Foreword

The purpose of this publication is to inform you about the checking values, setting data and technical de-
tails of MANs 6cylinder highperformance marine Diesel engines.

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

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

Danger:
This refers to working and operating procedures which must be complied with so as not to en-
danger persons.

Caution:
This refers to working and operating procedures which must be complied with in order to prevent
damage to or destruction of material.

Note:
Explanations that are useful for understanding the working or operating procedure to be per-
formed.

MAN Nutzfahrzeuge Aktiengesellschaft

Nuremberg Works

We reserve the right to make technical modifications in the course of further development.
2004 MAN Nutzfahrzeuge Aktiengesellschaft
Reprinting, copying or translation, even in the form of excerpts, is forbidden without the written permission
of MAN. MAN expressly reserves all rights in accordance with the law on copyright.
MTDA Technical status: 01.2004 51.995988033

1
 Contents

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Checking and setting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Service Data

Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Vbelts / Powerband . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Torque guide values

New cylinder head seal and modified cylinder bush from March 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Retightening of the cylinder head bolts on engines up to 28.02.2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tightening the cylinderhead bolts following a repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Retightening the cylinderhead bolts following a repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Retightening of new and rebuilt engines from 01.03.2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Tightening the cylinderhead bolts following a repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Retightening the cylinderhead bolts following a repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2
 Technical data

Engine models D 2876 LE 401 / 402 / 404 / 405

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in-line
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4stroke Diesel with turbocharger and in-
tercooler
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Compression ratio
D 2876 LE 401 / 404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 : 1
D 2876 LE 402 / 405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,5 : 1
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 mm
Engine capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 816 cm3
Direction of rotation viewed from flywheel . . . . . . . . . . . . . . . . . . . anti clockwise
Firing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153624
Firing interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120_
Max. engine output
D 2876 LE 401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515 kW / 700 hp at 2200 rpm
D 2876 LE 402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412 kW / 560 hp at 2100 rpm
D 2876 LE 404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 kW / 630 hp at 2200 rpm
D 2876 LE 405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537 kW / 730 hp at 2200 rpm
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure circulation
by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear oil pump
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid cooling
by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . impeller pump
Coolant temperature
before start of full load . . . . . . . . . . . . . . . . . . . . . . . . . . . 60C
normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90C
temporarily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95C

3
 Checking and setting values

Valve train
The checking values are valid for all engines listed in this publication

Valve clearance:
(when engine is cold)
Inlet 0.50 mm
Exhaust 0.60 mm

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

Valve clearance too small:

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

Valve clearance too large:

The valve opening crosssections are reduced and cylinder charging is impaired. Valve train wear and
valve noise is greatly increased.

1
TDC
2
3
Valve timing
1 = direction of engine rotation
2 = intake valve opens 23 before TDC
3 = exhaust valve closes 30 after TDC
4 = exhaust valve opens 60 before BDC
5 = intake valve closes 37 after BDC 6 7
6 = exhaust valve open for 270
7 = intake valve open for 240
The degrees specified refer to the crankshaft angle
4

5
BDC

4
 Checking and setting values

Compression pressures
(Engine was run before measurement, warm to the touch)
good bar over 28
permissible bar 2528
in need of repair bar under 24
pressure difference bar max. 4
(between the individual cylinders)

Fuel system
Delivery rate of fuel supply pump:
n= 2.200 rpm l/h 280
Opening pressure of overflow valve:
at injection pump bar 2.02.5

Lubricating system
Oil pump delivery rate:
The speeds are pump speeds.
Oil pump speed: Engine speed x 0.977 (i = 1.023).
Delivery rates with SAE 20 oil at 90_C and 6 bar oil pressure.
n = 585 rpm l / min 42
n = 2.150 rpm l / min 195
Valve opening pressures in lubricating oil circuit:
Bypass valve for oil filter
Opening pressure bar 2
Pressure at maximum opening bar 4
Relief valve on oil pump bar 910
Pressure valve of the oil injection nozzles
Opening pressure bar 1.92.1
Pressure at maximum opening bar 1.41.6

5
 Filling capacities

Oil filling capacities

Model Oil pan Min. capacity Max. capacity

D 2876 L.. deep 26 l 30 l

Sump FW*

D 2876 L.. flat 29 l 34 l

*FW = adjacent to flywheel

6
 Dimensions
Service data
Limit values

Crankcase
Standard size:
153.90153.94 mm
for cylinder liners with 0.5 and 1.0 mm
larger outside :
154.40154.44 mm

standard size:
145.80145.84 mm
for cylinder liners with 0.5 mm larger out-
side diameter:
146.30146.34 mm
for cylinder liners with 1.0 mm larger out-
side diameter:
146.80146.84 mm

9.95510.025 mm

Standard size:
144.50144.54 mm
for cylinder liners with 0.5 mm larger out-
side diameter:
145.00145.04 mm
for cylinder liners with 1.0 mm larger out-
side diameter:
145.50145.54 mm

Cylinder liner
Standard size:
153.694153.757 mm
with 0.5 and 1.0 mm larger outside
diameter:
154.194154.257 mm

Standard size: 10.0510.07 mm

with 0.5 mm more flange height:
10.5510.57 mm
Liner protrusion above upper deck of
0.005
crankcase: 0.030.08 mm
Standard size:
145.761145.786 mm
with 0.5 mm larger outside diameter:
146.261146.286 mm
with 1.0 mm larger outside diameter:
146.761146.786 mm
127.990128.010
Max. wear limit:
0.15 mm below base dimension

Standard size:
144.432144.457 mm
with 0.5 mm larger outside diameter:
144.932144.957 mm
with 1.0 mm larger outside diameter:
145.432145.457 mm

7
 Dimensions
Service data
Limit values

Crankshaft

Crankshaft front end (opposite end to flywheel)

99.985100.020 mm

Standard size: 89.9890.00 mm

undersize 0.25: 89.7389.75 mm
undersize 0.50: 89.4889.50 mm
undersize 0.75: 89.2389.25 mm

undersize 1.00: 88.9889.00 mm

Standard size: 103.98104.00 mm

undersize 0.25: 103.73103.75 mm

undersize 0.50: 103.48103.50 mm
undersize 0.75: 103.23103.25 mm
undersize 1.00: 102.98103.00 mm

Bearing race for crankshaft, front end

Inner diameter: 99.90799.942 mm

Thrust bearing journal

Standard size: 46.00046.062 mm

undersize:
0.25 and 0.50: 46.50046.562 mm
0.75 and 1.00: 47.00047.062 mm

8
 Dimensions
Service data
Limit values

Main bearing

Standard size: 3.4663.478 mm

undersize 0.25: 3.5913.603 mm
undersize 0.50: 3.7163.728 mm
undersize 0.75: 3.8413.853 mm
undersize 1.00: 3.9663.978 mm

Internal bearing when fitted:

Standard size: 104.060104.106 mm
undersize 0.25: 103.810103.856 mm
undersize 0.50: 103.560103.606 mm
undersize 0.75: 103.310103.356 mm
undersize 1.00: 103.060103.106 mm
Spread: 0.31.2 mm
Marking: top / bottom
standard: 0005 / 0006
undersize 0.25: 0011 / 0012
undersize 0.50: 0013 / 0014
undersize 0.75: 0015 / 0016
undersize 1.00: 0017 / 0018

Permissible axial clearance of crankshaft:

0.2000.401 mm
Thrust bearing width (thrust washer):
Standard size: 3.3503.400 mm
Repair stage 1: 3.6003.650 mm
Repair stage 2: 3.8503.900 mm

38.96139.000 mm

9
 Dimensions
Service data
Limit values

Flywheel

0.05 A
Flywheel:
432.490432.645 mm
Internal gear ring :
432.000432.155 mm

Interference: 0.3350.645 mm
Installation temperature: 200230_C

m = 52.3 kg (with gear ring)

J = 1.975 kgm2
Number of teeth: Z = 160, module 3
Matching gear: Starter pinion (Z = 9)

Backlash: 0.60.9 mm

10
 Dimensions
Service data
Limit values

Flywheel

Flywheel:
432.490432.645 mm
Internal gear ring :
432.000432.155 mm

Interference: 0.3350.645 mm
Installation temperature: 200230_C
m = 32.5 kg (with gear ring)
J = 1.10 kgm2
Number of teeth: Z = 160, module 3
Matching gear: Starter pinion (Z = 9)

Backlash: 0.60.9 mm

11
 Dimensions
Service data
Limit values

Conrods
50.05550.065 mm
Conrods which are discoloured at the big

end must not be re-installed.
Bearing bore in measuring directions 1, 2
and 3 and in measuring planes a and b:

dia. 0.02 A
90.04490.086 mm
Edge condition:
New conrod bearing in place,
conrod assembled

1 8 mm 8 mm

2
A B
3

Conrod bearings
Standard size: 2.4682.478 mm
undersize 0.25: 2.5932.603 mm
undersize 0.50: 2.7182.728 mm
undersize 0.75: 2.8432.853 mm
undersize 1.00: 2.9682.978 mm
Spread: 0.61.5 mm
If signs of wear are present
(scores, antiwear coating damaged), re-
place both bearing shells.
Important: Note installation position
(upper half bearing shell has red mark on
the side)

Connecting rod bolts

Length With each tightening, the bolts are
deliberately stressed beyond the stretch
limit and each tightening thus extends
their length permanently.

Torx bolt M14x1.5

12
 Dimensions
Service data
Limit values

Pistons
Compression height: 79.2079.25 mm
with undersize:
0.2 mm 79.0079.05 mm
0.4 mm: 78.8078.85 mm
0.6 mm: 78.6078.65 mm
Piston protrusion above crankcase top:
0.0130.331 mm

50.0150.018 mm
Piston pin diameter:
49.99450.0 mm

127.855127.895 mm
20

Max. difference in weight per engine pis-

ton set: 100g

Piston ring grooves

1.5
3.473.50 mm

I
3.053.07 mm
II

III 4.024.04 mm

Piston rings
2.5

I 1st ring keystone ring

Height: 3.2963.330 mm

II 2nd ring Minute ring:

Height: 2.973.0 mm
Axial clearance: 0.050.10 mm
III
3rd ring bevelled ring
Height: 3.9753.990 mm
Axial clearance: 0.030.065 mm

Ring gap:
1st ring: 0.50.7 mm
2nd ring: 0.70.9 mm
3rd ring: 0.250.55 mm

13
 Dimensions
Service data
Limit values

Cylinder head

9.0009.015 mm

14.114.5 mm
Intake valve = 60_
Exhaust valve b = 45_

Bore in cylinder head for

valve guide:
15.00015.018 mm
External diameter of valve guide:
15.02815.046 mm

Standard size: 114114.2 mm

(observe specified dimensions for injector
projection and valve recess)

Bore in cylinder head:

48.0048.025 mm
External diameter of valve seat ring:
48.1048.11 mm

14
 Dimensions
Service data
Limit values

Cylinder head bolts

Length With each tightening, the bolts are
deliberately stressed beyond the stretch
limit and each tightening thus extends
their length permanently.
When the bolt has reached its maximum
length, it must not be re-used.
Angle of rotation symbol

51.904900041 / 0070:
new: 259259.5 mm, max. 261.5 mm
51.904900042 / 0071:
new: 197.5198 mm, max. 200 mm

Valve recess

Intake valve: 8.9638.977 mm
Exhaust valve: 8.958.964 mm

Valve recess: 0.80 mm

Valve springs

Inner spring:
Free length (L), approx. 64.8 mm
Spring force at L = 38 mm: 142158 N
Spring force at L = 26 mm: 213239 N
Outer spring:
Free length (L*), approx. 63.3 mm
Spring force at L* = 45 mm: 410470 N
L* L
Spring force at L* = 33 mm: 714790 N
The lowest spring force is at the same
time the wear limit value.

15
 Dimensions
Service data
Limit values

Valve gear

Rocker arm shaft

27.96127.97 mm

Rocker arm

28.00528.021 mm
Rocker arm radial clearance:
0.0350.06 mm

16
 Dimensions
Service data
Limit values

Camshaft

Replace if signs of wear are present

Camshaft axial clearance:
0.200.90 mm
Wear limit: 1.5 mm

69.91069.940 mm
Backlash:
Crankshaft gear and camshaft gear:
0.128 mm0.252 mm

Camshaft bearing

70.00070.030 mm

Valve tappet

Matching bore in crankcase:

20.00020.021 mm

19.94419.965 mm

17
 Dimensions
Service data
Limit values

Oil pump

Oil pump gear

Shaft: 21.93021.940 mm
Bore in housing lid:
22.00022.021 mm
Radial clearance: 0.0600.091 mm

Housing depth: 28.00028.033 mm

Gear axial clearance: 0.0400.106 mm
27.92727.960 mm
14.514.7 mm

Drive wheel with oil pump gear

14.514.7 mm

Shaft: 21.93021.940 mm
Bore in drive gear:

21.87021.885 mm
Press on force: 12.000 N
Backlash:
Drive wheel and crankshaft wheel:
0.0990.451 mm
0.5 mm

18
 Dimensions
Service data
Limit values

Cooling system

Coolant pump
Gap: 0.70.8 mm

impeller: 149.5150 mm

Bearing seat in housing:

54.94054.970 mm
of bearing: 54.98154.994 mm
Interference: 0.0110.054 mm

Bore for bearing shaft in impeller:

16. 00816.010 mm
of bearing shaft:
16.04316.056 mm
Interference: 0.0330.048 mm

Hub bore: 25.00725.020 mm

of bearing shaft :
25.04825.061 mm
Interference: 0.0280.054 mm

Raw water pump 51.06500-7026

If impeller is worn, replace it together with
seals (repair kit)

If wear in the bearing can be felt (air in

bearing), replace the bearing
Speed of raw water pump:
1.53 x engine speed (i=0.65)

19
 Dimensions
Service data
Limit values

Cover for heat exchanger

Working valve opens at
0.851.15 bar overpressure
0.020.08 bar negative pressure

Valve cap:
Safety valve opens at
1.31.7 bar overpressure
(pressure: 1.5 LR1103)
Warning:
When opening the cap with the working
valve there is a risk that it may remain
nontight after it has been closed again.

The overpressure required in the cooling

system no longer builds up. Premature
boiling occurs and coolant is lost.

To prevent damage to the engine, this cap

should only be opened in exceptional cir-
cumstances and then replaced with a new
one.

Thermostat

Opening begins at: 83_C (2_)

Fully open: 95_C
(The temperature for the start of opening
is printed on the thermostat)

24.525.8 mm

Lift at least 8 mm at 95_C

20
 Dimensions
Service data
Limit values

Turbocharger

Axial clearance

Axial clearance max. 0.16 mm

for turbochargers KKK K36 and all en-
gines D 2876 LE 4..

Radial clearance

Radial clearance max. 0.58 mm

for turbochargers KKK K36 and all en-

gines D 2876 LE 4..

21
 Dimensions
Service data
Limit values

Fuel system
Injection nozzles
Manufacturer Bosch
Type of injector DLLA 154 P 945
Number of holes 6
Opening pressure of injector
New nozzle holder: 320+8 bar
Used nozzle holder:

Projection above cylinder head contact surfaces

2.123.13 mm

Injection pump
Bosch control-slide pump RP 39
Governor Bosch-EDC MS 5

Start of delivery
Model Crank angle before TDC
D 2876 LE 401 up to engine no ... 9838 999 .... 7.50.5
D 2876 LE 401 engine no. and up ... 9839 001 .... 80.5
D 2876 LE 402 60.5
D 2876 LE 404 / 405 80.5

22
 Dimensions
Service data
Limit values

Starter motor
Manufacturer: Bosch
Type: KB
Operating method: splined shaft

Starter motor pinion:

Number of teeth: Z=9
Module: 3

Nominal power: 5.4 kW

Nominal voltage: 24 V

Alternator
Manufacturer: Bosch
Type: N1
Type: 2pole, insulated
Operation method: Threephase current
Voltage: 28 V
Max. current: 55 A

23
 Dimensions
Service data
Limit values

Vbelts / Powerband
Replace damaged Vbelts (cracks, wear,
oil)

Measuring tension withtension tester

Tensioning forces according to
the kg graduation on the tester
New installation When
Belt
servicing
width After 10 after long
Installa-
min. run- running
tion
ning time time
2/3VX 90-100 70-80 60

24
 Torque guide values

Note:
All screw connections, the purpose of which is not stated in the following table, are to be tightened in ac-
cordance with the guide values in our company standard M 3059 (see page 27). Fit the bolts slightly oiled!

Screw plugs
DIN 908
M14x1.5, M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
M18x1.5, M22x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm
M24x1.5, M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm
M30x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm

DIN 7604
AM10x1, M12x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
AM14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm

Crankcase, crankshaft drive

Gear case to crankcase M14, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Nm
Gear case to crankcase M10, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Inspection port cover to gear case M8, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Inspection port cover to gear case M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Crankshaft bearing caps to crankcase M18x2
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300330 Nm
Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90100
Vibration damper to crankshaft M16x1.5, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Nm
Flywheel to crankshaft M16x1.5
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100110 Nm
1st angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90100
2nd angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90100
Connecting rod bearing caps M14x1.5
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100110 Nm
Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 to 100

Cylinder head
Tightening / retightening the cylinder-head bolts, see page 28

Lubrication system
Oil pump to crankcase M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Cover oil pump M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Oil cooler to oil filter head M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Filter box to oil filter head M8, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Oil pan to crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Oil drain plug to oil pan M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Oil jet flange to crankcase M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm

Exhaust / intake manifold

Exhaust manifold to intermediate plate M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Exhaust manifold to intermediate plate M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Intermediate plate to cylinder head M10
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Intake pipe to cylinder head M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm

25
 Torque guide values

Fuel system
Assembly sequence for injector and injection line:
1. Collar nut for injector retainer , initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
2. Injection line , initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
3. Mounting bolt for connector to injection line , initial torque . . . . . . . . . . . . . . . . . . . . 10 Nm
4. Collar nut for injector retainer
Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90_
5. Mounting bolt for connector to injection line
Final torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm
Rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90_
6. Injection line
Rotation angle for first installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60_
Rotation angle for assembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30_
7. Collar nut for injector retainer
Rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45_
Let engine warm up
Rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90_

Starter / alternator
Starter to crankcase M12x1,5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Vbelt pulley on alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4050 Nm

26
 Torque guide values

Installation tightening torques according to company standard M 3059

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

Thread size Grades / tightening torques in Nm

x pitch
for 8.8 / 8 for 10.9 / 10 for 12.9 / 12
M4 2.5 4.0 4.5
M5 5.0 7.5 9.0
M6 9.0 13.0 15.0
M7 14.0 20.0 25.0
M8 22.0 30.0 35.0
M8x1 23.0 35.0 40.0
M10 45.0 65.0 75.0
M10x1.25 45.0 65.0 75.0
M10x1 50.0 70.0 85.0
M12 75.0 105.0 125.0
M12x1.5 75.0 110.0 130.0
M12x1.25 80.0 115.0 135.0
M14 115.0 170.0 200.0
M14x1.5 125.0 185.0 215.0
M16 180.0 260.0 310.0
M16x1.5 190.0 280.0 330.0
M18 260.0 370.0 430.0
M18x2 270.0 290.0 450.0
M18x1.5 290.0 410.0 480.0
M20 360.0 520.0 600.0
M20x2 380.0 540.0 630.0
M20x1.5 400.0 570.0 670.0
M22 490.0 700.0 820.0
M22x2 510.0 730.0 860.0
M22x1.5 540.0 770.0 900.0
M24 620.0 890.0 1040.0
M24x2 680.0 960.0 1130.0
M24x1.5 740.0 1030.0 1220.0

27
 Torque guide values

New cylinder head seal and modified cylinder bush from March 2003
From March 2003 the cylinder bush, the upper seal on the cylinder bush, the cylinder head seal and the
torque regulations on various series D 2876 four valve engineswithout Common Rail have been modified
as standard.

Note:
To aid recognition, these engines do not have the sticker First retightening of cylinderhead
bolts completed on one of the valve caps.

Retightening of the cylinder head bolts on engines up to 28.02.2003

(Engine cold or warm)
The cylinder heads are fitted with cylinderhead
Erster Nachzug der Zylinder- bolts for rotation angle tightening. On new engines,
kopfschrauben erledigt the cylinder-head bolts are retightened at the fac-
tory after running in and marked by the sticker
First retightening of cylinder-head bolts ...
First retightening of cylinder- on a cylinder head cover.
head-bolts completed

Spare part no. 51.978010211

Intake side

After the first 400 hours of operation, tighten the

cylinder-head bolts 1 4 in the order specified in
tightening schedule 1 by 90 (1/4 turn).

1 4 The two outer bolts (intake and exhaust side) must

not be retightened.

Note:
The cylinder-head bolts to be retightened
must not be loosened; they are to be
tightened further from their current posi-
tion by 90 (1/4 turn).

3 2

Exhaust side
Tightening schedule 1

Zweiter Nachzug der Zylinder- Remove the sticker First retightening of the cy-
kopfschrauben erledigt linder-head bolts ... and attach the sticker Se-
cond retightening of the cylinder-head bolts
... to verify the second retightening.
Second retightening of cylinder-
head-bolts completed

Spare part no. 51.978010212

28
 Torque guide values

Tightening the cylinder-head bolts following a repair

(engine cold)

Intake side Before inserting the cylinder head bolts, apply en-
gine oil to the threads (not the tapped holes) and
Optimoly White T installation past to the bolt
6
head contact faces. Do not use oils or oil additives
containing MoS2. The bolts are to be tightened
using the rotation angle method according to tigh-
tening schedule 2 as follows.
1 4
D 1st pretightening = to 10 Nm
D 2nd pretightening = to 80 Nm
D 3rd pretightening = to 150 Nm
D 4th pretightening = 90
D Final tightening = 90

Set the valve clearance.

3 2

Exhaust side

Tightening schedule 2

Note:
When the head has been removed, the cylinder head gasket must always be replaced.

Retightening the cylinder-head bolts following a repair

(Engine cold or warm)

After the first 10 to 20 hours of operation, following a repair, retighten the cylinder-head bolts in the order
specified in tightening schedule 2 by 90 (1/4 turn).
The cylinder-head bolts to be retightened must not be loosened; they are to be tightened further from their
current position by 90 (1/4 turn).
Attach the sticker First retightening of cylinder-head bolts ... (remove sticker that might already be
attached).
After the first 400 hours of operation, following a repair, tighten cylinder-head bolts 1 to 4 in the order
specified in tightening schedule 1 by another 90 (1/4 turn).
The two outer bolts (intake and exhaust side) must not be retightened.
Attach sticker Second retightening of cylinder-head bolts ....

29
 Torque guide values

Retightening of new and rebuilt engines from 01.03.2003

Intake side On engines which have modified cylinder liners,

the cylinder-head bolts are no longer retightened at
6 the factory.
Therefore the First retightening of cylinder-head
bolts completed sticker is omitted

1 4 After 400 hours of operation, retighten the cylinder-

head bolts by 90 (1/4 turn) in accordance with the
tightening schedule on the left without loosening
them first.

3 2

Exhaust side

Nachzug der Zylinder-

kopfschrauben erledigt Following successful tightening, attach the Re-
tightening of cylinder-head bolts completed
sticker to one of the valve caps.
Retightening of cylinder-
head-bolts completed

Spare part no. 51.978010315

30
 Torque guide values

Tightening the cylinder-head bolts following a repair

(engine cold)

Intake side Before inserting the cylinder head bolts, apply en-
gine oil to the threads (not the tapped holes) and
6 Optimoly White T installation past to the bolt
head contact faces. Do not use oils or oil additives
containing MoS2. The bolts must be tightened
using the torque angle method according to the
1 4 tightening sequence on the left.

D 1st pretightening = to 10 Nm
D 2nd pretightening = to 80 Nm
D 3rd pretightening = to 150 Nm
D 4th pretightening = 90
D Final tightening = 90
Set the valve clearance.
Following successful first tightening during a repair,
remove the existing sticker from the valve cap.
3 2

Exhaust side

Note:
When the head has been removed, the cylinder head gasket must always be replaced.

31
 Torque guide values

Retightening the cylinder-head bolts following a repair

(Engine cold or warm)

Following successful repair, retighten with cylinder head bolts once using the angle-of-rotation method.

Intake side After 400 hours of operation, tighten the cylinder

head bolts without unscrewing them by 90 (1/4
6 turn) in accordance with the tightening schedule on
the left.

1 4

3 2

Exhaust side

Nachzug der Zylinder-

kopfschrauben erledigt Following successful tightening, attach the Re-
tightening of cylinder-head bolts completed
sticker to one of the valve caps.
Retightening of cylinder-
head-bolts completed

Spare part no. 51.978010315

32
 Index

A S
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Start of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 T
Compression pressure . . . . . . . . . . . . . . . . . . . . . . 5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque guide values . . . . . . . . . . . . . . . . . . . . 2528
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 V
Crankshaft axial clearance . . . . . . . . . . . . . . . . . . . 9 Vbelts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Crankshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . 9 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . 15 Valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder liner protrusion . . . . . . . . . . . . . . . . . . . . . 7 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E
Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . 3, 5

F
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11
Fuel supply pump . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

I
Injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

O
Oil filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

P
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

R
Retightening the cylinder head . . . . . . . . . . . . . . 28
Retightening the cylinder head bolts . . . . . . 2830
Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

33
34