Man D2862 LE221 - Common Rail System Component Removal and Installation

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COMMONRAILSYSTEM

[30] Magneticpick-uptool

•Removingtherailconnection

80.99639-0009

[31]

Specialspanner,size17

•Detachingandattachingthehigh-pressurelines

inconjunctionwith:

•Angleextension[15]

80.99603-0309

[32] Angleextension

•Detachingandattachingthehigh-pressurelines

inconjunctionwith:

•Specialspanner,size17[14]

08.06139-9025

[33] Endplug

•Pluggingthehigh-pressurelines

81.96002-0521

[34] ProtectivesleeveZ14x15

•Pluggingthehigh-pressurelineconnections

81.96002-0512

AE63stedition119

Main Page

Table of Contents5
Introduction11
Safety Instructions11
The Engine18
Model Plate / Model Designation18
Characteristic Data19
Engine Description20
Engine Electrics25
Engine Wiring Harness27
Removing, Installing the Engine Wiring Harness27
Engine Control Units29
Removing, Installing Engine Control Units29
Engine Electrics35
Removing, Installing the Charge Air Pressure Sensor EDC35
Removing, Installing the EDC Fuel Temperature Sensor37
Removing, Installing the EDC Fuel Pressure Sensor39
Removing, Installing the Engine Oil Pressure Sensor41
Removing, Installing the Crankshaft Speed Sensor43
Removing, Installing the Camshaft Speed Sensor45
Removing, Installing the Coolant Temperature Sensor47
Removing, Installing the Engine Oil Temperature Sensor49
Removing, Installing the Coolant Pressure Sensor51
Removing, Installing the Engine Oil Pressure Sensor53
Cooling System55
Cooling System57
Removing, Installing the Cooling System57
Ramfan63
Removing, Installing the Ramfan63
Intermediate Ange65
Removing, Installing the Intermediate Ange65
Coolant Pipes67
Removing, Installing Coolant Lines67
Thermostat71
Removing, Installing Thermostats71
Coolant Pump Coolant Manifold75
Removing, Installing the Coolant Pump Coolant Manifold75
Coolant Pump79
Removing, Installing the Coolant Pump79
Add-On Units81
Starter83
Removing, Installing the Starter83
Fan V-Belt87
Removing, Installing the Fan V-Belt87
Fan Tensioning Pulley91
Removing, Installing the Fan Tensioning Pulley91
Fan Carrier93
Removing, Installing the Fan Carrier with Fan Bearing93
Poly-V-Belt95
Removing, Installing the Poly-V-Belt95
Removing, Installing the Automatic Belt Tensioner97
Removing, Installing the Guide Roller99
Alternator101
Removing, Installing the Alternator101
Common Rail System107
High-Pressure Lines and Rails109
Removing, Installing the High-Pressure Lines and Rails109
Injector with Nozzle117
Removing, Installing Injector with Nozzle117
Checking the Injector Seat, Rail and Leakage Oil Lines for Leaks127
High-Pressure Pump/High-Pressure Pump Drive131
Removing, Installing the High-Pressure Pump/High-Pressure Pump Drive131
Dismantling, Assembling the High-Pressure Pump/High-Pressure Pump Drive137
Fuel Lines143
Removing, Installing Fuel Lines143
Fuel Lter157
Removing, Installing the Fuel Lter157
Dismantling, Assembling the Fuel Lter162
Hand Pump167
Removing, Installing the Hand Pump167
Dismantling, Assembling the Hand Pump170
Turbocharging173
Turbocharger175
Removing, Installing the Turbocharger175
Charge Air Manifold183
Removing, Installing the Charge Air Manifold183
Intake/Exhaust System187
Combination Air Lter189
Removing, Installing the Combination Air Lter189
Air Lter193
Removing, Installing the Air Lter193
Combination Air Lter Holder195
Removing, Installing the Combination Air Lter Holder195
Air Distribution Pipes199
Removing, Installing Air Distribution Pipes199
Exhaust Pipes207
Removing, Installing Exhaust Pipes207
Cylinder Head215
Removing, Installing the Cylinder Head Cover215
Removing, Installing the Rocker Arm Mechanism219
Dismantling, Assembling the Rocker Arm Mechanism221
Removing, Installing the Cylinder Head225
Removing, Installing the Valve Stem Seals233
Checking and Setting the Valve Clearance240
Valve Timing245
Camshaft247
Removing, Installing the Camshaft / Camshaft Bearings247
Valve Timing253
Checking the Valve Timing253
Front Timing Gears/Rear Timing Gears257
Front Timing Gears259
Removing, Installing Front Timing Gears259
Rear Timing Gears265
Removing, Installing Rear Timing Gears265
Engine Lubrication269
Oil Modules271
Removing, Installing Oil Modules271
Dismantling and Assembling the Oil Module276
Oil Injector Nozzles281
Removing, Installing the Oil Injector Nozzles281
Oil Sump283
Removing, Installing the Oil Sump283
Dismantling, Assembling the Oil Sump287
Oil Pumps291
Removing, Installing Oil Pumps291
Crankshaft Oil Seals299
Removing, Installing the Front Radial Shaft Seal299
Removing, Installing the Rear Radial Shaft Seal302
Crank Mechanism309
Vibration Damper311
Removing, Installing the Vibration Damper311
Flywheel317
Removing, Installing the Ywheel317
Pistons and Connecting Rods325
Removing, Installing a Piston with Its Connecting Rod325
Crankshaft335
Removing, Installing the Crankshaft335
Positive Crankcase Ventilation357
Removing, Installing the Positive Crankcase Ventilation357
Cover361
Removing, Installing the Cover361
Flywheel Housing365
Removing, Installing the Ywheel Housing365
Cylinder Liner369
Removing, Installing the Cylinder Liner369
Engine Mount375
Removing, Installing Engine Mounts375
Technical Data377

Man D2862 LE221 - Common Rail System Component Removal and Installation

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