MAN D28 (D2868) Engine Workshop Manual DTC

A complete guide to repair, maintenance and diagnostics of faults of the MAN D28 (D2868) engine - a powerful V8 diesel engine used in trucks, buses, ships and special equipment. Includes detailed instructions for eliminating DTC (Diagnostic Trouble Codes) errors, diagrams, technical data and procedures for complete diagnostics.

📘 The manual contains:

• DTC error code decoding
• Detailed electrical and functional diagrams
• Step-by-step repair and maintenance instructions
• Information on injection, turbocharging, cooling and lubrication systems
• Tightening torques, pressure standards, maintenance regulations

🚛 Where MAN D2868 is used:

• MAN TGS, TGX Trucks
• MAN and Neoplan tourist and intercity buses
• Special equipment (fire, airport, construction vehicles)
• Marine installations and diesel generators

• General>>
• MAN Home Page>>

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

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

🧰 General recommendations for MAN D2868 maintenance:

• Use only original spare parts and filters
• Keep a maintenance log
• Carry out diagnostics not only by symptoms, but also by DTC
• Observe intervals for changing oil, filters, belts, coolant
• Work according to the official Workshop Manual for this model

🔧 1. Engine overheating

Causes:

Clogged radiator

Faulty thermostat or pump

Low coolant level

Maintenance:

• Flush radiator every 500 m.h.
• Check thermostat condition and replace as scheduled
• Use only recommended MAN coolants

🛢️ 2. Oil pressure drop

Causes:

Worn oil pump

Clogged filter

Leaks through seals

Maintenance:

• Change oil and filter every 500–750 m.h.
• Use original filters and oils with MAN M 3277 approval
• Check oil level and pressure at every maintenance

💨 3. Exhaust smoke

Black smoke: over-enriched mixture, clogged air filter

Blue smoke: piston ring wear, oil ingress

White smoke: cylinder head problems, coolant leak

Maintenance:

• Clean the air system, change filters
• Check compression and condition of the cylinder-piston group
• Use diagnostic scanners to read DTC

⚙️ 4. Knocking or vibration

Causes:

Worn crankshaft bearings

Injector malfunctions

Timing phase malfunctions

Maintenance:

• Adjust valves and injectors
• Check the tension and condition of the timing chains/gears
• Use standard diagnostic software MAN-cats

🌀 5. Turbocharging problems

Causes:

Turbine wear

Intake system contamination

Insufficient oil pressure on the turbine

Maintenance:

• Check and clean the intercooler
• Use oil of the correct viscosity
• Let the engine idle for 2-3 minutes after loading

⚡ 6. Electronic errors and failures

Causes:

Corrosion of connectors

Failures in the operation of sensors (temperature, pressure, MAP)

Unstable power supply

Maintenance:

• Conduct a visual inspection of harnesses and connectors
• Use original sensors
• Periodically update the ECU software if recommended by the manufacturer