Repair Manua

Engine

D 2565 ME
,D 2566 ME IMTE IMLE
D 2866 E I T E I L E
 3 TABLE OF CONTENTS 4
ltem Chapter Ik g e

ALPHABETICAL INDEX 5to6

I ENGINE VIEWS 7 t o 14
LONGITUDINAL SECTION D 2565 ME 15
LONGITUDINAL SECTION D 2566 ME 16
CROSS SECTION D 2565 ME/ D 2566 ME 17
CROSS SECTION D 2566 MLE 18
LONGlTUDINAL SECTION D 2866 E 19
CROSS SECTION D 2866 E 20
LONGITUDINAL SECTION D 2866 LE 21
CROSS SECTION D 2866 LE 22
SCHEMATIC DIAGRAM OF ENGINE LUBRICATION SYSTEM 23
SCHEMATIC DIAGRAM OF FUEL SYSTEM 24
SCHEMATIC DIAGRAM OF FLAME STARTING DEVICE 25
SCHEMATIC DiAGRAM OF TIMING GEARS 26

Checking, controlling, adjusting

Checking compression I/I

Checking drive belt tightness 211
Adjusting valve clearance 3/1
i Checkingladjusting start of delivery 411

Fuel system

Removing and installing fuel injection pump 511

Removing and installing fuel injection lines 611
Removing, repairing and installing fuel injectors 711
Removing, installing and repairing flame starting device 811
Removing and installing shut-down devices 911
Removing and installing speed governor 1011
Removing and installing speed adjuster 1111

Cooling System

Removing, repairing and installing water pump 1211

Removing and installing surge tank and plenum tank 1311
Removing and installing heat exchanger and thermostats 1311
Removing and installing raw water pump 1411
PTO for raw water pump 1411
I
Removing and installing intercooler 15/1

Lubricating System

Replacing oil filter element 1611

Removing and installing oil cooler 1711
Removing and installing oil pan and oil drain 1811
Removing and installing oil separating valve 1911
Removing and installing oil spray jets 201l
Removing, repairing and installing oil pump 2111

Flywheel, Crankshaft Seals

Removing and installing clutch shaft pilot bearing 2211

Removing, installing and repairing flywheel 2311
Replacing starter gear ring 2411
Replacing rear crankshaft seal (flywheel end) 2511
Replacing front crankshaft seal and pilot bearing race 26/1
I
4 TABLE OF CONTENTS 4
ChapterfPage

Item

Intake and Exhaust Systems

Removing and installing inlet bend and inlet manifold 2711
Removing and installing exhaust manifold 2811
Removing and installing turbocharger 2911
Checking axial and radial play of turbinefrotor shaft 301I

Cylinder Head

Removing and installing cylinder head 31/I

Removing and installing cylinder head, summary 3211
Removing and installing valves 3311
Removing and installing valve guides 3411
Refacing valve seat 351l
Replacing valve seat rings 3611

Timing

Removing and installing timing case 3711

Removing and installing camshaft 3811
Replacing camshaft bearing 3814
Gh~king valve timing 3811

Crankshaft, Conrods, Pistons

Removing and installing crankshaft 3911

Removing and installing pistons with connecting rods 4011
Replacing piston rings 4111
Detaching and attaching piston on connecting rod, checking connecting rod 4211
Removing and installing cylinder liners 4311
Measuring piston protrusion 44/ 1

Compressor

Removing and installing compressor 4511

Disassembling and assembling ampressor 4611

Elecrrical Equipment, Monitoring Devices

Monitoring devices, instrument panel, tachometer 4711

Removing and installing starter 4811
Removing and installing alternator 4911
Removing and installing preheater 5011
Tension pulley for V-belt 5111

General lnstructions

lnstallation of flat gaskets 101

Technical Data

Specifications 201
Testing and adjusting values 203
Tightening torque guide values 219
Running-in engine 2 22
Special tools 301
 6 ALPHABETICAL INDEX 6
l tern ChapterJPage

Preheater 5011
Pilot bearing in flywheel 2211
Piston pins 4211
Piston rings 4111
Piston protrusion 4411
Pistons 4011
Plenum tank 1311
PTO for raw water pump 1411

Raw water pump 1411

Reconditioned engines (notes) 4411
Regulator, alternator 4911
Relief valve 2111
Rocker arms 3111
Running-in instructions (reconditionedengines( 224

Shutdown device 9/ 1
Small end bushes 3911
Solenoid valve (flame starting device) €311
1 Special tools 301 to 309
Specification (engine) 201
Speed adjuster (electric) I111
Speed governor (eleetronicf 1011
Starter 4811
Starter gear ring 24/1
Start inhibit relay 4911
Start of delivery 4fl
Surge tank 1311

Tachometer 4711
Tappet bores N I 3913
Technical data 201
Temperature monitor 4711
Tensioning pulley, Vee belt 5111
Testing and adjusting values 204to 218
Thermostat 1311
Tightening torques 219 to 222
Tightening torques (table) 2 23
1 Timing case 37/1
Timing gear adjustment 3912
Timing gear diagram 26
Tools 301 to 307
Turbocharger, checking axiallradial play 3011
Turbocharger, removing and installing 2911

Valve clearance 311

Valve guides 3411
Valve retrusion 3311
Valves 3311
Valve seat insert 3511, 3611
Valve timing, checking 3811
Vee belts 211

Water pump 1211

I
ENGENE VIEWS
 €3 2566 MTE (Marine Propulsion Engine)
Left-Hand Side

Surge tank with heat exchanger Injection pump and governor

Cover with relief valve Shutdown solenoid
Plenum tank with connection Raw water pump
for vent pipe Angle drive for tachometer
Pressure cover with pressure
regulating valves Vibration damper
Oil filler neck Engine turning hexagon
Tachometer Water pump
Oil separator valve for crankcase vent
Tensioning pulley
Fuel filter
Fuel lift pump with hand pump and
strainer
 ENGINE V I W S

D 2566 MTE (Marine Propulsion Engine)

Right-Hand Side

1 Crankcase vent pipe 8 Cooling water pipe (supply)

2 Exhaust manifold, water-cooled 9 Oil filter
3 Cooling water pipe (drain) 10 Lubricating oil pipe (return)
4 Turbocharger (turbine housing 11 Lubricating oil pipe (supply)
water-cooled)
12 Starter
5 Viscous air filter
13 . .
Oil drain Dumr,
6 Reversing chamber {heat exchanger)
14 Timinacase
7 Intake elbow
 D 2566 MLE (Marine Propulsion Engine)
Left-Hand Side

1 Surge lank with heat exchanger 7 Fuel lift pump with hand pump
and strainer
2 Cover with relief valve
8 l njection pump with governor
3 Plenum tank with connection
For vent pipe 9 l ntercooler

10 Raw water pump

5 Qit filler neck 11 Oil dipstick

6 Fuel filter, changeover type 12 Vibration damper

13 Engine turning hexagon

 D 2566 MLE (Marine Propulsion Engine)
Right-Hand Side

1 Oil separator valve for crankcase vent 9 Regulator for alternator

2 Vent pipe 10 Oil filter

3 Exhaust manifold water-cooled 11 Cooling water pipe (supply)

4 Cooling water pipe (drain) 12 Lubricating oil pipe (return)

5 Exhaust gas turbocharger 13 Lubricating oil pipe (supply)

water-cooled turbine housing
6 Viscous air cleaner 14 Sterter

7 Reversing chamber (heat exchanger) 15 Timingcase

8 Alternator
ENGINE VIEWS Ea 21%@6E
 LONGITUDINAL SECTION D 2565 ME

ili + I
GROSS SECTlOW D 2565 / D 2566 ME
I Oil rtrc:titxr? lint? 6 Bypassvalve

3 Dicrr tf,rrricrtr line 7 Oil filter

3 011 jc3r 8 Turbocharger (for MTEIWILEITEILE rnodtd9)

4 011 fjufnk) 9 Oil cooler

5 Pressure relief valve 10 Injection pump

3 Electric connection
4 Manual fuel pump
5 Fuel filter
6 Fuel tank
7 Injection pump r)
V)

8 Overflow valve T
z
3==
2
€3
 SGHEMATlC DlAGRAM OF TlMllUG GEARS

shaft, oil pump and injection pump are driven by gears on the
flywheel end.

Gears on flywheel end: Gears on vibration damper end:

1 Crankshaft 8 Compressor or raw water

2 Oil pump drive pump drive
3 Oil pump impeller gears 9 Compressor or raw water
4 Camshaft and injection timer pump intermediate gear
5 Intermediate gear far injection
pump drive
6 Injection pump drive
7 Pto
 Checking compression

Figure 1

Check valve clearance and adjust, if neces-

sary. Run engine until coolant tempera-
ture has reached 60 - 8 0 O ~ .Remove all
injectors with nozzles.

Figure 2

Install new gasket and connect compres-

sion pressure recorder with union nut and
special wrench. Screw compression pres-
sure recorder on connection with the
extension. Turn engine with starter motor
until needle deflection of compression
tester remains steady.

ach compression pressure recorder

connection. Install nozzle with new
and install injector. Apply ,,Never
to the injector contact points
o installation. Tighten union nut
specified torque. Connect fuel injec-
 Checking drive belt tightness with
,,KRI KIT" belt tightness tester

Figure 1

The life of the drive belt depends mainly

on belt tightness. For accurate measure-
ment of belt tightness the ,,KRIKITW
belt tightness tester can be used.

Figure 2

) Apply tightness tester to belt a t a point

midway between two pulleys so that edge
of bearing surface is on side of belt (arrow).
Before testing, the indicator arm must be
lowered into the scale.
To check tightness uniformly depress push
pad below rubber loop perpendicular to
belt upper side until the spring underneath
the push pad can be heard or felt to dis-
engage.

Important: Pressing further after disen- 2

gagement of the spring would result in
wrong readings. Do not knock tester be-
fore reading tightness value!

Figure 3

Read the tightening force value of the

) tested belt a t the point where the top
surface of the indicator arm intersects
with the scale.

Specified tightening forces:

Drive belt width Tightening forces in
new installation after 10 minutes when servicing after
running time long running time
450 (45) 400 (40)
500 (50) 450 (45)
700 (70) 600 (60)
700 (70) 600 (60)
 Adjusting valve clearance

Figure 1

Remove cylinder head covers. Adjust

valves on a cold engine only fmax. cool-
ant temperature 50°c).

Figure 2

LlNE OF SIGHT
SEN5 DU REGARD
QlRECClQN QE L A
VISTA

Figure 3

5-eylinder engines

Turn engine until ~xhdust valve BP 1st

cylinder ( A l ) is fully open (see ,,rnax,
valve lift" ccoturnn) and adjust intake valve
of 2nd cylinder (E2) in this engine pcasi-
lion. Turn engine Furclrer u f ~ r iintake
l valve
of 3rd cylinder (E3) i s fully open and
adjust exhaust valve of 5th cylinder (A5).
Continue according to rdble on the right
side,
 Adjusting valve clearance

Figure 4

6-cylinder engines

Valves adjusted for

cylinders:

Valves overlap in 6
cylinders:

Figure 5

1 Intake valve
2 Exhaust valve
3 Feeler gauge

Slide feeler gauge blade between valve stem

and rocker arm. Loosen lock nut and turn
adjusting screw until tight resistance i s
felt when movirrg the feeler gauge. Tighten
lock nut. R e c h ~ k clearance, Replace
cylinder heaci covers and remove engine
turning device.
Mote: Starting from April 1986, modified
camshafts will be installed successively in
production engines. The modification of
the camshafts invoives the standardization
of the vaive clearances for inlet and
exhaust valves to 0.50 mm. Engines whose
valve clearance is factory-set to 0.50 rnm
are marked bv a label to this effect rsn one
of the valve covers. After the previous
camshafts have been used up, the modified
camshafts will be supplied for all spare
pafls requiremerlts, The spare parts con-
signment wili include a note about the
valve clearance to be set, k i s recommended
that all engines in which the modified
camshafts are retrofitted be marked and a
hand--written correction included in the
relevant Operating I nstructions Manual to
ensure that rhe correct valve clearance
adjustment i s made during maintenance.
 Checking/adjusting start of delivery

Adjusting (injection pump)

Figure 4

I f the mark, Figure 3, is outside elongated

hole, correct as follows: Remove cover ( 1 )
for injection pump drive gear. Remove
screws 12). Apply special wrench (No.
80.99603-0041) and turn hub of injec-
tion pump until the mark has reached the
position shown in Figure 3. Tighten screws
(2) to specified torque. install cover (1)
with a new gasket. Close inspection hole,
Figure 1.

Nore: I f the specified setting cannot be

I reached by turning the injection pump
hub, check installation of pump,

Figure 5

1 Intermediate gear

2 Injection pump drive gear

3 Mounting bolts for 2

4 Holes for special wrench to turn pump

hub

5 MARK QN INJECTION PUMP HUB

6 POINTER

7 Injection pump mounting screws

8 Fuel lift pump

9 injection pump

Adjusting pointer on crankcase

Figure 6

After disassembly adjustment of pointer

(11, Figure 2 becomes necessary. For this
purpose set flywheel to TDC mark. Align
edge of pointer with TDG point on scale.
Secure pointer in this position,

Note: Qn engines equipped with an elee-

tronic speed governor the inspection hole
is used as access to the starter ring gear
for the pickup. In this case first remove
the mounting plate complete with the
pickup. Do not change the position of
the pickup in the mounting ptate.
 Removing and i n ~ a

Figure 1

Removing fuel injection pump

ecjuippd, For this reason it is recommend-

ed to mark the ariginal position of the in-
dividual components before removing them.
A~cording ru Figure 1, for instance, the
shutall device ( 3 ) with bracket (2) and
linkage (3) of electric speed adjusrer (4)
mu@ be removed.

Figure 2

Ascarding to Figure 2 the shutoff device

actuated via rope (1) and pulley (2). the
adjbasting linkage (3) has to be disconnect-
ed Prom the speed lever and the instrumen-
tation panal has to be removed.

I!! Should it he necessary to disconnect

electrical cables in all cases where the
electrical circuit of the engine includes a
battery, first discannflct tha earth cable of
the battery.

Figure 3

In the case uf turbocharged engines equipp-

ed with an injection pump with smoke
stop, remove contra! air line (arrow).

Figure 4

Injection punlps on engines exceeding a

certain operating angle are supplied with
lubricating oil through fine f I).
This line
mu% also be remaved. After removal of
all fines remove screws (2) on either side
of the pump. Remove also screws (3).
Another screw (3) and a stud with nut are
lomted between pump and crankcase and
can be removed using a socket and an ex-
tension with swivel joint. Remove injection
Pump.
Mote: Fit protective caps to disconnected
lines and their eannection paints to pre-
vent the ingress of dirt. Do not use rags or
cotton waste.
 Removing and installing fuel

Installing fuel injection pump

Figure 5

Turn engine so that cylinder No. 1 is a t

ignition TDC, on @-cylinder engines by
turning until the valves of cylinder No. 6
overlap and on 5-cylinder engines by
turning further one complete revolution
after valves of cylinder No. 1 overlap.
Turn engine in opposite direction beyond
angle mark (arrow) and then again in
direction of rotation to the angle mark of
the specified start of delivery to eliminate
gear backlash.

Figure 6

1 Secure pump drive gear to injection pump

hub (1). Turn injection pump hub ( 1 )
until mark (2) in elongated hole of pointer
(3) is visible through inspection hole (4).
Install new Q-ring (grease coated) into
flange groove 15). Install injection pump
by means of two guide pins aligning the
cleaned oil passages in flange and housing.
Tighten screws to specified torque. Check
start of delivery and correct if necessary.
Install injection lines, fuel lines and all
other parts according to Figures 1 to 4.
 Removing and installing f 6/9

Removal

Figure 1

To remove the fuel injection lines it is

mostly sufficient to remove oil separator
valve (1) of the crankcase vent and fuel
filter ( 2 ) with bracket and, in the case of
changeover filters, also tray (3).

Figure 2

Disconnect leak-off pipe 111 from injectors.

Disconnect fuel injection lines (2) using
open ring wrench {08.06013-0500).

Figure 3

Disconnect fuel injection lines from in-

jection pump outlet connections. After
removing clip ( I f from bracket (2) the
complete set of fuel injection lines can be
removed. In some eases, however, inlet
manifold (3) must first be removed.

Note: In the case of guarded fuel injection

lines clip (4) is replaced by a leakage con-
nection from which an overflow line leads
to float bowl, Figure 4. Disconnect this
line, too. Fit protective caps to disconnect-
ed lines and their connection points to pre-
vent the ingress of dirt,
 Removing and installing fuel injection lines Sf2

Figure 4

I f a leak occurs on guarded fuel injection

lines the leak oil will flow through over-
flow line (1) into float bowl ( 2 ) . Monitor
(3) (float solenoid switch) will send alarm
pulses via connection (4) causing the
engine to be shut down. Monitor (3)
cannot be repaired and must be replaced
in the event of malfunction. No fuel must
be emitted from vent pipe ( 5 ) . If fuel is
emitted, monitor 13) is defective.

Installation

Install removed or new fuel injection lines.

Note: Cleanliness is of utmost importance.
lnstall fuel injection lines free from con-
straint. Tighten union nuts to specified
torque. Connect leakoff line, Figure 2,
with new gaskets. In the case of non-
flame-proof tubing, replacement of tubes
and rubber caps is recommended after
each repair.
 Removing, repairing and installing fuel injectors

Removal

Figure 1

Remove fuel injection fines and leakoff

line. Remove slotted nuts (3) of injectors
(4)as follows:
- Clean recesses of slotted nuts (3) to
ensure correct seat of wrench (2).
- Screw nut ( 1 ) fingertight onto the fuel
injector thread (do not lock). Nut (1)
prevents slippage of wrench (2) during
removal.
- If nuts cannot be loosened due to
corrosion apply penetrating oil and loosen
by means of impact wrench, if available.

Figure 2

Secure inertia extractor t o fuel injector

and remove injector. Remove injector
gasket.

Figure 3

Check nozzle oo tester for blow-off pres-

sure (discharge pressure), rightness and
spray pattern.
Use pure test oil or pure Diesel fuel for
testing. Clean nozzle and c h ~ c kfor wear
before testing.

Test nozzle with essaciated injector.

Connect nozzle to Fuel pipe of tester.

blow-af pressure:
ith pressure gauge switched an, slowly
epress the hand tever until the nozzle
lows with a buzzing sound, check blow-
off pressure on pressure gauge. If pressure
i s below specified value insert thicker
shims, if pressure i s t7igher insert thinner

. Shims are available in increments of

0.05 mrn from 1,Qta 1,Sf mm.
2. Check tightness:
Depress hand lever of tEscer until pressure
gauge pointer is about 20 bar below the
specified test pressure, The nozzle is tight
if no drops are emitted at the nozzle tip
within 10 seconds,

3. Spray pattern:
With the pressure gauge switched off move
lever rapidly and c h ~ that
k a salid jet is
obtained. The nuzzle must produce a
buzzing sound which means that the needle
moves freely and ensures sufficient atomi-
zation under starz: conditions,
 Removing, repairing and installing fuel injectors

Figures 4 and 5

Insert injector with downward directed

nozzle in holding fixture and clamp fix-
ture in vise. Remove union nut, injector,
intermediate washer, pressure pin, coil
spring and shim, Remove pipe connection
from device and pull out rod-type filter.

Figure 5

1 Gasket
2 Union nut
3 Injector
4 Intermediate washer
5 Pressure pin
6 Coil spring
7 Shims

Figure 6

Clean interior of injector (1) with a stick

of wood and gasoline or Diesel fuel. Clean
needle (2) with a clean rag. Do not touch
lapped faces of needle to prevent corrosion.
Needle and nozzle are a selective fit and
must not be interchanged.
 Removing, repairing and installing fuel injectors

Figure 7

Check cleaned parts for wear and damage

and replace if necessary; degrease new
parts. lnsert clean rod-type filter in pipe
connection. lnsert pipe connection in
holding fixture and install shim and coil
spring.

Figure 8

Install pressure rod and intermediate

washer.

Figure 9

and needle individually

Figure 10

Install union nut and tighten to specified

torque using the special wrench.
Check injector on tester.
 Removing, repairing and installing fuel injectors

l nstallation

Figure 11

Note: Before installation spray ,,Never

Seize" 109.14001.0029) on the contact
areas of injectors (shaded) and into the
interior and the threads of slotted nuts.

Install new gasket and insert injector with

nozzle in cylinder head.

11
Note: In the case of reworked cylinder
heads, check for nozzle protrusion. If
necessary, insert thicker or thinner gasket.
install injection lines and leak-off pipe.
 Removing, installing and repairing flame starting device

Figure 1 {typical)

1 Hearer plug
2 Solenoid valve

Figure 2

Removing heater plug.

Dixonnect electrical cable from heater
plug. Unxrew union nut af fuel line.
Unscrew lock nut of heater plug and re-
move heater plug.

Figure 3

Disassembling heater plug: Using a screw

driver remove screw ( 1 ) in fuel inlet (4).
Remove filter screen (2) and metering
insert (3). Clean removed parts in white
spirit and check for wearldamage, Replace
damaged parts. l nstall metering insert,
fitter screens and screw.
Installing heater plug: Screw lock nut (51
on heater plug Sully upward. Screw plug
fully in against lock nut and align with
fuel line. Tighten lock nut 1/2 to 1 turn.
Connect fuel line and make electric con-
nection (6).
 Remaving, installing and repairing flame starting device 8/2

Figure 4

Checking solenoid valve f o r tightness:

Disconnect fuel line f r o m heater plug.
With the engine running and at operating
temperature n o fuel must emit.
Removing and installing solenoid valve:
Pull off electric cable f r o m valve. Dis-
connect fuel line to heater plug. Remove
valve.
The valve cannat be repaired. Replace
defective valves, Secure valve t o bracket.
Connect fuel lines w i t h gaskets. Connect
electric cable.

Circuit diagram of flame starting device

w i t h glow starting switch

Figure 5

1 Heater plugs
2 Compensating resistor
3 Glow starting switch
4 Ignition lock
5 Pilot lamp
6 Cable t o starter class 50
7 Solenoid valve
 Removing and installing shut-down devices

Note: The shut-down devices differ in their circuitry and in operation.

Circuit:
a) Open-circuit (,,ASn). In this circuitry the shut-down solenoid is energized for engine shut-down.
As long as the engine is running, the power supply to the shut-down solenoid is interrupted.
b) Closed-circuit (,,RSU). In this case the shut-down solenoid is energized as long as the engine is
running. The engine i s shut down by spring force when the solenoid is de-energized.

Operation

Figure 1
Shut-down device, type ,,AS" with Bowden
cable operation.
,,RS1' type not shown.

Removal
)i
During removal make sure the key in
pulley (2) does not get lost.

Installation

install Bowden cable pulley (2) together

with the key.
On engines where the Bowden cable is
horizontal, apply a generous amount of
grease to the cable before pulling it through
sheath (3). On engines where adjusting
sleeves (4) are a t different levels, Bowden
sheath (3) is provided with a grease nipple,
The grease nipple must be on the side of
higher adjusting sleeve (4).

Adjustment (AS)

) Using adjusting sleeves (4) adjust the Bow-

den cable so that a t the end of the stroke
of solenoid pulley (2) reaches ,,stop"
position. The shut-down pulley must not
contact the ,,stopM limit. Slight play
(approx. 0.5-1 mm) must be felt by hand.

The solenoid stroke end must be reached

under all circumstances (audible hard
click). In this position the engine must be
shut off.

Note: For the adjustment of the ,,RSrr

shut-down devices the same notes apply
as given above. In this case the opposite
connection of the solenoid must be taken
into account.
9/2 Removing and installing shut-down devices 9/2

Figure 2

Shutdown device, type ,,ASm, actuated

by linkage.
Type ,,RS" not shown.

No explanations required,

Adjustment (AS)

Adjust length of rod (3) so that a t the

end of the stroke of the solenoid shut-
down lever (2) reaches ,,stopm position.

hand. The solenoid stroke end must be

reached under all circumstances.

Adjustment (RS)

Adjust length of rod (3) so that at the

beginning of the stroke of the solenoid
shut-down lever (2) is in ,,stop" position.

A slight play (0.5 - 1 mm) must be felt

by hand. At the stroke end of the sole-
noid the shut-down lever must be in
,,operationH position. The solenoid stroke
end must be reached under all circum-
stances (audible hard cl ick).

Tension spring by displacing holder on

rod (3) only sufficiently so that when
speed lever (4) is pressed against ,,max.
speed" stop, shut-down lever (21 is moved
to ,,stopu position by spring force.

,,AS" and ,,RSW: Connect rod (3) and

angle joints should be free from any con-
straint and permit free motion.
 Electronic spee

Figure 1

Figure 1 shows the electronic speed gover-

nor ,W EIIVZMANN'? 1). Before removing
the governor carefully mark (note) i t s
position in the bracket on the engine and
the adjusting length of linkage (2) between
the two levers (3 and 4). On reinstallation
restore original installation position and
settings as accurately as possible. There
must be no play in the linkage and this
should move freely. With the governor in
,,stopM position pointer ( 5 ) must be on
0 - 2 graduations of the injection rate
scale.

Figure 2
t
1 Pulse generator
2 Starter ring gear
3 Adjusting cover (secured to timing
case on inspection hole for start-of
delivery check)
4 Lock nut

Adjust the distance between pulse gener-

ator and gear tip of starter ring gear as
follows: Screw pulse generator into cover 2
(3) until it contacts the gear tip and then
back off approx. 112 turn and tighten lock
nut (4).

Note: For detailed description see leaflets

E 80 001 and E 80 002 ,,Heinzmann elec-
tronic speed governors".

I
 Electronic speed gover 1012

Figure 3

Electronic speed governor ,,BARBER COL-

MAN".
1 Governor
2 Correcting unit
3 Lever
4 Governor shaft, serrated
5 Rod end bearing
6 Jam nuts
7 Screws
8 Threaded rod
9 Multiple connector
3
Before removing the governor ( 1 and 2
as one unit) mark the mounting points
of the two rod end bearings (5) in the
levers. Loosen screws 17) and remove the
complete rod (8) with end bearings. Do not
) loosen lock nuts (6). Do not remove
lever (3) from shaft (4).Disconnect cable
from multiple connector 19).
install the parts in their original positions.
I f during a test run minor corrections
appear to be necessary these corrections
can be performed b y rotating an end
bearing on rod 18).

Figure 4

1 Magnetic pickup
2 Starter ring gear
3 Adjustingcover
4 Jam nut

The distance between pickup and gear

) tip of the starter ring gear must be reset
after each removal. Screw pickup into
cover (3) until it contacts the gear tip
and then back off approx. 1/4 turn and
tighten jam nut (4).

Note: For detailed description see Tech-

nical Manual ,,DYNA I Governor", Bar-
ber-Colman Co.
Figure 1

Speed adjuster, M.A.N. type

Disconnect power cable from motor (1).

Loosen screws (2). Remove complete speed
adjuster (shown without cover) with
bracket (3). After any check and repair
of the speed adjuster coat threaded rod
(4f, guide pin (on the threaded rod) and
compression spring and ball in hand wheel
( 5 ) with multipurpose grease (lithium
soap base). Carry out function test after
re-installation. The two limit switches on
the bar must shut down the engine imme-
diately before speed lever ( 6 ) reaches the
stops in the injection pump governor
(clearance between lever and stop approx.
0.5 mm). I f required shift switches on the
bar accordingly. Replace cover.

Figure 2

Speed adjuster ,,MAGNETICv

Disconnect cable from adjusting device

bottom. Remove screws (2)and disconnect
lever ( 1 ) from speed fever. Loosen screws
(3) and remove complete adjuster with
pipe clip. Oo not disturb senings of unit
and linkage, After re-installation carry
out functional test. The limit switches in
the adjuster must shut down immediately
before the speed lever has reached the me-
chanical stops in the injection pump
governor (clearance between lever and stop
approx, 0.5 rnrn), The internal limit switch
is fixed in the adjuster. Correction of the
shut-off position is possible only by shift-
ing the adjuster in pipe clip (4). The ex-
ternal limit switch can be adjusted from
outside. The adjusting head is accessible
after removal of plug 15) in the front
guide flange. Clockwise rotation increases
the stroke 0.6 mmlrev. Reinstall plug
(tightness).
 1211 Removing, repairing and installing water pump 12/1

Removing

Figure 1

Drain coolant. Remove coolant lines.

Depending on engine type remove surge
tank with heat exchanger ( I ) , heat ex-
changer tank or fan. Remove V-belt, el-
bow (21, thermostat housing, cooling
water connection (3) and bypass inserts I
thermostats. Remove V-belt pulley (4).

Figure 2

Extract water pump hub using a 3-arm

) puller. Remove water pump screws and
take off water pump.

Disassembly, repair

Figure 3

Remove circlip from water pump body.

Figure 4

Remove impeller from shaft using a suitab-

le mandrel.

Nate: The impeller can also be extracted

by means of a 3-arm puller. This is of
advantage when the seal only has to be
replaced.
 Removing, repairing and installing water pump 12/2

Figure 5

Using a suitable mandrel press water pump

shaft with bearing out of body. Shaft and
bearing are encapsulated and can only be
replaced together.

Figure 6

Water pump components

b
1 Hub
2 Circlip
3 Pump bearing
4 Housing
5 Gasket
6 Seal
(cassette seal)
7 Impeller

Check all parts for serviceable condition.

Assembly

Figure 7

Press water pump shaft with bearing into

housing. Apply hollow mandrel to outer
rim of bearing housing, not on bearing
shaft. Install cirelip,
 Removing, repairing and installing water pump

Figure 8

Apply a thin coat of liquid sealant (Tero-

Ian 307 Fluid) to seal housing a t (1) over
i t s full circumference.

Turn around housing, position the seal

together with plastic cap (2) on bearing
shaft (7) and press in until the protruding
edge is in full contact with the pump
housing. Remove plastic cap (2). Race (3)
forms part of the seal.

Figure 9

Press impeller onto shaft while observing

gap dimension, i.e. first press on impeller
until almost flush with the shaft. Check
gap. Continue to press on impeller in steps
until correct gap dimension has been ob-
tained. Reverse pump housing and press
1 hub onto bearing shaft until flush.

9
Installation

Figure 10

Clean sealing surfaces on water pump and

crankcase. Install water pump (1) with new
gasket. Install thermostat or dummy ther-
mostat with new O-rings and f i t cooling
water connection 121. Replace cooling
water hoses and all other parts that were
removed. Connect coolant temperature
monitor (3), see also Page 47/1.
 1311 Removing and installing :;urge tank, plenum tank, 13/
heat exchanger and thermostats

Plenum tank (removal/installation)

Figure 1

Drain cooling water. Disconnect hose ( 1 )

of vent line ( 3 ) from housing (2). Remove
all screws 14) and take off plenum tank.

Figure 2

Check hose connection ( 1 ) and hose and

plenum tank ( 2 ) with hollow screw and
drain plate (3). Plenum tank ( 2 ) i s only
available as an assembly with housing
(5).Carefully clean sealing surfaces (4).
Replace gasket.

Removing heat exchanger insert

Figure 3

Disconnect raw water supply pipe (1)

from upper flange. Remove hose from raw
water pump (2) and take off pipe (1).
1 Disconnect drain pipe from bottom flange
( 3 ) . Remove cover 14) and channel (5).

Figure 4

O-rings (1) on the heat exchanger end

keep the channel cover under preload.
To remove the channsl cover use two
seredrivers but do no drop cover.
Remove O-rings (1) and push heat ex-
changer insert through it.
 Removing and installing surge rank, plenum tank,
heat exchanger and thermostats

lnstalling heat exchanger insert

Figure 5

Replace insert if damaged. Clean sealing

surface (1) and use new gasket. Clean
also sealing surface (2) and fully push in
insert.

Figure 6

Install new gasket (1) Align heat exchanger

insert and cover (2) so that pin (4) engages
hole (3).Secure cover (2).

Figure 7

Install the two O-rings, Figure 4, lightly

coated with oil in insert grooves. Use new
gasket for channel cover ( 1).

; Removing/installing thermostats

Loosen screws 12) and remove cooling

water connection (3).

Figure 8
2
Using a screwdriver lift thermostat inserts
.
off their seats, Replace O-rings ( I ) Install
thermostats with vent holes (2) pointing 1
upward. Fit cooling water connection.
2

1
 Removing and installing surge tank, plenum tank 13/3
heat exchanger and thermosTats

Removing/installing surge tank

Figure 9

Remove complete surge tank (1) with heat

exchanger as follows: Disconnect pipes
from flanges 12-31. Remove screws securing
bracket (4) to support ( 5 ) .

Figure 10

Remove vent pipe (11 and cooling water

1 connection (21, screws (3) and take off
tank complete with heat exchanger.

Note: In some cases the heat exchanger

housing is secured from below to a bracket.
Connection to the engine cooling water
circuit is via an elbow flange-mounted to
the housing bottom,
When installing the casing, Figure 9,
replace gasket for thermostat housing.
 Removing, disassembling, assembling and installing PTO 14/1
for raw water pump

Removing PTO

Figure I

Drain heat exchanger housing. Open water

drain cock (1) on the raw water pump and
collect raw water. Remove water lines
from pump flanges (2). Remove support
(3) from bracket (4).

Figure 2

In the case of MLE engines remove con-

) nection hose (41 to intercooler. Remove
screws 15). Remove PTO complete with
raw water pump and with or without
support (3). After loosening nuts (6)
from studs separate raw water pump from
PTO. Retain connection sleeve (pump
shaft - PTO).

Disassembling PTO

Figure 3

Clamp PTO housing in vice using support

f 31, Figures 1 and 2. Remove cover. Using
an assembly tool, block drive gear (asshown
in Figure 4).
Remove screw (I)of intermediate gear
and washer. Remove housing from vice
and drop on two adjacent wooden blocks
so that the bearing pin drops out of inter-
mediate gear. Remove intermediate gear
from housing.

Figure 4

Block drive gear. Remove screw and

washer. Remove ball bearing with drive
pinion and shaft. Tap shaft end with ham-
mer handle if necessary, Press second
bearing out of the housing. Remove cir-
clip from housing groove. Clean all parts.
Replace worn or damaged parts.
 Removing, disassembling, assembling and installing PTO

Assembling PTO

Figure 5

1 Raw water pump

2 Housing
3 PTO gear (on camshaft)
4 Drive pinion
5 Intermediate gear
6 Circlip
7 Ball bearing

lnstall circlip (6) in housing groove. Slide

in ball bearing (7) until seated.

Figure 6

Insert drive pinion with ball bearing

mounted and press to make sure that the
circlip in the bearing groove contacts the
housing.
5
Note: Washer and screw can be installed
again. However, they are not necessary
and will be omitted in future. The tapped
hole in the shaft and circlip ( I ) will also be
omitted.

Figure 7

Install intermediate gear and bearing pin.

l nsert bearing pin with pilot pin first. Place
washer in position and lock bearing pin by
means of screw (see also Figure 3). Install
cover with new gasket. Remove any gasket
residuals (arrow).
Place new gasket in position and place
raw water pump with coupling sleeve on
shaft on studs and secure with washers and
nuts (see Figure 2).

l nstallation

Secure complete PTO with raw water pump

to crankcase, see also Page 3813, Figure 7.
Connect cooling water pipes, Figures 1 and
2 after priming the uaw water pump with
water.
Note: With the engine shut-off and under
freezing temperatures the raw water pump
must be drained.
 lntercoaler 15/1

Figure 1

Open drain cock (1) and allow raw water

contained in intercooler (2) to drain.
Remove all screws (5) securing discharge
housing (3)to intake manifold (4). Release
clips of connecting hose (6). Do not re-
move plug (7).

Figure 2

Remove hose and flange connections (1)

I from inlet and outlet of intercooler (3).
Remove screws (2) from bracket supports.
Remove intercooler (3) complete with inlet
housing (4) and discharge housing (5).
Release cooler (3) by removing screws
(6)on circumference on both sides. Re-
place gaskets between intercooler and two
housings (4 and 5).

Figure 3

Clean intercooler in accordance with the

operating instructions for the engine. Re-
move top and bottom cover (1), if re-
quired, and replace gaskets (2). Replace
intercooler should the cover be damaged
(leaking). install in accordance with Fi-
gures 1 - 2.
 Replacing oil filter element

Figure 5

Replace gaskets and coat with (3il. Install

filter bowl with element so that the drain
plug points downward. Tighten screw to
specified torque.

Figure 6

' 1
2
3
Valve piston
Compression spring
Plug and gasket

Remove bypass valve of oil filter from

filter head and check for wear; replace if
necessary. lnstall bypass valve with new
gasket.

Figure 7

1 Filter head, changeover type with in-

stalled bypass valve
2 Filter element
3 O-ring
) 4 Filter bowl
5 Drain plug
6 Screw

Change filter element in the same way as

in the case of a single-element oil filter.
 Removing and ingalling oil cooler 17/1

Figure 1

Drain oil, remove oil filter, remove housing

securing screws and take off housing.

Figure 2

1 Clamp housing i n vice (use protective

jaws). Remove oil cooler screws, take off
oil cooler.

Figure 3

Check oil cooler for damage and replace

if necessary. Install oil cooler with new
gaskets. lnstall housing with new gasket.
I
 Removing and installing oil pan, oil dipstick, oil drain

Removal

Drain oil by means of hand pump ( 5 ) or 1

by removing drain plugs (Figure 2/1).
Remove return pipe (2). Remove hose
(3) and three-way cock (4) if provided.
Remove hand pump from bracket only if
defective. Hand pump and three-way
1 cock cannot be repaired.

Figure 2

Pull out oil dipstick (2).Remove screws

(3) from oil pan. Remove oil pan and
clean it. Replace oil pan gasket.

lnstallation

Secure oil pan. Tighten screws to speci-

fied torques. Connect oil drain and oil
return pipe (turbocharger). If the oil dip-
stick has to be replaced follow instructions
for Figure 3.
 Removing and installing oil pan, ail dipstick, oil drain

Figure 3

Matching of oil dipsticks and guide tubes to engine types

The oil dipsticks and guide tubes for the different engines differ in length. Incorrectly matched parts will
cause incorrect engine oil level readings. The dimensions listed below will make it possible to find the
,,maxu and ,,minu oil level marks on the dipstick (,,Bf').

Engine type Total length Dist. A Dist. B 4-digit end No, 4-digit end No.
in nnm in rnrn in mm oil dipstick guide tube

C) 2868 LE (with nil sump 350 286 40 5289 0104

for 4 5 O inclination)
 Removing and installing oil separating valve 19/1
(crankcase vent)

Figure 1

The crankcase i s provided with forced

ventilation. The air from the crankcase is
drawn through a vent housing, oil separator
valve and a pipe into the intake manifold
to the engine. The vent housing and the
pipe from the oil separator valve to the in-
take manifold can be of completely dif-
ferent configuration. See Figures 2 and 3.
The oil separator valves are equipped with
fatigue-resistant diaphragms and are there-
fore maintenance-free, On engines which
have to be overhauled after an extended
operation time due to general wear, the oil
separating valves have to be replaced.

Figures 2 and 3

Disconnect hose (1) from oil separating

valve 12). Loosen clip (3). Pull oil separat-
ing valve and O-ring off vent housing (4).
Remove vent housing and gaskets. Clean
all parts and check for damage. Replace
gaskets on vent housing, O-ring, hoses and
clips.
 Removing and installing oil spray jets

Figure 1

valves of spray jets.

Note: The current oil spray jets contain
two balls. The new crankcase does not have
these holes {arrow). When tightening the
oil pressure valve the balls will be pressed
in thereby forming the ball indentations in
the crankcase which are used as installation
marks for the oil jets in repair work.

Figure 2

Using a screw driver check that the valve

piston is s t i l l held in contact by spring
force.

Figure 3

Install oil spray jet. Make sure oil spray

jet is positioned correctly. Place spring
washer on jet body and tighten oil pressure
valve to specified torque; check for correct
1 spraying direction. The oil jet must im-
pinge directly on the piston bottom. Never
repair bent oil spray jets by bending.

Figure 4 -

Turbocharged "Nlf'engines have an annular

cooling channel inside the piston. In
aligning the spray jet, care should be
taken to have the nozzle orifice aimed
accurately a t the inlet hoie of the cooling
channel.
 Removing and installing oil spray jets 20/2

Figure 5

The oil spray jets of the turbocharged " M u

engines with internally cooled pistons
(annular cooling channel), differ from
those of other engines. This should be
noted when replacing these jets.

1 Jet for D 25. . . naturally aspirated

engines and all D 2866. . . engines

2 Jet for D 25. .. turbocharged "M"

engines
 Removing and installing, disassembling and assembling oil pump 2111

Figure 1

Remove oil pan and screws of oil suction

pipe. Measure backlash between oil pump
drive pinion and crankshaft gear. Observe
specified value and replace gears if ne-
cessary.

Figure 2

Remove oil pump screws and take off oil

pump.

Figure 3

Clamp oil pump in a vice (fitted with soft

jaws). Remove screws from oil pump
cover and take off cover.

Figure 4

Remove idler gear and check gears and

pump housing for wear; see ,,specified
values".
 Removing and installing, disassembling and assembling oil pump

Figure 5

pump on a suitable surface and pressing out

the gear with a mandrel,

Figure 6

For installation position the pump such

that the gear is in contact. Place drive gear
on shaft and press in until flush.

Figure 7

Install cover and tighten screws to the

specified torque.
Rework or replace covers with deep
grooves.
I

Figure 8

Check axial clearance of gear.

 Removing and installing, disassembling and assembling oil pump

Figure 9

The pressure relief valves are encapsulated.

To check them, connect pressure gauge
to the oil gallery with the engine cold. In
the case of naturally-aspirated engines
D 25 . . . ME, the pressure should reach
a level between 5 and 6 bar in the case
of all other engines between 9 and 10 bar
for a short period.
 Removing and installing clutch shaft pilot bearing 22/1

Figure 1

Remove flywheel screws.

Figure 2
i
Extract ball bearing with an internal claw
puller. Remove spacer.

Figure 3

l nstall spacer.
Drive in ball bearing by applying a suitable
piece of pipe to the outer race until it con-
) tacts the spacer.

Figure 4

Coat flywheel screws with oil, install them

and tighten to specified torque.

! I! Use new screws (elasticated screws).

 Removing, installing and re

Figure 1

Loosen screws; arrest starter ring gear by

applying tool. Remove -two screws and re-
place by two guide pins. Remove all screws
and take off flywheel. Use two long M 10
jacking screws and press off flywheel. Re-
move bearing race.
Clean and inspect flywheel.
If scores or burnt spots are found on clutch
surface remachine flywheel. Hairline cracks
which do not run into the rim or screw
flange are permissible; see ,,specified values".
1
Figure 2

The bearing race (see also 6, Figure 6) is

chamfered on the inside of one side and the
)' outside of the other side. Place bearina race
in installation tool with outer chamfered
side first and heat to approx. 150oC. Coat
seat of race in flywheel with Omnifit green
150 L and fully press in race. Then thor-
oughly clean and lubricate race with oil.

Figure 3

Crankshaft gear
Dowel pin
Dowel pin hole
Flywheel
Ball retrusion approx. 1 mm
Ball
8.3 + 0.2 mm dia.
Sealing area

Prior to flywheel installation after repair

work seal crank pin as follows: thoroughly
clean crank pin and flywheel within the
area marked by arrow 18). Coat with liylo-
mar universal sealant SQ 32/4. Hole (3) is
tightly sealed by ball (6)in the manufac-
turer's works.
 Removing, installing and r

Figure 4

Place flywheel on guide pins making sure

pin and hole {arrow) are in alignment and
install flywheel.

Figure 5

Coat flywheel screws with oil, screw in and

tighten to specified torque.

!!! Use new flywheel screws (elasticated

screws).

Figure 6

(Standard version)

1 Collar screw
2 CIutch shaft thrust bearing
1 3 Spacer
4 Flywheel
5 Starter gear ring
6 Bearing race
7 Dowel pin 8 h 8 x 32
6
Note: Not all engine versions are equipped
. ..
with ball bearing (2) and spacer (3).
 Replacing starter gear ring 24/1

Figure 1

Remove flywheel.
Drill hole in starter gear ring and cut ring
taking care not to damage the flywheel.

Figure 2
!
Heat new starter gear ring to max. 230°C
and press on as far as it will go. Max. axial
runout of starter gear ring 0.5 mm.
 Replacing rear crankshaft seal (flywheel end)

Figure 1

Figure 2

1 The pressing mandrel consists of two parts.

Before pressing in place guide ring of mand-
rel on crankshaft.

Figure 3

Apply a thin coat of sealing compound to

outer surface of new seal and place it on
mandrel. Apply thin coat of grease to
sealing lip.
1 When placing the mandrel in position
make sure the hole in the mandrel (arrow)
is in alignment with the pin (arrow).

Figure 4

Drive in seal until flush.

Install flywheel observing the seal.
 Removal

Figure 1

Remove belt guard ( 1 ). Loosen V-belt (for

water pump, alternator, depending on mo-
del) and remove it, Remove pressure line
( 2 ) , if provided, pointer (3) for start of de-
livery adjustment, engine turning device (4),
belt pulley (5), vibration damper (6) and
oil splash ring.

Note: On engines with fan cooler first drain

cooling water and remove radiator and fan.

Figure 2

Remove cover.
) ! ! ! The bottom of the cover is secured to the
oil pan.

Figure 3

Push guide ring (3) on race (4), apply

puller (1) with screw (2) and pull off bearing
race.
i
 Replacing crankshaft seal and bearing race 2612

l nstallation

Figure 4

Insert new bearing race with chamfered

end on outer diameter first in mandrel and
heat both to approx. 150 to 2000C. Press
bearing race onto crankshaft until in contact
with the drive-in mandrel. After installation
clean bearing race and coat with oil. The
correct distance between crankshaft front
edge and bearing race is ensured only if 4
modified mandrel 80.9961 7-0016 is used.

Figure 5

) Cover (1) and shaft seal (2) are supplied

for replacement as an assembled set only
to ensure satisfactory installation.

Figure 6

Apply a thin coat of grease to cleaned crank-

case surface (do not use liquid sealing com-
pound) and place cover gasket on top.
Apply multi-purpose grease to seal lips.
I Push cover over guide pins and carefully
bring into contact. Tighten cover screws to
specified torque. Install oil splash ring and
all other parts.
 Removing and installing inlet bend and inlet manifold

Note: There are various types of inlet bends and inlet manifolds. In most cases these parts are so arranged
that instructions for removal and installation are not required. However, do not overlook replacement of
gaskets and damaged parts and observe the specified torques for screws (test values, standard values).
In the following two possible cases will be described:

Figure I (D 2566 MLE)

Remove bend (3) after disconnecting hoses

(2)and removing screw (4). Remove inter-
cooler ( I ) , fuel filter ( 5 ) and manifold (6).

Figure 2 (D 2566 MTE)

To gain access for removal of manifold (1)

the parts fitted to it, such as speed pickup
(2), air filter, fuel filter or cable harnesses
must first be removed.

Note: When removing the parts it is ad-

visable to mark their original position to
facilitate reinstallation.
 Removing and installing exhaust manifold

Figure 1 (D 2565 ME)

Loosen stud nuts ( 1 ) and bend (3) on fly-

wheel end.
Remove screws (2).
Remove bends (4 and 5). Replace gaskets.
Check laminated ring between bends (4
and 51, inspect and replace, if necessary.
Observe tightening torques for screws during
re-installation.

Figure 2 (D 2566 ME)

Remove exhaust manifold consisting of

three parts; otherwise proceed as described
for Figure 1.

Figure 3 (D 2566 ME)

2-section, watercooled exhaust manifold (1)

with cooling water pipe (2) attached outside.
A t the parting joints (3) one gasket each is
installed. Before removal of the exhaust
b manifold drain engine cooling water and
remove cooling water connection (4). During
re-assembly replace all gaskets and damaged
parts. Tighten screws to specified torque.

Note: Follow recommendations given under

31/2, Figure 6 for installation of exhaust 3
manifold consisting of several parts.

Figure 4 (D 2566 MTE for marine propul-

sion)

In the case of engines D 2566 MTEIMLE

with watercooled exhaust manifold drain
cooling water. Remove turbocharger (1)
with inlet bend and air filter, heat ex-
changer, cooling water connection and
thermostat housing. Remove also vent
pipe (2). Remove exhaust manifold (3).
Replace gaskets and damaged parts. Tighten
screws to specified torque.
 Removing and Installing Turbocharger (example)

Figure 1 (D 2566 MTE for marine pro-

pulsion)

1 Viscous air filter

2 lnletbend
3 Charge air pipe to inlet manifold
4 Turbocharger (watercooled turbine hous-
ing)
5 Lube oil line (supply)
6 Lube oil line (return)
7 Cooling water pipe (supply)
8 Cooling water pipe (drain)

Figure 2

1 Inlet bend
2 Charge air pipe
3 Exhaust manifold (non-cooled)
4 Turbocharger
5 Lube oil line (supply)
6 Lube oil line (drain)

In the case of engines with watercooled

turbine housing drain cooling water. Re-
move air filter, inlet bend, charge air pipe
and cooling water pipes.

Figure 3

Remove lube oil pipes (5 and 6). Remove

complete turbocharger from exhaust mani-
fold. During re-installation replace gaskets,
hoses and hose clips.
3011 Checking axial and radial play of 1:urbine/rotor shaft

Checking axial play

Figure 1

Remove turbocharger. Mark position of tur-

bine housing relative to bearing housing.
Loosen clamp on turbine housing and re-
move turbine housing. Apply gauge holder
with dial gauge under preload to shaft end
face of turbine. Press rotor shaft against
dial gauge, read and note value. Push rotor
shaft in opposite direction, read and note
value. The difference between both values
,
is the axial play.
I!! Refer to Technical Data!
Replace turbocharger if play is exceeded.
Install turbine housing while observing
marks. Install clamp and tighten to speci-

turbine in opposite direction, read and

note value. The difference between both
values is the radial play.

! ! ! Refer to Technical Data!

install turbine housing while observing
marks. Install clamp and tighten to speci-
fied torque.

Figure 3
F%aelergauge: Push turbine to one direction
and measure gap between turbine housing
and turbine. Push turbine fully in opposite
direction and measure gap. The difference
between both gaps is the radial play.

I 1 I Refer to Technical Data!

Measure at rwa different points. Replace
turbocharger if play i s exceeded.

Mote: Radial play can be measured with

feeler gauge also while the turbocharger
is installed.
 Removing and installing cylinder head

Removal

Figure 1

Remove inlet bend, inlet manifold and

exhaust manifold. Remove fuel injection
lines and vent pipe for cooling water cir-
cuit. Remove cylinder head covers.

Figure 2

Back off valve adjusting screws. Remove

rocker arm bracket. Remove push rods.
1

Figure 3

Remove cylinder head bolts in reverse

order of tightening.
The cylinder head screw under the injector
can either be removed by means of the
special wrench or with a box wrench
after removal of injector.
Lift off and deposit cylinder head so that
the protruding end of the injector will
not be damaged. Remove cylinder head
gasket. Check cylinder head sealing sur-
face and cylinder block for flatness using
1 a straight edge.

Mote: Remove cylinder heads only with

engine in cold condition to avoid dis-
tortion.

Figure 4

Before installation clean and blow out

tappd holes in crankcase. Clean sealing
surfaces on cylinder head and crankcase.
When grinding the sealing surfaces ob-
serve specified finish. Place new cylinder
head gasket in dry condition in position
observing the hole pattern and mount
cylinder head.

Note: The cylinder head gaskets for

D 25 . . . and 0 28 . . . engines differ.
Check the diameter of the cutout for the
cylinder bore.
 Removing and i~?stalling cylinder head

Installation

Figure 5

Two dowel sleeves per cylinder head are

inserted in the crankcase top surface for
locating the cylinder heads.

Figure 6

ing method, see -instructions on -Pages

3211 and 3212 and ,,Torque Guide Values".
Mote: To avoid any distortion between
cylinder heads and manifolds we recom-
mend to proceed as follows:
- Place cylinder head gaskets in position.
- Place cylinder heads in position.
Screw in cylinder head screws a few
rotations.
- Secure steel ruler (80.99607.0044)
with ground surface on exhaust side

- Tighten cylinder head screws as speci-

f ied .
- Remove steel ruler. Install exhaust
manifold and inlet manifold.

Figure 7

Inspect push rods for distortion. When

inserting the push rods make sure they
f i t into the socket of the valve tappet.
Place rocker arm bracket in position.
Tighten screws lightly and align rocker
arms to valves. Tighten screws to speci-
fied torque.

Figure 8

Note: Before installing rocker arms (4)

on brackets (I f coat contact surfaces
(5 and 6) with OPTIMO LY-PASTE
WH ITET.
 Removing and installing cylinder head 31 /3

Figure 9

With the injectors installed the cylinder

head screw below the injector can be
tightened with the special wrench.

Figure 10
I
Adjust valve clearance. Install fuel injection
lines and inlet manifold and exhaust mani-
fold with graphite-coated side of gasket
facing inlet manifold. lnstall cylinder head
cover with new gasket in dry condition and
tighten screws to specified torque. Install
cooling water pipe. Fill in coolant.
 Removing and installing cylinder head

SUMMARY:

1. Tightening cylinder head screws (torque tightening method)

2. Re-tighteningcylinder head sGrews (torque tightening method)

3. Tightening cylinder head screws (angle-of-rotation mett.lod)

The sealing effect of the cylinder head gasket largely depends on whether the required preload for the
cylinder head screws is actually reached and maintained, Tests have shown that a considerable amount
of the tightening torque i s absorbed by friction due to dry threads and bolt head contact surfaces and
is therefore not available for screw preloading. Therefore proceed as follows:

1. Tightening

1.1 Before installing the cylinder head screws apply engine oil (no lubricants containing MoS2f to
the thread (do not lubricate tapped hole) and to the screw head contact surface.

1.2 To lock the cylinder heads in position tighten screws only lightly. Then tighten in specified
order and in steps to the specified torque. I f during initial tightening some screws are tightened
i excessively, cylinder head and gasket will be distorted and this distortion cannot be compensated
when tightening to the specified torque.

1.3 Use calibrated torque wrenches.

Permanently adjusted ,,snap-type" torque wrenches can also be used.

Calibration of the wrenches can be performed on calibration benches (tool manufacturers and
dealers) or by applying weights to the lever arm. Calibration by comparision of wrenches is not
acceptable. Calibration must be repeated a t certain intervals (approx. every 3 months) depending
on use.

1.4 During final tightening the specified torque must be maintained a t least 5 seconds (not required
in the case of snap-type torque wrenches).
When using snap-type torque wrenches tighten screws slowly since otherwise the torque selected
will not be fully transferred to the screws.

2.1 On new engines and re-conditioned engines the cylinder head screws are retightened to final
torque after the test run in the works. Consequently retightening is unnecessary. A label ,,do
not re-tighten cylinder head screws" i s attached to the engines for an extended period of time.

2.2 When repairs requiring the removal of one or more cylinder heads are carried out, the cylinder
head screws must be re-tightened under load not earlier than after one operating hour.

2.2,1 Re-tighten the cylinder screws with the engine in cold condition, e.g. crankcase hand-warm or
cooler. Proceed as follows:
- Disconnect fuel injection lines from injectors
Loosen cylinder head screws in specified order
- Apply oil to screw contact surface
- Tighten to specified torque

To make sure no screw has been overlooked re-check in specified order.

 Removing and installing cylinder head

3. Tightening cylinder head screws (angle-of-rotationmethod)

From the 4th quarter of 1983 onward the cylinder head screws described in Se
gradually be replaced by screws suitable for the angle-of-rotationtightening meth
white T must be applied to the screw thread (not the tapped hole) and the head
installation. Tighten screws in the specified order, see ,,Torque Guide Values".
Re-tightening of the screws is not ,acceptable, not even after repairs.

3.1 Distinguishingfeatures

In the installed condition these screws

can be distinguished by a triangular symbol
in the screw head. In addition, the thread
length of 90 to 93 mm considerably ex-
ceeds the thread length of the screws used
previously (34 to 36 mm). All engines
supplied with these new screws ex Works
will be marked with a label on one of the
I cylinder head covers.

3.2 Reusabiliw

After each application of the angle-of-

rotation tightening method as specified
the cylinder head screws will be subjected
to permanent elongation. Reuse is only
acceptable if the screw length has not yet
reached the following maximum values.

Left-hand: screw suitable for angle-of-

rotation tightening method
Right-hand: screw suitable for torque
tightening method
Screw length ,,L" max. permissible length
New condition after applying angle-of-
rotation tightening
i
108.5 to 109 mm
143.5 to 144 mm
167.5 to 168 mm

Moreover, the surface of the screws must be free from any defects. To prevent erroneous reuse, discard
all screws even with the slightest defects in the protective phosphate coating or rust or screws which
reach the max. permissible length after applying the angle-of-rotation tightening method. We re-
commend to destroy the threads of these screws using a hammer or by grinding to make them un-
usable.
 Removing and installing valves 33/1

Figure 1

Remove cylinder head.

Mount cylinder head o n valve fixture.
Press down valve spring retainers w i t h f o r k
and remove collets. Lift fork and remove
valve spring retainer, valve spring and
washers.

Figure 2

Note: Valve spring retainer and valve

spring can also b e replaced w i t h the cylin-
der head installed. The piston must be i n
TDC and the t o o l shown must be used.
Turn cylinder head. Remove valves and p u t
aside i n installed order o r mark.

Figure 3

A change o f valve head height ,,H" is n o t

acceptable. Replace damaged valves.

Note: Valve head height ,,H" varies f r o m

valve t o valve; see ,,Inspection Values".

Figure 4

Machine valve seat o r replace.

Lubricate valve w i t h oil and install. Mount
cylinder head o n valve fixture, l nsert valve
spring washers.
 Removing and installing valves 332

Figure 5

Insert valve springs and replace damaged

o r weak springs. The word ,,TOP" facing
upward and tight coifs facing downward.
l nstall valve spring retainers and collets.

Figure 6

1 Measure valve retrusion. Refer t o speci-

fied values. If necessary, replace seat insert
o r valve.
 Figure 1

Knock o r press o u t valve guide

Note: N I valve guides are n o longer avail-

able f o r installation.

Figure 2

Lubricate new valve guide w i t h oil and

I press o r drive into cylinder head using a
mandrel and spacer sleeve. Valve seat must
be machined when replacing the valve
guide.
 Refacing valve seat 3511
(with Hunger valve seat tool)

Figure 1

Insert pilot into valve guide and clamp in

position. The collet collar (arrow) must
contact the valve guide.

Figure 2

i
Clamp turning bit into tool side for the
valve seat angle (45' in illustration).
Attach handle so that bit is pulled.

Figure 3

Place head (1) on pilot and fully back off

feed screw (2) in clockwise direction,
position tip of bit (3) to valve seat centre
using quick-adjustment screw (4) after
I loosening coupling nut (5) and place care-
fully in position on the valve seat. Slightly
press drop pin (6) on the pilot and clamp
with screw (7).

Figure 4

Mount head (1) without constraint and

parallel to axis, back off tool bit with
quick-adjustment screw (2) and lightly
tighten coupling nut (3). Adjust depth
of cut (one graduation = 1/10 mm) by
turning knurled screw (4) anti-clockwise
and lock knurled screw with clamping
screw (5).Wold large knurled screw (6)
and machine valve seat by turning crank.
Loosen coupling nut if necessary, back off
bit using quick-adjustment screw and re-
Peat operation.
 Refacing valve seat
(with Hunger valve seat tool)

Figure 5
I
Note: When ,,remachiningU the valve seat I
rings minimum stock must be removed
from the seat (arrow). Valve retrusion I
serves as guide value. As long as valve re-
trusion is within the specified tolerances
the valve seat width (arrow) will also be
within tolerance. ,,Corrections" (top 15O, a
bottom 75') are not acceptable. If valve
retrusion has changed following remachin-
ing the cylinder head sealing surface t o an
extent that the depth of the valves in the
cylinder head has to be increased, remove
the valve seat rings, match the depth of
the seat rings in the cylinder head accord-
ingly and insert new seat rings, see ,,In-
spection Values".

Note: If valve seat cutters other than the

"Hunger tool" are used, the valves must
be ground in. 7"he valves should be checked
for tightness in any case.
 Replacing valve seat ring

Figure 1

Apply two short weld beads with arc weld-

ing set on valve seat ring and extract ring
by means of internal puller. Clean ring
contact surface in cylinder head.

Figure 2

Heat cylinder head to approx. 80 O C in

water bath. Deep-freeze valve seat ring to
-200 OC and drop it quickly into cylinder
head. Use mandrel (special tool) and
hammer to ensure the ring is in full
contact with the cylinder head seat.
 Removing and installing timing case 37/1

Figure 1

Remove flywheel and starter. Loosen

timing case screws farrows).

I!! The timing case is secured to the oil

pan bottom.

Figure 2

Remove timing case taking care of the oil

I pan gasket. Remove gasket from timing
case and replace it. Inspect thrust washer
on camshaft and replace if necessary.
Apply Loctite to screws of thrust washer
and screw them in.

Figure 3

1 Brace
2 Screws
On engine type D 2565 braces are pro-
vided between crankcase and timing case
for timing case reinforcement. These
braces must be fitted without constraint
to avoide damage to the case. For timing
case replacement completely loosen the
braces and then tighten them to the speci-
fied torque in the specified order, see
torque guide values.

Figure 4

Apply thin coat of grease to gasket and

place gasket in position. install timing case
taking care of locating pins (arrows), oil
pan gasket and crankshaft seal. Tighten
screws to specified torque. Install fly-
wheel .
 Removing and installing timing case 37/2

Figure 5

Timing case
Shaft seal
Thrust washer
Hex, collar screw M8 x 8
Cover (depending on installation)
O-ring
O-ring
Hex,collar screw M I 0 x 70
Stud M I 2 - M I 2 x 1.5 x 30
Gasket
Hex. collar screw M I 0 x 54
Cover
Gasket
Hex, screw M8 x 25
 Removing and installing camshaft / Replacing camshaft bearing
Checking valve timing

Figure 1

Drain engine oil and coolant. Remove heat

exchanger, raw water pump or compressor
with PTO. Remove V-belts, engine turn-
ing device, belt pulley and vibration dam-
per. Remove rocker arm brackets and push
rods. Remove flywheel, timing case and
angle drive for tachometer.

Note: Front cover and side cover can re-

main installed if the engine has no PTO
for raw water pump or compressor.

Before removing the camshaft bearings

remove cylinder heads, piston and con-
necting rod assemblies and the crankshaft.

1 Remove screws of PTO gear and take off

gear.

Figure 2

Turn engine upside down so that valve

tappets do not obstruct camshaft removal
(mushroom tappets cannot be removed
in upward direction). Pull out camshaft
taking care not to damage camshaft bear-
ings. Inspect camshaft for wear and re-
place if necessary. If the camshaft or
camshaft gear is defective the camshaft
and gear must both be replaced.

Figure 3

Push out valve tappet downward with

suitable mandrel, inspect for wear and
1 replace if necessary. Valve tappets can
only be removed after removal of cam-
shaft.

! !I Valve tappets, size N and N I can be

installed in one and the same engine.
IV I tappets are marked with a dot of red

Figure 4

Drive out camshaft bearing bushes with

suitable mandrel and drive in new bushes.
Make sure oil passages are positioned cor-
rectly.
3812 Removing and installing cam
Checkinig val

Figure 5

Carefully slide in camshaft making sure

the gear is in correct position relative to
the crankshaft gear (see 39/2, Figure 5).
When reinstalling the other parts pay spe-
cial attention to the following: Install
cover ( 1 ) with new gasket. Align cover (I )
so that i t s side outer edge is flush with the
crankcase edge of supporting surface (2)
for the PTO to avoid leakage a t the joint
(31. Completely remove any gasket residue
at the joint.

Figure 6

The cover can be aligned flush using a

straight edge; however, there are also
special tools for accurate alignment of the
cover, Fig. 7.

Figure 7

wing screws ( 6 ) to assembly plate; tighten

screws only lightly. Apply centring device
(2) for driver of speed transmitter. Clamp
cover (5) tightly against assembly plate ( I )
with wing screws (6). Tighten cover screws
to specified torque and remove assembly
plate. Carefully remove excess sealing com-
pound. Coat bottom of groove in com-
pressor housing and sealing surface on cut
surface of gasket with sealing compound
(Atmosit). Insert moulded seal in com-
pressor housing and install housing.
 3813 Removing and inst

Figure 8

Check axial play of camshaft. Push cam-

shaft against crankcase to take up the play.
Measure dimension (x) for camshaft gear
and dimension (y) for thrust washer. Add
gasket thickness z (0.5 mm) to dimension
y and subtract dimension x to obtain
camshaft axial play. I f the play is not
within the specified tolerance replace
thrust washer or timing case cover.

Dimension x = distance between crank-

case sealing face and camshaft gear
thrust face
Dimension y = distance between timing
case sealing face and thrust washer
Dimension z = thickness of gasket under
pressure
Camshaft axial play = (y + z) - x
i
1 Crankcase
2 Steel rule
3 Camshaft gear
4 Crankcasesealingface
5 Timing case sealing face
6 Thrust washer
7 Timing case

Figure 9

Camshaft axial play can also be checked

with timing case cover installed. To do so
remove compressor, apply dial gauge to
compressor drive gear and push camshaft
in axial direction using a screwdriver.

Install all removed parts as specified.

Check start of delivery and valve timing.
Mote: Starting from April 1986, modified
camshafts will be installed successively in
production engines. The modification of
the camshafts involves the standardization
of the valve clearances for inlet and
exhaust valves to 0.50 mm. Engines whose
valve clearance is factory-set to 0.50 mm
are marked by a label to this effect on one
of the valve covers. After the previous
camshafts have been used up, the modified
camshafts will be supplied for ali spare
parts requirements. The spare parts con-
signment will incfude a note about the
vake clearance to be set, !t i s recommended
that all engines in which the modified
camshafrs are retrofitted be marked and a
hand-written correction included in the
relevant Operating Instructions Manual to
ensure that the correct valve clearance
adjustment is made during maintenance.
 3814 Removing and installing camshaft 1Replacing camshaft bearing 38/4
Checking valve timing

CHECKING VALVE TIMING

Turning the shrink-fit camshaft drive gear may cause serious damage to engine. Consequently when
an engine condition existed which may have caused turning of the gear, e.g. resulting from com-
pressor failure, check for correct gear position by checking the valve timing.

Proceed as follows:

- Remove cylinder head cover from 1st cylinder

- Carefully adjust exhaust valve of this cylinder
- Turn engine until the valves of cylinder No. 1 overlap
- Turn engine to approx. 50' before TDC
- Then turn engine forward again to 30' before TDC (observe degree mark on flywheel)
- Apply dial gauge with approx. 10 mm preload on valve spring retainer of exhaust valve in cylin-
der No. 1 and set to ,,O"
- Turn engine through 180' in direction of rotation (exhaust valve fully closed)
- Read valve stroke on dial gauge

1 The following table contains the valve strokes which guarantee the correct position of the camshaft
gear and therefore correct timing.

Engine Model Valve lift

D2565166 ME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 to 3.9 mm

D2866E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8to4.8mm
D 2566 MTEIMLE, D 2866 TE/LE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 to 6.4 mm
 Removing and installing crankshaft

Figure 1

Remove oil pan, oil pump, timing case,

cylinder heads and front cover of crank-
shaft seal. Remove screws of connecting
rod bearing caps and remove mnnecting
rod with piston.

Figure 2

Remove screws of crankshaft bearing caps.

Number bearing caps in order of installa-
tion and take them off. Match mark bear-
ing shells with bearing caps (electric scri-
ber) unless already marked.

Figure 3

Lift out crankshaft. Remove bearing

shell halves of crankcase. Inspect crank-
shaft and replace if necessary.

Figure 4

Clean oil passages in crankcase and crank-

shaft with compressed air. Thoroughly
clean bearing shells and bearing pins and
install new bearing shells in crankcase if
necessary. Observe repair stage.
Numbering of crankshaft bearings: I =
water pump end!
 Removing and installing crankshaft

Figure 5

Lubricate bearing surfaces of bearing shells

with oil and install crankshaft. Observe
position of marks (arrow) of crankshaft
and camshaft gear.

Figure 6

l nstall crankshaft bearing caps with bearing

shells. Screw in and tighten bearing cap
screws to specified torque in steps. Tighten
finally with rotation angle gauge.

I!? Use screws only once (elasticated

screws).

Figure 7

Check axial play of crankshaft. The axial

play depends on the thrust bearing. Mount
dial gauge holder vvith dial gauge on crank-
case. Push crankshaft in axial direction and
1 read play on dial gauge.
After installation check crankshaft for free
rotation.

Figure 8

Measure connecting rod bearings. Install

pistons with connecting rods.
Coat connecting rod bearing shells with
oil and pull connecting rods onto the
crank pins. Mount connecting rod bearing
caps with bearing shells (observing po-
sition of mark - numbers must be on the
same side).
Screw in screws and tighten in steps to
specified torque.
 Removing and installing cranksha%

Tighten finally with rotation angle gauge;

apply rotation angle gauge so that the angle
hook contacts the casing. Tighten screw
through another 90'.

Figure 10

There are two sizes of big end and main

bearings as well as for tappet bores, also in
production models, viz Normal (N) and
Normal I (N I = 0.1 mrn deviation). To
make sure this difference is definitely
noted during repairs, the nameplates are
provided with an N I box (see arrow). If
N I parts are installed in an engine, the
following letters will be stamped in the
N I box:

P = Crankshaft; big-end bearing

ti = Crankshaft; main bearing N
S = Tappet bore N l
 Removing and installing crankshaft

Figure 11

In the case of an N I crankshaft all crank pins and main bearing journals are of N I size. The crank pins
and main bearing journals are marked grey as shown in the drawing below. Regarding the tappet bores
the figure after the ,,S" indicates the number of N I bores in the crankcase. These must be determined
by measurement.
 Removing and installing pistons with connecting rods

Figure 1

Remove oil pan, oil pump suction pipe

and cylinder heads; remove screws from
connecting rod bearing caps and lift off
caps with bearing shells.

Figure 2

Remove combustion deposits from cylinder

liner top edge (taking care not to damage
liner surface). Push out connecting rod
with piston in upward direction. Check
pistons and piston rings for damage. Re-
place piston if cracks are found on edge
of combustion chamber.

Figure 3

Inspect bearing shells for wear and damage

t o top layer. Measure spread. lnstall new
bearing shells if necessary. When repairing
the crank pins use bearing shells of the
I corresponding repair stage.

Figure 4

Install bearing shells into connecting rods

and connecting rod bearing caps (top coat
must not be damaged).
 Removing and installing pistons with cannecting rods

Figure 5

Lubricate cylinder liner and piston with

oil. Apply piston ring compression tool
or sleeve (piston ring gaps offset) and
install piston with connecting rod into
cylinder liner (entrant section on piston
crown facing fuel injector).

!!! Take care not to damage oil spray jets

during installation. See ,,oil spray jets",
Figure 4.

I Figure 6

l nstall connecting rod bearing caps (Iine

up figure in cap with figure on crankcase
edge). Tighten screws in steps to speci-
fied torque. Tighten finally by means of
rotation angle gauge.

! !! Note: After proper application of the

rotation angle tightening method the
connecting rod bearing screws will be sub-
jected to permanent elongation. Reuse is
only acceptable if the shaft length does
not exceed 69 mm. The shaft length of the
new screws ranges from 67.2 to

Figure 7

!! !?Note: After proper application of the

rotation angle tightening method the con-
necting rod bearing screws will be sub-
jected to permanent elongation. Re-use
is only acceptable if the shaft length does
not exceed 69 mm.

Screw length "L" max. permissible length

after applying angle-of
rotation tightening me-
thod
 Replacing piston rings

Figure 1

connecting rod in a vice fuse soft jaws).

Adjust piston ring pliers to piston size
(125 or 128 mm),

Figure 2

Remove piston rings. Clean piston ring

grooves. Be careful not to damage piston
ring grooves.

Note: The oil scaper rings are bevelled-

edged spring-loaded oil rings.

Figure 3

Check piston ring gaps. Observe specified

values. Install piston rings in piston using
piston ring pliers.
The ,,TOP" mark or the manufacturer's
designation must point upward. Adjust
piston ring gaps 120' offset on piston cir-
cumference. The piston ring gaps must not
be located above the piston pin bores.

Figure 4

Measure piston ring clearance in groove.

In the case of excessive clearance replace
piston and rings.

Note: Pistons and piston rings for "M"

naturally aspirated, "M" turbocarged
..
engines and D 2866 . engines differ. See
Chapters Testing and Adjusting Values
and "Oil-spray Jets".
 Detaching and attachiing piston on connecting rod
Checking coninecting rod

Figure 1

Remove piston with connecting rod. Clamp

connecting rod in a vice using soft liners.
Remove piston pin circlips. Remove piston
pin. Take off piston.

Figure 2

Install new big end bearings. Install cap

and measure bearing bore.

Note: Small end bushes are not available.

Replace connecting rod if bushes are de-
fect ive.

Figure 3

Clean connecting rod and inspect for ex-

ternal damage; scrap rod if defective.
Check connecting rod for parallel bores
and skewing of piston pin bore relative
t o bearing shell bore. Replace connecting
rod if the two bores are not parallel or
skewed relative to each other.
Place piston on connecting rod (entrant
section and long fork arm on the same
side). lnsert piston pin. l nstall circlips.
 Removing and installing cylinder liners

Figure 1

Remove cylinder head and piston. Insert

cylinder liner puller into liner making sure
not to damage the oil jet.

Figure 2

Place support on extraction screw and

install nut.
Hold extraction screw in position and ex-
tract cylinder liner by tightening nut.
Remove puller and park cylinder liner
upright. Remove O-rings.
Number cylinder liners in order of in-
stallation.

Figure 3

Before final installation of the liner check

protrusion over crankcase surface. Clean
bore in crankcase and liner for this pur-
pose. Install cylinder liner without O-
rings in crankcase and check protrusion of
cylinder liner a t four points using a dial
gauge holder and di
Note: Cylinder li e
diameter are also available for repairs
with an oversize flange depth, see Chapter
"festing and Adjusting Values".

Figure 4

lnstall new O-rings in dry condition in

crankcase. Install new O-rings under the
collar of the cylinder liner. Lightly lubri-
cate protruding parts of O-rings with engine
oil and insert liner into crankcase.

!!! Do not use the sealing compound

,,Dirk0 Transparent" for repairs.
 Removing and installing cylinder liners 43/2

Figure 5

Carefully insert cylinder liners by hand to

avoid twisting or pushing the O-rings out
of their groove. Place clean metal plate on
liner and exert uniform downward pressure
until the liner is seated in the crankcase
recess.

Figure 6

Reconditioned engines can be fitted with

0.5 mm oversize outside diameter cylinder
liners. On these engines the locating fea- Dieser Austauschmotor hat einbau-
tures taking up the liners in the crankcase
are also 0.5 mm oversize. The standard
O-rings for sealing the cylinder liners can
still be used. The oversize liners are avail-
able as spare parts; observe this when re-
placing liners. The liner version is identi-
fied by the data plate on the cylinder head
cover as shown on the right.
Translation of the @late, shown in the fig:
This exchange engine has ready to install, 6
easily replaceable shouldered cylinder liners.
Note: No oversize liners are used for the
D 2866 . . . engines.
 Measuring piston protrusion 4411

Figure 1

Turn engine via hexagon (32 mm across

flats) (arrow) to move piston to TDC.

Figure 2

For engines where the turning device

shown in Figure 1 is inaccessible, a turn-
ing gear is available as a special attachment.
With this special gear the engine can be
turned via the starter ring gear (inspwtion
hole for start of delivery adjustment).

Figure 3
\
Apply dial gauge in holder without con-
tacting the liner collar and measure piston
protrusion above cylinder head sealing
surface. Specified values must be main-
tained.

Figure 4

NOTES FOR RECONDITIONED EN-

GlNES

Selection of piston length for crankcases

with remachined sealing suvfaces
On reconditioned engines the cylinder
block parting faces may be remachined.
The machined size i s stamped in the face
of the erankcaselcylinder head parting
surface behind the cylinder head in the
crankcase. During assembly or disassembly
the following must be observed.
 Measuring piston protrusion

1. Depending on the repair stage pistons w h i ~ hare undersize (see ,,Checking Data") in respect of the
compression height X are used. The dimension is stamped into the piston crown below a 3digit
number (last three digits of the part No.).

2. The pistons (piston crowns) must not be remachined since they are hard anodized.

3. After piston replacement measure compression height X; piston protrusion above crankcase top
must be within the specified values.
 Removing and installing compressor

Figure 1

Disconnect coolant lines and suction as

well as discharge lines from compressor
cylinder head.

Figure 2

If a hydraulic pump is f lange-mounted to

the compressor instead of the cover, dis-
connect pump oil lines. Close pump ports
and lines with protective caps. Remove
compressor screws and take off compres-
sor. Inspect compressor for external da-
mage. Replace compressor housing if
fractures or cracks are found on mounting
holes or machined mating faces.

Figure 3

Remove hydraulic pump.

Figure 4

Install compressor with new gasket, Tight-

en screws to specified torque. Install
cover or hydraulic pump and oil .pipes.
.
Keep everything clean.
 Disassembling and assembling compressor 46ll

Figure 1

Remove compressor and clamp in a vice

w i t h soft jaws. Loosen cylinder head
screws and take o f f cylinder head w i t h
gasket.

Figure 2

Remove air-cooled valve plate (1) and

clamp in a vice w i t h soft jaws, Remove
screws (6) o f exhaust valve (2). Remove
bushes (5),exhaust valve catch (4), washer
(3) and exhaust valve (plate). Reverse
plate and remove intake valve (plate)
(7). Check exhaust valve, and replace
if necessary. Valve must not be scored o r
worn. Replace complete valve unit when
damaged.

Note: The water-cooled valve plate must

n o t be disassembled as effective sealing
between air and coolant spaces without
special test equipment is n o t ensured
after assembly. Even small leaks may re-
sult i n considerable damage by water.

Figure 3

Inspect inlet valve plate and replace if

necessary. Plate must not be worn o r
cracked.
 Disassembling and assembling compressor

Figure 4

Remove screws of compressor cylinder.

Pull off cylinder and remove with gasket.
Check cylinder liner and piston for x o r -
ing and seizure, especially if oil is ejected
a t the pressure regulator of if delivery is
insufficient.

Note: Modified compressor mounting

screws (2)have been used for some time.
1 = previous type
4

Figure 5

Remove circlips of air compressor piston

pin.

Figure 6

Remove compressor piston pin and piston.

Check piston rings and piston ring grooves
for wear and replace rings and pistons if
necessary.

Note: Piston and cylinder liner must be

replaced as matched set.

Figure 7

Loosen connecting rod screws and remove

connecting rod.
 Disassembling and assembling compressor 46/3

Figure 8

Remove cover of drive gear

Figure 9

i l nstall crankshaft locking device.

Figure 10

Remove compressor drive gear screw.

Figure 11

Remove compressor drive gear forcing it

off with a screwdriver.
 Disassembling and assembling compressor

Figure 12

Press out compressor crankshaft with com-

pressor bearing flange and remove O-ring
from bearing flange. Remove circlip in
front of compressor bearing.

Figure 13

Remove bearing of compressor shaft with

internal-claw puller and extraction bridge.

Note: We recommend bearing replacement

during engine overhaul to prevent any
failure and any consequential damage.

A t the same time check and replace if

necessary the following compressor parts:
- Piston and cylinder liner for scores
(seizure)
- Suction and discharge valve in inter-
mediate plate for proper functioning
and
- Pipe coil for oil carbon deposits.
Figure 14

Check bearings, replace if necessary and

fully press in with a mandrel. Install cir-
) clip in front of air compressor bearing.

Figure 15

Install compressor crankshaft.

 Disassembling and assembling compressor

Figure 16

Replace O-ring of compressor bearing rear

flange. Check bearing bush in flange for
wear and scores.

Figure 17

l nstall compressor bearing flange making

sure oil feed bore is not covered (arrowsf.

17

Figure 18

Install compressor drive gear. Lock crank-

shaft with locking device and screw in
mounting screw.

Figure 19

Tighten screw for compressor drive gear

to specified torque using a torque wrench.
Remove locking device.
 Disassembling and assembling compressor

Figure 20

Replace O-ring on cover of compressor

drive gear.

Figure 21

Install and secure compressor drive gear

cover.

Figure 22

lnstall connecting rod and tighten con-

necting rod bearing cap screws to speci-
fied torque.

Figure 23

Fit piston and piston pin to mnnecting

rod.
 Disassembling and assembling compressor

Figure 24

Install piston pin circlips.

Figure 25

' Piston and cylinder liners are available

in matched sets B, C, D in 0.01 mm in-
crements. Pistons and cylinders are marked
as illustrated. Only use parts with same
pairing letter.

1
r Gru2 e enhuchstabe
r c oder D

Figure 26

l nstall gasket between cylinder and crank-

case of compressor. Compress upper piston
rings with compression tool and carefully
push on cylinder.
Make sure that the two holes for center-
ing the valve diaphragm are on the side of
the bearing flange/hydraulic pump drive.
 4618 Disassembling and assembling compressar 46/8

Figure 27

Compress compressor bottom piston ring

by means of piston installation tool and
carefully push on cylinder. Remove in-
stallation tool and place cylinder on
casing.

Figure 28

Install and tighten cylinder mounting

screws.
I

Figure 29

Replace gasket between cylinder and valve

diaphragm.

Note: ,,OBENITOPn must point towards

valve diaphragm.
i

Figure 30

l nsert intake valve (diaphragm) into valve

diaphragm while observing centering pin.
Mate: Diaphragm is dome-shaped. Check
position of diaphragm as follows: Press
diaphragm a t Point A on valve diaphragm
and put finger on Point B. I f this causes a
noise, the diaphragm is inverted - turn
round.
Place valve diaphragm in position while
observing centering pins and diaphragm.
 Disassembling and assembling compressor

Figure 31

Position cylinder head with gasket for in-

stallation. Tighten screws to specified
torque.

Figure 32

Before flange mounting the hydraulic

pump install plate.
1

Figure 33

Replace O-rings of hydraulic pump or

gasket for cover.

Figure 34

Tighten screws of cover or hydraulic

pump. Install compressor with new gasket.
Tighten screws t o specified value. Re-
connect lines.
Note: For common installation of com-
pressor casing and camshaft cover refer to
Page 3812, Figure 7.
 Monitoring devices, instrument p

Figure 1

1 Cable, coolant temperature sensor to

switch cabinet
2 Coolant temperature monitor
3 Oil pressure monitor
4 Tachometer drive
5 Speed transmitter

Monitors (2 and 3) were set to switching

thresholds; when these thresholds are ex-
ceeded the engine monitor will receive
pulses for engine shut-down. The switch- 1
ins values are indicated on the inner side
o f the cover (2 + 3). If damaged, use new
devices. Adapt switching thresholds and
cable connections to previous ones.

1 The speeds picked up by angle drive (4)

are transmitted to the tachometer, Figure
2, via transmitter (5).

Figure 2

l nstrument panel types.

The instrument panels are adapted to the
requirements and the space available.
 Removing and installit79 alternator, regulator, overvoltage
protection, start inhibit relay

Figure 1

Note: Before carrying out any work on

the electrical system it is mandatory first
to disconnect the battery earth terminal.
Reconnect as last operation. Start inhibit
relay 11) prevents restarting as long as the
flywheel is rotating.
Overvoltage protection (3) intercepts vol-
tage peaks (above 28 V) which may occur
briefly in the system to protect voltage
regulator (2) and alternator (4) from
damage. If defective, disconnect voltage
regulator (2)'overvoltage protection (3)
and start inhibit relay (1) and replace.

Removing and installing alternator

I Figure2

Alternator with hose-proof enclosure

1 Voltage regulator
2 Generator protection plate
3 Eye bolt
4 Screws
5 Screw

Figure 3

Alternator with integrated voltage regu-

lator

1 Voltage regulator
2 Alternator with integrated regulator
3 Eye bolt
4 Screws
5 Screw
6 Cable

Figure 4

Remove protective plate (2), Figure 2

where provided.
Disconnect cable (6).
Loosen screws (4 and 5). Loosen tension-
ing nuts on eye bolts 13).Swivel alterna-
tor (2) and remove V-belt. Remove screw
(4). Remove alternator.
I f required, remove alternator bracket.

Alternator installation is in reverse order

of removal.

Tension V-belt as specified .

Tighten screws to specified torque.
 SO/l Removing and installing preheater

Figure 1

1 Immersion heater
2 Mains connection
3 Heater shell
4 Water line to crankcase
5 Temperature setting scale
6 Drain plug
7 Water pipe from cooling water con-
nection.

Figure 2

I Heater shell installed in vertical position.

Other positions are also acceptable.

For removal first disconnect cable from

connection (2). Remove drain plug (6),
Figure 1 and collect coolant. Remove
water pipes (4 and 7).
Remove heater shell assembly. Screw out
immersion heater. Clean all parts. Replace
defective parts. l nstallation is in reverse
order. Refill coolant.

Figure 3

Connect cooling water line to heater

shell.

Figure 4

Select most favourable preheating tem-

perature for engine. For this purpose
toosen clamping screw somewhat and
turn regulator switch until the desired
temperature on the scale lines up with the
mark on the heater shell. Tighten clamping
screw.
 5111 Removing and installing, disassembling and assembling 51/1
tensioning pulley

Figure 1

Remove belt guard.

Slacken V-belt and remove. Remove nut
(arrow) and take off tensioning pulley.

Disassembling tensioning pulley

Figure 2
t

Carefully drive out cover (1 and 2). Drive

through bearing pin (3). Remove bush
14) and Nilos rings (5). Extract one deep-
groove ball bearing (6) with internal pul-
ler, remove spacer (7), circlip (8) and press
out second bearing with suitable tool
applied to outer race. Clean, inspect and
replace parts, if necessary.

Assembling tensioning pulley

lnstall circlip (8) in tensioning pulley (9).

Fully press in one bearing 16) with lettering
facing circlip against circlip. Install spacer
(7) and fully press in second bearing with
lettering facing circlip.

Note: Different depths of circlip and spacer

r may cause stresses when pressing in the
bearings. To avoid this press in second bear-
ing simuitaneously a t inner and outer race.
Fill offset groove for Nilos rings (5) with
multi-purpose grease. lnstall individually
into tensioning pulley. Insert bearing pin
(3). Slide on bush (4). lnstall covers (1
and 2) and spread by applying a light blow
so that their rim is fully seated (tight)
in the notch of the tensioning pulley.
Lock cover in position with centre punch
at 4 or 5 points (arrow). Secure tensioning
pulley in bracket. Place V-belt in position
and tension as specified. Fit belt protec-
tion,
 Gaskets

INSTRUCTlQNS FOR lNSTALLATlON OF GASKETS

To facilitate installation or for improved sealing, sealing compound or adhesive is frequently applied to
gaskets. When parts of materials having different coefficients of expansion are assembled (e.g. aluminium
and cast iron) the gasket may be displaced during operation resulting fromi the so-called step or sewing
machine effect causing leaks.

Example: The cover of the front crankshaft seal on engines of D 25 series. The use of sealing compound
or adhesive will cause the gasket gradually to move inward due to differences in thermal expansion resulting
in oil losses which may be attributed to the shaft seal.

For satisfactory installation of gaskets, proceed as follows:

- Use only original M,A.N. gaskets
- Sealing surfaces must be clean and free from damage
- Never use adhesives or sealing compounds - to facilitate installation apply some grease, if necessary
so that the gasket will adhere to the component. Uniformly tighten screws to specified torque.
t
 Design in-line vertical
Principle:
Cycles 4 stroke
Method: D 25 .. ME, MTE, M LE engines ................................ Diesel method with direct fuel
injection into spherical com-
busrion chamber in centre of
piston (M-System, single hole nozzle)

Method: D 2866 E, TE, LE .................................................. Diesel method with direct fuel

injection (four-hole nozzles)

Number of cylinders
D 2565 ME I ME 125 ..................................................... 5
D 2566 M E / MTE /MLE ............................................... 6
D 2866 E / TE / LE ....................,
. ............................ 6
I

Piston-swept volume
D 2565 ........................................................................... 9.51 1 litress
D 2566 ........................................................................... 11.413 litres
D2866 ........................................................................... 11.967litres

Compression ratio
D 2565 ME / ME 125 / D 2566 ME ............................... 18
D 2566 MTE / MLE ................................................... 17
D 2866 E ...............................
... .......................... 17.5
D 2866 TE / LE ............................................................ 15.5

BorelStroke (D 25 . . . engines) ..................................... 125 / 155 mm

BorelStroke (D 28 . . .engines) .........................
a.....tsa.,........ 128 / 155 mm

Firing order
D 2565 ME /ME 125 ......................,.......~~.~...... 1 -2-4-5-3
D 2566 ME I MTE / MLE .......................,............. 1- 5-3 -6 -2 -4
D 2866 E / TE / LE .................................... 1-5-3-6-2-4
I
Lubrication ....................................................................... force-feed
by ............................................................................ gear oil pumps
filling capacities ........................................................ see operating instructions

Cooling system .................................................................. water-cooled

circulation by .............................................................. impeller pump
normal operating temperature ........................ , . ....... 80 to 900C

Note:
The ratings are indicated on the engine nameplate
 TESTlNG AND ADJUSTING VALUES

CRANKCASE

Case bore for liners

Press fit, uppar ......................... standard size ...*.a. 143.000 to I43,04O mm (dia 143 tl 7)
aversize 0,5 .......... 143,5011 to 143.5"1 mm {(dia 9435 H 7)
oversite l .0 .......... 144.000 to 144.040 mm (dia 144 H 7)
Press fit, lower .....................*... sravaderd size ......... 1411,000 ta 140,040 mm (dia 140 W 7)
ovarsrra 0.5 .......... 140.500 ta 140.5411 mm (dia 148.5 H 7)
oversite "10 .......... 141,000xa 141.0cSOmm (dia 141 H 7)

Collar diameter in engine block ......... standard &re ......... 152.100ro 152.350mm (dig 152.1 H 11)
oversize a,M1 .0 .,.. 152,600 to 152.850 rnrn (dia 152.6 H 11)

Depth of flange recess ......................................................... 9.980 to 10,000 mm

Flangedepth (cylinder liner) .............. sfandiardsirs ap
.., 10.030 to 10,050 rnm

Liner outside diameter

on flange .................................. standard size .......... 151"$94 to 151.95'1 rnm (dia 152 f 8)
oversize 0.511 .O ..... 152.394 to 152,457 mm (dia 4 52,5f 8)
ard size .......... 142.961 to 142.986 rnm fdia 143 g 6 )
ize 0.5 ............ 143.461 to 143.486 mm (dia 1435 g 6 )
oversize 1.0 ............ 143.961 to 143.986 mm {dia 144 g 6)
standard size .......... 139.932 to 139.957 mm (dia 140 f 6 )
oversize 0.5 ............ 140.432 to 140.457 mm fdia 140.5 f 6)
oversize 1.0 .......... 140.932 to 140.957 mm (dia 745 f 6)

Clearance
on flange ......................................................................
on upper press fit ..........................................................
on lower press fit .......................................................

Cylinder bore .......................... 125.000 t:, 125.020 mm

Max. wear limit .................................................................. 0.1 5 mm larger than basic size

Press fit, upper .............................................................. 145.80 to 145.84 mm (dia 145.8 H 7)

Press fit, lower .............................................................. 144.50 to 144.54 mm (dia 144.5 W 7)
Collar diameter in engine block .................................... 153.90 to 154.15 mm (dia 153.9 W 11

Depth of flange recess ...........................w......e..........n..........

Flange depth (cylinder liner) .............. standard size ..........
oversize ..................
Liner outside diameter
on flange ........................................................................ 153.694 to 153.757 mm (dia 153'8 f 8)
on upper press fit ........................................,....e........ 145.761 to 145.786 mrn (dia 145.89 6)
on lower press fit .......................... .............................. 144.432 to 144.457 rnm (dia 444.5 f 6)

Clearance
on flange .............................. ..
......................................
on upper press fit ........................................................
on lower press fit ..........................................................

Cylinder bore ........................

......................................
Max. wear limit ....................., ......................................... 0.15 mm larger than basic size

*Note: oversize depth only liners with standard outer diameter

 204 TESTlRIG ARID ADJUSTING VALUES 204

CRANKCASE (continued]

All engines

Permissible conicity over cylinder length

inareaa ...............................
.,................................... 0.005mm
inareab ............................. .
.. ................................... 0.008mm

Liner protrusion above upper edge of crankcase (measured a t

bearing surface for cylinder head gasket)
measured a t 4 point, liner without rubber rings .............. 0.05 to 0.07 mm

PISTONS

Piston diameter, measured a t right-angle to piston boss

D 2565 ME, D 2566 ME
KS, measured J9 mm above bottom edge of piston ........ 124.844 to 124.876 mm
Mahle, measured 19 mm above bottom edge of piston ... 124.845 to 124.875 mm
D 2566 MTE / MLE
KS, measured 25 rnm above bottom edge of piston ........ 124.834 to 124.866 mm
Mahle, measured 27 mm above bottom edge of piston .... 124.835 to 124,865 mm
D 2866 E
Mahle, measured 27 mm above bottom edge of piston ... 127.865 to 127,905 mm
KS, measured 25 mm above bottom edge of piston ........ 127.834 to 127.866 mm
D 2886 TE / LE
Mahle, measured 25 mm above bottom edge of piston ... 127.835 to 127.875 mm
KS, measured 25 mm above bottom edge of piston ........ 127.834 to 127.866 mm

D 2566 ME, D 2566 ME / MTE 1 MLE

Compression height "X" (see Page 44, Fig. 4) ...................,. 89.75 to 89.80 mm
Undersize 0.20 .............................................................. 89.55 to 89.60 mm
Undersize 0.40 .......................................................... 89.35 to 89.40 mm
I! Undersize 0.60 .............................................................. 89.15 to 89.20 mm

D 2866 E
djompression height "X" (see Page 44, Fig. 41 ........................ 89.820 to 89.870 mm
Undersize 0.20 ............................................................ 89.620 to 89.670 mm
Undersize 0.40 ........................ . . . .............................. 89.420 to 89.470 mm

D 2866 TE / LE
Compression height " X u (see Page 44, Fig. 4) ...................... .. 89.75 to 89.80 mm
Undersize 0.20 ............................................................ 89.55 to 89.60 mm
Undersize 0.40 ..................................... ................. 89.35 to 89.40 mm
 205 f ESXIMG AMD ADJtlSTlMG VALUES

Bore for pistan pins D 2665 ME, D2586 M E

..
Mahie .............................."..*.. .........*.....,...........*........
..
KS ..................... .........................................................
Bore for piston pins D 2566 MTE / MLE, D 2866 E / TE / LE
Mahfeand KS ................................................................
Piston protrusion above crankcase top
D 2565 ME, D 2566 ME, D 2866 E .............................. 0.1 1 to 0.43 rnrn
D 2566 MTE I M LE, D 2866 TE / LE ........................... 0.01 to 0.33 mm
Piston ring height
1st ring
Keystone-type ring D 2565 ME, D 2566 ME 2.575 to 2.595 mrn
Keystone-type ring D 2566 MTE / M LE,
D 2866 E / TE / LE .......................................
2nd ring
Taper face ring D 2565 ME, D 2566 ME ........................
Taper facelundercut ring D 2566 MTE / MLE, and
D 2866 E / TE / LE .....................................................
i
3rd ring
Oil scraper ring (bevelled ring) ......................................
Width of piston ring grooves
1st ring
Keystone-type ring D 2565 ME, D 2566 ME ................
Keystone-type ring D 2566 MTE / M LE
Mahle ....................................................................

Keystone-type ring D 2866 E / TE / LE

Mahle ..............................................a .............
2nd ring
3rd ring, oil scraper ring
Mahle ...................................................................

Piston ring axial play

1s t ring
Keystone-type ring D 2565 ME, D 2566 ME ................
Keystone-type ring D 2566 MTE / M LE ......................
Keystone-type ring D 2866 E / TE / LE
Mahle ...................................................................

2nd ring ........................................................................

3rd ring
Oil scraper ring
Mahle .......................... . . ....................................
Piston ring gap
D 2565 ME, D 2566 ME / MTE / MLE
1st and 2nd ring ......................,. . ..............................
3rd ring .......................................................................
D 2866 E / 3% / LLE
1st and 2nd ring ...........................................................
3rd ring ..........................
 LUO TESTING AND ADJUSTING VALUES

PISTONS (continued)

.
.
Max. wear limit ................... ......................................... 1.5 mm
Max, difference in weight per engine piston set .................... 50 g
Piston pin diameter ............................................................. 45.994 to 46,000 mm
CONNECTING RODS

Piston pin bushing inside diameter .................................... ... 46.055 to 46.065 mm

Piston pin radial play in connecting rod ............................... 0.055 to 0.071 mm
Conrod width a t small end ................................................ 45.808 to 45.870 mm
Conrod crank pin width .................................................... 46.000 to 46.100 mm
Conrod axial play ........................ .
.
.................................. 0.1 30 to 0.292 mm
Conrod bearing radial play .................. ............................. 0.060 to 0.142 mm
Bearing shell bore in connecting rod .................................., 95.000 to 95.022 mm (dia 95 ti 6)

Spread of conrod bearing shells

Glyco ........................... .
.. .........................................
Miba ...................................... .
.
Spread distance
Glyco ...........................................................................
Miba .......................... ..,................................................
Conrod bearing shell wall thickness
Standard size
Glyco .................................................................
"Miba ...................................................................
Standard size 1 0.10 mm oversize
Glyco ......................... .
.. ...................................
"Miba ....................................................................
Oversize 0,25 mm
G lyco .................... .
.. .......................................
"Miba ............................ ... ...................................
Oversize 0.50 mm
..
Glyco .......................... ....................................
"Miba ....................................................................
Oversize 0.75 mm
Glyco .......................... . . . . ................................
"Miba ...............................................................
Oversize 1.00 mm
Glyco ...................................................................
*Miba .................................... ,...............................

Bearing inside bore in installed condition

Glyco N .......................... .
.
.........................................
N 1 ...............................
..... .................................
Rep. 1 ................................ .,.................................
Rep. 2 ................................ .,..... .............................
Rep. 3 ........................ .
.. ....................................
Rep. 4 ....................................................................

"Not applicable to D 2866 TE / LE

207 TESTING AND ADJUSTING VALUES

CONNECT! NG RODS (continued)

"Miba N ....................................................................... 90.066 to 90.1 12 rnrn

N I ........................................................................ 89.966 to 90.012 rnrn
Rep. 1 .................................................................... 89.816 to 89.862 mm
Rep. 2 .................................................................... 89.566 t o 89.61 2 mm
Rep. 3 ...................................... .
. .................. 89.316 to 89.362 rnrn
Rep. 4 ................................................................... 89.066 t o 89.1 12 rnrn
Max, difference in weight per conrod set ............................. 50 g
Bearing basic bore:
Max. deviation of bore perpendicular to bearing surface
Max. deviation of bore parallel to piston pin inside bore

CRANKSHAFT

Case bore for main bearing ................................... ................. 111.000to 111.022 rnrn
Permissible centre deviation (runout) .................................... 0.03 mm
Fillet radius on main bearing journals .................................... 3.5 to 4.0 mm

............................................................... 103.98to104,OOmm
Standard size 1 0.10 mm ............................................ 103.88 to 103.90 rnm
1st undersize 0.25 mrn ........................................... 103.73 to 103.75 mrn
2nd undersize 0.50 mm ........................................... 103.48 to 103.50 mrn
3rd undersize 0.75 mm .............................. . . . . . .
. 103.23 to 103.25 mm
4th undersize 1.OO mm .............................................. 102.98 t o 103.00 rnm
Thrust bearing journal length
Standard size .............................................................. 46,000 to 46.062 rnm
..
Repair sizes 1 and 2 ...................... ........................... 46.500 t o 46.562 mrn
Repair sizes 3 and 4 ..................................................... 47.000 to 47.062 mm
Crank pin diameter
Standard size ..................................................... 89.98 t o 90.00 mrn
Standard size 1 0.10 mm ...................................... . .. 89.88 to 89.90 mm
1st undersize 0.25 mm ............................................ 89.73 to 89.75 rnm
2nd undersize 0.50 rnm ...................................,. . . . 89.48 to 89.50 rnm
3rd undersize 0.75 mm ............................................. 89.23 to 89.25 mm
4th undersize 1.OO rnm ........................................... 88.98 to 89.00 rnm
Crank pins
Max, permissible out-of-roundness .............................. 0.01 mm
.
.
Max. permissible taper ....................... ...................... 0.01 mm
Max. permissible runout of centre main bearing journal
with crankshaft; taken up in
Bearings I and VII (6cyl.) ................................... 0.09 mm
Bearings I 1 and Vl 15 cyl.) ................................... 0.08 mm
Crank journal nominal dia, for seal wear ring ........................ 99.985 t o 100.020 rnrn (dia 100j 7)
Inside dia. of seal wear ring .................................................. 99.907 to 99.942 mrn (dia 100 S 7)
Interference ..................................................................... 0.043 to 0.1 13 rnrn
Thrust bearing shell width
Standard size - Standard size I ...................... ........... .... 45.75 to 45.81 rnm
Oversize - 0.25 mrn and 0.50 mm ................................ 46.25 to 46.31 mm
Oversize - 0.75 mm and 1.00 mm ................................ 46.75 to 46.81 mm

"Not applicable to D 2866 TE / LE

208 TESTING AND ADJUSTING VALUES 208

CRANKSHAFT (continued)

Axi .......................................
.......................................
Bearing inside bore in installed condition
Main bearing shells, Glyco
Standard size ....................................................... 104.060 to 104.106 mm
Standard size I ...................................................... 103,960 to 104.006 mm
Repair size 1 ....................................................... 103.810 to 103.856 mm
Repair size 2 ................................... .................. 103.560 to 103.606 rnrn
Repair size 3 .......................................................... 103.310 to 103,356 mm
Repair size 4 ......................................................... 103.060 to 103.106 mm
' Main bearing shells, Miba
Standard size .......................................................... 104.080 to 104.126 mm
Standard size I ...................................................... 103,980 to 104.026 rnm
Repair size 1 ........................... ,.,............................. 103.830 t o 103.876 mm
Repair size 2 ................................,.........a............. 103.580 to 103.626 rnrn
Repair size 3 ....................................................... 103.330 to 103.376 mm
Repair size 4 .............................,.. ........................ 103,080 to 103.126 rnrn
Thrust bearing shells, Glyco
Standard size .......................... .
... ......................
Standard size I ......................................................
Repair size 1 ..........................................................
Repair size 2 ....................,.....................................
Repair size 3 ........................ .
.. ..........................
Repair size 4 ......................................................
Thrust bearing shells, Miba
Standard size ......................... .
. ...........................
.
.
Standard size I ........................ .........................
Repair size 1 ..........................................................
Repair size 2 ........................................................
Repair size 3 ..........................................................
Repair size 4 ................................,... ..................

Standard size 1 0.10 mm oversize

Glyco ..................................................................
..
Miba ................... ............................................
Oversize 0.25 rnrn
Glyco .................................................................... 3.591 to 3.603 rnrn
Miba ................................................................... 3.577 to 3.589 mm
Oversize 0.50 mm
Glyco .................................................................
Miba ....................................................................
Oversize 0.75 mm
Glyco .................................................................... 3.841 to 3.853 rnrn
Miba ...................................................................... 3.827 to 3.839 rnrn
Oversize 1.OO rnrn
Glyco .................................................................... 3,966 to 3.978 mm
Miba ................................................................... 3.952 to 3.964 rnrn
209 TESTING AND ADJUSTlNG VALUES

CRANKSHAFT (continued)

Main bearing radial play

Glyco .......................................................................... 0.060to0.126mm
Miba .............................................................................. 0.080 to 0.146 mm
Spread of main bearing shells
Glyco ................... .
.. ......................................... 0.3 to 1.2 mm
.
.
Miba ......................... ............................................. 0.9 to 1.4 mm
Thrust bearing she
Standard siz
Giyco/
Standard size 1 0.10 mm oversize
GlycolMiba ........................................................ 3.516 to 3.528 mm
Oversize 0.25 mm
.
.
GlycolMiba .......................... ....................... 3.591to3.603mm
Oversize 0.50 mm
Glyco/Miba .............................., . ................... 3,716 to 3.728 mm
Oversize 0.75 mm
GlycolMiba ......................................................... 3.841 to 3.853 mm
Oversize I.00 mm
Glyco/Miba ........................................................ 3.966 to 3.978 mm

Thrust bearing radial play

GlycolMiba ............................... .
.,......................... 0.060 to 0.1 26 mm

Spr~adof thrust bearing shells

Glyco .......................................................................... 0.1to0.5mm
Miba .............................................................................. 0.3 to 0.6 mm

FLYWHEEL

Diameter of starter gear ring spigot ...................................... 432,490 t o 432.645 mm

Starter gear ring - inside diameter (shrink-fit gear ring) .......... 432.000 t o 432.155 mm
Interference (shrink-fit gear ring) .................................. . ... 0.335 to 0.645 mm
Installation temperature .................... .................................. 200 to 230 06
Permissible axial runout after installation ............,............as... 0.5 mm

Wearing ring seat ................................................................ 114.980 to 115.015 mm

Wearing ring, outside diameter ......................... .
... .....a 119,860 t o 120.000 mm
Wearing ring, inside diameter .............................................. 114.899 t o 114.934 mm
Interference (shrink-fit) ................................................... 0.046 to 0.1 16 mm
1 nstallation temperature ................................ .,................... 200 QC
Max. amount of stock that can be removed from
clutch face in remachining .................... 2.0 mrn
Dimension a, new (depending on type ... 61.9 to 62.1 mm
or ..................................................... 103.1 to 103.3mm
2 10 TESTlNG AND ADJUSTING VALUES

CYLINDER HEADS AND VALVES

Thickness of cylinder head gasket

before installation approx. ............................................ 1.6 mm
after installation and tightening ...................................... 1.I63 to 1.297 mm
Cutout in cylinder head gasket for bore
All D 25 . . . engines ...................................................... 141.0 to 141.5 m
All D 28 . . . engines ..................................................... 144.5 to 145.0 m
Cylinder head height (observe specified recess dimensions for
injectors and valves)
.
.
Standard size ..................... ..................................... 113.9 to 114.0 mm
Minimum distance .......................................................... 112.9 rnm
Roughness, depth of cylinder head and crankcase mating surface 0.008 to 0.01 6 mm
Valve recess ...................................... .
. 0.7 to 1.3 mm . .
Valve head diameter
"Intake D 2565 ME, D 2566 ME, up to engine No. . . .3921 57.85 to 58.15 mm
"Intake D 2565 ME, D ME, starting from
engine No. . . . 3921 ......,.
...................... ..... 56.85 to 57.1 5 mm
Intake D 2566 MTE / 2866 E / TE I LE .......... 57.85 to 58.1 5 mm
Exhaust (all) ............................................................ 50.9 to 51.1 mm
Valve head height "'W" (see Page 33, Fig, 3)
Intake D 2565 ME, D 2566 ME ............................... .,. 3.2 to 3.3 mm
Intake D 2566 MTE / MLE, D 2866 E / TE / LE .......... 3.4 to 3.5 rnm
Exhaust (all) ............................................................... 3.0 to 3.1 rnm
Valve seat insert bore in cylinder head
Standard
Intake ........................... .
...
.. .... ................ 61.00 to 61.03 mm
Exhaust ................................................................ 53.00 to 53.03 mm
Standard I
Intake ................................................................. 61.20 to 61.23 mm
Exhaust ................................................................ 53.20 to 53.23 mm
Valve seat insert bore depth
N ............................................................................. 12.5 to 12.6 mm
N I .......................................................................... 12.7 to 12.8 mm
Valve seat insert outside diameter
IntakeN ................................................................... 61.10to61.11mm
N I ...................................... .
.61.30 to 61.31 mm
Exhaust N .................................................................... 53.10 to 53.1 1 mm
N I .............................................................. 53.30to53.31mm
Valve seat angle, D 2565 ME, D 2566 ME (Intake / Exhaust) 450
Valve seat angle, D 2566 MTE / MLE, D 2866 E / TE / LE
Intake ............................................................................ 30°
..
Exhaust .................... ........ . ................................. 45*
Valve shaft diameter
Intake........................
................... .
. 11.969 to 1 1.980 mrn
Exhaust ..................................................................... 11.944 to 1 13 5 5 mm

"Note:
In the case of all D 2565 ME and D 2566 ME engines use only
the new intake valve (marked " ... starting from engine
21 1 TESTING AND ADJUSTING VALUES 21 1

CY LlNDE R HEADS (continued)

Valve guide inside diameter (installed) ..................................

Valve radial clearance
..
l ntake ................... ....................................................
Exhaust ........................................................................
Max. wear limit ................................................................
Valve guide bore in cylinder head
N .................................................................................. 18.000 to 18.018 rnm Edia 18 H 7)
N I ............................................................................... 18.250 to 18,271 mm (dia 18.25 HI 7)
Valve guide outside diameter
N ............................................................................... 18.028 to 18.046 mm (dia 18 s 7)
N I ............................. . ............................................ 18.285 to 18.306 mm (dia 18.25 s 7)
l nterference
N ..................................................................................
.
.
N I ......................... .................................................
Max. runout, valve guide relative to valve seat
Valve guide projection above valve spring seat level ...............,
Valve lift (intake)
D 2565 ME, D 2566 ME ....................................,.........a.
D 2566 MTE I MLE, D 2866 E I TE / LE ......................
Valve lift (all exhaust valves) ..........................................

VALVE SPRINGS

lnner spring D 2565 ME, D 2566 ME / MTE / MLE, D 2866 E

.
..
Free length, approx. ............................ ....................
Spring force a t 46.3 rnm length ............................. ...
Spring force a t 32.3 mm length ......................................
lnner spring D 2866 TE / LE
Free length, approx. ................... .
..
...........................
Spring force a t 46.3 rnm length ....................................
Spring force a t 32.3 mm length .............................. ..,.....
Outer spring D 2565 ME, D 2566 ME / MTE 1 MLE
Free length, approx. ......................................................
Spring force a t 46.8 mm length ....................... .
..
......
Spring force a t 32.8 mm length ................................... ...
Outer spring D 2866 TE / LE
..
Free length, approx. ....,................,..... .......................
Spring force a t 46.8 mm length ........................ . , .......
Spring force a t 32.8 mm length ....................................

TIMING

..
Rocker arm bore ............................. .............. 25.000 to 25,021 rnm (dia 25 H 7)
Rocker arm bearing journal dia. ..................... .,................,.... 24.967 to 24.980 rnm (dia 25 f 6)
Rocker arm radial play .......................................................... 0.020 to 0.054 rnm
Max, wear limit ............................................................ 0.08 mm
Max, runout of push rods ..................................... ...*,............ 0.5 mm
 TESTING AND AJUSTlNG VALUES

TIMING (continued)

Casing bore for valve tappets

N .................................................................................. 20.000 to 20.021 mm (dia 20 H 7)
N I .................................................................................. 20.250 to 20.271 mm (dia 20.25 )-f 7)
Valve tappet stem, outside diameter
N ....................................................................................
N I .................................................................................
Valve tappet clearance in operation ........................... ........ ..
Camshaft bush, inside diameter ...........................................
Camshaft diameter ................................................................
Camshaft radial runout ...................................... .
. .........
Camshaft axial play ..............................................................
Max. wear limit .............................. . ...........................
Thickness of thrust washer .................... . . ..........................
Backlash between
crankshaft and camshaft gear .................... ..... ..
........
intermediate gear and injection pump gear ....................
Valve clearance (adjust on cold engine)
l ntake ............................................................................
Exhaust ..........................................................................
Timing degree crankshaft angle
D 2565 ME, D 2566 ME
..
l ntake opens ............................. ......................... 80 before TDC
l ntake closes .......................................................... 42O after BDC
Exhaust opens ..................................................... 590 before BDC
Exhaust closes ........................... ............
............... 80 after TDC
D 2866 E
lntake opens .......................................................... 130 before TDC
intake closes ................... .
...
............................... 470 after BDC
Exhaust opens ......................... . . ...................... 490 before BDC
Exhaust closes ...................................................... 7O after TDC
D 2566 MTE / MLE, D 2866 TE / LE
Intake opens ......................................................... 230 before TDC
lntake closes .......................................................... 370 after BDC
Exhaust opens ...................................................... 600 before BDC
Exhaust closes ...................................................... 30° after TDC

CHECKING COMPRESSION PRESSURE

Good ................................................................................... above 28 bar

.
.
Acceptable ..................... ...... .
........................................ 25 to 28 bar
Reconditioning necessary ..................................... ............. ... below 24 bar

Max. pressure difference ........................................................ 4 bar

"Note: see Page 3 / 2

214 TESTING AND AJUSTlNG VALUES

COOLING SYSTEM (continued)

Bore for bearing shaft in impeller ..................................,...

Diameter of bearing shaft ..............,.........................a,........,...
Interference ............................................................................
Bearing seat in housing .......................................................
Bearing diameter ......................... .... ................................
Interference ..........................................................................
Hub bore. ...................
. ..
. ................
. .
Diameter of bearing shaft ................... . . ............................
..
Interference ..................................... ..................................
Surge tank
Filler valve
Relief valve 0.85 TO 1.20 bar
Pressure cap with valves
Relief valve ........................................................ 0.6 to 0.8 bar
Breather valve ...................................................... 0.1 bar

TURBOCHARGER

Manufacturer ........................................................................ KKK

Type for D 2566 MTE
with non-cooled exhaust manifold ................... .
. .......
with water-cooled exhaust manifold ............................
Type for D 2566 MTE marine engine water-cooled,
for engines with constant or variable speeds
above 2000 rpm ...........................................................
water-cooled, for engines with constant speeds
below 2000 rpm ...........................................................
Type for D 2566 MLE
water-cooled, for engines with constant or variable speeds
above 2000 rpm ............................................................
water-cooled, for engines with constant speeds
below 2000 rprn ............................................................
non-cooled, for engines with non-cooled exhaust
manifold ................................... ....
.................................
Type for D 2866 TE
water-cooled, with constant speed
n = 1500 rpm ..................................... ........................
water-cooled, with constant speed
n = 1800 rprn and variable speeds of 1800 - 2X)O rprn ..
Type for D 2866 LE
non-cooled, with constant speeds
n = 1500 rpm and n = 1800 rpm ..................................
water-cooled, with constant speed n = 1500 rprn ..........
water-cooled, with variable speeds
n = 1500 rpm and n = 1800 rpm ..................................
Axial play of impeller shaft for
4LGZ .......................................................................... rnax. 0.20 mm
max. 0.1 6 mm
Radial play of impeller shaft for
4LGZ ........................................................................... max. 0.65 mm
K36 .....................................
..,........................................ max. 0.55 mm
Negative pressure in air intake pipe ................................... max, 0.05 bar (500 mm w.g.)
(ahead of turbocharger)
215 TESTlNG AND AJUSTlNG VALUES 21 5

FUEL SYSTEM (Bosch)

Injectors
D 2565 ME, single hole ........................ . ..................... DLLA 25 S 722
D 2566 MTE, M LEI single hole ........................ . , ......... DLLA 30 S 678
D 2866 E, four holes .................................................... DL LA 138 S 983
D 2866 TE / LE, four holes .................,.,,,,.,,,,,....,,,,,,,,,,. DLLA 136 S 943
D 2866 LE (n = 2200 rpm), four holes ........................,, DLLA 136 S 1002

Discharge pressure
D 2565 ME, D 2566 ME / MTE / MLE .......................... 175 + 8 bar
D 2866 E ...................................................................... 200 + 8 bar
D 2866 TE / LE ...................,.....,.,............................... 220 + 8 bar

Projection above cylinder head contact surface ...................... 1,5 to 2,O mm

l njector
Flame-proof design, D 2866 E ...................................... KDAL 80 S 36
Flame-proof design, D 2565 ME, D 2566 ME / MTE / MLE,
D 2866 LE ................................................................... KDAL 80 S 20119
Non-flame-proof design ................................................ KDAL 80 S 14/14
lnjection pump (Bosch)
In-line plunger-type injection pump, flange-mounted

Governor
Bosch (centrifugal governor) .......................................... Variable speed governor or no-load
max.-speed governor
Barber Colman ................................ . . ,, ...................... Electronic speed governor
Heinzmann .................................................................... Electronic speed governor
D 2565 ME
Injection pump ....................... ....,.... ,...............*
.
, PES 5A 95D 410LS2543
Governor ................................. .,.. ...................... RO 25011 100 AB 1039 DL

...
Injection pump ..................................... ............
Governor .............................................................
or (depending on engine model) ............................
D 2566 ME
injection pump ...................................................... PES 6A 950 410LS2542
Governor .............................................................. RQ 25011050 A6 965 DL

Injection pump ...................................................... PES 6A 95D 410LS2607

Governor ...................................... . , RQV 750 AB 955 L

Injection pump ................................... .,... ............ PES 6A 95D 410LS 2644

Governor .............................................................. RQV 250 . . . 1100 AB 956 DL
216 TESTING AND AJUSTlNG VALUES

FUEL SYSTEM (continued)

D 2566 MTE
Injection pump (for all engine models) ......................... PES 6P I IOA 720 LS
Governor .................................................................. RQV 750 PA 377 R
or
injection pump (for all engine models) .......................... PES 6P 11OA 720 LS 455
Governor ...................................................................... .
RQV 250 . ,1100 PA 334 R
or
lnjection pump (not for marine propulsion engines) ...... PES 6P 110A 720 LS 375
Governor ...................................................................... RQ 25011 100 PA 335 DR
or
lnjection pump (for marine propulsion only) ................ PES 6P 110A 720 LS 375
Governor ...................... .
..
......................................... RQ 750 PA 638
or
Governor ................................................................... RQV250.. . llOOPA334 R
0r
Governor (dependent on charge air pressure) ............... RQV 250 . . . 1100 PA 580
D 2566 MLE
i njection pump .............................
.......................... PES 6P 120 A 720 LS 388
Governor ..................................................................... RQ 750 PA 566
or
Governor ..................................................................... RQ 900 PAV 14684
or
Governor ....
......................... .................................. RQV 250 . , . 1050 PA 567
D 2866 E
Injection pump (for generator set engines) ................... PES 6P 110A 720 L V 16443
..
Governor ................................. ................................ RQ 750 PA V17144
or
Governor .................................................................... RQ 900 PA V17224
lnjection pump (for industrial engines) ......................... PES 6P 110A 720LV16442
Governor ..................................................................... .
RQV 300 . ,900 PA V17301
or
Governor ..................................................................... RQV 300 . . ,900 PA V 17427
or
Governor ...................................................................... RQV 300. . . 1050 PA V17429
or
Governor ....................................... .............................. RQV 300. . . 1050 PA V17428

Governor ..................................................................... RQV 300. .. 1I 0 0 PA V17286

D 2866 TE
lnjection pump (for generator set engines) .................... PES 6P 120A 720L Vl6564
Governor ..................................................................... RQ 750 PA V17502
lnjection pump (for marine propulsion engines) ............ PES 6P 120A V16500
Governor ...................................................................... RQV 300 . . . 1050 PA V 17448

Governor .... ............

...................... . . ...........,.... RQV 300. .. 1100 PA V17286
 TESTING AND ADJUSTlNG VALUES

FUEL SYSTEM (continued)

D 2866 LE
l njection pump (for generator set engines) .................... PES 6P 120A 720L V16564
Governor ...................................................................... RQ 750 PA V17503
lnjection pump (for marine propulsion engines) ............ PES 6P 120A 720L V16500
Governor ..................... RQV 300 . . .900 PA V1750.Q

Governor .........................,.....
.................................. ROV 300 . . . 1050 PA V17540
or
Governor ........................
.......................................... RQV 300 . . . 1100 PA V17449
Explanation of codes

1. lnjection pump, e. g. PES 5 A 95 D 410 L S 2543

PES .......................................................................... Pump with mounting flange
5 and 6 ...................................... .
. Number of barrets ...........
.
..
A and P: pump size: .............................. ......*........... A = 8 mm plunger stroke
P = 10 mm plunger stroke
Plunger dia, in 1/10 mm
Change code letter
Assembly code (for identification
of installed position of camshaft,
governor, injection timing adjuster
and fuel lift pump)
Direction of camshaft rotation:
L = anti-clockwise
Version code for pump size A:
S2000 to . . . = pump
design reinforced
Serial number for pump size P

2. Governor, e. g. RQV 250. . . 1100 AB 956 L or

RQV 250.. . 1100 PA 334 R

No-loadlmax. speed governor or

max. speed governor
RQV ............................................................................. Variable speed governor
Speed range
750 ............................ . . ...................................... Max. speed governor
250 I1050 .............................................................. No-loadlmax. speed governor
.
.
250 . . . 1100 ..................... ............................. Variable speed governor
A o r P .......................................,.................................. Governor mounted on injection pump
Size A or P
Change code letter
A = 1st change
956 or 334 .............................. .................................. Version code
L o r R ..................................... ....................................
.,. indicates on which side of pump
governor i s mounted.
L = left-hand
R = right-hand
 TESTING AND ADJUSTING VALUES

AI R COMPRESSOR

Swept volume
Single-cylinder air compres
Cylinder bore (3 matching stages
Matching stage B ..............
Matching stage C ..........................................................
Matching stage D ..........................................................
Piston diameter (3 matching stages)
Matching stage B
Alcan ....................................................................
KS ..................................
. . . . . . .......
Matching stage C
Alca n ............................................................. .......
KS ......................................................................
Matching stage D
Alca n ....................................................................
B KS ..........................
Piston ring groove width
Ist and 2nd ring ..........................................................
3rd ring
Alcan ...................................................................
KS ...............................................................
Piston clearance
Alcan ...................................................................
KS ........................................................................
Piston recess from cylinder liner top
Single-cylinder air compressor ......................................
Connecting rod radial clearance ...........................................
Backlash air compressor / camshaft ..............
Piston pin bore .....................................................................
Piston pin diameter ..............................................................
Piston pin bush, inside diameter ............................................
Connecting rod wall thickness .............................................. 2.004 to 2.01 1 mm
Crank pin diameter ................... .
..
...................................... 31.959 to 31.975 mm (dia. 32 f 6)
Rear main bearing journal diameter ......................2.......... 29.959 to 29.980 mm (dia. 30 f 7)
Rear main bearing bushes, inside diameter ............................ 30.020 to 30.041 mm (dia. 30 F 7)

ELECTRIC SYSTEM

Starter, Bosch ........................................................................ solenoid operated

Voltage ........................................................................ 24 V
Rating .......................................................................... 5 o r 5.4 kW
Alternator ............................................................................ a. c. three-phase
Voltage ...................................... .
. ........................ 28 V
Current ................................... ..................................... 27,35,55,60,85, 120 A
.
.
Preheating ................... .................................................... 2000 or 3000 W
(220 and 380 V)
 2 19 TlGHTENlNG TORQUE GUlDE VALUES 219

NOTE: All threaded fasteners the use of which is not listed in the following table, must be tightened
to the guide values specified by M.A.N. Work Standard N 269.
Lightly oil screws before installation!

PLUGS

DIN 908, M 14 x 1.5, 16 x 1.5 .......................................... 80 Nm (8kpm)

NI 18 x 1.5, M 22 x 1.5 ............................... , .,a**
100 Nm (10 kpm)
M 24 x 1.5, M 26 x 1.5 .......................................... 120 Nm (12 kpm)
MI 3 0 x 1.5 ............................................................ 150 Nm (15 kpm)
DIN 7604,
AM 10 x 1, M 12 x 1.5 ..................................... 50 Nm (5kpm)
AM 14 x 1.5 .......................................................... 80 Nm (8kpm)

CRANKCASE, CRANKSIdAFT ASSEMBLY

Crankshaft bearing caps to crankcas

Initial torque .......................... ......................... 300 Nm (30 kpm)
I Rotation angle .............................................................. 90 to 100°
Cover to crankcase (crankshaftseal, front) ............................ 25 Nm (2.5 kpm)
Cover to crankcase (camshaft, front) .................................... 65 Nm (6.5 kpm)
Thrust washer to timing case ................................................ 40 Nm (4.0 kpm)
Timing case to crankcase ................................... .............. 75 Nm (7.5 kpm)
Counterweight t o crankshaft
..
Initial torque ........................ .................................. 100 Nm (10 kpm)
Rotation angle ....................................,........................ 90 to 100°
Vibration damper to hub ......................................................
Vibration damper hub
Vibration damper hub t
Crankshaft extension (v
Pulley to hub for vibratt
Connecting rod bearing
Initiai torque .....
Rotation angle ............................................................
Flywheel to crankshaft ........................................................ 260 Nm (26 kpm)
I Gear ring carrier to crankshaft ............................................ 260 Nm (26 kpm)
Rear suspension eye to crankshaft ........................................ 150 Nm (15 kpm)
Fan damper to crankshaft .................................................... 22 Nm (2.2 kpm)

ENGINE D 2565 ME

On engines D 2565 ME one brace each is provided on the left-hand and right-hand side between
crankcase and timing case for reinforcement of the timing case. These braces must be fitted without
constraint to avoid damage to the case and the screws must therefore be tightened to the following
torques:

1. Screws for crankcase (NI 161, initial torque ........................ 10 Nm ( 1 kpm)

2. Bottom screws for timing case (M 12) ................................ 75 Nm (7.5 kpm)
3. Top screws for timing case (M 12) ................................... 75 Nm (7.5 kpm)
4. Screws for crankcase (M 16), final torque .......................... 185 Nm (18.5 kpm)

e as

CYLINDER HEAD

Cylinder head to crankcase (torque-tightening method)

Initial torque (in steps) ............................;...,;..............
i 10 - 50 - 100 Nm (1 - 5 - 10 kpm)
Final torque .......................................... ..................... 210 to 230 Nm (21 to 23 kpm)
 223 TlGWTENlNG TORQUE GUlDE VALUES 223

according to Works Standard N 269

Grade 8.8 10.9 12.8

Threads Nm Nm Nm

M 5 5.0 7.5 9.0

M 6 9.O 12.5 15.0
M 7 14.0 19.5 23.5
M 8 22.0 31.O 38.0
M 8x1.0 24.0 33.5 41 .0
M 10 44.0 62.0 74.0
M l o x 1,O 50.0 70.0 84.0
M 12 75.0 105.0 125.0
, M 12 x 1.5 80.0 112.0 134.0
M 14 120.0 170.0 200.0
M 14 x 1.5 130.0 185.0 220.0
M 16 185.0 260.0 310.0
M 1 6 x 1.5 200.0 280.0 335.0
M 18 250.0 360.O 430.0
M 18 x 1.5 285.0 410.0 490.0
M 20 360.0 510.0 600.0
M 2 0 x 1.5 410.0 580.0 680.0
M 22 490.0 670.0 750.0
M 22 x 1.5 560.0 750.0 850.0
M 24 630.0 820.0 920.0
M 24 x 1.5 740.0 930.0 1030.0
 RUNNING-IN ENGINE

GENERAL:

Reconditioned engines must be run in. New parts, in particular liners, pistons, piston rings and bearings
will reach the necessary surface finish only after running in.

Running in of the engine should be on a dynamometer. If no test rig is available, the engine can also be
run-in in installed condition.

For running in a special running-in oil (initial operation oil) or standard engine oil (not heavy-duty oil)
should be used.

During running-in the cooling water temperature must be maintained within the most favourable oper-
ating range from 65 to 75'~.

filter elements.

rnor, injectors and start of delivery (see also technical data).

2. Replace oil filter paper element.

RUNNING-IN

We recommend to operate new or reconditioned engines at not more than approx. 75 % load but at
varying speed during the first operating hours. Then gradually increase engine load to full load.
 SPECIAL TOOLS 303

Fig. No. Description M.A.N. No. Remarks

Cylinder liner puller, mechanical

Bush
Tension screw
Clevis
Eye screw
Support bracket for 1b
Pulling plate ( 125 dia.)
Pulling plate (128 dia.)
Piston ring pliers
Piston ring installation tool
Piston ring sleeve (128 dia.)
Piston ring sleeve (1 25 dia.)
Gauge holder
Rotation angle measuring device
Puller for front crankshaft race
Pressing tool for front crankshaft race
(see page 308)
Pressing tool for bearing race on
flywheel (diaphragm spacer)
Puller for crankshaft seal
Centering bush
Installation tool (2 parts) for timing
case cover seal
Special socket for injector
Lock nut
Special wrench for cylinder head screw
under injector (for 5 and 6-cylinder
engines)
Special wrench for cy tinder head screw
under injector (for all V engines)
Valve installation lever
Pressing ring (2 parts) for valve seat ring
Pressing tool (2 parts) for valve guide

NOT SHOWN

Guide sleeve for valve stem seal (for

naturally-aspirated V engines only)
Pressing sleeve for valve stem seal
(for naturally-aspirated V engines
only)
307 SPEGlAL TOOLS 307

Fig. No. Description M.A.N. No, Remarks

Equipment for adjusting injection comprises parts,

timing 80.99620.0014 Fig. Nos. 2 - 10
Fuel container 80.99607.0073
Suction hose,
thread size M 14 x 1.5 80.99607.0067
Return hose 80.99607.0068
Hand pump 80.99607.0065
High pressure hose,
thread size M 14 x 1.5 80.99607.0066
Pipe elbow,
thread size M 14 x 1.5 80.99607.0070
Pipe elbow,
thread size M 12 x 1.5 80.99607.0069
Ring connection,
thread size M 14 x 1.5 80.99607.007 1
Ring connection,
thread size M 12 x 1.5 80.99607.0072
Hollow screw M 14 x 1.5 06.78340.01 06
Hollow screw M 12 x 1.5 06.78340.0105
Screw plug M 14 x 1.5 06.08063.0203
Screw plug M 12 x 1.5 06.08069.0025