Man D 2866 LE 401 Operating instructions

1
Preface
This Repair Manual is designed to facilitate competent repair of the engines listed herein.
The pictures and relevant descriptions show typical work that may not always be applicable to the engine in
hand, which nevertheless does not mean that they are not correct. In such cases the repair work is to be
planned and carried out in a similar way.
The expert knowledge necessary for handling Diesel engines was taken for granted when this publication
was compiled.
Any repair of components such as injection pump, alternator etc. ought to be left to our or the manufactur-
er’s service department.
MAN Nutzfahrzeuge Aktiengesellschaft
Nuremberg Works
We reserve the right to make technical modifications in the course of further development.
1999 MAN Nutzfahrzeuge Aktiengesellschaft
Reprinting, copying or translation, even in the form of excerpts, is forbidden without the written permission
of MAN. MAN expressly reserves all rights in accordance with the law on copyright.
MTDA / 05.99 51.99493-8428

Contents
2
Page
Safety instructions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General information on the overhaul of engines 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble shooting table 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine views, D 2866 LE401 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic diagram of engine lubrication system 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic diagram of fuel system 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic diagram of cooling system 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system
Checking and adjusting start of fuel delivery 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing injection pump 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel injectors 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and repairing fuel injectors 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning fuel prefilter 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing fuel filter cartridges 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system
Draining and filling with coolant 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing thermostat 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing water pump 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing water pump 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing water pump 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and attaching expansion tank 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing heat exchanger 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning heat exchanger pipe set 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raw water pump 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication
Changing oil filter 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil cooler 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil pump 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil spray nozzle 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel / Crankshaft seal
Removing and installing vibration damper, changing front crankshaft seal 58. . . . . . .
Removing and installing flywheel, replacing gear ring 62. . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing crankshaft seal (flywheel end) 64. . . . . . . . . . . . . . . . . . . . . . .
Exchanging bearing race 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft seals 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake / exhaust system
Removing and installing intake manifold 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger, trouble shooting 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the charge-air pressure 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing turbocharger 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking axial and radial play of turbocharger rotor shaft 75. . . . . . . . . . . . . . . . . . . . .
Exchanging waste gate 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing intercooler 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
3
Cylinder head
Removing and installing cylinder head 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting valve clearance 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembling and assembling rocker arms 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing valves 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing valve guides 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing valve seat insert 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reworking valve seat 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refacing valves 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking compression 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve timing
Removing and installing timing case 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft, exchanging camshaft bearing 99. . . . . . . . . . . . . .
Checking valve timing 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankgear, pistons
Removing and installing crankshaft 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing piston with connecting rod 105. . . . . . . . . . . . . . . . . . . . . . . . . . .
Detaching piston from and attaching to connecting rod
checking - changing connecting rod 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, installing and changing piston rings 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing cylinder liners 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring piston protrusion 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing starter 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belts 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant level probe 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attachments
Special tools 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety instructions
4
General information
This brief overview summarises important instructions and is structured into areas of main concern in order
to impart the knowledge necessary to prevent accidents involving injury to persons, damage to the engine
or other property and harm to the environment. Additional notes are included in the operator’s manual for
the engine.
Important: If despite all safety precautions an accident occurs as a result of contact with caustic acids,
penetration of fuel into the skin, scalding with hot oil, anti-freeze splashes into the eyes etc, consult a doc-
tor immediately!
1. Instructions for preventing accidents with injury to persons
Checks, setting jobs and repair work must be carried out by authorised skilled personnel only.
DWhen carrying out maintenance and repair work, ensure that the engine cannot be ac-
cidentally started from the bridge by unauthorised persons.
DThe engine must be started and operated by authorised personnel only.
DWhen the engine is running, do not get too close to revolving components. Wear tight-
fitting working clothes.
DDo not touch hot engine with bare hands: risk of burning yourself.
ËË
DKeep engine vicinity, ladder and steps free of oil and grease. Accidents resulting from
slipping may have serious consequences.
DWork only with tools that are in good condition. Worn spanners slip: risk of injuries.
DPersons must not stand under an engine suspended from a crane hook. Keep lifting
gear in good order.
DOpen coolant circuit only after the engine has cooled down. If opening the coolant cir-
cuit while the engine is hot is unavoidable, observe the instructions in the chapter
”Maintenance and care” in the Operator’s Manual.
DNeither retighten nor open pressurised pipelines and hoses (lube oil circuit, coolant cir-
cuit and downstream hydraulic oil circuit if fitted): risk of injuries resulting from emerging
fluids.

Safety instructions
5
DWhen checking the injection nozzles, do not hold your hands in the fuel jet. Do not in-
hale fuel mist.
DWhen working on the electrical system, unplug earth cable from battery first and recon-
nect it last to avoid short-circuits.
DObserve the manufacturer’s instructions for handling batteries.
Caution:
Battery acid is toxic and caustic. Battery gases are explosive.
DWhen carrying out welding work, observe the ”Information sheets for welders”.

Safety instructions
6
2. Instructions for preventing damage to the engine and premature wear
DPrior to repairing the engine, clean it thoroughly. Ensure that dirt, sand or foreign matter will
not get into the engine during repair work.
DIn the event of operational faults immediately identy the cause and rectify to prevent more serious dam-
age.
DAlways use genuine MAN parts only. Installation of ”equally” good parts from other suppliers may cause
severe damage for which the workshop carrying out the work is responsible.
DNever operate the engine while it is dry, i.e. without lubricant or coolant.
Use a suitable label to mark engines not ready for operation.
DOnly use operating materials (fuel, engine oil, antifreeze and anticorrosion agents) approved by MAN.
Ensure that everything is kept clean. Diesel fuel must be free of water.
DDo not fill up with engine oil above the max. notch on the dipstick. Do not exceed the engine’s
maximum permissible operating inclination.
Non–compliance with these instructions may cause severe engine damage.
DControl and monitoring devices (charge check, oil pressure, coolant temperature) must work faultlessly.
DObserve the instructions for operating the alternator; see chapter ”Commissioning and operation” in the
Operator’s Manual.
3. Instructions for preventing environmental damage
Engine oil and filter cartridges and elements, fuel/fuel filters
DTake old oil to an old oil disposal point only.
DEnsure without fail that oil and Diesel fuel will not get into the sewerage system or the ground.
Caution:
Danger of contaminating potable water!
DTreat filter elements and cartridges as special waste.
Coolant
DTreat undiluted anticorrosion and/or antifreeze agents as special waste.
DThe regulations of the relevant local authorities are to be observed for the disposal of spent coolants.

Safety instructions
7
4. Instructions for handling used engine oil *
Prolonged or repeated contact of any kind of engine oil with the skin causes the skin to degrease, which
may result in dryness, irritation or inflammation. Old engine oil also contains hazardous substances which
in animal experiments have caused skin cancer. Handling old engine oil does not pose any health hazard if
the basic safety and hygiene related regulations are observed.
Health and safety regulations:
DAvoid prolonged, excessive or repeated contact of old engine oil with the skin.
DUse a suitable skin protection agent or wear protective gloves.
DClean the skin that has been in contact with engine oil.
– Wash yourself thoroughly with soap and water. A nailbrush is an effective aid.
– Special hand cleaning agents facilitate cleaning soiled hands.
– Do not use petrol, Diesel fuel, gas oil, fluxes or solvents as cleaning agents.
DAfter washing apply moisturising handcream to your skin.
DChange oil-soaked clothes and shoes.
DDo not put any oil-soaked cloths into pockets.
Pay meticulous attention to the proper disposal of old engine oil.
– Old oil is a water hazard –
Therefore, do not pour any old oil into the ground, the drains or the sewerage system. Any violation of this
rule is punishable.
Collect and dispose of old engine oil properly. For information concerning collection points, contact seller,
supplier or the local authorities.
∗Based on the ”Merkblatt für den Umgang mit gebrauchtem Motorenöl”
(Notes on how to handle old engine oil).

General information on the overhaul of engines
8
Very different factors have an influence on the life expectancy of an engine. For this reason it is not pos-
sible to give certain predetermined numbers of operating hours for basic overhauls.
Regular interim inspections and overhauls frequently carried out on large engines (e.g. on those from MAN
Augsburg) are generally not necessary on MAN Diesel engines from the MAN Nuremberg works.
In our opinion, opening an engine or carrying out a basic overhaul is not appropriate as long as the engine
achieves good compression values and the following operating values measured and recorded and have
not changed significantly since commissioning:
DCharge-air pressure
DExhaust-gas temperature
DCoolant and lube-oil temperature
DOil pressure and oil consumption
DFormation of smoke
The following criteria have a major influence on the life expectancy of an engine:
DCorrect output setting according to the type of operation.
DExpert installation in accordance with the installation instructions.
DInspection of the installation by authorized personnel.
DRegular maintenance as per maintenance plan
DSelection and quality of lube oil, fuel and coolant as specified in the publication
”Fuels, Lubricants, Coolants for Industrial and Marine Diesel Engines”.

Trouble shooting table
9
Faults and possible causes
We recommend
Repair work is to be considered complete only after the damage which has occurred and the possible
causes have been eliminated. Ascertaining the causes of damage is frequently more difficult than eliminat-
ing the damage caused. For this reason we recommend you have the operational fault exactly described to
you before removal or disassembly work is commenced. Then, track down the probable causes by asking
specific questions, examining and eliminating these causes one by one with the aid of the table and your
own experience. This helps to reduce repairs to those necessary and counter complaints about ”prema-
ture” exchange of parts and expensive working and downtimes.
Remark:
The subsequent list is meant to be a memory aid so that no causes of damage will be overlooked in the
elimination of faults. The precondition for this, however, is that you are familiar with the Repair Manual for
the engine and the relevant Operating Instructions as well as the publication ”Fuels, Lubricants, Coolants
for Industrial and Marine Diesel Engines”.

Trouble shooting table
10
Fault Probable cause Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
Starter does not crank
the engine or only too
slowly
DBattery main switch in ”off” position
DBatteries flat
DCrankgear blocks
DBattery cable connections loose or cor-
roded
DStarter electromagnetic switch sticking
(clicks)
DCable connection from ignition lock to
starter electromagnetic switch is loose
or interrupted
DStarter electromagnetic switch faulty
DStarter defective (carbon brushes loose,
winding faulty, short-circuit to earth)
DEngine oil viscosity not suitable
DStarter interlock relay defective
DKnock on the magnet
DCheck with check lamp
DSee ”Fuels, Lubricants ...”
DChecking: Connect terminals
50e and 50f
Engine does not start DFuel tank empty
DFuel valve shut
DCut-off solenoid in “STOP” position
DAir in fuel system
DFuel lines leaky, ruptured, clogged
DFuel filter / prefilter clogged
DSuction height of fuel delivery pump
(max. 1m) exceeded
DFuel delivery pump faulty
DAir supply/exhaust gas pipes clogged
DUnsuitable fuel
DDelivery start incorrect
DValve clearance incorrect
DInjection nozzles worn
DCompression insufficient
Engine does not start
while cold
DFuel filter clogged with paraffin
DEngine oil viscosity unsuitable
see: ”Engine does not start”
DSee ”Fuels, Lubricants ...”
Engine does not run
smoothly, and stops
DLower idle speed set too low
DAir in fuel system
DFuel lines leaky, ruptured, clogged
DFuel filter clogged
DInlet chamber pressure of injection
pump too low
DFuel high-pressure part leaky
DInjector needle sticking
DDelivery start set incorrectly
DInjection pump set incorrectly or
defective
DValve clearance incorrect
DCompression insufficient
DRemedy by Bosch Service

Trouble shooting table
11
Fault Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
Probable cause
Engine speed variations
during operation
DToo little fuel in fuel tank
DAir in fuel system
DFuel lines leaky
DFuel high-pressure part leaky
DInjection nozzles defective, worn
DSpeed governor defective DRemedy by Bosch Service
Engine cannot be
stopped
DCut-off linkage bent or jammed
DCut-off solenoid without voltage
DInjection pump set incorrectly or
defective
DRemedy by Bosch Service
Performance unsatis-
factory, max. boat
speed is not reached
DEngine speed adjusting lever not in
full-load position
DIncrustation of hull, shaft system and
propeller with foreign matter
DPropeller consumes too much power,
nominal speed is not reached
DPropeller consumes too much power,
engine runs in the breakaway range
DFlow of water on to the propeller insuffi-
cient
DFuel temperature too high
DUnsuitable, contaminated fuel
DFuel filter clogged
DAir in fuel system
DLack of fuel
DTemperature in engine room too high,
combustion air and fuel too hot
DSupply of combustion air insufficient,
intake vacuum too high
DCharge-air pipes leaky
DIntercooler contaminated
DTurbocharger contaminated or defective
DCompression insufficient
DInjection pump and / or governor
defective
DRoute the ship-mounted fuel
lines well apart from the hot en-
gine parts.
DSee ”Fuels, Lubricants ...”
DCheck fuel lines and delivery
pump
DCheck inward and outward ven-
tilation
DCheck intake air supply to air
filters
DRemedy by Bosch Service

Trouble shooting table
12
Fault Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
Probable cause
Coolant temperature
too high, coolant loss
DCoolant level too low
DAir in coolant circuit
DProportion of anti-freeze / anticorrosion
agent too high
DRaw water supply clogged
DRaw water supply insufficient
DCap with working valves on expansion
tank defective, leaky
DThermostat in closed position blocked
DHeat exchanger heavily contaminated,
pipe group coated with foreign matter
DV-belt for water pump drive not correctly
tensioned (slipping)
DWater pump leaky, defective (bearing
damage)
DCoolant circuit clogged by foreign matter
DThermostat jammed in ”shut” position
DSee ”Fuels, Lubricants ...”
DCheck inlet orifice
DImpeller worn. Measure delivery
of raw water pump and vacuum
at inlet
Lube oil pressure
varies/too low
DOil level in oil pan too low
DOil level in oil pan too high
DMax. inclination exceeded
DEngine temperature too high
DOil viscosity unsuitable (viscosity too
low)
DOil in oil pan too thin (mixed with con-
densation or fuel)
DHeavy bearing wear
DOil pump gears heavily worn
DSafety valve in oil circuit defective (does
not shut, spring fatigued or broken)
DOil pressure gauge defective
DDipstick marked correctly?
See Operator’s Manual
DSee ”Fuels, Lubricants ...”
Lub oil pressure too
high
DEngine cold
DOil viscosity unsuitable (viscosity too
high)
DSafety valve in oil circuit defective (does
not open)
DOil pipes/oil galleries clogged
DOil pressure gauge defective
DSee ”Fuels, Lubricants ...”
Lube oil consumption
too high
DLeaks in the lube oil circuit, particularly
at the turbocharger and oil cooler
DOil level in oil pan too high
DLube oil quality does not satisfy regula-
tions
DTurbocharger wear
DPiston rings heavily worn
DValve guides heavily worn
DSee ”Fuels, Lubricants ...”
DMeasure play of rotor

Trouble shooting table
13
Fault Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
Probable cause
Fuel consumption too
high
DConstant full-load operation
DSpeed resistance owing to incrustation
of hull, shaft system and propeller with
foreign matter
DPoor efficiency of the drive system
DFuel quality does not satisfy regulations
DFuel leaks in the system
DHigh power requirements by additional
units (hydraulic pumps, compressors
etc)
DDelivery start set incorrectly
DInjection pump set incorrectly or defec-
tive
DValve clearance incorrect
DIntake vacuum / exhaust backpressure
too high
DInjection nozzles worn
DAdjust propeller
DSee ”Fuels, Lubricants ...”
DRemedy by Bosch Service
Black smoke DLack of combustion air, intake vacuum
too high
DEngine speed reduction owing to the
propeller’s taking up too much power
DSudden full load after long low load or
idling periods
DAir filter contaminated
DLeaks in air pipes downstream of com-
pressor
DDiaphragm in wastegate leaky
DIntercooler leaky, defective
DUnsuitable fuel
DTurbocharger defective
DDelivery start set incorrectly
DInjection nozzles defective, coked
DInjection pump set incorrectly or
defective
DExhaust backpressure too high
DCheck intake air supply to air fil-
ters (engine room ventilation)
DSee ”Fuels, Lubricants ...”
DRemedy by Bosch Service
Blue smoke DEngine coolant/intake air still too cold
DMainly low-load operation
DPiston rings worn or broken
DValve guides worn
DCrankcase breather clogged (overpres-
sure in crankcase)
White smoke DEngine coolant/intake air still too cold
DWater evaporates in exhaust gas pipe
during raw water injection
DDelivery start set incorrectly
DCylinder head gasket leaky/burned
through
DFuel quality does not satisfy regulations
DInjection nozzles defective
DInjection pump set incorrectly or
defective
DSee ”Fuels, Lubricants ...”
DRemedy by Bosch Service

Trouble shooting table
14
Fault Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
Probable cause
Vibrations, droning
noise, structure-borne
sound
DDrive system not or inaccurately aligned
DUnsuitable clutch
DUnsuitable engine/gearbox mounts
DElastic mounts unequally loaded (height
adjustment)
DPropeller shaft unbalanced
Engine knocks DEngine in cold running phase
DDelivery start set incorrectly
DInjector needle sticking
DHigh load at low speed
DFuel is slow to ignite
DCompression too low
Engine is too loud DIntake or exhaust gas pipe leaky
DValve clearance too large
DV-belt slipping
DTiming gears worn, backlash of teeth
too large

Trouble shooting table
15
Fault Remedy
(This column is filled in only if the
”probable cause” gives no clue as
to what must be done).
Probable cause
Starter
DPinion does not turn
or turns too slowly
DPinion does not
engage
DPinion engages but
stops
DPinion continues to
run after starter
switch has been
released
DPinion does not
disengage after
successful start
DBattery insufficiently charged
DTerminals loose or oxidised, poor earth
connection
DTerminals or carbon brushes have short-
circuit to earth
DCarbon brushes are stuck or have poor
contact
DPinion or starter gear ring heavily con-
taminated or damaged
DElectromagnetic switch defective
DOne-way clutch slips
DStarter switch defective
DElectromagnetic switch defective
DStarter defective DSwitch off engine immediately
Alternator
DAlternator check
lamp does not come
on when engine is
stationary and starter
switch is switched on
DAlternator check
lamp brightly ilumi-
nated when engine is
running
DAlternator check
lamp brightly ilumi-
nated when engine is
stationary, dimmer or
glowing when engine
is running
DBattery does not
charge up
DCheck lamp burnt out
DBattery discharged
DTerminal clamps loose or oxidised
DRegulator defective
DShort-circuit in alternator
DCarbon brushes worn
DCable D+ has short-circuit to earth
DRegulator defective
DRectifier damaged, slip rings dirty
DV-belt slipping or cracked
DResistance in cable between alternator
and battery is too high, terminal clamps
oxidised
DRegulator defective
DAlternator defective
DCable between alternator and battery
interrupted
DBattery defective
DAlternator defective
DV-belt slipping
DChange regulator
DRepair in specialist workshop
DChange regulator
DRepair in specialist workshop
DChange regulator
DRepair in specialist workshop
DRepair in specialist workshop

Engine views, D 2866 LE401
16

Engine views, D 2866 LE401
17

Cross section of engine
18

Longitudinal section
19