MAN D28 (D2862) Engine Workshop Manual

The MAN D2862 factory manual covers all aspects of diagnostics, maintenance and overhaul of the modern V12 diesel engine of the D28 series, used in heavy commercial vehicles and marine installations. The manual is intended for professionals: engineers, mechanics, service stations and service centers.

📘 The manual contains:

• Diagrams and descriptions of all systems: fuel injection, turbocharging, lubrication, cooling
• Step-by-step instructions for disassembling, assembling and adjusting components
• Technical specifications and parameters
• Tightening torques, service intervals
• Electrical diagrams and diagnostic data

🚛 Where the MAN D2862 engine is used:

• MAN TGX / TGS trucks (heavy class)
• Fire and rescue vehicles
• Yachts, boats and marine diesel generators
• Industrial power plants

• General>>
• MAN Home Page>>

• D2868 LE433
• D2862 LE433/LE453
• D2862 LE423/LE443/LE463

• D2868 LE426/436
• D2862 LE426/LE446/436/456/476/496

🔧 1. Engine overheating

Causes:

Clogged radiator or heat exchangers

Faulty thermostat or water pump

Broken coolant circulation (air locks)

Solution:

• Check and flush the cooling system
• Replace faulty components
• Make sure the fans are working properly

💨 2. Increased smoking

Options:

Black smoke: over-enriched mixture, faulty air flow sensor, clogged air filter

White smoke: coolant entering the cylinders (gasket leak, cracks)

Blue smoke: oil entering the combustion chamber (wear of the CPG)

Solution:

• Check the turbine, condition of the filters, cylinder head gaskets
• Carry out diagnostics of the injection system

⚙️ 3. Noise or knocking in the engine

Causes:

Worn crankshaft bearings or pistons

Violation of valve clearances

Detonation due to incorrect injection angle

Solution:

• Measure clearances, oil pressure
• Check the condition of the liners and pistons
• Carry out diagnostics of the fuel system

🛢️ 4. Drop in oil pressure

Causes:

Worn oil pump

Leaks through seals and gaskets

Contamination of the oil receiver

Solution:

• Measure oil pressure
• Clean the oil system
• Replace damaged gaskets

⚡ 5. DTC errors and ECU failures

Causes:

Damaged sensors (MAP, temperature, pressure)

Unstable supply voltage

Corrosion of contacts and connectors

Solution:

• Read error codes using diagnostic software
• Check wiring and power supply
• Replace faulty sensors

🌀 6. Turbocharging malfunctions

Causes:

Turbine oil starvation

Bearing wear

Blade damage due to foreign particles

Solution:

• Check oil supply to the turbine
• Evaluate axial play
• Clean the intake system