8V & 10V QL2 WKSP Manual

Instructions for Exchange of Sub-
assemblies
Diesel engine
8V/10V2000M72
8V/10V2000M92
8V/10V2000M93
MS22008/02E
Engine model kW/cyl. Application group
8V2000M72 90 kW/cyl. 1B, continuous operation, variable, high load
8V2000M92 101 kW/cyl. 1DS, continuous operation, variable, low load
10V2000M72 90 kW/cyl. 1B, continuous operation, variable, high load
Table 1: Applicability
© 2015 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 consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-
tion, microfilming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.
Table of Contents
1 Safety 4.2.14 Conrod – Check 66
4.2.15 Conrod – Tolerances 68
1.1 Important provisions for all products 6 4.2.16 Conrod – Assembly 72
1.2 Personnel and organizational requirements 8 4.2.17 Piston and conrod – Assembly 74
1.3 Safety regulations for startup and operation 9 4.2.18 Piston and conrod – Installation 77
1.4 Safety regulations for maintenance and 4.2.19 Piston and conrod – Final steps 80
repair work 11 4.3 Cylinder Head 81
1.5 Fire prevention and environmental 4.3.1 Cylinder head – Overview 81
protection, fluids and lubricants, auxiliary 4.3.2 Cylinder head – Preparatory steps 82
materials 14 4.3.3 Cylinder head – Removal 83
1.6 Standards for safety notices in the text 16 4.3.4 Cylinder head – Cleaning 84
4.3.5 Cylinder head – Installation 85
4.3.6 Cylinder head – Final steps 87
2 General Information
4.4 Valve Gear 88
2.1 Engine side and cylinder designations 17 4.4.1 Roller tappets, pushrod – Overview 88
4.4.2 Roller tappets, pushrod – Preparatory steps 89
3 Technical Data 4.4.3 Roller tappets, pushrod – Removal 90
4.4.4 Pushrod – Cleaning 91
3.1 Settings 18 4.4.5 Roller tappet, pushrod – Check 92
4.4.6 Roller tappet, pushrod – Installation 93
4 Task Description 4.4.7 Roller tappets, pushrod – Final steps 95
4.4.8 Valve drive – Overview 96
4.1 Crankcase and Attachments 20 4.4.9 Valve drive – Preparatory steps 97
4.1.1 Cylinder liner – Overview 20 4.4.10 Valve drive – Removal 98
4.1.2 Cylinder liner – Preparatory steps 21 4.4.11 Valve drive – Cleaning 99
4.1.3 Cylinder liner – Removal 22 4.4.12 Valve gear – Check 100
4.1.4 Cylinder liner – Cleaning 24 4.4.13 Valve drive – Installation 101
4.1.5 Cylinder liner – Check 25 4.4.14 Valve gear – Final steps 103
4.1.6 Cylinder liner – Tolerances 26 4.4.15 Cylinder head cover – Overview 104
4.1.7 Cylinder liner – Installation 28 4.4.16 Cylinder head cover – Removal 105
4.1.8 Cylinder liner – Final steps 30 4.4.17 Cylinder head cover – Cleaning 106
4.1.9 Oil pan – Overview 31 4.4.18 Cylinder head cover – Check 107
4.1.10 Oil pan – Preparatory steps 32 4.4.19 Cylinder head cover – Installation 108
4.1.11 Oil pan – Removal 33
4.1.12 Oil pan – Cleaning 34 4.5 Fuel System (High Pressure) 109
4.1.13 Oil pan – Check 35 4.5.1 HP fuel system – Tightening procedure 109
4.1.14 Oil pan – Installation 36 4.5.2 HP pump – Overview 113
4.1.15 Oil pan – Final steps 37 4.5.3 HP fuel pump – Preparatory steps 114
4.5.4 HP pump – Removal 115
4.2 Running Gear 38 4.5.5 HP pump - Check 117
4.2.1 Vibration damper on PTO, free end – Overview 38 4.5.6 HP pump – Installation 118
4.2.2 Vibration damper on PTO free end – Removal 40 4.5.7 HP fuel pump – Final steps 122
4.2.3 Vibration damper on PTO, free end – 4.5.8 HP fuel line – Overview 123
Installation 42 4.5.9 HP line –- Removal 124
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4.2.4 Protective cover – Overview 45 4.5.10 HP line – Installation 125

4.2.5 Protective cover – Removal 49
4.2.6 Protective cover – Installation 50 4.6 Fuel System (Low Pressure) 126
4.2.7 Pistons and conrods – Overview 51 4.6.1 Fuel pipework from fuel delivery pump to fuel
4.2.8 Piston and conrod – Preparatory steps 54 filter – Overview 126
4.2.9 Piston and conrod – Removal 55 4.6.2 Fuel pipework from fuel delivery pump to fuel
4.2.10 Piston and conrod – Disassembly 57 filter - Removal 127
4.2.11 Piston – Cleaning 59 4.6.3 Fuel pipework from fuel delivery pump to fuel
4.2.12 Piston – Check 60 filter ‒ Installation 128
4.2.13 Piston – Tolerances 62 4.6.4 Fuel cooler – Overview 129
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4.6.5 Fuel cooler – Preparatory steps 130 4.11.7 Engine coolant pump – Final steps 186
4.6.6 Fuel cooler – Removal 131 4.11.8 Coolant cooler - Overview 187
4.6.7 Fuel cooler – Check 133 4.11.9 Coolant cooler – Preparatory steps 188
4.6.8 Fuel cooler – Installation 134 4.11.10 Coolant cooler – Removal 189
4.6.9 Fuel cooler – Final steps 136 4.11.11 Coolant cooler – Cleaning 190
4.6.10 Leak-off fuel pipework – Overview 137 4.11.12 Coolant cooler – Check 193
4.6.11 Leak fuel line – Removal 138 4.11.13 Coolant cooler – Installation 194
4.6.12 Leak-off fuel pipework – Installation 139 4.11.14 Coolant cooler – Final steps 196
4.11.15 Coolant pipework with thermostat – Overview 197
4.7 Exhaust Turbocharger 140 4.11.16 Coolant pipework with thermostat –
4.7.1 Exhaust turbocharger – Overview 140
Preparatory steps 198
4.7.2 Exhaust turbocharger – Preparatory steps 142
4.11.17 Coolant pipework with thermostat – Removal 199
4.7.3 Exhaust turbocharger – Removal 143
4.11.18 Coolant pipework with thermostat – Cleaning 200
4.7.4 Exhaust turbocharger – Cleaning 145
4.11.19 Coolant pipework with thermostat – Check 201
4.7.5 Exhaust turbocharger – Check 146
4.11.20 Coolant pipework with thermostat –
4.7.6 Exhaust turbocharger – Installation 147
Installation 203
4.7.7 Exhaust turbocharger – Final steps 150
4.11.21 Coolant pipework with thermostat – Final
4.8 Air Intake / Air Supply 151 steps 204
4.8.1 Intake housing – Overview 151 4.11.22 Raw-water pump – Overview 205
4.8.2 Intake housing – Preparatory steps 152 4.11.23 Raw water pump – Preparatory steps 206
4.8.3 Intake housing – Removal 153 4.11.24 Raw water pump – Removal 207
4.8.4 Intake housing – Cleaning 154 4.11.25 Raw water pump – Cleaning 208
4.8.5 Intake housing – Check 155 4.11.26 Raw water pump – Check 209
4.8.6 Intake housing – Installation 156 4.11.27 Raw water pump – Installation 210
4.8.7 Intake housing – Final steps 157 4.11.28 Raw water pump – Final steps 211
4.8.8 Air pipework to cylinders – Overview 158 4.11.29 Coolant pipework on raw water pump –
4.8.9 Air pipework to cylinders – Preparatory steps 159 Overview 212
4.8.10 Air pipework to cylinders – Removal 160 4.11.30 Coolant pipework on raw water pump –
4.8.11 Air pipework to cylinders – Installation 161 Preparatory steps 213
4.11.31 Coolant pipework on raw-water pump –
4.9 Exhaust Pipework 162 Removal 214
4.9.1 Exhaust pipework after engine – Overview 162 4.11.32 Coolant pipework on raw water pump ‒
4.9.2 Exhaust pipe bellows after engine – Removal 164 Installation 215
4.9.3 Exhaust pipe bellows after engine – 4.11.33 Coolant pipework on raw water pump – Final
Installation 165 steps 216
4.9.4 Carrier housing – Overview 166
4.9.5 Carrier housing cover – Removal and 4.12 Auxiliary Systems / Supplementary
installation 167 Equipment 217
4.9.6 Constant-pressure manifold – Overview 169 4.12.1 Bilge pump – Overview 217
4.9.7 Constant-pressure manifold – Preparatory 4.12.2 Bilge pump – Preparatory steps 220
steps 170 4.12.3 Bilge pump – Removal 221
4.9.8 Constant-pressure manifold – Removal 171 4.12.4 Bilge pump – Cleaning 222
4.9.9 Constant-pressure manifold – Installation 172 4.12.5 Bilge pump – Check 223
4.9.10 Constant-pressure manifold – Final steps 174 4.12.6 Bilge pump – Installation 224
4.12.7 Bilge pump – Final steps 225
4.10 Starting Equipment 175
4.10.1 Electric starter – Overview 175 4.13 Monitoring, Control and Regulation
4.10.2 Starter – Removal 176 Equipment 226
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4.10.3 Starter – Cleaning 177 4.13.1 Sensors and actuators – Overview 226
4.10.4 Starter – Check 178 4.13.2 Sensors, actuators and injectors – Preparatory
4.10.5 Starter – Installation 179 steps 231
4.13.3 Sensors and actuators – Removal 232
4.11 Coolant System 180
4.13.4 Sensors and actuators – Installation 236
4.11.1 Engine coolant pump – Overview 180
4.13.5 Sensors, actuators and injectors – Final steps 242
4.11.2 Engine coolant pump – Preparatory steps 181
4.11.3 Engine coolant pump – Removal 182
4.11.4 Engine coolant pump – Cleaning 183
4.11.5 Engine coolant pump – Check 184
4.11.6 Engine coolant pump – Installation 185
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5 Appendix A 5.4 Abbreviations 261
5.5 MTU contact persons/service partners 263
5.1 Tightening specifications for screws, nuts
and bolts 243
6 Appendix B
5.2 Conversion tables 256
5.3 Tolerances and wear limits list – General 6.1 Special Tools 264
information 260 6.2 Index 281
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MS22008/02E 2015-01 | Table of Contents | 5

1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine
in the EU: The second nameplate must be affixed in a prominent position as described in the accompa-
nying specifications.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use. Such improper use increases the risk of injury and damage
when working with the product. The manufacturer shall not be held liable for any damage resulting from
improper, non-intended use.
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Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise
safety.
Changes or modifications shall only be considered to comply with the intended use when expressly au-
thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.
6 | Safety | MS22008/02E 2015-01

Emission regulations and emission labels
Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions
regulation authorities. The manufacturer does not accept any liability for violations of the emission reg-
ulations. The maintenance schedules of the manufacturer must be observed over the entire life cycle of
the product.
Replacing components with emission labels

Emission labels are attached to all MTU engines. These must remain on the engine throughout its op-
erational life.
Engines used exclusively in land-based, military applications other than by US government agencies are
excepted from this proviso.
Please note the following when replacing components with emission labels:
• Appropriate emission labels must be affixed on spare parts.
• Emission labels may not be transferred from old components to new ones.
• Emission labels on old components must be removed and destroyed.
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MS22008/02E 2015-01 | Safety | 7

1.2 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Personnel must receive instruction on product handling and maintenance on the basis of this manual
with a special emphasis on safety requirements and warnings.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only:
• Training at the Training Center of the manufacturer
• Technical personnel from the areas mechanical engineering, plant construction and electrical engi-
neering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Personnel must not be under the influence of alcohol, drugs or strong medication.
Work clothing and personal protective equipment

When working, always wear the necessary personal protective equipment (e.g. safety shoes, ear protec-
tors, protective gloves, goggles, breathing protection). Observe the information on personal protective
equipment in the respective activity description.
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8 | Safety | MS22008/02E 2015-01

1.3 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica-
tions before putting the product into service. All necessary approvals must be granted by the relevant
authorities and all requirements for initial startup must be fulfilled.
When putting the product into operation, always ensure that
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is
switched on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• Keep clear of the service room during the first operating hours. Hazardous gases may occur as a re-
sult of the combustion of paints or oils.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.
Smoking is prohibited in the area of the product.
Safety regulations during operation

The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re-
gard to present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop

The procedures for emergencies, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond to the emergency appropriately, e.g. execute an emergency stop.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely neces-
sary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly in-
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structed to do so following a written procedure.

Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protectors.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder
agent.
Operation of electrical equipment

During operation of electrical devices, certain elements of these devices are live/under high voltage.
MS22008/02E 2015-01 | Safety | 9

Observe the warning information applicable to the devices.
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10 | Safety | MS22008/02E 2015-01

1.4 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collecting vessels of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately venti-
lated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the product.
Use special tools if they are specified for the relevant work.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be
painted. They may only be installed after painting the engine or must be covered before painting work is
carried out.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the
starter with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.
Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants which are properly secured.
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Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid
that components/tools fall down . Use the specified lifting equipment for all components.
Never use the product as a climbing aid.
When working high on the equipment, always use suitable ladders and work platforms. Never work on
engines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness
(e.g. components carrying oil, fuel, or air).
MS22008/02E 2015-01 | Safety | 11

Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.
Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all retainers and dampers are installed correctly.
Ensure that O-rings are not installed ina slanted/twisted condition.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.
Note cooling time for components which are heated for installation or removal (risk of burning).
Pay particular attention to cleanliness at all times.
Remove any condensate from components which were chilled before assembly. If necessary, coat the
components with a suitable corrosion inhibitor.
Safety regulations following maintenance and repair work

Before barring, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been re-
moved (especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding
in its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .
Hydraulic installation and removal

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Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only
the specified jigs and fixtures for hydraulic removal/installation procedures.
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or exert force on HP lines.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• During the installation procedure, screw on device with plunger extended.
• During the removal procedure, screw on device with plunger retracted.
12 | Safety | MS22008/02E 2015-01

For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into
shaft end until correct sealing is established.
During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of
the component being pressed on.
Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.
Gases released from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come into contact with skin or clothing.
Wear protective clothing, goggles and protective gloves.
Do not place tools on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.
Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be dam-
aged during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a functional testing on completion of all repair work. In
particular, check the function of the engine emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack-
age faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.
Working with laser devices

Laser work must only be performed by authorized and trained personnel. When working with laser
equipment, always observe the safety instructions in the manufacturer's Operating Instructions.
When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi-
ly focused radiation).
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Laser devices must be equipped with protective devices in accordance with their class and usage to
ensure safe operation.
Measuring deviations on components

At a reference temperature of 20 °C, workpieces, components and measuring instrument are within the
specified tolerances.
MS22008/02E 2015-01 | Safety | 13

1.5 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Flames, naked light and smoking are prohibited.
When working with combustible indirect materials, e.g. cleaning agent, ensure area is well ventilated.
The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmos-
phere.
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al-
ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground cable last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground cable from the external power
source to the ground cable of the engine or to the ground terminal of the starter.
Always have a suitable extinguishant (fire extinguisher) on hand and familiarize yourself fully with its
handling.
Noise
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating
danger are drowned.
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal

Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.
Fluids and lubricants, auxiliary materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
“Technical Info” or “Parts and Service” tabs at http://www.mtu-online.com.
Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as
well as other chemical substances, observe the information contained in the safety data sheet for the
product. The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Take special care when using hot, chilled or caustic materials.
Used oil
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Used oil contains combustion residues that are harmful to health.

Wear protective gloves!
Wash relevant areas after contact with used oil.
14 | Safety | MS22008/02E 2015-01

Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or pastes containing lead, avoid direct contact to the skin and do not inhale
lead vapors.
• Wash relevant areas after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. In-
stall pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems,
ensure that the area is well ventilated. Make sure that neighboring work areas are not adversely af-
fected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue®, DEF)

TIM-ID: 0000040536 - 009

• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After contact skin, wash body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possi-
ble.
MS22008/02E 2015-01 | Safety | 15

1.6 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Additional product information.
Safety notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.
TIM-ID: 0000040578 - 004
16 | Safety | MS22008/02E 2015-01

2 General Information
2.1 Engine side and cylinder designations
1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on
the left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The
cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 013
MS22008/02E 2015-01 | General Information | 17

3 Technical Data
3.1 Settings
Firing order for 2000CR engines
8V A1-B4-A4-A2-B3-A3-B2-B1
10 V A1-B4-A4-B3-A3-B2-A2-B5-A5-B1
12 V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1
16 V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7
Direction of rotation, viewed on driving end

Component Direction of rotation
Crankshaft c.c.w.
Camshaft c.w.
HP fuel pump c.c.w.
Oil pump c.c.w.
Engine coolant pump c.c.w.
Raw water pump c.c.w.
Battery-charging generator c.c.w.
Valve clearance with engine cold

Inlet 0.30 mm
Exhaust 0.40 mm
TIM-ID: 0000002716 - 004
18 | Technical Data | MS22008/02E 2015-01

Valve timing with valve clearance adjusted (view on free end)
No. Valve position Crank angle

1 Inlet opens 40.4° before TDC
2 Inlet closes 43.6° after BDC
3 Exhaust opens 67.6° before BDC
4 Exhaust closes 43.2° after TDC
5 Valve overlap 83.6°
Start of injection Controlled by performance map
A Top dead center (TDC)
B Bottom dead center (BDC)
Cam and valve stroke for camshaft adjustment

Inlet Exhaust
Cam lift in TDC 1.60 mm 1.60 mm
Valve lift in TDC (with zero valve 2.20 mm 2.20 mm
TIM-ID: 0000002716 - 004
clearance)
MS22008/02E 2015-01 | Technical Data | 19

4 Task Description
4.1 Crankcase and Attachments
4.1.1 Cylinder liner – Overview
1 Sealing ring 3 Cylinder liner

2 Metal sealing ring 4 Carbon scraper ring
TIM-ID: 0000059792 - 001
20 | Task Description | MS22008/02E 2015-01

4.1.2 Cylinder liner – Preparatory steps
Preconditions
☑Engine is stopped and starting disabled.
Preparatory steps
1. Remove cylinder head (→ Page 83).
2. Remove piston and conrod (→ Page 55).
TIM-ID: 0000011419 - 008
MS22008/02E 2015-01 | Task Description | 21

4.1.3 Cylinder liner – Removal
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Puller for liner F6783773 1
WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.
WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.
Removing carbon scraper ring

1. Extract carbon scraper ring from fit of cylinder liner.
2. Protect carbon scraper ring from damage.
Removing cylinder liner

1. Mark installation position of cylinder liner
in relation to crankcase with a marker
pen (arrow).
TIM-ID: 0000003320 - 004

Note: Do not damage the oil spray nozzle.
2. Fit puller plate (2) on lower collar of cylin-
der liner (1).
3. Place counter support onto the spindle and
studs and screw tight.
4. Turn puller nut (3) until cylinder liner is re-
leased from crankcase bore.
5. Remove puller.
6. Extract cylinder liner (1) from crankcase.
7. Remove sealing rings from cylinder liner.
8. Seal openings with suitable covers.
TIM-ID: 0000003320 - 004

4.1.4 Cylinder liner – Cleaning
Cleaner (Snow-White 11-0) X00054118 1
Cleaner (Hakupur 50/136) X00056700 1
WARNING
Cleaner is extremely caustic.
Risk of injury and suffocation!
• Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Wear protective clothing, gloves, and goggles / safety mask.
• Take measures against electrostatic charging.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
Cylinder liner – Cleaning

1. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 50/136).
2. Blow out all parts with compressed air.
TIM-ID: 0000003293 - 009

4.1.5 Cylinder liner – Check
Bore gauge, 160–290 mm Y20091483 1
Dial gauge Y20011268 1
Outside micrometer, 150–175 mm Y20000326 1
Oilstone F30454308/03 1
Cylinder liner (→ Spare Parts Catalog)
Carbon scraper ring (→ Spare Parts Catalog)
WARNING
Cylinder liner – Check

Item Findings Measure
Check outer wall for pitting. Pitting visible. Replace
Check sealing and mating faces • Signs of wear • Rework: Smooth with oilstone.
for stress marks and damage. • Damage • Replace
visible
Check floating mount of carbon Signs of jamming • Measure cylinder liner.
scraper ring in cylinder liner. • Replace carbon scraper ring.
Measure cylinder liner bore with Values exceeded. Replace
bore gauge and dial gauge. Meas-
urement plane and values
(→ Page 26).
TIM-ID: 0000011404 - 010

4.1.6 Cylinder liner – Tolerances
Item Name Re- Tol. size Deviation Clearance Interference Wear limit
pair Basic size Lower Upper Min. Max. Min. Max.
size
1 Cylinder liner protrusion: 10.440 to 10.540
2 Carbon scraper ring bore 134.400 H8 0 +0.063
3 Carbon scraper ring fit 139.000 H7 0 +0.040 0.014 0.094
Carbon scraper ring OD 139.000 g7 −0.054 −0.014
4 Housing bore 0 157.500 H7 0 +0.040 0.005 0.070
-upper fit
1 158.000 H7
Cylinder liner 0 157.500 −0.030 −0.005
- upper fit 1 158.000
5 Housing bore 0 154.000 H7 0 +0.040 0.025 0.090
-lower fit
1 154.500 H7
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Cylinder liner 0 154.000 −0.050 −0.025

- lower fit 1 154.500
6 0 to 0.03 > actual dimension ID
6 Cylinder liner 135.000 -0.015 +0.015
ID
7 Plane of measurement 30.000
8 Housing bore 170.500 −0.100 +0.300 0.300 0.900
Gasket 170.000 −0.100 +0.100
OD

Item Name Re- Tol. size Deviation Clearance Interference Wear limit
pair Basic size Lower Upper Min. Max. Min. Max.
size
9 Sealing ring 0.150 −0.010 +0.010
10 Cylinder liner 0 10.850 −0.020 0
collar thickness
Notes for reconditioning

re. 2 and 3
• Check scraper ring OD and ID when fitted.
Re 4 and 5:
• If there is cavitation on the upper and/or lower fit of the crankcase bore:
• Insert the next repair size and install the cylinder liner for the appropriate repair size.
• Only to be carried out by MTU-approved workshops.
re. A:
• Cylinder liner without groove: Repair size 0
• Cylinder liner with groove: Repair size 1
TIM-ID: 0000003298 - 005

4.1.7 Cylinder liner – Installation
Press-in tool for cylinder liner F6783388 1
Safety rail F6555715 2
Assembly compound (Kluthe Hakuform 30-15) X00067260 1
Engine oil
Sealing rings (→ Spare Parts Catalog)
Carbon scraper ring (→ Spare Parts Catalog)
WARNING
WARNING
Risk of injury!
NOTICE
Contamination of components.
Damage to component!
• Check components for special cleanliness.
Installing cylinder liner

1. Wipe lower fit and chamfer of cylinder lin-
er (4) with chamois leather.
2. Coat upper and lower fit with assembly
compound.
3. Coat sealing rings (1) with assembly com-
pound.
Note: Ensure that the flat side is against cylinder
liner (4) and convex side is against crank-
case (3).
4. Fit sealing rings (1) in grooves on cylinder
liner (4).
5. Fix sealing ring (2) on crankcase (3) with
assembly compound.
TIM-ID: 0000003330 - 006
6. Insert cylinder liner (4) in crankcase (3).

7. Install press-in tool (2) on crankcase.
8. Press cylinder liner (1) into crankcase bore.
9. Remove press-in tool (2).
Measure cylinder liner bore

1. Adjust bore gauge and dial gauge with micrometer or adjusting ring to basic size for cylinder liner. Value
and measurement planes (→ Page 26).
2. Measure cylinder liner bore with bore gauge.
3. Enter measured values in data sheet.
4. If out-of-round is measured:
a) Remove cylinder liner.
b) Remeasure cylinder liner bore and outside diameter.
c) Check sealing rings for correct seating.
Measuring protrusion of cylinder liner

1. Measure protrusion of cylinder liner collar to crankcase. Record protrusion. Carry out 4 x 90° offset
measurements.
2. For each measurement, set the scale of the dial gauge to zero. The difference of the 4 measured points
per cylinder liner must not exceed 0.02 mm. Protrusion (→ Page 26).
3. If the test values deviate, remove cylinder liner and check cause.
Installing carbon scraper ring

Note: Only insert carbon scraper ring after installing piston (→ Page 77).
1. Spray cylinder liner and carbon scraper ring with engine oil.
2. Insert carbon scraper ring into fit of cylinder liner.
3. Remove safety rail for cylinder liners.
TIM-ID: 0000003330 - 006

4.1.8 Cylinder liner – Final steps
Final steps
1. Assemble in reverse order of disassembly (→ Page 21).
2. Enable engine start.
TIM-ID: 0000011432 - 006

4.1.9 Oil pan – Overview
1 Gasket 6 Oil pan 11 Nut

2 Washer 7 Screw 12 Washer
3 Screw 8 Washer 13 Screw
4 Washer 9 Flange 14 Washer
5 Screw 10 O-ring
TIM-ID: 0000060104 - 001

4.1.10 Oil pan – Preparatory steps
Preconditions
☑Engine shut down and starting disabled.
Preparatory steps
1. Observe safety instructions.
2. Drain or draw off engine oil (→ Operating Instructions).
TIM-ID: 0000011478 - 002

4.1.11 Oil pan – Removal
Lowering device F6784104 3
DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
WARNING
Lowering the oil pan

Note: With the engine installed, the oil pan can
be lowered to facilitate assembly work.
1. Install lowering devices (1) on the left and
right engine sides.
2. Remove screws (4) for oil pan (3).
3. Lower oil pan (3) by evenly turning the
threaded rod (2) of the lowering devi-
ces (1).
TIM-ID: 0000011468 - 003

4.1.12 Oil pan – Cleaning
WARNING
WARNING
NOTICE
Oil pan – Cleaning

2. Thoroughly blow out oil pan and all threaded bores with compressed air.
TIM-ID: 0000003354 - 008

4.1.13 Oil pan – Check
Oil pan (→ Spare Parts Catalog)
Screw (→ Spare Parts Catalog)
WARNING
Checking oil pan

Item Finding Measure
Check mating face of oil pan on Unevenness exceeding 0.3 mm on Recondition mating face.
crankcase for unevenness. 8, 10, 12V engines
Unevenness exceeding 0.5 mm on
16V engines
Check sealing surfaces. Damaged • Rework
• Replace
Check threaded holes for easy Sluggish Replace thread inserts.
movement.
TIM-ID: 0000011457 - 002

4.1.14 Oil pan – Installation
Silicone rubber (Loctite 5970) 50773 1
Pipe thread sealant (Loctite 586) 40033 1
Engine oil
Gasket (→ Spare Parts Catalog)
Neck (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)
DANGER
Suspended load.
Danger to life!
WARNING
NOTICE
NOTICE
Incorrect installation of components and lines.
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
Install lowered oil pan

1. Clean and degrease mating face on oil pan
(3) and crankcase (4).
2. Coat contact surface at the crankcase/
flywheel housing joint and the crankcase/
gearcase joint with Loctite 5970.
3. Place gasket on to sealing surface of the oil
TIM-ID: 0000011491 - 003
pan.
4. Attach oil pan (3) to crankcase (4) by even-
ly turning the threaded rods (2) of the low-
ering devices (1).
5. Insert screws and washers for oil pan (3)
and tighten evenly.
6. Remove lowering devices (1), screw in and
tighten remaining screws and washers.

4.1.15 Oil pan – Final steps
Final steps
2. Fill with engine oil (→ Operating Instructions).
3. Fill with engine coolant (→ Operating Instructions).
TIM-ID: 0000011502 - 004

4.2 Running Gear
4.2.1 Vibration damper on PTO, free end – Overview
1 Belt drive 3 Vibration damper 5 Shaft seal

2 Crankshaft 4 Gearcase
TIM-ID: 0000003937 - 004

Arrangement of installation/removal device for vibration damper
1 Connection for hydraulic 5 Thrust sleeve B Push-on dimension:

nut 6 Connection for vibration 94.5 mm ±0.05 mm
2 Puller spindle damper C Push-on distance: 12 mm -
3 Nut 7 Crankshaft 14.6 mm
4 Hydraulic nut A Reference dimension =
348 mm
TIM-ID: 0000003937 - 004

4.2.2 Vibration damper on PTO free end – Removal
Removal/installation device F0140560 1
Lifting gear T80092026 1
Hand pump kit B80146887 1
Protective sleeve F6780523 1
DANGER
Suspended load.
Danger to life!
WARNING
Equipment can drop off.
Liquid is highly pressurized.
Risk of injury, knocks or crushing!
• Only use specified and tested equipment.
• Do not enter the danger zone.
Removing vibration damper

1. Remove flange for barring device.
2. Screw grub screw out of the expanding
bore in the vibration damper.
3. Screw puller spindle (5) into crankshaft.
4. Check reference dimension “A” of puller
spindle (→ Page 38).
5. Slide thrust sleeve (4) and hydraulic nut (2)
over puller spindle.
6. Screw on nut (1).
7. Screw reducer (3) into vibration damper
and connect high-pressure line.
8. Connect high-pressure line for hand pump
to hydraulic nut.
9. Set hydraulic nut to initial position with
zero stroke.
10. Back off nut past push-on dimension. Push-
on dimension “a” is stamped on vibration
damper
TIM-ID: 0000003961 - 004

11. Fill hand pumps (1) and (2) with engine oil
SAE 10 W.
12. Vent hand pump (1) and pipework until
bubble-free oil emerges.
13. Tighten high-pressure line.
14. Operate hand pump (2) for hydraulic nut
and use minimum pressure p2 (beginning
pressure increase) to bring into contact on
vibration damper.
15. Read off maximum expansion pressure pmax
at vibration damper.
16. Operate hand pump (1) for expanding the
hub, until half of the maximum expansion
pressure p1 is reached.
17. Maintain pressure p1 for approx. 5 minutes.
18. Increase the expansion pressure in steps of
0.1 x pmax, and hold each time for approx.
2 minutes, until the vibration damper is re-
leased from the crankshaft. Do not exceed
maximum permissible expansion pressure
pmax.
19. Keep falling expansion pressure constant
by continuing to use hand pump (1).
20. Monitor pressure p2 in hydraulic nut. The
release of the vibration damper from the
taper seat is indicated by an increase in
pressure p2.
21. Gradually drain oil from hydraulic nut while
continuing to use hand pump (1).
22. Relieve hand pumps (1) and (2).
23. Remove HP line and reducer.
24. Remove nut, hydraulic nut and thrust
sleeve.
25. Install lifting gear.
26. Remove vibration damper from crankshaft.
27. Seal all openings with suitable covers.
TIM-ID: 0000003961 - 004

4.2.3 Vibration damper on PTO, free end – Installation
Removal/installation device F0140560 1
Protective sleeve F6780523 1
Engine oil
O-ring (→ Spare Parts Catalog)
DANGER
Suspended load.
Danger to life!
WARNING
WARNING
NOTICE
NOTICE
TIM-ID: 0000003976 - 005

Installing vibration damper
1. Remove all covers prior to installation.
2. Clean and degrease tapers of crankshaft
and vibration damper.
3. Coat bearing surfaces of crankshaft bear-
ing and vibration damper with engine oil.
4. Coat sealing lip on shaft seal with assembly
compound.
5. Slide vibration damper onto crankshaft tap-
er.
6. In order to determine push-on distance,
use depth gauge to measure distance from
crankshaft front end to vibration damper
front end.
7. Calculate difference value (=push-on dis-
tance) between measured dimension and
dimension (B) (→ Page 38).
8. If measured distance is smaller than push-
on distance (a), (→ Page 38) check taper
for dimensional accuracy.
9. Screw puller spindle (5) into crankshaft.
10. Check reference dimension “A”
(→ Page 38).
11. Slide thrust sleeve (4) and hydraulic nut (2)
over puller spindle and screw on nut (1).
12. Screw high-pressure line onto reducer (3)
finger-tight.
13. Connect high-pressure line for hydraulic
nut.
14. Set hydraulic nut to initial position with
zero stroke.
TIM-ID: 0000003976 - 005

15. Fill hand pumps (1) and (2) with engine oil
SAE 10 W.
16. Vent hand pump (2) and pipework until
bubble-free oil emerges.
17. Tighten high-pressure line for reducer.
18. Prior to press-fitting, moisten taper fit sur-
faces with engine oil. Actuate hand
pump (2) to do this until engine oil escapes
at the hub end.
19. Operate hand pump (1) for hydraulic nut
and use minimum pressure to bring to con-
tact point on hub.
Note: Read off expansion pressure pmax at hub.
20. Pump in expansion fluid until expansion
pressure (p 1) no longer rises (do not ex-
ceed expansion pressure P max ) and then in-
crease force-on pressure (p2).
21. Select a push-on force so that the end po-
sition is reached in approx. 5 steps.
22. Open valve screw on hand pump (2) to re-
lieve expansion pressure.
23. Maintain maximum push-on pressure for
60 minutes, to ensure that the expansion
fluid is expelled from the joint and static
friction can build up between the fixed
components.
24. Remove high-pressure lines.
25. Remove nut, hydraulic nut, thrust sleeve
and puller spindle after prescribed holding
time.
26. Check push-on dimension “B”. Value
(→ Page 38)
27. Install flange for barring gear.
28. Do not subject press fitting to operating
load for at least 8 hours.
TIM-ID: 0000003976 - 005

4.2.4 Protective cover – Overview
Protective cover without bilge pump, without PTO flange
1 Screw 4 Spacer pin 7 Protective cover

2 Washer 5 Spacer pin
3 Protective cover 6 Spacer pin
TIM-ID: 0000040018 - 001

Protective cover with bilge pump, without PTO flange
1 Screw 7 Protective cover 13 Washer

2 Washer 8 Nut 14 Flange
3 Protective cover 9 Protective cover 15 Nut
4 Spacer pin 10 Washer 16 Washer
5 Spacer pin 11 Screw 17 Belt pulley
6 Spacer pin 12 Screw 18 Stud
TIM-ID: 0000040018 - 001

Protective cover with bilge pump, with PTO flange
1 Screw 5 Spacer pin 9 Belt pulley with drive

2 Washer 6 Stud flange
3 Protective cover 7 Spacer pin 10 Nut
4 Spacer pin 8 Protective cover 11 Washer
TIM-ID: 0000040018 - 001

Protective cover without bilge pump, with PTO flange
1 Screw 5 Spacer pin 9 Belt pulley with drive

2 Washer 6 Stud flange
3 Protective cover 7 Spacer pin 10 Nut
4 Spacer pin 8 Protective cover 11 Washer
TIM-ID: 0000040018 - 001

4.2.5 Protective cover – Removal
Removing the protective cover

1. Remove protective cover as shown in overview drawing (→ Page 45).
TIM-ID: 0000011862 - 002

4.2.6 Protective cover – Installation
Engine oil
Installing the protective cover

1. Remove all covers.
2. Install protective cover with screws and washers as shown in overview drawing (→ Page 45).
TIM-ID: 0000011863 - 002

4.2.7 Pistons and conrods – Overview
1 Snap ring 3 Piston 5 Taper-face compression

2 Piston pin 4 Oil-control ring ring
6 Keystone-type compres-
sion ring
TIM-ID: 0000004016 - 003

Overview drawing
1 Conrod 2 Conrod bearing (lower 3 Conrod bearing (upper

half) half)
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Overview drawing
1 Conrod 3 Conrod screw

2 Conrod bushing 4 Conrod cap
TIM-ID: 0000004016 - 003

4.2.8 Piston and conrod – Preparatory steps
Preconditions
Preparatory steps
1. Drain engine coolant (→ Operating Instructions).
2. Drain or extract engine oil (→ Operating Instructions).
3. Remove ECU (→ Operating Instructions).
4. Remove air filter (→ Operating Instructions) .
6. Lower oil pan (→ Page 33).
TIM-ID: 0000011917 - 001

4.2.9 Piston and conrod – Removal
Barring device F6783914 1
Lowering device F6784104 1
Assembly device F6783791 1
Socket F30005947 1
DANGER
Suspended load.
Danger to life!
WARNING
Removing piston and conrod

with oil pan lowered
1. Remove combustion residue in the cylinder
liner.
2. Remove carbon scraper ring (→ Page 22).
3. Install assembly device (1) in piston (2) and
apply compressed air.
4. After approx. 5 seconds, check assembly
device (1) for correct fit.
TIM-ID: 0000011908 - 003

Note: Bearing cap and conrod are a unit and may
not be mixed.
5. Check marking (arrows) of conrod bearing
cap and conrod. Mark if necessary.
6. Bar engine to corresponding removal posi-
tions with barring device.
1. A-side = after TDC
2. B-side = before TDC
7. Use socket, extension and ratchet to loos-
en conrod screws in specified sequence.
1. long arm
2. short arm
8. Remove conrod screws and take off conrod
caps.
9. Remove bearing shell from the conrod cap.
10. Protect bearing shell and conrod cap
against damage.
Note: Take care that the oil spray nozzle is not

damaged.
11. Pull piston (2) and conrod out of cylinder
liner until the second piston ring (3) ex-
pands.
12. Switch off compressed air.
13. Remove assembly device (1) from pis-
ton (2).
14. Remove bearing shell from conrod cap and
protect against damage.
15. Remove piston (2) and conrod.
16. Carefully set down piston and conrod on a
soft surface and protect against damage.
TIM-ID: 0000011908 - 003

4.2.10 Piston and conrod – Disassembly
Piston-ring pliers F30379877 1
Pliers F30453426 1
WARNING
WARNING
Risk of injury!
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
Removing conrod from piston

1. Place piston and conrod on workbench.
2. Check markings of conrod, piston and pis-
ton pin. If necessary, re-mark the compo-
nents.
3. Remove snap ring (1) with pliers (2).
TIM-ID: 0000004053 - 005

4. Press out piston pin (2) with round wood
(arrow), securing conrod (1) in so doing.
5. Remove conrod (1) from piston.
Removing piston rings

1. Stretch piston rings with pliers as far as the
stop so that they can be removed from the
piston.
2. Remove piston rings with piston ring pliers
in sequence from top to bottom.
TIM-ID: 0000004053 - 005

4.2.11 Piston – Cleaning
Solvent (SIMA SOLV K6) X00057281 1
DANGER
Cleaner is an explosive and poisonous substance.
Danger to life, major material damage!
• Avoid open flames, electrical sparks and ignition sources.
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.
WARNING
WARNING
WARNING
Risk of injury!
NOTICE
Cleaning piston
Note: The graphite layer on the piston skirt must not come into contact with strong cleaning agents or be
removed mechanically.
1. Clean all metallic parts with cleaning agent.
2. Clean piston ring groove area using rotating plastic roller brush.
3. After cleaning, blow out oil chamber and oil bores with compressed air.
TIM-ID: 0000004020 - 009

4.2.12 Piston – Check
Ring gauge Y4345226 1
Piston (→ Spare Parts Catalog)
Piston pin (→ Spare Parts Catalog)
Oil control ring (→ Spare Parts Catalog)
Taper-face compression ring (→ Spare Parts Catalog)
Keystone-type compression ring (→ Spare Parts Catalog)
WARNING
WARNING
Risk of injury!
Checking piston
Check that oil chamber and oil Unclean Clean
bores are particularly clean.
Check piston for wear. • Contact erosion at piston edge Replace piston.
and valve-clearance pockets
• Large area of polish wear on
piston skirt (appears matt)
• Concentrated occurrence of
scores
• Seizure marks
Measure piston pin boss. Values Values exceeded. Replace piston.
(→ Page 62)
Check sliding surface of bronze • Signs of wear Replace piston.
bushing for signs of wear and • Scores
scoring. visible
Check groove width with gauge Values exceeded. Replace piston.
blocks. If no gauge block is availa-
TIM-ID: 0000011885 - 002
ble, as an alternative, insert new

piston ring in groove and check
axial clearance with feeler gauge.
Values (→ Page 62)
Check condition of piston pin. • Wear traces Replace piston pin.
• Scoring
• Points of impact
visible

Measure piston pin outside diame- Values exceeded. Replace piston pin.
ter with outside micrometer. Val-
ues (→ Page 62)
Check piston rings. • Piston rings burred, chipped or Replace
sharp-edged
• If chrome layer shows scores,
cracks or burn marks.
Checking piston rings

1. Place piston ring (1) in ring gauge (3) to
measure piston ring end clearance. Make
sure that piston ring lies evenly in ring
gauge (3).
2. Check ring end clearance with feeler
gauge (2). Values (→ Page 62)
3. If values are exceeded: Replace piston
rings. Only replace piston rings in sets.
4. After installation of new piston rings, re-
place cylinder liners (→ Page 22).
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4.2.13 Piston – Tolerances
Item Designation Re- Toleranced Deviation Clearance Interference Wear limit

pair size Lower Upper Min. Max. Min. Max.
size Basic size
1 Piston bore, transverse - 52.000 +0.016 +0.022 0.018 0.030 - - -
out-of-round
Piston pin - 52.000 −0.008 −0.002
OD
A Measuring point for pis- 30.6
ton bore
(measured from piston
shaft)
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Piston rings

size Basic size
1 Measure thickness of keystone-type compression ring at 2.500 mm clearance.
2 Groove width - 3.374 -0.010 +0.010 0.130 0.184 - - -
Keystone-type compres- - 3.224 +0.010 -0.024
sion ring
3 Groove width - 3.070 -0.010 +0.010 0.060 0.110 - - -
Taper-face compression - 3.000 −0.030 0
ring
4 Groove width - 4.040 -0.010 +0.010 0.030 0.080 - - -
Oil-control ring - 4.000 −0.030 0
5 Ring end clearance
Keystone-type compres- - - - 0.500 0.600 - - -
-
sion ring
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Taper-face compression - - - 0.800 1.050 - - -

-
ring
Oil-control ring - - - - 0.400 0.750 - - -
Measure ring end clearance in ring gauge.

Piston clearance in cylinder liner

size Basic size
1 Piston clearance - 2.600 −0.500 +0.500 - - - - -
2 Liner dia. - 135.000 −0.015 +0.015 - - - - -
Piston skirt dia. - 133.527 −0.012 +0.012
3 Liner dia. - 135.000 −0.015 +0.015 - - - - -
Piston skirt dia. - 133.610 −0.012 +0.012
4 Liner dia. - 135.000 −0.015 +0.015 - - - - -
Piston skirt dia. - 134.440 −0.012 +0.012
5 Liner dia. - 135.000 −0.015 +0.015 - - - - -
Piston skirt dia. - 134,590 −0.012 +0.012
6 Liner dia. - 135.000 −0.015 +0.015 - - - - -
Piston skirt dia. - 134.797 −0.007 +0.007
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7 Liner dia. - 135.000 −0.015 +0.015 - - - - -

Piston skirt dia. - 134.870 −0.007 +0.007

size Basic size
A Measurement point - 115
B Measurement point - 108
C Measurement point - 104.5
D Measurement point - 94.5
E Measurement point - 64
F Measurement point - 15
Measure dimensions 2 to 7 parallel to the piston pin axis.
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4.2.14 Conrod – Check
Testing device Y4341492 1
Test mandrel Y4341915 1
Test mandrel Y4341916 1
Bore gage, 18-100 mm Y20091481 1
Dial gage Y20011268 1
Depth gage, 300 mm Y20002777 1
Engine oil
Conrod (→ Spare Parts Catalog)
Conrod screw (→ Spare Parts Catalog)
Conrod bushing (→ Spare Parts Catalog)
Conrod – Check
Item Finding Action
Check conrod basic bore for blue Blue discoloration Replace conrod.
discoloration.
Check conrod bushing for scores, Damaged • Recondition
contamination, stress marks and • Replace conrod bushing.
heat discoloration marks.
Check conrod thread and conrod Damaged • Replace conrod.
screw for damage. • Replace conrod screw.
Check conrod screw length. Val- Value exceeded Replace
ues (→ Page 68).
Check mating surface on conrod • Signs of wear Replace
bearing cap for conrod screws for • Scores
signs of wear and scores. visible
Check main bore for signs of wear • Signs of wear • Recondition
and scores. • Scores • Replace
visible
Inspect meshing for damage and Damaged Replace
check contact pattern with engi-
neer's blue.
Measuring conrod main bore without bearing shells

1. Assemble conrod (→ Page 72).
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2. Adjust bore gage and measure conrod main bore. Values (→ Page 68).
3. If values are exceeded, replace conrod.
Measuring conrod main bore with bearing shells

1. Assemble conrod (→ Page 72).
2. Coat sliding surfaces of bearing shells with engine oil.
3. Measure conrod bearing bore. Values (→ Page 68).
4. Enter measured values in data sheet.
5. Replace bearing shells if limit values are fallen short of or exceeded.
6. Remove conrod screws, conrod cap and bearing shells.
7. Protect bearing shells from damage.

Measuring conrod bore and conrod bushing on small conrod end
1. Set bore gage to zero dimension of conrod bushing bore and measure conrod bushing bore. Values
(→ Page 68).
2. If limit values are exceeded, replace conrod.
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4.2.15 Conrod – Tolerances
Conrod bearing

size Basic size
1 CONROD BORE 99.000 H6 0 +0.022
2 Conrod width 41.500 -0.220 −0.120
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Conrod screw length, measuring plane

size Basic size
1 Screw length, 67.500 −0.300 0 68.500
removed
Reassembly with bearing shells, measurement in the direction of a/b/c, smallest dimension must lie in the direction of a.
ID with bearing shell: 94.064 mm +0.042 mm
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Conrod bore parallelism

size Basic size
1 Conrod length - with 273.000 −0.030 +0.030
bushing and without
bearing shells
Conrod length - without 273.000 −0.050 +0.050
bushing and without
bearing shells
2 Parallelism of axial incli- max. 0.025 measured at 50 mm distance
nation
3 Parallelism of axial twist max. 0.05 measured at 50 mm distance
Conrod weight 3900 g -40 g +40 g
without bearing shells
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Conrod bore

size Basic size
1 Conrod bore 57.000 H6 0 +0.019 0.061 0.100
Conrod bushing OD 57.080 0 +0.020
Press-in force min. 10000 N max. 36000 N
2 Conrod bushing ID - com- 52.060 −0.005 +0.005
plete machining
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4.2.16 Conrod – Assembly
Torque wrench, 20-100 Nm F30026582 1
Ratchet adapter F30027340 1
Socket F30005947 1
Engine oil
WARNING
NOTICE
NOTICE
Preparing the conrod

1. Blow out joint faces (arrows) on conrod and
conrod bearing cap with compressed air
and clean.
2. Wipe bearing shell mating faces on conrod
and conrod bearing cap with chamois
leather.
3. Before installing conrod bearing shells,
compare repair size entries on conrod and
on crankshaft data sheet.
Note: Use aluminum jaws.
4. Clamp conrod in bench vise below conrod
big end in horizontal position.
Note: Ensure that position is correct (see arrow).
5. Insert upper conrod bearing shell (1) in
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conrod (2).

6. Use assembly device (1) to align conrod
bearing shell (2).
7. Carefully press conrod bearing cap (1) by

hand onto conrod (2).
8. Coat threads and screw head mating sur-
face of conrod screws with engine oil.
Note: Threads must not be recut.
9. Insert conrod screws in bore on conrod
bearing cap by hand three full turns with-
out tool.
10. Install conrod screws until screw heads
make contact and use socket wrench to
tighten firmly by hand. Make sure that con-
rod and conrod parting groove is closed at
short and long conrod arms.
11. Tighten conrod screws to specified tightening torque using a torque wrench. Sequence:
1. short arm (A)
2. long arm (B)
Name Size Type Lubricant Value/Standard
Conrod screw M16 x 1.5 Preload torque (Engine oil) 100 Nm +15 Nm
Conrod screw M16 x 1.5 Residual angle of rota- 90° +10°
tion
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4.2.17 Piston and conrod – Assembly
Piston-ring pliers F30378001 1
Engine oil
Snap ring (→ Spare Parts Catalog)
WARNING
WARNING
Risk of injury!
NOTICE
NOTICE
Installing piston rings

1. Turn coiled-spring expander (2) in oil con-
trol ring (1) in order to offset ring spring
butting face (arrow) to oil control ring butt
by 180°.
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Note: Note that new piston rings always need to
be replaced in sets.
2. Prepare piston rings according to installa-
tion sequence.
1 Keystone-type compression ring
2 Taper-face compression ring
3 Oil control ring
3. Replace cylinder liners after renewal of pis-
ton rings (→ Page 22).
4. Using piston ring pliers expand the piston

rings until they can be slid over the piston.
5. Install piston rings in annular grooves on
piston, starting from the bottom and work-
ing towards the top.
1. Oil control ring
2. Taper-face compression ring, TOP mark
facing towards piston crown
3. Keystone-type compression ring, TOP
mark facing towards piston crown
6. Check piston rings for easy movement.
Installing conrod in piston

1. Wipe down piston pin, conrod bush and piston pin bore with chamois leather and coat with engine oil.
2. Insert conrod in associated piston.
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3. Insert corresponding piston pin (2) in pis-
ton and conrod (1) until it makes contact
with the integral snap ring (arrowed).
4. Insert second snap ring.

5. Check both snap rings for correct seating
and position (arrows).
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4.2.18 Piston and conrod – Installation
Barring device F6783914 1
Mounting sleeve F6784287 1
Socket F30005947 1
Engine oil
DANGER
Suspended load.
Danger to life!
WARNING
WARNING
NOTICE
NOTICE
Preparing piston for installation

1. Coat piston and piston rings with engine oil.
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2. Ensure that piston ring joints are distributed at intervals of 120° around piston circumference.
3. Center piston rings and oil-control ring in grooves.

Preparing conrod bearing for in-
stallation
1. Wipe down conrod bearing shells with cha-
mois leather.
2. Insert upper conrod bearing shell (shell
with oil bore) with securing lug (arrowed) in
groove of conrod.
3. Insert lower bearing shell with securing lug
in groove of assembly device.
4. Coat bearing surfaces of conrod bearing
shells with engine oil.
5. Check that markings (arrows) on conrod

cap and conrod are aligned.
Note: The piston must installed by two persons in
order to guide the conrod and avoid dam-
age to the oil spray nozzle.
6. Turn crankcase in swivel stand so that the
cylinder liner is in horizontal position.
7. Turn crankpin of crankshaft of piston/
conrod to be installed into installation posi-
tion.
8. Wipe crankpin and bearing surface on cyl-
inder liner with chamois leather and coat
with engine oil.
9. Insert assembly sleeve in fit of carbon scra-
per ring.
10. Coat assembly sleeve and cylinder liner
with engine oil.
11. Twist piston and conrod slightly when in-
serting them into the cylinder liner to en-
sure that the oil spray nozzle is not dam-
aged.
12. Use assembly device to align conrod bear-
ing shell.
Note: Check conrod screw length because tight-
ening permanently elongates the conrod
screws. Conrod screw length max.
68.5 mm
13. Coat threads and screw head mating surfa-
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ces of conrod screws (arrows) with engine

oil.
Note: Do not let conrod screws fall into the bore.
14. Insert conrod screws into screw bore on
conrod cap (1) by hand, then turn first
three rotations without a tool.
15. Screw conrod screws into conrod (2) until
the screw head makes contact and then
tighten manually with socket wrench.

16. Tighten conrod screws to specified pretightening torque using a torque wrench. Sequence:
1. short arm (A)
2. long arm (B)
Conrod screw M16 x 1.5 Preload torque (Engine oil) 100 Nm +15 Nm
17. Check axial clearance of conrod.
18. Tighten conrod screws to specified angle of further rotation in the above sequence.
Conrod screw M16 x 1.5 Residual angle of rota- 90° +10°
tion
19. Check axial clearance of conrod.
20. Bar crankshaft and ensure that there is ease of movement between oil spray nozzle, piston and conrod.
Installing carbon scraper ring

1. Coat edge of cylinder liner and carbon scraper ring with engine oil.
2. Insert carbon scraper ring.
Measuring negative piston deck height

Note: Measure distance between piston crown and cylinder liner upper edge without cylinder-head gasket.
1. Remove deposits from piston and crankcase.
2. Turn crankshaft in engine direction of rotation until the piston to be checked is approx. 1 cm before
TDC.
3. Secure dial gauge under preload to bridge meter.
4. Set bridge meter down with dial-gauge anvil and set dial gauge to zero.
5. Turn crankshaft further in direction of engine rotation until piston is in TDC.
6. Measure positive piston deck height at dial gauge and record. Values (→ Page 62).
7. If tolerance deviation is not permitted, check conrod and replace if necessary.
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4.2.19 Piston and conrod – Final steps
Final steps
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4.3 Cylinder Head
4.3.1 Cylinder head – Overview
1 Valve collet 6 Valve-seat insert, exhaust 11 Cylinder head

2 Valve-spring retainer 7 Exhaust valve 12 Valve guide
3 Valve spring 8 Inlet valve 13 Gasket
4 Protective sleeve 9 Valve-seat insert, inlet 14 Washer
5 O-ring 10 End cover
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4.3.2 Cylinder head – Preparatory steps
Preconditions
Preparatory steps
2. Remove cylinder head covers (→ Operating Instructions).
3. Remove injector (→ Operating Instructions).
4. Remove constant-pressure manifold (→ Page 171).
5. Remove air pipework to the cylinders (→ Page 160).
6. Remove valve drive (→ Page 98).
7. Remove sensors, actuators and injectors (→ Page 232).
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4.3.3 Cylinder head – Removal
Preconditions
☑Preparatory steps completed.

Socket F30907150 1
WARNING
Risk of injury!
WARNING
Removing cylinder head

1. Release double-hex screws (1) evenly with
socket and unscrew them.
2. Lift off cylinder head (2) and place on a
firm surface.
3. Remove cylinder-head gaskets (3) and (4).
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4.3.4 Cylinder head – Cleaning
WARNING
WARNING
WARNING
Risk of injury!
WARNING
NOTICE
Cylinder head – Cleaning

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4.3.5 Cylinder head – Installation
Rotation-angle measuring device Y20044010 1
Socket F30907150 1
Torque wrench, 60–320 Nm F30047446 1
Ratchet adapter, ¾" F30450902 1
Engine oil -
Slotted spring pin (→ Spare Parts Catalog)
Sealing (→ Spare Parts Catalog)
WARNING
Risk of injury!
WARNING
NOTICE
Contamination in blind holes.
• Check and clean blind hole.
NOTICE
Installing cylinder head

1. Drive slotted spring pins (5) up to stop in
crankcase.
2. Place cylinder head gaskets (3) and (4) in
position.
3. Mount cylinder head (2).
4. Coat thread, head mating faces and shank
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of double-hex screws (1) with engine oil.

5. Screw double-hex screws (1) by hand into
crankcase.

Note: To check the angle of further rotation, apply marks (lines) to screw heads of double-hex screw after pre-
tightening.
6. Screw in double-hex screws (1), (2), (3) and (4) in six stages and in correct tightening sequence to the
specified tightening torque using the torque wrench.
Double-hex screw M18 x 2 Preload torque (Engine oil) 10 Nm
Double-hex screw M18 x 2 Residual torque 50 Nm
Double-hex screw M18 x 2 Residual angle of rota- 90° +10°
tion
Double-hex screw M18 x 2 Residual angle of rota- 90° +10°
tion
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4.3.6 Cylinder head – Final steps
Final steps
1. Assemble in reverse order to disassembly (→ Page 82).
3. Fill fuel system (→ Operating Instructions).
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4.4 Valve Gear
4.4.1 Roller tappets, pushrod – Overview
1 Valve roller tappets 2 Pushrod
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4.4.2 Roller tappets, pushrod – Preparatory steps
Preconditions
Preparatory steps
1. Remove cylinder head cover (→ Operating Instructions).
2. Remove valve drive (→ Page 98).
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4.4.3 Roller tappets, pushrod – Removal
Preconditions
☑Preparatory steps have been completed.

Pliers F30378037 1
Removing pushrod
1. Turn pushrod (1) to release roller tappet.
2. Pull out pushrod (1).
Removing roller tappet

2. Use pliers (2) to remove roller tappet (1)
from crankcase.
3. Mark position of roller tappet (1) in relation
to crankcase.
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4.4.4 Pushrod – Cleaning
Cleaning agent (Snow-White 11-0) 40460 1
Cleaning agent (Hakupur 312) 30390 1
WARNING
WARNING
NOTICE
Cleaning roller tappets, pushrod

1. Clean all parts with cleaning agent.
2. Clean all metallic parts with cleaning agent (Snow-White 11-0), then rinse with cleaning agent (Hakupur
312).
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4.4.5 Roller tappet, pushrod – Check
Pushrod (→ Spare Parts Catalog)
NOTICE
Checking roller tappet, pushrod

Check ball seat and ball head of • Wear Replace
pushrod for wear. • Indentations
• Scores
visible
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4.4.6 Roller tappet, pushrod – Installation
Locking pliers F30378037 1
Engine oil
WARNING
NOTICE
Installing roller tappets

1. Coat roller tappet (1) and bore in crank-
case with engine oil.
2. Use locking pliers (2) to insert roller tap-
pet (1); in doing so observe guide slot.
3. Check ease of movement of roller tappet
(1) in guide bore.
Installing pushrod
1. Install cylinder head (→ Page 85).
2. Coat pushrod (1) with engine oil.
Note: Ensure it is correctly seated in roller tap-
pet.
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3. Insert pushrod (1) with ball head side.

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4.4.7 Roller tappets, pushrod – Final steps
Final steps
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4.4.8 Valve drive – Overview
1 Screw 6 Cylinder head cover 11 Rocker arm, exhaust

2 Rocker arm, inlet 7 Valve bridge 12 Nut
3 O-ring 8 Washer 13 Rocker shaft support
4 Plug-in pipe 9 Snap ring
5 O-ring 10 Adjusting screw
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4.4.9 Valve drive – Preparatory steps
Preconditions
Preparatory steps
2. Remove air filter (→ Operating Instructions).
3. Remove cylinder head cover (→ Operating Instructions).
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4.4.10 Valve drive – Removal
Preconditions
Removing rocker shaft support

1. Remove screws (1).
2. Remove rocker shaft support (2).
Removing valve bridge

1. Mark valve bridges (1) in relation to valves.
2. Removing valve bridges (1).
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4.4.11 Valve drive – Cleaning
Cleaning agent (Snow-White 11-0) X00054118 1
Cleaning agent (Hakupur 50/136) X00056700 1
WARNING
WARNING
NOTICE
Cleaning valve drive

50/136).
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4.4.12 Valve gear – Check
Rocker shaft support (→ Spare Parts Catalog)
Rocker arm, exhaust (→ Spare Parts Catalog)
Rocker arm, inlet (→ Spare Parts Catalog)
Valve bridge (→ Spare Parts Catalog)
Adjusting screw (→ Spare Parts Catalog)
NOTICE
Checking valve gear

Check bearing surfaces on bearing • Wear • Rework
pedestal, valve bridges and rocker • Indentations • Replace
arms for wear, indentations and • Scores
scores. visible
Check mating faces on rocker Damaged • Rework
shaft support. • Replace
Check screws, nuts and adjusting Damaged Replace
screws for damage.
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4.4.13 Valve drive – Installation
Barring gear F6557929 1
Pointer for barring gear F6557932 1
Graduated disk Y4341946 1
Box wrench F30030450 1
Engine oil -
WARNING
NOTICE
Installing valve bridge

1. Position valve bridge (1) on valves as per
marking.
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2. Coat pushrod ball seat with engine oil.
3. Set engine to firing TDC with barring gear
(→ Operating Instructions).
4. Slacken nuts of adjusting screws on rocker
shaft support (2) and turn adjusting screws
back.
5. Position rocker shaft support (2) on cylin-
der head ensuring correct position of the
ball in the pushrod.
6. Coat threads and screw head mating faces
of screws (1) with engine oil.
7. Insert screws (1) in cylinder head and tighten to specified torque using a torque wrench.
Screw M10 x 1.5 Preload torque (Engine oil) 60 Nm +6 Nm
Screw M10 x 1.5 Residual angle of rota- 90° +5°
tion
8. Adjust valve clearance (→ Operating Instructions).
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4.4.14 Valve gear – Final steps
Final steps
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4.4.15 Cylinder head cover – Overview
1 Cylinder head cover, lower 4 Washer 7 Washer

section 5 Cylinder head cover, upper 8 Gasket
2 Gasket part
3 Screw 6 Screw
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4.4.16 Cylinder head cover – Removal
Cylinder head cover – Removal

1. Remove cylinder head cover as shown in overview drawing (→ Page 104).
2. Remove gaskets.
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4.4.17 Cylinder head cover – Cleaning
WARNING
WARNING
NOTICE
Cylinder head cover – Cleaning

TIM-ID: 0000004437 - 010

4.4.18 Cylinder head cover – Check
Whetstone F30454308/03 1
Cylinder head cover (→ Spare Parts Catalog)
Cylinder head cover – Check

Item Findings Action
Check cylinder head cover for Damaged • Rework: Smooth with oilstone.
damage. • Replace
Check screw threads for easy Sluggish • Rework: Re-cut thread.
movement. • Replace
Table 2: Check cylinder head cover: Findings – Measure

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4.4.19 Cylinder head cover – Installation
Magnetic pickup 8205892961/00 1
Engine oil
Gasket (→ Spare Parts Catalog) 1
Gasket (→ Spare Parts Catalog) 1
Screw (→ Spare Parts Catalog) 3
Washer (→ Spare Parts Catalog) 4
Washer (→ Spare Parts Catalog) 4
NOTICE
Installing cylinder head cover

2. Install plug-in pipe (1) prior to installing
bottom section of cylinder head cover (2).
3. Mount cylinder head cover bottom section
(2) with gasket on cylinder head and align
with injector (3). Tighten screws (8) to
specified tightening torque. (→ Page 104)
4. Tighten HP fuel system according to tight-
ening instructions.(→ Page 109)
5. Insert gasket (4) in cylinder head cover bot-
tom section (2).
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6. Insert screws (7) with washers (6) for cylinder head cover (5) and use torque wrench to tighten diago-
nally and evenly to specified tightening torque.
Screw M8 Tightening torque 20 Nm

4.5 Fuel System (High Pressure)
4.5.1 HP fuel system – Tightening procedure
Preconditions

Insertable fork wrench, 19 mm F30025897 1
Guide pin F30450460 1
Extraction tool F6784160 1
Socket wrench F30451502 1
Mounting sleeve F30450342 1
Alignment device F6783244 1
Alignment device F6790507
Engine oil
NOTICE
NOTICE
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Installing HP accumulator in
charge-air line
1. Install HP accumulator (1) in charge-air
line (2) (arrow).
2. Align thread of HP accumulator (1) with
bore on charge-air line (2).
3. Hand-tighten flanges (5) with screws.
4. Coat O-rings with assembly compound.
5. Install guide bushing (3) with O-ring.
6. Install bushing on installation side of HP
accumulator (1) with O-ring.
7. Prior to installation of bottom section of
cylinder head cover, position plug-in
pipe (4).
Installing HP lines
1. Hand-tighten HP line (4) on fuel distribu-
tor (3).
2. Hand-tighten HP line (4) on HP pump.
3. Hand-tighten HP lines (1) and (2) on HP ac-
cumulator (5).
4. Hand-tighten HP lines (1) and (2) on fuel
distributor (3).
5. Tighten all HP lines (1), (2) and (4) in the same sequence with torque wrench to specified tightening
torque.
HP line Residual torque (Engine oil) 60 Nm +5 Nm
6. Use torque wrench to tighten all HP lines in the same order to specified tightening torque.
TIM-ID: 0000004488 - 003
HP line Tightening torque (Engine oil) 60 Nm +5 Nm

7. Tighten fuel distributor (3).
8. Use torque wrench to tighten all screws on HP accumulator (5) to specified tightening torque.
9. Install pipe half-clamps (6).

Installing pressure relief valve
on fuel distributor
1. Coat O-ring on pressure relief valve with
assembly compound.
2. Insert new breather valve (1) in fuel distrib-
utor (2).
3. Tighten pressure relief valve (1) with torque wrench to specified tightening torque, ensuring that the
valve is not slanted.
Pressure relief Tightening torque (Engine oil) 100 Nm +5 Nm
valve
Installing injector
1. Install injector (1) in cylinder head and
align with alignment device.
2. Install hold-down clamp (3) and hand-tight-
en screw (2).
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Installing HP line on injector
1. Install union nut (1) of HP line on HP accu-
mulator and hand-tighten.
2. Install union nut (2) of HP line on injec-
tor (3) and hand-tighten.
3. Tighten hold-down clamp (4) on injector (3) with torque wrench to specified tightening torque.
Hex screw M10 Tightening torque (Engine oil) 40 Nm +4 Nm
4. Tighten union nut (2) on HP line with torque wrench to specified tightening torque.
5. Tighten union nut (1) of HP line on HP accumulator with torque wrench to specified tightening torque.
6. Tighten flanges.
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4.5.2 HP pump – Overview
TIM-ID: 0000026553 - 002

4.5.3 HP fuel pump – Preparatory steps
Preconditions
Preparatory steps
1. Remove fuel lines (low pressure) (→ Page 127).
2. Remove fuel lines (high pressure) (→ Page 124).
3. Remove sensors, actuators and injectors (→ Page 232).
TIM-ID: 0000012395 - 001

4.5.4 HP pump – Removal
Support bracket T80091665 1
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Removing HP pump
1. Remove clamps (1).
2. Remove screws (2).
TIM-ID: 0000004546 - 004

3. Install lifting device (3) and carrying brack-
et (2) for HP pump (1).
4. Remove HP pump (1).
6. Remove O-ring.
TIM-ID: 0000004546 - 004

4.5.5 HP pump - Check
HP pump (→ Spare Parts Catalog)
HP pump - Check
Check screws for damage. Damaged Replace
Check splines of drive for damage. Damaged Replace HP pump.
Check fuel connections. Corrosion Replace fuel connections.
Check sealing surfaces for dam- Damaged • Rework
age. • Replace
TIM-ID: 0000004535 - 002

4.5.6 HP pump – Installation
Support bracket T80091665 1
Guide pin F30450460 2
Engine oil
DANGER
Suspended load.
Danger to life!
WARNING
WARNING
Risk of injury!
NOTICE
NOTICE
TIM-ID: 0000004565 - 003

Attaching holder for HP pump
u Install holder (2), tighten screws (1) to specified tightening torque with torque wrench.
Screw M12x45 Tightening torque 74 Nm
Installing HP pump
2. Insert alignment tool (1) in correct position
in bore of HP pump.
3. Use lever (3) to align water pump shaft
meshing in such a way that the marked
lines (2) match.
4. Remove alignment device (1).
TIM-ID: 0000004565 - 003

5. Mount alignment tool (2) on HP pump (1) in
correct position.
6. Use wrench (3) to align meshing of HP
pump (1) in such a way that the marked
lines (4) match.
7. Remove alignment tool (2).
8. Coat O-rings with assembly compound and

insert in grooves.
9. Install lifting device (3) and carrying brack-
et (2) for HP pump (1).
10. Insert HP pump (1) into bore.
TIM-ID: 0000004565 - 003

11. Insert screws (2) and use torque wrench to tighten to specified tightening torque.
Screw M12x60 Tightening torque 74 Nm
Note: Ensure components are not tensioned during assembly
12. Install clamp (1) and tighten screws (3, 4) with torque wrench to specified tightening torque.
Screw M12 Tightening torque 74 Nm
13. Remove lifting device and carrying bracket for HP pump.
TIM-ID: 0000004565 - 003

4.5.7 HP fuel pump – Final steps
Final steps
TIM-ID: 0000012416 - 003

4.5.8 HP fuel line – Overview
1 Fuel line 3 Fuel distributor 5 High-pressure accumulator

2 Pressure relief valve 4 Fuel line
TIM-ID: 0000012504 - 003

4.5.9 HP line –- Removal
Preconditions
WARNING
• Do not smoke.
Removing HP line
1. Prior to removal of the lines, take photos or mark externally mounted components and lines.
2. Remove lines as per overview drawing (→ Page 123).
3. Seal openings with suitable plugs.
TIM-ID: 0000004671 - 003

4.5.10 HP line – Installation
WARNING
• Do not smoke.
NOTICE
NOTICE
Installing HP line
1. Install HP line as shown in overview drawing, photos taken or marks made prior to removal
(→ Page 123).
2. Tighten screws on HP line to specified torque using a torque wrench (→ Page 109).
TIM-ID: 0000004677 - 010

4.6 Fuel System (Low Pressure)
4.6.1 Fuel pipework from fuel delivery pump to fuel filter – Overview
1 Fuel filter 3 Fuel line

2 Valve housing 4 Fuel delivery pump
TIM-ID: 0000012626 - 003

4.6.2 Fuel pipework from fuel delivery pump to fuel filter - Removal
Preconditions
☑Disable engine start
☑Provide a suitable container to catch residual fuel.
WARNING
• Do not smoke.
Fuel pipework from fuel delivery pump to fuel filter – Removal

1. Prior to removal of lines, take photos or mark externally mounted components and lines.
2. Loosen screwed connection of fuel pipework and catch any fuel that emerges.
3. Remove fuel pipework as per overview drawing (→ Page 126).
TIM-ID: 0000004831 - 007

4.6.3 Fuel pipework from fuel delivery pump to fuel filter ‒ Installation
Grommet (→ Spare Parts Catalog)
WARNING
• Do not smoke.
NOTICE
NOTICE
Fuel pipework from fuel delivery pump to fuel filter

2. Install fuel pipework as per overview drawing, photos or markings (→ Page 126).
TIM-ID: 0000004838 - 005

4.6.4 Fuel cooler – Overview
1 Fuel cooler 2 Washer 3 Screw

TIM-ID: 0000040486 - 001

4.6.5 Fuel cooler – Preparatory steps
Preconditions
Preparatory steps
1. Observe safety instructions.
TIM-ID: 0000012662 - 002

4.6.6 Fuel cooler – Removal
WARNING
Risk of injury!
WARNING
• Do not smoke.
Removing the fuel cooler

1. Unscrew screws (1) and washers (2).
2. Catch fuel as it runs out.
3. Take off fuel cooler (1).

TIM-ID: 0000040424 - 002

4. Remove O-rings (1) from flange (2).
TIM-ID: 0000040424 - 002

4.6.7 Fuel cooler – Check
Fuel cooler (→ Spare Parts Catalog)
WARNING
Checking fuel cooler

Visually inspect fuel cooler for Damaged Replace
damage.
Check all contact and sealing • Damage • Recondition: Smooth with oil-
faces for wear traces and damage. • Signs of wear stone or emery cloth.
visible • Replace
TIM-ID: 0000004849 - 002

4.6.8 Fuel cooler – Installation
Engine oil
WARNING
• Do not smoke.
WARNING
Risk of injury!
NOTICE
Installing the fuel cooler

2. Coat O-rings (1) with assembly compound
and insert in grooves in flange (2).
TIM-ID: 0000040425 - 003

3. Place fuel cooler (1) in position on flange.
4. Screw on screws (1) and washers (2).

TIM-ID: 0000040425 - 003

4.6.9 Fuel cooler – Final steps
Final steps
TIM-ID: 0000012672 - 002

4.6.10 Leak-off fuel pipework – Overview
1 Leak-off fuel line 3 Leak-off fuel line 5 Leak-off fuel line

2 Leak-off fuel line 4 Distributor piece
TIM-ID: 0000012803 - 002

4.6.11 Leak fuel line – Removal
Preconditions
☑Provide a suitable container to collect the residual fuel.
WARNING
• Do not smoke.
Removing leak fuel line

1. Prior to removal of the lines take photos or mark externally mounted components and lines.
2. Release threaded union on fuel line and catch fuel as it escapes.
3. Remove fuel lines with mounting parts as shown in overview drawing (→ Page 137).
TIM-ID: 0000005013 - 008

4.6.12 Leak-off fuel pipework – Installation
Grommet (→ Spare Parts Catalog)
WARNING
• Do not smoke.
NOTICE
NOTICE
Installing leak-off fuel pipework

2. Blow out leak-off fuel lines with compressed air.
Note: Use new sealing rings when doing this.
3. Install the leak-off fuel lines as shown in overview drawing or according to photos or markings
(→ Page 137).
TIM-ID: 0000005018 - 008

4.7 Exhaust Turbocharger
4.7.1 Exhaust turbocharger – Overview
1 Screw 9 Threaded connection 17 Screw

2 Washer 10 O-ring 18 O-ring
3 Bracket 11 O-ring 19 Plug-in pipe
4 Cable retainer 12 Exhaust turbocharger 20 Plug-in pipe
5 Exhaust turbocharger 13 O-ring 21 Washer
6 Flange 14 Flange 22 Screw
7 Screw 15 Retainer
8 Washer 16 Washer TIM-ID: 0000060105 - 001

Overview drawing
1 Center bearing 14 Washer 27 Washer

2 Clamp 15 Thrust bearing 28 Heat shield
3 Threaded bushing 16 Washer 29 Nut
4 Sealing ring 17 Bearing bushing 30 Washer
5 Grooved pin 18 Snap ring 31 Screw
6 Identification plate 19 Washer 32 Spacer sleeve
7 Compressor casing 20 Clamp 33 Turbine housing
8 Nut 21 O-ring 34 Clamp
9 Compressor wheel 22 Bearing housing 35 Turbine wheel
10 Ring carrier 23 O-ring 36 Heat shield
11 Piston ring 24 Washer 37 Piston ring
12 Retaining ring 25 Screw 38 Bearing bushing
13 O-ring 26 Screw 39 Plug screw
TIM-ID: 0000060105 - 001

4.7.2 Exhaust turbocharger – Preparatory steps
Preconditions
Preparatory steps
2. Remove carrier housing cover (→ Page 167).
TIM-ID: 0000013105 - 002

4.7.3 Exhaust turbocharger – Removal
WARNING
Removing exhaust turbocharger

1. Remove screws (2) of flange (1).
2. Remove threaded union (1) on exhaust tur-

bocharger (2).
3. Remove screws (5) and take off ring (6).
4. Remove screws (3) with washers (4).
TIM-ID: 0000005215 - 003

5. Install lifting gear (1) on exhaust turbo-
charger (2) and attach to crane with a light-
ly tensioned rope.
6. Remove exhaust turbocharger (2) from car-
rier housing (3) and place on suitable sur-
face.
7. Remove lifting gear (1).
8. Remove O-rings.
TIM-ID: 0000005215 - 003

4.7.4 Exhaust turbocharger – Cleaning
WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.
WARNING
WARNING
NOTICE
Cleaning exhaust turbocharger

50/136).
TIM-ID: 0000005184 - 009

4.7.5 Exhaust turbocharger – Check
Exhaust turbocharger (→ Spare Parts Catalog)
Retaining ring (→ Spare Parts Catalog)
Exhaust turbocharger – Check

Item Findings Task
Check thread of screws. Damaged Replace
Check coolant channels and hous- Deposits visible Clean or replace
ing cover of bearing housing for
deposits.
TIM-ID: 0000013066 - 001

4.7.6 Exhaust turbocharger – Installation
Torque wrench, 6–50 Nm F30027336 1
Engine oil
WARNING
NOTICE
NOTICE
Installing exhaust turbocharger

2. Clean mating face on carrier housing (2).
3. Coat O-ring (1) with assembly compound
and insert in groove on carrier housing (2).
TIM-ID: 0000005250 - 003

4. Install lifting gear (1) on exhaust turbo-
charger (2) and attach to crane with a light-
ly tensioned rope.
5. Insert exhaust turbocharger (2) in correct
position in carrier housing (3).
6. Remove lifting gear (1).
7. Insert screws (3) with washers (4) for exhaust turbocharger (2) and use torque wrench to tighten to
specified tightening torque.
Screw M12 Tightening torque (Engine oil) 70 Nm +7 Nm
8. Install ring halves (6) with screws (5) on exhaust turbocharger (2) and tighten.
9. Insert union (1) on exhaust turbocharger (2) and use torque wrench to tighten to specified tightening
torque.
TIM-ID: 0000005250 - 003


10. Coat O-ring with assembly compound and
insert in groove.
11. Insert screws (2) in flange (1) and use torque wrench to tighten to specified tightening torque.
TIM-ID: 0000005250 - 003

4.7.7 Exhaust turbocharger – Final steps
Final steps
TIM-ID: 0000013149 - 002

4.8 Air Intake / Air Supply
4.8.1 Intake housing – Overview
1 Actuating cylinder 3 Clamp 5 Intake housing

2 Flap housing 4 Air filter 6 Service indicator
TIM-ID: 0000060182 - 001

4.8.2 Intake housing – Preparatory steps
Preconditions
Preparatory steps
2. Disconnect or remove electric cables.
TIM-ID: 0000013449 - 003

4.8.3 Intake housing – Removal
Preconditions
☑Preliminary steps are completed.
Removing the intake housing with flap

1. Release clamps and remove intake housing with flap or intake housing as shown in overview drawings
(→ Page 151).
2. After removal, seal all openings with suitable covers.
TIM-ID: 0000005508 - 002

4.8.4 Intake housing – Cleaning
WARNING
WARNING
NOTICE
Intake housing – Cleaning

2. Blow off all parts thoroughly with compressed air.
TIM-ID: 0000005487 - 010

4.8.5 Intake housing – Check
Red dye penetrant for surface crack-testing procedure
Magnetic crack-testing equipment with fluorescent magnetic
powder
Intake housing (→ Spare Parts Catalog)
Actuating cylinder (→ Spare Parts Catalog)
Flap (→ Spare Parts Catalog)
Lever (→ Spare Parts Catalog)
Shaft (→ Spare Parts Catalog)
Bushing (→ Spare Parts Catalog)
Cleaning intake housing

u (→ Page 154)
Checking intake housing

Using the surface crack-testing Crack indication Replace
method with fluorescent penetrant
dye, check intake housing, flap
and elbow for cracks.
Check shaft with fluorescent mag- Crack indication Replace
netic powder for cracks.
Check retainer for wear, cracks • Wear • Recondition
and damage. • Cracks • Replace
• Damage
visible
Check intake housing sealing, • Damaged • Rework: Smooth with oilstone.
mating and contact surfaces for • Uneven • Replace
damage and unevenness.
Check bore for flanged bushing in Damaged • Rework: Smooth with emery
intake housing for damage. cloth.
• Replace
Check key grooves on shaft and Damaged Replace
flap.
Check condition of vulcanized rub- Damaged Replace
ber insert of stop and flap.
TIM-ID: 0000005498 - 003
Check thread inserts and screws Sluggish • Recondition

for easy movement. • Replace
Carry out operation check on ac- Malfunction Replace
tuating cylinder.
Check cylinder individual compo- Damaged Replace
nents and lever for damage.
Check operation of service indica- Malfunction Replace
tor. Signal ring indication range:
25 mbar to 50 mbar

4.8.6 Intake housing – Installation
Engine oil
Clamp (→ Spare Parts Catalog)
NOTICE
NOTICE
Installing intake housing

1. Install intake housing with flap and bracket as per overview drawing (→ Page 151).
2. Install right-hand side intake housing and bracket as per overview drawing (→ Page 151).
TIM-ID: 0000005526 - 003

4.8.7 Intake housing – Final steps
Final steps
TIM-ID: 0000013464 - 002

4.8.8 Air pipework to cylinders – Overview
1 Charge-air line 3 Shroud 5 Sealing

2 Sealing ring 4 Sealing 6 Vent line
TIM-ID: 0000005585 - 003

4.8.9 Air pipework to cylinders – Preparatory steps
Preconditions
Preparatory steps
1. Remove engine governor (→ Operating Instructions).
3. Remove intake housing (→ Page 153).
TIM-ID: 0000013531 - 002

4.8.10 Air pipework to cylinders – Removal
Preconditions
☑Preliminary steps are completed.
Removing charge-air manifold

1. Remove charge-air manifold as shown in the overview drawing (→ Page 158).
2. Remove gaskets and O-rings.
TIM-ID: 0000005605 - 002

4.8.11 Air pipework to cylinders – Installation
Engine oil
NOTICE
NOTICE
Installing air pipework to cylinders

1. Prior to installation, remove all covers.
2. Place gaskets on cylinder heads.
3. Install air pipework to cylinders as shown in overview drawing (→ Page 158).
TIM-ID: 0000005612 - 004

4.9 Exhaust Pipework
4.9.1 Exhaust pipework after engine – Overview
Exhaust pipe bellows after engine – Horizontal version
1 Nut 4 Screw 7 Exhaust bellows

2 Flange 5 Washer
3 Washer 6 Screw
TIM-ID: 0000060106 - 001

1 Nut 4 Gasket 7 Screw
2 Flange 5 Washer 8 Washer
3 Exhaust elbow with ex- 6 Screw
haust pipe bellows
TIM-ID: 0000060106 - 001

4.9.2 Exhaust pipe bellows after engine – Removal
Preconditions
Removing exhaust pipe bellows after engine

1. Remove exhaust pipe bellows as per overview drawing (→ Page 162).
TIM-ID: 0000005919 - 005

4.9.3 Exhaust pipe bellows after engine – Installation
Assembly compound (Ultra-Therm MTU) 50547 1
Installing exhaust pipe bellows after engine

2. Coat threads of screws with assembly compound.
3. Install exhaust pipe bellows as per overview drawing (→ Page 162).
TIM-ID: 0000005922 - 007

4.9.4 Carrier housing – Overview
1 Screw 4 Sealing ring 7 Flange

2 Screw 5 Carrier housing, upper 8 Gasket
3 Carrier housing cover section 9 Gasket
6 Screw
TIM-ID: 0000005772 - 003

4.9.5 Carrier housing cover – Removal and installation
Preconditions
☑Engine is stopped and starting disabled
Removing carrier housing cover

1. Remove all screws (2).
2. Remove flange (1) with gasket.
3. Remove all screws (4).
4. Remove carrier housing cover (3).
Installing carrier housing cover

1. Coat O-rings with petroleum jelly.
2. Insert O-rings in grooves on upper carrier
housing section.
Note: Observe position of dowel pin (3) in rela-
tion to flap housing (2).
3. Install flap housing (2).
TIM-ID: 0000013826 - 002

4. Coat screws (2) and (4) with engine oil.
5. Install carrier housing cover (3).
6. Insert screws (4) and tighten.
7. Install flange (1) and gasket.
8. Install screws (2) and tighten.
TIM-ID: 0000013826 - 002

4.9.6 Constant-pressure manifold – Overview
1 O-ring 4 Heat shield 7 Nut

2 O-ring 5 Exhaust pipe housing, right 8 Exhaust elbow
3 Exhaust pipe bellows with exhaust manifold
6 Washer
TIM-ID: 0000054978 - 001

4.9.7 Constant-pressure manifold – Preparatory steps
Preconditions
Preparatory steps
2. Observe safety regulations.
TIM-ID: 0000013742 - 002

4.9.8 Constant-pressure manifold – Removal
Hook T80091769 1
Hook-ended chain sling T80090943 1
WARNING
Removing exhaust pipework

housing
1. Release exhaust pipe bellows from carrier
housing, lower part.
2. Remove connecting piece of coolant pipe.
3. Remove nuts and heat shield.
4. Insert hook (1) in bores in exhaust system
housing (2).
5. Attach exhaust system housing (2) to crane
with a lightly tensioned rope.
6. Undo and remove screws.
7. Remove exhaust system housing (2).
8. Set exhaust system housing (2) down on a
suitable surface.
9. Remove hook (1).
Removing intermediate flange

1. Remove screws (2) and (3) and remove in-
termediate flange with exhaust diffuser.
2. Remove O-ring and gasket.
3. Fit two nuts on studs (1) and lock.
4. Remove stud (1).
TIM-ID: 0000005743 - 004

4.9.9 Constant-pressure manifold – Installation
Hook-ended chain sling T80090943 1
Hook T80091769 1
Assembly compound (Ultra-Therm MTU) 50547 1
Stud (→ Spare Parts Catalog)
WARNING
NOTICE
NOTICE
Installing intermediate flange

2. Insert studs (1) in intermediate flange using
the insertion tool or two nuts and tighten.
TIM-ID: 0000005761 - 005

3. Install intermediate flange with gasket and use torque wrench to tighten screws (2) and (3) to specified
tightening torque.
Screw Tightening torque (Assembly compound 60 Nm +6 Nm
(Ultra-Therm MTU))
4. Coat threads of studs (1) with assembly compound (Ultra-Therm MTU).
5. Coat O-ring with assembly compound (Kluthe Hakuform 30-15) and position in annular groove on inter-
mediate flange.
Installing constant-pressure
manifold
1. Clean mating and sealing faces on exhaust
system housing and on intermediate flang-
es.
2. Insert hook (1) in bores in exhaust system
housing (2).
3. Attach exhaust system housing (2) to crane
with a lightly tensioned rope.
4. Raise exhaust system housing (2) until it
contacts intermediate flanges.
5. Exhaust system housing (2) and tighten screws to the specified tightening torque with a torque wrench.
Nut Tightening torque (Assembly compound 33 Nm +4 Nm
(Ultra-Therm MTU))
6. Install heat shield for exhaust system housing (2) with nuts and washers.
7. Remove hook (1).
8. Install exhaust pipe bellows on carrier housing, lower part.
9. Install connecting piece of coolant pipe.
TIM-ID: 0000005761 - 005

4.9.10 Constant-pressure manifold – Final steps
Final steps
TIM-ID: 0000013759 - 002

4.10 Starting Equipment
4.10.1 Electric starter – Overview
1 Starter 3 Washer
2 Nut 4 Stud
TIM-ID: 0000027243 - 002

4.10.2 Starter – Removal
Preconditions
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
WARNING
Disconnecting and removing starter

1. Prior to disconnection, mark all cables.
2. Remove all cables from starter.
3. Protect all cables from damage.
4. Remove starter nuts as shown in overview drawing (→ Page 175).
5. Remove starter.
6. Protect starter from damage.
TIM-ID: 0000006063 - 005

4.10.3 Starter – Cleaning
WARNING
Cleaning starter
1. Do not wet-clean. Clean starter with compressed air only.
2. Protect starter from moisture.
TIM-ID: 0000006055 - 009

4.10.4 Starter – Check
Whetstone F30454308/03 1
Starter (→ Spare Parts Catalog)
Checking starter
Check tooth flanks of pinion for • Signs of wear Replace
wear, indentations and chipping. • Indentations
• torn surface
visible.
Check condition of nuts, studs and • Sluggish Replace
connecting bolt, check threads for • Thread damaged
easy of movement.
Check contact surface on end Traces of wear visible. Rework: Smooth with oilstone.
housing for wear traces.
Table 3: Checking starter: Findings – Action
TIM-ID: 0000006059 - 015

4.10.5 Starter – Installation
Lubricating grease (Molykote Longtherm 2 Plus NLGI 2) X00057299 1
DANGER
Electric voltage supply for operation.
Danger of burns and fatal electric shock!
• Make certain that the power supply to the product is switched off before starting work. Secure
against unintentional switching on!
WARNING
Installing starter
1. Coat starter pinion with lubricating grease.
2. Install starter as shown in overview drawing (→ Page 175).
Connecting electric starter

1. Connect cables in accordance with the marking.
2. Check starter for correct operation.
TIM-ID: 0000006070 - 005

4.11 Coolant System
4.11.1 Engine coolant pump – Overview
1 Engine coolant pump 4 Taper ring 7 Stud

2 O-ring 5 Driver 8 Washer
3 O-ring 6 O-ring 9 Nut
TIM-ID: 0000006786 - 003

4.11.2 Engine coolant pump – Preparatory steps
Preconditions
Preparatory steps
2. Remove sensor cable for sensors B6, B6.2 and B16 (→ Operating Instructions).
3. Remove protective cover (→ Page 49).
4. Release coolant line from coolant pump elbow.
5. Remove fuel line from hand pump to high-pressure pump.
TIM-ID: 0000014643 - 002

4.11.3 Engine coolant pump – Removal
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
WARNING
WARNING
Risk of injury!
Removing engine coolant pump

1. Remove nuts from engine coolant pump (→ Page 180).
2. Loosen engine coolant pump with crowbar and remove.
3. Remove elbow.
5. Remove O-ring.
TIM-ID: 0000006820 - 004

4.11.4 Engine coolant pump – Cleaning
WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.
NOTICE
NOTICE
Cleaning engine coolant pump

1. Remove all deposits from functional and sealing surfaces.
2. Clean all functional and sealing surfaces with cleaner.
3. Wipe all functional and sealing surfaces dry with a clean, lint-free cloth.
4. Use cleaner to remove corrosion inhibitor from new component.
TIM-ID: 0000014616 - 019

4.11.5 Engine coolant pump – Check
Oilstone F30454308/03 1
Engine coolant pump (→ Spare Parts Catalog)
Spacer ring (→ Spare Parts Catalog)
WARNING
WARNING
Risk of injury!
Checking engine coolant pump

Check volute and impeller for cavi- Cavitation visible. Replace
tation.
Visually inspect sealing surfaces • Signs of wear • Rework: Smooth with crocus
for signs of wear, pitting and cavi- • Impact marks cloth or oilstone.
tation. • Cavitation • Replace
visible
Check gear for indentations, • Wear traces • Rework: Smooth with crocus
traces of wear and damage. • Indentations cloth or oilstone.
• Damage • Replace.
visible
Check spacer ring for damage. Damaged Replace
TIM-ID: 0000014629 - 005

4.11.6 Engine coolant pump – Installation
Engine oil
WARNING
WARNING
Risk of injury!
Installing engine coolant pump

2. Coat O-ring with assembly compound and insert in groove on bearing housing.
Note: Make sure that gears are correctly meshed and that driver fits.
3. Insert engine coolant pump in correct position in bore (→ Page 180).
4. Screw on nuts with washers and tighten evenly.
TIM-ID: 0000006850 - 003

4.11.7 Engine coolant pump – Final steps
Final steps
3. Vent fuel system (→ Operating Instructions).
TIM-ID: 0000014671 - 002

4.11.8 Coolant cooler - Overview
1 Cover plate 4 Cooler plate 7 Coolant distribution hous-

2 End plate 5 Cooler plate ing
3 Cooler plate 6 Initial plate
Engine Number First Coolant cooler End Tense state

of plates plate Cooler Cooler Cooler plate Tol. Deviation
plate A plate B plate C size Low- Up-
er per
8V M72, 41 1x - 19x 20x 1x 144.6 -4.5 +4.5
M92, M93
10V M72 41 1x - 19x 20x 1x 144.6 -4.5 +4.5
10V M92, 49 1x - 23x 24x 1x 167.5 -5.5 +5.5
M93
TIM-ID: 0000007133 - 004

4.11.9 Coolant cooler – Preparatory steps
Preconditions
Preparatory steps
2. Drain raw water.
3. Remove raw water lines (→ Page 214).
TIM-ID: 0000015013 - 002

4.11.10 Coolant cooler – Removal
Preconditions

Threaded pin 5362030462 2
WARNING
Risk of injury!
Removing coolant cooler

1. Remove oil return line (6).
2. Remove coolant elbow (→ Page 214).
3. Screw threaded pin (7) into threaded
pin (8).
4. Release all screws (1) with washers (2), (4)
and locking plates (3) and unscrew evenly
in stages.
5. Apply numbers to or mark cooler plates (3),

so that the installation sequence is com-
plied with at later assembly.
6. Remove cover plate (1) over threaded
pin (4).
7. Remove sealing sleeve (2).
8. Remove cooler plates (3) one by one.
9. Place cooler plates (3) to the side and pro-
tect from damage.
10. Remove threaded pin (5) only if damaged.
11. Remove elbow (→ Page 214).
TIM-ID: 0000040674 - 001

4.11.11 Coolant cooler – Cleaning
Sodium hydroxide
Sodium carbonate
Nitric acid
Sulfamic acid
Citric acid
Phosphoric acid
Kerosene
WARNING
WARNING
High-pressure water jet.
Risk of injury!
• Do not direct water jet at persons, electric or electronic equipment.
WARNING
Risk of injury!
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
• Use appropriate cleaning tool.
NOTICE
Cleaning agents containing chlorine and hydrochloric acid attack metal surfaces.
Risk of damage due to corrosion!
• Do not use hydrochloric acid with stainless steel.
• Chlorine concentration in water solution must not exceed 300 ppm for cleaning purposes. If a
higher chlorine concentration is required, contact MTU..
• Protect aluminum components against chemicals.
NOTICE
TIM-ID: 0000007136 - 004

Note: Do NOT use the following solvents:

• Ketones (e. g.: Acetone, methyl-ethylene ketone, methylisobutyl ketone)
• Esters (e. g.: Ethyl acetate, butyl acetate)
• halogenated carbon hydrides (e. g.: chlorothenes, carbon tetrachlorides, freon)

• Aromatic compounds (e. g.: Benzine, toluene)
Preparatory steps
1. Remove cooler plates (→ Page 189).
2. Place cooler plates on a suitable surface for cleaning.
3. Remove rubber seals.
Coarse fouling
Note: With the device open, mechanical cleaning to remove:
• Algae
• Bits of wood/fabric
• Crustaceans
1. Clean plates under running water with a soft brush. Take care not to damage the gasket.
2. Clean plates with high-pressure hose.
3. Dry gaskets with a cloth.
Biological fouling
Note: With the device open, mechanical or chemical cleaning to remove:
• Bacteria
• Nematodes
• Protozoa
3. Clean plates with alkaline cleaning agents e.g.:
• Sodium hydroxide
• Sodium carbonate
Concentration Temperature
max. 4% max. 60 °C
Removing aluminum/metal oxides and boiler deposit

• Calcium carbonate
• Calcium sulfate
• Silicate
3. Clean plates with acidic cleaning agents e.g.:
• Nitric acid
• Sulfamic acid
• Citric acid
• Phosphoric acid
TIM-ID: 0000007136 - 004
max. 4% max. 60 °C
4. The addition of a synthetic cleaning agent can improve the cleaning effect.

Sediments (deposits)
• Corrosion products
• Metal oxides
• Sludge
• Alumina clay
• Diatomic organisms
3. Clean plates with chemical cleaning agents e.g.:
• Nitric acid
• Sulfamic acid
• Citric acid
• Phosphoric acid
max. 4% max. 60 °C
Removing calcium carbonate

1. Clean plates with 10% nitric acid and a soft brush.
2. Rinse plates with water and dry with cloth.
Oil residues, asphalts and grease

• Oil residues
• Asphalts
• Grease
1. Clean plates with kerosene and soft brush.
2. Dry plates with a cloth or rinse with water.
Cleaning cover plate

Note: Protect aluminum parts from chemicals.
1. Clean cover plate with cold cleaner and a soft brush.
2. Remove cleaning agent.
3. Blow out cover plate with compressed air.
TIM-ID: 0000007136 - 004

4.11.12 Coolant cooler – Check
Oilstone F30454308/03 1
Cover plate (→ Spare Parts Catalog)
First plate (→ Spare Parts Catalog)
Cooler plates (→ Spare Parts Catalog)
End plate (→ Spare Parts Catalog)
Threaded pin (→ Spare Parts Catalog)
Checking coolant cooler

Check thread inserts of cover Sluggish Replace thread inserts
plate for easy movement.
Check contact and sealing surfa- • Signs of wear • Rework: Smooth with oilstone
ces of cover plate for signs of • Damage or crocus cloth.
wear and damage. visible • Replace
Check threaded pin for damage • Signs of wear • Rework: Recut threads
and signs of wear. • Damage • Replace
visible
TIM-ID: 0000015008 - 002

4.11.13 Coolant cooler – Installation
Threaded pin 5362030462 2
Assembly compound (Molykote G-N Plus) 40041 1
Engine oil
Locking plate (→ Spare Parts Catalog)
Nipple (→ Spare Parts Catalog)
WARNING
Risk of injury!
Installing coolant cooler

2. Install elbow (→ Page 215).
3. Screw threaded pin (5) into coolant distri-
bution housing and tighten.
4. Depending on the width of the plate pack-
age, screw in two studs (4) as assembly
aid.
5. Push cooler plates (3) over threaded
pins (4) and (5) in accordance with marked
positions made prior to removal.
6. Insert sealing sleeve (2).
7. Push cover plate (1) over threaded pins (4)
and (5).
8. Coat thread and screw head mating faces

of screw (1) with assembly compound.
9. Insert screws (1) with washers (2) and (4)
and tighten alternately to dimension (a)
(→ Page 187).
10. Select tightening sequence, so that a de-
flection of the plate of max. 1 mm (in rela-
TIM-ID: 0000040675 - 002
tion to plate length) and a non-parallelism

of the plate package of max. 2 mm are not
exceeded.
11. Unscrew threaded pin (7) from threaded
pin (8).
12. Secure screws (1) with locking plates (3).
13. Install coolant elbow (→ Page 214).
14. Install oil return line (6).

TIM-ID: 0000040675 - 002

4.11.14 Coolant cooler – Final steps
Final steps
4. Vent fuel system (→ Operating Instructions).
TIM-ID: 0000015018 - 002

4.11.15 Coolant pipework with thermostat – Overview
1 Screw 6 Flow restrictor 11 Plug screw

2 Washer 7 Thermostat housing 12 Sealing ring
3 Sealing ring 8 Washer 13 Plug screw
4 Thermostat element 9 Screw 14 Screw
5 Gasket 10 Sealing ring
TIM-ID: 0000007165 - 003

4.11.16 Coolant pipework with thermostat – Preparatory steps
Preconditions
Preparatory steps
2. Remove sensor cable for sensor B6.2 (→ Operating Instructions).
4. Disconnect coolant line from coolant pump elbow.
TIM-ID: 0000015040 - 002

4.11.17 Coolant pipework with thermostat – Removal
Preconditions
DANGER
Suspended load.
Danger to life!
Removing thermostat housing

1. Remove screws (8) with washers (7).
2. Remove elbow (6) with O-ring (5).
3. Remove screws (11) and (12) with wash-
ers (10).
4. Remove screws (13) with washers (14) and
take off holder (15).
5. Remove thermostat element (9) with ther-
mostat element (3) and sealing ring (4).
6. Remove gaskets (1) and restrictor (2).
TIM-ID: 0000040436 - 001

4.11.18 Coolant pipework with thermostat – Cleaning
WARNING
WARNING
NOTICE
Coolant pipework with thermostat – Cleaning

2. Blow off all parts thoroughly with compressed air.
TIM-ID: 0000007170 - 005

4.11.19 Coolant pipework with thermostat – Check
Oilstone F30454308/03 1
Thermostat housing (→ Spare Parts Catalog)
Thermostat element (→ Spare Parts Catalog)
WARNING
WARNING
Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.
Checking coolant pipework with thermostat

Check all contact and sealing • Signs of wear • Rework: Smooth with crocus
faces for wear traces and damage. • Damage cloth or oilstone.
visible • Replace
Check mounting holes for thermo- Damaged • Rework: smooth with oilstone.
stat elements for damage. • Replace
Check thread for easy movement. Sluggish replace Helicoils.
TIM-ID: 0000015031 - 003

Checking thermostat element
Note: Thermostat element must not touch the
container.
1. Hang thermostat element with a wire in a
container full of water.
2. Heat water with suitable heat source.
Note: Start-of-opening temperature is stamped
on thermostat element.
3. Check thermostat element start-of-opening
with a constant supply of heat and stir the
water to keep it circulating. From approx.
10 °C below start-of-opening temperature,
the heating-up speed must not exceed
1 °C per minute.
4. If test result is negative, replace thermo-
stat element.
5. Continue to heat water to full-opening tem-
perature.
Result: Thermostat element must be completely
open after 6 to 8 minutes.
6. Measure stroke travel of thermostat ele-
ment.
7. Replace thermostat insert if lifting stroke is
below 9.5 mm.
TIM-ID: 0000015031 - 003

4.11.20 Coolant pipework with thermostat – Installation
Installation tool F30378672 1
Installation tool F30450050 1
Engine oil
O-rings (→ Spare Parts Catalog)
Screws (→ Spare Parts Catalog)
Neck (→ Spare Parts Catalog)
Flow restrictor (→ Spare Parts Catalog)
DANGER
Suspended load.
Danger to life!
NOTICE
Installing thermostat housing

2. Install sealing rings in thermostat housing with drive-in tool.
3. Mount gaskets, restrictor and thermostat inserts on thermostat housing.
4. Install thermostat housing as shown in overview drawing (→ Page 197).
TIM-ID: 0000007199 - 002

4.11.21 Coolant pipework with thermostat – Final steps
Final steps
TIM-ID: 0000015051 - 002

4.11.22 Raw-water pump – Overview
1 Screw 11 Bearing housing 21 Intermediate piece

2 Precision washer 12 Cylindrical roller bearing 22 Rotary seal
3 O-ring 13 Gear 23 Impeller
4 Precision washer 14 Pump shaft 24 Volute
5 Shaft seal 15 Angular-contact ball bear- 25 Sealing ring
6 Snap ring ing 26 Screw
7 O-ring 16 Bearing housing 27 Screw
8 O-ring 17 Snap ring 28 Sealing ring
9 Snap ring 18 Nut
10 Snap ring 19 Stud
20 Track ring
TIM-ID: 0000007267 - 003

4.11.23 Raw water pump – Preparatory steps
Preconditions
Preparatory steps
1. Close raw water supply.
2. Drain raw water.
3. Remove protective cover and holder (→ Page 49).
4. Remove elbow (→ Page 212).
TIM-ID: 0000015198 - 003

4.11.24 Raw water pump – Removal
Preconditions
WARNING
WARNING
WARNING
Risk of injury!
Removing raw water pump

1. Remove plug-in sleeve and raw water el-
bow (→ Page 214).
2. Unscrew nuts (5) with washers (4) from
studs (3).
3. Release raw water pump (1) with crowbar
and remove.
4. Remove O-ring (2).
TIM-ID: 0000040439 - 003

4.11.25 Raw water pump – Cleaning
WARNING
WARNING
NOTICE
Cleaning raw water pump

50/136).
2. Blow off all components thoroughly with compressed air.
TIM-ID: 0000007273 - 004

4.11.26 Raw water pump – Check
Raw water pump (→ Spare Parts Catalog)
WARNING
Risk of injury!
WARNING
Checking raw water pump

Check volute and impeller for cavi- Cavitation visible. Replace
tation.
Visually inspect sealing surfaces • Signs of wear • Rework: Smooth with oilstone.
for signs of wear, pitting and cavi- • Impact marks • Replace
tation. • Cavitation
visible
Check gear for indentations, • Indentations • Rework: Smooth with oilstone.
traces of wear and damage. • Wear traces • Replace raw water pump.
• Damage
visible
TIM-ID: 0000015181 - 002

4.11.27 Raw water pump – Installation
Engine oil
DANGER
Suspended load.
Danger to life!
Installing raw water pump

2. Coat O-ring (2) with assembly compound
and insert into groove on bearing housing.
Note: Note engagement of gear.
3. Correctly insert raw water pump (1) in
bore.
4. Screw nuts (5) with washers (4) onto
stud (3) and tighten diagonally and evenly.
5. Install plug-in sleeve and seawater elbow
(→ Page 214).
TIM-ID: 0000040441 - 002

4.11.28 Raw water pump – Final steps
Final steps
2. Open raw water supply.
3. Fill raw water pump.
TIM-ID: 0000015223 - 005

4.11.29 Coolant pipework on raw water pump – Overview
1 Screw 10 Elbow 19 Flow restrictor

2 Washer 11 Sealing ring 20 O-ring
3 Clamping piece half 12 Flow restrictor 21 Clamping piece half
4 Screw 13 Sealing cone 22 Raw water elbow
5 Sealing ring 14 Nut 23 Sealing ring
6 Coolant elbow 15 O-ring 24 Plug screw
7 O-ring 16 Screw 25 Gasket
8 Plug screw 17 Washer 26 Washer
9 O-ring 18 Plug-in sleeve 27 Screw
TIM-ID: 0000007335 - 002

4.11.30 Coolant pipework on raw water pump – Preparatory steps
Preconditions
Preparatory steps
1. Close raw water supply.
2. Drain raw water.
TIM-ID: 0000015235 - 004

4.11.31 Coolant pipework on raw-water pump – Removal
Preconditions
☑Preparatory steps have been carried out.
Coolant pipework on raw-water pump – Removal

1. Remove raw-water lines and add-on components as shown in overview drawing (→ Page 212).
2. Remove O-rings, gasket and sealing rings.
TIM-ID: 0000007347 - 006

4.11.32 Coolant pipework on raw water pump ‒ Installation
Engine oil
O-rings (→ Spare Parts Catalog)
Clamp (→ Spare Parts Catalog)
Rubber sleeve (→ Spare Parts Catalog)
Screws (→ Spare Parts Catalog)
Blanking cone (→ Spare Parts Catalog)
Nut (→ Spare Parts Catalog)
NOTICE
NOTICE
Installing coolant pipework on raw water pump

2. Coat O-rings with assembly compound.
3. Install lines with new O-rings, sealing rings, gasket and fasteners as shown in overview drawing
(→ Page 212).
TIM-ID: 0000007350 - 006

4.11.33 Coolant pipework on raw water pump – Final steps
Final steps
1. Open raw water supply.
TIM-ID: 0000015244 - 004

4.12 Auxiliary Systems / Supplementary Equipment
4.12.1 Bilge pump – Overview
1 Pipe elbow 3 Screw 5 Bilge pump

2 Threaded adapter 4 Washer 6 Nut
TIM-ID: 0000007766 - 004

Carrier and clamping device
1 V-belt 7 Washer 13 Clamping element

2 Bilge pump carrier 8 Sleeve 14 Screw
3 Washer 9 Screw 15 Washer
4 Screw 10 Washer 16 Conical spring washer
5 Washer 11 Clamping screw 17 Bilge pump console
6 Screw 12 Clamping nut 18 Screw
TIM-ID: 0000007766 - 004

Bilge pump
1 Cover 9 Washer 17 Screw

2 Gasket 10 Seal 18 Wedge
3 Plate 11 Connecting piece 19 Ball bearing
4 Plate 12 Screw 20 Ball bearing
5 Sliding seal 13 Coil 21 Wedge
6 Cam 14 Screw 22 Housing
7 Screw 15 Belt pulley 23 Screw
8 Plug 16 Washer
TIM-ID: 0000007766 - 004

4.12.2 Bilge pump – Preparatory steps
Preconditions
Preparatory steps
2. Remove suction and pressure lines.
3. Mark electrical cable on bilge pump and disconnect.
TIM-ID: 0000015798 - 002

4.12.3 Bilge pump – Removal
Preconditions
Removing bilge pump

1. Release screw (5) for clamp (4).
2. Loosen clamping nut (6) until V-belt can be
removed.
3. Remove screws (1) with nut (9) and wash-
ers (2) and (8).
4. Remove bilge pump (3) from mounting
bracket (7).
TIM-ID: 0000040323 - 001

4.12.4 Bilge pump – Cleaning
WARNING
WARNING
NOTICE
Cleaning bilge pump

50/136).
2. Thoroughly blow all parts clean with compressed air.
TIM-ID: 0000007769 - 004

4.12.5 Bilge pump – Check
Bilge pump (→ Spare Parts Catalog)
Belt pulley (→ Spare Parts Catalog)
V-belt (→ Spare Parts Catalog)
Bilge pump – Check

Item Findings Task
Check housing and cover for cavi- Cavitation visible. Replace
tation.
Check belt pulley for wear, distor- • Wear Replace
tion and damage. • Distortion
• Damage
visible
Check condition of keyway in belt Damage visible. Replace
pulley.
Check all contact and mating sur- Stress marks visible. • Recondition: smooth with oil-
faces. stone or emery cloth.
• Replace
Check screws for damage. Damage visible. Replace
Check threads for ease of move- Sluggish • Recondition: recut threads.
ment. • Replace
If it is to be used again, check V- • Cracks • Clean
belt for cracks, fouling by oil, over- • Fouling by oil • Replace
heating and wear. • Overheating
– Wear
visible
TIM-ID: 0000015792 - 001

4.12.6 Bilge pump – Installation
Tester Y4345711 1
Engine oil
Snap ring (→ Spare Parts Catalog)
WARNING
Installing bilge pump

1. Place bilge pump (2) on mounting brack-
et (9).
2. Install screws (3) and nut (11) with wash-
ers (6) and (10).
3. Remove dirt and oil from grooves on belt
pulley.
4. Insert V-belt (1) in belt pulley (4) and bilge
pump (2).
5. Set parallelism of both belt pulleys with
alignment tool.
6. Tension V-belt (1) with tensioning nut (8).
7. After adjusting, tighten screw (5) for
clamp (7).
8. Check V-belt tension with test equipment.
9. If settings deviate, correct them and repeat
measurement.
Application Measured value Measured value

Initial assembly (new belt) Operating tension (run-in belt)
V-belt – bilge pump Frequency: 71.3 -3.9 Hz Frequency: 61.8 -4.6 Hz
Table 4: Settings for V-belt tension

TIM-ID: 0000040484 - 002

4.12.7 Bilge pump – Final steps
Final steps
2. Connect electrical cable to bilge pump.
3. Install suction and pressure lines.
TIM-ID: 0000015802 - 002

4.13 Monitoring, Control and Regulation Equipment
4.13.1 Sensors and actuators – Overview
Top view
Deviations from illustrations are insignificant.
Also valid for 8V engines.
No. Description Monitoring of

1 B10 Charge-air pressure
2 B9 Charge-air temperature
3 B7 Lube oil temperature
4 B3 Intake air temperature
TIM-ID: 0000008375 - 006

Engine free end

1 B34 Fuel line pressure after filter
2 B5.3 (optional) Lube oil pressure before filter
3 B5.1 Lube oil pressure
4 B5.2 (optional) Lube oil pressure
5 F33 Coolant level
6 B21 (optional) Raw water pressure
7 B6.2 (optional) Coolant pressure
8 B6.1 Coolant temperature
TIM-ID: 0000008375 - 006

Engine driving end

1 B4.21 Exhaust gas temperature, A side
2 B4.22 Exhaust temperature, B-side
3 B1 Camshaft speed
4 B13 Crankshaft speed
5 B13.2 (optional) Crankshaft speed
TIM-ID: 0000008375 - 006

Engine right side

1 B44 Turbocharger speed
2 B33 Fuel temperature
3 B48 Fuel pressure in Common Rail
4 B16 (optional) Coolant pressure
5 F46 Leak fuel level
TIM-ID: 0000008375 - 006

Engine left side

1 Y41 Solenoid valvesWastegate
2 Y27 Solenoid valves for turbocharger control
3 B54 (optional) Oil replenishment pump pressure
System sensors
The sensors are fitted on the off-engine system.
Description Monitoring of
B19 Starting-air pressure
B70 Water level in fuel prefilter
B41 Exhaust backpressure
S37 Start interlock, switching status
TIM-ID: 0000008375 - 006

4.13.2 Sensors, actuators and injectors – Preparatory steps
Preconditions
Preparatory steps
1. Observe safety regulations.
2. Drain engine coolant (only if coolant sensors are to be removed) (→ Operating Instructions).
TIM-ID: 0000016760 - 001

4.13.3 Sensors and actuators – Removal
WARNING
• Do not smoke.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
WARNING
Removing temperature sensors

(B3, B6.1, B7, B9, B26, B33)
1. Observe the following general information:
• The sensors are identical with regard to
their design and electrical functions. Re-
moval is identical.
• Arrangement and position of sensors
(→ Page 226).
2. Observe the following prior to removal:
B3 (intake air temperature) Procedure and safety notes (→ Operating Instructions)

B6.1 (coolant temperature) Procedure and safety notes (→ Operating Instructions)
B6.2 (coolant temperature) During removal, small amounts of coolant may emerge. Have a suit-
TIM-ID: 0000008404 - 005
able vessel ready to catch coolant.

B7 (oil temperature) During removal, small amounts of engine oil may emerge. Have a
suitable vessel ready to catch engine oil.
B9 (charge-air temperature) Procedure and safety notes (→ Operating Instructions)
B33 (fuel temperature) During removal, small amounts of fuel may emerge. Keep a suitable
container ready to collect the fuel.
3. Release bayonet lock (2) and remove connector (1).

4. Unscrew sensor via nut (3).

(B4.21, B4.22)
moval is identical.
(→ Page 226).
2. Release bayonet lock (1) and disconnect
connector (2).
3. Unscrew union nut (4) from temperature
sensor.
4. Pull temperature sensor out of threaded
adapter (3).
Removing pressure sensors

(B5.1, B5.2, B5.3)
moval is identical.
(→ Page 226).
• During removal of sensor, small amounts
of engine oil may emerge. Have a suita-
ble vessel ready to catch engine oil.
2. Release bayonet lock (2) and remove con-
nector (1).
Removing pressure sensor

(B10)
• Arrangement and position of sensor
(→ Page 226).
nector (1).
TIM-ID: 0000008404 - 005

(B16, B21, B34, B54)
• Arrangement and position of sensor
(→ Page 226).
• During removal of sensors, small
amounts of fuel may emerge. Keep a
suitable container ready to collect the
fuel.
nector (1).
Removing speed sensors (B1,

B13.1, B13.2)
moval is identical.
(→ Page 226).
2. Release bayonet lock (1) of speed sen-
sor (3) and remove connector (2) from en-
gine wiring system.
3. Remove screw (4).
4. Remove speed sensor (3).
Speed transmitter (B44)

(→ Page 226).
2. Release bayonet lock of speed transmitter
and remove from engine wiring connector.
3. Pull out speed transmitter at turbocharger.
TIM-ID: 0000008404 - 005

Pressure sensor (B48)
(→ Page 226).
nector (1).
Filling level sensor (F46)

(→ Page 226).
nector (1).
3. Remove sensor via nut (3).
Filling level sensor (F46)

(→ Page 226).
2. Release bayonet lock and pull off connec-
tor.
3. Remove sensor at nut (1).
TIM-ID: 0000008404 - 005

4.13.4 Sensors and actuators – Installation
Precision washer (→ Spare Parts Catalog)
Installing temperature sensors

(B3, B6.1, B6.2, B7, B9, B33)
their design and electrical functions.
Their installation is also identical.
(→ Page 226).
2. Coat sensor O-ring with assembly com-
pound.
3. Manually screw sensor into bore.
4. Tighten nut (3) to specified tightening torque using a torque wrench.

Nut M14 x 1.5 Tightening torque 15 Nm to 30 Nm
5. Fit connector (1) and tighten bayonet lock (2).
Installing temperature sensors

(B4.21, B4.22)
(→ Page 226).
2. Insert temperature sensor into threaded
TIM-ID: 0000008409 - 005
adapter (2).

3. Use torque wrench to tighten union nut (1) on temperature sensor to specified tightening torque.
Union nut Tightening torque 35 Nm +/-5 Nm
Installing pressure sensors

(B5.1, B5.2, B5.3)
(→ Page 226).
pound.

Installing pressure sensor (B10)

(→ Page 226).
pound.
TIM-ID: 0000008409 - 005


(B16, B54)
(→ Page 226).
pound.

Nut M14 x 1.5 Tightening torque 20 Nm +/-3 Nm

(B21, B34)
(→ Page 226).
pound.

TIM-ID: 0000008409 - 005
Nut G 1/4" Tightening torque 20 Nm +/-3 Nm


Installing speed sensors (B1,
B13.1, B13.2)
(→ Page 226).
pound.
3. Fit sensor in bore and press in.
4. Tighten sensor (3) with screw (4).
5. Determine clearance “A” see table below.
“A” (clearance between sensor and timing wheel)

Speed sensor B1 0.1 mm to 1.6 mm
Speed sensors B1.1 and B1.2 0.45 mm to 1.45 mm
6. Insert connector for sensor (1) in socket (2) of engine wiring system. Tighten bayonet lock (1).
7. If necessary, roll up sensor cable to correct length and secure with cable ties.
Speed transmitter (B44)

(→ Page 226).
2. Insert speed transmitter into bore at turbo-
charger and press in.
TIM-ID: 0000008409 - 005

Installing pressure sensor (B48)
(→ Page 226).
pound.

Nut M18 x 1.5 Tightening torque 30 Nm +/-3 Nm
Installing fill level sensor (F33)

(→ Page 226).
2. Coat O-ring with assembly compound.
4. Tighten nut of sensor (3) with torque wrench to specified tightening torque.
TIM-ID: 0000008409 - 005
Nut M18 x 1.5 Tightening torque Max. 25 Nm


Installing fill level sensor (F46)
(→ Page 226).
2. Coat O-ring with assembly compound.

Nut M18 x 1.5 Tightening torque Max. 25 Nm
5. Fit connector and tighten bayonet lock.
TIM-ID: 0000008409 - 005

4.13.5 Sensors, actuators and injectors – Final steps
Final steps
2. Check firm and precise seating of all plug connections.
TIM-ID: 0000012997 - 005

5 Appendix A
5.1 Tightening specifications for screws, nuts and bolts
Tightening torques for setscrew and stud joints to MTN 5008 standard
This standard applies to setscrews not subject to dynamic loads and the associated nuts according to:
• MMN 384
• ISO 4762 (DIN 912)
• ISO 4014 (DIN 931-1)
• ISO 4017 (DIN 933)
• DIN EN ISO 8765 (EN 28765; DIN 960)
• DIN EN ISO 8676 (EN 28676; DIN 961)
• DIN 6912
This standard applies to studs not subject to dynamic loads and the associated nuts according to:
• DIN 833
• DIN 835
• DIN EN ISO 5395 (DIN 836)
• DIN 938
• DIN 939
This standard applies to screws with hexalobular heads according to:
• DIN 34800
• DIN 34801
The standard does not apply to heat-resistant screws in the hot component zone.
Tightening torques MA are specified for screws of strength class 8.8 (surface finish bare metal, phosph-
atized or galvanized) and 10.9 (surface finish bare metal or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.
When hand-tightening (defined torque), an assembly tolerance of +10% of the figures in the table is per-
mitted.
When machine-tightening, the permissible assembly tolerance is ±15%.
Tightening torques for setscrews

Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
TIM-ID: 0000002333 - 017
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
MS22008/02E 2015-01 | Appendix A | 243

Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
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
MA= tightening torques
Tightening torques for studs

Screwed into
Thread Steel M A Gray cast iron MA Al alloy MA
(Nm) (Nm) (Nm)
M6 9 6 6
M8 11 9 10
M10 17 13 13
M12 27 23 18
M14 37 33 33
M16 55 45 –
Tightening torques for setscrews and nuts made of stainless steel

The values in the table are based on a friction coefficient µtot = 0.12, lubricated with Molykote on the
thread and under the screw head.
Strength class
70 80
Basic size Material
MA MA
TIM-ID: 0000002333 - 017
(Nm) (Nm)
M5 3.7 4.9 A2 / A4
M6 6.4 8.5 A2 / A4
M8 15,3 20,4 A2 / A4
M10 31 41 A2 / A4
M12 52 70 A2 / A4
M16 126 167 A2 / A4
244 | Appendix A | MS22008/02E 2015-01

Strength class
70 80
Basic size Material
MA MA
(Nm) (Nm)
M20 254 326 A2 / A4
Tightening torque for self-locking hex nuts

Thread MA (Nm) Lubricant
M6 7,5 +1 –
M8 17 +2 –
M10 35 +4 –
M12 59 +6 –
M14 100 +10 –
M16 140 +14 –
M20 290 +29 –
Tightening torques for stress bolt connections to MTN 5007 standard

This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic
load of strength class 10.9 as well as to the associated nuts.
Shank and junction dimensions to MMN 209 standard and material and manufacture to MMN 389
standard (bare metal or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations
during the tightening process.
The figures in the table are for hand-tightening using a torque wrench.
Thread Not torsion-protected MA(Nm) Torsion-protected 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
TIM-ID: 0000002333 - 017
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
MS22008/02E 2015-01 | Appendix A | 245

Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)
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 screw shaft from torsion when tightening.
Tightening torques for plug screws to MTN 5183-1 standard

This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852
Form A (sealed with sealing ring to DIN 7603-Cu).
TIM-ID: 0000002333 - 017
246 | Appendix A | MS22008/02E 2015-01

Tightening torques MA are given for screw plugs made of steel (St) with surface protected by a phos-
phate coating and oiled or galvanized.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
Tightening torques for plug screws to DIN 908, DIN 910 and DIN 7604A (with short threaded end).
Screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 25 25
M14 x 1.5 35 30
M16 x 1.5 40 35
M18 x 1.5 50 40
M20 x 1.5 60 50
M22 x 1.5 70 70
M24 x 1.5 85 80
M26 x 1.5 100 100
M27 x 2 100 100
M30 x 1.5 110 110
M30 x 2 120 120
TIM-ID: 0000002333 - 017
M33 x 2 160 160

M36 x 1.5 190 180
M38 x 1.5 220 200
M42 x 1.5 260 240
M45 x 1.5 290 270
M48 x 1.5 310 300
M52 x 1.5 325 320
M56 x 2 380 360
MS22008/02E 2015-01 | Appendix A | 247

Screwed into
(Nm) (Nm)
M64 x 2 400 400
Tightening torques for plug screws to DIN 7604C (with long threaded end)
Screwed into
Thread Steel/gray cast iron M A Al alloy MA
(Nm) (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
Tightening torques for banjo screws to MTN 5183-2 standard

This standard applies to banjo screws to MMN 223 and N 15011 sealed with sealing ring to DIN 7603-
Cu.
TIM-ID: 0000002333 - 017
248 | Appendix A | MS22008/02E 2015-01

The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface coating
and oiled, or galvanized, and to banjo screws made of copper/aluminum alloys.
Tightening torques for steel banjo screws

inserted in steel/gray cast iron/aluminum alloy
Thread 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
TIM-ID: 0000002333 - 017
Tightening torques for banjo screws made of copper-aluminum alloy

inserted in steel/gray cast iron/aluminum alloy
Thread MA
(Nm)
M10 x 1 15
M16 x 1.5 30
MS22008/02E 2015-01 | Appendix A | 249

Tightening torques for male unions to MTN 5183-3 standard
This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A
(sealed by sealing ring to DIN 7603-Cu).
Tightening torques MA are given for male unions made of steel (St) with phosphatized surface coating
and oiled, or galvanized.
inserted in steel/gray cast iron MA
Thread
(Nm)
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 35
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
TIM-ID: 0000002333 - 017
250 | Appendix A | MS22008/02E 2015-01

Tightening torques for union nuts to DIN 3859-2
1 Union nut
2 Union body
3 O-ring
4 Ferrule
Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable
increase in force), it should be tightened another 1/4 turn (90°) past this point.
Tightening torques for spigot unions with O-ring to ISO 6149-2
Thread Torque (Nm) +10%

TIM-ID: 0000002333 - 017
M8 x 1 10
M10 x 1 20
M12 x 1.5 35
M14 x 1.5 45
M16 x 1.5 55
M18 x 1.5 70
M20 x 1.5 1) 80
M22 x 1.5 100
MS22008/02E 2015-01 | Appendix A | 251

M27 x 2 170
M33 x 2 310
M42 x 2 330
M48 x 2 420
M60 x 2 500
1)
Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789)
Tightening torques for spigot unions with O-ring to ISO 6149-3

M8 x 1 8
M10 x 1 15
M12 x 1.5 25
M14 x 1.5 35
M16 x 1.5 40
M18 x 1.5 45
M22 x 1.5 60
M27 x 2 100
M33 x 2 160
M42 x 2 210
M48 x 2 260
TIM-ID: 0000002333 - 017
M60 x 2 315
252 | Appendix A | MS22008/02E 2015-01

Tightening torques for plug screws to MTN 5183-6
Screwed into
(Nm) (Nm)
M10 x 1 20 10 +2
M12 x 1.5 35 14 +2
M14 x 1.5 45 15 +3
M16 x 1.5 55 18 +3
M18 x 1.5 70 23 +3
M22 x 1.5 100 33 +4
M27 x 2 170 57 +5
M33 x 2 310 103 +10
M42 x 2 330 110 +11
M48 x 2 420 140 +14
M60 x 2 – 200 +20
Assembly instructions and tightening torques for hose fittings with union nuts
These instructions do not apply to ORFS fittings. In contrast to the instructions for pipe unions, hose
fittings with sealing heads and the matching adapters must be fitted and connected as follows.
Hose fitting forming metallic seal with union nut: tighten union nut by hand then tighten a further
TIM-ID: 0000002333 - 017
max. 1/4 of a turn with a wrench.

Hose fitting with O-ring and union nut: tighten union nut by hand then tighten a further max. 1/2 of a
turn with a wrench.
Hoses must be properly aligned before tightening the union nuts.
Sealing head/sealing cone with metric union nut

Metric thread Pipe outer dia. Torque (Nm)
M12 x 1.5 6 20
M14 x 1.5 8 38
MS22008/02E 2015-01 | Appendix A | 253

Sealing head/sealing cone with metric union nut
Metric thread Pipe outer dia. Torque (Nm)
M16 x 1.5 8 45
10
M18 x 1.5 10 51
12
M20 x 1.5 12 58
M22 x 1.5 14 74
15
M24 x 1.5 16 74
M26 x 1.5 18 105
M30 x 2 20 135
22
M36 x 2 25 166
28
M42 x 2 30 240
M45 x 2 35 290
M52 x 2 38 330
42
Sealing head with BSP union nut

BSPP thread Torque (Nm)
G1/4 20
G3/8 34
G1/2 60
G5/8 69
G3/4 115
G1 140
G1.1/4 210
G1.1/2 290
G2 400
SAE sealing cone with union nut JIC 37°

UNF thread Size Torque (Nm)
7/16–20 –4 15
1/2–20 –5 20
9/16–18 –6 30
3/4–16 –8 50
TIM-ID: 0000002333 - 017
7/8–14 –10 69
1.1/16–12 –12 98
1.3/16–12 –14 118
1.5/16–12 –16 140
1.5/8–12 –20 210
1.7/8–12 –24 290
2.1/2–12 –32 450
254 | Appendix A | MS22008/02E 2015-01

ORFS – flat sealing with union nut
UNF thread Size Torque (Nm)
9/16–18 –4 14 +2
11/16–16 –6 24 +3
13/16–16 –8 43 +4
1–14 –10 60 +8
1.3/16–12 –12 90 +5
1.3/16–12 –14 90 +5
1.7/16–12 –16 125 +10
1.11/16–12 –20 170 +20
2–12 –24 200 +25
2–1/2–20 –32 460 +30
TIM-ID: 0000002333 - 017
MS22008/02E 2015-01 | Appendix A | 255

5.2 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km
Nm 1.852 = km
yd 3 = ft
yd 36 = in
Unit B multiplied by factor = Unit A

mm 0.03937 = in
m 3.281 = ft
km 0.6215 = stat. mile
Area
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.59 = km2
Unit B multiplied by factor Unit A

mm 2 0.00155 = in2
m2 10.764 = ft2
m2 1.1960 = yd2
km2 0.3861 = stat. mile2
Volume
in 3 16387 = mm3
ft3 0.02832 = m3
yd3 0.7646 = m3
gallon (U.S.) 3.785 = dm3
TIM-ID: 0000002173 - 016
gallon (UK) 4.546 = dm3

cm 3 0.06102 = in3
m3 35.31 = ft3
dm3 0.2642 = gallon (U.S.)
dm3 0.22 = gallon (UK)
256 | Appendix A | MS22008/02E 2015-01

Volumetric flow
gal/min (GPM, U.S.) 3.79 = l/min
gal/min (GPM, U.S.) 0.134 = ft3/min (cfm)
ft3/min (cfm) 1.70 = m3/h

l/min 0.264 = gal/min (U.S.)
3
ft /min (cfm) 7.48 = gal/min (U.S.)
m3/h 0.589 = ft3/min (cfm)
Velocity
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (UK) 1.852 = km/h
Unit B multiplied by factor = Unit B

m/s 3.281 = ft/s
km/h 0.6214 = stat. mile/h (mph)
km/h 0.54 = knot (UK)
Mass
lb 0.4536 = kg
oz 28.35 =g
ton (imp.) 1.016 =t

g 0.03527 = oz
kg 2.205 = lb
t 0.9842 = ton (imp.)
Force
lbf 0.4536 = kp
lbf 4.4482 =N
TIM-ID: 0000002173 - 016
kp 9.80665 =N

kp 2.205 = lbf
N 0.10197 = kp
N 0.2248 = lbf
MS22008/02E 2015-01 | Appendix A | 257

Density
slug/ft 3 515.4 = kg/m3

kg/m 3 0.00194 = slug/ft3
Torque
lbf ft 1.3558 = Nm

Nm 0.7376 = lbf ft
Pressure
2
lbf/in (psi) 703.1 = kp/m2 (mmH2O)
lbf/in2 (psi) 0.06895 = bar
2
lbf/ft (psf) 47.88 = Pa
inHg 0.03386 = bar
inHg 345.3 = kp/m2 (mmH2O)

atm 760 = mmHg
atm 1.0133 = bar
atm 10332 = kp/m2 (mmH2O)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lbf/in2 (psi)
bar 14.504 = lbf/in2 (psi)
Pa 0.0209 = lbf/ft2 (psf)
2nd moment of mass

slug ft 2 1.3558 = kg m2

kg m 2 0.7376 = slug ft2
TIM-ID: 0000002173 - 016
Energy
lbf ft 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
258 | Appendix A | MS22008/02E 2015-01

J 0.7376 = lbf ft
J 0.0002388 = kcal
J 0.0009478 = BTU
J 0.00052656 = CHU
Power
PS 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.054 = kW
kcal/h 1.163 =W
HP 550 = lbf ft/s

kW 1.36 = PS
kW 1.341 = HP
kW 0.9487 = BTU/s
W 0.8598 = kcal/h
lbf ft/s 0.0018 = HP
Temperature
Celsius Kelvin
x °C - = x + 273.15 K
xK = x − 273.15 °C -
x °F = 5/9(x − 32) °C = 5/9(x − 32) + 273.15 K
x °R = 5/4x °C = (5/4x) + 273.15 K
Fahrenheit Réaumur
x °C = 9/5x + 32 °F = (4/5x) °R
xK = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15) °R
x °F - = 4/9(x − 32) °R
x °R = (9/4x) + 32 °F -
Fuel consumption
mile/gal (US) 0.4251 = km/l
TIM-ID: 0000002173 - 016
gal/mile (US) 2.3527 = l/km

km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)
MS22008/02E 2015-01 | Appendix A | 259

5.3 Tolerances and wear limits list – General information
The tolerances and wear limits are helpful clues when inspecting components and making repairs.
Explanation of terms for dimensions of new components
Toleranced size Designed size followed by a fits symbol (e.g. 24 H6) or by the permissible dimen-
sional deviation (e.g. 24 +0.013)
Basic size Designed size without fit symbol or permissible dimensional deviation
Deviation Permissible tolerance of toleranced/basic size. Deviation determines the upper
and lower limit of the toleranced/basic size
Clearance Difference between bore and shaft diameter when bore diameter is greater than
shaft diameter
Interference Difference between bore and shaft diameter when bore diameter is smaller than
shaft diameter
Explanation of terms for the dimension to be observed when overhauling components

Wear limit The wear limits do not denote the max. permissible wear for satisfactory function-
ing of the component. They are to be regarded as indications that the next required
major overhaul will be reached safely. A component must be replaced when its
wear limit is exceeded.
Reconditioning in- If a wear limit is exceeded or not reached, the parts in question must be repaired
struction or replaced in accordance with the reconditioning instructions.
Deviations from roundness, cylindrical form, parallelism and concentricity must be within specified lim-
its unless otherwise indicated. All dimensions are given in "mm" unless otherwise specified.
TIM-ID: 0000002848 - 013
260 | Appendix A | MS22008/02E 2015-01

5.4 Abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine governor
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger (ETC)
BR Baureihe Series
BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CCG Cross Connection Gear Transfer gearbox
CODAG Combined Diesel (engine) And Gas (tur-
bine propulsion)
CPP Controllable Pitch Propeller
DAG Diesel (engine) And Gas (turbine)
DE Diesel Engine
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards (DIN
= “Deutsche Industrie-Norm”)
DIS Display unit
DL Default Lost Alarm: CAN bus missing
ECS Engine Control System
ECS-UNI Engine Control System UNIversal
ECU Engine Control Unit Engine governor
EDM Engine Data Module
EMU Engine Monitoring Unit
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
GT Gas Turbine
HAT Harbor Acceptance Test
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
TIM-ID: 0000002049 - 005
HT High Temperature
ICFN ISO – Continuous rating – Fuel stop Power specification in accordance with DIN-ISO
power – Net 3046-7
IDM Interface Data Module
IMO International Maritime Organization
ISO International Organization for Stand- International umbrella organization for all national
ardization standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
MS22008/02E 2015-01 | Appendix A | 261

Abbrevia- Meaning Explanation
tion
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
MRG Main Reduction Gear
OT Oberer Totpunkt Top Dead Center (TDC)
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
PT Power Turbine
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus missing
SAE Society of Automotive Engineers U.S. standardization organization
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency-air shutoff flap(s)
SOLAS International Convention for the Safety
of Life at Sea
SS Safety System Safety system alarm
SSK Schnellschlussklappe(n) Emergency air shut-off flaps
SSS Synchronized Self-Shifting (clutch)
STBD Starboard
T-xyz Temperature-xyz Temperature measuring point xyz
TIM-ID: 0000002049 - 005
TD Transmitter Deviation Alarm: Deviation in transmitter values

UT Unterer Totpunkt Bottom Dead Center (BDC)
VS Voith Schneider Voith Schneider drive
WJ Water jet Water jet drive
WZK Werkzeugkatalog Tool Catalog (TC)
ZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for
signals from the ADEC engine governor
262 | Appendix A | MS22008/02E 2015-01

5.5 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015
MS22008/02E 2015-01 | Appendix A | 263

6 Appendix B
6.1 Special Tools
Alignment device
Part No.: F6783244
Qty.: 1
Used in: 4.5.1 HP fuel system – Tightening procedure
(→ Page 109)
Qty.: 1
Used in: 4.5.6 HP pump – Installation (→ Page 118)
Alignment device
Part No.: F6787011
Qty.: 1
(→ Page 109)
Alignment device
Part No.: F6790507
Qty.:
(→ Page 109) DCL-ID: 0000008118 - 002
264 | Appendix B | MS22008/02E 2015-01

Alignment device
Part No.: F6784786
Qty.: 1
Used in: 4.12.6 Bilge pump – Installation (→ Page 224)
Assembly device
Part No.: F6783791
Qty.: 1
Used in: 4.2.9 Piston and conrod – Removal (→ Page 55)
Assembly device
Part No.: F6557995
Qty.: 1
Used in: 4.2.16 Conrod – Assembly (→ Page 72)
Qty.: 1
Used in: 4.2.18 Piston and conrod – Installation (→ Page 77)
Barring device
Part No.: F6783914
Qty.: 1
Qty.: 1
DCL-ID: 0000008118 - 002
MS22008/02E 2015-01 | Appendix B | 265

Barring gear
Part No.: F6557929
Qty.: 1
Used in: 4.4.13 Valve drive – Installation (→ Page 101)
Bore gage, 18-100 mm

Part No.: Y20091481
Qty.: 1
Used in: 4.2.14 Conrod – Check (→ Page 66)
Bore gauge, 160–290 mm

Part No.: Y20091483
Qty.: 1
Used in: 4.1.5 Cylinder liner – Check (→ Page 25)
Box wrench
Part No.: F30030450
Qty.: 1
DCL-ID: 0000008118 - 002
266 | Appendix B | MS22008/02E 2015-01

Depth gage, 300 mm
Part No.: Y20002777
Qty.: 1
Dial gage
Part No.: Y20011268
Qty.: 1
Dial gauge
Part No.: Y20011268
Qty.: 1
Extraction tool
Part No.: F6784160
Qty.: 1
(→ Page 109)
DCL-ID: 0000008118 - 002
MS22008/02E 2015-01 | Appendix B | 267

Graduated disk
Part No.: Y4341946
Qty.: 1
Guide pin
Part No.: F30450460
Qty.: 1
(→ Page 109)
Qty.: 2
Hand pump kit

Part No.: B80146887
Qty.: 1
Used in: 4.2.2 Vibration damper on PTO free end – Removal
(→ Page 40)
Qty.: 1
Used in: 4.2.3 Vibration damper on PTO, free end – Installation
(→ Page 42)
Hand pump kit

Part No.: B80147075
Qty.: 1
(→ Page 40)
Qty.: 1
(→ Page 42)
DCL-ID: 0000008118 - 002
268 | Appendix B | MS22008/02E 2015-01

Hook
Part No.: T80091769
Qty.: 1
Used in: 4.9.8 Constant-pressure manifold – Removal
(→ Page 171)
Qty.: 1
Used in: 4.9.9 Constant-pressure manifold – Installation
(→ Page 172)
Hook-ended chain sling

Part No.: T80090943
Qty.: 1
Used in: 4.9.8 Constant-pressure manifold – Removal
(→ Page 171)
Qty.: 1
(→ Page 172)
Insertable fork wrench, 19 mm

Part No.: F30025897
Qty.: 1
(→ Page 109)
Installation tool
Part No.: F30378672
Qty.: 1
Used in: 4.11.20 Coolant pipework with thermostat – Installa-
tion (→ Page 203)
DCL-ID: 0000008118 - 002
MS22008/02E 2015-01 | Appendix B | 269

Installation tool
Part No.: F30450050
Qty.: 1
Used in: 4.11.20 Coolant pipework with thermostat – Installa-
tion (→ Page 203)
Lifting gear
Part No.: T80092026
Qty.: 1
(→ Page 40)
Qty.: 1
(→ Page 42)
Lifting gear
Part No.: T80091650
Qty.: 1
Used in: 4.5.4 HP pump – Removal (→ Page 115)
Qty.: 1
Lifting gear
Part No.: T80091621
Qty.: 1
Used in: 4.7.3 Exhaust turbocharger – Removal (→ Page 143)
Qty.: 1
Used in: 4.7.6 Exhaust turbocharger – Installation (→ Page 147)
DCL-ID: 0000008118 - 002
270 | Appendix B | MS22008/02E 2015-01

Locking pliers
Part No.: F30378037
Qty.: 1
Used in: 4.4.6 Roller tappet, pushrod – Installation (→ Page 93)
Lowering device
Part No.: F6784104
Qty.: 3
Used in: 4.1.11 Oil pan – Removal (→ Page 33)
Qty.: 1
Magnetic pickup
Part No.: 8205892961/00
Qty.: 1
Used in: 4.4.19 Cylinder head cover – Installation (→ Page 108)
Mounting sleeve
Part No.: F6784287
Qty.: 1
DCL-ID: 0000008118 - 002
MS22008/02E 2015-01 | Appendix B | 271

Mounting sleeve
Part No.: F30450342
Qty.: 1
(→ Page 109)
Oilstone
Part No.: F30454308/03
Qty.: 1
Qty.: 1
Used in: 4.11.5 Engine coolant pump – Check (→ Page 184)
Qty.: 1
Used in: 4.11.12 Coolant cooler – Check (→ Page 193)
Qty.: 1
Used in: 4.11.19 Coolant pipework with thermostat – Check
(→ Page 201)
Outside micrometer, 150–175 mm

Part No.: Y20000326
Qty.: 1
Piston-ring pliers
Part No.: F30379877
Qty.: 1
Used in: 4.2.10 Piston and conrod – Disassembly (→ Page 57)
DCL-ID: 0000008118 - 002
272 | Appendix B | MS22008/02E 2015-01

Piston-ring pliers
Part No.: F30378001
Qty.: 1
Used in: 4.2.17 Piston and conrod – Assembly (→ Page 74)
Pliers
Part No.: F30453426
Qty.: 1
Used in: 4.2.10 Piston and conrod – Disassembly (→ Page 57)
Pliers
Part No.: F30378037
Qty.: 1
Used in: 4.4.3 Roller tappets, pushrod – Removal (→ Page 90)
Pointer for barring gear

Part No.: F6557932
Qty.: 1
DCL-ID: 0000008118 - 002
MS22008/02E 2015-01 | Appendix B | 273

Press-in tool for cylinder liner
Part No.: F6783388
Qty.: 1
Used in: 4.1.7 Cylinder liner – Installation (→ Page 28)
Protective sleeve
Part No.: F6780523
Qty.: 1
(→ Page 40)
Qty.: 1
(→ Page 42)
Puller for liner

Part No.: F6783773
Qty.: 1
Used in: 4.1.3 Cylinder liner – Removal (→ Page 22)
DCL-ID: 0000008118 - 002
274 | Appendix B | MS22008/02E 2015-01

Ratchet adapter
Part No.: F30027340
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1
(→ Page 109)
Qty.: 1
Qty.: 1
Used in: 4.5.10 HP line – Installation (→ Page 125)
Qty.: 1
Qty.: 1
(→ Page 172)
Ratchet adapter, ¾"

Part No.: F30450902
Qty.: 1
Used in: 4.3.5 Cylinder head – Installation (→ Page 85)
Removal/installation device
Part No.: F0140560
Qty.: 1
(→ Page 40)
DCL-ID: 0000008118 - 002
Qty.: 1
(→ Page 42)
MS22008/02E 2015-01 | Appendix B | 275

Ring gauge
Part No.: Y4345226
Qty.: 1
Used in: 4.2.12 Piston – Check (→ Page 60)
Rotation-angle measuring device

Part No.: Y20044010
Qty.: 1
Safety rail
Part No.: F6555715
Qty.: 2
Used in: 4.1.7 Cylinder liner – Installation (→ Page 28)
Socket
Part No.: F30005947
Qty.: 1
Qty.: 1
DCL-ID: 0000008118 - 002
Qty.: 1
276 | Appendix B | MS22008/02E 2015-01

Socket
Part No.: F30907150
Qty.: 1
Used in: 4.3.3 Cylinder head – Removal (→ Page 83)
Qty.: 1
Socket wrench
Part No.: F30451502
Qty.: 1
(→ Page 109)
Support bracket
Part No.: T80091665
Qty.: 1
Used in: 4.5.4 HP pump – Removal (→ Page 115)
Qty.: 1
Test mandrel
Part No.: Y4341915
Qty.: 1
DCL-ID: 0000008118 - 002
MS22008/02E 2015-01 | Appendix B | 277

Test mandrel
Part No.: Y4341916
Qty.: 1
Tester
Part No.: Y4345711
Qty.: 1
Used in: 4.12.6 Bilge pump – Installation (→ Page 224)
Testing device
Part No.: Y4341492
Qty.: 1
Threaded pin
Part No.: 5362030462
Qty.: 2
Used in: 4.11.10 Coolant cooler – Removal (→ Page 189)
Qty.: 2
Used in: 4.11.13 Coolant cooler – Installation (→ Page 194)
DCL-ID: 0000008118 - 002
278 | Appendix B | MS22008/02E 2015-01

Torque wrench, 20-100 Nm
Part No.: F30026582
Qty.: 1
Qty.: 1
Qty.: 1
Qty.: 1
(→ Page 109)
Qty.: 1
Qty.: 1
(→ Page 172)
Torque wrench, 60–320 Nm

Part No.: F30047446
Qty.: 1
Torque wrench, 6–50 Nm

Part No.: F30027336
Qty.: 1
DCL-ID: 0000008118 - 002
MS22008/02E 2015-01 | Appendix B | 279

Torque wrench, 8-40 Nm
Part No.: F30043446
Qty.: 1
Qty.: 1
(→ Page 109)
Qty.: 1
Used in: 4.5.10 HP line – Installation (→ Page 125)
Whetstone
Part No.: F30454308/03
Qty.: 1
Used in: 4.4.18 Cylinder head cover – Check (→ Page 107)
Qty.: 1
Used in: 4.10.4 Starter – Check (→ Page 178)
DCL-ID: 0000008118 - 002
280 | Appendix B | MS22008/02E 2015-01

6.2 Index
A Coolant pipework on raw water pump
Abbreviations 261 – Final steps 216
Actuators – Overview 212
– Final steps 242 – Preparatory steps 213
– Installation 236 Coolant pipework on raw-water pump
– Overview 226 – Removal 214
– Removal 232 Coolant pipework with thermosat
Air pipework to cylinders – Check 201
– Installation 161 Coolant pipework with thermostat
– Overview 158 – Cleaning 200
– Preparatory steps 159 – Final steps 204
– Removal 160 – Installation 203
– Overview 197
B – Removal 199
Bilge pump Coolant pipework with thermostat
– Cleaning 222 – Preparatory steps 198
– Final steps 225 Cylinder
– Installation 224 – Designation 17
– Overview 217 Cylinder head
– Preparatory steps 220 – Cleaning 84
– Removal 221 – Final steps 87
Bilge pump – Check 223 – Installation 85
– Overview 81
C – Preparatory steps 82
Carrier housing – Removal 83
– Overview 166 Cylinder head cover
Carrier housing cover – Check 107
– Removal and installation 167 – Cleaning 106
Conrod – Installation 108
– Assembly 72, 74 – Overview 104
– Check 66 – Removal 105
– Disassembly 57 Cylinder liner
– Overview 51 – Check 25
– Tolerances 68 – Cleaning 24
Constant-pressure manifold – Final steps 30
– Final steps 174 – Installation 28
– Installation 172 – Overview 20
– Overview 169 – Preparatory steps 21
– Preparatory steps 170 – Removal 22
– Removal 171 – Tolerances 26
Contact persons 263
E
Conversion tables 256
Coolant cooler Electric starter
– Cleaning 190 – Overview 175
Engine circuit fuel cooler
DCL-ID: 0000008118 - 002
– Final steps 196

– Overview 187 Engine coolant pump
– Preparatory steps 188 – Check 184
– Removal 189 – Cleaning 183
Coolant cooler – Check 193 – Final steps 186
Coolant pipework – Installation 185
– On raw-water pump – Overview 180
– Installation 215 – Preparatory steps 181
– Thermostat – Removal 182
– Check 201 Engine driving end
– Definition 17
MS22008/02E 2015-01 | Appendix B | 281

Engine free end I
– Definition 17 Intake housing
Engine sides – Cleaning 154
– Designation 17 – Final steps 157
Exhaust pipe bellows after engine – Installation 156
– Removal 164 – Preparatory steps 152
Exhaust pipework after engine – Removal 153
– Overview 162 Intake housing – Check 155
Exhaust turbocharger
– Cleaning 145 L
– Final steps 150 Leak fuel line
– Installation 147 – Removal 138
– Overview 140 Leak-off fuel line - Overview 137
– Preparatory steps 142 Leak-off fuel pipework
– Removal 143 – Installation 139
Exhaust turbocharger – Check 146
M
F
MTU contact persons 263
Fuel
– HP line O
– Installation 125 Oil pan
– Removal 124 – Check 35
Fuel cooler – Cleaning 34
– Check 133 – Final steps 37
– Final steps 136 – Installation 36
– Preparatory steps 130 – Preparatory steps 32
– Removal 131 – Removal 33
Fuel pipework Overview
– Installation – Conrod 51
– From fuel delivery pump to fuel filter 128 – Piston 51
– Leak-off fuel
– Installation 139 P
Fuel pipework from delivery pump to fuel filter Piston
– Removal 127 – Assembly 74
Fuel pipework from fuel delivery pump to fuel filter – – Check 60
Overview 126 – Cleaning 59
– Disassembly 57
H – Overview 51
Hotline 263 – Tolerances 62
HP fuel line – Overview 123 Piston and conrod
HP fuel pump – Assembly 74
– Final steps 122 – Final steps 80
HP fuel pump – Preparatory steps 114 – Installation 77
HP fuel system – Removal 55
– Tightening procedure 109 Piston and conrod – Preparatory steps 54
DCL-ID: 0000008118 - 002
HP line Protective cover

– Installation 125 – Installation 50
– Removal 124 – Overview 45
HP pump – Removal 49
– Check 117 Pump
– Installation 118 – Engine coolant
– Overview 113 – Check 184
– Removal 115 – Cleaning 183
– Raw water
– Check 207
282 | Appendix B | MS22008/02E 2015-01

Pushrod T
– Check 92 Thermostat
– Cleaning 91 – Coolant pipework
– Final steps 95 – Check 201
– Installation 93 Tightening specifications
– Overview 88 – Nuts 243
– Preparatory steps 89 – Screws and bolts 243
– Removal 90 – Screws, nuts and bolts 243
Tolerance List
R
– General information 260
Raw water pump
– Check 209 V
– Cleaning 208 Valve drive
– Final steps 211 – Cleaning 99
– Overview 205 – Overview 96
– Preparatory steps 206 – Preparatory steps 97
– Removal 207 – Removal 98
Roller tappet Valve gear
– Check 92 – Check 100
– Cleaning 91 – Final steps 103
– Final steps 95 Vibration damper on PTO, free end
Roller tappets – Overview 38
– Overview 88 – Removal 40
– Preparatory steps 89
– Removal 90 W
Wear Limits List
S
– General information 260
Safety notices, standards 16
Safety regulations
– Auxiliary materials 14
– Environmental protection 14
– Fire prevention 14
– Fluids and lubricants 14
– Important provisions 6
– Maintenance work 11
– Operation 9
– Organizational requirements 8
– Personnel requirements 8
– Repair work 11
– Startup 9
Safety requirements
– Safety notices, standards 16
Sensors
– Final steps 242
– Installation 236
DCL-ID: 0000008118 - 002
– Overview 226
– Removal 232
Sensors, actuators and injectors – Preparatory steps 231
Service partners 263
Settings 18
Spare parts service 263
Starter
– Electric
– Check 178
– Cleaning 177
– Installation 179
– Removal 176
MS22008/02E 2015-01 | Appendix B | 283

8V & 10V QL2 WKSP Manual

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© 2015 Copyright MTU Friedrichshafen GmbH

4.2.4 Protective cover – Overview 45 4.5.10 HP line – Installation 125

MS22008/02E 2015-01 | Table of Contents | 3

4 | Table of Contents | MS22008/02E 2015-01

MS22008/02E 2015-01 | Table of Contents | 5

6 | Safety | MS22008/02E 2015-01

Replacing components with emission labels

MS22008/02E 2015-01 | Safety | 7

Work clothing and personal protective equipment

TIM-ID: 0000040531 - 006

8 | Safety | MS22008/02E 2015-01

Safety regulations during operation

Malfunctions and emergency stop

structed to do so following a written procedure.

Operation of electrical equipment

MS22008/02E 2015-01 | Safety | 9

TIM-ID: 0000040533 - 010

10 | Safety | MS22008/02E 2015-01

Safety regulations during maintenance and repair work

MS22008/02E 2015-01 | Safety | 11

Safety regulations following maintenance and repair work

Hydraulic installation and removal

12 | Safety | MS22008/02E 2015-01

Working with batteries

Working on electrical and electronic assemblies

Working with laser devices

Measuring deviations on components

MS22008/02E 2015-01 | Safety | 13

Environmental protection and disposal

Fluids and lubricants, auxiliary materials

Used oil contains combustion residues that are harmful to health.

14 | Safety | MS22008/02E 2015-01

Acids/alkaline solutions/urea (AdBlue®, DEF)

• Observe the relevant safety data sheet for all materials.

MS22008/02E 2015-01 | Safety | 15

TIM-ID: 0000040578 - 004

16 | Safety | MS22008/02E 2015-01

1 Left engine side (A-side) 3 Right engine side (B-side)

MS22008/02E 2015-01 | General Information | 17

Direction of rotation, viewed on driving end

Valve clearance with engine cold

TIM-ID: 0000002716 - 004

18 | Technical Data | MS22008/02E 2015-01

No. Valve position Crank angle

Cam and valve stroke for camshaft adjustment

MS22008/02E 2015-01 | Technical Data | 19

1 Sealing ring 3 Cylinder liner

TIM-ID: 0000059792 - 001

20 | Task Description | MS22008/02E 2015-01

MS22008/02E 2015-01 | Task Description | 21

Removing carbon scraper ring

Removing cylinder liner

TIM-ID: 0000003320 - 004

22 | Task Description | MS22008/02E 2015-01

MS22008/02E 2015-01 | Task Description | 23

Cylinder liner – Cleaning

TIM-ID: 0000003293 - 009

24 | Task Description | MS22008/02E 2015-01

Cylinder liner – Check

MS22008/02E 2015-01 | Task Description | 25

Cylinder liner 0 154.000 −0.050 −0.025

26 | Task Description | MS22008/02E 2015-01