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MTU_ValueService

Technical Documentation

Diesel Engine
12 V 2000 M84 (Common Rail)
16 V 2000 M84 (Common Rail)
12 V 2000 M94 (Common Rail)
16 V 2000 M94 (Common Rail)

Instructions for Exchange of Assemblies


MS22045/00E
Printed in Germany
© 2010 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the
prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution,
translation, microfilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or
damage during operation.
Subject to alterations and amendments.
Table of Contents 01

1 General Information ............................................................ 05


1.1 Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
1.1.1 Prerequisites for maintenance work and general assembly instructions . . . . . . . 05
1.2 General Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
1.2.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
1.2.2 Personnel and organizational requirements ............................ 08
1.2.3 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . 09
1.2.4 Auxiliary materials, fire prevention and environmental protection . . . . . . . . . . . . . 12
1.2.5 Standards for warning notices in the publication . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.6 General information on the Tolerances and Wear Limits List . . . . . . . . . . . . . . . . 15
1.2.7 Engine side and cylinder designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.8 Tightening specifications for screws, nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.9 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2.10 Conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2.11 Repairing threaded bores with threaded inserts (Heli-Coil) . . . . . . . . . . . . . . . . . 41
1.2.12 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Task Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Crankcase and Externally Mounted Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1.2 Cylinder liner – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.1.3 Cylinder liner – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1.4 Cylinder liner – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.1.5 Cylinder liner – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.1.6 Cylinder liner – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.1.7 Cylinder liner – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1.8 Cylinder liner – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.1.9 Cylinder liner – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1.10 Oil pan – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.1.11 Oil pan – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.1.12 Oil pan – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1.13 Oil pan – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.1.14 Oil pan – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.1.15 Oil pan – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1.16 Crankcase breather – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Crank Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.2.1 Vibration damper on PTO, free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.2.2 Protective cover – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.2.3 Protective cover – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.2.4 Vibration damper on PTO, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.2.5 Vibration damper on PTO, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2.6 Protective cover – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2.7 Piston and conrod – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.2.8 Piston and conrod – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.2.9 Piston and conrod – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.2.10 Piston and conrod – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2.11 Piston – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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2.2.12 Piston – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82


2.2.13 Piston – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.2.14 Conrod – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.2.15 Conrod – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.2.16 Conrod – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.2.17 Piston and conrod – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.2.18 Piston and conrod – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.2.19 Piston and conrod – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.2.20 Conrod bearing shells – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.3 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.3.1 Cylinder head – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.3.2 Cylinder head – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.3.3 Cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.3.4 Cylinder head – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.3.5 Cylinder head – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.3.6 Cylinder head – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.4 Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.4.1 Valve roller tappet, pushrod – Overview ............................... 113
2.4.2 Roller tappet, pushrod – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.4.3 Pushrod – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.4.4 Pushrod – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.4.5 Roller tappet, pushrod – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.4.6 Roller tappet, pushrod – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.4.7 Roller tappets, pushrod – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.4.8 Valve drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.4.9 Valve drive – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.4.10 Valve drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.4.11 Valve gear – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.4.12 Valve drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.4.13 Valve drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.4.14 Valve drive – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.5 High Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.5.1 HP fuel system – Tightening procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.5.2 HP fuel pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.5.3 HP fuel pump – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.5.4 HP fuel pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.5.5 HP fuel pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.5.6 HP fuel pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.5.7 HP pump – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.5.8 HP line – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.5.9 HP line – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.5.10 HP line – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.6 Low Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2.6.1 Fuel pipework from fuel delivery pump to fuel filter – Overview . . . . . . . . . . . . . . 143
2.6.2 Fuel pipework from fuel delivery pump to fuel filter – Removal . . . . . . . . . . . . . . . 147
2.6.3 Fuel pipework from fuel delivery pump to fuel filter – Installation . . . . . . . . . . . . . 148
2.6.4 Fuel cooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.6.5 Fuel cooler – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

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2.6.6 Fuel cooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151


2.6.7 Fuel cooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.6.8 Fuel cooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.6.9 Fuel cooler – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.6.10 Leak-off fuel system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2.6.11 Leak-off fuel system – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.6.12 Leak-off fuel system – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.7 Exhaust Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.7.1 Exhaust turbocharger – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.7.2 Exhaust turbocharger – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.7.3 Exhaust turbocharger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.7.4 Exhaust turbocharger – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.7.5 Exhaust turbocharger – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.7.6 Exhaust turbocharger – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.7.7 Exhaust turbocharger – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.8 Air Intake / Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.8.1 Air supply system to cylinders – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.8.2 Air pipework to cylinders – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.8.3 Air pipework to cylinders – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.9 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.9.1 Carrier housing – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.9.2 Carrier housing – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.9.3 Constant-pressure manifold – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.9.4 Carrier housing – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.9.5 Exhaust flap with actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.9.6 Exhaust flap with actuators – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.9.7 Exhaust flap with actuators – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.9.8 Carrier housing – Cover removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.9.9 Carrier housing – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.10 Starting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.10.1 Electric starter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.10.2 Starter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.10.3 Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.10.4 Starter – Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.10.5 Starter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.11 Lube-Oil System, Lube-Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.11.1 Exhaust turbocharger oil supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.11.2 Exhaust turbocharger oil supply – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.11.3 Exhaust turbocharger oil supply – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.12 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.12.1 Engine coolant pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.12.2 Engine coolant pump – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.12.3 Engine coolant pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.12.4 Engine coolant pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.12.5 Engine coolant pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.12.6 Engine coolant pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.12.7 Engine coolant pump – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

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2.12.8 Coolant cooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200


2.12.9 Coolant cooler – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.12.10 Coolant cooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.12.11 Coolant cooler – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.12.12 Coolant cooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.12.13 Coolant cooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.12.14 Coolant cooler – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.12.15 Coolant pipework with thermostat – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.12.16 Coolant pipework with thermostat – Preparatory steps . . . . . . . . . . . . . . . . . . . . 212
2.12.17 Coolant pipework with thermostat – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.12.18 Coolant pipework with thermostat – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
2.12.19 Coolant pipework with thermostat – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.12.20 Coolant pipework with thermostat – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.12.21 Raw water pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
2.12.22 Raw water pump – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
2.12.23 Raw water pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2.12.24 Raw water pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2.12.25 Raw water pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.12.26 Raw water pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.12.27 Raw water pump – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.12.28 Coolant pipework on raw water pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . 225
2.12.29 Coolant pipework on raw water pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . 226
2.12.30 Coolant pipework on raw water pump – Installation . . . . . . . . . . . . . . . . . . . . . . . 227
2.13 Auxiliary Systems / Supplementary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.13.1 Bilge pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.13.2 Bilge pump – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
2.13.3 Bilge pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2.13.4 Bilge pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.13.5 Bilge pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.13.6 Bilge pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.13.7 Bilge pump – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
2.14 Monitoring, Control and Regulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.14.1 Sensors, actuators and injectors – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.14.2 Sensors, actuators and injectors – Preparatory steps . . . . . . . . . . . . . . . . . . . . . 243
2.14.3 Sensors, actuators and injectors – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
2.14.4 Sensors, actuators and injectors – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3.1 Standard tools – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3.2 Special tools – Overview .................................................. 254
3.3 General workshop equipment – Overview .................................... 283
4 Appendix ..................................................................... 289
4.1 Manufacturer’s documentation ............................................. 289
4.2 MTU Contact/Service Partners ............................................. 290
4.3 Index .................................................................. 291

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General Information 05

1 General Information

1.1 Important Notes

1.1.1 Prerequisites for maintenance work and general


assembly instructions
This maintenance manual is intended for the technical personnel assigned to exchange of assemblies.
Contents: Instructions on exchange of assemblies

Prerequisites for maintenance work


If maintenance work is carried out by the customer, the following needs to be ensured:
• Observance of safety regulations.
• Deployment of trained and qualified personnel.
• Suitable shop equipment and general tools.
• Suitable testing equipment.
• Approved special tools.

General assembly instructions


Always use new sealing and securing elements for assembly.
Components that come into contact with oil, fuel, engine coolant and combustion air must be clean. Prior to assembly,
clean components with “Special cleanness” requirement (e.g. oil and fuel-carrying parts) using suitable cleaning
methods and then check for cleanness. Remove any packaging from components immediately before assembly.
Do not wash elastomer components (e.g. rubber, etc.) using diesel fuel, solvent or cold cleaner.
• Remove any oil or fuel film. Wipe parts down with a dry cloth to clean them.
• Do not paint elastomer components, such as e.g. engine mounts, damping elements, clutches and
V-belts. Only install them after painting the engine or cover them prior to painting.
Radial shaft seals that have been treated with oil by the manufacturer, have a defined moisture expansion on
delivery. Prior to installation, they may only be cleaned using abrasion-proof paper (not washed).
If not otherwise specified, the surfaces of parts that slide on each other should be moistened with SAE 30 engine oil.
If not otherwise specified, O-rings and surfaces (bores or shafts) that slide along them during installation, should be
coated with grease. During the assembly of O-rings with counterrings in coolant pumps, observe the assembly
instructions. After assembling O-rings in the grooves on shafts, push a rounded scriber under the O-ring in
circumferential direction, if the O-ring diameter is large enough. The O-ring may not be damaged.
Prior to assembling shaft seals:
• Coat shaft and sealing lip of shaft seal with grease and coat shaft running surface with
thin-film lubricant or SAE 30 engine oil.
• If no other information is specified on the drawing, coat the outer surface of mounting bores
on metal outer liners with surface sealant. Coat the outer surface of elastomer outer liners
or combined metal/elastomer outer liners with ethanol.

Graphical symbol applies to radial shaft seals and depends on the position. Dimension
TIM ID: 0000020679 – 003

arrow indicates the position of the sealing lip.


Use sealing paste to fix the position of flat gaskets. Apply sealing paste thinly and in the form of dots on the
flat gasket or opposite surface. Flat gaskets should be attached to a component shortly after applying the
sealing paste and the sealing point should then be bolted (at the latest after 20 minutes)

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06 General Information

Prior to installing antifriction bearings, lubricate the bearing seats. Only take bearings out of their
original packaging immediately before installation. Do not remove corrosion inhibitor from bearings
in original packaging. To clean the antifriction bearings, use denatured spirit or acid-free kerosene.
After cleaning, lubricate bearings with SAE 30 engine oil.
• Do not apply assembly forces (axial) over rolling elements and do not knock bearing
rings with hammers (use assembly aids).
• Do not use naked flames to heat inner bearing races!
• The temperature should be between 80°C and 100°C and may not exceed 120°C.
• Freezing as a method for the assembly of anti-friction bearings is not permitted (danger
of cracks, rust formation due to condensate).
Do not lubricate dry bearings with oil.
When installing gears, use SAE 30 engine oil to moisten teeth.
Prior to assembly, mating and contact surfaces of components (e.g. contact surfaces for centering,
flange and sealing faces, joint surfaces of interference fit assembles) must be clean, bright or have
the specified surface protection and also be free of surface irregularities and damage. Remove any
corrosion inhibitor (e.g. oil, grease) from mating and contact surfaces.
After joining components that are chilled with liquid nitrogen, remove any condensate
and preserve with SAE 30 engine oil.
Prior to installation in immersion sleeves, coat the sensor area of measuring sensors with long-life lubricant.
Preassemble line links with cutting ring union in the bench vise and tighten; coat thread with thin-film lubricant first.
If components need to be marked by means of etching, use neutralization agent to remove the marking
solution afterwards. Preserve the relevant areas with SAE 30 engine oil.
The mating/contact surfaces of components used in the hot-component area (e.g. V-belt clamps, bellows,
plug-in pipes), should be coated with assembly paste, if not otherwise specified.
The assembly surfaces of screws, nuts, washer components and parts to be tensioned must be clean,
bright or have surface protection and also be free of surface irregularities and damage. Remove
any corrosion inhibitors (e.g. oil, grease). Prior to assembly according to tightening specifications,
coat threads and screw bearing surfaces with lubricant.
If not otherwise specified, use SAE 30 engine oil as lubricant and in the hot-component area assembly paste.
Screw connections without tightening specification can be tightened freely, i.e. machine-tightening with
screwdriver or hand-tightening with open-end wrench or box wrench. For machine-tightening, take the torque
specification for thread size and property class from the general tightening specifications.
Screw connections with tightening specification:
• Establish the screw connections by hand-tightening with snap wrench or torque indicator wrench. Apply
tightening torque without taking the tolerance specified on the snap wrench into account. If a torque
indicator wrench is used, the torque must be within the tightening torque limit range. Proceed in the same
way for connections protected against torsion. This information also applies to test torques.
• If no tolerance is specified for the tightening torque, the tightening tolerance is +10 % of the specified torque.
• Rotation angle tightening:
The angles of further rotation specified in the torque specification must be established. They may be exceeded
within the specified tolerance range. If no tightening torque is specified, maintain the following tolerances: +5 °
for angle of further rotation below/equal 90 ° +10 ° for angle of further rotation above 90 °. Prior to rotation angle
tightening, apply a color line mark to each screw head to allow the inspection of the correct angle of rotation after
tightening (exception: the color line mark is not required for tightening using self-monitoring NC screwdrivers).
• Elongation tightening:
Tighten according to tightening specification, taking the tightening tolerance into account.
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General Information 07

1.2 General Provisions

1.2.1 General Instructions

General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Non-compliance with the Safety Instructions
Correct use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized engine modifications compromise safety.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis-à-vis the engine manufacturer will be accepted.
Reworking components
During repair or engine overhaul reworking can be carried out in workshops authorized by MTU.
However, no generally valid instructions can be issued for the reworking of components as
the machining tools available on site may differ.
TIM ID: 0000020683 – 001

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08 General Information

1.2.2 Personnel and organizational requirements

Personnel requirements
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).

TIM ID: 0000020689 – 001

MS22045/00E 2010-04 © MTU


General Information 09

1.2.3 Safety precautions when working on the engine

Safety precautions when putting the equipment into operation


Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications.
Before putting the device or the system into operation, always ensure
• that all maintenance and repair work is completed
• that all loose components have been removed from rotating parts
• that nobody is standing in the danger zone of moving engine components.
Safety requirements for operators
Procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must know the consequences of each operation to be carried out.
The operator must carry out the individual operations according to the documentation.
During operation, the display instruments and monitoring units must be permanently observed with regard
to present operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• notify the supervisory personnel in charge
• analyze the message
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Maintenance and repair
Compliance with maintenance and repair specifications is an important safety factor.
Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. Secure
the engine against inadvertent starting. With electric starter, disconnect the battery. With pneumatic starter, close
main shut-off valve of compressed-air system and release pressure from compressed-air supply line. Attach sign
"Do not operate" in operating area or to control equipment. Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Maintenance and repair work must only be carried out by authorized, qualified personnel.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane.
Always support these components in accordance with regulations on suitable frames or stands
before beginning any maintenance or repair work.
Before barring the engine, make sure that nobody is standing in the danger zone. After working on the engine, check
that all guards have been installed and that all tools and loose components have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.
TIM ID: 0000020691 – 003

Always seal connections with caps or covers if a line is removed or opened.


During maintenance and repair work, take care not to damage the fuel lines. To tighten the connections when
installing the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.

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10 General Information

Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. When subjected to fire
or temperatures above 300 °C the material degenerates, giving off hydrogen fluoride gas. Hydrogen fluoride
vapors are released in this case. The resulting acid leads to serious burning if it contacts the skin. Do not touch
elastomeric seals if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of burning!
Note cooling period for components which are heated for installation or removal ⇒ Risk of burning!
Do not touch hot components of the compressor and the exhaust system ⇒ Risk of burning!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of burning!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable binding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Observe special cleanness when conducting maintenance and repair work on the engine plant. After completion
of maintenance and repair work, make sure that no loose objects are in/on the engine plant.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. The welding
current could be induced in the cable harnesses and could possibly damage the electrical plant.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system
to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
TIM ID: 0000020691 – 003

into shaft end until correct sealing is achieved.


During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).

MS22045/00E 2010-04 © MTU


General Information 11

Working on electrical/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.
Prior to working on assemblies, the power of the appropriate areas must be switched off. Any measures
requiring power supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
Always tighten connectors with connector pliers.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
• Laser devices of classes 1, 2 or 3A,
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.
TIM ID: 0000020691 – 003

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12 General Information

1.2.4 Auxiliary materials, fire prevention and environmental protection

Fire prevention
Rectify any fuel or oil leakage immediately; even quantities of oil or fuel on hot parts can cause fires,
so keep the engine clean at all times. Do not leave cloths saturated with fluids or lubricants lying on
or near the engine. Do not store inflammable material near the engine.
Do not carry out welding work on pipes or components containing oil or fuel! Prior to welding,
clean components using a non-inflammable liquid.
When starting the engine with an external power source, connect the ground cable last and remove it first.
In order to avoid sparks in the proximity of the batteries, connect the ground cable of the external power
source to the ground cable of the engine or to the ground clamp on the starter.
Always have adequate extinguishing devices (fire extinguishers) ready and make sure you know how to use them.
Noise
Noise can result in an increased risk of accidents, if it affects the perception of acoustic signals,
shouts of warning or noises indicating danger.
Wear ear protectors at all workplaces with a sound pressure level exceeding 85 dB(A)
(protective cotton pads, plugs or capsules)!
Environmental protection
Modification or removal of mechanical or electronic components or the installation of additional components
as well as the execution of calibration processes that might affect the emission characteristics of the engine
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 MTU or equivalent components.
Noncompliance with these guidelines might represent a violation of the Clean Air Act and could involve
the termination of the operating license by the emission authorities. MTU does not accept any liability for
violations of the emission regulations. MTU will provide assistance and advice if emission-relevant components
are intended to be modified. The MTU Maintenance Schedules ensure the reliability and performance of
MTU engines and must be complied with over the entire life cycle of the engine.
Only fuel of prescribed quality may be used to comply with emission limit values.
In Germany the VAwS (regulation for installations concerning how to handle water-polluting substances)
applies, i.e. work may only be carried out by specialists (such as MTU).
Dispose of used fluids, lubricants and filters in accordance with national regulations.
Auxiliary materials, fluids and lubricants
Only use auxiliary materials, fluids and lubricants that have been checked and approved by MTU.
Store auxiliary materials, fluids and lubricants in suitable containers with appropriate labeling! When
handling fluids, lubricants and other chemical substances, observe the safety regulations that
apply. Caution when handling hot, chilled or aggressive substances. When handling inflammable
substances, avoid contact with easily ignitable sources, do not smoke!
Lead
• When working with lead or pastes containing lead, avoid direct contact, do not inhale lead fumes.
• Avoid the formation of lead dust!
• Switch on extraction fan!
• Clean hands after making contact with lead or lead-containing substances!
Acid and alkaline solutions
• When working with acid and alkaline solutions, wear goggles or face protection
shield, gloves and protective clothing.
• In the case of acid or alkali burns, remove contaminated clothing immediately!
TIM ID: 0000020692 – 002

• Rinse injured body parts thoroughly with water!


• Wash eyes out immediately with eye rinsing bottle or clean tap water!
Paints, enamels and varnishes
• When painting work is carried out in areas without extraction fans, provide for sufficient ventilation.
Make sure that neighboring workplaces are not contaminated!
• No open flames!
• Smoking prohibited!

MS22045/00E 2010-04 © MTU


General Information 13

• Observe the fire prevention regulations!


• Wear protective masks against paint and solvent fumes!
Liquid nitrogen
• Store liquid nitrogen only in small quantities and in containers that comply with regulations (not sealed tightly).
• Do not touch directly (eyes, hands). That would result in frostbite and even the
dying off of affected limbs and organs.
• Wear protective clothing, gloves, closed shoes and goggles!
• Provide for sufficient room ventilation. More than 88% nitrogen in the air will cause suffocation.
• Avoid knocking containers, valves and fittings or workpieces!
Compressed air
Compressed air is air that is overpressured and stored in pressure vessels, from which it is then extracted.
The current air pressure can be read off at the pressure gauges that must be installed on
pressure vessels and compressed-air lines.
When working with compressed air, specific safety precautions must always be observed:
• Monitor the pressure in the compressed-air lines and pressure vessels!
• Devices and apparatus to be connected must be designed to withstand this pressure, or equipped
with pressure reduction and safety valves (adjusted to the permitted level), if the permitted pressure
is lower. Hose couplings and connections must be fastened safely!
• Wear goggles when blowing off components or blowing away swarf!
• The air nozzle is fitted with an appropriate safety screen (e.g. rubber) to protect
(particularly the eyes) from particles in the air.
• Seal off compressed-air lines before disconnecting / replacing a compressed-air device / tool!
• The impermissible use of compressed air, e.g. for extracting inflammable fluids (danger classes
AI, AII and B) from containers will result in the "risk of explosion"!
• Forcing compressed air into thin-walled containers (e.g. sheet metal, plastic, glass) for drying
purposes or to check for leaks will result in the "risk of bursting"!
• Blowing dirt off clothing while still worn is prohibited!
Used oil
Used oil can contain combustion residues harmful to health.
Rub hands with skin protective lotion!
Wash hands after touching used oil!
TIM ID: 0000020692 – 002

MS22045/00E 2010-04 © MTU


14 General Information

1.2.5 Standards for warning notices in the publication


In the event of immediate danger.
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.
Consequences: Slight injury or material damage.
CAUTION • Preventive measures

Note: This Publication contains especially emphasized safety instructions in accordance with the American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:

Warning notices
1. Read and become acquainted with all cautions and symbols before operating or repairing this product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!

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General Information 15

1.2.6 General information on the Tolerances and Wear Limits List


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 dimensional 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 reconditioning of components

Wear limit The wear limits do not denote the max. permissible
wear for correct functioning 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 if its wear limit is exceeded.

Reworking instructions If wear limits are exceeded or values are below


specification, the components concerned must be
reworked as per reworking instructions or replaced.

Deviations from roundness, cylindricity, parallelism and coaxiality must be within wear limits unless
specifically indicated. All dimensions are given in “mm” unless otherwise specified.
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16 General Information

1.2.7 Engine side and cylinder designations


Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).
The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
The numbering of engine components is also from the driving end, starting with No. 1.

1 KGS = Free end 3 KS = Driving end


2 Right side 4 Left side

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General Information 17

1.2.8 Tightening specifications for screws, nuts and bolts

Crank drive
Designation Torque specification Lubricant

Conrod screw
• Nominal length: 67.2 mm to 67.5 mm
• Max. elongation: 68.5 mm

1 Pre-application torque 100 Nm +15 Nm


Sequence:
a Short arm
b Long arm

2 Angle of further rotation 90° +10°


Sequence:
a Short arm
b Long arm

Conrod screws can also be tightened together.

Cylinder head
Designation Torque specification Lubricant

Protective sleeve for injector 45 Nm +5 Nm Engine oil

Screw for cylinder head.


• Nominal length: 209.5 mm to 210.0 mm
• Max. length: 212 mm

Tightening sequence of screws: 1 to 4

Pretightening torque

1st stage 10 Nm

2nd stage 50 Nm

3rd stage 100 Nm

4th stage 200 Nm

Angle of further rotation

1st stage 90° +10°

2nd stage 90° +10°


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18 General Information

Valve gear
Designation Torque specification Lubricant

Nut on adjusting screw for rocker 50 Nm Engine oil

Screw for rocker shaft support

1 Pretightening torque 60 Nm

2 Angle of further rotation 90°

Screw for cylinder head cover 20 Nm

Fuel system – low pressure


Designation Torque specification Lubricant

Fuel priming pump on pump housing 30 Nm +3 Nm Engine oil

Exhaust turbocharger
Designation Torque specification Lubricant

Screws on carrier housing 70 Nm +7 Nm Engine oil

Screw connection on exhaust 35 Nm +4 Nm


turbocharger

Clamp on turbine housing 18 Nm +7 Nm


TIM ID: 0000020527 – 001

Clamp on compressor housing 18 Nm +2 Nm

Clamp on center bearing 5 Nm +1 Nm

Clamp on flap housing 5 Nm +1 Nm

Screw for flange on compressor 21 Nm +2 Nm


housing

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General Information 19

Designation Torque specification Lubricant

Screw on retaining ring 28 Nm +3 Nm

Magnetic nut on turbine wheel Ultra-Therm MTU

1 Pre-application torque 35 Nm +3 Nm
(left-hand thread)

2 Loosening

3 Pre-application torque 15 Nm +1 Nm
(left-hand thread)

4 Angle of further rotation 45° +5°

Charge-air cooling
Designation Torque specification Lubricant

Screw for intercooler on junction 21 Nm Engine oil


block (bottom)

Air intake / air supply


Designation Torque specification Lubricant

Screw for 4/2 directional control valve on 7.6 Nm Engine oil


mounting plate

Exhaust system
Designation Torque specification Lubricant

Screw for intermediate flange on cylinder head 60 Nm +6 Nm Engine oil

Screw for exhaust diffuser 30 Nm +3 Nm

Screw for exhaust manifold 33 Nm +4 Nm Ultra-Therm MTU

Screw for sliding block on exhaust manifold 57 Nm +6 Nm

Starting equipment
Designation Torque specification Lubricant

Terminal 30 28 Nm ±4 Nm
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Terminal 31 M10 16 Nm - 20 Nm

Terminal 45 28 Nm ±4 Nm

Terminal 50 2.4 Nm - 3 Nm

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20 General Information

Cooling system
Designation Torque specification Lubricant

Screw for bearing housing on engine 8.5 Nm Engine oil


coolant pump and raw water pump
bearing housing

Nuts for bearing housing on engine 20.5 Nm


coolant pump and raw water pump
volute

Screw for bearing housing on 41.5 Nm


housing (raw water pump)

Impeller test torque for engine 300 Nm - 400 Nm


coolant pump and raw water pump

Plug screw for impeller (raw water 75 Nm Loctite 638


pump)

Power supply, engine side


Designation Torque specification Lubricant

Nut for belt pulley on AC generator 140 Nm +20 Nm Engine oil

Pin for lever for clamping jig 100 Nm +10 Nm Assembly paste MTH 5109

Mounting / support
Designation Torque specification Lubricant

Engine mounting

Upper nut on threaded rod 350 Nm +35 Nm Engine oil

Lower nut on threaded rod 400 Nm

Monitoring, control and regulating equipment


Designation Torque specification Lubricant

Temperature sensor PT 1000 for 15 Nm to 30 Nm Engine oil


• charge air
• engine coolant
• lube oil
• fuel
• intake air
TIM ID: 0000020527 – 001

Temperature sensor PT 100 • Threaded connector: 40 Nm


• exhaust gas collective ±5 Nm
temperature, A-side • Union nut: 35 Nm ±5 Nm
• exhaust gas collective
temperature, B-side

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General Information 21

Designation Torque specification Lubricant

Pressure sensor for 20 Nm to 45 Nm


• lube oil
• charge air

Fuel pressure sensor after filter 20 Nm ±3 Nm

Pressure sensor 20 Nm to 45 Nm
• engine coolant pressure
• raw water pressure
• refill oil pressure

Differential pressure monitor for lube 27 Nm


oil

filling level probe max. 30 Nm


• engine coolant level
• Leak fuel level

High fuel pressure 30 Nm +5 Nm

Tightening specifications for setscrew and stud connections as per MTN 5008 standard
This standard applies to setscrews not subjected to dynamic loads as per MMN 384, DIN 912,
EN 24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and for
studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and to the corresponding nuts.
It does not apply to heat-resistant screws in the hot-component area.
Tightening torques MA are specified for screws of strength class 8.8 (surface condition bright, phosphatized
or galvanically zinc-plated) and 10.9 (surface condition bright or phosphatized).
The table values are based on a friction coefficient of µtotal= 0.125. Precondition: prior to assembly, threads
and screw-mating faces of screws and nuts need to be lubricated with engine oil.
When tightening by hand, due to unavoidable deviations of the tightening torques from the
table value during tightening, e.g. due to reading inaccuracies and overtightening, an assembly
tolerance of +10 % of the table values is permitted.
For machine-tightening, the permissible assembly tolerance is +15 %.

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

M10 x 1.25 45 63 42 60

M12 74 100 70 92

M12 x 1.25 80 110 75 105


TIM ID: 0000020527 – 001

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

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22 General Information

Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)

M16 x 1.5 190 270 180 255

M18 250 350 240 330

M18 x 1.5 280 400 270 380

M20 350 500 330 475

M2 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 specifications for stress bolt connections as per MTN 5007 standard
This standard applies to stress bolt connections subjected to static and dynamic loads of
strength class 10.9 and for the corresponding nuts.
Shaft and transition dimensions as per MMN 209 and material and production as per MMN 389
(surface condition bright or phosphatized).
The table values are based on a friction coefficient of µges.= 0.125. Precondition: prior to assembly, threads
and screw-mating faces of screws and nuts need to be lubricated with engine oil.
For unavoidable deviations of the tightening torques from the table value during tightening, e.g. due to reading
inaccuracies and overtightening, an assembly tolerance of +10 % of the table values is permitted.
The table values are for tightening by hand with a torque wrench.

Thread not protected from torsion MA(Nm) protected from torsion MA(Nm)

M6 9 12

M8 21 28

M8 x 1 24 30

M10 42 55
TIM ID: 0000020527 – 001

M10 x 1.25 46 60

M12 75 93

M12 x 1.5 78 99

M14 120 150

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General Information 23

Thread not protected from torsion MA(Nm) protected from torsion MA(Nm)

M14 x 1.5 135 160

M16 180 225

M16 x 1.5 200 245

M18 250 315

M18 x 1.5 300 360

M20 350 450

M20 x 1.5 430 495

M22 500 620

M22 x 1.5 560 675

M24 640 790

M24 x 2 700 850

M27 900 1170

M27 x 2 1000 1230

M30 1250 1575

*protect screw neck from twisting loads during tightening.


MA=tightening torques

Tightening specifications for plug screws as per MTN 5183-1 standard


This standard applies to plug screws as per DIN 908, DIN 910 and DIN 7604 with screwed ends
DIN 3852 shape A (sealed with sealing ring DIN 7603-Cu).
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24 General Information

Tightening torques MA are specified for plug screws made of steel (St) with surface protection: phosphatized and
oiled or galvanically zinc-plated. Threads and screw-mating surfaces under head need to be lubricated with engine
oil prior to assembly. For unavoidable deviations of the tightening torques from the table value during tightening, e.g.
due to reading inaccuracies and overtightening, an assembly tolerance of +10 % of the table values is permitted.
Tightening torques for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed end)

inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)

M10 x 1 15 15

M12 x 1.5 35 25
TIM ID: 0000020527 – 001

M14 x 1.5 35 25

M16 x 1.5 40 30

M18 x 1.5 50 35

M20 x 1.5 55 45

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General Information 25

inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)

M22 x 1.5 60 50

M24 x 1.5 70 60

M26 x 1.5 80 70

M27 x 2 80 70

M30 x 1.5 100 90

M30 x 2 95 85

M33 x 2 120 110

M36 x 1.5 130 115

M38 x 1.5 140 120

M42 x 1.5 150 130

M45 x 1.5 160 140

M48 x 1.5 170 145

M52 x 1.5 180 150

M56 x 2 190 160

M64 x 2 205 175

MA=tightening torques

Tightening specifications for plug screws as per DIN 7604C (with long screwed end)
inserted in
Thread Steel/gray cast iron MA AI 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


TIM ID: 0000020527 – 001

MA=tightening torques

Tightening specifications for banjo screws as per MTN 5183-2 standard


This standard applies to banjo screws as per MMN 223 and N 15011, sealed with sealing ring DIN 7603-Cu.

MS22045/00E 2010-04 © MTU


26 General Information

Tightening torques MA are specified for banjo screws made of steel (St) with surface protection: phosphatized
and oiled or galvanically zinc-plated and of copper/aluminum alloys.
Prior to assembly, threads and screw-mating surfaces under head need to be lubricated with engine oil.
For unavoidable deviations of the tightening torques from the table value during tightening, e.g. due to reading
inaccuracies and overtightening, an assembly tolerance of +10 % of the table values is permitted.

Tightening specifications for banjo screws made of steel


inserted in steel/gray cast iron/AI alloy MA
Thread
(Nm)

M8 x 1 10
TIM ID: 0000020527 – 001

M10 x 1 15

M12 x 1.5 20

M14 x 1.5 25

M16 x 1.5 25

M18 x 1.5 30

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General Information 27

inserted in steel/gray cast iron/AI alloy MA


Thread
(Nm)

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

MA=tightening torques

Tightening specifications for banjo screws made of copper/aluminum alloys


inserted in steel/gray cast iron/AI alloy MA
Thread
(Nm)

M10 x 1 15

M16 x 1.5 30

MA=tightening torques

Tightening specifications for male connectors as per MTN 5183-3 standard


This standard applies to male connectors, DIN 2353 L series, with screwed end, DIN 3852
shape A (sealed with sealing ring DIN 7603-Cu).

Tightening torques MA are specified for male connectors made of steel (St) with surface protection:
phosphatized and oiled or galvanically zinc-plated.
TIM ID: 0000020527 – 001

Prior to assembly, threads and screw-mating surfaces under head need to be lubricated with engine oil.

MS22045/00E 2010-04 © MTU


28 General Information

For unavoidable deviations of the tightening torques from the table value during tightening, e.g. due to reading
inaccuracies and overtightening, an assembly tolerance of +10 % of the table values is permitted.

inserted in steel/gray cast iron MA


Thread
(Nm)

M10 x 1 10

M12 x 1.5 20

M14 x 1.5 40

M16 x 1.5 50

M18 x 1.5 60

M22 x 1.5 70

M26 x 1.5 100

M32 x 2 160

M42 x 2 260

M48 x 2 320

MA=tightening torques

Tightening specifications for union nuts as per DIN 3859-2

1 Union nut
2 Junction block
3 O-ring
4 Linear ball bearing
Union nut: On installing the linear ball bearing, after tightening the union nut firmly by hand (noticeable
increase in force), it should be tightened another 1/4 turn (90°) past this point.
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General Information 29

Tightening specifications for screwed ends with O-ring as per ISO 6149-2

Thread Torque (Nm) + 10%

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 1.51) 80

M22 x 1.5 100

M27 x 2 170

M33 x 2 310

M42 x 2 330

M48 x 2 420

M60 x 2 500
1)Only for locks for installation spaces for screw-in valves (see ISO 7789)
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30 General Information

Tightening specifications for screwed ends with O-ring as per ISO 6149-3

Thread Torque (Nm) + 10%

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

M60 x 2 315 TIM ID: 0000020527 – 001

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General Information 31

Tightening specifications for plug screws as per MTN 5183-6

inserted in
Thread Steel/gray cast iron MA AI alloy MA
(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 1) 200+ 20
1) Value is still to be determined

Assembly instructions and tightening specifications for hose fittings with union nut
To connect hose fittings to sealing heads and the corresponding adapters, assembly must be carried out as follows,
as opposed to the instructions for pipe unions (these instructions do not apply to ORFS fittings).
TIM ID: 0000020527 – 001

Hose fitting, metallic sealing with union nut: tighten union nut by hand, then use wrench
to tighten by a maximum of a 1/4 turn.
Hose fitting with O-ring and union nut: tighten union nut by hand, then use wrench
to tighten by a maximum of a 1/2 turn.

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32 General Information

Prior to tightening the union nuts, the hose lines need to be aligned accordingly.

Sealing head/sealing cone with metric union nut

Metric thread Pipe A.D Torque (Nm)

M12 x 1.5 6 20

M14 x 1.5 8 38

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
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General Information 33

Sealing head with BSP union nut

BSPP thread Torque (Nm)

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

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

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


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2–12 –24 200+ 25

2–1/2–20 –32 460+ 30

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34 General Information

1.2.9 Settings

Firing order for 2000CR engines


8V A1-B4-A4-A2-B3-A3-B2-B1

10V A1-B4-A4-B3-A3-B2-A2-B5-A5-B1

12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1

16V 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 left

Camshaft right

High-pressure fuel pump left

Oil pump left

Engine coolant pump left

Raw water pump left

Battery-charging generator left

Valve clearance with cold engine


Inlet 0.30 mm

Exhaust 0.40 mm

Valve timing with valve clearance adjusted (viewed on free end)

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General Information 35

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 Overlap 83.6 °

Start of delivery Performance-map controlled

I Top dead center (TDC)

II Bottom dead center (BDC)

Cam and valve lift for camshaft adjustment


Inlet Exhaust

Cam lift at TDC 1.60 mm 1.60 mm

Valve lift at TDC (zero valve 2.20 mm 2.20 mm


clearance)
TIM ID: 0000020690 – 001

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36 General Information

1.2.10 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
Unit A multiplied by factor = Unit B

in2 645.16 = mm2

ft2 0.0929 = m2

yd2 0.8361 = m2

stat. mile2 2.5889 = km2

Unit B multiplied by factor Unit A


mm2 0.00155 = in2
m2 10.7643 = ft2
m2 1.1960 = yd2

km2 0.3863 stat. mile2


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General Information 37

Volume
Unit A multiplied by factor = Unit B

in3 16387 = mm3

ft3 0.02832 = m3

yd3 0.7646 = m3

gallon (US) 3.787 = dm3

gallon (Brit.) 4.546 = dm3

Unit B multiplied by factor = Unit A


cm3 0.06102 = in3
m3 35.31 = ft3

dm3 0.2642 = gallon (US)

dm3 0.22 = gallon (Brit.)

Speed
Unit A multiplied by factor = Unit B

ft/s 0.3048 = m/s

stat. mile/h (mph) 1.609 = km/h

knot (Brit.) 1.852 = km/h

Unit B multiplied by factor = Unit B

m/s 3.281 = ft/s

km/h 0.6215 = stat. mile/h (mph)

km/h 0.54 = knot (Brit.)

Mass
Unit A multiplied by factor = Unit B

lb 0.4536 = kg
oz 28.35 =g

ton =t
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1.016

Unit B multiplied by factor = Unit A


g 0.03527 = oz

kg 2.205 = lb

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38 General Information

Unit B multiplied by factor = Unit A

t 0.9843 = ton

Force
Unit A multiplied by factor = Unit B

lb 0.4536 = kp

lb 4.4483 =N

Unit B multiplied by factor = Unit A

kp 2.205 = lb

N 0.101972 = kp

kp 9.80665 =N

Density
Unit A multiplied by factor = Unit B

lb s2/ft4 515.4 = kg/m3

Unit B multiplied by factor = Unit A

kg/m3 0.00194 = lb s2/ft4

Torque
Unit A multiplied by factor = Unit B

ft lb 1.3563 = Nm

Unit B multiplied by factor = Unit A

Nm 0.7373 = ft lb

Pressure
Unit A multiplied by factor = Unit B
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lb/sq in (psi) 703.1 = kp/m2 (mm WS)

lb/sq in (psi) 0.06895 = bar

lb/sq ft 47.883 = Pa

in QS 0.03386 = bar

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General Information 39

Unit A multiplied by factor = Unit B

in QS 345.3 = kp/m2

Unit B multiplied by factor = Unit A

atm 760 = mm QS
atm 1.0133 = bar
atm 10332 = kp/m2 (mm WS)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lb/sq in

bar 14.503 = lb/sq in

Mass moment, 2nd grade


Unit A multiplied by factor = Unit B

ft lb s2 1.3563 = kg m2

Unit B multiplied by factor = Unit A

kg m2 0.7373 = ft lb s2

Energy
Unit A multiplied by factor = Unit B

ft lb 1.356 =J

kcal 4186.8 =J

BTU 1055 =J

CHU 1899 =J

Unit B multiplied by factor = Unit A

J 0.7376 = ft lb

J 0.0002389 = kcal

J 0.0009479 = BTU

J 0.00052656 = CHU
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40 General Information

Power
Unit A multiplied by factor = Unit B

HP (horse power) 0.7355 = kW

HP 0.7457 = kW

BTU/s 1.055 = kW

kcal/h 1.163 =W

HP 550 = ft lb/s

Unit B multiplied by factor = Unit A

kW 1.36 = PS

kW 1.341 = HP

kW 0.9479 = BTU/s

W 0.8598 = kcal/h

ft lb/s 0.0018 = HP

Temperature
Celsius Kelvin Fahrenheit Réaumur

x °C = x + 273.15 K = 9/5x + 32 °F = (4/5x) °R

xK = x − 273. 15 °C = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15) °R

x°F = 5/9(x − 32) °C = 5/9(x − 32) + 273.15 = 4/9(x − 32) °R


K

x°R = 5/4x °C = (5/4x) + 273.15 K = (9/4x) + 32 °F

Fuel consumption
Unit A multiplied by factor = Unit B

mile/gal (US) 0.4251 = km/l

gal/mile (US) 2.3527 = l/km

Unit B multiplied by factor = Unit A

km/l 2.3527 = mile/gal (US)


TIM ID: 0000020684 – 002

l/km 0.4251 = gal/mile (US)

MS22045/00E 2010-04 © MTU


General Information 41

1.2.11 Repairing threaded bores with threaded inserts (Heli-Coil)


Data

Thread Core hole diameter (max./min.) Twist drill diameter

M6 6.31/6.04 6.1–6.2–6.25

M8 8.35/8.04 8.1–8.2–8.25–8.3

M8x1 8.32/8.04 8.1–8.2–8.25–8.3

M 10 10.4/10.05 10.25

M 12 12.5/12.05 12.25–12.5

M 12 x 1.5 12.43/12.05 12.25

M 14 14.53/14.06 14.25–14.5

M 14 x 1.5 14.43/14.05 14.25

M 15 x 2 15.3/15.2 15.25

M 16 16.53/16.06 16.25–16.5

M 16 x 1.5 16.43/16.05 16.25

M 24 x 1.5 24.43/24.05 24.25

M 26 x 1.5 26.43/26.05 26.25

M 30 x 1.5 30.43/30.05 30.25

1. Remove thread insert with suitable removal tool


from bore (left).
2. Bore core hole with suitable twist drill - see table.
3. Cut thread with special tap.
4. Do not countersink hole!
5. Mount spindle (2) and snout (1) corresponding with
thread.
6. Groove on snout must be aligned with markings on
installation tool (arrows).

1 Snout
2 Spindle
TIM ID: 0000020687 – 002

MS22045/00E 2010-04 © MTU


42 General Information

7. Insert thread insert (2) into spindle (1) in installation


tool.
8. Driver journal of the thread insert must be in groove
(arrow).

1 Spindle
2 Thread insert

9. Use spindle to turn thread insert through snout until


it is flush at front (arrow).

10. Mount installation tool on threaded hole and install


thread insert without applying pressure to spindle.
11. Insert thread insert 1/2 to 1 1/2 turns deeper than
the threaded hole surface.
12. Use screw shearer to remove driver journals up
to M 14. With threaded inserts over M14, use
pointed pliers to move driver journal up and down
and remove.
TIM ID: 0000020687 – 002

MS22045/00E 2010-04 © MTU


General Information 43

1.2.12 Abbreviations

Abbrevia- Meaning Explanation


tion

AL Alarm

ANSI American National Standards Institute

ATL Abgasturbolader Exhaust Turbocharger

BDM Backup Data Module

BR Baureihe Engine Series

CAN Controller Area Network

CPP Controllable Pitch Propeller

CR Common Rail

DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards (DIN = "Deutsche
Industrie-Norm")

DIS Display Unit

DL Default Lost Alarm: CAN bus failure

ECS Engine Control System

ECU Engine Control Unit Engine governor

EDM Engine Data Module

EMU Engine Monitoring Unit

FLS Fluids and Lubricants Specifications MTU publication no. A01061/..

FPP Fixed Pitch Propeller

GCU Gear Control Unit

GMU Gear Monitoring Unit

HI High Alarm: Measured value exceeds 1st maximum limit

HIHI High High Alarm: Measured value exceeds 2nd maximum limit

HT High Temperature

ICFN ISO - Continuous rating - Fuel stop power Power specifications acc. to DIN-ISO 3046-7
- Net

IDM Interface Data Module

IMO International Maritime Organization


TIM ID: 0000020681 – 001

ISO International Organization for


Standardization

KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204

KS Kraftseite Engine driving end in accordance with DIN ISO 1204

MS22045/00E 2010-04 © MTU


44 General Information

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 is lower than 1st minimum limit

LOLO Low Low Alarm: Measured value is lower than 2nd minimum limit

LOP Local Operating Panel

LOS Local Operating Station

MCS Monitoring and Control System

MG Message

MPU Microprocessor Unit, Microprocessing


Unit

OT Oberer Totpunkt Top dead center (TDC()

P-xyz Pressure-xyz Pressure measuring point xyz

PAN Panel

PCU Propeller Control Unit

PIM Peripheral Interface Module

UPS Unit Pump System

RCS Remote Control System

RL Redundancy Lost Alarm: Redundant CAN bus failure

SAE Society of Automotive Engineers U.S. standardization organization

SD Sensor Defect Alarm: Sensor failure

SDAF Shut Down Air Flaps

SPC Spare Parts Catalog

SS Safety System Alarm initiated by safety system

SSK Schnellschlussklappe(n) Emergency Air Shutoff Flap(s)

T-xyz Temperature-xyz Temperature measuring point xyz

TC Tools Catalog
TIM ID: 0000020681 – 001

TD Transmitter Deviation Alarm: Deviation in transmitter values

UT Unterer Totpunkt Bottom dead center (BDC)

VS Voith Schneider Voith Schneider drive

WJ Water Jet Waterjet drive

MS22045/00E 2010-04 © MTU


Task Descriptions 45

2 Task Descriptions

2.1 Crankcase and Externally Mounted Components

2.1.1 Engine layout


Illustrations are examples only
Analogously also applies to 8/12/16 V 2000CR

010 Crankcase and externally mounted 100 Exhaust turbocharger 250 PTO systems, driving end and
components (→ Page 46) (→ Page 158) free end (coupling)
(→ Page 56) 110 Intercooler 360 Auxiliary systems and
020 Gear train 120 Air intake/air supply supplementary equipment (not
030 Crank drive (→ Page 74) 140 Exhaust system shown) (→ Page 228)
040 Cylinder head (→ Page 105) 170 Starting equipment (→ Page 182) 500 Monitoring and control devices,
050 Valve drive (→ Page 113) 180 Lube oil system / lube oil circuit general electric equipment
(→ Page 120) 200 Coolant system (→ Page 192) (→ Page 238)
070 HP fuel system (→ Page 132) 210 Power supply
080 LP fuel system (→ Page 149) 230 Mounting/support
TIM ID: 0000020680 – 001

MS22045/00E 2010-04 © MTU


46 Task Descriptions

2.1.2 Cylinder liner – Overview

1 Sealing ring 3 Cylinder liner


2 Sealing ring 4 Scraper ring

TIM ID: 0000020528 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 47

2.1.3 Cylinder liner – Preparatory steps

Preconditions
• Engine shut down and starting disabled.
Preparatory steps
1. Remove cylinder head (→ Page 108).
2. Remove piston and conrod (→ Page 78).
TIM ID: 0000020530 – 005

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48 Task Descriptions

2.1.4 Cylinder liner – Removal

Special tools

Designation / Use Part No. Qty.


Removal tool for liner F6783773 1

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Removing carbon scraper ring


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

Cylinder liner – Removal


1. Mark installation position of cylinder liner to
crankcase with a marking pen (arrow).

2. Insert removal tool (1) in cylinder liner (2).


Note: Do not damage oil spray nozzle.

3. Set extraction plate at the lower collar of the


cylinder liner (2).
4. Engage captive washer (4) on threaded rod.
5. Turn nut (3) on removal tool (1) until cylinder
liner (2) becomes loose on crankcase bore.
6. Take off removal tool (1).
7. Extract cylinder liner (2) from crankcase.
TIM ID: 0000020533 – 001

8. Remove sealing rings from cylinder liner (2).

MS22045/00E 2010-04 © MTU


Task Descriptions 49

2.1.5 Cylinder liner – Cleaning

Material

Designation / Use Part No. Qty.


Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1

Cleaner is extremely caustic.


Risk of injury and suffocation!
WARNING • 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.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Cylinder liner – Cleaning


1. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Blow out all parts with compressed air.
TIM ID: 0000020534 – 001

MS22045/00E 2010-04 © MTU


50 Task Descriptions

2.1.6 Cylinder liner – Check

Special tools

Designation / Use Part No. Qty.


Bore gauge, 160-280 mm Y20091483 1
Dial gauge Y20011268 1
C-frame micrometer, 150-175 mm Y20000326 1

Spare parts

Designation / Use Part No. Qty.


Cylinder liner
Carbon scraper ring

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Cylinder liner – Check

Item Findings Task

Check outer wall for corrosive Corrosive pitting visible. Replace


pitting.

Check sealing and mating faces for • Wear • Recondition: smooth with
wear and damage. • Damage oilstone.
visible • Replace

Check floating mount of the carbon Signs of jamming • Measure cylinder liner.
scraper ring in the cylinder liner. • Replace carbon scraper ring.

Measure cylinder liner bore with Values exceeded. Replace


bore gauge and dial gauge.
Measurement plane and values
(→ Page 51)

TIM ID: 0000020831 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 51

2.1.7 Cylinder liner – Tolerances

No. Designation Stage Toler- Deviation Clearance Interference Wear


anced limit
size
lower upper min. max. min. max.
Basic
size

1 Crankcase bore 0 157.500 0 +0.040 0.005 0.070


H7
- upper fit
1 158.000
H7

Cylinder liner 0 157.500 −0.030 −0.005


- upper fit
1 158.000

2 Crankcase bore 0 154.000 0 +0.040 0.025 0.090


H7
- lower fit
1 154.500
H7

Cylinder liner 0 154.000 −0.050 −0.025


- lower fit
TIM ID: 0000020832 – 001

1 154.500

3 Crankcase bore 170.500 −0.100 +0.300 0.300 0.900

Seal 170.000 −0.100 +0.100


outer Ø

MS22045/00E 2010-04 © MTU


52 Task Descriptions

No. Designation Stage Toler- Deviation Clearance Interference Wear


anced limit
size
lower upper min. max. min. max.
Basic
size

4 Liner bore 139.000 0 +0.040 0.014 0.094


H7

Carbon scraper 139.000 −0.054 −0.014


ring outer Ø g7

5 Carbon scraper 134.400 0 +0.063


ring bore H8

6 Cylinder liner 0 10.850 −0.020 0


Collar thickness

7 Sealing ring 0.150 −0.010 +0.010

8 Cylinder liner protrusion: 10.440 to 10.540

9 0 to 0.03 > actual dimension inner Ø

10 Plane of 30.000
measurement

Reconditioning instructions:
Re 1 and 2:If there is cavitation on the upper and/or lower fit of the crankcase bore:
Introduce next repair stage and install cylinder liner of corresponding stage.
To be carried out only in workshops authorized by MTU.
Re 4 and 5:Check scraper ring OD and ID when fitted.
Re A Cylinder liner without groove: stage 0Cylinder liner with groove: stage 1

TIM ID: 0000020832 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 53

2.1.8 Cylinder liner – Installation

Special tools

Designation / Use Part No. Qty.


Press-in device for cylinder liner F6783388 1
Safety rail F6555715 2

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


Sealing rings
Carbon scraper ring

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Cylinder liner – Installation


1. Wipe lower fit and chamfer of cylinder liner (4) with
chamois leather.
2. Coat upper and lower fits with grease.
3. Coat sealing rings (1) with grease.
Note: Make sure that flat side is resting against
cylinder liner (4) and curved side against
crankcase (3).

4. Fit sealing rings (1) in grooves on cylinder liner (4).


5. Fix sealing ring (2) with grease on crankcase (3).
TIM ID: 0000020536 – 002

6. Insert cylinder liner (4) in crankcase (3).

MS22045/00E 2010-04 © MTU


54 Task Descriptions

7. Install press-in device (3) on crankcase (1).


8. Press cylinder liner (2) into crankcase bore.
9. Remove press-in device (3).

Measuring cylinder liner ID


1. Adjust bore gauge and dial gauge with micrometer or gauge ring to basic size for cylinder liner. Value and
measurement planes (→ Page 51).
2. Measure cylinder liner bore with bore gauge.
3. Record measured values in data sheet.
4. If out-of-round is measured:
4.1. Remove cylinder liner.
4.2. Remeasure cylinder liner bore and outer diameter.
4.3. Check correct fit of sealing rings.

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 max. 0.02 mm. Protrusion (→ Page 51).
3. If the test values deviate, remove cylinder liner and check cause.

Installing carbon scraper ring


Note: Fit carbon scraper ring only after piston has been installed (→ Page 100).

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: 0000020536 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 55

2.1.9 Cylinder liner – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 47).
2. Enable engine start.
TIM ID: 0000020532 – 003

MS22045/00E 2010-04 © MTU


56 Task Descriptions

2.1.10 Oil pan – Overview

5 Oil pan 40 Screw 75 Washer


10 Gasket 45 Screw 80 Flange
25 Screw 50 Washer 85 O-ring
30 Washer 60 Screw 90 Screw
35 Screw 65 Sealing ring

TIM ID: 0000020539 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 57

2.1.11 Oil pan – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Observe safety regulations.
2. Drain or extract engine oil (→ Operating Instructions).
TIM ID: 0000020537 – 002

MS22045/00E 2010-04 © MTU


58 Task Descriptions

2.1.12 Oil pan – Removal

Special tools

Designation / Use Part No. Qty.


Lowering device F6784104 3

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Lowering oil pan


Note: With the engine being 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 (3) for oil pan (4).
3. Lower oil pan (4) by turning threaded rod (2) of
lowering devices (1) evenly.

TIM ID: 0000020833 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 59

2.1.13 Oil pan – Check

Spare parts

Designation / Use Part No. Qty.


Oil pan
Screw

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Oil pan – Check

Item Findings Task

Check mating face of oil pan on Unevenness exceeding 0.3 mm on Recondition mating face.
crankcase for surface irregularities. 8, 10, 12V engines

Unevenness exceeding 0.5 mm on


16V engines

Check sealing faces. Damaged • Recondition


• Replace

Check threaded bores for ease of Sluggish Replace thread inserts.


movement.
TIM ID: 0000020834 – 001

MS22045/00E 2010-04 © MTU


60 Task Descriptions

2.1.14 Oil pan – Installation

Material

Designation / Use Part No. Qty.


Silicone rubber (Loctite 5970) 50773 1
Pipe thread sealant (Loctite 586) 40033 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


Gasket
Screw
Union
Sealing ring

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

TIM ID: 0000020835 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 61

Installing oil pan in lowered condition


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 face of oil pan.
4. Turn the threaded rods (2) of the lowering
devices (1) evenly to attach oil pan (3) on
crankcase (4).
5. Insert screws and washers for oil pan (3) and
tighten evenly.
6. Remove lowering devices (1), insert residual
screws and washers and tighten.
TIM ID: 0000020835 – 001

MS22045/00E 2010-04 © MTU


62 Task Descriptions

2.1.15 Oil pan – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 57).
2. Fill up with engine oil (→ Operating Instructions).
3. Fill up with engine coolant (→ Operating Instructions).
4. Enable engine start.

TIM ID: 0000020538 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 63

2.1.16 Crankcase breather – Removal

Preconditions
• Preparatory steps have been completed.
Removing oil lines and oil separator
1. Take pictures prior to removal or mark installed components and lines.
2. Remove oil lines and oil separator as per overview drawings.
3. Seal openings with suitable covers.
4. Protect oil separator from damage.
TIM ID: 0000039489 – 001

MS22045/00E 2010-04 © MTU


64 Task Descriptions

2.2 Crank Drive

2.2.1 Vibration damper on PTO, free end – Overview

1 Belt drive 3 Vibration damper 5 Shaft seal


2 Crankshaft 4 Gear case

TIM ID: 0000020852 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 65

Layout of installation/removal tool for vibration damper

1 Connection for hydraulic nut 5 Pressure sleeve B Push-on dimension: 94.5 mm


2 Feed shaft 6 Connection for vibration damper ±0.05 mm
3 Nut 7 Crankshaft a Push-on travel: 12 mm - 14.6 mm
4 Hydraulic nut A Reference dimension = 348 mm
TIM ID: 0000020852 – 001

MS22045/00E 2010-04 © MTU


66 Task Descriptions

2.2.2 Protective cover – Overview

400 Spacer pin 1300 Spacer pin 2300 Washer


700 Threaded bushing 1400 Holder 2700 Screw
900 Spacer pin 1700 Screw 2800 Washer
1000 Spacer pin 1800 Washer
1200 Spacer pin 2200 Screw

TIM ID: 0000020869 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 67

2.2.3 Protective cover – Removal


Protective cover – Removal
1. Remove protective cover as shown in overview drawing (→ Page 66).
2. Seal openings with suitable covers.
TIM ID: 0000020870 – 001

MS22045/00E 2010-04 © MTU


68 Task Descriptions

2.2.4 Vibration damper on PTO, free end – Removal

Special tools

Designation / Use Part No. Qty.


Installation/removal tool F0140560 1
Lifting gear T80091925 1
Hand pump set B80146887 1
Hand pump set B80146893 1
Protective sleeve F6780523 1

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Equipment can drop off.


Liquid is highly pressurized.
WARNING Risk of injury, knocks or crushing!
• Only use specified and tested equipment.
• Do not enter the danger zone.
• Wear protective clothing, gloves, and goggles / safety mask.

Vibration damper – Removal


1. Remove flange for barring gear.
2. Remove grub screw from expansion bore in
vibration damper.
3. Screw puller spindle (5) into crankshaft.
4. Check reference dimension “A” of feed shaft
(→ Page 64).
5. Slide pressure sleeve (4) and hydraulic nut (2) on
to puller spindle.
6. Screw on nut (1).
7. Screw adapter (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. Turn nut back past push-on dimension value. For
push-on dimension “a”, see on vibration damper
TIM ID: 0000020853 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 69

11. Fill hand pumps (1) and (2) with SAE 10 engine oil.
12. Vent hand pump (1) and line system, 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) and bring to contact point 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 with holding times of approx. 2 minutes,
until the vibration damper is released from the
crankshaft. In doing so, do not exceed the
maximum expansion pressure pmax.
19. Continue to use hand pump (1) to keep falling
expansion pressure at constant level.
20. Monitor pressure p2 in hydraulic nut. The loosening
of the vibration damper from the taper seat is
indicated by a rise in pressure p2 .
21. Gradually drain oil from hydraulic nut, while at
the same time continuing to pump with the hand
pump (1).
22. Relieve hand pumps (1) and (2).
23. Remove high-pressure line and adapter.
24. Remove nut, hydraulic nut and pressure sleeve.
25. Install lifting gear.
26. Remove vibration damper from crankshaft.
27. Seal openings with suitable covers.
TIM ID: 0000020853 – 002

MS22045/00E 2010-04 © MTU


70 Task Descriptions

2.2.5 Vibration damper on PTO, free end – Installation

Special tools

Designation / Use Part No. Qty.


Installation/removal tool F0140560 1
Lifting gear T80091925 1
Hand pump set B80146887 1
Hand pump set B80146893 1
Protective sleeve F6780523 1

Material

Designation / Use Part No. Qty.


Engine oil
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1

Spare parts

Designation / Use Part No. Qty.


O-ring

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Equipment can drop off.


Liquid is highly pressurized.
WARNING Risk of injury, knocks or crushing!
• Only use specified and tested equipment.
• Do not enter the danger zone.
• Wear protective clothing, gloves, and goggles / safety mask.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
TIM ID: 0000020854 – 002

CAUTION
• Ensure correct installation position of components.

MS22045/00E 2010-04 © MTU


Task Descriptions 71

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 bearing and
vibration damper with engine oil.
4. Coat sealing lip on shaft seal with grease.
5. Slide vibration damper on to crankshaft taper.
6. To determine the push-on travel, measure distance
from crankshaft front end to vibration damper front
end with depth gauge.
7. Calculate difference value (= push-on travel)
between measured dimension and dimension (B)
(→ Page 64).
8. If measured distance is smaller than push-on travel
(a) (→ Page 64), check taper for dimensional
accuracy.

9. Screw puller spindle (5) into crankshaft.


10. Check the check dimension “A” (→ Page 64).
11. Mount pressure sleeve (4) and hydraulic nut (2) on
puller spindle and screw on nut (1).
12. Screw high-pressure line on to adapter (3) and
hand-tighten.
13. Connect high-pressure line for hydraulic nut.
14. Set hydraulic nut to initial position with zero stroke.

15. Fill hand pumps (1) and (2) with SAE 10 engine oil.
16. Vent hand pump (1) and line system, until
bubble-free oil emerges.
17. Tighten high-pressure line for adapter.
18. Before fitting, taper fits must be moistened with
expansion fluid. To do so, operate hand pump (1),
until expansion fluid emerges at hub end.
19. Operate hand pump (2) for hydraulic nut and use
minimum pressure to bring to contact point on hub.
Note: Read off expansion pressure Pmax at hub.
TIM ID: 0000020854 – 002

20. Pump in expansion fluid until expansion


pressure (p1) can no longer be increased (do not
exceed expansion pressure Pmax ), then increase
push-on force by increasing force-on pressure (p2).
21. Select push-on force so that end position is
reached after approx. 5 steps.
22. Open valve screw on hand pump (1) to relieve
expansion pressure.

MS22045/00E 2010-04 © MTU


72 Task Descriptions

23. Maintain maximum force-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. Allow specified retention time to elapse and
remove nut, hydraulic nut, pressure sleeve and
puller spindle.
26. Check push-on dimension “B”. Value (→ Page 64)
27. Install flange for barring gear.
28. Do not subject press-fitting to operating load for at
least 8 hours.

TIM ID: 0000020854 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 73

2.2.6 Protective cover – Installation

Material

Designation / Use Part No. Qty.


Engine oil

Protective cover – Installation


1. Remove all covers.
2. Install protective cover with screws and washers as shown in overview drawing (→ Page 66).
TIM ID: 0000020871 – 001

MS22045/00E 2010-04 © MTU


74 Task Descriptions

2.2.7 Piston and conrod – Overview

50 Piston 150 Snap ring 250 Taper-face compression ring


100 Piston pin 200 Keystone ring 300 Oil control ring

TIM ID: 0000020540 – 001

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Task Descriptions 75

Overview drawing

15 Conrod 25 Conrod bearing (upper half) 30 Conrod bearing (lower half)


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76 Task Descriptions

Overview drawing

5 Conrod 15 Conrod screw


10 Conrod cap 20 Conrod bushing

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Task Descriptions 77

2.2.8 Piston and conrod – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
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 ) .
5. Remove cylinder head (→ Page 108).
6. Lower oil pan (→ Page 58).
TIM ID: 0000020541 – 003

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78 Task Descriptions

2.2.9 Piston and conrod – Removal

Special tools

Designation / Use Part No. Qty.


Barring tool F6783914 1
Lowering device F6784104 1
Assembly jig F6783791 1
Socket F30005947 1

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Removing piston and conrod with oil pan lowered


1. Remove combustion residues in cylinder liner.
2. Remove carbon scraper ring (→ Page 48).
3. Install assembly jig (1) in piston (2) and apply
compressed air.
4. After approx. 5 seconds, check assembly jig (1) for
correct fit.

TIM ID: 0000020542 – 001

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Task Descriptions 79

Note: Bearing cap and conrod are a unit and


must not be interchanged.

5. Check marking (arrowed) of conrod bearing cap


and conrod. If necessary, mark components.
6. Use socket, extension and ratchet to loosen conrod
screws.
7. Unscrew conrod screws and remove conrod cap.
8. Remove bearing shell from conrod bearing cap.
9. Protect bearing shell and conrod cap from damage.

Note: Take care that the oil spray nozzle is not


damaged.

10. Pull piston (2) and connecting rod out of cylinder


liner until the second piston ring (3) expands.
11. Switch off compressed air.
12. Remove assembly jig (1) from piston (2).
13. Remove bearing shell from conrod and protect
from damage.
14. Remove piston (2) and conrod.
15. Place piston and conrod on a smooth surface and
protect from damage.
16. Seal all openings with suitable covers.
TIM ID: 0000020542 – 001

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80 Task Descriptions

2.2.10 Piston and conrod – Disassembly

Special tools

Designation / Use Part No. Qty.


Piston-ring pliers F30379877 1

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Spring/circlip/tensioning roller preload.


Risk of injury!
WARNING • Only use specified tool and equipment.

Removing conrod from piston


1. Place piston and conrod on workbench.
2. Check markings of conrod, piston and piston pin. If
necessary, mark components anew.
3. Remove snap ring.
4. Use round timber to press out piston pin (2) (arrow),
in doing so, hold on to conrod (1).
5. Remove conrod (1) from piston.

Removing piston rings


1. Stretch piston rings until they can be removed from
the piston.
2. Remove piston rings with piston ring pliers in
sequence from top to bottom.
TIM ID: 0000020545 – 001

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Task Descriptions 81

2.2.11 Piston – Cleaning

Material

Designation / Use Part No. Qty.


Cleaner (Sima Solv K6) 50632 1

Cleaner is an explosive and poisonous substance.


Danger to life, major material damage!
DANGER • Avoid open flames, electrical sparks and ignition sources.
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.
Cleaner is extremely caustic.
Risk of injury and suffocation!
WARNING • 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.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

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

1. Clean all metallic parts with the cleaner.


2. Clean area of piston ring grooves with rotating plastic brush.
3. After cleaning, blow out oil chamber and oil bores with compressed air.
TIM ID: 0000020546 – 003

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82 Task Descriptions

2.2.12 Piston – Check

Special tools

Designation / Use Part No. Qty.


Ring gauge Y4345226 1

Spare parts

Designation / Use Part No. Qty.


Piston
Piston pin
Oil control ring
Taper-face compression ring
Keystone-type compression ring

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Piston – Check

Item Findings Task

Ensure oil chamber and oil bores Uncleanness Clean


are particularly clean.

Check piston for wear. • Erosion on piston periphery Replace piston.


and valve-clearance dishes.
• Large area of polish wear on
piston skirt (appears matt)
• Concentrated occurrence of
scores
• Pitting

Measure piston pin boss. Values Values exceeded. Replace piston.


(→ Page 84)

Check sliding surface of bronze • Stress marks Replace piston.


bushing for stress marks and • Scores
scoring. visible

Check groove width with gauge Values exceeded. Replace piston.


blocks. If no gauge block is
TIM ID: 0000020836 – 001

available, alternatively a new piston


ring can be inserted in the groove
and the axial play checked with a
feeler gauge. Values (→ Page 84)

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Task Descriptions 83

Item Findings Task

Check condition of piston pin. • Wear traces Replace piston pin.


• Scores
• Impact points
visible

Measure piston pin outer Values exceeded. Replace piston pin.


diameter with micrometer. Values
(→ Page 84)

Check piston rings. • Piston rings with burring, Replace


chipping or sharp edges.
• 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 fits evenly in ring gauge (3).
2. Check ring end clearance with feeler gauge (2).
Values (→ Page 84)
3. If values are exceeded: replace piston rings.
Replace piston rings only in sets.
4. After installation of new piston rings, replace
cylinder liners (→ Page 48).
TIM ID: 0000020836 – 001

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84 Task Descriptions

2.2.13 Piston – Tolerances

No. Designation Stage Toler- Deviation Clearance Interference Wear limit


anced
size lower upper min. max. min. max.
Basic
size

1 Piston bore 52.000 +0.010 +0.016 0.012 0.024

Piston pin 52.000 −0.008 −0.002


Outer Ø

TIM ID: 0000020837 – 002

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Task Descriptions 85

Piston rings

No. Designation Stage Toler- Deviation Clearance Interference Wear limit


anced
size lower upper min. max. min. max.
Basic
size

1 Groove width 3.458 0 +0.020 0.102 0.136

Keystone-type 3.332 +0.010 +0.024


compression
ring

2 Groove width 3.000 +0.060 +0.080 0.060 0.110

Taper-face 3.000 −0.030 0


compression
ring

3 Groove width 4.000 +0.030 +0.050 0.030 0.080

Oil control ring 4.000 −0.030 0


TIM ID: 0000020837 – 002

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86 Task Descriptions

No. Designation Stage Toler- Deviation Clearance Interference Wear limit


anced
size lower upper min. max. min. max.
Basic
size

4 Ring end clearance

Keystone-type 0.350 0.600


compression
ring

Taper-face 0.800 1.050


compression
ring

Oil control ring 0.400 0.750

Measure ring end clearance in ring gauge.

5 Measure groove width / keystone-type compression ring thickness for 1.500 mm recess.

Piston clearance in cylinder liner for M72

TIM ID: 0000020837 – 002

No. Designation Stage Toler- Deviation Clearance Interference Wear limit


anced
size lower upper min. max. min. max.
Basic
size

1 Piston recess 2.600 −0.500 +0.500

MS22045/00E 2010-04 © MTU


Task Descriptions 87

No. Designation Stage Toler- Deviation Clearance Interference Wear limit


anced
size lower upper min. max. min. max.
Basic
size

2 Liner Ø 135.000 −0.015 +0.015 1.443 1.497

Piston skirt Ø 133.530 −0.012 +0.012

3 Liner Ø 135.000 −0.015 +0.015 1.353 1.407

Piston skirt Ø 133.620 −0.012 +0.012

4 Liner Ø 135.000 −0.015 +0.015 0.473 0.527

Piston crown Ø 134.500 −0.012 +0.012

5 Liner Ø 135.000 −0.015 +0.015 0.343 0.397

Piston crown Ø 134.630 −0.012 +0.012

6 Liner Ø 135.000 −0.015 +0.015 0.146 0.200

Piston crown Ø 134.827 −0.007 +0.007

7 Liner Ø 135.000 −0.015 +0.015 0.073 0.127

Piston crown Ø 134.900 −0.007 +0.007

Dimensions 2 to 7 measured in vertical position to piston pin axis.

Piston clearance in cylinder liner for M92 and M93


TIM ID: 0000020837 – 002

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88 Task Descriptions

No. Designation Stage Toler- Deviation Clearance Interference Wear limit


anced
size lower upper min. max. min. max.
Basic
size

1 Piston recess 2.600 −0.500 +0.500

2 Liner Ø 135.000 −0.015 +0.015 1.436 1.490

Piston skirt Ø 133.537 −0.012 +0.012

3 Liner Ø 135.000 −0.015 +0.015 1.353 1.407

Piston skirt Ø 133.620 −0.012 +0.012

4 Liner Ø 135.000 −0.015 +0.015 0.473 0.527

Piston crown Ø 134.500 −0.012 +0.012

5 Liner Ø 135.000 −0.015 +0.015 0.373 0.427

Piston crown Ø 134.600 −0.012 +0.012

6 Liner Ø 135.000 −0.015 +0.015 0.196 0.250

Piston crown Ø 134.827 −0.007 +0.007

7 Liner Ø 135.000 −0.015 +0.015 0.123 0.177

Piston crown Ø 134.900 −0.007 +0.007

Dimensions 2 to 7 measured in vertical position to piston pin axis.

TIM ID: 0000020837 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 89

2.2.14 Conrod – Check

Special tools

Designation / Use Part No. Qty.


Testing device Y4341492 1
Test mandrel Y4341915 1
Test mandrel Y4341916 1
Bore gauge, 100-160 mm Y20091481 1
Dial gauge Y20011268 1
Depth gauge, 300 mm Y20002777 1

Spare parts

Designation / Use Part No. Qty.


Conrod
Conrod screw
Conrod bushing

Conrod – Check

Item Findings Task

Check conrod main 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 threads of conrod and conrod Damaged • Replace conrod.


screw for damage. • Replace conrod screw.

Check conrod screw length. Values Value exceeded Replace


(→ Page 91)

Check conrod bearing cap mating • Wear Replace


face for conrod screws for traces of • Scores
wear and scoring. visible

Check basic bore for wear and • Wear • Recondition


scores. • Scores • Replace
visible

Inspect toothing for damage and Damaged Replace


check wear pattern with engineer’s
blue.
TIM ID: 0000020838 – 001

Measuring conrod main bore without bearing shells


1. Assemble conrod (→ Page 95).
2. Adjust bore gauge and measure conrod main bore. Values (→ Page 91).
3. If values are exceeded, replace conrod.

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90 Task Descriptions

Measuring conrod main bore with bearing shells


1. Assemble conrod (→ Page 95).
2. Coat sliding surfaces of bearing shells with engine oil.
3. Measure conrod bearing bore. Values (→ Page 91).
4. Record measured values in data sheet.
5. Replace bearing shells if limit values are not attained or exceeded.
6. Remove conrod screws, conrod cap and bearing shells.
7. Protect bearing shells from damage.

Measuring conrod bore and conrod bushing of conrod small end


1. Adjust bore gauge to zero dimension of conrod bushing bore and measure conrod bushing bore. Values
(→ Page 91).
2. If limit values are exceeded, replace conrod.

TIM ID: 0000020838 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 91

2.2.15 Conrod – Tolerances

Conrod bearings

No. Designation Stage Toleranced Deviation Clearance Interference Wear


size limit
Basic size upper max. max.
lower min. min.

1 Conrod bore 99.000 H6 0 +0.022

2 Conrod width 41.500 −0.190 −0.120


TIM ID: 0000020839 – 001

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92 Task Descriptions

Conrod screw length, plane of measurement

No. Designation Stage Toler- Deviation Clearance Interference Wear


anced limit
size
lower upper min. max. min. max.
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.
Inner Ø with bearing shell: 94.064 mm +0.042 mm

TIM ID: 0000020839 – 001

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Task Descriptions 93

Conrod bore parallelism

No. Designation Stage Toler- Deviation Clearance Interference Wear


anced limit
size
lower upper min. max. min. max.
Basic
size

1 Conrod length 273.000 −0.020 +0.020


- with bush and
without bearing
shell

Conrod length - 273.000 −0.050 +0.050


without bushing
and without
bearing shell

2 Parallelism of 0.050 measured over a distance of 100 mm


axial inclination

3 Parallelism of 0.100 measured over a distance of 100 mm


axial twist

Conrod weight 3930 g −30 g +30 g


without bearing shells
TIM ID: 0000020839 – 001

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94 Task Descriptions

Conrod bore

No. Designation Stage Toleranced Deviation Clearance Interference Wear


size limit
Basic size upper max. max.
lower min. min.

1 Conrod bore 57.000 H6 0 +0.019 0.061 0.100

Conrod bushing 57.080 0 +0.020


outer- Ø

Press-in force min. 10000 N max. 30000 N

2 Conrod bushing 52.060 −0.005 +0.005


inner Ø - finish
machining
TIM ID: 0000020839 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 95

2.2.16 Conrod – Assembly

Special tools

Designation / Use Part No. Qty.


Torque wrench, 40-200 Nm F30027337 1
Ratchet adapter F30027341 1
Assembly jig F6557995 1

Material

Designation / Use Part No. Qty.


Engine oil

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Preparing conrod
1. Blow out joint faces (arrowed) on conrod and
conrod bearing cap with compressed air and clean.
2. Leather off bearing shell contact surfaces on
conrod and conrod bearing cap.
3. Before installing bearing shells, compare repair
stage entries on conrod and on crankshaft data
sheet.
4. Using aluminum jaws, mount conrod in bench vise
under conrod big end in horizontal position.
5. Insert upper conrod bearing (2) in conrod (1).
TIM ID: 0000020842 – 004

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96 Task Descriptions

6. Use assembly jig (1) to align conrod bearing


shell (2).

7. Carefully press conrod bearing cap by hand onto


conrod.
8. Coat threads and mating faces of conrod screws
with engine oil.
Note: Thread must not be recut.

9. Screw conrod screws into bore on conrod bearing


cap three full turns by hand without using a tool.
10. Install conrod screws until screw heads make
contact and use socket wrench to tighten firmly by
hand. Make sure that conrod cap serrations are
closed at short and long conrod arms.
11. Tighten conrod screws with torque wrench to
specified tightening torque. Order:
11.1. Short arm
11.2. Long arm

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 rotation 90 ° +10 °
TIM ID: 0000020842 – 004

MS22045/00E 2010-04 © MTU


Task Descriptions 97

2.2.17 Piston and conrod – Assembly

Special tools

Designation / Use Part No. Qty.


Piston-ring pliers F30379877 1

Material

Designation / Use Part No. Qty.


Engine oil

Spare parts

Designation / Use Part No. Qty.


Snap ring

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Installing piston rings


1. Turn coiled spring expander (2) in oil control ring
(1) in order to offset ring spring butting face (arrow)
to oil control ring butt by 180°.
TIM ID: 0000020547 – 002

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98 Task Descriptions

Note: Make sure that new piston rings are


replaced in sets.

2. Prepare piston rings as per installation sequence.


3. Replace cylinder liners after renewal of piston rings
(→ Page 48).

1 Keystone-type compression ring


2 Taper-face compression ring
3 Oil control ring

4. Use piston-ring pliers to stretch piston rings until


they can be pushed over the piston.
5. Insert piston rings in annular grooves on piston in
sequence from bottom to top.
5.1. Oil control ring
5.2. Taper-face compression ring, TOP marking in
piston crown direction
5.3. Keystone-type compression ring, TOP
marking in piston crown direction
6. Check that piston rings move freely in their
grooves.

TIM ID: 0000020547 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 99

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 into the corresponding piston, in
accordance with the marking, so that the longer
side (A) of the angle-split conrod faces the
cavity (B).

3. Push corresponding piston pin (2) into piston and


conrod (1) until it connects with installed snap
ring (arrow).

4. Insert second snap ring.


5. Check that both snap rings (arrows) fit well and
are in correct position.
TIM ID: 0000020547 – 002

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100 Task Descriptions

2.2.18 Piston and conrod – Installation

Special tools

Designation / Use Part No. Qty.


Barring tool F6783914 1
Assembly sleeve F6784287 1
Assembly jig F6557995 1
Socket F30005947 1
Torque wrench, 40-200 Nm F30027337 1
Ratchet adapter F30027341 1

Material

Designation / Use Part No. Qty.


Engine oil

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Preparing piston for installation


1. Coat piston and piston rings with engine oil.
2. Ensure that piston rings are evenly fitted at 120° around piston circumference.
3. Center piston rings and oil control ring in grooves.
TIM ID: 0000020548 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 101

Preparing conrod bearing for installation


1. Wipe down conrod bearing shells with chamois
leather.
2. Insert upper conrod bearing shell (shell with oil
bore) with securing lug (arrow) in groove of conrod.
3. Insert lower bearing shell with securing lug in
groove of assembly jig.
4. Coat sliding surfaces of conrod bearing shells with
engine oil.

5. Make sure that the markings (arrows) on conrod


cap and conrod are aligned.
Note: In order to guide the conrod and avoid
damage to the oil spray nozzle, piston
installation must be carried out by two
people.

6. Rotate crankcase in assembly dolly until cylinder


liner is horizontal.
7. Turn crankshaft until crankpin of piston/conrod to
be installed has reached installation position.
8. Wipe crankpin and running surface of cylinder liner
with chamois leather and coat with engine oil.
9. Insert assembly sleeve into fit of carbon scraper
ring.
10. Coat assembly sleeve and cylinder liner with
engine oil.
Note: The piston recess for the oil spray nozzle
must face the engine Vee.

11. Twist piston and connecting rod slightly when


inserting them into the cylinder liner to ensure that
the oil spray nozzle is not damaged.

Installing conrod bearing cap


1. Use assembly jig to align conrod bearing shell.
2. Coat thread and screw head mating face of conrod screws (arrowed) with engine oil.
3. Insert conrod screws into screw bore on conrod cap by hand, then turn first three rotations by hand.
4. Insert conrod screws until screw head mates conrod cap and hand-tighen with socket wrench.
5. Pretighten conrod screws with torque wrench to specified tightening torque (→ Page 17).
TIM ID: 0000020548 – 001

6. Check conrod axial movement.


7. Tighten conrod screws with torque wrench to specified tightening torque (→ Page 17).
8. Check conrod axial clearance.
9. Turn crankshaft and ensure that there is ease of movement between oil spray nozzle, piston and conrod.

MS22045/00E 2010-04 © MTU


102 Task Descriptions

Installing carbon scraper ring


1. Spray edge of cylinder liner and carbon scraper ring with engine oil.
2. Insert carbon scraper ring.

Measuring 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. Arrange bridge meter with dial-gauge anvil and set dial gauge to zero.
5. Turn crankshaft further in engine direction of rotation until piston is in TDC.
6. Read off piston projection at dial gauge and note down. Values (→ Page 84).
7. If value is out of tolerance, check conrod and replace if necessary.

TIM ID: 0000020548 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 103

2.2.19 Piston and conrod – Final steps


Final steps
1. Assemble in reverse order of disassembly (→ Page 77).
2. Fill with engine oil (→ Operating Instructions ).
3. Fill up with engine coolant (→ Operating Instructions ).
4. Enable engine start.
TIM ID: 0000020550 – 002

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104 Task Descriptions

2.2.20 Conrod bearing shells – Check

Item Findings Task

Check the conrod bearing shells for Wear, scores, corrosion, erosion or Replace
wear, scores, corrosion, erosion and damage visible
damage.

Check conrod bearing shell butt and Fretting corrosion visible Replace and determine cause.
bearing rear side for damage and Possible causes:
fretting corrosion. • insufficient screw pretension
• assembly error
• spread dimension of bearing
shell out of tolerance
• faulty bearing support bore

measure spread dimension. Value exceeded Replace bearing shell.


(→ Page 91)

1 Slide layer
2 Barrier layer
3 Intermediate layer
4 Steel support shell

Assessment
An important indicator for assessing the extent of wear on the bearing shell is the shape
and extent of the blocking layer areas exposed.
Use of bearing shell is already restricted in friction area once the sliding layer is reduced to 70%!
It is often difficult to differentiate between the nickel barrier and softer slide layer.
If in doubt, consult a bearing specialist.
Damage to bearing
Damage to bearings occurs mainly through impressions and embedding, cavitation and
TIM ID: 0000038970 – 001

corrosion, pitting, fatigue and installation faults.


Bearings showing such damage must be replaced.

MS22045/00E 2010-04 © MTU


Task Descriptions 105

2.3 Cylinder Head

2.3.1 Cylinder head – Overview

10 Cylinder head 40 Valve spring 70 Valve collet


20 Inlet valve 50 Washer 80 Gasket
30 Exhaust valve 60 Valve-spring retainer
TIM ID: 0000020556 – 001

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106 Task Descriptions

Overview drawing

10 Cylinder head 30 Valve-seat insert, exhaust 50 O-ring


20 Valve-seat insert, inlet 40 Valve guide 60 Protective sleeve

TIM ID: 0000020556 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 107

2.3.2 Cylinder head – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Remove cylinder head covers . (→ Operating Instructions ) .
3. Remove injector (→ Operating Instructions ).
4. Remove constant-pressure manifold (→ Page 173).
5. Remove air pipework to cylinders (→ Page 169).
6. Remove valve drive (→ Page 123).
TIM ID: 0000039500 – 001

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108 Task Descriptions

2.3.3 Cylinder head – Removal

Preconditions
• Preparatory steps have been completed.

Special tools

Designation / Use Part No. Qty.


Socket F30907150 1

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Cylinder head – Removal


1. Use socket (2) to undo screws (1) on cylinder head
evenly and remove.
2. Take cylinder head off crankcase and place on firm
surface.
3. Remove cylinder head gasket from mating face
of crankcase.
4. Seal openings with suitable covers.

TIM ID: 0000020557 – 001

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Task Descriptions 109

2.3.4 Cylinder head – Cleaning

Material

Designation / Use Part No. Qty.


Cleaning agent (Snow-White 11-0) 40460 1
Cleaning agent (Hakupur 312) 30390 1

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Cleaner is extremely caustic.


Risk of injury and suffocation!
WARNING • 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.

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Cylinder head – Cleaning


1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then rinse with cleaning agent (Hakupur 312).
2. Blow all parts clear with compressed air.
TIM ID: 0000020558 – 003

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110 Task Descriptions

2.3.5 Cylinder head – Installation

Special tools

Designation / Use Part No. Qty.


Rotation gauge Y20044010 1
Socket F30907150 1
Torque wrench, 40-200 Nm F30027337 1
Ratchet adapter F30027341 1

Material

Designation / Use Part No. Qty.


Engine oil

Spare parts

Designation / Use Part No. Qty.


Clamping sleeve
Seal

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Contamination in blind hole.


Damage to component!
CAUTION • Inspect and clean blind hole. TIM ID: 0000020559 – 004

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Task Descriptions 111

Installing cylinder head


1. Drive clamping sleeves (1) up to stop in crankcase.
2. Install cylinder-head gasket (2).
3. Place cylinder head (3) on cylinder-head gasket
(2).
4. Coat thread, head mating faces and shaft of
double-hex screw (4) with engine oil.
5. Insert double-hex screw (4) in crankcase by hand.

Note: To check the angle of further rotation, apply


marks (lines) to screw heads of double-hex
screw after pre-tightening.

6. Tighten bihexagonal screws (4) in stages to


specified torque in the given order with a torque
wrench .

Name Size Type Lubricant Value/Standard


Bihexagonal screw M18 x 2 Preload torque Engine oil 10 Nm
Bihexagonal screw M18 x 2 Residual torque 50 Nm
Bihexagonal screw M18 x 2 Residual torque 100 Nm
Bihexagonal screw M18 x 2 Residual torque 200 Nm
Bihexagonal screw M18 x 2 Residual angle of rotation 90 ° +10 °
Bihexagonal screw M18 x 2 Residual angle of rotation 90 ° +10 °
TIM ID: 0000020559 – 004

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112 Task Descriptions

2.3.6 Cylinder head – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 107).
2. Fill with engine coolant (→ Operating Instructions).
3. Fill fuel system (→ Operating Instructions).
4. Enable engine start.

TIM ID: 0000020719 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 113

2.4 Valve Drive

2.4.1 Valve roller tappet, pushrod – Overview

35 Pushrod 45 Roller tappet


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114 Task Descriptions

2.4.2 Roller tappet, pushrod – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Remove cylinder head cover (→ Operating Instructions).
2. Remove valve drive (→ Page 123).

TIM ID: 0000020721 – 001

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Task Descriptions 115

2.4.3 Pushrod – Removal

Preconditions
• Preparatory steps have been completed.
Pushrod – Removal
1. Rotate pushrod so that the roller tappet is loosened.
2. Remove pushrod.
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116 Task Descriptions

2.4.4 Pushrod – Cleaning

Material

Designation / Use Part No. Qty.


Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1

Cleaner is extremely caustic.


Risk of injury and suffocation!
WARNING • 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.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Roller tappet, pushrod – Cleaning


1. Clean all parts with cleaner.
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).

TIM ID: 0000020553 – 001

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Task Descriptions 117

2.4.5 Roller tappet, pushrod – Check

Spare parts

Designation / Use Part No. Qty.


Pushrod

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Checking roller tappet, pushrod

Item Findings Task

Check ball socket and ball head of • Wear Replace


pushrod for stress marks. • Indentations
• Scores
visible
TIM ID: 0000020555 – 003

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118 Task Descriptions

2.4.6 Roller tappet, pushrod – Installation

Material

Designation / Use Part No. Qty.


Engine oil

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Installing pushrod
1. Coat pushrod with engine oil.
2. Insert pushrod with ball head side, in doing so
make sure that it fits correctly in roller tappet.

TIM ID: 0000020554 – 002

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Task Descriptions 119

2.4.7 Roller tappets, pushrod – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 114).
2. Enable engine start.
TIM ID: 0000020723 – 002

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120 Task Descriptions

2.4.8 Valve drive – Overview

100 Rocker arm with rocker shaft 105 Valve bridge 120 O-ring
support 115 Plug-in pipe

TIM ID: 0000020560 – 001

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Task Descriptions 121

Rocker, shaft support

5 Rocker shaft support 20 Adjusting screw 40 Snap ring


10 Rocker arm, exhaust 25 Nut 50 Screw
15 Rocker arm, inlet 35 Washer
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122 Task Descriptions

2.4.9 Valve drive – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions).
2. Remove air filter (→ Operating Instructions).
3. Remove cylinder head cover (→ Operating Instructions).

TIM ID: 0000020561 – 002

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Task Descriptions 123

2.4.10 Valve drive – Removal


Removing rocker arms
1. Remove screw (1).
2. Remove rocker shaft support (2).

Removing valve bridge


1. Mark position of valve bridges (1) and (2) to the
valves.
2. Remove valve bridges.
3. Seal openings with suitable covers.
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124 Task Descriptions

2.4.11 Valve gear – Cleaning

Material

Designation / Use Part No. Qty.


Cleaning agent (Snow-White 11-0) 40460 1
Cleaning agent (Hakupur 312) 30390 1

Cleaner is extremely caustic.


Risk of injury and suffocation!
WARNING • 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.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Cleaning valve gear


1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then rinse with cleaning agent (Hakupur 312).
2. Blow out all parts with compressed air.

TIM ID: 0000020563 – 002

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Task Descriptions 125

2.4.12 Valve drive – Check

Spare parts

Designation / Use Part No. Qty.


Rocker shaft support
Rocker arm, exhaust
Rocker arm, inlet
Valve bridge
Screw
Adjusting screw

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Valve drive – Check

Item Findings Task

Check bearing surfaces on shaft • Wear • Recondition


support, valve bridges and rocker • Indentations • Replace
for wear, indentations and scores. • Scores
visible

Check mating faces on rocker shaft Damaged • Recondition


support. • Replace

Check screws, nuts and adjusting Damaged Replace


screws for damage.
TIM ID: 0000020564 – 002

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126 Task Descriptions

2.4.13 Valve drive – Installation

Special tools

Designation / Use Part No. Qty.


Barring tool F6783914 1
Pointer for barring tool F6557932 1
Graduated disk for 8V Y4345595 1
Graduated disk for 10V Y4345536 1
Graduated disk for 12V Y4345886 1
Graduated disk for 16V Y4345887 1
Torque wrench, 20-100 Nm F30026582 1
Ratchet adapter F30027340 1

Material

Designation / Use Part No. Qty.


Engine oil

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Installing valve bridge and rocker arm


1. Remove all covers prior to installation.
2. Place valve bridges (1) and (2) on to the valves in
accordance with the markings.

TIM ID: 0000020565 – 002

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Task Descriptions 127

3. Coat ball seat of pushrod with engine oil.


4. Use barring tool to set piston to firing TDC.
5. Loosen nut of adjusting screws on rocker shaft
support (2) and turn back adjusting screws.
6. Place rocker shaft support (2) on to cylinder
head, in doing so, check position of the ball in the
pushrod.
7. Coat thread and screw head mating face of
screw (1) with engine oil.
8. Insert screw (1) and use torque wrench to tighten
to specified tightening torque (→ Page 17).
9. Adjust valve clearance (→ Operating Instructions).
TIM ID: 0000020565 – 002

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128 Task Descriptions

2.4.14 Valve drive – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 122).
2. Enable engine start.

TIM ID: 0000020566 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 129

2.5 High Pressure Fuel System

2.5.1 HP fuel system – Tightening procedure

Preconditions
• Engine is stopped and starting disabled.

Special tools

Designation / Use Part No. Qty.


Combination wrench, 19 mm F30025897 1
Torque wrench, 20-100 Nm F30026582 1
Torque wrench, 8-40 Nm F30043446 1
Ratchet adapter F30027340 1
Guide pin F30450460 1
Extraction tool F6784160 1
Socket wrench F30451502 1
Assembly sleeve F30450342 1
Alignment tool F6783244 1
Alignment tool F6787011 1

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
TIM ID: 0000020868 – 003

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130 Task Descriptions

Installing HP accumulator in charge-air line


1. Install HP accumulator (5) in charge-air line (arrow).
2. Align thread of HP accumulator (5) with bore on
charge-air line.
3. Hand-tighten corner flanges (a) and (b), then
remaining flanges (2) with screws.
4. Coat O-rings with grease.
5. Install guide bushing (4) with O-ring.
6. Install bushing (1) with O-ring.
7. Prior to installation of bottom section of cylinder
head cover, position plug-in pipe (3).

Installing HP lines
1. Hand-tighten HP line (5) on fuel distributor.
2. Hand-tighten HP line (5) on HP pump.
3. Hand-tighten HP lines (1) and (2) on HP
accumulator.
4. Hand-tighten HP lines (1) and (2) on fuel distributor.
5. Use torque wrench to tighten all HP lines in
the same order to specified tightening torque
(→ Table Tightening torque on page 131).
6. Tighten fuel distributor (3).
7. Use torque wrench to tighten all screws on HP
accumulator (4) to specified tightening torque
(→ Table Tightening torque on page 131).
8. Install pipe half-clamps (6).

TIM ID: 0000020868 – 003

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Task Descriptions 131

Installing injector
1. Install injector (1) in cylinder head and align.
2. Install hold-down clamp (2) and hand-tighten
screw.

Installing HP line on injector


1. Install union nut (3) of HP line on HP accumulator
and hand-tighten.
2. Install union nut (2) of HP line on injector (1) and
hand-tighten.
3. Tighten hold-down clamp on injector (1) with
torque wrench to specified tightening torque
(→ Table Tightening torque on page 131).
4. Tighten union nut (3) on HP line with torque wrench
to specified tightening torque (→ Table Tightening
torque on page 131).
5. Tighten union nut (2) of HP line on HP accumulator
with torque wrench to specified tightening torque
(→ Table Tightening torque on page 131).
6. Tighten flanges.

Tightening torque for HP fuel system

Tightening torque

Designation Tightening specifications Lubricant

HP line on fuel distributor 40 Nm +5 Nm Engine oil

HP line on HP pump 40 Nm +5 Nm

HP line on HP accumulator 40 Nm +5 Nm

HP line on injector 20 Nm +5 Nm
TIM ID: 0000020868 – 003

HP line of injector on HP accumulator 30 Nm +5 Nm

Screw on hold-down clamp 40 Nm +4 Nm

Pressure relief valve on fuel distributor 100 Nm +5 Nm

HP sensor on fuel distributor 30 Nm +5 Nm

MS22045/00E 2010-04 © MTU


132 Task Descriptions

2.5.2 HP fuel pump – Overview

10 HP pump 50 O-ring 60 Washer


15 O-ring 56 Retainer 61 Screw
25 Follower 57 Washer 62 Screw
35 Screw 58 Screw 63 Washer
40 Washer 59 Clamping element

TIM ID: 0000020567 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 133

2.5.3 HP fuel pump – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Remove fuel lines (low pressure) (→ Page 147).
2. Remove fuel lines (high pressure) (→ Page 141).
3. Remove sensors, actuators and injectors (→ Page 244).
TIM ID: 0000020569 – 001

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134 Task Descriptions

2.5.4 HP fuel pump – Removal

Special tools

Designation / Use Part No. Qty.


Lifting device T80091650 1
Carrying bracket T80091665 1

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

HP fuel pump – Removal


1. Remove clamps (1).
2. Remove screws (2).

3. Install lifting device (2) and carrying bracket (3) for


HP fuel pump (1).
4. Remove HP fuel pump (1).
5. Seal openings with suitable covers.
6. Remove O-ring.
TIM ID: 0000020568 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 135

2.5.5 HP fuel pump – Check

Spare parts

Designation / Use Part No. Qty.


HP pump
Screw

HP fuel pump – Check

Item Findings Task

Check screws for damage. Damaged Replace

Check drive gear for damage. Damaged Replace HP pump.

Check sealing faces for damage. Damaged • Recondition


• Replace
TIM ID: 0000020570 – 001

MS22045/00E 2010-04 © MTU


136 Task Descriptions

2.5.6 HP fuel pump – Installation

Special tools

Designation / Use Part No. Qty.


Lifting device T80091650 1
Carrying bracket T80091665 1
Alignment tool F6783244 1
Guide pin F30450460 2

Material

Designation / Use Part No. Qty.


Engine oil
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1

Spare parts

Designation / Use Part No. Qty.


O-ring

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
TIM ID: 0000020571 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 137

HP fuel pump – Installation


1. Remove all covers prior to installation.
2. Remove follower for HP fuel pump on water pump
shaft.
3. Insert alignment tool (1) in correct position in bore
of HP fuel pump.
4. Use lever (3) to align water pump shaft meshing in
such a way that the marked lines (2) match.
5. Remove alignment tool (1) and install follower on
water pump shaft.

6. Mount alignment tool (2) on HP fuel pump (1) in


correct position.
7. Use wrench (3) to align HP fuel pump meshing in
such a way that the marked lines (4) match.
8. Remove alignment tool (2).

9. Coat O-rings with grease and insert in grooves.


10. Install lifting device (2) and carrying bracket (3) for
HP fuel pump (1).
11. Insert HP fuel pump (1) in bore.
TIM ID: 0000020571 – 002

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138 Task Descriptions

12. Insert screws (2) and tighten.


13. Mount clamps (1).
14. Remove lifting device and carrying bracket for HP
fuel pump.

TIM ID: 0000020571 – 002

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Task Descriptions 139

2.5.7 HP pump – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 133).
2. Fill fuel system (→ Operating Instructions ).
3. Enable engine start.
TIM ID: 0000020572 – 003

MS22045/00E 2010-04 © MTU


140 Task Descriptions

2.5.8 HP line – Overview

10 HP accumulator 85 Pressure relief valve 182 Screw


20 Flange 95 O-ring 183 Washer
25 O-ring 105 Screw 184 Pipe half-clamp
30 Screw 110 Washer 185 Pipe half-clamp
35 Washer 112 Cable clamp 186 Washer
40 Screw 120 Fuel line 187 Screw
45 Washer 130 O-ring 188 Grommet
48 HP line 135 HP line 195 Retainer
50 Grommet 145 O-ring 196 Bracket
51 Pipe half-clamp 160 Grommet 200 Screw
52 Washer 165 Pipe half-clamp 205 Washer
53 Screw 166 Retainer 210 Pipe half-clamp
55 Washer 175 Washer 211 Pipe half-clamp
68 Grommet 176 Screw 215 Grommet
72 Pipe half-clamp 177 Nut 220 Screw
76 Clamp 178 Cable clamp 225 Washer
78 Fuel distributor 181 Retainer 235 Fuel line
TIM ID: 0000039443 – 001

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Task Descriptions 141

2.5.9 HP line – Removal

Preconditions
• Engine is stopped and starting disabled.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

HP line – Removal
1. Take pictures prior to removal or mark installed components and lines.
2. Remove lines as per overview drawing (→ Page 140).
3. Seal openings with suitable covers.
TIM ID: 0000020866 – 003

MS22045/00E 2010-04 © MTU


142 Task Descriptions

2.5.10 HP line – Installation

Special tools

Designation / Use Part No. Qty.


Torque wrench 6-50 Nm F30027336 1
Ratchet adapter F30027340 1

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

HP line – Installation
1. Install HP line as shown in overview drawing, photos taken or marks made prior to removal (→ Page 140).
2. Use torque wrench to tighten screws for HP line to specified tightening torque (→ Page 129).

TIM ID: 0000020867 – 006

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Task Descriptions 143

2.6 Low Pressure Fuel System

2.6.1 Fuel pipework from fuel delivery pump to fuel filter – Overview

Fuel pipework from fuel delivery pump to filter – 12V

20 Fuel line 120 Sealing cone 300 Washer


40 Sealing cone 130 Nut 320 Retainer
50 Nut 180 Fuel line 330 Screw
70 Nut 260 Valve housing 340 Washer
80 Sealing cone 280 Screw 350 Cable clamp
100 Fuel line 290 Screw 370 Fuel line
TIM ID: 0000039447 – 001

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144 Task Descriptions

90 Clamp 800 Fuel line 910 Clamp


110 Clamp 820 Fuel line 920 Screw
140 Pipe half-clamp 840 Grommet 925 Washer
150 Pipe half-clamp 850 Fuel line 930 Washer
160 Grommet 870 Clamp 940 Nut
170 Screw 880 Screw
180 Washer 890 Washer

TIM ID: 0000039447 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 145

Fuel pipework from fuel delivery pump to filter – 16V

20 Fuel line 240 Sealing ring 410 Screw


40 Nut 250 Adapter union 420 Screw
50 Sealing cone 270 Retainer 430 Washer
53 Grommet 280 Screw 450 Retainer
55 Washer 290 Washer 460 Screw
70 Fuel line 310 Clamp 470 Washer
120 Fuel line 320 Screw 480 Cable clamp
200 Fuel line 330 Washer 500 Fuel line
220 Union 350 Fuel line
230 Pressure relief valve 370 Valve housing
TIM ID: 0000039447 – 001

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146 Task Descriptions

90 Clamp 170 Screw 850 Fuel line


110 Clamp 180 Washer 860 Fuel line
140 Pipe half-clamp 800 Fuel line 880 Clamp
150 Pipe half-clamp 820 Fuel line 890 Screw
160 Grommet 840 Grommet 900 Washer

TIM ID: 0000039447 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 147

2.6.2 Fuel pipework from fuel delivery pump to fuel filter – Removal

Preconditions
• Disable engine start.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Fuel pipework from fuel delivery pump to fuel filter – Removal


1. Before removing the lines, take photos or mark attachments and lines.
2. Loosen screwed connection of the fuel pipes and catch any fuel that emerges.
3. Remove fuel lines as per overview drawing (→ Page 143).
4. Seal openings with suitable covers.
TIM ID: 0000020863 – 002

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148 Task Descriptions

2.6.3 Fuel pipework from fuel delivery pump to fuel filter – Installation

Spare parts

Designation / Use Part No. Qty.


Grommet
Sealing ring

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Installing fuel pipework from fuel delivery pump to filter


1. Remove all covers.
2. Install fuel lines as per overview drawing (→ Page 143), photos or markings.

TIM ID: 0000020864 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 149

2.6.4 Fuel cooler – Overview

2300 Fuel cooler 2500 Screw 2600 Washer


TIM ID: 0000020577 – 001

MS22045/00E 2010-04 © MTU


150 Task Descriptions

2.6.5 Fuel cooler – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Observe safety regulations.
2. Drain engine coolant (→ Operating Instructions ).

TIM ID: 0000020578 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 151

2.6.6 Fuel cooler – Removal


Components have sharp edges.
Risk of injury!
WARNING • Wear protective gloves.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Fuel cooler – Removal


1. Remove screws and washers as shown in overview drawing (→ Page 149).
2. Collect emerging fuel.
3. Remove fuel cooler.
4. Remove O-rings.
5. Seal openings with suitable covers.
TIM ID: 0000020579 – 001

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152 Task Descriptions

2.6.7 Fuel cooler – Check

Spare parts

Designation / Use Part No. Qty.


Fuel cooler

Equipment can drop off.


Liquid is highly pressurized.
WARNING Risk of injury, knocks or crushing!
• Only use specified and tested equipment.
• Do not enter the danger zone.
• Wear protective clothing, gloves, and goggles / safety mask.

Fuel cooler – Check

Item Findings Task

Visually inspect fuel cooler for Damaged Replace


damage.

Check all sealing and mating faces • Damage • Recondition: smooth with
for stress marks and damage. • Stress marks oilstone or emery cloth.
visible • Replace

TIM ID: 0000020840 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 153

2.6.8 Fuel cooler – Installation

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


O-ring

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Components have sharp edges.
Risk of injury!
WARNING • Wear protective gloves.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Fuel cooler – Installation


1. Remove all covers prior to installation.
2. Coat O-rings with grease and insert in grooves.
3. Install fuel cooler with screws and washers as shown in overview drawing (→ Page 149).
TIM ID: 0000020580 – 002

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154 Task Descriptions

2.6.9 Fuel cooler – Final steps


Final steps
1. Fill up with engine coolant (→ Operating Instructions ).
2. Enable engine start.

TIM ID: 0000020581 – 001

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Task Descriptions 155

2.6.10 Leak-off fuel system – Overview

40 Retainer 320 Fuel line 560 Washer


60 Screw 340 Banjo screw 600 Clamp
80 Washer 360 Sealing ring 620 Screw
120 Distribution 400 Clamp 640 Washer
140 Screw 420 Screw 660 Washer
160 Washer 440 Washer 700 Fuel line
200 Plug screw 460 Fuel line 740 Union
220 Sealing ring 500 Clamp 760 Sealing ring
260 Union 520 Screw
280 Sealing ring 540 Nut
TIM ID: 0000039451 – 001

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156 Task Descriptions

2.6.11 Leak-off fuel system – Removal

Preconditions
• Preparatory steps have been completed.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Leak-off fuel system – Removal


1. Before removing the lines, take photos or label attachments and lines.
2. Release threaded union on fuel line and catch fuel emerging.
3. Remove fuel lines with attachments as per overview drawing (→ Page 155).
4. Seal openings with suitable covers.

TIM ID: 0000020850 – 001

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Task Descriptions 157

2.6.12 Leak-off fuel system – Installation

Spare parts

Designation / Use Part No. Qty.


Sealing ring
Grommet

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Incorrect installation of components and lines.
Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Leak-off fuel system – Installation


1. Prior to installation, remove all covers.
2. Blow out leak-off fuel lines with compressed air.
3. Install leak-of fuel lines as per overview drawing (→ Page 155) and/or photographs or marking.
TIM ID: 0000020851 – 001

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158 Task Descriptions

2.7 Exhaust Turbocharger

2.7.1 Exhaust turbocharger – Overview

15 Exhaust turbocharger 50 O-ring 80 O-ring


20 Exhaust turbocharger 55 Flange 90 Threaded union
30 Screw 60 Flange 95 O-ring
35 Washer 70 Screw 100 O-ring
45 Plug-in pipe 75 Washer

TIM ID: 0000020582 – 001

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Task Descriptions 159

Overview drawing

5 O-ring 55 Thrust bearing 115 Nut


10 O-ring 60 Washer 120 Compressor housing
15 O-ring 65 Identification plate 121 Threaded bushing
20 Bearing housing 70 Grooved pin 122 Plug screw
25 Heat shield 80 Screw 123 Sealing ring
30 Circlip 85 Retaining ring 130 Clamp
35 Washer 90 Washer 135 Turbine housing
40 Bearing bushing 95 Ring carrier 145 Clamp
41 Bearing bushing 100 Piston ring 155 Boot
45 Turbine wheel 105 Piston ring 160 Clamp
50 Washer 110 Compressor wheel
TIM ID: 0000020582 – 001

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160 Task Descriptions

2.7.2 Exhaust turbocharger – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Remove carrier housing cover (→ Page 180).

TIM ID: 0000020584 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 161

2.7.3 Exhaust turbocharger – Removal

Special tools

Designation / Use Part No. Qty.


Lifting gear T80091621 1

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Exhaust turbocharger – Removal


1. Remove screws (2) for flange (1).

2. Remove threaded union (5) on exhaust


turbocharger (3).
3. Remove screws (1) and take off ring (2).
4. Remove screws (4).
TIM ID: 0000020585 – 001

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162 Task Descriptions

5. Attach lifting gear (1) to exhaust turbocharger (2)


and hang on to crane with rope lightly pretensioned.
6. Remove exhaust turbocharger (2) from carrier
housing (3) and place on suitable surface.
7. Remove lifting gear (1).
8. Remove O-rings.
9. Seal openings with suitable covers.

TIM ID: 0000020585 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 163

2.7.4 Exhaust turbocharger – Cleaning

Material

Designation / Use Part No. Qty.


Cleaner (Snow-White 11-0) 40460 1
Cleaning agent (Hakupur 312) 30390 1

Chemical substances in cleaners.


Risk of irritation and chemical burns!
WARNING • Always obey manufacturer’s instructions for use!

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Cleaner is extremely caustic.


Risk of injury and suffocation!
WARNING • 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.

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Cleaning exhaust turbocharger


1. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Dry all components using compressed air.
TIM ID: 0000020841 – 002

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164 Task Descriptions

2.7.5 Exhaust turbocharger – Check

Spare parts

Designation / Use Part No. Qty.


Exhaust turbocharger
Retaining ring

Exhaust turbocharger – Check

Item Findings Task

Check thread of screws. Damaged Replace

Check coolant channels and Deposits visible Clean or replace


housing cover of bearing housing
for deposits.

TIM ID: 0000020843 – 001

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Task Descriptions 165

2.7.6 Exhaust turbocharger – Installation

Special tools

Designation / Use Part No. Qty.


Lifting gear T80091621 1
Torque wrench, 6-50 Nm F30027336 1
Ratchet adapter F30027340 1

Material

Designation / Use Part No. Qty.


Engine oil
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1

Spare parts

Designation / Use Part No. Qty.


O-ring

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Exhaust turbocharger – Installation


1. Remove all covers prior to installation.
2. Clean mating face on carrier housing (2).
3. Coat O-ring (1) with grease and insert in groove
on carrier housing (2).
TIM ID: 0000020590 – 002

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166 Task Descriptions

4. Attach lifting gear (1) to exhaust turbocharger (2)


and hang on to crane with rope lightly pretensioned.
5. Insert exhaust turbocharger (2) in correct position
in carrier housing (3).
6. Remove lifting gear (1).

7. Insert screws (4) for exhaust turbocharger (3) and


use torque wrench to tighten to specified tightening
torque (→ Page 17).
8. Install ring halves (2) with screws (1) on exhaust
turbocharger (3) and tighten.
9. Insert union (5) on exhaust turbocharger (3) and
use torque wrench to tighten to specified tightening
torque (→ Page 17).

10. Coat O-ring with grease and insert in groove.


11. Insert screws (2) in flange (1) and use torque
wrench to tighten to specified tightening torque
(→ Page 17). TIM ID: 0000020590 – 002

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Task Descriptions 167

2.7.7 Exhaust turbocharger – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 160).
2. Fill up with engine coolant (→ Operating Instructions ).
3. Enable engine start.
TIM ID: 0000020591 – 001

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168 Task Descriptions

2.8 Air Intake / Air Supply

2.8.1 Air supply system to cylinders – Overview

10 Clamp 90 Sealing ring 159 Cable clamp


15 Washer 95 Nut 165 Sealing ring
20 Screw 100 Clamp 175 Guide bush
25 Shroud 105 Screw 180 Bush
35 Screw 110 Washer 185 O-ring
40 Screw 120 Connection 195 Screw
45 Washer 125 Sealing ring 200 Washer
46 O-ring 135 Charge-air line 210 Screw
51 Bracket 145 Seal 215 Washer
52 Cable clamp 150 Screw 220 Bracket
53 Screw 151 Washer 225 Washer
54 Washer 156 Bracket 230 Cable clamp
75 Vent line 157 Screw
85 Connection 158 Washer
TIM ID: 0000020727 – 001

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Task Descriptions 169

2.8.2 Air pipework to cylinders – Removal

Preconditions
• Preparatory steps have been completed.
Removing charge-air pipe
1. Remove charge-air pipe as shown in overview drawing (→ Page 168).
2. Remove gaskets and O-rings.
3. Seal openings with suitable covers.
TIM ID: 0000020728 – 001

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170 Task Descriptions

2.8.3 Air pipework to cylinders – Installation

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


Seal
Sealing ring
O-ring

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Air pipework to cylinders – Installation


1. Remove all covers prior to installation.
2. Fit seals on cylinder heads.
3. Install air pipework to cylinders as shown in overview drawing (→ Page 168).

TIM ID: 0000020729 – 002

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Task Descriptions 171

2.9 Exhaust System

2.9.1 Carrier housing – Overview

10 Carrier housing, upper part 60 Sealing ring 100 Plug screw


15 Threaded bushing 65 Dowel pin 105 Sealing ring
20 Sealing ring 70 Union 110 Union
50 Sealing ring 80 Carrier housing cover 115 Sealing ring
55 Plug screw 95 Sealing ring 120 Union
TIM ID: 0000039542 – 001

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172 Task Descriptions

2.9.2 Carrier housing – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Remove oil supply pipework for exhaust turbochargers (→ Page 190).
3. Remove coolant pipework from/to exhaust turbochargers (→ Operating Instructions ).
4. Remove crankcase breather (→ Page 63).
5. Remove sensors, actuators and injectors (→ Page 244).
6. Remove exhaust flap actuator (→ Page 178).

TIM ID: 0000020592 – 001

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Task Descriptions 173

2.9.3 Constant-pressure manifold – Removal

Special tools

Designation / Use Part No. Qty.


Hook T80091769 1
Hook-ended chain sling T80090943 1

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

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. Screw lifting hooks (1) into bores in exhaust
pipework housing (2).
5. Attach exhaust pipework housing (2) to crane
using a lightly tensioned rope.
6. Remove screws.
7. Remove exhaust pipework housing (2).
8. Set down exhaust pipework housing (2) on suitable
surface.
9. Remove hook (1).

Removing intermediate flange


1. Remove screws (1) and (3) and remove
intermediate flange with exhaust diffuser.
2. Remove O-ring and gasket.
3. Screw two nuts onto studs (2) and lock.
4. Remove stud (2).
5. Seal openings with suitable covers.
TIM ID: 0000039455 – 001

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174 Task Descriptions

2.9.4 Carrier housing – Disassembly

Preconditions
• Engine is stopped and starting disabled.
Carrier housing – Disassembly
1. Remove all screws (2).
2. Remove flange (1) with gasket.
3. Remove all screws (4).
4. Remove carrier housing cover (3).
5. Remove exhaust turbocharger and flap housing.

TIM ID: 0000039487 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 175

2.9.5 Exhaust flap with actuator

Valid for 10V 12V 16V (12V/16V one turbocharger and exhaust flap additionally)

15 Flap housing 236 Retainer 274 Screw


75 Lamellar ring 237 Screw 275 O-ring
80 Ring 238 Washer 285 Sealing ring
90 Bushing 240 Clamp 290 Sleeve
95 R-ring 241 Screw 300 Gasket
100 Flange 242 Washer 305 Screw
110 Screw 255 Gasket 310 Screw
115 Gasket 260 Screw 315 Screw
125 Coiled spring pin 265 Washer 320 O-ring
135 Screw 271 Gasket 325 Washer
140 Sealing ring 272 Screw 330 O-ring
230 Carrier housing 273 Washer 331 Washer
TIM ID: 0000039467 – 001

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176 Task Descriptions

Overview drawing

30 Exhaust flap 165 Flange 215 Cylinder


35 Bearing bushing 170 O-ring 217 Union
40 Bearing bushing 180 Screw 218 Sealing ring
50 Screw 185 Washer 225 Rod
55 Screw 190 O-ring 231 Screw
65 Screw 195 Lever 232 Washer
150 Shaft 200 Coiled spring pin 233 Nut
155 Shaft 205 Screw
160 Bushing 210 Washer

TIM ID: 0000039467 – 001

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Task Descriptions 177

Overview drawing

333 Bracket 396 Washer 455 Union


334 Clamp 397 O-ring 460 Retainer
335 Screw 401 Retainer 465 Washer
336 Washer 403 Screw 475 Nut
345 Clamp 404 Washer 485 Control line
350 Screw 406 Screw 490 Banjo screw
355 Washer 407 Washer 495 Sealing ring
365 Union 415 Control line 505 Hose
370 Support 425 Distributor piece 510 Hose
375 Sealing ring 430 Nut 515 Clamp
380 Bleeder valve 435 Solenoid valve 520 Control line
385 Screw 445 Screw 525 Control line
395 Screw 450 Washer
TIM ID: 0000039467 – 001

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178 Task Descriptions

2.9.6 Exhaust flap with actuators – Removal


Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Exhaust flap with actuators – Removal


1. Before removing the lines, take photos or label attachments and lines.
2. Remove actuator from exhaust flap as shown in overview drawing (→ Page 175).
3. Remove flap housing with exhaust flap (→ Page 174).
4. Seal openings with suitable covers.

TIM ID: 0000039525 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 179

2.9.7 Exhaust flap with actuators – Installation

Material

Designation / Use Part No. Qty.


Assembly paste (Ultra-Therm MTU) 50547 1

Spare parts

Designation / Use Part No. Qty.


Gasket
Grub screws

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Exhaust flap with actuators – Installation


1. Prior to installation, remove all covers.
2. Install flap housing with exhaust flap .
Note: Exhaust flap closed, position of bore on shaft 11 o’clock

3. Install actuator of exhaust flap as shown in overview drawing (→ Page 175).


4. Direct compressed air at actuating cylinder and check operation of exhaust flap.
TIM ID: 0000039555 – 001

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180 Task Descriptions

2.9.8 Carrier housing – Cover removal and installation

Preconditions
• Engine is stopped and starting disabled.
Removing carrier housing cover
1. Remove oil lines (4) from turbocharger.
2. Remove coolant lines (3).
3. Disconnect clevis head (6) from actuating cylinder.
4. Remove flange (7).
5. Remove union from oil supply to turbocharger.
6. Remove flange (1) with gasket.
7. Remove all screws (5).
8. Remove carrier housing cover (2).

Installing carrier housing cover


1. Coat O-rings with petroleum jelly.
2. Insert O-rings in grooves on carrier housing upper
section.
3. Coat all screws with engine oil.
4. Install carrier housing cover (2).
5. Install screws (5) and tighten.
6. Install flange (1) with gasket.
7. Insert O-rings for union in ring groove.
8. Install union in oil supply to turbocharger.
9. Install flange (7).
10. Connect clevis head (6) to actuating cylinder.
11. Install coolant lines (3).
12. Install oil lines (4) on turbocharger.

TIM ID: 0000039459 – 001

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Task Descriptions 181

2.9.9 Carrier housing – Final steps


Final steps
1. Assemble in reverse order of disassembly (→ Page 172).
2. Fill up with engine coolant (→ Operating Instructions ).
3. Enable engine start.
TIM ID: 0000020599 – 001

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182 Task Descriptions

2.10 Starting Equipment

2.10.1 Electric starter – Overview

1 Starter 3 Nut 5 Stud


2 Flange 4 Washer

TIM ID: 0000020600 – 001

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Task Descriptions 183

2.10.2 Starter – Removal

Preconditions
• Engine is stopped and starting disabled.

Electrical voltage.
Risk of serious injury - danger to life!
DANGER • Make certain that the power supply to the engine is switched off before starting to work.
Ensure that the power supply cannot be switched on unintentionally!

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Disconnecting and removing starter


1. Prior to disconnection, mark all cables.
2. Disconnect all cables from starter.
3. Protect all cables from damage.
4. Remove starter nut as shown in overview drawing (→ Page 182).
5. Remove starter.
6. Protect starter from damage.
TIM ID: 0000020601 – 002

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184 Task Descriptions

2.10.3 Starter – Cleaning


Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Cleaning starter
1. Do not wet-clean. Clean starter with compressed air only.
2. Protect starter from moisture.

TIM ID: 0000020602 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 185

2.10.4 Starter – Inspection

Spare parts

Designation / Use Part No. Qty.


Starter

Inspecting starter

Item Findings Action

Check tooth flanks of pinion for • Signs of wear • Rework


wear, indentations and chipping. • Indentations • Replace
• Chipping
visible.

Check nuts and studs for condition Stiff Replace


and check threads for ease of
movement.

Check mating face on end housing Wear traces are found. Rework: Smooth with crocus cloth
for wear. or oilstone.
TIM ID: 0000020603 – 003

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186 Task Descriptions

2.10.5 Starter – Installation

Material

Designation / Use Part No. Qty.


Lubricating grease (Longterm 2 Plus) 40336 1

Electrical voltage.
Risk of serious injury - danger to life!
DANGER • Make certain that the power supply to the engine is switched off before starting to work.
Ensure that the power supply cannot be switched on unintentionally!

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Starter – Installation
1. Coat starter pinion with lubricating grease.
2. Install starter according to overview drawing (→ Page 182).

Connecting starter cables


1. Connect cables in accordance with the marking.
2. Check starter operation.

TIM ID: 0000020604 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 187

2.11 Lube-Oil System, Lube-Oil Circuit

2.11.1 Exhaust turbocharger oil supply – Overview

760 Oil line 883 Nut 1062 Washer


781 Retainer 920 Oil line 1063 Nut
800 Clamp 960 T-piece 1100 Oil line
820 Screw 980 Oil line 1130 Retainer
840 Washer 1020 Oil line 1140 Clamp
880 Clamp 1041 Strap 1160 Screw
881 Screw 1060 Clamp 1180 Washer
882 Washer 1061 Screw
TIM ID: 0000039522 – 001

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188 Task Descriptions

Overview drawing

40 4/2-way directional control valve 280 Oil supply line 553 Washer
60 Plate 320 Union 554 Nut
100 Screw 340 Sealing ring 580 Screw
160 Union 400 Oil line 600 Washer
180 Sealing ring 420 Oil line 620 Washer
210 Retainer 460 Oil line 630 Nut
220 Screw 480 Oil line 650 Oil return line
240 Washer 510 Retainer, left side 660 Clamp
251 Bracket 520 Screw 665 Screw
252 Screw 540 Washer 670 Washer
253 Washer 551 Retainer, left side 700 Union
254 Washer 552 Screw 720 Sealing ring
TIM ID: 0000039522 – 001

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Task Descriptions 189

Overview drawing

1220 4/2-way directional control valve 1640 Oil line 1830 Nut
1240 Plate 1660 Oil line 1831 Clamp
1280 Screw 1700 Retainer 1832 Screw
1340 Union 1720 Screw 1833 Washer
1360 Sealing ring 1740 Washer 1834 Retainer
1400 Screw 1751 retainer, right side 1835 Screw
1420 Washer 1752 Screw 1836 Washer
1460 Oil supply line 1753 Washer 1850 Oil return line
1500 Union 1754 Nut 1900 Union
1520 Sealing ring 1780 Screw 1920 Sealing ring
1580 Oil line 1800 Washer
1600 Oil line 1820 Washer
TIM ID: 0000039522 – 001

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190 Task Descriptions

2.11.2 Exhaust turbocharger oil supply – Removal

Preconditions
• Engine is stopped and starting disabled.
Exhaust turbocharger oil supply – Removal
1. Before removing the lines, take photos or mark attachments and lines.
2. Remove oil lines, connecting and mounting parts as shown in overview drawing (→ Page 187).
3. Remove all sealing elements.
4. Seal openings with suitable covers.
5. Protect oil lines from damage.

TIM ID: 0000039462 – 001

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Task Descriptions 191

2.11.3 Exhaust turbocharger oil supply – Installation

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


Clamp
Gasket
Sealing ring

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Exhaust turbocharger oil supply – Installation


1. Remove all covers prior to installation.
2. Blow out oil lines with compressed air.
3. Coat O-rings with grease.
4. Insert O-rings in groove.
5. Install oil lines with connecting and mounting parts as shown in overview drawing (→ Page 187).
6. After engine start, visually inspect oil lines for leaks.
TIM ID: 0000039527 – 001

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192 Task Descriptions

2.12 Coolant System

2.12.1 Engine coolant pump – Overview

10 Engine coolant pump 25 Nut


20 Stud 30 Washer

TIM ID: 0000020605 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 193

Overview drawing

100 Engine coolant pump 600 Bearing housing 1000 Washer


300 O-ring 800 Stud
400 Taper ring 900 Nut
TIM ID: 0000020605 – 001

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194 Task Descriptions

2.12.2 Engine coolant pump – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Remove sensor cable for sensors B6, B6.2 and B16 (→ Operating Instructions).
3. Remove protective cover (→ Page 67).
4. Release coolant line from coolant pump elbow.
5. Remove fuel line from hand pump to high-pressure pump.

TIM ID: 0000020606 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 195

2.12.3 Engine coolant pump – Removal


Coolant is hot and under pressure.
Risk of injury and scalding!
WARNING • Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Engine coolant pump – Removal


1. Remove nuts from engine coolant pump (→ Page 192).
2. Loosen engine coolant pump with crowbar and remove.
3. Remove elbow.
4. Remove follower for high-pressure pump.
5. Seal openings with suitable covers.
6. Remove O-ring.
TIM ID: 0000020607 – 001

MS22045/00E 2010-04 © MTU


196 Task Descriptions

2.12.4 Engine coolant pump – Cleaning

Material

Designation / Use Part No. Qty.


Cleaning agent (Hakupur 312) 30390 1

Chemical substances in cleaners.


Risk of irritation and chemical burns!
WARNING • Always obey manufacturer’s instructions for use!

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Cleaning engine coolant pump


1. Remove all deposits from functional and sealing faces.
2. Clean all functional and sealing faces with cleaning agent (Hakupur 312).
3. Rub all functional and sealing faces dry with a clean, lint-free cloth.
4. Remove anticorrosive on new component using cleaning agent (Hakupur 312).

TIM ID: 0000020608 – 003

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Task Descriptions 197

2.12.5 Engine coolant pump – Check

Spare parts

Designation / Use Part No. Qty.


Engine coolant pump
Spacer ring

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Engine coolant pump – Check

Item Findings Task

Check volute and impeller for Cavitation visible. Replace


cavitation.

Visually inspect sealing surfaces for • Stress marks • Recondition: smooth with
stress marks, pitting and cavitation. • Pitting oilstone or emery cloth.
• Cavitation • Replace
visible

Check gear for indentations, traces • Wear traces • Recondition: smooth with
of wear and damage. • Indentations oilstone or emery cloth.
• Damage • Replace.
visible

Check spacer ring for damage. Damaged Replace


TIM ID: 0000020609 – 001

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198 Task Descriptions

2.12.6 Engine coolant pump – Installation

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


O-ring

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Engine coolant pump – Installation


1. Remove all covers prior to installation.
2. Coat O-ring with grease and insert in groove on bearing housing.
3. Install follower for HP pump on engine coolant pump shaft.
Note: Make sure that gears are correctly meshed and that follower fits.

4. Insert engine coolant pump in correct position in bore (→ Page 192).


5. Screw on nuts with washers and tighten evenly.

TIM ID: 0000020610 – 002

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Task Descriptions 199

2.12.7 Engine coolant pump – Final steps


Final steps
1. Assemble in reverse order of disassembly (→ Page 194).
2. Fill with engine coolant (→ Operating Instructions ).
3. Vent fuel system (→ Operating Instructions ).
4. Enable engine start.
TIM ID: 0000020611 – 002

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200 Task Descriptions

2.12.8 Coolant cooler – Overview

1 Coolant distribution housing 4 Cooler plate A Position of code letter (bottom left)
2 Initial plate 5 End plate B Position of gasket (to the
3 Cooler plate 6 Cover plate cover plate)

Engine Plate Initial Coolant cooler End Tense state


Qty. plate plate
Cooler Cooler Cooler Toler- Deviation
plate A plate B plate C anced
size lower upper

8V M72 to 41 1x 19x 20x 1x 139.500 −0.500 +1.000


M93

10V M72 to 49 1x 23x 24x 1x 166.500 −0.500 +1.000


M93

12V M72 to 55 1x 27x 26x 1x 187.000 −5.500 +5.500


M93
TIM ID: 0000020612 – 001

16V M72 to 75 1x 37x 36x 1x 255.000 −7.500 +7.500


M93

MS22045/00E 2010-04 © MTU


Task Descriptions 201

2.12.9 Coolant cooler – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Drain raw water.
3. Remove raw water lines (→ Page 226).
TIM ID: 0000020613 – 001

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202 Task Descriptions

2.12.10 Coolant cooler – Removal

Special tools

Designation / Use Part No. Qty.


Threaded pin 5362030462 2

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Coolant cooler – Removal


1. Screw threaded pin into threaded pin (3).
2. Unlock all screws (1) and unscrew evenly and in
stages.
3. Apply numbers to or mark cooler plates (2), so
that the installation sequence is complied with at
later assembly.
4. Remove cover plate over threaded pin.
5. Remove O-rings.
6. Remove plates one after the other.
7. Place cooler plates to the side and protect from
damage.
8. Remove threaded pin (3) only if damaged.
9. Remove elbow (5).
10. Seal openings with suitable covers.

TIM ID: 0000020614 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 203

2.12.11 Coolant cooler – Cleaning

Special tools

Designation / Use Part No. Qty.


High-pressure cleaner
Soft cleaning brush

Material

Designation / Use Part No. Qty.


Sodium hydroxide
Sodium carbonate
Nitric acid
Sulphamic acid
Citric acid
Phosphoric acid
Kerosene

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

High-pressure water jet.


Risk of injury!
WARNING • Do not direct water jet at persons, electric or electronic equipment.
• Wear protective clothing, gloves, and goggles / safety mask.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Cleaning agents containing chlorine and hydrochloric acid attack metal surfaces.
Risk of damage due to corrosion!
CAUTION • 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.

Unsuitable cleaning tools.


TIM ID: 0000020615 – 002

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Use appropriate cleaning tool.

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204 Task Descriptions

Note: Do not use the following solvents:


• Ketones (e.g.: acetone, methyl ethyl ketone, methylisobutylcetone)
• Esters (e.g.: ethyl acetate, butyl acetate)
• Halogenated hydrocarbons (e.g.: chlorothene, carbon tetrachloride, freon)
• Aromatic compounds (e.g.: benzene, toluene)

Preparatory steps
1. Remove cooler plates (→ Page 202).
2. Place cooler plates on a suitable surface for cleaning.

Heavy fouling
Note: Mechanically clean open unit to remove:
• Algae
• Pieces of wood/fiber
• Shellfish

1. Clean plates under running water with a soft brush. Avoid damaging the seal.
2. Clean plates with high-pressure hose.
3. Dry seals with a cloth.

Biological fouling
Note: Mechanically or chemically clean open unit to remove:
• Bacteria
• Nematodes
• Protozoa

1. Clean plates under running water with a soft brush. Avoid damaging the seal.
2. Clean plates with high-pressure hose.
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 sludge


Note: Mechanically or chemically clean open unit to remove:
• Calcium carbonate
• Calcium sulfate
• Silicates

1. Clean plates under running water with a soft brush. Avoid damaging the seal.
2. Clean plates with high-pressure hose.
3. Clean plates with acidic cleaning agents e.g.:
• Nitric acid
• Sulphamic acid
• Citric acid
TIM ID: 0000020615 – 002

• Phosphoric acid

Concentration Temperature

Max. 4% Max. 60°C

4. Synthetic cleaning additives may improve results.

MS22045/00E 2010-04 © MTU


Task Descriptions 205

Sediments (deposits)
Note: Mechanically or chemically clean open unit to remove:
• Corrosion products
• Metal oxides
• Sludge
• Loam
• Diatom organisms

1. Clean plates under running water with a soft brush. Avoid damaging the seal.
2. Clean plates with high-pressure hose.
3. Clean plates with chemical cleaning agents e.g.:
• Nitric acid
• Sulphamic acid
• Citric acid
• Phosphoric acid

Concentration Temperature

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 a cloth.

Oil residues, asphalt and grease


Note: Mechanically or chemically clean open unit to remove:
• Oil residues
• Asphalt
• Grease

1. Clean plates with kerosene and a 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 cleaner.
3. Blow out cover plate with compressed air.
TIM ID: 0000020615 – 002

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206 Task Descriptions

2.12.12 Coolant cooler – Check

Special tools

Designation / Use Part No. Qty.


Oilstone 8205893261/00 1

Spare parts

Designation / Use Part No. Qty.


Cover plate
Initial plate
Cooler plate
End plate
Threaded pin

Coolant cooler – Check

Item Findings Task

Check thread inserts of cover plate Sluggish Replace thread inserts


for ease of movement.

Check mating faces and sealing • Stress marks • Recondition: smooth with
surfaces of cover plate for stress • Damage oilstone or emery cloth
marks and damage. visible • Replace

Check threaded pin for damage and • Stress marks • Recondition: recut thread
stress marks. • Damage • Replace
visible

TIM ID: 0000020616 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 207

2.12.13 Coolant cooler – Installation

Special tools

Designation / Use Part No. Qty.


Threaded pin 5362030462 2

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Assembly compound (Molykote G-N Plus) 40041 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


O-ring
Tab washer
Nipple

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Coolant cooler – Installation


1. Remove all covers prior to installation.
Note: Tighten clamps for sleeve only when
coolant cooler has been installed.

2. Insert elbow (5) in coolant distribution housing and


slide sleeve over elbow.
3. Screw threaded pin (3) into coolant distribution
housing and tighten.
4. Push cooler plates (2) over threaded pin in
accordance with marked positions made prior to
removal.
5. Screw in two threaded pins, depending on width of
plate package, as mounting device.
6. Coat O-ring with grease and insert in grooves of
cover plate and union.
7. Push on cover plate over threaded pin.
TIM ID: 0000020617 – 002

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208 Task Descriptions

8. Coat thread and screw head mating face of screws


with assembly compound.
9. Insert screws with tab washers and washers and
tighten alternately to dimension (a) (→ Page 200).
10. Select tightening sequence, so that a deflection of
the plate of max. 1 mm (in relation to plate length)
and a non-parallelism of the plate package of
max. 2 mm are not exceeded.
11. Remove threaded pin.
12. Secure screws with tab washers.

TIM ID: 0000020617 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 209

2.12.14 Coolant cooler – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 201).
2. Fill up with engine coolant (→ Operating Instructions ).
3. Enable engine start.
4. Vent fuel system (→ Operating Instructions ).
TIM ID: 0000020618 – 001

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210 Task Descriptions

2.12.15 Coolant pipework with thermostat – Overview

360 Thermostat housing 380 Thermostat insert 390 Screw


370 Flow restrictor 385 Gasket 405 Washer

TIM ID: 0000020619 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 211

Plug screws for thermostat housing

10 Thermostat housing 30 Plug screw 50 Sealing ring


20 Plug screw 40 Sealing ring 60 Sealing ring
TIM ID: 0000020619 – 002

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212 Task Descriptions

2.12.16 Coolant pipework with thermostat – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Remove sensor cable for sensor B6.2 (→ Operating Instructions).
3. Remove protective cover (→ Page 67).
4. Disconnect coolant line from coolant pump elbow.

TIM ID: 0000020620 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 213

2.12.17 Coolant pipework with thermostat – Cleaning

Material

Designation / Use Part No. Qty.


Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1

Cleaner is extremely caustic.


Risk of injury and suffocation!
WARNING • 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.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Coolant pipework with thermostat – Cleaning


1. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Thoroughly blow out all components with compressed air.
TIM ID: 0000020621 – 002

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214 Task Descriptions

2.12.18 Coolant pipework with thermostat – Check

Special tools

Designation / Use Part No. Qty.


Oilstone 8205893261/00 1

Spare parts

Designation / Use Part No. Qty.


Thermostat housing
Thermostat insert

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Component is hot.
Risk of burning!
WARNING • Wear protective gloves.

Coolant pipework with thermostat – Check

Item Findings Task

Check all sealing and mating faces • Stress marks • Recondition: smooth with
for stress marks and damage. • Damage oilstone or emery cloth.
visible • Replace

Check locating bores of thermostat Damaged • Recondition: smooth with


inserts for damage. oilstone.
• Replace

Check threads for ease of Sluggish Replace thread inserts.


movement.

TIM ID: 0000020622 – 003

MS22045/00E 2010-04 © MTU


Task Descriptions 215

Checking thermostat insert


Note: Thermostat insert must not make contact
with the container.

1. Attach coolant thermostat to a wire, suspend in a


container full of coolant.
2. Heat water with suitable heat source.
Note: Start-of-opening temperature is stamped
on thermostat insert.

3. Check thermostat insert for start of opening


with constant heat supply and water constantly
circulating. As from approx. 10 °C below the
start-of-opening temperature, the heating-up rate
should not be more than 1 °C per minute.
4. Replace thermostat insert if results of check are
negative.
5. Continue to heat water to temperature of complete
opening.
Result: Thermostat insert must be completely open
after 6 to 8 minutes.
6. Measure stroke distance of thermostat insert.
7. If stroke distance is less than 9.5 mm, replace
thermostat insert.
TIM ID: 0000020622 – 003

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216 Task Descriptions

2.12.19 Coolant pipework with thermostat – Installation

Special tools

Designation / Use Part No. Qty.


Drive-in tool F30378672 1
Drive-in tool F30450050 1

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


O-rings
Sealing ring
Screws
Union
Gasket
Flow restrictor

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Installing thermostat housing


1. Remove all covers prior to installation.
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 210).
TIM ID: 0000020623 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 217

2.12.20 Coolant pipework with thermostat – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 212).
2. Fill up with engine coolant (→ Operating Instructions ).
3. Fill with engine oil (→ Operating Instructions ).
4. Fill fuel system (→ Operating Instructions ).
5. Enable engine start.
TIM ID: 0000020624 – 002

MS22045/00E 2010-04 © MTU


218 Task Descriptions

2.12.21 Raw water pump – Overview

1 Screw 11 Bearing housing 21 Intermediate piece


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

TIM ID: 0000020631 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 219

2.12.22 Raw water pump – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Close raw water supply.
2. Drain raw water.
3. Remove protective cover and holder.
4. Remove elbow.
TIM ID: 0000020632 – 001

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220 Task Descriptions

2.12.23 Raw water pump – Removal


Coolant is hot and under pressure.
Risk of injury and scalding!
WARNING • Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Raw water pump – Removal


1. Remove nuts for raw water pump as shown in overview drawing (→ Page 218).
2. Remove screws from sleeve.
3. Release raw water pump with crowbar and remove.
4. Remove O-ring.
5. Seal openings with suitable covers.

TIM ID: 0000020633 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 221

2.12.24 Raw water pump – Cleaning

Material

Designation / Use Part No. Qty.


Cleaning agent (Snow-White 11-0) 40460 1
Cleaning agent (Hakupur 312) 30390 1

Cleaner is extremely caustic.


Risk of injury and suffocation!
WARNING • 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.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Raw water pump - Cleaning


1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then rinse with cleaning agent (Hakupur 312).
2. Blow all parts clean thoroughly with compressed air.
TIM ID: 0000020634 – 002

MS22045/00E 2010-04 © MTU


222 Task Descriptions

2.12.25 Raw water pump – Check

Spare parts

Designation / Use Part No. Qty.


Raw water pump

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Raw water pump – Check

Item Findings Task

Check volute and impeller for Cavitation visible. Replace


cavitation.

Visually inspect sealing surfaces for • Stress marks • Recondition: smooth with
stress marks, pitting and cavitation. • Pitting oilstone or emery cloth.
• Cavitation • Replace
visible

Check gear for indentations, traces • Indentations • Recondition: smooth with


of wear and damage. • Wear traces oilstone or emery cloth.
• Damage • Replace raw water pump.
visible

TIM ID: 0000020635 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 223

2.12.26 Raw water pump – Installation

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


O-ring

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Raw water pump – Installation


1. Remove all covers.
2. Coat O-ring with grease and insert in groove on bearing housing.
Note: Make sure that gears are correctly meshed.

3. Insert raw water pump in correct position in bore (→ Page 192).


4. Screw on nuts with washers and tighten evenly.
TIM ID: 0000020636 – 002

MS22045/00E 2010-04 © MTU


224 Task Descriptions

2.12.27 Raw water pump – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 219).
2. Open raw water supply.
3. Fill raw water pump.
4. Enable engine start.

TIM ID: 0000020640 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 225

2.12.28 Coolant pipework on raw water pump – Overview

15 Elbow 65 Flow restrictor 120 Nut


20 Gasket 70 O-ring 125 O-ring
25 Clamping element half 75 Screw 135 Elbow
30 Screw 80 Washer 145 Screw
35 Washer 90 Elbow 150 O-ring
45 Plug screw 100 Union 155 Clamping element half
50 Sealing ring 105 Sealing ring 160 Washer
60 Plug-in sleeve 110 Sealing cone 170 Plug screw
61 O-ring 115 Plug screw 175 Sealing ring
TIM ID: 0000020872 – 002

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226 Task Descriptions

2.12.29 Coolant pipework on raw water pump – Removal

Preconditions
• Preparatory steps have been completed.
Coolant pipework on raw water pump – Removal
1. Remove raw water lines and securing parts as per overview drawing (→ Page 225).
2. Remove Orings, gaskets and sealing rings.
3. Seal openings with suitable covers.

TIM ID: 0000020873 – 002

MS22045/00E 2010-04 © MTU


Task Descriptions 227

2.12.30 Coolant pipework on raw water pump – Installation

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


O-rings
Gasket
Sealing ring
Clamp
Rubber sleeve
Screws
Sealing cone
Nut

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.


Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Coolant pipework on raw water pump – Installation


1. Remove all covers.
2. Coat O-rings with grease.
3. Install lines with new O-rings, sealing rings, gaskets and securing elements as shown in overview drawing
(→ Page 225).
TIM ID: 0000020874 – 002

MS22045/00E 2010-04 © MTU


228 Task Descriptions

2.13 Auxiliary Systems / Supplementary Equipment

2.13.1 Bilge pump – Overview

1 Bilge pump 3 Nut 5 Threaded adapter


2 Screw 4 Washer 6 Sealing tape

TIM ID: 0000020641 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 229

Carrier and clamping fixture

1 Carrier 8 Sleeve 15 Screw


2 Screw 9 Washer 16 Washer
3 Screw 10 Washer 17 Nut
4 Washer 11 Screw 18 Bearing cap stud
5 Screw 12 Washer 19 Screw
6 Washer 13 Clamping nut 20 Washer
7 Carrier 14 Clamping element 21 V-belt
TIM ID: 0000020641 – 001

MS22045/00E 2010-04 © MTU


230 Task Descriptions

Bilge pump

1 Screw 9 Screw 17 Belt pulley


2 Cover 10 Plug 18 Shaft
3 Seal 11 Washer 19 Wedge
4 Impeller 12 Sealing 20 Ball bearing
5 Plate 13 Adapter 21 Ring
6 Rotary seal 14 Screw 22 Repair kit
7 Housing 15 Coil 23 Washer
8 Cam 16 Screw 24 Screw

TIM ID: 0000020641 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 231

2.13.2 Bilge pump – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Remove protective cover (→ Page 67).
2. Remove suction and pressure lines.
3. Mark electrical cable on bilge pump and disconnect it.
TIM ID: 0000020642 – 001

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232 Task Descriptions

2.13.3 Bilge pump – Removal


V-belt – Removal
1. Loosen screw (3) for clamp (2).
2. Loosen tensioning nut until V-belt (1) can be
removed.

Bilge pump – Removal


1. Remove belt tensioner as shown in overview drawing (→ Page 228).
2. Remove bilge pump and bracket as shown in overview drawing (→ Page 228).

TIM ID: 0000020643 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 233

2.13.4 Bilge pump – Cleaning

Material

Designation / Use Part No. Qty.


Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1

Cleaner is extremely caustic.


Risk of injury and suffocation!
WARNING • 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.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.


Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Bilge pump – Cleaning


1. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Thoroughly blow all parts clean with compressed air.
TIM ID: 0000020649 – 001

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234 Task Descriptions

2.13.5 Bilge pump – Check

Spare parts

Designation / Use Part No. Qty.


Bilge pump
Belt pulley
V-belt

Bilge pump – Check

Item Findings Task

Check housing and cover for Cavitation visible. Replace


cavitation.

Check belt pulley for wear, distortion • Wear Replace


and damage. • Distortion
• Damage
visible

Check condition of keyway in belt Damage visible. Replace


pulley.

Check all contact and mating Stress marks visible. • Recondition: smooth with
surfaces. oilstone or emery cloth.
• Replace

Check screws for damage. Damage visible. Replace

Check threads for ease of Sluggish • Recondition: recut threads.


movement. • Replace

If it is to be used again, check V-belt • Cracks • Clean


for cracks, fouling by oil, overheating • Fouling by oil • Replace
and wear. • Overheating
• Wear
visible

TIM ID: 0000020650 – 001

MS22045/00E 2010-04 © MTU


Task Descriptions 235

2.13.6 Bilge pump – Installation

Special tools

Designation / Use Part No. Qty.


Alignment tool F6784786 1
Preloading force measuring device Y20097429 1

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil

Spare parts

Designation / Use Part No. Qty.


O-ring
Snap ring

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Bilge pump – Installation


1. Install clamping jig (3), bilge pump (2) and bracket
as shown in overview drawing (→ Page 228).
2. Mount V-belt (1) on belt pulley.
3. Set parallelism of both belt pulleys with alignment
tool.
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236 Task Descriptions

Adjusting V-belt tension


1. Tension V-belt (1) with clamping nut and adjust
V-belt tension, see following section.
2. After adjusting, tighten screw (3) for clamp (2).

3. The stop (arrow) of the measuring instrument must


be at the side of the V-belt and the pointer must be
sunk into the measuring instrument.
4. Place preload measuring device on to V-belt in the
middle between belt pulleys.
5. Use pushbutton to press it evenly in vertical
direction down on to V-belt upper side until click
pin can be heard or felt to engage. Do not press
any further, otherwise the indicated value will be
falsified.
6. Carefully remove preload measuring device
without changing the position of the pointer.
7. Read off measured value at point of intersection
between pointer and scale. Measured value x 10
equals strand pull in N.
8. If settings deviate, correct them and repeat
measurement.

Settings

New V-belt 450 N ±50 N

Run V-belt 400 N ±50 N


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Task Descriptions 237

2.13.7 Bilge pump – Final steps


Final steps
1. Assemble in reverse order to disassembly (→ Page 231).
2. Connect electrical cable to bilge pump.
3. Install suction and pressure lines.
4. Enable engine start.
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238 Task Descriptions

2.14 Monitoring, Control and Regulation System

2.14.1 Sensors, actuators and injectors – Overview

No. Designation For monitoring

1 B9 Charge air temperature

2 B10 Charge air pressure

3 B7 Lube oil temperature

4 B3 Intake air temperature


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Task Descriptions 239

Free end side V 2000CR

No. Designation For monitoring

1 B34 Fuel line pressure after filter

2 B5.3 Lube oil pressure before filter

3 B5.2 Lube oil pressure

4 B5 Lube oil pressure

5 F33 Coolant pressure

6 B21 Raw water pressure

7 B16 Coolant pressure

8 B6.2 Coolant temperature

9 B6 Coolant temperature
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240 Task Descriptions

Driving end side V 2000CR

No. Designation For monitoring

1 B4.22 Exhaust gas temperature

2 B1 Camshaft speed

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Task Descriptions 241

Right engine side V 2000CR

No. Designation For monitoring

1 B44 Turbocharger speed

2–6 Y39.x Injector


7 B33 Fuel temperature

8 B48 Fuel pressure in the rail

9 M8 HP pump

10 B13.2 Crankshaft speed

11 B13 Crankshaft speed

12 F46 Leak-off fuel level


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242 Task Descriptions

Left engine side V 2000CR

No. Designation For monitoring

1–5 Y39.x Injector

6 B4.21 Exhaust gas temperature A


7 Y27 Exhaust gas temperature B

System sensors
The sensors are mounted on the engine exterior.

Designation For monitoring

B19 Starting-air pressure

B70 Water level in fuel prefilter


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B41 Exhaust back pressure

S37 Start interlock, switch status

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Task Descriptions 243

2.14.2 Sensors, actuators and injectors – Preparatory steps

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Observe safety regulations.
2. Drain engine coolant (only if coolant sensors are to be removed) (→ Operating Instructions).
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244 Task Descriptions

2.14.3 Sensors, actuators and injectors – Removal


Fuels are combustible.
Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Coolant is hot and under pressure.


Risk of injury and scalding!
WARNING • Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Removing temperature sensors (B3, B6, B7, B9,


B33)
1. Always note:
• The sensors are identical with regard to design
and electrical function. Removal is also identical.
• Arrangement and position of sensors
(→ Page 238).
2. Observe the following prior to removal:

B6 (coolant temperature) For tasks and safety instructions (→ Operating Instructions)

B7 (oil temperature) During removal, small amounts of engine oil may emerge. Catch engine
oil in a suitable container.

B33 (fuel temperature) During removal, small amounts of fuel may emerge. Catch fuel in a
suitable container.

3. Release bayonet lock (1) and remove connector


(2).
4. Remove sensor via nut (3).
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Task Descriptions 245

Removing temperature sensors (B4.21, B4.22)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Removal is also identical.
• Arrangement and position of sensors
(→ Page 238).
2. Release bayonet lock (1) and remove connector
(2).
3. Remove union nut (3) from temperature sensor.
4. Remove temperature sensor from union (4).

Removing pressure sensors (B5, B10, B16, B21)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Removal is also identical.
• Arrangement and position of sensors
(→ Page 238).
• During removal of sensor B5 (oil pressure),
small amounts of engine oil may emerge. Catch
engine oil in a suitable container.
2. Release bayonet lock (1) and remove connector
(2).
3. Remove sensor via nut (3).

Removing pressure sensors (B34, B48)


1. Always note:
• Arrangement and position of sensor
(→ Page 238).
• During removal of sensors, small amounts of fuel
may emerge. Catch fuel in a suitable container.
2. Release bayonet lock (1) and remove connector
(2).
3. Remove sensor via nut (3).
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246 Task Descriptions

Removing speed sensors (B1, B13)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Removal is also identical.
• Arrangement and position of sensors
(→ Page 238).
2. Release bayonet lock (1) of speed sensor (2) and
remove connector (3) from engine wiring system.
3. Remove screw (4).
4. Remove speed sensor (2).

Speed sensors (B44.1, B44.2)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Removal is also identical.
• Arrangement and position of sensors
(→ Page 238).
2. Release bayonet lock of speed sensor and remove
connector from engine wiring system.
3. Remove speed sensor from turbocharger.

Level probe (F33)


1. Always note:
• Arrangement and position of sensors
(→ Page 238).
2. Release bayonet lock (2) and remove connector
(1).
3. Remove sensor (3) via nut.
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Task Descriptions 247

Level probe (F46)


1. Always note:
• Arrangement and position of sensors
(→ Page 238).
2. Release bayonet lock and remove from connector.
3. Remove sensor via nut (1).
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248 Task Descriptions

2.14.4 Sensors, actuators and injectors – Installation

Material

Designation / Use Part No. Qty.


Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1

Spare parts

Designation / Use Part No. Qty.


O-ring
Sealing ring
Adjusting shim

Installing temperature sensors (B3, B6, B7, B9, B33)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
• Arrangement and position of sensors
(→ Page 238).
2. Coat O-ring of sensor with grease.
3. Insert sensor in bore by hand.
4. Tighten nut (3) with torque wrench to specified
tightening torque (→ Page 17).
5. Fit connector (2) and tighten bayonet lock (1).

Installing pressure sensors (B5, B10, B16, B21)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
• Arrangement and position of sensors
(→ Page 238).
2. Coat O-ring of sensor with grease.
3. Insert sensor in bore by hand.
4. Tighten nut (3) with torque wrench to specified
tightening torque (→ Page 17).
5. Fit connector (2) and tighten bayonet lock (1).
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Task Descriptions 249

Installing pressure sensors (B34, B48)


1. Always note:
• Arrangement and position of sensor
(→ Page 238).
2. Coat O-ring of sensor with grease.
3. Insert sensor in bore by hand.
4. Tighten nut (3) with torque wrench to specified
tightening torque (→ Page 17).
5. Fit connector (2) and tighten bayonet lock (1).

Installing speed sensors (B1; B13)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
• Arrangement and position of sensors
(→ Page 238).
2. Coat O-ring of sensor with grease.
3. Fit sensor in bore and press in.
4. Tighten sensor (2) with screw (4).
5. Check clearance dimension “A”, see table below.

"A" (clearance between sensor and timing wheel)

Speed sensor B1 0.1 mm to 1.6 mm

Speed sensor B13 0.45 mm to 1.45 mm

6. Insert connector for speed sensor (2) in bush (3) of


engine wiring system. Tighten bayonet lock (1).
7. If necessary, roll up sensor cable to correct length
and secure with cable clamps.
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250 Task Descriptions

Installing temperature sensors (B4.21, B4.22)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
• Arrangement and position of sensors
(→ Page 238).
2. Insert temperature sensor in union (2).
3. Screw on union nut (1) for temperature sensor.

Speed sensors (B44.1, B44.2)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
• Arrangement and position of sensors
(→ Page 238).
2. Insert speed sensor on turbocharger in bore and
press in.

Installing level probe (F33)


1. Always note:
• Arrangement and position of sensors
(→ Page 238).
2. Coat O-rings with grease.
3. Insert sensor in bore by hand.
4. Tighten nut of sensor (3) with torque wrench to
specified tightening torque (→ Page 17).
5. Fit connector (1) and tighten bayonet lock (2).
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Task Descriptions 251

Installing level probe (F46)


1. Always note:
• Arrangement and position of sensors
(→ Page 238).
2. Coat O-rings with grease.
3. Insert sensor in bore by hand.
4. Tighten nut (1) with torque wrench to specified
tightening torque (→ Page 17).
5. Fit connector and tighten bayonet lock.
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252 Task Descriptions

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Special Tools 253

3 Special Tools

3.1 Standard tools – Overview

Order no. Designation Quan-


Use tity

8205891159/00 General tool kit 1


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254 Special Tools

3.2 Special tools – Overview

Part No. Designation / Use Qty.

Y20091483 Bore gauge, 160-280 mm 1

Y20011268 Dial gauge 1

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Special Tools 255

Part No. Designation / Use Qty.

Y20000326 C-frame micrometer, 150-175 1


mm

F6783773 Removal tool for liner 1


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256 Special Tools

Part No. Designation / Use Qty.

F6783388 Press-in device for cylinder 1


liner

F6555715 Safety rail 2

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Special Tools 257

Part No. Designation / Use Qty.

F6784104 Lowering device 3

F0140560 Installation/removal tool 1


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258 Special Tools

Part No. Designation / Use Qty.

T80091925 Lifting gear 1

B80146887 Hand pump set 1

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Special Tools 259

Part No. Designation / Use Qty.

B80146893 Hand pump set 1

F6780523 Protective sleeve 1


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260 Special Tools

Part No. Designation / Use Qty.

Y4345226 Ring gauge 1

F6783914 Barring tool 1

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Special Tools 261

Part No. Designation / Use Qty.

F6783791 Assembly jig 1

F30005947 Socket 1
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262 Special Tools

Part No. Designation / Use Qty.

F30005947-1-b Socket 1

F30379877 Piston-ring pliers 1

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Special Tools 263

Part No. Designation / Use Qty.

F6784287 Assembly sleeve 1

F6557995 Assembly jig 1


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264 Special Tools

Part No. Designation / Use Qty.

F30027337 Torque wrench, 40-200 Nm 1

F30027341 Ratchet adapter 1

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Special Tools 265

Part No. Designation / Use Qty.

Y4341492 Testing device 1

Y4341915 Test mandrel 1


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266 Special Tools

Part No. Designation / Use Qty.

Y4341916 Test mandrel 1

Y20091481 Bore gauge, 100-160 mm 1

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Special Tools 267

Part No. Designation / Use Qty.

Y20002777 Depth gauge, 300 mm 1

F30907150 Socket 1
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268 Special Tools

Part No. Designation / Use Qty.

Y20044010 Rotation gauge 1

F6557932 Pointer for barring tool 1

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Special Tools 269

Part No. Designation / Use Qty.

Y4345595 Graduated disk for 8V 1

Y4345536 Graduated disk for 10V 1


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270 Special Tools

Part No. Designation / Use Qty.

Y4345886 Graduated disk for 12V 1

Y4345887 Graduated disk for 16V 1

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Special Tools 271

Part No. Designation / Use Qty.

F30026582 Torque wrench, 20-100 Nm 1

F30027340 Ratchet adapter 1


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272 Special Tools

Part No. Designation / Use Qty.

F30025897 Combination wrench, 19 mm 1

F30043446 Torque wrench, 8-40 Nm 1

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Special Tools 273

Part No. Designation / Use Qty.

F30450460 Guide pin 2

F6784160 Extraction tool 1


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274 Special Tools

Part No. Designation / Use Qty.

F30451502 Socket wrench 1

F30450342 Assembly sleeve 1

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Special Tools 275

Part No. Designation / Use Qty.

F6783244 Alignment tool 1

F6787011 Alignment tool 1


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276 Special Tools

Part No. Designation / Use Qty.

T80091650 Lifting device 1

T80091665 Carrying bracket 1

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Special Tools 277

Part No. Designation / Use Qty.

F30027336 Torque wrench 6-50 Nm 1

T80091621 Lifting gear 1


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278 Special Tools

Part No. Designation / Use Qty.

F30027336 Torque wrench, 6-50 Nm 1

T80091769 Hook 1

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Special Tools 279

Part No. Designation / Use Qty.

T80090943 Hook-ended chain sling 1

8205893261/00 Oilstone 1
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280 Special Tools

Part No. Designation / Use Qty.

5362030462 Threaded pin 2

F30378672 Drive-in tool 1

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Special Tools 281

Part No. Designation / Use Qty.

F30450050 Drive-in tool 1

F6784786 Alignment tool 1


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282 Special Tools

Part No. Designation / Use Qty.

Y20097429 Preloading force measuring 1


device

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Special Tools 283

3.3 General workshop equipment – Overview

Order no. Designation Quan-


Use tity

F30004455 Open-end wrench 1

F30006068 Double open-end 1


wrench
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284 Special Tools

Order no. Designation Quan-


Use tity

F30025896 Open end wrench 1


bit

F30028338 Open end wrench 1


bit

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Special Tools 285

Order no. Designation Quan-


Use tity

F30029815 Open end wrench 1


bit

F30029816 Open end wrench 1


bit
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286 Special Tools

Order no. Designation Quan-


Use tity

F30047446 Torque wrench 1

F30450902 Ratchet bit 1

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Special Tools 287

Order no. Designation Quan-


Use tity

F30501631 Starter wrench 1

Y20097353 Endoscope 1
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288 Special Tools

Order no. Designation Quan-


Use tity

5505890921/00 Compression 1
pressure recorder

5505890921/06 Diagram sheets 1

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Appendix 289

4 Appendix

4.1 Manufacturer’s documentation


See manufacturer’s documentation.
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290 Appendix

4.2 MTU Contact/Service Partners

Service
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and customer
service centers ensure fast and direct support on site and ensure the high availability of our products.
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For our locally available support, go to MTU’s Internet site: http://www.mtu-online.com/mtu/mtu-worldwide/
24h Hotline
With our 24h hotline and high flexibility, we’re your contact around the clock: during each operating
phase, preventive maintenance and corrective operations in case of a malfunction, for information
on changes in conditions of use and for supplying spare parts.
Your contact at Headquarters: Service-support@mtu-online.com
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.
To this end we offer worldwide networked parts logistics
– a central depot at Headquarters, as well as decentralized depots among our subsidiaries,
representatives and contractual workshops.
Your contact at Headquarters:
e-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908779
Fax.: +49 7541 908102

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Appendix 291

4.3 Index
A Carrier housing – Final steps . . . . . . . . . . . . . 181
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . 43 Carrier housing – Overview . . . . . . . . . . . . . . 171
Air Intake / Air Supply . . . . . . . . . . . . . . . . . . . 168 Carrier housing – Preparatory steps . . . . . . . . 172
Air pipework to cylinders – Conrod – Assembly . . . . . . . . . . . . . . . . . . . . 95
Installation . . . . . . . . . . . . . . . . . . . . . . 170
Conrod – Check . . . . . . . . . . . . . . . . . . . . . . . 89
Air pipework to cylinders – Removal . . . 169
Air supply system to cylinders – Conrod – Tolerances . . . . . . . . . . . . . . . . . . . . 91
Overview . . . . . . . . . . . . . . . . . . . . . . . . 168 Conrod bearing shells – Check . . . . . . . . . . . . 104
Air pipework to cylinders – Installation . . . . . . 170 Constant-pressure manifold – Removal . . . . . 173
Air pipework to cylinders – Removal . . . . . . . . 169 Conversion tables . . . . . . . . . . . . . . . . . . . . . . 36
Air supply system to cylinders – Overview . . . 168 Coolant cooler – Check . . . . . . . . . . . . . . . . . . 206
Auxiliary materials, fire prevention and Coolant cooler – Cleaning . . . . . . . . . . . . . . . . 203
environmental protection . . . . . . . . . . . . . . . . . 12 Coolant cooler – Final steps . . . . . . . . . . . . . . 209
Auxiliary Systems / Supplementary Coolant cooler – Installation . . . . . . . . . . . . . . 207
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Coolant cooler – Overview . . . . . . . . . . . . . . . 200
Bilge pump – Check . . . . . . . . . . . . . . . 234
Bilge pump – Cleaning . . . . . . . . . . . . . 233 Coolant cooler – Preparatory steps . . . . . . . . . 201
Bilge pump – Final steps . . . . . . . . . . . 237 Coolant cooler – Removal . . . . . . . . . . . . . . . . 202
Bilge pump – Installation . . . . . . . . . . . . 235 Coolant pipework on raw water pump –
Bilge pump – Overview . . . . . . . . . . . . . 228 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Bilge pump – Preparatory steps . . . . . . 231
Coolant pipework on raw water pump –
Bilge pump – Removal . . . . . . . . . . . . . 232
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Coolant pipework on raw water pump –
B Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Bilge pump – Check . . . . . . . . . . . . . . . . . . . . 234 Coolant pipework with thermostat – Check . . . 214
Bilge pump – Cleaning . . . . . . . . . . . . . . . . . . 233 Coolant pipework with thermostat –
Bilge pump – Final steps . . . . . . . . . . . . . . . . . 237 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Bilge pump – Installation . . . . . . . . . . . . . . . . . 235 Coolant pipework with thermostat – Final
Bilge pump – Overview . . . . . . . . . . . . . . . . . . 228 steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Bilge pump – Preparatory steps . . . . . . . . . . . 231 Coolant pipework with thermostat –
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Bilge pump – Removal . . . . . . . . . . . . . . . . . . 232
Coolant pipework with thermostat –
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
C Coolant pipework with thermostat – Preparatory
Carrier housing – Cover removal and steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Carrier housing – Disassembly . . . . . . . . . . . . 174
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292 Appendix

Coolant System . . . . . . . . . . . . . . . . . . . . . . . 192 Protective cover – Removal . . . . . . . . . 67


Coolant cooler – Check . . . . . . . . . . . . 206 Vibration damper on PTO, free end –
Coolant cooler – Cleaning . . . . . . . . . . 203 Installation . . . . . . . . . . . . . . . . . . . . . . 70
Coolant cooler – Final steps . . . . . . . . . 209 Vibration damper on PTO, free end –
Coolant cooler – Installation . . . . . . . . . 207 Overview . . . . . . . . . . . . . . . . . . . . . . . . 64
Coolant cooler – Overview . . . . . . . . . . 200 Vibration damper on PTO, free end –
Coolant cooler – Preparatory steps . . . 201 Removal . . . . . . . . . . . . . . . . . . . . . . . . 68
Coolant cooler – Removal . . . . . . . . . . 202 Crankcase and Externally Mounted
Coolant pipework on raw water pump – Components . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation . . . . . . . . . . . . . . . . . . . . . . 227 Crankcase breather – Removal . . . . . . 63
Coolant pipework on raw water pump – Cylinder liner – Check . . . . . . . . . . . . . . 50
Overview . . . . . . . . . . . . . . . . . . . . . . . . 225 Cylinder liner – Cleaning . . . . . . . . . . . . 49
Coolant pipework on raw water pump – Cylinder liner – Final steps . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . 226 Cylinder liner – Installation . . . . . . . . . . 53
Coolant pipework with thermostat – Cylinder liner – Overview . . . . . . . . . . . 46
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Cylinder liner – Preparatory steps . . . . . 47
Coolant pipework with thermostat – Cylinder liner – Removal . . . . . . . . . . . . 48
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 213 Cylinder liner – Tolerances . . . . . . . . . . 51
Coolant pipework with thermostat – Final Engine layout . . . . . . . . . . . . . . . . . . . . 45
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Oil pan – Check . . . . . . . . . . . . . . . . . . 59
Coolant pipework with thermostat – Oil pan – Final steps . . . . . . . . . . . . . . . 62
Installation . . . . . . . . . . . . . . . . . . . . . . 216 Oil pan – Installation . . . . . . . . . . . . . . . 60
Coolant pipework with thermostat – Oil pan – Overview . . . . . . . . . . . . . . . . 56
Overview . . . . . . . . . . . . . . . . . . . . . . . . 210 Oil pan – Preparatory steps . . . . . . . . . 57
Coolant pipework with thermostat – Oil pan – Removal . . . . . . . . . . . . . . . . 58
Preparatory steps . . . . . . . . . . . . . . . . . 212
Crankcase breather – Removal . . . . . . . . . . . 63
Engine coolant pump – Check . . . . . . . 197
Engine coolant pump – Cleaning . . . . . 196 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . 105
Engine coolant pump – Final steps . . . . 199 Cylinder head – Cleaning . . . . . . . . . . . 109
Engine coolant pump – Installation . . . . 198 Cylinder head – Final steps . . . . . . . . . 112
Engine coolant pump – Overview . . . . . 192 Cylinder head – Installation . . . . . . . . . . 110
Engine coolant pump – Preparatory Cylinder head – Overview . . . . . . . . . . . 105
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Cylinder head – Preparatory steps . . . . 107
Engine coolant pump – Removal . . . . . 195 Cylinder head – Removal . . . . . . . . . . . 108
Raw water pump – Check . . . . . . . . . . . 222 Cylinder head – Cleaning . . . . . . . . . . . . . . . . 109
Raw water pump – Cleaning . . . . . . . . . 221 Cylinder head – Final steps . . . . . . . . . . . . . . 112
Raw water pump – Final steps . . . . . . . 224
Cylinder head – Installation . . . . . . . . . . . . . . . 110
Raw water pump – Installation . . . . . . . 223
Raw water pump – Overview . . . . . . . . 218 Cylinder head – Overview . . . . . . . . . . . . . . . . 105
Raw water pump – Preparatory Cylinder head – Preparatory steps . . . . . . . . . 107
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Cylinder head – Removal . . . . . . . . . . . . . . . . 108
Raw water pump – Removal . . . . . . . . . 220
Cylinder liner – Check . . . . . . . . . . . . . . . . . . . 50
Crank Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Cylinder liner – Cleaning . . . . . . . . . . . . . . . . . 49
Conrod – Assembly . . . . . . . . . . . . . . . 95
Conrod – Check . . . . . . . . . . . . . . . . . . 89 Cylinder liner – Final steps . . . . . . . . . . . . . . . 55
Conrod – Tolerances . . . . . . . . . . . . . . . 91 Cylinder liner – Installation . . . . . . . . . . . . . . . 53
Conrod bearing shells – Check . . . . . . . 104 Cylinder liner – Overview . . . . . . . . . . . . . . . . 46
Piston – Check . . . . . . . . . . . . . . . . . . . 82
Cylinder liner – Preparatory steps . . . . . . . . . . 47
Piston – Cleaning . . . . . . . . . . . . . . . . . 81
Piston – Tolerances . . . . . . . . . . . . . . . 84 Cylinder liner – Removal . . . . . . . . . . . . . . . . . 48
Piston and conrod – Assembly . . . . . . . 97 Cylinder liner – Tolerances . . . . . . . . . . . . . . . 51
Piston and conrod – Disassembly . . . . . 80
TIM ID: 0000020688 – 004

Piston and conrod – Final steps . . . . . . 103


Piston and conrod – Installation . . . . . . 100
E
Piston and conrod – Overview . . . . . . . 74 Electric starter – Overview . . . . . . . . . . . . . . . 182
Piston and conrod – Preparatory Engine coolant pump – Check . . . . . . . . . . . . 197
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Engine coolant pump – Cleaning . . . . . . . . . . 196
Piston and conrod – Removal . . . . . . . . 78
Engine coolant pump – Final steps . . . . . . . . . 199
Protective cover – Installation . . . . . . . . 73
Protective cover – Overview . . . . . . . . . 66 Engine coolant pump – Installation . . . . . . . . . 198

MS22045/00E 2010-04 © MTU


Appendix 293

Engine coolant pump – Overview . . . . . . . . . . 192 Fuel pipework from fuel delivery pump to fuel
Engine coolant pump – Preparatory steps . . . 194 filter – Installation . . . . . . . . . . . . . . . . . . . . . . 148
Engine coolant pump – Removal . . . . . . . . . . 195 Fuel pipework from fuel delivery pump to fuel
filter – Overview . . . . . . . . . . . . . . . . . . . . . . . 143
Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fuel pipework from fuel delivery pump to fuel
Engine side and cylinder designations . . . . . . 16
filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . 147
Exhaust flap with actuator . . . . . . . . . . . . . . . . 175
Exhaust flap with actuators – Installation . . . . 179
G
Exhaust flap with actuators – Removal . . . . . . 178
General information on the Tolerances and Wear
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . 171 Limits List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Carrier housing – Cover removal and
installation . . . . . . . . . . . . . . . . . . . . . . . 180 General Instructions . . . . . . . . . . . . . . . . . . . . 07
Carrier housing – Disassembly . . . . . . . 174 General Provisions . . . . . . . . . . . . . . . . . . . . . 07
Carrier housing – Final steps . . . . . . . . 181 Abbreviations . . . . . . . . . . . . . . . . . . . . 43
Carrier housing – Overview . . . . . . . . . 171 Auxiliary materials, fire prevention and
Carrier housing – Preparatory steps . . . 172 environmental protection . . . . . . . . . . . 12
Constant-pressure manifold – Conversion tables . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . 173 Engine side and cylinder designa-
Exhaust flap with actuator . . . . . . . . . . . 175 tions . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exhaust flap with actuators – General information on the Tolerances
Installation . . . . . . . . . . . . . . . . . . . . . . 179 and Wear Limits List . . . . . . . . . . . . . . . 15
Exhaust flap with actuators – General Instructions . . . . . . . . . . . . . . . 07
Removal . . . . . . . . . . . . . . . . . . . . . . . . 178 Personnel and organizational
Exhaust Turbocharger . . . . . . . . . . . . . . . . . . 158 requirements . . . . . . . . . . . . . . . . . . . . . 08
Exhaust turbocharger – Check . . . . . . . 164 Repairing threaded bores with threaded
Exhaust turbocharger – Cleaning . . . . . 163 inserts (Heli-Coil) . . . . . . . . . . . . . . . . . 41
Exhaust turbocharger – Final steps . . . 167 Safety precautions when working on the
Exhaust turbocharger – Installation . . . 165 engine . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Exhaust turbocharger – Overview . . . . . 158 Settings . . . . . . . . . . . . . . . . . . . . . . . . . 34
Exhaust turbocharger – Preparatory Standards for warning notices in the
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 publication . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust turbocharger – Removal . . . . . 161 Tightening specifications for screws, nuts
and bolts . . . . . . . . . . . . . . . . . . . . . . . . 17
Exhaust turbocharger – Check . . . . . . . . . . . . 164
General workshop equipment – Overview . . . 283
Exhaust turbocharger – Cleaning . . . . . . . . . . 163
Exhaust turbocharger – Final steps . . . . . . . . 167
Exhaust turbocharger – Installation . . . . . . . . . 165
H
High Pressure Fuel System . . . . . . . . . . . . . . 129
Exhaust turbocharger – Overview . . . . . . . . . . 158
HP fuel pump – Check . . . . . . . . . . . . . 135
Exhaust turbocharger – Preparatory steps . . . 160 HP fuel pump – Installation . . . . . . . . . . 136
Exhaust turbocharger – Removal . . . . . . . . . . 161 HP fuel pump – Overview . . . . . . . . . . . 132
Exhaust turbocharger oil supply – HP fuel pump – Preparatory steps . . . . 133
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 HP fuel pump – Removal . . . . . . . . . . . 134
HP fuel system – Tightening
Exhaust turbocharger oil supply –
procedure . . . . . . . . . . . . . . . . . . . . . . . 129
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
HP line – Installation . . . . . . . . . . . . . . . 142
Exhaust turbocharger oil supply – HP line – Overview . . . . . . . . . . . . . . . . 140
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 HP line – Removal . . . . . . . . . . . . . . . . 141
HP pump – Final steps . . . . . . . . . . . . . 139
F HP fuel pump – Check . . . . . . . . . . . . . . . . . . 135
HP fuel pump – Installation . . . . . . . . . . . . . . . 136
TIM ID: 0000020688 – 004

Fuel cooler – Check . . . . . . . . . . . . . . . . . . . . 152


Fuel cooler – Final steps . . . . . . . . . . . . . . . . . 154 HP fuel pump – Overview . . . . . . . . . . . . . . . . 132
Fuel cooler – Installation . . . . . . . . . . . . . . . . . 153 HP fuel pump – Preparatory steps . . . . . . . . . 133
Fuel cooler – Overview . . . . . . . . . . . . . . . . . . 149 HP fuel pump – Removal . . . . . . . . . . . . . . . . 134
Fuel cooler – Preparatory steps . . . . . . . . . . . 150 HP fuel system – Tightening procedure . . . . . 129
Fuel cooler – Removal . . . . . . . . . . . . . . . . . . 151 HP line – Installation . . . . . . . . . . . . . . . . . . . . 142
HP line – Overview . . . . . . . . . . . . . . . . . . . . . 140

MS22045/00E 2010-04 © MTU


294 Appendix

HP line – Removal . . . . . . . . . . . . . . . . . . . . . 141 Oil pan – Installation . . . . . . . . . . . . . . . . . . . . 60


HP pump – Final steps . . . . . . . . . . . . . . . . . . 139 Oil pan – Overview . . . . . . . . . . . . . . . . . . . . . 56
Oil pan – Preparatory steps . . . . . . . . . . . . . . 57
I Oil pan – Removal . . . . . . . . . . . . . . . . . . . . . 58
Important Notes . . . . . . . . . . . . . . . . . . . . . . . 05
Prerequisites for maintenance work and P
general assembly instructions . . . . . . . . 05
Personnel and organizational require-
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
Piston – Check . . . . . . . . . . . . . . . . . . . . . . . . 82
L Piston – Cleaning . . . . . . . . . . . . . . . . . . . . . . 81
Leak-off fuel system – Installation . . . . . . . . . . 157 Piston – Tolerances . . . . . . . . . . . . . . . . . . . . 84
Leak-off fuel system – Overview . . . . . . . . . . . 155 Piston and conrod – Assembly . . . . . . . . . . . . 97
Leak-off fuel system – Removal . . . . . . . . . . . 156 Piston and conrod – Disassembly . . . . . . . . . . 80
Low Pressure Fuel System . . . . . . . . . . . . . . . 143 Piston and conrod – Final steps . . . . . . . . . . . 103
Fuel cooler – Check . . . . . . . . . . . . . . . 152 Piston and conrod – Installation . . . . . . . . . . . 100
Fuel cooler – Final steps . . . . . . . . . . . . 154
Fuel cooler – Installation . . . . . . . . . . . . 153 Piston and conrod – Overview . . . . . . . . . . . . 74
Fuel cooler – Overview . . . . . . . . . . . . . 149 Piston and conrod – Preparatory steps . . . . . . 77
Fuel cooler – Preparatory steps . . . . . . 150 Piston and conrod – Removal . . . . . . . . . . . . . 78
Fuel cooler – Removal . . . . . . . . . . . . . 151 Prerequisites for maintenance work and general
Fuel pipework from fuel delivery pump to assembly instructions . . . . . . . . . . . . . . . . . . . 05
fuel filter – Installation . . . . . . . . . . . . . . 148
Fuel pipework from fuel delivery pump to Protective cover – Installation . . . . . . . . . . . . . 73
fuel filter – Overview . . . . . . . . . . . . . . . 143 Protective cover – Overview . . . . . . . . . . . . . . 66
Fuel pipework from fuel delivery pump to Protective cover – Removal . . . . . . . . . . . . . . 67
fuel filter – Removal . . . . . . . . . . . . . . . 147 Pushrod – Cleaning . . . . . . . . . . . . . . . . . . . . 116
Leak-off fuel system – Installation . . . . . 157
Leak-off fuel system – Overview . . . . . . 155 Pushrod – Removal . . . . . . . . . . . . . . . . . . . . 115
Leak-off fuel system – Removal . . . . . . 156
Lube-Oil System, Lube-Oil Circuit . . . . . . . . . . 187 R
Exhaust turbocharger oil supply – Raw water pump – Check . . . . . . . . . . . . . . . . 222
Installation . . . . . . . . . . . . . . . . . . . . . . 191
Raw water pump – Cleaning . . . . . . . . . . . . . . 221
Exhaust turbocharger oil supply –
Overview . . . . . . . . . . . . . . . . . . . . . . . . 187 Raw water pump – Final steps . . . . . . . . . . . . 224
Exhaust turbocharger oil supply – Raw water pump – Installation . . . . . . . . . . . . 223
Removal . . . . . . . . . . . . . . . . . . . . . . . . 190 Raw water pump – Overview . . . . . . . . . . . . . 218
Raw water pump – Preparatory steps . . . . . . . 219
M Raw water pump – Removal . . . . . . . . . . . . . . 220
Manufacturer’s documentation . . . . . . . . . . . . 289 Repairing threaded bores with threaded inserts
Monitoring, Control and Regulation (Heli-Coil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 Roller tappet, pushrod – Check . . . . . . . . . . . . 117
Sensors, actuators and injectors – Roller tappet, pushrod – Installation . . . . . . . . 118
Installation . . . . . . . . . . . . . . . . . . . . . . 248
Sensors, actuators and injectors – Roller tappet, pushrod – Preparatory steps . . . 114
Overview . . . . . . . . . . . . . . . . . . . . . . . . 238 Roller tappets, pushrod – Final steps . . . . . . . 119
Sensors, actuators and injectors –
Preparatory steps . . . . . . . . . . . . . . . . . 243
Sensors, actuators and injectors –
S
TIM ID: 0000020688 – 004

Removal . . . . . . . . . . . . . . . . . . . . . . . . 244 Safety precautions when working on the


engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
MTU Contact/Service Partners . . . . . . . . . . . . 290
Sensors, actuators and injectors –
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
O Sensors, actuators and injectors –
Oil pan – Check . . . . . . . . . . . . . . . . . . . . . . . 59 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Oil pan – Final steps . . . . . . . . . . . . . . . . . . . . 62

MS22045/00E 2010-04 © MTU


Appendix 295

Sensors, actuators and injectors – Preparatory Roller tappet, pushrod – Check . . . . . . 117
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Roller tappet, pushrod – Installation . . . 118
Sensors, actuators and injectors – Roller tappet, pushrod – Preparatory
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Roller tappets, pushrod – Final
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Special tools – Overview . . . . . . . . . . . . . . . . . 254 Valve drive – Check . . . . . . . . . . . . . . . 125
Standard tools – Overview . . . . . . . . . . . . . . . 253 Valve drive – Final steps . . . . . . . . . . . . 128
Standards for warning notices in the Valve drive – Installation . . . . . . . . . . . . 126
publication . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Valve drive – Overview . . . . . . . . . . . . . 120
Valve drive – Preparatory steps . . . . . . 122
Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . 184
Valve drive – Removal . . . . . . . . . . . . . 123
Starter – Inspection . . . . . . . . . . . . . . . . . . . . . 185 Valve gear – Cleaning . . . . . . . . . . . . . . 124
Starter – Installation . . . . . . . . . . . . . . . . . . . . 186 Valve roller tappet, pushrod –
Starter – Removal . . . . . . . . . . . . . . . . . . . . . . 183 Overview . . . . . . . . . . . . . . . . . . . . . . . . 113
Starting Equipment . . . . . . . . . . . . . . . . . . . . . 182 Valve drive – Check . . . . . . . . . . . . . . . . . . . . 125
Electric starter – Overview . . . . . . . . . . 182 Valve drive – Final steps . . . . . . . . . . . . . . . . . 128
Starter – Cleaning . . . . . . . . . . . . . . . . . 184 Valve drive – Installation . . . . . . . . . . . . . . . . . 126
Starter – Inspection . . . . . . . . . . . . . . . . 185
Valve drive – Overview . . . . . . . . . . . . . . . . . . 120
Starter – Installation . . . . . . . . . . . . . . . 186
Starter – Removal . . . . . . . . . . . . . . . . . 183 Valve drive – Preparatory steps . . . . . . . . . . . 122
Valve drive – Removal . . . . . . . . . . . . . . . . . . 123
T Valve gear – Cleaning . . . . . . . . . . . . . . . . . . . 124
Tightening specifications for screws, nuts and Valve roller tappet, pushrod – Overview . . . . . 113
bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Vibration damper on PTO, free end –
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Vibration damper on PTO, free end –
V Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Vibration damper on PTO, free end –
Pushrod – Cleaning . . . . . . . . . . . . . . . 116
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Pushrod – Removal . . . . . . . . . . . . . . . 115
TIM ID: 0000020688 – 004

MS22045/00E 2010-04 © MTU