M32

m
c
M32
M32 C
L - VEE
Caterpillar confidential: yellow
Engineers Handbook
M32
General Notes
- Cylinder arrangement according to DIN
In-line engine
Vee-engine
Edition
11.11.2004
Service Document of
Caterpillar Motoren GmbH & Co. KG
Page
2
Engineers Handbook
M32
General Notes
Engines beginning with number 38xxx belong to version C.

As far as data differ from the basic version, they are shown additionally.
Edition
11.11.2004
Service Document of
Page
3
Engineers Handbook
M32
Table of Contents
General Notes ................................................................................ 2

- Cylinder arrangement according to DIN ........................................................................ 2
Engine Data .................................................................................. 10

Engine Operating Data ................................................................ 10
Engine Block ................................................................................. 11
- Crank case cover ............................................................................................................... 11
- Tightening torques for plug screws ............................................................................ 11
Cylinder Head ............................................................................... 12

-
Tightening torque .............................................................................................................

Valve rocker bracket ........................................................................................................
Radial clearance .................................................................................................................
Valve clearance ..................................................................................................................
Valve rocker bracket C-engine ......................................................................................
Radial clearance .................................................................................................................
Valve clearance ..................................................................................................................
Setting of valve bridges and valve clearances ..........................................................
Valve guide .........................................................................................................................
Fuel injection valve C-engine .........................................................................................
Fuel injection valve ...........................................................................................................
Fuel injection valve - old design ....................................................................................
Removal - mounting .........................................................................................................
Starting valve .....................................................................................................................
Fuel delivery pipe ..............................................................................................................
Indicating and safety valve ..............................................................................................
Guiding bolts for the valve bridges ..............................................................................
Valve stem ..........................................................................................................................
Inlet and exhaust valve stem .........................................................................................
Valve seat ring ...................................................................................................................
Fitting of inlet and exhaust valve seats .......................................................................
Edition
11.11.2004
Service Document of
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20
20
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21
22
23
23
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4
Engineers Handbook
M32
Table of Contents
Piston ............................................................................................ 24
-
Mahle 1.90.7-26.70.00-01 / 02 / 05 / 07 ..............................................................................

Mahle 1.90.7-26.70.00-08 / 09 / 12 / 13 / 16 / 18 / 22 / 23 / 24 ..........................................
Dismounting Mahle 1.90.7-26.70.00-01 / 02 / 05 / 07 / 09 / 13 / 16 / 18 / 22 / 23 / 24 ...
Mahle 1.90.7-26.70.00-20 ...................................................................................................
MWH 1.90.7-26.70.00-06 .....................................................................................................
Mounting of the slider into the piston skirt ...............................................................
The pistons are inserted as follows: ..........................................................................
Dismounting .......................................................................................................................
Mounting .............................................................................................................................
Wear and limit clearances ...............................................................................................
24
24
25
26
27
27
28
28
29
29
Liner .............................................................................................. 30
-
Nominal size .......................................................................................................................

Wear limits ..........................................................................................................................
Installation ..........................................................................................................................
Flame ring - calibration ring ............................................................................................
Calibration ring ..................................................................................................................
30
30
31
32
32
Connecting Rod ........................................................................... 33

-
Tightening torque shank division: ................................................................................

Shank division ...................................................................................................................
Piston pin bush .................................................................................................................
Tightening torque big-end bearing nuts .....................................................................
Removal ...............................................................................................................................
Big end bearing .................................................................................................................
Reference dimensions of the big end bearings after correct tightening ..........
Marking ...............................................................................................................................
33
34
34
34
34
35
35
35
Crankshaft Bearing ..................................................................... 37

-
Tightening specification (in-line) ..................................................................................

Measurement of the gap (in-line) .................................................................................
Tightening specification (Vee-engine) ........................................................................
Measurement of the gap (Vee-engine) .......................................................................
Marking ...............................................................................................................................
Axial clearance S ...........................................................................................................
Limit clearance ..................................................................................................................
Bearing 1 (located main bearing) in-line and Vee-engine .......................................
37
38
39
40
41
41
41
41
Crankshaft .................................................................................... 42
-
Crank web deflection ......................................................................................................

Counterweight mounting ...............................................................................................
Counterweight mounting, tightening specification (In-line engine) ....................
Counterweight mounting, tightening specification (Vee-engine) ........................
Edition
11.11.2004
Service Document of
42
42
42
43
Page
5
Engineers Handbook
M32
Table of Contents
Gear Train L - VEE ....................................................................... 44

-
Gear wheel on crankshaft 1.90.7-25.30.00-02 ..............................................................

Intermediate gear wheel mounting 1.90.7-51.40.00- 01/02 ......................................
Intermediate gear wheel mounting 1.90.7-51.40.00-02 .............................................
Backlash ..............................................................................................................................
Intermediate gear wheel mounting 1.91.7-51.40.00- 01/02 .......................................
End clearance S1 ...........................................................................................................
Backlash ..............................................................................................................................
Lub. oil injectors for gear wheels ................................................................................
Camshaft gear wheel ......................................................................................................
44
44
45
46
47
47
48
49
49
49
50
Gear Train C-Engine.................................................................... 51

-
Intermediate gear wheel mounting (In-line engine) ................................................

End clearance S (In-line engine) ................................................................................
Camshaft gear wheel ......................................................................................................
Intermediate gear wheel mounting (Vee engine) ....................................................
End clearance S (Vee engine) ....................................................................................
Backlash ..............................................................................................................................
Lub. oil injectors for gear wheels ................................................................................
51
51
52
53
53
54
54
Governor Drive L + VEE ............................................................. 55

- Old design ........................................................................................................................... 55
- New design ........................................................................................................................ 55
Governor Drive C-Engine .......................................................... 57

- Backlash and End clearance ........................................................................................... 57
Camshaft Bearing ........................................................................ 59

-
Camshaft
Camshaft
Camshaft
Camshaft
Camshaft
bearing 1.90.7-31.91.01-30 .............................................................................

bearing 1.90.7-31.91.01-32 .............................................................................
bearing C-engine ...........................................................................................
bearing clearance ..........................................................................................
bearing Vee-engine for row A and B ........................................................
Edition
11.11.2004
Service Document of
59
59
61
61
62
Page
6
Engineers Handbook
M32
Table of Contents
Camshaft ....................................................................................... 63
- Camshaft mounting In-line engine ...............................................................................
- Mounting of camshaft segments
(for separate bearing journals / In-line engine) .........................................................
(for integrated bearing journals / In-line engine) ......................................................
- Camshaft mounting In-line engine C ...........................................................................
- Camshaft mounting 6 and 9cyl. engines C .................................................................
- Camshaft mounting 8-cyl. engines C ...........................................................................
- Mounting camshaft Vee-engine ....................................................................................
- Arrangement for 12 cyl. - engines ................................................................................
- Aarrangement for 16 cyl. - engines ..............................................................................
- Camshaft mounting Vee - engine C .............................................................................
- Camshaft mounting 12-cyl. engine C row A ...............................................................
- Camshaft mounting 12-cyl. engine C row B ...............................................................
- Camshaft mounting 16-cyl. engine C row A ...............................................................
- Camshaft mounting 16-cyl. engine C row B ...............................................................
- Vibration damper ..............................................................................................................
63
64
65
66
68
69
70
71
72
73
74
75
76
77
78
Starting Air Distributor ................................................................ 79

- Instruction for setting ..................................................................................................... 79
Fuel Injektion Pump ..................................................................... 80

-
Pump attachement ...........................................................................................................

Setting and ascertainment of thickness of the distance steel plates .................
Setting of commencement fuel of delivery ................................................................
Commencement of fuel delivery for engines without eccentric .........................
Commencement of fuel delivery for engines with eccentrics .............................
IMO-adjustment, lower valve drive ...............................................................................
Adjusting commencement of fuel delivery IMO variant with FlexCam (FCT) .....
Check of IMO adjustment ...............................................................................................
Fuel distributing and collecting pipe, flanges ...........................................................
Fuel distributing and collecting pipe, in-line engine ................................................
Fuel distributing and collecting pipe, mounting ........................................................
Pipe mounting, fuel supply .............................................................................................
80
81
82
82
83
86
87
90
91
92
93
94
Lower Valve Drive ....................................................................... 95

- Bearing brackets ............................................................................................................... 95
- Rocking lever, fuel ............................................................................................................ 96
Edition
11.11.2004
Service Document of
Page
7
Engineers Handbook
M32
Table of Contents
Sundries ....................................................................................... 97
- Regulating shaft ................................................................................................................ 97
- Articulated lever ................................................................................................................ 97
- Starting fuel limiter ........................................................................................................... 98
- Fuel rack position transmitter ....................................................................................... 99
-Main starting air valve ....................................................................................................... 99
- Emergency start via master starting valve ............................................................... 100
- Oil sump - mounting standard oil pan with discharge outlet ............................... 101
- Oil sump - mounting high oil pan ................................................................................ 101
- Bracket mounting (for supply and disposal pipes, OSC) ..................................... 102
- Pipe mounting ................................................................................................................. 102
- Cooling water collecting and distributing pipe ....................................................... 103
- Cooling water pipe mounting ...................................................................................... 104
- Exhaust gas manifold ..................................................................................................... 105
- Barring gear mounting .................................................................................................. 106
- Engine adjustment EPG ................................................................................................. 107
Crankshaft Sealing with Flywheel Hub Mounting .................. 108

-
Crankshaft sealing 1.90.7-73.40.00-01 ......................................................................... 108

Flywheel hub 1.90.7-73.40.00-02 ................................................................................... 108
Crankshaft sealing 1.90.7-73.40.00-03 / -04 (In-line) .................................................. 110
Crankshaft sealing 1.91.7-73.40.00-02 / -03 (Vee) ...................................................... 110
Dismounting and mounting of flywheel hub and crankshaft gear wheel .......... 112
Flywheel Mounting ..................................................................... 113

Opposite Side of Coupling ........................................................ 114
-
Mounting without power take-off ................................................................................ 114

Mounting with power take-off ...................................................................................... 115
Mounting with power take-off ...................................................................................... 117
Mounting PTO coupling hub .......................................................................................... 118
Pump Carrier with Attached Pumps .......................................... 119

-
Pump carrier ..................................................................................................................... 119

Cooling water pumps, HT and LT circuit ................................................................... 119
Gear wheel mounting ..................................................................................................... 119
Lub. oil pumps, suction and pressure pump ........................................................... 119
Fuel feed pump ............................................................................................................... 120
Edition
11.11.2004
Service Document of
Page
8
Engineers Handbook
M32
Table of Contents
Turbocharger Mounting ............................................................ 121

-
Mounting turbocharger NA295 CS and OSC, in-line engine ..................................

Mounting turbocharger NA297 CS and OSC, in-line engine ..................................
Mounting turbocharger NA355 and NA357 CS and OCS, in-line engine ..............
Air inlet casing to the charge air cooler ....................................................................
Mounting turbocharger NA 297 CS and OSC, in-line engine C ..............................
Mounting turbocharger NA 357 CS and OSC, in-line engine C ..............................
Mounting turbocharger TPL 65D coupling side, vee-engine ................................
Air inlet casing to the charge air cooler ....................................................................
Mounting turbocharger NA 297 opposite side of coupling, Vee-engine C ........
Mounting turbocharger TLP 65D CS and OSC, Vee-engine C ...............................
121
121
121
121
122
124
126
126
127
130
Charge Air Cooler ...................................................................... 133

- Mounting coupling side and opposite side of coupling ........................................ 133
- Installation ........................................................................................................................ 134
- Drain pipe charge air manifold ..................................................................................... 135
Flexible Mounting ...................................................................... 136

- Locking device in case of average ............................................................................. 140
Firing Sequences ...................................................................... 141

Dimensions and Weights .......................................................... 142
Edition
11.11.2004
Service Document of
Page
9
Engineers Handbook
M32
Engine Data
Engine Operating Data
In-line engine
Temperatures
Stroke:
480
mm
Bore:
320
mm
Speed:
600
rpm
Number of cylinders:
Lub. oil, inlet
60 - 65 C
Temperature rise:
6 - 12 C *1
Fresh water circulation cooling
6-8-9
Engine outlet:
Vee-engine
Stroke:
420
mm
Bore:
320
mm
Speed:
750
rpm
Number of cylinders:
12 - 16
Crankshaft bearing in-line engine

Inside
300
mm
Outside
318
mm
Temperature rise:
80 - 90 C
4 - 6 C *1
Charge air, inlet:
35 - 40 C
IMO - engines:
32
Distillate fuel:
35 - 40 C
Pressures
Lub. oil
4.0 - 5.0 bar *2
Crankshaft bearing Vee-type engine

Inside
340
mm
Fresh water circulation cooling:
Outside
With min. 4mWs
2.5 - 5.0 bar
Nozzle cooling:
1.5 - 3.0 bar
Fuel pressure before

injection pumps:
MDO-operation
3.0 - 5.0 bar
HFO-operation
4.0 - 5.0 nar
358
mm
Big end bearing in-line and Vee-type

engine
Inside
280
mm
Outside
293
mm
Valves (inlet and exhaust)

Length
567
mm
Shaft
25.94
mm
Valve disk
105
mm
*1 = At rated engine output

*2 = At rated engine speed
Valve guide
Length
324
mm
Inside
26
mm
Edition
11.11.2004
Service Document of
Page
10
Engineers Handbook
M32
Engine Block
In-line engine
C-engine
Vee-engine
- Crank case cover

Insert only flat gaskets slightly greased. Use Dirko, Nr.610.020 (Dirko, grey) for coverings
without any gasket.
Tighten threaded pins DIN 976 - M16 x l - B - 8.8 and
studs DIN 835 - M16 x l - 8.8 with

(dry, without lubricant)
M =40
Nm
Tighten the screws - 1 - for the

cover with blow-off valve 162EVA with
M =24,5
Nm
1 (6x)
- Tightening torques for plug screws

Tighten plug screws M16x1,5 with
M =40
Nm
Tighten plug screws M18x1,5 In-line engine with
M =140
Nm
Tighten plug screws M18x1,5 Vee-engine with
M =50
Nm
Verschlussschrauben M26x1,5 with
M =180
Nm
Tighten plug screws M27x2 with
M =180
Nm
M =200
Nm
M =350
Nm
Tighten plug screws M155x2,5 with
M =750
Nm
Tighten plug screws G 3/4 with
M =190
Nm
Edition
11.11.2004
Service Document of
Page
11
Engineers Handbook
M32
Cylinder Head
In-line engine
- Tightening
The tightening
Molykote
Oil
Vee-engine
torque
torque for inserting the tie bolts is
old In-line and Vee- engines
newer C-engines
1. Pretighten round nuts manually with a pin.

2. Lengthen tie bolts with
and tighten round nuts with a pin, taking
care of easy motion.
M = 250
Nm
P = 850 - 25
bar
The pressure must remain constant, when the pump is not operated, otherwise faulty
tightening.
Check: Reduce pressure by 50 bar. Further loosening of the round nuts must not be
possible .
If the cyl. head nuts cannot be loosened at the prescribed pressure, pressure increase
by 50 bar is possible. The pressure must not be increased further, because elongation of
the thread and consequently jamming of the
nuts cannot be excluded.
At the control bore - 1 - leakages between

cylinder head, flame ring and cooling water
distributing housing can be detected.
On the M32 C engine some modifications have
been carried out at the cylinder head.
The most important ones are:
1. The cast-on exhaust gas flange

2. The guide bolts are frozen in.
Exhaust gas flange
3. The rocker arm shaft is straight

4. The cap has changed.
5. There is only one spring per valve.
It is possible to use the cylinder head
of the M 32 C engine in older engines.
It is necesarry to recall the customer
sevice.
Edition
11.11.2004
Service Document of
Page
12
Engineers Handbook
M32
Cylider Head
In-line engine
Vee-engine
- Valve rocker bracket

The tightening torque for inserting the studs - 1 - is
Molykote
Tighten nuts - 2 - with
M = 150
Nm
M = 300
Nm
3x hexagon nut M20 DIN 6331

1
2
Reference size for the bush after pressing-in
74.99 + 0.12
Reference size
74,99 + 0,12
mm
1
The bushes shall recede after

pressing-in by
Before pressing-in coat
the bushes slightly with oil,
Molykote must not be used.
- Radial clearance
Original size
Limit clearance
- Valve clearance
Inlet
Exhaust
0.20 + 0.30
When shrinking in new ball pins in cooled state attention must be paid to the accurate
position - 1 - in order to guarantee perfect oil supply. (Supercooling to - 195 C with
nitrogen)
0.20 - 0.30
mm
0.02 - 0.15
mm
0.25
mm
0.40 + 0.10
mm
1.10 + 0.10
mm
Setting under hot running conditions abt. 15 min. after stopping the engine.
Edition
15.04.2005
Service Document of
Page
13
Engineers Handbook
M32
Cylider Head
C-engine
- Valve rocker bracket C-engine
Molykote
M = 150
Nm
M = 300
Nm
79.99 + 0.12
mm
3x hexagon nut M20 DIN 6331

1
2
Reference size for the bush after pressing-in
Reference size
74,99 + 0,12
The bushes shall recede after

pressing-in by
Before pressing-in slightly coat
the bushes with oil,
Molykote must not be used.
- Radial clearance
Original size
Limit clearance
- Valve clearance
Inlet
Exhaust
0.20 + 0.30
When shrinking in new ball pins in cooled state attention must be paid to the accurate
position - 1 - in order to guarantee perfect oil supply. (Supercooling to - 195 C with
nitrogen)
0.20 - 0.30
mm
0.02 - 0.15
mm
0.25
mm
0.40 + 0.10
mm
1.10 + 0.10
mm
Setting under hot running conditions abt. 15 min. after stopping the engine.
Edition
15.04.2005
Service Document of
Page
14
Engineers Handbook
M32
Cylinder Head
In-line engine
C-engine
- Setting of valve bridges and valve

clearances
Vee-engine
valve
rocker
1
2
1. Turn out adjusting screws - 1 - of the

valve rockers to obtain a sufficient
clearance.
2. Turn out adjusting screws - 2 - of the
valve bridges to obtain a clearance when
valve bridges X are touching Y.
3. Screw in adjusting screws - 2 - until the
valve bridges rest on the valves
without clearance.
valve bridge
4. Hold adjusting screws - 2 - fast and

lock them.
2
X
5. Adjust valve clearance.
- Valve guide
Nominal clearance
Inlet
0,11 - 0,17
mm
Exhaust
0,18 - 0,24
mm
Inlet C-engine
0,25
mm
Inlet L+Vee -engine
0,35
mm
Exhaus
0,35
mm
inlet
exhaust
- Limit clearance
Edition
11.11.2004
Service Document of
Page
15
Engineers Handbook
M32
Cylinder Head
C-engine
- Fuel injection valve C-engine

Tighten the sleeve for the fuel injection valve with
Molykote
M = 300
Nm
O-ring 58 x 3,55 Viton

O-ring 58 x 3,55 Perbunan
Here Loctite 510

on thread and
sealing surface
The tightening torque for inserting the studs is

Molykote
Pretighten nuts steadily by hand (without tool).

Take care of flush fit of the flange to the nozzle
holder and tighten nuts in two steps with
Molykote
Tighten nozzle nut with
Oil
M = 40
Nm
M = 60
Nm
M = 350
Nm
No gasket here
Edition
11.11.2004
Service Document of
Page
16
Engineers Handbook
M32
Cylinder Head
Vee-engine
In-line engine
- Fuel injection valve
Tighten the sleeve for the fuel injection valve with
Molykote
M = 300
Nm
O-ring 58 x 3,55 Viton

O-ring 58 x 3,55 Perbunan
Tighten nozzle nut with

Oil
M = 350
Nm
M = 40
Nm
M = 40
Nm
Here Loctite 510

on thread and
sealing surface
- Fuel injection valve - old design

The tightening torque for inserting the studs is
Molykote
Pretighten nuts steadily by hand (without tool).

Take care of flush fit of the flange to the nozzle
holder and tighten nuts with
Molykote
New design
Old design
Short
screws
Long
screws
Attention!
The injection valve is
inserted in the
cylinder head without
joint ring.
Edition
11.11.2004
Service Document of
Page
17
Engineers Handbook
M32
Cylinder Head
In-line engine
C-engine
Vee-engine
- Removal - mounting
For removal screw threaded rod - 1 - with nut - 2 - on setscrew - 3 -.Then place the
torsion limiting device - 4 - on the threaded rod and studs and loosen the injection valve by
turning nut - 5 -.
The seat in the screwed-in sleeve is cleaned with a cleaning tool - 6 -. When inserting the
injection valve take care of the position of the fixing pin - 7 -, the flange is mounted with
clamping pin - 8 - to the exhaust gas side, the lug downwards.
8
5
1
7
4
2
3
Edition
11.11.2004
Service Document of
Page
18
Engineers Handbook
M32
Cylinder Head
In-line engine
C-engine
- Starting valve
The tightening torque is for nut - 1 The inspection proceeds by measuring from top
edge nut to top edge valve stem.
The dimension is
Vee-engine
M = 50
Nm
7.5
mm
Clamping nut, self-locking VM 12x1.25 DIN 980

Tightening specification applies also to the
valve dummy at the B-row of the Vee-engines.
7.5 mm
Reference
dimension
7.5 mm
Reference
dimension
Row B Vee-engines
Edition
11.11.2004
Service Document of
Page
19
Engineers Handbook
M32
Cylinder Head
In-line engine
C-engine
- Fuel delivery pipe

Tighten both sides with
by hand.
Vee-engine
Dw = 25
In-line engine
Vee-engine
- Indicating and safety valve

Molykote
Pretighten nuts - 2 - finger-tight, then tighten alternately
in 2 steps with
2
Molykote
M = 50
Nm
Dw = 30
- Guiding bolts for the valve bridges

The tightening torque is
Insert with Loctite 243
Edition
11.11.2004
M = 500
Service Document of
Nm
Page
20
Engineers Handbook
M32
Cylinder Head
- 8'
- Valve stem
Grinding
Apply small dots of the diamond paste Dp 30/10-15
my with a syringe to the seat surface of the new or
remachined valve cone and distribute the paste
equally. Thereafter the seat ring surface is to be
sprayed with a thinner (F25) belonging to the
diamond paste, for dilution and in order to increase
the grip. Insert the oiled valve stem into the guide
bush. Fasten the device at the valve head and grind
the valve face and seat by hand applying a
moderate pressure, rotating the device. The contact
reflection a, visible by the smooth grinding
process, shall not exceed 30 % of the seat width
starting from the outside diameter. If the bearing
characteristics described above are not reached,
remachining of both sealing surfaces is necessary.
After machining both seats have to be checked with
a luminous magnifier. The fillet must not be refinished.
After machining round off the outside edge with a
stone.
The dimensions stated in the sketch must be
observed:
Dimension Y
Exhaust valve stem: 1.5 mm
Inlet valve stem: 0.2 mm
Vee-engine
30
C-engine
Dimension Y
In-line engine
Reuse of the valve stems is not possible if:

1. there are damages in the valve seat face
(cracks, blow-bys),
2. there is severe pitting on the bottom side of the valve disk (formation of so-called
paving stones"),
3. there are corrosion pits and mechanical
damages in the area of the valve stem, stem
transition and valve disk,
5. there is high-temperature corrosion S on the

bottom of the valve disk exceeding 1.5 mm.
Edition
11.11.2004
4. the limit for refinishing is exceeded,
Service Document of
Page
21
Engineers Handbook
M32
Cylinder Head
In-line engine
C-engine
Vee-engine
20
20
A
B
389.8
- Inlet and exhaust valve stem

Measuring distance
389.80
mm
0.04
mm
The deviation from true running on the valve cone must

not exceed
0.03
mm
Reuse of a valve stem is not possible:

In case of corrosive material wear of
from the valve disk diameter.
2%
The deviation from true running on the valve stem must

not exceed
for the above measuring distance and
supporting points in " A " and " B ".
Edition
11.11.2004
Service Document of
Page
22
Engineers Handbook
M32
Cylinder Head
In-line engine
C-engine
Vee-engine
- Valve seat ring

When refinishing the valve seats, the dimensions stated in the sketches must be
observed. Dimension X for
refinishing = 107 + 0.2 mm.
At a" material removal is not permitted.
Inlet valve seat ring
5+
30
a
X
30
5+
Exhaust valve seat ring
- Fitting of inlet and exhaust valve seats

1. Cool valve seat rings down to -195 C.
2. Insert the
valve seat
rings.
3. When being
tight the valve
seat rings are
tight are pressed on with the pressure device.
Tighten nut - 1 - of the pressure device with M = 150 Nm.
4. Check: At the inlet

valve seat ring an air gap - 2 between valve seat ring and
cyl. head is not admissible.
At the exhaust valve seat ring
an air gap - 3 - of 0.6 + 0.5 mm
3
2
Edition
11.11.2004
Service Document of
Page
23
Engineers Handbook
M32
Piston
In-line engine
C-engine
Vee-engine
- Mahle 1.90.7-26.70.00-01 / 02 / 05 / 07
The tightening torque for inserting the studs in
M = 10
the piston crown is

Coat thread and contact surface of the nuts with Molykote paste G-n.
Pretighten nuts crosswise with

M = 30
Nm
Nm
Tighten nuts with

Loosen nuts again and check the tightening
torque for inserting the studs with
Dw = 250
M = 10
Nm
M = 30
Nm
and tighten with
Dw = 160
M = 90
Nm
Check: At a torque of
further turning of the nuts must not be possible.

Attention ! In case of reinstallation replace studs if projecting length of bottom
support exceeds - 205.5 mm.
- Mahle 1.90.7-26.70.00-08 / 09 / 12 / 13 / 16 / 18 / 22 / 23 / 24
The tightening torque for inserting the studs in
M
the piston crown is

Coat thread and contact surface of the nuts with Molykote
Tighten nuts crosswise with

M
Loosen nuts again and check the tightening
M
torque for inserting the studs with
= 10
Nm
paste G-n.
= 100
Nm
= 10
Nm
Nm
M = 35
and tighten with
Dw = 90
M = 100
Nm

Warning ! The test torque does not correspond to the tightening values !
Attention ! In case of reinstallation replace studs if projecting length of bottom
support exceeds - 129.5 mm.
Edition
11.11.2004
Service Document of
Page
24
Engineers Handbook
M32
Piston
C - engine
- Dismounting Mahle 1.90.7-26.70.00-01 / 02 / 05 / 07 / 09 / 13 / 16 / 18 / 22 / 23 / 24
If for removal of the pistons the screws on the shank division of the connecting rods are
loosened, the connecting rod must be fixed at the counterweights. As the 8 and 9 cyl.
engines are not equipped with a full set of counterweights, there are different retainers in
the tool set.
The engines are equipped with fire rings to be inserted in the upper part of the liner.
The rings have smaller diameters than the liner. They must be removed before drawing the
piston.
Edition
11.11.2004
Service Document of
Page
25
Engineers Handbook
M32
Piston
In-line engine
Vee-engine
- Mahle 1.90.7-26.70.00-20
Lubricate tread and contact face of the bolt with Molykote Paste G-n.
The tightening torque for the bolt in
the Piston crown is
M = 300
Nm
Pretighten screws with a joining moment of
M = 50
Nm
Rotate on screw throughout
Dw = 140
Loosen the screw aigain.
Check:
M = 300
At a torque of
further turning of the screw must not be possible.

Attention! The test torque does not correspond to the tightening values!
Nm
Attention! In case of reinstallation replace the studs if projekting length of bottom support
exceeds 146mm.
Edition
11.11.2004
Service Document of
Page
26
Engineers Handbook
M32
Piston
In-line engine
- MWH 1.90.7-26.70.00-06
Insert dowel pin (spring cotter) into the piston crown. Coat thread in the piston crown
with engine oil.
Coat thread of the piston bolt with graphite paste, screw piston bolts smoothly into the
piston crown
with
M = 50
Nm
Spray piston crown and skirt with corrosion preventing oil.
- Mounting of the slider into the piston skirt

Insert the Seeger circlip ring into the piston skirt, complete the slider with supporting disks
and pressure spring. Insert the slider from below, slide it on 25 mm against the spring
pressure and hold it. Mount the Seeger circlip ring at the slider. Grease the joint ring and
insert it into the piston skirt torsion-free. Place the piston skirt on the piston crown.
Grease thrust pieces as well as threads and contact surfaces of the nuts with graphite
paste (Molykote paste HSC or Copaslip).
Mount thrust pieces and nuts and tighten crosswise with M = 90
Nm
Loosen nuts again.
Check tightening torque M = 50 Nm of the piston bolts in the piston crown.
and tighten
with
Edition
11.11.2004
M = 25
Dw = 90
M =65
Service Document of
Nm
Nm
Page
27
Engineers Handbook
M32
Piston
In-line engine
Vee-engine
- The pistons are inserted as follows:

Piston
1.90.7-26.70.00-01
1.90.7-26.70.00-02
1.90.7-26.70.00-05
1.90.7-26.70.00-06
1.90.7-26.70.00-07
1.90.7-26.70.00-08
1.90.7-26.70.00-09
1.90.7-26.70.00-12
1.90.7-26.70.00-13
1.90.7-26.70.00-15
1.90.7-26.70.00-16
1.90.7-26.70.00-17
1.90.7-26.70.00-18
1.90.7-26.70.00-20
1.90.7-26.70.00-22
1.90.7-26.70.00-23
1.90.7-26.70.00-24
In-line
kW
440
480
480
480
480
480
engine
IMO
HFO
X
X
X
X
X
X
X
X
X
X
X
480
480
480
X
X
480/500 X
480/500 X
480/500 X
480/500 X
480/500 X
MDO
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Vee-engine
kW
IMO
HFO
MDO
480
480
X
X
X
X
480
480
480
480
480
X
X
X
X
X
X
X
X
480/500 X
480/500
480/500
480/500
480/500 X
480/500
480/500
X
X
X
X
X
X
X
X
X
X
X
X
- Dismounting
If for removal of the pistons the screws on the shank division of the connecting rods are
loosened, the connecting rod must be fixed at the counterweights. As the 8 and 9 cyl.
engines are not equipped with a full set of counterweights, there are different retainers in
the tool set.
The engines are equipped with different rings. The first engines have a flame ring which
is mounted on the liner. The following engines have a fire ring which is inserted in the
upper part of the liner.
Both rings have smaller diameters than the liner. They must be removed before drawing the
piston.
Edition
11.11.2004
Service Document of
Page
28
Engineers Handbook
M32
Piston
In-line engine
Vee-engine
Minimum
clearance
Maximum
clearance
Limit
clearance
Piston bosses piston pin c
0.005 mm
0.029 mm
0.06 mm
Piston pin bush piston pin
0.144 mm
0.238 mm
0.25 mm
Piston boss distance a small end bush width
0.200 mm
0.800 mm
1.10 mm
- Mounting
Arrange the ring butts in longitudinal direction of engine alternately opposed, then oil
pistons and piston rings well.
Fit piston rings with marking upward.
Fit piston mounting device and tighten clamping screw so far that free motion of the rings
is still guaranteed. This can be checked by turning the piston mounting device.
- Wear and limit clearances
Piston 1.90.7-26.70.00-01 / - 02 / - 05 / -07
Nominal ring
Groove width
Grooves
thickness
wear limit
1
8.00
8.45
2/3
4
Limit
clearance
0.50
6.00
6.45
0.50
10.00
10.20
0.30
Piston 1.90.7-26.70.00-06 / -08 / - 09 / -12 / -13

Nominal ring
Groove width
Grooves
thickness
wear limit
1
8.00
8.45
Limit
clearance
0.50
6.00
6.45
0.50
10.00
10.20
0.30
Gas oil and heavy fuel operation

Ring grooves
Ring
1
Rectangular ring
2+3
Rectangular ring
4
Oil scraper ring
1.90.7-26.17.01-01
1.90.7-26.17.01-02 *1
0.00.6-35.41.02-26 *2
*1= alternate 1.90.7-26.17.01-03

*2= old variation 0.00.6-35.41.01-23.3
Edition
15.04.2005
Service Document of
Page
29
Engineers Handbook
M32
Liner
In-line engine
C-engine
- Nominal size
(original size)
- Wear limits
Wear and tear value
Max. ovality
Wedge shape
Height
Depth *
Vee-engine
320.00-320.057
mm
1.00
mm
0.30
mm
8.00
mm
0.03
mm
Wedge-shaped indentation across the entire circumference, beginning at TDC 1st piston ring.
Canyon
Max. number
Length
Total width
3
8.00
mm
4.00
mm
Individual deep blow-through ducts in the area of the 1st piston ring (TDC)
Score
Number
Length
Depth
3
180.00
mm
0.03
mm
Hard vertical, linear friction marks.
Pocket
Number
Length
Width * *
Depth *
Areal, irregular indentations.
90.00
mm
30.00
mm
0.02
mm
Radius r 3 mm
**
in circumferential direction.
Edition
15.04.2005
Service Document of
Page
30
Engineers Handbook
M32
Liner
In-line engine
C-engine
Wedge
Pocket
Score
Vee-engine
TDC 1st ring
Canyon
- Installation
During installation take care
that marking - 1 - of the liner
coincides with marking - 2 of the cooling water distributor
casing.
Attention! On the in-line engines and
on the B-side of the Vee-engines the
marking shows to the coupling side. At
the A-side the cooling water distributor
casing is fitted, turned by 180, and
the marking at the cooling water
distributor casing shows to the pump
side.
Here the liner must also be fitted with
the marking to the pump side.
Wrongly inserted liners may cause

extensive damages.
Edition
11.11.2004
Service Document of
Page
31
Engineers Handbook
M32
Liner
In-line engine
C-engine
Vee-engine
- Flame ring - calibration ring

The engine Nos. 37002 - 37014 and 37019 - 37025 are provided with a flame ring. The
flame ring is located on the cylinder liner. Its diameter is smaller than the liner and must,
therefore, be dismounted before drawing the piston. For pushing out use the below
mentioned tool.
In-line engine
Vee-engine
- Calibration ring
The diameter of the calibration ring is also smaller than the liner. It is located in the upper
part of the liner. For removing use device 1 - shown below.
Edition
11.11.2004
Service Document of
Page
32
Engineers Handbook
M32
Connecting Rod
In-line engine C
In-line engine
- Tightening torque shank division:
Tighten studs crosswise with
Molykote G rapid plus
Studs marked with chalk/felt-tip pen to check angle of rotation.
Check of the angle of rotation
M = 230 + 25
Nm
Dw = 50 + 10
Vee-engine C
Vee-engine
- Tightening torque shank division:
Tighten studs crosswise with
Molykote G rapid plus
Studs marked with chalk/felt-tip pen to check angle of rotation.
Check of the angle of rotation
M = 250
Nm
Dw = 50 + 10
Tightening tool for the screws

of the shank division. If at - 1 250 Nm are applied, at - 2 230 Nm are reached.
2
2
Edition
11.11.2004
Service Document of
Page
33
Engineers Handbook
M32
Connecting Rod
In-line engine
Vee-engine
- Shank division
For loosening and tightening screws
- 2 - with a torque spanner there is a
spanner holding device to be fastened at
the screws of the crankcase cover.
1
Attention! The engine must not be turned
with mounted support.
Warning! Top and bottom parts of

the connecting rod are
interchangeable.
- Piston pin bush
removal of piston pin bush
The piston pin bush must not be pressed out of the connecting rod. It must be made
stress-free by sawing or milling at the point marked - 1 -.
fitting of piston pin bush

Cool the piston pin bush down to - 160 C and push it into the piston pin boss, taking
care of the correct position of the oil bores. The lateral projection must be the same on both
sides. After reaching the normal temperature the piston pin bush has to be measured.
The reference dimension after shrinking-in is
- Tightening torque big-end bearing nuts

Pretighten the round nut at the pin side (camshaft side)
with
then firmly tighten both
round nuts with
150.144
+ 0.076
P = 50
P = 1200
mm
bar
+ 25
bar
Check: Drop the pressure by 50 bar, the round nuts must not be detachable any more.
Tightening torque applies to hydraulic cylinder with 66 cm2 hydraulic jack area, hydraulic jack No.
0.9213 C.
- Removal
Are the nuts not detachable with the prescribed pressure, increase by 50 bar.
Another pressure increase is not advisable because otherwise the thread gets stretched
and the nut jammed.
Edition
11.11.2004
Service Document of
Page
34
Engineers Handbook
M32
Connecting Rod
In-line engine
C-engine
Vee-engine
- Big end bearing

For fixing in the connecting rod and in the big end bearing cap the
bottom and top shells are provided with fixing lugs. During installation
take care that the fixing lugs show to the camshaft side.
- Reference dimensions of the big end bearings after correct tightening
Dimension A
+ 0.05
A + 0.04 + 0.02
Dimension B
280.25
mm
mm
- Marking
The connecting rod is marked with the eng. No. and the cyl. No., the big end bearing cap
only with the cyl. No.
The big end bearing shell is marked with the cyl. No.
All marks are on camshaft side.
Edition
11.11.2004
Service Document of
Page
35
Engineers Handbook
M32
Connecting Rod
In-line engine
Vee-engine
For this connecting rod with

the straight oil bore only
use the big end bearing
bolts with the collar at a
distance of 10 mm.
Locking screw
oil bore
10
For this connecting rod both

big end bearing bolts may
be used.
Locking screw
oil bore
20
Is this big end bearing

bearing bolt inserted in the
connecting rod with straight
oil bore the collar with
20 mm distance would be
closing part of the oil bore.
Edition
11.11.2004
Service Document of
Page
36
Engineers Handbook
M32
Crankshaft Bearing
In-line engine C
In-line engine
- Tightening specification (in-line)
Molykote
M = 500
Nm
Tighten crankshaft bearing nuts - 2 - steadily by hand.
Tighten studs - 3 - with

Molykote
Tighten round nuts - 4 - steadily by hand.
Tighten round nuts - 4 - on camshaft side with
then tighten round nuts - 4 - with
M = 150
Nm
P = 150 + 50
bar
P = 650 20
bar
Tighten both round nuts of one bearing pocket in one operation.

Hydraulic jack area = 66.0 cm 2
Tighten crankshaft bearing nuts - 2 - with
P = 1150 20
Check: Reduce pressure by 50 bar. Further loosening of the round nuts must not be possible.
Tighten both main bearing nuts of one bearing pocket in one operation.
The pressure must remain constant during tightening, when the pump is not operated, otherwise
faulty tightening.
If the nuts of the lateral bolts and the main bearing bolts cannot be loosened with the prescribed
pressure, pressure increase by P=50bar is possible.
Insert the M6-screws for the fastening of the ring (at the inner side of the through borehole of stud 3) with Molykote and tighten these with 7Nm.
Edition
11.11.2004
Service Document of
Page
37
Engineers Handbook
M32
Crankshaft Bearing
In-line engine
In-line engine C
- Measurement of the gap (in-line)

Remove round nuts - 4 - and studs - 3 -. Loosen round nuts - 4 - of the adjacent
crankschaft bearings. Loosen both crankshaft bearing nuts - 2 - in one operation, then
tighten both crankshaft bearing nuts - 2 - with a pin alternately and steadily until the joint
faces of the bearing shells just touch each other. Measure the gap between cylinder
crankcase and main bearing cap on camshaft and exhaust gas side.
Sum of gap
After longer operation the sum shall not be less than
1.00 - 1.25
mm
0.80
mm
Then tighten all studs and nuts again acc. to specification.
Edition
11.11.2004
Service Document of
Page
38
Engineers Handbook
M32
Crankshaft Bearing
Vee-engine C
Vee-engine
- Tightening specification (Vee-engine)

Molykote
Tighten crankshaft bearing nuts - 3 - steadily by hand.
M = 500
Nm
Tighten studs - 2 - with

Molykote
Tighten round nuts - 4 - steadily by hand.
Tighten round nuts - 4 - on B-side with
M = 150
Nm
P = 150 + 50
bar
then tighten round nuts - 4 - with
P = 680 - 25
bar
Tighten both round nuts of one bearing pocket in one operation.

Tighten crankshaft bearing nuts - 3 Vee engines with
Vee engines C with
P = 1025 - 25
bar
P = 1000 - 25
bar
Check: Reduce pressure by 50 bar. Further loosening of the round nuts by a pin must not be
possible.
Tighten both main bearing nuts of one bearing pocket in one operation.
The pressure must remain constant during tightening, when the pump is not operated,
otherwise faulty tightening.
If the nuts of the lateral bolts and the main bearing bolts cannot be loosened with the
prescribed pressure, pressure increase by P=50 bar is possible.
View on pump side

B-side
A-side
1
3
Edition
11.11.2004
Service Document of
Page
39
Engineers Handbook
M32
Crankshaft Bearing
Vee-engine
Vee-engine C
- Measurement of the gap (Vee-engine)

Remove round nuts - 4 - and studs - 2 -. Loosen round nuts - 4 - of the adjacent crankshaft
bearings.
Loosen both round nuts in one operation.
Loosen both crankshaft bearing nuts - 3 - in one operation, then tighten both crankshaft
bearing nuts - 3 - with a pin alternately and steadily until the joint faces of the bearing shells
just touch each other. Measure the gap between cylinder crankcase and crankshaft bearing
cap on A-side and B-side.
Sum of gap
After longer operation the sum shall not be
less than
1.00 - 1.20
mm
0.90
mm
Then tighten all studs and nuts again acc. to specification.
Edition
11.11.2004
Service Document of
Page
40
Engineers Handbook
M32
Crankshaft Bearing
In-line engine
C-engine
- Marking
Bearing caps and bearing shells are
marked on camshaft side with the relative
cylinder numbers, counted from flywheel
side. The parts must not be mixed up.
1
Located and normal main bearings are
identical, for axial fixing thrust washers
2
are fitted at bearing 1 (located main
bearing). The lower parts of the thrust
washers - 1 - are fixed with clamping pins
- 2 - at the bearing cap - 3 -. The upper
parts are inserted in the cylinder
crankcase without pins.
- Axial clearance S
= S1 + S2
- Limit clearance
Vee-engine
S1
S2
0.30 - 0.50
mm
0.80
mm
Attention ! On the Vee-engine the

thrust washers are of different
thicknesses. The thicker one - 32.85
mm - is mounted on flywheel side, the
thinner one - 23.85 - in the direction
of crankshaft bearing 2. The lower
Bearing No.
parts are fixed with clamping pins at
the bearing cap, just as on the in-line stamped here
engine, whereas the upper parts are
inserted without pins.
X
X
The protection against

torsion on camshaft side
- Bearing 1 (located main bearing) in-line and Vee-engine

On this bearing the lateral bolts are screwed in with an O-ring 30 x 3,55.
The bearings with maximum stress are:
Edition
15.04.2005
6 cyl. engine
bearings 4 + 6
8 cyl. engine
bearings 5 + 7
9 cyl. engine
bearings 6 + 8
Service Document of
Page
41
Engineers Handbook
M32
Crankshaft
In-line engine
C - engine
Vee-engine
- Crank web deflection

Limit values
Cylinder without external load (generelly valid for all cylinders,
also for cylinder 1 if flywheel hub and flywheel are not yet
mounted, as well as for the last cylinder if the auxiliary PTO
0.06 to - 0.09
with bearing in pump mounting plate is not connected.)
mm
Cylinder with additional load (normally cylinder 1

by means of flywheel and last cylinder if power is
actually taken of at the free end.)
mm
0.06 to - 0.13
- Counterweight mounting
The engines are differently equipped with counterweights.
6 cyl. engine 12 counterweights
Crankpin 1
2 pcs.
Crankpin 1
2 pcs.
Crankpin 2
1 pc.,
left side *
Crankpin 2
1 pc.,
left side *
Crankpin 3
1 pc.,
right side *
Crankpin 3
without counterweight
Crankpin 4
2 pcs.
Crankpin 4
2 pcs.
Crankpin 5
2 pcs.
Crankpin 5
2 pcs.
Crankpin 6
1 pc.,
left side *
Crankpin 6
2 pcs.
Crankpin 7
1 pc.,
right side *
Crankpin 7
without counterweight
Crankpin 8
2 pcs.
Crankpin 8
1 pc.,
right side *
Crankpin 9
2 pcs.
* = seen from camshaft side.
Due to the different counterweight mountings there are different supports
for the connecting rods when drawing the piston.
In-line engine
In-line engine C
- Counterweight mounting, tightening specification (In-line engine)

Tightening specification
M = 150
The tightening torque for inserting the tie bolts is
Molykote
P = 380
1. Tighten one tie bolt with
2. Tighten the second tie bolt with
P = 650
-25
Nm
bar
bar
Reduce pressure by 50 bar. Round nuts must not be detachable any more.
Edition
15.04.2005
Service Document of
Page
42
Engineers Handbook
M32
Crankshaft
In-line engine
3. Tighten the tie bolt of point 1 with
In-line engine C
P = 650 -25
bar
Hydraulic jack area A = 66 cm 2.
Tie bolt: M36, length: 412 mm.
Tightening specification (alternative). Both tie bolts on one counterweight lengthened at the same
time.
Vee-engine
Vee-engine C
- Counterweight mounting, tightening specification (Vee-engine)

Coat thread of the tie bolts with Molykote and screw it into
M = 150
the crankshaft with
1. Tighten one tie bolt with
2. Tighten the second tie bolt with
P = 375
P = 750 + 25
Nm
bar
bar
3. Tighten the tie bolt of point 1 with
P = 750 + 25
bar
- Alternative tightening specification
Tighten both tie bolts on one counterweight
simultaneously with
P = 750 + 25
bar
Hydraulic jack area A = 145 cm 2.
Edition
11.11.2004
Service Document of
Page
43
Engineers Handbook
M32
Gear Train L - VEE

In-line engine
- Gear wheel on crankshaft 1.90.7-25.30.00-02
This variant is only fitted in engine No. 37005, record 261009
Press gear wheel with device and oil
hydraulic mounting - connection Z -
on the crankshaft cone into final position.
P = 450
bar
The final position is reached when the gear wheel touches the spacer. The
spacer simulates the located bearing. It must be adjusted in a way that there is a dimension of
174+ 0.1 between gear wheel and crank web cyl. 1 at final gear wheel position.
The slide-on distance is 12.5 - 3.2 mm.
The device must still remain fitted 20 minutes after pressure relief.
Engine start 2 hours after pressure relief at the earliest.
A modification to variant 1.90.7-25.30.00-03 is possible.

hydraulic mounting - connection Z
on the crankshaft cone into the final position.
P = 650
bar
The final position is reached when the gear wheel touches the spacer. The spacer simulates the
located bearing. It must be adjusted in a way that there is a dimension of 174+ 0.1 between gear
wheel and crank web cyl. 1 at final gear wheel position.
The slide-on distance is 17.5 -3.2 mm.
This variant is fitted in the following engines:
Engine No.
37002
Engine No.
37004
37006
37007
37009
37010
37011
37012
37013
37014
37017
Edition
11.11.2004
37021
37022
37023
37024
37025
37038
37039
37040
37060
Service Document of
Page
44
Engineers Handbook
M32
Gear Train L - VEE

In-line engine
Spacer
174 + 0.1
Connection Z

hydraulic mounting connection Z
on the crankshaft cone into final position.
P = 650
bar
The final position is reached when the gear wheel touches the spacer. The spacer simulates the
located bearing. It must be adjusted in a way that at final gear wheel position there is a
dimension of 174 + 0.1 mm between gear wheel and crank web cyl. 1.
The slide-on distance is 15 -3.2 mm.
This variant is fitted in the following engines:
Engine No.
37003
Engine No.
37019
37008
37020
For mounting gear wheel on crankshaft on all other in-line and Vee-engines please look into
the chapter crankshaft sealing with flywheel hub mounting.
Edition
11.11.2004
Service Document of
Page
45
Engineers Handbook
M32
Gear Train L - VEE

In-line engine
- Intermediate gear wheel mounting 1.90.7-51.40.00- 01/02
1.90.7-51.40.00-01
1.90.7-51.40.00-02
1
Tighten screws - 1 - with

Molykote
M = 130
Nm
Hexagon screws M16 x 70 ISO 4014 8.8-A3C
Gap size between axle and locking sheet

see - X - - 2 Min.
Max.
0.30
mm
1.40
mm
X
2
Edition
11.11.2004
Service Document of
Page
46
Engineers Handbook
M32
Gear Train L - VEE

In-line engine
- Intermediate gear wheel mounting 1.90.7-51.40.00-02
End clearance S
Min.
Max.
0.30
mm
0.60
mm
0.28 - 0.44
mm
0.20 - 0.37
mm
M = 160
Nm
- Backlash
Crankshaft gear - intermediate gear wheel
Intermediate gear wheel - camshaft gear
Lub. oil injectors for gear wheels
Tighten screws with
Molykote
Edition
11.11.2004
Service Document of
Page
47
Engineers Handbook
M32
Gear Train L - VEE

Vee-engine
- Intermediate gear wheel mounting 1.91.7-51.40.00- 01/02
1.91.7-51.40.00-01
1.91.7-51.40.00-02
X
Intermediate wheel mounting

Molykote
M = 130
Nm

X
referance dimension after glue in
Clearance - S -
Edition
11.11.2004
120,50 + 0,40
0.20 - 0.50
Service Document of
mm
Page
48
Engineers Handbook
M32
Gear Train L - VEE

Vee-engine
Intermediate wheel mounting 1.91.7-51.40.00-02

- End clearance S1
engine block 1.96 / 98.7-11.11.00-02
Min.
Max.
engine block 1.96 / 98.7-11.11.00-04
Min.
Max.
0.30
mm
0.60
mm
0.70
mm
1.00
mm
0.31 - 0.43
mm
0.19 - 0.38
mm
M = 160
Nm
- Backlash
- Lub. oil injectors for gear wheels
Tighten screws with
Molykote
Edition
11.11.2004
S1
Service Document of
Page
49
Engineers Handbook
M32
Gear Train L - VEE

In-line engine
Vee-engine
- Camshaft gear wheel

gear wheel mounting
Journal - 1 - must not extend into the gear box. Turn camshaft gear wheel - 2 - into the
gear box using the device. Push the journal until it touches the camshaft gear wheel cone.
Prefit helical gear - 3 - until it touches the camshaft gear wheel. Mount the camshaft gear
wheel hydraulically on the bearing journal cone by tightening screws - 4 - up to the end
of the cone.
Attention! Tighten screws - 4 - steadily. Final position: Draw helical wheel - 3 - against
bearing journal - 1 -.
Slide-on distance: 11.5 - 2.9 mm
Oil pressure old variation
Oil pressure new variation
P = 1200
bar
P = 1200 - 1600
bar
1
3
Edition
11.11.2004
Service Document of
Page
50
Engineers Handbook
M32
Gear Train C-Engine

In-line engine C
For mounting the gear wheel on the crankshaft see crankshaft sealing
- Intermediate gear wheel mounting (In-line engine)
Y

Molykote
M = 130
Nm
0.30
mm
1.40
mm
Gap size between axle and locking sheet

see - X - - 2 Min.
Max.
Intermediate gear wheel mounting

- End clearance S (In-line engine)
Min.
Max.
0.30
mm
0.60
mm
Edition
11.11.2004
Service Document of
Page
51
Engineers Handbook
M32
Gear Train C-Engine
In-line engine C
Vee-engine C
- Camshaft gear wheel

Gear wheel mounting
Journal - 1 - must not extend into the gear box. Turn camshaft gear wheel - 2 - into the
gear box using the device. Push the journal until it touches the camshaft gear wheel cone.
Prefit helical gear - 3 - until it touches the camshaft gear wheel. Mount the camshaft gear
wheel hydraulically on the bearing journal cone by tightening screws - 4 - up to the end
of the cone.
Attention! Tighten screws - 4 - steadily. Final position: Draw helical wheel - 3 - against
bearing journal - 1 -.
Slide-on distance: 11.5 - 2.9 mm
Oil pressure
P = 1200 - 1600
bar
Grease here
Edition
11.11.2004
Service Document of
Page
52
Engineers Handbook
M32
Gear Train C-Engine

Vee-engine C
For mounting the gear wheel on the crankshaft crankshaft sealing.

- Intermediate gear wheel mounting (Vee engine)
M = 130
Molykote
Nm
- End clearance S (Vee engine)

Min.
Max.
0.30
mm
0.60
mm
1
O-ring
Edition
11.11.2004
Service Document of
Page
53
Engineers Handbook
M32
Gear Train C-Engine

In-line engine C
- Backlash
Lub. oil injectors for gear wheels

Tighten screws with
Molykote
0.28 - 0.44
mm
0.20 - 0.37
mm
M = 160
Nm
Vee-engine C
- Backlash
- Lub. oil injectors for gear wheels
Tighten screws with
Molykote
Edition
11.11.2004
0.31 - 0.43
mm
0.19 - 0.38
mm
M = 160
Service Document of
Nm
Page
54
Engineers Handbook
M32
Governor Drive L + VEE

In-line engine
Vee-engine
- Old design
Tighten hexagon screws - 1 - for fixing the
big helical gear wheel
M = 190
Nm
0,30 - 0,80
mm
M = 260
Nm
0,30 - 0,75
mm
M16 x 220 DIN 931
End clearance - 2 -
- New design
Tighten hexagon screws - 3 - for fixing the big helical
gear wheel with
Molykote
M20 x 130 DIN 931
End clearance - 4 -
old design
new design
4
1
backlash - 5 -
0,30 - 0,60
mm
Edition
11.11.2004
Service Document of
Page
55
Engineers Handbook
M32
Governor Drive L +VEE

In-line engine
Vee-engine
Tighten castellated nut - 1 - for the small

helical gear wheel with
Molykote
M = 70
Nm
M = 100
Nm
0.30 - 0.60
mm
M16 x 1,5 DIN 935
Attention! The same nut

on Vee-engine
2
is tightened with
End clearance - 2 -
If the bushes - 1 - and - 2 - in the cylinder

crankcase must be exchanged, take care that
the dimensions stated in the sketch are
observed.
Slightly oil the bushes before pressing them in,
do not use Molykote.
370
410
Edition
11.11.2004
38
Oval hole centered to

the bore.
2
Service Document of
Page
56
Engineers Handbook
M32
Governor Drive C-Engine

In-line engine C
- Backlash and End clearance
Backlash from gear wheel - 1 - to
camshaft gear wheel
End clearance at - 2 -
0.25 + 0.15
mm
0.20 + 0.30
mm
0.20 + 0.20
mm
Serration
1
2
For shrink fitting
heat up to 40C
Cooled
down to 195C
For shrink fitting

heat up to 70C
For shrink fitting

heat up to 110C
The backlash between camshaft gear wheel and governor drive gear is adjusted by
gaskets which are available in 2 different thicknesses:
0.30 mm corresponds to a backlash difference of 0.19 mm
Tighten screw plug DIN 908 M33x2 St-A3C with
if onhand.
Edition
11.11.2004
200
Service Document of
Nm
Page
57
Engineers Handbook
M32
Governor Drive C-Engine

Vee-engine C
- Backlash and End clearance

Backlash from gear wheel - 1 - to
camshaft gear wheel
0.25 + 0.15
mm
0.20 + 0.30
mm
0.20 + 0.20
mm
3
2
For shrink fitting

heat up to 40C
Cooled
down to
-195 C
For shrink fitting

heat up to 110C
For shrink fitting

heat up to 70C
The backlash between camshaft gear wheel and governor drive gear is adjusted by
gaskets which are available in 2 different thicknesses:
Tighten screw plug DIN 908 M33x2 St-A3C with

if onhand.
Edition
11.11.2004
200
Service Document of
Nm
Page
58
Engineers Handbook
M32
Camshaft Bearing
In-line engine
- Camshaft bearing 1.90.7-31.91.01-30

A - The engines 37002 / 37003 and 37008 are
equipped with camshaft bearings shrunk in by cooling.
If these bearings must be changed, they are replaced
by the variant 1.90.7-31.01.01-32 with fixing screw
1.90.7-11.10.11-01.
For removal the shrunk-in bearings must be made stressfree by sawing or similar measures.
The bores provided for the fixing screws are plugged by
locking screws M33x2 DIN 908 and joint ring A33x39
DIN 7603.
The fixing screw 1.90.7-11.10.11-01 is inserted

medium-tight with screw lock Loctite 243 and
tightened with
M = 250
Nm
Molykote to the contact surfaces, Loctite to the threads.

B - The engine Nos. 37002 - 37017 / 37019 - 37030 / 37036 - 37041 as well as the Nos.
37043, 37046, 37050, 37051, 37054, 37055 and 37103 are equipped with camshaft end
bearings shrunk in by cooling. They are replaced by the variant 1.90.7-31.92.02-32 with
fixing screw 1.90.7-11.10.11-01. All other engines are equipped with the variant 1.90.731.91.02-32 with fixing screw 1.90.7-11.10.11-01.
with fixing screw 1.90.7-11.10.11-01
The following engines are equipped with this variant:
37007 / 37009 - 37017 / 37019 - 37031 / 37036 / 37038 - 37044 / 37046 - 37060 / 37062 37067 / 37069 - 37071 / 37074 / 37079 - 37081 / 37084 - 37088 / 37091 - 37093 / 37096 37107
Pay attention to the
They are replaced by the same
position of the bores
variant.
Fixing screw
1.90.7-11.10.11-01
Attention! If theres a notch in the bearing shell, it has to point upwards.
Edition
11.11.2004
Service Document of
Page
59
Engineers Handbook
M32
Camshaft Bearing
In-line engine
with allen screw M16 x 100-ZA DIN 912
All other engines which have not been mentioned before are equipped with this variant.
Tighten allen screw - 1 - with
Molykote
M = 60
Nm
Allen screw
M16 x 100 - ZA ISO 4762
Pay attention
to the position
of the bores
Fixing screw- 1 1.90.7-11.10.11-01

with Loctite 243
Edition
11.11.2004
Service Document of
Page
60
Engineers Handbook
M32
Camshaft Bearing
In-line engine C
- Camshaft bearing C-engine
Tighten Allen screws - 1 - and - 2 - with
Molykote
Tighten fixing screw - 3 - with
Molykote to the thread and Loctite 243
on the surface.
M = 60
Nm
M = 250
Nm
2
3
- Camshaft bearing clearance

Original clearance
Limit clearance
0.23 - 0.37
mm
0.50
mm
Edition
11.11.2004
Service Document of
Page
61
Engineers Handbook
M32
Camshaft Bearing
Vee-engine C
Vee-engine
- Camshaft bearing Vee-engine for row A and B

Tighten allen screws - 1 - with
Molykote
M = 60
Nm
- Camshaft bearing clearance

Original clearance
0.23 - 0.37
mm
0.50
mm
Clearance limit
Edition
11.11.2004
Service Document of
Page
62
Engineers Handbook
M32
Camshaft
In-line engine
- Camshaft mounting In-line engine
M = 210

Molykote
M = 210

Molykote
At modifications with separate bearing journals between the camshaft segments
M = 220
tighten bolts - 3 - with

Molykote
At modifications without separate bearing journals between the camshaft segments
M = 260
tighten bolts - 3 - with

Molykote
Nm
Nm
Nm
Nm
In-line engine with bearing journals

3
In-line engine without bearing journals
Edition
11.11.2004
Service Document of
Page
63
Engineers Handbook
M32
Camshaft
In-line engine
7.5 - Mounting of camshaft segments

(for separate bearing journals / In-line engine)
Before fitting the camshaft sections the bearing journals must be
provided with 2 cylindrical pins each.
7.5 -
marking on the bearing journal, seen from coupling side

arrangement for
6 cyl. engines
1
arrangement for
8 cyl. engines
1
2
4
6
3
5
4
5
arrangement for
9 cyl. engines
5
6
7
9
8
The pins must be arranged acc.8to the following table.
Insert the pins in the following bores.
Bearing journal No.
6 cyl. engine
coupling side
opposite
1
1
2
2
3
3
4
4
5
5
6
6
8 cyl. engine
coupling side
opposite
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9 cyl. engine
coupling side
opposite
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
Edition
11.11.2004
side of coupling
2
3
4
5
6
--side of coupling
2
3
4
5
6
7
8
--side of coupling
2
3
4
5
6
7
8
9
---
Service Document of
Page
64
Engineers Handbook
M32
Camshaft
In-line engine
inlet cam

(for integrated bearing journals / In-line engine)
Before fitting the camshaft sections the bearing journals must be provided with 1
cylindrical pin arranged acc. to the following table.
6 cyl. engine
coupling side
opposite side of coupling
1
5
2
1
3
6
4
5
5
3
6
7
8 cyl. engine
coupling side
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9 cyl. engine
coupling side
1
5
2
8
3
2
4
6
5
4
6
4
7
6
8
2
9
8
6-1
cyl. 1
here
characteristic flange no.
1 for 6 cyl. engines,
2 for 8 cyl. engines and
8 for 9 cyl. engines
cyl. 2
cyl. 6 / 8 / 9
here characteristic flange no.

5 for 6+9 cyl. engines,
characteristic flange no. 1
for 8 cyl.-engines
Edition
11.11.2004
Service Document of
Page
65
Engineers Handbook
M32
Camshaft
In-line engine C
- Camshaft mounting In-line engine C
Molykote
Dry without oil and Molykote
M = 260
Nm
M = 50
Nm
Thrust washer
2
4
Firmly fixed to the

lay-on surface
Edition
11.11.2004
Service Document of
Page
66
Engineers Handbook
M32
Camshaft
In-line engine C
Tighten nuts - 2 with

Molykote
M = 210
Nm

Molykote
M = 130
Nm
Screws M16 x 45 ISO 4017
Edition
11.11.2004
0.50 - 0.95
Service Document of
mm
Page
67
Engineers Handbook
M32
Camshaft
In-line engine C
- Camshaft mounting 6 and 9cyl. engines C
Here flange code

number 0 + 7
Here flange code

number 0 + 3
Here flange code

number 0 + 5
Here flange code

number 0 + 6
Here flange code

number 0 + 1
Here flange code

number 0 + 5
Press in cylindrical pin at the corresponding flange code number.
Here flange code

number 0 + 8
Here flange code

number 0 + 2
Here flange code

number 0 + 6
Here flange code

number 0 + 4
Here flange code

number 0 + 4
Here flange code

number 0 + 6
Here flange code

number 0 + 2
Here flange code

number 0 + 8
Here flange code

number 0 + 5

Section cylinder
1
2
3
4
5
6
Flange code number
0+5
0+1
0+6
0+5
0+3
0+7
The bores 2 - 4 and 8 are left out of count on the 6-cylinder engine.

Section cylinder
1
2
3
4
5
6
7
8
Flange code number
0+5
0+8
0+2
0+6
0+4
0+4
0+6
0+2
The bores 1 - 3 and 7 are left out of count on the 9-cylinder engine.
9
0+8
1
8
1
Edition
11.11.2004
Service Document of
Page
68
Engineers Handbook
M32
Camshaft
In-line engine C
- Camshaft mounting 8-cyl. engines C
Here flange code

number 0 + 8
Here flange code

number 0 + 7
Here flange code

number 0 + 6
Here flange code

number 0 + 5
Here flange code

number 0 + 4
Here flange code

number 0 + 3
Here flange code

number 0 + 2
Here flange code

number 0 + 1

Section cylinder
1
2
3
4
5
6
7
8
Flange code number
0+1
0+2
0+3
0+4
0+5
0+6
0+7
0+8
Edition
11.11.2004
Service Document of
Page
69
Engineers Handbook
M32
Camshaft
Vee - engine
- Mounting camshaft Vee-engine
Tighten bolts - 1 - with

Molykote

Molykote
Bei Varianten mit Anlaufscheibe / Reglerantriebsrad

Molykote

Molykote
M = 210
Nm
M = 210
Nm
M = 190
Nm
M = 220
Nm
camshaft row A
1
Kupplungsseite
Kupplungsseite
camshaft row B without thrust washer

(it is also a modification with governor drive gear possible / at A-side it is a thrust washer)
1
Edition
11.11.2004
Service Document of
Page
70
Engineers Handbook
M32
Camshaft
Vee - engine
- Arrangement for 12 cyl. - engines
bearing journal A 1
6
Pin code numbers at

bearing journal, seen
from coupling side.
7
Coupling side
1
1
1
1
1
1
B1
B2
B3
B4
B5
B6
6-1
6-1
1
coupling side
8
6
3
3
6
4
4
5
7
2
2
1
1
6-1
Opposite side of coupling

2
3
4
5
6
---
2
3
4
5
6
1
row B
6-1
bearing journal No.

12 cyl. engine
A1
A2
A3
A4
A5
A6
coupling side
row A
1
1
1
1
1
--Pin code numbers
at bearing journal,
seen from
coupling side.
5
bearing journal B1
Edition
11.11.2004
Service Document of
Page
71
Engineers Handbook
M32
Camshaft
Vee - engine
5
6
5
4
Pin code numbers at

from coupling side.
B1
B2
B3
B4
B5
B6
B7
B8
Coupling side
2
3
4
5
6
7
8
1
6-1
6-1

1
1
1
1
1
1
1
--2
3
4
5
6
7
8
--Pin code numbers at
from coupling side.
3
3
bearing journal B1
Edition
11.11.2004
6-1
6-1
1
1
1
1
1
1
1
1
coupling side
row B
bearing journal No.

16 cyl. engine
A1
A2
A3
A4
A5
A6
A7
A8
coupling side
row A
bearing journal A1
4
- Aarrangement for 16 cyl. - engines
Service Document of
Page
72
Engineers Handbook
M32
Camshaft
Vee - engine C
- Camshaft mounting Vee - engine C
Molykote
Molykote
Molykote
the end clearance at - 5 - is
M = 210
Nm
M = 210
Nm
M = 260
Nm
0,50 - 0,95
mm
thrust washer
Edition
11.11.2004
Service Document of
Page
73
Engineers Handbook
M32
Camshaft
Vee - engine C
- Camshaft mounting 12-cyl. engine C row A

Coupling side
1
8
Pin opposite
side of
coupling
2
Opposite side of
coupling
Example
Bearing journal A1
Pin coupling side
4
4
Here flange code number 1
Here flange code number

1

Bearing journal No.
A1
A2
A3
A4
A5
A6
Flange code number

coupling side
Flange code number

Edition
11.11.2004
Service Document of
Page
74
Engineers Handbook
M32
Camshaft
Vee - engine C
- Camshaft mounting 12-cyl. engine C row B
Opposite side
of coupling
2
Example
Pin coupling side Bearing journal B1
Coupling side
Pin opposite
side of
coupling
1
4
8
5
3
6

Bearing journal No.
B1
B2
B3
B4
B5
B6
Flange code number

coupling side
Flange code number

Edition
11.11.2004
Service Document of
Page
75
Engineers Handbook
M32
Camshaft
Vee - engine C
- Camshaft mounting 16-cyl. engine C row A
Coupling side
Pin opposite
side of coupling
1
8
Opposite side of
coupling
1
Pin coupling side
Example
Bearing journal A1
4
4

Bearing journal No.
A1
A2
A3
A4
A5
A6
A7
A8
Flange code number

coupling side
Flange code number

Edition
11.11.2004
Service Document of
Page
76
Engineers Handbook
M32
Camshaft
Vee - engine C
- Camshaft mounting 16-cyl. engine C row B

Opposite side of
coupling
1 Pin coupling side
8
Coupling side
Example
Bearing journal B1
Pin opposite
side of coupling
4
5

Bearing journal No.
B1
B2
B3
B4
B5
B6
B7
B8
Flange code number

coupling side
Flange code number

Edition
11.11.2004
Service Document of
Page
77
Engineers Handbook
M32
Camshaft
In-line engine
C - engine
Vee - engine
- Vibration damper
6+8 -cyl. engines / Vee - engines
Molykote 12 screws M10 x 60-10.9 DIN 933
M = 50
Nm
9-cyl. engines
Molykote 8 screws M16 x 80 ISO 4014
M = 130
Nm
On engines with higher engine number the intermediary is provided with an oil groove. The
oil serves for cooling the vibration damper.
Fixation of the intermediary at the camshaft.

Molykote
M = 210
In-line engine C
In-line engine
2
Vee - engine
Nm
Vee - engine C
position last bearing

journal A-side
position last bearing
journal A-side
Edition
11.11.2004
Service Document of
Page
78
Engineers Handbook
M32
Starting Air Distributor

C - engine
In-line engine
Vee - engine
M = 17
Nm
M = 34
Nm
M = 30 - 40
Nm
Tighten nut - 3 - with

Molykote
on in-line engine:
Helical gear
on Vee-engine:
Shim
5
3
to the right
cyl. 1
A
to the left
2
B
4
1
- Instruction for setting

1. Turn piston cyl.1 to 7 after firing TDC.
2. Loosen nut - 3 -. Attention ! The nut has a left-hand thread.
3. Turn disk - 4 - on the shaft cone until the disk slot touches the bore for cyl.1.
When the assembly is finished the setting must be checked. Attention! Take care of the
direction of engine rotation.
4. Tighten nut - 3 - by hand.

5. Clamp shaft - 5 - in vise and tighten nut - 3 - with 30 - 40 Nm Molykote.
6. Before assembly check position of shaft and disk.
Clearance at - A - =0.5 + 0.02 mm
Attention ! There must be a clearance of 1.5 0.5 mm at - B - between nut with left-hand
thread and cover, otherwise damages will result.
On the Vee-engine the starting air distributor is fitted at the A-side.
Edition
11.11.2004
Service Document of
Page
79
Engineers Handbook
M32
Fuel Injektion Pump

C - engine
In-line engine
Vee - engine
- Pump attachement
The tightening torque for inserting the studs in the engine block
is
M = 150
Molykote
Tighten fastening nuts with
M = 260
Molykote
- Pumps PEO-G055a, PEO-G058 and PEO-G062
Tighten bolts - 1 - with M = 140
Nm
M = 70
Nm
M = 30
Nm
Nm
Nm
1
2
- Pumps PEO-G055c, PEO-G058a and PEO-G062a

Tighten bolts - 1 - with M = 140
Nm
M = 80
Nm
M = 30
Nm
M = 140
Nm
M = 70
Nm
M = 30
Nm
- Pump PEO-G072
Oil
Oil
Oil
The pumps PEO-G055a, PEO-G055c, PEO-G058 are used in in-line engines.

The pump type PEO-G058 is used in all engine modifications.
The pumps PEO-G062 and PEO-G062a are used in Vee-engines.
The pump type PEO-G072 is used in in-line engines C.
Edition
11.11.2004
Service Document of
Page
80
Engineers Handbook
M32
Fuel Injektion Pump

C - engine
In-line engine
Vee - engine
- Setting and ascertainment of thickness of the distance steel plates

1. Place the control ring - 78.5 - of the device 11.01-0913 on a level support.
Mount digital dial gauge with device and set it to 0.
2. Turn roller of the fuel pump drive on the cam base circle.
3. Insert measuring device into the injection pump bore in the engine block and read the
value from the dial gauge.
4. Indicated value = thickness of distance steel plates.
During dismounting / mounting attention must be paid that the appertaining distance steel plates
are not removed. If for any reason removal of the distance steel plates is necessary, they have to
be marked with the relevant cylinder number.
The thickness of the distance steel

acceptance test record.
Available sizes:
2,40 mm
2,90 mm
3,40 mm
3,90 mm
plates for each cylinder is stated in the

2,50
3,00
3,50
4,00
mm
mm
mm
mm
2,60
3,10
3,60
4,10
mm
mm
mm
mm
2,70 mm
3,20 mm
3,70 mm
2,80 mm
3,30 mm
3,80 mm
> 78,5
>
Edition
11.11.2004
Service Document of
Page
81
Engineers Handbook
M32
Fuel Injektion Pump

In-line engine
- Setting of commencement fuel of delivery

for the engine Nos. 37003* - 37005 - 37006 - 37008* - 37010
* = twin engine installation
Adjust the eccentric of the rocking lever shaft dependent on the sense of rotation.
Counterclockwise engine: 33.6 towards outer edge of engine.
Clockwise engine: 47.7 towards center engine.
Clockwise
engine
47,7
Counterclockwise
engine
33,6
Normal position
- Commencement of fuel delivery for engines without eccentric

1. The flywheel diameter of all engines is 1439 mm, i.e. 1 12.6 mm.
2. The TDC-position of each cylinder is marked on the flywheel.
3. Turn the roller of the fuel pump drive cylinder 1 on cam base circle.
4. Remove the connection piece from the fuel injection pump of cylinder 1.
Attention! Take care of pressure valve spring and valve spring.
Insert the digital dial gauge (magnet support) with a pretension of abt. 3 mm into the
bore for the pressure valve and set it to 0.
Turn engine into sense of rotation until the digial dial gauge indicates the value
7.8 mm (pre-stroke).
5. Attach the hydraulic connection to the hub for the camshaft gear wheel and increase
the pressure to P = 800 bar.
6. Turn the engine until on flywheel: - 11.5 - crank angle before TDC for
cylinder 1 appears.
Attention! Remove hydraulic connection immediately because otherwise damages are
unavoidable.
7. For checking turn the engine into sense of rotation until the digital dial gauge at
cylinder 1 indicates the value 7.8 mm.
Now the value - 11.5 - crank angle before TDC must appear again on the flywheel.
Setting is finished.
This setting must be applied after general overhaul when the fuel injection pumps are
empty.
Edition
11.11.2004
Service Document of
Page
82
Engineers Handbook
M32
Fuel Injektion Pump

New type of camshaft
gear wheel
Hub for camshaft gear

wheel
Hydraulic connection for

setting.
Remove the connection
immediately after setting.
For setting remove
locking screw
In-line engine
Vee-engine
- Commencement of fuel delivery for engines with eccentrics

on the rocking lever shafts
The flywheel diameter of all engines is 1439 mm, i.e. 1 12.6 mm.
These engines are equipped with a new fuel injection pump, furthermore the rocking lever
shafts - 1.50 mm - are eccentric. By turning the rocking lever shafts - dependent on
the sense of rotation - the commencement of fuel delivery and firing pressure can be
adjusted. The distance steel plates of each cylinder are ascertained as described before.
1. Place dial gauge with control ring - 72.3 mm - on level support and set it to 0.
(Pretension)
2. Remove fuel injection pump from cylinder 1, mount dial gauge with control ring and
turn the engine until the dial gauge shows 0 again.
The camshaft must be retained in its position.
3. Remove locking screw from below the starting air distributor, pump camshaft gear
wheel up and turn the engine until on flywheel there appears 6.5 0.5 crank angle
before TDC for the in-line engine of the IMO version and 11.5 crank angle
before TDC for the in-line engine with and without eccentric as well as 14
crank angle before TDC for the Vee-engine which is generally equipped with
eccentrics on rocking lever shafts.
During this process the dial gauge must be observed, it must still show 0. Then
upon the hydraulic connection to the camshaft gear wheel must be removed by all
means. Do not turn before the hydraulic connection has been removed.
4. Turn the engine once, at 6.5 0.5 mm / 11.5 crank angle before TDC resp. 14
crank angle before TDC the dial gauge must show again to 0- position. If
necessary, repeat the procedure. Deviations in firing pressure between the cylinders
can now be equalized by adjusting the rocking lever shafts. For adjusting only the
small covers of the camshaft door must be removed.
Then the two outside bearing brackets can be loosened. The bearing cap of the
central bearing bracket must be removed. After removal a bore 6 mm is visible
serving for adjusting. Turning by 1 mm abt. 8 bar.
Edition
11.11.2004
Service Document of
Page
83
Engineers Handbook
M32
Fuel Injektion Pump

In-line engine
clockwise engine
advanced ignition
retarded ignition
rocking lever shaft with eccentric
counterclockwise engine
retarded ignition
Edition
11.11.2004
advanced ignition
Service Document of
Page
84
Engineers Handbook
M32
Fuel Injektion Pump

Vee-engine
clockwise engine
advanced ignition
retarded ignition
rocking lever shaft with eccentric
counterclockwise engine
retarded ignition
Edition
11.11.2004
advanced ignition
Service Document of
Page
85
Engineers Handbook
M32
Fuel Injektion Pump

C - engine
- IMO-adjustment, lower valve drive

1. Adjust the mounting reference dimension 78.5 mm with spacer plates at all
cylinders. The lower valve drive is to be fitted with - 3 mm - base plate.
2. Turn the camshafts into engine direction until the injection pump of cyl. 1 is positioned
on commencement of fuel delivery.
3. Loosen the camshaft gear wheel with 1200 1600 bar and turn the engine until
the graduated disc indicates the value 6.5 (+0.5 - 1.0) for the in-line engine and
9.0 (+0.5 - 1.0) for the Vee-engine. Fix the camshaft gear wheel.
4. Check the commencement of delivery on all other cylinders. Correct the commencement of fuel delivery at the lower valve drive only if necessary.
5. For this purpose turn out bottom screw 1 (M20 x 180). Turn out the outer top
screw 2 by max. 3 mm.
6. Exchange the shim (base shim 3.0 mm).
7. If the checkup compared with cyl. 1 is not okay, readjustment is necessary starting
with step 2. From step 3 on the camshaft is to be turned to the left/right again until all
cylinders are within the tolerance range compared with cyl. 1.
Tighten screws 1 and 2 2 (M20 x 180) with
M = 300
Nm
Shims are available of the sizes 2.4 mm, 2.7 mm, 3.0 mm, 3.3 mm, and 3.6 mm.
Edition
11.11.2004
Service Document of
Page
86
Engineers Handbook
M32
Fuel Injection Pump

C - Motor
- Adjusting commencement of fuel delivery IMO variant with FlexCam (FCT)

(CW and CCW by means of miniature eccentric)
1.0 Adjust the mounting reference size 78,5mm by means of spacer plates on all cylinders.
2.0 Check the position of the cam follower shaft depending on the direction of revolution.
CCW rotation: Stopper of cylinder 1 is pointing downwards.
CW rotation: Stopper of cylinder 1 is pointing upwards.
Check whether the cam follower shafts are in the same mounting position (compare the
position of the stoper of cylinder 1 with the direction of the 8 mm bore in the cam
follower shafts) Fix the full load state of the cam follower shaft by admitting
compressed air to the pneumatic drive unit (max. 7,5 bar)
3.0 Turn the camshaft in direction of rotation of the engine until the injection pump of
cylinder 1 is at the position of commecement of fuel delivery. After that fix the camshaft.
4.0 Loosen the camshaft gear wheel (by inflating) and turn the crankshaft until the
graduated disc shows appropriate value according to the engine asjustment for cyl. 1.
Fix the camshaft gear wheel.
5.0 Turn the other cylinders to the same position and check the commencement of fuel
delivery. Only if required, adjust the commencement of fuel delivery on the lower valve
train as follows.
6.0 Screw the pressure connection into the cam follower and inflate with high-pressure
pump until oil is leaking laterally.
7.0 Put a mandrel into the bores of the miniature eccentric and turn until the respective
injektion pump is at delivery commencement position (max. +/- 90). Take notice of the
following table (viewed from flywheel end).
CW turning engine
CCW turning engine
miniature eccentric
turned CCW
KW
miniature eccentric
turned CCW
KW
90
late
0,99
90
early
0,99
75
late
0,96
75
early
0,96
60
late
0,86
60
early
0,86
45
late
0,71
45
early
0,71
30
late
0,50
30
early
0,50
15
late
0,26
15
early
0,26
0,00
0,00
15
early
0,26
15
late
0,26
30
early
0,50
30
late
0,50
45
early
0,70
45
late
0,70
60
early
0,86
60
late
0,86
75
early
0,96
75
late
0,96
90
early
1,00
90
late
1,00
miniature eccentric
turned CW
KW
miniature eccentric
turned CW
KW
8.0 After completing the adjustment remove the pressure connections.

9.0 Carry out a subsequent check of the commencement of fuel delivery! (if the miniature
eccentric was readjusted) If the commencement of fuel delivery is not within the
tolerance range with respect to cyl.1 a readjustment starting with assembly step 2.0 is
required. On the test bed the position of miniature eccentric should not be changed.
Check the firing adjustment by measuring the injection starts (needle striking) by means
of an injection start tester (as average value of all cylinders).
Edition
11.11.2004
Service Document of
Page
87
Engineers Handbook
M32
Fuel Injection Pump

The following engines are eqipped with eccentric on the rocking lever shafts
to equalize the firing pressure.
Bold-faced type IMO engines
6 cyl. engines
37032
37035
37073
37075
37076
37082
37083
37103
37105
37122
37134
37135
37136
37137
37150
37151
37155
37156
37170
37171
37200
37201
37202
37207
37018
37033
37034
37077
37078
37085
37087
37088
37089
37090
37098
37106
37107
37108
37109
37110
37111
37112
37113
37114
37115
37116
37118
37119
37123
37124
37125
37126
37127
37128
37129
37130
37131
37132
37133
37138
37139
37140
37141
37152
37153
37154
37157
37158
37159
37161
37162
37163
37164
37165
37166
37167
37168
37169
37172
37173
37174
37175
37176
37177
37178
37179
37180
37181
37182
37183
37184
37185
37186
37187
37188
37189
37197
37198
37206
37209
37220
37221
37208
8 cyl. engines
Edition
11.11.2004
Service Document of
Page
88
Engineers Handbook
M32
Fuel Injection Pump
The following engines are eqipped with eccentroc on the rocking lever shafts
to equalize the firing pressure.
Bold-faced type IMO engines
9 cyl. engines
37061
37071
37072
37093
37094
37095
37099
37100
37120
37121
37143
37144
37190
37191
37192
37193
37203
37204
37205
37214
37215
37225
All other engines are equipped with eccentrics on the rocking lever shafts.
From engine No. 37238 on all engines are IMO engines.
The Vee-engines are generally equipped with eccentrics on the rocking lever
shafts.
Edition
11.11.2004
Service Document of
Page
89
Engineers Handbook
M32
Fuel Injection Pump

- Check of IMO adjustment
Remove locking screw - 1 - and turn engine until the IMO tell tale hole and the groove are
congruent. At the flywheel the IMO notch must be congruent with the dead center indicator.
IMO tell tale hole
groove
Edition
11.11.2004
Service Document of
Page
90
Engineers Handbook
M32
Fuel Injection Pump

C - engine
In-line engine
Vee - engine
- Fuel distributing and collecting pipe, flanges
PEO-U131
PEO-U131 In-line and Vee- engines (1.90.7-85.17.00-06)

M = 60
Nm
M = 65
Nm
M = 80
Nm
Mount bolts with Loctite and hydraulical gasket.

2
PEO-U107 In-line engines (1.90.7-85.17.00-05)

M = 100
Hold Pos - 3 - at slot.
Nm
Nm
M = 65
PEO-U198 In-line engines C (1.90.7-85.17.00-09)

M = 25
Loctite
Nm
M = 80
Nm
M = 25
Nm
Mount locking screw randomly at engine

M = 50
and tighten with
PEO-U107
3
PEO-U198
Nm
2
3
Edition
11.11.2004
Service Document of
Page
91
Engineers Handbook
M32
Fuel Injection Pump

In-line engine
- Fuel distributing and collecting pipe, in-line engine

Tighten screws - 1 - in 2 steps with
M = 130
Nm
Old design
New design
1
- Fuel distributing and collecting pipe

Bracket with fuel inlet, new design
Molykote 6 screws M16 x 90 ISO 4014
M = 130
Nm
Reference dimension for all throttle pipes 4mm
Edition
11.11.2004
Service Document of
Page
92
Engineers Handbook
M32
Fuel Injection Pump

C - engine
In-line engine
- Fuel distributing and collecting pipe

Molykote
Vee-engine
M = 25
Nm
4
1
old modification
new modification
- Fuel distributing and collecting pipe, mounting

Preparation: Dismount the pipes that shall be exchanged. Remove old joint rings and
clean pipe connections at the pumps.
Coat sealing surfaces - 1 - of pipes - 2 - with lubricant and check sliding pieces - 3 - for
easy motion.
For better mounting the pipes loosen the fixing screws of the pipes. After fitting the new
pipes retighten the pumps as prescribed.
Edition
11.11.2004
Service Document of
Page
93
Engineers Handbook
M32
Fuel Injection Pump

Vee - engine
- Pipe mounting, fuel supply

Tighten threaded rods - 1 - (M16 side) with
Molykote
Tighten orifice screws - 2 - with

Molykote
Tighten screws M10x??-12.9 with

Molykote
Tighten all other screwed connections with Molykote and the
specifications.
M = 130
Nm
M = 130
Nm
M = 52
Nm
standard tightening torque

A-A
threaded rods
-1-
-2-
M16
view
free end
A
-1-
Edition
11.11.2004
Service Document of
Page
94
Engineers Handbook
M32
Lower Valve Drive

In-line engine
Vee-engine
- Bearing brackets
Tighten screws - 1 - for the bearing brackets
with
Molykote
M = 260
Nm
3
2
For adjusting the firing pressure in a certain range, the rocking lever shafts have got an
eccentric design. The engines concerned can be made out as follows: After loosening
screws - 2 - from the bearing bracket and removing part - 3 -, boring - 4 - becomes
visible. Then the rocking lever shaft can be turned by means of a cylindrical lever.
Pins - 5 - are no longer fitted on this type.
Adjust end clearance - 6 - of
by shifting the unpinned bearing brackets.
Edition
11.11.2004
0,30
Service Document of
mm
Page
95
Engineers Handbook
M32
Lowere Valve Drive
In-line engine
Vee-engine
- Rocking lever, fuel

clockwise type
counterclockwise type
The following engines are equipped with this rocking lever.
Eng. Nos. 37003 - 37005 - 37006 - 37008 - 37010

On these engines rocking lever shafts of a different type are fitted.
Eng. Nos. 37003 and 37008 Twin-engine plant.
The rocking lever for inlet and exhaust valves are always of the same type.
Screws for the clamps in eccenter operation on
this type are to be tightened with
Molykote
M = 210
Nm
C - engine
See chapter Fuel Injection Pump
paragraph - IMO - adjustment, lower valve drive
Edition
11.11.2004
Service Document of
Page
96
Engineers Handbook
M32
Sundries
In-line engine
C-engine
- Regulating shaft
Tighten screw - 1 - for the
bearing bracket with
Molykote
Vee-engine
1
M = 130
Nm
Grease the shaft slghtly at the bearing positions, use NO Molykote.

Clearance at - 3 -
0.20
mm
3
- Articulated lever
current modification:
Tighten screws - 2 - for the articulated lever with
Molykote
older modification:
Tighten screws - 2 - for the articulated lever with
Molykote
M = 15
Nm
M = 60
Nm
older
modification
current
modification
2
2
Mounting instructions for the screws:

Grease is assigned to the screws NOT
Molykote! Tighten by hand up to the
limit stop and loosen by 1/4 turn. The
screws must be movable.
Edition
11.11.2004
Service Document of
Page
97
Engineers Handbook
M32
Sundries
In-line engine
C-engine
- Starting fuel limiter

Tighten allen screws - 2 - with
Tighten throttle screw - 1 - and screws - 3 - with
Vee-engine
M = 20
Nm
M = 20
Nm
Edition
11.11.2004
Service Document of
Page
98
Engineers Handbook
M32
Sundries
In-line engine
C-engine
Vee-engine
- Fuel rack position transmitter

The cam - 1 - must be adjusted so that in stop position the center of the fuel rack position
transmitter is in line with the punch mark - 2 -.
1
Stop position
2
Fuel rack
-Main starting air valve

Tighten screws and nuts - 1 and - 2 - with
M = 12
Nm
M = 2.5
Nm
M = 40
Nm
M = 24
Nm
Tighten hexagon nut - 4 - with
Tighten screws for the pilot

valve with
Edition
11.11.2004
Service Document of
Page
99
Engineers Handbook
M32
Sundries
In-line engine
C-engine
Vee-engine
- Emergency start via master starting valve

old modification
The classification societies require a possibility for emergency start directly on the engine.
For this reason a mechanical emergency start button is arranged on the master starting
valve.
According to classification society regulations the emergency start systems must work
without intervention of the safety system. By actuating the emergency start button the
entire automatic starting interlock is, therefore, bypassed! Starting air is then admitted
directly to the engine, even with barring device engaged and/or other starting interlock
criteria.
In order to prevent operating errors and the related risks, a warning sign has to been
fitted to the master starting valve at a clearly visible position.
Notstartknopf
Emergency Start
Button
Notstart
Emergency Start
Achtung, keine automatische
Startverblockung!
Attention, no automatic
starting interlock!
Edition
11.11.2004
Service Document of
Page
100
Engineers Handbook
M32
Sundries
In-line engine
C-engine
Vee-engine
- Oil sump - mounting standard oil pan with discharge outlet

Tighten screws from the engine block to the oil sump with M = 170
Oil lubrication
6 cylinder engines
8 cylinder engines
9 cylinder engines
12 cylinder engines
16 cylinder engines
42
18
54
18
60
18
58
16
74
16
Nm
screws M16 x 100 ISO 4014 with distance piece

screws M16 x 80 ISO 4014 with conical spring washer
screws M16 x 100 DIN 931with distance piece
screws M16 x 100 ISO 4014with distance piece
screws M16 x 110 ISO 4014 with spacer
screws M16 x 110 ISO 4014 with spacer
standard oil pan
high oil pan

3
7
2
4
- Oil sump - mounting high oil pan

Tighten screws - 1 - and - 2 - from the engine block to the oil sump
M = 200
stepwise with
1.
5 6
Nm
2.
M = 280
Nm
3.
M = 300
Nm
M = 130
Nm
M = 130
Nm
M = 75
Nm
M = 260
Nm
M = 260
Nm
Oil lubrication
Tighten screws - 4 - M16 (for blind flange) with

Molykote
Tighten screws - 7 - (for flexible compensators) with

Molykote
In-line engine
Oil lubrication
Molykote
Tighten screws - 6 - M20 (for blind flange) with
Molykote
Edition
11.11.2004
Service Document of
Page
101
Engineers Handbook
M32
Sundries
Vee-engine EPG (CPGS)
- Bracket mounting (for supply and disposal pipes, OSC)

M = 900
Molykote
Tighten nuts - 2 - mit

M = 900
Molykote

M = 260
Molykote
Nm
Nm
Nm
- Pipe mounting
(supply and disposal pipes, OSC)
Tighten all screwed connections
with the standard bolt specifications.
Use Molykote.
Bracket
Oil
sump
Edition
11.11.2004
Service Document of
Page
102
Engineers Handbook
M32
Sundries
Vee-engine
- Cooling water collecting and distributing pipe
Molykote
M = 130
Nm
M = 65
Nm
M = 130
Nm
M = 100
Nm
M = 260
Nm
Hexagon screw M16 x 330 ISO 4014

1
In-line engine C
- Cooling water collecting and distributing pipe
Pretighten screws to the cooling water block with
and
tighten with
Molykote
Pretighten screw - 1 - with
and tighten
with
Molykote
Edition
11.11.2004
Service Document of
Page
103
Engineers Handbook
M32
Sundries
Vee-engine C
- Cooling water pipe mounting

Pretighten screws - 1 - with
and
tighten with
Molykote

and
tighten with
Molykote

and
tighten with
Molykote
M = 50
Nm
M = 105
Nm
M = 65
Nm
M = 130
Nm
M = 100
Nm
M = 210
Nm
1
2
Edition
11.11.2004
Service Document of
Page
104
Engineers Handbook
M32
Sundries
In-line engine
Vee-engine
- Exhaust gas manifold

The compensators are fitted without gaskets. Attention must be paid to their fitting
direction/direction of flow (arrow on flange). Bolts are passed through from compensator
side. All screws are inserted with paste Rivolta G.W.F.
If new compensators are fitted in older exhaust gas manifolds, the gaskets at the
compensator outlet side are omitted.
M = 36
Nm
Tighten bolts - M12 - in the exhaust gas manifold with
Rivolta G.W.F.
Tighten bolts - M16 - in the exhaust gas manifold with
M = 90
Nm
Rivolta G.W.F.
Constant pressure charging, in-line engine:
When clamps are used tighten their
hexagon screws - 1 - (ISO4014-M16x200-8.8) with

M = 110
Nm
Rivolta G.W.F.
Tighten plug screws - 2 - (DIN910-G1/2A-St-A3C) with
M = 180
Nm
Rivolta G.W.F.
Tighten hexagon screws - 3 - (ISO4014-M20x90-(marking V or VH)) for 6-cylinder engines
for fixing of the shown bracket - 4 - with

M = 180
Nm
Rivolta G.W.F.
Tighten hexagon screws - 5 - (ISO4014-M20x150-8.8-A3C) for 8- and 9-cylinder engines

M = 180
Nm
Rivolta G.W.F.
Tighten hexagon screws - 7 - (ISO4014-M20x220-8.8) for 8- and 9-cylinder engines

M = 260
Nm
Molykote
6-Zylinder-Motoren
8- + 9-Zylinder-Motoren
2
3
1
6
7
Edition
15.04.2005
Service Document of
Page
105
Engineers Handbook
M32
Sundries
In-line engine
- Barring gear mounting
Molykote
M = 130
Nm
M = 130
Nm
Vee-engine
- Barring gear mounting
Molykote
Edition
15.04.2005
Service Document of
Page
106
Engineers Handbook
M32
Sundries
Vee-engine
- Engine adjustment EPG
480 kW/cyl.
720/750 rpm
1. Commencement of fuel delivery
Commencement of fuel delivery as arithmetic mean value over all cylinders
Nominal value: 14,0 (+1
-1) before TDC
Measured according to the overflow method; control travel 30mm or pre stroke
dimension 6,2mm at the auxiliary device
2. Piston distance
Distance: piston - cylinder liner:
Nominal value: 20mm (1,0mm)
Measured from border of bowl to the top edge sealing ring
Adjustment of TDC mark and adjustment of commencement of fuel delivery of the injection
pumps as well as the appropriate working sheets.
Edition
11.11.2004
Service Document of
Page
107
Engineers Handbook
M32
Crankshaft Sealing with Flywheel Hub Mounting

In-line engine
- Crankshaft sealing 1.90.7-73.40.00-01
Variant 1.90.7-73.40.00-01 is only fitted on engine No. 37003, record No. 261014.
Attention! Engine is operated together with engine No. 37008 as twin engine istallation.
- Flywheel hub 1.90.7-73.40.00-02

Insert clamping pins - 1 - in gear wheel on crankshaft. Align end plate centered to the
crankshaft and flush with the bottom edge of the cylinder crankcase.
M = 130
Nm
Molykote
Oil crankshaft cone with hydraulic oil.
Guide flywheel hub over the crankshaft and slide it on the crankshaft cone until contact is
reached.
Edition
11.11.2004
Service Document of
Page
108
Engineers Handbook
M32

In-line engine
Fit tightening device by fixing the flywheel hub on the dowel pin of the device. In this
position the projecting clamping pins at the gear wheel on crankshaft are aligned to the
relative receiving bores on the flywheel hub. Prerequisite is cyl. 1 in TDC position. Press
flywheel hub into final position with tightening device and oil hydraulic mounting.
Oil pressure
Tighten nut on the device with
The slide-on distance is 30
- 3,5
P = 1350
bar
M = 1350
Nm
M = 50
Nm
mm.
Tighten the screws for the splash ring - 3 - with

Molykote
The device must not be loosened earlier than 60 minutes after pressure relief.
Engine start 24 hours after pressure relief at the earliest, in case of an emergency engine start
after 12 hours with a max. output of 60 %.
16 pcs.
16 pcs.
hexagon screws
hexagon screws
Edition
11.11.2004
M10 x 50
M16 x 45
DIN931
ISO 4017
10.9
8.8-A3C
Service Document of
Page
109
Engineers Handbook
M32
In-line engine
C-engine
- Crankshaft sealing 1.90.7-73.40.00-03 / -04 (In-line)

- Crankshaft sealing 1.91.7-73.40.00-02 / -03 (Vee)
Tighten screws - 2 with
Molykote
Vee-engine
M = 215
Nm
Mount flange ring - 1 - and crankshaft gear wheel - 3 - on flywheel hub.

Molykote
M = 50
Nm
1
2
3
4
Edition
11.11.2004
Service Document of
Page
110
Engineers Handbook
M32
In-line engine
C-engine
Vee-engine
Align and mount end plate - 5 - centered to the crankshaft and flush with the bottom edge
of the cylinder crankcase.
M = 130
Nm
Molykote
Oil crankshaft cone with hydraulic oil.
Guide the flywheel hub with the crankshaft gear wheel over the crankshaft and slide it on
the crankshaft cone until contact is reached. Fit tightening device by fixing the flywheel
hub on the dowel pin of the tightening device. Slide the crankshaft with the crank web on
the axial bearing (located bearing) and secure axially.
Increase oil pressure to
P = 1650
using a hand pump and press the flywheel hub and the
crankshaft gear wheel into the final position by means of the tightening device.
The hydraulic pressure at the tightening device is
P = 300
bar
bar
Piston area of the hydraulic device = 133 cm2
The final position is reached when the end clearance

at - 7 - is
The slide-on distance is 33 -6.5 mm.
End clearance 0.3 +0.2
Molykote
0.30 + 0.20
M = 215
mm
Nm
The device must not be loosened before than 24 hours after pressure relief.
Engine start not before 72 hours after removal of the device.
Screws used for the flywheel hub mounting 1.90.7-73.40.00-03 / -04
6 pcs.
hexagon screws
M 10 x 50
DIN 931
10.9
16 pcs.
hexagon screws
M 16 x 45
ISO 4017
8.8-A3C
38 pcs.
fillister head screws
M 16 x 100
ISO 4762
10.9
1.91.7-73.40.00-02 / -03
6 pcs.
hexagon screws
M 10 x 50
DIN 931
10.9
19 pcs.
hexagon screws
M 16 x 45
ISO 4017
8.8-A3C
38 pcs.
fillister head screws
M 16 x 100
ISO 4762
10.9
Edition
11.11.2004
Service Document of
Page
111
Engineers Handbook
M32
In-line engine
C-engine
Vee-engine
- Dismounting and mounting of flywheel hub and crankshaft gear wheel

Fitting of the device
1. Fasten sleeve - 1 - with threaded bolt - 2 -.
2. Fitt thrust plate - 3 - together with high-pressure tube - 4 - and screw high-pressure
tube into the crankshaft connection.
3. Slide on thrust plate - 3 - and screw on hydraulic jack - 5 -.
3
4
5
1
6
Dismounting of flywheel hub and gear wheel

1. Fit the device as described avove.
2. Unscrew the stepped piston of the hydraulic jack by approx. 30 mm. Join hand _
pump to connection - 6 - and pump the hydraulic jack up.
3. Connect the pump aggregate to the high-pressure tube - 4 - and slowly increase the
pressure.
4. Open the valve at the hand pump slowly so that the flywheel hub creeps from the
cone together with the gear wheel.
Mounting of flywheel hub and gear wheel
1. Fit the device as described above.
2. Connect pump aggregate for oil pressure - approx. 1650 bar - and hand pump.
3. Slowly increase the pressure at the pump aggregate and at the same time the
pressure of the hand pump - approx. 300 bar - until the flywheel hub together with
the gear wheel fits closely at the locating bearing. Take care of the end clearance.
Edition
11.11.2004
Service Document of
Page
112
Engineers Handbook
M32
Flywheel Mounting
In-line engine
C-engine
Vee-engine
Drive dowel pin - 1 - into the flywheel hub. Turn crankshaft into position cyl. 1 in TDC.
Hang flywheel vertically into transport opening. In this position the projecting dowel pin in
the flywheel hub is in line with the relative bore on the flywheel.
Molykote
M = 1800
Nm
Edition
11.11.2004
Service Document of
Page
113
Engineers Handbook
M32
Opposite Side of Coupling
In-line engine
C-engine
- Mounting without power take-off

Vibration damper mounting
Pretighten tie bolts - 1 - with
and tighten with
Molykote
Vee-engine
M = 400
Nm
Dw = 60
Tie bolts M30 x 280, spanner size 46

6 cyl. engine = 12 pcs. -- 8 cyl. engine = 16 pcs.
9 cyl.engine = 18 pcs. -- 12 cyl. engine = 20 pcs.
16 cyl. engine = 20 pcs.
Tighten fixing screws - 2 - and screws - 3 for the pump gear carrier with
Molykote
M = 130
Nm
Fixing screw M16 x 130, DIN 931

Screw M16 x 110
All M16 screws are to be tightened with M = 130 Nm.
Molykote
All M12 screws are to be tightened with M = 60 Nm.
Molykote
1
3
Edition
11.11.2004
Service Document of
Page
114
Engineers Handbook
M32

In-line engine
In-line engine C
- Mounting with power take-off

and tighten
with
Molykote
M = 660
Nm
Dw = 60
For mounting at 6 / 8 / 9 cyl. engine - 20 tie bolts M30 x 280 spanner size = 46 are provided.

Molykote
M = 130
Nm
M = 130
Nm
2 hexagon screws M16 x 110 DIN 931

Molykote
1
2
Edition
15.04.2005
Service Document of
Page
115
Engineers Handbook
M32

In-line engine
Molykote
In-line engine C
M = 350
Nm
M = 80
Nm

Molykote
1
2
All M16 screws are tightened with M=130 Nm Molykote

All M12 screws are tightened with M= 60 Nm Molykote
Edition
15.04.2005
Service Document of
Page
116
Engineers Handbook
M32

Vee-engine
and tighten
with
Molykote
20 tie bolts M30 spanner size 46 are provided.
M = 400
Nm
Dw = 60
M = 130
Nm
2x ISO4014 M16x120-8.8 with
M = 130
Nm
Tighten screws - 2 - 2x ISO4014 M16x140-8.8 with

Molykote
Tighten screws - 3 - 13x ISO4014 M16x80-8.8 and
Molykote
1
2
3
tightening
torque
260 Nm
tightening
torque
130 Nm
Degrease flange surfaces before assembling. Apply only a thin coat of sealing compound
DIRKO HT. Grooves and surfaces inside of grooves have to be free of sealing compound.
Edition
11.11.2004
Service Document of
Page
117
Engineers Handbook
M32

- Mounting PTO coupling hub
The hub mounting is carried with an oil-hydraulic pressure unit. The oil-hydraulic pressure
unit ist designed different for each application. For this reason a generel statement about
push-up distances and hydraulic oil pressures is not possible.
Generally valid information:
- Hub has to be slided onto the shaft without pressure until the contact surfaces are fitting
closely.
- In standard cases hydraulic oil SAE10 is used as compression liquid.
- The hydraulic oil pressure, the push-up force and the push-up distance are varying in
according to the application.
(For that different devices can be used.)
- The push-up force may only be released after one hour at the earliest.
- After removal of the oil hydraulic pressure unit stress on the hub is not allowed for
at least 24 hours.
Edition
11.11.2004
Service Document of
Page
118
Engineers Handbook
M32
Pump Carrier with Attached Pumps
In-line engine
C-engine
- Pump carrier
Tighten screws M12 with
Molykote
Tighten screws M16 with
Molykote
Vee-engine
M = 60
Nm
M = 130
Nm
M = 60
Nm
M = 100
Nm
- Cooling water pumps, HT and LT circuit

Tighten screw for the gear wheel at in-line engine with
and at the Vee-eninge with
Molykote
Backlash
0.20 - 0.45
mm
- Gear wheel mounting

Test contact reflection on the related pump shaft cone by means of gear cone covered with
blue paste. Only a contact reflection displaced to the thick end is admissible. Heat gear
wheel up to 90 - 100C above the temperature of the cooling water pump shaft and firmly
mount it on the related pump shaft cone up to stop position.
Example: 20 C shaft temperature 110 - 120 C gear wheel temperature. The slide-on
distance is 0.43 - 0.47 mm for the in-line engine and 0,51 - 0.57 mm for the Vee-engine.
- Lub. oil pumps, suction and pressure pump

Tighten screw for gear wheel at In-line engine with
Molykote
First tighten screw for gear wheel at Vee- or C-engine
with
After the connection has cooled down to room temperature
tighten with
Molykote
Backlash
M = 60
Nm
M = 45
Nm
M = 60
Nm
0.20 - 0.45
mm

Test contact reflection on the related pump shaft cone by means of gear cone covered
with blue paste. Only a contact reflection displaced to the thick end is admissible. Heat
gear wheel up to 110 - 120 C above the temperature of the oil pump shaft and firmly
mount it on the related pump shaft cone up to stop position.
Example: 20 C shaft temperature 130 - 140 C gear wheel temperature.
The slide-on distance is for In-line engines 0.58 - 0.63 mm.
The slide-on distance is for Vee- or C-engines 0.58 - 0.68 mm.
Edition
11.11.2004
Service Document of
Page
119
Engineers Handbook
M32
Pump Carrier with Attached Pumps

In-line engine
- Fuel feed pump
Tighten screw for gear wheel with
Molykote
Backlash
M = 60
0.20 - 0.45
Nm
mm

Test contact reflection on the related pump shaft cone by means of gear cone covered
with blue paste. Only a contact reflection displaced to the thick end is admissible. Heat
gear wheel up to 30 - 40 C above the temperature of the oil pump shaft and firmly mount
it on the mating pump shaft cone up to stop position.
Example: 20 C shaft temperature 50 - 60 C gear wheel temperature.
The slide-on distance is 0.14 - 0.18 mm.
Edition
11.11.2004
Service Document of
Page
120
Engineers Handbook
M32
Turbocharger Mounting
In-line engine
- Mounting turbocharger NA295 CS and OSC, in-line engine

(6 cylinder engines)*
M = 500
Tighten fixing screws with
Molykote
Nm
Hexagon screws M24 class of strength 8.8
- Mounting turbocharger NA297 CS and OSC, in-line engine

(6 cylinder engines)*
M = 380
Molykote
Nm
- Mounting turbocharger NA355 and NA357 CS and OCS, in-line engine

(8 and 9 cylinder engines)*
M = 640
Molykote
Nm
- Air inlet casing to the charge air cooler

Molykote
Rivolta G.W.F.
M = 52
Nm
M = 90
Nm
no gaskets here
fixing screws
* CS= coupling side, flywheel end

OSC= opposite side of coupling,
free end
Edition
11.11.2004
Service Document of
Page
121
Engineers Handbook
M32
In-line engine C
- Mounting turbocharger NA 297 CS and OSC, in-line engine C

(6 cylinder engines) (CS = coupling side, flywheel end;
OSC = opposite side of coupling, free end)
Tighten screw - 1 newer modification: ISO 4014 M20x_-12.9 with
M = 450
or
M = 380
older modification: ISO 4014 M20x_-10.9 with
Molykote
M = 52
Tighten screws - 2 - DIN 933 M12x_-8.8 with
Molykote
Nm
Nm
Nm
Edition
11.11.2004
Service Document of
Page
122
Engineers Handbook
M32
In-line engine C

(6 cylinder engines) (CS = coupling side, flywheel end;
Tighten screw plug - 1 - (if onhand) with
Rivolta G.W.F.
Tighten bolts - 2 - and - 3 - with
Rivolta G.W.F.
Tighten bolts - 4 - (M12x__-8.8 / CS+OCS) with
Rivolta G.W.F.
Molykote
1
2
3
M = 130
Nm
M = 10
Nm
M = 36
Nm
M = 30
Nm
4
5
Note for clamp screws:

In general clamp screws M8 in possibly warm/hot areas are tightened with Rivolta G.W.F.
and 10Nm. Clamp screws M8 wich are not in warm/hot areas are tightened with
Molykote and 15Nm.
Tighten bolts in the assembly turbocharger mounting wich are not specified here with the
standardized tightening torques. Use Molykote.
Edition
11.11.2004
Service Document of
Page
123
Engineers Handbook
M32
In-line engine C

(8 and 9 cylinder engines)
(CS = coupling side, flywheel end;
Tighten screws - 1 - and - 2 newer modification: class of strengt 12.9 with
or older modification: class of strengt 10.9 with

Molykote
Molykote
M = 750
Nm
M = 640
Nm
M = 52
Nm
Edition
11.11.2004
Service Document of
Page
124
Engineers Handbook
M32
In-line engine C

Tighten bolts - 1 - and - 3 - with

M = 10
Rivolta G.W.F.
Tighten screw plug - 2 - (if onhand) with

M = 130
Rivolta G.W.F.

M = 90
Rivolta G.W.F.
Tighten bolts - 5 - (M10x__-10.9) with

M = 30
Rivolta G.W.F.
1
2
3
4
5
Nm
Nm
Nm
Nm

Molykote and 15Nm.
Edition
11.11.2004
Service Document of
Page
125
Engineers Handbook
M32
Vee-engine
- Mounting turbocharger TPL 65D coupling side (flywheel end), vee-engine

The tightening torque for inserting
M = 150
Nm
the studs - 1 - is
Molykote
M = 420
Nm
Tighten fixing nuts - 2 - with
Molykote
2
8 hexagon nuts M20 ISO 4032
- Air inlet casing to the charge air cooler

Molykote
M = 80
Nm
56 hexagon screws DIN931-M12x80-10.9 with sleeve E21 x 40 DIN2510
no gaskets here
Exhaust pipe
The expansion joints of the Vee-engines are fitted without gaskets.
Attention must be paid to the installation direction of the expansion joints.
Edition
11.11.2004
Service Document of
Page
126
Engineers Handbook
M32
Vee - engine C
- Mounting turbocharger NA 297 opposite side of coupling, Vee-engine C

(12 cyl. engine) (free end)
Tighten screws - 1 M = 450
Nm
new variation: class of strength 12.9 with
old variation: class of strength 10.9 with
M = 375
Nm
Molykote
M = 130
Nm
Tighten screws - 2 - and - 3 - with
Molykote
M = 130
Nm
Molykote
1
Edition
11.11.2004
Service Document of
Page
127
Engineers Handbook
M32
Vee - engine C
- Mounting turbocharger NA 297 opposite side of coupling, Vee-engine C

M = 30
Nm
Tighten screws - 10 - 6x DIN 933 M10x35-10.9 with
M = 50
Nm
M = 130
Nm
Tighten screws - 2 - 10x ISO 4014 M16x80-8.8 and

screws - 3 - 10x ISO 4014 M16x110-8.8 with
Tighten screws -1- 22x ISO 4014 M20x100-8.8, screws -7- 2x ISO 4014 M20x220-8.8 and
M = 260
Nm
M = 520
Nm
M = 640
Nm
Tighten screws - 4 - 10x ISO 4017 M24x80-8.8 and
- 6 - x ISO 4014 M24x130-10.9 with

Tighten screws
Molykote
10
5 see -1- page before

6
9
1
Edition
11.11.2004
11
Service Document of
Page
128
Engineers Handbook
M32
Vee - engine C
- Mounting turbocharger NA 297 coupling side, Vee-engine C

Tighten screws - 3 - 12x ISO 4014 M8x40-8.8 with
M = 15
Nm
M = 50
Nm
M = 55
Nm
Tighten screws - 6- 28x ISO 4017 M16x45-8.8 with
M = 110
Nm
M = 450
Nm
M = 375
Nm
M = 520
Nm
old variation ISO 4014 M20x70-10.9 with

Molykote
1
5

Molykote and 15Nm.
Edition
11.11.2004
Service Document of
Page
129
Engineers Handbook
M32
Vee - engine C
- Mounting turbocharger TLP 65D CS and OSC, Vee-engine C
(16 cyl. engine)
Tighten studs- 1 - with
M = 220
oil
M = 455
oil
Nm
Nm
(only exeption: engine 034001

Tighten studs -1- with a torque of M=150 Nm, use Molykote.
Tighten nuts -2- with a torque of M=150 Nm, use Molykote.)
1
2

Molykote
Tighten screws - 4 -, - 5 - and - 6 - with

Molykote
Edition
11.11.2004
M = 260
Nm
M = 130
Nm
Service Document of
Page
130
Engineers Handbook
M32
Vee - engine C
- Mounting turbocharger TPL 65D CS and OSC, Vee-engine C

(16 cyl. engine)
M = 520
Molykote
M = 130
Molykote
Nm
Nm
6
7
Tighten screws - 3 - and - 4 - with

Molykote
M = 130
Nm

Molykote
M = 260
Nm

Molykote
M = 50
Nm

Molykote
M = 30
Nm
Edition
11.11.2004
Service Document of
Page
131
Engineers Handbook
M32
Vee - engine C
- Mounting turbocharger TPL 65D CS and OSC, Vee-engine C
(16 cyl. engine)
M =40
Molykote
M =50
Molykote
Nm
Nm
Edition
11.11.2004
Service Document of
Page
132
Engineers Handbook
M32
Charge Air Cooler

In-line engine
- Mounting coupling side and opposite side of coupling
(CS = coupling side, flywheel end; OSC = opposite side of coupling, free end)
Tighten fixing screws - 1 - with
M = 260
Molykote
M = 20
Molykote
Nm
Nm
1
1
2
3
Edition
11.11.2004
Service Document of
Page
133
Engineers Handbook
M32
Charge Air Cooler

In-line engine
Molykote
M = 70
Nm
4
4
- Installation
1. Fix L-strap - 3 - with screws - 2 - at the charge air cooler without water separator.
2. Push the charge air cooler into the casing.
3. Draw the charge air cooler with screws - 4 - against the sealing surface of the casing.
4. Fix the charge air cooler with screws - 5 - at the casing.
Edition
11.11.2004
Service Document of
Page
134
Engineers Handbook
M32
Charge Air Cooler

Vee - engine C
- Drain pipe charge air manifold
Tighten screws ISO4017-M16x??-8.8 for retainer
(- 1 - example variation)
with
Molykote
Tighten bolts ISO4014-M8x??-8.8 for tubular joint
(- 2 - example variation)
with
Molykote
M = 130
Nm
M = 15
Nm
example
1
retainer
tubular
joint
2
Edition
11.11.2004
pipe
Service Document of
Page
135
Engineers Handbook
M32
Flexible Mounting
1.
When using casting resin:

When using steel chocks:
2.
Position the engine and align it by means of jacking screws as follows:

radially:
Clean unmachined top plates

Machine the top plates
approx. 2.00 mm above gear shaft (gearbox with vertical shaft

offset)
approx. 2.00 mm above gear shaft (gearbox with horizontal shaft
offset)
angularly: in line with gear input shaft

axially:
Coupling axially relieved (observe reference dimension)
3.
Bore top plates for fixing of the bonded rubber rails.
4.
Screw the bonded rubber rails - 1 -, - 2 - and - 3 - with screws and nuts below
the engine. The contact surfaces of the bonded rubber rails must be absolutely
clean. Impurities by scale, rust etc. are to be mechanically removed before
screwing.
5.
5.1
When using casting resin: Cast the bonded rubber rails according to
the instructions of the resin manufacturer (casting resin must not
come into contact with the rubber). After curing the casting resin
lower the engine (relieve the jacking screws completely). Static
deflection approx. 1.50 mm.
5.2
When using steel chocks: Measure the distance between top plate and
bonded rubber rails. Manufacture steel chocks and insert them.
Lower the engine according to 5.1.
Edition
11.11.2004
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Page
136
Engineers Handbook
M32
Flexible Mounting
6.
Further settlement (lowering of the engine after 24 hours) approx. 0.40 mm. The
engine will then be approximately in line with the gear shaft.
7.
Fix the bonded rubber rails with screws - 4 - and washers - 5 - on the top plate.
20
20
Reach of screw
17 mm
Vee-engines:
27mm-30mm
5
4
8.
5
4
Before mounting the stoppers machine a chamfer 1 x 45 at the engine mount in

the area of the stoppers over a length of 350 mm.
Edition
11.11.2004
Service Document of
Page
137
Flexible Mounting
Mounting of lateral stoppers - 6 - and plate - 7 -. Fasten screws - 8 - finger-tight.

Before screwing locking ring - 11 - on stopper pipe - 12 - insert screws - 9 - and
washers - 10 -. Screw locking ring - 11 - upwards up to the limit stop.
18
17
19
2 mm
adjusted
during
assembly
9.
Engineers Handbook
M32
15
16
6
13
11
12
9
7
10
10.
Measure the distance top plate - bottom edge of locking ring - 11 -.

(Dimension - H -).
Add 7.00 mm to the measured dimension - H -. The calculated dimension is the
new pipe length - R -. Manufacture the pipe according to length - R -.
11.
Remove lateral stoppers - 6 - and plate - 7 -.
12.
Mount lateral stoppers - 6 - and plate - 7 - above pipe - 12 -. Fasten screws - 8 finger-tight.
13.
Pipe - 12 - is centred by screwing down locking ring - 11 -. The conical surfaces

must come to rest with a positive fit. Level any unevenness of the top plates, tack
the pipe and weld it.
Edition
11.11.2004
Service Document of
Page
138
Engineers Handbook
M32
Flexible Mounting
14.
Remove lateral stoppers - 6 - and plate - 7 -.
15.
Bore top plates for tie rods - 13 -.
16.
Insert rubber cladding - 14 - into welded pipe - 12 -. Mount lateral stoppers - 6 and plate - 7 -.
17.
Screw locking ring - 11 - upwards up to the limit stop and secure it with 2 grub
screws.
18.
At normal operating temperatures the engine stands by about 1.00 mm higher than
the gear shaft (due to growth of bonded rubber rail, engine, gearbox, and
foundation). The flexible coupling has been designed accordingly. Later realignment is not necessary
19.
After reaching the normal operating temperature adjust the vertical clearance of
2.00 mm between lateral stopper and nut/washer - 15 - / - 16 -.
Put on washer - 17 - and secure with locknut - 18 -. Control the vertical clearance
every six months. If the vertical clearance becomes 3 mm adjust the vertical
clearance of 2.00 mm again.
Tightening torques:
Screws
-4-
250 Nm
Secure with Loctite 242
Nuts
-8-
800 Nm
In-line engine
Nuts
-8-
1900 Nm
V-engine
Screws
- 10 -
650 Nm
Nuts
- 15 -
1250 Nm
Oil
Nuts
- 19 -
1250 Nm
Oil
alternative for In-line engines 300 Nm+60
Screws
- 20 -
250 Nm
Screws
- 20 belonging stud
250 Nm
In-line engine
V-engine
V-engine
Oil the spot faces of the screws if possible.
Edition
11.11.2004
Service Document of
Page
139
Engineers Handbook
M32
Flexible Mounting
- Locking device in case of average

(not possible in all modifications)
1.
Dismantle nuts and washer - 15 - , - 16 - , - 17 - , - 18 - .
2.
Release grub screws M12 with hexagon socket (not shown in view).
3.
Screw down locking ring - 11 - until it rests against the tube. Auxiliary bore
10mm for tool is provided in the locking ring.
4.
Put washer with nut - 15 - , - 16 - on to side stopper - 6 - and
tighten it with
l.
Shown in locked condition (average)
M = 1250
Nm
Shown in normal operation
17
19
15
2 mm
adjusted
during
assembly
18
16
6
13
11
12
9
7
Edition
11.11.2004
10
Service Document of
Page
140
Engineers Handbook
M32
Firing Sequences
In-line engine
6 cyl. engines
8 cyl. engines
9 cyl. engines
12 cyl. engines
16 cyl. engines
Edition
11.11.2004
Vee-engine
clockwise
1-3-5-6-4-2
counterclockwise
1-2-4-6-5-3
clockwise
1-2-4-6-8-7-5-3
counterclockwise
1-3-5-7-8-6-4-2
clockwise
1-2-4-6-8-9-7-5-3
counterclockwise
1-3-5-7-9-8-6-4-2
clockwise
1-3-5-6-4-2
counterclockwise
1-2-4-6-5-3
clockwise
1-2-4-6-8-7-5-3
counterclockwise
1-3-5-7-8-6-4-2
Service Document of
Page
141
Engineers Handbook
M32
Dimensions and Weights
Designation
Length mm
Width mm
Height mm
Weight kg
3.972
1.550
1.885
11.800
8 cyl. engine
5.032
1.550
1.885
14.600
9 cyl. engine
5.562
1.550
1.885
16.450
12 cyl. engine
4.891
2.415
2.150
22.600
16 cyl. engine
6.241
2.415
2.150
27.500
433
982
280
122
318
10,7
23,85
410
3,0
122
358
9,45
Thrust washer Vee-engine Flywheel end
32,85
408
4,0
To crankshaft bearing 2
23,85
457
4,0
Crankcase, without studs,

with bearing caps and
bearing bolts.
6 cyl. engine
Liner
Crankshaft bearing In-line engine
Thrust washer In-line engine
Crankshaft bearing Vee-engine
Crankshaft with counterweights

6 cyl. engine
4.795
8 cyl. engine
6.020
9 cyl. engine
6.170
12 cyl. engine
6.236
16 cyl. engine
8.450
Edition
11.11.2004
Service Document of
Page
142
Engineers Handbook
M32

Designation
Length mm
Crankshaft without
6 cyl. engine
Width mm
Height mm
Weight kg
counterweights
3.920
3.175
8 cyl. engine
4.980
4.400
9 cyl. engine
5.510
4.550
12 cyl. engine
4.839
3.750
16 cyl. engine
6.189
5.000
Counterweight
650
Gear wheel on crankshaft
98
348
128,3
133
460
82
Oil sump
6 cyl. engine
4.069
1.158
474
777
8 cyl. engine
5.129
1.158
474
957
9 cyl. engine
5.659
1.158
474
1.045
12 cyl. engine
4.986
1.338
453
985
16 cyl. engine
6.336
1.338
453
1.213
282
59,1
60
240
2,8
124
288
7,2
90
225
22
252
225
61,7
900
487
Camshaft section
440
Camshaft bearing
Camshaft end bearing
Bearing journal
End bearing journal
Gear wheel on camshaft complete with hub
Edition
11.11.2004
100
Service Document of
Page
143
Engineers Handbook
M32

Designation
Length mm
Width mm
Height mm
Weight kg
120
450
126,1
122
31,2
556
205
125
25
200
900
811
8 cyl. engine
200
1000
1.022
9 cyl. engine
200
900
806
200
1.025
1.080
62
330
29
8 cyl. engine
62
330
29
9 cyl. engine
85
400
62
62
330
29
Intermediate wheel In-line engine

Intermediate wheel axle
In-line engine
370
Intermediate wheel
Vee-engine
Intermediate wheel axle
Vee-engine
Vibration damper Crankshaft
6 cyl. engine
120
342
12 cyl. engine
16 cyl. engine
Vibration damper Camshaft

6 cyl. engine
12 cyl. engine
16 cyl. engine
Edition
11.11.2004
Service Document of
Page
144
Engineers Handbook
M32

Designation
Length mm
Width mm
Height mm
Charge air cooler 6 cyl. engine
Weight kg
450
8 - 9 cyl. engine
500
16 cyl. engine
1000
Cyl. head with inlet and exhaust valves
345
Cyl. head without inlet and exhaust valve with guide bushes
300
Cooling water distributing case
267
Piston with connecting rod 1.568

Built-up piston
393
320
Connecting rod In-line engine

Small-end bore of connecting rod
In-line engine
Connecting rod
150
Vee-engine
Small-end bore of connecting rod

Vee-engine
Piston pin
264
130
150
500
115,4
1.351
236
330
38
1.382
241
350
41
150
33,3
Pump carrier plate In-line engine thickness 40 1.130
1.115
195
Pump carrier plate Vee-engine thickness 40 1.275
1.355
340
1.439
1.404
Flywheel
170
Turbocharger NA 295
590
Turbocharger NA 355
700
Edition
11.11.2004
Service Document of
Page
145
Edition
11.11.2004
Engineers Handbook
M32
Service Document of
Page
146

M32

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Caterpillar confidential: yellow

Caterpillar confidential: yellow

Engines beginning with number 38xxx belong to version C.

Caterpillar confidential: yellow

General Notes ................................................................................ 2

Engine Data .................................................................................. 10

Cylinder Head ............................................................................... 12

Tightening torque .............................................................................................................

Caterpillar confidential: yellow

Mahle 1.90.7-26.70.00-01 / 02 / 05 / 07 ..............................................................................

Nominal size .......................................................................................................................

Connecting Rod ........................................................................... 33

Tightening torque shank division: ................................................................................

Crankshaft Bearing ..................................................................... 37

Tightening specification (in-line) ..................................................................................

Crank web deflection ......................................................................................................

Caterpillar confidential: yellow

Gear Train L - VEE ....................................................................... 44

Gear wheel on crankshaft 1.90.7-25.30.00-02 ..............................................................

Gear Train C-Engine.................................................................... 51

Intermediate gear wheel mounting (In-line engine) ................................................

Governor Drive L + VEE ............................................................. 55

Governor Drive C-Engine .......................................................... 57

Camshaft Bearing ........................................................................ 59

bearing 1.90.7-31.91.01-30 .............................................................................

Caterpillar confidential: yellow

Starting Air Distributor ................................................................ 79

Fuel Injektion Pump ..................................................................... 80

Pump attachement ...........................................................................................................

Lower Valve Drive ....................................................................... 95

Caterpillar confidential: yellow

Crankshaft Sealing with Flywheel Hub Mounting .................. 108

Crankshaft sealing 1.90.7-73.40.00-01 ......................................................................... 108

Flywheel Mounting ..................................................................... 113

Mounting without power take-off ................................................................................ 114

Pump Carrier with Attached Pumps .......................................... 119

Pump carrier ..................................................................................................................... 119

Caterpillar confidential: yellow

Turbocharger Mounting ............................................................ 121

Mounting turbocharger NA295 CS and OSC, in-line engine ..................................

Charge Air Cooler ...................................................................... 133

Flexible Mounting ...................................................................... 136

Firing Sequences ...................................................................... 141

Caterpillar confidential: yellow

Engine Operating Data

Lub. oil, inlet

Fresh water circulation cooling

Crankshaft bearing in-line engine

Charge air, inlet:

4.0 - 5.0 bar *2

Crankshaft bearing Vee-type engine

Fresh water circulation cooling:

With min. 4mWs

2.5 - 5.0 bar

1.5 - 3.0 bar

Fuel pressure before

3.0 - 5.0 bar

4.0 - 5.0 nar

Big end bearing in-line and Vee-type

Valves (inlet and exhaust)

*1 = At rated engine output

Caterpillar confidential: yellow

- Crank case cover