Regeneration of MAN Lion's City and Lion's Coach injectors – D0836, D2066, D2676
Professional regeneration of MAN Common Rail injectors for city buses and coaches. D0836LFL, D2066LUH, D2676LF, Euro 3–6 engines. Bosch and Delphi catalog numbers, test on the EPS 815 table, 12 months warranty.
Common Rail injection systems in MAN buses – engine characteristics
MAN buses are one of the most frequently used vehicles in public transport in Central Europe. The Lion's City (urban), Lion's Coach (coach), Lion's Regio (regional) and Lion's Intercity product lines are equipped with in-line engines of the D08, D20 and D26 series, driving Common Rail systems with Bosch or Delphi injectors.
The working pressure of the CR rail in MAN D2066 and D2676 series engines is up to 1,800 bar (Euro 5) and up to 2,000 bar (Euro 6). The precision of fuel dosing has a direct impact on consumption, NOx and PM emissions and engine durability - particularly important in the context of stringent emission standards for public transport.
MAN engines used in buses - injector catalog numbers
| MAN bus model | Engine | Injector | Part number | Euro |
|---|---|---|---|---|
| Lion's City A21 / A23 | D0836LFL (Euro 3) | Bosch CRI2-P | 0 445 120 030 / 0 445 120 031 | Euro 3 |
| Lion's City A20 / NL263 | D0836LFL (Euro 4–5) | Bosch CRI2-16 | 0 445 120 157 / 0 445 120 158 | Euro 4–5 |
| Lion's City NL313 / NG313 | D2066LUH (Euro 4–5) | Bosch CRI2-18 | 0 445 120 218 / 0 445 120 219 | Euro 4–5 |
| Lion's City NL323 / NG323 | D2066LUH (Euro 6) | Bosch CRI3-20 | 0 445 126 030 / 0 445 126 031 | Euro 6 |
| Lion's Coach R07 / RH | D2066LUH | Bosch CRI2-18 | 0 445 120 218 / 0 445 120 220 | Euro 4–5 |
| Lion's Coach RR8 / RL | D2676LF | Bosch CRI3-20 | 0 445 126 032 / 0 445 126 033 | Euro 6 |
| Lion's Regio R12 | D2066LUH / D2676 | Bosch CRI2-18 / CRI3 | 0 445 120 219 / 0 445 126 030 | Euro 5–6 |
| MAN SÜ 263 / 313 | D0836LUH | Delphi EJBR02301Z | EJBR02301Z / EJBR03301D | Euro 3–4 |
Typical symptoms of injector damage in MAN buses
City buses are operated intensively - dozens of starts and stops a day, hours of idling at bus stops. Such operating conditions generate intense thermal and hydraulic stresses in the injection system. The first symptoms of injector wear usually appear after 350,000-500,000 km or after 5-7 years of operation.
Symptoms requiring injector diagnostics
- Smoke on start-up – white or blue-gray smoke for the first dozen or so seconds
- Uneven engine operation – vibrations especially noticeable at idle (800-900 rpm)
- Loss of power – the bus does not achieve full power when leaving the stop
- Increased fuel consumption – monitored by fleet management systems (e.g. MAN TeleMatics)
- Error codes in MAN CATS / MAN DiagBus – indication of a specific injector or bank
- Clatter when starting cold – characteristic metallic sound that disappears after warming up
- Increased soot content in engine oil - a sign of lack of combustion in a given cylinder
DTCs for MAN buses (MAN CATS / MANTED)
| DTC | Description | Applies to |
|---|---|---|
| P0201–P0206 | Cylinder injector circuit. 1–6 – open/short circuit | D0836 / D2066 (6-cyl.) |
| P0261–P0272 | Low/high signal of cylinder injector coil. 1–6 | all CR engines |
| P0087 | Low CR rail pressure below threshold | all |
| P0093 | System leakage - excessive back-leak | all |
| SPN 651–656 FMI 6 | Too high injector coil current - cyl. 1–6 | D2066 Euro 5–6 |
| SPN 2791 FMI 2 | Injection time outside the norm – cyl. 1–6 | D2676 Euro 6 |
| P2146 / P2149 | Power bank 1/2 - break | D2676 6-cyl. |
Man injector regeneration process step by step
1. Pre-test and identification
Each injector is identified by the serial number engraved on the housing and the catalog number on the sticker. We connect it to the Bosch EPS 815 test bench and perform a full input test: injection doses at 5 operating points, back-leak, solenoid valve opening time. The results are saved in the service card.
2. Disassembly and inspection of components
Disassembly is carried out at a station with controlled cleanliness. We check carefully:
- Condition of the needle and nozzle seat - clearances below 2 μm
- Control valve – tightness and clearance
- Solenoid valve coil and core – resistance, working clearance
- Hull – cracks, condition of mounting threads, fuel channels
- Fuel inlet mesh filters – contamination, dents
3. Replacement of Bosch / Delphi OEM components
We only replace items that do not meet factory tolerances. We use Bosch repair kits (F 00V C99 002–F 00V C99 006) for CRI2 and CRI3 and original Delphi kits (7135-573 / 7135-574) for EJBR injectors. Each replacement is documented in the service card.
4. Calibration with a precision of up to 1 μm
The selection of spacer washers regulating the initial tension of the firing pin spring is made with a precision of up to 1 μm. This stage directly determines the compliance of the injection dose with the nominal values of the MAN engine.
5. Post-test and final report
After assembly and calibration, each injector undergoes an identical test as the pre-test. The results must be within a tolerance of ±2% of the Bosch/MAN factory values. A report with the pre- and post-test results is printed and attached to the returned injector.
MAN bus models supported by A-Core
- MAN Lion's City – A20, A21, A23, NL223, NL263, NL313, NG313 (solo and articulated)
- MAN Lion's City G – NG363 (18 m, Euro 6, D2066/D2676)
- MAN Lion's Coach – R07, R08, RH, R12, RL, RR8 (tour coach)
- MAN Lion's Regio – R12, RL (regional)
- MAN Lion's Intercity – RI4 (intercity)
- MAN SÜ 263 / 313 – older Euro 3/4 models with Delphi UI
Service for fleets and carriers
We serve municipal transport companies, companies managing coach fleets and private carriers from all over Poland. The shipping service works for customers from outside Silesia - disassembly on the customer's side, shipping by DPD or InPost courier. Delivery time: 3-5 business days. For regular customers with large fleets - individually agreed service conditions and priority delivery time.
Frequently asked questions - FAQ
Are Bosch CRI2 and CRI3 injectors in MAN D2066 interchangeable?
No – CRI2 (Euro 4/5) and CRI3 (Euro 6) are different generations with different solenoid valves and calibration codes. CRI3 cannot be installed in place of CRI2 without modifying the controller. We always use the type consistent with the engine number and emission standard of the vehicle.
Is adaptation of the MAN EDC7 controller required after regeneration?
CRI2 injectors do not require reprogramming after mechanical regeneration. CRI3 injectors in Euro 6 engines may require new correction values to be introduced by MAN CATS - we recommend performing the adaptation procedure after installation.
How to pack injectors for courier delivery?
Each injector should be wrapped in bubble wrap or placed in a separate string bag. Please attach a card to the box with the bus model, engine number, mileage and description of symptoms. Before shipment – short telephone contact: +48 504 511 170.
Contact
A-Core Diesel Serwis, Knurów (Silesia)
Tel.: +48 504 511 170 – Mon–Fri 8:00–16:00
Free quote after initial diagnostics. Shipping service – all over Poland.
Having a problem with your injection pump?
Contact us – we respond during working hours (Mon–Fri 8:00–16:00).