Man D 2876 le 101 Operating instructions

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Foreword

This Repair Manual is designed to facilitate proper repair of the engines listed here.

The pictures and associated 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.

It is compulsory that the engine be removed before performing any of the work described in this Repair

Manual.

The expert knowledge necessary for handling diesel engines was taken for granted when this publication

was compiled.

Note:

Only use fuel, coolants and lubricants in accordance with MAN regulations, otherwise the manu-

facturer’s liability for defects will not apply!

For basic information on the fuels see the publication “Fuels, Lubricants and Coolants for MAN

Diesel Engines”.

You can find the approved products on the Internet at:

−http://www.man-mn.com/ "Products & Solutions "E-Business−

Any repair of components such as injection pump, alternator etc. ought to be left to our or the

manufacturer’s service department.

Best regards

MAN Nutzfahrzeuge Aktiengesellschaft

Nuremberg Plant

Since our products are in continuous development, we reserve the right to make technical modifications.

2004 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, copying or translation, even of extracts, is not allowed without written permission from MAN.

All rights under the copyright law are strictly reserved by MAN.

MTDB Technical status: 05.2004 51.99598−8068

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Instruction

Important instructions concerning technical safety and personal protection are, as shown below, especially

highlighted.

Danger:

This refers to working and operating procedures which must be complied with in order to rule out

the risk to persons.

Caution:

This refers to working and operating procedures which must be complied with in order to prevent

damage to or destruction of material.

Note:

Explanatory descriptions which help in understanding the relevant work or operating procedure to

be carried out.

Fitting flat seals / gaskets

Gaskets are frequently used with sealants or adhesives as an aid to assembly or to achieve a better seal.

Above all when parts with different levels of thermal expansion (e.g. aluminium and cast iron) are bonded,

this can mean that the gasket is shifted during operation by the so-called stitching or sewing machine effect

and leaks occur.

Example: The cap of the front crankshaft seal. If a sealing agent or an adhesive is used here the flat seal

will move inwards in the course of time as a result of the different expansion rates of the materials. Oil will

be lost, for which the shaft seal may be thought to be responsible.

Perfect assembly of gaskets can only be achieved if the following instructions are adhered to:

DUse only genuine MAN seals / gaskets.

DThe sealing faces must be undamaged and clean.

DDo not use any sealing agent or adhesive −as an aid to fitting the seals a little grease can be used if

necessary so that the seal will stick to the part to be fitted.

DTighten bolts evenly to the specified torque.

Assembly of round sealing rings

DUse only genuine MAN round sealing rings.

DThe sealing faces must be undamaged and clean.

DAlways wet round sealing rings with engine oil before fitting them.

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Contents

Engine type classification 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety instructions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Table 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Notes on Engine Overhaul 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning after engine overhaul 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine views D 2876 LE 103 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication System Diagram 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System Diagram 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System Diagram 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Timing Arrangement Diagram 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel system

Checking and setting start of fuel delivery 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing injection pump 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing injection nozzles 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking injection nozzles 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel prefilter 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing fuel filter cartridge, venting fuel filter 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filter heating 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system

Draining and adding coolant 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing thermostats 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing coolant pump 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing coolant pump 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing coolant pump −New front end 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing coolant pump −New front end 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning cooling system 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication

Changing oil filter 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing oil cooler 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing oil pan 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remove / install crankcase yoke 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing / repairing oil pump 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing oil spray nozzle 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel / crankshaft seal

Removing and installing vibration damper, replacing front crankshaft seal 68. . . . . . . . . . . . . . . . . . . . .

Removing and installing flywheel, replacing starter ring gear 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing crankshaft seal (flywheel end) 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing bearing race 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft seals 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intake / exhaust system

Removing and installing intake manifolds 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing exhaust manifold 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger, troubleshooting 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking boost pressure 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing turbocharger 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring axial / radial clearance of turbocharger shaft 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wastegate 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder head

Removing and Installing Cylinder Head 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting valve clearance 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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