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Technical Publication

Diesel Engine
8/12/16V 4000 M

Tolerances and
Wear Limits List
M070036/00E

DaimlerChrysler Off-Highway
Printed in Germany
E 2002 Copyright MTU Friedrichshafen GmbH
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Printed in Germany
E 2002 Copyright MTU Friedrichshafen GmbH
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Subject to alterations and amendments.

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Modifications réservées.

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Contents Page 1

Contents

General Information

010 Crankcase

020 Gear train

030 Running gear

040 Cylinder head

050 Valve gear

200 Coolant system

300 Accessories

Preliminary Note

Data Sheets

M070036/00E 02-07 © MTU


Page 2 Contents

General Information

The tolerances and wear limits indicated in this publication are intended as a guide for the examination of engine components
during inspection and repair.

Explanation of terms for dimensions of new components


H6
Tol. size Designed size followed by a letter/number symbol (e.g. 24 ) or by the permissible dimensional
+0.013
deviation (e.g. 24 )
Basic size Designed size without fit symbol or quotation of dimensional deviation
Deviation Permissible deviation from the basic or toleranced size,
indicated by the upper and lower limits
Clearance Difference between bore and shaft diameters
when bore diameter is greater than shaft diameter
Interference Difference between bore and shaft diameters
when bore diameter is smaller than shaft diameter

Explanation of terms for reconditioning and operational limits


Wear limit The limit dimensions specified do not represent the absolute maximum values permissible for
satisfactory engine operation.
They indicate that the next basic overhaul can be reached safely.
If a limit value is exceeded, the component must be replaced.
Reconditioning If values exceed or drop below limit values, the components must be reconditioned in
instructions accordance with the relevant reconditioning instructions or replaced.

Deviations from roundness, cylindricity, parallelism and coaxiality must be within specified limit values, unless exceptions are
specifically indicated.
All dimensions are given in "mm", unless alternative units of measurement are specifically indicated.

M070036/00E 99-11 © MTU


Crankcase Group 010
Page 1

Cylinder Liner

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H7
1 Housing bore 0 196.000 0 + 0.046 0.059 0.16
H7
- upper fit 1 196.500
Cylinder liner 0 196.000 j6 - 0.013 + 0.016
- upper fit 1 196.500 j6
H7
2 Housing bore 0 189.000 0 + 0.046 0.050 0.125
H7
- lower fit 1 189.500
Cylinder liner 0 189.000 f6 - 0.079 - 0.050
- lower fit 1 189.500 f6
H7
3 Bush bore 170.000 0 + 0.040 0.014 0.94
Scraper ring 170.000 g7 - 0.054 - 0.014
OD
H8
4 Scraper ring bore 164.000 0 + 0.063
H7
5 Bush bore 165.000 0 + 0.040
- installed
6 Marking for stage

Reconditioning instructions:
Re 1 and 2: In event of cavitation at upper and/or lower fit of crankcase bore:
Introduce next repair stage and install cylinder liner of corresponding stage
Re 3 and 4: Check scraper ring OD and ID when fitted
Re 6: Stamp markings with 6 mm high numeral punches
- at stage 1 + 0.5

M070036/00E 99-11 © MTU


Group 010 Crankcase
Page 2

Crankshaft Bearing Cap

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
E9
1 Bearing cap bed 298.000 + 0.110 + 0.240 0.022 0.184
Bearing cap width 298.000 p6 + 0.056 + 0.088
H7
2 Bearing cap bed 298.000 0 + 0.052 0.004 0.088
Bearing cap width 298.000 p6 + 0.056 + 0.088
3 Screw length 348.000 - 0.500 + 0.500

Note:
Re 1: Install bearing cap as specified and tighten screws as per tightening specification.

M070036/00E 99-11 © MTU


Crankcase Group 010
Page 3

Crankshaft Bearing Bore

Insert crankshaft bearing cap in crankcase as per installation instructions and tighten screws as per tightening specification.
Measure main bearing bores:
- Determine diameters a, b1 and b2 each in 2 measuring planes and from the results determine the mean values of a, b1 and
b2.
- Check roundness of bores:
Possible deviations from roundness result from the mean values of a, b1 and b2
in accordance with the equation 0.5 (b1+b2)-a
Vertical ovality - a greater than 0.5 (b1+b2) - is not permissible.

M070036/00E 99-11 © MTU


Group 010 Crankcase
Page 4

Coaxiality of Crankcase Bores for Crankshaft Bearings

Max. permissible deviation from coaxiality New condition Wear limit


a in each case, adjacent left and right bearings dia. 0.040 dia. 0.050
b 8 V from crankshaft bearing 1 to 5 dia. 0.060 dia. 0.100
c 12 V from crankshaft bearing 1 to 7 dia. 0.080 dia. 0.120
d 16 V from main bearing 1 to 9 dia. 0.120 dia. 0.140
e applicable for all bearings ^ 0.100 ^ 0.120
f applicable for all bearings O 0.010 O 0.015
g applicable for all bearings, not concave - 0.010 - 0.012
h applicable for all bearings // 0.015 // 0.018

M070036/00E 99-11 © MTU


Crankcase Group 010
Page 5

Coaxiality of Crankcase Bores for Camshaft Bearings

Max. permissible deviation from coaxiality New condition Wear limit


a in each case, adjacent left and right bearings dia. 0.040 dia. 0.050
b 8 V from camshaft bearing 1 to 5 dia. 0.060 dia. 0.100
c 12 V from camshaft bearing 1 to 7 dia. 0.080 dia. 0.120
d 16 V from camshaft bearing 1 to 9 dia. 0.120 dia. 0.140

M070036/00E 99-11 © MTU


Group 01 Crankcase
Page 6

M070036/00E 99-11 © MTU


Gear Train Group 020
Page 1

Idler Gear, Free End

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H7
1 Equipment carrier 81.000 0 + 0.035 0 0.070 Clearance
bore max. 0.080
Axle OD 81.000 h7 - 0.035 0
H7
2 Gear bore 80.000 0 + 0.030 0.029 0.078
Bush OD 80.000 s6 + 0.059 + 0.078
3 Bush bore
H8
- installed 75.000 0 + 0.046 0.060 0.136
E6
- removed 75.000 + 0.060 + 0.079
Axle OD 75.000 e7 - 0.090 - 0.060
P7
4 Equipment carrier 75.000 - 0.051 - 0.021 0.009 0.069 Clearance
bore max. 0.080
Axle OD 75.000 e7 - 0.090 - 0.060
5 Equipment carrier 41.200 0 + 0.200 0.050 0.800 Clearance
width max.
Gear width 40.700 - 0.100 0 0.090
6 Crankcase

Note:
Re 5: Measure equipment carrier width when it is free of tension.

M070036/00E 99-11 © MTU


Group 020 Gear Train
Page 2

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 1

Crankshaft Bearing Arrangement, Free End

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H6
1 Equipment carrier 193.000 0 + 0.029 0.175 0.233 Interference
bore min. 0.150
Bearing OD 193.204 0 + 0.029
- not installed
2 Bearing bush bore 180.121 0 + 0.069 0.321 0.430 Clearance
max. 0.450
- bearing fitted
Driver flange OD 179.800 h7 - 0.040 0
- not press-fitted

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 2

Crankshaft Seal, Free End

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H7
1 Inner star bore 198.000 0 + 0.046 0.059 0.016
Driver flange OD 198.000 j6 - 0.013 + 0.016
- not press-fitted
H8
2 Seal carrier bore 230.000 0 + 0.072 0.278 0.590
Shaft seal OD 230.470 - 0.120 + 0.120
3 Running surface 199.800 h9 - 0.115 0
OD
4 Radial-lip oil seal fitted flush

Reconditioning instructions:
Re 3: Running surface worn: Metal-spray running surface and grind using feed-in method

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 3

Crankshaft Bearing Arrangement, Alignment Bearing

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H6
1 Housing bore 0-0 171.000 0 + 0.025 171.035
H6
0-1 171.000 Transverse
0-2 171.000
H6 ovality
0-3 171.000
H6 max. 0.050
H6
1-0 171.500 0 + 0.025
1-1 171.500
H6 171.535
1-2 171.500
H6 Transverse
H6 ovality
1-3 171.500
max. 0.050
2 Alignment bearing 0-0 160.120 0 + 0.054 0.120 0.199 Transverse
diameter 0-1 159.620 ovality max.
- installed 0.050
0-2 159.120
0-3 158.620
1-0 160.120 0 + 0.054
1-1 159.620
1-2 159.120
1-3 158.620
Main bearing 0-0 160.000 h6 - 0.025 0 159.970
journal 0-1 159.500 h6 159.470
OD
0-2 159.000 h6 158.970
0-3 158.500 h6 158.470
1-0 160.000 h6 - 0.025 0 159.970
1-1 159.500 h6 159.470
1-2 159.000 h6 158.970
1-3 158.500 h6 158.470

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 4

Crankshaft Mounting, Alignment Bearing Spreading Dimension

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Alignment bearing, upper half
2 Alignment bearing, lower half
3 Spreading dimension 0 - 0 171.200 0 + 0.500
- Alignment 0 - 1 171.200
bearing, upper 0 - 2 171.200
and lower halves 0 - 3 171.200
1 - 0 171.700 0 + 0.500
1 - 1 171.700
1 - 2 171.700
1 - 3 171.700

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 5

Crankshaft Bearing Arrangement

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H6
1 Housing bore 0-0 171.000 0 + 0.025 171.035
H6
0-1 171.000 Transverse
0-2 171.000
H6 ovality
0-3 171.000
H6 max. 0.050
H6
1-0 171.500 0 + 0.025
1-1 171.500
H6 171.535
1-2 171.500
H6 Transverse
H6 ovality max.
1-3 171.500 0.050
2 Crankshaft bearing 0 - 0 160.120 0 + 0.054 0.120 0.199 Transverse
diameter 0-1 159.620 ovality max.
- installed 0.050
0-2 159.120
0-3 158.620
1-0 160.120 0 + 0.054
1-1 159.620
1-2 159.120
1-3 158.620
Main bearing 0-0 160.000 h6 - 0.025 0 159.970
journal dia. 0-1 159.500 h6 159.470
0-2 159.000 h6 158.970
0-3 158.500 h6 158.470
1-0 160.000 h6 - 0.025 0 159.970
1-1 159.500 h6 159.470
1-2 159.000 h6 158.970
1-3 158.500 h6 158.470

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 6

Crankshaft Bearing Arrangement

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Main bearing, upper half
2 Main bearing, lower half
3 Spreading 0-0 171.400 0 + 1.000
dimension 0-1 171.400
- Main bearing, 0-2 171.400
upper and lower 0 - 3 171.400
halves
1-0 171.900 0 + 1.000
1-1 171.900
1-2 171.900
1-3 171.900

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 7

Axial Clearance - Crankshaft

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Axial clearance 0.200 0.600 Clearance
- crankshaft min. 0.100
max. 0.700
2 Drive flange 156.000 - 0.010 + 0.010
- press-fitted

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 8

Crankshaft Mounting, Driving End

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H6
1 Flywheel housing 223.000 0 + 0.029 0.234 0.292
bore
Bearing OD 223.263 0 + 0.029
- removed
2 Bearing bush bore 210.142 0 + 0.069 0.157 0.272
- bearing fitted
Hub OD 210.000 g7 - 0.061 - 0.015

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 9

Crankshaft Seal, Driving End

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H8
1 Flywheel housing 240.000 0 + 0.072 0.278 0.590
bore
Radial-lip oil seal 240.470 -0.120 + 0.120
OD
2 Running surface 210.000 h11 - 0.290 0
OD
3 Radial-lip oil seal fitted flush

Reconditioning instructions:
Re 2: Running surface worn: Metal-spray running surface and grind using feed-in method.

M070036/00E 02-07 © MTU


Group 030 Running Gear
Page 10

Crankshaft Bearing Shells

Install bearing shells and tighten bearing cap according to tightening specifications.
Measure crankshaft bearing bores:
- Determine diameters, a, b1 and b2 in measuring planes 1 and 2 and in each case calculate mean values of a, b1 and b2.
- Check roundness of bores:
Possible deviations from roundness result from the mean values of a, b1 and b2 in accordance with the equation 0.5
(b1+b2) -a
Replace bearing shells
- If deviation from roundness > 0.040
- If b1 to b2 greater than / less than 0.040
- With vertical ovality - a > 0.5 (b1+b2) - is not permissible.

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 11

Counterweight Fixture

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Screw length 130.000 - 0.400 0 max. length
- removed 132.000

Reconditioning instructions:
Re 1: If wear limit has been exceeded: replace screw

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 12

Crankshaft Gear, Free End

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Gear press-fitted 145.500 - 0.300 + 0.300
- Crankshaft end
to gear face

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 13

Crankshaft, Coaxiality of Main Bearing Journal 8 V 4000

Max. permissible deviation from coaxiality New condition Wear limit


From main bearing journal 1 to main bearing journal 5 Ú 0.100
From main bearing journal to main bearing journal Ú 0.050

Note:
The crankshaft must be supported in main bearings 1 and 5.

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 14

Crankshaft, Coaxiality of Main Bearing Journal 12 V 4000

Max. permissible deviation from coaxiality New condition Wear limit


From main bearing journal 1 to main bearing journal 7 Ú 0.100
From main bearing journal to main bearing journal Ú 0.050

Note:
The crankshaft must be supported in main bearings 2 and 6.

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 15

Crankshaft, Concentricity of Main Bearing Journal 16 V 4000

Max. permissible deviation from coaxiality New condition Wear limit


From main bearing journal 1 to main bearing journal 9 Ú 0.100
From main bearing journal to main bearing journal Ú 0.050

Note:
The crankshaft must be supported in main bearings 2 and 8.

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 16

Crankshaft, Dynamic Balancing 8 V 4000

Balancing specification New condition Wear limit


Max. operating speed: 2100 rpm
Mass of balancing group: 463 kg
The crankshaft must be supported in main bearings 1 and 5.
Balancing speed: 150 rpm
Permissible residual imbalance for each balancing plane during initial balancing: 135 gcm
Permissible residual imbalance for each balancing plane for comparable balancing 400 gcm
in other clamping or balancing machinery

Reconditioning instructions:
It will only be necessary to rebalance the crankshaft if the counterweights have been replaced.
If a crankshaft has been reworked to the next repair stage, rebalancing will not be necessary provided that the counterweights
have not been replaced.
Mark the counterweights and reassemble them according to marking.

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 17

Crankshaft, Dynamic Balancing 12 V 4000

Balancing specification New condition Wear limit


Max. operating speed: 2100 rpm
Mass of balancing group: 525 kg
The crankshaft must be supported in main bearings 2 and 6.
Balancing speed: 150 rpm
Permissible residual imbalance for each balancing plane during initial balancing: 200 gcm
Permissible residual imbalance for each balancing plane for comparable balancing 600 gcm
in other clamping or balancing machinery

Reconditioning instructions:
It will only be necessary to rebalance the crankshaft if the counterweights have been replaced.
If a crankshaft has been reworked to the next repair stage, rebalancing will not be necessary provided that the counterweights
have not been replaced.
Mark the counterweights and reassemble them according to marking.

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 18

Crankshaft, Dynamic Balancing 16 V 4000

Balancing specification New condition Wear limit


Max. operating speed: 2100 rpm
Mass of balancing group: 775 kg
The crankshaft must be supported in main bearings 2 and 8.
Balancing speed: 150 rpm
Permissible residual imbalance for each balancing plane during initial balancing: 200 gcm
Permissible residual imbalance for each balancing plane for comparable balancing 600 gcm
in other clamping or balancing machinery

Reconditioning instructions:
It will only be necessary to rebalance the crankshaft if the counterweights have been replaced.
If a crankshaft has been reworked to the next repair stage, rebalancing will not be necessary provided that the counterweights
have not been replaced.
Mark the counterweights and reassemble them according to marking.

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 19

Conrod Bearing

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H6
1 Conrod bore 126.000 0 + 0.025
2 Conrod bearing 0-0 117.082 0 + 0.048 0.082 0.152
bore 0-1 116.882
- Conrod bearing 0-2 116.682
installed
0-3 116.482
Crankpin journal 0-0 117.000 h6 - 0.022 0
dia. 0-1 116.800 h6
0-2 116.600 h6
0-3 116.400 h6
3 Crankpin length 97.500 - 0.100 + 0.100 0.200 0.600
Conrod width 48.600 - 0.100 0
4 Spreading 0-0 126.400 0 + 1.000
dimension 0-1 126.400
- Conrod bearing 0-2 126.400
shell, upper and
lower halves 0-3 126.400

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 20

Conrod Bearing, Locating Pin

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H7
1 Locating pin bore 7.000 0 + 0.015 0.004 0.028
Locating pin OD 7.000 r6 + 0.019 + 0.028

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 21

Conrod Bearing Bore

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Screw length 103.000 - 0.400 + 0.200 104.500
- removed

Note:
Tighten conrod - conrod cap as per tightening specifications.
Conrod bearing - measure bearing bore in a, b and c. Min. dimension must be in direction a.

Re 1: If wear limit has been exceeded: replace screw

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 22

Conrod Bearing Shells

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Screw length 103.000 - 0.400 + 0.200 104.500
- removed

Note:
Tighten conrod bearing - conrod - conrod cap as per tightening specifications.
Conrod bearing - measure bearing bore in a, b and c. Min. dimension must be in direction a.

Re 1: If wear limit has been exceeded: replace screw

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 23

Parallellity of Conrod Bores

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Conrod length 354.000 - 0.100 + 0.100
- with bush and
without bearing
shells
Conrod length 354.000 - 0.100 + 0.100
- without bush and
without bearing
shells
2 Parallellity of axles 0.070 measured at 100 mm distance Inclination
max. 0.100
- Inclination
3 Parallellity of axles 0.250 measured at 100 mm distance Twist max.
0.350
- twist
Conrod weight 9.530 kg - 0.060 kg + 0.060 kg

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 24

Piston Bearing

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H6
1 Conrod bore 0 75.000 0 + 0.019 0.101 0.139 Axial test
1 75.200
H6 load for
H6 bush
2 75.400 installed
Bush OD 0 75.000 v6 + 0.120 + 0.139 min.
1 75.200 v6 17000 N
2 75.400 v6
2 Bush ID 68.000 + 0.070 + 0.080 0.070 0.085 Clearance
- finished- max. 0.090
machined
Piston pin OD 68.000 - 0.005 0
3 Bush ID 68.000 + 0.008 + 0.018 0.008 0.023 Clearance
- finished- max. 0.025
machined
Piston pin OD 68.000 - 0.005 0
4 MTU part number and stage stamped on

Reconditioning instructions:
Re 1: Bush loose at 17000 N test load: replace bush and introduce next repair stage if necessary.

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 25

Piston Rings

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Groove width 4.000 + 0.170 + 0.190 0.170 0.225 Clearance
Rectangular-section ring 4.000 - 0.035 0 max. 0.300
2 Groove width 4.000 + 0.080 + 0.100 0.080 0.135 Clearance
Rectangular-section ring 4.000 - 0.035 0 max. 0.200
3 Groove width 5.000 + 0.080 + 0.100 0.080 0.135 Clearance
Oil control ring 5.000 - 0.035 0 max. 0.200
4 Ring end clearance Max. play:
Rectangular-section ring 0.400 0.700 0.900
Rectangular-section ring 1.000 1.300 1.500
Oil control ring 0.450 0.800 1.000

Note:
H6
Re 4: Measure ring end clearance in ring gauge 165.0

M070036/00E 02-07 © MTU


Group 030 Running Gear
Page 26

Piston Clearance in Cylinder Liner

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H7
1 Cylinder liner bore 165.000 0 + 0.040 0.184 0.246
Piston skirt OD 164.805 - 0.011 + 0.011
H7
2 Cylinder liner bore 165.000 0 + 0.040 0.270 0.330
Piston skirt OD 164.720 - 0.010 + 0.010
H7
3 Cylinder liner bore 165.000 0 + 0.040 0.400 0.840
Piston crown OD 164.580 - 0.020 + 0.020
H7
4 Cylinder liner bore 165.000 0 + 0.040 0.315 0.355
Piston crown OD 164.665 - 0.020 + 0.020
H8
5 Scraper ring bore 164.000 0 + 0.063 0.585 0.698
Piston crown OD 163.390 - 0.025 + 0.025
H8
6 Scraper ring bore 164.000 0 + 0.063 0.720 0.833
Piston crown OD 163.255 - 0.025 + 0.025
7 Piston skirt, crowned-oval

Reconditioning instructions:
Re 1 to 5: Measure piston crown dia. and piston skirt dia. vertically to piston pin axis

M070036/00E 99-11 © MTU


Running Gear Group 030
Page 27

Piston Crown Fixture

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Screw length 49.000 - 0.100 + 0.100 max. length
- removed 49.800

Note:
Re 1: If wear limit has been exceeded: replace screw

M070036/00E 99-11 © MTU


Group 030 Running Gear
Page 28

M070036/00E 99-11 © MTU


Cylinder Head Group 040
Page 1

Valve Guides, Inlet, Exhaust

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H7
1 Cylinder head bore 19.000 0 + 0.021 0.007 0.041
Valve guide OD 19.000 r6 + 0.028 + 0.041
H7
2 Valve guide bore 11.000 0 + 0.018 0.055 0.093
- installed
Valve stem dia. 10.935 - 0.010 + 0.010
Note:
Re 2: Finish-machine valve guide bore after pressing into cylinder head.
Pushing slightly, it must be possible to insert the go-end of the plug gauge on the valve guide length.
The no-go-end of the plug gauge must not make contact
Max. clearance exceeded: Install manufactured valve guide.

Manufactured valve guide for repair version


No. Designation Stage Tol. Size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H7
1 Cylinder head bore 0 19.000 0 + 0.021 0.007 0.041
H7
1 19.100
H7
2 19.300
Valve guide OD 0 19.000 r6 + 0.028 + 0.041
1 19.100 r6
2 19.300 r6
H9
2 Valve guide bore 11.000 0 + 0.043 0.055 0.108
- installed
Valve stem dia. 10.935 - 0.010 + 0.100
Reconditioning instructions:
Re 1: Cylinder head bore max. dimension exceeded: Ream to next stage
Re 2: Max. clearance exceeded: Install new manufactured valve guide
Pushing slightly, it must be possible to insert the go-end of the plug gauge on the valve guide length.
No-go side plug gauge contact max. 5 mm

M070036/00E 99-11 © MTU


Group 040 Cylinder Head
Page 2

Valve Clearance

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Valve clearance 0.400 max. 2.400
- Exhaust
2 Valve clearance 0.500 max. 2.500
- Inlet

M070036/00E 99-11 © MTU


Cylinder Head Group 040
Page 3

Valve Seats, Exhaust

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Plug gauge 73.200 0 0
diameter
2 Valve seat surface
Check dimension 4.800 - 0.100 + 0.100 min. 2.300
- Plug gauge
3 Cylinder head 13.800 0 + 0.100
depth
- Combustion
chambers sealing
ring surface

Reconditioning instructions:
Re 2: Recondition valve seat surface only until good support is achieved.

M070036/00E 99-11 © MTU


Group 040 Cylinder Head
Page 4

Valve Seats, Inlet

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Plug gauge 87.130 0 0
diameter
2 Valve seat surface
Check dimension 4.800 - 0.100 + 0.100 min. 2.300
- Plug gauge
3 Cylinder head 13.800 0 + 0.100
depth
- Combustion
chambers sealing
ring surface

Reconditioning instructions:
Re 2: Recondition valve seat surface only until good support is achieved.

M070036/00E 99-11 © MTU


Cylinder Head Group 040
Page 5

Exhaust Valve

No. Designation Stage Tol. Size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Valve head OD 56.000 - 0.200 + 0.200
2 Check dimension
- with ring gauge
- Valve seat dia. 54.000
- Valve seat height 4.180 - 0.200 + 0.100 min. 3.480
3 Check dimension
- without ring
gauge 3.200 - 0.200 + 0.100 min. 2.500
- Valve seat height

Reconditioning instructions:
Re 2 and 3: Recondition valve seat height only until good support is achieved.

M070036/00E 99-11 © MTU


Group 040 Cylinder Head
Page 6

Inlet Valve

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Valve head OD 57.000 - 0.200 + 0.200
2 Check dimension
- with ring gauge
- Valve seat dia. 54.000
- Valve seat height 4.050 - 0.200 + 0.100 min. 3.350
3 Check dimension
- without ring
gauge 3.200 - 0.200 + 0.100 min. 2.500
- Valve seat height

Reconditioning instructions:
Re 2 and 3: Recondition valve seat height only until good support is achieved.

M070036/00E 99-11 © MTU


Cylinder Head Group 040
Page 7

Outer Valve Springs

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Spring length 83.900
- Unloaded
2 Spring length 66.000
- Loaded
2.1 Spring force with 530.000 N
spring length 66.00
3 Spring length 51.750
- Loaded
3.1 Spring force with 952.000 N - 39 N + 39 N Spring
spring length 51.75 power min.
897.000 N
4 Spring length 47.700 Block
- Block dimension dimension
max.
47.700
5 Coil dia. 34.400
6 Wire dia. 5.300
e1 Permissible deviation of surface line from vertical with unloaded spring max. 2.500
e2 Spring support permissible deviation from parallelism max 0.600

M070036/00E 99-11 © MTU


Group 040 Cylinder Head
Page 8

Inner Valve Springs

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Spring length 78.400
- Unloaded
2 Spring length 61.000
- Loaded
2.1 Spring force with 256.000 N
spring length 61.00
3 Spring length 46.750
- Loaded
3.1 Spring force with 466.000 N - 19 N + 19 N Spring
spring length 46.75 power min.
420.000 N
4 Spring length 42.500 Block
- Block dimension dimension
max.
42.500
5 Coil dia. 23.000
6 Wire dia. 3.600
e1 Permissible deviation of surface line from vertical with unloaded spring max. 2.300
e2 Spring support permissible deviation from parallelism max 0.400

M070036/00E 99-11 © MTU


Cylinder Head Group 040
Page 9

Cylinder Head - Mating Face - Protective Sleeve - Valve Bridge

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Cylinder head 184.000 - 0.100 + 0.100
height
2 Protective sleeve 124.000 0 + 0.200
support
3 Protective sleeve 44.200 0 + 0.100 0.100 0.300
bore
Protective sleeve 44.100 - 0.100 0
OD
4 Cylinder head M 24x1.5
thread
Protective sleeve M 24x1.5
thread
N7
5 Cylinder head bore 14.000 - 0.023 - 0.005 0.012 0.041
Sliding pin dia. 14.000m6 + 0.007 + 0.018
D7
6 Valve bridge bore 14.000 + 0.050 + 0.068 0.032 0.061
Sliding pin dia. 14.000m6 + 0.007 + 0.018

M070036/00E 99-11 © MTU


Group 040 Cylinder Head
Page 10

M070036/00E 99-11 © MTU


Valve Gear Group 050
Page 1

Camshaft, Coaxiality of Bearings

Max. permissible deviation from coaxiality New condition Wear limit


from bearing 1 to bearing 2 Ú 0.050
a from bearing to bearing Ú 0.025
b all cams and bearings // 0.010
__ 0.010

M070036/00E 99-11 © MTU


Group 050 Valve Gear
Page 2

Camshaft Bearing

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H6
1 Housing bore 0-0 97.000 0 + 0.022 0.058 0.130
H6
1-0 97.500
Bush OD 0-0 97.080 0 + 0.050
- not installed 1-0 97.580
2 Bush bore 92.012 0 + 0.052 0.084 0,171
- installed
Camshaft OD 92.000 e7 - 0.107 - 0.072
a in each case, adjacent left and right bearings
b from camshaft bearing 1 to 2

M070036/00E 99-11 © MTU


Valve Gear Group 050
Page 3

Axial Clearance - Camshaft

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H7
1 Gear bore 32.000 0 + 0.025 0 0.050
Camshaft OD 32.000 h7 - 0.025 0
2 Axial clearance 0.100 0.178
- Camshaft

M070036/00E 99-11 © MTU


Group 050 Valve Gear
Page 4

Rocker Arm Bearing, Inlet and Exhaust

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H7
1 Rocker arm bore 50.000 0 + 0.025 0.018 0.059
Bush OD 50.000 s6 + 0.043 + 0.059
2 Bush bore Clearance
- installed 45.000 0 + 0.050 0.025 0.091 max. 0.100
E6
- not installed 45.000 + 0.050 + 0.066
Rocker shaft OD 45.000 f6 - 0.041 - 0.025
U7
3 Bearing pedestal 45.000 - 0.086 - 0.061 0.020 0.061
bore
Rocker shaft OD 45.000 f6 - 0.041 - 0.025

M070036/00E 02-07 © MTU


Valve Gear Group 050
Page 5

Rocker Arm Bearing, Inlet and Exhaust

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H7
1 Rocker arm bore 36.000 0 + 0.025 0.018 0.059
Bush OD 36.000 s6 + 0.043 + 0.059
2 Bush bore Clearance
- installed 32.000 0 + 0.050 0.025 0.091 max. 0.100
E6
- not installed 32.000 + 0.050 + 0.066
Shaft OD 32.000 f6 - 0.041 - 0.025
E7
3 Roller bore 21.000 + 0.040 + 0.061 0.040 0.082 Clearance
Bush OD 21.000 h7 - 0.021 0 max. 0.090
E7
4 Bush bore 14.000 + 0.032 + 0.050 0.032 0.058 Clearance
Pin OD 14.000 h5 - 0.008 0 max. 0.065
P6
5 Rocker arm bore 14.000 - 0.026 - 0.015 0.007 0.026
Pin OD 14.000 h5 - 0.008 0

M070036/00E 99-11 © MTU


Group 050 Valve Gear
Page 6

M070036/00E 99-11 © MTU


Coolant System Group 200
Page 1

Engine Coolant Pump for H.P. Temperature System

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
K7
1 Seal carrier bore 90.000 - 0.025 + 0.010 0.025 0.025
Bearing OD 90.000 - 0.015 0
K7
2 Housing bore 90.000 - 0.025 + 0.010 0.025 0.025
Bearing OD 90.000 - 0.015 0
3 Bearing bore 40.000 - 0.012 0 0.002 0.025
Shaft OD 40.000 k5 + 0.002 + 0.013
N7
4 Spacer sleeve bore 40.000 - 0.033 - 0.008 0.010 0.046
Shaft OD 40.000 k5 + 0.002 + 0.013
K7
5 Housing bore 80.000 - 0.021 + 0.009 0.022 0.021
Bearing OD 80.000 - 0.013 0
6 Bearing bore 40.000 - 0.012 0 0.002 0.025
Shaft OD 40.000 k5 + 0.002 + 0.013
H7
7 Gear bore 39.000 0 + 0.025 0.018 0.059
Shaft OD 39.000 s6 + 0.043 + 0.059

M070036/00E 99-11 © MTU


Group 200 Coolant System
Page 2

Engine Coolant Pump for H.P. Temperature System

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H8
1 Seal carrier bore 72.000 0 + 0.046 0.084 0.230
Shaft seal OD 72.000 + 0.130 + 0.230
2 Shaft OD 48.000 - 0.100 0
H7
3 Seal carrier bore 78.100 0 + 0.030 0.040 0.100
Rotary seal OD 78.200 - 0.030 0
H5
4 Impeller bore 30.000 0 + 0.009 0.032 0.050
Shaft OD 30.000 t5 + 0.041 + 0.050
5 Rotary seal
Counter ring

Note:
Re 2: Running surface worn: Metal-spray pump shaft and grind using feed-in method
Re 5: In the event of wear marks, replace parts together

M070036/00E 99-11 © MTU


Coolant System Group 200
Page 3

Raw Water Pump

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
K7
1 Seal carrier bore 90.000 - 0.025 + 0.010 0.025 0.025
Bearing OD 90.000 - 0.015 0
K7
2 Housing bore 90.000 - 0.025 + 0.010 0.025 0.025
Bearing OD 90.000 - 0.015 0
3 Bearing bore 40.000 - 0.012 0 0.002 0.025
Shaft OD 40.000 k5 + 0.002 + 0.013
N7
4 Spacer sleeve bore 40.000 - 0.033 - 0.008 0.010 0.046
Shaft OD 40.000 k5 + 0.002 + 0.013
K7
5 Housing bore 80.000 - 0.021 + 0.009 0.022 0.021
Bearing OD 80,000 - 0.013 0
6 Bearing bore 40.000 - 0.012 0 0.002 0.025
Shaft OD 40.000 k5 + 0.002 + 0.013
H7
7 Gear bore 39.000 0 + 0.025 0.018 0.059
Shaft OD 39.000 s6 + 0.043 + 0.059

M070036/00E 99-11 © MTU


Group 200 Coolant System
Page 4

Raw Water Pump

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H8
1 Seal carrier bore 72.000 0 + 0.046 0.084 0.230
Shaft seal OD 72.000 + 0.130 + 0.230
2 Shaft OD 48.000 - 0.100 0
H8
3 Seal carrier bore 50.000 0 + 0.039 0 0.039
Rotary seal OD 50.000 0 0
H5
4 Impeller bore 35.000 0 + 0.011 0.030 0.050
Shaft OD 35.000 t5 + 0.041 + 0.050
5 Rotary seal

Reconditioning instructions:
Re 2: Running surface worn: Metal-spray pump shaft and grind using feed-in method
Re 5: In the event of wear marks, replace parts together

M070036/00E 99-11 © MTU


Accessories Group 300
Page 1

Bilge Pump

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
K7
1 Bearing housing bore 80.000 - 0.021 + 0.009 0.022 0.021
Bearing OD 80.000 - 0.013 0
2 Bearing bore 40.000 - 0.012 0 0.002 0.025
Shaft OD 40.000 k5 + 0.002 + 0.013
J7
3 Bearing housing bore 80.000 - 0.012 + 0.018 0.031 0.012
Bearing OD 80.000 - 0.013 0
4 Bearing bore 40.000 - 0.012 0 0.002 0.025
Shaft OD 40.000 k5 + 0.002 + 0.013
H7
5 Gear bore 39.000 0 + 0.025 0.018 0.059
Shaft OD 39.000 + 0.043 + 0.059
H7
6 Shaft bore 22.000 0 + 0.021 0 0.024
Shaft OD 22.000 h6 - 0.013 0

M070036/00E 99-11 © MTU


Group 300 Accessories
Page 2

Bilge Pump

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
H6
1 Housing bore 80.000 - 0.024 - 0.005 0.008 0.024
Bearing OD 80.000 - 0.013 0
2 Bearing bore 40.000 - 0.012 0 0.002 0.030
Shaft OD 40.000 h6 + 0.002 + 0.018
H7
3 Housing bore 70.000 0 + 0.030 0 0.049
Control disc OD 70.000 h6 - 0.019 0
H7
4 Control disc bore 55.000 0 + 0.030 0.220 0.450
Shaft seal OD 55.000 + 0.250 + 0.450
5 Shaft OD 35.000 - 0.100 0
H7
6 Control disc bore 55.000 0 + 0.030 0.430 0.800
Boot OD 55.600 - 0.200 + 0.200
H6
7 Impeller bore 35.000 0 + 0.016 0.007 0.025
Shaft OD 35.000 h6 + 0.009 + 0.025
8 Rotary seal
Thrust ring
9 Gear fitted flush

Reconditioning instructions:
Re 5: Running surface worn: Metal-spray pump shaft and grind using feed-in method
Re 8: In the event of wear marks, replace parts together

M070036/00E 99-11 © MTU


Preliminary Note 00

Data Sheets
To ensure that unusable components are not installed or components which can still be used are not discarded all
inspection work should only be carried out by qualified personnel using the necessary measuring instruments.
All measuring and testing equipment is naturally subject to wear.
To determine resulting tolerance deviations in good time, the measuring and test equipment must be inspected
annually at a location equipped with appropriate technical facilities.
Alternatively, equipment can be inspected by our Product Support Service and MTU, Friedrichshafen, or DDC, or
by an external product support service.
Adherence to the limits specified in this Tolerances and Wear Limits List is mandatory.
The following data sheets should be used to record the individual examination results:
- Cylinder liner, installed
- Cylinder liner, upper fit
- Cylinder liner, lower fit
- Main bearing (bearing installed)
- Conrod bearing (bearing shells installed)
- Timing

M070036/00E 02-07 © MTU


Preliminary Note 00

M070036/00E 02-07 © MTU


Data Sheet 01

Cylinder Liner, Installed

Engine model:
Engine No.:
Order No.:
Crankcase No.:
Cylinder liner
Part No.:
Specified bore dimension:

To measure: In measurement direction a (direction of travel) and b


(transverse).
Measurement plane 1 - 2

Cyl. Measur- Basic Actual dimensions Cyl. Measur- Basic Actual dimensions
No. ement dimen- Measuring planes No. ement dimen- Measuring planes
direc- sion direc- sion
tion tion
1 2 1 2
a a
A1 B1
b b
a a
A2 B2
b b
a a
A3 B3
b b
a a
A4 B4
b b
a a
A5 B5
b b
a a
A6 B6
b b
a a
A7 B7
b b
a a
A8 B8
b b
a a
A9 B9
b b
a a
A10 B10
b b
Remarks:

Date: .......................... Checked by: ........................................................

M070036/00E 02-07 © MTU


Data Sheet 01

M070036/00E 02-07 © MTU


Data Sheet 02

Cylinder Liner, Upper Fit

Engine model:
Engine No.:
Order No.:
Crankcase No.:
Cylinder liner
Part No.:
Specified dimension,
upper fit: mm
- Crankcase bore mm
- Cylinder liner OD mm

Specified clearance: mm

Actual dimensions
Cylinder No. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

Crankcase bore
1 Cylinder liner OD

Clearance/overlap

Actual dimensions
Cylinder No. B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Crankcase bore
1 Cylinder liner OD

Clearance/overlap

Remarks:

Date: ......................... Checked by: ........................................................

M070036/00E 02-07 © MTU


Data Sheet 02

M070036/00E 02-07 © MTU


Data Sheet 03

Cylinder Liner, Lower Fit

Engine model:
Engine No.:
Order No.:
Crankcase No.:
Cylinder liner
Part No.:
Specified dimension,
lower fit: mm
- Crankcase bore mm
- Cylinder liner OD mm

Specified clearance: mm

Actual dimensions
Cylinder No. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

Crankcase bore
1 Cylinder liner OD

Clearance/overlap

Actual dimensions
Cylinder No. B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Crankcase bore
1 Cylinder liner OD

Clearance/overlap

Remarks:

Date: ......................... Checked by: ........................................................

M070036/00E 02-07 © MTU


Data Sheet 03

M070036/00E 02-07 © MTU


Data Sheet 04

Main Bearing (Bearing Installed)

Engine model: Measurement and Entry:


Diameter a, b1 and b2
Engine No.: Measuring planes 1 and 2
Order No.: Determining bearing
clearance:
Crankcase No.: One-part bearing:
Crankshaft No.: Min. dimension a, b1 or b2
Standard:
Min. dimension a

Free end: Crankshaft


bearing Specified dia.: mm

Drive
flange Specified dia.: mm

Driving end: Crankshaft


bearing Specified dia.: mm

Drive
flange Specified dia.: mm

Main bearing: Specified dia.: mm

Crankshafts Specified dia.: mm

Radial
clearance: Free end: mm (min.) mm (max.)
Driving end: mm (min.) mm (max.)
Main bearing: mm (min.) mm (max.)

Crankshaft Actual
axial clearance: mm (min.) mm (max.) dimension: mm

Actual dimensions
Bearing No. 1 2 3 4 5 6 7 8 9 10
1
Bearing dia. b1 2
1
Bearing dia. b2 2
1
Bearing dia. a 2
Crankshaft dia.
(actual dimension)

Bearing clearance
(radial)
Remarks:

Date: .......................... Checked by: ........................................................

M070036/00E 02-07 © MTU


Data Sheet 04

M070036/00E 02-07 © MTU


Data Sheet 05

Conrod Bearing (Bearing Shells Installed)

Engine model: Specified dimensions:


Engine No.: - Conrod bearing bore mm
Order No.:
Crankcase No.: - Radial clearance min.: mm
Crankshaft No.: max.: mm

Conrod, A bank
To measure:
Actual dimensions, dia. Diameter a, b, c
Cyl. Rod No. Batch Basic Crankshaft Radial To determine clearance
No. dimen- clearance Min. dimension a, b or c
sion
a b c
1
2
3
4
5
6
7
8
9
10

Conrod, B bank
Actual dimensions, dia.
Cyl. Rod No. Batch Basic Crankshaft Radial
No. dimen- clearance
sion
a b c
1
2
3
4
5
6
7
8
9
10

Remarks:

Date: .......................... Checked by: ........................................................

M070036/00E 02-07 © MTU


Data Sheet 05

M070036/00E 02-07 © MTU


Data sheet 06

Timing

Engine model:
Engine No.:
Order No.:

1. Timing Diagram:

Spec- Toler- Actual


ified ance Cylinder No.
in °
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10
Exhaust valve
opens before
±
BDC
Inlet valve
opens before TDC
±
Exhaust valve
closes after TDC
±
Inlet valve
closes after BDC
±

Spec- Toler- Actual


ified ance Cylinder No.
in °
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
Exhaust valve
opens before
±
BDC
Inlet valve
opens before TDC
±
Exhaust valve
closes after TDC
±
Inlet valve
closes after BDC
±
Settings for valve timing correspond to the adjustment diagram

2. Cam Lift/Valve Lift:

Spec- Toler- Actual


ified ance Cylinder No.
in mm
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10
Exhaust ±
Inlet ±

Spec- Toler- Actual


ified ance Cylinder No.
in mm
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
Exhaust ±
Inlet ±

3. Injection Timing:
For start of delivery, see engine master card
Remarks:

Date: .......................... Checked by: ........................................................

M070036/00E 02-07 © MTU


Data Sheet 06

M070036/00E 02-07 © MTU