Technical Information

MAN-industrial Diesel engines

Engineering S Data S Setting values

D 2866 LE 2..
 Introduction

The purpose of this publication is to inform you about the checking values, setting data
and technical details of MAN’s 6-cylinder industrial Diesel engines.

It is intended to serve as a basis for maintenance and repair.

Yours faithfully,
MAN Nutzfahrzeuge Aktiengesellschaft
Werk Nürnberg

Subject to change to keep abreast with technological progress.

 1998 MAN Nutzfahrzeuge Aktiengesellschaft

No parts of this publication may be reproduced or translated without prior written permission of MAN.
MAN explicitly reservs all rights according to copyright law.

MTDA Technical status: 08.1998 51.99598-8004

1
 Contents

Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Model designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Technical information
General engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Timing gear arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Oil filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Service Data
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Piston 51.02511-0245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Piston 51.02511-0268 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Speed pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tightening torque guide values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2
 Basic knowledge

What do model designations mean ?

The sequence of letters and numbers which make up the model designation reveal a
number of characteristic properties of the engine in question to those familiar with the
basic nomenclature.

D The ”D” at the beginning of the model designation stands for ”Diesel”.

28 The number ”28” indicates that the engine has a 128 mm bore.

6 The first ”6” means 160 mm stroke. This figure is, however, only
approximate for this model. The actual stroke is 155 mm.

6 The second ”6” refers to the number of cylinders, 6.

L This letter stands for the German word ”Ladeluftkühlung”, meaning

”intercooling”.

E ”E” stands for the German word ”Einbaumotor”, meaning ”installation

engine”, and distinguishes these engines from MAN vehicle engines.

201 / 2.. This is a internal MAN development number.

3
 Technical information

General engine data

Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-stroke Diesel with turbocharger
and intercooler
Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct injection
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cylinders in-line
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 mm
Swept volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.967 l
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 : 1
Rotation viewed from flywheel . . . . . . . . . . . . . . . . . . . anti-clockwise
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 5 – 3 – 6 – 2 – 4 – 1
Firing interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120_
Continuous Power (COP) according to ISO 3046-1 (without auxiliaries)
D 2866 LE 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 kW at 1500 1/min
280 kW at 1800 1/min
Prime Power (PRP) according to ISO 3046-1 (without auxiliaries)
D 2866 LE 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 kW at 1500 1/min
322 kW at 1800 1/min
Prime Power (PRP) according to ISO 3046-1 (without auxiliaries)
D 2866 LE 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 kW at 1500 1/min
265 kW at 1800 1/min
Limited-time running Power (LTP) according to ISO 3046-1 (without auxiliaries)
D 2866 LE 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 kW at 1500 1/min
364 kW at 1800 1/min
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced-feed lubrication
by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear oil pumps

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . liquid cooled

by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . impeller pump
Coolant temperature (D 2866 LE 201 / LE 202 / LE 211)
normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°C
short period . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 95°C
Coolant temperature (D 2866 LE 203)
normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105°C
short period . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 110°C

4
 Technical information

Timing gear arrangement

(viewed from flywheel)

2 3

Gear designation No. of teeth Module Gear tooth cutting

1 Crankshaft gear 43 2,75 helical (23_40’)

2 Drive gear, oil pump 44 2,75 helical (23_40’)

3 Oil pump supply gear 7 6 straight
4 Drive gear, camshaft 86 2,75 helical (23_40’)
5 Intermediate gear 51 2,75 straight

6 Drive gear, injection pump 51 2,75 straight

5
 Technical information

Valve train
The checking values are valid for all engines dealt with in this publication

Valve clearance inlet 0,50 mm

exhaust 0,50 mm

Why valve clearance?

The individual valve train components expand slightly as they warm up. Valve
clearance ensures that the valves close safely and that an effective seal is formed
even when the engine is warm.

Valve clearance too small:

The valves do not sit correctly on the valve seat inserts when closed and are therefore
no longer able to conduct the heat to the cylinder head. In this situation the exhaust
valves in particular are prone to burning because of the high thermal stress to which
they are exposed as a result of the hot combustion gases which are constantly flowing
past them.

Valve clearance too large:

The valve opening cross-sections are reduced and cylinder charging worsens. Valve
train wear and valve noise is increased greatly.

Timing diagram 1
2 OT
3
1= Direction of engine rotation
2= Inlet opens 23° before TDC
3= Exhaust closes 30 after TDC
4= Exhaust opens 60° before BDC
5= Inlet closes 12° after BDC 6 7
6= Exhaust open for 270°
7= Inlet open for 215°
Figures in degrees refer to the
crankshaft angle 4

5
UT

Compression pressures
(Engine has run before the measurement and is warm to the touch)
good over 28 bar
permissible 25 – 28 bar
in need of repair under 24 bar
pressure difference (between individual cylinders) max. 4 bar

6
 Technical information

Lubricating system
Oil pump feed rate at oil pump speed:
(feed rates with SAE 20W/20 oil at 90°C and 6 bar)
Oil pump speed = engine speed x 0,977

Oil pump, standard

at n = 1465 1/min 80 ltr./min
at n = 1760 1/min 100 ltr./min

Oil pump (for oil pan with max. permissible

inclination of 30 degrees)
at n = 1465 1/min 160 ltr./min
at n = 1760 1/min 195 ltr./min

Valve opening pressures

Bypass valve for oil filter
Opening pressure 2 bar
Pressure at max. opening 4 bar
Oil pump pressure regulating valve 9 – 10 bar
Pressure valve of oil spray jets
Opening pressure 1,9 – 2,1 bar
Closing pressure 1,4 – 1,6 bar

Oil filling capacities

Engine model Oil pan Min. capacity Max. capacity

D 2866 L.. deep 24 l 30 l

D 2866 L.. flat 16 l 20 l

D 2866 L.. deep, max. inclination 24 l 30 l

25 degrees

D 2866 L.. deep, max. inclination 14 l 18 l

30 degrees

7
 Dimensions
Service Data
Limiting values

Crankcase

153,90 – 153,94 mm standard

for cylinder liners with 0,5 and 1,0 mm
outside diameter
154,40 – 154,44 mm
Ø

Ø 145,80 – 145,84 mm standard

for cylinder liners with 0,5 mm larger out-
side diameter
146,30 – 146,34 mm
for cylinder liners with 1,0 mm larger out-
side diameter
146,80 – 146,84 mm

9,955 – 10,025 mm standard

144,50 – 144,54 mm
for cylinder liners with 0,5 mm outside di-
ameter
145,00 – 145,04 mm
for cylinder liners with 1,0 mm larger out-
Ø
2542 side diameter
145,50 – 145,54 mm

Cylinder liner
153,694 – 153,757 mm standard
154,194 – 154,257 mm with 0,5 and
1,0 mm larger outside diameter
Ø
Ø

10,05 – 10,07 mm standard

10,55 – 10,57 mm with 0,5 mm more
flange height
Max. permissible cylinder liner protrusion:
0,005
0,03 – 0,08 mm
145,761 – 145,786 mm standard
146,261 – 146,286 mm with 0,5 mm
larger outside diameter
146,761 – 146,786 mm with 1,0 mm
Ø
larger outside diameter

127,990 – 128,010
Max. wear limit:
0,15 mm larger than basic size

144,432 – 144,457 mm standard

144,932 – 144,957 mm with 0,5 mm
larger outside diameter
Ø
145,432 – 145,457 mm with 1,0 mm
2543 larger outside diameter

8
 Dimensions
Service Data
Limiting values

Crankshaft

Crankshaft front end (opposite end to flywheel)

99,985 – 100,020 mm

89,98 – 90,00 mm standard size

89,73 – 89,75 mm undersize 0,25
89,48 – 89,50 mm undersize 0,50
89,23 – 89,25 mm undersize 0,75
Ø Ø 88,98 – 89,00 mm undersize 1,00

103,98 – 104,00 mm standard size

2628 103,73 – 103,75 mm undersize 0,25
103,48 – 103,50 mm undersize 0,50
103,23 – 103,25 mm undersize 0,75
102,98 – 103,00 mm undersize 1,00

max. axial clearance of crankshaft:

0,190 – 0,322 mm
Max. wear limit: 1,25 mm

Bearing race for crankshaft, front end

Inner diameter:
99,907 – 99,942 mm

2536

9
 Dimensions
Service Data
Limiting values

Thrust bearing journal

46,000 – 46,062 mm standard size

46,500 – 46,562 mm undersize 0,25
46,500 – 46,562 mm undersize 0,55
47,000 – 47,062 mm undersize 0,75
47,000 – 47,062 mm undersize 1,00

2633

Mounting bolts for crankshaft bearing caps

Length: During tightening the bolts are

intentionally stressed beyond the yield
point and therefore subjected to some
100 permanent elongation each time they are
tightened. When the bolt has reached its
maximum length it must not be reused.
51.90020–0293:
new: 152,5 – 153
2563 max. 154,5 mm

Main bearing
Data for wall thickness and bearing
bore also apply to thrust bearing
3,466 – 3,478 mm standard size
3,591 – 3,603 mm undersize 0,25
3,716 – 3,728 mm undersize 0,50
3,841 – 3,853 mm undersize 0,75
3,966 – 3,978 mm undersize 1,00
Bearing bore in installed condition:
104,060 – 104,106 mm standard size
103,810 – 103,856 mm undersize 0,25
103,560 – 103,606 mm undersize 0,50
103,310 – 103,356 mm undersize 0,75
103,060 – 103,106 mm undersize 1,00

Spread: 0,3 – 1,2 mm

2634 Marking:
top / bottom
0005 / 0006 standard size
0011 / 0012 undersize 0,25
0013 / 0014 undersize 0,50
0015 / 0016 undersize 0,75
0017 / 0018 undersize 1,00

10
 Dimensions
Service Data
Limiting values

Thrust bearing
3,363 – 3,388 mm standard size
3,613 – 3,638 mm undersize 0,25
3,613 – 3,638 mm undersize 0,50
3,863 – 3,888 mm undersize 0,75
3,863 – 3,888 mm undersize 1,00
Spread: 0,1 – 0,5 mm
Marking:
top / bottom
0017 / 0018 standard size
0023 / 0024 undersize 0,25
0025 / 0026 undersize 0,50
0027 / 0028 undersize 0,75
0029 / 0030 undersize 1,00
45,74 – 45,81 mm standard size
46,24 – 46,31 mm undersize 0,25
2635 46,24 – 46,31 mm undersize 0,50
46,74 – 46,81 mm undersize 0,75
46,74 – 46,81 mm undersize 1,00
Data for wall thickness and bearing
bore see ”main bearing”

Flywheel

Ø Flywheel:
432,490 – 432,645 mm

Starter gear ring, inside diameter:

432,000 – 432,155 mm

Interference: 0,335 – 0,645 mm

Installation temperature: 200 – 230_C

Ø
m = 66,9 kg (with starter gear)
J = 2,48 kgm2

Number of teeth: Z = 160, Modulus 3

Matching gear: Starter pinion

Number of teeth: 9
2561 Backlash: 0,6 – 0,9 mm

11
 Dimensions
Service Data
Limiting values

Connecting rods

46,055 – 46,065 mm
Max. wear limit: 46,09 mm
Ø

Ø 0,02 A

A
Bearing bore in directions 1, 2 and 3 and
in planes a and b:
1 8 mm 8 mm 90,075 – 90,120 mm

Pre-condition:
2 new big-end bearing in place,
a b
3 conrod assembled

2541

Conrod bearing

2,468 – 2,478 mm standard size

2,593 – 2,603 mm undersize 0,25
2,718 – 2,728 mm undersize 0,50
2,843 – 2,853 mm undersize 0,75
2,968 – 2,978 mm undersize 0,1,00
Spread: 0,6 – 1,5 mm
If signs of wear are present (scores, anti-
wear coating damaged) change both
2540
bearing shells.
Important: note installation position (upper
half bearing shell has red or yellow mark
on side)

Connecting rod bolt

Length: During tightening the bolts are
intentionally stressed beyond the yield
point and therefore subjected to some
permanent elongation each time they are
tightened.
When the bolt has reached its maximum
length it must not be reused.
51.90020-0139:
2585 new: 67,2 – 67,5 mm, max. 69 mm

12
 Dimensions
Service Data
Limiting values

Connecting rods

46,055 – 46,065 mm
Max. wear limit: 46,09 mm

Ø
Ø 0,02 A
A

1 8 mm 8 mm
Bearing bore in directions 1, 2 and 3 and
in planes a and b:
2
a b 90,075 – 90,120 mm
3
Pre-condition:
new big-end bearing in place,
conrod assembled
3848

Conrod bearing

2,468 – 2,478 mm standard size

2,593 – 2,603 mm undersize 0,25
2,718 – 2,728 mm undersize 0,50
2,843 – 2,853 mm undersize 0,75
2,968 – 2,978 mm undersize 0,1,00
Spread: 0,6 – 1,5 mm
If signs of wear are present (scores, anti-
wear coating damaged) change both
2540
bearing shells.
Important: note installation position (upper
half bearing shell has red or yellow mark
on side)

Connecting rod bolt

Length: During tightening the bolts are
intentionally stressed beyond the yield
point and therefore subjected to some
permanent elongation each time they are
tightened.
When the bolt has reached its maximum
length it must not be reused.
51.90020-0139:
2585 new: 67,2 – 67,5 mm, max. 69 mm

13
 Dimensions
Service Data
Limiting values

Piston 51.02511-0245
Compression height: 89,70 – 89,75 mm
with undersize
0,2 mm: 89,50 – 89,55 mm
0,4 mm: 89,30 – 89,35 mm
0,6 mm: 89,10 – 89,15 mm
Piston protrusion above crankcase top:
0,013 – 0,331 mm
Ø
46,005 – 46,013 mm
Piston pin diameter:
45,994 – 46,000 mm
Ø
127,825 – 127,865 mm
27

2636 Max. difference in weight per

engine piston set: max. 100g

Piston ring grooves

2,5
2,935 – 2,965 mm

I
3,040 – 3,060 mm
II

III 5,020 – 5,040 mm

2533

Piston rings
2,5

I 1st. ring – keystone-type ring:

height: 2,796 – 2,83 mm

II 2nd. ring – taper face ring:

height: 2,978 – 2,990 mm
axial play: 0,050 – 0,082 mm

III
3rd. ring – bevelled ring:
height: 4,978 – 4,990 mm
axial play: 0,030 – 0,062 mm

Ring gap:
1st. ring: 0,5 – 0,7 mm
2534 2nd. ring: 0,45 – 0,70 mm
3rd. ring: 0,25 – 0,40 mm

14
 Dimensions
Service Data
Limiting values

Piston 51.02511-0268
Compression height: 89,70 – 89,75 mm
with undersize
0,2 mm: 89,50 – 89,55 mm
0,4 mm: 89,30 – 89,35 mm
0,6 mm: 89,10 – 89,15 mm
Piston protrusion above crankcase top:
0,013 – 0,331 mm
Ø
46,005 – 46,013 mm
Piston pin diameter:
45,994 – 46,000 mm
Ø
127,835 – 127,875 mm
27

2636 Max. difference in weight per

engine piston set: max. 100g

Piston ring grooves

1,5
3,695 – 3,725 mm

I
3,040 – 3,060 mm
II

III 4,020 – 4,040 mm

2533

Piston rings
2,5

I 1st. ring – keystone-type ring:

height: 3,296 – 3,330 mm

II 2nd. ring – taper face ring:

height: 2,978 – 2,990 mm
axial play: 0,050 – 0,082 mm

III
3rd. ring – bevelled ring:
height: 3,975 – 3,990 mm
axial play: 0,030 – 0,065 mm

Ring gap:
1st. ring: 0,5 – 0,7 mm
2534 2nd. ring: 0,45 – 0,70 mm
3rd. ring: 0,05 – 0,40 mm

15
 Dimensions
Service Data
Limiting values

Cylinder head

Ø 12,000 – 12,018 mm Intake valve guide

Ø 12,000 – 12,018 mm Exhaust valve guide

17,1 – 17,5 mm

Intake valve α = 60_

α β
Exhaust valve β = 45_

a = 3,3 – 3,8 mm
a b b = 3,3 – 3,8 mm

2544

Valve guide bore in cylinder head:

Ø 18,000 – 18,018 mm
Valve guide outside diameter:
Ø
18,028 – 18,046 mm

standard: 113,9 – 114 mm

minimum: 112,9 mm
(observe specified dimensions for valve
recess and injector projection)

Ø
Ø Valve seat insert bore in cylinder head:
53,00 – 53,03 mm
Valve seat insert outside diameter:
53,10 – 53,11 mm

Valve seat insert bore in cylinder head:

2622 61,00 – 61,03 mm
Valve seat insert outside diameter:
61,10 – 61,11 mm

16
 Dimensions
Service Data
Limiting values

Valve recess

Valve recess for intake and exhaust

2545 valve:
0,7 – 1,3 mm

Inlet valve
Ø 11,969 – 11,980 mm
Radial clearance: 0,020 – 0,049 mm
Max. wear limit: 0,1 mm

Valve springs:

Inner spring:
Free length (L), approx. 65,5 mm
L* L L = 46,3 mm: at spring force 128 – 152 N
L = 32,3 mm: at spring force 255 – 294 N

Outer spring:
Free length (L*), approx. 59 mm
L* = 46,8 mm at spring force 324 – 353 N
L* = 32,8 mm at spring force 696 – 755 N

2546 Valve cone face: 3,3 – 4,3 mm

Valve seat (= grinding face): 2 – 2,5 mm

Exhaust valve
Ø 11,944 – 11,955 mm
Radial clearance: 0,045 – 0,074 mm
Max. wear limit: 0,1 mm

Valve springs:

Inner spring:
Free length (L), approx. 65,5 mm
L* L L = 46,3 mm at spring force128 – 152 N
L = 32,3 mm at spring force 255 – 294 N

Outer spring:
Free length (L*), approx. 59 mm
L* = 46,8 mm: at spring force 324 – 353 N
L* = 32,8 mm: at spring force 696 – 755 N

2547

17
 Dimensions
Service Data
Limiting values

Valve cone: 3,97 – 4,0 mm

Valve seat (= grinding face): 2 – 2,5 mm
Valve train

Rocker bracket

24,967 – 24,980 mm
14

2548

Rocker arm
Rocker arm radial clearance:
0,025 – 0,054 mm
Max. wear limit: 0,08 mm

25,005 –25,021 mm
2549

Camshaft

Change if signs of wear are present

Camshaft axial clearance:
0,20 – 0,90 mm, max. wear limit: 1,5 mm
Camshaft radial clearance:
Ø Ø 0,06 – 0,12 mm,
max. wear limit: 0,18 mm

69,910 – 69,940 mm

Backlash between
2550 crankshaft gear and camshaft gear:
0,128 mm – 0,252 mm

18
 Dimensions
Service Data
Limiting values

Camshaft bearing

Ø 70,000 – 70,030 mm

2658

Valve tappet

Matching bore in crankcase:

20,000 – 20,021 mm standard size
20,250 – 20,271 mm oversize

Ø
19,944 – 19,965 mm standard size
20,194 – 20,215 mm oversize

2552

19
 Dimensions
Service Data
Limiting values

Oil pump

Oil pump gear

Shaft: 17,930 – 17,940 mm

Ø Matching bore in housing:
18,000 – 18,018 mm
Radial clearance: 0,060 – 0,088 mm

Housing depth: 34,000 – 34,039 mm

Gear axial clearance: 0,050 – 0,128 mm
33,911 – 33,950 mm

2610 14,5 mm

Drive gear with oil pump gear

14,5 mm

Shaft: 17,930 – 17,940 mm

Ø Bore in drive gear:
17,885 – 17,870 mm
Pressing force: 10000 N

0,5 mm

Backlash:
Drive gear and crankshaft gear:
0,099 – 0,451 mm

2565

20
 Dimensions
Service Data
Limiting values

Double oil pump for oil pan, max. 2 30 deg.

Oil pump gear

Shaft: 17,930 – 17,940 mm

Ø Matching bore in housing:
18,000 – 18,018 mm
Radial clearance: 0,060 – 0,088 mm

Housing depth: 34,000 – 34,039 mm

Radial clearance: 0,050 – 0,128 mm
33,911 – 33,950 mm

2610 14,5 mm

33,911 – 33,950 mm

40,8 – 41,0 mm
2554

Drive gear with oil pump gear

14,5 mm

Shaft: 17,930 – 17,940 mm

Ø Bore in drive gear:
17,885 – 17,870 mm
Pressing force: 10000 N

0,5 mm
Backlash:
Drive gear and crankshaft gear:
0,099 – 0,451 mm

2565

21
 Dimensions
Service Data
Limiting values

Double oil pump for oil pan, max. 2 30 deg.

Oil pump gear

Shaft: 17,93 – 17,94 mm

Ø Matching bore in housing:
18,000 – 18,018 mm
Radial clearance: 0,060 – 0,088 mm

Housing depth: 38,000 – 38,039 mm

Radial clearance: 0,050 – 0,088 mm
37,911 – 37,950 mm

2610 14,5 mm

37,911 – 37,950 mm

40,8 – 41,0 mm
2554

22
 Dimensions
Service Data
Limiting values

Cooling system

Engine coolant pump

gap between housing and impeller:

0,5 – 0,9 mm

Ø impeller: 135 – 136 m

Bearing seat in housing:

54,940 – 54,970 mm
Ø of bearing: 54,981 – 54,994 mm
Interference: 0,011 – 0,054 mm

Hub bore:
25,000 – 25,021 mm
Ø of bearing shaft: 25,048 – 25,061 mm
Interference: 0,027 – 0,061 mm

Bore for bearing shaft in impeller:

16,000 – 16,018 mm
Ø of bearing shaft: 16,043 – 16,056 mm
2632
Interference: 0,025 – 0,056 mm

Thermostat

Opening begins at: 79 _C ("2_)

Fully open: 94_C

25,4 – 25,8 mm

Lift at least 8 mm at 94_C

2557

23
 Dimensions
Service Data
Limiting values

Cover for expansion tank

Working valve opens at 0,6 bar – 0,7 bar
above atmospheric pressure,
0,02 bar – 0,08 bar below
atmospheric pressure
Filler cap with safety valve (big cover)
opens at
0,85 bar – 1,2 bar above atmospheric
pressure

24
 Dimensions
Service Data
Limiting values

Turbocharger

Axial clearance

Max. axial clearance: max. 0,12 mm

2605

Radial clearance

Max. radial clearance: 0,64 mm

2606

25
 Dimensions
Service Data
Limiting values

Fuel system
Injectors
D 2866 LE 2..
Make Bosch
Type of nozzle DLLA 152 P 581
Number of holes 6
Discharge pressure
Injector new 340 + 10 bar
Injector run 320 bar
Injector body KDEL 82 P 30

Injector projection above cylinder head contact

surfaces

Eliminate nozzle protrusion by using Cu

sealing rings of different thickness. These
sealing rings are available in thicknesses
of 0,5 / 1,0 / 1,5 / 2,0 / 2,5 / 3,0 mm

2564 2,58 – 3,08 mm

Injection pump and governer

D 2866 LE 201 / 202 / 203
In-line pump: Bosch PES 6 P 120 A 700 LV, B 401 863 234
Final control element: GAC ACB 275 H

Start of delivery
Model Start of delivery ± 1 deg. before TDC
(Constant speed)

with optimised with optimised NOx

consumption
D 2866 LE 201
1500 1/min, constant 16° 11°
1800 1/min, constant 17° 14°
D 2866 LE 202
1500 1/min, constant 16° 11°
1800 1/min, constant 17° 14°
D 2866 LE 203
1500 1/min, constant 16° 11°
1800 1/min, constant 17° 14°

26
 Dimensions
Service Data
Limiting values

Starter
Manufactorer: Bosch
Type: KB
Operation: sliding-gear type

Starter pinion:
Number of teeth: Z=9
Modulus: 3

Output: 5,4 kW
Voltage: 24 V

2562

Alternator
Manufactorer: Bosch
Type: K1
Design: 1-pole, insulated
Operation: Threephase current
Voltage: 28V
Max. current: 35A

or

Manufactorer: Bosch
Type: N1
Design: 2-pole, insulated
Operation: Threephase current
2630 Voltage: 28V
Max. current: 55A

V-belts
Change damaged V-belts (cracks, wear,
oil)

Measuring tension with

tension tester

Tension forces according

to the kg graduation on the
tester
Drive
New installation When
belt
servicing
width After 10 after long
2595 Installa-
min. run- running
tion
ning time time
2/3VX 90–100 80–90 60
3/3VX 135–150 120–135 90

27
 Dimensions
Service Data
Limiting values

Speed pickup

Turn one tooth of gear ring in centre posi-

4388 tion relative to the thread bore,
screw in speed pickup until it stops, turn it
back by one revolution and fit counter nut

28
 Tightening torque guide values

Note:
All screws and bolts not listed in the following table must be tightened according to the
guiding values of MAN works standard M 3059.
Apply a light film of oil to all screws and bolts before they are fitted!

Plugs
DIN 908
M14 x 1,5, M16 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
M18 x 1,5, M22 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
M24 x 1,5, M26 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
M30 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
DIN 7604
AM10 x 1, M12 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
AM14 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm

Crankcase, crankshaft assembly

Engine mounting to crankcase M14, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Nm
Timing case to crankcase M10, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Thrust washer to timing case M8, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Crankshaft bearing caps to crankcase M18 x 2
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 – 330 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 – 100°
Counterweight to crankshaft M16 x 1,5, 10.9
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 – 110 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 – 100°
Vibration damper hub to crankshaft M16 x 1,5, 10.9 . . . . . . . . . . . . . . . . . . 260 Nm
Flywheel to crankshaft M16 x 1,5
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 – 260 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 – 100°
Connecting rod bearing caps M16 x 1,5, 10.9
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 – 110 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 bis 100°

Cylinder head
Rocker arm bracket to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Nm
Locknut on valve adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm

Lubrication system
Oil pump to crankcase M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Oil pump cover M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Oil cooler to oil filter head M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Filter bowl to oil filter head M12, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Plug (oil drain plug) in oil pan M26 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Oil jet to crankcase M14 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm

29
 Tightening torque guide values

Exhaust / Intake manifolds

Exhaust manifold to cylinder head M10
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 – 65 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 – 100°
Intake pipe to cylinder head M8, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm

Fuel system
Injection pump drive gear M8, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Injection pump to crankcase M10, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Injector to cylinder head M28 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 – 125 Nm
Nozzle tensioning nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Fuel filter M12, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Pressure pipe to injector and injection pump
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
rotation angle for first installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
rotation angle for following installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

Starter / alternator
Starter to timer case M12 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
V-belt pulley on alternator M14 x 1,5 und M16 x 1,5 . . . . . . . . . . . . . . . . . . . 40 – 50 Nm

Transmitter
Oil pressure transmitter M18 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Temperature transmitter M14 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm

30
 Tightening torque guide values

Tightening torque values according to Works Standard M 3059

Bolts / nuts with external or internal hexagon, head without collar or flange

Thread size Grade / Tightening torque in Nm

x pitch
for 8.8 / 8 for 10.9 / 10 for 12.9 / 12
M4 2,5 4,0 4,5
M5 5,0 7,5 9,0
M6 9,0 13,0 15,0
M7 14,0 20,0 25,0
M8 22,0 30,0 35,0
M8x1 23,0 35,0 40,0
M 10 45,0 65,0 75,0
M 10 x 1,25 45,0 65,0 75,0
M 10 x 1 50,0 70,0 85,0
M 12 75,0 105,0 125,0
M 12 x 1,5 75,0 110,0 130,0
M 12 x 1,25 80,0 115,0 135,0
M 14 115,0 170,0 200,0
M 14 x 1,5 125,0 185,0 215,0
M 16 180,0 260,0 310,0
M 16 x 1,5 190,0 280,0 330,0
M 18 260,0 370,0 430,0
M 18 x 2 270,0 290,0 450,0
M 18 x 1,5 290,0 410,0 480,0
M 20 360,0 520,0 600,0
M 20 x 2 380,0 540,0 630,0
M 20 x 1,5 400,0 570,0 670,0
M 22 490,0 700,0 820,0
M 22 x 2 510,0 730,0 860,0
M 22 x 1,5 540,0 770,0 900,0
M 24 620,0 890,0 1040,0
M 24 x 2 680,0 960,0 1130,0
M 24 x 1,5 740,0 1030,0 1220,0

31
 Tightening torque guide values

Cylinder head bolts

General notes

The engine may have either of the following two types of cylinder head bolt:

D Cylinder head bolts with hex head tightened y the

angle-of-rotation method, socket size 19

D Cylinder head bolts with Torx head tightened by the

angle-of-rotation method, Torx wrench size E18

Bolts to be used in event of repairs:

Bolts with hex head may be replaced by bolts with Torx head if all the bolts on the en-
gine are to be changed.

Do not use bolts with hex head and bolts with Torx head on the same engine.

32
 Tightening torque guide values

Retightening cylinder head bolts on new engines

(engine cold or warm)

The cylinder heads are mounted with cyl-

inder head bolts which are tightened by Erster Nachzug der Zylinder-
the angle-of-rotation method. On new en- kopfschrauben erledigt
gines the cylinder head bolts are tigh-
tened up for the first time at the factory First retightening of cylinder-
after the engine has been broken in. head-bolts completed
The sticker ”First retightening of cylin-
der head bolts ...” is then attached to
one of the cylinder head covers.
Spare part No. 51.97801-0211

Intake side / injector

After the first 400 hours of operation re-
tighten cylinder head bolts 1 to 4 in the
order shown in Tightening diagram ”1”
by a further 90° (1/4 revolution).
1 4

The two outer screws (intake and ex-

haust sides) must not be retightened.

Note:
The cylinder head bolts to be retigh- 3 2
tened must not be loosened first, but
simply tightened by a further 90° (1/4
revolution) from their actual position. MAN
Exhaust side

Tightening diagram ”1”

Remove the sticker ”First retightening

of cylinder head bolts ...” and attach Zweiter Nachzug der Zylinder-
the sticker ”Second retightening of cyl- kopfschrauben erledigt
inder head bolts ...” to show that the
cylinder head bolts have been retigh- Second retightening of cylinder-
tened for the second time. head-bolts completed

Spare part No. 51.97801-0212

33
 Tightening torque guide values

Tightening cylinder head bolts after a repair

(engine cold)

Before inserting the cylinder head bolts

oil them with engine oil on the thread (not Intake side / injector
to the bore) and coat the contact face of
the bolt head with ”Optimoly White T” as- 6
sembly paste. Do not use any oils or oil
additives that contain MoS2. The bolts
must be tightened by the angle-of-rota- 1 4
tion method as shown in Tightening dia-
gram ”2”.

D 1st pretightening step = to 10 Nm

D 2nd pretightening step = to 80 Nm
D 3rd pretightening step = to 150 Nm
D 4th pretightening step = turn by 90°
D Final tightening = turn by 90°
3 2
Adjust valve clearance.
MAN 5

Exhaust side

Tightening diagram ”2”

Retightening cylinder head bolts after repairs

(engine cold or warm)

After the first 10 to 20 hours of operation after a repair turn the cylinder head bolts by a
further 90° (1/4 revolution) in the order shown in Tightening diagram ”2”.
The cylinder head bolts to be retightened must not be loosened first, but simply tigh-
tened by a further 90° (1/4 revolution) from their actual position.
Attach the sticker ”First retightening of cylinder head bolts ...” (Remove any other
stickers which may already be attached).
After the first 400 hours of operation after a repair tighten cylinder head bolts 1 to 4 in
the order shown in Tightening diagram ”1” again by a further 90° (1/4 revolution).
The two outside screws (intake and exhaust side) must not be retightened.
Attach the sticker ”Second retightening of cylinder head bolts ...”.

Note:
When a cylinder head has been removed the cylinder head gasket must always be
changed.

34
 Tightening torque guide values

Re-using old cylinder head bolts

Checking
Before re-using old cylinder head bolts
check them as follows:
90+3
L
Length
During tightening the bolts are intention-
ally stressed beyond the yield point and L = Shank length
therefore subjected to some permanent
elongation each time they are tightened.
Shank lengths ”L” Permissible maxi-
on new bolts mum dimension
Surface 109 mm 111 mm
The surface of the bolts must be in satis-
144 mm 146 mm
factory condition, i.e. the phosphate coat-
ing must be intact and there must be no 168 mm 170 mm
rust.
Rusted or damaged bolts or bolts elon-
gated beyond the maximum permissible
length must immediately be made unus-
able – e.g. by destroying the threads with
a hammer – and scrapped.

35
 Index

A L
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . 7

C O
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Oil filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . 7
Compression pressures . . . . . . . . . . . . . . . . . . . . . 6 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Conrod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 P
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cover for expansion tank . . . . . . . . . . . . . . . . . . . 24
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 R
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Crankshaft bearings . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
S
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . 10 Speed pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cylinder liner protrusion . . . . . . . . . . . . . . . . . . . . . 8 Start of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
E
Engine coolant pump . . . . . . . . . . . . . . . . . . . . . . 23
T
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Timing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
V
V–belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
I Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Valve recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

36
 MAN Nutzfahrzeuge Aktiengesellschaft
Vogelweiherstraße 33 Telefon (0911) 420-0
D-90441 Nürnberg Telex 6 22 291 mn d
Telefax (0911) 44 65 22

GB Printed in Germany 51.99598-8004