Foreword

The purpose of this publication is to inform you about the checking values, setting data and technical de-
tails of MAN’s 6-cylinder high−performance marine Diesel engines.

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

Instructions
Important instructions which concern technical safety and protection of persons are emphasised as shown
below.

Danger:
This refers to working and operating procedures which must be complied with so as not to en-
danger 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:
Explanations that are useful for understanding the working or operating procedure to be per-
formed.

MAN Truck & Bus AG

Nuremberg Works

We reserve the right to make technical modifications in the course of further development.
© 2011 MAN Truck & Bus AG
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.
EMDGG Technical status: 07.2004 51.99493−8402

1
 Contents

Page

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Basic knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Technical information
Technical features in summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Checking and setting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Service Data
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Start of delivery (marine propulsion engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Injection pumps and governers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Tightening torque guide values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2
 Basic knowledge

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 2866 LXE 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.

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

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

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

“intercooling”.

X The letter “X” represents a development and power stage.

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

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

4.. This is a internal MAN development number. This engine generation was
launched at the beginning of 1994 with modified turbocharger tuning and
governor characteristic.

3
 Basic knowledge

A brief history

The idea of developing a high power-density marine Diesel engine specifically suitable
for light and fast hydroplanes had already become reality at the beginning of the
eighties in the form of the D 2566 MLE.

As its classification shows, this engine is a 6-cylinder model with a bore of 125 mm
and a stroke of 155 mm, making a swept volume of 11,41 l. With intercooling the
engine was able to develop 250 kW (340 hp) at 2200 rpm.

Widening the bore to 128 mm and employing a modified injection process gave birth
to the 300 kW (408 hp) model D 2866 LE. The total swept volume was thereby
increased to 11,97 l.

At the end of the eighties the output of the D 2866 LXE engine was increased to
324 kW (440 hp). The rated speed remained unchanged at 2200 rpm.

In 1994 drastic modifications were necessary to comply with the call for even more
power at an unaltered piston displacement and a comparably low weight. An increase
to 441 kW (600 hp) was achieved for the D 2866 LE401 engine through improving
intercooling and increasing charge-air pressure.

Comprehensive flanking measures were introduced at this stage in evolution to ensure

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

Worthy of mention in this context are:

D Load-dependent charge-air temperature control for eliminating the

formation of white smoke in the low-load range.
D Turbocharger with wastegate for increasing the torque in the lower speed
range at improved exhaust emission.
D Engine speed governor with charge-pressure dependent full-load stop
D RQV-K governor for increased tractive power at low speeds.

These measures also contribute to keeping the stresses on the engine within limits
despite high outputs, extending the engine service life and enhancing engine reliability.

4
 Technical features in summary

General engine data D 2866 LXE / LE 4..

Mode of operation four-stroke, Diesel
Combustion process direct injection
Design 6 cylinders in-line
Bore / stroke 128 / 155 mm
Swept volume 11,967 l
Compression ratio 15,5 : 1
Rotation viewed from flywheel anti-clockwise
Firing order 1−5−3−6−2−4−1
Firing interval 120_
Engine rating see model plate
Rated speed see model plate

General engine data D 2876 LE 301 / 403

Mode of operation four-stroke, Diesel
Combustion process direct injection
Design 6 cylinders in-line
Bore / stroke 128 / 166 mm
Swept volume 12,816 l
Compression ratio 15,5 : 1
Rotation viewed from flywheel anti-clockwise
Firing order 1−5−3−6−2−4−1
Firing interval 120_
Engine rating see model plate
Rated speed see model plate

5
 Technical features in summary

1 2 3 4

9 8 7 6

10 11 12 13

14 15

6
 Technical features in summary

Taking the 6-cylinder D 2866 LE401 engine as an example, we shall explain the com-
ponents of the engine singly using the adjacent drawing.

1 Coolant expansion tank

2 Sea water-cooled intercooler

3 Fuel filter

4 Air filter

5 Waste Gate

6 Fuel return line

7 Fuel supply line

8 Three-way control valve for controlling the charge-air temperature

9 Sea water pump

10 Pressure relief valve at the coolant expansion tank

11 Heat exchanger

12 Exhaust manifold, water-cooled

13 Turbocharger, water-cooled

14 Coolant filler neck

15 Oil separator valve of crankcase breather

7
 Timing gear

Timing gear arrangement

2 3

1 Crankshaft gear 4 Drive gear, camshaft

2 Drive gear, oil pump 5 Intermediate gear
3 Oil pump supply gear 6 Drive gear, injection pump

8
 Checking and setting values

Valve train
The checking values are valid for all engines dealt with in this publication
Valve clearance inlet 0,50 mm " 0,05 mm
(when engine is cold)
exhaust 0,50 mm " 0,05 mm

Why valve clearance?

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

Valve clearance too small:

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

Valve clearance too large:

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

Timing diagram
1
1 Direction of engine rotation 2
TDC
3
(viewed from V-belt pulley)

2 Inlet opens 23_ before TDC

3 Exhaust closes 30_ after TDC
4 Exhaust opens 60_ before BDC
5 D 2866 LE 4..: Inlet closes 37_ after BDC 6 7
D 2876 LE 301 / 403:
Inlet closes 37_ after BDC
D 2866 LXE: Inlet closes 12_ after BDC
6 Exhaust open for 270_ 4
7 Inlet open for 240_

Figures in degrees refer to the 5

crankshaft angle BDC

Valve lift: 14 mm
(intake / exhaust)

9
 Checking and setting values

Compression pressures
good bar over 28
permissible bar 25−28
in need of repair bar under 24
pressure difference bar max. 4
(between individual cylinders)

Fuel system
Delivery rate of fuel supply pump D 2866 LXE D 2866 LE4..
n = 2200 rpm l/h 150 250
Delivery rate of fuel supply pump D 2876 LE 301 D 2876 LE 403
n = 1500 rpm l/h 310
n = 1800 rpm l/h 315 229
Opening pressure of overflow valve (all engine models)
at injection pump bar 1,3−1,8

Lubricating system
Oil pump feed rates:
The rotation speeds are those of the pumps.
Oil pump speed: engine speed x 0.977 (i = 1.023)
(Feed rates with SAE 20 oil at 90_C and 6 bar.)
Oil pump (width of gear 34mm)
n = 635 rpm l / min 28
n = 2150 rpm l / min 130
Oil pump (width of gear 43mm)
n = 635 rpm l / min 40
n = 2150 rpm l / min 155
Oil pump (for oil pan with max. permissible inclination of 30 degrees)
n = 635 rpm l / min 63
n = 2150 rpm l / min 250

Valve opening pressures in lubricating oil circuit:

Bypass valve for oil filter
Opening pressure bar 2
Closing pressure bar 4
Oil pump pressure regulating valve bar 9−10
Pressure valve of oil spray jets
Opening pressure bar 1,9−2,1
Closing pressure bar 1,4−1,6

10
 Capacities

Oil filling capacities

Engine model Oil pan Min. capacity Max. capacity

D 2866 L.. deep 14 l 18 l

D 2866 L.. flat 16 l 20 l

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

30 degrees

D 2876 L.. deep 26 l 30 l

Coolant
Engine with heat exchanger Litres
D 2866 LE 4.. 58
D 2876 LE 301 / 403 58

11
 Dimensions
Service Data
Limiting values

Crankcase
153,90−153,94 mm standard
for cylinder liners with 0,5 and 1,0 mm
outside diameter
154,40−154,44 mm
Ø

Ø 145,80−145,84 mm standard
for cylinder liners with 0,5 mm larger out-
side diameter
146,30−146,34 mm
for cylinder liners with 1,0 mm larger out-
side diameter
146,80−146,84 mm

9,955−10,025 mm

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

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

10,05−10,07 mm standard
10,55−10,57 mm with 0,5 mm more
flange height
Max. permissible cylinder liner protrusion:
0,005
0,03−0,08 mm
145,761−145,786 mm standard
146,261−146,286 mm with 0,5 mm
larger outside diameter
146,761−146,786 mm with 1,0 mm
Ø
larger outside diameter

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

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

12
 Dimensions
Service Data
Limiting values

Crankshaft

Crankshaft front end (opposite end to flywheel)

99,985−100,020 mm

89,98−90,00 mm standard size

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

103,98−104,00 mm standard size

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

max. axial clearance of crankshaft:

0,190−0,322 mm

Bearing race for crankshaft, front end

Inner diameter:
99,907−99,942 mm

13
 Dimensions
Service Data
Limiting values

Thrust bearing journal

46,000−46,062 mm standard size

46,500−46,562 mm undersize 0,25
46,500−46,562 mm undersize 0,50
47,000−47,062 mm undersize 0,75
47,000−47,062 mm undersize 1,00

Mounting bolts for crankshaft bearing caps

Length: During tightening the bolts are

intentionally stressed beyond the yield
100 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.
new: 152,5−153
max. 154,5 mm

Main bearing

Data for wall thickness and bearing

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

Spread: 0,3−1,2 mm

Marking:
top / bottom
0005 / 0093 standard size
0011 / 0095 undersize 0,25
0013 / 0096 undersize 0,50
0015 / 0097 undersize 0,75
0017 / 0098 undersize 1,00

14
 Dimensions
Service Data
Limiting values

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

15
 Dimensions
Service Data
Limiting values

Flywheel (SAE #14)

Ø Flywheel:
432,490−432,645 mm

Starter gear ring, inside diameter:

432,000−432,155 mm

Interference: 0,335−0,645 mm
Installation temperature: 200−230_C

Ø
m = 52,9 kg (with starter gear)
J = 2,003 kgm2

Number of teeth: Z = 160, Modulus 3

Matching gear: Starter pinion
Number of teeth: 9

Backlash: 0,6−0,9 mm

16
 Dimensions
Service Data
Limiting values

Flywheel for cardan-shaft coupling

Ø Flywheel:
432,490−432,645 mm

Starter gear ring, inside diameter:

432,000−432,155 mm

Installation temperature: 200−230 deg.C

m = 32,5 kg (with starter gear)

Ø
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

17
 Dimensions
Service Data
Limiting values

Connecting rods

46,055−46,065 mm

Ø 0,02 A

A Bearing bore in directions 1, 2 and 3 and

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

Conrod bearing

2,468−2,478 mm standard size

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

Connecting rod bolt

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

18
 Dimensions
Service Data
Limiting values

Connecting rods

46,055−46,065 mm

Ø
Ø 0,02 A
A

Bearing bore in directions 1, 2 and 3 and

1 8 mm 8 mm in planes a and b:

90,075−90,120 mm
2
a b
3 Pre-condition:
new big-end bearing in place,
conrod assembled

Conrod bearing

2,468−2,478 mm standard size

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

Connecting rod bolt

Length: During tightening the bolts are
intentionally stressed beyond the yield
point and therefore subjected to some
permanent elongation each time they are
tightened.

Torx bolt M14x1.5

19
 Dimensions
Service Data
Limiting values

Piston 51.02511-0055
Compression height: 89,70−89,75 mm
with undersize
0,2 mm: 89,50−89,55 mm
0,4 mm: 89,30−89,35 mm
0,6 mm: 89,10−89,15 mm
Piston protrusion above crankcase top:
0,013−0,331 mm
Ø
46,003−46,009 mm
Piston pin diameter:
45,994−46,000 mm
Ø
127,850−127,880 mm
27

Max. difference in weight per

engine piston set: max. 100g

Piston ring grooves

1,5
3,195−3,225 mm

I
3,040−3,060 mm
II

III 5,020−5,040 mm

Piston rings
1,5

I 1st. ring−keystone-type ring:

height: 3,075−3,095 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: 4,978−4,990 mm
axial play: 0,030−0,062 mm

Ring gap:
1st. ring: 0,35−0,55 mm
2nd. ring:
(Goetze) 0,45−0,70 mm
(Riken) 0,40−0,65 mm
3rd. ring: 0,25−0,40 mm

20
 Dimensions
Service Data
Limiting values

Piston 51.02511-0177
Compression height: 89,70−89,75 mm
with undersize
0,2 mm: 89,50−89,55 mm
0,4 mm: 89,30−89,35 mm
0,6 mm: 89,10−89,15 mm
Piston protrusion above crankcase top:
0,013−0,331 mm
Ø
46,003−46,013 mm
Piston pin diameter:
45,994−46,000 mm
Ø
127,840−127,880 mm
27

Max. difference in weight per

engine piston set: max. 100g

Piston ring grooves

1,5
3,195−3,225 mm

I
3,040−3,060 mm
II

III 5,020−5,040 mm

Piston rings 1,5

I 1st. ring−keystone-type ring:

height: 3,075−3,095 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: 0,35−0,55 mm
or 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

21
 Dimensions
Service Data
Limiting values

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

Max. difference in weight per

engine piston set: max. 100g

Piston ring grooves

2,5
2,935−2,965 mm

I
3,040−3,060 mm
II

III 5,020−5,040 mm

Piston rings 2,5

I 1st. ring−keystone-type ring:

height: 2,796−2,83 mm

II 2nd. ring−taper face ring:

height: 2,978−2,990 mm
axial play: 0,050−0,082 mm
III
3rd. ring−bevelled ring:
height: 4,978−4,990 mm
axial play: 0,030−0,062 mm

Ring gap:
1st. ring: 0,35−0,55 mm
or 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

22
 Dimensions
Service Data
Limiting values

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

Max. difference in weight per

engine piston set: max. 100g

Piston ring grooves

2,5
3,695−3,725 mm

I
3,040−3,060 mm
II

III 4,020−4,040 mm

Piston rings 2,5

I 1st. ring−keystone-type ring:

height: 3,296−3,330 mm

II 2nd. ring−taper face ring:

height: 2,978−2,990 mm
axial play: 0,050−0,082 mm
III
3rd. ring−bevelled ring:
height: 3,975−3,990 mm
axial play: 0,030−0,065 mm

Ring gap:
1st. ring: 0,5−0,7 mm
2nd. ring:
(Goetze) 0,45−0,70 mm
(Riken) 0,40−0,65 mm
3rd. ring: 0,25−0,55 mm

23
 Dimensions
Service Data
Limiting values

Piston 51.02511-0374
Compression height: 89,70−89,75 mm
with undersize
0,2 mm: 89,50−89,55 mm
0,4 mm: 89,30−89,35 mm
0,6 mm: 89,10−89,15 mm
Piston protrusion above crankcase top:
0,013−0,331 mm
Ø
46,008−46,016 mm
Piston pin diameter:
45,994−46,000 mm
Ø
127,960−127,990 mm
27

127,1−127,15 (oval)
Max. difference in weight per
engine piston set: max. 100g

Piston ring grooves

2,5
3,470−3,500 mm

I
3,050−3,070 mm
II

III 4,020−4,040 mm

Piston rings 2,5

I 1st. ring−keystone-type ring:

height: 3,296−3,330 mm

II 2nd. ring−taper face ring:

height: 2,978−2,990 mm
axial play: 0,050−0,082 mm
III
3rd. ring−bevelled ring:
height: 3,975−3,990 mm
axial play: 0,030−0,065 mm

Ring gap:
1st. ring: 0,5−0,7 mm
2nd. ring: 0,45−0,70 mm
3rd. ring: 0,25−0,55 mm

24
 Dimensions
Service Data
Limiting values

Piston 51.02511-0537 (D 2876 LE 301 / 403)

Compression height: 79,20−79,25 mm
with undersize
0,2 mm: 79,00−79,05 mm
0,4 mm: 78,80−78,85 mm
0,6 mm: 78,60−78,65 mm
Piston protrusion above crankcase top:
0,013−0,331 mm
Ø
50.032−50,058 mm
Piston pin diameter:
49,994−50,000 mm
Ø
127,838−127,872 mm
20

Max. difference in weight per

engine piston set: max. 100g

Piston ring grooves

2,5
3,445−3,475 mm

I
3,040−3,060 mm
II

III 4,020−4,040 mm

Piston rings 2,5

I 1st. ring−keystone-type ring:

height: 3,296−3,330 mm

II 2nd. ring−taper face ring:

height: 2,978−2,990 mm
axial play: 0,050−0,082 mm
III
3rd. ring−bevelled ring:
height: 3,975−3,990 mm
axial play: 0,030−0,065 mm

Ring gap:
1st. ring: 0,5−0,7 mm
2nd. ring: 0,45−0,70 mm
3rd. ring: 0,25−0,55 mm

25
 Dimensions
Service Data
Limiting values

Cylinder head

Ø 12,000−12,018 mm Intake valve guide

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

17,1−17,5 mm

Intake valve ö = 60_

ö b
Exhaust valve b = 45_

a = 3,3−3,8 mm
a b b = 3,3−3,8 mm

Valve guide bore in cylinder head:

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

standard: 113,9−114 mm
minimum: 112,9 mm
(observe specified dimensions for valve
recess and injector projection)

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

Valve seat insert bore in cylinder head:

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

26
 Dimensions
Service Data
Limiting values

Cylinder head bolts

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.
Angle-of-rotation symbol

51.90020−0268 and 51.90490−0022

new: 167,5−168 mm, max. 170 mm
51.90020−0269 and 51.90490−0023
new: 143,5−144 mm, max. 146 mm
51.90020−0270 and 51.90490−0024
new: 108,5−109 mm, max. 111 mm

Valve recess

Valve recess for intake and exhaust

valve:
0,7−1,3 mm

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

Valve springs:

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

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

Valve cone face: 3,3−4,3 mm

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

27
 Dimensions
Service Data
Limiting values

Inlet valve D 2876 LE 301 / 403

11,968−11,982 mm
Ø

Valve springs:

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

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

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

Valve springs:

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

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

Valve cone: 3,97−4,0 mm

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

28
 Dimensions
Service Data
Limiting values

Exhaust valve D 2876 LE 301 / 403

Ø 11,945−11,955 mm

Valve springs:

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

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

29
 Dimensions
Service Data
Limiting values

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

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:
0,128 mm−0,252 mm

30
 Dimensions
Service Data
Limiting values

Camshaft bearing

Ø 70,000−70,030 mm

Valve tappet

Matching bore in crankcase:

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

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

31
 Dimensions
Service Data
Limiting values

Oil pump

Oilpump for deep and flat oil pans

(width of gear: 34 mm)

Oil pump gear

Shaft: 17,930−17,940 mm
Ø Matching bore in housing:
18,000−18,018 mm
Radial clearance: 0,060−0,088 mm

Housing depth: 34,000−34,039 mm

Gear axial clearance: 0,050−0,128 mm
33,911−33,950 mm
14,5 mm

Drive gear with oil pump gear

14,5 mm

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

0,5 mm

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

32
 Dimensions
Service Data
Limiting values

Oilpump for deep and flat oil pans

(width of gear: 43 mm)

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

Gear axial play: 0,050−0,128 mm
42,911−42,950 mm
11,5−11,7 mm

Drive gear with oil pump gear

11,5−11,7 mm

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

0,5 mm

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

33
 Dimensions
Service Data
Limiting values

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

Oil pump gear

Shaft: 17,930−17,940 mm
Ø Matching bore in housing:
18,000−18,018 mm
Radial clearance: 0,060−0,088 mm

Housing depth: 34,000−34,039 mm

Radial clearance: 0,050−0,128 mm
33,911−33,950 mm
14,5 mm

33,911−33,950 mm

40,8−41,0 mm

Drive gear with oil pump gear

14,5 mm

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

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

34
 Dimensions
Service Data
Limiting values

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

Oil pump gear

Shaft: 17,93 −17,94 mm

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

Housing depth: 38,000−38,039 mm

Radial clearance: 0,050−0,088 mm
37,911−37,950 mm
14,5 mm

37,911−37,950 mm

40,8−41,0 mm

35
 Dimensions
Service Data
Limiting values

Cooling system

Coolant pump

gap between housing and impeller:

0,5−0,9 mm

Ø impeller: 135,5−136 mm

Bearing seat in housing:

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

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

Bore for bearing shaft in impeller:

16,000−16,018 mm
Ø of bearing shaft: 16,045−16,056 mm
Interference: 0,027−0,056 mm

Sea water pump (D 2866 LE401 only,

up to engine number ... 8120 999 ....)

If impeller is worn, change it together with

seals (treat with an acid-free lubricant and
install in turning direction)
If wear in bearing can be felt (air in bear-
ing), change the bearing
Speed of sea water pump:
1,53 x engine speed (i = 0,65)

36
 Dimensions
Service Data
Limiting values

Sea water pump (D 2866 LE401 only,

engine number and up ... 8121 001 ....)
If impeller is worn, change it together with
seals (treat with an acid-free lubricant and
install in turning direction)
If wear in bearing can be felt (air in bear-
ing), change the bearing
Speed of sea water pump:
1,53 x engine speed (i = 0,65)

Sea water pump 51.06500−7026

(D 2876 LE 301 / 403)

If impeller is worn, change it together with

seals (treat with an acid-free lubricant and
install in turning direction)
If wear in bearing can be felt (air in bear-
ing), change the bearing
Speed of sea water pump:
1,53 x engine speed (i = 0,65)

37
 Dimensions
Service Data
Limiting values

Cover for heat exchanger

Working valve opens at

0,85−1,15 bar above and
0,02−0,08 bar below
atmospheric pressure
Filler cap with safety valve:
Safety valve opens at
0,85−1,2 bar above atmospheric
pressure (imprint: 1,0),
1,3−1,7 bar above atmospheric pressure
(imprint: 1,5 LR1103)

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
and fit a new one as soon as possible.

38
 Dimensions
Service Data
Limiting values

Thermostat for D 2866 LXE

Opening begins at: 79 _C ("2_)

Fully open: 94_C

24,5−25,8 mm

Lift at least 8 mm at 94_C

Thermostat for
D 2866 LE 4..
D 2876 LE 301 / 403

up to engine number ... 8515 999 ....

Opening begins at: 71 _C ("2_)
Fully open: 86_C

engine number and up ... 8516 001 ....

Opening begins at: 83_C ("2_)
Fully open: 95_C

24,5−25,8 mm

Lift at least 8 mm at 86_C

39
 Dimensions
Service Data
Limiting values

Injection nozzles

Projection above cylinder head contact

surfaces
for nozzle DLLA 136 S 1002 with
injector KDAL 80 S41

Eliminate nozzle protrusion by using Cu

sealing rings of different thickness. These
sealing rings are available in thicknesses
of 0,5 / 1,0 / 1,5 / 2,0 / 2,5 / 3,0 mm
1,76−2,59 mm

Projection above cylinder head contact

surfaces
for nozzle DLLA 146 P 166 with injector
KDEL 82 P7 and nozzle DLLA 152 P 486 with
injector KDEL 82 P30

Eliminate nozzle protrusion by using Cu

sealing rings of different thickness. These
sealing rings are available in thicknesses
of 0,5 / 1,0 / 1,5 / 2,0 / 2,5 / 3,0 mm
2,42−3,25 mm

40
 Service Data

Injectors

Engine model Type of injector Discharge pressure Number of ho-

nozzle (bar) les / hole Ø
(Bosch) Injector new / run

D 2866 LXE up to engine DLLA 136 S 1002 220 (+8 ) / 220 (+8) 4 / 0,43 mm
number ... 6876 999 ....

D 2866 LXE engine number DLLA 146 P 166 295 (+8) / 280 ( +8) 4 / 0,412 mm
and up ... 6877 001 ....

D 2866 LE4.. up to engine DLLA 152 P 486 340 (+10) / 320 (+10) 6 / 0,346 mm
number ... 8580 999 ....
D 2866 LE4.. engine num- DLLA 152 P 486+ 340 (+10) / 320 (+10) 6 / 0,346 mm
ber and up ... 8581 001 ....

D 2876 LE301 / 403 DLLA 152 P 486+ 340 (+10) / 320 (+10) 6 / 0,346 mm

Injector for nozzle DLLA 136 S 1002: KDAL 80 S41

Injector for nozzle DLLA 146 P 166: KDEL 82 P7
Injector for nozzle DLLA 152 P 486: KDEL 82 P30

41
 Service Data

Start of delivery (marine propulsion engines)

Model Start of delivery / deg. before TDC

D 2866 LXE (324 kW / 2200 1/min) 15
up to engine number ... 6876 999 ....

D 2866 LXE (324 kW / 2200 1/min) 24

engine number and up ... 6877 001 ....

D 2866 LXE (250 kW / 1800 1/min) 19

D 2866 LXE (279 kW / 1800 1/min) 19
D 2866 LXE (294 kW / 2100 1/min) 20
D 2866 LXE (300 kW / 2200 1/min) 24

D 2866 LE401 (441 kW / 2200 1/min) 18±0,5

D 2866 LE402 (368 kW / 2200 1/min) 18±0,5
D 2866 LE403 (368 kW / 2100 1/min) 14±0,5
D 2866 LE405 (449 kW / 2200 1/min) 19±0,5

D 2876 LE403 (331 kW / 1800 1/min) 14

Start of delivery (Auxiliary marine engines)

D 2866 LXE (constant speed 1500 1/min) 17

D 2866 LXE (constant speed 1800 1/min) 17
D 2876 LE 301 (constant speed 1500 1/min) 13

D 2876 LE 301 (constant speed 1800 1/min) 15

42
 Service Data

Injection pumps and governers

all engines: Bosch - In-line pump with speed governor

Marine propulsion engines

Engine model Injection pump Governor

D 2866 LXE PES 6 P120 A 720 LV16500 RQV 300-1100 PAV 17449
P = 324 kW / 2200 1/min or or
up to engine number PES 6 P120 A 720 LS3167 RQV 300-1100 PA 667-2
... 6876 999 ...
D 2866 LXE PES 6 P120 A 720 LV18994 RQV 300-1100 PAV 20433K
P = 324 kW / 2200 1/min or or
engine number and up PES 6 P120 A 720 LS7209-1 RQV 300-1100 PA 1006K
... 6877 001 ....
D 2866 LXE PES 6 P120 A 720 LV18994 RQV 300-1100 PAV 20796K
P = 250 kW / 1800 1/min or
PES 6 P120 A 720 LS7209-1
D 2866 LXE PES 6 P120 A 720 LV18994 RQV 300-1100 PAV 20636K
P = 279 kW / 1800 1/min or
PES 6 P120 A 720 LS7209-1
D 2866 LXE PES 6 P120 A 720 LV18994 RQV 300-1100 PAV 20637K
P = 294 kW / 2100 1/min or
PES 6 P120 A 720 LS7209-1
D 2866 LXE PES 6 P120 A 720 LV18994 RQV 300-1100 PAV 20794K
P = 300 kW / 2200 1/min or
PES 6 P120 A 720 LS7209-1
D 2866 LE401 / LE403 PES 6 R120 720 LS 1505 RQV 300-1100 R3K

D 2866 LE402 PES 6 P120 A 720 LS7209-3 RQV 300-1000 PA 1006-2K

P = 368 kW / 2200 1/min
D 2866 LE405 PES 6 P120 A 720 LS1505-1 RQV 300-1000 R3K
P = 368 kW / 2200 1/min
D 2876 LE403 PES 6 R120 / 720 LV RQV 300−900 RV
P = 331 kW / 1800 1/min

43
 Service Data

Auxiliary marine engines at constant speed

D 2866 LXE PES 6 P120 A 720 LV18899 RQ 750 PAV 20594

P = 215 kW / 1500 1/min or or
PES 6 P120 A 720 LS7244 RQ 750 PA 981-1
D 2866 LXE PES 6 P120 A 720 LV18899 RQ 900 PAV 20595
P = 245 kW / 1800 1/min or
PES 6 P120 A 720 LS7244
D 2866 LXE PES 6 P120 A 720 LV18899 RQ 750 PAV 20594
P = 244 kW / 1500 1/min or or
PES 6 P120 A 720 LS7244 RQ 750 PA 981-1
D 2866 LXE PES 6 P120 A 720 LV18899 RQ 900 PAV 20595
P = 280 kW / 1800 1/min or
PES 6 P120 A 720 LS7244
D 2876 LE301 PES 6 R120 / 700 LS 1520 GAC
P = 345 kW / 1500 1/min
D 2876 LE301 PES 6 R120 / 700 LS 1520 GAC
P = 390 kW / 1800 1/min

44
 Dimensions
Service Data
Limiting values

Starter

Manufacturer: Bosch
Type: KB
Operation: sliding-gear type

Starter pinion:
Number of teeth: 9
Modulus: 3

Output: 5,4 kW
Voltage: 24 V

Alternator

Manufactorer: Bosch
Type: N1
Design: 2-pole, insulated
Operation: Threephase current
Voltage: 28V
Max. current: 55A
or (optional equipment)
Manufactorer: Bosch
Type: T1
Design: 2-pole, insulated
Operation: Threephase current
Voltage: 28V
Max. current: 85A
or (optional equipment)
Manufactorer: Bosch
Type: T1
Design: 2-pole, insulated
Operation: Threephase current
Voltage: 28V
Max. current: 120A

45
 Dimensions
Service Data
Limiting values

V-belts / Powerband

Change damaged V-belts (cracks, wear,

oil)

Measuring tension with

tension tester
Tension forces according
to the kg graduation on the
tester
Drive
New installation When
belt
servicing
width After 10 after long
Installa-
min. run- running
tion
ning time time
12,5 50-55 45-50 35
2/3VX 90-100 70-80 60

46
 Tightening torque guide values

Retightening cylinder head bolts on new engines

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

The cylinder heads are mounted with cyl-

Erster Nachzug der Zylinder- inder head bolts which are tightened by
kopfschrauben erledigt the angle-of-rotation method. On new en-
gemäß SI 88 05 20/0
gines the cylinder head bolts are tight-
First retightening of cylinder- ened up for the first time at the factory af-
head-bolts completed ter the engine has been broken in.
according to SI 88 05 20/0
The sticker “First retightening of cylin-
der head bolts ...” is then attached to
Spare part No. 51.97801-0211 one of the cylinder head covers.

After the first 400 hours of operation re-

Intake side / injector 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 cylinder head bolts to be re-
tightened must not be loosened
first, but simply tightened by a fur-
ther 90° (1/4 revolution) from their
actual position.

3 2

MAN
Exhaust side

Tightening diagram “1” Remove the sticker “First retightening

of cylinder head bolts ...” and attach the
sticker “Second retightening of cylinder
head bolts ...” to show that the cylinder
Zweiter Nachzug der Zylinder-
kopfschrauben erledigt head bolts have been retightened for the
gemäß SI 88 05 20/0 second time.

Second retightening of cylinder-

head-bolts completed
according to SI 88 05 20/0

Spare part No. 51.97801-0212

47
 Tightening torque guide values

Tightening cylinder head bolts after a repair

(engine cold)
in accordance with SI 88 05 20/0
Before inserting the cylinder head bolts oil
Intake side / injector them with engine oil on the thread (not to
the bore) and coat the contact face of the
6 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 angle-of-rotation 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.

MAN 5

Exhaust side

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

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

48
 Tightening torque guide values

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

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

Crankcase, crankshaft assembly

Engine mounting to crankcase M14, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Nm
Timing case to crankcase M10, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Thrust washer to timing case M8, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Crankshaft bearing caps to crankcase M18 x 2
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300−330 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100°
Counterweight to crankshaft M16 x 1,5
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100−110 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100°
Vibration damper hub to crankshaft M16 x 1,5, 10.9 . . . . . . . . . . . . . . . . . . 260 Nm
Crankshaft extension for power take-off at front
Hex bolt M16 x 1,5, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Nm
Crankshaft extension for power take-off at front, Collar bolt M16 x 1,5
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°
Flywheel to crankshaft M16 x 1,5
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250−260 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90−100°
Connecting rod bearing caps M16 x 1,5
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100−110 Nm
rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 bis 100°

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

49
 Tightening torque guide values

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
Injection pump drive gear M8, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Nm
Injector to cylinder head M28 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120−125 Nm
Nozzle tensioning nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Fuel filter M12, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Pressure pipe to injector and injection pump
initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
rotation angle for first installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
rotation angle for following installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

Starter / alternator
Starter to timer case M12 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
V-belt pulley on alternator M14 x 1,5 and M16 x 1,5 . . . . . . . . . . . . . . . . . . . 40−50 Nm
V-belt pulley on alternator M24 x 1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120−150 Nm

50
 Tightening torque guide values

Tightening torque values according to Works Standard M 3059

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

Thread size Grade / Tightening torque in Nm

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

51
 Index

A L
Lubricating system . . . . . . . . . . . . . . . . . . . . . . 10
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
O
C Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Compression pressures . . . . . . . . . . . . . . . . . . 10 P
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . 18 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Conrod bearing . . . . . . . . . . . . . . . . . . . . . . 18, 19 Piston rings . . . . . . . . . . . 20, 21, 22, 23, 24, 25
Coolant filling capacities . . . . . . . . . . . . . . . . . . 11
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
R
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 36 Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankshaft bearings . . . . . . . . . . . . . . . . . . . . . 14
S
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Sea water pump . . . . . . . . . . . . . . . . . . . . . . . . 36
Cylinder head bolts . . . . . . . . . . . . . . . 14, 27, 47 Start of delivery . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cylinder liner protrusion . . . . . . . . . . . . . . . . . . 12 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

E T
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tightening torque guide values . . . . . . . . . . . . 48
Timing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
V
Fuel supply pump . . . . . . . . . . . . . . . . . . . . . . . 10 V−belt / Powerband . . . . . . . . . . . . . . . . . . . . . . 46
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 9
I Valve train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . 40 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

52