electrical connection ►Push the electrical connection 1 together until the spring latch 2 engages ►Carefully pull on the electrical plug connector 1 and check that it is locked in place (the electrical plug connector must not come loose) If the electrical plug connector 1 comes loose, pull the electrical plug connector 1 off and connect it again. ►Route the cable and secure with a cable tie ►Tighten and trim the cable ties using the cable tie pliers [1].

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

433

434

9 Hydraulics, air-conditioning system working devices 9.1 Air-conditioning

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools Removing/installing the charge pressure sensor 1

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

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

Removing/installing the EDC fuel temperature sensor

17

08.02960-0100

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

19

1

End plug Quantity 1

81.96002-0556

2

Protective sleeve Quantity 1

81.96002-0555

3

Cable tie pliers Quantity 1

08.02960-0100

4

Plug housing wrench Quantity 1

80.99603-0418

Removing/installing the pressure sensor

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

21

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

435

436

Special tools 1

End plug Quantity 1 GPN 330 L 18, closing the hole of the rail pressure sensor and the pressure-limiting valve in the pressure pipe in the common rail system

81.96002-0556

2

Protective sleeve Quantity 1 Z18 x 15, closing the pressure-limiting valve and the rail pressure sensor in the common rail system

81.96002-0555

3

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

4

Plug housing wrench Quantity 1 Disconnecting electrical plug connectors with bayonet catch

80.99603-0418

Removing/installing the rail pressure sensor/transmitter (common rail) 1

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

Protective sleeve Quantity 1 Z18 x 15, closing the pressure-limiting valve and the rail pressure sensor in the common rail system

24

81.96002-0555

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 2

End plug Quantity 1 GPN 330 L 18, closing the hole of the rail pressure sensor and the pressure-limiting valve in the pressure pipe in the common rail system

81.96002-0556

3

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing/installing the oil pressure sensor (left)

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

28

1

Plug housing wrench Quantity 1 Disconnecting electrical plug connectors with bayonet catch

80.99603-0418

2

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing/installing the oil pressure sensor (right) 1

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

Plug housing wrench Quantity 1 Disconnecting electrical plug connectors with bayonet catch

30

80.99603-0418

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

437

438

Special tools 2

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

Removing/installing the engine oil temperature sensor

08.02960-0100

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

33

1

Plug housing wrench Quantity 1 Disconnecting electrical plug connectors with bayonet catch

80.99603-0418

2

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing/installing the coolant temperature sensor

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

36

1

Plug housing wrench Quantity 1 Disconnecting electrical plug connectors with bayonet catch

80.99603-0418

2

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing/installing the crankshaft speed sensor

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

39

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 1

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

Removing/installing the camshaft speed sensor 1

1

45

08.02960-0100

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

Special wrench kit Quantity 1 Attaching and detaching ribbed V-belt disc (alternator) in conjunction with 08.06460-0002

42

08.02960-0100

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

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

Removing/installing the alternator 1

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

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

Removing/installing EDC control unit (Electronic Diesel Control)

08.02960-0100

51

80.99603-6029

Special wrench kit insert Quantity 1

80.99603-0317

Multi-tooth screwdriver insert Quantity 1

80.99603-0318

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

439

440

Special tools 2

Handle Quantity 1 Attaching and detaching ribbed V-belt disc (alternator) in conjunction with 80.99603-6029

08.06460-0002

3

Cable tie pliers Quantity 1 Tightening and cutting the cable ties

08.02960-0100

Removing/installing the starter/starter motor

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

56

1

Engine cranking unit Quantity 1 Crank the engine in conjunction with 80.99627-0001

80.99626-6008

2

Gear ratchet Quantity 1 Crank the engine 1/2" in conjunction with 80.99626-6008

80.99627-0001

Removing/installing the coolant pump coolant manifold

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

61

Removing/installing the air compressor ........................................................................................... coolant line

63

Removing/installing the coolant manifold on the engine block (left)

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

67

Removing/installing the coolant manifold on the engine block (right)

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

70

Removing/installing the coolant line for ........................................................................................... the heater supply

74

Removing/installing the coolant line on ........................................................................................... the cylinder head (left)

76

Removing/installing the coolant line on ........................................................................................... the cylinder head (right)

79

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools Removing/installing the thermostat housing coolant manifold 1

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

Cable tie pliers Quantity 1

83

08.02960-0100

Removing/installing the thermostat housing

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

Removing/installing the thermostat insert

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

85 89

1

Extraction tool Quantity 1 Removing/installing the sealing rings on the thermostat insert in conjunction with 80.99613-0027

80.99602-6042

2

Thrust spindle Quantity 1 For tightening the differential lock

80.99613-0027

3

Plug-on handle Quantity 1 1. Removing/installing the sealing rings on the

80.99617-0237

thermostat insert, D3876 in conjunction with 80.99616-0147, 80.99604-0440, 80.99604-0441 2.

Pressing the sealing ring into the front of the crankcase, D2868 / 62 in conjunction with 80.99604-0342

4

Pressing tool Quantity 1 Ø67.5 x 68.5 journal 1 Ø57.5 x 8.5 journal 2 Ø44,85 x 50 in conjunction with 80.99604-0467 , 08.99615-2700 , 80.99602-0207 , 80.99602-0016

80.99604-0440

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

441

442

Special tools 5

Guide bush Quantity 1 Ø73 x 38 journal Ø67.5 x 8 bore Ø45 in conjunction

80.99604-0441

with 80.99604-0467 , 08.99615-2700 , 80.99602-0207 , 80.99602-0016

6

Washer Quantity 1 Removing/installing the sealing ring 51.06904-0038 in the thermostat insert in conjunction with 80.99617-0237, 80.99604-0440, 80.99604-0441

80.99616-0147

Removing/installing the coolant pump

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

Removing/installing the charge-air manifold/air distributor pipe

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

Removing/installing the intake manifold/air distributor pipe (left)

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

1

Cable tie pliers Quantity 1

94 97 100

08.02960-0100

Removing/installing the intake manifold/air distributor pipe (right)

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

Removing/installing the turbocharger exhaust pipe connector (left)

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

Removing/installing the turbocharger exhaust pipe connector (right)

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

Removing/installing the exhaust manifold (left)

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

Removing/installing the exhaust manifold (right)

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

Dismantling/assembling the exhaust manifold

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

Checking/adjusting valve/valves

........................................................................................... 117

103 107 108 110 112 114

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 1

Engine cranking unit Quantity 1 Cranking the engine in conj. with 80.99626-0017

80.99626-6009

• Cranking the engine in conjunction with: • Gear ratchet [2]

2

Gear ratchet Quantity 1 Crank the engine 1/2" in conjunction with 80.99626-6008

80.99627-0001

3

Feeler gage holding device Quantity 1 Holding the feeler gage • Checking and adjusting the valve clearance in conjunction with: • Feeler gage blade 0.5 [4] • Feeler gage blade 0.8 [5] • Valve wrench size 14 [6]

08.75300-0000

4

Feeler gage blade 0.50 Quantity 1 Feeler gage blade 0.50 • Checking and adjusting the valve clearance in conjunction with: • Holding device [3] • Valve wrench size 14 [6]

80.99607-0177

5

Feeler gage blade 0.8 Quantity 1 Feeler gage blade 0.8 • Checking and adjusting the valve clearance in conjunction with: • Holding device [3] • Valve wrench size 14 [6]

80.99607-0179

6

Valve adjustment spanner size 14 Quantity 1 size 14 Adjust the valve clearance in conjunction with 08.06460-0003

80.99603-6031

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

443

444

Special tools

Valve adjustment wrench insert Quantity 1

7

Handle Quantity 1 Detachable handle 9 x 12 - 150 mm Adjust the valve clearance

Removing/installing the valve stem seals

80.99603-0337

08.06460-0003

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

122

1

Intermediate piece Quantity 1 Intermediate piece • Removing and installing the valve springs in conjunction with: • Bracket [7] • Bracket [8] • Valve-spring compressor [6] • Extension [5] • Assembly device [4]

80.99606-0588

2

Fixing bracket Quantity 1 Fixing bracket • Removing and installing the valve springs in conjunction with: • Intermediate piece [3] • Bracket [7] • Bracket [8] • Valve-spring compressor [6] • Extension [5]

80.99606-6092

3

Extension Quantity 1 In conjunction with 80.99606-6094 • Removing and installing the valve springs in conjunction with: • Intermediate piece [3] • Bracket [7] • Bracket [8] • Valve-spring compressor [6] • Assembly device [4]

80.99606-6094

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 4

Valve spring compressor Quantity 1 Removing and installing the valve springs in conjunction with 80.99613-0041, 80.99613-0052, 80.99613-0053, 80.99606-6094, 80.99606-6092

80.99613-6000

5

Bracket, short Quantity 1 • Removing and installing the valve springs in conjunction with: • Intermediate piece [3] • Bracket [8] • Valve spring compressor [6] • Extension [5] • Assembly device [4]

80.99613-0050

6

Bracket, short LH Quantity 1 • Removing and installing the valve springs in conjunction with: • Intermediate piece [3] • Bracket [7] • Valve spring compressor [6] • Extension [5] • Assembly device [4]

80.99613-0051

7

Magnetic lifter Quantity 1 Magnetic lifter • Removing the valve keys in conjunction with: • Intermediate piece [3] • Bracket [7] • Bracket [8] • Valve spring compressor [6] • Extension [5] • Assembly device [4]

80.99639-0009

8

Assembly and removal device Quantity 1 Assembly and removal device for the valve stem seal • Installing and removing the valve stem seal in conjunction with: • Sleeve [11]

80.99606-6088

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

445

446

Special tools 9

Assembly sleeve Quantity 1 Sleeve

80.99606-0287

• Installing the valve stem seal in conjunction with: • Assembly device [10]

Checking the rocker arm

........................................................................................... 129

1

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71000-3217

2

Dial gage holder Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71082-0005

3

Measuring tip Quantity 1 Adjusting the pre-loading of the EGR adjusting cylinder within the intake / exhaust system in conjunction with 08.71082-0005, 80.71000-3217

80.99605-0197

Removing/installing the rocker arm mechanism

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

131

Dismantling/assembling the rocker arm ........................................................................................... mechanism 133 Checking the rocker arm bracket 1

........................................................................................... 135

Micrometer Quantity 1 Measurement range 25 - 50 mm

Removing/installing the camshaft

08.71200-9002

........................................................................................... 137

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 1

Guide pin Quantity 1 Guide pin

80.99617-6009

• Removing and installing the camshaft

Checking the valve timing

........................................................................................... 142

1

Engine cranking unit Quantity 1 Cranking the engine in conj. with 80.99626-0017 • Cranking the engine in conjunction with: • Gear ratchet [2]

80.99626-6009

2

Gear ratchet Quantity 1 Crank the engine 1/2" in conjunction with 80.99626-6008

80.99627-0001

3

Dial gage holder Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71082-0005

4

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71000-3217

Removing/installing the camshaft gear ........................................................................................... 144 Removing/installing the cylinder head

........................................................................................... 147

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

447

448

Special tools 1

Socket Quantity 1 Loosening and tightening the size 22 cylinder head bolts

80.99612-0024

2

Power amplifier Quantity 1 i=1:3.3 / up to 800 Nm 1 loosening the cylinder head bolts and tightening 1 in conjunction with 80.99606-0551, 80.99607-0172, 80.99606-0553, 06.02191-0407, 06.22729-0006, 06.56331-3274, 80.99606-0552, 80.99612-0023, 80.99612-0024 2 undoing and tightening the flywheel screws in the crank gear

80.99619-0006

3

Support Quantity 1 Loosening and tightening the cylinder head bolts

80.99606-0551

4

Angle gage Quantity 1 Loosening and tightening the cylinder head bolts

80.99607-0172

5

Column Quantity 1 Support • Loosening and tightening the cylinder head bolts in conjunction with: • Socket wrench insert size 22 [1] • Power amplifier wrench i = 1 : 3,3 [2] • Support [3] • Angle gage [4] • Stud bolt [6] • Connecting pin [7] • Rubber ring 42 mm [8] • Guide adapter [9] • Socket wrench insert [10]

80.99606-0641

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 6

Stud bolt Quantity 1 M8 x 20 - 10.9 - MAN 183-PHR Loosening and tightening the cylinder head bolts

06.02191-0407

7

Connecting pin Quantity 1 5.5 x 35 for 3/4" inserts, loosening and tightening the cylinder head bolts

06.22729-0006

8

Rubber ring Quantity 1 42 mm rubber ring for 3/4" inserts

08.06142-9006

9

Guide adapter Quantity 1 Component of 80.99606-6101 support for power amplifier, loosening and tightening the cylinder head bolts

80.99606-0552

10

Socket Quantity 1 • Loosening and tightening the cylinder head bolts in conjunction with: • Socket wrench insert size 22 [1] • Power amplifier wrench i = 1 : 3.3 [2] • Support [3] • Angle gage [4] • Holder [5] • Stud bolt [6] • Connecting pin [7] • Rubber ring 42 mm [8] • Guide adapter [9]

80.99603-0327

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

449

450

Special tools 11

Alignment strip Quantity 1 Alignment device

80.99606-0582

• Aligning cylinder heads

12

Dial gage holder base plate 80.99605-0172 Quantity 1 Dial gage holder base plate Checking the cylinder liner protrusion in conjunction with: • Dial gage [13] • Measuring plate [14] • Hex set screw [15] • Washer [16]

13

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder in the intake / exhaust system

08.71000-3217

14

Measuring plate Quantity 1 Measuring plate • Checking the cylinder liner protrusion in conjunction with: • Dial gage Holder [12] • Dial gage [13] • Hex set screw[15] • Washer [16]

80.99605-0289

15

Hex set screw Quantity 1 Hex set screw • Checking the cylinder liner protrusion in conjunction with: • Dial gage Holder [12] • Dial gage [13] • Measuring plate [14] • Washer [16]

06.01499-0015

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 16

Washer Quantity 1 Washer

80.99609-0033

Component of 80.99606-6101 support for power amplifier • Checking the cylinder liner protrusion in conjunction with: • Dial gage Holder [12] • Dial gage [13] • Measuring plate [14] • Hexagonal shanks screw [15] Removing/installing the cylinder head cover

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

155

1

Torque screwdriver Quantity 1 Range 40 - 200 cNm suitable interchangeable bits 6 mm

08.06510-9024

2

Adapter Quantity 1 1/4" mount the injector cable

08.06139-9029

3

Socket Quantity 1 SW 7 mount the injector cable

08.06141-0700

Removing/installing the oil filter insert 1

........................................................................................... 159

Socket Quantity 1 Size 36, 3/8", removing and installing the cover of the fuel pre-filter of the common rail system

80.99603-0325

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

451

452

Special tools 2

Torque wrench Quantity 1 Torque wrench 6-50 Nm square drive 3/8" square for insertion tool 9x12 adjust to valve clearance, tighten the lock nut of the adjusting screw

08.06450-0006

3

Ratchet insert Quantity 1 Size 1 3/8", square

08.06455-0001

4

Handle Quantity 1 Detachable handle 9 X 12 - 400 mm

08.06460-0001

Removing/installing the oil module (left) ........................................................................................... 161 1

Hose clip pliers Quantity 1 Hose clamp pliers, angled version • Installing/removing spring band clamps

Removing/installing the oil module (right) 1

80.99625-0073

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

Hose clip pliers Quantity 1 Hose clamp pliers, angled version • Installing/removing spring band clamps

165

80.99625-0073

Dismantling/assembling the oil module ........................................................................................... 169

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 1

Handle Quantity 1

08.06460-0001

2

Torque wrench Quantity 1

08.06450-0006

3

Ratchet insert Quantity 1

08.06455-0001

4

Socket Quantity 1 Size 36, 3/8", removing and installing the cover of the fuel pre-filter of the common rail system

80.99603-0325

Removing/installing the heat exchanger/engine oil cooler

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

Removing/installing the oil pump suction line manifold

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

Removing/installing the oil pump suction line/intake pipe

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

Removing/installing the oil pump

........................................................................................... 182

1

Dial gage holder base plate Quantity 1 Dial gage holder base plate • Checking the ring gear axial and radial play in conjunction with: • Dial gage [2]

176 178 179

80.99605-0172

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

453

454

Special tools 2

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder in the intake / exhaust system

08.71000-3217

Removing/installing the oil sump

........................................................................................... 185

Dismantling/assembling the oil sump

........................................................................................... 188

Removing/installing the alternator Vbelt

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

191

Removing/installing the automatic belt ........................................................................................... tensioner 192 Removing/installing the ribbed V-belt guide roller

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

194

1

Torque wrench Quantity 1

08.06450-0006

2

Ratchet insert Quantity 1

08.06455-0002

Removing/installing the vibration damper 1

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

Centering pin Quantity 1 Guide mandrels

Removing/installing the flywheel

197

80.99617-0020

........................................................................................... 201

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 1

Centering pin Quantity 2 Ø18.8 x 145 external thread M18x1.5 x 18 external hexagon size 10 x 9 • Detaching and attaching the flywheel

80.99617-0220

2

Socket Quantity 1 Loosening and tightening the size 22 cylinder head bolts

80.99612-0024

3

Power amplifier 80.99619-0006 Quantity 1 i=1:3.3 / up to 800 Nm 1 loosening the cylinder head bolts and tightening 1 in conjunction with 80.99606-0551, 80.99607-0172, 80.99606-0553, 06.02191-0407, 06.22729-0006, 06.56331-3274, 80.99606-0552, 80.99612-0023, 80.99612-0024 2 loosening and tightening the flywheel screws in the crank gear

4

Support Quantity 1 Loosening and tightening the cylinder head bolts

80.99606-0551

5

Angle gage Quantity 1 Loosening and tightening the cylinder head bolts

80.99607-0172

6

Column Quantity 1 Support • Loosening and tightening the flywheel bolts in conjunction with: • Socket wrench insert size 22 [2] • Support [4] • Power amplifier wrench i = 1 : 3.3 [3]

80.99606-0641

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

455

456

Special tools • Angle gage [5] • Stud bolt [8] • Connecting pin [9] • Rubber ring 42 mm [10] • Adapter [11] • Socket wrench insert [7] 7

Socket Quantity 1 Socket wrench insert E24 x size 22 • Loosening and tightening the flywheel bolts in conjunction with: • Socket wrench insert size 22 [2] • Support [4] • Power amplifier wrench i = 1 : 3.3 [3] • Angle gage [5] • Stud bolt [8] • Connecting pin [9] • Rubber ring 42 mm [10] • Adapter [11] • Holder [6] • Socket wrench insert [7]

80.99603-0327

8

Stud bolt Quantity 1 M8 x 20 - 10.9 - MAN 183-PHR Loosening and tightening the cylinder head bolts

06.02191-0407

9

Connecting pin Quantity 1 5.5 x 35 for 3/4" inserts, loosening and tightening the cylinder head bolts

06.22729-0006

10

Rubber ring Quantity 1 42 mm rubber ring for 3/4" inserts

08.06142-9006

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 11

Guide adapter Quantity 1 Component of 80.99606-6101 support for power amplifier, loosening and tightening the cylinder head bolts

80.99606-0552

12

Socket Quantity 1 Socket wrench insert E24 x size 22 • Loosening and tightening the vibration damper mounting bolts in conjunction with: • Socket wrench insert size 22 [2] • Power amplifier wrench i = 1 : 3.3 [3] • Support [4] • Angle gage [5] • Holder [6] • Stud bolt [8] • Connecting pin [9] • Rubber ring 42 mm [10] • Adapter [11]

80.99603-0327

13

Eye-bolt Quantity 1 M12-C35 • Removing/installing the flywheel

06.05110-0103

Removing/installing flywheel ring gear

........................................................................................... 207

Mounting/removing the engine cranking unit

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

1

Engine cranking unit Quantity 1 Cranking the engine in conj. with 80.99626-0017 • Crank the engine in conjunction with: • Gear ratchet [2]

210

80.99626-6009

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

457

458

Special tools 2

Gear ratchet Quantity 1 Crank the engine 1/2" in conjunction with 80.99626-6008

Coolant pump crankshaft gear 1

80.99627-0001

........................................................................................... 211

Centering mandrel Quantity 1 Set consists of two units Ø18.8 x 145 external thread M18x1.5 x 18 external hex SW10 x 9 for removing/installing front crankshaft

80.99617-0020

Removing/installing the coolant pump intermediate gear

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

Dismantling/assembling the coolant pump intermediate gear

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

Removing/installing the crankshaft gear (front)

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

1

Centering pin Quantity 1 Guide pin • Removing/installing the oil pump gear

213 215 217

80.99617-0020

Removing/installing the crankshaft gear (rear)

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

Removing/installing the crankshaft

........................................................................................... 220

1

Dial gage Quantity 1 Adjusting the pre-loading of the EGR adjusting cylinder within the intake / exhaust system

219

08.71000-3217

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 2

Dial gage holder Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71082-0005

3

Measuring tip Quantity 1 Adjusting the pre-loading of the EGR adjusting cylinder within the intake / exhaust system in conjunction with 08.71082-0005, 80.71000-3217

80.99605-0197

4

Settling tool Quantity 1 Setting tool • Positioning the bearing shell on a cracked connecting rod

80.99622-0052

5

Centering pin Quantity 1 Guide mandrels

80.99617-0020

6

Centering pin Quantity 1 Ø18.8 x 145 external thread M18x1,5 x 18 external hex SW10 x 9 • Removing/installing the crankshaft in conjunction with: • Centering pin [5]

80.99617-0220

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

459

460

Special tools 7

Lifting bolt Quantity 1 Ø16 x 112.7 external thread M20x2 x 14 hex SW20

80.99615-0039

• Removing the crankcase lower section • Centering pin [5]

8

Eye-bolt Quantity 2 Removing and attaching the cylinder head

80.99606-0660

9

Power amplifier Quantity 1

80.99619-0007

10

Brace Quantity 1

80.99622-6037

11

Angle gage Quantity 1 Loosening and tightening the cylinder head bolts

80.99607-0172

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 12

Connecting pin Quantity 1 5.5 x 35 for 3/4" inserts, loosening and tightening the cylinder head bolts

06.22729-0006

13

Rubber ring Quantity 1 42 mm rubber ring for 3/4" inserts

08.06142-9006

14

Socket Quantity 2 Loosening and tightening the size 22 cylinder head bolts

80.99612-0024

15

Socket Quantity 2

80.99603-0327

16

Ratchet insert Quantity 1

08.06455-0003

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

461

462

Special tools 17

Handle Quantity 1

08.06460-0003

18

Torque wrench Quantity 1

08.06450-0011

Checking the crankshaft

........................................................................................... 237

1

Dial gage Quantity 1 Check the inner diameter of the crankshaft bearing

08.71000-3217

2

Micrometer Quantity 1

08.71200-9005

Checking the piston protrusion 1

........................................................................................... 241

Dial gage holder base plate Quantity 1 Dial gage holder base plate • Checking the cylinder liner protrusion in conjunction with: • Dial gage [2]

80.99605-0172

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 2

Dial gage Quantity 1 Measuring piston protrusion

Removing/installing the piston with connecting rod

08.71000-3217

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

242

1

Piston ring pliers Quantity 1 Removing and installing the piston rings, replaced with 80.99625-0167

83.09144-6090

2

Piston ring clamping pliers Quantity 1 Piston ring clamping pliers • Installing the piston

80.99613-0040

3

Settling tool Quantity 1 Setting tool • Positioning the bearing shell on a cracked connecting rod

80.99622-0052

Dismantling and assembling the piston ........................................................................................... with connecting rod 248 1

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

Checking the piston with connecting rod

08.71000-3217

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

250

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

463

464

Special tools 1

Feeler gage Quantity 1 Feeler gage

08.75310-0806

• Checking the axial play and ring gap of the piston rings

2

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71000-3217

3

Depth gage Quantity 1 Check the dimensions of the impeller to the coolant pump housing

08.71195-9003

4

Settling tool Quantity 1 Setting tool • Positioning the bearing shell on a cracked connecting rod

80.99622-0052

5

Dial gage holder Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71082-0005

Removing/installing the end cover

........................................................................................... 257

Removing/installing the flywheel housing

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

Dismantling/assembling the flywheel housing

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

259 260

Removing/installing the rear crankshaft ........................................................................................... radial shaft seal 265

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 1

Engine cranking unit Quantity 1 Cranking the engine in conj. with 80.99626-0017

80.99626-6009

• Locking the engine

2

Slide hammer puller Quantity 1 Slide hammer puller • Extracting the crankshaft gear and radial shaft seal in conjunction with: • Extractor tool [3] • Centering pin [8]

80.99602-0016

3

Puller Quantity 1 Extractor tool • Extracting the crankshaft gear and radial shaft seal in conjunction with: • Slide hammer puller [2] • Centering pin [8]

80.99601-6033

4

Plug-on handle Quantity 1 Pressing in the axial face seal of the coolant pump

80.99617-0187

5

Thrust washer Quantity 1 Pressing in the axial face seal of the coolant pump

80.99617-0144

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

465

466

Special tools 6

Guide plate Quantity 1 Ø139 x 50 attachment Ø62 x 20 bore Ø45

80.99606-0703

Installing the radial shaft seal in conjunction with: • Detachable handle [4] • Washer [5] • Press-in bushing [7] • Centering pin [8]

7

Press-in bush Quantity 1 Ø163 x 62 inside Ø139.2 x 32.25 Ø21.5 Ø19 (2x) • Installing the radial shaft seal in conjunction with: • Detachable handle [4] • Washer [5] • Guide plate [6] • Centering pin [8]

80.99604-0340

8

Centering pin Quantity 1 Ø18.8 x 145 external thread M18x1,5 x 18 external hex size 10 x 9 • Removing/installing the flywheel • Installing the radial shaft seal in conjunction with: • Detachable handle [4] • Washer [5] • Guide plate [6] • Press-in bushing [7] • Extracting the crankshaft gear and radial shaft seal in conjunction with: • Slide hammer puller [2] • Extractor [3]

80.99617-0220

Removing/installing the front crankshaft radial shaft seal

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

269

1

Slide hammer puller Quantity 1 Slide hammer puller • Extracting the radial shaft seal in conjunction with: • Extractor hook [2]

80.99602-0016

2

Extractor hook Quantity 1 Extractor hook for removing the shaft seal Extracting the radial shaft seal in conjunction with: • Slide hammer puller [1]

80.99602-0175

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 3

Centering pin Quantity 1 Guide mandrels

80.99617-0020

4

Plug-on handle Quantity 1 Pressing in the axial face seal of the coolant pump

80.99617-0187

5

Thrust washer Quantity 1 Pressing in the axial face seal of the coolant pump

80.99617-0144

6

Pressure plate Quantity 1 Ø145 x 38 attachment Ø110 x 12 bore Ø50 x 8 Ø20.1 Ø17 (2x) Installing the radial shaft seal in conjunction with: • Centering pin [3] • Detachable handle [4] • Washer [5]

80.99604-0342

Removing/installing the cylinder liner 1

........................................................................................... 273

Puller Quantity 1 Extracting cylinder liners • Extracting cylinder liner in conjunction with: • Extractor plate [2]

80.99601-6018

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

467

468

Special tools 2

Extractor plate Quantity 1 Extractor plate for D = 128 mm

80.99601-0187

• Extracting the cylinder liner in conjunction with: • Extractor tool [1]

3

Dial gage holder base plate Quantity 1 Dial gage holder base plate • Checking the cylinder liner protrusion in conjunction with: • Gage holder [4] • Dial gage [5]

80.99605-0172

4

Dial gage Quantity 1 Adjusting the pre-load of the EGR adjusting cylinder within the intake / exhaust system

08.71000-3217

5

Measuring plate Quantity 1 Measuring plate • Checking the cylinder liner protrusion in conjunction with: • Dial gage holder [3] • Dial gage [4]

80.99605-0289

6

Hex set screw Quantity 1 Hex set screw • Checking the cylinder liner protrusion in conjunction with: • Dial gage holder [3] • Dial gage [4] • Measuring plate [5] • Washer [7]

06.01499-0015

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 7

Washer Quantity 1 Washer

06.15013-0417

• Checking the cylinder liner protrusion in conjunction with: • Dial gage holder [3] • Dial gage [4] • Measuring plate [5] • Bolt [6] 8

Depth gage Quantity 1 Check the dimensions of the impeller to the coolant pump housing

08.71195-9003

Removing/installing the oil nozzle

........................................................................................... 278

Removing/installing the crankcase ventilation (left)

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

1

Hose clip pliers Quantity 1 Hose clamp pliers, angled version • Installing/removing spring band clamps

Removing/installing the crankcase ventilation (right) 1

80.99625-0073

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

Hose clip pliers Quantity 1 Hose clamp pliers, angled version • Installing/removing spring band clamps

280

281

80.99625-0073

Removing/installing the crankcase ventilation oil separator (left)

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

Removing/installing the crankcase ventilation oil separator (right)

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

Intake fitting, left turbocharger

........................................................................................... 288

Intake fitting, right turbocharger

........................................................................................... 289

Removing/installing the turbocharger (left)

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

283 285

293

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

469

470

Special tools 1

Box wrench size 15, bent Quantity 1 Box wrench size 15; i = 1 1.22

80.99603-0323

• Tightening turbocharger mounting nuts in conjunction with: • Torque wrench [2]

2

Torque wrench Quantity 1 Torque wrench 80 - 400 Nm / 14 x 18 Square drive ¾" square for socket tool 14x18 • Tightening the turbocharger mounting nuts in conjunction with: • Box wrench size 15 i =1 : 1.22 [1]

Removing/installing the turbocharger (right)

08.06450-0003

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

298

1

Box wrench size 15, bent Quantity 1 Box wrench size 15; i = 1 1.22 • Tightening turbocharger mounting nuts in conjunction with: • Torque wrench [2]

80.99603-0323

2

Torque wrench Quantity 1 Torque wrench 80 - 400 Nm / 14 x 18 Square drive ¾" square for socket tool 14x18 • Tightening the turbocharger mounting nuts in conjunction with: • Box wrench size 15 i = 1.22 [1]

08.06450-0003

Removing/installing the fuel filter insert ........................................................................................... 307 1

Socket Quantity 1

Removing/installing the fuel service center

80.99603-0325

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

310

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 1

End plug Quantity 2

81.96002-0521

2

Protective sleeve Quantity 2

81.96002-0555

Dismantling/assembling the fuel service center

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

313

1

Socket Quantity 1

80.99603-0325

2

Torque wrench Quantity 1

08.06450-0006

3

Ratchet insert Quantity 1

08.06455-0001

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

471

472

Special tools 4

Protective sleeve Quantity 11

81.96002-0555

5

End plug Quantity 8

81.96002-0521

6

End plug Quantity 2

81.96002-0520

7

End plug Quantity 1

81.96002-0519

Removing/installing the fuel line 1

End plug Quantity 22

........................................................................................... 320 81.96002-0556

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 2

Protective sleeve Quantity 21

81.96002-0555

3

End plug Quantity 4

81.96002-0519

4

Protective sleeve Quantity 4

81.96002-0513

Removing/installing the fuel return line ........................................................................................... (left) 331 1

Protective sleeve Quantity 3 Protective sleeve GPN 200 Z16 x 8

81.96002-0513

2

End plug Quantity 11 GPN 330L16, closing the hole of the pressure pipe socket in the common rail system

81.96002-0519

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

473

474

Special tools 3

End plug Quantity 6 Closing the high-pressure lines and the bore of the air distributor pipe of GPN 330L14 in the common rail system

81.96002-0521

4

Cap Quantity 2 GPN 695 BE 10, closing the hollow screw connections in the common rail system

81.96002-0518

Removing/installing the fuel return line ........................................................................................... (right) 335 1

Protective sleeve Quantity 2 Protective sleeve GPN 200 Z16 x 8

81.96002-0513

2

End plug Quantity 10 GPN 330L16, closing the hole of the pressure pipe socket in the common rail system

81.96002-0519

3

End plug Quantity 6 Closing the high-pressure lines and the bore of the air distributor pipe of GPN 330L14 in the common rail system

81.96002-0521

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 4

Cap Quantity 2 GPN 695 BE 10, closing the hollow screw connections in the common rail system

81.96002-0518

Removing/installing the pump - rail CR ........................................................................................... pressure line 340 1

Protective sleeve Quantity 4

81.96002-0512

2

End plug Quantity 4

81.96002-0521

3

Special wrench, size 19 Quantity 1 Fuel line assembly, universally applicable, all engines

80.99603-0310

4

Angle extension 08.06139-9025 Quantity 1 3/8" x 150 mm, removing and installing the high-pressure lines of the common rail system

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

475

476

Special tools 5

Ratchet insert Quantity 1 Size 1 3/8", square

08.06455-0001

6

Handle Quantity 1 Attaching and detaching ribbed V-belt disc (alternator) in conjunction with 80.99603-6029

08.06460-0002

7

Torque wrench Quantity 1 Torque wrench 6-50 Nm square drive 3/8" square for insertion tool 9x12 adjust to valve clearance, tighten the lock nut of the adjusting screw

08.06450-0006

Removing/installing the injection pressure line (left)

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

345

1

Protective sleeve Quantity 12 Closing the connection of the pressure line to the pressure pipe and the connection of the pressure line to the high-pressure pump of Z14 x 15 in the common rail system

81.96002-0512

2

End plug Quantity 12 Closing the high-pressure lines and the bore of the air distributor pipe of GPN 330L14 in the common rail system

81.96002-0521

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 3

Special wrench, size 19 Quantity 1 Fuel line assembly, universally applicable, all engines

4

Angle extension 08.06139-9025 Quantity 1 3/8" x 150 mm, removing and installing the high-pressure lines of the common rail system

5

Ratchet insert Quantity 1 Size 1 3/8", square

08.06455-0001

6

Handle Quantity 1 Attaching and detaching ribbed V-belt disc (alternator) in conjunction with 80.99603-6029

08.06460-0002

7

Torque wrench Quantity 1 Torque wrench 6-50 Nm square drive 3/8" square for insertion tool 9x12 adjust to valve clearance, tighten the lock nut of the adjusting screw

08.06450-0006

Removing/installing the injection pressure line (right)

80.99603-0310

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

350

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

477

478

Special tools 1

Protective sleeve Quantity 12 Closing the connection of the pressure line to the pressure pipe and the connection of the pressure line to the high-pressure pump of Z14 x 15 in the common rail system

81.96002-0512

2

End plug Quantity 12 Closing the high-pressure lines and the bore of the air distributor pipe of GPN 330L14 in the common rail system

81.96002-0521

3

Special wrench, size 19 Quantity 1 Fuel line assembly, universally applicable, all engines

80.99603-0310

4

Angle extension 08.06139-9025 Quantity 1 3/8" x 150 mm, removing and installing the high-pressure lines of the common rail system

5

Ratchet insert Quantity 1 Size 1 3/8", square

08.06455-0001

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 6

Handle Quantity 1 Attaching and detaching ribbed V-belt disc (alternator) in conjunction with 80.99603-6029

08.06460-0002

7

Torque wrench Quantity 1 Torque wrench 6-50 Nm square drive 3/8" square for insertion tool 9x12 adjust to valve clearance, tighten the lock nut of the adjusting screw

08.06450-0006

Removing/installing the rail (left)

........................................................................................... 355

1

Protective sleeve Quantity 1 Protective sleeve GPN 200 Z16 x 8

81.96002-0513

2

End plug Quantity 1 GPN 330L16, closing the hole of the pressure pipe socket in the common rail system

81.96002-0519

3

Cap Quantity 1 GPN 695 BE 10, closing the hollow screw connections in the common rail system

81.96002-0518

Removing/installing the rail (right)

........................................................................................... 359

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

479

480

Special tools 1

Protective sleeve Quantity 1 Protective sleeve GPN 200 Z16 x 8

81.96002-0513

2

End plug Quantity 1 GPN 330L16, closing the hole of the pressure pipe socket in the common rail system

81.96002-0519

3

Cap Quantity 1

81.96002-0518

Removing/installing the common rail pressure-limiting valve

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

363

1

Protective sleeve Quantity 1 Z18 x 15, closing the pressure-limiting valve and the rail pressure sensor in the common rail system

81.96002-0555

2

End plug Quantity 1 GPN 330 L 18, closing the hole of the rail pressure sensor and the pressure-limiting valve in the pressure pipe in the common rail system

81.96002-0556

Removing/installing the injector with nozzle (common rail)

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

367

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 1

Storage sleeve Quantity 12 Keep the injector in a safe place.

09.81020-1000

2

End plug Quantity 12 330L28 Plugging the injector bore on the cylinder head

81.96002-0520

3

Protective sleeve Quantity 12 Plugging the injector nozzle

81.96002-0522

4

Protective sleeve Quantity 12 B43 Plugging the injector feed bore

81.96002-0523

5

Plug Quantity 12 Plug for threaded holes in the pressure pipe connection • Closing the hole for pressure pipe connection

81.96002-0541

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

481

482

Special tools 6

Pressure shim Quantity 12 Ø29 x 65 bore Ø24.5 35 deep

80.99606-0655

• Installing injectors

7

Protective sleeve Quantity 12 Closing the connection of the pressure line to the pressure pipe and the connection of the pressure line to the high-pressure pump of Z14 x 15 in the common rail system

81.96002-0512

8

Extractor tool Quantity 1 Removing the pressure pipe socket in the common rail system

80.99602-0011

9

Injector extractor Quantity 1 Pulling out the injector in the common rail system in conjunction with 80.99601-0275, 80.99615-0069, 80.99602-0011

80.99601-6058

10

Threaded adapter Quantity 1 Removing the pressure pipe connector in the common rail system in conjunction with 80.99602-0011

80.99615-0064

Removing/installing the high pressure pump (front)

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

376

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 1

Locking ring pliers Quantity 1 Locking ring pliers

Removing/installing the high pressure pump (rear) 1

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

Locking ring pliers Quantity 1 Locking ring pliers

Dismantling/assembling the highpressure pump

08.04046-9000

379

08.04046-9000

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

383

1

Protective sleeve Quantity 1 Closing the connection of the pressure line to the pressure pipe and the connection of the pressure line to the high-pressure pump of Z14 x 15 in the common rail system

81.96002-0512

2

End plug Quantity 1 Closing the high-pressure lines and the bore of the air distributor pipe of GPN 330L14 in the common rail system

81.96002-0521

3

Extractor Quantity 1 Extractor

80.99601-6041

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

483

484

Special tools 4

Guide sleeve Quantity 1 Guide sleeve

80.99604-0374

5

Pressing sleeve Quantity 1 Pressing sleeve

80.99604-0375

6

Internal six-lobe profile bit TX25 Quantity 1 Size = Torx profile TX25 Holding device ¼" entire length 25

08.06527-1007

7

Internal six-lobe profile bit TX30 Quantity 1 Size = Torx profile TX30 Holding device ¼" entire length 25

08.06527-1009

8

Extension Quantity 1 Extension for screwdriver bits

08.06564-9000

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 9

Ratchet insert Quantity 1 Ratchet insert for 5/16" - 9 x 12 bits

08.06410-9072

10

Torque wrench Quantity 1 Torque wrench 6-50 Nm square drive 3/8" square for insertion tool 9x12 adjust to valve clearance, tighten the lock nut of the adjusting screw

08.06450-0006

Removing/installing the high-pressure pump drive housing

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

Dismantling and assembling the highpressure pump drive housing

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

Removing/installing the cooling plate/ console for the control unit (EDC)

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

1

Cable tie pliers Quantity 1

390 392 398

08.02960-0100

Removing/installing the alternator bracket

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

Removing/installing the crane lifting eye / engine lifting eye

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

401 403

Removing/installing the air compressor ........................................................................................... (single cylinder) 407 Dismantling/assembling air compressor (single cylinder) 1

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

Disassembly device Quantity 1

411

80.99606-6118

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

485

486

Special tools 2

Piston ring pliers Quantity 1

80.99625-0167

3

Piston ring clamping strap Quantity 1

80.99613-0035

4

Ratchet insert Quantity 1

08.06455-0002

5

Torque wrench Quantity 1

08.06450-0006

6

Ratchet insert Quantity 1

08.06455-0020

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

Special tools 7

Torque wrench Quantity 1

08.06450-0011

8

Handle Quantity 1

08.06460-0002

9

Locking ring pliers Quantity 1

08.04046-9000

Removing/installing the air compressor ........................................................................................... cap 422 Removing/installing the PTO cover

........................................................................................... 425

Removing/installing the engine bracket ........................................................................................... (left) 427 Removing/installing the engine bracket ........................................................................................... (right) 428 Removing/installing the refrigerant compressor 1

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

Cable tie pliers Quantity 1

431

08.02960-0100

Observe the safety instructions. Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and material damage. Before commencing work, ensure that the latest documentation is used.

487

MAN Truck & Bus AG Vogelweiherstraße 33 90441 Nuremberg, Germany man-engines@man.eu www.man-engines.com

MAN Truck & Bus – a member of the MAN Group