Introduction

The purpose of this publication is to inform you about the checking values, setting data
and technical details of MAN’s 8, 10 and 12cylinder highperformance marine Diesel
engines.
It is intended to serve as a basis for maintenance and repair.

Yours faithfully,
MAN Nutzfahrzeuge Aktiengesellschaft
Werk Nürnberg

We reserve the right to make technical modifications in the course of further development.

© 2008 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, copying or translation, even in the form of excerpts, is forbidden without the written permis
sion of MAN. MAN expressly reserves all rights in accordance with the law on copyright.

EMDGG Technical status: 06.2008 51.994938392

1
 Contents

General engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Technical information

Enginespecific data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Service Data

Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Conrod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Connecting rod bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Start of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Injection pumps and governers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Power takeoff for hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Vbelts / Powerband . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Tightening torque guide values

Retightening cylinder head bolts on new engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Tightening cylinder head bolts after a repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Retightening cylinder head bolts after repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Flange of exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Tightening torque values, injection pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Tightening torque values according to Works Standard M 3059 . . . . . . . . . . . . . . . . 54

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2
 Basicknowledge

What do model designations mean?

All the engines dealt with here are related by design and together form a family.

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.

We will explain the system using model D 2842 LYE as an example:

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.

4 The 4" means 142 mm stroke.

2 The 2" shows that the engine has 12 cylinders. If there is a 0 here instead,
the engine is a 10cylinder model.

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

intercooling".

Y The development and power stages are represented by the letters X", Y"
and Z". Classifications Y and Z are found only with 12cylinder engines.

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

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

401 / 4.. These are internal MAN development numbers. This engine generation was
launched at the beginning of 1994 with modified turbocharger tuning and
governor characteristic.

3
 Basicknowledge

A brief history

The idea of developing a high powerdensity marine Diesel engine specifically suitable
for light and fast planing boats had already become reality at the end of the seventies
in the form of the D 2542 MLE.

As its classification shows, this engine is a 12cylinder model with a bore of 125 mm
and a stroke of 142 mm, making a swept volume of 20.91 l. With intercooling the
engine was able to develop 478 kW (650 hp). Soon it was possible to increase its
output to 700 hp.

Development work on a 10cylinder model, D 2540 MLE, was progressing parallel to

that on the 12cylinder engine. The 10cylinder model was capable of 405 kW (550 hp)
at its debut.

Widening the bore to 128 mm and employing a modified injection process gave birth
to the 560 kW (760 hp) model D 2842 LE. The total swept volume was thereby in
creased to 21.93 l.10 and 8cylinder engines with ratings of 467 kW (635 hp) and
375 kW (510 hp) followed.

In 1988 radical modifications became necessary to further increase output without

increasing swept volume. By improving the intercooling, increasing charge air pres
sure and reducing the compression ratio the output of the 12cylinder engine was
raised initially to 735 kW (1000 hp), subsequently to 809 kW (1100 hp). The 1000 hp
variant bears the designation D 2842 LYE, the 1100 hp variant D 2842 LZE.

Comprehensive side measures were introduced at this stage of evolution to ensure

that the engines met demands for smooth running characteristics and environmental
compatibility even at this power output.

Worthy of mention in this context are:

D Injection pump with cylinder cutout

D Engine speed governor with chargepressure dependent fullload stop
D Intake air preheating in warmingup phase

The 10cylinder D 2840 LXE developing 603 kW (820 hp) was followed by the 8cylin
der D 2848 LXE with an output of 500 kW (680 hp).

To meet demands for more power in the lower engine speed range, work started on
the 401/402 engine generation at the start of 1994. Although the rated power was
provisionally unchanged, torque was increased and progress made with respect to
exhaust emissions.

This has been achieved principally by means of retuned turbochargers with wastega
tes and injection pumps with K governors.

4
 Technicalfeaturesinsummary

General engine data

Mode of operation fourstroke, Diesel
Combustion process direct injection
Design V 90_
Bore / stroke 128 / 142 mm
Compression ratio
D 2840 LE 402, D 2842 LE 403 / 405 / 412 / 413 15,5 : 1
all other engine models 13,5 : 1
Rotation viewed from flywheel anticlockwise
Engine rating see model plate
Rated speed see model plate

5
 Technicalfeaturesinsummary

1 2 3 4 5 6 7

10

11 12 13

14

15

20 19 18 17 16

2553

6
 Technicalfeaturesinsummary

Taking the 12cylinder D 2842 LE 402 engine as an example, we shall explain the
components of the engine singly using the adjacent drawing. The only difference
between the general design of this engine and the 10 and 8cylinder models,
D 2840 LXE / LE 4.. and D 2848 LXE / LE 4.., is in the number of cylinders.

1 Heat exchanger and expansion tank

2 Sea watercooled intercooler

3 Air filter

4 Charge air pipe

5 Fuel prefilter

6 Turbocharger with watercooled turbine integrated into the engine cooling circuit

7 Diffuser

8 Wastegate

9 Starter

10 Alternator

11 Double oil filter

12 Injection pump with two fuel feed pumps in parallel

13 Engine shut down solenoid

14 Hand priming pump

15 Fuel filter

16 Sea water pump

17 Oil separator valve of crankcase breather

18 Charge air pressure equalisation valve

19 Exhaust manifold, watercooled, integrated into the engine coolant circuit

20 Intake air preheating

7
 Technicalfeaturesinsummary

Enginespecific data

D 2848 LXE, D 2848 LE 4..

5
No. of cylinders 8 1
Swept volume 14,62 l
6
Firing sequence 2
without cylinder cutout 157263481 8
with cylinder cutout 17641 7 7
6
5 3
Firing interval 4
3
without cylinder cutout 90_ 8 2
1 4
with cylinder cutout 180_

D 2840 LXE, D 2840 LE 4..

No. of cylinders 10 6
1
Swept volume 18,27 l 7
Firing sequence 10 2
9
without cylinder cutout 165102738491 8 8
7 3
with cylinder cutout 152341 6
9 5
Firing interval 4 4
3
without cylinder cutout 90_, 54_, 90_, 54_... 10 2
1 5
with cylinder cutout 144_

D 2842 LYE, D 2842 LZE, D 2842 LE 4..

No. of cylinders 12
7
Swept volume 21,93 l 1
Firing sequence 8
without cylinder cutout 1125831067211491 2
12
9 11
with cylinder cutout 1536241 10 3
9
Firing interval 10 8
7 4
without cylinder cutout 90_, 30_, 90_, 30_... 6
11 5
with cylinder cutout 120_ 4 5
3
12 2
1 6

8
 Timinggear

Timing gear arrangement

(viewed from flywheel)

3
9

6
8

Gear designation No. of teeth Module Gear tooth cutting

1 Drive gear, injection pump 51 2,75 straight
2 Power takeoff 34 2,75 helical (23_40’)
3 Intermediate gear 51 2,75 straight
4 Drive gear, camshaft 86 2,75 helical (23_40’)
5 Crankshaft gear 43 2,75 helical (23_40’)
6 Drive gear, oil pump 44 2,75 helical (23_40’)
7 Oil pump supply gear 7 6 straight
8 Oil pump supply gear 7 6 straight
9 Drive gear, sea water pump 40 2,75 helical (23_40’)

9
 Checkingandsettingvalues

Valve train
The checking values are valid for all engines dealt with in this publication
Valve clearance (when engine is cold) inlet 0,25 mm  0,05 mm
exhaust 0,40 mm  0,05 mm

Note: Starting with following engine numbers valve clearance has been changed:
D 2848 L: ...7678 001.... , D 2840 L: ...7661 035...., D 2842 L: ...7651 046....
See instruction label on valve cover! New values for valve clearance are:
Valve clearance (when engine is cold) inlet 0,50 mm  0,05 mm
exhaust 0,60 mm  0,05 mm

Why valve clearance?

The individual valve train components expand slightly as they warm up. Valve clear
ance 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 crosssections are reduced and cylinder charging worsens. Valve
train wear and valve noise is increased greatly.

Timing diagram 1
OT
1 Direction of engine rotation 2 8 5
(viewed from Vbelt pulley)

2 Inlet opens 24_ before TDC

3 Inlet closes 36_ after BDC
4 Exhaust opens 63_ before BDC
5 Exhaust closes 27_ after TDC

6 Inlet open for 240_ 7 6

7 Exhaust open for 270_
8 Overlap 51_

Figures in degrees refer to the 4

crankshaft angle

Valve lift: 14,0 mm 3

(intake / exhaust)
UT

10
 Checkingandsettingvalues

Compression pressures
(Engine has run before the measurement and is warm to the touch)
good bar over 18
permissible bar 16−18
in need of repair bar under 16
pressure difference bar max. 4
(between individual cylinders)

Fuel system
Delivery rate of fuel supply pump: D 2848 LXE D 2848 LE 4..
D 2840 LXE D 2840 LE 4..
D 2842 LYE / LZE D 2842 LE 4..
n = 2300 rpm l/h 500 750
Opening pressure of overflow valve (all engine models):
at injection pump bar 1,3−1,8
at fuel filter bar 3,0−3,5

Lubricating system
Oil pump feed rate:
The oil pumps have the following rotation speeds:
Oil pump speed: engine speed x 0.977 (i = 1.023)
(Feed rates with SAE 20 oil at 90_C and 6 bar.)
D 2848 LXE / LE 4..
n = 635 rpm l / min 40
n = 2248 rpm l / min 165
D 2840 LXE / LE 4..
(oil sump at front and flat oil pan)
n = 635 rpm l / min 45
n = 2248 rpm l / min 205
D 2842 LYE / LZE / LE 4..
and D 2840 L.. (oil sump at rear)
n = 635 rpm l / min 43
n = 2248 rpm l / min 205
Valve opening pressures in lubricating oil circuit:
Bypass valve for oil filter
Model: Mann bar 2,2−2,8
Model: Hengst bar 2,8−3,6
Oil pump pressure regulating valve bar 9−10
Pressure valve of oil spray jets
Opening pressure bar 1,6−1,9
Closing pressure bar 1,3−1,6

11
 Fillingcapacities

Oil

Engine model Oil pan Min. capacity Max. capacity

D 2848 L.. deep 12 l 18 l

D 2848 L.. flat 20 l 24 l

D 2840 L.. deep 14 l 22 l

sumpOFW*

D 2840 L.. deep 26 l 30 l

sumpFW*

D 2840 L.. flat 26 l 30 l

D 2842 L.. deep 24 l 32 l

D 2842 L.. semiflat 22 l 30 l

*OFW = opposite end to flywheel, FW = adjacent to flywheel

Coolant
Engine with heat exchanger Litres
D 2848 LE 4.. 63
D 2840 LE 4.. 80
D 2842 LE 4.. 96

12
 Dimensions
ServiceData
Limitingvalues

Crankcase

153,90−154,00 mm standard
154,40−154,50 mm for cylinder liners with
Ø 0,5 and 1,0 mm larger outside Ø
Ø 145,80−145,84 mm standard
146,30−146,34 mm for cylinder liners with
0,5 mm larger outside diameter
146,80−146,84 mm for cylinder liners with
1,0 mm larger outside diameter

9,97−9,99 mm

144,50−144,54 mm standard
145,00−145,04 mm for cylinder liners with
Ø 0,5 mm larger outside diameter
145,50−145,54 mm for cylinder liners with
1,0 mm larger outside diameter

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

10,030−10,050 mm
10,230−10,250 mm with 0,2 mm more
flange height
Liner protrusion above upper deck of
0,005
crankcase: 0,04−0,08 mm
145,761−145,786 mm
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
144,932−144,957 mm with 0,5 mm larger
outside diameter
Ø
145,432−145,457 mm with 1,0 mm larger
outside diameter

13
 Dimensions
ServiceData
Limitingvalues

Crankshaft

Crankshaft front end (opposite end to flywheel)

99,987−100,022 mm
89.98−90,00 mm standard size
1 89,73−89,75 mm undersize 0,25
89,48−89,50 mm undersize 0,50
89,23−89,25 mm undersize 0,75
88,98−89,00 mm undersize 1,00

2
103,98−104,00 mm standard size
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

1 = Colour marking for size identification

of crank pin diameter

2 = Colour marking for size identification

of main bearing journal diameter

undersize 0,25: red

undersize 0,50: white
undersize 0,75: yellow
undersize 1,00: lilac

max. axial clearance of crankshaft:

0,190−0,322 mm

Bearing race for crankshaft, front end

Inner diameter:
99,907−99,942 mm

14
 Dimensions
ServiceData
Limitingvalues

Crankshaft rear end (adjacent to flywheel)

Max. permissible runout with crankshaft

taken up in end bearings:
D 2848 L at bearing 3 0,06 mm
D 2840 L at bearing 3
and bearing 4 0,06 mm
D 2842 L at bearing 4 0,08 mm

1
38,000−38,062 mm standard size
38,500−38,562 mm undersize 0,25
38,500−38,562 mm undersize 0,50
39,000−39,062 mm undersize 0,75
39,000−39,062 mm undersize 1,00
1 = Colour marking for size identification
of thrust bearing journal length
undersize 0,25: red
undersize 0,50: white
undersize 0,75: yellow
undersize 1,00: lilac

Main bearing
Data for wall thickness and bearing
bore also apply to thrust bearing
3,455−3,467 mm standard size
3,580−3,592 mm undersize 0,25
3,705−3,717 mm undersize 0,50
3,830−3,842 mm undersize 0,75
3,955−3,967 mm undersize 1,00

Bearing bore in installed condition

104,066−104,1 12 mm standard size
103,816−103,862 mm undersize 0,25
103,566−103,612 mm undersize 0,50
103,316−103,362 mm undersize 0,75
103,066−103,1 12 mm undersize 1,00

Spread: 0,3−1,2 mm

Marking:
top / bottom
standard size: 0958 / 0079
undersize 0,25: 0962 / 0081
undersize 0,50: 0964 / 0082
undersize 0,75: 0966 / 0083
undersize 1,00: 0968 / 0084

15
 Dimensions
ServiceData
Limitingvalues

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
standard size: 0164 / 0165
undersize 0,25: 0168 / 0169
undersize 0,50: 0170 / 0171
undersize 0,75: 0172 / 0173
undersize 1,00: 0174 / 0175

31,01−31,04
Data for wall thickness and bearing
bore see main bearing"

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.

new: 152,5−153
max. 154,5 mm

16
 Dimensions
ServiceData
Limitingvalues

Flywheel and starter gear ring

Ø Flywheel:
432,490−432,645 mm (Ø 432 u9

Starter gear ring, inside diameter:

432,000−432,155 mm (Ø 432 H9)

Interference: 0,335−0,645 mm
Installation temperature: 200−230 deg.C

Ø
m = 52,9 kg (with starter gear)
J = 1,975 kgm2

Number of teeth: Z = 160, Module 3

Matching gear:
Starter pinion (Z = 9, gear ratio: i = 17,78)

Backlash: 0,6−0,9 mm

17
 Dimensions
ServiceData
Limitingvalues

Flywheel and
with starter gearmassKolben
additional ring for D 2840
(alleLE 403 and
Typen D 2842
außer LE LE406)
D 2842 404

Ø Flywheel:
432,490−432,645 mm (Ø 432 u9)

Starter gear ring, inside diameter:

432,000−432,155 mm (Ø 432 H9

Interference: 0,335−0,645 mm
Installation temperature: 200−230 deg.C

Ø
m = 54,4 kg (with starter gear)
J = 1,921 kgm2

Number of teeth: Z = 160, Module 3

Matching gear:
Starter pinion (Z = 9, gear ratio: i = 17,78)

Backlash: 0,6−0,9 mm

18
 Dimensions
ServiceData
Limitingvalues

Flywheel with additional mass and starter

massKolben (alle gear
Typenring
außer D 2842 LE406)

Ø Flywheel:
432,490−432,645 mm (Ø 432 u9)

Starter gear ring, inside diameter:

432,000−432,155 mm (Ø 432 H9)

Interference: 0,335−0,645 mm
Installation temperature: 200−230 deg.C

Ø
m = 102 kg (with starter gear)
J = 4,12 kgm2

Number of teeth: Z = 160, Module 3

Matching gear:
Starter pinion (Z = 9, gear ratio: i = 17,78)

Backlash: 0,6−0,9 mm

19
 Dimensions
ServiceData
Limitingvalues

Flywheel for cardanshaft coupling

Ø Flywheel:
432,490−432,645 mm (Ø 432 u9)

Starter gear ring, inside diameter:

432,000−432,155 mm (Ø 432 H9)

Interference: 0,335−0,645 mm
Installation temperature: 200−230 deg.C

Ø
m = 32,5 kg (with starter gear)
J = 1,10 kgm2

Number of teeth: Z = 160, Module 3

Matching gear:
Starter pinion (Z = 9, gear ratio: i = 17,78)

Backlash: 0,6−0,9 mm

20
 Dimensions
ServiceData
Limitingvalues

Flywheel for elastomer propshaft coupling

Ø Flywheel:
432,490−432,645 mm (Ø 432 u9)
Starter gear ring, inside diameter:
432,000−432,155 mm (Ø 432 H9)
Interference: 0,335−0,645 mm
Installation temperature: 200−230_C

m = 38,5 kg (with starter gear)

Ø J = 1,17 kgm2

Number of teeth:Z = 160, Module 3

Matching gear: Starter pinion number of
teeth: (Z= 9)

Backlash between: 0,6−0,9 mm

21
 Dimensions
ServiceData
Limitingvalues

Connecting rods

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

Ø0,02 A

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

Precondition:
2 new bigend bearing in place,
a b
3 conrod assembled

Conrod bearing
2,463−2,473 mm standard size
2,588−2,598 mm undersize 0,25
2,713−2,723 mm undersize 0,50
2.838−2,848 mm undersize 0,75
2,963−2,973 mm undersize 1,00
Spread: 0,6−1,5 mm
If signs of wear are present (scores, anti
wear coating damaged) change both
bearing shells.
Important: note installation position (upper
half bearing shell has red 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. 900200139:
new: 67,2−67,5 mm, max. 69 mm

22
 Dimensions
ServiceData Limitingvalues

Connecting rods

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

Ø
Ø0,02 A
A
Bearing bore in directions 1, 2 and 3 and
in planes a and b:
1 8mm 8mm 90,075−90, 120 mm

Precondition:
2 new bigend bearing in place,
a b
3 conrod assembled

Conrod bearing
2,463−2,473 mm standard size
2,588−2,598 mm undersize 0,25
2,713−2,723 mm undersize 0,50
2.838−2,848 mm undersize 0,75
2,963−2,973 mm undersize 1,00
Spread: 0,6−1,5 mm
If signs of wear are present (scores, anti
wear coating damaged) change both
bearing shells.
Important: note installation position (upper
half bearing shell has red 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. 900200338:
new: 68,2−68,5 mm, max. 69,5 mm

23
 Dimensions
ServiceData
Limitingvalues

Piston
Kolben(offset pistons,
(alle Typen marked
außer with
D 2842 R" or L" on top of piston)
LE406)
Compression height: 81,250−81,300 mm
with undersize
0,2 mm: 81,050−81,100 mm
0,4 mm: 80,850−80,900 mm
0,6 mm: 80,650−80,700 mm
Piston protrusion above crankcase top:
0,01−0,38 mm
Ø
46,005−46,013 mm
Piston pin diameter:
45,994−46,000 mm
Ø
127,835−127,875 mm
15

Max. difference in weight per

engine piston set: 100g

Piston ring grooves

1,5
2,935−2,965 mm

I
3,040−3,060 mm
II

III 5,020−5,040 mm

Piston ring height / Piston ring axial play / Piston ring gap

1,5
1st. ring − keystonetype ring:
I
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
2nd. ring:
(Goetze) 0,45−0,70 mm
(Riken) 0,40−0,65 mm
3rd. ring: 0,25−0,40 mm

24
 Dimensions
ServiceData
Limitingvalues

Piston
Compression height: 81,250−81,300 mm
with undersize
0,2 mm: 81,050−81,100 mm
0,4 mm: 80,850−80,900 mm
0,6 mm: 80,650−80,700 mm
Piston protrusion above crankcase top:
0,01−0,38 mm
Ø
46,005−46,013 mm
Piston pin diameter:
45,994−46,000 mm
Ø 127,835 −127,875 mm
15

Max. difference in weight per

engine piston set: 100g

Piston ring grooves

1,5
3,695−3,725 mm

I
3,040−3,060 mm
II

III 4,02−4,04 mm

Piston ring height / Piston ring axial play / Piston ring gap

1,5

I 1st. ring − keystonetype ring:

height: 3,296−3,33 mm

2nd. ring − taper face ring:

II
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
2nd. ring: 0,45−0,70 mm
3rd. ring: 0,25−0,55 mm

25
 Dimensions
ServiceData
Limitingvalues

Cylinder head

12,000−12,018 mm Intake valve

12,000−12,018 mm Exhaust valve

17,1−17,5 mm

Intake valve α = 60_

α β
Exhaust valve β = 45_

a = 3,3−3,8 mm
a b b = 3,3−3,8 mm

Ø Valve guide bore in cylinder head:

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

standard: 113,9−1 14 mm
minimum: 112,9 mm
(observe specified dimensions for valve
recess and injector projection, see pages
21, 31)

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:

61,00 −61,03 mm
Valve seat insert outside diameter:
61,10−61,1 1 mm

26
 Dimensions
ServiceData
Limitingvalues

Cylinder head bolts (hex head or Torx head)

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
90+3 maximum length it must not be reused.

Angleofrotation symbol
new: 167,5−168 mm, max. 170 mm
new: 143,5−144 mm, max. 146 mm
new: 108,5−109 mm, max. 111 mm

Valve recess
Ø
Intake valve: 11,968−1 1,982 mm
Exhaust valve: 11,943−1 1,957 mm
Max. wear limit: 0.1 mm below base
dimension
Do not reuse valves with damaged chro
mium layer!

Valve recess for intake and exhaust

valve:
0,7−1,3 mm

Inlet valve
Ø
Intake valve: 11,968−1 1,982 mm
Exhaust valve: 11,943−1 1,957 mm
Max. wear limit: 0.1 mm below base
dimension
Do not reuse valves with damaged chro
mium layer!

Valve recess for intake and exhaust

valve:
0,7−1,3 mm

27
 Dimensions
ServiceData
Limitingvalues

Exhaust valve

Inner spring:
Free length (L), approx. 65,5 mm
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* L L* = 46,8 mm: at spring force 324−353 N
L* = 32,8 mm: at spring force 696−755 N

The lowest spring force is at the same

time the wear limit value.

Exhaust valve

Inner spring:
Free length (L), approx. 65,5 mm
L = 46,3 mm: at spring force 131−155 N
L = 32,3 mm: at spring force 260−300 N

Outer spring:
Free length (L*), approx. 59 mm
L* L L* = 46,8 mm: at spring force 330−360 N
L* = 32,8 mm: at spring force 710−770 N

The lowest spring force is at the same

time the wear limit value.

28
 Dimensions
ServiceData
Limitingvalues

Valve train

Rocker bracket

24,967−24,980 mm
14

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

25,005 −25,021 mm

29
 Dimensions
ServiceData
Limitingvalues

Camshaft

Change if signs of wear are present

Camshaft axial clearance:

0,20−0,90 mm
Ø Ø Max. wear limit: 1,5 mm

69,910−69,940 mm

Backlash between
crankshaft gear and camshaft gear:
0,118 mm−0,242 mm

Camshaft bearing

70,000−70,030 mm or
70,070−70,090 mm for bush 5 (V8),
6 (V10) or 7 (V12) = bush at timing case
end

Valve tappet

Matching bore in crankcase:

20,000−20,021 mm

Ø
19,944−19,965 mm

30
 Dimensions
ServiceData
Limitingvalues

Oil pump

Twogears oil pump for D 2848 L..

Oil pump gear

Shaft: 21,930−21,940 mm
Ø Matching bore in housing:
22,000−22,021 mm
Radial clearance: 0,060−0,091 mm

Housing depth: 43,000−43,039 mm

Axial clearance: 0,050−0,128 mm
42,911−42,950 mm
11,5−1 1,7 mm

Drive gear with oil pump gear

11,5−1 1,7 mm

Shaft: 21,930−21,940 mm
Bore in drive gear:
Ø
21,870−21,885 mm
Pressing force: 12000 N

0,5mm

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

31
 Dimensions
ServiceData
Limitingvalues

Twogears double oil pump for D 2840 L..

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: 28,000−28,033 mm

Axial clearance: 0,040−0,106 mm
27,927−27,960 mm
14,5 mm

27,927−27,960 mm

40,8−41,0 mm

Drive gear with oil pump gear

14,5 mm

Shaft: 17,930−17,940 mm
Bore in drive gear:
Ø
17,885−17,870 mm
Pressing force: 10000 N

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

2565

32
 Dimensions
ServiceData
Limitingvalues

Threegears oil pump for D 2840 L.., D 2842 L..

Oil pump gear

Shaft: 21,930−21,940 mm
Ø Matching bore in housing:
22,000−22,021 mm
Radial clearance: 0,060−0,091 mm

Housing depth: 28,000−28,033 mm

Axial clearance: 0,040−0,106 mm
27,927−27,960 mm
14,5−14,7 mm

Drive gear with oil pump gear

14,5−14,7 mm

Shaft: 21,930−21,940 mm
Bore in drive gear:
Ø
21,870−21,885 mm
Pressing force: 12000 N

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

33
 Dimensions
ServiceData
Limitingvalues

Cooling system

Engine coolant pump

gap between housing and impeller:

0,3−0,4 mm
Ø impeller: 149,5−150 mm

Bearing seat in housing:

54,940−54,970 mm
Ø of bearing: 54,981−54,994 mm
Interference: 0,011−0,054 mm
Bore for bearing shaft in impeller:
15, 992−16,010 mm
Ø of bearing shaft: 16,045−16,056 mm
Interference: 0,035−0,064 mm

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

Engine coolant pump

D 2848 LE 401 / 403 / 405
D 2842 LE 403 / 404 / 410 / 414 / 415 / 416 / 417

gap between housing and impeller:

0,3−0,4 mm
Ø impeller: 149,5−150 mm

Bearing seat in housing:

54,940−54,970 mm
Ø of bearing: 54,981−54,994 mm
Interference: 0,011−0,054 mm
Bore for bearing shaft in impeller:
15, 992−16,010 mm
Ø of bearing shaft: 16,045−16,056 mm
Interference: 0,035−0,064 mm

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

34
 Dimensions
ServiceData
Limitingvalues

Raw water pump 50.065007011

If impeller is worn, change it together with

seals and small parts (repair kit)

If wear in bearing can be felt (free play in

bearing), change the bearing
Speed of raw water pump:
1,075 x engine speed (i= 0,9302)
Use 9vane impeller only! Treat impeller
before installation with an acidfree
lubricant and install in turning direction
Delivery rate at
engine speed n = 2300 rpm: 430 l / min

Raw water pump 51.065007025

If impeller is worn, change it together with
seals and small parts
If wear in bearing can be felt (free play in
bearing), change the bearing
Speed of raw water pump:
1,075 x engine speed (i= 0,9302)
Treat impeller before installation with an
acidfree lubricant and install in turning
direction
Delivery rate at
engine speed n = 2300 rpm: 620 l / min

Raw water pump 51.065007031

If impeller is worn, change it together with
seals and small parts

If wear in bearing can be felt (free play in

bearing), change the bearing
Delivery rate at
engine speed n = 1800 rpm: 540 l / min
engine speed n = 2300 rpm: 590 l / min

35
 Dimensions
ServiceData
Limitingvalues

Cover for heat exchanger

Filler cap with safety valve:

Safety valve with imprint 1,0 opens at
0,85 bar−1,2 bar above atmospheric pres
sure. Safety valve with imprint 1,5 opens
at 1,3 bar−1,7 bar above
atmospheric pressure
Valve cover:
Working valve with imprint 0,6 opens at
0,6 bar−0,7 bar above atmospheric pres
sure and 0,02 bar −0,08 bar below atmo
spheric pressure
Working valve with imprint 1,0 opens at
0,85 bar−1,15 bar above atmospheric
pressure and 0,02 bar −0,08 bar below
atmospheric pressure

Warning:
If the cap with the working valve is
opened, there is the risk that it will not
close tightly again afterwards.

The excess pressure required in the sys

tem will then no longer build up. Prema
ture boiling occurs and coolant is lost.

To prevent damage to the engine open

this cap only in exceptional circumstances
or during service work and fit a new one
as soon as possible.

36
 Dimensions
ServiceData
Limitingvalues

Thermostat

opening begins at: 79_C (2_)

Fully open: 90_C
(The temperature for the start of opening
is printed on the thermostat)

24,5−25,8 mm

Lift at least 8 mm at 90_C

Thermostat

opening begins at: 71_C (2_)

Fully open: 86_C
(The temperature for the start of opening
is printed on the thermostat)

24,5−25,8 mm

Lift at least 8 mm at 86_C

37
 Dimensions
ServiceData
Limitingvalues

Thermostat

opening begins at: 79_C (2_)

Fully open: 92_C (2_)
Lift at least 9,5 mm at 92_C
or
opening begins at: 82_C (2_)
Fully open: 95_C (2_)
Lift at least 9,5 mm at 95_C
(The temperature for the start of opening
is printed on the thermostat)

Change seal if thermostat is removed

38
 ServiceData

Injectors

Engine model Type of injector Discharge pressure, Number of

(Bosch) (bar) holes / hole Ø
Injector (new / run)

D 2848 LXE DLLA 146 P 203 295 (+ 8) / 280 5 / 0,406 mm

D 2848 LE 401 DLLA 146 P 203 295 (+ 8 ) / 280 5 / 0,406 mm

D 2848 LE 403 DLLA 146 P 203 295 (+ 8 ) / 280 5 / 0,406 mm

D 2848 LE 405 DLLA 146 P 203 295 (+ 8 ) / 280 5 / 0,406 mm

D 2840 LXE up to engine DLLA 136 S 1002 295 (+ 8) / 280 4 / 0,43 mm

number ... 6143 095 ....

D 2840 LXE engine number DLLA 146 P 203 295 (+ 8) / 280 5 / 0,406 mm
and up ... 6143 096 ....

D 2840 LE 401 DLLA 146 P 203 295 (+ 8) / 280 5 / 0,406 mm

D 2840 LE 402 DLLA 144 P 184 295 (+ 8) / 280 4 / 0,398 mm

D 2840 LE 403 DLLA 146 P 708 290 (+ 8) / 280 5 / 0,406 mm

D 2840 LE 404 DLLA 146 P 708 290 (+ 8) / 280 5 / 0,406 mm

D 2840 LE 407 DLLA 146 P 203 290 (+ 8 ) / 280 5 / 0,406 mm

D 2842 LYE up to engine DLLA 136 S 1002 295 (+ 8) / 280 4 / 0,43 mm

number ... 6143 095 ....

D 2842 LYE engine number DLLA 146 P 203 295 (+ 8) / 280 5 / 0,406 mm
and up ... 6143 096 ....

D 2842 LZE DLLA 146 P 203 295 (+ 8) / 280 5 / 0,406 mm

D 2842 LE 401 DLLA 146 P 203 295 (+ 8) / 280 5 / 0,406 mm

D 2842 LE 402 DLLA 146 P 203 295 (+ 8) / 280 5 / 0,406 mm

D 2842 LE 403 DLLA 146 P 581 295 (+ 8) / 280 6 / 0,312 mm

D 2842 LE 404 DLLA 146 P 708 290 (+ 8) / 280 5 / 0,406 mm

D 2842 LE 405 DLLA 146 P 581 295 (+ 8) / 280 6 / 0,312 mm

D 2842 LE 406 DLLA 146 P 203 295 (+ 8) / 280 5 / 0,406 mm

D 2842 LE 407 DLLA 146 P 708 295 (+ 8 ) / 280 5 / 0,406 mm

D 2842 LE 408 DLLA 146 P 203 295 (+ 8) / 280 5 / 0,406 mm

39
 ServiceData

Injectors

Engine model Type of injector Discharge pressure, Number of

(Bosch) (bar) holes / hole Ø
Injector (new / run)

D 2842 LE 410 DLLA 146 P 708 290 (+ 8) / 280 5 / 0,406 mm

D 2842 LE 411 DLLA 146 P 203 295 (+ 8 ) / 280 5 / 0,406 mm

D 2842 LE 412 DLLA 146 P 581 295 (+ 8 ) / 280 6 / 0,312 mm

D 2842 LE 413 DLLA 146 P 581 295 (+ 8 ) / 280 6 / 0,312 mm

D 2842 LE 414 DLLA 146 P 708 295 (+ 8 ) / 280 5 / 0,406 mm

D 2842 LE 415 DLLA 146 P 708 295 (+ 8 ) / 280 5 / 0,406 mm

D 2842 LE 416 DLLA 146 P 708 295 (+ 8 ) / 280 5 / 0,406 mm

D 2842 LE 417 DLLA 146 P 708 295 (+ 8 ) / 280 5 / 0,406 mm

D 2842 LE 419 DLLA 146 P 581 295 (+ 8 ) / 280 6 / 0,312 mm

40
 ServiceData

Start of delivery

Model Start of delivery / deg. before TDC

D 2848 LXE up to engine no. ... 6190 999 .... 161

up to engine no. ... 6191 001 .... 221

D 2848 LE 401 221

D 2848 LE 403 up to engine no. ... 9211 019 .... 241

engine no. and up ... 9211 020 .... 181

D 2848 LE 405 up to engine no. ... 9261 016 .... 211

engine no. and up ... 9261 017 .... 151

D 2840 LXE up to engine no. ... 6143 095 .... 231

engine no. and up ... 6143 096 .... 241

D 2840 LE 401 241

D 2840 LE 402 with optimised consumption 150,5

with optimised NOx 120,5

D 2840 LE 403 up to engine no. ... 9218 038 .... 241

engine no. and up ... 9218 039 .... 211

D 2840 LE 404 with optimised consumption 200,5

with optimised NOx 160,5

D 2840 LE 407 with optimised consumption 240,5

with optimised NOx 220,5

D 2842 LYE up to engine no. ... 6143 095 .... 181

engine no. and up ... 6143 096 .... 241

D 2842 LZE up to engine no. ... 6143 095 .... 231

engine no. and up ... 6143 096 .... 241

D 2842 LE 401 221

D 2842 LE 402 221

D 2842 LE 403 with optimised consumption 150,5

with optimised NOX 120,5

D 2842 LE 404 up to engine no. ... 9029 044 .... 231

engine no. and up ... 9029 045 .... 201

D 2842 LE 405 150,5

D 2840 LE 406 with optimised consumption 240,5

with optimised NOx 210,5

41
 ServiceData

Start of delivery

Model Start of delivery / deg. before TDC

D 2842 LE 407 200,5

D 2842 LE 408 up to engine no. ... 9044 035 .... 200,5

engine no. and up ... 9044 036 .... 180,5

D 2842 LE 410 190,5

D 2842 LE 411 180,5

D 2842 LE 412 130,5

D 2842 LE 413 160,5

D 2842 LE 414 200,5

D 2842 LE 415 190,5

D 2842 LE 416 200,5

D 2842 LE 417 200,5

D 2842 LE 419 100,5

42
 ServiceData

Injection pumps and governers

all engines: Bosch Inline pump with variable speed governor

Engine model Injection pump Governor

D 2848 LXE PE8 P120 A 520 LV 17789 RQV 2501150 PAV19234

P = 500 kW / 2300 rpm

D 2848 LE 401 PE8 P120 A 520 LS 78182 RQV 3001150 PA10392K

P = 500 kW / 2300 rpm

D 2848 LE 401 PE8 P120 A 520 LS 78182 RQV 3001050 PAV21270K

P = 397 kW / 2100 rpm

D 2848 LE 403 PE8 P120 A 520 LS 8518 RQV 3251150 PA10393K

P = 588 kW / 2300 rpm

D 2848 LE 405 PE8 P120 A 520 LV RQV 3001050 PAV

P = 478 kW / 2100 rpm

D 2840 LXE PE10 P120 A 520 LV 17899 RQV 2501150 PAV19234

P = 603 kW / 2300 rpm or or
up to engine number PE10 P120 A 520 LS 7825 RQV 2501150 PA 9023
...6143 095....

D 2840 LXE PE10 P120 A 520 LV 17899 RQV 2501150 PAV19234

P = 603 kW / 2300 rpm or or
engine number and up PE10 P120 A 520 LS 78251 RQV 2501150 PA 9023
...6143 096....

D 2840 LE 401 PE10 P120 A 520 LV 19382 RQV 3001050 PAV21272K

P = 478 kW / 2100 rpm or
PE10 P120 A 520 LS 7853

D 2840 LE 401 PE10 P120 A 520 LV 19382 RQV 3001150 PAV21076K

P = 603 kW / 2300 rpm or or
PE10 P120 A 520 LS 7853 RQV 3001150 PA10392K

D 2840 LE 402 PE10 P120 A 520 LV RQV 300900 PAV

P = 441 kW / 1800 rpm

D 2840 LE 403 PE10 P120 A 520 LS 8523 M (S) 5EDC

P = 772 kW / 2300 rpm

D 2840 LE 404 PE10 P120 A 520 LS 8523 M (S) 5EDC

P = 603 kW / 2100 rpm

D 2840 LE 407 PE10 P120 A 520 LS 7853 RQV 3001150 PA10392K

P = 772 kW / 2300 rpm

43
 ServiceData

Injection pumps and governers

all engines: Bosch Inline pump with variable speed governor

Engine model Injection pump Governor

D 2842 LYE PE12 P120 A 520 LV 17898 RQV 3001050 PAV19766

P = 588 kW / 2100 rpm or
PE12 P120 A 520 LS 7824

D 2842 LYE PE12 P120 A 520 LV 17898 RQV 2501150 PAV19235

P = 735 kW / 2300 rpm or or
PE12 P120 A 520 LS 7824 RQV 3001150 PA 9023

D 2842 LYE PE12 P120 A 520 LV 17898 RQ 1200 PAV18952

with electronic governor or
PE12 P120 A 520 LS 7824

D 2842 LZE PE12 P120 A 520 LV 18128 RQV 2501150 PAV19535

P = 809 kW / 2300 rpm or or
PE12 P120 A 520 LS 7829 RQV 3001150 PA9431

D 2842 LE 401 PE12 P120 A 520 LS 78291 RQV 3001050 PAV21271K

P = 588 kW / 2100 rpm

D 2842 LE 401 PE12 P120 A 520 LS 78291 RQV 3001150 PAV21076K

P = 735 kW / 2300 rpm or
RQV 3001150 PA10391K

D 2842 LE 402 PE12 P120 A 520 LS 78291 RQV 3001150 PAV21075K

P = 809 kW / 2300 rpm or
RQV 3001150 PA 1039K

D 2842 LE 403 PE12 P120 A 520 LV RQV 300900 PAV

P = 529 kW / 1800 rpm

D 2842 LE 404 PE12 P120 A 520 LV M (S) 5EDC

P = 956 kW / 2300 rpm or
PE12 P120 A 520 LS 8525

D 2842 LE 405 PE12 P120 A 520 LS 8531 RQV 300900 PA1454K

P = 662 kW / 1800 rpm

D 2842 LE 406 PE12 P120 A 520 LS 8507 RQV 3001150 PA10393K

P = 882 kW / 2300 rpm

D 2842 LE 407 PE12 P120 A 520 LS 8525 M (S) 5EDC

P = 882 kW / 2300 rpm

D 2842 LE 408 PE12 P120 A 520 LS 8507 RQV 3001050 PA10394K

P = 735 kW / 2100 rpm

44
 ServiceData

Injection pumps and governers

all engines: Bosch Inline pump with variable speed governor

Engine model Injection pump Governor

D 2842 LE 410 PE12 P120 A 520 LS 8525 M (S) 5EDC

P = 809 kW / 2300 rpm
P = 809 kW / 2100 rpm

D 2842 LE 411 PE12 P120 A 520 LS 8507 RQV 3001150 PA10393K

P = 735 kW / 2300 rpm

D 2842 LE 412 PE12 P120 A 520 LS 8531 RQV 300900 PAV

P = 588 kW / 1800 rpm

D 2842 LE 413 PE12 P120 A 520 LV RQV 3001050 PAV

P = 735 kW / 2100 rpm

D 2842 LE 414 PE12 P120 A 520 LV M (S) 5EDC

P = 809 kW / 2300 rpm

D 2842LE 415 PE12 P120 A 520 LS 8525 M (S) 5EDC

P = 809 kW / 2100 rpm

D 2842 LE 416 PE12 P120 A 520 LS 8525 M (S) 5EDC

P = 809 kW / 2100 rpm

D 2842 LE 417 PE12 P120 A 520 LS 8525 M (S) 5EDC

P = 824 kW / 2300 rpm

D 2842 LE 419
P = 440 kW / 1800 rpm

45
 Dimensions
ServiceData
Limitingvalues

Starter

Manufacturer: Bosch
Type: KB
Operation: slidinggear type

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

D 2848 LXE standard

Output: 5,4 kW
Voltage: 24 V
Shortcircuit current: 1800 A
(at 20_C, battery capacity: 170 Ah,
feed line 1mW / m)

D 2848 LXE optional,

all D 2840 L.. / D 2842 L..
Output: 6,6 kW
Voltage: 24 V
Shortcircuit current: 1910 A
(at 20_C, battery capacity: 210 Ah,
feed line 1mW / m)

Power takeoff for hydraulic pump

Ø 52,000 − 52,046 mm

Pin diameter: 29,959 − 29,980 mm

Bearing bore: 30,020 − 30,041 mm

Speed of power takeoff:

engine speed x 1,26 (i = 0,791)

Backlash: 0,098 − 0,330 mm

46
 Dimensions
ServiceData
Limitingvalues

Vbelts / Powerband

Change damaged Vbelts (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
Installa
min. run running
tion
ning time time
2/3VX 90−100 80−90 60
3/3VX 135−150 120−135 90

Drive dog for angle drive

ø
9,96−9,969 mm

ø
9,991−10 mm

47
 Tighteningtorqueguidevalues
Drehmomentichtwerte
Retightening cylinder head bolts on new engines
(engine cold or warm)

The cylinder heads are mounted with cyl

Erster Nachzug der Zylinder inder head bolts which are tightened by
kopfschrauben erledigt the angleofrotation method. On new en
gines the cylinder head bolts are tight
First retightening of cylinder ened up for the first time at the factory af
headbolts completed ter the engine has been broken in.
The sticker First retightening of cylin
der head bolts ..." is then attached to
Spare part No. 51.978010211 one of the cylinder head covers.

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).

The two outer screws (intake and exhaust

1 4 sides) must not be retightened.

Note:
The cylinderhead bolts to be re
tightened must not be loosened;
they are to be tightened further
from their current position by 90°
(1/4 turn).
3 2

Exhaust side

Tightening diagram 1"

Remove the sticker First retightening

Zweiter Nachzug der Zylinder
kopfschrauben erledigt of cylinder head bolts ..." and attach the
sticker "Second retightening of cylinder
head bolts ..." to show that the cylinder
Second retightening of cylinder head bolts have been retightened for the
headbolts completed
second time.

Spare part No. 51.978010212

48
 Tighteningtorqueguidevalues

Tightening cylinder head bolts after a repair

(engine cold)

Intake side / injector Before inserting the cylinder head bolts oil
them with engine oil on the thread (not to
6 the bore) and coat the contact face of the
bolt head with Optimoly White T" assem
bly paste. Do not use any oils or oil addi
tives that contain MoS2. The bolts must be
1 4 tightened by the angleofrotation method
as shown in Tightening diagram 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.

Exhaust side

Tightening diagram 2"

Retightening cylinder head bolts after repairs

(engine cold or warm)
in accordance with SI 88 05 20/0

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 tight
ened by a further 90° (1/4 revolution) from their original 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.

49
 Tighteningtorqueguidevalues
Drehmomentichtwerte

Note:
All screws and bolts not listed in the following table must be tightened according
to the guiding values of MAN works standard N 269. Apply a light film of oil to all
screws and bolts before they are fitted!

Plugs
DIN 908
M 14 x 1,5, M 16 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
M 18 x 1,5, M 22 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
M 24 x 1,5, M 26 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
M 30 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
DIN 7604
AM 10 x 1, M 12 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
AM 14 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Crankcase, crankshaft assembly
Engine mounting to crankcase M 14, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Nm
Timing case to crankcase M 10, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Timing case to crankcase M 12 x 1,5, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
Thrust washer to timing case M 8, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Timing case cover to crankcase M 8, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Crankshaft bearing caps to crankcase M 18 x 2
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300−330 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100 °
Crankshaft main bearing caps (side)
Hex bolt M 12 x 1,5 x 85, 10.9 (06.01494−4316)
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°
Hex collar bolt M 12 x 1,5 x 85, 12.9 (51.90020−0382)
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180°
Counterweight to crankshaft M 14 x 1,5
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100−120 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100 °
Counterweight to crankshaft M 16 x 1,5
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140−160 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100 °
Vibration damper hub to crankshaft
Length of the bolt shank 75 mm, M16 x 1,5, 10.9 . . . . . . . . . . . . . . . . . . . 260 Nm
Length of the bolt shank 100 mm, M16 x 1,5, 10.9
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
1st rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100 °
2nd rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100 °
Flywheel to crankshaft M16 x 1,5 (see also pages 17, 19, 20)
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
1st rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100 °
2nd rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100 °

50
 Tighteningtorqueguidevalues

Crankcase, crankshaft assembly

Connecting rod bearing caps M16 x 1,5 or M14 x 1,5
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100−1 10 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100 °

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

Timing devices
Adjusting segment to camshaft gear M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Adjusting segment to intermediate gear M10 . . . . . . . . . . . . . . . . . . . . . . . . . 90 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
Oil pan to crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Plug (oil drain plug) in oil pan M26 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Oil jet flange to crankcase M14 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm

Exhaust / Intake manifolds

Exhaust manifold to cylinder head M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Intake pipe to cylinder head M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm

Fuel system
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 timing case M12 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Vbelt pulley on alternator M14 x 1,5 and M16 x 1,5 . . . . . . . . . . . . . . . . . . . 40−50 Nm
Vbelt pulley on alternator M24 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120−150 Nm

Power takeoff for raw water pump

Nut for drive gear on PTO shaft (punch lock after final tightening) . . . . . . 300−320 Nm

Power takeoff for hydraulic pump

Bolt for drive gear on PTO shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 Nm

51
 Flange
Tighteningtorqueguidevalues
Exhaustmanifold

Flange of exhaust manifold

3 8hole flange
Order of tightening:
1−2−3−4−5−6−7−8
8 6
or
2−1−4−3−6−5−8−7
Tightening: 100−1 10 Nm
Retightening after 1−2
hours of operation: 100−1 10 Nm

1 2

5 7

4hole flange
Order of tightening: crosswise
Tightening: according to Works Standard
M 3059, see page 54.

52
 Fixing
Tighteningtorqueguidevalues injectionpumps

Tightening torque values, injection pumps

D 2848 L.., D 2840 L..

qOrder of tightening: 1−2−3−4
4 in the steps:
2
1. initial torque: 10 Nm
2. initial torque: 50−55 Nm
3. final torque: 90_
1 Bracket tightening method effective only if
3 bolts of the strength class 8.8 (no more)
are used.

D 2842 L..
4 Order of tightening: 1−2−3−4−5−6
2 in the steps:
6
1. initial torque: 10 Nm
5 2. initial torque: 50−55 Nm
3. final torque: 90_
1
Bracket tightening method effective only if
3
bolts of the strength class 8.8 (no more)
are used.

53
 Tighteningtorqueguidevalues

Tightening torque values according to Works Standard M 3059

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

Thread size x pitch Grade / Tightening torque in Nm

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

54
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55
 Index

A O
Angle drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Oil filling capacities . . . . . . . . . . . . . . . . . . . . . . 12
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
C Oil pump feed rates . . . . . . . . . . . . . . . . . . . . . 11
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Compression pressures . . . . . . . . . . . . . . . . . . 11 P
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . 22 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Conrod bearing . . . . . . . . . . . . . . . . . . . . . . 22, 23 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Coolant filling capacities . . . . . . . . . . . . . . . . . . 12 Power take off . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 34
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 R
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Raw water pump . . . . . . . . . . . . . . . . . . . . . . . . 35
Crankshaft bearings . . . . . . . . . . . . . . . . . . . . . 15 Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cylinder head bolts . . . . . . . . . . . . . . . 16, 27, 48 S
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Start of delivery . . . . . . . . . . . . . . . . . . . . . . 41, 42
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
E Starter gear ring . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine coolant pump . . . . . . . . . . . . . . . . . . . . 34
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 T
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F Tightening torque guide values . . . . . . . . . . . . 49
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Timing diagram . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel supply pump . . . . . . . . . . . . . . . . . . . . . . . 11 Timing gear aarangement . . . . . . . . . . . . . . . . . 9

G V
Governer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Vbelt / Powerband . . . . . . . . . . . . . . . . . . . . . . 47
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . 10
I Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Injection pump . . . . . . . . . . . . . . . . . . . 43, 44, 45 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 40

L
Lubricating system . . . . . . . . . . . . . . . . . . . . . . 11

56