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Technical Publication

Diesel Engine
12V 183 TE94

Maintenance Manual
M020081/00E

Engine type:
444.901-520

DaimlerChrysler Off-Highway
Printed in Germany
E 2004 Copyright MTU Friedrichshafen GmbH
Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung,
Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken
und Online-Diensten.
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.

Printed in Germany
E 2004 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.

Imprimé en Allemagne
E 2004 Copyright MTU Friedrichshafen GmbH
Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU
Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches,
la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à
l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.
Modifications réservées.

Impreso en Alemania
E 2004 Copyright MTU Friedrichshafen GmbH
Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su
reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se
incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania
E 2004 Copyright MTU Friedrichshafen GmbH
Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione,
alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici,
comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto
alla manutenzione e alla condotta.
Con riserva di modifiche.

Printed in Germany
 2004 Copyright MTU Friedrichshafen GmbH
A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a
autorização prévia e por escrito da MTU Friedrichshafen GmbH.
Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e a memorização e/ou processamento em
sistemas eletrônicos, inclusive bancos de dados e serviços on-line.
Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento
economicamente consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores.
Salvo alterações.
Amendment Service!
Any changes in contents will be sent to you in the form of an amendment,
provided you complete the reverse of this receipt card and return it to us.

M020081/00E
Maintenance
Manual

Postcard

MTU Friedrichshafen GmbH

12V 183 TE94


Department SCT
88040 Friedrichshafen
GERMANY
No. Date Name
Please mark all filed amendments here.
1.
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Receipt Amendment No. 1.


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Wichtig - Important - Importante

Bitte die Karte „Inbetriebnahmemeldung” abtrennen und ausgefüllt an MTU Friedrichshafen GmbH
zurücksenden.
Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten Logistik-
Support (Gewährleistung, Ersatzteile etc.).

Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support
(warranty, spare parts, etc.).

Veuillez séparer la carte “Signalisation de mise en service” et la renvoyer à la MTU Friedrichshafen


GmbH.
Les informations concernant la signalisation de mise en service constituent la base pour l’assistance en
exploitation contractuelle (garantie, rechanges, etc.).

Rogamos separen la tarjeta “Aviso de puesta en servicio” y la devuelvan rellenada a MTU


Friedrichshafen GmbH.
Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logístico
contractual (garantía, piezas de repuesto, etc.).

Ritagliare “Avviso di messa in servizio” e rispedirlo debitamente compilato alla MTU


Friedrichshafen GmbH.
Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.).

É gentileza cortar o cartão ”Participação da colocação em serviço”, preenché-lo e devolvé-lo a MTU


Friedrichshafen.
Os dados referentes à colocação em serviço representam a base para o suporte logístico (garantia, peças
sobressalentes, etc.) estabelecido contratualmente.

Postcard

MTU Friedrichshafen GmbH


Abteilung SCSD
88040 Friedrichshafen
GERMANY
Bitte in Blockschrift ausfüllen!
Please use block capitals!
Prière de remplir en lettres capitales!
¡A rellenar en letras de imprenta!
Scrivere in stampatello!
Favor preencher com letras de forma!!

Motornr.: Auftragsnr.:
Engine No.: MTU works order No.:
No du moteur: No de commande: Inbetriebnahmemeldung
No de motor: No de pedido:
Motore N.: N. commessa:
No. do motor No. do pedido
Commissioning Note
Motortyp: Inbetriebnahmedatum:
Engine model: Date put into operation:
Type du moteur: Mise en service le: Notice de mise en service
Tipo de motor: Fecha de puesta en servicio:
Motore tipo: Messa in servizio il:
Tipo do motor Data da colocação em serviço:
Aviso de puesta en servicio
Eingebaut in: Schiffstyp / Schiffshersteller:
Installation site: Vessel/type/class / Shipyard:
Lieu de montage: Type du bateau / Constructeur: Avviso di messa in servizio
Lugar de montaje: Tipo de buque / Constructor:
Installato: Tipo di barca / Costruttore:
Incorporado em: Tipo de embarcação/estaleiro naval:
Participação da colocação
Endabnehmer/Anschrift: em serviço
End user‘s address:
Adresse du client final:
Dirección del cliente final:
Indirizzo del cliente finale:
Usuário final/endereço:

Bemerkung:
Remarks:
Remarques:
Observaciones:
Commento:
Observações:
Section 1
General Page 1

Contents

1.1 Important information

1.2 Hazards at the workplace

1.3 Designation of engine side

1.4 Tightening specifications

1.5 Settings

1.6 Publication overview

1.7 Repairing threaded bores

1.8 Keyword index

M020081/00E - 03.10 - E MTU


Section 1
Page 2 General

E MTU - 03.10 - M020081/00E


Section 1.1
General Page 1

1.1 Important Information


This manual is intended for use by technical personnel responsible for the maintenance and servicing of the MTU
Diesel Engine, 183 series.
The manual describes the
- scheduled maintenance tasks of the W5 and W6 maintenance schedule and the
- non-scheduled service operation on the individual subassemblies.
Index sheets divide this handbook into 3 main sections.
Component group structure
The third main section is subdivided into assemblies 01 to 88.
The subdivision follows the structure of the Equipment List and Spare Parts Catalogue.
Every assembly section is further divided into subassembly sections (where required).
Example:
3. 1. 2

Subassembly group
Assembly section
Main section
Since the component groups and subgroups are arranged in a module system which applies to different engine
types, this numbering system is not in series.
Alternative subassemblies are either without an index, or are provided with indices ”a, b, c” etc.
Example: 3.1.2a
There can be only one subassembly group 3.1.2 for any individual engine, thus:
3.1.2 without index
or
3.1.2a
or
3.1.2b etc..

The section on each subassembly group is divided into seven operations; the final digit is always identical for all of
these:
.1 Before-removal operations
.2 Removal
.3 Disassembly
.4 Inspection and repair
.5 Assembly
.6 Installation
.7 After-installation operations
All seven procedures will not be required for every subassembly. In these cases, the corresponding sections will
not appear in either the text or the table of contents, but the remaining sections will retain their respective end di-
gits.
Alternative operations are identified in the index with ”a, b, c” etc., while the basic operation is not provided with an
index.
Example:
3.1.2.1 Before-removal operations
3.1.2.2 Removal
3.1.2.4 Inspection and repair
3.1.2.6 Installation
3.1.2.7 After-installation operations

M020081/00E - 03.10 - E MTU


Section 1.1
Page 2 General

When several operations are combined in a single section (e.g. where no supplementary illustrations are required),
a corresponding note will appear in the table of contents.
Example:
3.1.9.1 Before-removal operations (see 3.1.9)
3.1.9.2 Removal (see 3.1.9)
3.1.9.4 Inspection and repair (see 3.1.9)
3.1.9.6 Installation (see 3.1.9)
Quickly finding the sought-after information
The manual provides the following aids for assistance in finding the desired section:
- The contents listings on the main cover sheets provide references to the tables of contents for the individual sec-
tions.
- An alphabetical subject index in the first main section provides direct access to the individual sections.
- The individual assemblies are listed in the group summary on the cover sheet to the 3rd main section.
Basic requirements for maintenance and service work
Customers performing their own maintenance must ensure that the following conditions and basic requirements
are satisfied:
- All safety regulations are observed
- Comprehensive assortment of general-purpose tools is provided
- Cleaning and testing equipment is provided
- Work is performed by trained personnel
- Special tools are provided
- Service area is adequately equipped
For further supplements to this handbook, see 1.6

E MTU - 03.10 - M020081/00E


Section 1.1
General Page 3

General assembly instructions are observed


D Component cleanness:
Areas of all components that come in contact with oil, fuel, engine coolant and combustion air must be kept
clean.
D Components requiring “special cleanliness” (e.g. oil- and fuel-carrying components) must be cleaned with suit-
able cleaning procedures before assembly, checked for particular cleanness and treated accordingly.
D Component packaging must only be removed immediately before installation.
D Elastomer components (e.g. rubber parts etc.) must not be washed with diesel fuel, solvents or cold cleaners.
Parts dirtied with oil and fuel must be cleaned immediately. The parts should be wiped with a dry cloth.
Elastomer components such as engine mounts, damping elements, couplings and V-belts must not be painted.
They can only be installed after painting the engine or must be covered before painting work is carried out.
D Radial-lip shaft seals treated by the manufacturer with oil show as a result definite signs of swelling when deliv-
ered. They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before installation.
D The surfaces of parts that slide against each other must be lubricated with SAE30 engine oil when installed,
unless otherwise specified.
D O-rings and surfaces moving against them during installation (bores and shafts) must be coated with petroleum
jelly, unless otherwise specified.
When installing O-rings with counterrings in coolant pumps, always follow the installation instructions.
D After installing O-rings in shaft grooves, in order to remedy twists caused by installation, pass a rounded mark-
ing tool under the sealing ring in the direction of the circumference if the O-ring diameter is sufficiently large.
Make sure that the O-ring is not damaged.
D Before installing shaft seals:
On the shaft, the sealing lip of the shaft seal must be coated with petroleum jelly and the shaft running surface
with thin-film lubricant or SAE30 engine oil.
In the support bore, in the case of a metal outer jacket the outer surface must be coated with surface sealant,
unless otherwise specified in the drawing. For elastomer outer jackets or combined metal/elastomer outer
jackets, the outer surface must be coated with denaturated ethanol.

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

D Sealing paste must be used to fix the position of flat gaskets. Sealing paste is to be thinly applied in spots on
the flat gaskets or mating faces. Immediately after application of the sealing paste, the flat gaskets must be
fitted to the component and then (no more than 20 minutes later) the seal components screwed together.
Oil, multi-purpose grease or other materials must not be used to fix the position.
D Before installing antifriction bearings, lightly lubricate the bearing seats.
Only remove the bearings from their original packaging immediately before installation so they do not get dirty.
Do not remove the corrosion inhibitor from the bearings in original packaging.
Use petroleum spirit or acid-free kerosene to clean the antifriction bearings.
After cleaning, relubricate the bearings with engine oil.
During assembly, do not apply (axial) forces to rolling elements and do not hit the bearing rings with a hammer
(use assembly aids).
Do not use an open flame to heat bearing inner races.
The temperature should be between 80 °C and 100 °C and must never exceed 120 °C.
Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate).
D Dry bearings must not be oiled.
D When installing gears, the splines must be lubricated with SAE 30 engine oil.
D All support and mating surfaces of components (e.g. mating surfaces for centring devices, flange and sealing
surfaces, joint surfaces of press fits) must be clean, polished or provided with the specified surface protection
and free from warping and damage. Corrosion inhibitors (e.g. oil, grease) must be removed from support and
mating surfaces.

M020081/00E - 03.10 - E MTU


Section 1.1
Page 4 General

D After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate must be re-
moved and the parts coated with SAE 30 engine oil.
D Sensors must be coated with long-life lubricant before installation in the immersion sleeves.
D Cable connections with cutting ring threaded connections must be preassembled in a vice and tightened, the
thread first being coated with thin-film lubricant.
D If components are to be marked by etching, after the etching is completed the solution must be removed by
means of neutralization agent. The affected parts must then be preserved with SAE30 engine oil.
D Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes) must be coated at the support and
mating surfaces with assembly paste, unless otherwise specified.
D The assembly surfaces of screws, nuts, washers and of parts to be tensioned must be clean and polished or
provided with the specified surface protection and free from warping and damage. Corrosion inhibitors (e.g. oil,
grease) must be removed. Threads and screw heads must be coated with lubricant before assembly as per
tightening specifications.
Unless otherwise specified, the following lubricants should be used:
- SAE30 engine oil for general application
- Assembly paste in hot part areas.
a) Threaded connections without tightening specifications
For threaded connections without tightening specifications, the tightening procedure can be selected as re-
quired, i.e. mechanical tightening with screwdriver or normal manual tightening with an open-end wrench or box
wrench is possible.
In the event of mechanical tightening, the tightening torque must be taken from the general tightening specifica-
tions according to thread size and property class.

b) Threaded connections with tightening specifications


- Torque tightening
The screw connections must be tightened by hand with a torque wrench or angle-of-rotation torque wrench.
The specified torques must be set at the torque wrench without consideration of the specified tolerance.
When using an angle-of-rotation torque wrench, the torque indicated must be within the torque specification
limit value. Proceed in a similar manner with torsionally protected threaded connections. These instructions
apply also to testing torque.
Note: If no tolerance for tightening torque is stated, the tightening tolerance is + 10% of specified
torque.
- Angle-of-rotation tightening:
The additional angles-of-rotation specified in the tightening specifications must be achieved and may be ex-
ceeded within the specified tolerance.
If no tightening tolerance is specified, the following tolerances must be observed:
+ 5° for angle of further rotation less than or equal to 90°
+ 10° for angle of further rotation greater than 90°
Before angle-of-rotation tightening, each screw head must be colour-marked so that after tightening it is poss-
ible to check that the angle of rotation is correct (exception: colour-marking is not necessary in the case of a
self-monitoring NC screwdriver).
- Elongation tightening
tightening must be carried out in accordance with tightening specifications taking the tightening tolerance into
consideration.

E MTU - 03.10 - M020081/00E


Section 1.2
General Page 1

1.2 Hazards at the Workplace

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

General Safety and Accident Prevention Regulations


D In addition to the instructions given in this publication, general safety and accident prevention regulations and
laws must be taken into consideration; these may vary from country to country.
D This engine is a state-of-the-art product and conforms to the applicable specifications and regulations. Acci-
dents can still occur, however, causing serious bodily harm or damage to property under the following condi-
tions:
- Incorrect use
- Servicing, maintenance and repair carried out by untrained members of staff
- Modifications or Conversions
- Noncompliance with the Safety Instructions
Correct Use of the Engine
D The engine is designed solely for the contractually-defined purpose. Another use, or a use beyond that defined,
is regarded as not being for the purpose intended. The manufacturer accepts no liability for damage resulting
from unauthorised use. The responsibility is borne by the operator alone.
D The contractually-defined use includes the careful reading of the Operating Instructions and Maintenance Man-
ual, and following the maintenance and repair directions.
Personnel Requirements
D Work must be carried out by qualified personnel only. The minimum age required by law must be observed.
D Only fully-trained or qualified personnel are to be employed. Responsibilities of the operating, maintenance and
repair personnel must be specified.
Modifications or Conversions
D Engine modification or conversions carried out by the customer may affect safety. No modifications or conver-
sions must be implemented without prior consent from DDC or MTU.
D No liability will be accepted for damage resulting from unauthorised modifications or conversions.
Organisational Measures
D This manual is to be given to the maintenance and repair personnel.
D With assistance from this manual, the personnel must be instructed on the operation and maintenance of the
engine, with special emphasis on the safety instructions. This is especially important for personnel who work
only occasionally on the engine.
Note: Amendments to this publication will be sent to you provided the receipt card is returned to
MTU.
This also applies to in-house use by MTU personnel.
Spare Parts
D Spare parts must at least satisfy the requirements specified by the manufacturer. This is guaranteed when
genuine components are used.
Working Clothes and Protective Equipment
D Always wear protective shoes when working on plant.
D Select protective goggles according to the work to be carried out. Always wear protective goggles when working
with mallets, cutting tools, drift punches or similar.

M020081/00E - 03.10 - E MTU


Section 1.2
Page 2 General

D Work clothing must be tight-fitting so that it does not catch on rotating or projecting components. Do not wear
jewellery (rings, chains, etc.).
Welding Operations
D Never use the engine as a ground terminal! (This prevents the welding current from passing through the engine,
resulting in burnt or scorched points on the bearings, friction surfaces and tooth flanks which can lead to bear-
ing seizure and/or material damage).
D Welding on the engine or engine-mounted components is forbidden.
D Never lay the welding cable over or near the cable harnesses of the DDC/MTU plants. (The welding current
could be induced in the cable harnesses which could possibly damage the electrical plant).
D The ground terminal of the welding unit must be connected to the welding point at a distance of no greater then
60 cm.
D If welding must be carried out on components (e.g. exhaust pipe), these components must be removed from
the engine beforehand.
D On the DDC/MTU electronics system, it is not necessary to remove the connector and connections to carry out
welding operations if the master switch of the power supply is switched from “On” to “Off” and the cable has
been disconnected from the negative and positive poles on the battery.
D During welding operations, always wear welding gloves, headgear, goggles, protective apron and other suitable
protective clothing.
Transport
D Lift the engine using only the lifting eyes provided.
D Use only the transport and lifting equipment approved by DDC/MTU.
D Take into consideration engine centre of gravity.
D Transport the engine only in the installation position.
D In event of special packaging with aluminium foil, attach engine to lifting eyes of bearing pedestal or transport
with forklift truck.
D Before transporting the engine, the crankshaft transportation locking device and engine mount locking device
must be installed.
Engine Operation
D When the engine is running, ear protectors must always be worn in the engine room.
D The engine room must be well ventilated.
D To avoid injuries caused by falling, leaked or spilt engine oil and coolant must be cleaned up immediately or ab-
sorbed with appropriate bonding agents.
D Exhaust gases from combustion engines are poisonous. They can be injurious to health if inhaled. The exhaust
system must be leaktight and discharge the gases to atmosphere.
D 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.
D If engine is running, never release coolant, oil, fuel, compressed air or hydraulic lines.
Maintenance and Repair
D Compliance with the maintenance and repair instructions is a major safety factor.
D Unless expressly permitted, no maintenance or repair work is to be carried with the engine running. The engine
must be secured against inadvertent starting and the battery disconnected. Attach sign “Do not operate” in op-
erating area or to control equipment. Persons not involved must keep clear.
D Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Maintenance and repair work must only be carried out by authorised and qualified personnel.
D Use only tools in perfect condition.

E MTU - 03.10 - M020081/00E


Section 1.2
General Page 3

D Do not work on engines or components which are held only by lifting equipment or crane. Always support them
on suitable trestles or stands before beginning any maintenance or repair work.
D Before barring the engine, ensure nobody is within the danger area. After working on the engine, check that all
guards have been reinstalled and that all tools and loose components have been removed from the engine.
D Fluids emerging under high pressure can penetrate clothing and skin and cause serious injury. Before starting
work, relieve pressure in systems and H.P. lines which are to be opened.
D Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean. Always seal
connections with caps or covers if a line is removed or opened.
D During maintenance or repair work, do not hit fuel lines with wrenches or other tools. To tighten connections
when installing lines, use the correct tightening torque and ensure that all retainers and dampers are installed
correctly.
D Ensure that all fuel injection lines and compressed-oil lines have sufficient play to avoid contact with other com-
ponents. Do not position fuel or oil lines near hot components.
D The H.P. lines for hydraulic installation and removal are tested at 3,800 bar.
D Do not attempt to bend or apply force to lines while under pressure.
D In order to avoid burning, take special care when handling hot components on products just taken out of use
and when working with hot liquids in pipelines, pipes and chambers.
D Until the engine has cooled, the breather cap must not be opened. Release the breather cap and allow pressure
to escape before cap removal.
D Take special care when removing plugs or vent plugs from engine. In order to avoid being sprayed with highly-
pressurised liquids, hold a cloth over the screw or plug. It is even more dangerous if the engine has recently
been shut down as the liquids can still be hot.
D Take special care when draining hot liquids - risk of injury. Drain the liquids into a suitable container and wipe
up any spillage.
D When changing engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
D When working high up on the engine, always use suitable ladders and work platforms. Make sure components
are placed on stable surfaces.
D To prevent back injury, when lifting components weighing 25 kg (50 lb.) or more, always use suitable lifting gear
and equipment. Ensure that all chains, hooks, slings, etc. are in good condition, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes are not to be unevenly loaded.
D When operating electrical equipment, remember that certain components of this equipment are live.
D Noncompliance with warning notices could result in serious physical injury or damage to property.
D Work must be carried out by qualified personnel only. Prior to working on electrical equipment, switch off live
units.
D Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acid to
come into contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Check polar-
ity before connecting the cables to the battery. Battery pole reversal may lead to injury through the sudden dis-
charge of acid or bursting of the battery casing.
D 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 another component or by a hot surface. Never
connect wiring to a line carrying hot liquid.
D On completion of the maintenance and repair work, any cables which have become loose must be correctly se-
cured.
D Always tighten connectors with connector pliers.
D If cables are present at mechanical components and there is a risk of wear, the cables must be retained in
cable clamps.
D For this purpose, no cable straps must be used as, during maintenance and/or repair work, the straps can be
removed but not installed a second time.
D Check that all plug-in connections are secure.

M020081/00E - 03.10 - E MTU


Section 1.2
Page 4 General

D It is not sufficient to tighten the bayonet union connections by hand. There is the risk that the locking unit does
not engage correctly and that the connector becomes loose during engine operation. Therefore pliers must be
used for turning the bayonet union nut in clockwise direction.
Fire Prevention
D Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires - there-
fore always keep the engine in a clean condition. Do not leave oil-soaked cloths on the engine. Do not store
combustible fluids near the engine. Do not allow dirt or foreign matter to accumulate near the engine, as this
constitutes a fire hazard.
D Do not weld pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid.
D Never mix petrol (gasoline) with diesel fuel. If petrol/gasoline is added to diesel fuel, there is increased risk of
fire.
D When starting the engine with a foreign power source, connect the ground lead last and remove it first. To avoid
sparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of
the engine or to the ground terminal of the starter.
D Always keep a fire extinguisher at hand and learn how to use it.
Noise
D Hearing may be impaired at workplaces where the sound pressure level is in excess of 85 dB(A).
D Wear earplugs or earmuffs!
Environmental Protection
D Dispose of used fluids and lubricants and filters in accordance with local regulations.
D Manipulation of the injection or control system can influence the engine performance and exhaust emissions. As
a result, compliance with environmental regulations may no longer be guaranteed.
Skin Complaints
D Barrier creams issued for prophylactic use are not suitable for treatment of skin complaints. Seek medical ad-
vice on skin rashes of any type, even if symptoms are very slight.
Warning Signs
D Before putting the engine into service and before working on the engine, read and follow all warning signs. Do
not paint over warning signs. Replace illegible signs.
Fluids and Lubricants, Auxiliary Materials
D Use only fluids and lubricants that have been tested and approved by DDC and/or MTU.
D Fluids and lubricants must be kept in properly designated containers. When using fluids, lubricants and other
chemical substances, follow the safety instructions applicable to the product. Take special care when using hot
and caustic materials. When using inflammable materials, avoid all sparks and do not smoke.
Lead
D When working with lead or pastes that contain lead, take care that the body does not absorb even tiny amounts
of lead (from air-borne lead dust, smoke, dirty hands).
- Adopt suitable measures to avoid the formation of lead dust!
- Switch on extraction system!
- - Wash hands before eating and drinking!
Chlorinated Hydrocarbons
D When working with chlorinated hydrocarbons (e.g. perchlorethylene, trichlorethane) or other cold cleaners which
contain declared hazardous substances, health-endangering substances may be inhaled.
- Switch on ventilation and extraction systems!
- Observe fire-prevention regulations!
- No smoking and no consumption of alcoholic beverages!
- Do not permit substances to enter the waste-water system!

E MTU - 03.10 - M020081/00E


Section 1.2
General Page 5

Acids and Alkalis


D When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
- Immediately remove clothing wetted by acids and alkalis!
- Rinse injured parts of the body thoroughly with water!
- Rinse eyes immediately with water from rinsing bottle or clean mains water!

Painting
D When painting in other than spray booths equipped with extractors, ensure good ventilation. Ensure that neigh-
bouring workplaces suffer no detrimental effects.
- Always wear a mask providing protection against paint and solvent vapours!
- Observe all fire-prevention regulations!
- No smoking!
- No naked flame!

Liquid Oxygen
D Liquid oxygen is highly flammable.
D Store liquid oxygen only in small quantities and always in regulation containers (without fixed seal)! Do not allow
liquid oxygen to come into contact with parts of body (hands); this could cause frostbite and possibly the loss of
tissue.
- No smoking, no naked flame (risk of explosion)! Oxygen enrichment in the air causes flash combustion.
- Do not store any inflammable substances (e.g. oils and greases) within 5 m of the area of work.
- Under no circumstances wear oily or greasy clothing!
- Do not allow vapours to penetrate clothing! Oxygen enrichment in fabric can cause working clothes to ignite
suddenly!
- After working with liquid oxygen, do not smoke until clothing is free of vapours!
- Take great care to avoid impacts and shocks when working with liquid oxygen!

Liquid Nitrogen

D Store liquid nitrogen only in small quantities and always in regulation containers (without fixed seal)!
D Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands). Liquid nitrogen causes cold
burns and severe frostbite.
- Always wear protective clothing (e.g. gloves, tight-fitting shoes) and protective goggles!
- Ensure good ventilation (suffocation if nitrogen enrichment in inhaled air reaches 88%)
- Do not subject containers, fittings and tools to impact or shock!

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Section 1.2
Page 6 General

Compressed Air
D Compressed air is compressed, pressurised air and is stored in pressure vessels from which the compressed
air is then extracted.
D The compressed air pressure can be read off at the pressure indicator (pressure gauge); the pressure vessels
and compressed air lines must also be at this pressure.
D Pressure can cause serious bodily harm, especially if applied suddenly.
D When working with compressed air, safety precautions must be constantly observed:
- Pay special attention to the pressure level in the compressed air network and pressure vessel!
- Connecting devices and equipment must either be designed for this pressure or, if the permitted pressure for the
connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to per-
mitted pressure) must form an intermediate connection. Hose couplings and connections must be securely at-
tached!
- Always wear protective goggles when blowing off tools or extracting chips!
- The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents air-borne particles
being reflected and thereby prevents damage to the eyes.
- First shut off compressed air lines before compressed air equipment is disconnected from the supply line or before
equipment or tool is to be replaced!
- Unauthorised use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers,
results in a “Risk of explosion”!
- Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying pur-
poses or to check for leaks results in a “Risk of explosion”.
- Removing dirt on soiled clothes while still worn can result in a “Risk of injury”.
Even compressed air at low pressure penetrates clothing and, if the jet is directed at the back of the body, the air
can enter the anal cavity and cause a potentially fatal rupture of the intestines!

Used Oil

D Used oil may contain health-threatening combustion residues.


- Rub barrier cream into hands!
- Clean hands thoroughly after contact with used oil!

Warning Notices

D Section “3” of this Publication contains especially emphasised safety instructions in accordance with the Ameri-
can standard ANSI Z535, which begin with one of the following signal words according to the degree of danger:
- Take extreme care in these situations!
- Read and become acquainted with all warning notices and symbols before operating or repairing this product!
- Inform operating and maintenance personnel on all Safety Instructions!

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Section 1.2
General Page 7

DANGER
An instruction of this type draws attention to an
impending danger which, if ignored, may lead to
serious or death.

WARNING
An instruction of this type draws attention to a
possible danger which, if ignored, may lead to
serious injury or death.

CAUTION
An instruction of this type draws attention to a
danger which, if ignored, may lead to minor in-
jury.

M020081/00E - 03.10 - E MTU


Section 1.2
Page 8 General

E MTU - 03.10 - M020081/00E


Section 1.3
General Page 1

1.3 Designation of Engine Sides and Cylinders

Engine sides are always designated as viewed from the driving end.
The cylinders are designated (as per DIN ISO 1204) as viewed from the side opposite the driving end i.e. from the
free end.
The cylinders are viewed from the left and are designated in consecutive order 1, 2, 3, 4 etc.

Applicable designations and abbreviations


Driving end = KS
Free end = KGS
Left side
Right side
Top
Bottom

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Section 1.3
Page 2 General

E MTU - 03.10 - M020081/00E


Section 1.4
General Page 1

1.4 Tightening Specifications for Screws, Nuts and Bolts


Designation Tightening specification (Nm) Lubricant
Engine, crankcase, cylinder head
Crankshaft bearing cap to crankcase Details in item (1) Engine oil
Oil separator to crankcase 8 Engine oil
Oil pan to crankcase Details in item (4) Engine oil
Oil drain plug on oil pan 80 Engine oil
Oil filler neck to oil pan 25 Engine oil
Oil dipstick guide pipe union to oil pan 50 Engine oil
Gear case cover and crankcase 25 Engine oil
Further details in item (3)
Gear case to crankcase
M10 60 Engine oil
M12 x1.5 100 Engine oil
Cover to front of crankcase 25 Engine oil
Plug at front and rear oil channel
M30x1.5-10.9 180 Engine oil
Plug at main oil gallery, fan side
M26x1.5-10.9 150 Engine oil
Plug at auxiliary drive oil supply
M18x1.5 80 Engine oil
Plug at turbocharger oil supply
M14x1.5 50 Engine oil
Plug at oil return oil filter, front 50 Engine oil
Temperature transmitter plug
M14x1.5 50 Engine oil
Plug, coolant supply and return pipe Engine oil
Compressor
M14x1.5 50 Engine oil
Coolant drain plug
M14x1.5 50 Engine oil
Plug at coolant channel, top
M26x1.5 150 Engine oil
Sealing nut, camshaft bore
M22x1.5 100 Engine oil
Friction washer to gear case 25 Engine oil
End cover, compressor opening to gear case 30 Engine oil
Plug, start of delivery inspection port
M26x1.5 80 Engine oil
M38 x 1.5 40 Engine oil
Cover upper dead centre inspection port to 25 Engine oil
gear case
Plug, cylinder head core hole
M22x1.5 100 Engine oil

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Section 1.4
Page 2 General

Designation Tightening specification (Nm) Lubricant


Cylinder head to crankcase Details in item (2) Engine oil
Cylinder head cover to cylinder head (flat 25 Engine oil
gasket)
Cylinder head cover to cylinder head (profile 10 Engine oil
gasket)
Union, crankcase ventilation Engine oil
Coolant channel, right
M14x1.5 50 Engine oil
Oil dipstick guide pipe to oil pan 35 Engine oil
Tachometer drive front camshaft end 35 Engine oil
Retainer, speed transmitter to gear case 25 Engine oil
Clamping screw to speed transmitter retainer 10 Engine oil
Running gear
Counterweight to crankshaft 1st Stage 50 Nm Molykote G-n plus
2nd Stage 140 to 160 Nm
3rdStage 90° to
100° angle of rotation
Max. shaft length:
75.5/86.4 mm
Belt pulley hub to crankshaft 200 Engine oil
Vibration damper to crankshaft 200 Engine oil
Belt pulley to hub 25 Engine oil
Belt pulley to vibration damper 25 Engine oil
Connecting rod bearing cover to connecting 1st Stage 100 Nm Engine oil
rod 2nd Stage 90° to
100° angle of rotation
Max. shaft length:
68.5 mm
Flywheel/ring-gear carrier to crankshaft 1st Stage 50 Nm Engine oil
2nd Stage 200 to 220 Nm
3rd Stage 90° to
100° angle of rotation
Max. shaft length:
75/86 mm
Viscose vibration damper to hub / belt pulley 40
Valve gear, valves
Rocker shaft support on cylinder head 75 Engine oil
Locknut to adjusting screw for rocker arm 50 Engine oil

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Section 1.4
General Page 3

Designation Tightening specification (Nm) Lubricant


Adjusting segment to camshaft gear Engine oil
Expansion shaft 50 Nm
Max. shaft length:
25.3 mm
Massive shaft 1. Stage 30 to 35 Nm
2. Stage 90° to 100° angle
of rotation
Max. shaft length:
25.3 mm
Fuel system- engine
Drive gear to injection pump 35 Engine oil
Injection pump to crankcase Details in item (5) Engine oil
Injection pressure lines to injection pump and 25 Engine oil
injection nozzle
Securing clamp, injection lines 10 Engine oil
Locknut max-speed seal/idle stop injection 5 Engine oil
pump M6
Retaining cap for maximum-speed sealing M6 5 Engine oil
Connecting cable to charge air manifold 25 Engine oil
Lever to control shaft 10 Engine oil
Control lever to injection pump lever 10 Engine oil
Actuator retainer to crankcase 50 Engine oil
Actuator to retainer 10 Engine oil
Lever to actuator 10 Engine oil
Ball studs/pressure rod on setting lever and in- 12 Engine oil
jection pump control lever
Fuel filter to retainer 80 Engine oil
Fuel filter retainer to gear case/intake pipe 80 Engine oil
cover
Filter bowl to fuel filter cover 15 Engine oil
Fuel lines to delivery pump, filter and injection 30 Engine oil
pump
Fuel filter vent plug 15 Engine oil
Nozzle in nozzle holder 80 Engine oil
Nozzle holder thrust screw to cylinder head 70 Engine oil
Air filter, exhaust turbocharger, charge air line
Charge air manifold to cylinder head 35 Ultratherm MTU
Charge air lateral pipe to charge air longitudinal
pipe
M10 50 Ultratherm MTU

M12 80 Ultratherm MTU


Plug to charge air lateral pipe 80 Ultratherm MTU
Turbocharger to exhaust elbow 50 Ultratherm MTU

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Section 1.4
Page 4 General

Designation Tightening specification (Nm) Lubricant


Charge air manifold/air intake pipe mounting
M8 25 Ultratherm MTU

M10 50 Ultratherm MTU


Exhaust pipes to exhaust elbow and turbo- 50 Ultratherm MTU
charger
Connection of crankcase ventilation to air in- 80 Engine oil
take pipe
Measuring probe plug 50 Engine oil
Emergency air shut-off flap, axle in lever 20+2 Engine oil
Emergency air shut-off flap, screw control cam 8+1 Engine oil
screw
Belt drive
Plugs/unions to engine/compressor
M14x1.5 30 Engine oil
M22x1.5 50 Engine oil
M26x1.5 80 Engine oil
Coolant line to unions 35 Engine oil
Compressor coolant line to turbocharger oil 25 Engine oil
pressure line
Pressure diaphragm to spacer plate 15 Engine oil
Spacer plate to cylinder head 30 Engine oil
Bearing bush to gear case 30 Engine oil
Mounting flange for bush bearing 50 Engine oil
Bearing flange to gear case 30 Engine oil
Cylinder head to cylinder liner 30 Engine oil
Cylinder head with cylinder liner to gear case 30 Engine oil
Bearing flange with cap to gear case 60 Engine oil
Exhaust line
Exhaust elbow to cylinder head 50 Ultratherm MTU
Intake pipe to cylinder head 35 Ultratherm MTU
Lateral intake pipe to intake pipe 50 Ultratherm MTU
Plug on intake pipe
M26x1.5 80 Ultratherm MTU
Intake air pipe to retainer 50 Engine oil
Exhaust system flange to cylinder head
Pretighten 30+3 Ultratherm MTU

Additional angle of rotation 60+5° Ultratherm MTU


Sliding element to hot parts 55+6 Ultratherm MTU
Exhaust turbocharger to carrier housing 18+2
Engine electrical system

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Section 1.4
General Page 5

Designation Tightening specification (Nm) Lubricant


Alternator carrier/tension roller to crankcase
M14 160 Engine oil
Alternator carrier to gear case
M10 60 Engine oil
M16 150 Engine oil
Alternator to carrier
M10 50 Engine oil
M12 x1.5 80 Engine oil
Clamping element bearing cap stud to alterna- 40+4 Engine oil
tor
Stud to oil pan/carrier 50 Engine oil
Fan belt pulley to alternator
M16x1.5 55 Engine oil
Belt pulley to alternator
M27x1.5 150 Engine oil
Alternator cover 50 Engine oil
Air intake supports to alternator 5 Engine oil
Swivel head alternator to screw
M12 74+6 Engine oil
Clamping arm to retainer 80 Engine oil
Belt pulley to clamping arm 130 Engine oil
Locknut to clamping nut/stud 35 Engine oil
Starter to gear case 80 Engine oil
Engine lubrication, engine cooling
Oil pressure relief valve to oil pump 35 Engine oil
Oil pump to crankcase 35 Engine oil
Oil pump cover 25 Engine oil
Oil pump cover (three-gear pump) 35 Engine oil
Oil intake pipe mounting 35 Engine oil
Oil intake pipe to suction basket 25 Engine oil
Oil spray nozzle to crankcase (piston spray) 40 Engine oil
Bulkhead wall to oil cooler housing
M10x25 60 Engine oil
Oil cooler housing to crankcase
M10x25 60 Engine oil
M10x35 50 Engine oil
M10x40 50 Engine oil
Oil cooler cover to oil cooler
M8x60 25 Engine oil
M8x35 25 Engine oil
Oil cooler cover to oil cooler housing
M8x60 25 Engine oil
M10x35 25 Engine oil

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Section 1.4
Page 6 General

Designation Tightening specification (Nm) Lubricant


Oil filter bowl to oil cooler cover
M10x125 50 Engine oil
M10x60 50 Engine oil
M10x100 50 Engine oil
Coolant pump
Coolant pump to crankcase and/or distributor 25 Engine oil
housing
Union, coolant discharge to coolant pump 25 Engine oil
Union, coolant inlet to coolant pump 25 Engine oil
Belt pulley to coolant pump 25 Engine oil
Raw water pump
Impeller clamping nut to drive shaft 32+3 Engine oil
Nut M8, bearing housing with intermediate el- 20+2 Engine oil
ement to pump housing
Plug, pump housing
M18x1.5 50+10 Engine oil
G1 1/4 A 140+10 Engine oil
Coolant cooler (plate-core cooler)
Plate-core pack securing element M12 Engine oil
Tighten diagonally and evenly
Pretighten 25+3
Further tightening 45+5
but not beyond block dimension (see
plate)
Intermediate element, coolant temperature 180 Engine oil
transmitter to crankcase
Coolant temperature transmitter to crankcase 25 Engine oil
Engine suspension/Engine mounting
Front engine carrier to crankcase 110 Engine oil
Front lifting eye front to crankcase
M10 50 Engine oil
M20 330 Engine oil
Rear lifting eye to gear case 150

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Section 1.4
General Page 7

Item 1

Crankshaft bearing cap to crankshaft


Central screws (1)
- 1st Stage 100 Nm
- 2nd Stage 200 Nm
- 3rd Stage 300 to 330 Nm
- 4th Stage 90° to 100° angle of rotation
- Max. shaft length: 156 mm
Central screws (2)
- Hex screws 80 Nm
- Double-hex screws
1st Stage 80 to 90 Nm
2nd Stage 90° 100° angle of rotation
Max. shaft length: 86.5 mm

Note: Tighten central screws (1) before the lat-


eral screws (2).

Item 2

Cylinder head to crankcase


Sequence for tightening cylinder head screws.
Tighten n 6 stages:
- 1st Stage 10 Nm
- 2nd Stage 50 Nm
- 3rd Stage 100 Nm
- 4th Stage 140 to 150 Nm
- 5th Stage 180 to 190 Nm
- 6th Stage 90° to 100° angle of rotation
- Max. shaft length 111 / 146 / mm

Note: Do not retighten!

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Section 1.4
Page 8 General

Item 3

Tightening sequence for gear case

Item 4

Oil pan to crankcase


Tighten corner screws and nuts diagonally and
evenly ( A - C ) and ( B - D ) to 35 Nm.
Tighten the remaining screws / nuts in peripheral
sequence to a torque of 35 Nm (starting from the
last corner screw tightened).
Retighten corner screws and / or nuts to a torque of
35 Nm.

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Section 1.4
General Page 9

Item 5

Injection pump to crankcase


- 1st Stage 10 Nm all screws
- 2nd Stage 50 Nm
- 3rd Stage 90° to 100° angle of rotation
Max. shaft length:
Short screw 72 mm
Long screw 102 mm

M020081/00E - 03.10 - E MTU


Section 1.4
Page 10 General

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

Thread Manually tightened Machine tightened


8.8 10.9 8.8 10.9
MA (Nm) MA (Nm) MA (Nm) MA (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8x1 23 32 21 30
M10 42 60 40 57
M10x1.25 45 63 42 60
M12 74 100 70 92
M12x1.25 80 110 75 105
M12x1.5 76 105 72 100
M14 115 160 110 150
M14x1.5 125 180 120 170
M16 180 250 170 235
M16x1.5 190 270 180 255
M18 250 350 240 330
M18x1.5 280 400 270 380
M20 350 500 330 475
M20x1.5 390 550 350 520
M22 480 680 450 650
M22x1.5 520 730 490 700
M24 600 850 570 810
M24x1.5 680 950 640 900
M24x2 660 900 620 850
M27 900 1250 850 1175
M27x2 960 1350 900 1275
M30 1200 1700 1100 1600
M30x2 1350 1900 1250 1800

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Section 1.4
General Page 11

Tightening torques for stress bolt connections according to MTN 5007


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

Thread Without torsion protection With torsion protection *


MA (Nm) MA (Nm)
M6 9 12
M8 21 28
M8x1 24 30
M10 42 55
M10x1.25 46 60
M12 75 93
M12x1.5 78 99
M14 120 150
M14x1.5 135 160
M16 180 225
M16x1.5 200 245
M18 250 315
M18x1.5 300 360
M20 350 450
M20x1.5 430 495
M22 500 620
M22x1.5 560 675
M24 640 790
M24x2 700 850
M27 900 1170
M27x2 1000 1230
M30 1250 1575
*Protect shank against torsion when tightening.

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Section 1.4
Page 12 General

Tightening torques for plugs prescribed in standard MTN 5183-1


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

DIN 908 DIN 910 DIN 7604A/C

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

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

Thread Inserted in
Steel/gray cast iron Al-alloy
MA (Nm) MA (Nm)
M10x1 15 15
M12x1.5 35 25
M14x1.5 35 25
M16x1.5 40 30
M18x1.5 50 35
M20x1.5 55 45
M22x1.5 60 50
M24x1.5 70 60
M26x1.5 80 70
M27x2 80 70
M30x1.5 100 90
M30x2 95 85
M33x2 120 110
M36x1.5 130 115
M38x1.5 140 120
M42x1.5 150 130
M45x1.5 160 140
M48x1.5 170 145
M52x1.5 180 150
M56x2 190 160
M64x2 205 175

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Section 1.4
General Page 13

Tightening torques for plugs DIN 7604C (with long screwed plug)

Thread Inserted in
Steel/gray cast iron Al-alloy
MA (Nm) MA (Nm)
M8x1 10 10
M22x1.5 80 65
M26x1.5 105 90
M30x1.5 130 130
M38x1.5 140 120
M45x1.5 160 140

Tightening torques for banjo screws according to MTN 5183-2


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

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

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

Tightening torques for banjo screws made of steel

Thread Inserted in
Steel/gray cast iron/Al-alloy
MA (Nm)
M8x1 10
M10x1 15
M12x1.5 20
M14x1.5 25
M16x1.5 25
M18x1.5 30
M22x1.5 60
M26x1.5 90
M30x1.5 130
M38x1.5 140
M45x1.5 160

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Section 1.4
Page 14 General

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

Thread Inserted in
Steel/gray cast iron/Al-alloy
MA (Nm)
M10x1 15
M16x1.5 30

Tightening torques for male connectors as per MTN 5183-3


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

DIN 2353 Form C

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

Thread Inserted in
Steel/gray cast iron
MA (Nm)
M10x1 10
M12x1.5 20
M14x1.5 40
M16x1.5 50
M18x1.5 60
M22x1.5 70
M26x1.5 100
M32x2 160
M42x2 260
M48x2 320

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Section 1.5
General Page 1

1.5 Settings

Firing order

Firing order 1 - 12 -5 -8 -3 -10 - 6 - 7 - 2 -11 - 4 - 9

Direction of rotation viewed on the driving end

Crankshaft c.c.w.
Camshafts c.w.
Engine oil pump c.c.w.
Engine coolant pump c.c.w.
Raw water pump c.c.w.

Valve clearance, engine cold (20 5C)

Inlet 0.40 mm
Exhaust 0.60 mm

Engine timing with valve clearance adjusted

Valve clearance adjusted Crank angle_


1 Inlet valve opens . . . . . . . . . . . . . . 17° before TDC
2 Inlet valve closes . . . . . . . . . . . . . . . . 29° after BDC
3 Exhaust valve opens . . . . . . . . . . . 71° before BDC
4 Exhaust valve closes . . . . . . . . . . . . . 13° after TDC
5 Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
6 Start of delivery of fuel injection pump, see Engine
Acceptance Test Record

I . . . . . . . . . . . . . . . . . . . . . . . . Top dead centre (TDC)


II . . . . . . . . . . . . . . . . . . . . Bottom dead centre (BDC)

Opening pressure of fuel injectors

Setting pressure with new spring 200 bar to 208 bar


Minimum pressure with run-in spring 185 bar

M020081/00E - 03.10 - E MTU


Section 1.5
Page 2 General

E MTU - 03.10 - M020081/00E


Section 1.6
General Page 1

1.6 Publication overview

Description and Operating Instructions M015535/00


Fluids and Lubricants Specification A001061
Test Procedures and Auxiliary Materials M070007
Tolerances and Wear Limits List M070042
Tools List M004018/20
Specialised information on subjects such as
- Engine electronics
can be obtained from the acceptance test record of the respective engine.

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Section 1.6
Page 2 General

E MTU - 03.10 - M020081/00E


Section 1.7
General Page 1

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

Data

Thread Core hole bore-dia. (max./min.) Twist drill-dia.


M6 6.31 6.1-6.2-6.25
6.04
M8 8.35 8.1-8.2-8.25-8.3
8.04
M8x1 8.32 8.1-8.2-8.25-8.3
8.04
M 10 10.40 10.25
10.05
M 12 12.50 12.25-12.5
12.05
M12x1.5 12.43 12.25
12.05
M 14 14.53 14.25-14.5
14.06
M14x1.5 14.43 14.25
14.05
M7x1 15.30 15.25
15.20
M 16 16.53 16.25-16.5
16.06
M16x1.5 16.43 16.25
16.05
M7x1 24.43 24.25
24.05
M7x1 26.43 26.25
26.05
M7x1 30.43 30.25
30.05

Repair
If necessary, remove thread insert with suitable re-
moval tool from bore (left).
Bore core hole with suitable twist drill - see table.
Cut thread with special tapped bore.
Note: Do not countersink bore!
Mount spindle (2) and snout (1) corresponding with
thread.
Groove on snout must be aligned with markings on
installation tool (arrows).

L92_23443

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Section 1.7
Page 2 General

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


tool.
Driver journal of thread insert must be in groove
(arrow).
2

L92_23443

Use spindle to turn thread insert through snout until


it is flush at front (arrow).

L92_23443

Mount installation tool on threaded hole and install


thread insert without applying pressure to spindle.
Note: Insert thread insert 1/2 to 1 1/2 turns
deeper than threaded bore surface.
Use bolt shearer to remove driver journal to M14.
In event of threaded inserts over M14, move driver
journal up and down with pointed pliers and remove.

L92_23443

E MTU - 03.10 - M020081/00E


Section 1.8
General Page 1

1.8 Keyword Index

A
Accessories, group 3.88
Air system 3.10.2

C
Camshaft 3.6.1
Camshaft axial clearance check 3.6.1.7
Camshaft bearing bush 3.1.5
Carrier housing with exhaust turbocharger and exhaust elbow 3.10.6
Checking engine condition before a major overhaul 2.1
Coolant expansion tank 3.14.5
Coolant pump, group 3.13
Coolant thermostat 3.14.7
Cooling system 3.14
Crankcase bore measurement 3.1.1.4
Crankcase ventilation 3.1.7
Crankcase, group 3.1
Crankshaft 3.3.1
Cylinder designation 1.2
Cylinder head cover 3.6.4
Cylinder head, group 3.5
Cylinder liner 3.1.3

D
Designation of engine sides and cylinders 1.3
Distributor housing 3.14.5
Drain lines, intercooler 3.10.14

E
Electric starter 3.18.1
Engine assembly 2.5
Engine coolant chamber pressure testing 3.14.9
Engine coolant cooler 3.14.6
Engine coolant lines 3.14.1
Engine coolant pump 3.13.1
Engine disassembly 2.4
Engine disassembly 2.4
Engine governor 3.7
Engine installation and operation 2.7

M020081/00E - 03.10 - E MTU


Section 1.8
Page 2 General

Engine mounting with carrier 3.19.1


Engine mounts, group 3.19
Engine oil cooler 3.16.2
Engine oil filter 3.16.3
Engine oil lines 3.16.1
Engine oil pump 3.15.1
Engine oil system, group 3.16
Engine removal 2.3
Engine removal 2.3
Engine run-in 2.6
Engine, initial operation 2.7
Exhaust system 3.10.3
Exhaust turbocharger, carrier housing 3.10.6
Exhaust turbocharger, group 3.9

F
Firing order 1.5
Flywheel 3.3.3
Fuel duplex filter 3.12.3
Fuel injection equipment 3.11
Fuel injection nozzle with nozzle holder 3.11.6
Fuel injection pump 3.11.5
Fuel injection pump drive 3.11.1
Fuel lines 3.12.2
Fuel system 3.12

G
Gear case 3.1.8
General assembly instructions are observed 1.1
General, main section 1
Group Summary 3
Group summary 3

H
H.P. fuel lines 3.12.1
Hazards at the workplace 1.2

I
Important information 1.1
Intake air system/exhaust system, group 3.10
Intercooler 3.10.1

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Section 1.8
General Page 3

K
Keyword index 1.8

M
Monitoring system, group 3.84

O
Oil bore check 3.1.1.4
Oil dipstick 3.1.11
Oil pan 3.1.6
Oil pump, group 3.15
Oil system, group 3.16
Opening pressure of fuel injectors 1.5
Operation Schedules 2

P
Piston-cooling oil spray nozzle 3.1.4
Pistons and conrods 3.3.2
Pistons and conrods 3.3.2
Pressure relief valve 3.15.5
Publication Summary 1.8
Pushrods and rocker arms 3.6.3

R
Raw water lines 3.14.3
Raw water pump 3.13.2
Repairing threaded bores with threaded inserts 1.7
Rockers and pushrods 3.6.3
Roller tappets 3.6.2
Run-in program 2.6
Running gear, group 3.3

S
Safety Instructions 1.5
Semirotary hand pump for oil extraction 3.15.8
Sensor and transmitter 3.84
Settings 1.5
Spring pin check and replacement 3.1.1.4
Starting system, group 3.18
Summary, groups 3

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Section 1.8
Page 4 General

T
Task descriptions 3
Three-phase alternator 3.86.1
Tightening sequence for gear case 1.4
Tightening sequence, crankshaft bearing cap to crankshaft 1.4
Tightening sequence, cylinder head to engine block 1.4
Tightening sequence, injection pump to crankcase 1.4
Tightening sequence, oil pan to crankcase 1.4
Tightening specifications for screws, bolts and nuts 1.4
Timing 1.5

V
Valve clearance check and adjustment 3.6.3.7
Valve gear, group 3.6
Valve overlap 1.4
Valve tappet 3.6.2
Vent and drain lines 3.14.2
Vibration damper 3.3.4

W
W5 maintenance operations 2.2
Wiring 3.84.9

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Section 2
Operation Schedules Page 1

2 Operation Schedules
Contents

2.1 Checking engine condition before a major overhaul

2.2 W5 maintenance operations

2.3 Engine removal

2.4 Engine disassembly

2.5 Engine assembly

2.6 Engine run-in

2.7 Engine installation and startup

M020081/00E - 03.10 - E MTU


Section 2
Page 2 Operation Schedules

E MTU - 03.10 - M020081/00E


Section 2.1
Operation Schedules Page 1

2.1 Engine Condition Check prior to W5 Maintenance Operations and


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

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

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Section 2.1
Page 2 Operation Schedules

E MTU - 03.10 - M020081/00E


Section 2.2
Operation Schedules Page 1

2.2 W5 Maintenance operations


Instructions for carrying out work:
No provision is made for W5 maintenance operations with this engine.

M020081/00E - 03.10 - E MTU


Section 2.2
Page 2 Operation Schedules

E MTU - 03.10 - M020081/00E


Section 2.3
Operation Schedules Page 1

2.3 Engine Removal


Operations see
Shut off fuel supply line Operating Instructions
Close compressed air supply line Operating Instructions
Shut off raw water supply line Operating Instructions
Drain oil with engine warm when possible Operating Instructions
Drain oil sludge from engine oil filter Operating Instructions
Oil sludge metallic residue check Operating Instructions
Drain engine coolant; coolant temperature must be below 60 °C Operating Instructions
Drain raw water (sea water) Operating Instructions
Wash machinery plant; do not use chemical solvents -
Release all connections -
Install non-fibrous plugs and blanking plates to seal all open connections -
Remove engine securing screws -
Remove engine and place on stands -
Install transportation locking devices (for road or rail transport) Operating Instructions
Using a lifting device, attach engine only on suspension brackets provided as shown in Operating Instructions
installation drawing, taking centre of gravity and transportation specifications into con-
sideration.

Engine weight
See Operating Instructions

M020081/00E - 03.10 - E MTU


Section 2.3
Page 2 Operation Schedules

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Section 2.4
Operation Schedules Page 1

2.4 Engine Disassembly


Before beginning complete engine disassembly, it is advisable to take photographs of the engine from all sides or
to record all components installed on the engine in writing.
The sequence of the required operations in the following list corresponds to the order in which actual disassembly
is to be carried out.
The individual tasks are described in detail in the Sections listed in the right-hand column.

Operations see
Mark and disconnect electric cables 3.84.9.9
Remove wiring 3.84.9.9
Remove governor 3.84.11
Remove crankcase vent line 3.1.7.2
Disconnect vent and drain lines 3.14.2.2
Disconnect engine coolant lines 3.14.1.2
Disconnect water lines 3.14.3.2
Remove coolant thermostat 3.14.7.2
Remove coolant expansion tank 3.14.5.2
Remove engine coolant cooler 3.14.6.2
Remove sensor and transmitter 3.84.1.2
Disconnect engine oil lines 3.16.1.2
Remove starter 3.18.1
Remove three-phase alternator 3.86.1
Remove cylinder head covers 3.6.4.2
Remove fuel supply and return lines 3.12.2.2
Disconnect H.P. fuel lines 3.12.1.2
Remove fuel duplex filter 3.12.3.2
Remove exhaust turbocharger with carrier housing and exhaust elbow 3.10.6.2
Disconnect exhaust pipework 3.10.3.2
Remove drain line from intercooler 3.10.14.2
Remove intercooler 3.10.1.2
Remove air intake system 3.10.2.2
Remove engine oil filter 3.16.3.2
Remove engine oil cooler 3.16.2.2
Remove engine coolant pump 3.13.1.2
Remove raw water pump 3.13.2.2
Remove fuel injection pump 3.11.5.2
Remove fuel injection pump drive 3.11.1.2
Remove fuel injector nozzles 3.11.6.2
Remove valve gear housing 3.6.4.2
Remove rockers and pushrods 3.6.3.2
Remove cylinder heads 3.5.1.2
Remove roller tappets 3.6.2.2
Remove flywheel 3.3.3.2
Remove vibration damper 3.3.4.2

M020081/00E - 03.10 - E MTU


Section 2.4
Page 2 Operation Schedules

Operations see
Remove engine mounts 3.19.1.2
Remove dipstick and oil filler neck 3.1.11.2
Install engine in roll-over assembly dolly 3.1.1.2
Remove oil pan 3.1.6.2
Remove engine oil pump from crankcase 3.15.1.2
Pressure relief valve removal 3.15.8
Remove camshafts 3.6.1.2
Remove pistons and conrods 3.3.2.2
Remove crankshaft 3.3.1.2
Remove oil spray nozzles 3.1.4.2
Remove cylinder liners 3.1.3.2
Remove crankcase from roll-over assembly dolly 3.1.1.6

E MTU - 03.10 - M020081/00E


Section 2.5
Operation Schedules Page 1

2.5 Engine Assembly


The sequence in which the following required procedures are listed corresponds to the order in which actual as-
sembly is performed.
The individual tasks are described in detail in the Groups listed in the right-hand column.

Operations see
Inspect and repair crankcase 3.1.1.4
Install camshaft bearing bushes 3.1.5.6
Install crankcase in roll-over assembly dolly 3.1.1.2
Install end cover, pin, dowel pins and studs in crankcase 3.1.1.4
Install cylinder liners in crankcase 3.1.3.6
Check crankcase for leaks 3.1.1.4
Measure crankcase bore 3.1.1.4
Measuring cylinder liner bore 3.1.3.7
Install and measure crankshaft bearing shells 3.3.1.6
Install oil spray nozzles for piston cooling 3.1.4.6
Install crankshaft in crankcase 3.3.1.6
Install camshafts with drive gear 3.6.1.6
Install piston and conrod in crankcase with intermediate frame 3.3.2.6
Install engine oil pump on crankcase 3.15.1.6
Install oil pan on crankcase 3.1.6.6
Remove engine from roll-over assembly dolly 3.1.1.6
Install valve gear housing 3.1.8.6
Install flywheel 3.3.3.6
Install vibration damper 3.3.3.6
Install roller tappets 3.6.2.6
Install cylinder heads 3.5.1.6
Install rocker arms and pushrods 3.6.3.6
Check and adjust valve clearance 3.6.3.7
Check camshaft timing/valve lift 3.6.1.7
Install fuel injection nozzles 3.11.6.6
Install valve gear housing 3.6.4.6
Install engine oil hear exchanger 3.16.2.6
Install engine oil filter 3.16.3.6
Install fuel injection pump drive 3.11.1.6
Install fuel injection pump 3.11.5.6
Determine crank angle before TDC 3.11.5.7
Adjust injection pump delivery 3.11.5.7
Install air intake system 3.10.2.6
Install intercooler 3.10.1.6
Connect drain lines 3.14.2.6
Install exhaust pipework 3.10.3.6
Install exhaust turbocharger with carrier housing and exhaust elbow 3.10.6.6

M020081/00E - 03.10 - E MTU


Section 2.5
Page 2 Operation Schedules

Operations see
Install sensor and transmitter 3.84.1.6
Install engine coolant pump 3.13.1.6
Install raw water pump 3.13.2.6
Install engine coolant cooler 3.14.6.6
Install coolant expansion tank 3.14.5.6
Install coolant thermostat 3.14.7.6
Connect engine coolant lines 3.14.1.6
Connect raw water lines 3.14.3.6
Connect vent lines 3.14.2.6
Install fuel duplex filter 3.12.3.6
Install fuel lines 3.12.2.6
Install engine mount on crankcase intermediate frame 3.19.1.6
Install oil supply and return lines 3.16.1.6
Install engine oil lines 3.16.1.6
Install H.P. fuel lines 3.12.1.6
Install fuel supply and return lines 3.12.2.6
Connect leak-off fuel lines 3.12.2.6
Install cylinder head covers 3.6.4.6
Install starter 3.18.1.6
Install crankcase breather 3.1.7.6
Install oil dipstick and oil filler neck 3.1.11.6
Install monitoring instrument 3.84
Install and connect electric wiring 3.84.9.6
Install three-phase alternator 3.84.1.6
Pressure-test engine coolant chambers 3.14.9

E MTU - 03.10 - M020081/00E


Section 2.6
Operation Schedules Page 1

2.6 Engine run-in


Run-in program
Request instructions on this from MTU Service.
After the installation of pistons, piston rings or cylinder liners, the engine must be run in as per the appropriate
run-in schedule.
A thorough running-in is of critical importance regarding the engine’s durability and operational reliability.
Use a dynamometer or generator to absorb the power developed in the braking run.
Power must be transmitted from the engine to the dynamometer/alternator by means of a resilient coupling.
Settings
Set intake-air temperatures before engine according to those given for the engine in its MTU Engine Acceptance
Test Record.
The engine coolant temperature depends on the operating range of the coolant thermostat.
Record readings for power, fuel, lube oil, coolant, charge air and exhaust gas at each test point (time, speed and
effective power) of the run-in schedule and enter readings under “Engine Running-In” in “MTU Diesel Engine Fac-
tory Test” record.
The values stated in the Engine Acceptance Test Record for the respective engine are mandatory.

Instructions for carrying out work


- A = MTU Acceptance Test Record
- B = Operating Instructions
- C = MTU Fluids and Lubricants Specification
- H = Manufacturer’s Instructions

Operations see
Install engine on test stand -
Connect intake air, exhaust gas, starting air, engine coolant, oil and fuel lines -
Fill expansion tank with coolant with 2% corrosion inhibitor oil up to max. mark B
Vent coolant lines at vent cock and lines until bubble-free coolant emerges B
Check that fuel in service or supply tank is to specification C
Vent fuel system with hand pump B
Fill up with fresh engine oil to the max. mark B
Check compressed air supply -
Before engine start-up, governor and fuel injection pump regulator must be checked B
Check shutdown position of governor and full-load injection of fuel injection pump at shutdown A
housing
Check function of emergency air shut-off flaps B
Check function of shutdown equipment B
Remove cylinder head covers. B
Always build up oil pressure with priming pump before starting engine -
Start engine B
Check lowest adjustable zero-setting speed, adjust at engine governor as necessary A
After 15 mins running, check valve gear lubrication -
At zero-load speed, check that oil emerges evenly at sides of all rocker arms and bearings B
Check oil supply of ball sockets at adjusting screws -
Check for leaks at coolant, oil and fuel lines, crankcase seals, air system and exhaust pipework B

M020081/00E - 03.10 - E MTU


Section 2.6
Page 2 Operation Schedules

Operations see
Run in engine and record measurements in accordance with the running-in schedule A
Check engine speed and brake load -
Measure fuel temperature before engine/before measuring glass, fuel density, consumption and con- -
trol rack travel
Measure engine oil pressure before filter and measuring block -
Measure engine oil temperature before and after engine -
Measure coolant temperature before engine after coolant pump -
Measure coolant temperature after engine in air/coolant manifold -
Measure coolant pressure before pump, after pump and after engine in air/coolant manifold -
Measure raw water temperature before and after engine -
Measure raw water pressure before pump and before heat exchanger -
Check charge air temperature before engine and before cylinder -
Check intake depression before turbocharger and charge air pressure before cylinder -
Measure exhaust temperature after exhaust turbocharger, left and right sides -
Measure exhaust pressure (back pressure) after engine -
Check exhaust gas colour -
Check barometer level and enter in record A
Check engine for abnormal running noises and leaks -
After running in, check lowest and highest possible zero-power speeds and stop and full-load set- -
tings of governor; readjust if necessary
Recheck idle-speed and full-load settings -
Check oil filter B
After running-in, perform factory test according to the MTU Engine Acceptance Test Record -
Enter operational values in the enclosed Factory Test Record A
Compare measured values with those in the Acceptance Test Record A
Shut down engine B
In event of an extended out-of-service period, preserve the engine and carry out protective B
measures appropriate for sea transportation.
Remove engine from test stand -
Install monitoring and measuring units for engine monitoring B
Spray engine with protective paint -

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Section 2.7
Operation Schedules Page 1

2.7 Engine Installation and Startup


Instructions for carrying out work
- B = Operating Instructions
- D = Special Publication

Operations see
Open all connections, remove covers and plugs -
Using a lifting device, attach engine only on suspension brackets provided as shown in installation B
drawing, taking centre of gravity and transportation specifications into consideration.
Install engine in machinery plant -
Join connections appropriately -
Removing transportation locking device B
Align engine D
Fill engine coolant system B
Fill engine oil system B
Prepare engine for operation B
Start engine B
Perform checks while engine is running B
Carry out test run B
Shut down engine B
Perform after-shutdown services B
Preservation measures are required if an extended out-of-service period is intended D

M020081/00E - 03.10 - E MTU


Section 2.7
Page 2 Operation Schedules

E MTU - 03.10 - M020081/00E


Section 3
Task Description Page 1

3 Group Summary
Deviation from illustrations possible

3.01 Crankcase 3.14 Coolant system


3.02 Gear train * 3.15 Oil pump *
3.03 Running gear * 3.16 Oil system *
3.04 End cover, free end 3.17 Speed monitoring drive *
3.05 Cylinder head 3.18 Starting system
3.06 Valve gear 3.19 Engine mount
3.07 Engine governor * 3.20 Fan drive (not installed on this engine)
3.08 Governor linkage (not installed on this engine) 3.27 Supplementary control units (not installed on this engine)
3.09 Exhaust turbocharger * 3.84 Monitoring system
3.10 Air/exhaust system 3.86 Accessories (electrical, pneumatic) *
3.11 Injection system * 3.87 Engine and gearbox controls (not installed on this engine)
3.12 Fuel system 3.88 Accessories (Mechanical)
3.13 Coolant pump *
*not shown

M020081/00E - 03.10 - E MTU


Section 3
Page 2 Task Description

E MTU - 03.10 - M020081/00E


Section 3.1
Task Description Page 1

3.1 Crankcase
Contents

3.1.1 Crankcase
3.1.1.1 Before-removal operations
3.1.1.2 Removal
3.1.1.3 Disassembly
3.1.1.4 Inspection and repair
3.1.1.5 Assembly
3.1.1.6 Installation
3.1.3 Cylinder liner
3.1.3.1 Before-removal operations
3.1.3.2 Removal
3.1.3.4 Inspection and repair
3.1.3.6 Installation
3.1.3.7 After-installation operations

3.1.4 Piston cooling oil spray nozzle


3.1.4.1 Before-removal operations
3.1.4.2 Removal
3.1.4.4 Inspection and repair
3.1.4.6 After-installation operations
3.1.4.7 After-installation operations
3.1.5 Camshaft bearing bush
3.1.5.1 Before-removal operations
3.1.5.2 Removal
3.1.5.4 Inspection and repair
3.1.5.6 Installation
3.1.5.7 After-installation operations

3.1.6 Oil pan


3.1.6.1 Before-removal operations
3.1.6.2 Removal
3.1.6.4 Inspection and repair
3.1.6.6 Installation

3.1.7 Crankcase breather


3.1.7.1 Before-removal operations
3.1.7.2 Removal
3.1.7.4 Inspection and repair
3.1.7.6 Installation
3.1.8 Valve housing
3.1.8.1 Before-removal operations
3.1.8.2 Removal
3.1.8.3 Disassembly
3.1.8.4 Inspection and repair
3.1.8.5 Assembly
3.1.8.6 Installation

M020081/00E - 03.10 - EMTU


Section 3.1
Page 2 Task Description

3.1.8 Valve housing


3.1.8.1 Before-removal operations
3.1.8.2 Removal
3.1.8.4 Inspection and repair
3.1.8.6 Installation

3.1.11 Oil filler neck and oil dipstick


3.1.11.1 Before-removal operations
3.1.11.2 Removal
3.1.11.4 Inspection and repair
3.1.11.6 Installation

EMTU - 03.10 - M020081/00E


Section 3.1
Task Description Page 3

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

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Section 3.1
Page 4 Task Description

EMTU - 03.10 - M020081/00E


Section 3.1.1
Task Description Page 1

3.1.1 Crankcase

1 Crankcase 12 Cover
2 Sealing cap 13 Sealing ring
3 Sealing rings 14 Gasket
4 Seal 15 Spring washer
5 Plug 16 Hex screw
6 Sealing ring 17 Oil spray nozzle
7 Plug 18 Banjo screw
8 Sealing ring 19 Plug
9 Plug 20 Sealing ring
10 Sealing ring 21 Plug
11 Spring pin 22 Sealing ring

M020081/00E - 03.10 - EMTU


Section 3.1.1
Page 2 Task Description

1 Dowel pin 12 Plug


2 Dowel pin 13 Sealing ring
3 Hex screw 14 Plug
4 Hex screw 15 Sealing ring
5 Camshaft bearing 16 End cover
6 Camshaft bearing 17 Plug
7 End element 18 Sealing ring
8 Plug 19 Dowel pin
9 Sealing ring 20 Dowel pin
10 Plug 21 Ball
11 Sealing ring

EMTU - 03.10 - M020081/00E


Section 3.1.1
Task Description Page 3

3.1.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Carry out tasks as specified in disassembly plan
- x x Removal not planned

M020081/00E - 03.10 - EMTU


Section 3.1.1
Page 4 Task Description

3.1.1.2 Removal
Set crankcase on assembly pedestal
Place crankcase with lifting device on assembly pedestal.

3.1.1.3 Disassembly
Removing plugs
Remove all plugs (1, 3, 7, 9 and 11) from crankcase
(14).
Remove sealing rings ( 2, 4, 6, 8, 10).
Remove spring pin (13) only if necessary - see In-
spection and repair 3.1.1.4.

3.1.1.4 Inspection and repair


Clean all parts, remove paint if necessary.
Check crankcase and main oil gallery for cracks using surface crack-testing method with red penetrant dye.
Check the mating faces, top and bottom cylinder liner fits and the bores for the crankshaft bearing for wear, dam-
age and cavitation.
For advice on matters relating to cracks and crankcase reconditioning, please contact our Product Support service.
Use straight edge and feeler gauge to check mating surfaces of crankcase partition walls for evenness.
If irregularities of greater than 0.05 mm are detected, recondition the seating surfaces on the partition walls in ac-
cordance with MTU specifications.
Request the relevant work instructions from MTU Friedrichshafen.

Inspecting oilways
Inspecting main oil gallery
Endoscopically inspect main oil gallery with cold light source and makesure it is perfectly clean.
If necessary, clean oilways with a bristle brush. Do not use wire brushes!

WARNING

Test fluid is highly pressurized. Risk of injury!


Liquids emerging under high pressure can lead to serious injury!
Always wear protective clothing, protective gloves and protective goggles/safety mask.
After cleaning, flush oilways with a flushing system that has a minimum working pressure of 10 bar.

EMTU - 03.10 - M020081/00E


Section 3.1.1
Task Description Page 5

Closing main oil gallery


Before installing plug, check that threads of main oil gallery and plug are in proper condition.
Clean and degrease thread and coat with Activator.
Fit sealing ring on plug.
Coat thread of plug with Loctite 270.
Screw plug into main oil gallery, driving end - see Removing plugs.
Use torque wrench and Allen key to tighten plug. For torque setting, see Section 1.4.

Checking and replacing spring pin


Check general condition of spring pin, replace if necessary.
Checking and replacing studs
Only remove studs if necessary.
Coat new studs with Loctite 270.

Measuring crankcase bore for cylinder liner


Always measure all bores at four points.
Check upper and lower locating bores in crankcase for wear or pitting.
If badly worn or pitted, recondition bore to next repair stage with suitable boring mill.
When reconditioning, always machine both upper and lower locating bores.
Adjust bore gauge.
Measure upper and lower locating bores for cylinder liners in crankcase.
Record measured values in data sheet.
For limit values, see Tolerances and Wear Limits List.
If wear limits are exceeded, machine locating bores to next repair stage.
Mark outside of reconditioned crankcase with numeral punch 6 mm high:

Roller tappet guide bush


Adjust bore gauge.
Measure bore.
Record measured values in data sheet.
For limit values, see Tolerances and Wear Limits List.
Camshaft bearing bush bore
Adjust bore gauge.
Measure bore for camshaft bearing bush on crankcase.
Record measured values in data sheet.
For limit values, see Tolerances and Wear Limits List.
Check bearing bushes for scoring and damage.

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Section 3.1.1
Page 6 Task Description

3.1.1.5 Assembly
Installing plugs
Install all plugs (1, 3, 7, 9 and 11) with sealing rings
( 2, 4, 6, 8 and 10) on crankcase (14).
Install spring pin (13).

3.1.1.6 Installation
Installing crankcase in assembly dolly

Note: Engine barring when engine is in assembly dolly is allowed only until running gear is installed, i.e. with-
out oil pan, cylinder heads and other installation components.
Once the engine has been swivelled, the crankcase must be removed from the roll-over assembly dolly
in order to continue the assembly process.
Secure crankcase with lifting device.
Remove bolts securing crankcase to assembly dolly.
Using lifting device, remove crankcase from assembly dolly and set on supports.

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Section 3.1.3
Task Description Page 1

3.1.3 Cylinder liner

1 Cylinder liner 3 O-rings


2 Tombak ring

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Section 3.1.3
Page 2 Task Description

3.1.3.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- - X Drain engine coolant Oper. Instr.
- - X Drain or draw off engine oil Oper. Instr.
- X X Remove crankcase breather (only as required) 3.1.7.2
- X X Remove coolant system vent line 3.14.2.2
- X X Remove engine coolant line 3.14.1.2
- X X Disconnect engine oil lines 3.16.1.2
- X X Remove exhaust pipework (remove screws from respective cylinder head) 3.10.3.2
- X X Disconnect H.P. fuel lines 3.12.1.2
- X X Remove intake air pipework (remove screws from respective cylinder 3.10.2.2
head)
- X X Disconnect leak-off fuel lines 3.12.2.2
- X X Remove cylinder head covers and gear case 3.6.4.2
- X X Remove rocker arm with pushrods at appropriate cylinder head 3.6.3.2
- X X Remove cylinder head 3.5.1.2
- X X Remove engine oil heat exchanger (only as required) 3.16.2.2
- X X Remove oil pan 3.1.6.2
- X X Remove piston and conrod 3.3.2.2
X X X Measure cylinder liner ID in installed condition 3.1.3.7

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Section 3.1.3
Task Description Page 3

3.1.3.2 Removal
Mark liner position with regard to crankcase (arrow)
Fit studs (1).
Insert and secure removal/installation tool in cylinder
liner up to lower edge of cylinder liner.
Turn nut (2) until clamping jaws contact inner diam-
eter of liner.

Install counter-support and tighten spindle of clamp-


ing jaws.
Hold spindle firmly on hexagon with box wrench.
Turn nut (arrow) to withdraw cylinder liner.
Turn clamping jaws together.
Unscrew counter-support and
remove complete installation/removal tool.

Remove cylinder liner.


Remove O-ring and Tombak sealing ring.

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Section 3.1.3
Page 4 Task Description

3.1.3.4 Inspection and repair


Clean parts.
Check cylinder liner running surface for scoring and pitting, replace liner if necessary.
Using the magnetic crack-testing method and fluorescent magnetic powder, check cylinder liner for cracks, and
replace if necessary. Check outer walls of cylinder liner for pitting.
In event of minor pitting, install liner turned through 90°.
In such cases, rehone the cylinder liner bore and insert new piston rings.
Replace the liner if pitting is deeper than 1.5 mm.
Measure diameter of cylinder liner fits and thickness of liner collar. Using an electronic engraver, mark collar height
and cylinder no. at circumference of seating collar.
Adjust bore gauge.
Measure bore of bush at appropriate measuring point height turned through 90° twice.
Record measured values in data sheet.
For limit values, see Tolerances and Wear Limits List.
If wear limits are exceeded, replace liner.
When using new piston rings, rehone cylinder liner.
Check liner collar sealing surfaces for wear, smooth with oilstone if necessary.
Replace O-rings and sealing rings (replace in sets only).

3.1.3.6 Installation
Note: The thickness (0.15 mm) of the Tombak
sealing ring is balanced by means of
liners with a thinner (0.15 mm) collar.
A - Cylinder liner protrusion 80.03 to 0.09 mm.
1 - Tombak sealing ring
2 - Fillet (stays free)
3 - O-ring

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Section 3.1.3
Task Description Page 5

Clean all sealing surfaces in crankcase.


Insert new O-ring in crankcase.

Wipe outside of cylinder liner at fits and chamfer.


Install new O-ring (3) on cylinder liner.
Fit Tobak sealing ring (1) on bush collar.
Space (2) remains free.
Coat upper and lower fits with petroleum jelly.

Insert cylinder liners into crankcase turned 90°


(arrow) with respect to the old installation position.

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Section 3.1.3
Page 6 Task Description

Screw studs of installation/removal tool into threaded


bores.
Place the pressure plate (arrow) on the cylinder liner.
Mount installation tool.
Keep cylinder liner pretensioned for 5 minutes by
turning spindle with 100 Nm.

3.1.3.7 After-installation operations

Adjust bore gauge and dial gauge with micro-


meter or gauge ring to basic size for cylinder
liner as per Tolerances and Wear Limits List.
Examine four measurement levels, offset by 90°
to each other - see Tolerance and Wear Limits
List.
Record measured values in data sheet.
If out-of-roundness is measured:
- Remove cylinder liner.
- Again measure cylinder liner bore and outer di-
ameter.

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Section 3.1.4
Task Description Page 1

3.1.4 Piston cooling oil spray nozzle

1 Seal 3 Banjo screw


2 Oil spray nozzle

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Section 3.1.4
Page 2 Task Description

3.1.4.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- - X Drain engine coolant Oper. Instr.
- - X Drain or draw off engine oil Oper. Instr.
- X X Remove crankcase breather (only as required) 3.1.7.2
- X X Remove coolant system vent line 3.14.2.2
- X X Remove engine coolant line 3.14.1.2
- X X Disconnect engine oil lines 3.16.1.2
- X X Remove exhaust pipework (remove screws from respective cylinder head) 3.10.3.2
- X X Remove H.P. fuel lines with damping tape 3.12.1.2
- X X Remove intake air pipework (remove screws from respective cylinder 3.10.2.2
head)
- X X Disconnect leak-off fuel lines 3.12.2.2
- X X Remove cylinder head covers and gear case 3.6.4.2
- X X Remove rocker arm with pushrods at appropriate cylinder head 3.6.3.2
- X X Remove cylinder head 3.5.1.2
- X X Remove engine oil heat exchanger (only as required) 3.16.2.2
- X X Remove oil pan 3.1.6.2
- X X Remove piston and conrod 3.3.2.2

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Section 3.1.4
Task Description Page 3

3.1.4.2 Removal
Take care not to damage the oil spray nozzle (1).
Remove screw (2) and oil spray nozzle.
Place oil spray nozzle in a suitable transport trestle.

Remove seal (1), from 3rd cylinder.

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Section 3.1.4
Page 4 Task Description

3.1.4.4 Inspection and repair

WARNING

Fuels are combustible.


Risk of burning and explosion.
- do not use naked flame, no electric sparks, avoid all sources of ignition

WARNING

Compressed air is highly pressurised. Risk of injury!


Never direct a compressed air jet at other people.
Always wear protective goggles/safety mask and ear protectors.
Clean oil spray nozzle in fuel.
Carefully blow out oilways with dry compressed air.
Check that oilways are not obstructed.
Using surface crack-testing method and red penetrant dye, check oil spray nozzle for cracks when necessary. If
cracks are detected, replace.
Check mating faces and spray nozzles for damage, replace if necessary.

3.1.4.6 Installation
Before installing oil spray nozzle, check that mating faces on crankcase and nozzle are smooth.
Install oil spray nozzle with screw in crankcase.
Tighten screw with socket insert and torque wrench as per Tightening Specifications 1.4.

3.1.4.7 After-installation operations


Note: After installing pistons, bar engine and
ensure there is clearance between oil
spray nozzle and piston.

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Section 3.1.5
Task Description Page 1

3.1.5 Camshaft bearing bush

1 Cross handle 7 Centring pipe


2 Shell half 8 Spindle pipe
3 Bearing housing 9 Bearing retainer
4 Locking pin 10 Locking element
5 Bearing flange 11 Locating element
6 Screw 12 Collar bearing fixture

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Section 3.1.5
Page 2 Task Description

3.1.5.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- - X Removal not scheduled -
- X X Drain engine coolant Oper. Instr.
- X X Drain or draw off engine oil Oper. Instr.
- X - Mark and disconnect cables 3.84.9.2
- X - Remove terminal box and wiring 3.84.9.2
- X - Remove exhaust silencer 3.10.12.2.
- X - Remove engine coolant line 3.14.1.2
- X - Remove coolant expansion tank 3.14.5.2
- X - Disconnect engine oil lines 3.16.1.2
- X - Disconnect engine oil return lines from cylinder head 3.5.1.2
- X - Disconnect fuel lines 3.12.2.2
- X - Disconnect leak-off fuel lines 3.12.2.2
- X - Remove cylinder head covers 3.6.4.2
- X - Remove rocker arm with pushrods at appropriate cylinder head 3.6.3.2
- X - Remove valve gear housing 3.6.4.2
- X - Remove cylinder head 3.5.1.2
- X - Remove roller tappets 3.6.2.2
- X - Remove upper end cover 3.1.9.2
- X - Remove fuel injection pump drive 3.11.1.2
- X - Remove camshaft. 3.6.1.2

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Section 3.1.5
Task Description Page 3

3.1.5.2 Removal
Note: Remove and replace camshaft bearing
only if damaged.
Unscrew cap nut from end cover.

Remove end cover from crankcase with special tool.

Remove radial-lip oil seal.

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Section 3.1.5
Page 4 Task Description

Insert centring pipe (2) into bearing bore and secure


bearing flange (1) with two hex screws M10x25 to
crankcase.

Insert spindle pipe (3) into bearing flange (2).


Turn spindle tube until locking pin (1) engages in
groove (arrow).

Insert spindle pipe (1) into cylinder housing and


bearing flange (2) behind relevant bearing so that
support for bearing (arrow) points in direction of
cross handle.

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Section 3.1.5
Task Description Page 5

Insert bearing retainer (2) into bearing bore and in-


sert stop element (1) into groove behind bearing re-
tainer.

Collar bearing (1) is pressed out at rear. For this pur-


pose, connect cross handle with bearing flange by
means of shell half.
Remove cross handle and spindle pipe.
Remove bearing retainers and collar bearings.
Unscrew bearing flange.
Clean bearings in crankcase.

3.1.5.4 Inspection and repair


Inspect camshaft bearing bushes for scoring or damage.
Remove bushes from crankcase with puller if scoring or damage is identified or if wear limits are exceeded.

Measuring camshaft bearing bush locating bore


Adjust bore gauge.
Measure locating bore in crankcase.
Record measured values in data sheet.
For limit values, see Tolerances and Wear Limits List.
Install next repair-size bush if specified limits are exceeded.

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Section 3.1.5
Page 6 Task Description

3.1.5.6 Installation
Insert centring pipe (2) into bearing bore and secure
bearing flange (1) with two hex screws M10x25 to
crankcase.

Insert spindle pipe (3) into bearing flange (2).


Turn spindle tube until locking pin (1) engages in
groove (arrow).

Fit camshaft bearing (1) on bearing retainer (2), se-


cure (arrows) and lubricate externally.
Insert spindle pipe into crankcase and insert bearing
retainer with camshaft bearing behind relevant bear-
ing so that camshaft bearing points in direction of
cross handle.

Note: Install a maximum of two camshaft bear-


ings per operation.

EMTU - 03.10 - M020081/00E


Section 3.1.5
Task Description Page 7

When pulling inner camshaft bearings into bearing


bore of collar bearing, install locating ring (1).

Note: By securing bearing retainer for spindle


pipe, oil bore (2) of bearing is simulta-
neously aligned to oil bore (1) in crank-
case.
Insert stop element (3) into spindle pipe.
Turn cross handle clockwise and pull in bearing until
oil bore (2) of bearing is aligned with oil bore (1) in
crankcase.

When securing collar bearing to bearing retainer en-


sure oil bores are aligned (1 aligned with 3 and 2
aligned with 4).
Remove bearing insertion tool and measure bearing.
For values, see Tolerances and Wear Limits List.
Ensure oil ducts are free from obstruction.

M020081/00E - 03.10 - EMTU


Section 3.1.5
Page 8 Task Description

Install end cover with sealant in crankcase.

Install radial-lip oil seal.

Install cap nut on end cover.

EMTU - 03.10 - M020081/00E


Section 3.1.6
Task Description Page 1

3.1.6 Oil pan


Oil pan with gaskets

1 Oil pan 5 Stud


2 Gasket 6 Hex nut
3 Gasket 7 Washer
4 Stud

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Section 3.1.6
Page 2 Task Description

1 Thread insert 4 Sealing ring


2 Thread insert 5 Plug
3 Plug 6 Sealing ring

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Section 3.1.6
Task Description Page 3

3.1.6.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- - X Drain or draw off engine oil Oper. Instr.
- X X Remove elbow with connecting cable from oil pan 3.16.2.2
- X X Remove engine oil return lines from exhaust turbochargers 3.16.1.2
- X X Remove guide tube for oil dipstick from crankcase intermediate frame 3.1.11.2
- X X Remove oil pressure lines and elbow from oil pan to oil heat exchanger 3.16.1.2
- X X Remove bottom securing screws from flywheel housing 3.1.8.2

M020081/00E - 03.10 - EMTU


Section 3.1.6
Page 4 Task Description

3.1.6.2 Removal

WARNING

Suspended load. Risk of injury!


Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a
suspended load.
Attach lifting device for complete engine. Unscrew nut and remove with washers - see overview drawing.
Carefully raise engine with lifting gear and place on trestles.
If necessary and using a plastic mallet, remove oil pan from locating pin.
Place oil pan on pallet.
Remove gaskets from oil pan.

3.1.6.4 Inspection and repair


Clean oil pan.
Carefully remove all cleaning agent residue.
Using the surface crack-testing method and red penetrant dye, check the oil pan for cracks.
Replace oil pan if cracks are found.
Check sealing surfaces of oil pan for irregularities using a steel straightedge and feeler gauge.
Smooth sealing surfaces in event of unevenness.
Check thread of stud for ease of movement, replace stud if necessary.
Replace gaskets.

3.1.6.6 Installation

WARNING

Suspended load. Risk of injury!


Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a
suspended load.
Attach lifting device for complete engine. Carefully raise engine with lifting gear.
Check sealing surfaces on oil pan and crankcase intermediate frame for cleanliness.
Apply a thin coat of sealing paste in dots to gasket. Place gasket on oil pan sealing surface.
Coat studs with engine oil.
Lower engine with lifting gear down on oil pan until the sealing surfaces are approx. 1 cm apart.
Tighten nut with washers - see Fig. 3.1.6.
Tighten nut with torque wrench in accordance with Tightening Specifications 1.4.

EMTU - 03.10 - M020081/00E


Section 3.1.7
Task Description Page 1

3.1.7 Crankcase breather

1 Gasket 7 Nut
2 Cylinder head cover 8 Vent line
3 Oil separator 9 Clamp
4 Sealing ring 10 Hose
5 Sealing ring 11 Clamp
6 Elbow 12 Hose

M020081/00E - 03.10 - EMTU


Section 3.1.7
Page 2 Task Description

3.1.7.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Perform operations as per Disassembly Plan 2.4
- - x Disable engine start Op. Man.
- - x No preparatory work required -

EMTU - 03.10 - M020081/00E


Section 3.1.7
Task Description Page 3

3.1.7.2 Removal
Unscrew vent line, oil separator and cylinder head cover - overview drawing.

3.1.7.4 Inspection and repair


Clean all components.
Check vent lines, cylinder head cover and hoses for damage, replace as required.

3.1.7.6 Installation
Install oil separator
Install cylinder head cover and oil separator - see overview drawing.
Replace sealing rings.

Connect vent lines


Install vent line - see overview drawing.

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Section 3.1.7
Page 4 Task Description

EMTU - 03.10 - M020081/00E


Section 3.1.8
Task Description Page 1

3.1.8 Valve housing


Valve housing with attachments

1 Spacer tube 10 Hex screw


2 Bracket 11 Washer
3 Lifting attachment 12 Gasket
4 Hex screw 13 Hex screw
5 Washer 14 Washer
6 Hex screw 15 Hex screw
7 Bracket 16 Bracket
8 Hex screw 17 Eyebolt
9 Washer

M020081/00E - 03.10 - EMTU


Section 3.1.8
Page 2 Task Description

1 Valve housing 9 Sealing ring


2 End cover 10 Gasket
3 Sealing ring 11 Hex screw
4 Shaft seal 12 Spring washer
5 Screw 13 Cover
6 Screw 14 Hex screw
7 Cover 15 Spring ring
8 Plug

EMTU - 03.10 - M020081/00E


Section 3.1.8
Task Description Page 3

3.1.8.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- - X Drain engine coolant Oper. Instr.
- - X Drain/draw off engine oil Oper. Instr.
- X X Remove vent lines 3.14.2.2
- X X Remove intercooler 3.10.1.2
- X X Remove engine flange with driver 3.3.3.2
- X X Remove clamp ring with grooved ball bearing, driving end 3.3.4.2

M020081/00E - 03.10 - EMTU


Section 3.1.8
Page 4 Task Description

3.1.8.2 Removal

WARNING

Suspended load. Risk of injury!


Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a
suspended load.

Oil seal removal


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

Suspend valve housing with lifting device and lifting gear.


Remove all screws from valve housing.
Remove housing from centring ring and raise from crankcase.

3.1.8.3 Disassembly
Disassembly of valve housing as shown - see overview drawing

3.1.8.4 Inspection and repair


Clean all parts, remove paint if necessary.
Crack-test the valve housing using the surface crack-testing method and red penetrant dye.
Check mating faces and bores for wear, damage and cavitation.
Adjust bore gauge and measure respective bores - see Tolerance and Wear Limits List.

3.1.8.5 Assembly
Assembly of valve housing - see overview drawing.
Coat gaskets with sealing paste and install with cover on valve housing.
Coat sealing ring with petroleum jelly.
Fit on end cover and insert end cover.

EMTU - 03.10 - M020081/00E


Section 3.1.8
Task Description Page 5

3.1.8.6 Installation

WARNING

Suspended load. Risk of injury!


Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a
suspended load.
Clean mating faces on crankcase and valve housing.
Coat sealing surfaces evenly in area of crankcase with surface sealant.
Suspend valve housing with lifting device and lifting gear.
Install valve housing on crankcase.
Fit securing screws and tighten by hand.
Remove lifting device.
Tighten securing screws with torque wrench to Tightening Specifications 1.4.

Installing shaft seal


Fit spacer sleeve (arrow) of mandrel on crankshaft.

M020081/00E - 03.10 - EMTU


Section 3.1.8
Page 6 Task Description

Fit shaft seal on mandrel and install in valve housing.


Lubricate counter-track ring on flywheel.

EMTU - 03.10 - M020081/00E


Section 3.1.11
Task Description Page 1

3.1.11 Oil dipstick


Installation on right side

1 Oil dipstick 6 Hex screw


2 Guide tube 7 Washer
3 Sealing ring 8 Hex nut
4 Adapter 9 Hex screw
5 Bracket

M020081/00E - 03.10 - EMTU


Section 3.1.11
Page 2 Task Description

Installation on left side

1 Oil dipstick 6 Hex screw


2 Guide tube 7 Washer
3 Sealing ring 8 Hex nut
4 Adapter 9 Hex screw
5 Bracket

EMTU - 03.10 - M020081/00E


Section 3.1.11
Task Description Page 3

3.1.11.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- - X Drain or draw off engine oil Oper. Instr.

M020081/00E - 03.10 - EMTU


Section 3.1.11
Page 4 Task Description

3.1.11.2 Removal
Remove oil dipstick as shown in overview drawing.

3.1.11.4 Inspection and repair

CAUTION

When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for
use, safety instructions and waste disposal specifications.
Clean guide tube, oil dipstick and attachments with cold cleaner and check condition.
Replace damaged parts.
Replace sealing ring.
Make sure that a replacement oil dipstick is the correct version.

3.1.11.6 Installation

WARNING

Compressed air is highly pressurized.


Risk of injury! Test pressure must not be exceeded.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Before installation, blow out oil extraction pipe with compressed air and make sure all components are perfectly
clean.
Install in reverse sequence.

EMTU - 03.10 - M020081/00E


Section 3.3
Task Description Page 1

3.3 Running Gear

Contents
3.3.1 Cranshaft
3.3.1.1 Before-removal operations
3.3.1.2 Removal
3.3.1.3 Disassembly
3.3.1.4 Inspection and repair
3.3.1.5 Assembly
3.3.1.6 Installation

3.3.2 Piston and connecting rod


3.3.2.1 Before-removal operations
3.3.2.2 Removal
3.3.2.3 Disassembly
3.3.2.4 Inspection and repair
3.3.2.5 Assembly
3.3.2.6 Installation
3.3.3 Flywheel
3.3.3.1 Before-removal operations
3.3.3.2 Removal
3.3.3.3 Disassembly
3.3.3.4 Inspection and repair
3.3.3.5 Assembly
3.3.3.6 Installation

3.3.4 Vibration damper


3.3.4.1 Before-removal operations
3.3.4.2 Removal
3.3.4.4 Inspection and repair
3.3.4.6 Installation

M020081/00E - 03.10 - E MTU


Section 3.3
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

E MTU - 03.10 - M020081/00E


Section 3.3.1
Task Description Page 1

3.3.1 Crankshaft
Crankshaft

1 Crankshaft 3 Cover plate


2 Crankshaft gear

M020081/00E - 03.10 - EMTU


Section 3.3.1
Page 2 Task Description

1 Track ring 3 Screw


2 Counter weight

EMTU - 03.10 - M020081/00E


Section 3.3.1
Task Description Page 3

3.3.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- - X Drain engine coolant Oper. Instr.
- - X Drain or draw off engine oil Oper. Instr.
X X - Remove oil pan 3.1.6.4

M020081/00E - 03.10 - EMTU


Section 3.3.1
Page 4 Task Description

3.3.1.2 Removal

WARNING

Suspended load. Risk of injury!


Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a
suspended load.

Check marking of main bearing cap to crankcase.


If there is no marking: Punch numbers of main bear-
ings in same direction, starting with driving end,
making sure they are clearly legible.
Height of numeral punches: 6 mm.
Remove all screws (1 and 2) and remove crankshaft
bearing cap.

Install guide mandel (arrow).


Fit sling and lift crankshaft with crane out of crank-
case.
Make sure crankshaft is positioned horizontally.
Remove bearing shells from crankshaft.
Place crankshaft on stable supports.

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Section 3.3.1
Task Description Page 5

3.3.1.3 Disassembly

WARNING

Devices may be released suddenly.


Fluid is highly pressurised. Risk of injury!
Only use specified and tested equipment.
It is forbidden to stand in the danger zone.
Always wear protective gloves and protective goggles/safety mask.

Removing crankshaft gear


Mount puller (3) on crankshaft gear and turn it so
that locking pin (2) engages between two teeth.
Connect and secure hydraulic hand pump (4) and
H.P. line to puller.
Observe guidelines for using H.P. lines, see 1.5.
Fill hydraulic hand pump with SAE10 engine oil.
Bleed pump and line until bubble-free oil emerges.
Close valve.
Operate hand pump until a greater resistance is
achieved (approx. 200 to 300 bar) and gear is re-
leased from crankshaft.
Relieve pressure at oil pressure hand pump.
Remove H.P. line.
Pull gear off crankshaft.
Remove puller.

Removing counterweights
To remove counterweights (1), install crankshaft in a
stable, heavy-duty assembly stand.
Ensure that counterweights are numbered consecu-
tively; punch in new numbers if necessary.
Install retaining jig and power amplifier to release
stress bolts.
Unscrew stress bolts with ratchet from counter-
weight.
Remove counterweight, place in appropriate trans-
port trestle.

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Section 3.3.1
Page 6 Task Description

Removing track ring


Remove face ring (1) with extractor from crankshaft.

3.3.1.4 Inspection and repair


Clean crankshaft surface and bores with cold cleaner.
Using the magnetic crack-testing method with fluorescent magnetic powder, check crankshaft for longitudinal and
transverse cracks. Include oil bores and journal bores, counterweight mating faces and tapped bores in scope of
inspection.
Clamp crankshaft longitudinally between jaws of testing device.
Required magnetic electric field strength during testing is 20 to 60 A/cm.

Instructions for thermal cracks


Hot-running cracks are characterised by running al-
most only parallel to the axis.
Transverse cracks sometimes originate from these
cracks.
Severe thermal cracks are usually as deep as the
case-hardening.
Replace crankshaft with such cracks.
Crankshafts with minor thermal cracking can be re-
paired, provided that the cracks can be removed by
regrinding to the next repair stage or by local grind-
ing.
Consult MTU for details.
Carefully grind the affected journals until close to a
permissible repair size, depending on depth of crack-
ing.
Minor cracks can also be repaired by local grinding.
Preliminary grinding must be carried out before the
after-curing, otherwise there is the danger that the
thermal cracks will increase in length and depth.
Finish grinding the bearing journals to the specified
repair stage only after the hardening process is com-
pleted.

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Section 3.3.1
Task Description Page 7

Remarks on cracks caused by grinding


Fine branching is characteristic for grinding cracks.
The illustration shows a bearing journal with grinding
cracks.
Grinding cracks result from inadequate cooling or if
rate of feed is too great during the grinding process.

Demagnetising crankshaft.
After crack-testing, demagnetise crankshaft; the residual field strength must not exceed 2 to 4 A/cm.
Measuring journals
Using an outside micrometer, measure crankshaft main bearing journal and crankpin each at four points to check
that they are round and even.
Record measured values in data sheet.
If limit values are exceeded (see Tolerance and Wear Limits List), regrind crankshaft to next repair stage.

Marking diameter stages of main bearing journal


and crankpin
Stage 0 is not marked on crankshaft.
If individual main bearings and crankpin bearings are
reconditioned on the crankshaft, stamp actual diam-
eter (rated dimension) on crank web next to recondi-
tioned bearings with numeral punch 5 mm high/
0.5 mm deep, horizontal, as shown in adjacent dia-
gram.
Exception: Last main bearing journal, free end. Here,
stamp on last web, free end.
1 = Designation of repair stage for crankpin
2 = Designation of repair stage for main bearing journal
3 = Crankshaft

Checking crankshaft journal and taper


Check main journal for drive gear on crankshaft for wear.
Using an external micrometer, measure main journals.
Record values.
Check crankshaft taper for damage.
If necessary, recondition main journal for drive gear and crankshaft taper as per MTU specifications.

M020081/00E - 03.10 - EMTU


Section 3.3.1
Page 8 Task Description

Measuring crankshaft radial runout


Position support bearing at following main bearing journals: 12V on II and VI (see Dynamic balancing).
Check main bearing journals for radial runout and mating face for flywheel for face runout.
Secure dial gauge on adjustable support and carry out check.
When measuring contact face for flywheel, hold crankshaft against axial stop.
Check main bearing journals showing uneven wear at circumference only at transition from cylindrical section of
journal to web radius, at same time holding crankshaft against axial stop.
If radial runout is greater than specified value, crankshaft must be aligned before grinding.
If a journal requires rehardening, this must be performed before straightening.
Bearing journals must be hardened and crankshaft aligned only after consulting MTU.
For radial runout limit values, see Tolerance and Wear Limits List.

Checking hardness of journals


Check hardness of all journals using the Microdur
tester or other suitable hardness tester.
Test hardness of each journal at four points at 90°
intervals around circumference.
Specified hardness = from 49 HRC to 53 HRC
A journal that has lost its hardness due to seizure
must be rehardened.
When checking hardness of bearing journals, note
that the curves between the surfaces are not har-
dened.
Rub down all journals with emery cloth.
Important:
Hardness tests on installed or ready-to-be
installed crankshafts are not permitted.

Checking counterweights and screws


Check mating faces on counterweights for wear; grind mechanically if necessary.
For limit values, see Tolerances and Wear Limits List.
Using the magnetic crack-testing method with fluorescent magnetic powder, check screws for counterweights for
cracks, replace parts if necessary. Check that threaded bores in crankshaft and counterweight screws are in per-
fect condition and move freely. For max. permissible screw length, see Section 1.4.
Using engineer’s blue, check that screw heads are correctly seated on counterweights; recondition if necessary.

Checking track ring ring


Using the magnetic crack-testing method with fluorescent magnetic powder, check track ring for cracks; replace if
necessary.

Checking crankshaft gear


Using magnetic crack-testing method and fluorescent magnetic powder, check gear for cracks. Replace if necess-
ary.
Examine gear for wear, if necessary smooth with oilstone or Emery cloth, otherwise replace gear.
Adjust bore gauge, measure and record gear inner diameter.
Checking main bearing shells
Inspect crankshaft bearing shells for surface damage and wear; replace worn or spalled shells. Replace crankshaft
bearing shells as part of every W6 overhaul.

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Section 3.3.1
Task Description Page 9

Grinding crankshaft
When regrinding, always try to limit operations to next repair size. Adhere strictly to all specifications for sizes and
tolerances. This also includes those applicable to fillets and surface condition.
For limit values, see Tolerances and Wear Limits List.
Necessary checks after grinding:
- Check all journals for correct dimensions and surface smoothness.
- Check journal fillets.
- Check whether oil duct outlets are perfectly rounded and smooth. Take special care when carrying out this task in order
to avoid damaging the bearing shells and to ensure perfect lubrication.
- Check radial and face runout.
- Perform hardness test.
- Crack testing
Dynamic balancing
For dynamic balancing, crankshaft must be assembled with crankshaft gear, sealing components and counter-
weights.

Seal all oilways against dirt before balancing crankshaft.


To balance the crankshaft, position support A and B of the balancing machine at the following main bearing jour-
nals: 12V on II and VI
Crankshaft gear, counterweights and sealing components must be installed.
Balance crankshaft at 200 rpm.
Remove material for balancing only from the counterweights by means of radial drilling (max. depth 20 mm). When
doing this, the minimum width (between the individual bores, between the bores and side surfaces and/or screw holes)
must not be below 5 mm.
Permissible residual imbalance at supports:
- for initial balancing: 0.02 Nm (200 cmg) each
- for check balancing: 0.03 Nm (300 cmg) each
On completion of balancing, recheck numbering of counterweights and renumber if necessary.

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Section 3.3.1
Page 10 Task Description

3.3.1.5 Assembly

WARNING

Fuels are combustible.


Risk of burning and explosion.
- do not use naked flame, no electric sparks, avoid all sources of ignition

WARNING

Compressed air is highly pressurized. Risk of injury!


Never direct a compressed air jet at other people.
Always wear protective goggles/safety mask and ear protectors.
Thoroughly clean all crankshaft oil bores with cold cleaner or petroleum spirit and suitable bristle brush and blow
through with compressed air.

WARNING

Devices may be released suddenly.


Fluid is highly pressurised. Risk of injury!
Only use specified and tested equipment.
It is forbidden to stand in the danger zone.
Always wear protective gloves and protective goggles/safety mask.

Pressure-testing crankshaft
Mount locking device on crankshaft stub at driving end.
Seal oilways in crankshaft stub. Insert pressure-test segments into covers of crankshaft stub.
Mount blanking brackets on main bearing journal and crankpin in such a way that the oil bores are covered.
Tighten clamping levers to secure clamps.
Inserting pressure-test segment
Insert the pressure-test segment into the end cover in the crankpin so that the position of the eyebolt is approxi-
mately equal to the position of the bore, dia.1 mm in end cover. Secure pressure-test segment by tightening
threaded pin in centre of segment to 4 Nm. Place O-ring with threaded pin (eccentric) in position at bore dia.1 mm
at the end cover and seal the bore by turning the threaded pin.
Connect hydraulic pressure-testing device.
Pressure-test crankshaft with engine oil (test pressure 30 bar).
Check all end covers and core plugs for leaks.
Remove hydraulic pressure testing device and blanking bracket.
Before removing pressure-test segments, release off-centre threaded pin by approx. one turn and return to original
position.
Remove pressure-test segment.
Seal all oilways with plastic plugs.

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Section 3.3.1
Task Description Page 11

Counterweight Installation
Fit counterweight (1) on crankshaft and tighten
slightly with hexagonal socket-head screw (2).
Position V-block (3) on respective main bearing cap
so that lug (arrow) is between counterweight and
main bearing cap.

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


curely positioned.
Tighten hex nut (5) to centre counterweight.
Tighten hex socket screw (2) with torque wrench to
specified torque. For torque setting, see Section 1.4.
Remove centring screw (4) and tighten second hex
socket screw with torque wrench as per Tightening
Specifications 1.4 .
Remove V-block (3).

Tighten hex socket screws in the following stages:


1. Stage 140 Nm to 160 Nm
2nd stage 90° to 100° angle of rotation
Install remaining counterweights in same sequence
as described.

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Section 3.3.1
Page 12 Task Description

3.3.1.6 Installation
Installing crankshaft bearing
Turn crankcase upside down in assembly dolly.
Measure crankshaft bearing main bore.
Clean bores and bearing shells with chamois leather.
Check repair stage of crankshaft main bearing bore and repair stage of bearing shells, see crankcase data sheet
and crankshaft data sheet.
Prior to installing crankshaft bearing, measure crankshaft bearing spreading dimension. For dimensions, see Toler-
ance and Wear Limits List.
Bearing shells with no spreading must not be installed.
If main bearing bore in crankcase has been machined, it is necessary to increase depth of locating pin bore and
crankcase oil groove.
Install upper bearing shell with oil groove and oilways in main bearing bore, observing correct location of identifica-
tion number.
Install lower bearing shell without oil groove with one butting face against corresponding face of upper bearing
shell.
Exert thumb pressure on shell and seat other end in crankcase. Make sure that butting faces of shells are parallel.
Mark new bearing shells with 2 mm punch numerals pointing towards driving end.
Install crankshaft bearing cap.

Measuring crankshaft bearing bore


Adjust bore gauge with adjusting ring or micrometer
to basic size of bearing bore - see Tolerance and
Wear Limits List.
Coat running surfaces of crankshaft bearing shells
with engine oil.
Measure main bearing cap with bore gauge.
Record measured values in data sheet.
Compare measurement values with Tolerance and
Wear Limits List.
Replace bearing shells or recondition to next repair
stage if limit values are exceeded.
After measuring main bearing bore I.D., if necessary
mark bearing shell according to bearing shell
number.

WARNING

Suspended load. Risk of injury!


Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a
suspended load.

EMTU - 03.10 - M020081/00E


Section 3.3.1
Task Description Page 13

Installing bearing shells

Note: Note: Locking lug (arrow) of bearing


shells must sit in grooves of main bores
and of crankshaft bearing caps.
Insert bearing shell halves in correct sequence into
crankcase and crankshaft bearing cap and press
firmly into place by hand.
Ensure that oil bores in bearing shells and in crank-
case are aligned.
Install marked crankshaft bearing cap with bearing
shell in crankcase.

Crankshaft installation
Wipe crankshaft bearing surface.
Spray running face of crankcase bearing shells with
engine oil.
Install guide mandrel (arrow).
Fit sling and use crane to fit crankshaft in bearing
shells in crankcase.
Make sure crankshaft is positioned horizontally.

Install marked crankshaft bearing cap (arrow) with


bearing shell into crankcase.
Hit the crankshaft bearing cap lightly to settle in final
position.

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Section 3.3.1
Page 14 Task Description

Coat threads and contact surface of screws (1) with


engine oil.
Tighten screws in following stages.
1st stage 100 Nm
2nd stage 200 Nm
3rd stage 300 to 400 Nm
4th stage 90° to 100° angle of rotation
Tighten side screws (2) with torque wrench as per
Tightening Specifications 1.4.

EMTU - 03.10 - M020081/00E


Section 3.3.2
Task Description Page 1

3.3.2 Piston and connecting rod

1 Snap ring 4 Conrod bearing shells


2 Piston pin 5 Conrod with cap
3 Piston 6 Conrod bolts

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Section 3.3.2
Page 2 Task Description

3.3.2.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain engine coolant Oper. Instr.
- X X Drain or draw off engine oil Oper. Instr.
- X X Remove terminal box and wiring as required 3.84.9.2
- X X Disconnect engine coolant lines 3.14.1.2
- X X Disconnect engine oil return pipes from cylinder head 3.5.1.2
- X X Disconnect leak-off fuel lines 3.12.2.2
- X X Remove cylinder head covers 3.6.4.2
- X X Disconnect H.P. fuel lines 3.12.1.2
- X X Intake air system: Remove screws from respective cylinder head 3.10.2.2
- X X Exhaust system: Remove screws from respective cylinder head 3.10.3.2
- X X Remove cylinder head 3.5.1.2
- X X Remove oil pan

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Section 3.3.2
Task Description Page 3

3.3.2.2 Removal
Remove combustion residue on bore of cylinder
liners at TDC point of piston.
Rotate crankshaft sot that piston is at BDC.
Rotate crankpin of crankshaft of conrod to be re-
moved towards BDC position.
Check marking of conrod cap cover to conrod, mark
components if necessary.

Unscrew conrod cap screws (1) approx. 15 mm


using a ratchet and socket wrench.
Using a plastic mallet, tap conrod cap screws gently
to release conrod from conrod cap.
Unscrew conrod cap bolts.
Remove conrod cap and bearing shell.

Removing conrod with piston


With conrod installed, turn piston from working position clockwise so that during further disassembly damage to the
oil spray nozzle by the conrod is avoided. Slowly push piston back into cylinder liner until long arm of conrod con-
tacts cylinder liner.
Using removal tool, drive out piston and conrod through cylinder liner.
Ensure that bearing shell does not fall out of conrod.
Remove bearing shell from conrod.

3.3.2.3 Disassembly
Removing snap rings
Place piston and conrod on workbench. Remove snap rings with snap ring pliers.

CAUTION

Component is hot. Risk of injury! Handle components only when wearing protective gloves.

M020081/00E - 03.10 - EMTU


Section 3.3.2
Page 4 Task Description

Remove piston pin


With round piece of wood, press piston pin out of piston pin boss. If too firmly seated, heat the piston on a hot plate
to 60 °C.
Hold conrod and remove piston pin.
Remove conrod from piston.
Removing piston rings
Remove piston rings with piston ring pliers in sequence from top to bottom.
Do not under any circumstances stretch piston rings!

3.3.2.4 Inspection and repair

CAUTION

Decarbonizer must be used only in conjunction with a fume extraction system. Pay attention to manufac-
turer’s safety instructions. Always wear gloves and protective goggles.

Cleaning piston
Use decarbonizer to remove soot deposits or cleaning jet in area of piston ring grooves with synthetic abrasive
agent MTH 608 (rated granulation 16-20).
Cover chromium-faced sealing surfaces and top land with masker.
Checking piston for cracks
Using the magnetic crack-testing method with fluorescent magnetic powder, check piston for cracks.
Replace complete piston if cracks are found.

Inspecting condition of piston crown.


Replace piston if valve pockets or edges of piston are scorched.
Remove scoring or scuffing on top land if local and not extending as far as 1st ring groove.
Do not remove material to depth of more than 50 mm.
If damage is more extensive or if scoring or scuffing extends to 1st ring groove, replace entire piston.
Inspecting piston ring grooves
If carbon residues cause piston rings to stick or if rings contact carbon residues in groove root, piston crown must
be decarbonized.
Replace complete piston if cracks are found.
Insert new piston ring in groove.
Check axial clearance of piston rings with feeler gauge. Check piston ring grooves for cracks
Replace complete piston if cracks are found.
If limit values are exceeded or if oil control ring has less axial clearance than specified, replace piston. For limit va-
lues, see Tolerances and Wear Limits List.

EMTU - 03.10 - M020081/00E


Section 3.3.2
Task Description Page 5

Inspecting piston rings and measuring piston ring


gap
Replace rings if first and second rings have sharp
upper edges. If slots of oil control ring are clogged
by carbon deposits, ring must be decarbonized.
Measure piston ring gap by inserting new piston ring
(3) in cylinder liner (2) scheduled for installation. En-
sure that piston ring is inserted to uniform depth all
round. Measure piston ring gap with feeler gauge
(1). Replace piston rings if specified limits are ex-
ceeded.
For limit values, see Tolerances and Wear Limits
List.
Piston rings must be replaced as a set. The cylinder
liner must be rehoned if the piston rings are re-
placed.
Replace piston rings during W6 maintenance.
Measure length of piston crown screws.
For limit values, see Tolerances and Wear Limits
List.

Inspecting piston skirt


Using surface crack-testing method with fluorescent penetrant dye, check piston skirt for hairline cracks.
Replace piston skirt if cracks are identified. Check wear pattern on piston skirt.
Using an outside micrometer, measure OD at the non-phosphatised measuring points.
Replace piston if clearance exceeds limit value and if piston skirt exhibits large areas worn to a dull sheen.
For limit values, see Tolerances and Wear Limits List.
Replace pistons exhibiting even minor, localized scuffing or large areas of concentrated scores on piston skirt.
Inspecting piston pin bore
Adjust bore gauge.
Measure piston pin bore. For limit values, see Tolerances and Wear Limits List.
Replace piston if specified limits are exceeded.
Replace piston if one of press-fitted bronze bushes is slack or exhibits scuffing marks.

Inspecting piston pin


Using the magnetic crack-testing method with fluorescent magnetic powder, check piston pin for cracks.
Replace piston pin if cracked.
Remove minor traces of wear and scoring by polishing.
Replace pins exhibiting scuffing, indentations and severe wear.
Measure piston pin with micrometer and determine pin clearance (see Tolerances and Wear Limits List). If limit va-
lues are exceeded, replace piston pin.
Inspecting and repairing conrods
Uusing magnetic crack-testing method with fluorescent magnetic powder, check conrods, conrod caps and conrod
cap bolts for cracks.
Replace components exhibiting cracks.
Check conrod cap screws - see Tolerances and Wear Limits List.
Polish out all traces of nicks in conrod; replace conrod if necessary.

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Section 3.3.2
Page 6 Task Description

Checking axial fit of conrod bush

WARNING
Tools can fall down.
Fluid is highly pressurised.
Risk of injury!
Only use specified and tested equipment.
Personnel must stay clear of the danger area.
Always wear protective gloves and protective
goggles/safety mask.

Check axial fit of conrod bush using mandrel (3) and


hydraulic press (1), see Tolerances and Wear Limits
List.
If limit value is not obtained, force bush out of conrod
(2) using mandrel and hydraulic press.

Measuring conrod bush


Adjust bore gauge. Measure conrod bush bore, see Tolerance and Wear Limits List.
If limit values are exceeded, replace conrod bush. Replace conrod bush exhibiting severe scoring, dirt, wear and
hot-running damage. Remove light scoring by polishing with Emery cloth.

Replacing conrod bush

WARNING
Tools can fall down.
Fluid is highly pressurised.
Risk of injury!
Only use specified and tested equipment.
Personnel must stay clear of the danger area.
Always wear protective gloves and protective
goggles/safety mask.

Press out worn or loose conrod bushes (4).


Adjust bore gauge. Measure small-end bore of con-
rod (1) at several points, see Tolerances and Wear
Limits List.
If limit values are exceeded, replace conrod or ma-
chine bore to repair size.
Check repair sizes of bore and conrod bush prior to
installation of conrod bush. See Tolerances and
Wear Limits List.
Stamp rated dia. in marking field j(5).

EMTU - 03.10 - M020081/00E


Section 3.3.2
Task Description Page 7

CAUTION
Nitrogen is liquid at (- 200 °C).
Danger of freezing and suffocation!
Do not allow liquid nitrogen to come into contact
with body parts (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles. Ensure good ventila-
tion at workplace.

Chill new conrod bush in liquid nitrogen and insert


without applying force using plastic or wooden man-
drel. Install bush in conrod bore so that it is flush
with conrod on both sides and ensure that lubricating
bores and in bush are aligned with bores in conrod.
Check that bush is tightly seated and machine ID to
size with precision boring machine.

Using a triangular scraper, break edges (x) in the


conrod bush and fit with felt disc, dia. 30 to 40.
Measure conrod bush with bore gauge.
For wear limits, see Tolerances and Wear Limits List.

Identification marks for conrod bushes


1 Identification mark, stage 1
2 Conrod bush
1+3 Identification mark, stage 2
None Marking stage 0

WARNING

›‹Compressed air is highly pressurized. Risk of injury!


Never direct a compressed air jet at other people.
Always wear protective goggles/safety mask and ear protectors.

Check thread of connecting rod


Check conrod and conrod cap screw threads for ease of movement. Threads must not be recut (furrowed thread).
Replace damaged conrod cap screws.
Thoroughly clean conrod, conrod cap and conrod cap screws.

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Section 3.3.2
Page 8 Task Description

Pretightening conrod cap screws with torque wrench


Coat threads of conrod cap screws and screw head seating surfaces with engine oil.
Carefully insert cap screws by hand until initial contact with thread flanks is made.
Screw in bolts three full turns by hand.
Initial pretightening:
Using torque wrench, pretighten conrod cap screw on short arm until conrod and conrod cap serrations are closed
on both short and long arms. For torque setting, see Section 1.4.
Then tighten conrod cap screw on long arm.
Second pretightening:
Using torque wrench, tighten screw on short arm followed by screw on long arm to specified torque. For torque
setting, see Section 1.4.
Tightening conrod cap screws with angle-of-rota-
tion tightening tool
Place angle-of-rotation tightening tool (2) on conrod
cap screws.
Set pointer (1) to zero.
In the order short conrod arm - long conrod arm,
tighten conrod screws in accordance with Tightening
Specification 1.4.
Apply checking torque 100 % in tightening direction
as specified in Section 1.4.
If bolt turns in tightening direction beyond specified
torque:
Release and retighten as specified in Section 1.4.
Replace conrod screws if necessary.

Checking conrod big-end bore


Before measuring, smooth main bore with emery cloth.
Adjust bore gauge. Measure conrod big-end bore.
If limits specified in Tolerances and Wear Limits List are exceeded, replace conrod or machine big-end bore to re-
pair size.
Check big-end bore for wear and scoring. If necessary, replace conrod or machine bore to repair size.
If big-end bore is machined to repair size, machine locating bore to appropriate depth and replace locating pin.
Marking repair sizes on conrod
Stamp conrod cap with numeral punches in area of
conrod cap (arrow).
For dimensions, see Tolerance and Wear Limits List.

EMTU - 03.10 - M020081/00E


Section 3.3.2
Task Description Page 9

Checking axial parallelism of conrod bore


Arrangement of testing device
1 Conrod
2 Alignment mandrel, large conrod eye
3 Locking screw for alignment mandrel
4 V-block
5 Resilient stop
6 Locknut
7 Screw-in housing
8 Adjustable resilient stop
9 Dial gauge for axial twist
10 Locking screw for alignment mandrel
11 Base plate
12 Dial gauge for axial parallelism
13 Adjustable dial gauge carrier
14 Alignment mandrel, small conrod eye

Clean big-end and small-end bores.


Insert alignment mandrel (3) in big-end bore.
Make sure that mandrel is installed correctly.
Wide fit side (1) of alignment mandrel facing conrod
shaft; narrow fit side facing conrod cap.
Secure mandrel by hand with adjustment screw (2).
Take care not to damage test mandrel.

Insert alignment mandrel (3) in small-end bore.


Make sure that mandrel is installed correctly.
Wide fit side (1) of alignment mandrel facing conrod
shaft; narrow fit side facing oil bores of small conrod
bore.
Secure mandrel by hand with adjustment screw (2).
Install mandrels so that narrow fits in big-end and
small-end bores lie in a plane.
Alignment mandrels are installed in same way for
conrod bend and twist checks.

M020081/00E - 03.10 - EMTU


Section 3.3.2
Page 10 Task Description

Checking conrod bend


Lay conrod (2) with mandrel (1) installed in big-end
bore in both V-blocks (6) of test equipment. Lay con-
rod (2) with mandrel (1) installed in big-end bore in
both V-blocks (6) of test equipment. Position small
end (3) against resilient stop (5).
Adjust resilient stop so that centreline of mandrel
shaft is approx. 2 mm below dial gauge stylus (4).
Adjust dial gauges so that their readings indicate
approx. 2 mm preload at highest point on small-end
mandrel, and set to zero.
Turn conrod through 180° and lay carefully in test
equipment.
Move small-end mandrel through dial gauge styluses
at highest point on mandrel.
Determine and record deviations from zero on dial
gauges.

Calculating conrod bend


Test equipment is set for measuring axial parallelism
over a distance of 200 mm.
To obtain correct bend over 100 mm as required for
comparison with Tolerances and Wear Limits List,
use dial gauge readings to calculate bend as follows:
Example:
Left dial gauge A= -0.05 mm
Right dial gauge A= +0.03 mm
0.08 mm
Conrod twist in example:
Axial parallelism 0.08 : 4 = 0.02 mm
For specified limit, see Tolerances and Wear Limits
List.

Checking conrod twist


Use template (1) to set both dial gauges (3) for conrod
twist to zero via styluses (2).
Remove template from test equipment.

EMTU - 03.10 - M020081/00E


Section 3.3.2
Task Description Page 11

Position conrod (2) with installed test mandrels (1)


(3) into the two V-blocks (6) of the testing unit. Set
rigid stop on adjustable resilient stop (4) so that dial
gauge styluses still have travel of approx. 2 mm.
Press conrod at small conrod eye on fixed support.
Read and record values on dial gauges (5). The dif-
ference between the values read off the two dial
gauges is the conrod twist.
Calculating axial twist
To obtain correct bend over 100 mm as required for
comparison with Tolerances and Wear Limits List,
use dial gauge readings to calculate bend as follows:
Example:
Dial gauge 1 = 0.00 mm
Dial gauge 2 = 0.10 mm
Difference = 0.10 mm
Conrod twist in example:
Axial twist 0.10 : 2 = 0.05 mm
For limit values - see Tolerances and Wear Limits
List. Release adjustment screws on alignment man-
drels. Release adjustment screws on alignment
mandrels.

Installing bearing shells in conrod


New bearing shells must be installed during W6
overhaul.
Before installing the conrod bearing shells, observe
the diameter stage at conrod and crankshaft journal,
see data sheets.
Replace bearing shells which are worn, damaged or
scored.
Prior to installing conrod bearing shells, measure
spreading dimension of conrod bearing shell.
For dimensions, see Tolerance and Wear Limits List.
Install bearing shells (1) in locating bore as marked,
paying attention to positions of locating grooves (ar-
rows).
Mark any new bearing shells with cylinder number
using electric engraver.

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Section 3.3.2
Page 12 Task Description

Insert conrod bearing shell (1) into conrod bearing


cap.
Lug (arrow) must be seated in groove of conrod
bearing cap.
Coat threads of conrod cap screws and screw head
seating surfaces with engine oil.
Degrease serrations on conrod and cap.
Mount conrod cap.
Using torque wrench, tighten conrod screws to
specified torque. For torque setting, see Section 1.4.
Conrod and conrod cap have same serial number.
When assembling, ensure that numbers on compo-
nents match.

Measuring big-end bearing bore


Adjust bore gauge. Measure big-end bearing bore.
Measure inner dia. of installed bearing shells at three
points (vertical and at a distance of 30° above and
below the partition).
The values given in the Tolerance and Wear Limits
List must be kept to.
Record measured values in data sheet.
Unscrew conrod cap bolts.
Remove conrod cap.
Protect components against damage.

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Section 3.3.2
Task Description Page 13

3.3.2.5 Assembly
Installing piston rings

Note: The spring-loaded oil control ring has no


”TOP” marking.
Turn the spring (2) so that its end (arrow) is 180° to
the control-ring end.

Note: Ensure that piston rings are correctly in-


stalled.
Oil control ring in groove III
Taper face compression ring in groove II.
Rectangular-section ring in groove I

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Section 3.3.2
Page 14 Task Description

Installing piston rings

Note: To avoid breakage, do not under any cir-


cumstances overstretch piston rings!
In sequence from bottom to top, insert piston rings
with piston ring pliers into annular grooves on piston
crown.
Stretch piston rings only until they can be fitted over
the piston crown.
Replace piston rings during W6 maintenance.
”Top” and manufacturer’s designation must be leg-
ible on all rings from above.

Installing conrod in piston


Using snap ring pliers, insert snap ring into piston
boss.
Make sure that snap ring is properly seated.
Install conrod in matching piston with long arm posi-
tioned as shown in adjoining illustration.
Long arm (A) of conrod must face in same direction
as funnel (B) in piston.

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Section 3.3.2
Task Description Page 15

Wipe piston pin (2) with soft chamois leather and


coat with engine oil.
Push piston pin into piston and conrod (1) (arrow)
until seated against snap ring installed beforehand.
Check whether piston pin moves freely in piston
boss.

Insert second snap ring.


Ensure that snap ring is correctly seated in groove.
Note: Position of snap rings - see arrows.

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Section 3.3.2
Page 16 Task Description

3.3.2.6 Installation
Note: If new pistons are to be installed, they
should be assigned together with the
liners according to the tolerance-group
coding. The tolerance-group coding
(arrow) is given on the top cylinder liner
surface and the piston crown.
For coding, see Table.

Code:

Piston (group of letters) Cylinder liner (identification letter)


“BC” “B”
“BCD” “C”
“CDE” “D”
“DE” “E”

Coat piston and piston rings with engine oil.


Position ring butts (arrow) consecutively at 120° in-
tervals.

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Section 3.3.2
Task Description Page 17

Guide band clamp over piston rings and compress to


outside diameter of piston.

Insert conrod bearing shell (1) into conrod.


Lug (arrow) must be seated in groove of conrod.
Note: Bore in the conrod bearing shell and con-
rod must be aligned.
Coat running surface of conrod bearing shells with
engine oil.
Position protective strip on long arm of conrod.

Insert piston in lubricated cylinder liner in direction of


arrow to engine centre.
Remove protective strip.

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Section 3.3.2
Page 18 Task Description

Check code markings on bearing cap and conrod.


Use only conrod cap screws up to max. 68.5 mm
length.
Coat threads of conrod cap screws and screw head
seating surfaces with engine oil.

Note: Do not allow conrod screws to drop into


bores in conrod cap.
Carefully insert conrod cap screws by hand up to
initial contact on thread flanks.
Without using tools, insert screws into conrod three
full turns.

Tightening conrod screws


Using torque wrench, tighten conrod cap screw on short arm until conrod and conrod cap serrations are closed on
both short and long arms. For torque setting, see Section 1.4.
Then tighten conrod cap screw on long arm.
When tightening screw, check whether conrod moves freely in axial direction.
If conrod cannot move in axial direction, locating pin is not seated in groove of conrod bearing and is stuck.
Disassemble conrod and discard damaged bearing shells.
Using torque wrench, tighten conrod cap screws to specified torque. For torque setting, see Section 1.4.
Tightening sequence: short arm, then long arm.
Mount angle-of-rotation tightening tool on conrod cap screw.
Beginning with short arm, tighten to specified torque. For torque setting, see Section 1.4.
Apply checking torque in tightening direction as specified in Section 1.4.
If screw turns beyond specified torque, release both screws and retighten as specified in Section 1.4. Replace
screws if necessary.
Check conrod bearing axial play with feeler gauge.
Disassemble conrod if bearing has no axial play.
Discard damaged bearing shells.
Measure conrod bore again, see 3.3.2.4.

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Section 3.3.3
Task Description Page 1

3.3.3 Flywheel

1 Flywheel 2 Screw

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Section 3.3.3
Page 2 Task Description

3.3.3.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Carry out tasks as specified in disassembly plan 2.4
- - x Disable engine start Op. Man.

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Section 3.3.3
Task Description Page 3

3.3.3.2 Removal
Remove screws (1).

Insert guide mandrels into two opposing threaded


bores.
Remove flywheel via guide mandrels.

3.3.3.3 Disassembly

CAUTION

Component is hot. Risk of injury! Handle components only when wearing protective gloves.

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Section 3.3.3
Page 4 Task Description

Removing ring gear


Remove flywheel ring (1).

Heat ring gear (1).


Remove ring gear from flywheel (2).

3.3.3.4 Inspection and repair


Clean parts.
Using the magnetic crack-testing method with fluorescent magnetic powder, check ring gear, flywheel ring and fly-
wheel for cracks. If cracks are found, replace components.
Remove burrs and chipping from teeth by grinding or filing.
Check mating surface of flywheel for traces of wear and damage; recondition with oilstone as required.

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Section 3.3.3
Task Description Page 5

3.3.3.5 Assembly
Removing ring gear

CAUTION
Component is hot.
Risk of injury!
Handle components only when wearing protec-
tive gloves.
Heat ring gear (1) to approx. 200 °C and fit on flywheel
(2).

Fit flywheel ring (1).

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Section 3.3.3
Page 6 Task Description

3.3.3.6 Installation
Insert guide mandrels into two opposing threaded
bores.
Install flywheel via guide mandrels; the centering pin
in the crankshaft gear must be aligned with the cen-
tring bore in the flywheel.

Insert screws (1) and tighten with torque wrench to


Tightening Specifications 1.4.

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Section 3.3.4
Task Description Page 1

3.3.4 Vibration damper

1 Vibration damper 3 Hex screw


2 Cover plate 4 Timing pointer

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Section 3.3.4
Page 2 Task Description

3.3.4.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Relieve V-belt tension 3.86.1.2

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Section 3.3.4
Task Description Page 3

3.3.4.2 Removal
Before removal, mark the position of the vibration
damper to the crankshaft with numeral punches (1).

Remove hex screw and remove vibration damper.


Remove cover plate and timing pointer - see overview drawing.

3.3.4.4 Inspection and repair


Clean all components.
Check vibration damper, cover plate and timing pointer for damage.
Check mating surface of vibration damper for traces of wear and damage; recondition with oilstone as required.

3.3.4.6 Installation
Before the marked vibration damper (1) is installed,
the TDC of cylinder 1 must be set by means of the
flywheel marking (2).
If a marked part has to be replaced, a new mark
must be made using the start-of-delivery TDC setting
on the flywheel. Start-of-delivery settings are to be
taken from the start-of-delivery plate on the cylinder-
head cover.
When the vibration damper is re-installed after disas-
sembly, ensure that the markings are aligned.
The vibration damper hex screws must not be tigh-
tened until the timing pointer is aligned with the mark
on the damper (2).
Use torque wrench to tighten hex screws to specified
torque. For torque setting, see Section 1.4.

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Section 3.3.4
Page 4 Task Description

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Section 3.5
Task Description Page 1

3.5 Cylinder head


Contents

3.5.1 Cylinder head


3.5.1.1 Before-removal operations
3.5.1.2 Removal
3.5.1.3 Disassembly
3.1.5.4 Inspection and repair
3.5.1.5 Assembly
3.5.1.6 Installation

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Section 3.5
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

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Section 3.5.1
Task Description Page 1

3.5.1 Cylinder head

1 Hex screw 5 Cylinder head screws


2 Rocker arms 6 Cylinder head
3 Cylinder head screws 7 Centring sleeve
4 Cylinder head screws 8 Cylinder head gasket

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Section 3.5.1
Page 2 Task Description

1 Taper element 6 Valve stem seal


2 Valve spring retainer 7 Washer
3 Valve spring, outer 8 Cylinder head
4 Washer 9 Exhaust valve
5 Valve spring, inner 10 Inlet valve

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Section 3.5.1
Task Description Page 3

3.5.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain engine coolant Oper. Instr.
- X X Remove wiring as required 3.84.9.2
- X X Remove coolant system vent line 3.14.2.2
- X X Disconnect leak-off fuel lines 3.12.2.2
- X X Remove cylinder head covers 3.6.4.2
- X X Disconnect H.P. fuel lines 3.12.1.2
- X X Intake air system: Remove screws from respective cylinder head 3.10.2.2
- X X Exhaust system: Remove screws from respective cylinder head 3.10.3.2
- X X Remove rocker arms and push rods 3.6.3.2

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Section 3.5.1
Page 4 Task Description

3.5.1.2 Removal
Removing cylinder head screws
Unscrew cylinder head screws (1 and 2) with ratchet
diagonally and evenly.

With nozzle holder installed:


Note: If the nozzle holder is still installed, the
cylinder head screw (arrow) cannot be
removed.
Remove cylinder head screw with special tool.

WARNING

Heavy object. Risk of crushing!


Use suitable equipment and lifting gears.
Remove cylinder head.
If injection nozzle is to remain installed, place cylinder head to the side as the injection nozzle protrudes at the bot-
tom of the cylinder head.
Remove centering sleeves - see overview.
Remove cylinder head gasket
Remove cylinder head gasket.
If cylinder head gaskets are to be reused, they must be marked with respective cylinder numbers.

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Section 3.5.1
Task Description Page 5

3.5.1.3 Disassembly
CAUTION
Spring preload.
Risk of injury!
Only use specified tool.

Removing valves
Remove fuel injection nozzle, see 3.11.6.
Before removal, use electric engraver to apply ident-
ifying marks to valve heads.
Position cylinder head on workbench so that valve
heads are seated.
Insert securing screw (1) of valve spring com-
pressor (2) into tapped bore of cylinder head.
Compress valve springs with valve spring com-
pressor and remove valve taper - see also overview
drawing.
Remove valve springs - see also overview drawing.

Remove valve stem seal (1) and washers (2 and 3).

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Section 3.5.1
Page 6 Task Description

Turn cylinder head on its side.


Remove inlet (2) and exhaust valve (1) from valve
guides.
It is advisable to use a storage rack to protect valves
against damage.

3.1.5.4 Inspection and repair

CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use,
safety instructions and waste disposal specifications.

CAUTION

Decarbonizer must be used only in conjunction with a fume extraction system. Pay attention to manufac-
turer’s safety instructions. Always wear gloves and protective goggles.

CAUTION

Heated water, 80 °C - handle components only when wearing protective gloves. Do not exceed the pre-
scribed test pressure.
Clean cylinder head base, valve seats, inlet and exhaust valves with cold cleaner.
If necessary, pretreat oil carbon deposits on valves and cylinder heads with ”decarbonizer”; for this purpose, place
components in a container filled with ”decarbonizer” – dwell time depends on degree of contamination.
Add enough solvent to cover valve seats.
After completion of the solvent bath, flush or spray cylinder heads valves with water heated to approx. 60 °C to 80 °C.
Clean valve seats in cylinder head and valves with a rotary steel-wire brush.
Clean bores of inlet and exhaust valve guides with cylinder wiper with brass bristles.
Check cylinder head screws for cracks using magnetic crack-testing method with fluorescent magnetic powder;
replace screws if cracks are found.
Clean cylinder head gaskets. Check for flatness.
Check sealing surface for scoring and damage, if necessary nickle-plate and/or replace cylinder head gaskets.
Check condition of centring sleeves, replace parts as necessary.
Replace valve stem seal.

EMTU - 03.10 - M020081/00E


Section 3.5.1
Task Description Page 7

Inspecting cylinder head face


Check cylinder head face and valve seats for cracks using surface crack-testing method with red penetrant dye.
Cracks in cylinder head face can be removed by machining concentrically to limit size.
Repeat crack test after machining.
Replace cylinder head if further cracks are found.
Replace valve seats if cracked.
Check cylinder head support surface for flatness and indentations with straight-edge or bridge meter.
Indentations can be removed by concentric machining on a lathe. Machine towards centre of cylinder head.
Do not remove more material than is necessary in order to obtain a perfect seating face; see Tolerances and Wear
Limits List.
After reconditioning the cylinder head partitions
- Check valve recess, see Valve seat machining.
- Checking nozzle projection
For limit values, see Tolerances and Wear Limits List.

Checking cylinder head for leaks

WARNING

Test fluid is highly pressurized. Risk of injury!


Liquids emerging under high pressure can lead to serious injury!
Always wear protective clothing, protective gloves and protective goggles/safety mask.

Hydraulic pressure-testing procedure:


Install hydraulic pressure testing device.
Install nozzle holder.
Pump water heated to approx. 80 °C through the cylinder head until the cylinder head warms up.
Add 1% corrosion inhibitor oil to water.
Close shut-off valve in vent line.
Pressure-test cylinder head at 4 bar water pressure.
Pressure must be maintained for at least 30 minutes.
Pneumatic pressure-testing procedure:
Place cylinder head in a water bath heated to 80 °C until cylinder head has warmed up.
Pressure-test cylinder head at 0.5 bar air pressure.
Check cylinder head for leaks.
Pressure must be maintained for at least 30 minutes.
Check cylinder head for leaks.
Remove removal device.
Replace end cover if leaking.

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Section 3.5.1
Page 8 Task Description

Removing end cover


When removing cover (2), take care to prevent it
from falling into bore.
Do not spot-hole end cover to remove.
Using a mandrel (1), carefully knock the edge of one
side of the end cover (1) inwards until it tilts in the
bore.
Take care not to damage bore.

Installing end cover


Use only new end covers.
Clean and degrease cylinder head bore and seating
surface at end cover.
Coat seating surface of end cover with Loctite 270.
Final strength at 20 °C [12h
Using suitable drift (1), drive end cover (2) into cylin-
der head bore.
Rim of end cover must be recessed to a depth of
approx. 1 mm in cylinder head bore.

EMTU - 03.10 - M020081/00E


Section 3.5.1
Task Description Page 9

Inspecting and removing valve guides


Clean valve guide bores in cylinder head.
Adjust bore gauge.
Bore in inlet and exhaust valve guide, according to
measurement planes.
For measurement planes, see Tolerances and Wear
Limits List.
Check ends of valve guides protruding into inlet and
exhaust ports for cracks using surface crack-testing
method with red penetrant dye.
Check that inlet and exhaust valve guides are se-
curely seated.
Replace damaged valve guides.
Check bore with mandrel gauge.
Mandrel gauge’s own weight must be enough to
cause ”go” end of mandrel to slide through installed
valve guide.
If ”no-go” end can be inserted, replace valve guide.
If measurements of valve guides or clearance be-
tween valve and valve guides exceed or drop below
wear limits, replace valve guides.
Using extractor mandrel, press valve guides out of
cylinder head.

Removing valve guide


Clamp cylinder head in position.
From the combustion side, press valve guide out
with mandrel.
Measuring locating bore for valve guide
Using a cylinder wiper, clean the valve guide bore in
the cylinder head.
Adjust bore gauge.
Measure locating bores in cylinder head.
If limit values are exceeded, recondition bores to
next repair size.
For limit values, see Tolerances and Wear Limits
List.

M020081/00E - 03.10 - EMTU


Section 3.5.1
Page 10 Task Description

Installing valve guide


Clean valve guide in cylinder head and valve guide.
Coat new valve guide with graphite oil.
Drive in with mandrel (A) and spacer sleeve (B).
For dimensions, see Tolerance and Wear Limits List.
Check bores of valve guides with control mandrel –
the ”go”-end length of the mandrel must correspond
to the length of the valve guide.
Checking valve guides
Control mandrel’s own weight must be enough to
cause ”go” end of mandrel to slide through installed
valve guide.
If the ”no-go” end can be inserted, the valve guide
must be replaced.
Note: When the finished valve guides are in-
stalled, using a control mandrel, check
from the compression side and control
side of the cylinder head.

Measuring valve seat recess


Install new valve into cylinder head.
Using depth gauge, measure distance from cylinder
head face to valve head.
For limit values, see Tolerances and Wear Limits
List.
Install new valve seat inserts if specified limits are
exceeded.

EMTU - 03.10 - M020081/00E


Section 3.5.1
Task Description Page 11

Removing valve seat inserts


Place internal extractor (2) for inlet and exhaust
valve seat inserts in annular groove.
Place copper plate (arrow) under support surfaces of
counter-supports (1).
Note: The internal extractor and counter-holder
for inlet and exhaust valve seat inserts
differ.

Checking basic bore for valve seat insert


Set bore gauge with micrometer to rated dimension.
Measure basic bore in cylinder head.
Machine to repair size as required.
For limit values, see Tolerances and Wear Limits
List.

Basic bore reconditioning


Insert appropriate pilot (1) into valve guide until
slotted rod stop contacts valve guide; if necessary,
press down slotted rod with screwdriver.
Secure with mandrel inserted at top and bottom of
pilot (arrows).
Secure turning tool in support.

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Section 3.5.1
Page 12 Task Description

Release locknut (1), fit rotator (3) over pilot


moistened with oil (5).
Turn rapid adjustment screw (2) until turning tool (4)
has moved to beyond the bore.
Push cutting tool downwards until turning tool (15)
rests on cylinder head.

Note: Carefully position rotating tool so that car-


bide tip of cutting tool is not damaged.

Release securing screw (2) on pilot support (1),


press pilot support downwards until it contacts the
pilot.
Retighten locking screw.

Turn knurled washer (1) clockwise until turning tool is


just clear.
Horizontally clamp cone pin with steady rest clamp;
in doing so, working depth ”b” must be set between
adjusting ring and cone pin.
Measure depth ”b” of bore in cylinder head, see Tol-
erance and Wear Limits List.

EMTU - 03.10 - M020081/00E


Section 3.5.1
Task Description Page 13

Calculating setting dimension ”B”:


Setting dimension ”B” is basic bore ”a” in cylinder
head (see Tolerance and Wear Limits List) and pilot
diameter ”A” divided by 2.
Example:
”a” = 60 mm
”A” = 14.55 mm (pilot diameter)
”B” =(a + A) :2
”B” =(60 mm + 14.55 mm) :2 = 37.28 mm

Release locknut (2).


Set micrometer to dimension ”B”.
Slightly raise rotating tool.
Place micrometer on pilot and adjust turning tool with
rapid adjusting screw (1) to dimension ”B”.
Tighten locknut (2).
Note: It is advisable to set turning tool diameter
0.1 mm smaller for the initial material cut.

Install horizontal stop screw (1) until it makes contact


with housing and tighten clamping screw (2); this
secures the horizontal stop screw against twisting.

M020081/00E - 03.10 - EMTU


Section 3.5.1
Page 14 Task Description

Secure knurled washer (1) with mandrel (arrow) to


turning crank.

Turn crank (1) clockwise, simultaneously holding top


knurled washer (2) for vertical advance.
Recondition bore for valve seat insert until adjusting
ring (3) contacts steady rest mount (4).

Note: Readjust turning tool as often as necess-


ary to achieve calculated setting dimen-
sion. Then turn again without adjustment
to achieve a roughness depth of max.
0.006 mm.
Slightly raise rotating tool.
Release locknut and using rapid adjusting screw
reset turning tool.
Turn crank clockwise, simultaneously holding bottom
knurled washer for horizontal advance.
Grind the end plane and flat until stop screw con-
tacts housing.
Remove rotating tool and measure bore.

EMTU - 03.10 - M020081/00E


Section 3.5.1
Task Description Page 15

Check that the alignment between valve seat insert


and bore is in compliance with Tolerance and Wear
Limits List.

Installing valve seat inserts


Measure OD of valve seat inserts.
Check interference against Tolerances and Wear
Limits List.
CAUTION
Component is hot.
Risk of injury!
Handle components only when wearing protec-
tive gloves.
Head cylinder head in a water bath heated to approx.
80 °C.
CAUTION
Nitrogen is liquid at (- 200 °C).
Danger of freezing and suffocation!
Do not allow liquid nitrogen to come into contact
with body parts (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles. Ensure good ventila-
tion at workplace.
Chill new valve seat insert in liquid nitrogen.
Fit mandrel into valve seat insert (2) and insert valve
seat insert into cylinder head.

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Section 3.5.1
Page 16 Task Description

Recondition valve seat.


Insert appropriate pilot (1) into valve guide until
slotted rod stop contacts valve guide; if necessary,
press down slotted rod with screwdriver.
Secure with mandrel inserted at top and bottom of
pilot (arrows).
Secure turning tool in support.

EMTU - 03.10 - M020081/00E


Section 3.5.1
Task Description Page 17

Adjusting valve rotator


Clamp cutting tool (6) in support. For angle, see Tol-
erances and Wear Limits List.
Insert valve rotator in pilot.
Release locknut (5) on rapid adjuster (4).
Turn rapid adjuster until cutting tool (6) is positioned
at centre of valve seat face.
Secure rapid adjuster with locknut.
Carefully push valve tool down onto pilot until turning
tool contacts centre of valve seat.
Release locking screw (3) on knurled nut (2).
Press down pilot rest until it is seated on pilot.
Tighten locking screw of knurled nut.
Turn knurled nut counterclockwise until cutting tool
no longer contacts valve seat face.
Mount steady rest on cylinder head.
Secure steady rest eye to crutch.

Valve seat surface reconditioning

Note: The valve seat face is machined from the


inside outwards.
To adjust cutting tool (6):
Release locknut (5) on rapid adjuster (4).
Turn rapid adjuster until turning tool is positioned at
valve seat face ID (7).
Tighten locknut on rapid adjuster.
To set rate of cut:
Set rate of cut with knurled nut (2).
Secure with locking screw (3).
Grip knurled screw (8) securely.
Turn crank (1) clockwise until turning tool moves
freely.
When refacing valve seats, do not remove more ma-
terial than is necessary to obtain perfect seats.
For limit values, see Tolerances and Wear Limits
List.
Rework refaced valve seats in cylinder head with
turning tool or countersink.
Remove valve seat rotating tool, steady rest and pi-
lots.

Inspecting valves
Measure valve stem with outside micrometer. For limit values, see Tolerances and Wear Limits List.
If limit values are exceeded, replace valve.
Check valves for damage, pitting, scoring and indentations on stem, plate, neck and pressure surface.
Replace valve if chrome plating is damaged or worn through, if indentations are found, if valve stem reveals scores
or if pitting is found at transition from valve head to valve stem.
Remove severe indentations at pressure face of valve by machining to MTU specifications. Replace valve if
necessary.

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Section 3.5.1
Page 18 Task Description

Regrinding valve head


Regrind only to the minimum extent required to pro-
duce a perfect valve seat.
If a valve grinding machine is not available, machine
valve on a valve turning machine.
Measure height of outer edge of valve seat.
Replace valve if specified limits are exceeded (see
Tolerances and Wear Limits List).
Check valves for cracks using surface crack-testing
method with fluorescent penetrant dye; replace if
necessary.
Protect valves from damage, store in transportation
trestle.

Measuring valve recess


Install new valve into cylinder head.
Using depth gauge, measure distance from cylinder
head face to valve head.
For limit values, see Tolerances and Wear Limits
List.
Install new valve seat inserts if specified limits are
exceeded.

Checking valve springs

CAUTION
Spring preload.
Risk of injury!
Only use specified tool.

Check valve springs with spring testing unit.


If limit values are exceeded, replace valve springs.
For wear limits, see Tolerances and Wear Limits List.
Check valve springs for indentations, flatness, bur-
ring and deformation.
Flatness deviations of up to 0.2 mm on inner diam-
eter of end coils are permissible.
Surface irregularities and burrs on windings can be
removed and springs then reused.

EMTU - 03.10 - M020081/00E


Section 3.5.1
Task Description Page 19

3.5.1.5 Assembly
Installing valves

WARNING
Fuels are combustible.
Risk of fire and explosion!
- No open flame
- No electric sparks
- Avoid all sources of ignition

Clean valve guides with cylinder wiper and fuel.


Clean valves and spray with engine oil.
Install exhaust valves (1) and inlet valves (2).

Installing valve stem seals


(1) Valve stem seal
(2) Washer
(3) Cylinder head

Before installing valve stem seal, spray upper valve


guide seat (arrow) with denaturated ethanol.
Fit assembly sleeve (1) on a valve.

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Section 3.5.1
Page 20 Task Description

Press valve stem seal (1) via assembly sleeve (2)


onto valve guide.

Installing valve springs


Insert washer for inner and outer valve spring -see
also overview drawing.
Ensure washers for valve springs are correctly
seated.
Install inner and outer valve springs.
Install narrower end of valve springs in direction of
cylinder head.
CAUTION
Spring preload.
Risk of injury!
Only use specified tool.
Insert securing screw of valve spring compressor (1)
into tapped bore of cylinder head.
Place upper spring retainers (2) on valve springs.
Operate valve spring compressor to force springs
down.
Install valve collets in valve spring retainers.
Relieve pressure on valve spring compressor and
remove.
Place cylinder head on its side and tap valve stem
lightly with plastic mallet to settle valve collets cor-
rectly on valve stem.
Check valve recess.

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Section 3.5.1
Task Description Page 21

3.5.1.6 Installation/Assembly
Installing cylinder head
Clean threaded bores in crankcase.
Clean cylinder head partitions and crankcase end
surface.
Clean pushrods and insert in crankcase.
Place the new cylinder head gasket over the centring
sleeve (1) onto the cylinder crankcase end surface.
Note: With replacement engines, the cylinder
crankcase partitions and bush collar seat
are machined if necessary. With a new
cylinder head gasket, the piston protru-
sion must be measured. If the piston pro-
trusion is less than 0.3 mm, install series
cylinder head.

Check threads of cylinder head screws for damage


and blow clean with compressed air.
Replace damaged cylinder head screws.
Coat cylinder head screws (1 and 2) with engine oil,
screw into crankcase and tighten lightly.
Tighten all cylinder head screws on all cylinder
heads with torque wrench in accordance with
Tightening Specifications 1.4 and tightening diagram
for individual cylinder head.

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Section 3.5.1
Page 22 Task Description

EMTU - 03.10 - M020081/00E


Section 3.6
Task Description Page 1

3.6 Valve gear


Contents

3.6.1 Camshaft
3.6.1.1 Before-removal operations
3.6.1.2 Removal
3.6.1.4 Inspection and repair
3.6.1.6 Installation
3.6.1.7 After-installation operations

3.6.2 Roller tappet


3.6.2.1 Before-removal operations
3.6.2.2 Removal
3.6.2.4 Inspection and repair
3.6.2.6 Installation

3.6.3 Rockers and pushrods


3.6.3.1 Before-removal operations
3.6.3.2 Removal
3.6.3.3 Disassembly
3.6.3.4 Inspection and repair
3.6.3.5 Assembly
3.6.3.6 Installation
3.6.3.7 After-installation operations

3.6.4 Valve housing, cylinder head cover


3.6.4.1 Before-removal operations
3.6.4.2 Removal
3.6.4.4 Inspection and repair
3.6.4.6 Installation

M020081/00E - 03.10 - EMTU


Section 3.6
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

EMTU - 03.10 - M020081/00E


Section 3.6.1
Task Description Page 1

3.6.1 Camshaft

1 Camshaft 3 Tappet rod


2 Tappet

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Section 3.6.1
Page 2 Task Description

3.6.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- - X Removal not scheduled -
- X X Drain or draw off engine oil Oper. Instr.
- X X Drain engine coolant Oper. Instr.
- X - Disconnecting engine coolant lines 3.14.1.2
- X - Remove coolant expansion tank 3.14.5.2
- X - Disconnect engine oil lines 3.16.1.2
- X - Remove exhaust pipework (as required) 3.10.3.2
- X - Remove air intake system 3.10.2.2
- X - Remove crankcase breather 3.1.7.
- X - Remove fuel injection pump drive 3.11.1.2
- X - Remove valve gear housing 3.6.4.2
- X - Remove rocker arms and push rods 3.6.3.2
- X - Remove cylinder head 3.5.1.2
- X - Remove roller tappets 3.6.2.2

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Section 3.6.1
Task Description Page 3

3.6.1.2 Removal
Remove camshaft.
Attach rope to camshaft.
Withdraw camshaft horizontally out of crankcase.

3.6.1.4 Inspection and repair


Clean camshaft and drive gears.

WARNING

Compressed air is highly pressurized. Risk of injury!


Never direct a compressed air jet at other people.
Always wear protective goggles/safety mask and ear protectors.
Flush oil bores with as high a pressure as possible and blow out with compressed air.
Using the magnetic crack-testing method with fluorescent magnetic powder, check camshaft, drive gear and driver
for cracks, replace parts if necessary.
Check components for damage or excessive wear; if necessary, recondition in accordance with MTU information
and/or replace.
Check camshaft alignment bearings for scoring and wear. For wear limits, see Tolerances and Wear Limits List.
Measure camshaft bearing and cam with outside micrometer. For limit values, see Tolerances and Wear Limits
List.
If limit values are exceeded, recondition camshaft in accordance with instructions from MTU; replace camshaft if
necessary.
Replace damaged dowel pins.
Check radial runout of journal with dial gauge.
If necessary, straighten camshaft on work bench.
For limit values, see Tolerances and Wear Limits
List.

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Section 3.6.1
Page 4 Task Description

3.6.1.6 Installation
Rub journal with chamois leather and spray with en-
gine oil.
Insert camshaft into bearing.
Bar engine in direction of rotation so that markings of
camshaft in relation to crankshaft are aligned (ar-
rows).

3.6.1.7 After-installation operations


Axial clearance of camshaft check
Press camshaft on camshaft gear (arrow) in direc-
tion of gear case.
Install dial gauge holder with dial gauge on crank-
case.
Mount dial gauge with preload on camshaft gear and
set scale to ”0”.

EMTU - 03.10 - M020081/00E


Section 3.6.1
Task Description Page 5

Press camshaft on camshaft gear against dial gauge


and read off axial running clearance of camshaft on
dial gauge.
For axial clearance, see Tolerances and Wear Limits
List
If limit values are exceeded, remove drive gear and
alignment bearing of camshaft.
If axial clearance is too small:
Recondition camshaft alignment bearing with fine
emery cloth on ink-check plate.
If axial clearance is too large, replace camshaft
alignment bearing.

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Section 3.6.1
Page 6 Task Description

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Section 3.6.2
Task Description Page 1

3.6.2 Valve tappet

3.6.2.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Remove cylinder head covers 3.6.4.2
- X X Disconnect H.P. fuel lines 3.12.1.2
- X X Remove rocker arms and push rods 3.6.3.2

M020081/00E - 03.10 - EMTU


Section 3.6.2
Page 2 Task Description

3.6.2.2 Removal
Remove valve tappet from crankcase.

3.6.2.4 Inspection and repair


Wash valve tappet.
Using magnetic crack-testing method and fluorescent magnetic powder, check valve tappet for cracks. Replace if
necessary.
Measure valve tappet with outside micrometer.
Replace component if specified limits are exceeded.
For limit values, see Tolerances and Wear Limits List.
In event of scoring, wear and indentations, smooth components with emery cloth.
Replace components in event of chipping and damage.

3.6.2.6 Installation
Spray valve tappet with engine oil and insert into guide in crankcase.

EMTU - 03.10 - M020081/00E


Section 3.6.3
Task Description Page 1

3.6.3 Rockers and Pushrods

1 Snap ring 5 Nut


2 Washer 6 Hex screw
3 Rocker arms 7 Rocker arm bearing
4 Adjusting screw

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Section 3.6.3
Page 2 Task Description

1 Rocker arms 2 Pushrod

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Section 3.6.3
Task Description Page 3

3.6.3.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Remove cylinder head covers 3.6.4.2

M020081/00E - 03.10 - EMTU


Section 3.6.3
Page 4 Task Description

3.6.3.2 Removal
Unscrew stress bolts from rocker shafts.
Remove carrier with rocker from cylinder head.
Remove locknuts from rocker.
Remove adjusting screws.
Store rocker in transport trestle and protect against damage.
Remove push rods from tappets.

3.6.3.3 Disassembly
Disassembling rocker arm
Clamp rocker arm bearing (use protective jaws).
Release locknuts (2) and remove adjusting screws
(2).

Remove snap ring (1).

EMTU - 03.10 - M020081/00E


Section 3.6.3
Task Description Page 5

Remove washer (1) and rocker arm (2).


Store rockers and rocker shafts in transport trestle
and protect against damage.

3.6.3.4 Inspection and repair


Clean parts.
Using the magnetic crack-testing method with fluorescent magnetic powder, check rocker shafts, rocker arms and
pushrods for cracks, replace parts if necessary.
Smooth rocker shafts with minor wear and scoring with emery cloth.
Remove minor scoring, indentations and wear on bearing bushes with emery cloth; replace as necessary.
Measure rocker shafts with outside micrometer.
Adjust bore gauge.
Measure bores of rocker bearing bushes, see Tolerances and Wear Limits List.
Record measurements and determine bearing clearance.
If the limit values are exceeded, replace parts.
Check threaded bores in rockers and locknuts for ease-of-movement, rechase with tapped bore if necessary.
Check nut hexagon for damage, replace if necessary.
Check condition of adjusting screw threads and replace if necessary.
Check screw slot for damage.
Check pushbutton caps for clearance and pitting; replace as necessary.
Check ball stud on rocker for wear and damage; press out and replace as necessary.
Turn push rod end and top to check if securely seated.
Check push rod seat and ball head for wear; replace as necessary.
Check push rod for wear; up to max. 0.3 mm permitted.
Check carrier for rocker shaft for flatness and damage; smooth with oilstone if necessary.

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Section 3.6.3
Page 6 Task Description

Replacing rocker bearing bushes

CAUTION
Nitrogen is liquid at (- 200 °C).
Danger of freezing and suffocation!
Do not allow liquid nitrogen to come into contact
with body parts (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles. Ensure good ven-
tilation at workplace.
Use mandrel to press bearing bush out of rocker
arm.
Ensure that rocker is perfectly seated!
Adjust bore gauge and measure bore.
For dimensions, see Tolerance and Wear Limits List.
Chill new bearing bushes in liquid nitrogen and insert
into rocker arms.
Oil bores in rocker arm and bearing bush must be
aligned.
After installation, machine bearing bushes on fine
drill to specified dimension - see Tolerance and
Wear Limits List.
Adjust bore gauge.
Measure bore of bearing bush.
After processing, carefully clean oil bores and deburr
if necessary.

3.6.3.5 Assembly

WARNING

Compressed air is highly pressurized. Risk of injury!


Never direct a compressed air jet at other people.
Always wear protective goggles/safety mask and ear protectors.

EMTU - 03.10 - M020081/00E


Section 3.6.3
Task Description Page 7

Assembling rocker arm


Check oil bores in rocker and shaft for cleanliness
and blow through with compressed air.
Coat rocker shafts with engine oil.
Clamp rocker arm bearing (use protective jaws).
Fit rocker arm (2) on rocker shaft.
Fit washer (1).

Install snap ring (1).

Make sure adjusting screws (1) move easily!


Insert adjusting screws into threaded holes in the
rocker arm.
Fit locknuts (2) on adjusting screws.

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Section 3.6.3
Page 8 Task Description

3.6.3.6 Installation
Coat ball heads of push rods with engine oil.
Insert push rods into tappet with ball head end.
Check contact surfaces on cylinder head and carrier for evenness; smooth with oilstone as necessary.
Set appropriate cylinder to firing TDC.
Fit rocker arms on cylinder head.
Coat screw thread with engine oil.
Install stress bolt in cylinder head and, using torque wrench, tighten as per Tightening Specifications 1.4.

3.6.3.7 After-installation operations

Checking and adjusting valve clearance


Install engine barring tool on flywheel housing.
Turn crankshaft in normal direction of engine rotation
until valves of one cylinder are aligned.
Note: Valves on cylinder to be set are closed,
rocker arms are completely unloaded and
pushrods cannot be turned.
The associated piston is now at firing TDC and the
valves can now be set.

Check
Position feeler gauge between inlet valve and rocker
arm and/or between exhaust valve and rocker arm.
For valve clearance, see Section 1.5.
Note: Valve clearance is set correctly if it is
possible to pull the gauge through with
slight resistance.

EMTU - 03.10 - M020081/00E


Section 3.6.3
Task Description Page 9

Setting
Place valve adjusting wrench on adjusting screw.

Release locknut (2).


Set adjusting screw (1) so that feeler gauge can still
just be pulled through.
In this position, securely hold adjusting screw and
tighten locknut.
When tightening, the adjusting screw must not turn.
After locking locknut, check valve clearance.
Remove engine barring tool from flywheel housing.
Install cylinder head cover, see 3.6.4.6.

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Section 3.6.3
Page 10 Task Description

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Section 3.6.4
Task Description Page 1

3.6.4 Cylinder head cover

1 Hex screw 3 Cylinder head cover


2 Spring washer 4 Gasket

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Section 3.6.4
Page 2 Task Description

3.6.4.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Remove cylinder head covers 3.6.4.2

EMTU - 03.10 - M020081/00E


Section 3.6.4
Task Description Page 3

3.6.4.2 Removal
Remove screws (1).
Remove cylinder head cover (3).
Remove gasket (4).

3.6.4.4 Inspection and repair


Crack-test the cylinder head cover using the surface crack-testing method with fluorescent penetrant dye, replace
if necessary.
Check cylinder head cover for flatness and damage; replace as necessary.
Check hex screw for damage and check condition of threads; replace if necessary.
Check condition of gasket.
If a gasket is damaged, porous or cracked: replace gasket.

3.6.4.6 Installation
Smooth cylinder head mating faces with oilstone and
clean.
Coat cylinder head cover (3) in sealing area with pe-
troleum jelly.
Press gasket (4) onto cylinder head cover.
Place cylinder head cover on cylinder head.
Fit screws with washers and tighten with torque
wrench as per Tightening Specifications 1.4.

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Section 3.6.4
Page 4 Task Description

EMTU - 03.10 - M020081/00E


Section 3.7
Task Description Page 1

3.7 Engine governor


Electronic governor; See Special Publication Engine Electronics.

M020081/00E - 03.10 - E MTU


Section 3.7
Page 2 Task Description

E MTU - 03.10 - M020081/00E


Section 3.9
Task Description Page 1

3.9 Exhaust turbocharger

Removal, see 3.10.6.2.


Installation, see 3.10.6.6.
Carry out exhaust turbocharger disassembly and assembly in accordance with Assembly Instructions appropriate
to the respective engine model.

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Section 3.9
Page 2 Task Description

EMTU - 03.10 - M020081/00E


Section 3.10
Task Description Page 1

3.10 Air/exhaust system


Contents

3.10.1 Intercooler
3.10.1.1 Before-removal operations
3.10.1.2 Removal
3.10.1.3 Disassembly
3.10.1.4 Inspection and repair
3.10.1.5 Assembly
3.10.1.6 Installation
3.10.2 Air system
3.10.2.1 Before-removal operations
3.10.2.2 Removal
3.10.2.4 Inspection and repair
3.10.2.6 Installation

3.10.3 Exhaust system


3.10.3.1 Before-removal operations
3.10.3.2 Removal
3.10.3.3 Disassembly
3.10.3.4 Inspection and repair
3.10.3.5 Assembly
3.10.3.6 Installation
3.10.6 Carrier housing with exhaust turbocharger and exhaust elbow
3.10.6.1 Before-removal operations
3.10.6.2 Removal
3.10.6.3 Disassembly
3.10.6.4 Inspection and repair
3.10.6.5 Assembly
3.10.6.6 Installation

3.10.14 Drain line


3.10.14.1 Before-removal operations
3.10.14.2 Removal
3.10.14.4 Inspection and repair
3.10.14.6 Installation

M020081/00E - 03.10 - EMTU


Section 3.10
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

EMTU - 03.10 - M020081/00E


Section 3.10.1
Task Description Page 1

3.10.1 Intercooler
Intercooler

1 Intercooler 8 Bracket
2 Connector 9 Hex screw
3 Banjo screw 10 Clamp
4 Sealing ring 11 Hex screw
5 Hose 12 Hex screw
6 Clamp 13 Washer
7 Washer

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Section 3.10.1
Page 2 Task Description

Connection components

1 Flange 3 O-ring
2 O-ring

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Section 3.10.1
Task Description Page 3

Cover and connection components of air junction on intercooler

1 Air junction 8 Washer


2 O-ring 9 Plug-in pipe
3 O-ring 10 O-ring
4 Hex screw 11 O-ring
5 Hex screw 12 Flange
6 Hex screw 13 Hex screw
7 Sleeve 14 Washer

M020081/00E - 03.10 - EMTU


Section 3.10.1
Page 4 Task Description

3.10.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain engine coolant Oper. Instr.
- X X Disconnect engine coolant lines 3.14.1.2
- X X Remove air intake system, intercooler/exhaust turbocharger 3.10.2.2

EMTU - 03.10 - M020081/00E


Section 3.10.1
Task Description Page 5

3.10.1.2 Removal

DANGER
Suspended load
Risk of injury!
Use suitable tools and lifting equipment.
Never stand beneath a suspended load.
Screw lifting eyes into intercooler.
Attach rope to lifting gear.
Remove securing screws for intercooler.
Raise intercooler.

3.10.1.3 Disassembly
Removing cover for air inlet and air outlet
Mark parts before removal.
Remove securing screws from cover, see overview drawing.
Remove screws and washers.
Remove cover from intercooler, ensuring that the sealing surfaces are not damaged.
Remove sealing paste from sealing surfaces.
After removal, seal all connections with suitable plugs and covers.
Protect intercooler (especially cooling fins) from mechanical damage.
Cover cooler nets (e.g. with cardboard).

3.10.1.4 Inspection and repair


Clean all components, check for condition and damage by visual inspection. Replace components as necessary.
Check cover for cracks using surface crack-testing method with red penetrant dye.
If cracks are detected, replace parts.
Check all sealing, mating and contact surfaces for damage and unevenness; smooth with oilstone or emery cloth
as necessary.
Check thread in intercooler housing for ease of movement; recondition if necessary.
Clean intercooler on air and water sides.

WARNING

Compressed air is highly pressurised. Risk of injury!


Never direct a compressed air jet at other people.
Always wear protective goggles/safety mask and ear protectors.

Cleaning air side:


Blow out the cooler with a compressed air jet or spray with a pressurised water jet in the opposite direction of the
cooling air. The jet must be directed parallel to the cooling fins in order to prevent the fins being deformed.

M020081/00E - 03.10 - EMTU


Section 3.10.1
Page 6 Task Description

WARNING

Hard water jet. Risk of injury!


Never direct water jet at other personnel, electric or electronic equipment.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
If the cooler has a contaminant layer of grease or oil, the cooler must be spray-cleaned with a steam jet in the op-
posite direction to cooling air.
Use nozzle for multi-point water jet. Operating pressure of H.P. cleaning unit should be approx. 80 bar.
Use clear water at a temperature of approx. 70 °C (to prevent steam).
After cleaning, blow through cooling air ducts with compressed air in vertical direction.
Cleaning coolant side:
It is essential to examine extent of contamination of water side prior to cleaning.
The water side must be cleaned if there is visible encrustation on the water side (inlet area) due to crustations,
contamination and oil deposits.
Fill cooler with descaling agent.

CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use,
safety instructions and waste disposal specifications.
An agent which is not aggressive to metal surfaces (e.g. Porodox from Henkel or Porozink from Parobe-Chemie,
Basel) must be used to remove deposited material.
It is essential to follow the manufacturer’s instructions when preparing the cleaning agent.
Dwell time depends on the condition and temperature of the solution and the nature and stubbornness of the de-
posits.
After cleaning, flush the cooler with water until pH values of clean water and rinsing water are approximately the
same (difference 1 pH).
Normal coolant can be used for rinsing.
If cooler is not satisfactorily clean, repeat cleaning process.
If the cooler is not put into operation immediately afterwards, after this cleaning the water side must be dried and
then preserved.
Dry in a drying oven between 110 °C and 120 °C. Oven drying time: approx. 3 hours.
Spray preservation agent (Branol 32/10 from Brangs and Heinrich) into cooler.
The preservation agent condenses and falls to form a protective layer over the inner surfaces.
Make sure dosages are correct! 2 ml Branorol 32/10 per litre of coolant.
After preservation, seal all openings with suitable end covers air-tight.

EMTU - 03.10 - M020081/00E


Section 3.10.1
Task Description Page 7

Intercooler leak check


Seal coolant chamber connections on intercooler
with suitable flanges (2) and gasket (3).
Connect compressed air line to one flange.

WARNING
Test liquid is hot and highly pressurised. Risk of
injury!
Liquid emerging under high-pressure can lead to
serious injury!
Always wear protective clothing, protective
gloves and protective goggles/safety mask.
Use lifting equipment to immerse intercooler into test
bath filled with coolant heated to 80 °C .
Open compressed air supply and set pressure re-
ducer (1) to 0.5 bar.
Pressure-test intercoolers with air in water bath for
leaks.
Rotate cooler around lateral axis and repeat test.
Replace intercooler if leaks are found.

WARNING
Compressed air is highly pressurised.
Risk of injury!
Never direct a compressed air jet at other people.
Always wear protective goggles/safety mask and
ear protectors.
After checking, blow through cooling air ducts with
compressed air in vertical direction.

3.10.1.5 Assembly
Installing cover on air junction
Clean sealing surfaces on intercooler and cover, smooth with oilstone if necessary.
Coat sealing surfaces evenly with sealing paste.
Tighten cover on intercooler air inlet with torque wrench as per Tightening Specifications 1.4.

M020081/00E - 03.10 - EMTU


Section 3.10.1
Page 8 Task Description

3.10.1.6 Installation
DANGER
Suspended load
Risk of injury!
Use suitable tools and lifting equipment.
Never stand beneath a suspended load.

Check that mating faces on intercooler are clean.


Screw in lifting eyes on intercooler and attach with
rope to lifting gear.
Place intercooler on carrier.
Take care not to damage O-rings.
Secure intercooler with hex screws.

EMTU - 03.10 - M020081/00E


Section 3.10.2
Task Description Page 1

3.10.2 Air system


Charge air line

1 Charge air line 15 Plug 29 Banjo screw


2 Gasket 16 Gasket 30 Sealing ring
3 Hex screw 17 Hex screw 31 Hose
4 Hex screw 18 Hex screw 32 Clamp
5 Washer 19 Washer 33 Clamp
6 Hex screw 20 Hex screw 34 Clamp
7 Hex screw 21 Washer 35 Hex screw
8 Washer 22 Flange 36 Washer
9 Washer 23 O-ring 37 Hex screw
10 Flange 24 Hex screw 38 Clamp
11 O-ring 25 Washer 39 Hex screw
12 Hex screw 26 Plug-in pipe 40 Washer
13 Washer 27 O-ring
14 Charge air manifold 28 Connector

M020081/00E - 03.10 - EMTU


Section 3.10.2
Page 2 Task Description

3.10.2.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain engine coolant Oper. Instr.
- X X Disconnect engine coolant lines 3.14.1.2
- X X Disconnect H.P. fuel lines 3.12.1.2

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Section 3.10.2
Task Description Page 3

3.10.2.2 Removal
Disconnecting charge air line
Remove screws and washers from charge air line on air collecting pipework - see overview drawing.
Remove securing screws from flanges - see overview drawing.
Remove O-rings, see overview drawing.
Disconnect charge air line from cylinder heads - see overview drawing.
Remove gaskets from cylinder heads - see overview drawing.
Removing connecting line for intercooler/exhaust turbocharger
Remove intermediate flanges from intercooler and plug-in pipe from exhaust turbocharger.

3.10.2.4 Inspection and repair

CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use,
safety instructions and waste disposal specifications.
Wash charge air line for charge air manifold, plug-in pipes and flanges with cleaner.
Using the surface crack-testing method and fluorescent penetrant dye, check the charge air line for cracks.
Replace component if cracks are found.
Check charge air line sealing surfaces and screw interfaces for evenness and damage, smooth with oilstone if
necessary.
Check bores for sleeves on charge air lines for wear and damage, smooth slight wear and damage with polishing
cloth, if necessary line in accordance with MTU regulations.
Check condition of threaded inserts and bushes on charge air lines, replace if necessary.
Check connecting lines, elbow, sleeves and plug-in pipes for damage and wear, smooth with polishing cloth or oil-
stone if necessary, replace parts as required.

WARNING

Test fluid is highly pressurized. Risk of injury!


Liquids emerging under high pressure can lead to serious injury!
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Pressure-test charge air line at room temperature in water bath with air.
Test pressure 0.5 bar.
Note: The water for pressure testing must be treated with anti-corrosive agent.
Replace all gaskets and O-rings.

3.10.2.6 Installation
Installing manifolds
Smoothe sealing surfaces on cylinder heads and charge air line with oilstone.
Check that charge air line is clean.
Coat gaskets with sealing paste and O-rings with petroleum jelly.
Fit all gaskets and O-rings.
Coat threads of screws with engine oil.
Install charge air line with screws and washers.
Tighten charge air line on cylinder head with torque wrench as per Tightening Specifications 1.4.

M020081/00E - 03.10 - EMTU


Section 3.10.2
Page 4 Task Description

WARNING

Test fluid is highly pressurized. Risk of injury!


Liquids emerging under high pressure can lead to serious injury!
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Before installing cover on manifold, pressure-test the engine with water.
Install cover with gasket, screws and spring washers on manifold (see overview drawing) and tighten with torque
wrench. For torque settings, see Section 1.4.
Installing connecting line for intercooler/exhaust turbocharger
After installing exhaust turbocharger, insert O-rings into groove on plug-in pipe and on compressor housing of ex-
haust turbocharger and coat with petroleum jelly.
Insert O-ring in groove on flanges and coat with petroleum jelly.
Fit flanges on plug-in pipe.
Fit plug-in pipe with flanges on compressor housing on exhaust turbocharger.
Mount flanges on intercooler with screws and washers and tighten.
After installing exhaust turbocharger, insert O-rings into groove on plug-in pipe and on compressor housing of ex-
haust turbocharger and coat with petroleum jelly.
Insert O-ring in groove on flanges and coat with petroleum jelly.
Fit flanges on plug-in pipe.
Fit plug-in pipe with flanges on compressor housing on exhaust turbocharger.
Install flanges on intercooler with screws and washers.

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Section 3.10.3
Task Description Page 1

3.10.3 Exhaust system


Exhaust elbow
Overview drawing 1

1 Exhaust elbow 14 Washer 27 Hex screw


2 Blanking plug 15 --------- 28 Exhaust manifold
3 O-ring 16 O-ring 29 Gasket
4 Adapter 17 Hex screw 30 Hex screw
5 Sealing ring 18 Hex screw 31 Washer
6 Surface sealant 19 Washer 32 ----------
7 Adapter 20 Exhaust elbow 33 O-ring
8 O-ring 21 Plug 34 Hex screw
9 Washer 22 Sealing ring 35 Plug
10 Hex screw 23 Surface sealant 36 Sealing ring
11 Exhaust manifold 24 Adapter 37 Hex screw
12 Gasket 25 O-ring 38 Washer
13 Hex screw 26 Washer

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Section 3.10.3
Page 2 Task Description

Attachments on exhaust line


Overview drawing 2

1 Cover 14 Plug-in pipe 27 Intermediate element


2 Cover 15 O-ring 28 Plug-in pipe
3 Hex screw 16 Plug-in pipe 29 O-ring
4 Hex screw 17 O-ring 30 Plug-in pipe
5 Socket-head screw 18 O-ring 31 O-ring
6 Washer 19 O-ring 32 O-ring
7 O-ring 20 Hex screw 33 O-ring
8 Cover 21 Washer 34 Hex screw
9 Hex screw 22 O-ring 35 Washer
10 Washer 23 O-ring 36 O-ring
11 --------- 24 Hex screw 37 O-ring
12 Flange 25 Washer 38 Hex screw
13 Intermediate element 26 Flange 39 Washer

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Section 3.10.3
Task Description Page 3

Exhaust line with exhaust housing


Overview drawing 3

1 Flange 12 Exhaust line 23 Hex screw


2 Gasket 13 Exhaust line 24 Washer
3 Socket-head screw 14 Plug-in pipe 25 Hex screw
4 Flame pipe 15 Gasket 26 Washer
5 Hex screw 16 Grooved pin 27 Sliding element
6 Washer 17 Hex screw 28 Washer
7 Exhaust housing 18 Hex screw 29 Spacer bush
8 Plug 19 Washer 30 Hex screw
9 Sealing ring 20 Clamp 31 Hex screw
10 Exhaust line 21 Dowel pin
11 Exhaust line 22 Hex screw

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Section 3.10.3
Page 4 Task Description

Exhaust elbow with transverse connecting pipe


Overview drawing 4

1 Exhaust elbow 21 Washer 41 O-ring


2 Bracket 22 Brace 42 O-ring
3 O-ring 23 Hex screw 43 O-ring
4 Hex screw 24 Washer 44 Hex screw
5 Washer 25 Exhaust elbow 45 Washer
6 Protective tube 26 Bracket 46 Hex screw
7 Hex screw 27 O-ring 47 Washer
8 Washer 28 Hex screw 48 Stud
9 -------- 29 Washer 49 Hex screw
10 Plug-in pipe 30 Protective tube 50
11 O-ring 31 Hex screw 51 Hex nut
12 O-ring 32 Washer 52 Spacer sleeve
13 O-ring 33 --------- 53 Washer
14 O-ring 34 Plug-in pipe 54 Threaded bush
15 O-ring 35 Exhaust transverse connection 55 Sealing ring
16 O-ring 36 O-ring 56 Plug
17 Hex screw 37 O-ring 57 Sealing ring
18 Hex screw 38 O-ring
19 Washer 39 O-ring
20 Socket-head screw 40 O-ring

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Section 3.10.3
Task Description Page 5

3.10.3.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain engine coolant Oper. Instr.
- X X Disconnect or remove electrical cable (if necessary) 3.84.
- X X Disconnect engine coolant lines 3.14.1.2
- X X Disconnect drain line 3.10.14.2

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Section 3.10.3
Page 6 Task Description

3.10.3.2 Removal

WARNING

Heavy object. Risk of crushing!


Use suitable equipment and lifting gears.

Removing exhaust manifold cover

Note: See overview drawing 2.


Remove screws securing cover (1 and 2).
Remove cover.
Removing exhaust manifold

Note: See overview drawing 3.


Remove screws securing exhaust lines (12 and 13).
Withdraw exhaust lines from exhaust housing (7), left and right engine sides simultaneously.
Removing exhaust housing

Note: See overview drawing 3.


Remove screws securing exhaust housing (7), left and right engine sides simultaneously.
Remove exhaust housing.
Removing exhaust elbow

Note: See overview drawing 4.


Remove screws for exhaust elbows (1 and 25).
Remove exhaust elbow, at the same time withdrawing exhaust transverse connection (35) from exhaust elbow.
Remove all O-rings from exhaust elbow, remove exhaust transverse connection and exhaust turbocharger.
Removing exhaust elbow

Note: See overview drawing 1.


Remove screws for exhaust manifold (11 and 28).
Remove screws for exhaust elbows (1 and 20).
Remove exhaust elbow.
Remove all O-rings.

3.10.3.3 Disassembly
Disassembling exhaust elbow

Note: See overview drawing 4.


Remove screws for carriers (2 and 26 ).
Remove carrier and protective tube (6 and 30).
Remove plug-in pipes (10 and 34).
Remove O-rings.
Removing constant-pressure manifold half

Note: See overview drawing 3.


Remove plug-in pipe (14) from exhaust line.
Remove slide element (27) and spacer bush (29).

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Section 3.10.3
Task Description Page 7

Disassembling exhaust elbow

Note: See overview drawing 1.


Remove adapters (7 and 24).
Remove O-rings.
Remove all plugs and adapters.

3.10.3.4 Inspection and repair

CAUTION

Decarbonizer must be used only in conjunction with a fume extraction system. Pay attention to manufac-
turer’s safety instructions. Always wear gloves and protective goggles.
Place exhaust line, exhaust housing, cover, exhaust elbow, exhaust transverse connecting pipe, protective tube
and plug-in pipe in a tank filled with decarbonizer for approx. 12 to 24 hours.
After cleaning, rinse parts until they are free from residues.
Stubborn rust deposits can also be treated later by spraying synthetic abrasive MTH (rated grain 16 to 20); coolant
inlets and outlets must be sealed for this purpose.
Using the surface crack-testing method with red penetrant dye, check the exhaust line, exhaust housing, cover,
exhaust elbow, exhaust transverse connecting pipe, protective tube and plug-in pipe for cracks. If cracks are de-
tected, replace parts.
Check exhaust line, exhaust housing, cover, exhaust elbow, exhaust transverse connecting pipe, protective tube
and plug-in pipe for wear or pitting; recondition or replace as necessary.
Check thread and thread inserts for damage.
Check sealing surfaces and bores for damage.
Replace damaged thread inserts.
Smooth sealing surfaces and bores with polishing cloth and oilstone.
Replace securing screws and nuts.
Clamping element, flame pipe, flange

WARNING

Test liquid is hot and highly pressurised. Risk of injury!


Liquids emerging under high pressure can lead to serious injury!
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Pressure-test water-carrying components.
Pressure-testing regulations:
Liquid test pressure = 7.0 bar with water
Air test pressure: 0.5 bar in water bath at 80 °C

3.10.3.5 Assembly
Preassembling exhaust line

Note: See overview drawing 3.


Coat screw thread for sliding element (27) with assembly paste.
Coat sliding element with spacer bush (29) with assembly paste and install.
Join the two exhaust pipes with plug-in pipe (14).

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Section 3.10.3
Page 8 Task Description

3.10.3.6 Installation
Installing left and right exhaust elbow on valve housing

Note: See overview drawing 1.


Coat O-rings with petroleum jelly and fit on exhaust elbow (1).
Coat thread of screws and mating faces of washers with assembly paste.
Install exhaust elbows (1 and 20) on valve housing.
Fit O-rings (8 and 25) on adapters (7 and 24) and coat with petroleum jelly.
Install adapter.
Install exhaust manifold (11 and 28) with gaskets (12 and 29).
Install all plugs and adapters with new O-rings and sealing rings.

Installing left and right exhaust housing

Note: See overview drawing 3.


Before installing exhaust housing (7), check all cylinder heads on one engine side with a steel ruler for evenness;
max. permissible deviation: 0.1 mm.
Coat flame pipe (4), flange (1), clamping element (20) with assembly paste and install.
Coat gasket (2) with assembly paste and fit.
Make sure that gasket is correctly positioned.
Coat thread of screws and support surface of washers with assembly paste.
Fit exhaust housing and secure.
Installing left and right exhaust line

Note: See overview drawing 3.


Insert preassembled exhaust line into exhaust housing or exhaust elbow.
Make sure that sliding elements are correctly positioned (27).
Coat thread of screws and mating face of washers securing covers (1 and 20), see overview drawing 1, with as-
sembly paste.
Install covers (1 and 20).
Installing left and right exhaust elbow

Note: See overview drawing 4.


Coat all O-rings with petroleum jelly.
Coat plug-in pipes (10 and 34) with assembly paste.
Install protective tubes (6 and 30) with plug-in pipe.
Coat all threads of screws and mating faces of washers with assembly paste.
Install exhaust elbows (1 and 25) together with exhaust transverse connection (35).
Install carriers (2 and 26) and screw together with protective tube (6) or (30).

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Section 3.10.6
Task Description Page 1

3.10.6 Exhaust turbocharger

1 Exhaust turbocharger 3 Bleed valve


2 Exhaust turbocharger

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Section 3.10.6
Page 2 Task Description

3.10.6.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain engine coolant Oper. Instr.
- X X Disconnect engine coolant lines 3.14.1.2
- X X Disconnect vent and drain lines 3.14.2.2
- X X Disconnect or remove electrical cable (if necessary) 3.84.9.2
- X X Remove air intake system, intercooler/exhaust turbocharger 3.10.2.2
- X X Cover for exhaust manifold and constant-pressure manifold half 3.10.3.2

EMTU - 03.10 - M020081/00E


Section 3.10.6
Task Description Page 3

3.10.6.2 Removal

CAUTION
Suspended load
Risk of injury!
Use suitable tools and lifting equipment.

Never stand beneath a suspended load.


Attach rope to exhaust turbocharger (1) and lifting
gear.
Remove hex screws (2).
Lift off exhaust turbocharger.

3.10.6.3 Disassembly
See Special Publication.

3.10.6.6 Installation

CAUTION
Suspended load
Risk of injury!
Use suitable tools and lifting equipment.
Never stand beneath a suspended load.

Attach rope to exhaust turbocharger (1) and lifting


gear.
Place exhaust turbocharger (1) on exhaust elbow
(2).
Tighten hex screws (2).

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Section 3.10.6
Page 4 Task Description

EMTU - 03.10 - M020081/00E


Section 3.10.14
Task Description Page 1

3.10.14 Drain line


Drain line arrangement

1 Intercooler 7 Washer
2 Connector 8 Bracket
3 Banjo screw 9 Hex screw
4 Sealing ring 10 Clamp
5 Hose 11 Hex screw
6 Clamp

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Section 3.10.14
Page 2 Task Description

3.10.14.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Carry out tasks as specified in disassembly plan 2.4
- - x Disable engine start Op. Man.

EMTU - 03.10 - M020081/00E


Section 3.10.14
Task Description Page 3

3.10.14.2 Removal
Removal as shown in overview drawing.

3.10.14.4 Inspection and repair


No inspection and repair necessary.
Replace drain line.

3.10.14.6 Installation
Installation as shown in overview drawing.

M020081/00E - 03.10 - EMTU


Section 3.10.14
Page 4 Task Description

EMTU - 03.10 - M020081/00E


Section 3.11
Task Description Page 1

3.11 Fuel injection equipment


Contents

3.11.1 Fuel injection pump drive


3.11.1.1 Before-removal operations
3.11.1.2 Removal
3.11.1.3 Disassembly
3.11.1.4 Inspection and repair
3.11.1.5 Assembly
3.11.1.6 Installation
3.11.5 Fuel injection pump
3.11.5.1 Before-removal operations
3.11.5.2 Removal
3.11.5.4 Inspection and repair
3.11.5.6 Installation
3.11.5.7 After-installation operations

3.11.6 Fuel injection nozzle with holder


3.11.6.1 Before-removal operations
3.11.6.2 Removal
3.11.6.4 Inspection and repair
3.11.6.6 Installation

M020081/00E - 03.10 - EMTU


Section 3.11
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

EMTU - 03.10 - M020081/00E


Section 3.11.3
Task Description Page 1

3.11.1 Fuel injection pump drive

1 Drive gear 3 Washer


2 Hex screw

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Section 3.11.3
Page 2 Task Description

3.11.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain raw water Oper. Instr.
- X X Remove exhaust silencer 3.10.12.2
- X X Drain engine coolant Oper. Instr.
- X X Disconnect engine coolant lines 3.14.1.2
- X X Disconnect water lines 3.14.3.2
- X X Remove coolant expansion tank 3.14.5.2
- X X Disconnect engine oil lines 3.16.1.2
- X X Disconnect H.P. fuel lines 3.12.1.2
- X X Remove fuel lines (if necessary) 3.12.2.2
- X X Remove fuel injection pumps 3.11.5.2

EMTU - 03.10 - M020081/00E


Section 3.11.3
Task Description Page 3

3.11.1.2 Removal
Remove coupling half.
Remove screws (1).
Remove drive gear (1).

3.11.1.4 Inspection and repair


Clean all components.
Using the magnetic crack-testing method with fluorescent magnetic powder, check coupling half for cracks.
If cracks are found, replace coupling half.
Check teeth on coupling half for wear.
Level with oilstone as required, replace if necessary.

3.11.1.6 Installation
Install coupling half.
Install drive gear (1) and tighten screw (2) by hand.

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Section 3.11.3
Page 4 Task Description

EMTU - 03.10 - M020081/00E


Section 3.11.5
Task Description Page 1

3.11.5 Fuel injection pump 12V

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Section 3.11.5
Page 2 Task Description

Arrangement of fuel injection lines

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Section 3.11.5
Task Description Page 3

3.11.5.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain raw water Oper. Instr.
- X X Remove exhaust silencer 3.10.12.2
- X X Drain engine coolant Oper. Instr.
- X X Disconnect engine coolant lines 3.14.1.2
- X X Disconnect water lines 3.14.3.2
- X X Remove coolant expansion tank 3.14.5.2
- X X Disconnect engine oil lines 3.16.1.2
- X X Disconnect H.P. fuel lines 3.12.1.2
- X X Remove fuel lines (if necessary) 3.12.2.2
- X X Remove fuel injection pumps 3.11.5.2

M020081/00E - 03.10 - EMTU


Section 3.11.5
Page 4 Task Description

3.11.5.2 Removal

DANGER
Suspended load
Risk of injury!
Use suitable tools and lifting equipment.
Never stand beneath a suspended load.

Attach lifting device to H.P. line connections of injec-


tion pump.
Attach rope to lifting device and lifting gear.
Remove screws (1-8).
Lift out injection pump.
Remove lifting device.

Remove O-rings (1).

3.11.5.4 Inspection and repair


Overhaul fuel injection pump as per Special Publication.

EMTU - 03.10 - M020081/00E


Section 3.11.5
Task Description Page 5

3.11.5.6 Installation
Install barring tool.

Turn crankshaft with barring tool in normal direction


of engine rotation until in the compression stroke of
the 1st cylinder the mark for start of delivery is
aligned with edge (arrow) in inspection port.
The engine must not be rotated backwards.
Inspection: The valves of the 1st cylinder must be
closed, the rocker arms must be unloaded.

Turn injection pump camshaft until mark on drive


flange (arrow) is aligned with mark on injection
pump.
Move injection pump drive gear to central position in
elongated holes.

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Section 3.11.5
Page 6 Task Description

Coat O-ring with petroleum jelly and insert.

WARNING
Heavy object.
Risk of injury!
Use suitable equipment and lifting gears.

Fit assembly gauge on injection pump and secure


with knurled-head screw (arrow).
Move injection pump to and fro until assembly gauge
is in contact with crankcase.
Insert injection pump with lifting device in bearing on
crankcase.
Make sure the injection pump markings are aligned.
The gears must engage in the teeth without tension.
Remove lifting device.

Coat thread of screws (1) with engine oil.


Use torque wrench to tighten screws to specified
torque. For torque setting, see Section 1.4.

EMTU - 03.10 - M020081/00E


Section 3.11.5
Task Description Page 7

Coat securing screws with engine oil and install with


spring washers.
Tightening sequence for injection pump securing
screws
1. Fit all screws (with battery screwdriver).
2. Pretighten screws in accordance with
arrangement opposite.
3. Carry out final tightening in same sequence.
For tightening specifications, see 1.4.
Adjusting pump timing, see 3.11.5.7.

3.11.5.7 After-installation operations


Checking and adjusting start of delivery
Connecting supply line (1) from high-pressure pump
Remove fuel return line and overflow valve from in-
jection pump.
Seal injection pump return with plug (2).
Remove injection line to 1st engine cylinder.
Connect test line with sight glass (3) to connection of
injection pump for the 1st engine cylinder.
Set engine approx. 1/2 a rotation before TDC with
barring tool.
Switch on high-pressure pump.

Bar engine slowly in direction of rotation and observe


fuel flow in sight glass until spray pattern shows cor-
rect atomisation.
A = Good atomisation
B = Fuel jet constricted, just before start of delivery.
Droplets, start of delivery

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Section 3.11.5
Page 8 Task Description

EMTU - 03.10 - M020081/00E


Section 3.11.6
Task Description Page 1

3.11.6 Fuel injection nozzle with holder

1 Nozzle holders 3 Screw, nozzle holder


2 Sealing ring 4 Plug

M020081/00E - 03.10 - EMTU


Section 3.11.6
Page 2 Task Description

3.11.6.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Disconnect H.P. fuel lines 3.12.1.2

EMTU - 03.10 - M020081/00E


Section 3.11.6
Task Description Page 3

3.11.6.2 Removal
Removing nozzle holder
Remove thrust screw (1).

Fit puller (1) on injector (2) and withdraw.


Remove sealing ring from cylinder head.

3.11.6.4 Inspection and repair


For disassembly, cleaning, assembly and inspection of fuel injectors, see Engine Operating Instructions.
Replace sealing ring.
Check condition of leak-off fuel lines, replace cracked leak-off fuel lines.

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Section 3.11.6
Page 4 Task Description

3.11.6.6 Installation
Installing nozzle holder
Attach sealing ring on nozzle holder so that, when
installing, the gap between nozzle and cylinder head
is sufficiently filled with grease.
Insert injector into cylinder head.
Fit thrust screw (1) over nozzle holder.
Coat thrust screw with engine oil.
Screw in pin wrench and tighten with torque wrench
as per Tightening Specifications 1.4.

EMTU - 03.10 - M020081/00E


Section 3.12
Task Description Page 1

3.12 Fuel system


Contents

3.12.1 H.P. fuel lines


3.12.1.1 Before-removal operations
3.12.1.2 Removal
3.12.1.4 Inspection and repair
3.12.1.6 Installation

3.12.2 Fuel lines


3.12.2.1 Before-removal operations
3.12.2.2 Removal
3.12.2.4 Inspection and repair
3.12.2.6 Installation
3.12.3 Fuel duplex filter
3.12.3.1 Before-removal operations
3.12.3.2 Removal
3.12.3.3 Disassembly
3.12.3.4 Inspection and repair
3.12.3.5 Assembly
3.12.3.6 Installation

M020081/00E - 03.10 - EMTU


Section 3.12
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

EMTU - 03.10 - M020081/00E


Section 3.12
Task Description Page 3

Fuel system, 12V

1 Engine 12 Leak-of f fuel indicator*


2 Fuel delivery pump 13 Fuel prefilter
3 Fuel duplex filter 14 Drip tray
4 Fuel injection pump 15 Flexible connection
5 Fuel injection nozzle 16 From fuel tank
6 Overflow valve 17 To fuel tank
7 Injection line 18 To leak-off fuel collecting tank
8 Jacket* * Order-specific version
9 Leak-of f fuel line A Connection on engine
10 Leak-of f fuel from jacket*
11 Leak-of f fuel tank*

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Section 3.12
Page 4 Task Description

EMTU - 03.10 - M020081/00E


Section 3.12.1
Task Description Page 1

3.12.1 H.P. fuel lines


H.P. fuel lines

1 Set of injection lines 4 Hex screw


2 Set of injection lines 5 Hex screw
3 Spacer tube

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Section 3.12.1
Page 2 Task Description

H.P. fuel line arrangement

EMTU - 03.10 - M020081/00E


Section 3.12.1
Task Description Page 3

3.12.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.

M020081/00E - 03.10 - EMTU


Section 3.12.1
Page 4 Task Description

3.12.1.2 Removal
Removing leak-off fuel line
Remove leak-off fuel lines (1 and 3) from nozzle
holder.
Remove plug (2).

Remove H.P. fuel line


Remove union nut.

Unscrew H.P. fuel line from fuel injection pump.


Remove pipe clamps from charge air manifold.

EMTU - 03.10 - M020081/00E


Section 3.12.1
Task Description Page 5

3.12.1.4 Inspection and repair


Clean all components.
Check injection line for damage and scuffing.
Replace damaged injection lines, or lines with dented or corroded tapers.
A new, straight injection line must be bent to conform precisely to damaged injection line.
Inspect union nuts for damage and, if necessary, replace injection line.

WARNING

Compressed air is highly pressurized. Risk of injury!


Never direct a compressed air jet at other people.
Always wear protective goggles/safety mask and ear protectors.

3.12.1.6 Installation
Install H.P. fuel line
Before installing, blow out injection line with com-
pressed air.
Install union nut, ensuring it is free from tension.
Arrangement of injection lines - see overview draw-
ing.
Tighten union nut on nozzle holder as per Tightening
Specifications 1.4.

Screw injection line onto fuel injection pump and


tighten with special wrench and torque wrench as
per Tightening Specifications 1.4.
Remove pipe clamps from charge air manifold.

M020081/00E - 03.10 - EMTU


Section 3.12.1
Page 6 Task Description

EMTU - 03.10 - M020081/00E


Section 3.12.2
Task Description Page 1

3.12.2 Fuel lines


Fuel lines to fuel injection pump

1 Fuel line 15 Sealing ring 29 Banjo union


2 T-piece 16 Banjo union 30 Sealing ring
3 Sealing cone 17 Sealing ring 31 Banjo screw
4 Nut 18 Overflow valve 32 Banjo screw
5 Adapter 19 Adapter 33 Sealing ring
6 Sealing ring 20 Fuel line 34 Plug
7 Fuel line 21 Fuel line 35 Fuel line
8 Banjo screw 22 Fuel line 36 Banjo union
9 Banjo union 23 Fuel line 37 Sealing ring
10 Sealing ring 24 Sealing ring 38 Adapter
11 Fuel line 25 Adapter 39 Plug
12 Banjo screw 26 Banjo screw 40 Fuel line
13 Sealing ring 27 Reduction union 41 Fuel line
14 Adapter 28 Fuel line

M020081/00E - 03.10 - EMTU


Section 3.12.2
Page 2 Task Description

Fuel lines, pump, injection nozzle, cylinders 7 to 12

1 Injection line, cylinder 7 10 Sealing ring


2 Injection line, cylinder 8 11 O-ring
3 Injection line, cylinder 9 12 Half-clamp
4 Injection line, cylinder 10 13 Half-clamp
5 Injection line, cylinder 11 14 Half-clamp
6 Injection line, cylinder 12 15 Half-clamp
7 Threaded pin 16 Hex screw
8 Threaded pin 17 Hex screw
9 Cap nut 18 Hex screw

EMTU - 03.10 - M020081/00E


Section 3.12.2
Task Description Page 3

Fuel lines, pump, injection nozzle, cylinders 1 to 6

1 Injection line, cylinder 6 10 Sealing ring


2 Injection line, cylinder 5 11 O-ring
3 Injection line, cylinder 4 12 Half-clamp
4 Injection line, cylinder 3 13 Half-clamp
5 Injection line, cylinder 2 14 Half-clamp
6 Injection line, cylinder 1 15 Half-clamp
7 Threaded pin 16 Hex screw
8 Threaded pin 17 Hex screw
9 Cap nut 18 Hex screw

M020081/00E - 03.10 - EMTU


Section 3.12.2
Page 4 Task Description

Leak-off fuel lines

1 Leak-off fuel line 4 Sealing cone


2 Banjo screw 5 Nut
3 Sealing ring

EMTU - 03.10 - M020081/00E


Section 3.12.2
Task Description Page 5

Fuel line on fuel cooler, fuel duplex filter

1 Union 13 Clamp
2 Hose line 14 Clamp
3 Elbow 15 Hex screw
4 Union 16 Sealing ring
5 Sealing ring 17 Adapter
6 Hose line 18 Sealing cone
7 Banjo union 19 Nut
8 Sealing ring 20 Washer
9 Banjo screw 21 Hex nut
10 Reduction union 22 Hose line
11 Drip tray 23 Elbow
12 Hose

M020081/00E - 03.10 - EMTU


Section 3.12.2
Page 6 Task Description

Fuel line on distributor

1 Fuel line 10 Washer


2 Fuel line 11 Hex screw
3 Fuel line 12 Sealing ring
4 Banjo screw 13 Plug
5 Banjo screw 14 Sealing ring
6 Banjo union 15 Adapter
7 Sealing ring 16 Union
8 Distributor 17 Sealing cone
9 Spacer sleeve 18 Nut

EMTU - 03.10 - M020081/00E


Section 3.12.2
Task Description Page 7

3.12.2.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Carry out tasks as specified in disassembly plan 2.4
- - x Disable engine start Op. Man.

M020081/00E - 03.10 - EMTU


Section 3.12.2
Page 8 Task Description

3.12.2.2 Removal

WARNING

Fuels are combustible.


Risk of burning and explosion.
- do not use naked flame, no electric sparks, avoid all sources of ignition
Before removing the fuel lines, it is advisable to take photos of the engine-mounted fuel pipework, or to mark the
fuel lines with tabs, to eliminate the possibility of confusion when reinstalling the fuel lines.
After removing fuel lines, seal all connections with suitable plugs.

3.12.2.4 Inspection and repair


Clean all fuel lines with cleaner and visually inspect for condition and damage; If necessary, repair or pressure-test
fuel lines with air in water bath for leaks.

WARNING

Compressed air is highly pressurized.


Risk of injury! The pressure must not exceed 0.5 bar.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Test pressure: 0.5 bar, coolant temperature: 60 Cº min. 30 °C.
Replace damaged, deformed and corroded sealing cones and banjo adapters.

CAUTION

Component is hot. Risk of injury! Handle components only when wearing protective gloves.
Using welding torch, heat lines which do not fit until red-hot.
Tighten connections and adapters.
Do not cool off lines with water.

WARNING

Hydrochloric acid is extremely caustic. Risk of injury and suffocation!


Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Ensure good ventilation at workplace.
After reshaping lines, remove from engine and pickle in a hydrochloric acid solution (9 parts water to 1 part hydro-
chloric acid).

EMTU - 03.10 - M020081/00E


Section 3.12.2
Task Description Page 9

WARNING

Compressed air is air which has been compressed under pressure. Fluid is hot.
Risk of injury!
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Then wash the pipes in hot water, blow dry with compressed air.
Then preserve lines in oil bath and allow to drip dry.
Check condition of hoses and for signs of aging; replace if necessary.
Check brackets, buffers, grommets, damping strips and securing elements for fuel lines for damage and wear;
replace parts if necessary.
Check condition of threads of union nut and adapter.
Check sealing and screw-on surfaces for damage. smooth with oilstone as necessary.
Replace plugs, studs and unions as required.

3.12.2.6 Installation

WARNING

Compressed air is highly pressurized. Risk of injury!


Never direct a compressed air jet at other people.
Always wear protective goggles/safety mask and ear protectors.
Before installing, blow fuel lines clear with compressed air.
Install fuel lines with fixtures (see overview drawings), take photos or apply markings, ensuring lines are tension-
free.

M020081/00E - 03.10 - EMTU


Section 3.12.2
Page 10 Task Description

EMTU - 03.10 - M020081/00E


Section 3.12.3
Task Description Page 1

3.12.3 Fuel duplex filter


Installing fuel duplex filter

1 Hex screw 7 Washer


2 Washer 8 Drip tray
3 Fuel duplex filter 9 Washer
4 Valve 10 Hex nut
5 Sealing ring 11 Washer
6 Hex screw 12 Hex screw

M020081/00E - 03.10 - EMTU


Section 3.12.3
Page 2 Task Description

Fuel duplex filter

1 Fuel duplex filter 7 Sealing ring


2 Filter element 8 Plug
3 Filter head 9 Plug
4 Screw 10 Spring
5 Sealing ring 11 Threaded pin
6 Sealing ring 12 Cover

EMTU - 03.10 - M020081/00E


Section 3.12.3
Task Description Page 3

3.12.3.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Carry out tasks as specified in disassembly plan 2.4
- - x Disable engine start Op. Man.

M020081/00E - 03.10 - EMTU


Section 3.12.3
Page 4 Task Description

3.12.3.2 Removal
Remove fuel duplex filter
Remove screws securing fuel duplex filter as per overview drawing.
Remove fuel duplex filter.
Remove drip tray.

3.12.3.3 Disassembly

WARNING

Fuels are combustible.


Risk of burning and explosion.
- do not use naked flame, no electric sparks, avoid all sources of ignition

Disassembling fuel duplex filter:


See also fuel duplex filter overview drawing.
Unscrew filter element (2).
Remove screw (4) and remove sealing ring.
Remove plugs (8 and 9).
Unscrew threaded pin (11) and remove spring (10).

3.12.3.4 Inspection and repair

WARNING

Test fluid is highly pressurized. Risk of injury!


Liquid emerging under high-pressure can lead to serious injury!
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Clean all components.
Remove corrosion and/or water stains in filter housing with brush.
Using red penetrant dye method, crack-test filter head surfaces; replace components as necessary.
Pressure-test filter head with diesel fuel at 12 bar.
Use emery cloth to polish out slight wear and pitting; replace filter housing if necessary.
Check filter head for warping and wear; replace component as necessary.
Check condition of securing screw.
Check condition of drip tray.
Replace filter element.
Check condition of springs and replace if necessary.

3.12.3.5 Assembly
Fuel duplex filter assembly:
See also fuel duplex filter overview drawing.
Screw in filter element (2).
Secure screw (4) with sealing ring.
Tighten plugs (8 and 9).
Fit spring (10) on threaded pin (11) and install.

EMTU - 03.10 - M020081/00E


Section 3.12.3
Task Description Page 5

3.12.3.6 Installation
Install fuel duplex filter
Install fuel duplex filter as per overview drawing.
Install drip tray as per overview drawing.

M020081/00E - 03.10 - EMTU


Section 3.12.3
Page 6 Task Description

EMTU - 03.10 - M020081/00E


Section 3.13
Task Description Page 1

3.13 Coolant pump


Contents

3.13.1 Engine coolant pump


3.13.1.1 Before-removal operations
3.13.1.2 Removal
3.13.1.3 Disassembly
3.13.1.4 Inspection and repair
3.13.1.5 Assembly
3.13.1.6 Installation
3.13.2 Raw water pump
3.13.2.1 Before-removal operations
3.13.2.2 Removal
3.13.2.3 Disassembly
3.13.2.4 Inspection and repair
3.13.2.5 Assembly
3.13.2.6 Installation

M020081/00E - 03.10 - EMTU


Section 3.13
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20D

EMTU - 03.10 - M020081/00E


Section 3.13.1
Task Description Page 1

3.13.1 Engine coolant pump


Engine coolant pump arrangement

1 V-belt pulley 6 O-ring


2 Spacer ring 7 O-ring
3 Washer 8 Washer
4 Screw 9 Hex screw
5 Engine coolant pump

M020081/00E - 03.10 - EMTU


Section 3.13.1
Page 2 Task Description

1 Coolant pump housing 4 Rotary seal


2 Coolant pump bearing 5 Impeller
3 Snap ring 6 Flange

EMTU - 03.10 - M020081/00E


Section 3.13.1
Task Description Page 3

1 Pump housing 6 Impeller


2 Snap ring 7 Flange
3 Pump bearing with shaft a Reference distance
4 Rotary seal b Installation dimension, rotary seal 11.9 ± 0.3 mm
5 Rotary seal s Gap, impeller 0.6 + 0.4 mm

M020081/00E - 03.10 - EMTU


Section 3.13.1
Page 4 Task Description

3.13.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Carry out services as per disassembly plan 2.4
- - x Disable engine start Op. Inst.
- - x Drain engine coolant Op. Inst.
- x x Remove engine coolant pipework 3.14.1.2
- x x Remove raw water lines 3.14.3.2

EMTU - 03.10 - M020081/00E


Section 3.13.1
Task Description Page 5

3.13.1.2 Removal
Remove hex screws (1) with washers (2).
Remove spacer ring (4) and V-belt pulley (4).
Remove hex screws (9) with washers (10).
Remove engine coolant pump (5) and remove O-
rings (6 and 7).

3.13.1.3 Disassembly
Removing flange
Withdraw flange (1) with puller from pump bearing
shaft.

Removing coolant pump bearing


Remove snap ring (2).
Place coolant pump housing on a hollow body.
Press coolant pump bearing with shaft (1) out of im-
peller and coolant pump housing.

M020081/00E - 03.10 - EMTU


Section 3.13.1
Page 6 Task Description

Removing rotary seal


Remove rotary seal (2) from coolant pump housing
(1).

3.13.1.4 Inspection and repair


Clean all components.
Using the surface crack-testing method and red penetrant dye, check the coolant pump housing, impeller and
flange for cracks.
Using the magnetic crack-testing method with fluorescent magnetic powder, check the coolant pump bearing for
cracks.
Replace relevant components if cracks are found.
Check coolant pump housing and impeller for pitting.
Replace parts if pitting is deeper than 1 mm.
Always replace coolant pump bearing.
Check sealing surfaces on coolant pump housing for wear, smooth with emery cloth as necessary.
Replace rotary seal during overhaul .

3.13.1.5 Assembly
CAUTION
Component is hot.
Risk of injury!
Handle components only when wearing protec-
tive gloves.

Installing coolant pump bearing


Heat coolant pump housing (1) to 80 °C.

Note: Press in pump shaft bearing only on outer


race.

Wearing protective gloves, use drift to drive pump


shaft bearing (2) into pump housing until seated.

EMTU - 03.10 - M020081/00E


Section 3.13.1
Task Description Page 7

Installing rotary seal and impeller

CAUTION
Component is hot.
Risk of injury!
Handle components only when wearing protec-
tive gloves.
Coat support in coolant pump housing (4) with Loc-
tite.
Press dry rotary seal (1) onto shaft (2) and with sur-
face sealant into coolant pump housing.
Hold shaft end firmly in position.
Projection and installation dimensions - see over-
view drawing.
Installation dimension (position of gasket on im-
peller) is achieved by shrink-fitting the impeller.

Installing flange
CAUTION
Component is hot.
Risk of injury!
Handle components only when wearing protec-
tive gloves.
Heat flange (1) to 260 °C.
Using protective gloves, push flange flush onto
shaft, holding shaft end firmly in position.

M020081/00E - 03.10 - EMTU


Section 3.13.1
Page 8 Task Description

EMTU - 03.10 - M020081/00E


Section 3.13.2
Task Description Page 1

3.13.2 Raw water pump


Raw water pump with attachments

1 Raw water pump 12 Clamping nut


2 Gasket 13 Hex screw
3 Hex screw 14 Swivel head
4 Stud 15 Hex screw
5 Nut 16 Washer
6 Washer 17 Hex screw
7 Belt pulley 18 Washer
8 Hex screw 19 Nut
9 Washer 20 Cover plate
10 V-belts 21 Washer
11 Clamping element

M020081/00E - 03.10 - EMTU


Section 3.13.2
Page 2 Task Description

Raw water pump cross-section

1 Pump housing 12 Angular-contact ball bearing


2 Impeller 13 Grooved ball bearing
3 Intermediate element 14 Adjusting shim
4 Bearing housing 15 Adjusting shim
5 Drive shaft 16 Snap ring
6 Clamping nut 17 Snap ring
7 Rotary seal 18 Adjusting screw
8 Shaft seal 19 Plug
9 O-ring 20 Plug
10 Sealing ring 21 Stud
11 Sealing ring 22 Nut

EMTU - 03.10 - M020081/00E


Section 3.13.2
Task Description Page 3

3.13.2.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Perform operations as per Disassembly Plan 2.4
- - x Disable engine start Op. Inst.
- - x Drain engine coolant Op. Inst.
- - x Drain raw water Op. Inst.
- x x Remove engine coolant lines 3.14.1.2
- x x Remove raw water lines 3.14.3.2

M020081/00E - 03.10 - EMTU


Section 3.13.2
Page 4 Task Description

3.13.2.2 Removal
Removing elbow
Remove screws (3) and (5) and remove sleeve (2).
Remove hex screw (7).

3.13.2.3 Disassembly
Removing pump housing
Remove nut (4).
Gently tap pump housing (1) with a rubber mallet to
remove.
Remove O-ring (3).
Remove intermediate element (4).

EMTU - 03.10 - M020081/00E


Section 3.13.2
Task Description Page 5

Removing cap nut and thrust ring


Remove cap nut (3) from impeller (1).

Removing impeller
Install puller on impeller.
Withdraw impeller with thrust screw from drive shaft
(2).
Remove rotary seals.

Rotary seal removal


Remove rotary seal (2) from intermediate element
(1).

Removing drive shaft and grooved ball bearing


Remove snap rings (2 and 8) with snap ring pliers.
Remove shaft seal (4).
Remove adjusting shims (1 and 6).
Fit bearing housing (3) on a hollow body.
Using removal tool and manual press, remove drive
shaft (5) together with grooved ball bearing (7) from
bearing housing.
Remove grooved ball bearing from drive shaft.

M020081/00E - 03.10 - EMTU


Section 3.13.2
Page 6 Task Description

Removing angular-contact ball bearing


Remove snap rings (1 and 3) with snap ring pliers.
Fit bearing housing (2) on a hollow body.
Use removal tool and manual press to remove angu-
lar-contact ball bearing (4) from bearing housing.

3.13.2.4 Inspection and repair


Clean all components.
Using the surface crack-testing method and red penetrant dye, check the pump housing, impeller, intermediate
element and bearing housing for checks.
Using the magnetic crack-testing method and fluorescent magnetic powder, check the drive shaft and clamping
nut for cracks.
If cracks are detected, the respective parts must be replaced.
Check pump housing and impeller for pitting. Replace parts if pitting is deeper than 1 mm.
Check drive shaft for wear and damage. Smooth minor traces of wear and damage with an emery cloth.
Metal-spray sealing surface as per MTU specifications as required.
Check thread for ease of movement; rechase or fit thread insert as required.
Check stud for damage.
Check tapers with taper gauge; replace components as necessary.
Check sealing surfaces and bearing bore on bearing flange for wear, smooth with polishing cloth if necessary.
Adjust bore gauge and measure bore for grooved ball bearing and angular-contact ball bearing in bearing housing.
Using an outside micrometer, measure the bearing seat and fitting diameter on the drive shaft.
Replace components if specified limits are exceeded (see Tolerances and Wear Limits List).
Replace rotary seals, shaft seal and O-rings at every overhaul.
Always replace angular-contact and grooved ball bearings during W6 overhaul.

EMTU - 03.10 - M020081/00E


Section 3.13.2
Task Description Page 7

3.13.2.5 Assembly
Installing grooved ball bearing
CAUTION

Part is hot.
Risk of injury!
Handle components only when wearing protec-
tive gloves.
Clean all components.
Heat grooved ball bearing (2) to 180 °C and push
onto the drive shaft (1) as far as the stop.
Using circlip pliers, insert the snap ring (3) in the
groove in the drive shaft.
Ensure that the snap ring is correctly fitted in the
groove!

Installing drive shaft

CAUTION

When using these miscellaneous materials, it is


essential to observe the manufacturer’s instruc-
tions for use, safety instructions and waste dis-
posal specifications.

Place bearing housing (1) on a hollow body, with


flange surface up.
Insert drive shaft (3) in direction of drive end into
bearing housing up to 10 mm to bearing housing.
Insert adjusting shim (4).
Clean and degrease bore for shaft seal (2) in bearing
housing with denaturated ethanol.
Rub down shaft seal seating surface with denatu-
rated ethanol.
Press-fit shaft seal with impact bush into the bearing
housing until it is in contact.
Ensure installation direction is correct.

M020081/00E - 03.10 - EMTU


Section 3.13.2
Page 8 Task Description

Installing intermediate element and rotary seal


Place intermediate element (1) on bearing housing.
Insert contact surface with boot of rotary seal (3)
with petroleum jelly via drive shaft (2) into intermedi-
ate element.

Mounting the impeller


Clean and degrease taper of drive shaft (2) and im-
peller (1).
Push impeller onto drive shaft.
Coat thread of clamping nut (3) and mating face of
clamping nut with engine oil.
Fit clamping nut and tighten with torque wrench as
per Tightening Specifications 1.4.

EMTU - 03.10 - M020081/00E


Section 3.13.2
Task Description Page 9

Installing angular-contact ball bearing


Mount assembled unit on assembly stand.
Using a gauge, 0.5 mm, check axial clearance
0.5 ±0.2 mm at a minimum of three positions.
Using a suitable tool, clamp impeller and bearing
housing together.
Using circlip pliers, insert the inside snap ring in the
groove in the bearing housing .
Ensure that the snap ring is correctly fitted in the
groove!
Compensate dimension “x” with adjusting shims as
required.
Dimension “x” = A-B
Heat bearing housing in the bearing seat area of the
angular-contact ball bearing to 130 + 20°C.
Press-fit angular-contact ball bearing into bearing
housing.
Using circlip pliers, insert the outer snap ring in the
groove in the pump shaft.
Ensure that the snap ring is correctly fitted in the
groove!
Compensate dimension “Z” with adjusting shims as
required.
Using circlip pliers, insert the outer snap ring in the
groove in the bearing housing .
Ensure that the snap ring is correctly fitted in the
groove!
Tighten clamping nut with torque wrench according
to specifications. For torque settings, see Section
1.4.
Again check axial clearance 0.5 ± with gauge.

Installing pump housing


Coat O-ring (2) with petroleum jelly and insert in
pump housing.
Install completely assembled unit in pump housing.
Fit nut (1) and tighten with torque wrench as per
Tightening Specifications 1.4.

3.13.2.6 Installation
Install raw water pump in reverse sequence - see overview drawing: Raw water pump with attachments.

M020081/00E - 03.10 - EMTU


Section 3.13.2
Page 10 Task Description

EMTU - 03.10 - M020081/00E


Section 3.14
Task Description Page 1

3.14 Cooling system


Contents

3.14.1 Engine coolant pipework


3.14.1.1 Before-removal operations
3.14.1.2 Removal
3.14.1.4 Inspection and repair
3.14.1.6 Installation

3.14.2 Vent lines/drain lines


3.14.2.1 Before-removal operations
3.14.2.2 Removal
3.14.2.4 Inspection and repair
3.14.2.6 Installation
3.14.3 Raw water lines
3.14.3.1 Before-removal operations
3.14.3.2 Removal
3.14.3.4 Inspection and repair
3.14.3.6 Installation

3.14.5 Coolant expansion tank


3.14.5.1 Before-removal operations
3.14.5.2 Removal
3.14.5.3 Disassembly
3.14.5.4 Inspection and repair
3.14.5.5 Assembly
3.14.5.6 Installation
3.14.6 Engine coolant cooler
3.14.6.1 Before-removal operations
3.14.6.2 Removal
3.14.6.3 Disassembly
3.14.6.4 Inspection and repair
3.14.6.5 Assembly
3.14.6.6 Installation

3.14.7 Coolant thermostat


3.14.7.1 Before-removal operations
3.14.7.2 Removal
3.14.7.3 Disassembly
3.14.7.4 Inspection and repair
3.14.7.5 Assembly
3.14.7.6 Installation

3.14.9 Pressure-testing engine coolant chambers

M020081/00E - 03.10 - EMTU


Section 3.14
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

EMTU - 03.10 - M020081/00E


Section 3.14.1
Task Description Page 1

3.14.1 Engine coolant pipework


Engine coolant pipework on distribution housing

1 Elbow 15 Coolant line 29 Grommet


2 O-ring 16 Bracket 30 Hex screw
3 Hex screw 17 Hex screw 31 Washer
4 Washer 18 Washer 32 Hex screw
5 Threaded bush 19 Pipe clamp half 33 Washer
6 Threaded bush 20 Hex screw 34 Bracket
7 - 21 Coolant line 35 Sleeve
8 Plug 22 Banjo screw 36 Hex screw
9 Sealing ring 23 Sealing ring 37 Washer
10 Adapter 24 Spacer bushing 38 Spacer bushing
11 Sealing ring 25 Pipe clamp half 39 Pipe clamp half
12 - 26 Grommet 40 Grommet
13 Rubber sleeve 27 Spacer bushing 41 Hex screw
14 Clamp 28 Pipe clamp half 42 Washer

M020081/00E - 03.10 - EMTU


Section 3.14.1
Page 2 Task Description

Coolant distributor housing connections

1 Connector 7 O-ring
2 Adapter 8 Plug
3 Threaded bush 9 Washer
4 Plug 10 Socket-head screw
5 Sealing ring 11 Washer
6 O-ring

EMTU - 03.10 - M020081/00E


Section 3.14.1
Task Description Page 3

Connection on distribution housing

1 Elbow 7 Sealing ring


2 Sealing ring 8 Hex screw
3 Union 9 Hex screw
4 Sealing cone 10 Washer
5 Nut 11 Hex screw
6 Plug 12 Washer

M020081/00E - 03.10 - EMTU


Section 3.14.1
Page 4 Task Description

Engine coolant pipework on coolant distributor housing

1 Rubber sleeve 13 Hex screw 25 Bracket


2 Clamp 14 Washer 26 Hex screw
3 Washer 15 Hex screw 27 Hex screw
4 Clamp 16 Washer 28 Washer
5 Coolant line 17 Spacer bush 29 Pipe clamp half
6 Rubber sleeve 18 Plug 30 Pipe clamp half
7 Clamp 19 Sealing ring 31 Hex screw
8 Coolant line 20 Pipe clamp half 32 Pipe clamp half
9 Coolant line 21 Pipe clamp half 33 Pipe clamp half
10 Bracket 22 Hex screw 34 Spacer bush
11 Pipe clamp half 23 Washer 35 Hex screw
12 Pipe clamp half 24 Washer 36 Washer

EMTU - 03.10 - M020081/00E


Section 3.14.1
Task Description Page 5

Engine coolant pipework between distribution housing and intercooler

1 Elbow 14 Clamp
2 Elbow 15 Engine coolant line
3 O-ring 16 Rubber sleeve
4 Hex screw 17 Clamp
5 Hex screw 18 Double elbow
6 Hex screw 19 O-ring
7 Hex screw 20 O-ring
8 Washer 21 Hex screw
9 Pipeline 22 Washer
10 Rubber sleeve 23 Bracket
11 Clamp 24 Spacer tube
12 Engine coolant line 25 Hex screw
13 Rubber sleeve 26 Washer

M020081/00E - 03.10 - EMTU


Section 3.14.1
Page 6 Task Description

3.14.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain engine coolant Oper. Instr.
- X X Drain raw water Oper. Instr.

EMTU - 03.10 - M020081/00E


Section 3.14.1
Task Description Page 7

3.14.1.2 Removal
Before removing coolant lines, it is advisable to take photographs of engine from all sides or to identify lines with
markers so as to avoid confusion during subsequent reassembly.
Remove all monitoring devices.
After removing coolant lines, seal all connections with suitable plugs.

3.14.1.4 Inspection and repair

CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use,
safety instructions and waste disposal specifications.

Clean coolant lines with cold cleaner and brushes.


Visually inspect plug-in connections and annular grooves on elbows, plug-in pipes, connecting lines and flanges for
wear, pitting and cavitation.
Provide damaged plug-in connections with bushes in accordance with MTU specifications, replace if necessary.
Pressure-test components as required.
Recondition damaged sealing surfaces and inspect for irregularities on an ink-check plate.
Replace sealing cones and banjo unions that are damaged, indented or corroded.

CAUTION

Component is hot. Risk of injury! Handle components only when wearing protective gloves.

Realign badly fitting lines. Heat the lines red-hot with welding torch, tighten connections and unions.
Allow lines to cool slowly, do not cool with water.

WARNING

Hydrochloric acid is extremely caustic. Risk of injury and suffocation!


Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Ensure good ventilation at workplace.

Pickle lines in hydrochloric acid solution (9 parts water and 1 part hydrochloric acid).

M020081/00E - 03.10 - EMTU


Section 3.14.1
Page 8 Task Description

WARNING

Compressed air is air which has been compressed under pressure. Fluid is hot.
Risk of injury! The pressure must not exceed 3.0 bar.
Always wear protective clothing, protective gloves and protective goggles/safety mask.

After pickling, wash the pipes in hot water, blow dry with compressed air,
Then immerse lines in an oil bath and allow to drip dry.
Check restrictors and strainers for damage, replace as necessary.
Check all retaining elements and attaching hardware for damage and wear - replace parts if necessary.
Replace grommets as part of every W6 overhaul.
Replace sealing rings, O-rings and gaskets.
Replace unions if necessary.

3.14.1.6 Installation

WARNING

Compressed air is highly pressurized.


Risk of injury! Test pressure must not be exceeded.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Before installation, blow coolant lines, plug-in pipes and connecting lines clear with compressed air.
Note: Do not remove blanking plug until just before installation.
Coat O-rings with petroleum jelly and insert into grooves of plug-in pipes and flanges, ensuring they are not
twisted.
Install coolant lines, plug-in pipes, connecting lines and flanges with new gaskets, O-rings and fixtures so that they
are free from strain in accordance with photographs, markers and overview drawing.

EMTU - 03.10 - M020081/00E


Section 3.14.2
Task Description Page 1

3.14.2 Vent and drain lines


Drain and vent lines

1 Drain line 15 Hex screw 29 Hex screw


2 Banjo screw 16 Washer 30 Washer
3 Sealing ring 17 Clamp 31 Washer
4 Bracket 18 Hex screw 32 Clamp
5 Pipe clamp half 19 Washer 33 Clamp
6 Grommet 20 T-piece 34 Clamp
7 Hex screw 21 Vent line 35 Hex screw
8 Washer 22 Vent line 36 Hex screw
9 Spacer bush 23 Bracket 37 Vent line
10 Hex screw 24 Hex screw 38 Transition
11 Washer 25 Washer 39 Sealing ring
12 Vent line 26 Clamp 40 Vent line
13 Bracket 27 Hex screw 41 Banjo screw
14 Washer 28 Washer 42 Sealing ring

M020081/00E - 03.10 - EMTU


Section 3.14.2
Page 2 Task Description

3.14.2.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.

EMTU - 03.10 - M020081/00E


Section 3.14.2
Task Description Page 3

3.14.2.2 Removal
Before removing vent and drain lines, it is advisable to take photographs of engine from all sides or to identify lines
with markers so as to avoid confusion during subsequent reassembly.
After removing lines, seal all open connections by installing suitable plugs.

3.14.2.4 Inspection and repair

CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use,
safety instructions and waste disposal specifications.

Clean vent and drain lines with cold cleaner and brushes.
Replace sealing cones and banjo unions that are damaged, indented or corroded.

CAUTION

Component is hot. Risk of injury! Handle components only when wearing protective gloves.

Realign badly fitting lines. Heat the lines red-hot with welding torch, tighten connections and unions.
Allow lines to cool slowly, do not cool with water.

WARNING

Hydrochloric acid is extremely caustic. Risk of injury and suffocation!


Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Ensure good ventilation at workplace.

Pickle lines in hydrochloric acid solution (9 parts water and 1 part hydrochloric acid).

WARNING

Compressed air is air which has been compressed under pressure. Fluid is hot.
Risk of injury! The pressure must not exceed 3.0 bar.
Always wear protective clothing, protective gloves and protective goggles/safety mask.

After pickling, wash the pipes in hot water, blow dry with compressed air,
Then immerse lines in an oil bath and allow to drip dry.
Check all retaining elements and attaching hardware for damage and wear - replace parts if necessary.
Replace grommets as part of every W6 overhaul.
Replace O-rings and hose sleeve.
Replace unions if necessary.

M020081/00E - 03.10 - EMTU


Section 3.14.2
Page 4 Task Description

3.14.2.4 Inspection and repair

WARNING

Compressed air is highly pressurized.


Risk of injury! Test pressure must not be exceeded.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Before installation, blow vent and drain lines clear with compressed air.
Note: Do not remove blanking plug until just before installation.
Fit vent and drain lines with new sealing rings and fixtures so that they are free from strain in accordance with
photographs, markers and overview drawing.

EMTU - 03.10 - M020081/00E


Section 3.14.3
Task Description Page 1

3.14.3 Raw water line


Raw water line on distribution housing

1 Moulded tubing 18 Raw water line 35 Plug


2 Clamp 19 Rubber sleeve 36 Sealing ring
3 Raw water line 20 Clamp 37 Raw water line
4 Plug 21 Bracket 38 Gasket
5 Sealing ring 22 Pipe clamp halves 39 Hex screw
6 Clamp 23 Pipe clamp halves 40 Hex nut
7 Pipe clamp halves 24 Hex screw 41 Washer
8 Pipe clamp halves 25 Hex screw 42 Plug
9 Hex screw 26 Washer 43 Sealing ring
10 Hex screw 27 Bracket 44 Bracket
11 Washer 28 Pipe clamp halves 45 Hex screw
12 Bracket 29 Pipe clamp halves 46 Washer
13 Bracket 30 Hex screw 47 Hex screw
14 Hex screw 31 Hex nut 48 Sealing cone
15 Washer 32 Washer 49 Nut
16 Hex screw 33 Hex screw
17 Washer 34 Washer

M020081/00E - 03.10 - EMTU


Section 3.14.3
Page 2 Task Description

Raw water line to raw water pump

1 Elbow 6 Washer
2 Sleeve 7 Hex screw
3 Hex screw 8 Plug
4 Washer 9 Sealing ring
5 Hex screw

EMTU - 03.10 - M020081/00E


Section 3.14.3
Task Description Page 3

Engine coolant pipework on distribution housing

1 Elbow 7 Sealing ring


2 Sealing ring 8 Hex screw
3 Union 9 Hex screw
4 Sealing cone 10 Washer
5 Nut 11 Hex screw
6 Plug 12 Washer

M020081/00E - 03.10 - EMTU


Section 3.14.3
Page 4 Task Description

3.14.3.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Perform operations as per Disassembly Plan 2.4
- - x Disable engine start Op. Man.
- x x Drain raw water Op. man.

EMTU - 03.10 - M020081/00E


Section 3.14.3
Task Description Page 5

3.14.3.2 Removal
Before removing raw water lines, it is advisable to take photographs of engine from all sides or to identify lines with
markers so as to avoid confusion during subsequent reassembly.
After removing raw water lines, seal all connections with suitable plugs.

3.14.3.4 Inspection and repair

CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use,
safety instructions and waste disposal specifications.

Clean raw water lines with cold cleaner and brushes.


Make visible inspection of plug-in connections and annular grooves on elbows, plug-in pipes, connecting lines and
flanges for wear, pitting and cavitation.
Provide damaged plug-in connections with bushes in accordance with MTU specifications, replace if necessary.
Pressure-test components as required.
Recondition damaged sealing surfaces and inspect for irregularities on an ink-check plate.
Replace sealing cones and banjo unions that are damaged, indented or corroded.

CAUTION

Component is hot. Risk of injury! Handle components only when wearing protective gloves.

Realign badly fitting lines. Heat the lines red-hot with welding torch, tighten connections and unions.
Allow lines to cool slowly, do not cool with water.

WARNING

Hydrochloric acid is extremely caustic. Risk of injury and suffocation!


Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Ensure good ventilation at workplace.

Pickle lines in hydrochloric acid solution (9 parts water and 1 part hydrochloric acid).

WARNING

Compressed air is air which has been compressed under pressure. Fluid is hot.
Risk of injury! The pressure must not exceed 3.0 bar.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
After pickling, wash the pipes in hot water, blow dry with compressed air,
Then immerse lines in an oil bath and allow to drip dry.
Check all retaining elements and attaching hardware for damage and wear - replace parts if necessary.
Replace grommets as part of every W6 overhaul.
Replace all gaskets, sealing rings and O-rings.
Replace unions if necessary.

M020081/00E - 03.10 - EMTU


Section 3.14.3
Page 6 Task Description

3.14.3.6 Installation

WARNING

Compressed air is highly pressurized.


Risk of injury! Test pressure must not be exceeded.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Before installing, blow raw water lines clear with compressed air.
Before installing, coat O-rings with petroleum jelly.

Note: Do not remove blanking plug until just before installation.


Fit raw water lines with new sealing rings and O-rings and attaching hardware so that they are free from strain in
accordance with photographs and overview drawing.

EMTU - 03.10 - M020081/00E


Section 3.14.5
Task Description Page 1

3.14.5 Distribution housing

1 Distribution housing 12 Sealing ring


2 Gasket 13 Plug
3 Hex screw 14 Sealing ring
4 Washer 15 Filler neck
5 Socket-head screw 16 Sheet-metal eye
6 Washer 17 Marker plate
7 Hex screw 18 Gasket
8 Hex screw 19 Gasket
9 Hex screw 20 Hex screw
10 Washer 21 Washer
11 Plug

M020081/00E - 03.10 - E MTU


Section 3.14.5
Page 2 Task Description

3.14.5.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Op. Man.
- X X Drain engine coolant Op. Man.
- X X Disconnecting engine coolant lines 3.14.1.2
- X X Disconnect vent lines 3.14.2.2

E MTU - 03.10 - M020081/00E


Section 3.14.5
Task Description Page 3

3.14.5.2 Removal
Install eyebolt on distribution housing.
Attach lifting device to eyebolt.

Remove screws (3; 5; 7; 8 and 11) from distribution


housing (2) and remove washers (4; 6; 9 and 10).
Lift off distribution housing.
Remove gasket (1).
Remove lifting device.

M020081/00E - 03.10 - E MTU


Section 3.14.5
Page 4 Task Description

3.14.5.3 Disassembly
Removing bracket for three-phase alternator and
V-belt tension
Release hex screws (1; 7; 9 and 10) from bracket
(3) and remove together with washers ( 2; 8 and 11).
Remove bracket (3).
Releasing hex screws (5 and 6)
Remove bracket (4).

Removing filler neck and plug


Release hex screw (3) and remove with spring
washer (2).
Remove sheet-metal eyelet (1) with filler neck (4).
Remove gaskets (5 and 7) and marker plate (6).
Remove all plugs from distribution housing (8)

3.14.5.4 Inspection and repair

CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use,
safety instructions and waste disposal specifications.
Clean distributor housing and attachments with cold cleaner and brush.
Remove scale with a descaling product that does not attack the metal surface (e.g. P3 T288 from Henkel or Euron
1308 amidosulfonic acid from Hoechst).
Once cleaning is completed, rinse all parts with water.
Check distribution housing for wear and cavitation, smooth sealing surfaces and mating faces with oilstone if
necessary, replace as required.
Check threaded bores for ease of movement, recut thread if necessary, or install threaded inserts.
Check seal on valve cover, replace valve cover if necessary.
Replace gaskets and sealing rings.
Rub down screw-down and sealing surfaces with oilstone.

E MTU - 03.10 - M020081/00E


Section 3.14.5
Task Description Page 5

3.14.5.5 Assembly
Installing filler neck and plug
Clean sealing surfaces, smooth with oilstone if
necessary.
Fit new gaskets (5 and 7) and marker plate on dis-
tribution housing (8), making sure they are correctly
positioned.
Secure sheet-metal eyelet (1) and filler neck (4) with
hex screw (3) and washer (3).
Tighten hex screws diagonally and evenly.
Screw in all plugs with new sealing rings into dis-
tribution housing.

Installing bracket for three-phase alternator and V-


belt tension
Secure bracket (3) with hex screws (1; 10; 9 and 7)
and washers (2; 8 and 11) on distribution housing.
Secure bracket (4) with hex screws (5 and 6) to dis-
tribution housing.

M020081/00E - 03.10 - E MTU


Section 3.14.5
Page 6 Task Description

3.14.5.6 Installation
Install eyebolt on distribution housing.
Attach lifting device to eyebolt.

Clean installation surfaces for gasket (1).


Coat gasket with petroleum jelly and
fit on distribution housing (2).
Install distribution housing with screws (3; 5; 7; 8 and
11) and washers (4; 6; 9 and 11).
Remove lifting device and eyelet.

E MTU - 03.10 - M020081/00E


Section 3.14.6
Task Description Page 1

3.14.6 Engine coolant cooler

1 Pin 10 Cooling plate


2 Initial plate 11 End plate
3 Cooling plate 12 Cover
4 Cooling plate 13 Spacer sleeve
5 Intermediate plate 14 Washer
6 Sleeve 15 Hex screw
7 O-ring 16 Warning plate
8 Intermediate plate 17 Round-head grooved pin
9 Intermediate plate

M020081/00E - 03.10 - EMTU


Section 3.14.6
Page 2 Task Description

Example of plate pack arrangement

1 Distributor housing 4 Channel plate


2 Sealing ring 5 Channel plate
3 Initial plate 6 Pressure plate

Number of initial, channel and end plates to be installed:


Item 3 = 1x, Item 4 =24x, Item 5 =24x

Note: Items 4 and 5 always arranged alternately !


View ”Z2” is a view on gasket side.
”X” component no. for all plates on left side.

EMTU - 03.10 - M020081/00E


Section 3.14.6
Task Description Page 3

3.14.6.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Carry out tasks as per Disassembly Plan 2.4
- - x Disable engine start Op. Man.
- - x Drain engine coolant Op. Man.
- - x Close raw water supply and return Op. Man.
- - x Drain raw water -
- x x Disconnect raw water outlet line 3.14.3.2
-x x Disconnect raw water outlet line 3.14.3.2
- x x Disconnect drain line to cooler housing 3.14.1.2

M020081/00E - 03.10 - EMTU


Section 3.14.6
Page 4 Task Description

3.14.6.2 Removal
Identify plate pack with a coloured diagonal stroke
(arrowed) in correct installation sequence for pur-
poses of subsequent reassembly.

Cover plate removal


Insert guide pin (1).
Unscrew threaded sleeves (2).
Remove pressure plate.

3.14.6.3 Disassembly
CAUTION
Cooler plates have sharp edges.
Risk of injury!
Handle plates only when wearing protective
gloves.

Channel plate removal


Beginning at top, remove channel plates in turn.
Remove sealing rings for coolant transfer on distribu-
tion housing.
Remove spacer sleeves from stud bolts.

EMTU - 03.10 - M020081/00E


Section 3.14.6
Task Description Page 5

3.14.6.4 Inspection and repair


Cleaning plates

CAUTION

Cooler plates have sharp edges.


Risk of injury!
Handle plates only when wearing protective gloves.

Mechanical cleaning
Clean cooler plates only with a soft brush and flow-
ing water.
Note: Use only a soft brush to avoid damaging
the plates.

Cleaning with steam jet.

WARNING
Take special care when using high-pressure jet.
Risk of injury!
Never direct water jet at humans, animals,
equipment or electric components.
Always wear protective clothing, protective
gloves and protective goggles/safety mask.

Note: Maintain specified service pressure and


minimum spraying distance to avoid dam-
aging plates.
Observe Operating Instructions of equip-
ment manufacturer.
Remove deposits with H.P. spraying jet.

M020081/00E - 03.10 - EMTU


Section 3.14.6
Page 6 Task Description

Chemical cleaning

CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for
use, safety instructions and waste disposal specifications.

Note: Do not use the following solvents: Ketone (e. g. acetone, methyl ethyl ketone, methyl isobutyl ketone),
ester (e.g. ethyl acetate, butyl acetate), halogenised hydrocarbon (e.g. chlorothene, carbon tetrachlo-
ride, freon), aromatic compounds, benzine, toluene.

Note: After chemical cleaning, flush cooling


plates with water and dry with a towel.
Encrustation - scale and sediment (calcium bi-
carbonate, calcium sulphate, corrosion prod-
ucts, metallic oxides)
To clean use:
- Nitric acid*
- Citric acid*
- Phosphoric acid*
- Sodium polyphosphate
* Concentration max. 4 %; Temperature max. 60° C
Note: Remove scale with a descaling product
(e.g. Porodox from Henkel or Euron 1308
from Hoechst, concentration from 5 % to
10 %).

Deposits on carbon-hydrogen basis (oil residue,


greases)
Use a solution on parafin or naphta basis
(z. B. kerosene).
Cleaning cover plate

Note: Protect aluminium components from chemicals.

Clean cover plate with cold cleaner and brush.


Use only a soft brush to avoid damaging the plates and sealing faces.
Inspection and Repair
If necessary, use the surface crack-testing method with red penetrant dye or fluorescent penetrant dye to check
heat exchanger plates and cover plate for cracks: Replace components as necessary.
Check parts for damage; replace if necessary.
Check mating faces and sealing surfaces of cover plate for wear and damage; smooth with emery cloth or oilstone
as necessary, or replace component.
If necessary, replace cover plate thread inserts.
Check thread for ease of movement; replace part as necessary.
Replace all gaskets and O-rings.

EMTU - 03.10 - M020081/00E


Section 3.14.6
Task Description Page 7

3.14.6.5 Assembly
Installing distribution housing
Coat threads of pins (4) and studs (2) with Loctite
270.
Screw pins and studs into distribution housing (1).
Note: Final strength at 20 °C ≈ 12h

3.14.6.6 Installation
Channel plate installation

CAUTION
Cooler plates have sharp edges.
Risk of injury!
Handle plates only when wearing protective
gloves.
Insert coolant transfer sealing rings in distribution
housing.
Insert guide pins (1) and coat with petroleum jelly.
Fit channel plates (4) on guide pins in accordance
with overview drawings and colour markings.
Push spacer sleeves (3) onto studs (2).

Cover plate installation


Coat hex screw threads with engine oil.
Fit cover plate (3) on guide pins (1).
Secure plates in position by tightening threaded
sleeve (2) diagonally and evenly.
Use torque wrench to tighten hex screws to specified
torque. For torque setting, see Section 1.4.
Note: The degree of pretensioning for the profile
seal is determined by the spacer sleeves.
Remove guide pins.

M020081/00E - 03.10 - EMTU


Section 3.14.6
Page 8 Task Description

EMTU - 03.10 - M020081/00E


Section 3.14.7
Task Description Page 1

3.14.7 Coolant thermostat

1 Coolant distribution housing 11 Washer


2 Restrictor 12 O-ring
3 End cover 13 O-ring
4 - 14 O-ring
5 O-ring 15 Plug
6 O-ring 16 Sealing ring
7 Hex screw 17 Thermostat insert
8 Washer 18 O-ring
9 Thermostat housing 19 Sealing ring
10 Hex screw

M020081/00E - 03.10 - EMTU


Section 3.14.7
Page 2 Task Description

3.14.7.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see
X - - Remove engine 2.3
X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain engine coolant Oper. Instr.
- X X Disconnect engine coolant lines 3.14.1.2

EMTU - 03.10 - M020081/00E


Section 3.14.7
Task Description Page 3

3.14.7.2 Removal
Remove hex screws (1).
Remove washers (2).
Remove coolant distribution housing (3).
Remove O-rings (4, 7 and 8).
Remove restrictor (6) and end cover (5).

3.14.7.3 Disassembly
Remove thermostat insert
Remove hex screws (1).
Remove washers (2).
Remove thermostat elements (6, 8 and 10) from
thermostat housing (3).
Remove O-rings (3; 4; 7 and 9).
Remove sealing ring (5).

M020081/00E - 03.10 - EMTU


Section 3.14.7
Page 4 Task Description

3.14.7.4 Inspection and repair

CAUTION

When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for
use, safety instructions and waste disposal specifications.
Clean all parts with cold cleaner.
Check thermostat housing for indentations, wear and cavitation.
Smooth mating faces and bores as required with oilstone or polishing cloth, replace as required.
Check annular slide running surface for wear; rub down with emery cloth as required and replace if necessary.
Check slide in guide bands of thermostat housing for ease of movement.
Check condition of tapped bores; recut threads if necessary and install thread inserts as required.
Check cover, threaded bush, locking bush, stop pin, washer and pin for wear.
Check condition of threads; rechase threads if necessary.
Rub down bolt-on and sealing surfaces with oilstone as required; replace components if necessary.
Check springs for impact marks, burrs and frictional wear; deburr areas of minor wear and replace springs if
necessary.
Replace scraper rings during W6 overhaul.
Replace thermal element as required.
Replace O-rings.

3.14.7.5 Assembly
Installing thermostat insert
Coat sealing ring (5) with sealing paste.
Coat O-rings (3; 4; 7 and 9) with petroleum jelly and
fit.
Insert thermostat elements (6, 8 and 10) in thermo-
stat housing (3).
Secure hex screws (1) with washers (2).

EMTU - 03.10 - M020081/00E


Section 3.14.7
Task Description Page 5

3.14.7.6 Installation
Insert restrictor (6).
Coat end cover (5) with sealing paste and install.
Coat O-rings (4, 7 and 8) with petroleum jelly and
install.
Fit coolant distribution housing (3).
Secure hex screws (1) with washers (2).

M020081/00E - 03.10 - EMTU


Section 3.14.7
Page 6 Task Description

EMTU - 03.10 - M020081/00E


Section 3.14.9
Task Description Page 1

3.14.9 Pressure-testing engine coolant chambers


Install hydraulic pressure testing device on distribution housing.
Connect connecting hose.
Connect vent line to intercooler.
Unscrew plug from oil pan.

WARNING

Test liquid is hot and highly pressurised. Risk of injury!


Liquid emerging under high-pressure can lead to serious injury!
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Install hydraulic pressure testing device on elbow of engine coolant pipework.
Connect connecting hose.
Fill engine coolant chambers with treated water (coolant).
Open cock on vent line until coolant emerges.
Close hydraulic pressure testing device on coolant expansion tank.
Pressure-test engine with water at 80 °C for at least 20 minutes with max. 7 bar.
Check coolant transfer pipes between cylinder heads and charge air/coolant manifolds and constant-pressure
manifold housing for leaks.
Relieve pressure.
Drain or draw off engine coolant.
Remove hydraulic pressure testing device.
Screw in drain plugs and tighten.

M020081/00E - 03.10 - E MTU


Section 3.14.9
Page 2 Task Description

E MTU - 03.10 - M020081/00E


Section 3.15
Task Description Page 1

3.15 Oil pump


Contents

3.15.1 Engine oil pump on crankcase


3.15.1.1 Before-removal operations
3.15.1.2 Removal
3.15.1.3 Disassembly
3.15.1.4 Inspection and repair
3.15.1.5 Assembly
3.15.1.6 Installation
3.15.5 Pressure relief valve
3.15.5.1 Before-removal operations
3.15.5.2b Removal, engine with intermediate frame
3.15.5.4 Inspection and repair
3.15.5.6b Installation, engine with intermediate frame

3.15.8 Semirotary hand pump for oil extraction


3.15.8.1 Before-removal operations
3.15.8.2 Removal
3.15.8.3 Disassembly
3.15.8.4 Inspection and repair
3.15.8.5 Assembly
3.15.8.6 Installation
3.15.8.7 After-installation operations

M020081/00E - 03.10 - EMTU


Section 3.15
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

EMTU - 03.10 - M020081/00E


Section 3.15.1
Task Description Page 1

3.15.1.1 Engine oil pump


Installation on crankcase (12V two intake pipes)

1 Hex screw 3 Washer


2 Hex screw 4 Oil pump with oil extraction pipe

M020081/00E - 03.10 - EMTU


Section 3.15.1
Page 2 Task Description

3.15.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- - X Drain engine coolant Oper. Instr.
- - X Drain or draw off engine oil Oper. Instr.
- X X Remove oil pressure lines and elbow from oil pan to oil heat exchanger 3.16.2.2
- X X Remove guide tube for oil dipstick 3.1.11.2
- X X Remove oil pan 3.1.6.2
- X X Remove engine oil intake and pressure lines 3.15.1.2

EMTU - 03.10 - M020081/00E


Section 3.15.1
Task Description Page 3

3.15.1.2 Removal

WARNING

Heavy object. Risk of crushing!


Use suitable equipment and lifting gears

Remove intake pipe.


Unscrew hex screws (2 and 3)
Remove oil extraction pipe (1) and gasket (4).

Removing oil pump and pressure relief valve


Unscrew hex screws (2 and 3).
Remove pressure relief valve (4) and oil pump (1).

M020081/00E - 03.10 - EMTU


Section 3.15.1
Page 4 Task Description

3.15.1.3 Disassembly
Unscrew hex screws (4 and 5) from cover (3).
Remove cover.
Place oil pump housing with cover installation side
on a hollow body.
Use manual press to remove oil pump gear (2) from
drive gear.

Remove drive gear (1).

3.15.1.4 Inspection and repair


Clean all components.
Using the magnetic crack-testing method with fluorescent magnetic powder, check oil pump gears for cracks.
Check oil pump housing and intake pipe for cracks using surface crack-testing method with red penetrant dye.
If cracks are detected, replace parts.
Check oil pump gears and drive gear.
Check tooth flanks for wear, indentations and chipping.
Check bearings for wear, scoring and indentation.
Check oil pump housing for wear, remove slight scoring.
In event of wear marks deeper than 0.3 mm in oil chamber of pump housing, replace oil pump housing.
Check suction basket on intake pipe for cleanness and damage; replace intake pipe if necessary.
Inspect sealing and contact surfaces for irregularities; rub down as required.
Inspect contact surface of cover for irregularities and rub down as required.
Check thread, recut as required, replace thread inserts if necessary.
Replace components as necessary.

EMTU - 03.10 - M020081/00E


Section 3.15.1
Task Description Page 5

3.15.1.5 Assembly
Ensure that contact surface of pump housing and
cover (3) are clean.
Coat bearing bushes in cover with engine oil.
Fit cover on oil pump housing so that oil pump gear
shafts (2 and 3) engage in bearing bore.
Insert screws (4 and 5) into cover and screw into oil
pump housing.
Tighten with torque wrench to specified torque. For
torque setting, see Section 1.4.
Check ease of movement of oil pump.
It must be possible to turn the pump by hand without
feeling resistance.

Clean and degrease mating faces on oil pump gear


and drive gear.
Heat drive gear and press in leaving a clearance of
0.5 mm to shaft.

M020081/00E - 03.10 - EMTU


Section 3.15.1
Page 6 Task Description

3.15.1.6 Installation

WARNING

Heavy object. Risk of crushing!


Use suitable equipment and lifting gears.

Installing oil pump and pressure relief valve


Fit oil pump (1) and screw in with hex screws (2).
Fit pressure relief valve (4 ) and screw in with hex
screws (3).
Use torque wrench to tighten hex screws to specified
torque. For torque setting, see Section 1.4.

Installing intake pipes


Fit oil extraction pipe (1) with gasket (4) on flange.
Tighten hex screws (2)
Tighten hex screws (3) with torque wrench as per
Tightening Specifications 1.4.

EMTU - 03.10 - M020081/00E


Section 3.15.5
Task Description Page 1

3.15.5 Pressure relief valve

3.15.5.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Perform operations as per Disassembly Plan 2.4
- - x Disable engine start Op. Man.
- - x Drain or draw off engine oil Op. Man.

M020081/00E - 03.10 - EMTU


Section 3.15.5
Page 2 Task Description

3.15.5.2 Removal
See Section 3.15.1.2

3.15.5.4 Inspection and repair


Clean pressure relief valve.
For limit values, see Tolerances and Wear Limits List.
Replace pressure relief valve if valve does not open at specified pressure.

3.15.5.6 Installation
See Section 3.15.1.2

EMTU - 03.10 - M020081/00E


Section 3.15.8
Task Description Page 1

3.15.8. Semirotary hand pump for oil extraction


Semirotary hand pump

1 Lever 5 Suction chamber


2 Pressure chamber 6 Suction valve seat
3 Valve plate 7 Vane
4 Housing 8 Vane pump

M020081/00E - 03.10 - EMTU


Section 3.15.8
Page 2 Task Description

3.15.8.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


- - x Disable engine start Op. Man.
- x x Remove engine oil lines 3.16.1.2

EMTU - 03.10 - M020081/00E


Section 3.15.8
Task Description Page 3

3.15.8.2 Removal
Removing semirotary hand pump
Drain engine oil, catch in a suitable container and dispose of oil in an appropriate manner.
Release securing screws on semirotary hand pump.
Remove semirotary hand pump.

3.15.8.3 Disassembly
Removing lever
Remove nuts (1).
Remove lever (2) from pump (4).
Release union nut (3).

Cover removal
Hold hex screws (2) firmly in position and unscrew
nuts (1).
Remove cover (3) from pump housing (4).
Remove gasket.
Remove union nut, thrust pad and gland packing.
Remove washer from shaft.

M020081/00E - 03.10 - EMTU


Section 3.15.8
Page 4 Task Description

Removing vane
Remove vane with shaft (1) from pump housing (3).
Remove pressure valve seat (2) from pump housing.

Removing valve plates


Unscrew socket-head screws (1) from suction valve
seat (3).
Remove valve plates (2).
Remove gasket.
In a similar manner, remove valve plates from the
vanes.

3.15.8.4 Inspection and repair


Remove gland packing and gaskets after every disassembly.
Check vanes, suction valve seat and housing for cracks using surface crack-testing method with red penetrant
dye.
If cracks are detected, replace parts.
Check sealing surface for flatness and perfect condition.

3.15.8.5 Assembly
Installation in reverse order to disassembly.

3.15.8.6 Installation
Installing semirotary hand pump
Install semirotary hand pump, align and secure with securing screws.

EMTU - 03.10 - M020081/00E


Section 3.16
Task Description Page 1

3.16 Engine oil system


Contents

3.16.1 Engine oil lines


3.16.1.1 Before-removal operations
3.16.1.2 Removal
3.16.1.3 Disassembly
3.16.1.4 Inspection and repair
3.16.1.5 Assembly
3.16.1.6 Installation
3.16.2 Engine oil cooler
3.16.2.1 Before-removal operations
3.16.2.2 Removal
3.16.2.3 Disassembly
3.16.2.4 Inspection and repair
3.16.2.5 Assembly
3.16.2.6 Installation

3.16.3 Engine oil filter


3.16.3.1 Before-removal operations
3.16.3.2 Removal
3.16.3.3 Disassembly
3.16.3.4 Inspection and repair
3.16.3.5 Assembly
3.16.3.6 Installation

M020081/00E - 03.10 - EMTU


Section 3.16
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

EMTU - 03.10 - M020081/00E


Section 3.16.1
Task Description Page 1

3.16.1 Engine oil lines


Oil return lines from injection pump

1 Oil return 13 Oil return line


2 Sealing ring 14 Sealing cone
3 Banjo screws 15 Nut
4 Oil line 16 Oil return line
5 Pipe clamp half 17 Banjo screw
6 Grommet 18 Sealing ring
7 Hex screw 19 Adapter
8 Washer 20 Sealing ring
9 Threaded bush 21 Pipe clamp half
10 Sealing ring 22 Grommet
11 Sealing ring 23 Washer
12 Adapter 24 Hex screws

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Section 3.16.1
Page 2 Task Description

Oil line on turbocharger

1 Oil line 17 Oil line


2 T-piece 18 T-piece
3 Banjo screw 19 Bracket
4 Sealing ring 20 Clamp
5 Bracket 21 Hex screw
6 Clamp 22 Washer
7 Hex screw 23 Hex screw
8 Washer 24 Washer
9 Oil line 25 Oil line
10 Gasket 26 Gasket
11 Hex screw 27 Hex screw
12 Washer 28 Washer
13 Oil line 29 Bracket
14 Clamp 30 Clamp
15 Hex screw 31 Hex screw
16 Washer 32 Washer

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Section 3.16.1
Task Description Page 3

Oil line on oil filter

1 Hose line 2 Elbow

M020081/00E - 03.10 - EMTU


Section 3.16.1
Page 4 Task Description

Oil line on driving end

1 Oil line 14 Oil line


2 Sealing ring 15 Banjo screw
3 Banjo screw 16 Sealing ring
4 End cover 17 Union
5 Nut 18 Sealing cone
6 Bracket 19 Nut
7 Hex screws 20 Bracket
8 Washer 21 Hex screws
9 Grommet 22 Grommet
10 Pipe clamp halves 23 Pipe clamp halves
11 Pipe clamp halves 24 Washer
12 Washer 25 Hex screws
13 Hex screws

EMTU - 03.10 - M020081/00E


Section 3.16.1
Task Description Page 5

3.16.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

x - - Remove engine 2.3


x - - Perform operations as per Disassembly Plan 2.4
- - x Disable engine start Op. Man.
- - x Drain or draw off engine oil Op. Man.

M020081/00E - 03.10 - EMTU


Section 3.16.1
Page 6 Task Description

3.16.1.2 Removal
Before removing oil lines, it is advisable to photograph the engine from all sides or attach metal tags to the oil lines
so that they can be reinstalled in their original positions.
Remove oil pipework with gaskets and pipe clamp halves from the engine.
After removing oil lines, seal all connections with suitable plugs.
Protect thin-walled oil lines against damage.

3.16.1.4 Inspection and repair

CAUTION

When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for
use, safety instructions and waste disposal specifications.
Clean engine oil lines with cold cleaner.
Check condition of all lines and inspect for scuffing and damage, repair or remove hydraulically as required. Re-
condition damaged sealing surfaces and inspect for irregularities on an ink-check plate.
Check plug-in connections for wear; smooth wear or replace components as necessary.
Replace sealing cones and banjo unions that are damaged, indented or corroded.

CAUTION

Component is hot. Risk of injury! Handle components only when wearing protective gloves.
Realign badly fitting lines. Heat the lines red-hot with welding torch, tighten connections and unions.
Allow lines to cool slowly, do not cool with water.

WARNING

Hydrochloric acid is extremely caustic. Risk of injury and suffocation!


Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Ensure good ventilation at workplace.
Pickle lines in hydrochloric acid solution (9 parts water and 1 part hydrochloric acid).

WARNING

Compressed air is highly pressurized.


Risk of injury! The pressure must not exceed 3.0 bar.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
After pickling, wash the pipes in hot water, blow dry with compressed air,
Then immerse lines in an oil bath and allow to drip dry.
Check all hose lines and attaching hardware for damage and wear - replace parts if necessary.
Replace grommets as part of every W6 overhaul.
Replace O-rings.

EMTU - 03.10 - M020081/00E


Section 3.16.1
Task Description Page 7

3.16.1.6 Installation
Ensure that components are particularly clean.

WARNING

Compressed air is highly pressurized.


Risk of injury! The pressure must not exceed 3.0 bar.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Before installing, blow engine oil lines clear with compressed air.

Note: Do not remove blanking plug until just before installation.


Coat O-rings with petroleum jelly.
Install engine oil lines with new gaskets in accordance with photos, markings or overview drawing, ensuring they
are tension-free.

M020081/00E - 03.10 - EMTU


Section 3.16.1
Page 8 Task Description

EMTU - 03.10 - M020081/00E


Section 3.16.2
Task Description Page 1

3.16.2 Engine oil cooler

1 Engine oil cooler 7 O-ring


2 Gasket 8 O-ring
3 Socket-head screws 9 Hex screw
4 Hex screw 10 Socket-head screw
5 Washer 11 Hex screw
6 Intermediate plate

M020081/00E - 03.10 - EMTU


Section 3.16.2
Page 2 Task Description

Intermediate plate on oil cooler

1 Intermediate plate 6 Sealing rings


2 Adapter 7 Plug
3 Sealing ring 8 Sealing ring
4 Plug 9 Intermediate element
5 Plug

EMTU - 03.10 - M020081/00E


Section 3.16.2
Task Description Page 3

3.16.2.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Op. Man.
- - X Drain engine coolant Op. Man.
- X X Remove engine coolant lines and vent line from engine oil heat exchanger 3.14.1.2
- X X Remove elbow for oil supply to oil heat exchanger 3.16.1.2

M020081/00E - 03.10 - EMTU


Section 3.16.2
Page 4 Task Description

3.16.2.2 Removal
Removing engine cooler
WARNING
Heavy object.
Risk of injury!
Use suitable equipment and lifting gears.

Remove securing screws (9; 10 and 11).


Lift off intermediate plate.
Remove O-rings (7 and 8).
Remove screws (3 and 4).
Remove engine oil cooler (1).
Remove gasket.

3.16.2.3 Disassembly
Disassembling intermediate plate
See overview drawing: Intermediate plate on oil cooler

3.16.2.4 Inspection and repair


Check engine oil cooler for damage, replace if necessary.

Cleaning intermediate washer on coolant side


It is essential to examine extent of contamination of coolant chamber prior to cleaning.
If greasy scale deposits are found, coolant chamber must first be degreased.
Immerse intermediate washer in a cleaning bath containing a cleansing agent solution.

CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use,
safety instructions and waste disposal specifications.
Suitable cleaning chemicals are buffered alkaline agents such as a 3 to 5% solution of Henkel P3 FD.
The immersion period depends on the condition and temperature of the bath and on the type and degree of conta-
mination.
Prepare cleaning bath in accordance with manufacturer’s instructions.
To remove scale deposits, use a decalcifying agent which is not harmful to metal surfaces (e.g. P3 T288 manufac-
tured by Henkel or amidosulfonic acid Euron 1308 manufactured by Hoechst).
With extremely stubborn deposits, it may be necessary to use a hydrochloric acid solution. In this case, however,
the appropriate inhibited acid (e.g. Euron 1144 from Hoechst) must be used.
Cleaning process is completed when loosened contaminants can be flushed away with a powerful water jet.
After cleaning, system must be flushed with water until pH values of fresh water and flushing water are roughly
equal (permissible difference 1 pH).

EMTU - 03.10 - M020081/00E


Section 3.16.2
Task Description Page 5

Cleaning and flushing oil side of intermediate plate

Note: If the oil cooler is badly contaminated, e.g. in event of piston scuffing, damage to bearings or chippings
in engine oil system, the engine oil cooler must be replaced!
Connect oil side to sealed, forced-circulation flushing system.
The forced-circulation flushing system must be equipped with a filter (0.05 mm mesh).

Note: Cleaning solution must be pumped through oil cooler in direction opposite to normal oil flow, i.e. oppo-
site to direction of arrow on cooler.
Suitable descaling agents are buffered alkaline agents such as a 3 to 5% solution of P3 FD from Henkel.
It is essential to follow the manufacturer’s instructions when preparing the cleaning agent.
Cleaning can be improved by using ultrasonic equipment.
After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are roughly
equal (permissible difference 1pH).
This releases contaminants, particularly particles from wear parts, from swirl plates, so that they are flushed out
with water.
Continue cleaning process until flushing medium leaving cooler is same as that entering.

WARNING

Test fluid is highly pressurized. Risk of injury!


Liquids emerging under high pressure can lead to serious injury!
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Flushing pressure 3 to 4 bar at 150 to 300 litres/minute.
After this cleaning procedure, dry oil side with hot air to remove remaining flushing water from swirl plates and oil
ducts.
After drying, oil cooler must be rinsed with engine oil or Haku rinsing oil in order to preserve swirl plates.

Note: This preservation is not necessary if engine oil cooler is reinstalled on engine and put into operation im-
mediately after cleaning.
Insert protective caps in inlet and outlet bore and protect plate-type oil cooler against damage.

3.16.2.5 Assembly
Assembling intermediate plate
See overview drawing: Intermediate plate on oil cooler
Coat sealing rings with petroleum jelly before installing.

M020081/00E - 03.10 - EMTU


Section 3.16.2
Page 6 Task Description

Installing engine oil cooler and intermediate plate


Check that clean-oil-carrying channels of engine oil
cooler (1) and intermediate plate (6) are perfectly
clean.
Clean mating faces on engine oil cooler and engine.
Coat gasket (2) with petroleum jelly and fit on engine
oil cooler.
Insert screws (3; 4 and 5) and tighten.
Coat O-rings (7 and 8) with petroleum jelly and fit on
intermediate plate.
Fit intermediate plate on engine oil filter.
Insert screws (9; 10 and 11) and tighten.

EMTU - 03.10 - M020081/00E


Section 3.16.3
Task Description Page 1

3.16.3 Engine oil filter


Engine oil filter with filter bowl

1 Filter bowl 7 Plug


2 Gasket 8 Sealing ring
3 Screw 9 Filter element with gaskets
4 Screw 10 Sealing ring
5 Spring washer 11 Sealing ring
6 Oil filter bowl 12 Screw

M020081/00E - 03.10 - EMTU


Section 3.16.3
Page 2 Task Description

3.16.3.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Op. Man.

EMTU - 03.10 - M020081/00E


Section 3.16.3
Task Description Page 3

3.16.3.2 Removal
Remove oil filter
WARNING
Heavy object.
Risk of injury!
Use suitable equipment and lifting gears.

Remove securing screws (3 and 4).


Remove engine oil filter (1).
Remove gasket (2).

3.16.3.3 Disassembly
Disassemble engine oil filter.
Unscrew plug (5) and remove sealing ring (4).
Drain oil into oil filter bowls (1) via bores.
Remove screw (3) and remove sealing ring (2).
Remove oil filter bowl from filter bowl (7) and remove
sealing ring (6).

++

3.16.3.4 Inspection and repair


Inspecting filter bowl
Using the surface crack-testing method with red penetrant dye, check filter bowl for cracks; replace component if
cracks are found.
Check screw-down surfaces for irregularities and damage; rub down or replace as required.
Make sure oilways and oil-carrying parts are particularly clean, clean as required.
Replace sealing ring.
Check oil filter bowl for damage, replace if necessary.

M020081/00E - 03.10 - EMTU


Section 3.16.3
Page 4 Task Description

Cleaning/rinsing filter bowl


Suitable descaling agents are buffered alkaline agents such as a 3 to 5% solution of P3 FD from Henkel.
It is essential to follow the manufacturer’s instructions when preparing the cleaning agent.
Cleaning can be improved by using ultrasonic equipment.
After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are roughly
equal (permissible difference 1pH).
This releases contaminants, particularly particles from wear parts, from swirl plates, so that they are flushed out
with water.
Continue cleaning process until flushing medium leaving cooler is same as that entering.
After this cleaning procedure, dry hot air to remove remaining cleaning agent.

3.16.3.5 Assembly
Assembling engine oil filter
Check that clean-oil-carrying channels of filter bowl
(6) are perfectly clean.
Insert filter element in oil filter bowl (1).
Coat sealing ring (6) with petroleum jelly and insert
into filter bowl.
Fit oil filter bowl.
Coat screw (3) with engine oil.
Insert screw and sealing ring (2) into oil filter bowl.
Secure with torque wrench as per Tightening Specifi-
cations 1.4 on filter bowl (7).
Screw plug (5) with sealing ring (4) into oil filter bowl
and tighten.

3.16.3.6 Installation
Install engine oil filter
WARNING
Heavy object.
Risk of injury!
Use suitable equipment and lifting gears.

Coat gasket (2) with petroleum jelly and fit on engine


oil filter (1).
Fit engine oil filter.
Install securing screws (3 and 4) and tighten.

EMTU - 03.10 - M020081/00E


Section 3.18
Task Description Page 1

3.18 Starting system


Contents

3.18.1 Starter
3.18.1.1 Before-removal operations
3.18.1.2 Removal
3.18.1.4 Inspection and repair
3.18.1.6 Installation
3.18.1.7 After-installation operations

M020081/00E - 03.10 - EMTU


Section 3.18
Page 2 Task Description

The following tools are required in order to perform the operations described in this section:
Tools from the Tool Catalogue
M004018/20

EMTU - 03.10 - M020081/00E


Section 3.18.1
Task Description Page 1

3.18.1 Electric starter

1 Electric starter 4 Earth wire


2 Hex nut 5 Electrical wire
3 Spring washer

M020081/00E - 03.10 - EMTU


Section 3.18.1
Page 2 Task Description

3.18.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.

EMTU - 03.10 - M020081/00E


Section 3.18.1
Task Description Page 3

3.18.1.2 Removal

DANGER

Electric voltage.
Risk of serious or even fatal injury
- Before starting work, ensure that the engine is not energised. Secure against inadvertent switching on.

Disconnecting starter
Before disconnecting, mark all cables with adhesive
labels.
Disconnect all cables from starter.
Protect cables against damage.

Removing starter
Unscrew hex nut (3) and remove spring washer (2).
Remove starter (1).
Protect starter from damage.

3.18.1.4 Inspection and repair


Clean starter only with compressed air.
Check tooth flanks of pinion for wear, indentations and chipping; if necessary recondition or replace starter.
Check condition of nuts, check thread for ease of movement, replace if necessary.
Check condition of studs, check thread for ease of movement.
Check mating face on connecting housing for wear.

M020081/00E - 03.10 - EMTU


Section 3.18.1
Page 4 Task Description

3.18.1.6 Installation
Install starter
Coat starter pinion with long-life grease.
Place starter (1) on connecting housing.
Fit nuts (3) with spring washer (2).

Connecting electric starter


Connect lines as per marking on starter.
Check operation of starter.

EMTU - 03.10 - M020081/00E


Section 3.19
Task Description Page 1

3.19 Engine mounting


Contents

3.19.1 Engine mounting with carrier


3.19.1.1 Before-removal operations
3.19.1.2 Removal
3.19.1.3 Disassembly
3.19.1.4 Inspection and repair
3.19.1.5 Assembly
3.19.1.6 Installation

M020081/00E - 03.10 - E MTU


Section 3.19
Page 2 Task Description

The following is a list of tools needed for the assembly operations:


Tools from the tool catalogue
M004018/20

E MTU - 03.10 - M020081/00E


Section 3.19.1
Task Description Page 1

3.19.1 Engine mount with carrier


Engine mount, driving end/free end

1 Carrier, driving end 10 Washer


2 Hex screw 11 Hex screw
3 Hex screw 12 Hex screw
4 Washer 13 Hex screw
5 O-ring 14 Washer
6 Hex screw 15 O-ring
7 Carrier, driving end 16 Engine carrier, free end
8 Hex screw 17 Washer
9 Hex screw 18 Hex screw

M020081/00E - 03.10 - E MTU


Section 3.19.1
Page 2 Task Description

Rubber mounting

1 Rubber mount

E MTU - 03.10 - M020081/00E


Section 3.19.1
Task Description Page 3

3.19.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- - X Removal of engine mounting not scheduled -

M020081/00E - 03.10 - E MTU


Section 3.19.1
Page 4 Task Description

3.19.1.2 Removal
Removing free end carrier, right side of engine
Remove screws (3; 5; 7; 9; and 10) from carrier (8).
Remove washers (2; 4; 6; 11 and 12).
Remove carrier.
Remove O-ring (1).

Removing free end carrier, left side of engine


Remove screws (5 and 7) from carrier (1). Remove
washers (4 and 6).
Remove carrier (1).
Remove O-ring (2).

Removing carrier, free end, left/right engine side


Unscrew screws (2) from carrier (3).
Remove washers (1).
Remove carrier.

E MTU - 03.10 - M020081/00E


Section 3.19.1
Task Description Page 5

3.19.1.3 Disassembly
Removing rubber mounts
Example: carrier, free end
Remove nut (1) from carrier (3) and take off washers
(2).
Remove rubber mount.

3.19.1.4 Inspection and repair


Crack-test the carrier using the surface crack-testing method and red penetrant dye.
Replace relevant components if cracks are found.
Check mating faces on engine carrier and carrier for evenness, smooth with an oilstone if necessary.
Check threads on screw and nut for ease of movement, recut as necessary.

3.19.1.5 Assembly
Installing rubber mounts
Example: carrier, free end
Place rubber mount in position on carrier (3).
Screw on nut (1) with washers (2) and tighten.

M020081/00E - 03.10 - E MTU


Section 3.19.1
Page 6 Task Description

3.19.1.6 Installation
Installing free end carrier, right side of engine
Coat O-ring (1) with petroleum jelly and fit on carrier
(8).
Place carrier in position on gear case.
Insert screws (3; 5; 7; 9 and 10) with washers (2; 4;
6; 11 and 12) in carrier and tighten.

Installing free end carrier, left side of engine


Coat O-ring (2) with petroleum jelly and fit on carrier
(1).
Place carrier in position on gear case.
Insert screws (3; 5 and 7) with washers (4 and 6) in
carrier and tighten.

Installing carrier, free end, left/right engine side


Place carrier (3) in position on crankcase.
Insert screws (2) with washers (1) in carrier and
tighten.

E MTU - 03.10 - M020081/00E


Section 3.84
Task Description Page 1

3.84 Monitoring system


Contents

3.84.1 Sensor and transmitter


3.84.1.1 Before-removal operations
3.84.1.2 Removal
3.84.1.4 Inspection and repair
3.84.1.6 Installation

3.84.9 Wiring
3.84.9.1 Before-removal operations
3.84.9.2 Removal
3.84.9.4 Inspection and repair

3.84.11 Governor
3.84.11.1 Before-removal operations
3.84.11.2 Removal
3.84.11.4 Inspection and repair
3.84.11.6 Installation

M020081/00E - 03.10 - E MTU


Section 3.84
Page 2 Task Description

The following is a list of tools needed for the assembly operations:


Tools from the tool catalogue
M004018/20

E MTU - 03.10 - M020081/00E


Section 3.84.1
Task Description Page 1

3.84.1 Sensor and transmitter

P 005 004 b1

1 Pressure sensor 5 Sealing ring


2 Coolant level sensor 6 Temperature sensor PT 1000
3 Probe for oil or fuel 7 Temperature sensor NI1000
4 Sealing ring 8 Speed transmitter

M020081/00E - 03.10 - E MTU


Section 3.84.1
Page 2 Task Description

50700065a

1 Distributor plate 5 Sealing ring


2 Pressure sensor 6 O-ring
3 Plug 7 Nameplate
4 Transition element 8 Nameplate

E MTU - 03.10 - M020081/00E


Section 3.84.1
Task Description Page 3

3.84.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Drain engine coolant Oper. Instr.
- X X Drain engine oil Oper. Instr.

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Section 3.84.1
Page 4 Task Description

3.84.1.2 Removal
Remove sensor and transmitter.

3.84.1.3 Inspection and repair


Check sensor and transmitter for general condition; replace if necessary.

3.84.1.4 Installation
Install sensor and transmitter.

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Section 3.84.9
Task Description Page 1

3.84.9 Wiring

1 Wiring harness 7 Pressure sensor


2 Speed transmitter 8 Coolant level sensor
3 Temperature sensor NI 1000 9 -
4 Temperature sensor PT 1000 10 Probe for oil or fuel
5 -
6 Hose line

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Section 3.84.9
Page 2 Task Description

3.84.9.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.
- X X Switch off control voltage to engine -

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Section 3.84.9
Task Description Page 3

3.84.9.2 Removal

GEFAHR

Electrical voltage.
Risk of injury.
De-energise affected junction box prior to starting work.

Note: During such repair work, partial removal of the electrical equipment may be sufficient, depending on the
space available.
Make sketches or take photos to record wiring on engine.
Mark wiring to terminal boxes and disconnect or unplug.
Remove dust caps for sockets.
Release wiring on engine as much as necessary and protect from mechanical damage.
Note: Before disconnecting wiring from electrical equipment, check whether the wire and cable numbering is in
accordance with the MTU wiring diagram. Provide labels as necessary.
For equipment from which the connecting lines can be removed completely with the connecting housing, discon-
nect only the cables on the equipment and separate the connecting line with connecting housings from the equip-
ment.
Otherwise, proceed as follows:
- Disconnect conductors.
- Carefully cut open and remove thermofil moulded part.
- Remove thrust screw from cable gland
- Withdrawe line from cable gland
- Secure inserts on cable gland on line or
- Reinstall inserts in cable glands.
- Tighten terminals and seal connection chamber
For further removal procedure, see MTU Elektronik Documentation.
Release lines and wiring harness from engine, leave wiring harness tied as far as possible.
It may be necessary to remove some pipes beforehand.
Remove securing screws from terminal box.
Remove terminal box with wiring harness from engine and store in a safe place, protected from oil and dirt.
Mark securing material of electrical installation and store separately from other securing material.

3.84.9.4 Inspection and repair


Clean all components.
Check wires and terminals for damage.
Check plug-in contacts for burning and wear through vibration damage.
Check resilience of gasket in terminal box.
Visually check rubber elements for terminal box mounting for cracks and, deformation; replace components if dam-
aged.
Check condition of securing plates and base plates, replace if necessary.
Using the surface crack-testing method with red penetrant dye, check securing plates and base plates for cracks;
replace components if cracks are found.
Check and repair terminal boxes as per MTU Elektronik Documentation.

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Section 3.84.9
Page 4 Task Description

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Section 3.84.11
Task Description Page 1

3.84.11 Governor

1 Bracket 12 Hex screw 23 Hex screw


2 Hex screw 13 Shock damping metal 24 Washer
3 Washer 14 Hex screw 25 Socket-head screw
4 Bracket 15 Washer 26 Socket-head screw
5 Hex screw 16 Hex screw 27 Spacer sleeve
6 Washer 17 Hex screw 28 Socket-head screw
7 Hex screw 18 Washer 29 Spacer sleeve
8 Bracket 19 Shock damping metal 30 Washer
9 Bracket 20 Hex screw 31 Spacer sleeve
10 Hex screw 21 Washer 32 Socket-head screw
11 Washer 22 Shock damping metal 33 Washer

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Section 3.84.1
Page 2 Task Description

3.84.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations see

X - - Remove engine 2.3


X - - Perform operations as per Disassembly Plan 2.4
- - X Disable engine start Oper. Instr.

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Section 3.84.11
Task Description Page 3

3.84.1.2 Removal
For securing screws for governor, see overview drawing

3.84.1.4 Inspection and repair


Check governor for external damage.

3.84.1.6 Installation
Install in reverse sequence as shown in overview drawing.

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Section 3.84.1
Page 4 Task Description

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Section 3.86
Task Description Page 1

3.86 Accessories
Contents

3.86.1 Three-phase alternator


3.86.1.1 Before-removal operations
3.86.1.2 Removal
3.86.1.4 Inspection and repair
3.86.1.6 Installation

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Section 3.86
Page 2 Task Description

The following is a list of tools needed to carry out the work:


Tools from the tool catalogue
M004018/20

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Section 3.86.7
Task Description Page 1

3.86.1 Three-phase alternator


Attachments on engine

1 Bracket 4 Three-phase alternator


2 Washer 5 Washer
3 Nut 6 Hex nut

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Section 3.86.7
Page 2 Task Description

Three-phase alternator attachments

1 Alternator 7 Hex nut


2 Adjusting shim 8 Washer
3 Belt pulley 9 Hex nut
4 Washer 10 Grommet
5 Hex nut 11 Protective cap
6 Washer

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Section 3.86.7
Task Description Page 3

3.86.1.1 Before-removal operations


A distinction must be made as to whether:
1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Tasks See

x - - Remove engine 2.3


x - - Perform operations as per Disassembly Plan 2.4
- - x Disable engine start Op. Man.
- - x Disconnect electrical wires -

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Section 3.86.7
Page 4 Task Description

3.86.1.2 Removal
Removing clamping device.
Remove nut (2).
Remove V-belt (1).
Remove nut (8).
Remove bush (4), threaded bush (5) and washer (7).
Remove hex screws (12 and 16) and take off
threaded pin (3).
Remove clamping element (14), clamping nut (13)
and ball joint (10).

Removing three-phase alternator


Remove three-phase alternator as shown in overview drawing (installation).

3.86.1.4 Inspection and repair


Clean all components.
Crack-test the bracket using the surface crack-testing method and red penetrant dye.
If cracks are detected, replace parts.
Remove minor wear, indentation and scoring with emery cloth or oilstone, replace components as necessary.
Check threads of screws, nuts and threaded pins for ease of movement.
Test and repair three-phase alternator, see special publication.

3.86.1.6 Installation
Installing clamping device.
Install clamping device in reverse order.

Installing three-phase alternator


Install three-phase alternator as shown in overview drawing (installation).

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