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Technical Publication

Engine Series 183


Basis: Mercedes--Benz OM 440

Diesel Engine
8V 183 TA.2
8V 183 TC/TE.2/.3
12V 183 TA.2
12V 183 TB/TC.2/.3
12V 183 TD/TE.2/.3
Maintenance Manual
M020080/10E

DaimlerChrysler Off-Highway
Printed in Germany
E 2002 Copyright MTU Friedrichshafen GmbH
Diese Verffentlichung einschlielich aller seiner Teile ist urheberrechtlich geschtzt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere fr Vervielfltigung, Verbreitung, Bearbeitung,
bersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschlielich Datenbanken
und Online-Diensten.
Das Handbuch ist zur Vermeidung von Strungen oder Schden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfgung zu stellen.
nderungen bleiben vorbehalten.

Printed in Germany
E 2002 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of
MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on
electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.

Imprim en Allemagne
E 2002 Copyright MTU Friedrichshafen GmbH
Tout droit rserv pour cet ouvrage dans son intgralit. Toute utilisation ou exploitation requiert au pralable laccord crit de MTU
Friedrichshafen GmbH. Ceci sapplique notamment la reproduction, la diffusion, la modification, la traduction, larchivage sur microfiches,
la mmorisation et / ou le traitement sur des systmes lectroniques, y compris les bases de donnes et les services en ligne.
Le manuel devra tre observ en vue dviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous
lexploitant de le mettre la disposition du personnel charg de lentretien et de la conduite.
Modifications rserves.

Impreso en Alemania
E 2002 Copyright MTU Friedrichshafen GmbH
Esta publicacin se encuentra protegida, en toda su extensin, por los derechos de autor. Cualquier utilizacin de la misma, as como su
reproduccin, difusin, transformacin, traduccin, microfilmacin, grabacin y/o procesamiento en sistemas electrnicos, entre los que se
incluyen bancos de datos y servicios en lnea, precisa de la autorizacin previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daos durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposicin del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania
E 2002 Copyright MTU Friedrichshafen GmbH
Questa pubblicazione protetta dal diritto dautore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla
riproduzione, alla diffusione, alla modifica, alla traduzione, allarchiviazione in microfilm ed alla memorizzazione od allelaborazione in
sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen
GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall utente al personale addetto
alla manutenzione e alla condotta.
Con riserva di modifiche.

Printed in Germany
2002 Copyright MTU Friedrichshafen GmbH
A presente publicao, inclusive todas as suas partes, est protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a
autorizao prvia e por escrito da MTU Friedrichshafen GmbH.
Isto diz respeito em particular reproduo, divulgao, tratamento, traduo, microfilmagem, e a memorizao e/ou processamento em
sistemas eletrnicos, inclusive bancos de dados e servios on--line.
Para evitar falhas ou danos durante a operao, os dizeres do manual devem ser respeitados. Quem explora o equipamento
economicamente consequentemente deve coloc--lo disposio do respetivo pessoal da conservao, e disposito dos operadores.
Salvo alteraes.
Amendment Service!
Any changes in contents will be sent to you in the form of an amendment,
provided you complete the reverse of this receipt card and return it to us.

M020080/10E
Maintenance
Manual

Postcard

MTU Friedrichshafen GmbH

V 183 T..2/..3
Department SCT
88040 Friedrichshafen
GERMANY
No. Date Name
Please mark all filed amendments here.
1. 22.06.99
2.
3.
4.
5.
6.
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8.
9.
10.
11.
12.
13.
14.
15.
16.

Please use block capitals!

Receipt Amendment No. 1. 22.06.99


2.
3.
Publication number:
4.
M020080/10E
5.
6.
Name 7.

Manufacturer 8.
9.
Department
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Fax Telephone 11.
Street 12.
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Postal box number
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(Postal code) City 15.
Country 16.
Group 00
Task Description Subgroup
Page

General Work Items

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20080/1 E 98-12
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General Subgroup
Page 1

00 General

Contents

00-0001 Important information

00-0002 Designation of engine sides and cylinders

00-0003 Tightening Torques

00-0004 Setting values

00-0005 Safety at Work

00-0006 Inspection reports

00-0007 Checking engine condition before W5 overhaul and main overhaul

00-0008 Engine removal

00-0009 Engine running-in

00-0010 Engine installation and operation

00-0011 Group survey

00-0910 Repairing threaded bores with threaded inserts (Heli-Coil)

00-1000 Keyword Index

20080/1 E 98-12
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Subgroup General
Page 2

20080/1 E 98-12
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General Subgroup 0001
Page 1

00-0001 Important Information

This manual is intended for use by technical personnel responsible for the maintenance and servicing of the MTU
Diesel Engine 183 series.

This manual describes:


scheduled service operations from maintenance echelons W5 and W6 as well as
non-scheduled service operations on the individual assemblies.

Component group structure

The manual is divided into component groups 00 to 22 These component groups are based on the Mercedes-Benz
assembly group key.
Each component group is subdivided into subgroups (Work Item Number).

Example:
01 - 1205
Subgroup (Work Item Number)
Group (Assembly Group)

Since the Groups and Subgroups are arranged in a module system which applies to different engine types, the
numbering system is not in series. Alternative subgroups either have no index or are marked with an index "a, b, c"
etc.

Fast information search results

The manual offers you the following options to help you quickly find the information you want:
The designation in the component parts index indicates the subgroup
An alphabetically sorted keyword index at the end of component group 00 provides direct access to the
individual component groups and subgroups.
The Group Summary at the end of "Important Information" lists the individual component groups.

This manual is supplemented by:


Operating Instructions M015190/30 (Genset and rail versions)
Operating Instructions M015200/40 (Ship version)
Fluids and Lubricants Specification A001061
Tools List M004018/10
Tolerance and Wear Limits List M070037
Repair Instructions for Exhaust Turbocharger

Specialised information on subjects such as:


Governor setting
Injection timing
can be found in each engine's Acceptance Test Record.

20080/1 E 98-12
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Subgroup 0001 General
Page 2

Basic requirements for maintenance and service work

Customers performing their own maintenance must ensure that the following conditions and basic requirements are
satisfied:
Observation of all safety regulations
Provision a of comprehensive assortment of general-purpose tools
Provision of cleaning and testing equipment
Performance of work by trained personnel
Provision of special tools
Adequate equipping of service area
Use of genuine MTU spare parts

General assembly instructions


Component cleanness:

Clean the removed parts with cold cleaner or a similar substance and immerse in engine oil SAE 30 to protect
against corrosion.
To clean components with combustion residues, immerse in decarboniser.
Areas of all components that come into contact with oil, fuel, coolant, water and combustion air must be clean.
Components requiring "special cleanness" (e.g. oil and fuel-carrying components) must be cleaned with suitable
cleaning procedures before assembly, checked for particular cleanness and treated accordingly.
Elastomer components (e.g. rubber and similar) must not be washed with diesel fuel, solvent or cold cleaners.

Parts dirtied with oil and fuel must be cleaned immediately.


The parts should be wiped with a dry cloth.
Elastomer parts, e.g. engine mounts, damping elements, couplings and V-belts, are not to be painted and must
be covered over before all painting work.

Note:Component packaging must only be removed immediately before installation.


Radial-lip shaft seals treated by the manufacturer with oil show as a result definite signs of swelling when
delivered. They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before
installation.
The surfaces of parts that slide against each other must be lubricated with SAE30 engine oil when installed,
unless otherwise specified.
Before installing shaft seals:

On the shaft, the sealing lip of the shaft seal must be coated with petroleum jelly and the shaft running surface
with thin-film lubricant or SAE30 engine oil.
In the support bore, the outer surface of metal outer jackets - unless otherwise specified in the drawing - must be
coated with surface sealant. For elastomer outer jackets or combined metal/elastomer outer jackets, the outer
surface must be coated with denaturated ethanol.

This symbol applies to radial-lip shaft seals and its significance depends on its position.
The arrow indicates the position of the sealing lip.

O-rings and surfaces (bores and shafts) moving against them during installation must be coated with petroleum
jelly, unless otherwise specified.

When installing O-rings with counter-rings in coolant pumps, always follow the installation instructions.

20080/1 E 98-12
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General Subgroup 0001
Page 3

After installing O-rings in shaft grooves, and in order to remedy twists caused by installation, pass a rounded
scriber under the sealing ring in the direction of the circumference if the O-ring diameter is sufficiently large.
Make sure that the O-ring is not damaged.
Sealing paste must be used to fix the position of flat gaskets. Sealing paste is to be thinly applied in spots on the
flat gaskets or mating faces. Immediately after application of the sealing paste, the flat gaskets must be fitted to
the component and then (no more than 20 minutes later) the sealed components screwed together.
Oil, multi-purpose grease or other materials must not be used to fix the gasket position.

Before installing anti-friction bearings, lightly lubricate the bearing seats.

Only remove the bearings from their original packaging immediately before installation so they do not get dirty.
Do not remove the corrosion inhibitor from the bearings in original packaging.
Use petroleum spirit or acid-free kerosene to clean the antifriction bearings.
After cleaning, relubricate the bearings with engine oil.

During assembly, do not apply (axial) forces to rolling elements and do not hit the bearing rings directly with a
hammer (use assembly aids).
Do not use an open flame to heat bearing inner races.
The temperature must be between 80C and 100C and never exceed 120C.
Chilling for friction-bearing installation is not permissible (risk of cracking, rusting through condensate).
Dry bearings must not be oiled.
When installing gears, the teeth must be lubricated with SAE30 engine oil.
All support and mating surfaces of components (e.g. mating surfaces for centring devices, flange and sealing
surfaces, joint surfaces of press fits) must be clean, polished or provided with the specified surface protection
and free from warping and damage. Corrosion inhibitors (e.g. oil, grease) must be removed from support and
mating surfaces.
After joining the parts installed by means of cooling with liquid nitrogen, all condensate must be removed and the
parts coated with SAE30 engine oil.
Sensors must be coated with long-life lubricant before installation in the immersion sleeves.
Cable connections with cutting-ring threaded connections must be pre-assembled in a vice and tightened, the
thread first being coated with thin-film lubricant.
After any etch-marking of parts, the etching solution must be removed by means of a neutralisation agent. The
affected parts must then be preserved with SAE30 engine oil.
Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes, O-rings) must be coated at the
support and mating surfaces with assembly paste, unless otherwise specified in the drawing.
All mating surfaces of screws, nuts and washers for assembly and of components to be fitted must be bright
metal or have the specified surface protection and be free of warping and damage; corrosion inhibitors (e.g. oil,
grease) must be removed. Threads and screw heads must be coated with lubricant before assembly as per
tightening specifications.

Unless otherwise specified, the following lubricants should be used:


SAE30 engine oil for general application
Assembly paste in hot part areas.

20080/1 E 98-12
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Subgroup 0001 General
Page 4

a) Threaded connections without tightening specifications


For threaded connections without tightening specifications, the tightening procedure can be selected as
required, i.e. mechanical tightening with screwdriver or normal manual tightening with an open-end wrench or
box wrench is possible.
In the event of mechanical tightening, the tightening torque must be taken from the general tightening
specifications according to thread size and property class.
b) Threaded connections with tightening instructions - Torque tightening
The screw connections must be tightened by hand with a torque wrench or angle-of rotation torque wrench. The
specified torques must be set at the torque wrench without consideration of the specified tolerance. When using
an angle-of-rotation torque wrench, the torque indicated must be within the torque specification limit value.
Proceed in a similar manner with torsionally protected threaded connections. These instructions apply also to
testing torques.
Note: If no tolerance for tightening torque is stated, the tightening tolerance is + 10% of specified torque.
- Angle-of-rotation tightening:
The additional angles-of-rotation specified in the tightening specifications must be achieved and may be
exceeded within the specified tolerance.
If no tightening tolerance is specified, the following tolerances must be observed:
+ 5 for angle-of-rotation less than or equal to 90
+ 10 for angle-of-rotation greater than 90
Before angle-of-rotation tightening, each screw head must be colour-marked so that after tightening it is possible
to check that the angle-of-rotation is correct (Exception: colour-marking is not necessary in the case of a self-
monitoring NC screwdriver).
- Elongation tightening
Tightening must be carried out in accordance with tightening specifications and taking the tightening tolerance
into consideration.

20080/1 E 98-12
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General Subgroup 0002
Page 1

00-0002 Designation of Engine Sides and Cylinders

According to Automobile Standard DIN 73021

8 V 183
Engine sides are always designated as viewed from the
driving end.

The cylinders are designated (as per DIN 73021) as


viewed opposite from the driving end, i.e. from the free
end (KGS).

Starting on the left of KGS, the cylinders are designated


in consecutive order 1, 2, 3, 4 etc.

12 V 183

Designations and abbreviations


Driving end = KS = Rear
Free end = KGS = Front
Left side Viewed from driving end
Right side Viewed from driving end
Top
Bottom

20080/1 E 98-12
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Subgroup 0002 General
Page 2

20080/1 E 98-12
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General Subgroup 0003
Page 1

00-0003 Tightening Specifications for Screws and Nuts

Group Designation Nm

01 Engine, Crankcase, Cylinder head

Crankshaft bearing cap to crankcase 1)

Oil separator to crankcase 8

Oil pan to crankcase 8)

Oil drain plug to oil pan 80

Oil filler neck to oil pan 25

Oil dipstick guide pipe union to oil pan 50

Gear case cover and crankcase 25 7)

Drive housing (steering assist pump) to gear case and crankcase 25 7)

Gear case to crankcase M10 60

M12 x1.5 100

Cover to front of crankcase 25

Plug at front and rear oil channel M30 x1.5-10.9 180

Plug at main oil channel on fan side M26 x1.5-10.9 150

Plug, oil supply auxiliary drive M18 x 1.5 80

Plug, oil supply turbocharger M18 x 1.5 50

Plug, oil return turbocharger M18 x 1 to

gear case/steering assist pump drive housing 80

Plug, oil return oil filter front 50

Plug, temperature sensor M14 x 1.5 50

Plug, coolant supply and return pipe

Compressor M14 x 1.5 50

Coolant drain plug M14 x 1.5 50

Plug, top of coolant channel M26 x 1.5 150

See pages 11 to 13 for footnotes

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Subgroup 0003 General
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Group Designation Nm

01 Sealing nut, camshaft bore M22 x 1.5 100

Friction washer to gear case 25

End cover, compressor opening to gear case 30

Plug, inspection port at start of delivery M26 x 1.5 80

M38 x 1.5 40

Cover upper dead center inspection port to gear case 25

Plug, blind hole cylinder head M22 x 1.5 100

Cylinder head to crankcase 2)

Cylinder head cover to cylinder head (flat gasket) 25

Cylinder head cover to cylinder head (profile gasket) 10

Union, crankcase ventilation

Coolant channel, right, M14 x 1.5 50

Oil dipstick guide pipe to oil pan 35

Tachometer drive front camshaft end 35

Retainer, speed transmitter to gear case 25

Clamping screw to speed transmitter retainer 10

03 Running gear

Counterweight to crankshaft 6)

Belt pulley hub to crankshaft 200

Vibration damper to crankshaft 200

Belt pulley to hub 25

Belt pulley to vibration damper 25

Connecting rod bearing cover to connecting rod 3)

Flywheel / ring-gear carrier to crankshaft 5)

Viscose vibration damper to hub / belt pulley 40

See pages 11 to 13 for footnotes

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General Subgroup 0003
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Group Designation Nm

05 Valve gear, valves

Rocker shaft support on cylinder head 75

Locknut to adjusting screw for rocker arm 50

Adjusting segment to camshaft gear 10)

07 Fuel system- engine

Drive gear to injection pump 35

Injection pump to crankcase 9)

Injection pressure lines to injection pump and injection nozzle 25

Securing clamp, injection lines 10

Locknut max-speed seal / idle stop injection pump M6 5

Retaining cap for maximum-speed sealing M6 5

Connecting cable to charge air manifold 25

Lever to control shaft 10

Control lever to injection pump lever 10

Actuator retainer to crankcase 50

Actuator to retainer 10

Lever to actuator 10

Ball studs/pressure rod on setting lever and injection pump control lever 12

Fuel filter to retainer 80

Fuel filter retainer to gear case/intake pipe cover 80

Filter bowl to fuel filter cover 15

Fuel lines to delivery pump, filter and injection pump 30

Fuel filter vent plug 15

Nozzle in nozzle holder 80

Nozzle holder thrust screw to cylinder head 70

See pages 11 to 13 for footnotes

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Subgroup 0003 General
Page 4

Group Designation Nm

09 Air Filter, Exhaust Turbocharger, Charge Air Lines

Charge air manifold to cylinder head 35

Charge air lateral pipe to charge air longitudinal pipe M10 50

M12 80

Plug to charge air lateral pipe 80

Turbocharger to exhaust elbow 50

Charge air manifold/air intake pipe mounting M8 25

M10 50

Exhaust pipes to exhaust elbow and turbocharger 50

Connection of crankcase ventilation to air intake pipe 80

Measuring probe plug 50

Emergency air shut-off flap, compact intercooler

Axle in lever 20 + 2

Control cam screw 8+1

13 Belt Drives, Air Compressor

Plug/unions to engine/compressor M14x1.5 30

M22x1.5 50

M26x1.5 80

Coolant line to unions 35

Compressor coolant line to turbocharger oil pressure line 25

Pressure diaphragm to spacer plate 15

Spacer plate to cylinder head 30

Bearing bush to gear case 30

Mounting flange for bush bearing 50

Bearing flange to gear case 30

Drive gear to crankshaft compressor 360 4)

See pages 11 to 13 for footnotes

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Group Designation Nm

13 Connecting rod to crankshaft compressor 30

Cylinder liner to gear case 30

Cylinder head to cylinder liner 30

Cylinder head with cylinder liner to gear case 30

Steering assist pump to gear case/drive housing 60

Bearing flange with cap to gear case 60

Drive gear to steering assist pump 100 -110

14 Exhaust pipework

Exhaust elbow to cylinder head 50

Intake pipe to cylinder head 35

Lateral intake pipe to intake pipe 50

Plug to intake pipe M26 x 1.5 80

Intake air pipe to retainer 50

Start pilot M10 plug 30

MTU Exhaust system(8/12V 183 T..3)

Flange to cylinder head Pretighten 30 + 3


Nm
Angle of further
rotation 60 + 5

Flame pipe to flange 18 + 2

Hot-air longitudinal line to aluminium profile 55 + 6

Sliding element to hot parts 55 + 6

Exhaust turbocharger to carrier housing 18 + 2

15 Engine Electrical System


Alternator carrier/tension roller to crankcase M14 160

Alternator carrier to gear case M10 60

M16 150

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Subgroup 0003 General
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Group Designation Nm

15 Alternator to carrier M10 50

M12x1.5 80

Clamping element bearing cap stud to alternator 40 + 4

Stud to oil pan/carrier 50

Fan belt pulley to alternator M16x1.5 55

Belt pulley to alternator M27x1.5 150

Alternator cover 50

Air intake supports to alternator 5

Swivel head alternator to screw M12 74 + 6

Clamping arm to retainer 80

Belt pulley to clamping arm 130

Locknut to clamping nut/stud 35

Starter to gear case 80

18 Engine lubrication, engine cooling

Oil pressure relief valve to oil pump 35

Oil pump to crankcase 35

Oil pump cover 25

Oil pump cover (three-gear pump) 35

Oil intake pipe mounting 35

Oil intake pipe to suction basket 25

Oil spray nozzle to crankcase (piston spray) 40

Oil cooler, Mercedes-Benz versions

Oil cooler to oil-filter carrier 20

Plug to bypass valve oil-filter carrier 60

Oil filling plug to oil-filter carrier 80

Coolant drain plug/threaded fitting on oil-filter carrier 50

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Group Designation Nm

18 Oil drain plug to oil filter bowl 50

Threaded fitting to oil-filter carrier (oil-filter bowl securing screw) 80

Oil-filter bowl to oil-filter carrier M12 x 1.5 50

Oil filter with oil cooler to crankcase 70

Oil cooler cover to auxiliary crankcase 25

Coolant drain plug to oil cooler 50

Oil channel plug auxiliary cooler 80

Heating connection blank flange to oil-filter carrier 25

Jacket to gear case 150

Union to oil-filter carrier M24 x 1.5 35

Cover to oil-filter carrier 25

Plug to cover of oil filter M18X1.5 50

M20x1.5 60

18 Oil-filter carrier to crankcase M10 50

M26x1.5 80

Oil-filter bowl to oil-filter carrier M12 x 1.5 40

Oil cooler with flange-mounted, standing oil filter


(MTU version)

Bulkhead wall to oil-cooler housing M10x25 60

Oil cooler housing to crankcase

M10x25 60

M10x35 50

M10x40 50

Oil cooler to oil cooler cover M 8x60 25

M8x35 25

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Group Designation Nm

18 Oil cooler cover to oil cooler housing

M8x60 25

M10x35 25

Oil filter bowl to oil cooler cover M 10x125 50

M10x60 50

M10x100 50

Long-life oil filter

Cover to housing 80

Oil supply connection to housing 150

Oil return connection to housing 80

Plug to housing 80

Oil return connection to gear case cover 25

Oil pressure line to turbocharger/crankcase 25

Oil return elbow to turbocharger/oil pan 25

Oil return turbocharger union to gear case 120

Locknut, oil return turbocharger to gear case 30

Intermediate element/connector, oil pressure transmitter to crankcase

M26x1.5 150

M30x1.5 180

Union, oil pressure transmitter to connector 60

Oil pressure transmitter to intermediate element/oil filter/union 50

Oil temperature transmitter to intermediate element/oil filter 60

20 Coolant pump

Coolant pump to crankcase and/or distributor housing 25

Union, coolant discharge to coolant pump 25

Union, coolant inlet to coolant pump 25

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Group Designation Nm

20 Belt pulley to coolant pump 25

Raw water pump

Impeller clamping nut to drive shaft 32 + 3

Nut M8, bearing housing with intermediate element

to pump housing 20 + 2

Plug to pump housing M18X1.5 50 + 10

G1 1/4 A 140 + 10

Coolant cooler (plate-core cooler)

Plate-core pack securing element M12

Tighten diagonally and evenly

Pretighten 25 + 3

Further tightening 45 + 5

but not over block dimension


(See sign)

Rigid fan to resilient hub 30

Viscose fan/resilient hub/intermediate element and belt pulley to 30


hub/vibration damper

Hub/vibration damper 30

Fan bracket to crankcase 60

Clamping arm to fan bracket 80

Stud to fan bracket 50

Clamping element for clamping screw to clamping arm 80

Fan shroud to engine carrier/oil pan 50

Intermediate element, coolant temperature transmitter to crankcase 180

Coolant temperature transmitter to crankcase 25

Retainer to fan shroud 50

Viscose fan to belt-pulley hub 30

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Subgroup 0003 General
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Group Designation Nm

22 Engine suspension/Engine mounting

Front engine carrier to crankcase 110

Front lifting eye to crankcase M10 50

M20 330

Rear lifting eye to gear case 150

23 Special installations

Bearing housing and bearing flange to gear case 25

Drive flange to auxiliary drive shaft 300

Drive gear to shaft 300

Drive flange to bearing housing 25

Oil supply for auxiliary drive (oil nozzle) 80

Bearing housing to gear case 25

Intermediate flange to bearing housing 80

Hub to hydraulic pump 80

Flange to hydraulic pump 10

Hydraulic pump with hub or blank flange to auxiliary drive 30

Carrier for steering assist pump to crankcase 160

Hydraulic pump (Bosch) to slide valve 25

Belt pulley to hydraulic pump (Bosch) 90

Bearing pedestal to alternator carrier 50

Support to bearing pedestal 25

Locknut to support 80

Belt pulley to drive flange (alternator top rear) 25

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Footnotes

1) Crankshaft bearing cap to crankcase

Central screws (1)


1. Stage 100 Nm
2. Stage 200 Nm
3. Stage 300 to 330 Nm
4. Stage 90 to 100 angle of rotation
Max. shaft length: 156 mm

Lateral screws (2)

Hex bolts: 80 Nm

Double-hex screws

1. Stage 80 to 90 Nm
2. Stage 90 to 100 angle of rotation
Max. shaft length: 86.5 mm
Note
Tighten central screws (1) before the lateral screws (2).

2) Cylinder head to crankcase

Tighten in 6 stages

1. Stage 10 Nm
2. Stage 50 Nm
3. Stage 100 Nm
4. Stage 140 Nm to 150 Nm
5. Stage 180 Nm to 190 Nm
6. Stage 90 to 100 angle of rotation
Max. shaft length: 111 / 146 / 170 mm

Do not retighten!

Sequence for tightening cylinder head screws.

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Subgroup 0003 General
Page 12

3) Connecting rod bearing cap to connecting rod


1. Stage 100 Nm
2. Stage 90 to 100 angle of rotation
Max. shaft length: 68.5 mm

4) Drive gear to crankshaft compressor


With special tool
442 589 00 03 00, 270 Nm

5) Flywheel / ring-gear carrier to crankshaft


1. Stage 50 Nm
2. Stage 200 to 220 Nm
3. Stage 90 to 100 angle of rotation
Max. shaft length: 75 / 86 mm

6) Counterweights to crankshaft
1. Stage 50 Nm
2. Stage 140 Nm to 160 Nm
3. Stage 90 to 100 angle of rotation
Max. shaft length: 75.5 / 84.5 mm

7) Tightening arrangement, gear case cover

8) Oil pan to crankcase

a) Tighten corner screws and / or nuts diagonally A-


C and B-D to a torque of 35 Nm.

b) Tighten the remaining screws / nuts in peripheral


sequence to a torque of 35 Nm (starting from the
last corner screw tightened).

c) Retighten corner screws and / or nuts to a


torque of 35 Nm.

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9) Injection pump to crankcase

Double-hex screws
in 8V/12V 183 up to 1000 HP
Align pump with assembly gauge 422 589 00 63 00

1. Stage 10 Nm
2. Stage 50 Nm
3. Stage 90 to 100 angle of rotation

Max. shaft length:


Short screws 72 mm
Long screws 102 mm

Double-hex screws
in 12V 183 1000 HP
Align pump with assembly gauge 422 589 00 63 00

1. Stage 10 Nm all screws


2. Stage 50 Nm all screws
for screws 1, 3, 5, 6
3. Stage angle of further rotation 90 to 100

Max. shaft length:


Short screws 72 mm
Long screws 102 mm

10) Adjusting-segment on camshaft gear

Stress bolt: 50 Nm
Max. shaft length: 25.3 mm

Rolled shank bolt: 1. Stage 30 to 35 Nm


2. Stage 90 to 100 angle of
rotation
Max. shaft length: 25.3 mm

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Tightening torques in Nm for non-yielding screws with normal nuts and locknuts.
(Extract from MBN 10 130 "Tightening torques for screws and nuts with metric threads").
The table values apply to screws and nuts with head dimensions corresponding to MBN 10 105 and
MBN 10 143 (without consideration of the torque scatter of the various tightening procedures).The tightening
torques are for a friction coefficient range of: = 0.08 - 0.14

Hexagonal screw with flange Hexagonal round screw with flange

Standard thread Fine thread


Strength class 8.8 10.9 Strength class 8.8 10.9
M5 x 0.8 5 8 -- -- --
M6 x 1 9 13 -- -- --
M7 x 1 15 22 -- -- --
M8 x 1.25 22 32 M8 x 1 23 33
M10 x 1.5 42 62 M10 x 1 45 67
M12 x 1.75 74 108 M12 x 1.5 76 111
M14 x 2 120 175 M14 x 1.5 125 185
M16 x 2 180 265 M16 x 1.5 190 280
M18 x 2.5 260 370 M18 x 1.5 280 400
M20 x 2.5 365 515 M20 x 1.5 390 555

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Tightening torques for screws and nuts with metric threads.


(Extract from MBN 10 130 "Tightening torques for screws and nuts with metric threads").
The table values apply to screws and nuts with head dimensions corresponding to DIN 912 (without consideration of
the torque scatter of the various tightening procedures).The tightening torques are for a coefficient range of: =
0.08 - 0.14

Socket head screw

Standard thread Fine thread


Strength class 8.8 10.9 Strength class 8.8 10.9
M5 x 0.8 5 7 -- -- --
M6 x 1 8 12 -- -- --
M7 x 1 14 20 -- -- --
M8 x 1.25 20 29 M8 x 1 21 31
M10 x 1.5 39 57 M10 x 1 42 61
M12 x 1.75 67 98 M12 x 1.5 69 101
M14 x 2 110 155 M14 x 1.5 115 165
M16 x 2 165 240 M16 x 1.5 170 250
M18 x 2.5 235 335 M18 x 1.5 255 360
M20 x 2.5 330 465 M20 x 1.5 350 495
M22 x 2.5 440 630 M22 x 1.5 470 665
M24 x 3 565 805 M24 x 2 595 850
M27 x 3 820 1165 M27 x 2 860 1220
M30 x 3.5 1115 1590 M30 x 2 1190 1690
M33 x 3.5 1510 2150 M33 x 2 1595 2270

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Tightening torques for set screw- and stud connections according to MTN 5008.
#This works standard applies to set screws subjected to little dynamic load as per MMN 384, DIN 912, EN 24014
(DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to studs as per DIN
833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts.
It does not apply to heat-proof screws in the hot component area.
Tightening torques MA are for of strength class 8.8 (bright surface, phosphate coating or galvanised) and 10.9
(bright surface or phosphate coating).
The values in the table are based on a friction coefficient tot = 0.125. Precondition: Threads and mating faces of
screws and nuts must be coated with engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g.
resulting from inaccurate readings and overtightening during assembly.
When tightening mechanically, the permitted assembly tolerance is + 15 %.
Tightening torques = MA.

Thread Manually tightened Machine tightened


8.8 10.9 8.8 10.9
MA (Nm) MA (Nm) MA (Nm) MA (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M20 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800

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Tightening torques for stress bolt connections according to MTN 5007.


This work standard applies to stress pin bolts and stress bolts of strength class 10.9 which are subjected to static
and dynamic load, and their associated nuts.
Shaft and transition dimensions as to MMN 209 standard and material and machining to MMN 389 (bright surface
or phosphate coating).
The values in the table are based on a friction coefficient tot = 0.125. Precondition: Threads and mating faces of
screws and nuts must be coated with engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g.
resulting from inaccurate readings and overtightening during assembly.
The values in the tables are for manual tightening with torque wrench.
Tightening torques = MA.

Thread Without torsion protection With torsion protection*


MA (Nm) MA (Nm)
M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
*Protect shank against torsion when tightening.

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Tightening torques for plugs according to MTN 5183-1


This works standard applies to plugs as per DIN 908, DIN 910 and DIN 7604 with screwed plug DIN 3852 model A
(sealed by sealing ring DIN 7603-Cu).

DIN 908 DIN 910 DIN 7604A/C

Tightening torques MA are given for plugs made of steel (St) with surface protected by a phosphate coating and
oiled or galvanised.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g.
resulting from inaccurate readings and overtightening during assembly.
Tightening torques = MA.

Tightening torques for plugs DIN 908, DIN 910 and DIN 7604 A
(with short screwed plug).

Thread Inserted in
Steel/grey cast iron Al-alloy
MA (Nm) MA (Nm)
M10 x 1 15 15
M12 x 1.5 35 25
M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
M22 x 1.5 60 50
M24 x 1.5 70 60
M26 x 1.5 80 70
M27 x 2 80 70
M30 x 1.5 100 90
M30 x 2 95 85
M33 x 2 120 110
M36 x 1.5 130 115
M38 x 1.5 140 120
M42 x 1.5 150 130
M45 x 1.5 160 140
M48 x 1.5 170 145
M52 x 1.5 180 150
M56 x 2 190 160
M64 x 2 205 175

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Tightening torques for plugs DIN 7604 C


(with long screwed plug).

Thread Inserted in
Steel/grey cast iron Al-alloy
MA (Nm) MA (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140

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Tightening torques for banjo screws according to MTN 5183-2


This works standard applies to banjo screws according to MMN 223 and N 15011 sealed with sealing ring DIN
7603-Cu

MMN 223 (4 flow holes) N 15011 (3 flow holes)

Tightening torques MA are given for banjo screws made of steel (St) with surface protected by a phosphate coating
and oiled or galvanised and for banjo screws made of copper-aluminium alloys.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g.
resulting from inaccurate readings and overtightening during assembly.
Tightening torques = MA.
Tightening torques for banjo screws made of steel.

Thread Inserted in
Steel/grey cast iron/Al-alloy
MA (Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160

Tightening torques for banjo screws made of copper-aluminium alloys.

Thread Inserted in
Steel/grey cast iron/Al-alloy
MA (Nm)
M10 x 1 15
M16 x 1.5 30

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Tightening torques for male connectors as per MTN 5183-3


This works standard applies to male connectors DIN 2353, row L with screwed plug DIN 3852 model A
(sealed by sealing ring DIN 7603-Cu).

DIN 2353 Form C

Tightening torques MA are given for male connectors made of steel (St) with surface protected by a phosphate
coating and oiled or galvanised.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g.
resulting from inaccurate readings and overtightening during assembly.
Tightening torques = MA.

Thread Inserted in
Steel/grey cast iron
MA (Nm)
M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320

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00-0004 Settings
Firing order

8V183 : 1 - 5 - 7 - 2 - 6 - 3 - 4 - 8
12V183 : 1- 12 - 5 - 8 - 3 - 10 - 6 - 7 - 2 - 11 - 4 - 9

Direction of rotation viewed from the driving end


Crankshaft c.c.w.
Camshaft c.w.
Oil pump c.c.w.
Engine coolant pump c.c.w.

Valve clearance with engine cold (20 C)

Inlet 0.40 mm
Exhaust 0.60 mm

Engine timing with valve clearance adjusted


Crankshaft
1 Inlet opens 17 before TDC

2 Inlet closes 29 after BDC

3 Exhaust opens 71 before TDC

4 Exhaust closes 13 after BDC

Start of delivery See plate on cylinder


head cover or in the engine acceptance
test record

Nozzle opening pressure

Initial pressure setting with new spring 200 to 208 Nm


Minimum pressure setting with run-in 185 bar
spring

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Valve stroke at specified valve clearance


Engine Inlet Exhaust
8V 183 12.35 12.30
11.95 11.90
12V 183 12.30 12.25
11.90 11.85

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00-0005 Safety at Work


These safety instructions must be read and followed by every person who operates,
maintains or repairs the machine plant.

General safety and accident prevention regulations


In addition to the instructions given in this publication, general safety and accident prevention regulations
required by law must be taken into consideration; these may vary from country to country.
This engine is a state-of-the-art product and conforms to the applicable specifications and regulations. Danger
can still occur, however, causing serious bodily harm or damage to property under the following conditions:
- Incorrect use of the plant
- Operation, maintenance and repair by untrained personnel.
- Modifications or conversions
- Non-observance of safety regulations

Correct use of the engine


The engine is designed solely for the contractually-defined purpose. Another use, or a use beyond that defined,
is regarded as not being for the purpose intended. The manufacturer accepts no liability for damage resulting
from unauthorised use. The responsibility is borne by the operator alone.
The contractually-defined use includes the careful reading of the Operation Manual and Maintenance Manual,
and following the maintenance and repair directions.

Personnel Requirements
Work must be carried out by reliable personnel only. The minimum age required by law must be observed.
Only fully-trained or qualified personnel are to be employed. Responsibilities of the operating, maintenance and
repair personnel must be specified.

Modifications or Conversions
Engine modification or conversions carried out by the customer may affect safety. No modifications or
conversions may be carried out without prior consent from DB or MTU.
No liability will be accepted for damage resulting from unauthorised modifications or conversions.

Organisational Measures
This manual is to be given to the maintenance and repair personnel.
With assistance from this manual, the personnel must be instructed on the operation and maintenance of the
engine, with special emphasis on the safety instructions. This is especially important for personnel who work only
occasionally on the engine.
Note: Amendments to this publication will be sent to you provided the receipt card is returned to MTU.
This also applies to in-house use by MTU personnel.

Spare Parts
Spare parts must at least satisfy the requirements specified by the manufacturer. This is guaranteed when
genuine components are used.

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Working Clothes and Protective Equipment


Always wear protective shoes when working on plant.
Select protective goggles according to the work to be carried out. Always wear protective goggles when working
with mallets, cutting tools, drift punches or similar.
Work clothing must be tight-fitting so that it does not catch on rotating or projecting parts. Do not wear jewellery
(rings, chains, etc.).

Welding Operations
Never use the engine as a ground terminal! (This prevents the welding current from passing through the engine,
resulting in burnt or scorched points on the bearings, friction surfaces and tooth flanks which can lead to bearing
scorching and/or material damage).
Welding on the engine or engine-mounted components is forbidden.
Never lay the welding cable over or near the cable harnesses of the DB/MTU plants. (The welding current could
be induced in the cable harnesses which could possibly damage the electrical plant).
The ground terminal of the welding unit must be connected to the welding point at a distance of no greater then
60 cm.
If work must be carried out on components, (e.g. exhaust pipe), then these components must be removed from
the engine beforehand.
With the DB/MTU electronics system, it is not necessary to remove the connector and connections to carry out
welding if the power supply master switch has been switched from "On" to "Off", and the cables have been
disconnected from the negative and positive battery terminals.
During welding operations, always wear welding gloves, headgear, goggles, protective apron and other suitable
protective clothing.

Transport
Lift the engine using only the lifting eyes provided.
Use only the transport and lifting equipment approved by DB or MTU.
Transport the engine only in the installation position.

Engine Operation
Wear ear protectors in the engine room when the engine is running.
Ensure the engine room is well ventilated.
Leaked or spilt engine oil and coolant must be cleaned up immediately or absorbed with appropriate bonding
agents to avoid injuries caused by falling.
Exhaust gases from combustion engines are poisonous. They can be injurious to health if inhaled. The exhaust
system must be leak-tight and discharge the gases to atmosphere.
Do not touch battery terminals, generator terminals or cables during engine operation. Inadequate protection of
the electrical components can lead to electric shocks and serious injuries.
If engine is running, never release coolant, oil, fuel, compressed air or hydraulic lines.

Maintenance and Repair


Compliance with the maintenance and repair instructions is a major safety factor.
Unless expressly permitted, no maintenance or repair work is to be carried with the engine running. The engine
must be secured against inadvertent starting, the battery disconnected and the "Do not operate" sign put up in
the operating area or attached to the control equipment. Persons not involved must be kept clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Maintenance and repair work must only be carried out by authorised and qualified personnel.

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Use only tools in perfect condition.


Do not work on engines or components which are held only by lifting equipment or crane. Always support them
on suitable trestles or stands before beginning any maintenance or repair work.
Before barring the engine, ensure nobody is within the danger area. After working on the engine, check that all
guards have been re-installed and that all tools and loose components have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and cause serious injury. Before starting
work, relieve pressure in systems and H.P. lines which are to be opened.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean. Always seal
connections with caps and covers if a line is to be removed or opened.
During maintenance or repair work, do not hit fuel lines with wrenches or other tools. To tighten connections
when installing lines, use the correct tightening torque and ensure that all retainers and dampers are installed
correctly.
Ensure that all fuel injection lines and compressed-oil lines have sufficient play to avoid contact with other
components. Do not position fuel or oil lines near hot components.
The H.P. lines for hydraulic installation and removal are tested at 3,800 bar.
Do not attempt to bend or apply force to lines while under pressure.
In order to avoid burns, pay special attention to hot spots on components just removed and when working with
hot liquids in pipelines, pipes and chambers.
Do not open the breather cap until the engine has cooled. Turn the cap to the stop and allow the pressure to
escape; then remove the cap!
Take special care when removing plugs or vent plugs from engine. In order to avoid being sprayed with highly-
pressurised liquids, hold a cloth over the plugs. There is increased danger if the engine has only recently been
shut down as the liquids can still be hot.
Take special care when draining hot liquids - risk of injury. Drain the liquids into a suitable container and wipe up
any spillage.
When changing engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high up on the engine, always use suitable ladders and work platforms. Make sure components
are placed on stable surfaces.
To avoid back injuries when lifting components weighting 25 kg (50 lb) or more, use lifting gear or request aid
from other workers. Ensure that all chains, hooks, slings, etc. are in good condition, are sufficiently strong and
that hooks are correctly positioned. Lifting eyes are not to be unevenly loaded.
When operating electrical equipment, remember that certain components of this equipment are live.
Non-compliance with warning notices could result in serious bodily harm or damage to property.
Work must be carried out by qualified personnel only. Prior to working on electrical equipment, switch off live
units.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acid to
come into contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Check
polarity before connecting the cables to the battery. Battery pole reversal may lead to injury through the sudden
discharge of acid or bursting of the battery casing.

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Do not damage the wiring during removal work. Re-install so that it is not damaged and, during operation, does
not come into contact with sharp objects, does not rub against another component or contact a hot surface.
Never connect wiring to a line carrying hot liquid.
On completion of the maintenance and repair work, correctly secure any cables which have become loose.
Always tighten connectors with connector pliers.
Cables belonging to mechanical components are to be secured with cable clamps if there is risk of scuffing.
Do not use cable straps to secure as they cannot be used a second time after removal for maintenance and
repair work.
Check that all plug-in connections are secure.
It is not sufficient to tighten the bayonet union connections by hand. There is the risk that the locking unit does
not engage correctly and that the connector becomes loose during engine operation. For this reason, connector
pliers must be used to turn the bayonet union in a clockwise direction.

Fire Prevention
Rectify any fuel or oil leaks immediately. Even splashes of fuel or oil on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave oil-soaked cloths on the engine. Do not store
combustible fluids near the engine. Do not allow dirt or foreign matter to accumulate near the engine, as this
constitutes a fire hazard.
Welding work must not be carried out on pipes and components carrying oil or fuel. Before welding, clean with a
non-combustible fluid.
Never mix petrol (gasoline) with diesel fuel. If petrol (gasoline) is added to diesel fuel, there is increased danger
of fire.
When starting the engine with a foreign power source, connect the ground lead last and remove it first. To avoid
sparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of
the engine or to the ground terminal of the starter.
Always keep a fire extinguisher at hand and learn how to use it.

Noise
Hearing may be impaired at all workplaces where the sound pressure level is in excess of 85 dB(A).
Wear earplugs or earmuffs!

Environmental Protection
Dispose of used fluids and lubricants and filters in accordance with local regulations.
Manipulation of the injection or control system can influence the engine performance and exhaust emissions. As
a result, compliance with environmental regulations may no longer be assured.

Skin Complaints
Barrier creams issued for prophylactic use are not suitable for treatment of skin complaints. Seek medical advise
on skin rashes of any type, even if symptoms are very slight.

Warning Signs
Before putting the engine into service and before working on the engine, read and follow all warning signs. Do
not paint over warning signs. Replace illegible signs.

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Fluids and Lubricants, Auxiliary Materials


Use only DB or MTU-tested and approved fuels and lubricants.
Fluids and lubricants must be kept in properly designated containers. When using fluids, lubricants and other
chemical substances, follow the safety instructions applicable to the product. Take special care when using hot
and caustic materials. When using inflammable materials, avoid all sparks and do not smoke.
Lead
When working with lead or pastes that contain lead, take care that the body does absorb even tiny amounts of lead
(from air-borne lead dust, smoke, dirty hands).
- Adopt suitable measures to avoid lead dust!
- Switch off extraction system!
- Wash hands before eating and drinking!
Chlorinated Hydrocarbons
When working with chlorinated hydrocarbons (e.g. perchlorethylene, trichlorethane) or other cold cleaners which
contain declared hazardous substances, health-endangering substances may be inhaled.
Switch on ventilation and extraction systems!
Observe fire-prevention regulations!
Do not smoke, do not drink alcohol!
- Do not permit substances to enter the waste-water system!
Acids and Alkalis
When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
- Immediately remove clothing wetted by acids and alkalis!
- Rinse injuries with lots of clean water!
- Rinse eyes immediately with water from rinsing bottle or clean mains water!
Painting
Ensure good ventilation when not painting in spray booths equipped with extractors.Ensure that neighbouring
workplaces suffer no detrimental effects.
- Always wear a mask to protect against paint and solvent fumes!
- Observe all fire-prevention regulations!
- No smoking!
- No naked flame!
Liquid Oxygen
Liquid oxygen is highly flammable.
Store liquid oxygen only in small quantities and always in regulation containers (without fixed seal)! Do not bring
into contact with parts of the body (hands); causes cold burns and severe frostbite.
- No smoking, no naked flame (risk of explosion)! Oxygen enrichment in the air causes flash combustion.
- Do not store combustible substances (e.g. oils and greases) within 5 m of the working area!
- Under no circumstances wear oily or greasy clothing!
- Do not allow fumes to penetrate clothing! Oxygen enrichment in fabric can cause working clothes to ignite
suddenly!
- After working with liquid oxygen, do not smoke until clothing is free of vapours!
- Take great care to avoid any impact and shock when working with liquid oxygen!

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Liquid Nitrogen
Store liquid nitrogen only in small quantities and always in regulation containers (without fixed seal)!
Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands). Liquid nitrogen causes cold
burns and severe frostbite.
- Wear protective clothing (including gloves and closed shoes) and goggles.
- Ensure good ventilation (suffocation if nitrogen enrichment in inhaled air reaches 88%)
- Take great care not to subject containers, fittings and tools to any impact or shock.
Compressed Air
Compressed air is highly pressurised air and stored in pressure vessels from which it is then extracted.
The prevailing pressure can be read off at the pressure indicators (pressure gauges) which are to be fitted on
the pressure vessels and the compressed air lines.
Pressure can cause serious bodily harm, especially if applied suddenly.
When working with compressed air, safety precautions must be constantly observed:
- Pay special attention to the pressure level in the compressed air network and pressure vessel!
- Connecting devices and equipment must either be designed for this pressure or, if the permitted pressure for the
connecting devices is lower than the pressure required, pressure-reducing valves and safety valves (set to the
permitted pressure) must be installed. Hose couplings and connections must be securely attached!
- Always wear protective goggles when blowing tools clean or blowing chips away!
- The air-nozzle mouthpiece is provided with a protective disc (e.g. rubber), which prevents air-borne particles
rebounding and thereby protects against eye injury.
- First shut off compressed air lines before compressed air equipment is disconnected from the supply line or
before equipment or tool is to be replaced.
- Unauthorised use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a "Risk of explosion"!
- Forcing compressed air into thin-walled containers (z. B. containers made of tin, plastic and glass) for drying
purposes or to check for leaks results in a "Risk of explosion"!
- Removing dirt from soiled clothes while still being worn can result in a "Risk of injury"! Even compressed air at
low pressure penetrates clothing and, if the jet is directed at the back of the body, the air can enter the anal
cavity and cause a potentially fatal rupture of the intestines!
Used Oil
Used oil may contain health-threatening combustion residues.
- Rub barrier cream into hands!
- Clean hands thoroughly after contact with used oil!

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Warning Notices
- This publication contains specially emphasised safety instructions starting with signal words graded according to
the degree of danger.
- Take extreme care in these situations!
- Read and become acquainted with all the warning notices and symbols before operating or repairing this
product!
- Pass on all safety instructions to your operating and maintenance personnel as well!

Notice!

Caution!

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00-0006 Data Sheets


To ensure that unusable components are not re-installed, or that usable components are not discarded, all
inspection work should only be carried out only by qualified personnel using the necessary measuring instruments.
All measuring and testing equipment is naturally subject to wear.
In order to register the resulting tolerance deviations in good time, the measuring and test equipment must be
inspected annually at a location equipped with the appropriate technical facilities.
Alternatively, an inspection can be carried out through our Product Support service and DaimlerChrysler/MTU or by
an external Product Support service.
On no account are the measurements to exceed or fall short of the values given in the Tolerance and Wear Limits
List.
Data sheets are to be used to record the inspection results.

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00-0007 Engine Condition Check before W5 Overhaul and Main Overhaul

Before the engine is removed, a brief test should be conducted to assist in evaluating its condition and running
behaviour. Deviations from the Engine Acceptance Test Record Data found during the test run provide valuable
information for subsequent overhaul services.

Instructions for carrying out work:


B = Operating Instructions
P = MTU Test Kit

Operations see
Perform operations preparatory to starting the engine B
Start engine B
Perform warm-up run B
Test engine at highest possible power
Check engine speed, temperatures and pressures, where gauges are installed and compare with
Acceptance Test Record
Check running noises: No noises other than normal operating noise should be audible B
Check engine and external pipework for leaks during test run (visual inspection) B
Check exhaust gas colour B
Run engine at lower adjustable no-load speed
Connect fuel line connections for leaks
Extract sample of engine oil B
Analyze engine oil sample (spot test, water content, dilution with fuel) P
Extract sample of coolant B
Analyze coolant sample P
Check operation of monitoring system B
Air filter: Check contamination indicator B
Shut down engine B
Check turbocharger rundown
Drain coolant B
Fill system with cleaning solution B
Start engine B
Flush cooling system B
Shut down engine B
Disconnect H.P. fuel lines
Remove fuel injection nozzles with nozzle holders B
Compression pressure check B
Work listed here which is not relevant to the respective engine version can be disregarded.

20080/1 E 98-12
Group 00
Subgroup 0007 General
Page 2

20080/1 E 98-12
Group 00
General Subgroup 0008
Page 1

00-0008 Engine Removal

Instructions for carrying out work


B = Operating Instructions

Operations see
Shut off fuel supply line B
Shut off compressed air supply B
Shut off raw water supply line B
Drain oil with engine warm when possible B
Drain oil sludge from engine oil filter B
Oil sludge metallic residue check B
Drain engine coolant when temperature of coolant is below 60C B
Drain raw water (sea water) B
Wash machinery plant; do not use chemical solvents -
Release all connections
Seal open connections with lint-free plugs and covers
Remove engine securing bolts
Remove engine and support it on support pedestals
Install transportation locking devices (for road or rail transport)
Suspend engine only by purpose-designed attachments as per engine installation drawing (taking into
account centre of gravity and transport regulations).

Engine weight
See specification on engine nameplate

20080/1 E 98-12
Group 00
Subgroup 0008 General
Page 2

20080/1 E 98-12
Group 00
General Subgroup 0009
Page 1

00-0009 Engine Running-in


After the installation of pistons, piston rings or cylinder liners, the engine must be run-in as per the appropriate run-
in schedule.

A thorough running-in is of critical importance regarding the engine's durability and operational reliability.

Use a dynamometer or generator to absorb the power developed during the braking run.

The power from engine to dynamometer must be transmitted through a resilient coupling.

Settings
Set intake-air temperatures before engine according to those given for the engine in its MTU Engine Acceptance
Test Record.

The engine coolant temperature depends on the operating range of the coolant thermostat.

Record the readings for power, fuel, lube oil, coolant, charge air and exhaust at each test point (time, speed and
effective power) of the run-in schedule, and enter them under "Engine Run-in" in the MTU Diesel Engine Factory
Test" record.

Operations See
Install engine on test stand. -
Connect engine to dynamometer or generator. -
Connect intake air, exhaust, coolant and fuel lines. -
Connect charge-air coolant line. -
Connect oil pressure line and oil temperature sensor -
Connect crankcase ventilation line -
Connect all measuring hoses and cables -
Fill expansion tank up to the max. mark with coolant containing 2% corrosion- Operation Manual
inhibitor oil
Check that fuel in service or supply tank is to specification Fluids and Lubricants
SpecificationA001061
Fill up with fresh engine oil to the max. mark. Operation Manual
Check function of engine governor before starting engine -
Check function of emergency shutdown system -
Start engine Operation Manual
After approx. 1 minute operation at idle, shut down engine and check oil level -
Start engine and check idling speed -
Check for leaks in the coolant, oil and fuel lines and the crankcase, air-intake and Operation Manual
exhaust gaskets
Run in engine and record measurements in accordance with the running-in MTU Engine Acceptance
schedule Test Record
Check engine speed and brake load -
Check injection, temperatures, pressures and speeds at the gauges and compare -
with Acceptance Test Record
Measure lube oil temperature before engine -
Measure intake depression before turbocharger -
Measure exhaust temperature after turbocharger -
Measure exhaust pressure (back pressure) after engine -
Check exhaust gas colour -

20080/1 E 98-12
Group 00
Subgroup 0009 General
Page 2

Enter barometric reading and relative humidity in record MTU Engine Acceptance
Test Record
Check engine for abnormal running noises and leaks -
Check idle and full-load positions, adjust if necessary. -
Check oil filter Operation Manual
After running-in, perform factory test according to the MTU Engine Acceptance -
Test Record
Enter operational values in the enclosed Factory Test Record MTU Engine Acceptance
Test Record
Compare measured values with those in the Acceptance Test Record MTU Engine Acceptance
Test Record
Shut down engine Operation Manual
Preserve engine if it is to be stored for a prolonged period Operation Manual
Take appropriate protective measures if engine is to be sent by sea freight -
Remove engine from test stand -
Spray engine with protective paint -

Running-in Schedule 8V 183TE


Engine speed 820 1330 1740 2130 2350 F (N)
(rpm) 6.7 10.9 14.3 17.5 19.3 pe (bar)

1500 123 199 262 320 350

1800 240 314 384 425

2000 349 427 470 Peff (kW)


2100 366 448 495

2300 400 490


2400 420 512 564

Running time (t) 5 5 10 5 10 (min)


Note: Measurements to be recorded only at n = 1500 rpm and 2400 rpm
(complete measurement) P = F x n (kW)
For load F, the brake constant is x = 1000
The engine is to be run for 10 minutes at 2400 rpm

20080/1 E 98-12
Group 00
General Subgroup 0009
Page 3

Running-in Schedule 12V183TE


Engine speed 1280 2190 2750 3196 3525 F (N)
(rpm) 7 12 15 17.5 19.3 pe (bar)

1500 192 329 412 480 530

1800 413 494 576 635

2000 549 640 705 Peff (kW)


2100 576 673 740

2300 631 737


2400 660 770 846

Running time (t) 5 5 10 5 10 (min)


Note: Measurements to be recorded only at n = 1500 rpm and 2400 rpm
(complete measurement) P = F x n (kW)
For load F, the brake constant is x = 1000
The engine is to be run for 10 minutes at 2400 rpm

20080/1 E 98-12
Group 00
Subgroup 0009 General
Page 4

20080/1 E 98-12
Group 00
General Subgroup 0010
Page 1

00-0010 Engine Installation and Operation

Instructions for carrying out work


B = Operation Manual

Tasks See
Open all connections, remove covers and rubber plugs
Attach engine only at the lifting brackets provided as shown in installation drawing, taking centre of
gravity and transportation specifications into consideration, and install in plant
Join connections appropriately
Align engine
Fill engine coolant system B
Fill engine oil system B
Prepare engine for operation B
Start engine B
Perform checks while engine is running B
Carry out test run B
Shut down engine B
Perform after-shutdown services B
Preservation measures are required if an extended out-of-service period is intended B

20080/1 E 98-12
Group 00
Subgroup 0010 General
Page 2

20080/1 E 98-12
Group 00
General Subgroup 0011
Page 1

Group Survey

00 General work items 13 Belt drive, air compressor

01 Engine, 14 Exhaust pipework


engine block,
cylinder head 15 Electrical motor

03 Running gear 17 Air starting system

05 Valve gear, valves 18 Engine lubrication, engine cooling

07 Fuel system engine 20 Engine cooling

09 Air filter 22 Engine suspension/Engine mounting


exhaust turbocharger,
charge air lines 23 Special installations

20080/1 E 98-12
Group 00
Subgroup 0011 General
Page 2

20080/1 E 98-12
Group 00
General Subgroup 0901
Page 1

00-0901 Repairing threaded bores with threaded inserts (Heli-Coil)

Data

Metric thread Blind hole bore dia. Drill


6.31
M6 6.1-6.2-6.25
6.04
8.35
M8 8.1-8.2-8.25-8.3
8.04
8.32
M8 x 1 8.1-8.2-8.25-8.3
8.04
10.40
M10 10.25
10.05
12.50
M12 12.25-12.5
12.05
12.43
M12 x 1.5 12.25
12.05
14.53
M14 14.25-14.5
14.06
14.43
M14 x 1.5 14.25
14.05
15.30
M15 x 2 15.25
15.20
16.53
M16 16.25-16.5
16.06
16.43
M16x1.5 16.25
16.05
24.43
M24 x 1.5 24.25
24.05
26.43
M26 x 1.5 26.25
26.05
30.43
M30 x 1.5 30.25
30.05

20080/1 E 98-12
Group 00
Subgroup 0901 General
Page 2

Special tools

Repair
Drill blind hole open with drill
Note
Do not countersink bore
Re-cut damaged thread with special Heli-Coil tapped
drill.
Mount spindle (1) and mouth piece (2) appropriate to
thread on installation tool.
Note
Groove on mouthpiece (2) must be aligned with
markings on installation tool (arrows).

20080/1 E 98-12
Group 00
General Subgroup 0901
Page 3

Insert Heli-Coil thread insert (3) into spindle (1) in


installation tool.

Note
Angled end of Heli-Coil thread insert must be in groove
(arrow).

Use spindle to turn thread insert (3) through mouth


piece until it is flush at front.

Mount installation tool on threaded hole and install


thread insert without applying pressure to spindle.
Note
Insert thread insert 1/2 to 1 1/2 gears deeper than
threaded bore surface.
Use bolt shearer to remove driver journal to M12. In
event of threaded inserts over M12. move driver journal
up and down with pointed pliers and remove.

20080/1 E 98-12
Group 00
Subgroup 0901 General
Page 4

20080/1 E 98-12
Group 00
General Subgroup 1000
Page 1

00-1000 Keyword Index

A
Exhaust line removal and installation (V183T..2) 14-3630

Exhaust line removal and installation (V183T..3) 14-3630a

Exhaust turbocharger removal and installation (8V/12V 183 T..3) 09-6030a

Exhaust turbocharger removal and installation (Engine version with top-mounted turbocharger) 09-6030

Exhaust turbocharger check, examination, fault diagnosis 09-6010

Exhaust turbocharger disassembly and assembly 09-6263

Tightening torques for screws and nuts 00-0003

Engine removal 00-0008

Axial clearance of camshaft check 05-6210

B
Designation of engine sides and cylinders 00-0002

Reconditioning collar seat in cylinder crankcase 01-9304

D
Pressure of delivery pump(s) and opening pressure of overflow valve measurement 07-5700/2

Measuring fuel filter flow rate 07-5700/3

Nozzle holder and injection nozzle disassembly, cleaning and assembly 07-6750

E
Engine installation and operation 00-0009

Settings 00-0004

Injection lines 07-9200

Injection line removal, inspection/repair and installation 07-9224

20080/1 E 98-12
Group 00
Subgroup 1000 General
Page 2

Injection nozzle with nozzle holder, removal and installation 07-6812

Injection nozzle check 07-6712

Installing and removing injection pump 07-8410

F
Start of delivery check 07-8234

Guide bearing replacement in flywheel 03-8400

G
Safety at Work 00-0005

Front Housing Cover Removal and Installation, Radial-Lip Oil Seal Replacement 01-8810

Alternator (generator) removal and installation 15-5030

Group survey 00-0011

I
Repairing threaded bores with threaded inserts (Heli-Coil) 00-0910

K
V-belt replacement 13-1402

Rocker arm replacement 05-5542

Piston removal, disassembly, check and installation 03-7004

Piston ring removal, check and installation 03-7312

Removal of corroded sections on cylinder crankcase surfaces 01-9112

Fuel duplex filter (with cut-out) disassembly, inspection/repair and installation 07-5580a

Fuel duplex filter removal, disassembly, inspection/repair and installation 07-5580

Fuel lines 07-5500

Fuel line removal, inspection/repair and installation 07-5501

20080/1 E 98-12
Group 00
General Subgroup 1000
Page 3

Fuel delivery pump(s) check 07-5700

Fuel system diagram 07-0001

Coolant pump removal and installation 20-1290


(Rail and genset versions)

Coolant pump removal and installation 20-1290a


(Marine version 8/12V 183 T..2/T..3)

Coolant pump disassembly and assembly 20-1401


(Rail and genset versions)

Coolant pump disassembly, inspection, repair and assembly 20-1401a


(Marine version 8/12V 183 T..2/T..3)

Coolant thermostat removal, installation and check 20-2470


(Rail and genset versions)

Coolant thermostat removal, installation and check 20-2470a


(Marine version 8/12V 183 T..2 with top-mounted intercooler)

Coolant thermostat removal, installation and check 20-2470b


(Marine version 8/12V 183 T..2 with compact intercooler)

Coolant thermostat removal, installation and check 20-2470c


(Marine version 8/12V 183 T..3 with compact intercooler)

Degreasing, decalcifying cooling system, leak check 20-1030

Coolant connections with external cooling 20-1000c


(Marine version 8/12V 183 T..2 with compact intercooler)

Coolant lines 20-1000


(Marine version 8/12V 183 T..2 with top-mounted intercooler)
Coolant lines 20-1000a
(Marine version 8/12V 183 T..2 with compact intercooler)

Coolant lines 20-1000b


(Marine version 8/12V 183 TE.93 with compact intercooler)

Coolant line removal, inspection, repair and installation 20-1001

Coolant distribution housing removal and installation 20-2670


(Marine version 8/12V 183 T..2 with top-mounted intercooler)

Coolant distributor housing removal and installation 20-2670a


(Marine version 8/12V 183 T..2 with compact intercooler)

Coolant distribution housing removal and installation 20-2670b


(Marine version 8/12V 183 T..3 with compact intercooler)

Crankshaft removal, storage and installation 03-4352

20080/1 E 98-12
Group 00
Subgroup 1000 General
Page 4

Crankshaft grinding 03-4465

L
Intercooler removal and installation
09-6810
(Engine version with top-mounted intercooler)

Intercooler Removal and Installation


09-6810a
(Engine version with compact intercooler)

Intercooler leak check 09-6800

Charge air Lines Removal and Installation


09-6812
(Engine version with top-mounted intercooler)

Charge air Lines Removal and Installation


09-6812a
(Engine version with compact intercooler)

Track ring replacement on flywheel 03-3203

Replace track ring on crankshaft 01-8825

Air filter removal and replacement 09-1030

M
Data sheets 00-0006

Repairing engine PTO 01-9444

Engine oil system filling 18-1601

Checking engine condition before W5 overhaul and main overhaul 00-0007

Engine running-in 00-0009

N
Camshaft removal and installation 05-6300

Camshaft bearing replacement 05-7102

O
Oil separator check, removal and installation 01-9751

20080/1 E 98-12
Group 00
General Subgroup 1000
Page 5

Oil filter element removal and installation 18-3476

Oil cooler removal and installation (hanging oil filter) 18-6840

Oil cooler disassembly and assembly (flange-mounted, standing oil filter) 18-7109a

Oil cooler disassembly and assembly (hanging oil filter) 18-7109

Oil lines 18-1600

Oil pump removal and installation 18-6023

Oil pump disassembly and assembly 18-6068

Oil spray nozzle removal and installation 18-5471

Oil pan removal and installation 01-7500

P
Conrod storage 03-6312

R
Radial-lip oil seal replacement in gear case. 03-3062

Belt drive: Installation of V-belt, adjustment specifications, tension check, installation 13-1001
of tensioning devices
(Example: Marine version with alternator and seawater pump)

Crankshaft belt pulley removal and installation 03-1300

Belt drive: Installation of V-belt, adjustment specifications, tension check, installation 13-1001a
of tensioning devices
(Example: Marine version without alternator with tension roller)

S
Emergency air shut-off flap removal and installation
09-6820
(Engine version with top-mounted intercooler)

Emergency air shut-off flap removal and installation


09-6820a
(Engine version with compact intercooler)

Vibration damper removal and installation (8V/12V 183 T..3) 03-1600a

Vibration damper and/or hub removal and installation. 03-1600

20080/1 E 98-12
Group 00
Subgroup 1000 General
Page 6

Flywheel removal and installation 03-8001

Flywheel machining 03-8042

Seawater pump removal and installation 20-1390


(Marine version 8/12V 183 T..2 with top-mounted intercooler)

Seawater pump removal and installation 20-1390a


(Marine version 8/12V 183 T..2/T..3 with compact intercooler)

Seawater pump disassembly, inspection, repair and assembly 20-1402


(Marine version 8/12V 183 T..2 with top-mounted intercooler)

Seawater pump disassembly, inspection, repair and assembly 20-1402a


(Marine version 8/12V 183 T..2/T..3 with top-mounted intercooler)

Starter removal and installation 15-7100

Starter ring gear replacement 03-8312

Gear case removal and installation 01-8205

Gear case cover removal and installation 01-8000

Timing check via valve stroke 05-6010

Keyword Index 00-1000

U
Measuring delivery pump vacuum 07-5700/1

Measure cylinder liner protrusion. 01-9314

V
Valve removal and installation 05-4102

Valve grinding 05-4202

Valve spring removal, installation and check 05-3133

Valve guide removal and installation 05-3731

Valve stroke check 05-1500

Valve stem seals assembly 05-3514

Valve seat insert machining 05-4532

20080/1 E 98-12
Group 00
General Subgroup 1000
Page 7

Valve seat insert replacement 05-3832

Valve clearance adjustment 05-1122

Compressor disassembly and assembly 13-7001

Compression pressure check 01-1205

W
Coolant heat exchanger (plate core) with "SWEP": Plate removal, disassembly, inspection, repair 20-2570b
and installation
(Marine version 8/12V 183 T..2/T..3 with compact intercooler)

Coolant heat exchanger (plate core) with "GEA": Plate removal, inspection, repair and installation 20-2570
(Marine version 8V 183 T..2 with top-mounted intercooler)

Coolant heat exchanger (plate core) with "GEA": Plate removal, inspection, repair and installation 20-2570a
(Marine version 12V 183 T..2 with top-mounted intercooler)

Important information 00-0001

Z
Cylinder head removal and installation 01-6110

Cylinder head plane machining 01-7162

Cylinder head cover removal and installation 01-5014

Cylinder liner removal, check, repair, installation and sealing 01-9324

20080/1 E 98-12
Group 00
Subgroup 1000 General
Page 8

20080/1 E 98-12
Group 01
Task Description Subgroup
Page

Engine, Crankcase, Cylinder head

20080/1 E 98-12
Group 02
Subgroup Task Description
Seite

20080/1 E 98-12
Group 01
Task Description
Page 1

01 Engine, Crankcase, Cylinder head

Contents

01-1205 Compression pressure check

01-5014 Cylinder head cover removal and installation

01-6110 Cylinder head removal and installation

01-7162 Cylinder head plane machining

01-7500 Oil pan removal and installation

01-8000 Gear case cover removal and installation

01-8205 Gear case removal and installation

01-8810 Front Housing Cover Removal and Installation, Radial-Lip Oil Seal Replacement

01-8825 Replace track ring on crankshaft

01-9112 Removal of corroded sections on cylinder crankcase surfaces

01-9304 Reconditioning collar seat in cylinder crankcase

01-9314 Measure cylinder liner protrusion.

01-9324 Cylinder liner removal, check, repair, installation and sealing

01-9444 Repairing engine PTO

01-9751 Oil separator check, removal and installation

20080/1 E 98-12
Group 01
Subgroup General
Page 2

20080/1 E 98-12
Group 01
Task Description Subgroup 1205
Page 1

01-1205 Compression Pressure Check

Preparatory operations
Valve clearance adjusted (05-1122).
Leave engine at operating temperature (70C - 95C).
Injection Nozzle with Nozzle Holder, Removal and Installation (07-6812).

Data
Compression pressure min. 17 bar
Pressure difference in individual cylinders max. 4 bar

Special tools

Checking
Fit sealing ring (1) to sealing surface in cylinder head.
Insert connector (2) and tighten thrust screw (3).

Connector 403 589 00 21 00


Pin wrench 403 589 04 07 00,

Secure compression pressure recorder with extension


to connector (2).

Check compression pressure at starting speed and with


injection pump at complete standstill. Bar the engine
until the pointer in the compression pressure recorder
no longer rises.

Compression pressure recorder 001 589 78 21 00

20080/1 E 98-12
Group 01
Subgroup 1205 General
Page 2

Note
If the compression pressure is less than 17 bar or the pressure difference between individual cylinders is greater
than 4 bar, remove the cylinder heads in order to check the valve seats and cylinder bores.

Remove compression pressure recorder and connector. Remove sealing ring from the sealing surface in the
cylinder head.

20080/1 E 98-12
Group 01
Task Description Subgroup 5014
Page 1

01-5014 Cylinder Head Cover Removal and Installation

1 Hex bolt 25 Nm
2 Spring washer
3 Cylinder head cover
4 Gasket

Removal/installation

Remove hexagon bolts (1), lift off cylinder head cover


(3) and gasket (4).

Note on installation

Clean cylinder head cover and sealing face on cylinder


head.

Replace gasket (4).

Tighten hexagon bolts (1), 25 Nm.

20080/1 E 98-12
Group 01
Subgroup 5014 Task Description
Page 2

20080/0 E 97-02
Group 01
Task Description Subgroup 6110
Page 1

01-6110 Cylinder Head, Removal and Installation

Preparatory operations:
Engine coolant drained
Intake manifold removed (14-1421).
Exhaust manifold removed (14-0068).
Cylinder head cover removed (01-5014).

1 Rocker arm screw 75 Nm


2 Rocker arms
3 Cylinder head screw Socket wrench insert 422 589 00 09 00,
Reusable up to max. shaft length of 170 mm.
4 Cylinder head screw Socket wrench insert 422 589 00 09 00,
Reusable up to max. shaft length of 146 mm.
5 Cylinder head screw Box wrench insert 403 589 02 03 00,
Reusable up to max. shaft length of 111 mm
Tightening torques: 1. Stage 10 Nm,
2. Stage 50 Nm,
3. Stage 100 Nm,
4. Stage 140 to 150 Nm
5. Stage 180 to 190 Nm,
6. Stage 90 to 100
Angle of rotation
6 Push rod
7 Cylinder head Place to the side, follow tightening diagram.
8 Centring sleeve
9 Cylinder head gasket Replace, see note.

20080/1 E 98-12
Group 01
Subgroup 6110 Task Description
Page 2

Tightening torques Nm
Injection line on pump and nozzle 25
Intake elbow 40
Cylinder head cover 25
Exhaust elbow 50
Rocker shaft support on cylinder head 75

Arrangement of injection lines


8 V 183 12 V 183

Special tools

20080/1 E 98-12
Group 01
Task Description Subgroup 6110
Page 3

Removal

Unscrew union nut for injection lines on nozzle holder.

Box wrench 000 589 07 03 00

Unscrew union nuts of the injection lines on the


injection pump. Hold pipe connection firmly in position.

Note
Do not bend injection line.

Box wrench 000 589 07 03 00


Serrated wrench 000 589 50 03 00,

Remove leak oil tubes from nozzle holder.

Unscrew rocker arm screws (1) and remove rocker


shaft support

Remove the push rods from the crankcase.

20080/1 E 98-12
Group 01
Subgroup 6110 Task Description
Page 4

Remove cylinder head screws (3 and 4).

Socket wrench insert 422 589 00 09 00

Remove cylinder head screw (5) under the nozzle


holder.

Note
If the nozzle holder is still installed, the cylinder head
screw (5) cannot be removed.

Box wrench insert 403 589 02 03 00

Remove cylinder head

Note
With the injector nozzle installed, place cylinder head to
the side. The injector nozzle projects from the bottom of
the cylinder head.

20080/1 E 98-12
Group 01
Task Description Subgroup 6110
Page 5

Installation

Clean threaded bores in crankcase.

Clean cylinder head partitions and crankcase end


surface.

Place the new cylinder head gasket over the centring


sleeves (8) onto the cylinder crankcase end surface.

Note
With replacement engines, the cylinder crankcase
partitions and bush collar seat are machined if
necessary.

For this reason, when replacing the cylinder head


gasket (with replacement engines), the piston clearance
must be measured.

If the piston clearance is less than 0.3 mm, install


series cylinder head gasket.

If the piston clearance is 0.3 mm or more , install a


cylinder head gasket which is 0.1 mm thicker.

Mount the cylinder head on cylinder head gasket.

Measure shaft length of cylinder head screws.

20080/1 E 98-12
Group 01
Subgroup 6110 Task Description
Page 6

Slightly lubricate cylinder head screws, screw in and


tighten using socket wrench insert 422 589 00 09 00 in
the specified sequence in the following stages:

1. Stage 10 Nm
2. Stage 50 Nm
3. Stage 100 Nm
4. Stage 140 to 150 Nm
5. Stage 180 to 190 Nm
6. Stage 90 to 100 angle of rotation

Socket wrench insert 422 589 00 09 00

Note
- Use a special wrench for the cylinder head screw
under
the nozzle holder.
- If a cylinder head screw was tightened too far during
assembly, remove all six cylinder head screws, check
for elongation and retighten starting at stage 1.

Box wrench insert 403 589 02 03 00

Insert push rods.

Mount rocker arm bracket, align rocker arm after valves


and push rods.
Tighten rocker arm screws (1), 75 Nm.

Set valve clearance (05-1122).

20080/1 E 98-12
Group 01
Task Description Subgroup 6110
Page 7

Install injection lines (10) install and secure to nozzle


holder and injection pump, 25 Nm.

Box wrench insert 000 589 68 03 00.

Note
Hold injection pump thrust nut firmly in position
Serrated wrench 000 589 50 03 00,
Box wrench insert 000 589 68 03 00.

Connect leak oil tube to nozzle holder.

Note
The cylinder head screws are not tightened any more.

20080/1 E 98-12
Group 01
Subgroup 6110 Task Description
Page 8

20080/1 E 98-12
Group 01
Task Description Subgroup 7162
Page 1

01-7162 Cylinder Head Reconditioning

Preparatory operations:
Cylinder head removed (01-6110).
Valves removed (05-4102).
Injection nozzle removed (07-6812).

Check cylinder head support surface for flatness and indentations with straight-edge or bridge meter.
Cylinder heads with worn support surfaces can be reconditoned with a grinding machine.
Stop reconditioning as soon as the specified surface is reached, refer here to the Tolerance and Wear Limits List.

After reconditioning the cylinder head partitions, check


Valve recession check, see Valve Seat Insert Machining (05-4532).
Check nozzle protrusion, correct with nozzle plate if necessary.
See Tolerance and Wear Limits List for limit values (01-7162).

In order to achieve the prescribed roughness depth when grinding, we recommend that you observe the following
specifications:

Required segments:
Form DA 19
Dimensions 79/70 x 21 x 80
Specification 50C 36F 5V 15
Manufacturer: Tyrolit-Schleifmittelgesellschaft
Heidemannstr. 166e
80939 Mnchen

Machine settings:
Speed n = 1400 rpm
Advance u = 920 mm/min
Cutting speed Vs = 27 m/s

The specified cutting speed is reached at a segment grinding wheel diameter of 370 mm With another diameter
(depending on machine type) the speed should be altered so that

d x 3.14 x n
vs = = 27 m/s, so that deviation is no more than 10%.
1000 x 60

Note
If the advance is smaller, or manual, there is a considerable effect on the grinding pattern and no guarantee that a
roughness depth of Rz = 0 - 16 will be achieved.

20080/1 E 98-12
Group 01
Subgroup 7162 Task Description
Page 2

20080/1 E 98-12
Group 01
Task Description Subgroup 7500
Page 1

01- 7500 Oil Pan, Removal and Installation

1 Gasket
2 Gasket Replace.
3 Oil pan
4 Washer
5 Hex bolt Corner hex bolts, 35 Nm. Remaining hexagon bolts 35 Nm. Follow tightening diagram.
6 Oil drain plug 80 Nm.
7 Gasket Replace.

20080/1 E 98-12
Group 01
Subgroup 7500 Task Description
Page 2

1 Gasket
2 Gasket Replace.
3 Oil pan
4 Hex nut Corner hex nuts 35 Nm. Remaining hexagon nuts 35 Nm. Follow tightening
diagram.
5 Washer
6 Stud
7 Oil drain plug 80 Nm.
8 Gasket Replace.

20080/1 E 98-12
Group 01
Task Description Subgroup 7500
Page 3

Removal, installation
Extract or drain off engine oil.

Notice!
Danger of scalding with hot oil.
Remove attachments and lines (corresponding to the
engine type).

Remove all hex bolts and nuts and lift off the oil pan.

Tightening-up schematic
Installation instructions
Tighten oil drain plug, 80 Nm.

Clean oil pan and engine crankcase sealing face.


Replace gasket.

Tighten corner hex bolts and nuts diagonally and


evenly, A-C and B-D, 35 Nm.

Tighten hex bolts and nuts in sequence around the


circumference, 35 Nm (starting with the last tightened
corner screw).

Tighten corner hex bolts and nuts,


35 Nm.
Fill with oil according to MTU Fluids and Lubricants
Specification

Start the engine and observe the oil-pressure indicator


at idling speed. After approx. 10 seconds the oil-
pressure gauge must indicate oil pressure. Do not
increase engine speed until oil pressure is displayed.

Switch off the engine, check the oil pan for leaks.

After approx. 5 minutes check and correct the engine oil


level.

20080/1 E 98-12
Group 01
Subgroup 7500 Task Description
Page 4

20080/1 E 98-12
Group 01
Task Description Subgroup 8000
Page 1

01- 8000 Gear Case Cover Removal and Installation

1 Gear case cover Assembly bracket 403 589 05 63 00.


2 Gasket Replace, spray gun 000 589 01 25 00.
Notes
Up to engine end No. 473 000, the gear case cover gasket can only be replaced together with
the injection pump sealing ring.
Remove grease from both corners between the cylinder crankcase partition surfaces and the
injection pump flange gasket and seal with silicone sealing agent.
Seal the partition surface between cylinder crankcase and gear case, right and left, with
silicone sealing agent.
3 Hex bolt 25 Nm, follow tightening diagram.
4 Spring washer

Special tools

20080/0 E 97-02
Group 01
Subgroup 8000 Task Description
Page 2

Sealing

Remove the attachments (depending on engine type),


lines, fuel filter, on gear case cover.

Remove gear case cover (1) and sealing ring.

Clean gear case cover and insert new sealing ring (2).

Note
Beginning engine end No. 473 001, improved gaskets
have been installed for the injection pump sealing and
gear case cover.

Up to engine end No. 473 000, the valve gear housing


gasket can only be replaced together with the injection
pump sealing ring.

Clean the sealing faces at the cylinder crankcase and


gear case.

Remove grease from both corners (arrows) between


the cylinder crankcase partition surface and the
injection pump flange gasket and seal with silicone
sealing agent.

20080/0 E 97-02
Group 01
Task Description Subgroup 8000
Page 3

Seal the partition surface between cylinder crankcase


and gear case, right and left, with silicone sealing
agent.

Spray gun 000 589 01 25 00

Mount the gear case cover and secure with assembly


bracket (arrow).

Assembly bracket 403 589 05 63 00

Tighten the hex bolts in the specified sequence to 25


Nm.

20080/0 E 97-02
Group 01
Subgroup 8000 Task Description
Page 4

20080/0 E 97-02
Group 01
Task Description Subgroup 8205
Page 1

01-8205 Gear Case, Removal and Installation

Preparatory operations:
Engine removed
Gear case cover removed (01-8000).
Flywheel removed (03-8003).

1 Gear case Spray gun 000 589 01 00, seal partition


surface between cylinder crankcase and oil
pan with silicone sealing agent.
2 Double hex bolt M12x1.5 100 Nm.
3 Hex bolt M10 60 Nm.
4 Gasket Replace, cut to size.

20080/0 E 97-02
Group 01
Subgroup 8205 Task Description
Page 2

Special tools

Removal

Remove intercooler
(depending on engine model)

Remove turbocharger (09-6030) if necessary.

Remove starter from gear case.

Release all hex bolts (9) and bolts and lower oil pan.

Note
Do not damage oil pan seal.

Unscrew double hex bolts (6) and hex bolt (7) and lift
off the gear case.

20080/0 E 97-02
Group 01
Task Description Subgroup 8205
Page 3

Installation

Clean gear case and sealing face on cylinder


crankcase.

Mount the new gasket via the guide pins on cylinder


crankcase and adjust to correct length (arrow).

Seal partition surfaces between gear case gasket and


oil pan gasket with silicone sealing agent.

Spray gun 000 589 01 25 00

Place the gear case against the crankcase and tighten


the double hex bolts (6) and hex bolt (7).
Hex screw (7) 60 Nm.
Double hex bolt (6) 100 Nm.

Note
Take care not to damage the guide pins.

20080/0 E 97-02
Group 01
Subgroup 8205 Task Description
Page 4

Mount the oil pan and tighten hex bolts and nuts.

Tighten the corner hex bolts and nuts diagonally and


evenly A-C and B-D, 35 Nm.

Tighten hex bolts and nuts in sequence around the


circumference to 35 Nm (starting from the last
tightened corner hex bolt or nut).

Tighten the corner hex bolts and nuts to 35 Nm.

Install gear case cover and seal


(01-8000).
Install starter.

Install turbocharger (09-6030).

Mount intercooler.

20080/0 E 97-02
Group 01
Task Description Subgroup 8810
Page 1

01-8810 Front Housing Cover, Removal and Installation, Radial-Lip Oil


Seal Replacement

Preparatory operation:
Vibration damper and hub, removed (03-1600).

1 Injection ring
2 Radial-lip oil seal Replace, mandrel 312 589 13 15 00.
3 Housing cover
4 Hex screws 25 Nm.
5 Spring washer
6 Gasket Replace.
7 Guide pins
8 Hex screws 35 Nm.

Special tool

20080/0 E 97-02
Group 01
Subgroup 8810 Task Description
Page 2

Removal

Remove injection ring (1).

Release oil pan hex bolts and nuts and lower the oil
pan.

Unscrew front hex bolts and nuts (8) for the oil pan and
housing cover.

Unscrew the hex bolts (4) around the circumference of


the housing cover and remove the housing cover with
radial-lip oil seal.

20080/0 E 97-02
Group 01
Task Description Subgroup 8810
Page 3

Remove the radial-lip oil seal (2) from the cover.

Note
Support the cover when removing the radial-lip oil seal.

Mandrel 312 589 13 15 00

Installation
Place the housing cover flatly on an even surface and
install radial-lip oil seal flush to the surface.

Mandrel 312 589 13 15 00

Oil track ring on the crankshaft and sealing lip on the


radial-lip oil seal.

Fit new gasket over guide pins on cylinder crankcase.

Mount housing cover with radial-lip oil seal and tighten


hex bolts (4) to 25 Nm.

Check security of radial-lip oil seal on crankshaft.

Tighten hex bolts and nuts for oil pan, 35 Nm.

Mount the injection ring.

20080/0 E 97-02
Group 01
Subgroup 8810 Task Description
Page 4

Install oil pan.

Note
Check gasket for damage.

Tighten hex bolts and nuts on oil pan.

Tighten corner hex bolts and nuts diagonally A-C


and D, 35 Nm.

Tighten hex bolts and nuts in sequence around the


circumference to 35 Nm (beginning at the last
tightened corner hex bolt or nut).

Tighten the corner hex bolts and nuts to 35 Nm.

20080/0 E 97-02
Group 01
Task Description Subgroup 8825
Page 1

01-8825 Replacing Track Ring on Crankshaft

Preparatory operation:
Front of housing cover removed (01-8810).

1 Track ring Removal tool 442 589 00 33 00,


Installation temperature approx. 200C,
Mandrel 403 589 06 15 00.

Special tools

20080/1 E 98-12
Group 01
Subgroup 8825 Task Description
Page 2

Track ring replacement

Place the removal tool via the track ring on the


crankshaft and tighten the hex bolts (arrows).

Note
Track ring with a dust collar: Press off dust collar.

Pull off track ring.

Removal tool 442 589 00 33 00,

Heat new track ring to approx. 200C.

Notice!
Risk of injury!

Mount track ring on the crankshaft.

Mandrel 403 589 06 15 00.

Coat running face for the radial-lip oil seal with engine
oil.

20080/1 E 98-12
Group 01
Task Description Subgroup 9112
Page 1

01-9112 Removal of Corroded Sections on Cylinder Crankcase


Surfaces

Preparatory operation:
Cylinder head removed (01-6110).

Machine surfaces
Note
If the corrosion is in the immediate area of the cylinder
liner collar, the piston and cylinder liners should be
removed.

Seal cylinder bores and oil channels.

Grind off the section to be machined (arrow) until metal


is smooth.

Using a degreasing agent (from repair kit), remove any


oil, grease and coolant residues from the part that has
been ground.

Note
The repair kit (part No. 402 989 50 29) consists of a
degreasing agent, base, reactor and two wooden
spatulas.

Using the appropriate wooden spatula (red for reactor,


black for base), empty both components from the cans
onto letter scales, weigh to equal amounts and mix
thoroughly.

Using a hot air blower, heat the section that has to be


sealed to a temperature of approx. 60C to 70C.

Notice!
Risk of injury!

Using a wooden spatula, apply the binding metal


compound to the section that has been cleaned.
Heat the coating of binding metal compound with a
thermal lamp and, at a temperature of approx. 60C,
allow to harden for at least 4 hours.

20080/1 E 98-12
Group 01
Subgroup 9112 Task Description
Page 2

File surface of the section to be machined (arrow) with


a finishing file.

Clean partition surface and remove covers from


cylinder bores and oil channels.

20080/1 E 98-12
Group 01
Task Description Subgroup 9304
Page 1

01-9304 Reconditioning Liner Collar Seat

Preparatory operation:
Cylinder liners removed (01-9324).

Special tools

Equipment

Liner collar seat - machining device

Cylinder crankcase reconditioning

Cover crankshaft, shaft journals, oil bores and cylinder


bores.

Clean partition surface on cylinder crankcase and


cylinder liner support.

Determine mean value of liner collar:


Measure liner collar "B" at 4 different places; maximum
margin between 4 points of measurement is 0.02 mm
per cylinder liner.

20080/1 E 98-12
Group 01
Subgroup 9304 Task Description
Page 2

Note Tombak ring thickness: 0.15 0.01


0.30 0.01
After the collar seat has been machined, different
thicknesses of Tombak rings are permitted for sealing. 0.50 0.01
Support ring thickness: 0.80 0.01
If, prior to collar seat machining, the liners were sealed 1.00 0.01
with O-ring and sealant, then Tombak rings, and also 1.50 0.01
the previously used support rings, may be used for Liner collar height
resealing. see 01-9324
Series installation of appropriate liner sealing, see 01- Permitted collar protrusion
9324 See Tolerance and Wear Limits List (01-9304)

Sample calculation of required balcony


depth:
Mean value of liner collar: 9.90
+ Tombak ring 0.50
= 10.40
- desired liner protrusion 0.09
= required balcony depth "a" 10.31

Clean turning chisel and grinding machine. Slightly oil


turning chisel and threaded insert (arrow).

20080/1 E 98-12
Group 01
Task Description Subgroup 9304
Page 3

Pull fast adjusting ring (2) in the direction of the turning


crank and insert turning chisel (1). Insert the turning
chisel so that the centring roller (arrow) comes to rest in
the middle of the side of the turning chisel support
which is marked with an "R".

Note
During initial operation of the machine, the blue
protective paint on the magnetic flange (arrows) must
be removed with diluter.
Align the machine so that the distance from the edge of
the cylinder bore to the edge of magnetic ring is uniform
around the whole circumference (pre-centring).
Plug in mains connection. Mount the machine on the
cylinder bore which has to be machined and switch on
the electromagnet (position "1").

Turn the advance nut (5) counterclockwise until the


turning chisel (centring roller) (1) is above the liner
collar (arrow). Hold turning crank (4) firmly in position.

20080/1 E 98-12
Group 01
Subgroup 9304 Task Description
Page 4

Lift up the fast adjusting ring (2) and push the turning
chisel (1) through until the centring roller lies against the
side wall (arrow) of the liner collar.

Bring the toggle switch (3) to middle position (middle


position "0"). This results in residual magnetic force in
the magnetic ring which holds the machine lightly on the
sealing surface.

Note
During any subsequent work, the advance nut (5) must
not move when the driving crank is being turned,
otherwise the depth setting of the turning chisel is
altered. If necessary, the stud screw (6) in the advance
nut (5) must be tightened.

Turn driving crank clockwise and check that the


centring roller runs along the entire circumference
and the machine does not shift (with toggle switch in
middle position). If the machine shifts, turn over the
driving crank clockwise while holding the face feed ring
(7) firmly in place. If the centring roller loses contact
with the collar edge, the driving crank must be turned
over counterclockwise (while the face feed ring (7) is
held firmly), until the roller makes contact around the
entire circumference.

Note
Centring is correct when the centring roller has even
contact all the way around and the machine remains
securely in place when in position "0".

20080/1 E 98-12
Group 01
Task Description Subgroup 9304
Page 5

After centering, press toggle switch (3) to position "1".


Lift up fast adjusting ring (2) and push the turning chisel
(1) through until the cutter lies above the section of the
bush collar seat which has to be machined (but not
against the side wall).

Simultaneously turn driving crank (4) and advance nut


(5) clockwise until the turning chisel makes contact with
the bush collar seat (arrow).

Release internal hex bolt (8) for vernier adjustment; set


vernier ring to "0" (arrow) and tighten internal hex bolt
(8).

Lift up the fast adjusting ring (2) and push the turning
chisel (1) back into the free space to a position just in
front of the liner collar seat (arrow).

Using the advance nut, set to the desired material


removal of 0.05.

Note
Graduation on vernier = 0.01 mm

20080/1 E 98-12
Group 01
Subgroup 9304 Task Description
Page 6

Turn over driving crank (4) evenly in a clockwise


direction while holding the face feed ring (7).

Note
The advance nut (5) must remain firmly in position.

Turn over driving crank (4) until the turning chisel


reaches the cylinder bore outer diameter.
The turning chisel has been ground in a such a way to
ensure that the desired diameter is not exceeded. The
front face of the chisel runs around the cylinder
bore diameter. If the driving crank is difficult to move,
release the face feed ring and turn the crank a few
times.
Note
The turning chisel should only be grounded according
to the drawing which is enclosed with the grinding
machine.

Every time the equipment is turned over, measure the


balcony depth from the plane surface of the turning
device:

A Turning device with measuring point


Secure dial gauge with extension (arrow)
(approx. 26 mm) to gauge holder.
Dial gauge 001 589 53 21 00
Dial gauge holder 343 589 00 40 00

Mount the dial gauge holder with dial gauge on the


plane surface of the turning device and mount the dial
gauge feeler to the liner collar (arrow).

Check pretension (approx. 3 - 4 mm) of the dial gauge.

Set scale of dial gauge to "0".

20080/1 E 98-12
Group 01
Task Description Subgroup 9304
Page 7

Position dial gauge feeler (arrow) on partition on


cylinder crankcase and read off balcony depth.

B Turning device without measuring point

Remove the machine approx. 0.3 mm before reaching


the determined balcony depth and measure the balcony
depth again with the dial gauge to ensure that the
desired final dimension has also been reached. The
machine must be centred after every measurement.

Dial gauge 001 589 53 21 00


Dial gauge holder 343 589 00 40 00

Lift up the fast adjusting ring (2) and push the turning
chisel (1) back into its initial position. Adjust to 0.05 mm
with advance nut and repeat turning procedure until
desired dimension has been reached.

Switch off magnet and lift off machine.

20080/1 E 98-12
Group 01
Subgroup 9304 Task Description
Page 8

Re-measure balcony depth. The difference between the


4 measuring point must be no more than 0.02 mm.

Dial gauge 001 589 53 21 00


Dial gauge holder 343 589 00 40 00

Using a flat scraper, break the upper edge of the upper


lining fit approx. 15.

a = Balcony depth

Clean cylinder crankcase.

20080/1 E 98-12
Group 01
Task Description Subgroup 9314
Page 1

01-9314 Measuring Cylinder Liner Protrusion

Preparatory operation:
Cylinder head removed (01-6110).

Special tools

Measurement

Clean cylinder liner collar.

Place measuring plate on cylinder liner.


Tighten short cylinder head screws with spacer sleeve
(1) to 50 Nm.

Measuring plate 402 589 00 21 00

Mount dial gauge holder (C) on measuring plate and


install the dial gauge (A) with extension so that the
feeler is pretensioned on the cylinder crankcase. Screw
in dial gauge.

Set dial gauge scale to "0" and measure the cylinder


liner protrusion at 4 different points.

A Dial gauge 001 589 53 21 00


B Measuring plate 402 589 00 21 00
C Dial gauge holder 343 589 00 40 00

Cylinder liner protrusion,


See Tolerance and Wear Limits List (01-9304)

20080/1 E 98-12
Group 01
Subgroup 9314 Task Description
Page 2

Note
At every measuring point set the dial gauge scale on
the partition surface to "0". Maximum difference
between 4 measuring points, per liner, is 0.02 mm.
The cylinder heads of the neighbouring cylinders must
be removed in order to measure the cylinder lining
protrusion.

20080/1 E 98-12
Group 01
Task Description Subgroup 9324
Page 1

01-9324 Cylinder Liner Removal, Inspection, Repair, Installation and


Sealing

Preparatory operation:
Piston removed (03-7004).

Special tools

Note
The seal between liner and crankcase has been
changed to a tombac sealing ring (1). The sealing ring
and sealant in the fillet (2) has been omitted. The
thickness (0.15 mm) of the tombac sealing ring is
balanced by means of liners with a thinner (0.15 mm)
collar.

A Cylinder liner protrusion 0.03 to 0.09 mm


1 Tombac sealing ring
2 Filet (stays free)
3 O-ring

Series production
Engine As of engine end No.
8 V 183 535119
12 V 183 011295

Note on liner collar thickness:


- Cylinder liners with thin collars from 9.90 to 9.92 mm
must be sealed with a tombac sealing ring. The O-ring
in the filet and sealing agent in the lining collar have
been omitted.
- Cylinder liners with thick collars from 10.05 to 10.07
mm must continue to be sealed at the collar with O-
rings and sealing agent.

20080/1 E 98-12
Group 01
Subgroup 9324 Task Description
Page 2

Removal

Mark the cylinder liners to the crankcase (arrow).

Note:
Before operating the liner removal tool, check the
spacer sleeve (4) and, if necessary, shorten to a level
of 175 mm.

Insert stud screws (5) in opposite threaded bores for


cylinder head screws.

Extractor and installation tool 403 589 00 33 00

Insert liner extractor in cylinder liner.

Separate the gripping jaws of the extractor by turning


until they reach the inner diameter of the cylinder liner
on the spindle.

Note:
Apply the gripping jaws of the extractor only lightly.

Mount counter support on studs and tighten.

Pull out cylinder liners by turning the hexagon nut


(arrow). Hold spindle in place when doing this.

Turn at the spindle until the gripping jaws of the


extractor come together. Unscrew counter screws and
lift off with extractor.

Extractor and installation tool 403 589 00 33 00

Remove the cylinder liner from the crankcase.

Remove the O-rings from the crankcase and from the


cylinder line.

Clean cylinder liners, bore, liner collar, liner support and


grooves for O-rings.

Note:
Check repair stage or dimensional accuracy before
installing cylinder liner.
See Tolerance and Wear Limits List (01-9324).

20080/1 E 98-12
Group 01
Task Description Subgroup 9324
Page 3

Inspection and repair


Check liner for cracks and cavitation
Clean liner and test with magnetic particle inspection
and fluorescent magnetic-powder penetration methods
for cracks (3).
Replace liner if cracks are found.
Check outer wall for cavitiation (2) and corrosion,
replace liner if necessary.
If light cavitation and corrosion is found, rotate liner by
90 before re-installing.
Inspect sealing and mating surfaces of collar (1) for
damage and wear; replace liner if necessary.
Replace sealing rings and tombac ring

Inspect liner surface.


Check surface for polished areas, scoring and
corrosion, replace liner if necessary.
Surface should show no signs of heat discolouration.
Check the return stroke position of the first piston ring
for wear, replace liner if necessary.

20080/1 E 98-12
Group 01
Subgroup 9324 Task Description
Page 4

If liners are to be re-used, the hone pattern over the


total surface must be more or less quite recognizable.
Individual light scorings when extracting are not critical.
No signs of wear should be felt at the return stroke
position of the first piston ring.

Measure cylinder liner bore.


Adjust the internal bore guage (1) and dial gauge with
either micrometer or gauge ring (2) to the basic liner
bore dimension as given in the Tolerances and Wear
Limits List
01-9324.

Measure liner bore with gauge.

Refer to the Tolerance and Wear Limits List for


measuring levels and limit values (01-9324).

If limit values are exceeded, replace liner.

20080/1 E 98-12
Group 01
Task Description Subgroup 9324
Page 5

Installation and Sealing


If new liners are to be installed, they should be assigned
together with the pistons according to the tolerance-
group coding.
The tolerance-group coding (arrow) is given on the top
liner surface and the piston crown.
Code:
Cylinder liner Piston
(Code letter) (Letter group)
"B" "BC"

"C" "BCD"

"D" "CDE"

"E" "DE"

Note
Seal the liner collar as appropriate with a tombac
sealing ring or with sealing agent.

A Sealing with sealing agent

Insert new, dry O-rings for the lower cylinder lining


sealing in the cylinder crankcase.

Insert new sealing rings (1, 2) for the upper cylinder


lining sealing in the cleaned recesses of the lining.

20080/1 E 98-12
Group 01
Subgroup 9324 Task Description
Page 6

Coat sealing agent (bead of approx. 2-3 mm dia) in


front of the sealing ring on lining collar.

Note
Work with the sealing agent in viscous form only.

Spray gun 000 589 01 25 00

Apply thin coat of ATE assembly grease to exterior of


cylinder liner at lower fit surface and chamfer.

Insert cylinder liner into cylinder crankcase while it is


turned at 90 (arrows) to the old installation position.

Insert stud screws for the extractor and installation tool


in the threaded bores for the cylinder head screws
opposite.

Place the pressure plate (arrow) on the cylinder liner.

Place the extractor (spindle with counter support) on


stud screws and tighten.

Extractor and installation tool 403 589 00 33 00


Hold the cylinder liner by turning the
spindle at 100 Nm for 5 minutes under pretension.

20080/1 E 98-12
Group 01
Task Description Subgroup 9324
Page 7

Lift the installation tool off the cylinder crankcase.

Using a plastic spatula, carefully remove the sealing


agent (arrow) that is forced out between the crankcase
and cylinder liner when the cylinder liner is being
pretensioned.

Measure cylinder liner protrusion (01-9314).

Using a bore gauge, measure inside diameter of the


liner in the area of the lower fit at three points (each
time offset by 60).

Note
If the out-of-round measured is greater than 0.04 mm, a
security check of the lower sealing ring must be carried
out..

Dial gauge 001 589 53 21 00

To prevent the cylinder liners from loosening during


piston installation, hold them with two sleeves (arrows)
made at the customer, (approx. 30 Nm pretension).

Note
If the pistons being reinstalled during repair have
already been used, always replace the second piston
ring.

20080/1 E 98-12
Group 01
Subgroup 9324 Task Description
Page 8

B Sealing with a tombac ring


Insert new, dry O-rings for the lower cylinder lining
sealing in the cylinder crankcase.

Place the tombac ring (1) via the cylinder liner on the
cylinder liner collar.

Insert new O-ring (3) for the upper cylinder liner sealing
in the cleaned recesses of the lining.

Note
The cylinder liner fillet (2) remains free.

Apply thin coat of ATE assembly grease to exterior of


cylinder liner at lower fit surface and chamfer.

Insert cylinder liner into cylinder crankcase while it is


turned at 90 (arrows) to the old installation position.

20080/1 E 98-12
Group 01
Task Description Subgroup 9324
Page 9

Insert stud screws for the extractor and installation tool


in the threaded bores for the cylinder head screws
opposite.

Place the pressure plate (arrow) on the cylinder liner.

Place the extractor (spindle with counter support) on


stud screws and tighten.

Removal and installation tool 403 589 00 33 00

Press in the cylinder liner by turning the spindle.

Lift the installation tool off the cylinder crankcase.

Measure cylinder liner protrusion (01-9314).

Using a bore gauge, measure inside diameter of the


liner in the area of the lower fit at three points (each
time offset by 60).
See Tolerance and Wear Limits List for limit values 01-
9324.
Notes
>If the out-of-round measured is greater than 0.04 mm,
a security check of the lower sealing ring must be
carried out.
- If the pistons being reinstalled during repair have
already been used, always replace the second piston
ring.

Dial gauge 001 589 53 21 00

20080/1 E 98-12
Group 01
Subgroup 9324 Task Description
Page 10

20080/1 E 98-12
Group 01
Task Description Subgroup 9444
Page 1

01- 9444 Repairing Engine PTO

Preparatory operations:
Universal shaft removed.
Gear case cover removed (01-8000).

1 Gear case
2 O-Ring Replace
3 Housing bush Counter support 000 589 35 33 00,
Internal extractor 000 589 68 33 00.
Oil.
4 Roller bearing Extractor 001 589 19 33 00.
5 Shaft Extractor 354 589 00 33 00.
6 Spacer sleeve
7 Angular-contact ball bearing Oil.
8 Roller bearing Oil.
9 Track ring
10 Shim
11 O-Ring Replace.
12 Main bearing cap
13 Radial-lip oil seal Replace.
14 Spring washer
15 Hex bolt 25 Nm
16 Cover plate
17 Flange Retaining wrench 460 689 01 31 00.
18 Hex nut Tighten to 300 Nm.
19 Gear
20 Securing nut Tighten to 300 Nm.
Box wrench 402 589 03 03 00.

20080/1 E 98-12
Group 01
Subgroup 9444 Task Description
Page 2

Special tools

Disassembly
Unscrew securing nut (20) for drive gear (19).

20080/1 E 98-12
Group 01
Task Description Subgroup 9444
Page 3

Unscrew securing nut (18).

Lift off drive flange (17) and cover plate (16).

Unscrew hex bolts (15), lift off bearing cover (12).

Remove O-ring (11) and shim (10).

Secure extractor with securing nut (18).

Extractor 354 589 00 33 00

Pull out shaft (5) with bearings.

Remove drive gear from the gear case.

Remove spacer sleeve from housing bush.

Pull housing bush (3) out of gear case.


Internal extractor 000 589 68 33 00
Counter support 000 589 35 33 00
Remove O-ring from housing bush.

20080/1 E 98-12
Group 01
Subgroup 9444 Task Description
Page 4

Push both bearings (7, 8) and track ring (9) on the


driving end from the shaft.

Pull the inner bearing race (4a) for the driving end roller
bearing from the shaft.

Extractor 001 589 19 33 00

Press the roller bearing (4) on the driving end side from
the housing bush.

20080/1 E 98-12
Group 01
Task Description Subgroup 9444
Page 5

Assembly

Mount the O-ring (2) above the housing bush (3).

Drive rear (wide) roller bearing (4) into housing bush


(3). Oil bearing.

Place the housing bush (3) in the gear case with the
machined surface facing the gear case cover.

20080/1 E 98-12
Group 01
Subgroup 9444 Task Description
Page 6

Heat gear case with a hot air blower and drive the
housing bush (3) into the gear case.

Heat the inner race for rear bearing (4) on a heating


plate to approx. 80C and - on the drive side - mount on
the shaft (5).

Notice!
Risk of injury!

Heat the first half of the divided angular-contact ball


bearing inner race to approx. 80C and - on the PTO
side - mount on the shaft (5).

Notice!
Risk of injury!
Mount the angular-contact ball bearing (7) on the inner
bearing race.
Heat the second half of the divided angular-contact ball
bearing inner race to approx. 80 and mount on the
shaft (5).

Notice!
Risk of injury!
Ensure bearing (7) is firmly seated.

20080/1 E 98-12
Group 01
Task Description Subgroup 9444
Page 7

Heat the inner race for roller bearing - PTO side - to


approx. 80C and mount on the shaft (5).

Notice!
Risk of injury!
Mount the roller bearing (8) on the inner bearing race.

Heat the track ring (9) for the shaft seal to approx. 80C
and mount on the shaft (5).

Notice!
Risk of injury!
Oil both bearings.

Insert spacer sleeve in the housing bush.

Note
Take care not to damage stop catch.

Insert shaft with bearing in the housing bush.

Note
When inserting the shaft, mount the drive gear over the
taper spline and insert in the new securing nuts over the
shaft thread.

20080/1 E 98-12
Group 01
Subgroup 9444 Task Description
Page 8

Mount the shaft seal (13) and sealing ring (11) in the
bearing flange (12). Mount the shim (10).

Mount bearing cover (12) and tighten hex bolts (15)


diagonally to 10 Nm.

Using a feeler gauge, determine the distance between


bearing cover and housing bush.

Specified value = 0.10 to 0.20 mm.

Note
If the distance is big, install thin shims; if the distance is
small, install thicker shims.

Secure bearing cover with hex bolts (15) to 25 Nm.

Push cover plate (16) onto the shaft.

20080/1 E 98-12
Group 01
Task Description Subgroup 9444
Page 9

Mount PTO flange (17).

Tighten new securing nuts to 300 Nm and secure.


Retaining wrench 460 589 01 31 00
Box wrench 402 589 03 03 00.
Note
Hold PTO flange firmly in position.

Tighten securing nut (20) for drive gear (19) to 300 Nm.

Note
Hold PTO flange firmly in position.

Secure (arrow) securing nut (2).

20080/1 E 98-12
Group 01
Subgroup 9444 Task Description
Page 10

20080/1 E 98-12
Group 01
Task Description Subgroup 9751
Page 1

01-9751 Oil Separator, Checking, Removal and Installation

Preparatory operations:
Oil level checked and corrected.
Engine at operating temperature.

1 Clamp 8 Nm.
2 O-Ring Replace.
3 Oil separator Control range: + 10 to - 100 mm water column
4 Clamp
5 Tube

Tool for customer production

Water-pressure gauge
Secure U-shaped, plastic tube (7) (inside diameter 20
mm, length approx. 2000 mm) to a board.

Draw up a scale (in mm) in accordance with the


drawing.

6 Securing clamp
7 Plastic tube
8 Dipstick guide tube

20080/1 E 98-12
Group 01
Subgroup 9751 Task Description
Page 2

Checking

Connect the corresponding long end of the water-


pressure gauge with the oil dipstick guide pipe and fill
the water-pressure gauge up to the "zero mark" with
water.

Start the engine and observe the water level in pressure


gauge.

There is overpressure in the cylinder crankcase if the


water column at the free end of the tube (left) is higher
than at the connected end (right) - ( maximum + 10 mm
water column).

The correct level is indicated as the difference between


the two water surfaces.

20080/1 E 98-12
Group 01
Task Description Subgroup 9751
Page 3

There is a vacuum in the cylinder crankcase if the


water column at the connected end of the tube (right) is
higher than at the free end (left) - (maximum - 100 mm
water column).

The correct level is indicated as the difference between


the two water surfaces.
Note
The pressure in the crankcase over the entire engine
speed range must lie between
+10 mm water column (overpressure) and -100 mm
water column (vacuum).
If the limit values are exceeded, this could have the
following causes:

If pressure is too low: Remedy:


Clear vent opening.
Vent opening to diaphragm obstructed
Replace vent hose.
Diaphragm does not close because spring force is too Replace oil separator.
high.
Spring is not properly secured or diaphragm is torn

If pressure is too high: Remedy:


Leaks at connection points of the oil separator to the Check that connection points are correctly seated.
intake pipe.
Intake depression is insufficient due to leakage in intake Check air filter and intake ducts to the exhaust
ducts. turbocharger (danger of damage due to dust).
Filter section of oil separator contaminated. Clean oil separator, replace if necessary.

20080/1 E 98-12
Group 01
Subgroup 9751 Task Description
Page 4

Removal, installation

Disconnect water-pressure gauge tube at the oil


dipstick guide pipe, insert oil dipstick.

Remove charge air manifold (09-8621).

Release clamp (4) and pull off tube (5) at oil separator
(3).

Release clamp (1) and lift oil separator (3) off cylinder
crankcase.

Note on installation

Replace O-ring at oil separator.

Tighten clamp (1), 8 Nm.

Install in reverse order.

Note
Take care not to damage oil separator during
maintenance and repair work. Even minor damage can
lead to oil separator failure. Always replace a damaged
oil separator. If the engine is continually leaky or there
is engine oil in the intake system, check oil separator.

20080/1 E 98-12
Group 03
Task Description Subgroup
Page

Running Gear

20080/1 E 98-12
Group 03
Subgroup Task Description
Seite

20080/1 E 98-12
Group 03
Task Description Subgroup
Page 1

03 Running gear

Contents

03-1300 Crankshaft belt pulley removal and installation

03-1600 Vibration Damper and Hub, Removal and Installation

03-1600a Vibration Damper , Removal and Installation (8/12V 183 T..3)

03-3062 Gear Case Radial-Lip Oil Seal Replacement

03-3203 Track ring on Flywheel, Replacement

03-4352 Crankshaft removal, storage, installation

03-4465 Crankshaft grinding

03-6312 Conrod Storage

03-7004 Piston Removal, Disassembly, Inspection and Installation

03-7312 Piston Ring Removal, Inspection and Installation

03-8001 Flywheel Removal and Installation

03-8042 Flywheel Machining

03-8312 Starter Ring Gear Replacement

03-8400 Guide Bearing in Flywheel, Replacement

20080/1 E 98-12
Group 03
Subgroup Task Description
Seite 2

20080/1 E 98-12
Group 03
Task Description Subgroup 1300
Page 1

03-1300 Crankshaft belt pulley removal and installation

1 Belt pulley
2 Belt pulley
3 Spring washer
4 Hex bolt Tightening torque: 21 + 2 Nm. Lubrication: Engine oil
5 Set of V-belts

Removal and installation

See diagram.

20080/0 E 98-04
Group 03
Subgroup 1300 Task Description
Page 2

20080/0 E 98-04
Group 03
Task Description Subgroup 1600
Page 1

03-1600 Vibration Damper and Hub, Removal and Installation

1 Hex nut 25 Nm.


2 Stud
3 Hex bolt 25 Nm.
4 Spring washer
5 Intermediate element
6 Belt pulley
7 Hex screws 200 Nm.
8 Vibration damper (one-part)
9 Hub
10 Injection ring
11 Crankshaft
12 Hexagon socket screw 40 Nm.
13 Vibration damper (two-part)

20080/0 E 97-02
Group 03
Subgroup 1600 Task Description
Page 2

Removal, installation

Remove drive belt.

Remove fan with intermediate element and belt pulley.*

* Only for engines with fan cooler.

Unscrew hex bolts (7) and remove vibration damper.


Installation instructions
Tighten hex bolts (7) to 200 Nm.
Install in reverse order.

20080/0 E 97-02
Group 03
Task Description Subgroup 1600a
Page 1

03-1600a Vibration Damper, Removal and Installation(8 / 12V183...3)

1 Vibration damper
2 Cover plate
3 Hex bolt 200 Nm.
4 Timing pointer

20080/1 E 98-12
Group 03
Subgroup 1600a Task Description
Page 2

Removal and installation

Remove drive belt.

Unscrew hex bolts (7) and remove vibration damper.

Installation instructions:
The position of the vibration damper to the crankshaft
should be marked during initial assembly as shown in
the drawing 506 005 00 01.
When the vibration damper is re-installed after
disassembly, ensure that the markings are aligned.
If a marked part has to be replaced, a new mark must
be made using the start-of-delivery TDC setting on the
flywheel. Start-of-delivery settings are to be taken from
the start-of-delivery plate on the cylinder-head cover.
Before installing the marked vibration damper,
determine the TDC of cylinder 1 using the flywheel
marking. The securing screws must not be tightened
until the timing pointer is aligned with the mark on the
damper.
Notice!
Cylinder designation according to DIN 73021 for motor
vehicle engines.

Tighten hex bolts (7) to 200 Nm.

20080/0 E 98-12
Group 03
Task Description Subgroup 3062
Page 1

03-3062 Gear Case Radial-Lip Oil Seal Replacement

Preparatory operation:
Flywheel removed (03-8001).

1 Radial-lip oil seal Replace. Mandrel 403 589 04 15 00.

Special tool

20080/0 E 97-02
Group 03
Subgroup 3062 Task Description
Page 2

Replacement

Using suitable tool, remove radial-lip oil seal (1) from


gear case.

Note
Do not damage gear case and crankshaft.

Fit spacer sleeve (arrow) of mandrel 403 589 04 15 00


on crankshaft.

Mandrel 403 589 04 15 00

Fit radial-lip oil seal on mandrel and install into gear


case.

Lubricate counter-track ring on flywheel.

Mandrel 403 589 04 15 00

20080/0 E 97-02
Group 03
Task Description Subgroup 3203
Page 1

03-3203 Track Ring on Flywheel, Replacement

Preparatory operation:
Flywheel removed (03-8001).

1 Track ring Thrust pad 312 589 00 15 00.


2 Flywheel Mandrel 403 589 03 15 00.
Puller 000 589 45 33 00.

Special tools

20080/1 E 98-12
Group 03
Subgroup 3203 Task Description
Page 2

Replacement
Remove track ring (1) with puller and thrust pad (3)
from flywheel.
Removal tool 000 589 45 33 00.
Thrust pad 312 589 00 15 00.

Fit new track ring with rounded edge in direction of


mandrel and heat to max. 200C.

Notice!
Risk of injury!

Mount track ring on flywheel.

20080/1 E 98-12
Group 03
Task Description Subgroup 4352
Page 1

03- 4352 Crankshaft Removal, Storage and Installation

Preparatory operations:
Gear case removed (01-8205).
Front housing cover removed (01-8810).
Vibration damper removed (03-1600).
Piston removed (03-7004).
Flywheel removed (03-8001).
Oil filter carrier removed.

1 Crankshaft bearing cap screws (centre) Re-usable until shaft length max. 156 mm,
Tightening torques 1st Stage 100 Nm,
2. stage 200 Nm,
3. stage 300 to 330 Nm,
4th stage 90 to 100
Angle of rotation
2 Crankshaft bearing cap screws (lateral) 80 Nm.
2a Main bearing cap
3 Track ring
4 Crankshaft Hardness tester 000 589 20 21 00,
Dial gauge 001 589 53 21 00,
Dial gauge holder 363 589 02 21 00,
Guide mandrel 403 589 02 63 00.
5 Dowel pin
6 Crankshaft gear
7 Main bearing shells, up to and including 280 kW Dial gauge 000 589 20 21 00.
engine
8 Main bearing shells, engine as of 320 kW Dial gauge 000 589 20 21 00.
9 Alignment bearing shells Dial gauge 000 589 20 21 00
10 Hex bolt 25 Nm.
11 Housing cover
12 Gasket Replace.

20080/1 E 98-12
Group 03
Subgroup 4352 Task Description
Page 2

Special tools

Removal

Withdraw hex bolts (9) and remove front housing cover


(10) and gasket.

Mark crankshaft bearing cap and crankshaft bearing in


sequence with respect to one another.

Remove all screws (1 and 2) and remove crankshaft


bearing cap.

20080/1 E 98-12
Group 03
Task Description Subgroup 4352
Page 3

Insert a guide mandrel (arrows) at both the top and


bottom crankshaft ends and remove crankshaft.

Guide mandrel 403 589 02 63 00.

Remove bearing shell halves from crankcase and


allocate to respective crankshaft bearing caps.

Check components for wear and damage.

Note
The bearing shells for the crankshaft are supplied ex
works ready for installation. No reconditioning must be
carried out. The alignment bearing is supplied oversized
for repair purposes. The crankshaft must be reground
according to bearing shell width. Maintain the
crankshaft axial clearance.
Refer to the Tolerance and Wear Limits List for values;
03-4352 and 03-4465.

Storage

Clean bearings in crankcase and bearing caps with


chamois leather only.

Insert bearing shell halves in correct sequence into


crankcase and crankshaft bearing cap and lubricate.

Note
Locking lugs (arrow) of bearing shells must sit in
grooves of main bores and of crankshaft bearing caps.
Oil bores in bearing shells and in crankcase must be
aligned.

Install marked crankshaft bearing cap with bearing


shells into crankcase.

20080/1 E 98-12
Group 03
Subgroup 4352 Task Description
Page 4

Measure shaft length of centre crankshaft bearing cap


screws (1) (max. reusability up to 156 mm).

Tighten centre crankshaft bearing cap screws (1) in the


following stages:
1. Stage 100 Nm
2. Stage 200 Nm
3. Stage 300 to 330 Nm
4. Stage 90 to 100 angle of rotation
Tighten lateral crankshaft bearing cap screws (2), 80
Nm.

Set bore gauge 100 - 160 mm dia. and dial gauge with
micrometer 100 - 125 mm to zero dimension of
crankshaft bearing pin.

Dial gauge 001 589 53 21 00

20080/1 E 98-12
Group 03
Task Description Subgroup 4352
Page 5

Measure crankshaft bearing bore with bore gauge at


three points (vertical and at a distance of 30 above and
below the partition).

Dial gauge 001 589 53 21 00

Note
The values given in the Tolerance and Wear Limits List
(03-4352) must be kept to.

Remove crankshaft bearing cap again.

Storage and installation


Note
Engine up to and including 280 kW
Bearing shell halves with dark reverse side must be
installed on cap side because they are specially treated
for high pressures.
Engine as of 320 kW:
Bearing shell halves (8) with collars must be installed
on cap side.

From the oil pump side, blow out oil ducts in crankcase
with compressed air.

Clean crankshaft, bearings and bearing seats with


chamois leather. Clean oil ducts of crankshaft with wire
brush and blow out with compressed air.

20080/1 E 98-12
Group 03
Subgroup 4352 Task Description
Page 6

Check hardness of crankshaft with hardness tester.

Note
Conversion table is supplied with hardness tester.

Hardness tester 000 589 20 21 00

The values given in the Tolerance and Wear Limits List


(03-4352) must be kept to.

Insert bearing shell halves in correct sequence into


crankcase and crankshaft bearing cap and lubricate.

Note
Locking lugs (arrow) of bearing shells must sit in
grooves of main bores and crankshaft bearing cap. Oil
bores in bearing shells and in crankcase must be
aligned.

Insert crankshaft with guide mandrels (arrows) into


bearing shells in crankcase.

Remove guide mandrels.

Guide mandrel 403 589 02 63 00.

20080/1 E 98-12
Group 03
Task Description Subgroup 4352
Page 7

Markings (arrows) on camshaft gear and crankshaft


gear must be aligned.

Install marked crankshaft bearing cap (arrow) with


bearing shells into crankcase.

Measure shaft lengths of centre crankshaft bearing cap


screws (1) (max. reusability up to 156 mm) and tighten
in the following stages:
1. Stage 100 Nm
2. Stage 200 Nm
3. Stage 300 to 330 Nm
4. Stage 90 to 100 angle of rotation
Tighten lateral crankshaft bearing cap screws (2), 80
Nm.

20080/1 E 98-12
Group 03
Subgroup 4352 Task Description
Page 8

Install dial gauge holder with dial gauge on crankcase


and check axial clearance (0.150 to 0.322 mm) of
crankshaft.
Dial gauge 001 589 53 21 00
Dial gauge holder 363 589 02 21 00

Fit new gasket over guide pins on cylinder crankcase.

Install housing cover (11) and tighten hex bolts (10), 25


Nm.

20080/1 E 98-12
Group 03
Task Description Subgroup 4465
Page 1

03- 4465 Crankshaft Grinding

Preparatory operation:
Crankshaft removed (03-4352).

Tightening torques
1. Stage 140 to 160 Nm
Counterweight on crankshaft
2. Stage 90 to 100 angle of rotation
Shaft length of counterweight screws Up to engine end No. 517 Max. 84.5 mm
490 Max. 75.5 mm
As of engine end No. 517
491

Equipment

Crankshaft grinding machine

Special tools

Crankshaft grinding

Mark counterweights in relation to position on


crankshaft and remove

Remove crankshaft gear.

Clean crankshaft and check for alignment, roundness


of journals, hardness and check bearings for cracks.
Replace cracked or deformed crankshaft.

20080/1 E 98-12
Group 03
Subgroup 4465 Task Description
Page 2

Check crankshaft hardness:


Refer to the Tolerance and Wear Limits List 03-4352.

Hardness tester 000 589 20 21 00

Centre crankshaft prior to grinding (support crankshaft


at 1st and last main bearing journal).

When machining, regrind all bearings to the next


dimension.

Notes
Keep to values given in the Tolerance and Wear Limits
List 03-4465.
Machine all main bearing journals and conrod bearing
journals to the same dimension. The width of the
alignment bearing simultaneously changes with the
dimensions which requires the mating faces of the
crankcase to be machined. The dimensions of
connecting rod and main bearing journals can vary.

Observe transition radii at main bearing and conrod


bearing journals
.

Lap surface after grinding.

Clean oil ducts of crankshaft.

Measure shaft length of hexagonal socket-head screws


for counterweights.
Maximum reusability:
Up to engine end No. 517 490 = 84.5 mm
As of engine end No. 517 491 = 75.5 mm

20080/1 E 98-12
Group 03
Task Description Subgroup 4465
Page 3

Note
Install counterweights according to markings
Fit counterweight (1) on crankshaft and tighten slightly
with hexagonal socket-head screw (2).

Note
Do not fully tighten hexagonal socket-head screw (2).

Position V-block (3) on respective main bearing cap so


that lug (arrow) is between counterweight (1) and main
bearing cap.

V-block 442 589 07 6300

Insert centring screw (4) into free bore until it is securely


positioned.
Centering screw 442 589 06 63 00
V-block 442 589 07 63 00
Tighten hex nut (5) to centre counterweight.

Tighten hexagonal socket-head screw (2), 50 Nm.

Remove centring screw (4) and tighten second


hexagonal socket-head screw, 50 Nm.

Remove V-block (3).

Note
By tightening hexagonal socket-head screws, the
counterweight on crankshaft is secured in its centred
position.

Tighten hexagonal socket-head screws for


counterweight in following stages:
1. Stage 140 to 160 Nm,
2. Stage 90 to 100 angle of rotation
Install remaining counterweights in same sequence as
described.

20080/1 E 98-12
Group 03
Subgroup 4465 Task Description
Page 4

20080/1 E 98-12
Group 03
Task Description Subgroup 6312
Page 1

03-6312 Conrod Storage

Preparatory operation:
Piston removed (03-7004).

1 Conrod bearing shell


2 Conrod with cap
3 Conrod bushing
4 Conrod bolt Re-usable until shaft length max. 68.5 mm,
Tightening torques: 1. Stage 100 Nm,
2. Stage 90 to 100 angle of rotation

20080/1 E 98-12
Group 03
Subgroup 6312 Task Description
Page 2

Special tool

Equipment

Bore gauge 50 - 100 mm

Micrometer 75 - 100 mm

Storage

Note:
Conrod bearing shells are ready for installation when
supplied. No reconditioning can be carried out. Bearing
shell halves with dark reverse side must be installed on
the rod side because they are specially treated for high
pressures.

Clean bearings of conrod and bearing cap with chamois


leather only.

Insert bearing shell halves in correct sequence into


conrods and bearing cap. Position securing lug (arrow)
of bearing shell (1) into groove of main bore.

Fit bearing caps with appropriate bearing shells on


conrods.

20080/1 E 98-12
Group 03
Task Description Subgroup 6312
Page 3

Tighten conrod bearing screws (4) in the following


stages:
1. Stage 100 Nm
2. Stage 90 to 100 angle of rotation
Note
Secure conrod just below conrod bearing to prevent
conrod from twisting.

Set bore gauge 50 - 100 mm dia. and dial gauge with


micrometer 75 - 100 mm to zero dimension of conrod
bearing bore.

Dial gauge 001 589 53 21 00

Measure conrod bearing bore with bore gauge at three


points (vertical and at a distance of 30 above and
below the partition).

Dial gauge 001 589 53 21 00

Note
The values given in the Tolerance and Wear Limits List
(03-6312) must be kept to.

Remove bearing cap.

20080/1 E 98-12
Group 03
Subgroup 6312 Task Description
Page 4

20080/1 E 98-12
Group 03
Task Description Subgroup 7004
Page 1

03-7004 Piston Removal, Disassembly, Inspection and Installation

Preparatory operations:
Cylinder head removed (01-6110).
Oil pump removed (18-6023).

1 Snap rings
2 Piston pin
3 Piston Band clamp 000 589 38 31 00, arrow to engine centre.
4 Conrod bearing shells
5 Conrod with cap
6 Conrod bolts Re-usable until shaft length max. 68.5 mm,
Tightening torques: 1. Stage 100 Nm,
2. Stage 90 to 100 angle of rotation

20080/1 E 98-12
Group 03
Subgroup 7004 Task Description
Page 2

Special tools

Removal

Use a scraper to carefully remove the combustion


deposits from above the top land zone in the liner. Do
not damage the liner surface.

Note
This is to avoid damage to the piston rings when
removing pistons.

Check code markings of conrod bearing cap and


conrod.
Mark parts if necessary.

Note
Bearing caps and conrods form individual units and are
not to be interchanged with others.

20080/1 E 98-12
Group 03
Task Description Subgroup 7004
Page 3

Remove conrod bearing screws (6) with socket wrench.


Remove bearing cap with bearing shell from conrod.
Remove bearing shell from bearing cap and protect
from damage.
Notes
When removing piston do not damage or warp oil spray
nozzle.
In event of damage, remove oil spray nozzle, check and
install (18-5471).
Press conrod with piston and bearing shell out of
cylinder liner and remove.

Disassembly
Remove conrod from piston.
Check code markings of conrod, piston and piston pin,
remark if necessary.
Clamp conrod with piston.

Caution!
Snap ring pretension. Risk of injury!
Use correct circlip pliers.
Wear protective goggles/safety mask.

Remove snap ring (1) for piston pin.

Press out piston pin (2) with dowel (arrow).


Note
Never use a sharp-edged object to press out the pin.
Remove conrod from piston.

Remove piston rings


See Group/Subgroup 03-7312.

20080/1 E 98-12
Group 03
Subgroup 7004 Task Description
Page 4

Inspection and repair


Piston
Note
The graphite layer on the piston skirt must not be mechanically removed or treated with strong cleaners!

Caution!
When using chemical substances, follow the manufacturer's instructions for use, safety instructions and
waste disposal specifications.

Treat carbon deposits on piston crown and piston ring grooves with a carbon deposit remover.
Remove remaining deposits from crown and grooves by brushing.
Note
Only use a soft (e.g. Perlon) brush to avoid damage to piston surface.

Caution!
Compressed air is air which has been compressed under pressure. Risk of injury!
Always wear protective goggles when blowing out or drying out with compressed air.
The pressure must not exceed 3 bar.

After cleaning, blow out the oil chamber and oil bores with compressed air: ensure high level of cleanliness.

Check piston for cracks using the surface crack-testing method with fluorescent penetrant dye, replace piston if
necessary.
Inspect piston ring grooves carefully for cracks.

Checking piston skirt and top land


Check piston skirt surface condition for wear, pitting
and scoring.
The piston skirt micro-profile must cover most of the
surface and the machining grooves must be easily
identifiable.
Note
The maching grooves are intentional and fill with oil to
aid better lubrication.

20080/1 E 98-12
Group 03
Task Description Subgroup 7004
Page 5

Replace complete piston if signs of contact erosion are


present at the piston edge.
Remove scoring or scuffing on the top land if local and
not extending as far as the first annular groove.
Replace piston if damage is more extensive, i.e. if
scoring or pitting extends as far as the first annular
groove (arrow).
In the event of extensive polishing wear on piston skirt
(appears dull rather than shiny) and concentrated
scoring, replace piston.
Replace pistons exhibiting even minor, localized
scuffing on piston skirt.

Measure piston skirt diameter


Use an outside micrometer to measure diameter on
points free of graphite.
If measurements are below limit values as per
Tolerances and Wear Limits List, replace piston.

Inspecting piston ring grooves


Check groove width with final measurements.
Alternatively, a new piston ring (2) can be fitted and
axial clearance checked with feeler gauge (1).
If the limit values as per Tolerance and Wear Limits List
are exceeded, or the measurements are below limits for
the oil control-ring groove, replace piston.

20080/1 E 98-12
Group 03
Subgroup 7004 Task Description
Page 6

Inspecting piston pin bore


Adjust bore gauge and measure pin bore.
If measurements exceed the limits as per Tolerances
and Wear Limits List, 03-7004, replace piston.
Check bronze bush surface for wear and scoring,
replace piston if necessary.

Inspecting piston pin


Using the magnetic crack-testing method with
fluorescent penetrant powder, check piston pin for
cracks; if cracks are found, replace piston pin.
Remove minor traces of wear and scoring by polishing.
Replace pins exhibiting scuffing, indentations and
severe wear.
Use an outside micrometer to measure diameter and
determine pin clearance.
If measurements exceed the limits as per Tolerances
and Wear Limits List, 03-7004, replace pin.

Inspecting piston rings


See Group/Subgroup 03-7312.

20080/1 E 98-12
Group 03
Task Description Subgroup 7004
Page 7

Connecting rod
Note
Replace conrod bolts every time the engine is disassembled.

Using the magnetic crack-testing method with fluorescent penetrant powder, check conrod, conrod cap and conrod
bolts for cracks.
Replace cracked parts.

Check condition of conrod and conrod-bolt threads for ease-of-movement.


Polish out all traces of nicks in conrod, replace conrod if necessary.

Check conrod main bore for blueing. If blueing is present (due to bearing damage), replace conrod.

Check main bore for wear and scoring; if necessary, machine bore to repair stage or replace conrod.

Check bush for scoring, dirt, wear and hot runs.


Use emery cloth to polish out slight wear and pitting; replace conrod bush if necessary.

Smooth conrod main bore with emery cloth.

Caution!
Compressed air is air which has been compressed under pressure. Risk of injury!
Always wear protective goggles or safety mask when blowing out or drying out with compressed air.
The pressure must not exceed 3 bar.

Clean interfaces of conrod and bearing cap, blow dry with compressed air.
The interfaces are not to be damaged, replace conrod as necessary.

Check conrod oil bore for cleanliness, clean with bore brush and blow out with compresseed air.
Note:
Do not use a steel brush!

20080/1 E 98-12
Group 03
Subgroup 7004 Task Description
Page 8

Check parallelity of conrod bores.


Measure permissible parallelity deviation (B) between
conrod bearing and conrod bush bore to measuring
distance (C).
Measure distance (A) from centre conrod bearing bore
to centre conrod bush bore.
For required measurements and limit values, refer to
the Tolerance and Wear Limits List.
If limit values are exceeded, replace conrod.
Note
The conrod is not to be straightened!

Checking and assessing conrod bearing shells


Check bearing shells' surface condition and for signs of
wear; replace worn or chipped shells.
Replace bearing shells as part of every W6 overhaul,
see Group/Subgroup 03-6312.
The bearing shells have the following material structure:
1 Running surface (from 12 m to 20 m)
2 Intermediate layer (nickel barrier)
3 Bearing metal
4 Steel support shell
An important factor for assessing extent of bearing shell
wear is the shape and extent of exposed nickel barrier
areas.
Use of bearing shell is reduced to 70% of running
surface in friction area!

Note
It is often difficult to differentiate between the nickel barrier and softer running surface. If in doubt, consult a bearing
specialist.

20080/1 E 98-12
Group 03
Task Description Subgroup 7004
Page 9

Check condition of bearing shell butt and reverse side and check for friction corrosion (pitting); if there is pitting,
replace shell and determine cause.
Possible causes: Screws not sufficiently pretensioned, assembly fault, bearing shell spread dimension is outside
tolerance limit and defective bearing support bore.
Measure spread dimension of shells.
If spread dimension is too low, (refer to Tolerance and Wear Limits List) replace bearing shells.

Checking conrod bolts


Note
Replace conrod bolts at every W6 major overhaul.
Check screw head support and thread (arrow)) for
scoring or damage; replace screw if necessary.
Measure shaft length of conrod bolts with depth gauge.
Maximum permissible shaft length: 68.5 mm.

Assembly
Note
Ensure a high degree of cleanliness during all assembly work

Installing piston rings


See Group/Subgroup 03-7312.

Conrod storage
See Group/Subgroup 03-6312.

20080/1 E 98-12
Group 03
Subgroup 7004 Task Description
Page 10

Installing conrod in piston

Caution!
Snap ring pretension. Risk of injury!
Use correct circlip pliers.
Wear protective goggles/safety mask.

Using snap ring pliers (2), insert snap ring (1) into
piston boss.
Note
Make sure snap ring is perfectly seated in groove! snap
ring must sit securely in the groove.

Caution!
Compressed air is air which has been compressed
under pressure. Risk of injury!
Always wear protective goggles or safety mask
when blowing out or drying out with compressed
air.
The pressure must not exceed 3 bar.
Blow out conrod oil bore with compressed air, check for
cleanliness.

Wipe down piston pin, conrod bush and piston pin bore
with chamois leather and coat with engine oil.
Insert conrod into appropriate piston according to
markings so that the longer end (A) of the angle-split
conrod faces recess (B) for oil spray nozzle.

20080/1 E 98-12
Group 03
Task Description Subgroup 7004
Page 11

Push associated piston pin (2) into piston and conrod


(arrow) until seated against snap ring installed
beforehand.

Caution!
Snap ring pretension. Risk of injury!
Use correct circlip pliers.
Wear protective goggles/safety mask.

Using snap ring pliers, insert second snap ring.


Note
Make sure snap ring is perfectly seated in groove! Snap
ring must sit securely in the groove.

20080/1 E 98-12
Group 03
Subgroup 7004 Task Description
Page 12

Installation

Installing piston with conrod


Note
If used pistons are reinstalled the surface of the piston
rings must be visually inspected for chipping; replace
piston rings as necessary (03-7312).

If new pistons are to be installed, they should be


assigned together with the liners according to the
tolerance-group coding.
The tolerance-group coding (arrow) is given on the top
liner surface and the piston crown.
Code:
Piston Liner
(Letter group) (Code letter)
"BC" "B"

"BCD" "C"

"CDE" "D"

"DE" "E"

Coat piston and piston rings with engine oil. Position


ring butts (arrows) consecutively at 120 intervals.

20080/1 E 98-12
Group 03
Task Description Subgroup 7004
Page 13

Guide band clamp over piston rings and compress to


outside diameter of piston.
Band clamp 000 589 38 31 00

Check code markings (arrow) on bearing cap and


conrod.

Insert conrod bearing shell (4) into conrod. Lug (arrow)


of conrod bearing shell must be seated in groove of
connecting rod.

Note
Bores in conrod bearing shell and conrod must be
aligned.

Coat running surface of conrod bearing shells with


engine oil.

20080/1 E 98-12
Group 03
Subgroup 7004 Task Description
Page 14

Insert piston in cylinder liner in direction of arrow to


engine centre.

Press in piston until conrod bearing contacts the


crankpin on crankshaft.

Notes
Do not damage or warp oil spray nozzle when installing
piston.
In event of damage, remove oil spray nozzle, check and
install (18-5471).

Insert conrod bearing shell (4) into conrod bearing cap.


Lug (arrow) of conrod bearing shell must be seated in
groove of conrod bearing cap.
Coat running surface of conrod bearing shells with
engine oil.

Measure shaft length (max. 68.5 mm) of conrod bearing


screws.

20080/1 E 98-12
Group 03
Task Description Subgroup 7004
Page 15

Insert bearing cap and manually install conrod bearing


screws.

Note
Markings on bearing cap and conrod must be aligned.

Tighten conrod bearing screws alternately in several


stages to 100 Nm and then further rotate to 90 to 100
angle of rotation.

Measuring piston protrusion.

Note
Check projection between piston crown and crankcase
partition with piston at TDC.
Secure dial gauge (7) in dial gauge holder (8).

Dial gauge 001 589 53 21 00


Dial gauge holder 343 589 00 40 00

Position dial gauge holder (8) with dial gauge (7) on


appropriate measuring block and feeler (arrow) on
piston crown with preload (approx. 3 to 4 mm) .

Set scale of dial gauge to "0".

Position feeler (arrow) on partition on crankcase and


read off measured value = piston projection.
See Tolerance and Wear Limits List for specified values
(03-7004).

Note
If projection is greater than 0.3 mm install thicker
cylinder head gasket

Dial gauge 001 589 53 21 00


Dial gauge holder 343 589 00 40 00

Bar engine and check for clearance between oil spray


nozzle and piston. If necessary, align oil spray nozzle.

20080/1 E 98-12
Group 03
Subgroup 7004 Task Description
Page 16

20080/1 E 98-12
Group 03
Task Description Subgroup 7312
Page 1

03-7312 Piston Ring Removal, Inspection and Installation

Preparatory operation:
Piston removed (03-7004).

1 Piston ring Piston rings:


See Tolerance and Wear Limits List 03-7312.
Offset piston ring joints by 120; TOP mark-
ing must point upwards, pliers F3 0378 001.

Special tool

20080/1 E 98-12
Group 03
Subgroup 7312 Task Description
Page 2

Removing piston rings

Set pliers to 128 mm dia.

Remove rings with the pliers in sequence from top to


bottom.

Pliers F3 0378 001

Inspecting piston rings

Replace rings during a W6 overhaul.


Visually inspect surface of piston rings for chipping prior
to reinstallation and after assembly; replace piston rings
as necessary.
Remove combustion residues from rings, decarbonize if
necessary. Check for damage, replace if necessary.
The condition/wear level of the chrome layer (arrow) is
decisive whether rings can be re-used or replaced.
The chrome layer should show no scoring, cracking or
thermal discolouration.
Replace sharp-edged rings.

Insert piston rings in unworn area of cylinder liner.

Measure piston ring end clearance: see Tolerance and


Wear Limits List 03-7312.

If measurements exceed the limits as per Tolerances


and Wear Limits List, replace piston rings.

20080/1 E 98-12
Group 03
Task Description Subgroup 7312
Page 3

Installing piston rings

Set pliers to 128 mm dia.

Using the pliers, insert the rings in sequence from


bottom to top (insert spring-loaded oil-control ring first).
"TOP" marking on rings must face upwards.
Offset piston ring joints by 120.

Pliers F3 0378 001

Note:
The spring-loaded oil control ring has no "TOP"
marking.

Turn the spring (2) in the oil-control ring (1) so that its
end (arrow) is 180 to the control-ring end.

20080/1 E 98-12
Group 03
Subgroup 7312 Task Description
Page 4

20080/1 E 98-12
Group 03
Task Description Subgroup 8001
Page 1

03-8001 Flywheel Removal and Installation

Preparatory operation:
Coupling removed.

1 Flywheel Guide mandrel 403 589 02 63 00.


2 Flywheel screw Re-usable until shaft length max. 75 mm,
Tightening torque: 1. Stage 200 to 220 Nm,
2. Stage 90 to 100
Angle of rotation

Special tool

20080/1 E 98-12
Group 03
Subgroup 8001 Task Description
Page 2

Removal/installation

Remove flywheel screws (2).


Installation instructions
Measure shaft length (max. 75 mm) of flywheel screws.
Apply a thin coat of oil when assembling.
Tightening torques:
1 Stage 200 to 220 Nm.
2 Stage 90 to 100 angle of rotation

Insert guide mandrels into two opposing threaded


bores.

Guide mandrel 403 589 02 63 00.

Remove flywheel via guide mandrels.

Installation instructions
Centering pin in crankshaft gear and centering bore in
flywheel must be aligned.

Install in reverse order.

20080/1 E 98-12
Group 03
Task Description Subgroup 8042
Page 1

03-8042 Flywheel Machining

Preparatory operation:
Flywheel removed (03-8001).

Flywheel machining

Clean flywheel, check for cracks and scoring.

Using straightedge, check contact surface (friction


surface) for evenness.

Check mating face and threaded bores for crankcase


support.

Prior to machining flywheel ensure that it is still possible


to remove material.

Note
Roughness depth of friction surface 15 m.

20080/0 E 97-02
Group 03
Subgroup 8042 Task Description
Page 2

20080/0 E 97-02
Group 03
Task Description Subgroup 8312
Page 1

03-8312 Starter Ring Gear Replacement

Preparatory operation:
Flywheel removed (03-8001).

1 Ring gear Heat to between 200C and 230C .


2 Flywheel

Starter ring gear replacement

Heat ring gear and remove.

Heat new ring gear to between 200C and 230C


(yellow temper colour) and fit.

Notice!
Risk of injury due to heat!

For engines that have a hole-circle diameter of 450 mm


for securing coupling, after assembly the ring gear must
be bored and provided with thread M10x1.5.

Notes
After assembly, the max. ring gear radial runout must
not be exceeded, see the Tolerance and Wear Limits
List 03-8312.
Grease ring gear prior to initial operation.

20080/1 E 98-12
Group 03
Subgroup 8312 Task Description
Page 2

20080/1 E 98-12
Group 03
Task Description Subgroup 8400
Page 1

03-8400 Guide Bearing in Flywheel, Replacement

Preparatory operation:
Flywheel removed (03-8001).

1 Flywheel
2 Guide bearing Mandrel 403 589 05 15 00,
Internal extractor 000 589 27 33 00,
Counter support 000 589 34 33 00,
Guide mandrel 403 589 02 63 00.

Special tools

20080/0 E 97-02
Group 03
Subgroup 8400 Task Description
Page 2

Replacement

Remove guide bearing in flywheel.

Mandrel 403 589 05 15 00

Install new guide bearing flush with screw mating face.

Mandrel 403 589 05 15 00

20080/0 E 97-02
Group 03
Task Description Subgroup 8400
Page 3

Guide bearing replacement with installed flywheel:

Remove flywheel screws.


Insert guide mandrels (A) into two opposing threaded
bores.

Remove guide bearing with internal extractor and


counter support.

Install new guide bearing flush with screw mating face.


A Guide mandrel 403 589 02 63 00.
B Counter support 000 589 34 33 00,
C Internal extractor 000 589 27 33 00,
Remove guide mandrels.

Measure shaft length (max. 75 mm) of flywheel screws.


Apply a thin coat of oil when assembling.

Install flywheel screws and tighten.


Tightening torque:
1 Stage 200 to 220 Nm.
2 Stage 90 to 100 angle of rotation

20080/0 E 97-02
Group 03
Subgroup 8400 Task Description
Page 4

20080/0 E 97-02
Group 05
Task Description Subgroup
Page

Valve Gear, Valves

20080/1 E 98-12
Group 05
Subgroup Task Description
Seite

20080/1 E 98-12
Group 05
Task Description Subgroup
Page 1

05 Valve Gear, Valves

Contents

05-1122 Valve clearance adjustment

05-1500 Valve stroke check

05-3133 Valve spring removal, installation and check

05-3514 Valve stem seals assembly

05-3731 Valve guide removal and installation

05-3832 Valve seat insert replacement

05-4102 Valve removal and installation

05-4202 Valve grinding

05-4532 Valve seat insert machining

05-5542 Rocker arm replacement

05-6010 Timing check via valve stroke

05-6210 Axial clearance of camshaft check

05-6300 Camshaft removal and installation

05-7102 Camshaft bearing replacement

20080/0 E 98-12
Group 05
Subgroup Task Description
Page 2

20080/0 E 98-12
Group 05
Task Description Subgroup 1122
Page 1

05-1122 Valve Clearance Setting

Preparatory operation:
Cylinder head covers removed (01-5014).

Data
Inlet 0.40
Valve clearance
Exhaust 0.60
8V 183 Firing order 1-5-7-2-6-3-4-8
Overlap 6-3-4-8-1-5-7-2
12V 183 Firing order 1-12-5-8-3-10-6-7-2-11-4-9
Overlap 6-7-2-11-4-9-1-12-5-8-3-10

Tightening torque Nm

Locknut on adjusting screw 50

Special tools

Note
Set valve clearance with engine cold and/or thoroughly heated engine (at least 30 minutes after engine shutdown).

20080/1 E 98-12
Group 05
Subgroup 1122 Task Description
Page 2

Setting

Method 1

Mount rotator with screws M8x20 on gear case.

Rotator 407 589 00 63 00

Turn engine in direction of rotation until valves of a


cylinder (e.g. 6th cylinder on V8 engine) overlap.

The synchronous piston is now in firing TDC (e.g. 1st


cylinder on V8 engine) and valves can be set.

Note
Valves on cylinder to be set are closed, rocker arms are
completely unloaded and push rods cannot be turned.

X = Free end

Set all other valves in accordance with firing order.


Example: V8 engine
If the following cylinders are in overlap top dead centre
the valves can be set in accordance with the firing
order.

Overlap TDC 6- 3- 4- 8- 1- 5- 7- 2

Cylinder to be set 1- 5- 7- 2- 6- 3- 4- 8

If valves on 6th cylinder overlap, valves on 1st cylinder


can be set.

20080/1 E 98-12
Group 05
Task Description Subgroup 1122
Page 3

Position feeler gauge between inlet valve and rocker


arm and/or between exhaust valve and rocker arm.

Note
Valve clearance is set correctly if it is possible to pull
the gauge through with slight resistance.

Gauge 0.60 mm 422 589 01 23 00


Gauge 0.40 mm 617 589 04 23 00
Gauge retainer 617 589 00 40 00

If it is necessary to correct valve clearance, fit valve


setting wrench on adjusting screw, release locknut and
correct valve clearance. Tighten locknut, 50 Nm.

Valve setting wrench 422 589 00 11 00

Remove rotator No. 407 589 00 63 00 on gear case.

20080/1 E 98-12
Group 05
Subgroup 1122 Task Description
Page 4

Method 2
Data
Inlet valves Inlet valves
Engine 1. cylinder in:
to be set to be set
8V 183 Overlap TDC 2, 5, 6, 7 3, 4, 6, 8,
Firing TDC 1, 3, 4, 8, 1, 2, 5, 7,
12V 183 Overlap TDC 3, 5, 6, 8, 10, 12 2, 4, 6, 7, 10, 11
Firing TDC 1, 2, 4, 7, 9, 11 1, 3, 5, 8, 9, 12

Mount rotator with screws M8x20 on gear case and turn


engine in direction of rotation until TDC mark is aligned
with edge (arrow) in inspection port.

Rotating device 407 589 00 63 00

Check whether 1st cylinder is in firing TDC or in overlap


TDC (in firing TDC the two valves are closed, rocker
arms are completely unloaded and push rod cannot be
turned).

When 1st cylinder is in firing TDC the following valves


can be set:

X = Free end
Engine Inlet valve Exhaust valve
8V 183 1,3,4,8, 1,2,5,7
12V 183 1,2,4,7,9,11 1,3,5,8,9,12

When 1st cylinder is at overlap TDC the following


valves can be set:

Engine Inlet valve Exhaust valve


8V 183 2,5,6,7 3,4,6,8
12V 183 3,5,6,8,10,12 2,4,6,7,10,11

20080/1 E 98-12
Group 05
Task Description Subgroup 1122
Page 5

Position feeler gauge between inlet valve and rocker


arm and/or between exhaust valve and rocker arm.

Note
Valve clearance is set correctly if it is possible to pull
the gauge through with slight resistance.

Valve setting wrench 422 589 00 11 00


Gauge 0.60 mm 422 589 01 23 00
Gauge 0.40 mm 617 589 04 23 00
Gauge retainer 617 589 00 40 00

If it is necessary to correct valve clearance, fit valve


setting wrench on adjusting screw, release locknut and
correct valve clearance. Tighten locknut, 50 Nm.

Remove rotator on gear case.

Rotating device 407 589 00 63 00

20080/1 E 98-12
Group 05
Subgroup 1122 Task Description
Page 6

20080/1 E 98-12
Group 05
Task Description Subgroup 1500
Page 1

05-1500 Valve Stroke Check

Preparatory operations:
Cylinder head cover removed (01-5014).
Valve clearance set (05-1122).

Valve stroke

Engine 8V 183 12V 183


Valve stroke at specified Inlet 12.35 12.30
Valve clearance 11.95 11.90
Exhaust 12.30 12.25
11.90 11.85

Special tools

Check

Note
Rotating device (1) installed.

Rotator 407 589 00 6300

Set piston of cylinder to be checked to firing TDC.

20080/1 E 98-12
Group 05
Subgroup 1500 Task Description
Page 2

Position dial gauge holder. Position dial gauge with pre-


load on valve head of inlet valve set scale to "0".

Dial gauge 001 589 53 21 00


Dial gauge holder 363 589 02 21 00

Note
Set dial gauge max. 5 mm under pre-load so that
measuring distance is sufficient for valve stroke.

Bar engine in normal direction of rotation and observe


dial gauge. Inlet valve is completely open when pointer
moves in opposite direction.

Note
Due to saddle cams, measured value must be achieved
twice on scale.

Read off measured value "valve stroke inlet valve".

Reset piston of cylinder to be checked to firing TDC.

Position pre-loaded dial gauge on valve head of


exhaust valve set scale to "0".

Dial gauge 001 589 53 21 00


Dial gauge holder 363 589 02 21 00

Bar engine in direction of rotation and observe dial


gauge. Exhaust valve is completely open when pointer
moves in opposite direction.

Note
Due to saddle cams, measured value must be achieved
twice on scale.

Remove dial gauge with dial gauge holder.

Remove rotating device.

Rotating device 407 589 00 63 00

20080/1 E 98-12
Group 05
Task Description Subgroup 3133
Page 1

05-3133 Valve Spring Removal, Installation and Check

Preparatory operation:
Cylinder head removed (01-6110).

1 Taper element
2 Valve spring retainer
3 Valve spring, outer
4 Washer
5 Valve spring, inner
6 Valve stem seal Replace (05-3514).
7 Washer
8 Cylinder head
9 Exhaust valve
10 Inlet valve

20080/1 E 98-12
Group 05
Subgroup 3133 Task Description
Page 2

Equipment
Supplier
Valve spring compresor
Ludwig Hunger
D-81309 Mnchen
Spring testing scales Supplier
Hahn und Kolb GmbH & Co
D-70005 Stuttgart

Special tool

Removal

Set cylinder head on support surface of valve spring


compresor and secure with clamping claws.

Notes
All valve springs can be removed with valve spring
compresor or with valve lever (A).

Insert stud (arrow) on valve lever (A) into a free


threaded bore (for rocker shaft support) in cylinder head
and remove valve springs.

A Valve lever 442 589 00 31 00

Set spring retainer clamp (11) according to valve spring


retainer (2) diameter.

Insert pressure rod (12) into lever eye (13) and press
down valve spring retainer. Remove taper elements.

Unload pressure rod (12) and remove valve spring


retainer, valve springs and washers.

20080/1 E 98-12
Group 05
Task Description Subgroup 3133
Page 3

Checking

Check valve springs with spring testing unit.

If limit values are exceeded, replace valve springs.

See Tolerance and Wear Limits List for limit values


(05-3133).

Check valve springs for indentations, flatness, burring


and deformation.

Flatness deviations of up to 0.2 mm on inner diameter


of end coils are permissible.

Springs with deformations and burring on spring turns


can continue to be used after burnishing.

Replace valve springs if necessary.

Installation

Insert washer for inner and outer valve spring.

Insert valve springs and valve spring retainer.

Notes
Install narrower end of valve springs in direction of
cylinder head.

Ensure washers for valve springs are correctly seated.

Set spring retainer clamp (11) according to valve spring


retainer (2) diameter.

Insert pressure rod (12) into lever eye (13) and press
down valve spring retainer (2). Insert taper elements
into groove of valve stem and unload pressure rod.
Note
Ensure parts are correctly seated.

Remove valve spring lever.

20080/1 E 98-12
Group 05
Subgroup 3133 Task Description
Page 4

20080/1 E 98-12
Group 05
Task Description Subgroup 3514
Page 1

05-3514 Valve Stem Seal Assembly

Preparatory operation:
Valves removed (05-4102).

6 Valve stem seals Assembly sleeve 403 589 00 61 00.


7 Washers
8 Cylinder head

Special tool

20080/0 E 97-02
Group 05
Subgroup 3514 Task Description
Page 2

Installation

Lubricate valve shafts (arrows) and insert valves into


valve guides.

Secure cylinder head on valve spring compresor.

Fit assembly sleeve (A) for valve stem seal on a valve.

A Assembly sleeve 403 589 00 61 00

Press valve stem seal (6) via assembly sleeve (A) onto
valve guide.

Remove assembly sleeve (A) .

A Assembly sleeve 403 589 00 61 00

20080/0 E 97-02
Group 05
Task Description Subgroup 3731
Page 1

05-3731 Valve Guide Check, Removal and Installation

Preparatory operations:
Injection nozzle with nozzle holder removed (07-6812).
Valves removed (05-4102).

Mandrel 403 589 00 15 00


1 Valve guides Reamer 000 589 12 53 00
Adjustable reamer 000 589 17 53 00
2 Cylinder head

Special tools

Equipment

Order No. Supplier


Valve guide plug gauge 299 05 001 Ludwig Hunger
Valve guide cleaning brush 865 01 001 81039 Mnchen

20080/1 E 98-12
Group 05
Subgroup 3731 Task Description
Page 2

Check

Clean valve guides with valve guide cleaning brush.

Measure valve guides with plug gauge (1).


If end of plug gauge (1) marked with "+" fits into valve
guide, valve guide must be replaced.

Replace valve guides in cylinder head if measurements,


or the clearance between valve and guide, exceed or
are below the limits in the Tolerance and Wear Limits
List 05-3731.

Removal

Clamp cylinder head in position.

Drive valve guides out of cylinder head from the


combustion side.

Mandrel 403 589 00 15 00

Installation
Recondition bore in cylinder head with adjustable
reamer
(part No. 000 589 17 53 00) to next biggest dimension
See Tolerance and Wear Limits List for limit values
(05-3731).

20080/1 E 98-12
Group 05
Task Description Subgroup 3731
Page 3

Coat new valve guide with oil containing graphite and


drive in with mandrel (A) and spacer sleeve (B).
A Mandrel 403 589 00 15 00
B Spacer sleeve 403 589 00 15 00
Re-ream internal diameter of valve guide with reamer
part No. 000 589 12 53 00.

See Tolerance and Wear Limits List for limit values


(05-3731).

20080/1 E 98-12
Group 05
Subgroup 3731 Task Description
Page 4

20080/1 E 98-12
Group 05
Task Description Subgroup 3832
Page 1

05-3832 Valve Seat Insert Replacement

Preparatory operation:
Valves removed (05-4102).

1 Cylinder head
2 Valve seat insert - exhaust Internal extractor 000 589 29 33 00,
Counter support 000 589 34 33 00,
3 Valve seat insert - inlet Internal extractor 000 589 30 33 00,
Counter support 000 589 35 33 00,

20080/1 E 98-12
Group 05
Subgroup 3832 Task Description
Page 2

Special tools

Equipment

Bore gauge

Valve spring compressor Supplier:


Ludwig Hunger
81309 Mnchen

Removal

Note
Valve guides are installed.
Fit cylinder head on valve spring compressor.
Insert valves into cylinder head in accordance with
markings. Check clearance of valve stem in valve
guide.
See Tolerance and Wear Limits List for limit values
(05-3731).
Remove valves.
Insert pilot (5) (11.9 mm dia.) into valve guides until
slotted rod stop contacts valve guide; if necessary,
press down slotted rod with screwdriver. Secure with
mandrel inserted at top and bottom of pilot (arrows).
Secure cutting tool for annular groove in support.
Valve seat rotating tool 366 589 00 69 00

20080/1 E 98-12
Group 05
Task Description Subgroup 3832
Page 3

Release locknut (2). Insert rotating tool (4) via pilot (5)
coated in oil. Turn screw (1, rapid adjustment) until
cutting tool (3) contacts pilot (5). Then push rotating tool
(4) downwards until cutting tool is in centre of valve seat
insert. Hold rotating tool in this position.

Release securing screw (6) on pilot support (7), press


pilot support (7) downwards until it contacts the pilot.
Retighten securing screw (6).

Clamp cone pin (16) horizontally approx. in centre of pin


with steady rest clamp (17). The rotating tool must turn
as easily as before.
Back off screw (1) of rapid adjuster until cutting tool is in
front of valve seat insert (but not resting against it).
Tighten locknut (2). Install horizontal stop screw (8) until
it makes contact with housing and then back off 2 to 3
mm. Tighten clamping screw (9) positioned underneath.
Adjust height of cutting tool so that approx. 1 mm of
material is still under the valve seat insert after
machining.

20080/1 E 98-12
Group 05
Subgroup 3832 Task Description
Page 4

Note
Hold knurled-head washer (10) in position and turn
crank (11) clockwise to move cutting tool downwards;
turn crank counterclockwise to move cutting tool
upwards.
Turn crank (11) clockwise and hold knurled-head
washer (12) firmly.
In event of increasing turning resistance, briefly release
knurled-head washer (12). Ring groove depth approx.
2 - 3 mm.

Note
Removed material must not be too large. The rotating
tool must turn as easily as before; this is achieved by
briefly releasing knurled-head washer (12).

Remove rotating tool.

Fit internal extractor (13) for inlet and/or exhaust valve


seat insert in annular groove and remove valve seat
insert with counter support (14).

Note
Place copper sheet under mating faces of counter
supports (arrows) so that cylinder head surfaces cannot
be damaged.
Internal extractor valve seat insert - inlet
000 589 30 33 00
Internal extractor valve seat insert - exhaust
000 589 29 33 00
Counter support valve seat insert - inlet
000 589 35 33 00
Counter support valve seat insert - exhaust
000 589 34 33 00

Remove internal extractor and counter support.

20080/1 E 98-12
Group 05
Task Description Subgroup 3832
Page 5

Set bore gauge with micrometer.

Dial gauge 001 589 53 21 00

Using bore gauge, measure basic bores for valve seat


inserts in cylinder head.
Check limit values according to Tolerance and Wear
Limits List 05-3832 or 05-3832a.
Machine to repair size as required.
Dial gauge 001 589 53 21 00

Basic bore reconditioning

Insert pilot (5) (11.9 mm dia.) into valve guide until


slotted rod stop contacts valve guide; if necessary,
press down slotted rod with screwdriver. Secure with
mandrel inserted at top and bottom of pilot (arrows).

Secure rotating tool in support.

20080/1 E 98-12
Group 05
Subgroup 3832 Task Description
Page 6

Release locknut (2), fit rotating tool (4) over pilot (5)
coated in oil, turn rapid adjusting screw (1) until cutting
tool (15) has moved horizontally beyond the bore. Push
rotating tool (4) downwards until cutting tool (15) rests
on cylinder head.

Note
Carefully position rotating tool (4) so that carbide tip of
cutting tool (15) is not damaged.

Release securing screw (6) on pilot support (7), press


pilot support (7) downwards until it contacts the pilot.
Retighten securing screw (6).

Turn knurled washer (10) clockwise until cutting tool is


just clear.

Horizontally clamp cone pin with steady rest clamp; in


doing so, working depth "b" must be set between
adjusting ring and cone pin.
For bore depth "b", see Tolerances and Wear Limits
List) 05-3832 or 05-3832a.

20080/1 E 98-12
Group 05
Task Description Subgroup 3832
Page 7

Calculating setting dimension "B":


Setting dimension "B" is basic bore "a" in cylinder head
(see Tolerance and Wear Limits List 05-3832 or
05-3832a) and pilot diameter "A" divided by 2.
Example
"a" = 60 mm
"A" = 14.55 mm (pilot diameter)

"B"= a+A
2

"B" = 60 mm + 14.55 mm = 37.28 mm


2

Release locknut (2) and set micrometer to dimension


"B". Slightly raise rotating tool, place micrometer on pilot
and using rapid adjusting screw (1) set cutting tool to
dimension "B" and tighten locknut (2).

Note
It is advisable to set cutting tool diameter 0.1 mm
smaller for the initial material cut.

Insert horizontal stop screw (8) until it contacts housing


and tighten clamping screw (9) to prevent horizontal
stop screw (8) from turning.

20080/1 E 98-12
Group 05
Subgroup 3832 Task Description
Page 8

Secure knurled washer (10) with mandrel (arrow) to


turning crank.

Turn crank (11) clockwise, simultaneously holding top


knurled washer (10) for vertical advance. Recondition
bore for valve seat insert until adjusting ring (18)
contacts steady rest mount (16).

Note
Readjust cutting tool as often as necessary to achieve
calculated setting dimension. Then turn again without
adjustment to achieve a roughness depth of max. 0.006
mm.
Slightly raise rotating tool. Release locknut and using
rapid adjusting screw reset cutting tool.

Turn crank (11) clockwise, simultaneously holding


bottom knurled washer (12) for horizontal advance.
Grind the end plane and flat until stop screw contacts
housing.

Remove rotating tool and measure bore.


Matching between valve seat insert and bore
according to Tolerance and Wear Limits List 05-
3832 or 05-3832a must be guaranteed.

Dial gauge 001 589 53 21 00

20080/1 E 98-12
Group 05
Task Description Subgroup 3832
Page 9

Installation

Heat cylinder head to approx. 80C in water bath.

Notice!
Part is hot. Risk of injury!
Handle part only when wearing gloves.

Insert valve seat inserts in chillbox, part No. 346 589 00


63 00, and fill with liquid nitrogen. Chill valve seat
inserts for approx. 20 to 30 minutes.

Notice!
Nitrogen liquefies under extreme cold:
-200 C (-328 F).
Danger of freezing and suffocation!
Do not allow liquid nitrogen to come into contact
with body parts (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles.
Ensure good ventilation at workplace.

Note
Liquid nitrogen is available from any nitrogen producer.

Use pliers to remove valve seat insert from chillbox and


fit on bore of heated cylinder head.

Drive in valve seat insert and settle correctly once


temperature has equalised.
Mandrel 403 589 00 15 00
Sleeve 403 589 01 15 00

Machine valve seat (05-4532).

Replace or grind valve (05-4202).

20080/1 E 98-12
Group 05
Subgroup 3832 Task Description
Page 10

20080/1 E 98-12
Group 05
Task Description Subgroup 4102
Page 1

05-4102 Valve Removal and Installation

Preparatory operation:
Valve springs removed (05-3133).

4 Washers
6 Valve stem seals Replace (05-3514).
7 Washers
8 Cylinder head
9 Exhaust valve Lubricate valve stem.
10 Inlet valve Lubricate valve stem.

Equipment
Supplier
Valve spring compresor
Ludwing Hunger
81309 Mnchen

20080/1 E 98-12
Group 05
Subgroup 4102 Task Description
Page 2

Removal/installation

Remove valve stem seals (6) from valve guides.

Installation instructions
Assemble valve stem seals (05-3514).

Remove washers (4 and 7) for valve springs.

Remove cylinder head from valve spring compresor


and remove valves (9 and 10).

Installation instructions
Lubricate valve stems.

Install in reverse sequence and check clearance.

For valve shaft clearance in valve guide, see


Tolerances and Wear Limits List 05-4102.

20080/1 E 98-12
Group 05
Task Description Subgroup 4202
Page 1

05-4202 Valve Grinding

Preparatory operation:
Valves removed (05-4102).

Valve grinding

Clean removed valves and remove stubborn carbon


deposits.
Check valves for reusability. Surface of valve stem
ends must not be damaged. Valve keyways must not be
chipped and chrome layer on valve stems must be
uninterrupted.
Replace burnt valves.
Check valves for concentricity and dimensional
accuracy. Valves must not be straightened.

Minor deviations in concentricity can be compensated


by regrinding valve seat on a valve grinding machine.

Clamp valve as closely as possible behind valve head


to avoid vibrations.

Set required grinding angle on the scale according to


Tolerance and Wear Limits List 05-4202 or 05-4202a.

Slowly advance valve towards rotating grinding stone


until stone comes into contact with valve seat surfaces.

Grind with small advance until valve seat is smooth


around the entire circumference.

Measure height of outer edge of valve seat.

Replace valve if the limit values are exceeded (see


Tolerance and Wear Limits List 05-4202 or 05-4202a).

20080/0 E 97-02
Group 05
Subgroup 4202 Task Description
Page 2

Valve stem end can be ground using the prism block


mounted on the valve grinding machine. Valve length
must remain above minimum permissible value.

Measure valve stem with outside micrometer.

For limit values, see Tolerance and Wear Limits List


05-4202 or 05-4202a.

If limit values are exceeded, replace valve.

20080/0 E 97-02
Group 05
Task Description Subgroup 4532
Page 1

05-4532 Valve Seat Insert Machining

Preparatory operations:
Valves removed (05-4102).

Note
Under no circumstances should the bottom edge of the valve seat on the valve contact the inside of the cylinder
head as otherwise the edge wears into the seat, the valve sealing is impaired and the valve tends to burn away.
Adjust the valve seat so that the bottom edge of the valve is free.

Special tools

Equipment
Order No. Supplier
Valve seat testing equipment
217 93 601 Ludwing Hunger
81309 Mnchen

20080/1 E 98-12
Group 05
Subgroup 4532 Task Description
Page 2

Valve seat machining

Note
Valve guides are installed.

Clamp cylinder head on valve spring compresor.

Valve clearance measurement

Insert valves.

Secure dial gauge (14) to dial gauge holder (15).

Mount dial gauge holder (15) on plane surface on


cylinder head and feeler of dial gauge (14) on valve
head with preload (approx. 3 to 4 mm).

Set scale of dial gauge to "0".

Mount feeler of dial gauge (14) on plane surface on


cylinder head and read off valve clearance.

Dial gauge 001589 53 21 00


Dial gauge holder 343 589 00 40 00
For limit values, see Tolerance and Wear Limits List
05-4532 or 05-4532a.
If limit values are exceeded, replace valve.

Note
If valve seats are only slightly indented they can be
reconditioned without replacing valve seat inserts
provided limit values are not exceeded.

Remove valves.

20080/1 E 98-12
Group 05
Task Description Subgroup 4532
Page 3

Valve seat surface reconditioning

Insert pilot (5) (11.9 mm dia.) into valve guide until


slotted rod stop contacts valve guide; if necessary,
press down slotted rod with screwdriver. Secure with
mandrel inserted at top and bottom of pilot (arrows).

Valve seat rotating tool 366 589 00 69 00

Secure cutting tool (3) with clamping screw to support

Note
Ensure that cutting tool is secured to support with
correct scale setting.
Release locknut to deactivate free support. Mount crank
on arm marked with appropriate scale setting, (see
Tolerance and Wear Limits List 05-4532 or 05-4532a).

Release locking screw (7) of pilot rest (6).

20080/1 E 98-12
Group 05
Subgroup 4532 Task Description
Page 4

Release locknut (2). Fit rotating tool (4) over pilot (5)
and turn screw (1, rapid adjustment) so that cutting tool
(3) is positioned on centre of valve seat.

Note
Carefully postition rotating tool on valve seat.

Release securing screw (9) and screw knurled wheel


(8) downwards. Retighten securing screw (9).

Press down pilot rest (6) until it contacts pilot. Retighten


securing screw (7).

20080/1 E 98-12
Group 05
Task Description Subgroup 4532
Page 5

Clamp core pin (10) in centre of guide with steady rest


clamp (11) .

Note
The rotating tool must turn as easily as before.

Raise turning device and turn rapid adjusting screw (1)


to position cutting tool (3) beside inner valve seat edge.
Tighten locknut (2). Avoid cutting.

Hold knurled wheel (12) for feed and turn crank (13)
clockwise. At this point, cutters usually remove an
irregular amount of material. After turning, release
locknut of rapid adjusting screw and reposition cutting
tool inwards.

20080/1 E 98-12
Group 05
Subgroup 4532 Task Description
Page 6

Release securing screw (9) and turn knurled wheel (8)


counter-clockwise approx. to 2 lines of graduation (1
line of graduation = 0.1 mm). Retighten securing screw
(9) and locknut of rapid adjusting screw and turn again.

Hold knurled wheel in position (12) for advance and turn


crank until top of cutting tool has come outwards.

Cutting must continue until seat is smooth (machining


limits must not be exceeded). Then turn again without
cutting. The values given in the Tolerance and Wear
Limits List 05-4532 or 05-4532a must achieved for
newly installed inserts.

Note
Valve seat must be replaced if valve seat inner contour
(arrows) was damaged or worn when machining inlet
valve seat.

Measure valve clearance (See Page 2).

20080/1 E 98-12
Group 05
Task Description Subgroup 4532
Page 7

Outer valve seat correction

Raise turning device and release securing screw (7) of


pilot rest (6).

Release locknut (2). Turn rapid adjusting screw (1) so


that cutting tool (3) rests on outer valve seat edge.
Tighten locknut (2).

Note
Carefully position rotating tool on valve seat edge.

Press down pilot rest (6) until it contacts pilot. Tighten


securing screw (7).

Release securing screw (9) and turn knurled wheel (8)


counter-clockwise approx. line of graduation.
Retighten securing screw (9).

Hold crank arms (13/16) with both hands and apply light
pressure to turn turning device in stages around pilots.

Repeat two working steps until required valve seat


width is achieved.

20080/1 E 98-12
Group 05
Subgroup 4532 Task Description
Page 8

Set feeler of measuring unit with preload on valve seat


centre. Check radial runout of valve seat in relation to
valve guide (see Tolerance and Wear Limits List 05-
4532 or 05-4532a).

Remove valve seat rotating tool, steady rest and pilots.

20080/1 E 98-12
Group 05
Task Description Subgroup 5542
Page 1

05-5542 Rocker Arm Replacement

Preparatory operation:
Rocker shaft support removed.

1 Snap ring
2 Washer
3 Rocker arms
4 Valve adjusting screw
5 Locknut 50 Nm.
6 Screw 75 Nm.
7 Rocker shaft support

20080/1 E 98-12
Group 05
Subgroup 5542 Task Description
Page 2

Removal/installation

Clamp rocker shaft support (use protective jaws).

Release locknuts (5) and remove valve setting screws


(4).

Installation instructions
Tighten locknut (5) after adjusting valve, 50 Nm.

Remove snap ring (1) for rocker arm.

Remove washer (2) and rocker arm (3).

Clean all components thoroughly and check for wear.


(see Tolerance and Wear Limits List 05-5542).

Note
Rocker shaft supports are supplied ex-works ready for
installation with balls installed and rocker arms with
bushes.

Install in reverse order.

20080/1 E 98-12
Group 05
Task Description Subgroup 6010
Page 1

05-6010 Valve Stroke Timing Check

Data

Valve stroke TDC inlet 0.75


With clearance-free valve 0.55
adjustment
TDC exhaust 0.85
0.65

Timing Inlet opens before TDC 17


At specified valve clearance
Inlet closes after BDC 29

Exhaust opens before BDC 71

Exhaust closes after TDC 13

20080/1 E 98-12
Group 05
Subgroup 6010 Task Description
Page 2

Special tools

Check

Remove cylinder head cover of first and of synchronous


cylinder (01-5014).

Fit rotating device (1).

Rotating device 407 589 00 63 00

Set piston of 1st cylinder to TDC mark (arrow) in firing


TDC.

Note
In firing TDC, both valves must be closed, rocker arms
completely unloaded and pushrods must move easily in
pushrod seats.

Release locknuts of valve adjusting screws and


compensate valve clearance of 1st cylinder.

Further rotate engine in direction of rotation by one


rotation until exact TDC position (arrow) is achieved at
flywheel.

Note
Piston of 1st cylinder is thereby at overlap TDC.

20080/1 E 98-12
Group 05
Task Description Subgroup 6010
Page 3

Mount dial gauge holder on cylinder head .

Position dial gauge with pre-load on valve head of inlet


valve set scale to "0".

Dial gauge 001 589 53 21 00


Dial gauge holder 363 589 02 21 00

Turn back engine and observe dial gauge until pointer


on dial gauge is stationary.

Read off measured value for TDC inlet.

Remove dial gauge with dial gauge holder.

Set piston of 1st cylinder to overlap TDC.

Mount dial gauge holder; to do so position dial gauge


with pre-load on valve head of exhaust valve and set
scale to "0".

Dial gauge 001 589 53 21 00


Dial gauge holder 363 589 02 21 00

Rotate engine further in direction of rotation and


observe dial gauge until pointer of dial gauge is
stationary.

Read off measured value for TDC exhaust.

Remove dial gauge holder and dial gauge.

Set valve clearance of 1st cylinder (05-1122).

Install cylinder head screws (01-5014).

Remove rotating device.

20080/1 E 98-12
Group 05
Subgroup 6010 Task Description
Page 4

20080/1 E 98-12
Group 05
Task Description Subgroup 6210
Page 1

05-6210 Axial Clearance of Camshaft Check

Preparatory operations:
Gear case cover removed (01-8000).
Injection pump removed (07-8410).

Special tools

Checking

Press camshaft on camshaft gear (arrow) in direction of


gears case.

Install dial gauge holder with dial gauge on


crankase.Mount dial gauge with pre-load on camshaft
gear and set scale to 0.

Dial gauge 001 589 53 21 00


Dial gauge holder 363 589 02 21 00

Press camshaft on camshaft gear against dial gauge


and read off axial running clearance of camshaft on dial
gauge.
See Tolerance and Wear Limits List 05-6210 for axial
clearance.

If limit values are exceeded, remove drive gear and


alignment bearing of camshaft.
If axial clearance is too small:
Recondition camshaft alignment bearing with fine
emery cloth on ink-check plate.
If axial clearance is too large:
Replace alignment bearing with another one having the
top manufacturing limits (see Tolerance and Wear
Limits List 05-7102).

20080/1E 98-12
Group 05
Subgroup 6210 Task Description
Page 2

20080/1 E 98-12
Group 05
Task Description Subgroup 6300
Page 1

05-6300 Camshaft Removal and Installation

Preparatory operations:
Engine removed (00-0008)
Rocker shaft supports removed.
Push rods removed.
Engine rotated (cylinder heads facing downwards).
Oil pan removed (01-7500).
Gear case removed (01-8205).

Removal/installation

Remove tachometer drive (if installed) from crankcase


at front.

Bar engine in direction of rotation so that markings of


camshaft in relation to crankshaft are aligned (arrows).

Remove camshaft.

Note
Do not damage camshaft bearing.

Install in reverse order.

Fill engine oil system, (18-1601).

20080/1 E 98-12
Group 05
Subgroup 6300 Task Description
Page 2

20080/1 E 98-12
Group 05
Task Description Subgroup 7102
Page 1

05-7102 Camshaft Bearing Replacement

Preparatory operations:
Camshaft removed (05-6300).
Crankshaft removed (03-4352).
Oil filter housing removed (18-3031).
Cooler and intercooler removed.

Special tools

20080/1 E 98-12
Group 05
Subgroup 7102 Task Description
Page 2

Removal and installation tool, Part No. 403 589 02 33 00


1 Cross handle 7 Centring pipe
2 Shell half 8 Spindle pipe
3 Bearing housing 9 Bearing retainer
4 Stop pin 10 Stop element
5 Bearing flange 11 Locating element
6 Screw M10x25 12 Collared bearing retainer

Removal

Engine with speed transmitter

Remove lead seal and remove plug-in connection.

Remove speed transmitter (B6).

20080/1 E 98-12
Group 05
Task Description Subgroup 7102
Page 3

Engine without speed transmitter

Remove cap nut (27) on end cover.

Remove end cover (13) from crankcase.

Drift 355 589 01 63 00


Adapter 360 589 03 63 00

Remove radial-lip oil seal (29).

20080/1 E 98-12
Group 05
Subgroup 7102 Task Description
Page 4

Insert centring pipe (7) into bearing bore and secure


bearing flange (5) with two hex bolts M10x25 to
crankcase.

Removal and installation tool 403 589 02 33 00

Insert spindle pipe (8) into bearing flange (5).

Turn spindle pipe (8) until stop pin (10) engages in


groove (arrow) of spindle pipe (8).

Insert spindle pipe (8) into cylinder housing retainer (9)


behind relevant bearing so that support for bearing
(arrow) points in direction of cross handle.

Note
Remove a maximum of two camshaft bearings per
operation.

20080/1 E 98-12
Group 05
Task Description Subgroup 7102
Page 5

Insert bearing retainer (9) into bearing bore and insert


stop element (10) into groove behind bearing retainer
(9).

Turn cross handle clockwise and remove camshaft


bearing.

Collar bearing (21) is pressed out at rear. For this


purpose, connect cross handle with bearing flange by
means of shell half.

Remove cross handle and spindle pipe. Remove


bearing retainers and collar bearing (21) and remove
bearing flange.

Clean bearings in crankcase.

Installation

Insert centring pipe (7) into bearing bore and secure


bearing flange (5) with two hex bolts M10x25 to
crankcase.

20080/1 E 98-12
Group 05
Subgroup 7102 Task Description
Page 6

Insert spindle pipe (8) into bearing flange (5).

Turn spindle pipe (8) until stop pin (10) engages in


groove (arrow) of spindle pipe (8).

Fit camshaft bearing (14) on bearing retainer (9),


secure (arrows) and lubricate externally.

Insert spindle pipe into crankcase and insert bearing


retainer with camshaft bearing (14) behind relevant
bearing so that camshaft bearing (14) points in direction
of cross handle.

Note
Install a maximum of two camshaft bearings (14) per
operation.

When pulling inner camshaft bearings into bearing bore


of collar bearing, install locating ring (11).

20080/1 E 98-12
Group 05
Task Description Subgroup 7102
Page 7

Note
By securing bearing retainer for spindle pipe, oil bore
(15) of bearing is simultaneously aligned to oil bore (16)
in crankcase.
Insert stop element (10) into spindle pipe. Turn cross
handle clockwise and pull in bearing until oil bore (15)
of bearing is aligned with oil bore (16) in crankcase.

When securing collar bearing to bearing retainer ensure


oil bores are aligned (17 aligned with 19 and 18 aligned
with 20).

Remove bearing insertion tool and measure bearing.


See Tolerance and Wear Limits List 05-7102 for limit
values.

Ensure oil ducts are free from obstruction.

Install end cover (13) with sealant


(part No. 001 899 25 20) into crankcase.

20080/1 E 98-12
Group 05
Subgroup 7102 Task Description
Page 8

Install radial-lip oil seal (29).

Engine with speed transmitter

Install speed transmitter (B6) and tighten,


35 Nm.

Fit plug-in connector (62) on speed transmitter, tighten


and close seal (arrow).

Engine without speed transmitter


Tighten cap nut, 35 Nm.

20080/1 E 98-12
Group 07
Task Description Subgroup
Page

Engine Fuel System

20080/1 E 98-12
Group 07
Subgroup Task Description
Seite

20080/1 E 98-12
Group 07
Task Description Subgroup
Page 1

07 Engine Fuel System

Contents

07-0001 Fuel system diagram

07-5500 Fuel lines

07-5501 Fuel fuel line removal, inspection/repair and installation

07-5580 Fuel duplex filter removal, disassembly, inspection/repair and installation

07-5580a Fuel duplex filter (with cut-out) disassembly, inspection/repair and installation

07-5700 Fuel delivery pump(s) check

07-5700/1 A Measuring in delivery pump vacuum

07-5700/2 B Pressure of delivery pump(s) and opening pressure of overflow valve measurement

07-5700/3 C Measuring fuel filter flow rate

07-6712 Injector check

07-6750 Injector disassembly, cleaning and assembly

07-6812 Injector removal and installation

07-8234 Start of delivery check

07-8410 Installing and removing injection pump

07-9200 Injection lines

07-9224 H.P. injection line removal, inspection/repair and installation

20080/1 E 98-12
Group 07
Subgroup Task Description
Page 2

20080/1 E 98-12
Group 07
Task Description Subgroup 0001
Page 1

07-0001 Fuel System Diagram 8V 183 (Ship Version)

1 Engine 12 Leak-off fuel indicator*


2 Fuel delivery pump with hand pump 13 Fuel prefilter
3 Fuel duplex filter, with diverter valve 14 Drip tray
4 Fuel injection pump 15 Flexible connection
5 Fuel injection nozzle 16 From fuel tank
6 Overflow valve 17 To fuel tank
7 H.P. fuel line (injection pressure line) 18 To leak-off fuel collecting tank
8 Jacket*
9 Leak-off fuel from injection nozzles A = Connecting point at engine or plant
10 Leak-off fuel from jacket* * Only for engine version with jacketed
11 Leak-off fuel tank* H.P. fuel lines

20080/0 E 97-02
Group 07
Subgroup 0001 Task Description
Page 2

Fuel System Diagram 12V 183 (Ship Version)

1 Engine 12 Leak-off fuel tank*


2 Fuel delivery pump 13 Leak-off fuel indicator*
3 Fuel delivery pump with hand pump 14 Fuel prefilter
4 Fuel duplex filter, with diverter valve 15 Drip tray
5 Fuel injection pump 16 Flexible connection
6 Fuel injection nozzle 17 From fuel tank
7 Overflow valve 18 To fuel tank
8 H.P. fuel line (injection pressure line) 19 To leak-off fuel collecting tank
9 Jacket*
10 Leak-off fuel from injection nozzles A = Connecting point at engine or plant
11 Leak-off fuel from jacket* * Only for engine model with jacketed H.P. fuel lines

20080/0 E 97-02
Group 07
Task Description Subgroup 5500
Page 1

07-5500 Fuel Lines

Fuel lines to injection pump 8V 183

20080/0 E 98-04
Group 07
Subgroup 5500 Task Description
Page 2

1 Banjo union 26 Pipe clamp half


2 Adaptor 27 Grommet
3 Sealing ring 28 Hex bolt
4 Banjo screw 29 Washer
5 Sealing cone 30 Sealing ring
6 Nut 31 Banjo union
7 Connector 32 Fuel line from injection pump
8 Banjo screw 33 Reduction union
9 Sealing ring 34 Sealing ring
10 Overflow valve 35 Fuel line to fuel tank
11 Sealing ring 36 Bracket
12 Union 37 Pipe clamp half
13 Banjo union 38 Grommet
14 Sealing ring 39 Washer
15 Fuel line from connector to filter 40 Hex bolt
16 Fuel line from filter to injection pump 41 Hex nut
17 Banjo screw 42 Hex bolt
18 Sealing ring 43 Washer
19 Union 44 Fuel return line
20 Union 45 Fuel line from injection nozzles, right
21 Sealing ring
22 Hex bolt 46 Sealing cone
23 Spacer 47 Nut
24 Bracket 48 Sealing cone
25 Pipe clamp half 49 Sealing cone

20080/0 E 98-04
Group 07
Task Description Subgroup 5500
Page 3

Fuel lines to injection pump 12V 183

20080/0 E 98-04
Group 07
Subgroup 5500 Task Description
Page 4

1 Banjo union 31 Grommet


2 Adaptor 32 Hex bolt
3 Sealing ring 33 Washer
4 Adaptor 34 Connecting lines fuel outlet from injection pump
5 Sealing cone
6 Nut 35 Union
7 Banjo union 36 Banjo screw
8 Banjo screw 37 Banjo screw
9 Sealing ring 38 Sealing ring
10 Adaptor 39 Fuel line to tank
11 Fuel supply line 40 Bracket
12 Fuel supply line 41 Pipe clamp half
13 Adaptor 42 Grommet
14 Sealing ring 43 Washer
15 Fuel supply line 44 Hex bolt
16 Fuel supply line 45 Hex nut
17 Banjo screw 46 Hex bolt
18 Sealing ring 47 Washer
19 Union 48 Fuel return line from injection nozzles, left
20 Adaptor 49 Fuel line from injection nozzles, right
21 Elbow
22 Hose line 50 Clamp
23 Union 51 Clamp
24 Banjo screw 52 Hex bolt
25 Sealing ring 53 Hex nut
26 Hex bolt 54 Washer
27 Spacer 55 Sealing cone
28 Bracket 56 Nut
29 Pipe clamp half 57 Sealing cone
30 Pipe clamp half 58 Sealing cone

20080/0 E 98-04
Group 07
Task Description Subgroup 5500
Page 5

Fuel line from drip tray to engine connection on free end, left side

1 Adaptor 6 Pipe clamp half


2 Sealing ring 7 Washer
3 Fuel line 8 Grommet
4 Hex bolt 9 Sealing cone
5 Hex bolt 10 Nut

20080/0 E 98-04
Group 07
Subgroup 5500 Task Description
Page 6

Leak-off fuel lines 8V 183 T..2


(only for jacketed H.P. injection lines)

1 Leak-off fuel line from H.P. injection pressure lines 10 Spacer sleeve
2 Leak-off fuel line to distributor (leak-off fuel tank) 11 Washer
3 Banjo screw 12 Hex nut
4 Banjo screw 13 Hex bolt
5 Sealing ring 14 Sealing ring
6 Distributor (leak-off fuel tank) 15 Plug
7 Banjo screw 16 Sealing ring
8 Sealing ring 17 Adaptor
9 Clamp

20080/0 E 98-04
Group 07
Task Description Subgroup 5500
Page 7

Leak-off fuel lines 12V 183 T..2


(only for jacketed H.P. injection lines)

1 Leak-off fuel line 10 Sealing ring


2 Leak-off fuel line 11 Clamp
3 Leak-off fuel line to distributor (leak-off fuel tank) 12 Spacer sleeve
4 Leak-off fuel line 13 Washer
5 Banjo screw 14 Hex nut
6 Banjo screw 15 Hex bolt
7 Sealing ring 16 Sealing ring
8 Distributor (leak-off fuel tank) 17 Plug
9 Banjo screw 18 Sealing ring
19 Adaptor

20080/0 E 98-04
Group 07
Subgroup 5500 Task Description
Page 8

Leak-off fuel lines 12V 183 T..3


(only for jacketed H.P. injection lines)

1 Leak-off fuel line 11 Washer


2 Leak-off fuel line 12 Hex nut
3 Leak-off fuel line 13 Hex bolt
4 Banjo screw 14 Sealing ring
5 Banjo screw 15 Plug
6 Banjo union 16 Sealing ring
7 Sealing ring 17 Adaptor
8 Distributor (leak-off fuel tank) 18 Banjo screw
9 Hex bolt 19 Clamp
10 Bracket

20080/0 E 98-04
Group 07
Task Description Subgroup 5501
Page 1

07-5501 Fuel Line Removal, Inspection/Repair and Installation

Removal

Before removing the fuel lines, it is advisable to photograph the engine from all sides or affix metal tags to the lines
so that they can be reinstalled in their original positions.

Notice!
Fuels and fuel vapours are inflammable and toxic. Risk of fire, explosion and poisoning!
When handling fuel: - no naked flames - no electric sparks - no smoking - do not spill fuel.
Do not inhale. Wear protective gloves and protective goggles/safety mask.
Ensure good ventilation at workplace.

Loosen fuel-line connections, catch emerging fuel.

Remove fuel lines and connecting hardware according to schematics in Group 07-5500.

After removing fuel lines, seal all connections with suitable plugs.

Remove non-return valves from fuel lines, fuel duplex filter and connector.

Remove leak-off fuel tank from carrier and remove carrier from crankcase.

Inspection and repair

Clean fuel lines with "cleaner", visually inspect for damage and defects; replace as necessary.

Notice!
Compressed air is air which has been compressed under pressure. Always wear protective goggles/safety
mask when blowing out or drying out with compressed air. Compressed air must not be directed at the
body. The pressure must not exceed 3 bar.

Blow out fuel lines with compressed air, check for cleanliness.

If necessary, check for leaks in the fuel lines using air under water; replace line if a leak is found.

Notice!
Compressed air is air which has been compressed under pressure. Risk of injury! The pressure must not
exceed 0.5 bar. Wear protective clothing, protective gloves and goggles/safety mask.

Water temperature: At least 30C, whereby the part must also have the same temperature: or a maximum of 40C if
the part has to be held manually.

Test pressure: 0.5 bar

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Subgroup 5501 Task Description
Page 2

Check union nut threads and threaded connections for obstructions: recondition or replace part if necessary.

Tighten connections and adapters.

Check condition of hoses and for signs of ageing; replace if necessary.

Inspect brackets, grommets and mounting components of fuel lines for damage and wear; replace if necessary.

Check condition of threads of union nut and adapter.

Clean leak-off fuel tank.

Check sealing and mating faces for damage and defects; smooth with oilstone as necessary.

Replace plugs and unions as necessary.

Replace sealing rings.

Installation

Prior to installation, blow out fuel lines with compressed air and install free of tension with gaskets and attachments
- See 07-5500 and/or photographs or markings.
Install carrier with securing bolts and spring washers to crankcase.

Install leak-off fuel tank with screws and spring washers on carrier - See 07-5500.

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Task Description Subgroup 5580
Page 1

07-5580 Fuel Duplex Filter Removal, Disassembly, Inspection/Repair and


Installation

Fuel duplex filter

1 Fuel duplex filter 12 Bracket


2 Filter head 13 Thread insert
3 Filter element 14 Screw
4 Sealing ring 15 Screw
5 Housing 16 Bracket
6 Screw 15 Nm 17 Screw
7 Sealing ring 18 Spring washer
8 Vent plug 19 Nut
9 Plug
10 Sealing ring
11 Overflow valve

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Page 2

Fuel duplex filter

1 Filter head
2 Connection, pressure relief valve
3 Securing screw
4 Vent plug
5 Filter housing
6 Felt-filter element

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Page 3

Preparatory operations:
Drain fuel from duplex filters
Remove fuel lines (07-5500 and 07-5501).

Removal

Remove nuts and securing screws,

Remove fuel duplex filter from carrier.

Remove carrier from engine.

Remove overflow valves.

Remove filter elements (see Operating Instructions).

Inspection and repair

Clean all components.

Remove corrosion and/or water stains in filter housing with brush.

Using red penetrant dye method, crack-test filter housing and filter head surfaces; replace components as
necessary.

Pressure-test filter housing with diesel fuel at 6 bar.

Use emery cloth to polish out slight wear and pitting; replace filter housing if necessary.

Check filter head for warping and wear; replace component as necessary.

Check condition of screws

Replace filter elements (see Operating Instructions).

Replace valves for constant venting as necessary.

Check carrier for flatness and defects; smooth with oilstone as necessary, check thread for ease of movement;
rechase as necessary.

Replace O-rings.

Installation

Install filter elements (see Operating Instructions).

Install carrier with securing screws.

Install fuel duplex filter with screws, spring washers and nuts on carrier.

Install overflow valves.

Install fuel lines (07-5500).

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Page 4

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Task Description Subgroup 5580a
Page 1

07-5580a Fuel Duplex Filter Removal, Disassembly, Inspection/Repair and


Installation

Fuel duplex filter (with cut-out)

1 Fuel duplex filter 6 Sealing ring


2 Hex bolt 7 Clamp
3 Washer 8 Clamp
4 Vent valve 9 Hex bolt
5 Tube 10 Washer

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Page 2

Fuel duplex filter

1 Spring 8 Sealing ring


2 Threaded pin 9 Filter element with gasket
3 Sealing ring 10 Cover
4 Sealing ring 11 Sealing ring
5 Plug 12 Filter head
6 3-way cock 13 Vent plug (not provided if
7 Plug vent valves installed)

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Task Description Subgroup 5580a
Page 3

Preparatory operations:
Drain fuel from duplex filters
Remove fuel lines (07-5500 and 07-5501).

Removal

Remove tubes on vent valves.

Remove vent valves.

Remove filter elements (see Operating Instructions).

Remove filter head from carrier.

Inspection and repair

Clean all components.

Remove corrosion and/or water stains in filter head with brush.

Using red penetrant dye method, crack-test filter head surfaces; replace components as necessary.

Replace filter elements (see Operating Instructions).

Pressure-test filter with diesel fuel - test pressure 6 bar.

Replace vent valves as necessary.

Inspect vent valve hoses; replace as necessary.

Installation

Install fuel duplex filter on carrier.

Install vent valves (with new hoses if necessary).

Install fuel lines (07-5500).

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Page 4

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Task Description Subgroup 5700
Page 1

07-5700 Fuel Delivery Pump(s) Check

A Measuring delivery pump vacuum

Connect testing equipment (1), part No. 617 589 04 21 00, between supply line from fuel tank and fuel prefilter.

Start engine. When hose (arrow) is compressed, pressure gauge displays vacuum in delivery pump(s), 0.5 to 0.8
bar.

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Page 2

B Pressure of delivery pump(s) and opening pressure of overflow valve measurement

Connect testing equipment (1), part No. 617 589 04 21 00 between delivery pump and fuel filter.

Start engine. Pressure gauge displays opening pressure of overflow valve (2), min. 1.3 bar.

When hose (arrow) is compressed, pressure gauge displays pressure of delivery pump, >2.0 bar.

For 12V 183 engines, repeat procedure on second delivery pump.

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Page 3

C Measuring fuel filter flow rate

Connect testing equipment (1) part No. 617 589 04 21 00 between fuel filter outlet and injection pump.

Start engine. Pressure gauge displays filter output pressure, min. 1.3 bar.

Note
During measurements it can be seen whether diesel fuel flowing through pipework is bubble-free.

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Page 4

20080/0 E 97-02
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Task Description Subgroup 6712
Page 1

07-6712 Fuel Injector Check

Preparatory operation:
Fuel injector removed (07-6812).

Injection pressure 1)
Setting value 200 +8 bar
Lowest permissible value for
worn nozzles 185 bar

1) Difference in nozzle pressure within engine must not exceed 10 bar.

Special tool

Fuel Injector Check

Notice!
Keep hands well away from operating nozzles!
The fuel jet from a nozzle can penetrate deep into
the flesh and destroy tissue. Fuel entering the
bloodstream can cause blood poisoning.

Under no circumstances use petrol (gasoline) to


test the injection nozzles.
Risk of explosion!
Only use ISO 4113 test oil.

Test oil and resulting vapour is inflammable and


could cause an explosion.
Do not permit oil vapour to enter the workplace
atmosphere!
Use a ventilation system. No naked flames, no
electric sparks. No smoking.

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Page 2

Note:
Combustion deposits around the nozzle openings
strongly influence the spray pattern.

Connect test line (6) to injector (5). Fill test-oil container


(7) with ISO 4113 test oil.

Carry out pre-check, opening-pressure check, leak test


and visual inspection of nozzle openings.

Pre-check

Close shut-off valve (2) on pressure gauge (1).

Push pump lever (4) of nozzle tester (3) strongly


downwards several times.
This should get rid of any minor malfunctions, e.g. the
nozzle needle sticking, and effect a short flushing of the
nozzle holder and nozzle with clean test oil.

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Task Description Subgroup 6712
Page 3

Opening Pressure Check

Open shut-off valve (2) on pressure gauge (1).

Slowly push pump lever (4) downwards.

Note!If the pressure gauge is connected, allow the


pressure to increase and decrease slowly to avoid
damage to the gauge.

Read off the opening pressure on the gauge at opening


of the nozzle or begin of injection spray.

If the opening pressure is below the minimum (see


page 1), it must be increased to the specified value.

The injector's opening pressure is set by replacing the


compensating washer.

A thicker compensating washer increases the spring


pretension, the opening pressure increases.

Leak Test

Carry out leak test with closed nozzle needle.

Push hand pump lever (4) slowly downwards until the


pressure gauge (1) shows approx. 20 bar below the set
opening pressure. The injection nozzle is in order if
drops do not fall from the nozzle openings within 10
seconds.

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Page 4

Visual inspection of possibly obstructed nozzle


openings.

Switch off pressure gauge of test device.

Push pump lever down as fast as possible, at least


twice per second.

A Spray Pattern Check


Spray jets must correspond to number of openings.

B Visual Inspection of Nozzle Openings.


If a defect is found during inspection A (a jet is missing
or looks different to the others), the openings are to be
inspected with a lamp for obstructions.

Note:
Combustion deposits around the nozzle openings
strongly influence the spray pattern.

Judgement of the spray jet is only possible with the


above described rapid pump movement.

Other test methods are not permitted.

Replace defective injection nozzles.

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Task Description Subgroup 6750
Page 1

07-6750 Injector Disassembly, Cleaning and Assembly

Preparatory operation:
Fuel injector removed (07-6812).

1 Thrust nut 80 Nm, Socket 403 589 00 13 00


2 Nozzle Ultrasonic cleaning unit
3 Intermediate washer with locating pin
4 Thrust pin
5 Compression spring
6 Washer
7 Nozzle holder Retainer 403 589 00 31 00.

Special tool

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Subgroup 6750 Task Description
Page 2

Recommended equipment and cleaning fluids


Magnifying glass with lamp (min. 6 x enlargement) Commercially available tool

Ultrasonic cleaning equipment Order No. (Manufacturer)


Equipment model: SONOREX SUPER RK 100 SH 192
Nozzle holder: ED 8 081
Basket: K3S 115
Cover: D 3B 343
Manufacturer: BANDELIN electronic GmbH & Co. KG
Postfach 45 01 60
12171 Berlin
Tel.: 030/76880-0
Fax: 030/7722014

Cleaning fluid: to DBL 7821.00


Trade name: P3 neutrapon 5032
Container size: 2 l.
Manufacturer: HENKEL KGaA, 40191 Dsseldorf
Supplier: BANDELIN electronic GmbH & Co. KG
Postfach 45 01 60
12171 Berlin
Tel.: 030/76880-0
Fax: 030/7722014
Order No.: 920

Disposing of cleaning fluid

Use acid-proof gloves and protective goggles.

The cleaning agent must not penetrate into surface/ground water.

The cleaning fluid is biologically degradable and can be passed to the sewerage system via the oil separator.

Local sewage requirements must always be observed!

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Task Description Subgroup 6750
Page 3

Fuel Injector Disassembly


Ensure greatest workplace cleanliness during
disassembly and assembly of injectors!
If more than one injector are disassembled, ensure that
the individual components of each injector remain
together and are not interchanged with components
from other injectors.

Position injector (1) vertically in support.

Socket 403 589 00 13 00


Support 403 589 00 31 00.

Remove thrust nut (1) from nozzle holder, remove


intermediate washer (4), thrust pin (5), compression
spring and washer (7)
When removing the injector, take care that the nozzle
needle does not drop out.
Hold the needle only at the thrust flanges to avoid
corrosion forming on the running and guide surfaces.

Fuel Injector Cleaning

When cleaning, use the ultrasonic equipment SONOREX SUPER RK 100 SH with holder ED 8 and basket K 3 S.
We recommend cleaning agent "P3 neutrapon 5032" from Henkel. This cleaning agent is approved in DBL 7821.00.

Notes
Use acid-proof gloves and protective goggles.

Pour approx. 2.0 l. cleaning fluid into the ultrasonic cleaning unit. Dilute the cleaning fluid in the volume ratio 1: 10
with water (0.18 l. cleaner + 1.8 l. water).

Heat cleaning bath to 50C.

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Page 4

Cleaning complete nozzle holder combinations:


Position nozzle holder combinations vertically into the
bracket
ED 8 and clean in the ultrasonic bath.
The duration of the cleaning process depends on the
level of contamination but must be at least 10 minutes.

Cleaning nozzle elements:


When cleaning the nozzle elements, remove the nozzle
needle completely from the body and clean two parts
separately. To do so, position nozzle body vertically in
holder ED 8 with orifices pointing downwards.
Ensure that needle and body are not interchanged
with parts of other nozzles.

The duration of the cleaning process depends on the


level of contamination but must be at least 10 minutes.

Cleaning individual parts of nozzle holder:


Position individual parts of nozzle holder in basket K 3
S.
Ensure that parts are not interchanged with other
nozzle holders.

The duration of the cleaning process depends on the


level of contamination but must be at least 10 minutes.

Individual parts to be cleaned must be completely covered with cleaning fluid.

Directly after cleaning, wash parts in diesel fuel, blow out with compressed air and immerse the cleaned parts
immediately in clean test oil and/or purified diesel oil.

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Task Description Subgroup 6750
Page 5

After cleaning, visually inspect used nozzles to confirm cleaning process has been successful.

With nozzle holder assemblies and nozzle elements:


Examine orifice outlet edge for mechanical damage.

With nozzle elements:


If damage or coarse areas are found on the needle seat of the nozzle needle, replace nozzle completely.
Using a magnifying glass with lamp, inspect orifices on nozzle tip for any possible carbon deposits remaining or
for other blockages; replace nozzle elements as necessary.

After visual inspection, carry out sliding test on all


nozzle elements (new and used).
In this way, a drop test checks the sliding action
between the nozzle needle and nozzle body. Parts must
be coated with test oil or diesel oil.
Drop test: When the nozzle needle, 1/3 of which has
been pulled out of the nozzle body, is
released, it must slide down onto the seat
under its own weight.
If this is not the case, replace nozzle
needle and nozzle body.

Replace cleaning fluid as necessary.

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Page 6

Fuel Injector Assembly

Clean injectors as described before re-assembling.

Check compression spring (6) for cracks and the thrust


pin for wear, replace if necessary.

Position nozzle holder (8) vertically in support.

Insert washer (7), compression spring and thrust pin


into holder.

Insert intermediate washer (4) and injection nozzle (2)


into nozzle holder.
Ensure that the locating pins in the intermediate washer
are correctly positioned!
Ensure the smooth surfaces are absolutely clean!
Note
Install an appropriate washer (7) if the injection
pressure was found to be too low or too high when the
nozzle was inspected.

If the pressure is too high or too low replace washer


with a thinner or thicker washer respectively.

Tighten thrust nut (1) onto nozzle holder with torque


wrench.
Tightening torque: 80 Nm.
Lubricant: Engine oil
Do not tighten the thrust nut with higher torque
otherwise the nozzle is under stress, leading to
jamming or catching of the nozzle needle.

Socket 403 589 00 13 00


Support 403 589 00 31 00.

Check injection nozzle (07-6712).

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Task Description Subgroup 6812
Page 1

07-6812 Injector Removal and Installation

25 Nm, Box wrench (open) 000 589 07 03 00,


1 Injection line Serrated wrench 000 589 50 03 00,
Box wrench insert 000 589 68 03 00.
2 Thrust screw 70 Nm, Pin wrench 403 589 03 07 00,
Pin wrench 403 589 04 07 00,
Pin wrench 403 589 05 07 00.
3 Nozzle holder Removal tool 355 589 01 63 00,
with hot lubricating paste
4 Sealing ring Replace.
5 Plug
6 Cylinder head

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Page 2

Special tools

Fuel Injector Removal

Notice!
No naked flames and no smoking when working on
the fuel system!
Do not spill fuel!

Remove union nut of injection line on nozzle holder.

Box wrench (open) 000 589 07 03 00

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Task Description Subgroup 6812
Page 3

Remove union nut of injection line on injection pump;


hold pipe connection in position with serrated wrench.
Remove all pipe clamps from injection line and remove
line.

Note
Do not bend injection line.

Box wrench (open) 000 589 07 03 00


Serrated wrench 000 589 50 03 00,

Remove fuel hoses (7) for leak-off oil cap and


protective cap from the injection nozzle.

Remove rubber plug (5).

Remove thrust screw (2).

Pin wrench 403 589 04 07 00,


Pin wrench 403 589 05 07 00
(in extreme circumstances)

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Page 4

Install impact puller on injector (3), remove injector.

Remove sealing ring from cylinder head.

Removal tool 355 589 01 63 00

Clean nozzle externally, also remove combustion


deposits from nozzle body end (mainly at the nozzle
openings) with a wooden scraper and fuel.

Notice! Under no circumstances scrape over the nozzle


openings with a hard object or clean the nozzle body
around the openings with a wire brush.
Note
Check injection nozzles before reinstalling
(07-6712).
Repair or replace nozzles which are not in perfect
condition.

Fuel Injector Installation


Attach new sealing ring to injector with heat-resistant
paste.

Install injector into cylinder head.

Slide thrust screw (2) over the nozzle.

Thread thrust screw into cylinder head with socket


wrench and tighten with torque wrench.
Tightening torque: 70 Nm.
Lubricant: Engine oil

Install rubber plug (5).


Push leak-off fuel hose (7) and protective rubber cap
onto injector.

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Task Description Subgroup 6812
Page 5

Lightly hand-tighten the injection line on the injection


pump and injector.

Install pipe clamps.

Tighten union nut of injection line on injection pump with


box-wrench socket and torque wrench.
Tightening torque: 25 Nm.
Lubricant: Engine oil

Tighten union nut of injection line on injector with box-


wrench and torque wrench.
Tightening torque: 25 Nm.
Lubricant: Engine oil

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Page 6

20080/1 E 98-12
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Task Description Subgroup 8234
Page 1

07-8234 Start of Delivery Check


Note: Carry out start of delivery check only if performance is reduced or specific fuel consumption high.

1 High pressure pump Part No. 422 589 00 71 00 7 Injection pump lever Set to full load and lock
2 Fuel tank 8 Injection pump
3 Return line 9 Connecting line (supply)
4 Sight glass with test line 10 Battery (12V)
5 Hand pump Part No. 124 589 15 21 00 11 Connection cable
Note: Subject Bosch governor to 12 ON / OFF switch
pressure of 2 bar

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Subgroup 8234 Task Description
Page 2

Tightening torques Nm
Injection lines 25
Bracket for fuel filter on gear case cover 80
Drive gear to injection pump 35

Special tools

For injection pump start of delivery, see Engine Acceptance Test Record !

Check

Notice!
Risk of fire and explosion!
When working on fuel system, catch fuel emerging.
After working on fuel system, start engine. Check fuel
system for leaks.

Note
Start of delivery test is different for engines with split-
element injection pumps!

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Task Description Subgroup 8234
Page 3

Engines with electronic diesel control:

Remove supply line (15) to injection pump and connect


to test line (12).

Special wrench 000 589 50 03 00


Test line 442 589 01 90 00

Connect H.P. pump, supply line


part No. 422 589 00 71 00 to injection pump

Remove return line (13) with overflow valve (14) on


injection pump and connect to test line (12).

Seal injection pump return with plug (5) from adapters,


part No. 403 589 00 91 00.

Power the injection-pump actuator using a suitable


adapter cable. This moves the pump's control rack to
the full-load travel position, approx. 11 mm.
Remove injection line to 1st engine cylinder . Connect
test line with sight glass (4) from H.P. pump, part No.
422 589 00 71 00, to injection pump connection for 1st
engine cylinder.

Special wrench 000 589 07 03 00


Special wrench 000 589 50 03 00
H.P. pump 422 589 00 71 00
Adapters 403 589 00 91 00

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Page 4

Engines without electronic diesel control:

Remove fuel supply line to injection pump.

Connect H.P. pump, supply line (8)


part No. 422 589 00 71 00.

Remove return line and overflow valve on injection


pump.

Seal injection pump return with plug (5) from adapters,


part No. 403 589 00 91 00.

Set injection pump lever to full load and lock.


Remove injection line to 1st engine cylinder . Connect
test line with sight glass (4) from H.P. pump, part No.
422 589 00 71 00, to injection pump connection for 1st
engine cylinder .

Special wrench 000 589 07 03 00


Special wrench 000 589 50 03 00
H.P. pump 422 589 00 71 00
Adapters 403 589 00 91 00

Install rotating device and set engine approx. rotation


before TDC.

Rotating device 407 589 00 63 00

Connect H.P. pump part No. 422 589 00 71 00 to a 12-


Volt battery and switch on.

Note
A charge-pressure-dependent full-load stop "LDA" is
installed in engines with Bosch governors. For this
reason, when checking start of injection the charge air
line must be disconnected from governor and line of
hand pump, part No. 124 589 15 21 00 must be
installed. The governor is subjected to pressure of 2 bar

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Task Description Subgroup 8234
Page 5

Bar engine slowly in direction of rotation and observe


fuel flow in sight glass until spray pattern shows correct
atomisation. The exact pump timing is achieved at the
transition.

A = Good atomisation
B = Poor atomisation "just before start of delivery"
C = Faulty atomisation (droplets)

Note
For engines with split-element injection pump:
Bar engine slowly in direction of rotation and observe
fuel flow in sight glass until atomisation is correct and
then dribble recommences (pre-injection).
Bar engine further until dribble recommences. At this
transition, the exact pump timing (main injection) is
achieved.

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Subgroup 8234 Task Description
Page 6

A = Good atomisation
B = Fuel dribble "just before start of delivery" (pre-injection)
C = Droplets, start of delivery, pre-injection
D = Again good atomisation
E = Fuel dribble "just before start of delivery" (main injection)
F = Droplets, start of delivery, main injection

Remove plug from gear case cover. Check start of


injection marking between drive gear and pump flange
(arrows) via inspection port in gear case cover and
between flywheel and inspection port edge.

For start of delivery, see Engine Acceptance Test


Record !

20080/1 E 99-06
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Task Description Subgroup 8234
Page 7

If it is necessary to correct the start-of-delivery position,


set engine - in direction of rotation - exactly to start of
delivery between flywheel and inspection port edge
(arrow).

Remove gear case cover (01-8000) and release hex


bolts (16) on drive gear.

Force lever of injection pump to full load and switch on


H.P. pump, part No. 422 589 00 71 00.

Turn camshaft of injection pump on securing nut


(arrow) of drive flange so the fuel jet in sight glass
changes to dribble (droplets).

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Subgroup 8234 Task Description
Page 8

Tighten hex bolts (16) on drive gear, 35 Nm.

Repeat start of delivery test.

Install gear case cover and seal


(01-8000).

Remove H.P. pump, part No. 422 589 00 71 00.

Tighten injection line, 25 Nm.

Tighten fuel supply line, 25 Nm.

Install fuel return line with overflow valve.

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Group 07
Task Description Subgroup 8410
Page 1

07-8410 Installing and Removing Injection Pump

Preparatory operations:
Charge-air manifold removed (09.8621).

1 Injection pump Assembly gauge 422 589 63 00


2 Drive gear
3 Hex bolt 35 Nm
4 Washer
5 Double-hex screw For tightening diagram, see Page 8
6 Double-hex screw For tightening diagram, see Page 8
7 Washer
8 Sealing ring Replace.
Note
Replace sealing ring only together with gear case cover gasket.
9 O-Ring Replace.
10 LDA air line
11 Adaptor
12 Sealing ring Replace.
13 Banjo screw
14 Sealing ring Replace.

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Subgroup 8410 Task Description
Seite 2

Danger!
Risk of fire and explosion!
Catch any fuel emerging when working on the fuel system. After working on fuel system, start engine. Check fuel
system for leaks.

Special tools

Injection line arrangement


8 V 183 12 V 183

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Task Description Subgroup 8410
Page 3

Removal

Remove charge air manifold from intercooler (only with


top-mounted intercooler).

Disconnect fuel lines from injection pump.

Serrated wrench 000 589 50 03 00,

Remove union nut of injection lines from nozzle holder


and from injection pump. Hold pipe connection at
injection pump firmly in position.

Note
Do not bend injection lines.

Box wrench (open) 000 589 07 03 00


Serrated wrench 000 589 50 03 00,

Remove brackets for injection lines from left and right


intake pipe.

Note
Before removing left bracket (8), remove right injection
lines (9).

20080/1 E 98-12
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Subgroup 8410 Task Description
Seite 4

Remove oil pressure line to turbocharger.

Remove oil separator (01-9751).

Disconnect fuel lines from injection pump.

Release ball socket (11) on control lever of injection


pump and press off from ball head.

Note
As engine versions differ, the illustration shows one
example.
Does not apply to engines with electronic governor.

20080/1 E 98-12
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Task Description Subgroup 8410
Page 5

Remove gear case cover (13) from above.

Remove double-hex screws (2) from injection pump


and remove injection pump (example).

Remove hex screws (7).

Remove drive gear (5) from drive flange.

20080/1 E 98-12
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Subgroup 8410 Task Description
Seite 6

Remove sealing ring (4) from injection pump.

Installation

Install rotator with M8x20 screws on gear case and turn


engine in compression stroke of first cylinder until mark
for start of delivery is aligned with edge (arrow) in
inspection port.
The engine must not be turned back (the valves of the
first cylinder must be closed, the rocker arms fully
unloaded and the push rods must turn easily in the ball
sockets.

Rotating device 407 589 00 63 00

Fit sealing ring (4) on drive flange of injection pump.

20080/1 E 98-12
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Task Description Subgroup 8410
Page 7

Install drive gear (5) on drive flange.

Note
Do not fully tighten hex screws (7).

Turn injection pump camshaft until mark on drive flange


is aligned with mark on injection pump (arrow).

Move injection pump drive gear to central position in


elongated holes.

Replace O-ring (9) for injection pump oil pressure duct.

Place injection pump in bearings on crankcase. Make


sure the injection pump markings are aligned. The drive
gear must engage tension-free in the injection timer
splines.

20080/1 E 98-12
Group 07
Subgroup 8410 Task Description
Seite 8

Fit assembly gauge on injection pump and secure with


knurled-head screw (arrow). Move injection pump to
and fro until assembly gauge is in contact with
crankcase.

Assembly gauge 422 589 01 63 00

Tighten injection pump screws with washers in


specified sequence in the following stages:
Double-hex screws
for 8/12V 183 to 1000 PS
1. Align pump with assembly gauge 422 589 00 63 00.
2. 1 Stage 10 Nm
3. 2 Stage 50 Nm
4. 3 Stage 90 to 100 angle of rotation

Max. shaft length:


Short screws 72 mm
Long screws 102 mm

Double-hex screws
for 12V 183 1000 HP
1. Align pump with assembly gauge 422 589 00 63 00.
2. 1 Stage 10 Nm all screws
3. 2 Stage 50 Nm all screws
4. For screws 1, 3, 5, 6
3 Stage angle of further rotation 90 to 100

Max. shaft length:


Short screws 72 mm
Long screws 102 mm

20080/1 E 98-12
Group 07
Task Description Subgroup 8410
Page 9

Tighten hex bolts (7) on drive gear, 35 Nm.

Install gear case cover and seal.


(01-8000).

Install fuel lines with new gaskets and tighten, 30 Nm.

Coat pushrod seat (11) of engine control with long


duration grease, press on control lever of injection
pump and secure.(Example).
Does not apply to engines with electronic governor.

20080/1 E 98-12
Group 07
Subgroup 8410 Task Description
Seite 10

Tighten oil pressure line with new gasket on


turbocharger and new sealing rings on crankcase, 25
Nm.

Fit injection lines free of tension and tighten, 25 Nm.


Hold pipe connection of injection pump firmly in
position.

Box wrench insert 000 589 68 03 00.


Serrated wrench 000 589 50 03 00,

Note
Ensure that injection lines are installed in the correct
order.

Remove rotator on gear case.

Install charge air manifold (09-8621).

Note
Prior to initial operation, fill governor housing with 1.5 l
of engine oil (only for Bosch governors).

20080/1 E 98-12
Group 07
Task Description Subgroup 9200
Page 1

07-9200 Injection Lines

Injection lines, 8V 183

1 Set of injection lines Cylinders 1 to 4


2 Set of injection lines Cylinders 5 to 8
3 Spacer
4 Hex bolt
5 Hex bolt

20080/0 E 97-02
Group 07
Subgroup 9200 Task Description
Page 2

Injection lines, 12V 183

1 Set of injection lines Cylinders 1 to 6


2 Set of injection lines Cylinders 7 to 12
3 Spacer
4 Hex bolt
5 Hex bolt

20080/0 E 97-02
Group 07
Task Description Subgroup 9224
Page 1

07-9224 Injection Line Removal, Inspection/Repair and Installation

Removing pressure lines

Disconnect H.P. fuel lines from cylinder heads.

Disconnect H.P. fuel lines from injection pump.

Remove hex bolts from charge air lines.

Remove H.P. fuel lines and spacers.

Inspection and repair

Clean all components.

Check H.P. fuel lines for damage and scuffing. The H.P. fuel lines may be twin-walled, according to engine version.

Replace damaged H.P. fuel lines, or lines with dented or corroded tapers.

Note: Where possible, replace damaged H.P. fuel lines as complete sets.

Install new, bent H.P. fuel lines from spare parts kit.

Notice!
Autofretted H.P. fuel lines may be bent only to a very slight degree ( 2).

"A" code for autofretted pressure lines is on the union nut at the nozzle holder end.

Check union nuts for damage, replace H.P. fuel lines as necessary.

Installing H.P. fuel lines

Before installing, blow H.P. fuel lines clear with compressed air.

Connect H.P. fuel lines with spacers tension-free to charge air lines.
For arrangement, see Group 07-9200

Press the sealing cone of lines centrally into the nozzle holder taper or press injection pump elements.

Tighten union nuts of H.P. fuel lines on nozzle holder with torque wrench to 25 Nm.
Tighten union nuts of H.P. fuel lines on injection pump with torque wrench to 25 Nm.

Check lines for leaks with engine running.

Release union nuts and retighten to specified torque if leaking connections are found.

Repeat procedure if connections are still leaking.

20080/1 E 98-12
Group 07
Subgroup 9224 Task Description
Page 2

Important Information:

A Damage to injection lines

Damage is often detected on the engine's injection lines:

Lines leaking at sealing cones


Scuffed lines
Ruptured lines

Damage can be avoided if attention is paid to the following points:

1. Before tightening the union nut, press the sealing cone centrally into the nozzle holder taper or press injection
pump elements, then tighten the union nut.

2. Tightening torque for union nut: 25 Nm (do not exceed).

3. Injection lines with faults such as:

Inner diameter at nipples less than 1.8 mm


(resulting in insufficient injection/power loss)
Nipple squashed
Lines scuffed or leaking must be replaced.

Note: Use nozzle gauge to check nipple inner diameter (see commercially available tools).

4. With engine running, check lines for leaks. Leaks cause a jet of fine spray and are difficult to detect. Use a
suitable material for detecting leaks (e.g. chalk, blotting paper, etc.).

5. Ensure that there is sufficient clearance between the lines of a set of injection lines. If necessary, reposition
slightly.

6. Ensure that rigidly mounted engine components have sufficient clearance. Injection lines are subjected to heavy
vibrations.

7. If individual lines from the set of injection lines are replaced, realign slightly as necessary. Make sure the
lines are correctly positioned in the clamps and the rubber gaskets are properly seated.

Note: Use only pre-formed lines from the spare parts kit.

8. Do not secure any other components to injection lines (lines, cable clamp etc.).

9. Do not use force to bend injection lines or install under pretension (e.g. for assembly work on injection pump or
nozzles). Only when sets of injection lines are installed without pretension is the system sufficiently secure from
vibration ruptures.

20080/1 E 98-12
Group 07
Task Description Subgroup 9224
Page 3

B Measures to prevent foreign bodies entering injection lines and injection nozzles during repair work
Foreign bodies may enter the area of the nozzle injection bores and result in the following complaints:

Engine shaking, uneven operation


Engine knocking
Increased smoke generation

Always use protective caps, therefore, during work on the engine to protect:

Injection lines
Nozzle holder
Nozzles
Injection pump pipe connections

against penetration of foreign bodies and dirt.

Note: Make sure protective caps of spare-part nozzle holders and pipe connections are in clean condition. Seal
injection lines with blanking plugs 201 987 00 40 (see spare part).

Before reinstalling, blow removed injection lines clear with compressed air.

Commercially available tool Supplied by


Nozzle gauge 362 251 010 (1.8 mm) Hahn und Kolb GmbH & Co., Stuttgart

Part

Designation Part No.

Plug 201 987 00 40

20080/1 E 98-12
Group 07
Subgroup 9224 Task Description
Page 4

20080/1 E 98-12
Group 09
Task Description Subgroup
Page

Air Filter, Exhaust Turbocharger,


Charge Air Lines

20080/1 E 98-12
Group 09
Subgroup Task Description
Page

20080/1 E 98-12
Group 09
Task Description Subgroup
Page 1

09 AIR FILTER, EXHAUST


TURBOCHARGER, CHARGE AIR LINES

Contents

09-1030 Air filter removal and replacement

09-6010 Exhaust turbocharger check, examination, fault diagnosis

09-6030 Exhaust turbocharger removal and installation


(Engine version with top-mounted turbocharger)

09-6030a Exhaust turbocharger removal and installation (8V/12V 183 T..3)

09-6263 Exhaust turbocharger disassembly and assembly

09-6800 Intercooler leak check

Intercooler removal and installation


09-6810
(Engine version with top-mounted intercooler)

Intercooler removal and installation


09-6810a
(Engine version with compact intercooler)

Charge air lines removal and installation


09-6812
(Engine version with top-mounted intercooler)

Charge air lines removal and installation


09-6812a
(Engine version with compact intercooler)

Emergency air shut-off flap removal and installation


09-6820
(Engine version with top-mounted intercooler)

Emergency air shut-off flap removal and installation


09-6820a
(Engine version with compact intercooler)

20080/1 E 98-12
Group 09
Subgroup Task Description
Page 2

20080/1 E 98-12
Group 09
Task Description Subgroup 1030
Page 1

09-1030 AIR FILTER REMOVAL AND


REPLACEMENT
Removal

Release clamp (3) and remove air filter (2).

Replace damaged filter.

Always replace air filters during W5 and W6


maintenance.

Remove contamination indicator (1).

Installation

Screw contamination indicator (1) into new filter


- reference dimension approx. 78 mm.

Fit air filter on intake elbow.

Fit clamp (3) and secure with stress bolt.

20080/0 E 97-02
Group 09
Subgroup 1030 Task Description
Page 2

20080/0 E 97-02
Group 09
Task Description Subgroup 6010
Page 1

09-6010 Exhaust Turbocharger Check, Examination, Fault Diagnosis

Data KKK K26 K27/29 K36 K37


Turbocharger

Permissible axial clearance up


to max. 0.16 mm 0.16 mm 0.16 mm 0.16 mm

Permissible radial clearance up


to max. 0.45 mm 0.46 mm 0.58 mm 0.57 mm

Special tools

Note: Oil pressure loss may lead to insufficient lubrication, overheating, power loss and destruction of the
turbocharger.

20080/1 E 98-12
Group 09
Subgroup 6010 Task Description
Page 2

Axial clearance check

Remove turbocharger (09-6030).

Clamp turbocharger in vice.

Note
Use protective jaws.

Fit dial gauge on turbine wheel hub.

Press rotor shaft down and set dial gauge to "0".

Press rotor shaft against dial gauge and read off


clearance.

Dial gauge 001 589 53 21 00


Dial gauge holder 363 589 02 21 00

Radial clearance check

Note
Radial clearance is determined only on turbine side.

Press turbine wheel to side, then use a feeler gauge to


measure gap between turbine wheel and housing and
record measurements.

Press turbine wheel in opposite direction and use feeler


gauge to measure gap.

The difference between the two values is the radial


clearance.

Note
Carry out measurement at 2 points.

20080/1 E 98-12
Group 09
Task Description Subgroup 6010
Page 3

Fault diagnosis

Malfunction Cause Remedy

Exhaust opacity and power reduction Air filter heavily contaminated. Clean or replace air filter element.
Replace Donaldson air filter.

Turbine or compressor wheel Repair or replace turbocharger.


scrapes against housing.

Foreign bodies in exhaust. Remove foreign bodies.

Compressor contaminated. Clean dirt and deposits from


compressor.

Leak between exhaust elbow and Seal turbocharger to exhaust elbow.


exhaust turbocharger.

Charge air line deformed. Replace charge air line.

Insufficient air Check flanges and hose


connections between turbocharger
and charge air manifold for leaks,
renew seals as necessary.

Exhaust pipework behind Check exhaust pipework, clean,


turbocharger or silencer repair or replace silencer.
contaminated or damaged.

Oil separator damaged or Replace oil separator.


contaminated.

Oil level in turbocharger rises, oil The reduced pipe cross-section Clean or replace oil return line.
emerges at seal on turbine and (through carbon deposits) results in
compressor side. increased flow resistance in the oil
return line.

Oil supply line at turbocharger Gasket defective. Replace gasket at oil connection.
leaking.

20080/1 E 98-12
Group 09
Subgroup 6010 Task Description
Page 4

Malfunction Cause Remedy

Whistling noises in area of Leaks at: Replace faulty gaskets.


turbocharger

- Flange connections or gaskets on Check tightness and security of


air and exhaust pipework. flanges and connections.

- Flange seals (shape) Check whether gaskets jut into pipe


cross-sections. If so, replace
gasket.

- Hose or plug-in connections. Check connections for condition and


security.

- Rotor scraping due to excessive Remove lines and check housing on


bearing clearance. turbine and compressor side for
traces of scraping. If traces are
found, replace turbocharger.

Low oil pressure Pressurised oil line to turbocharger Replace pressurised oil line.
damaged.

Oil contamination Oil filter contaminated, wrong filter Replace oil filter. Install oil filter in
installed. accordance with applicable
documentation.

Note:
- Determine exact diagnosis for oil
contamination and rectify.
- Due to high speed, the
turbocharger requires clean oil.

- Check whether correct oil type is


used.

- Fill with oil type in accordance with


Fluids and Lubricants
Specifications.

20080/1 E 98-12
Group 09
Task Description Subgroup 6030
Page 1

09-6030 EXHAUST TURBOCHARGER REMOVAL AND INSTALLATION

Engine 8V 183 T..2 (Engine version with top-mounted intercooler and turbocharger K27)

1 Exhaust turbocharger, left


2 Exhaust turbocharger, right
3 O-Ring replace
4 Hex nut replace
Lubricant: Assembly paste
Tightening torque: 50 Nm.
5 Stud

20080/1 E 98-12
Group 09
Subgroup 6030 Task Description
Page 2

Engine 8V 183 T..2 (Engine version with compact intercooler and turbocharger K27)

1 Exhaust turbocharger, left


2 Exhaust turbocharger, right
3 O-Ring replace
4 Stud
5 Hex nut replace
6 Spring washer

20080/1 E 98-12
Group 09
Task Description Subgroup 6030
Page 3

Engine 12V 183 T..2 (Engine version with exhaust turbocharger K36)

1 Exhaust turbocharger, left


2 Exhaust turbocharger, right
3 Gasket replace
4 Stud
5 Hex nut replace
6 Spring washer

20080/1 E 98-12
Group 09
Subgroup 6030 Task Description
Page 4

Preparatory operations:
Air filter removed (09-1030).
Oil supply and return lines removed (18-1600).
Connecting line to intercooler removed.
Vent lines removed.

Note:
The removal and installation instructions apply to both turbochargers.

Before the turbocharger is removed, the intake line before the compressor, the exhaust elbows and exhaust lines,
as well as the oil supply and return lines, must be checked for foreign bodies, contamination and damage.

The protective caps on the turbocharger openings must only be removed just before installation.

Before connecting the oil supply line, fill the bearing housing through the oil inlet bore with clean engine oil.
In doing so, turn the rotating parts by hand to ensure that the bearings are lubricated with oil.

Removal and installation

Unscrew hex nuts and remove turbocharger.

Installation instructions:

Replace gasket or O-Ring and hex nuts, tighten to 50 Nm.

Install in reverse order.

Coat mating faces with sealing paste, aux. material No. 50546.

Fit hex nuts with assembly paste, aux. material No. 50547.

20080/1 E 98-12
Group 09
Task Description Subgroup 6030a
Page 1

09-6030a Exhaust Turbocharger removal and installation

Engine 8V/12V 183 T..3 (with exhaust turbocharger K29 or K37)


Exhaust turbocharger, left

1 Carrier housing 17 Cover


2 Carrier housing upper section 18 Hex screw
3 Carrier housing lower section 19 Washer
4 Washer 20 Cover
5 Stud 21 Hex screw
6 Stud 22 Hex screw
7 Hex screw 23 Hex screw
8 Hex screw 24 Washer
9 Hex nut 25 O-ring
10 O-ring 26 Flange
11 Hex screw 27 R-ring (piston ring)
12 Hex screw 28 Dowel pin
13 Hex screw 29 Threaded bush, sealed
14 Dowel pin with pipe-thread sealant 40 033
15 Hex screw 30 Sealing ring
16 Washer 31 Plug

20080/1 E 98-12
Group 09
Subgroup 6030a Task Description
Page 2

Exhaust turbocharger, right

1 Carrier housing 11 Washer


2 Carrier housing upper section 12 Tab washer
3 Carrier housing lower section 13 Tab washer
4 O-ring 14 O-ring
5 Stud 15 Cover
6 Stud 16 Sealing ring
7 Hex screw 17 Plug
8 Hex screw 18 Hex screw
9 Hex nut
10 Screw (turbocharger fixture)
Lubricant: Engine oil
Tightening torque: 18+2 Nm

20080/1 E 98-12
Group 09
Task Description Subgroup 6030a
Page 3

Preparatory operations:
Air filter removed (09-1030).
Oil supply and return lines removed (18-1600).
Connecting line to intercooler removed.
Vent lines removed.
Air line to vent valve (waste gate) removed.

Note
The removal and installation instructions apply to both turbochargers.

Before the turbocharger is removed, the intake line before the compressor, the exhaust elbows and exhaust lines,
as well as the oil supply and return lines, must be checked for foreign bodies, contamination and damage.

The protective caps on the turbocharger openings must only be removed just before installation.

Before connecting the oil supply line, fill the bearing housing through the oil inlet bore with clean engine oil.
In doing so, turn the rotating parts by hand to ensure that the bearings are lubricated with oil.

Removal

Remove turbocharger flange.

Remove front cover from carrier housing.

Remove securing screws and tab washers from turbocharger fixtures.

Remove carrier housing upper section.

Remove exhaust turbocharger.

Remove R-rings (piston rings) from turbocharger turbine outlet.

Remove plug-in pipes from exhaust line.

Remove O-ring from carrier housing lower section.

20080/1 E 98-12
Group 09
Subgroup 6030a Task Description
Page 4

Installation

Note:
Carry out installation operations in accordance with arrangement drawings 506 002 27 14 and 506 002 28 14.
Exhaust line and carrier housing lower section are installed.

Fit plug-in pipes (8) in exhaust line (7).


Installation instructions:
Plug-in pipe with bores in long duct (direction of exhaust outlet).

Coat new O-ring (5) with petroleum jelly and fit in carrier housing lower section.

Place locating pins (4) for carrier housing upper section at hand, but do not insert.

Fit new R-rings (piston rings) on turbocharger turbine outlet.

Coat flange of bearing housing (3) and / or opposite carrier housing sealing surface on contact face of carrier
housing lower section / bearing housing (axial) with sealing paste, part No. 50545.

Insert exhaust turbocharger in carrier housing lower section with a distance to the bolt-on surface, threading plug-in
pipes (8) in turbocharger.

Installation instructions
Make absolutely sure that no sealing paste is scraped off.

Fit sealing ring (5), then position turbocharger axially on the flange surface by means of its securing screws with tab
washers.

Coat new O-rings with petroleum jelly and fit in carrier housing lower section.

20080/1 E 98-12
Group 09
Task Description Subgroup 6030a
Page 5

Coat carrier housing upper section with sealing paste (aux. material No. 50545) at mating surface to lower section
and turbocharger.

Thread upper section onto turbocharger, maintaining distance to turbocharger flange-mounting surface.

After installing turbocharger securing screws and tab washers, position upper section on turbocharger
flange-mounting surface.

Drive locating pins (4) into carrier housing upper section.

Pretighten turbocharger threaded connections.

Also pretighten carrier housing upper and lower section threaded connections.

Insert exhaust outlet flange (2) roughly half way so that housing position is finally established.

Tighten carrier housing upper and lower section threaded connections.

Tighten turbocharger securing screws and tab washers to tightening torque 18+2 Nm.

Withdraw exhaust outlet flange and coat collar side of flange with sealing paste, aux. material No. 50545.

Drive locating pins (1) into carrier housing.

Press in exhaust outlet flange at suitable angle (exhaust transfer from waste gate) so that the locating pin fixes the
angle.

20080/1 E 98-12
Group 09
Subgroup 6030a Task Description
Page 6

20080/1 E 98-12
Group 09
Task Description Subgroup 6263
Page 1

09-6263 EXHAUST TURBOCHARGER DISASSEMBLY AND ASSEMBLY

SEE SPECIAL PUBLICATION.

20080/0 E 98-04
Group 09
Subgroup 6263 Task Description
Page 2

20080/0 E 98-04
Group 09
Task Description Subgroup 6800
Page 1

09-6800 INTERCOOLER LEAK CHECK

20080/0 E 97-02
Group 09
Subgroup 6800 Task Description
Page 2

20080/0 E 97-02
Group 09
Task Description Subgroup 6810
Page 1

09-6810 Intercooler Removal and Installation


(Engine version with top-mounted intercooler)

1 Intercooler, installed with sealing paste, aux. material No. 11 Hex screw
50546
2 Socket-head screw 12 Washer
3 Washer 13 Bracket
4 Intercooler 14 Bracket
5 Sealing ring, replace 15 Bracket
6 Union 16 Housing, installed with sealing paste, aux. material No. 50546
7 Sealing cone 17 Hex screw
8 Nut 18 Washer
9 Hex screw
10 Hex screw

Removal and installation


as shown in illustration.

20080/1 E 98-12
Group 09
Subgroup 6810 Task Description
Page 2

20080/1 E 98-12
Group 09
Task Description Subgroup 6810a
Page 1

09-6810A Intercooler Removal and installation


(Engine version with compact intercooler)

1 Connecting housing, sealing paste, part No. 50546 13 Socket-head screw


2 Plug 14 Socket-head screw
3 Sealing ring, replace 15 Washer
4 Intercooler 16 Hex screw
5 Hex screw 17 Washer
6 Hex screw 18 Connecting box, sealing paste, part No. 50546
7 Socket-head screw 19 Socket-head screw
8 Hex screw 20 Hex screw
9 Washer 21 Washer
10 Washer 22 Washer
11 Washer

Removal and installation


as shown in illustration.

20080/1 E 98-12
Group 09
Subgroup 6810a Task Description
Page 2

20080/1 E 98-12
Group 09
Task Description Subgroup 6812
Page 1

09-6812 Charge Air Lines Removal and Installation


(Engine version with top-mounted intercooler)

Crankcase breather and intake elbow

1 Hex screw 12 Cylinder head cover


2 Washer 13 Oil separator
3 Intake elbow before turbocharger 14 Intake hose
4 Bracket 15 Clamp
5 Bracket 16 Connecting pipe
6 Hex screw 17 Sealing ring, replace
7 Washer 18 Elbow, installed with sealing paste, aux. material No. 50546
8 Hex screw 19 Hex screw
9 Washer 20 Washer
10 Rubber sleeve 21 Gasket, for compensating tolerances
11 Clamp

Removal and installation


as shown in illustration.

20080/1 E 98-12
Group 09
Subgroup 6812 Task Description
Page 2

Charge air manifold and charge air lines

1 Charge air manifold 14 Charge air manifold, left (charge air line)
2 Sealing ring, replace 15 Charge air manifold, right (charge air line)
3 Plug 16 Plug
4 Gasket, replace 17 Sealing ring, replace
5 Flange 18 Plug
6 Hex screw 19 Sealing ring, replace
7 Gasket, replace 20 Adapter
8 Socket-head screw 21 Sealing ring, replace
9 Socket-head screw 22 Gasket, replace
10 Washer 23 Hex screw
11 Gasket, replace 24 Hex screw
12 Socket-head screw 25 Sealing cone
13 Washer 26 Nut

Removal and installation


as shown in illustration.

20080/1 E 98-12
Group 09
Task Description Subgroup 6812a
Page 1

09-6812A Charge Air Lines Removal and Installation


(Engine version with compact intercooler)

Crankcase breather and intake elbow

1 Cylinder head cover 13 Clamp


2 Oil separator 14 O-ring, replace
3 Intake hose 15 Plug-in pipe
4 Clamp 16 O-ring, replace
5 Intake elbow 17 Flange
6 Mounting bracket 18 O-ring, replace
7 Hex screw 19 Hex screw
8 Washer 20 Washer
9 Hex screw 21 Hex screw
10 Washer 22 Bush
11 Hex nut 23 Eyebolt
12 Rubber sleeve 24 Eyebolt

Removal and installation


as shown in illustration.

20080/1 E 98-12
Group 09
Subgroup 6812a Task Description
Page 2

Air supply housing and charge air lines

1 Air supply housing *, sealing paste, aux. material No. 50546 13 Charge air line, left
2 Hex screw 14 Plug
3 Hex screw 15 Sealing ring, replace
4 Washer 16 Hex screw
6 Plug-in pipe with bell 17 Washer
7 O-ring, replace 18 Gasket, replace
8 Connecting flange, sealing paste, aux. material No. 50546 19 Charge air line, right
9 Connecting flange, sealing paste, aux. material No. 50546 20 Hex screw
10 Socket-head screw 21 Hex screw
11 Washer

* Does not apply if emergency air shut-off flap fitted

Removal and installation


as shown in illustration.

20080/1 E 98-12
Group 09
Task Description Subgroup 6820
Page 1

09-6820 Emergency Air Shut-Off Flap Removal and Installation


(Engine version with top-mounted intercooler)

1 Bearing bush 11 Lever, right side


2 Shaft seal 12 Lever, left side
3 O-ring, replace 13 Spring pin
4 Shaft 14 Hex screw
5 Flap 15 Washer
6 Key 16 Pull rod
7 Washer 17 Hex screw
8 Sleeve 18 Washer
9 Lockwasher 19 Hex nut
10 Bending spring, right side

20080/1 E 98-12
Group 09
Subgroup 6820 Task Description
Page 2

Shutdown system for emergency air shut-off flap

1 Bracket 15 Spring washer


2 DC solenoid 16 Hex screw
3 Flange 17 Cable entry
4 Spring washer 18 Threaded bush
5 Hex screw 19 Insert
6 Spring washer 20 Washer
7 Hex screw 21 Sealing ring, replace
8 Hex screw 22 Lever
9 Miltac microswitch 23 Hex screw
10 Bracket 24 Spring washer
11 Hex screw 25 Hex nut
12 Spring washer 26 Axle, secured with thread-locking agent, aux. material No. 40083
13 Washer 27 Grease nipple
14 Hex nut

20080/1 E 98-12
Group 09
Task Description Subgroup 6820
Page 3

Arrangement of emergency air shut-off flap with shutdown system

1 Bracket 15 Flap
2 Lever, right side 16 Key
3 Miltac microswitch 17 Lockwasher
4 Pull rod 18 DC solenoid
5 Lever, left side 19 Flange
6 Bracket 20 O-ring
7 Spring pin 21 Lever
8 Shaft 22 Grease nipple,
9 Bending spring installed with thread-locking agent,
10 Washer aux. material No. 40083
11 Bearing bush
12 Shaft seal
13 O-ring
14 Sleeve X = 3 mm, set trip point during assembly

Removal and installation


as shown in illustration.

20080/1 E 98-12
Group 09
Subgroup 6820 Task Description
Page 4

20080/1 E 98-12
Group 09
Task Description Subgroup 6820a
Page 1

09-6820a Emergency Air Shut-Off Flap Removal and Installation


(Engine version with compact intercooler)

1 Miltac microswitch 16 Key 28 Dowel pin


2 Cable entry 17 Grease nipple 29 Lever
3 Threaded bush 18 Bearing bush, 30 Cam
4 Insert Surface sealant 31 Washer
5 Washer aux. material No. 40031 32 Hex nut
6 Sealing ring, replace 20 Shaft seal, replace 33 Axle
7 Washer 21 Washer Tightening torque: 20+2 Nm
8 Hex screw 22 Lockwasher Lubricant: Engine oil
9 Hex nut 23 Sleeve 34 Grease nipple
10 Bracket 24 Bending spring, right 35 Lever
11 Hex screw 25 Control cam 36 Socket-head screw
12 Washer 26 Hex screw 37 Washer
13 Flap housing Tightening torque: 8+1 Nm
14 Flap Lubricant: Engine oil
15 Shaft 27 Spring washer

20080/1 E 98-12
Group 09
Subgroup 6820a Task Description
Page 2

Arrangement of emergency air shut-off flap with shutdown system

1 Flange 8 Bending spring


2 DC solenoid 9 Lever
3 Bracket 10 Axle
4 Lever 11 Grease nipple
5 Bearing bush 12 Control cam
6 Flap 13 Grease nipple
7 Shaft 14 Flap housing

A = 28.6 0.5 mm
Pull rod adjustment dimension
B = 2.1 0. 5 mm
Miltac microswitch
(with emergency air shut-off flap open)
C = 4.9 0.5 mm
Adjustment of inductive
proximity switch
(with emergency air shut-off flap open)

Removal and installation


as shown in illustration.

20080/1 E 98-12
Group 13
Task Description Subgroup
Page

Belt Drives, Air Compressor

20080/1 E 98-12
Group 13
Subgroup Task Description
Seite

20080/1 E 98-12
Group 13
Task Description Subgroup
Page 1

13 Belt Drives, Air Compressor

Contents

13-1001 Belt drive: Installation of V-belts, adjustment specifications, tension check, installation
of clamps
(Example: ship version with alternator and raw water pump)

13-1001a Belt drive: Installation of V-belts, adjustment specifications, tension check, installation
of clamps
(Example: ship version without alternator with tension roller)

13-1402 V-belt replacement

13-7001 Compressor disassembly and assembly

20080/1 E 98-12
Group 13
Subgroup Task Description
Page 2

20080/1 E 98-12
Group 13
Task Description Subgroup 1001
Page 1

13-1001 Belt Drive: Installation Of V-Belts, Adjustment Specifications, Tension


Check, Installation of Clamps
(Example: ship version with alternator and raw water pump)

1 and 3 Screw for clamping element 13 M 12x50 screw for ball joint
2 and 4 Clamping nut with bush
5 and 6 Clamping screw 14 Generator
7 Screw for raw water pump (see Page 2) 15 Raw water pump
8 Screw for raw water pump 16 Fresh water pump
9 Screw M 12x40 17 V-belt 1325 LA (1 unit)
10 Bracket 18 1 V-belt set 1450 LA (2 units)
11 Screw M 10x180 19 Bracket
12 Screw M 8x130

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Group 13
Subgroup 1001 Task Description
Page 2

View Z

20080/1 E 98-12
Group 13
Task Description Subgroup 1001
Page 3

V-belt installation

1. Grooves must be clean and free from oil.

2. Check belt pulleys for axial alignment in at least two positions, offset by 180 to each other.
Deviation of pulley alignment, max. permissible:
Between pulley on crankshaft and pulley on alternator 2 mm
Between pulley on crankshaft and pulley on engine coolant pump 2.5 mm
Between pulley on generator (alternator) and pulley on engine coolant pump 3 mm
Between pulley on crankshaft and pulley on raw water pump 3 mm

The belt pulley of the raw water pump can, if necessary, be aligned with the crankshaft pulley ( 3 mm)
by releasing and then retightening screw No. 9 (see Page 2).

3. For multi-groove drive pulleys, replace V-belts only as complete sets.

4. V-belts must be fitted into the grooves without force: that means gensets to be driven must be released.

5. Lock clamping nuts (2 and 4) with clamping elements and securing screws on adjustable auxiliary gensets
(alternator and raw water pump) after testing the clamping forces.

Adjustment specifications:

Check strand pull of individual V-belts by means of Gates tension tester after approx. 5 engine revolutions. For
initial installation, individual tension must be 550 50 N.
After approx. 15 mins. running under full load, carry out further checks with reference value (if necessary
adjustment value) 400 50 N per belt.

Test specifications

1. Lower indicator arm in measuring device.

2. Place measuring device centrally between two belt pulleys.


The stop must be to the side of the V-belt.

3. With pushbutton, press down evenly at right angle to V-belt until click spring can be heard and felt to disengage.
Do not continue pressing, otherwise the indicated value is distorted.
4. Carefully lift the measuring unit without altering the position of the indicator arm.

5. Read off value of V-belt tension at intersection of crankcase scale and indicator arm.
(Measured value in kg x 10 gives strand pull in N).

6. Rectify V-belt tension as necessary and repeat measurements.

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Subgroup 1001 Task Description
Page 4

Fitting stress bolts:


(Lubricant: engine oil for all threaded unions)

1. Before tensioning the V-belt for the raw water pump, release screws 7 (see Page 2, View Z) and screw No. 8
(do not remove).

2. The swivel heads must be tightened to tightening torque 74 + 7 Nm for screw M12 and 21 + 2 Nm for screw M8
(on 55A alternator), and screw 6 and threaded rod 5 must be locked in the swivel heads.
3. Screws 1 and 3 must only be fitted first by hand only.

4. After tensioning the V-belts as specified, tighten screws 1 and 3 to tightening torque (40 + 4 Nm).

5. Tighten screws 7 (for raw water pump) to tightening torque 21 + 2 Nm.


Tighten screw No. 8 to 25 + 3 Nm.

20080/1 E 98-12
Group 13
Task Description Subgroup 1001a
Page 1

13-1001a belt Drive: Installation of v-Belts, Adjustment Specifications,


tension Check, Installation of Clamp
(Example: ship version without alternator with tension roller)

1 Screw for clamping element


2 Clamping nut
3 Clamping screw

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Group 13
Subgroup 1001a Task Description
Page 2

1 Bracket 23 Ball joint, fitted with thread-locking agent,


2 Tension roller, filled with antifriction bearing grease, aux. material No. 40083
aux. material No. 50524 24 Hex screw
3 Hub 25 Washer
4 Ball bearing 26 Washer
5 Securing element 27 Hex nut
6 Sealing ring 28 V-belts
7 Sealing ring 29 Bracket
8 Sealing ring 30 Hex screw
9 End cover 31 Spacer sleeve
10 Bracket 32 Washer
11 Washer 33 Hex screw
12 Washer 34 Spacer bushing L = 88
13 Hex screw 35 Washer
14 Hex screw 36 Hex screw
15 Washer 37 Hex screw
16 Hex nut 38 Washer
17 Hex screw 39 Washer
18 Hex screw
19 Washer
20 Clamping element
21 Clamping nut
22 Threaded pin

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Group 13
Task Description Subgroup 1001a
Page 3

V-belt installation
1. Grooves must be clean and free from oil.

2. Check belt pulleys for axial alignment in at least two positions, offset by 180 to each other.
Deviation of pulley alignment, max. permissible:
Between pulley on crankshaft and pulley on tensioning roller 2 mm
Between pulley on crankshaft and pulley on engine coolant pump 2.5 mm
Between pulley on tension roller and pulley on engine coolant pump 3 mm.

3. V-belts must be fitted into the grooves without force.

4. After checking clamping forces, lock clamping nut 2 on tension roller by means of clamping element and
securing screw No. 1.

Adjustment specifications:

Check strand pull of individual V-belts by means of Gates tension tester after approx. 5 engine revolutions.
For initial installation, individual tension must be 550 50 N.
After approx. 15 mins. running under full load, carry out further checks with reference value (if necessary
adjustment value) 400 50 N per belt.

Check tension by means of Gates tension tester:

1. Lower indicator arm in measuring device.

2 Place measuring device centrally between two belt pulleys.


The stop must be to the side of the V-belt.

3. With pushbutton, press down evenly at right angle to V-belt until click spring can be heard and felt to disengage.
Do not continue pressing, otherwise the indicated value is distorted.

4. Carefully lift the measuring unit without altering the position of the indicator arm.

5. Read off value of V-belt tension at intersection of crankcase scale and indicator arm. (kg value x 10 gives strand
pull in N).

6. Rectify V-belt tension as necessary and repeat measurements.

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Subgroup 1001a Task Description
Page 4

Fitting stress bolts:


(Lubricant: engine oil for all threaded unions)

1. Secure ball joint to tightening torque (74 + 7 Nm) and lock threaded rod in ball joint.

2. Screws 1 must only be fitted first by hand only.

3. After tensioning the V-belts as specified, tighten screw 1 to tightening torque (40 + 4 Nm).

20080/1 E 98-12
Group 13
Task Description Subgroup 1402
Page 1

13-1402 V-Belt Replacement


(Example: ship version)

Data
V-belt tension new 500 to 600 N
worn 350 to 450 N

Special tool

Replacement

Release clamping screw (1) on alternator and/or raw


water pump and/or tension roller.
Release V-belt with clamping nut (2) and remove via
belt pulley.

Installation instructions
Tighten clamping screw (1) to 40 + 4 Nm.

Fit new V-belt and tension to specified value.


Note
Check V-belt tension with measuring device (see
Section 1001 and 1001a).

20080/1 E 98-12
Group 13
Subgroup 1402 Task Description
Page 2

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 1

13-7001 Compressor Disassembly and Assembly

Preparatory operation:
Gear case cover removed (01-8000).

A Compressor with piston diameter 90 mm

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Group 13
Subgroup 7001 Task Description
Page 2

1 Hex screw, intermediate plate 30 Nm.


2 Hex screw, cylinder head 30 Nm.
3 Cylinder head
4 Gasket replace.
5 Hex screw 15 Nm.
6 Spacer bushing
7 Bracket
8 Washer
9 Delivery valve diaphragm
10 Intermediate plate
11 Suction valve diaphragm
12 Gasket replace.
13 Cylinder liner
14 Hex screw 30 Nm.
15 Spring washer
16 Piston ring
17 Piston ring
18 Piston ring
19 Snap ring
20 Piston pin
21 Piston Band clamp 000 589 20 61 00.
22 Gasket replace.
23 Conrod bolt 30 Nm.
24 Connecting rod with conrod bearing
25 Flange
26 Bush Mandrel 363 589 03 15 00.
27 Sealing ring replace.
28 Crankshaft with support disc Locking device 442 589 09 63 00.
29 Main bearing cap
30 Hex screw 50 Nm.
31 Roller bearing with support disc Internal extractor 000 589 28 33 00,
Counter support 000 589 34 33 00,
Mandrel 198 589 03 39 00.
32 Drive gear
33 Hex screw Tighten with box wrench 442 589 00 03 00, 270 Nm. This corresponds
to an actual value of 360 Nm.

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Task Description Subgroup 7001
Page 3

B Compressor with piston diameter 100 mm

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Group 13
Subgroup 7001 Task Description
Page 4

46 Hex screw, cylinder head 30 Nm.


47 Hex screw, intermediate plate 30 Nm.
48 Cylinder head
49 Gasket replace.
50 Hex nut 15 Nm.
51 Valve plates
52 Delivery valve diaphragm
53 Intermediate plate
54 Suction valve diaphragm
55 Gasket replace
56 Cylinder liner
57 Gasket replace.
58 Piston ring
59 Piston ring
60 Piston ring
61 Snap ring
62 Piston Band clamp 000 589 20 61 00.
63 Piston pin
64 Hex screw 60 Nm.
65 Outer bearing flange
66 O-Ring replace.
67 Bearing bush Check, replace
68 Crankshaft Locking device 442 589 09 63 00.
69 Connecting rod
70 Bearing bush
71 Inner bearing flange
72 Hex screw 30 Nm.
73 Drive gear
74 Hex screw Tighten with box wrench 442 589 00 03 00, 270 Nm. This corresponds
to an actual value of 360 Nm.

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Group 13
Task Description Subgroup 7001
Page 5

Piston clearance/projection (to upper edge of cylinder liner)


1 cylinder dia. 90 mm - 0.16 to - 1.09
2 cylinders dia. 90 mm - 1.66 to - 2.59
1 cylinder dia. 100 mm + 0.09 to -0.71

Tightening torques Nm
Steering assist pump on gear case 60
Bearing cap on gear case 25

Delivery rates

rpm
rpm

A Compressor 2 cyl. dia. 90 mm


B Compressor 1 cyl. dia. 100 mm
C Compressor 1 cyl. dia. 90 mm
D Engine speed
E Compressor speed

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Group 13
Subgroup 7001 Task Description
Page 6

Special tools

A Compressor with piston diameter 90 mm


Note
When installing a new compressor or replacement
engine, check the compressor H.P. line for
carbonisation. If the line is restricted, the H.P. lines and
pressure regulator must be replaced.

Disassembly

Remove coolant supply and return lines (arrows).

Box wrench (open) 000 589 07 03 00

Remove compressed air line (35) and intake line (36).

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Task Description Subgroup 7001
Page 7

Remove cylinder head (3) with intermediate plate.

Unscrew cylinder liner (arrows) and remove over piston.

Remove snap ring (19) for piston pin (20).

Press out piston pin (20) and remove piston.

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Subgroup 7001 Task Description
Page 8

Remove side cover (39).

Remove conrod (24) together with bearing cap and


bearing shells.

Remove steering assist pump (37) and driver disc (38).

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Task Description Subgroup 7001
Page 9

Place locking device over crankshaft and secure.

Note
The crankshaft must be rotated until the crankpin is
facing upwards.

Locking device 442 589 09 63 00

Unscrew hex screw on front drive gear (32) with box


wrench insert and remove drive gear (32) with hex
screw.

Box wrench 442 589 00 03 00

Remove locking device, part No. 442 589 09 63 00.

Use an assembly lever to press crankshaft (28) from


bearing and remove bearing flange (25).

Note
When the crankshaft (28) is pressed out, the roller
bearing inner race must be held firmly in position
(arrow) to prevent it from falling into the gear case.

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Subgroup 7001 Task Description
Page 10

Remove lockwasher (29) for bearing.

Withdraw bearing (31) with internal extractor and


customer-furnished support plate.

Internal extractor 000 589 28 33 00


Spindle from counter-support 000 589 34 33 00

Use mandrel to remove bearing bush from bearing


flange.

Mandrel 363 589 03 15 00

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Task Description Subgroup 7001
Page 11

Remove hex screw (1) from cylinder head.

Remove cylinder head gasket (12) and suction valve


diaphragm (11).

Remove intermediate plate (10) and gasket (4).

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Subgroup 7001 Task Description
Page 12

Remove delivery valve diaphragm (9) from intermediate


plate.

Assembly

Install bearing bush (26) in the bearing flange (25) and


recondition with a reamer. See Tolerances and Wear
Limits List for specified values (13-7001).
Note
The oil bores in the bearing bush (26) and bearing
flange (25) must be aligned.

Mandrel 363 589 03 15 00

Bolt roller bearings together with 2 metal discs (arrow)


to prevent their separation.

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Task Description Subgroup 7001
Page 13

Position roller bearing so that collar of bearing inner


race points towards fan.

Install roller bearing in bearing cap.

Mandrel 198 589 03 39 00

Remove metal washers.

Install bearing cap (29) and tighten hex screws


(50 Nm).

Fit loose support disc, with chamfer (arrow) facing


crankpin, on crankshaft.

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 14

Hold roller bearing inner race firmly in position and


install crankshaft (28).

Replace O-ring (27).

Oil bearing flange (25) at fit and O-ring (27), place on


housing and crankshaft. Oil bores (arrows) in housing
and in bearing flange (25) must be aligned.

Install bearing flange (25) by tightening hex screws


(arrows) evenly.

Again remove hex screws.

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Group 13
Task Description Subgroup 7001
Page 15

Mount drive gear (32) with hex screw.

Place locking device over crankshaft and secure.

Locking device 422 589 09 63 00

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 16

Tighten hex screw of drive gear (270 Nm).

Note
This value corresponds to an actual torque of 360 Nm.

Torque wrench (40), ratchet adapter (41) and box


wrench (42) must be positioned in one line with respect
to each other.

Box wrench (42) 442 589 00 03 00

Remove locking device, part No. 442 589 09 63 00.

Install steering assist pump (37) with new O-ring and


driver disc (38), tighten hex screws (60 Nm).

Insert conrod bearing shells in conrod cap and conrod.


The oil bores (arrows) in the conrod bearing and in the
conrod must be aligned.

The markings (43) on the conrod cap and (44) on the


conrod must be aligned.

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 17

Install conrod (24) with conrod cap and bearing shells,


tighten conrod bolts to 30 Nm.

Place piston over conrod and install piston pin (20) and
snap ring (19).

Fit cylinder liner gasket on gear case.

Offset piston ring butts by 120 (arrows).

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 18

Compress piston rings with pliers until band clamp can


still just be displaced.

Position cylinder liner over piston and press into place.

Band clamp 000 589 20 61 00

Tighten hex screws (arrows). 25 Nm.

Fit delivery valve diaphragm (9) on intermediate plate


and insert washer (8) into recess (arrow) on diaphragm.

Fit valve plate (7) with curved surface facing up on


delivery valve diaphragm (9) and tighten. Tighten hex
screws (5) to 15 Nm.

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 19

Fit intermediate plate (10) with new gasket (4) on


cylinder head and tighten by hand.

Fit suction valve diaphragm (11) and cylinder head


gasket (12) with designation "Top" in direction of
suction valve diaphragm on locking pins.

Tighten hex screws for cylinder head (3) and hex screw
(1) for intermediate plate to 30 Nm.

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 20

Tighten end cover (39) with new gasket on gear case to


25 Nm.

Install gear case cover and seal


(01-8000).

Install coolant supply and return lines (arrows).

Box wrench (open) 000 589 07 03 00

Install compressed air line (35) and intake line (36).

Secure lines on steering assist pump.

B Compressor with piston diameter 100 mm

Disassembly

Unscrew coolant supply and return lines (arrows).

Box wrench (open) 000 589 07 03 00

Remove compressed air line (75).

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 21

Remove hex screws (46) for compressor.

Remove cylinder head (48) with intermediate plate.

Remove cylinder liner (56).

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 22

Remove snap ring (61) for piston pin (63).

Press out piston pin (63) and remove piston.

Remove steering assist pump (37) and driver disc (38).

Remove side cover (39).

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 23

Place locking device over connecting rod or crankshaft


and tighten.

Note
The crankshaft must be rotated until the crankpin with
connecting rod is facing upwards.

Locking device 442 589 09 63 00

Unscrew hex screw from drive gear (73) with box


wrench and remove drive gear (73) with hex screw.

Box wrench 442 589 00 03 00

Remove locking device.

Use an assembly lever to press crankshaft (68) with


connecting rod (69) out of bearing bush and remove
outer bearing flange (65).

Remove crankshaft (68) with connecting rod (69) from


above.

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 24

Remove inner bearing flange (71) from gear case.

Use a suitable mandrel to remove bearing bush from


inner bearing flange.

Use a suitable mandrel to remove bearing bush from


outer bearing flange.

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 25

Remove gasket (55) and suction valve diaphragm (54)


from intermediate plate or from cylinder head.

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 26

Unscrew hex screw (47) and remove cylinder head with


gasket (49) from intermediate plate (53).

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 27

Remove hex nuts (50).

Remove valve plates (51) and delivery valve


diaphragms (52).

Assembly

Install bearing bush (67) in outer bearing flange (65)


and recondition with a reamer.
See Tolerances and Wear Limits List for specified
values (13-7001).

Note
The oil bores in the bearing bush (67) and bearing
flange (65) must be aligned.

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 28

Install bearing bush (70) in inner bearing flange (71)


and recondition with a reamer.
See Tolerances and Wear Limits List for specified
values (13-7001).

Note
The groove (arrow) of the divided bearing bush must
face upwards when installed.

Install inner bearing flange (71) and tighten with hex


screws to 30 Nm.

Install crankshaft with connecting rod from above.

Replace O-ring (66).

Oil outer bearing flange (65) at fit and O-ring (66).

Position bearing flange (65) on housing and crankshaft.


Oil bores (arrows) in housing and in bearing flange (65)
must be aligned.

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 29

Install bearing flange (65) by tightening hex screws


(arrows) evenly.

Again remove hex screws.

Mount drive gear (73) with hex screw.

Place locking device over connecting rod or crankshaft


and tighten.

Locking device 442 589 09 63 00.

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 30

Tighten hex screw of drive gear (270 Nm).

Note
This value corresponds to an actual torque of 360 Nm.

Torque wrench (77), ratchet adapter (78) and box


wrench (79) must be positioned in one line with respect
to each other.

Box wrench (79) 442 589 00 03 00

Remove locking device, part No. 442 589 09 63 00.

Install steering assist pump (37) with new O-ring and


driver disc (38), tighten hex screws (60 Nm).

Place piston over conrod and install piston pin (63) and
snap ring (61).

Fit cylinder liner gasket on gear case.

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 31

Offset piston ring butts by 120 (arrows).

Compress piston rings with pliers until band clamp can


still just be displaced.

Position cylinder liner over piston and press into place.

Band clamp 000 589 20 61 00.

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 32

Fit delivery valve diaphragms (52) and valve plates (51)


and tighten hex nuts to 15 Nm.

Note
Delivery valve diaphragms (52) and valve plates (51)
must snap into place.

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 33

Bolt cylinder head (48) and new gasket (49) with


intermediate plate (53) and tighten by hand.

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 34

Fit suction valve diaphragm (54) and cylinder head


gasket (55) with designation "Top" in direction of
suction valve diaphragm (54) on locking pins.

Place cylinder head (48) on cylinder liner.

20080/1 E 98-12
Group 13
Task Description Subgroup 7001
Page 35

Tighten hex screws (46) for compressor and hex screw


(47) for intermediate plate to 30 Nm.

Tighten end cover (39) with new gasket on gear case to


25 Nm.

Install gear case cover and seal


(01-8000).

Install coolant supply and return lines (arrows).

Box wrench (open) 000 589 07 03 00

Connect delivery line (75).

Secure lines on steering assist pump.

20080/1 E 98-12
Group 13
Subgroup 7001 Task Description
Page 36

20080/1 E 98-12
Group 14
Task Description Subgroup
Page

Exhaust Line

20080/1 E 98-12
Group 14
Subgroup Task Description
Page

20080/1 E 98-12
Group 14
Task Description Subgroup
Page 1

14 EXHAUST LINE

Contents

14-3630 Exhaust lines removal and installation (V183T..2)

14-3630a Exhaust lines removal and installation (V183T..3)

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Group 14
Subgroup Task Description
Page 2

20080/1 E 98-12
Group 14
Task Description Subgroup 3630
Page 1

14-3630 Exhaust Lines (exhaust elbows) Removal and Installation


(V183T..2)

Exhaust lines, uncooled, 12V 183

1 Exhaust elbow, rear, left 10 Spring washer


2 Exhaust elbow, front, left 11 Screw
3 Exhaust elbow, centre, left 12 Gasket replace
4 Exhaust elbow, centre, right 13 Screw
5 Exhaust elbow, rear, right 14 Nut
6 Exhaust elbow, front, right 15 Gasket replace
7 Sealing ring replace 16 Screw 50 Nm
8 Link 17 Clamping element
9 Cover plate 18 Spring washer

20080/0 E 97-02
Group 14
Subgroup 3630 Task Description
Page 2

Exhaust lines, liquid-cooled, 12V 183

1 Exhaust line 8 Link


2 End cover 9 Sealing ring replace.
3 Plug, ventilation 10 Blank flange
4 Sealing ring replace. 11 Gasket replace.
5 Plug, drain 12 Screw
6 Gasket replace. 13 Securing screw
7 Link 14 Gasket replace.

20080/0 E 97-02
Group 14
Task Description Subgroup 3630
Page 3

Exhaust elbow, liquid-cooled

1 Left elbow, installed with sealing paste, aux. material No. 50546
2 Right elbow, installed with sealing paste, aux. material No. 50546
3 Socket-head screw 80 Nm.
4 Socket-head screw 23 Nm.
5 Link
6 O-Ring replace.
7 Plug-in pipe

20080/0 E 97-02
Group 14
Subgroup 3630 Task Description
Page 4

Exhaust elbow between turbocharger and exhaust line

1 Elbow
2 Gasket
3 Link
4 O-Ring
5 Hex screw

Note
Remove exhaust pipework attachments according to engine version.

Removal, installation
Remove and install exhaust lines in accordance with sequence shown in illustration.

20080/0 E 97-02
Group 14
Task Description Subgroup 3630a
Page 1

14-3630a Exhaust Line Removal and Installation (v183 t..3)

Exhaust lines 8V 183 T..3

1 Flange 15 Exhaust line (hot component) 31 Cover, free end, right


2 Socket-head screw MMN 384 16 O-ring 32 Cover, free end, left
Lubricant: Engine oil 17 Hex screw 33 Washer
Pretighten: 30+3 Nm 18 Hex screw 34 O-ring
Additional angle of rotation: 60+5 19 Washer 35 Hex screw
3 Gasket 20 Clamp 36 Socket-head screw MMN 384
4 Flame pipe 21 Dowel pin
5 Hex screw 22 Hex screw
Lubricant: Assembly paste 23 Washer
Tightening torque: 18+2 Nm 24 Stud
6 Washer 25 Hex nut
7 Exhaust line (aluminium profile) 26 Hex screw, SB
8 Plug Lubricant: Assembly paste
9 Sealing ring Tightening torque: 55+5 Nm
10 Exhaust line (hot component) 27 Washer
11 Gasket 28 Sliding element
12 Grooved pin 29 Washer
13 Plug-in pipe 30 Hex screw, SB
14 Plug-in pipe, drilled, fitted in long duct Lubricant: Assembly paste
Tightening torque: 55+5 Nm.

20080/0 E 97-02
Group 14
Subgroup 3630a Task Description
Page 2

Exhaust lines 12V 183 T..3

1 Flange 17 Hex screw 31 Washer


2 Socket-head screw MMN 384 18 Hex screw 32 Cover
Lubricant: Engine oil 19 Clamp 33 Cover
Pretighten: 30+3 Nm 20 Dowel pin 34 Hex screw
Additional angle of rotation: 60+5 21 Washer 35 Hex screw
3 Gasket 22 Hex screw 36 Washer
4 Flame pipe 23 Washer 37 O-ring
5 Hex screw 24 Spring pin 38 O-ring
Lubricant: Assembly paste 25 Hex screw, SB 39 Plug-in pipe
Tightening torque: 18+2 Nm Lubricant: Assembly paste
6 Washer Tightening torque: 55+5 Nm
7 Exhaust line (aluminium profile) 26 Washer
8 Plug 27 Sliding element
9 Sealing ring 28 Washer
10 Exhaust line (hot component) 29 Hex screw, SB
11 Exhaust line (hot component) Lubricant: Assembly paste
12 Exhaust line (hot component) Tightening torque: 55+5 Nm
13 Exhaust line (hot component) 30 Hex screw, SB
14 Plug-in pipe Lubricant: Assembly paste
15 Gasket Tightening torque: 55+5 Nm
16 Grooved pin

20080/0 E 97-02
Group 14
Task Description Subgroup 3630a
Page 3

Carrier housing, left, 8V/12V 183 T..3

1 Carrier housing 17 Cover


2 Carrier housing upper section 18 Hex screw
3 Carrier housing lower section 19 Washer
4 Washer 20 Cover
5 Stud 21 Hex screw
6 Stud 22 Hex screw
7 Hex screw 23 Hex screw
8 Hex screw 24 Washer
9 Hex nut 25 O-ring
10 O-ring 26 Flange
11 Hex screw 27 R-ring (piston ring)
12 Hex screw 28 Dowel pin
13 Hex screw 29 Threaded bush, sealed with pipe-thread sealant 40033
14 Dowel pin 30 Sealing ring
15 Hex screw 31 Plug
16 Washer

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Subgroup 3630a Task Description
Page 4

Carrier housing, right, 8V/12V 183 T..3

1 Carrier housing 11 Washer


2 Carrier housing upper section 12 Tab washer
3 Carrier housing lower section 13 Tab washer
4 O-ring 14 O-ring
5 Stud 15 Cover
6 Stud 16 Sealing ring
7 Hex screw 17 Plug
8 Hex screw 18 Hex screw
9 Hex nut
10 Screw (turbocharger fixture)
Lubricant: Engine oil
Tightening torque: 18+2 Nm

20080/0 E 97-02
Group 14
Task Description Subgroup 3630a
Page 5

Drain valve (waste gate), 8V/12V 183..3

1 Bracket 10 Washer
2 Hex screw 11 Hex screw
3 Washer 12 Clamp
4 Socket-head screw 13 Clamp
5 Drain valve DM 35 14 Washer
6 Air line, right 15 Hex screw
7 Air line, left 16 Hex nut
8 Banjo screw 17 Sealing ring
9 Clamp

20080/0 E 97-02
Group 14
Subgroup 3630a Task Description
Page 6

Preparatory operations:
Air filter removed (09-1030)
Exhaust turbocharger removed (09-6030a)

Removal

Remove exhaust lines in sequence shown in illustration.

Installation

Note:
Install in accordance with arrangement drawing 506 002 27 14.

Installation instructions:
SB screws and MMN 384 screws can be used once only. Fit with assembly paste MTH 5128-Ultra-Therm, aux.
material No. 50542.
All sealing joints are sealed with sealing paste MTS 7025-Elastosil N189, aux. material No. 50545; exception:
intermediate flanges to cylinder head / to profile.

Assembly sequence:

Install flanges with gaskets and flame pipes on cylinder heads.

Assemble exhaust lines with manifolds (hot) and carrier housing lower section on engine.

Install sliding element.

Install exhaust turbocharger in carrier housing (09-6030a).

Fit front cover on exhaust line and carrier housing.

Install vent lines, oil supply and return lines.

20080/0 E 97-02
Group 15
Task Description Subgroup
Page

Engine Electrical System

20080/1 E 98-12
Group 15
Subgroup Task Description
Page

20080/1 E 98-12
Group 15
Task Description Subgroup
Page 1

15 Engine Electrical System

Contents

15-5030 Alternator (generator) removal and installation

15-7100 Starter removal and installation

20080/1 E 98-12
Group 15
Subgroup Task Description
Page 2

20080/1 E 98-12
Group 15
Task Description Subgroup 5030
Page 1

15-5030 alternator (generator) Removal and Installation


(Example: ship version)

1 Alternator 140 A 21 Washer


2 Belt pulley 22 Clamping element
3 Air intake cover 23 Clamping nut
4 Hex nut M5 24 Ball joint, fitted with thread-locking agent, aux. No. 40083
5 Grommet Tightening torque 74 + 6 Nm
6 Protective cap 25 Bracket
7 Protective cap 26 Hex screw M12
8 Hex nut M8 27 Bush
9 Washer 28 Hex screw
10 Hex nut M6 29 Washer
11 Washer 30 Hex screw
12 Washer 31 Spacer sleeve
13 Adjusting shim 32 Washer
14 Bracket 33 Hex screw
15 Hex screw 34 Spacer bushing
16 Hex screw 35 Washer
17 Hex nut 36 Hex screw
18 Washer 37 Washer
19 Hex screw 38 Hex screw tightening torque 40 + 4 Nm
20 Hex screw 39 Set of V-belts

20080/1 E 98-12
Group 15
Subgroup 5030 Task Description
Page 2

Removal/installation

Disconnect battery negative terminal.

Separate earth connection.

Disconnect electrical wires from alternator.

Release clamping screw (38) on alternator.

Release V-belt with clamping nut (23) and remove via


belt pulley.

Installation instructions
Replace and tension V-belt (13-1402).

Tighten hex screw (38) for clamping element -


tightening torque 40 + 4 Nm.

Remove securing screws and securing nuts and


remove alternator.

Install in reverse order.

20080/1 E 98-12
Group 15
Task Description Subgroup 7100
Page 1

15-7100 Starter Removal and Installation

Preparatory operations:
Disconnect battery negative terminal.

1 Hex nut
2 Spring washer
3 Earth wire
4 Hex nut
5 Spring washer
6 Electrical wire
7 Hex nut
8 Spring washer
9 Electrical wires
10 Hex nut 80 Nm
11 Spring washer
12 Starter Remove starter from below, lubricate starter pinion with long-lasting
lubricant grease.

20080/1 E 98-12
Group 15
Subgroup 7100 Task Description
Page 2

Note
Remove components in order of numbers and reinstall in reverse sequence.

For cleaning work:

With starter removed, clean with bearing flange facing down - i.e. hanging
so that no moisture can penetrate the magnetic switch.

With starter installed, do not clean with direct water jet.

Penetrating moisture leads to corrosion and interrupted contact of magnetic switch.

Check starter ring gear for wear.

20080/1 E 98-12
Group 17
Task Description Subgroup
Page

Air Starting System

20080/1 E 98-12
Group 17
Subgroup Task Description
Page

20080/1 E 98-12
Group 17
Task Description Subgroup
Page 1

17 Air Starting System

Contents

20080/1 E 98-12
Group 17
Subgroup Task Description
Page 2

20080/1 E 98-12
Group 18
Task Description Subgroup
Page

Engine Lubrication, Engine Oil Cooling

20080/1 E 98-12
Group 18
Subgroup Task Description
Page

20080/1 E 98-12
Group 18
Task Description Subgroup
Page 1

18 Engine Lubrication, Engine oil Cooling

Contents

18-1600 Oil lines

18-1601 Engine oil system filling

18-3476 Oil filter element removal and installation

18-5471 Oil spray nozzle removal and installation

18-6023 Oil pump removal and installation

18-6068 Oil pump disassembly and assembly

18-6840 Oil cooler removal and installation (for hanging oil filter)

18-7109 Oil cooler disassembly and assembly (for hanging oil filter)

18-7109a Oil cooler disassembly and assembly (for flange-mounted, standing oil filter)

20080/1 E 98-12
Group 18 18
Subgroup Task Description
Page 2

20080/1 E 98-12
Group 18
Task Description Subgroup 1600
Page 1

18-1600 Oil Lines

Oil supply and return for exhaust turbocharger (8/12V 183 T..2)

1 Adapter 14 Hex screw


2 Sealing ring 15 Hex screw
3 Oil line 16 Elbow
4 T-piece 17 Elbow
5 Oil line, left 18 Washer
6 Oil line, right 19 Gasket
7 Gasket 20 Hex screw
8 Hex screw 21 Hex screw
9 Washer 22 Elbow
10 Bracket 23 Nut
11 Pipe clamp half 24 Oil line
12 Grommet 25 Sealing ring
13 Washer

20080/1 E 98-12
Group 18
Subgroup 1600 Task Description
Page 2

Oil supply and return for exhaust turbocharger (8/12V 183 T..3)

1 Adapter 15 Hex screw


2 Sealing ring 16 Hex screw
3 Oil line 17 Flange
4 T-piece 18 O-ring
5 Oil line, left 19 Hex screw
6 Oil line, right 20 Washer
7 Socket-head screw 21 Flange
8 O-ring 22 O-ring
9 Washer 23 Hex screw
10 Clamp 24 Washer
11 Bracket 25 Oil line
12 Pipe clamp half 26 Sealing ring
13 Grommet 27 Elbow
14 Washer 28 Nut

20080/1 E 98-12
Group 18
Task Description Subgroup 1600
Page 3

Oil return from injection pump

1 Oil return line


2 Banjo screw
3 Sealing ring

20080/1 E 98-12
Group 18
Subgroup 1600 Task Description
Page 4

Removal

Remove oil lines

Remove oil lines, connecting and fixture elements from engine as per overview.

Remove sealing rings and gaskets.

After removal, seal all connections with suitable plugs.

Protect oil lines from damage.

Inspection and repair

Note:
Ensure that components are particularly clean.

Clean fuel lines with cleaner. Check condition of lines and inspect for damage; replace lines if necessary.

Pressure-test oil lines with air in water bath for leaks as necessary.

Caution!
Compressed air is air which has been compressed under pressure. Risk of injury!
Pressure must not exceed 0.5 bar.
Wear protective clothing, protective gloves and protective goggles/safety mask.

Coolant temperature: min. 30 C, whereby the component must also be at this temperature, max. 40 C,
if the component is to be held in the hand.
Test pressure: 0.5 bar

If leaks are found, replace oil line.

Caution!
Compressed air is air which has been compressed under pressure. Risk of injury!
Always wear protective goggles when blowing out or drying out with compressed air.
The pressure must not exceed 3 bar.
Then blow dry lines with compressed air.

Check connecting components and fixtures of oil lines for damage and wear; replace components as necessary.

Check sealing and mating faces, smooth with oilstone or emery cloth if necessary.

Check condition threads for ease of movement; machine or replace components as necessary.

Replace sealing rings and gaskets.

20080/1 E 98-12
Group 18
Task Description Subgroup 1600
Page 5

Installation

Note:
Before installation, remove all blanking plugs.

Caution!
Compressed air is air which has been compressed under pressure. Risk of injury!
Always wear protective goggles when blowing out or drying out with compressed air.
The pressure must not exceed 3 bar.

Blow out oil lines with compressed air and ensure that they are perfectly clean.

Install oil lines with new sealing rings, gaskets with connecting and fixture components free of tension in accordance
with overview drawings.
Note:
After engine start, visually inspect oil lines for leaks.

20080/1 E 98-12
Group 18
Subgroup 1600 Task Description
Page 6

20080/1 E 98-12
Group 18
Task Description Subgroup 1601
Page 1

18-1601 Engine Oil System Filling

Special tools

Scope of work
Remove cylinder head cover of 1st and last cylinder
(01-5014).

Engine with hanging oil filter


Remove hex socket screw from oil cooler cover.

Screw in intermediate element (2) with reduction union


(M18x1.5) (1) and connecting hose from oil filler tank
352 589 11 63 00.
Note:
Do not remove oil bypass valve.

20080/1 E 98-12
Group 18
Subgroup 1601 Task Description
Page 2

Engine with standing oil filter

Remove hex socket screw (3) at oil duct to oil filter


housing.

Screw reduction union (M20x1.5) to connecting hose


from oil filler tank (5).

Oil tank 352 589 11 63 00


Reduction union 442 589 12 63 00

Note:
Do not remove oil bypass valve.

Fill oil filler tank with approved engine oil and seal.

With hand pump fitted, create approx. 3 bar


overpressure, shut-off valve closed.

Open shut-off valve until approx. 4.0 l engine oil is


pumped from the oil filler tank into the oil ducts and the
engine oil emerges bubble free at the rocker arms of
the 1st and last cylinder. The overpressure in the oil
filler tank should not drop below 1.5 bar, otherwise keep
pumping.

Note:
If oil filler pump is completely empty, air is forced in.

20080/1 E 98-12
Group 18
Task Description Subgroup 1601
Page 3

Unscrew connecting hose and reduction union or


intermediate element and tighten hex socket screw with
new gasket to 60 Nm.

Install cylinder head cover (6) of 1st and last cylinder


with new gaskets (7), tighten hex screws (8) to 25 Nm
(01-5014).

Top up remaining engine oil at filler neck up to "Max"


mark on oil dipstick.

Priming oil and starting engine

DANGER!
Before starting the engine, ensure nobody is
within the danger area.
After working on the engine, check that all guards
have been reinstalled on the engine and that all
tools and loose components have been removed
from the engine.

Move injection pump shutdown lever to Stop position


(shutdown button or emergency shutdown lever).

Bar engine with starter until oil pressure is displayed.


This is necessary to prevent bearing damage.

When oil pressure is displayed, cancel shutdown


measure.

Note:
Do not increase engine speed until oil pressure is
displayed.

Allow engine to run at idle and check oil filter for leaks.

20080/1 E 98-12
Group 18
Subgroup 1601 Task Description
Page 4

Shut down engine after approx. 5 minutes.


(Systems with long-life oil filter after approx. 10 minutes
operation).

Check engine oil level, top up if necessary


(see operating instructions).

20080/1 E 98-12
Group 18
Task Description Subgroup 3476
Page 1

18-3476 Oil Filter Element Removal and Installation

See Operating Instructions

20080/0 E 98-04
Group 18
Subgroup 3476 Task Description
Page 2

20080/0 E 98-04
Group 18
Task Description Subgroup 5043
Page 1

18-5043 Pressure Relief Valve Removal and Installation

Preparatory operations:
Oil pan removed (01-7500).

1 Pressure relief valve Opening pressure at 6.5 0.7 bar


2 Hex screw 35 Nm

Removal and installation


as shown in illustration.

20080/1 E 98-12
Group 18
Subgroup 5043 Task Description
Page 2

20080/1 E 98-12
Group 18
Task Description Subgroup 5471
Page 1

18-5471 OIL SPRAY NOZZLE


REMOVAL AND INSTALLATION

Preparatory operations:
Crankshaft removed (03-4352).

Data
Oil spray nozzle inner dia. 2 mm

Special tools

Removal/installation

Remove oil spray nozzle (1) from crankcase.

Installation instructions:
The dowel pin of the oil spray nozzle (1) must engage in
the crankcase bore.
Tighten banjo screw (2) to 40 Nm.

Note:
After installing piston, bar engine and ensure there is
clearance between oil spray nozzle and piston.

20080/1 E 98-12
Group 18
Subgroup 5471 Task Description
Page 2

Checking

Secure oil spray nozzle (1) with banjo screw (2) on


testing device.

Note:
Take care not to damage dowel pin.

Testing device 403 589 01 23 00

With guide (3), check spraying direction of oil spray


nozzle (1).

Note:
For the 3rd cylinder, an oil deflector (4) is installed with
the oil spray nozzle.

Install in reverse sequence.

20080/ 98-12
Group 18
Task Description Subgroup 6023
Page 1

18-6023 Oil Pump Removal and Installation

Preparatory operations:
Pressure relief valve removed (18-5043).

1 Hex screw 35 Nm.


2 Hex screw 35 Nm.
3 Washer
4 Oil pump with oil extraction pipe

Removal and installation


Remove components in order of numbers and reinstall in reverse sequence.

20080/1 E 98-12
Group 18
Subgroup 6023 Task Description
Page 2

20080/1 E 98-12
Group 18
Task Description Subgroup 6068
Page 1

18-6068 Oil Pump Disassembly and Assembly

Preparatory operations:
Oil pump removed (18-6020).

1 Hex screw 25 Nm, for 12V 183 35 Nm.


2 Cover
3 Gear, driven for 12V 183, 2 units.
4 Gear, driving
5 Oil pump housing
6 Drive gear
7 Gasket replace.
8 Hex screw 35 Nm.
9 Intake pipe for 12V 183, 2 units.

20080/1 E 98-12
Group 18
Subgroup 6068 Task Description
Page 2

Special tools

Disassembly, Assembly

Remove intake pipe (9).


Note:
For 12V 183. Remove two intake pipes.

Installation instructions
Replace gasket.

Tighten hex screws (8) to 25 Nm.

Place dial gauge holder with dial gauge on oil pump.

Place test prod of dial gauge under preload on oil pump


shaft.

Press oil pump shaft down and set dial gauge to "0".

Press oil pump shaft against dial gauge and read off
axial clearance.
See Tolerances and Wear Limits List 18-6068 for axial
clearance.

Dial gauge 001 589 53 21 00


Dial gauge holder 363 589 02 21 00

20080/1 E 98-12
Group 18
Task Description Subgroup 6068
Page 3

Remove housing cover (2).

Installation instructions
Tighten hex screws (1) to 25 Nm.

For 12V 183, tighten hex screws (1) to 35 Nm.

Remove driven gear (3) with shaft from housing.

Note:
For 12V 183, remove two driven gears.

Remove drive shaft with driving gear from drive gear


(6).

20080/1 E 98-12
Group 18
Subgroup 6068 Task Description
Page 4

Installation instructions
Heat drive gear (6) and press onto drive shaft (4)
with a clearance of 0.5 mm to drive shaft (4).

Remove driving gear (4) with drive shaft from housing.

Assemble in reverse sequence.

20080/1 E 98-12
Group 18
Task Description Subgroup 6840
Page 1

18-6840 Oil Cooler Removal and Installation (for hanging oil filter)

Preparatory operations:
Engine coolant drained
Oil filter element removed (see Operating Instructions)

1 Gasket replace.
2 Oil cooler, complete
3 Sealing ring replace.
4 Oil drain plug remove and drain oil, 50 Nm.
5 Sealing ring replace.
6 Coolant drain plug remove and drain coolant, 50 Nm.
7 Hex screw 70 Nm.
8 Spring washer
9 Hex screw 70 Nm.

20080/1 E 98-12
Group 18
Subgroup 6840 Task Description
Page 2

Removal and installation

Remove components in order of numbers and reinstall in reverse sequence.

Fill engine oil system with engine oil, see 18-1601.

Check and correct coolant level - see Operating Instructions.

Oil priming and engine starting - see 18-1601.

Switch off the engine, check the oil cooler for leaks.

After approx. 5 minutes check and correct the engine oil and coolant levels.

20080/1 E 98-12
Group 18
Task Description Subgroup 7109
Page 1

18-7109 Oil Cooler Disassembly and Assembly (for hanging oil filter)

Preparatory operations:
Oil cooler removed (18-6840)

1 Plug 80 Nm.
2 Sealing ring replace.
3 Hex screw 70 Nm.
4 Spring washer
5 Cover
6 Oil cooler
7 Gaskets replace.
9 Hex screw 25 Nm.

20080/0 E 98-04
Group 18
Subgroup 7109 Task Description
Page 2

Disassembly, assembly
Remove plug (1) for oil filling.

Installation instructions
Replace sealing ring (2) and tighten plug (1), 80 Nm.

Remove hex screws (8) for oil cooler and remove oil
cooler.

Installation instructions
Tighten hex screws (8) to 25 Nm.

Fit graphitised side of gasket (7) in direction of oil


cooler.

Assemble in reverse sequence.

20080/0 E 98-04
Group 18
Task Description Subgroup 7109a
Page 1

18-7109a Oil Cooler Disassembly and Assembly


(for flange-mounted standing oil filter)

Oil cooler with oil filter

1 Filter bowl
2 Gasket, replace.
3 Screw M10x125 Tightening torque 50 Nm
4 Screw M10x60 Tightening torque 50 Nm
5 Spring washer B10
6 Oil filter bowl
7 Plug Tightening torque 50 Nm
8 Sealing ring replace.
9 Filter element with gaskets replace, see operating instructions.
10 Sealing ring replace.
11 Sealing ring replace.
12 Screw Tightening torque 40+5 Nm.
13 Oil cooler cover
14 Thread insert
15 Plug, oil duct
16 Sealing ring replace.
17 Coolant drain plug
18 Sealing ring replace.

20080/1 E 98-12
Group 18
Subgroup 7109a Task Description
Page 2

19 Gasket, graphitised replace.


20 Screw M8x60 Tightening torque 25 Nm
21 Spring washer
22 Oil cooler
23 Screw M8x60 Tightening torque 25 Nm
24 Screw M8x35 Tightening torque 25 Nm
25 Spring washer
26 Gasket replace.
27 Oil cooler housing
28 Thread insert
29 Bulkhead wall
30 Thread insert
31 Spring washer
32 Screw M10x25 Tightening torque 60 Nm
33 Screw M10x35 Tightening torque 25 Nm
34 Screw M10x25 Tightening torque 60 Nm
35 Screw M10x40 Tightening torque 50 Nm
36 Spring washer
37 Gasket replace.

Arrangement of oil cooler with oil filter

20080/1 E 98-12
Group 18
Task Description Subgroup 7109a
Page 3

Removal, disassembly, assembly, installation

Removal/disassembly
Remove oil filter - see Operating Instructions.

Remove oil filter head.

Remove oil cooler cover with oil cooler.

Remove oil cooler from oil cooler cover

Remove oil cooler housing from crankcase.

Remove bulkhead wall from oil cooler housing.

Assembly/installation
Replace all gaskets and sealing rings.

Check and clean sealing surfaces.

Install bulkhead wall on oil cooler housing


- observe specified torque.

Install oil cooler housing on crankcase


- observe specified torques.

Install oil cooler on oil cooler cover


- observe specified torques.
- fit graphitised side of gaskets (item 19) in
direction of oil cooler.
Install oil cooler cover with mounted oil cooler on oil cooler housing
- observe specified torques.

Install oil filter head on oil filter cover


- observe specified torque.

Install oil filter - see Operating Instructions.

Fill engine oil system with engine oil, see 18-1601.

Check and correct coolant level - see Operating Instructions.

Oil priming and engine starting - see 18-1601.

Switch off the engine, check the oil cooler for leaks.

After approx. 5 minutes check and correct the engine oil and coolant levels.

20080/1 E 98-12
Group 18
Subgroup 7109a Task Description
Page 4

20080/1 E 98-12
Group 20
Task Description Subgroup
Page

Engine Cooling

20080/1 E 98-12
Group 20
Subgroup Task Description
Page

20080/1 E 98-12
Group 20
Task Description Subgroup
Page 1

20 Engine Cooling

Contents

20-1000 Coolant lines


(Ship version 8/12V 183 T..2 with top-mounted intercooler)
20-1000a Coolant lines
(Ship version 8/12V 183 T..2 with compact intercooler)

20-1000b Coolant lines


(Ship version 8/12V 183 T..3 with compact intercooler)

20-1000c Coolant connections with external cooling


(Ship version 8/12V 183 T..2 with compact intercooler)

20-1001 Coolant lines, removal, check, repair and installation

20-1030 Degrease, decalcify cooling system, check for leaks

20-1290 Coolant pump removal and installation


(Rail and genset version)

20-1290a Coolant pump removal and installation


(Ship version 8/12V 183 T..2/T..3)

20-1390 Raw water pump removal and installation


(Ship version 8/12V 183 T..2 with top-mounted intercooler)

20-1390a Raw water pump removal and installation


(Ship version 8/12V 183 T..2/T..3 with compact intercooler)

20-1401 Coolant pump disassembly and assembly


(Rail and genset version)

20-1401a Coolant pump disassembly, check, repair and reinstallation


(Ship version 8/12V 183 T..2/T..3)

20-1402 Raw water pump disassembly, check, repair and reinstallation


(Ship version 8/12V 183 T..2 with top-mounted intercooler)

20-1402a Raw water pump disassembly, check, repair and reinstallation


(Ship version 8/12V 183 T..2/T..3 with top-mounted intercooler)

20080/1 E 98-12
Group 20
Subgroup Task Description
Page 2

20-2470 Coolant thermostat, removal, check and installation


(Rail and genset version)

20-2470a Coolant thermostat, removal, check and installation


(Ship version 8/12V 183 T..2 with top-mounted intercooler)

20-2470b Coolant thermostat, removal, check and installation


(Ship version 8/12V 183 T..2 with compact intercooler)

20-2470c Coolant thermostat, removal, check and installation


(Ship version 8/12V 183 T..3 with compact intercooler)

20-2570 Coolant cooler (plate-type cooler) with "GEA" - plates removal, check, repair and
installation
(Ship version 8V 183 T..2 with top-mounted intercooler)

20-2570a Coolant cooler (plate-type cooler) with "GEA" - plates removal, check, repair and
installation
(Ship version 12V 183 T..2 with top-mounted intercooler)

20-2570b Coolant cooler (plate-type cooler) with "SWEP" - plates, removal, check, repair and
installation
(Ship version 8/12V 183 T..2/T..3 with compact intercooler)

20-2670 Coolant distributor housing removal and installation


(Ship version 8/12V 183 T..2 with top-mounted intercooler)

20-2670a Coolant distributor housing removal and installation


(Ship version 8/12V 183 T..2 with compact intercooler)

20-2670b Coolant distributor housing removal and installation


(Ship version 8/12V 183 T..3 with compact intercooler)

20080/1 E 98-12
Group 20
Task Description Subgroup 1000
Page 1

20-1000 Coolant Lines


(ship version 8/12v 183 t..2 with top-mounted intercooler)
Connecting lines between coolant distributor housing and intercooler

1 Connection elbow, left


2 Connection elbow, right
3 O-ring replace.
4 Hex screw M10x80
5 Hex screw M10x45
6 Plug-in pipe
7 Plug-in pipe
8 O-ring replace.

20080/1 E 98-12
Group 20
Subgroup 1000 Task Description
Page 2

Connection between the exhaust turbochargers

1 Elbow
2 Gasket replace.
3 Hex screw M10x35
4 Washer
5 Pipe
6 Rubber sleeve replace.
7 Clamp
8 Union
9 Sealing ring replace.
10 Sealing cone
11 Nut

20080/1 E 98-12
Group 20
Task Description Subgroup 1000
Page 3

Vent lines

1 Cover 11 Gasket, replace.


2 Hex screw M8x55 12 Hose line
3 Sealing ring, replace 13 Sealing cone
4 Adapter 14 Nut
5 Hose line 15 Adapter
6 Sealing cone 16 Hose line
7 Nut 17 Sealing cone
8 Adapter 18 Nut
9 Filler neck 19 Adapter
10 Washer

Coolant line installation and removal


as shown in illustration - see also 20-10001.

20080/1 E 98-12
Group 20
Subgroup 1000 Task Description
Page 4

20080/1 E 98-12
Group 20
Task Description Subgroup 1000a
Page 1

20-1000a Coolant Lines


(Ship version 8/12v 183 t..2 with compact intercooler)
Connection between coolant thermostat, intercooler and turbocharger

1 Elbow, left side


2 Gasket replace.
3 Hex screw M10x60
4 Washer
5 Elbow
6 Plug
7 Sealing ring replace.
8 Gasket replace.
9 Hex screw M10x70
10 Washer
11 Rubber sleeve replace.
12 Clamp
13 Elbow, right side
14 Hex screw M10x80
15 Washer
16 Gasket replace.

20080/1 E 98-12
Group 20
Subgroup 1000a Task Description
Page 2

17 Plug
18 Sealing ring replace.
19 Coolant line
20 Sealing ring replace.
21 Plug
22 Bracket
23 Hex screw M10x150
24 Washer
25 Pipe clamp half
26 Hex screw M8x80
27 Washer
28 Nut
29 Rubber sleeve replace.
30 Clamp

20080/1 E 98-12
Group 20
Task Description Subgroup 1000a
Page 3

Connection between coolant distributor housing and intercooler

1 Elbow
2 Gasket replace.
3 Hex screw M8x50
4 Hex screw M8x80
5 Washer
6 Pipeline
7 Rubber sleeve replace.
8 Clamp

20080/1 E 98-12
Group 20
Subgroup 1000a Task Description
Page 4

Vent lines

1 Vent line
2 Threaded bush
3 Banjo screw
4 Sealing ring replace.
5 Washer
6 Hex screw M18x25
7 Clamp
8 Vent line
9 Threaded bush
10 Banjo screw
11 Sealing ring replace.
12 Vent line
13 Banjo screw
14 Sealing ring replace.
15 Vent line
16 T-piece

Coolant line installation and removal


as shown in illustration - see also 20-10001.

20080/1 E 98-12
Group 20
Task Description Subgroup 1000b
Page 1

20-1000b Coolant Lines


(Ship version 8/12V 183 T..3 with compact intercooler)
Connection between coolant distributor housing and intercooler

1 Elbow
2 Gasket replace.
3 Hex screw M8x50
4 Hex screw M8x80
5 Cover
6 Hex screw M8x28
7 Washer
8 Pipeline
9 Rubber sleeve replace.
10 Clamp
11 Rubber sleeve replace.
12 Clamp

20080/1 E 98-12
Group 20
Subgroup 1000b Task Description
Page 2

Connection between intercooler and turbocharger

1 Elbow
2 O-ring replace.
3 Hex screw M8x105
4 Cover
5 O-ring replace.
6 Hex screw M8x25
7 Hex screw M8x80
8 Washer
9 Elbow
10 Gasket replace.
11 Hex screw M10x85
12 Washer
13 Rubber sleeve replace.
14 Rubber sleeve replace.
15 Clamp
16 Elbow
17 Gasket replace.
18 Hex screw M10x85
19 Washer

20080/1 E 98-12
Group 20
Task Description Subgroup 1000b
Page 3

Vent lines

1 Flange
2 Gasket replace.
3 Hex screw M10x30
4 Washer
5 Vent line
6 Threaded bush
7 Banjo screw
8 Sealing ring replace.
9 Clamp
10 Hex screw M8x20
11 Washer
12 Vent line
13 Clamp
14 Clamp
15 Washer
16 Hex screw M6x20
17 Nut
18 Banjo screw
19 Sealing ring replace.
20 Vent line
21 Threaded bush
22 Sealing ring replace.

20080/1 E 98-12
Group 20
Subgroup 1000b Task Description
Page 4

23 Banjo screw
24 Sealing ring replace.
25 Vent line
26 T-piece
27 Adapter
28 Sealing ring replace.
29 Plug secured with thread-locking agent, aux. No. 40083.

Coolant line installation and removal


as shown in illustration - see also 20-10001.

20080/1 E 98-12
Group 20
Task Description Subgroup 1000c
Page 1

20-1000c Coolant Connections with External Cooling


(Ship version 8/12V 183 T..2 with compact intercooler)

1 Flange
2 O-ring 83x5 replace
3 Hex screw M12x80
4 Hex screw M20x1.5x80
5 Washer
6 Washer
7 Cover
8 Hex screw M8x55
9 Adapter
10 Sealing ring A26x31 replace.
11 Sealing cone
12 Nut
13 Adapter
14 Filler neck for additional expansion tank.
15 Gasket
16 Hex screw M8x20
17 Washer

20080/0 E 98-04
Group 20
Subgroup 1000c Task Description
Page 2

20080/0 E 98-04
Group 20
Task Description Subgroup 1001
Page 1

20-1001 Coolant Lines, Removal, Check, Repair, Reinstallation

Remove coolant lines

Note:
Before removing lines, it is advisable to photograph the engine from all sides or attach metal tags to the lines and
fixtures so that they can be reinstalled in their original positions.

Remove lines as per overview drawings - see 20-1000 / 20-1000a / 20-1000b.

After removing lines, seal all open connections by installing suitable plugs.

Inspection and repair

Clean lines with cold cleaner and brushes.

Visually inspect all components, especially sealing and mating faces, for wear, pitting and cavitation; rub down with
emery cloth or an oilstone or replace component.

If necessary, repair lines and check for leaks with air under water with corrosion inhibitor.

Caution!
Compressed air is air which has been compressed under pressure. Risk of injury!
Pressure must not exceed 0.5 bar.
Wear protective clothing, protective gloves and protective goggles/safety mask.

Coolant temperature: min. 30 C, whereby the component must also be at this temperature, max. 40 C, if the
component is to be held in the hand.
Test pressure: 0.5 bar.

Replace hose lines as part of every W6 overhaul.

Replace gaskets as part of every disassembly.

Install coolant line

Caution!
Compressed air is air which has been compressed under pressure. Risk of injury!
Always wear protective goggles when blowing out or drying out with compressed air.
The pressure must not exceed 3 bar.
Prior to installing, remove all blanking plugs and blow lines clear with compressed air.
Install lines with new gaskets, hose lines with connecting and fixture elements as per overview drawings -
see 20-1000 / 20-1000a / 20-1000b, ensuring they are free from tension.
Note:
After engine start, visually inspect lines for leaks.

20080/1 E 98-12
Group 20
Subgroup 1001 Task Description
Page 2

20080/1 E 98-12
Group 20
Task Description Subgroup 1030
Page 1

20-1030 Degrease, decalcify cooling system, check for leaks

Notice!
Hot coolant: danger of scalding.
Open coolant expansion tank end cover only when coolant temperature is under 90 C.

A. Degreasing, decalcifying and removing rust

Suitable cleaning additives e.g.

Designation Supplier

P3 Croni e.g. Henkel Dsseldorf

Grisiron 7220 e.g. Farbwerke Hoechst

Degreasing
Drain engine coolant completely

Remove coolant thermostat (20-2470)

Set heating control to "warm" if a heating system is


fitted.

Fill the cooling system with a 5% solution of water and a


mild alkaline cleaner such as P3-Croni (supplier:
Henkel) or Grisiron 7220 (supplier: Farbwerke Hoechst)
(50 g P3-Croni/1 litre water).

Run the engine at medium speed up to a temperature


of approx. 80 C and retain this temperature for
approx. 5 minutes.

Switch off the engine and allow to cool to approx. 50 C.

Drain solution completely

Immediately after this, fill the cooling system twice with


fresh water, heat up for approx. 5 minutes and drain.

20080/1 E 98-12
Group 20
Subgroup 1030 Task Description
Page 2

Degreasing, removing rust


Note:
The cooling system must always be degreased before
decalcifying even if there is no visible oil fouling.

After rinsing for a second time during degreasing, fill the


cooling system with a 10% solution (100g/l) of water
and citric, tartaric or oxalic acid (available through
regular chemical-trade outlets), whereby preference
should be given to citric acid.

Run the engine at medium speed up to a temperature


of approx. 80 C and retain this temperature for approx.
10 minutes.

Switch off the engine and allow to cool to approx. 50 C.

Drain decalcifying solution completely

Rinse the cooling system at least 3 times with fresh


water and run the engine each time for approx.
5 minutes.

Install coolant thermostat (20-2470).

Fill cooling system with prescribed coolant and check


for leaks.

Note:
For decalcifying and removing rust, commercially
available products containing the above-named acids
can be used.
For environmental reasons, chromic acid or other
products containing chromium cannot be used.

B Leak Check
See Operating Instructions

20080/0 E 98-04
Group 20
Task Description Subgroup 1290
Page 1

20-1290 Coolant Pump Removal and Installation


(Rail and genset version)

1 V-belts Tension, new 450 to 500 N, retension 300 to 400 N


Measuring device 001 589 69 21 00.
2 Coolant hose
3 Coolant hose
4 Hex screw 25 Nm.
5 Spring washer
6 Coolant pump
7 Gasket replace.

Removal and installation


Remove components in order of numbers and reinstall in reverse sequence.
V-belt removal and installation - see Section 13-1001.
Drain engine coolant

Notice!
Hot coolant: danger of scalding.

Fill cooling system with specified coolant and check for leaks - see Operating Instructions.

Disassembly and assembly


See Section 20-1401.

20080/1 E 98-12
Group 20
Subgroup 1290 Task Description
Page 2

20080/1 E 98-12
Group 20
Task Description Subgroup 1290a
Page 1

20-1290a Coolant Pump Removal and Installation


(Ship version 8/12V 183 T..2/T..3)

1 Water pump
2 V-belt pulley
3 Washer
4 Hex screw M8x16 Tightening torque 25 Nm
5 O-ring 130x3 replace.
6 O-ring 158x3 replace
7 Washer
8 Hex screw M8x30

Removal and Installation

Remove and install parts in illustrated sequence.


V-belt removal and installation - see Section 13-1001.
Drain engine coolant

Notice!
Hot coolant: danger of scalding.

Fill cooling system with specified coolant and check for leaks - see operating instructions.

20080/1 E 98-12
Group 20
Subgroup 1290a Task Description
Page 2

Disassembly, inspection, repair and assembly

See Section 20-1401a.

20080/1 E 98-12
Group 20
Task Description Subgroup 1390
Page 1

20-1390 Raw Water Pump Removal and Installation


(Ship version 8/12V 183 T..2 with top-mounted intercooler)

1 Raw water pump


2 Wedge belt
3 Bracket
4 Hex screw M10x120
5 Nut
6 Washer
7 Washer
8 Swivel head secured with thread-locking agent, aux. No. 40 083
9 Washer
10 Washer
11 Hex screw M10x25
12 Hex screw M10x45
13 Washer

Removal and installation

Remove and install parts in illustrated sequence.

V-belt removal and installation - see Section 13-1001.

20080/1 E 98-12
Group 20
Subgroup 1390 Task Description
Page 2

Disassembly, inspection, repair and assembly

See Section 20-1402.

20080/1 E 98-12
Group 20
Task Description Subgroup 1390a
Page 1

20-1390a Raw Water Pump Removal and Installation


(Ship version 8/12V 183 T..2/T..3 with compact intercooler)

1 Raw water pump


2 Gasket replace.
3 Hex screw M10x60
4 Stud M10x30
5 Nut
6 Washer
7 Belt pulley
8 Hex screw M12x45
9 Washer
10 V-belts
11 Clamping element
12 Clamping nut
13 Hex screw M12x120
14 Swivel head secured with thread-locking agent, aux. No. 40 083
15 Hex screw M12x35
16 Washer
17 Hex screw M12x60
18 Washer
19 Nut
20 Cover plate
21 Washer

20080/1 E 98-12
Group 20
Subgroup 1390a Task Description
Page 2

Removal and installation

Remove and install parts in illustrated sequence.

V-belt removal and installation - see Section 13-1001.

Disassembly, inspection, repair and assembly

See Section 20-1402a.

20080/1 E 98-12
Group 20
Task Description Subgroup 1401
Page 1

20-1401 Coolant Pump, Disassembly and Assembly


(Rail and genset version)

Preparatory operations:
Coolant pump removed (20-1290)
Coolant thermostat (20-2470) removed

1 Hex screw 25 Nm
2 Washer
3 Housing cover
4 O-ring replace.
5 Coolant thermostat
6 Coolant pump housing
7 Bearing
8 Modular seal replace, mandrel 352 589 08 13 00
9 Impeller
10 Gasket replace.
11 Hex screw 25 Nm.
12 Washer
13 Belt pulley
14 Hub Puller 000 589 65 33 00,
Thrust pad 321 589 00 63 00.
15 Snap ring
16 Inlet adapter
17 Gasket replace.
18 Hex screw 25 Nm
19 Hex screw 25 Nm
20 Washer

20080/1 E 98-12
Group 20
Subgroup 1401 Task Description
Page 2

Dimensions - see Tolerances and Wear Limits List


20-1401.

Special tools

20080/1 E 98-12
Group 20
Task Description Subgroup 1401
Page 3

Disassembly
Remove belt pulley (13).

Pull off flange (14) for belt pulley.

Puller 000 589 65 33 00


Thrust pad 321 589 00 63 00

Remove snap ring (15).

20080/1 E 98-12
Group 20
Subgroup 1401 Task Description
Page 4

Using a suitable thrust pad, force the bearing out of the


impeller and housing.

Remove modular seal.

Assembly
Using a suitable mandrel, press fit bearing in housing.

Note:
Press the bearing only on the bearing outer race
(arrow).

20080/1 E 98-12
Group 20
Task Description Subgroup 1401
Page 5

Install snap ring (15).

Heat flange (14) for belt pulley and press-fit flush on


bearing.

Mount new modular seal on the shaft.

20080/1 E 98-12
Group 20
Subgroup 1401 Task Description
Page 6

Press in modular seal until it reaches coolant pump


housing.
Mandrel 352 589 08 15 00

Note:
Check that modular seal is securely fitted.

Mount coolant pump wheel (9).

20080/1 E 98-12
Group 20
Task Description Subgroup 1401
Page 7

Press-fit coolant pump wheel (9) until there is a gap of


0.6-1.0 mm to the bearing.

Using a gauge (arrow), check the gap.

Install belt pulley (13), 25 Nm.

20080/1 E 98-12
Group 20
Subgroup 1401 Task Description
Page 8

20080/1 E 98-12
Group 20
Task Description Subgroup 1401a
Page 1

20-1401a Coolant Pump Disassembly, Check, Repair and Reinstallation


(Ship version 8/12V 183 T..2/T..3)
Preparatory operation:
Coolant pump removed (20-1290a)

1 Coolant pump housing Support for rotary seal with surface sealant MMN 377 D
- sealed with Loctite 573.
2 Coolant pump bearing
3 Snap ring
4 Modular rotary seal replace.
5 Impeller
6 Flange

20080/1 E 98-12
Group 20
Subgroup 1401a Task Description
Page 2

1 Coolant pump housing


2 Snap ring
3 Pump bearing with shaft
4 Rotary seal optional with item 5.
5 Rotary seal optional with item 4.
6 Impeller
7 Flange

A = Control dimension 100 mm


B = Installation dimension, rotary seal, 11.9 0.3 mm
S = Cleavage dimension, impeller, 0.6 + 0.4 mm

For further dimensions - see Tolerances and Wear Limits List 20-1401a.

20080/1 E 98-12
Group 20
Task Description Subgroup 1401a
Page 3

Disassembly
Using the removal tool, pull off flange (7).

Using circlip pliers, take the snap ring (2) out of the coolant pump housing.

Using a suitable thrust pad, force the pump bearing and shaft (3) - assembly unit - out of the impeller and pump
housing.

Remove modular rotary seal (4 or 5) from pump housing.

Inspection and repair


Clean all components.

Using the surface crack-testing method and red penetrant dye, check the pump housing, impeller and flange for
cracks.

Using the magnetic crack-testing method and fluorescent magnetic powder, check the pump bearing and shaft for
cracks.

If cracks are detected, replace complete bearing with shaft.

Check coolant pump housing and impeller for pitting.


Replace parts if pitting is deeper than 1 mm.

Check coolant pump for wear and damage.


Smooth minor traces of wear and damage with an emery cloth.

Always replace pump bearing with shaft during W6 overhaul.

Replace modular rotary seal during overhaul.

20080/1 E 98-12
Group 20
Subgroup 1401a Task Description
Page 4

Assembly

Installing coolant pump bearing

Heat coolant pump housing (1) on hotplate.

Using a suitable mandrel, press fit pump bearing (3) into housing.

Note:
Press the bearing only at the outer race!

Using circlip pliers, insert the snap ring (2) in the groove in the coolant pump housing.

Make sure that the snap ring is secure in the groove.


Check control dimension a = 100 mm

Press-fit flange for belt pulley

Heat flange (7) to 260 C.

Caution!
Risk of injury!

Using the protective glove, push the flange flush onto the bearing, holding shaft end firmly in position.

Insert modular rotary seal

Insert modular rotary seal (4 or 5) in the pump housing.

Assembly instruction for rotary seal, item 4:

Seal support in housing with surface sealant MMN 377 D


- Loctite 573.

Lubricate inside of rubber sleeve for shaft support with engine oil.

Using a suitable assembly tool, press-fit the rotary seal into the housing and onto the shaft; hold shaft end firmly
in position. When doing this, make sure the counterring is correctly positioned in relation to the rubber shoulder
(the rubber knobs must be engaged in the counterring - to prevent rotation).
Protrusion of rotary seal from the housing edge when rubber knobs are correctly engaged: 13 + 0.1 mm.
Installation dimension 11.9 0.3 mm (position of gasket on impeller) is achieved by shrink-fitting the impeller.

20080/1 E 98-12
Group 20
Task Description Subgroup 1401a
Page 5

Assembly instruction for rotary seal, item 5:

Seal support in housing with surface sealant MMN 377 D


- Loctite 573.

Using a suitable assembly tool, press-fit the rotary seal into the housing and press-fit dry onto the shaft; hold
shaft end firmly in position.
Protrusion of rotary seal from the housing edge: 11.3 + 0.1 mm.
Installation dimension 11.9 0.3 mm (position of gasket on impeller) is achieved by shrink-fitting the impeller.

This dimension is indicated by internal overpressure (1 bar) or by a vacuum in the fluid chamber.

Press-fit impeller

Heat impeller (6) to 80 C.

Notice!
Risk of injury!
Using the protective glove, mount the impeller on the shaft.

Press-fit impeller, free of oil and grease, onto shaft to a gap of 0.6 + 0.4 mm; hold shaft firmly in position.

Using a gauge, check the gap.

Check impeller for ease of movement.

20080/1 E 98-12
Group 20
Subgroup 1401a Task Description
Page 6

20080/1 E 98-12
Group 20
Task Description Subgroup 1402
Page 1

20-1402 Raw Water Pump Disassembly, Check, Repair and Reinstallation


(Ship version 8/12V 183 T..2 with top-mounted intercooler)
Preparatory operation:
Raw water pump removed (20-1390)

1 Raw water pump


2 Belt pulley
3 Tab washer replace.
4 Hex nut

20080/1 E 98-12
Group 20
Subgroup 1402 Task Description
Page 2

1 Pump housing
2 Impeller
3 Intermediate element
4 Bearing housing
5 Drive shaft
6 Spacer bushing
7 Clamping nut Tightening torque 32 + 3 Nm
Lubricant: Engine oil
8 Rotary seal replace.
9 Shaft seal replace.
10 O-ring 160x3 replace.
11 Sealing ring A18x22 replace.
12 Sealing ring A33x39 replace.
13 Angular-contact ball bearing
14 Grooved ball bearing
15 Key
16 Snap ring 20x1.2
17 Snap ring 52x2
18 Plug M18x1.5
19 Plug Designation groove in accordance with MTN 5053
20 Stud M8x25
21 Nut M8, self-locking replace, tightening torque 20 + 2 Nm
22 Adjusting shim 42x1 Axial gap setting.
23 Adjusting shim 42x0.5 Axial gap setting.
24 Adjusting shim 42x0.1 Axial gap setting.
25 Name plate
26 Round-head grooved pin

20080/1 E 98-12
Group 20
Task Description Subgroup 1402
Page 3

Disassembly

20080/1 E 98-12
Group 20
Subgroup 1402 Task Description
Page 4

Inspection and repair


Clean all components.

Using the surface crack-testing method and red penetrant dye, check the pump housing, impeller, intermediate
element and bearing housing for checks.

Using the magnetic crack-testing method and fluorescent magnetic powder, check the drive shaft for cracks.
If cracks are detected, the respective parts must be replaced.

Check coolant pump housing and impeller for pitting.


Replace parts if pitting is deeper than 1 mm.

Check drive shaft for wear and damage.


Smooth minor traces of wear and damage with an emery cloth.

Metal-spray sealing surface as per MTU specifications as required.

Check thread for ease of movement; rechase or fit thread insert as required.

Check clamping nut for damage.

Using a taper gauge, check taper seat 1:20, replace shaft as required.

Check sealing surfaces and bearing bore at bearing housing and intermediate element for wear, smooth with emery
cloth as required.

Adjust bore gauge, measure bore for grooved ball bearing in bearing housing.
Using an outside micrometer, measure the bearing seat and fitting diameter on the drive shaft.
If the limit values are exceeded, replace parts.

Replace rotary seal, shaft seal and O-rings at every overhaul.

Always replace angular-contact ball bearings and grooved ball bearings at W6 overhaul.

20080/1 E 98-12
Group 20
Task Description Subgroup 1402
Page 5

Assembly

Installing angular-contact ball bearing

Clean all components.

Heat angular-contact ball bearing (13) to 130 + 20 C


push onto the drive shaft (5) as far as the thrust collar.

Notice!
Risk of injury!

Using circlip pliers, insert the inside snap ring (17) in the
groove in the bearing housing (4). Ensure that the snap
ring is correctly fitted in the groove!

Using adjusting shims (22, 29, 24), adjust to dimension


"x" as required
Dimension "x" = A-B

Heat bearing housing (4) in the bearing seat area of the


angular-contact ball bearing (13) to 130 + 20 C.

Notice!
Risk of injury!

Installing drive shaft

Insert drive shaft (5) with mounted angular-contact ball bearing in the direction of the impeller in the bearing housing
(4) up to the snap ring stopper.

Using adjusting shims (22, 23, 24), adjust to dimension "Z" as required

Using circlip pliers, insert the outer snap ring (17) in the groove in the bearing housing (4). Ensure that the snap ring
is correctly fitted in the groove!

20080/1 E 98-12
Group 20
Subgroup 1402 Task Description
Page 6

Installing grooved ball bearing

Push the spacer bush (6) onto the drive shaft.

Heat grooved ball bearing (14) to 180 C push onto the drive shaft (5) until it rests against the spacer bush.

Notice!
Risk of injury!

Using circlip pliers, insert the snap ring (16) in the groove in the drive shaft (5).

Ensure that the snap ring is correctly fitted in the groove!

Installing shaft seal

Clean bore for radial-lip shaft seal (9) in bearing housing to ensure it is dry and free of grease.

Rub down shaft seal seating surface with denaturated ethanol.

Press-fit radial-lip shaft seal with impact bush into the bearing housing until it is in contact.
Ensure installation direction is correct!

Installing intermediate element

Pull the O-ring (10) onto the intermediate element (3).

Insert intermediate element (3) into bearing housing (4).

Installing thrust ring and pot sleeve

Insert thrust ring with rotary seal (8) pot sleeve with petroleum jelly in the intermediate element (3).
Clean sliding surfaces with alcohol.

Mount the rotary seal (8) gasket on the impeller (2).

Mounting the impeller

Mount the impeller (2) with installed sealing ring, free of oil and grease, on the taper of the drive shaft (5).
Check dimension y = 114.3 mm.

Slightly oil clamping surface and clamping nut (6) thread.


Fit clamping nut and tighten to specified torque.
Tightening torque 35 + 3 Nm

20080/1 E 98-12
Group 20
Task Description Subgroup 1402
Page 7

Check axial gap

Using a gauge, 0.5 mm, check axial gap 0.5 0.2 at a minimum of three positions.

Installing completely assembled unit in pump housing.

Insert studs (20) in the pump housing (1).

Insert O-ring (10) into the intermediate element (3).

Apply thin coat of grease to the fit in the pump housing (1) and insert the completely assembled unit in the pump
housing.

Screw on self-locking nuts (21) and tighten to specified torque.


Tightening torque 20 + 2 Nm.

20080/1 E 98-12
Group 20
Subgroup 1402 Task Description
Page 8

20080/1 E 98-12
Group 20
Task Description Subgroup 1402a
Page 1

20-1402a Raw Water Pump Disassembly, Check, Repairand Reinstallation


(Ship version 8/12V 183 T..2/T..3 with compact intercooler)
Preparatory operation:
Raw water pump removed (20-1390a)

1 Pump housing
2 Impeller
3 Intermediate element
4 Bearing housing
5 Drive shaft
6 Clamping nut Tightening torque 32 + 3 Nm
7 Rotary seal replace.
8 Shaft seal replace.

20080/1 E 98-12
Group 20
Subgroup 1402a Task Description
Page 2

9 O-ring replace.
10 Sealing ring A18x22 replace.
11 Sealing ring A42x49 replace.
12 Angular-contact ball bearing
13 Grooved ball bearing
14 Adjusting shim 56x1 Axial gap setting.
14A Adjusting shim 56x0.5 Axial gap setting.
14B Adjusting shim 56.01 Axial gap setting.
15 Key
16 Outer snap ring
17 Snap ring 30x1.5
18 Fitted screw 56x2
19 Plug M18x1.5 Tightening torque 50 + 10 Nm.
20 Plug G1 A Tightening torque 140 + 10 Nm.
21 Stud M8x30
22 Nut M8, self-locking replace, tightening torque 20 + 2 Nm

20080/1 E 98-12
Group 20
Task Description Subgroup 1402a
Page 3

Disassembly
Removing complete unit from pump housing.

Unscrew self-locking nuts (22).

By knocking gently with a rubber mallet, release the complete unit from the pump housing (1) and remove it.

20080/1 E 98-12
Group 20
Subgroup 1402a Task Description
Page 4

Inspection and repair


Clean all components.

Using the surface crack-testing method and red penetrant dye, check the pump housing, impeller, intermediate
element and bearing housing for checks.

Using the magnetic crack-testing method and fluorescent magnetic powder, check the drive shaft for cracks.

If cracks are detected, the respective parts must be replaced.

Check coolant pump housing and impeller for pitting.


Replace parts if pitting is deeper that 1 mm.

Check drive shaft for wear and damage.


Smooth minor traces of wear and damage with an emery cloth.

Metal-spray sealing surface as per MTU specifications as required.

Check thread for ease of movement; rechase or fit thread insert as required.

Check clamping nut for damage.

Using a taper gauge, check taper seat 1:20, replace shaft as required.

Check sealing surfaces and bearing bore at bearing housing and intermediate element for wear, smooth with emery
cloth as required.

Adjust bore gauge, measure bore for grooved ball bearing in bearing housing.
Using an outside micrometer, measure the bearing seat and fitting diameter on the drive shaft.
If the limit values are exceeded, replace parts.

Replace rotary seal, shaft seal and O-rings at every overhaul.

Always replace angular-contact ball bearings and grooved ball bearings at W6 overhaul.

20080/1 E 98-12
Group 20
Task Description Subgroup 1402a
Page 5

Assembly

Installing grooved ball bearing

Clean all components.

Heat grooved ball bearing (13) to 180 C and push onto the drive shaft (5) as far as the thrust collar.

Notice!
Risk of injury!

Using circlip pliers, insert the snap ring (17) in the groove in the drive shaft (5).

Ensure that the snap ring is correctly fitted in the groove!

Installing drive shaft

Insert drive shaft (5) with mounted bearing in the direction of the drive side in the bearing housing (4).
Check dimension y = 10 mm.

Insert adjusting shim (18) into bearing housing (4).

Installing shaft seal

Clean bore for radial-lip shaft seal (8) in bearing housing to ensure it is dry and free of grease.

Rub down shaft seal seating surface with denaturated ethanol.

Press-fit radial-lip shaft seal with impact bush into the bearing housing until it is in contact.
Ensure installation direction is correct.

Installing intermediate element

Insert intermediate element (3) into bearing housing (4).

Installing thrust ring and pot sleeve

Insert thrust ring with rotary seal (7) pot sleeve with petroleum jelly in the intermediate element (3).
Clean sliding surfaces with alcohol.

Mount the rotary seal (7) gasket on the impeller (2).

20080/1 E 98-12
Group 20
Subgroup 1402a Task Description
Page 6

Mounting the impeller

Mount the impeller (2) with installed sealing ring, free of oil and grease, on the taper of the drive shaft (5).

Slightly oil clamping surface and clamping nut (6) thread.

Fit clamping nut and tighten to specified torque.


Tightening torque 35 + 3 Nm

Mounting the assembled unit onto the assembly bearing.

Checking axial gap

Using a gauge, 0.5 mm, check axial gap 0.5 0.2 mm


at a minimum of three positions.

Installing angular-contact ball bearing

Using a suitable tool, clamp impeller (2) and bearing


housing (4) together.

Using circlip pliers, insert the inside snap ring in the


groove in the bearing housing (4).

Using adjusting shims (14, 14A, 14B), adjust to


dimension "x" as required
Dimension "x" = A-B

Heat bearing housing (4) in the bearing seat area of the


angular-contact ball bearing (12) to 130 + 20 C.

Notice!
Risk of injury!

Heat angular-contact ball bearing (12) to 130 + 20 C and press-fit into bearing housing (4).

Notice!
Risk of injury!
Using circlip pliers, insert the outer snap ring in the groove in the pump shaft.

Using adjusting shims (14, 14A, 14B), adjust to dimension "Z" as required.

20080/1 E 98-12
Group 20
Task Description Subgroup 1402a
Page 7

Using circlip pliers, insert the outer snap ring (16) in the groove in the bearing housing (4).

Tighten clamping nut (6) to specified torque.


Tightening torque 35 + 3 Nm

Using a gauge, check axial gap 0.5 0.2 mm once again.

Installing completely assembled unit in pump housing.

Insert studs (21) in the pump housing (1).

Insert O-ring (9) into the intermediate element (3).

Apply thin coat of grease to the fit in the pump housing (1) and insert the completely assembled unit in the pump
housing.

Screw on self-locking nuts (22) and tighten to specified torque.


Tightening torque 20 + 2 Nm.

20080/1 E 98-12
Group 20
Subgroup 1402a Task Description
Page 8

20080/1 E 98-12
Group 20
Task Description Subgroup 2470
Page 1

20-2470 Coolant Thermostat, Removal, Check and Installation


(Rail and genset version)

1 Hex screw 25 Nm.


2 Washer
3 Housing cover
4 O-ring replace.
5 Coolant thermostat install with vent opening (arrows) pointing upwards.

Removal

Remove hex screws and remove housing cover.

Remove coolant thermostat from crankcase.

Remove O-rings from housing cover.

20080/1 E 98-12
Group 20 20
Subgroup 2470 Task Description
Page 2

Check
Secure thermostat on a wire in a container filled with
water; thermostat must not contact container.

Heat water with suitable heat source.

At approx. 8 C below opening temperature (depending


on design), the heating speed must not exceed 1-2 C
per minute.
Start-of-opening temperature is stamped on thermostat.
Note:
Never use a welding torch or soldering lamp to heat the
coolant thermostat.

!
Part is hot. Risk of injury!
Handle part only when wearing gloves.

Stir coolant to achieve uniform temperature and check


thermostat start of opening.
If result is negative, replace coolant thermostat.

Continue to heat coolant to full-opening temperature.


Full-opening temperature = 94 C
Thermostat insert must be completely open after
approx. 6 to 8 minutes.
Measure coolant thermostat stroke travel.
Travel must be at least 8.0 mm; otherwise replace
coolant thermostat.

Installation
Check sealing and mating faces.
Grease new O-rings with petroleum jelly and insert in
housing cover.
Insert coolant thermostat, with vent notches (arrows)
facing upwards, into crankcase.
Install housing cover with hex screws.

20080/1 E 98-12
Group 20
Task Description Subgroup 2470a
Page 1

20-2470a Coolant Thermostat, Removal, Check and Installation


(Ship version 8/12V 183 T..2 with top-mounted intercooler)

1 Elbow, left
2 Gasket replace.
3 Washer
4 Hex screw M8x25
5 Hex screw M8x95
6 Plug-in pipe
7 O-ring 50x5 replace.
8 Thermostat housing
9 Thermostat insert with vent notch facing upwards.
10 Sealing ring replace.
11 Washer
12 Hex screw M8x80
13 Hex screw M8x90
14 Flange
15 Gasket replace.
16 Washer
17 Hex screw M8x35
18 O-ring 50x5 replace.
19 Sealing ring A18x22 replace.
20 Plug M18x1.5

20080/1 E 98-12
Group 20
Subgroup 2470a Task Description
Page 2

Removal

Remove hex screws and remove thermostat housing.

Remove thermostat elements from coolant distributor


housing.

Remove O-rings from coolant distributor housing.

Check
Secure thermostat insert on a wire in a container filled
with water; thermostat insert must not contact
container.

Heat water with suitable heat source.

At approx. 8 C below opening temperature (depending


on design), the heating speed must not exceed 1-2 C
per minute.
Start-of-opening temperature is stamped on thermostat
insert.
Note:
Never use a welding torch or soldering lamp to heat the
coolant thermostat element.

Caution!
Part is hot. Risk of injury!
Handle part only when wearing gloves.

Stir coolant to achieve uniform temperature and check


thermostat element start of opening.
Replace thermostat insert if results of check are
negative.

Continue to heat coolant to full-opening temperature.


Full-opening temperature = 94 C
Thermostat insert must be completely open after
approx. 6 to 8 minutes.

Measure coolant thermostat stroke travel.


Stroke must be 8.0 mm; if not, replace thermostat
insert.

20080/1 E 98-12
Group 20
Task Description Subgroup 2470a
Page 3

Installation

Check sealing and mating faces.

Grease new O-rings with petroleum jelly and insert in


coolant distributor housing.

Insert thermostat elements, with ventilation notches


facing upwards, into coolant distributor housing.

Install thermostat housing with hex screws.

20080/1 E 98-12
Group 20
Subgroup 2470a Task Description
Page 4

20080/1 E 98-12
Group 20
Task Description Subgroup 2470b
Page 1

20-2470b Coolant Thermostat, Removal, Check and Installation


(Ship version 8/12V 183 T..2 with compact intercooler)

1 Elbow, left
2 Gasket replace.
3 Hex screw M8x30
4 Hex screw M8x95
5 Washer
6 Link
7 O-ring replace.
8 Thermostat housing
9 Screw-in restrictor
10 Hex screw M10x120
11 Washer
12 Thermostat insert with vent notch facing upwards.
13 Sealing ring replace.
14 O-ring 50x4 replace.
15 Threaded bush M18x1.5 secured with thread-locking agent
16 Threaded bush M22x1.5 aux. No. 40 083
18 Plug M18x1.5
19 Plug M22x1.5
20 Sealing ring A18x22 replace.
21 Sealing ring A22x27 replace.
22 Link
23 O-ring replace.

20080/1 E 98-12
Group 20
Subgroup 2470b Task Description
Page 2

Removal

Remove hex screws and remove thermostat housing.

Remove thermostat elements from coolant distributor


housing.

Remove O-rings from coolant distributor housing.

Check

Secure thermostat insert on a wire in a container filled


with water; thermostat insert must not contact
container.
Heat water with suitable heat source.

At approx. 8 C below opening temperature (depending


on design), the heating speed must not exceed 1-2 C
per minute.
Start-of-opening temperature is stamped on thermostat
insert.
Note:
Never use a welding torch or soldering lamp to heat the
coolant thermostat element.

Notice!
Part is hot. Risk of injury!
Handle part only when wearing gloves.

Stir coolant to achieve uniform temperature and check


thermostat element start of opening.
Replace thermostat insert if results of check are
negative.

20080/1 E 98-12
Group 20
Task Description Subgroup 2470b
Page 3

Continue to heat coolant to full-opening temperature.


Full-opening temperature = 94 C
Thermostat insert must be completely open after
approx. 6 to 8 minutes.
Measure coolant thermostat stroke travel.
Stroke must be 8.0 mm; if not, replace thermostat
insert.

Installation

Check sealing and mating faces.

Grease new O-rings with petroleum jelly and insert in


coolant distributor housing.

Insert thermostat elements, with ventilation notches


facing upwards, into coolant distributor housing.

Install thermostat housing with hex screws.

20080/1 E 98-12
Group 20
Subgroup 2470b Task Description
Page 4

20080/1 E 98-12
Group 20
Task Description Subgroup 2470c
Page 1

20-2470c Coolant Thermostat, Removal, Check and Installation


(Ship version 8/12V 183 T..3 with compact intercooler)

1 Elbow, left
2 Plug M36x2 secured with thread-locking agent, aux. No. 40 083
3 O-ring 54x5 replace.
4 Hex screw M8x95
5 Washer
6 Thermostat housing
7 Thermostat insert with vent notch facing upwards.
8 Sealing ring replace.
9 Hex screw M10x120
10 Washer
11 O-ring 50x4 replace.
12 Threaded bush M18x1.5 secured with thread-locking agent, aux. No. 40 083
13 Threaded bush M22x1.5 secured with thread-locking agent, aux. No. 40 083
14 Plug M22x1.5
15 Sealing ring A22x27 replace.
16 Plug M18x1.5
17 Sealing ring A18x22 replace.
18 Plug M26x1.5 sealed with pipe-thread sealant, aux. No. 40 033.
19 Rubber sleeve 55x70 replace.
20 Clamp

20080/1 E 98-12
Group 20
Subgroup 2470c Task Description
Page 2

Removal

Remove hex screws and remove thermostat housing.

Remove thermostat elements from coolant distributor


housing.

Remove O-rings from coolant distributor housing.

Check

Secure thermostat insert on a wire in a container filled


with water; thermostat insert must not contact
container.
Heat water with suitable heat source.

At approx. 8 C below opening temperature (depending


on design), the heating speed must not exceed 1-2 C
per minute.
Start-of-opening temperature is stamped on thermostat
insert.
Note:
Never use a welding torch or soldering lamp to heat the
coolant thermostat element.

Notice!
Part is hot. Risk of injury!
Handle part only when wearing gloves.

Stir coolant to achieve uniform temperature and check


thermostat element start of opening.
Replace thermostat insert if results of check are
negative.

20080/1 E 98-12
Group 20
Task Description Subgroup 2470c
Page 3

Continue to heat coolant to full-opening temperature.


Full-opening temperature = 75 C
Thermostat insert must be completely open after
approx. 6 to 8 minutes.
Measure stroke travel of thermostat insert.
Stroke must be 8.0 mm; if not, replace thermostat
insert.

Installation

Check sealing and mating faces.

Grease new O-rings with petroleum jelly and insert in


coolant distributor housing.

Insert thermostat elements, with ventilation notches


facing upwards, into coolant distributor housing.

Install thermostat housing with hex screws.

20080/1 E 98-12
Group 20
Subgroup 2470c Task Description
Page 4

20080/1 E 98-12
Group 20
Task Description Subgroup 2570
Page 1

20-2570 Coolant Cooler (Plate-Type Cooler) with "GEA" - Plates


Removal, Check, Repair and Installation
(Ship version 8V 183 T..2 with top-mounted intercooler)
Plate-type cooler

1 End plate (raw water)


2 Second-last plate (fresh water)
3 Intermediate plate (raw water)
4 Intermediate plate (fresh water)
5 Plate pair required 14 times.
6 Initial plate

20080/1 E 98-12
Group 20
Subgroup 2570 Task Description
Page 2

Plate-type cooler installation components

1 Tab washer
2 Hex screw M12x180 lubricated with Ultratherm paste
tighten diagonally and evenly.
pretightening 25 + 3 Nm.
further tightening 45 + 5 Nm, but not over block dimension,
see sign
3 Cover plate
4 Grooved pin 2.5x5
5 Sign - plate arrangement attached to cover plate.
and block dimension as per MTV 5008, Part 2
6 Sealing ring A26x37 replace.
7 Threaded pin
8 Elbow, raw water inlet
9 Sealing ring A18x22 replace.
10 Plug M18x1.5
11 Gasket replace, both sides sealed with surface sealant,
aux. No. 40 031
12 Spring washer
13 Stud
14 Hex nut
15 Flange
16 Spring washer
17 Hex screw M8 x 25
18 Elbow, raw water outlet
19 Spring washer
20 Hex screw M8x20
21 Hex screw M8x65
22 Sealing ring replace
23 Sleeve

20080/1 E 98-12
Group 20
Task Description Subgroup 2570
Page 3

Removal
To facilitate subsequent reassembly, apply a diagonal coloured mark to plate core.

Cover plate removal (illustration, see page 2)

Release tab washers (1).


Unscrew hex screws (2) diagonally and evenly and remove with tab washers.

Remove cover plate (3) from threaded pins.

Channel plate removal (illustration, see Page 1)

Remove end plate (1), second-last plate (2), intermediate plates (3,4) and initial plate (6) from threaded pins.

20080/1 E 98-12
Group 20
Subgroup 2570 Task Description
Page 4

Inspection and repair

Distributor housing and cover plate cleaning

Caution!
When using chemical agents, always follow the
manufacturer's instructions for use.
Clean distributor housing and cover plate with cold
cleaner and brush.

To remove lime scale deposits, use lime scale remover


which does not attach metal surfaces.
(e.g. P3 T288 from Henkel or Amidosulphuric acid
Euron 1308 from Hoechst).

Channel plate cleaning

Notice!
Never use hydrochloric acid for cleaning purposes!
Water with more than ppm C1 must not be used to
prepare a cleaning solution.
Protect aluminium components from chemicals.

20080/1 E 98-12
Group 20
Task Description Subgroup 2570
Page 5

Coarse fouling (algae, wood, barnacles, crabs)

Carry out mechanical cleaning with soft brush and


flowing water or high-pressure water cleaner.

Caution!
Do not damage seals.

Biological fouling and sludge (bacteria, protozoa)

Carry out mechanical cleaning with soft brush and


flowing water or high-pressure water cleaner.

Note:
In order to avoid damage to plates, observe specified
service pressure and minimum spray distance of H.P.
cleaner.
Observe operating instructions of equipment
manufacturer.

Chemical cleaning, select from


- caustic soda*
- sodium carbonate*
*concentration max. 4 %; temperature max. 80 C

Note:
The cleaning effect can be considerably increased by
adding small amounts of Hypochlorite or agents for
forming complexes and foam producers.

20080/1 E 98-12
Group 20
Subgroup 2570 Task Description
Page 6

Encrustations, scale and sediments

Carry out mechanical cleaning with soft brush and


flowing water or high-pressure water cleaner.

Caution!
Do not damage seals.

Chemical cleaning with


- Nitric acid*
- Citric acid*
- Phosphoric acid*
- Sodium polyphosphates*
* Concentration max. 4 %; Temperature max. 60 C

Oil residues, greases

Hydrocarbon-based deposits can be removed using a


soft brush and a paraffin- or naphtalene-based solvent
(e.g. kerosene).

Caution!
Solvents cause seals and gaskets to expand
Contact period: max. 30 min.

20080/1 E 98-12
Group 20
Task Description Subgroup 2570
Page 7

Following solvents should not be used:

- Ketones (e.g. acetone, methylethyketone, methyliso


butyl ketone)
- Esters (e.g. ethyl acetate, butyl acetate)
- halogenised hydrocarbon (e.g. chlorothene, carbon
tetrachlorides, feron)
- Aromas (e.g. benzine, toluen)

Clean profile gaskets of plates, check for damage.


If gasket is damaged, replace respective channel plate.
Repair work may involve the manufacturer replacing the rubber, if necessary.

Check leak-off grooves (in rubber seals).


In unpressed condition, leak-off groove must be approx. 8 mm wide.
If leak-off groove is pressed together, it must be recut with a knife.

Check screw-on surfaces, sealing surfaces and bores on distributor housing and cover plate for wear and damage,
smooth with oilstone as necessary.

Check condition of threads; rechase threads if necessary.


Fit threaded inserts if necessary.

Check flanges, sleeves and elbows for wear, smooth with oilstone or emery cloth as necessary.

Check thread of studs and threaded pins for ease of movement.


Replace components as necessary.

Using the surface crack-testing method with red penetrant dye, check components for cracks; replace component if
cracks are found.

Replace O-rings.

Replace tab washers.

20080/1 E 98-12
Group 20
Subgroup 2570 Task Description
Page 8

Installation

Raw water inlet elbow installation (illustration, see Page 2).

Grease elbow (8), raw water inlet, and flange (15) with petroleum jelly and insert in coolant distributor housing.

Secure flange (15) and elbow with screws (17) and washers (16) together.

Screw plug (10) with new sealing ring (9) in elbow (8).

Raw water outlet elbow removal (illustration, see Page 2).

Grease elbow (18), raw water outlet, O-ring (22) and sleeve (23) with petroleum jelly and fit in distributor housing.
Secure elbow with screws (20, 21) and washers (19).

Channel plate installation (illustration, see Pages 1 and 2)

Fit guide pin (7) with new sealing ring (6) and coat with petroleum jelly.
Fit initial plate (6) on guide pins.
Install channel plates (3, 4), if possible in pairs (5), as per arrangement or markings on guide pins.
Fit second-last plate (2) and end plate (1) on guide pins.

Note:(illustration, see Page 2).


Arrangement - see sign (5) on cover plate (3); direction of arrow of plate seats must always alternate between left
and right.

Cover plate installation (illustration, see Page 2)

Coat securing screws (2) on threaded stem and under head sufficiently with Ultratherm paste.
Fit cover plate (3) on guide pin.

Note:
If channel plates are significantly bent, if necessary preassemble plate core with longer M12 screws (assembly aid).

Install securing screws (2) with tab washers (1) and tighten:
Observe sequence as required (preferable diagonally and evenly), i.e. ensure parallel arrangement of channel
plates.
Pretightening approx. 25 + 3 Nm
Further tightening 45 + 5 Nm
but not beyond block dimension as per sign (5).
If necessary, make a break in tightening (min. 10 mins., max. 1 day), so that gaskets in channel plates can settle in
gaps of channel plates (Sh 70 elastomer).
Then tighten securing screws to block dimension as per sign (27), not exceeding max. tightening torque of
60 + 6 Nm.

Sign installation

Install sign (5) - plate arrangement and block dimension - with grooved pin on cover plate (19).

20080/1 E 98-12
Group 20
Task Description Subgroup 2570a
Page 1

20-2570a Coolant Cooler (Plate-Type Cooler) with "GEA" - Plates


Removal, Check, Repair and Installation
(Ship version 12V 183 T..2 with top-mounted intercooler)
Plate-type cooler

1 End plate (raw water)


2 Second-last plate (fresh water)
3 Intermediate plate (raw water)
4 Intermediate plate (fresh water)
5 Plate pair required 23 times.
6 Initial plate

20080/1 E 98-12
Group 20
Subgroup 2570a Task Description
Page 2

Plate-type cooler installation components

1 Tab washer
2 Hex screw M12x260 lubricated with Ultratherm paste
tighten diagonally and evenly.
pretightening 25 + 3 Nm.
further tightening 45 + 5 Nm, but not over block dimension,
see sign
3 Cover plate
4 Grooved pin 2.5x5
5 Sign - plate arrangement attached to cover plate.
and block dimension as per MTV 5008, Part 2
6 Sealing ring A26x37 replace.
7 Threaded pin
8 Elbow, raw water inlet
9 Sealing ring A18x22 replace.
10 Plug M18x1.5
11 Gasket replace, both sides sealed with surface sealant,
aux. No. 40 031
12 Spring washer
13 Stud
14 Hex nut
15 Flange
16 Spring washer
17 Hex screw M8x25
18 Elbow, raw water outlet
19 Spring washer
20 Hex screw M8x20
21 Hex screw M8x65
22 Sealing ring replace.
23 Sleeve

20080/1 E 98-12
Group 20
Task Description Subgroup 2570a
Page 3

Removal
To facilitate subsequent reassembly, apply a diagonal coloured mark to plate core.

Cover plate removal (illustration, see page 2)

Release tab washers (1), unscrew hex screw (2) diagonally and evenly and remove with tab washers.
Remove cover plate (3) from threaded pins.

Channel plate removal (illustration, see Page 1)

Remove end plate (1), second-last plate (2), intermediate plates (3,4) and initial plate (6) from threaded pins.

20080/1 E 98-12
Group 20
Subgroup 2570a Task Description
Page 4

Inspection and repair


Distributor housing and cover plate cleaning

Caution!
When using chemical agents, always follow
the manufacturer's instructions for use.
Clean distributor housing and cover plate with cold
cleaner and brush.

To remove lime scale deposits, use lime scale remover


which does not attack metal surfaces.
(e.g. P3 T288 from Henkel or Amidosulphuric acid
Euron 1308 from Hoechst).

Channel plate cleaning

Notice!
Never use hydrochloric acid for cleaning purposes!
Water with more than ppm C1 must not be used
to prepare a cleaning solution.
Protect aluminium components from chemicals.

20080/1 E 98-12
Group 20
Task Description Subgroup 2570a
Page 5

Coarse fouling (algae, wood, barnacles, crabs)

Carry out mechanical cleaning with soft brush and


flowing water or high-pressure water cleaner.

Caution!
Do not damage seals.

Biological fouling and sludge (bacteria, protozoa)

Carry out mechanical cleaning with soft brush and


flowing water or high-pressure water cleaner.

Caution!
Do not damage seals.

Note:
In order to avoid damage to plates, observe specified
service pressure and minimum spray distance of H.P.
cleaner.
Observe operating instructions of equipment
manufacturer.

Chemical cleaning, select from


- caustic soda*
- sodium carbonate*
*concentration max. 4 %; temperature max. 80 C
Note:
The cleaning effect can be considerably increased by
adding small amounts of hypochlorite or agents for
forming complexes and foam producers.

20080/1 E 98-12
Group 20
Subgroup 2570a Task Description
Page 6

Encrustations, scale and sediments

Carry out mechanical cleaning with soft brush and


flowing water or high-pressure water cleaner.

Caution!
Do not damage seals.

Chemical cleaning with


- Nitric acid*
- Citric acid*
- Phosphoric acid*
- Sodium polyphosphates*
* Concentration max. 4 %; Temperature max. 60 C

Oil residues, greases

Hydrocarbon-based deposits can be removed using a


soft brush and a paraffin- or naphtalene-based solvent
(e.g. kerosene).

Caution!
Solvents cause seals and gaskets to expand
Contact period: max. 30 min.

Following solvents should not be used:

- Ketones (e.g. acetone, methylethyketone, methyliso


butyl ketone)
- Esters (e.g. ethyl acetate, butyl acetate)
- halogenised hydrocarbon (e.g. chlorothene, carbon
tetrachlorides, feron)
- Aromas (e.g. benzine, toluen)

20080/1 E 98-12
Group 20
Task Description Subgroup 2570a
Page 7

Clean profile gaskets of plates, check for damage.


If gasket is damaged, replace respective channel plate.
Repair work may involve the manufacturer replacing the rubber, if necessary.

Check leak-off grooves (in rubber seals).


In unpressed condition, leak-off groove must be approx. 8 mm wide.
If leak-off groove is pressed together, it must be re-cut with a knife.

Check screw-on surfaces, sealing surfaces and bores on distributor housing and cover plate for wear and damage,
smooth with oilstone as necessary.

Check condition of threads; rechase threads if necessary.


Fit threaded inserts if necessary.

Check flanges, sleeves and elbows for wear, smooth with oilstone or emery cloth as necessary.

Check thread of studs and threaded pins for ease of movement.


Replace components as necessary.

Using the surface crack-testing method with red penetrant dye, check components for cracks; replace component if
cracks are found.

Replace O-rings.
Replace tab washers.

20080/1 E 98-12
Group 20
Subgroup 2570a Task Description
Page 8

Installation

Raw water inlet elbow installation (illustration, see Page 2).

Grease elbow (8), raw water inlet, and flange (15) with petroleum jelly and insert in coolant distributor housing.

Secure flange (15) and elbow with screws (17) and washers (16) together.
Screw plug (10) with new sealing ring (9) in elbow (8).

Raw water outlet elbow removal (illustration, see Page 2).

Grease elbow (18), raw water outlet, O-ring (22) and sleeve (23) with petroleum jelly and fit in distributor housing.
Secure elbow with screws (20, 21) and washers (19).

Channel plate installation (illustration, see Pages 1 and 2)

Fit guide pin (7) with new sealing ring (6) and coat with petroleum jelly.
Fit initial plate (6) - see Page 1 - on guide pin.
Install channel plates (3, 4) - see Page 2 - if possible in pairs (5), as per arrangement or markings on guide pins.
Fit second-last plate (2) and end plate (1) on guide pins.

Note:
(illustration, see Page 2).
Arrangement - see sign (5) on cover plate (3); direction of arrow of plate seats must always alternate between left
and right.

Cover plate installation (illustration, see Page 2)

Coat securing screws (2) on threaded stem and under head sufficiently with Ultratherm paste.
Fit cover plate (3) on guide pin.

Note:
If channel plates are significantly bent, if necessary preassemble plate core with longer M12 screws (assembly aid).

Install securing screws (2) with tab washers (1) and tighten:
Observe sequence as required (preferable diagonally and evenly), i.e. ensure parallel arrangement of channel
plates.
Pretightening approx. 25 + 3 Nm
Further tightening 45 + 5 Nm
but not beyond block dimension as per sign (5).
If necessary, make a break in tightening (min. 10 mins., max. 1 day), so that gaskets in channel plates can settle in
gaps of channel plates (Sh 70 elastomer).
Then tighten securing screws to block dimension as per sign (5), not exceeding max. tightening torque of
60 + 6 Nm.

Sign installation

Install sign (5) - plate arrangement and block dimension - with grooved pin on cover plate (3).

20080/1 E 98-12
Group 20
Task Description Subgroup 2570b
Page 1

20-2570b Coolant Cooler (Plate-Type Cooler) with "SWEP" - Plates


Removal, Check, Repair and Installation
(Ship version 8/12V 183 T..2/T..3 with compact intercooler)

1 Elbow, raw water inlet


2 Sleeve
3 Hex screw M8x30
4 Washer
5 Hex screw M8x55
6 Washer
7 Hex screw M10x70
8 Elbow, raw water outlet
9 Hex screw M10x35
10 Hex screw M10x110
11 Hex screw M8x85
12 Washer
13 Washer
14 Plug M42x1.5
15 Sealing ring A42x49 replace.
16 Plug M18x1.5
17 Sealing ring A18x22 replace.
18 Threaded pin
19 Cover plate
20 Initial plate (H)

20080/1 E 98-12
Group 20
Subgroup 2570b Task Description
Page 2

21 Intermediate plate (H), (fresh water)


22 Intermediate plate (raw water)
23 Plate pair (H) required for 8V 183 - 16 times,
for 12V 183 - 23 times
24 End plate (H)
25 Hex screw M12x170 for 8V 183
M12x220 for 12V 183
lubricated with Ultratherm paste
tighten diagonally and evenly:
pretightening 25 + 3 Nm
further tightening 45 + 5 Nm, but not over block dimension -
see sign.
26 Washer
27 Sign - plate arrangement and block dimension

Removal
To facilitate subsequent reassembly, apply a diagonal coloured mark to plate core.

Cover plate removal

Unscrew hex screws (25) diagonally and evenly and remove with washers (26).

Remove cover plate (19) from threaded pins.

Channel plate removal

Withdraw end plate (24), intermediate plates (21,22) and initial plate (20) from threaded pins.

20080/1 E 98-12
Group 20
Task Description Subgroup 2570b
Page 3

Inspection and repair


Clean all components.
If necessary, use the surface crack-testing method with red penetrant dye or fluorescent penetrant dye to check
channel plates for cracks; replace plates as necessary.
Check gaskets of channel plates for damage, replace plates as necessary.
Repair work may involve the manufacturer replacing the rubber, if necessary.
Check leak-off grooves (rubber profile) in gaskets for obstruction, recut with knife as necessary.
Replace gaskets as part of every W6 major overhaul.

Channel plate cleaning


Mechanical cleaning

Clean channel plates with a soft brush and flowing


water.

Note:
Use only a soft brush to avoid damaging the plates and
sealing faces.

Cleaning with steam jet.

Notice!
Take special care when using high-pressure jet.
Risk of injury!
Never direct water jet at humans, animals,
equipment or electric components.
Always wear protective clothing, protective gloves
and protective goggles/safety mask.
Note:
Maintain specified service pressure and minimum
spraying distance to avoid damaging plates and
gaskets. Observe operating instructions of equipment
manufacturer.
Remove deposits with H.P. spraying jet.

20080/1 E 98-12
Group 20
Subgroup 2570b Task Description
Page 4

Chemical cleaning

Caution!
When using chemical substances, follow the manufacturer's instructions for use, safety instructions and
waste disposal specifications.

Note:
Do not use the following solvents: Ketone (e.g. acetone, methyl ethyl ketone, methyl isobutyl ketone), ester (e.g.
ethyl acetate, butyl acetate), halogenised hydrocarbon (e.g. chlorothene, carbon tetrachloride, Freon), aromatic
compounds, benzine, toluene.

Note:
After chemical cleaning, flush channel plates with water
and dry with a cloth.

Biological growth and sludge (bacteria, nematoda,


protozoa)

To clean use alkaline cleaning agent:


- caustic soda*
- sodium carbonate*
*concentration max. 4%; temperature max. 80 C

Encrustation - scale and sediment (calcium


bicarbonate, calcium sulphate, corrosion products,
metallic oxides)

To clean use:
- Nitric acid*
- Citric acid*
- Phosphoric acid*
- Sodium polyphosphate
* Concentration max. 4%; Temperature max. 60 C
Note:
A decalcifying agent which is not aggressive to metal
surfaces (e.g. Porodox from Henkel or Euron 1308 from
Hoechst, concentration from 5% to 10%).

Deposits on carbon-hydrogen basis (oil residue,


greases)
Use a solution on paraffin or naphta basis
(e.g. kerosene).

20080/1 E 98-12
Group 20
Task Description Subgroup 2570b
Page 5

Distributor housing and cover plate cleaning and repair

Clean components with cold cleaner and brush.


Use only a soft brush to avoid damaging the plates and sealing faces.

To remove lime scale deposits, use lime scale remover which does not attack metal surfaces.
(e.g. Porodox from Henkel or Euron 1308 from Hoechst, concentration from 5% to 10%).

Check all mating faces, sealing faces and bores in distributor housing, cover plate for wear and damage; rub down
with emery cloth or an oilstone if necessary.

Check thread for ease of movement; rechase if necessary or replace insert as required.

Check thread of socket-head screws, pins and nuts for coolant cooler for ease of movement; replace as necessary.

Installation

Raw water inlet elbow removal

Grease elbow (1), raw water inlet, and sleeve (2) with petroleum jelly and insert in coolant distributor housing.

Secure elbow with screws (3) and washers (4) on distributor housing.

Secure sleeve and elbow with screws (5) and washers (6) together.

Install clamping screw (7) in distributor housing, screw plug (16) with new sealing ring (17) in elbow (1).

Raw water outlet elbow removal

Grease elbow (8), raw water outlet, with petroleum jelly and insert in coolant distributor housing.

Secure elbow with screws (9, 10, 11) and washers (12, 13).

20080/1 E 98-12
Group 20
Subgroup 2570b Task Description
Page 6

Channel plate installation

Install guide pins (18) and coat with petroleum jelly.

Fit initial plate (20) on guide pins.

Install channel plates (21, 22), if possible in pairs (23), as per arrangement or markings on guide pins.

Fit end plate (24) on guide pins.

Note:
For arrangement, see plate sign (27) on cover plate (19). Direction of arrows on plate seats must always alternate
between left and right.

Cover plate installation

Coat securing screws (25) on threaded stem and under head sufficiently with Ultratherm paste.
Fit cover plate (19) on guide pins.

Note:
If channel plates are significantly bent, if necessary preassemble plate core with longer M12 screws (assembly aid).

Install securing screws (25) with washers (26) and tighten:


Observe sequence as required (preferable diagonally and evenly), i.e. ensure parallel arrangement of channel
plates.
Pretightening approx. 25 + 3 Nm
Further tightening 45 + 5 Nm
but not beyond block dimension as per sign (27).
If necessary, make a break in tightening (min. 10 mins., max. 1 day), so that gaskets in channel plates can settle in
gaps of channel plates (Sh 70 elastomer).
Then tighten securing screws to block dimension as per sign (27), not exceeding max. tightening torque of
60 + 6 Nm.

Sign installation

Install sign (27) - plate arrangement and block dimension - with grooved pin on cover plate (19).

20080/1 E 98-12
Group 20
Task Description Subgroup 2670
Page 1

20-2670 Coolant Distributor Housing Removal and Installation


(Ship version 8/12V 183 T..2 with top-mounted intercooler)

1 Distributor housing
2 Plug M18x1.5
3 Sealing ring A18x22 replace.
4 Plug M38x1.5
5 Sealing ring A38x44 replace.
6 Flange
7 Gasket replace.
8 Hex screw M10x22
9 Washer
10 Gasket replace.
11 Socket-head screw M8x60
12 Socket-head screw M8x150
13 Socket-head screw M10x140
14 Hex screw M8x65
15 Washer
16 Hex screw M10x70
17 Washer
18 Hex screw M16x75
19 Washer

20080/1 E 98-12
Group 20
Subgroup 2670 Task Description
Page 2

1 Plug-in pipe Fixed in position.


2 Sealing ring replace.
3 Locking screw

Removal and Installation


as shown in illustration.

Note:
Before installing the coolant distributor housing, it is essential to install the coolant inlet and
outlet elbows, shown in Subgroups 2570 and 2570a, Page 2.

20080/1 E 98-12
Group 20
Task Description Subgroup 2670a
Page 1

20-2670a Coolant Distributor Housing Removal and Installation


(Ship version 8/12V 183 T..2 with compact intercooler)

1 Distributor housing
2 Plug M36x2
3 Plug M18x1.5
4 Sealing ring A18x22 replace.
5 Filler neck
6 Marker plate
7 Gasket replace.
8 Gasket replace.
9 Hex screw M18x25
10 Washer
11 Gasket replace.
12 Socket-head screw M8x60
13 Hex screw M8x170
14 Hex screw M10x70
15 Hex screw M10x170
16 Hex screw M10x80
17 Hex screw M16x80
18 Washer
19 Washer
20 Washer
21 Washer

Removal and installation


as shown in illustration.
Note:
Before installing the coolant distributor housing, it is essential to install the coolant inlet and
outlet elbows, shown in Subgroup 2570b.

20080/1 E 98-12
Group 20
Subgroup 2670a Task Description
Page 2

20080/1 E 98-12
Group 20
Task Description Subgroup 2670b
Page 1

20-2670b Coolant Distributor Housing Removal and Installation


(Ship version 8/12V 183 T..3 with compact intercooler)

1 Distributor housing
2 Plug M18x1.5
3 Sealing ring A18x22 replace.
4 Filler neck
5 Marker plate
6 Gasket replace.
7 Gasket replace.
8 Hex screw M8x25
9 Washer
10 Gasket replace.
11 Hex screw M8x170
12 Washer
13 Socket-head screw M8x60
14 Washer
15 Hex screw M10x70
16 Hex screw M10x80
17 Hex screw M10x170
18 Washer
19 Hex screw M16x80
20 Washer

Removal and installation


as shown in illustration.
Note:
Before installing the coolant distributor housing, it is essential to install the coolant inlet and
outlet elbows, shown in Subgroup 2570b.

20080/1 E 98-12
Group 20
Subgroup 2670b Task Description
Page 2

20080/1 E 98-12
Group 22
Task Description Subgroup
Page

Engine Suspension/Engine Mounting

20080/1 E 98-12
Group 22
Subgroup Task Description
Page

20080/1 E 98-12
Group 23
Task Description Subgroup
Page

Special Installations

20080/1 E 98-12
Group 23
Subgroup Task Description
Page

20080/1 E 98-12