8 V 2000 M72 M92 M93 - Workshop - Manual

Technical Publication
Diesel Engine
8 V 2000 M72 / M92 / M93
10 V 2000 M72 / M92 / M93
Workshop Manual
M020127/02E
Printed in Germany
© 2005 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,
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Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.
Printed in Germany
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
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
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
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.
Impresso na Alemanha
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.
Table of Contents 01
1 General ...................................................................... 11
1.1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1.1 Reman assemblies – Prerequisites for maintenance tasks and general assembly
instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 General Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 General conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 Personnel and organizational requirements ............................ 15
1.2.3 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.4 Auxiliary materials, fire prevention and environmental protection . . . . . . . . . . . . . 19
1.2.5 Standards for warning notices in the publication . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.6 General information regarding the Tolerances and Wear Limits List . . . . . . . . . . . 22
1.2.7 Engine side and cylinder designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.8 Torque specifications for screws, nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.9 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.2.10 Conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.2.11 Repairing threaded bores with threaded inserts (Heli-Coil) . . . . . . . . . . . . . . . . . 47
1.2.12 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.2.13 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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02 Table of Contents
2 Operation Schedules ........................................................... 53

2.1 Engine condition check before a major overhaul .............................. 53
2.2 Preface ................................................................ 54
2.3 Maintenance schedule matrix 2000 M72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.6 Maintenance tasks ....................................................... 62
2.7 Engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.8 Engine – Disassembly .................................................... 66
2.9 Engine – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.10 Engine installation ....................................................... 72
2.11 Engine run-in ........................................................... 73
3 Task Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1 Crankcase and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1.2 Cylinder liner – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.1.3 Cylinder liner – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.1.4 Cylinder liner – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1.5 Cylinder liner – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.1.6 Cylinder liner – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.1.7 Cylinder liner – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.1.8 Oil pan – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.1.9 Oil pan – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.1.10 Oil pan – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.1.11 Oil pan – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.1.12 Oil pan – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.1.13 Engine lifting equipment – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.1.14 Engine lifting equipment – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.1.15 Engine lifting equipment – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.1.16 Engine lifting equipment – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.1.17 Engine lifting equipment – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.1.18 Crankcase breather – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.1.19 Crankcase breather – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.1.20 Hengst oil separator – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.1.21 Crankcase ventilation – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1.22 Crankcase breather – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.1.23 Hengst oil separator – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.1.24 Hengst oil separator – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.1.25 Crankcase ventilation – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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3.2 Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

3.2.1 Flywheel housing – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.2.2 Flywheel housing – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.2.3 Flywheel housing – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.2.4 Flywheel housing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.2.5 Flywheel housing – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.2.6 Flywheel housing – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.2.7 Radial-lip shaft seal – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.2.8 Sensor sleeve – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.2.9 Gearcase, free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.2.10 Gearcase, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.2.11 Gearcase, free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.2.12 Gearcase, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.2.13 Gearcase, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.2.14 Gearcase, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.2.15 Gearcase, free end – Removal and installation of crankshaft bearing . . . . . . . . . 137
3.2.16 Radial-lip shaft seal – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.2.17 Gear train – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.2.18 Gear train, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.2.19 Gear train, free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.2.20 Gear train, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.2.21 Gear train, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.2.22 Gear train, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.2.23 Bearing bush – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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3.3 Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

3.3.1 Crankshaft – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.3.2 Crankshaft – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.3.3 Crankshaft – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.3.4 Crankshaft – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3.3.5 Crankshaft – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.3.6 Crankshaft – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.3.7 Crankshaft – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.3.8 Crankshaft – Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.3.9 Main bearing shells – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.3.10 Crankshaft bearing bore – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.3.11 Crankshaft – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3.3.12 PTO flange, driving end, flywheel – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.3.13 PTO flange, driving end, flywheel – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.3.14 PTO flange, driving end – Flywheel disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.3.15 PTO flange, driving end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.3.16 PTO flange, driving end – Flywheel check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.3.17 PTO flange, driving end – Flywheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.3.18 PTO flange, driving end, flywheel – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.3.19 Vibration damper on PTO, free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3.3.20 Vibration damper on PTO, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.3.21 Vibration damper on PTO, free end – Disassembly . . . . . . . . . . . . . . . . . . . . . . . 204
3.3.22 Vibration damper on PTO, free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.3.23 Vibration damper on PTO, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3.3.24 Vibration damper on PTO, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . 207
3.3.25 Vibration damper on PTO, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.3.26 Vibration damper on PTO, free end – Replacement of track ring . . . . . . . . . . . . . 211
3.3.27 Piston and conrod – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3.3.28 Piston and conrod – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.3.29 Piston and conrod – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3.3.30 Piston – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3.3.31 Piston – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3.3.32 Piston – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.3.33 Conrod – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.3.34 Conrod – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3.3.35 Conrod – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3.3.36 Conrod – Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.3.37 Conrod – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3.3.38 Conrod bearing shells – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3.3.39 Piston and conrod – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3.3.40 Piston and conrod – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
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3.4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

3.4.1 Valve-seat turning machine for cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3.4.2 Cylinder head – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3.4.3 Cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3.4.4 Cylinder head – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3.4.5 Cylinder head – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3.4.6 Cylinder head – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3.4.7 Cylinder head – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
3.4.8 Cylinder head – Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.4.9 Cylinder head – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3.4.10 Cylinder head – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
3.4.11 Cylinder head seals – Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.5 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3.5.1 Camshaft – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3.5.2 Camshaft – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
3.5.3 Camshaft – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3.5.4 Camshaft – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
3.5.5 Camshaft – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3.5.6 Camshaft – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3.5.7 Camshaft timing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
3.5.8 Valve roller tappet, pushrod – Overview ............................... 303
3.5.9 Roller tappet and pushrod – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
3.5.10 Roller tappet, pushrod – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
3.5.11 Roller tappet, pushrod – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3.5.12 Roller tappet, pushrod – Tolerances .................................. 308
3.5.13 Roller tappet, pushrod – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3.5.14 Valve drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3.5.15 Valve drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3.5.16 Valve drive – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3.5.17 Valve drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3.5.18 Valve drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
3.5.19 Valve drive – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3.5.20 Valve drive – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3.5.21 Valve drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3.5.22 Cylinder head cover – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3.5.23 Cylinder head cover – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3.5.24 Cylinder head cover – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3.5.25 Cylinder head cover – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3.5.26 Cylinder head cover – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3.6 HP Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3.6.1 High-pressure fuel system – Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3.6.2 HP fuel pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3.6.3 HP fuel pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3.6.4 High-pressure pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3.6.5 HP fuel pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3.6.6 High-pressure fuel pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
M020127/02E 05-08 © MTU

3.7 LP Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

3.7.1 Fuel supply to fuel delivery pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3.7.2 Fuel supply to fuel delivery pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3.7.3 Fuel supply to fuel delivery pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 343
3.7.4 Fuel supply to fuel delivery pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
3.7.5 Fuel supply to fuel delivery pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3.7.6 Fuel supply to fuel delivery pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
3.7.7 Fuel supply to fuel delivery pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 347
3.7.8 Fuel cooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
3.7.9 Fuel cooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
3.7.10 Fuel cooler – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3.7.11 Fuel cooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
3.7.12 Fuel cooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3.7.13 Fuel duplex filter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3.7.14 Fuel duplex filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
3.7.15 Fuel duplex filter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
3.7.16 Fuel duplex filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
3.7.17 Fuel duplex filter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
3.7.18 Fuel duplex filter – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
3.7.19 Fuel duplex filter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
3.7.20 Leak-off fuel system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
3.7.21 Leak-off fuel system – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3.7.22 Leak-off fuel line – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
3.7.23 Leak-off fuel line – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
3.7.24 Leak-off fuel system – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
3.8 Exhaust Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
3.8.1 Exhaust turbocharger – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
3.8.2 Exhaust turbocharger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
3.8.3 Exhaust turbocharger – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
3.8.4 Turbocharger cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
3.8.5 Exhaust turbocharger – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
3.8.6 Exhaust turbocharger – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
3.8.7 Exhaust turbocharger – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
3.8.8 Exhaust turbocharger – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
3.9 Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
3.9.1 Intercooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
3.9.2 Intercooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
3.9.3 Intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
3.9.4 Intercooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
3.9.5 Intercooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
M020127/02E 05-08 © MTU

3.10 Air Intake/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

3.10.1 Air filter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
3.10.2 Air filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
3.10.3 Air filter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3.10.4 Air filter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3.10.5 Air supply system to cylinders – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3.10.6 Air supply to the cylinders – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
3.10.7 Air supply system to cylinders – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
3.10.8 Air supply system to cylinders – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
3.10.9 Air supply to the cylinders – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
3.11 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
3.11.1 Constant-pressure manifold – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
3.11.2 Constant-pressure manifold – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
3.11.3 Constant-pressure manifold – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
3.11.4 Constant-pressure manifold – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
3.11.5 Constant-pressure manifold – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
3.11.6 Constant-pressure manifold – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
3.11.7 Constant-pressure manifold – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
3.11.8 Carrier housing – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
3.11.9 Carrier housing – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
3.11.10 Carrier housing – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
3.11.11 Carrier housing – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
3.11.12 Carrier housing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
3.11.13 Carrier housing – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
3.11.14 Carrier housing – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
3.11.15 Exhaust flap with actuators – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
3.11.16 Exhaust flap with actuators – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
3.11.17 Exhaust flap with actuators – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
3.11.18 Exhaust flow control flap with actuators – Cleaning . . . . . . . . . . . . . . . . . . . . . . . 436
3.11.19 Exhaust flap with actuators – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
3.11.20 Exhaust flap with actuators – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
3.11.21 Exhaust flap with actuators – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
3.11.22 Exhaust flap with actuators – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
3.12 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
3.12.1 Electric starter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
3.12.2 Starter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
3.12.3 Starter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
3.12.4 Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
3.12.5 Starter – Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
3.12.6 Starter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
M020127/02E 05-08 © MTU

3.13 Lube Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449

3.13.1 Oil heat exchanger – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
3.13.2 Oil heat exchanger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
3.13.3 Oil heat exchanger – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
3.13.4 Oil heat exchanger – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
3.13.5 Oil heat exchanger – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
3.13.6 Exhaust turbocharger oil supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
3.13.7 Turbocharger oil supply – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
3.13.8 Turbocharger oil supply – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
3.13.9 Turbocharger oil supply – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
3.13.10 Turbocharger oil supply – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
M020127/02E 05-08 © MTU

3.14 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462

3.14.1 Engine coolant pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
3.14.2 Engine coolant pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
3.14.3 Engine coolant pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
3.14.4 Coolant pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
3.14.5 Engine coolant pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
3.14.6 Engine coolant pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
3.14.7 Engine coolant pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
3.14.8 Coolant pipework from/to exhaust turbocharger – Overview . . . . . . . . . . . . . . . . 477
3.14.9 Coolant pipework from/to exhaust turbocharger – Removal . . . . . . . . . . . . . . . . . 478
3.14.10 Coolant pipework from/to exhaust turbocharger – Cleaning . . . . . . . . . . . . . . . . . 479
3.14.11 Coolant pipework from/to exhaust turbocharger – Check .................. 480
3.14.12 Coolant pipework from/to exhaust turbocharger – Installation . . . . . . . . . . . . . . . 481
3.14.13 Engine coolant and charge-air coolant ventilation – Overview .............. 482
3.14.14 Engine coolant and charge-air coolant ventilation – Removal . . . . . . . . . . . . . . . 483
3.14.15 Engine coolant and charge-air coolant ventilation – Cleaning . . . . . . . . . . . . . . . 484
3.14.16 Engine coolant and charge-air coolant ventilation – Check . . . . . . . . . . . . . . . . . 485
3.14.17 Engine coolant and charge-air coolant ventilation – Installation . . . . . . . . . . . . . . 486
3.14.18 Coolant cooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
3.14.19 Coolant cooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
3.14.20 Coolant cooler – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
3.14.21 Coolant cooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
3.14.22 Coolant cooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
3.14.23 Engine coolant cooler – Replacement of gasket . . . . . . . . . . . . . . . . . . . . . . . . . . 496
3.14.24 Coolant pipework with thermostat – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
3.14.25 Coolant pipework with thermostat – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
3.14.26 Coolant pipework with thermostat – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
3.14.27 Coolant pipework with thermostat – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
3.14.28 Coolant pipework with thermostat – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 504
3.14.29 Raw water pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
3.14.30 Raw water pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
3.14.31 Raw water pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
3.14.32 Raw water pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
3.14.33 Raw water pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
3.14.34 Raw water pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
3.14.35 Raw water pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
3.14.36 Coolant pipework to raw water pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . 519
3.14.37 Raw water pump pipe system – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
3.14.38 Raw water pump pipe system – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
3.14.39 Raw water pump pipe system – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
3.14.40 Raw water pump pipe system – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
M020127/02E 05-08 © MTU

3.15 Mounting/Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525

3.15.1 Engine mount – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
3.15.2 Engine mount – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
3.15.3 Engine mount – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
3.15.4 Engine mount – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
3.15.5 Engine mount – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
3.15.6 Engine mounting/support – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
3.15.7 Engine mount – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
3.15.8 Engine mount – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
3.15.9 Engine mount – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
3.15.10 Engine mount – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
3.16 Auxiliary Systems/Accessory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
3.16.1 Auxiliary systems / accessory equipment – Overview . . . . . . . . . . . . . . . . . . . . . 539
3.16.2 Bilge pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
3.16.3 Bilge pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
3.16.4 Bilge pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
3.16.5 Bilge pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
3.16.6 Bilge pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
3.16.7 Bilge pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
3.16.8 Bilge pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
3.17 Monitoring, Control and Regulation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
3.17.1 Sensors, actuators and injectors – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
3.17.2 Sensors, actuators and injectors – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
3.17.3 Sensors, actuators and injectors – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
3.17.4 Sensors, actuators and injectors – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
4.1 Standard tools – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
4.2 Special tools – Overview .................................................. 574
4.3 General workshop equipment – Overview .................................... 635
4.4 Measuring tools – General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
5 Annex ....................................................................... 647
5.1 Manufacturer’s documentation ............................................. 647
5.2 MTU contact/service partner ............................................... 648
5.3 Index .................................................................. 656
M020127/02E 05-08 © MTU

General 11
1 General
1.1 Important Information
1.1.1 Reman assemblies – Prerequisites for maintenance tasks

and general assembly instructions
These Maintenance Instructions are for technicians responsible for maintenance.
Contents:
• Scheduled W6 maintenance tasks
• Non-scheduled service operations on the individual assemblies.
Reman assemblies
The following assemblies are only available through the exchange procedure:
Series 2000 Series 4000
Vibration damper Vibration damper
Camshaft Camshaft
Injection pump High-pressure fuel pump
Injector
MDEC MDEC
Basic requirements for maintenance and service work

Customers performing their own maintenance must ensure that the following conditions are fulfilled:
• All safety regulations are observed.
• Use of trained and qualified personnel.
• Suitable workshop equipment with general tools.
• Suitable test equipment.
• Approved special tools.
General assembly instructions

Assemblies that are exposed to contact with oil, fuel, coolant and combustion air must be clean. Assemblies with
the requirement ”Specially clean” (e.g. components carrying oil and fuel) should be cleaned in the appropriate
manner and checked for cleanness. Remove packaging of components immediately before assembly.
Elastomer components (e.g. rubber and similar) must not be washed with diesel fuel, solvent or cold cleaners.
• Remove oil or fuel coatings. 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.
Radial-lip shaft seals treated by the manufacturer with oil show as a result definite signs of swelling when delivered.
They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before installation.
The surfaces of parts that slide against each other must be lubricated with SAE 30 engine
oil when installed, unless otherwise specified.
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. After installing O-rings in shaft grooves, pass a rounded marking tool under the O-ring in the
direction of the circumference if the O-ring diameter is sufficiently large. Make sure that the O-ring is not damaged.
Before shaft seal assembly:
• 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 SAE 30 engine oil.
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12 General
• 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 denatured 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.
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. .
Before installing antifriction bearings, lubricate the bearing seats. Only remove the bearings from their
original packaging immediately before installation. Do not remove the corrosion inhibitor from the
bearings in the 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 must be between 80 °C and 100 °C and never exceed 120 °C.
• Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate).
Do not oil dry bearings.
When installing gears, the splines must be lubricated with SAE 30 engine oil.
All support and mating surfaces of components (e.g. mating surfaces for centering 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 inhibitor (e.g. oil, grease) must be removed from the contact and mating faces.
After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate
must be removed and the parts coated with SAE 30 engine oil.
Sensors must be coated with long-life lubricant before installation in the immersion sleeves.
Cable connections with cutting ring unions must be preassembled and tightened in a vice, after
the threads have been previously coated with thin-film lubricant.
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 SAE 30 engine oil.
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.
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. Thread and screw contact surfaces must be coated with
lubricant before installation in accordance with tightening specifications.
Unless otherwise specified, use engine oil as a lubricant (SAE 30) and assembly paste in hot-part areas.
For threaded connections without tightening specifications, the tightening procedure can be selected
as required, i.e. mechanical tightening with screwdriver or normal manual tightening with an open-end
wrench or box wrench is possible. When machine-tightening is carried out, look up tightening torque
of thread size and strength class in the general tightening specifications.
Threaded connections with tightening specifications:
• The threaded connections must be tightened manually with a click wrench or angle-of-rotation torque
wrench. The specified tightening torques must be set without considering the specified tolerance
at the click wrench. 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. This information also applies to checking torques.
• If no tolerance is specified for tightening torque, the tightening tolerance is + 10% of specified torque.
• Angleofrotation tightening:
The angles of further rotation specified in the tightening specifications must be achieved and may be
exceeded within the specified tolerance. If no tightening tolerance is specified, the following tolerances
must be observed: +5° for additional angle of rotation less than or equal to 90° +10° for additional
M020127/02E 05-08 © MTU

General 13
angle of rotation greater than 90°. Before angle-of-rotation tightening, each screw head must be
color-marked so that after tightening it is possible to check that the angle of rotation is correct (exception:
color-marking is not necessary in the case of a self-monitoring NC screwdriver).
• Elongated tightening:
Carry out tightening according to tightening specifications, taking tightening tolerance into consideration.
M020127/02E 05-08 © MTU

14 General
1.2 General Conditions
1.2.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Non-compliance with the Safety Instructions
Correct use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or Conversions
Modifications made by the customer to the engine affect safety.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis-à-vis the engine manufacturer will be accepted.
Reworking components
As part of repair work or an engine overhaul, reworking of components may be carried
out by workshops authorized by MTU.
However, no generally valid instructions can be issued for the reworking of components as
the machining tools available on site may differ.
M020127/02E 05-08 © MTU

General 15
1.2.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).
M020127/02E 05-08 © MTU

16 General
1.2.3 Safety precautions when working on the engine
Safety precautions when putting the equipment into operation

Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications.
Before putting the device or the system into operation, always ensure
• that all maintenance and repair work is completed
• that all loose components have been removed from rotating parts
• that nobody is standing in the danger zone of moving engine components.
Safety requirements for operators
Procedures for cases of emergency must be practised regularly.
The operator must be familiar with the controls and displays.
The operator must know the consequences of each operation to be carried out.
The operator must carry out the individual operations according to the documentation.
During operation, the displays and monitoring units must be permanently observed with regard to present
operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• notify the supervisory personnel in charge
• analyze the message
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Maintenance and repair
Compliance with maintenance and repair specifications is an important safety factor.
Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. Secure
the engine against inadvertent starting. With electric starter, disconnect the battery. With pneumatic starter, close
main shut-off valve of compressed-air system and release pressure from compressed-air supply line. Attach sign
"Do not operate" in operating area or to control equipment. Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Maintenance and repair work must only be carried out by authorized, qualified personnel.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane.
Always support these components in accordance with regulations on suitable frames or stands
before beginning any maintenance or repair work.
Before barring the engine, make sure that nobody is standing in the danger zone. After working on the engine, check
that all guards have been installed and that all tools and loose components have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and H.P. lines which are to be opened.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
During maintenance and repair work, take care not to damage the fuel lines. To tighten the connections when
installing the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
M020127/02E 05-08 © MTU

General 17
Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. When subjected to fire
or temperatures above 300 °C the material degenerates, giving off hydrogen fluoride gas. Hydrogen fluoride
vapors are released in this case. The resulting acid leads to serious burning if it contacts the skin. Do not touch
elastomeric seals if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!
Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!
Do not touch hot components of the compressor and the exhaust system ⇒ Risk of injury!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of injury!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable bonding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. The welding
current could be induced in the cable harnesses and could possibly damage the electrical plant.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.
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18 General
Prior to working on assemblies, the power of the appropriate areas must be switched off. Any measures
requiring power supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
Always tighten connectors with connector pliers.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when despatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
• Laser devices of classes 1, 2 or 3A,
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.
M020127/02E 05-08 © MTU

General 19
1.2.4 Auxiliary materials, fire prevention and environmental protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants
lying around on the engine. Do not store combustible fluids near the engine.
Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible fluid.
When starting the engine with a foreign power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source
to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or
noises indicating danger are drowned.
At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors
(protective wadding, plugs or capsules).
Environmental protection
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Manipulation of the injection control system can influence the engine performance and exhaust emissions.
As a result, compliance with environmental regulations may no longer be guaranteed.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applicable, which
means work must only be carried out by authorized specialist companies (MTU is an authorized specialist company).
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions applicable to the product. Take care when handling
hot, chilled or caustic materials. When using inflammable materials, avoid sparks and do not smoke.
Lead
• When working with lead or lead-containing pastes, avoid direct contact with the
skin and do not inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust!
• Switch on fume extraction system.
• After coming into contact with lead or lead-containing materials, wash hands!
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
• Immediately remove clothing wetted by acids and alkalis!
• Rinse injuries with plenty of water!
• Rinse eyes immediately with eyedrops or clean tap water.
Painting
• When painting in other than spray booths equipped with extractors, ensure good ventilation.
Make sure that adjacent work areas are not affected.
• No naked flames!
• No smoking.
• Observe fire prevention regulations!
• It is absolutely necessary to wear masks providing protection against paint and solvent fumes.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing.
• Wear protective clothing, gloves, closed shoes and protective goggles!
• Ensure the room is well ventilated. 88% contamination of breathing air with nitrogen will result in suffocation.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
M020127/02E 05-08 © MTU

20 General
Compressed air
Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.
The pressure at which the air is kept can be read off at pressure gauges which must be connected
to the compressed air tanks and the compressed air lines.
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 permitted pressure) must form an intermediate connection. Hose
coupling and connections must be securely attached!
• 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 injury to 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!
• Unauthorized 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 purposes or to check for leaks, results in a risk of explosion!
• Do not blow dirty clothing with compressed air when being worn on the body.
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.
M020127/02E 05-08 © MTU

General 21
1.2.5 Standards for warning notices in the publication

In the event of immediate danger.
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.
Consequences: Slight injury or material damage.
CAUTION • Preventive measures
Note: This Publication contains especially emphasized safety instructions in accordance with the American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:
Warning notices
1. Read and become acquainted with all cautions and symbols before operating or repairing this product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!
M020127/02E 05-08 © MTU

22 General
1.2.6 General information regarding the Tolerances and Wear Limits List
The tolerances and wear limits are intended as a guide for the examination of engine components
as well as for engine inspection and repair.
Explanation of terms for dimensions of new components
Tolerance size Designed size followd by a fit symbol (e.g. 24 H6) or by

the permissible dimensional deviation (e.g. 24 +0.013)
Basic size Designed size without fit symbol or permissible

dimensional deviation
Deviation Permissible deviation from the basic or tolerance size.

Deviation indicates the upper and lower limits of the
tolerance size/basic size.
Clearance Difference between bore and shaft diameter when bore

diameter is greater than shaft diameter
Interference Difference between bore and shaft diameter when bore

diameter is smaller than shaft diameter
Explanation of terms for reconditioning of components
Wear limit The wear limits specified do not represent the maximum
wear limits permissible for satisfactory component
operation. They indicate that the next major overhaul
can be reached safely. If a wear limit is exceeded, the
component must be replaced.
Reworking instructions If wear limits are exceeded or values are below

specification, the components concerned must be
reworked as per reworking instructions or replaced.
Deviations from roundness, cylindricity, parallelism and coaxiality must be within specified limits unless specifically
indicated. All dimensions are stated in "mm" unless alternative units of measurement are specifically indicated.
M020127/02E 05-08 © MTU

General 23
1.2.7 Engine side and cylinder designations

Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).
The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
The numbering of engine components is also from the driving end, starting with No. 1.
1 KGS = Free end 3 KS = Driving end

2 Right side 4 Left side
M020127/02E 05-08 © MTU

24 General
1.2.8 Torque specifications for screws, nuts and bolts
Crankcase
Designation Torque specification Lubricant
Screw for crankshaft bearing cap Engine oil

• Nominal length: 172.5 mm to 173.0 mm
• max. length: 176.0 mm
1 Pretightening torque 300 Nm + 30 Nm
2 Angle of further rotation 90° + 10°
Side screw for crankshaft bearing cap

1 Tightening torque 140 Nm + 10 Nm
Plug screw 180 Nm
Screw for Hengst oil separator 6 Nm + 2 Nm
Gear train
Nut for drive gear (auxiliary drive) 285 Nm + 30 Nm Engine oil
M020127/02E 05-08 © MTU

General 25
Running gear
Screw for counterweight Engine oil

• max. length: 84 mm
Screw for flywheel 42 Nm +4 Nm
Screw for side on plate vibration damper 52 Nm
Conrod screw
• max. elongation: 68.5 mm

Sequence:
a Short arm
b Long arm

Sequence:
a Short arm
b Long arm
Conrod screws can also be tightened together.
Cylinder head
Protective sleeve for injector 45 Nm + 5 Nm Engine oil
Screw for cylinder head.

• max. length: 212 mm
Tightening sequence of screws: 1 to 4
Pretightening torque
1st stage 10 Nm
2nd stage 50 Nm
3rd stage 100 Nm
4th stage 200 Nm
Angle of further rotation
1st stage 90° + 10°
2nd stage 90° + 10°
M020127/02E 05-08 © MTU

26 General
Valve gear
Nut on adjusting screw for rocker 50 Nm Engine oil
Screw for rocker shaft support
1 Pretightening torque 60 Nm
2 Angle of further rotation 90 °
Screw for cylinder head cover 20 Nm
Fuel system – high-pressure

Breather valve 100 Nm ± 5 Nm Engine oil
Screw for hold-down clamp 40 Nm + 4 Nm
HP line from HP pump to fuel distributor 40 Nm + 5 Nm
HP line from fuel distributor to HP accumulator 40 Nm + 5 Nm
HP line from HP accumulator to injector 15 Nm + 5 Nm
Fuel system – low-pressure

Fuel priming pump at pump housing 30 Nm + 3 Nm Engine oil
M020127/02E 05-08 © MTU

General 27
Exhaust turbocharger
Screws on carrier housing 70 Nm + 7 Nm Engine oil
Threaded union on exhaust 35 Nm + 4 Nm

turbocharger
Clamp on turbine housing 18 Nm + 7 Nm
Clamp on compressor housing 18 Nm + 2 Nm
Clamp on center bearing 5 Nm + 1 Nm
Clamp on flap housing 5 Nm + 1 Nm
Screw for flange on compressor 21 Nm + 2 Nm

housing
Screw on retaining ring 28 Nm + 3 Nm
Magnetic nut on turbine wheel Ultra-Therm MTU
1 Pretightening torque 35 Nm + 3 m
(left-hand thread)
2 Loosen
(left-hand thread)
4 Angle of further rotation 45° +5°
Intercooler
Screw for intercooler at connection 21 Nm Engine oil

housing (bottom)
Air intake / air supply

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

mounting plate
M020127/02E 05-08 © MTU

28 General
Exhaust system
Screw for intermediate flange on cylinder head 60 Nm + 6 Nm Engine oil
Screw for exhaust diffuser 30 Nm + 3 Nm
Screw for exhaust manifold 33 Nm + 4 Nm Ultra-Therm MTU
Screw for slide on exhaust manifold 57 Nm + 6 Nm
Starting system
Terminal 30 28 Nm ±4 Nm
Terminal 31 M10 16 Nm - 20 Nm
Terminal 45 28 Nm ±4 Nm
Terminal 50 2.4 Nm - 3 Nm
Lube oil system

Screw for oil spray nozzle 25 Nm Engine oil
Coolant system
Screw for bearing housing on 8.5 Nm Engine oil

bearing housing engine coolant
pump and raw water pump
Nuts for bearing housing on volute 20.5 Nm

engine coolant pump and raw water
pump
Screw for bearing housing on 41.5 Nm

housing (raw water pump)
Impeller test torque for engine 300 Nm - 400 Nm

coolant pump and raw water pump
Plug screw for impeller (raw water 75 Nm Loctite 638

pump)
M020127/02E 05-08 © MTU

General 29
Power supply, engine side

Nut for belt pulley on generator 140 Nm + 20 Nm Engine oil
Pin for lever on clamping jig 100 Nm + 10 Nm Assembly paste MTH 5109
Mount/support
Engine mount
Nut on threaded rod 400 Nm Valvoline Tectyl 472
Monitoring, control and regulation devices

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

• Charge air
• Engine coolant
• Lube oil
• Fuel
• Intake air
Temperature sensor PT 100 • Unions: 40 Nm ± 5 Nm

• Exhaust gas - collective • Union nut: 35 Nm ± 5 Nm
temperature, A side
• Exhaust gas - collective
temperature, B side
Pressure sensor for 20 Nm to 45 Nm

• Lube oil
• Charge air
Fuel pressure sensor after filter 20 Nm + 3 Nm
Pressure sensor 20 Nm to 45 Nm
• Engine coolant pressure
• Raw water pressure
• Refill oil pressure
Differential pressure monitor for lube 27 Nm

oil
Level probe max. 30 Nm

• Engine coolant level
• Leak-off fuel level
Fuel high-pressure 30 Nm + 5 Nm
Tightening specifications for setscrew and stud connections according

to works standard MTN 5008
This works standard applies to setscrews not subjected to dynamic loads as per MMN 384, DIN 912, EN
24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to
studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts.
M020127/02E 05-08 © MTU

30 General
It does not apply to heatproof screws in the hot component area.

Tightening torques MA are for screws of strength class 8.8 (bright surface, phosphate coating or
galvanized) and 10.9 (bright surface or with phosphate coating).
The values in the table are based on a friction coefficient µtot.= 0.125. Precondition: Thread and mating
faces of screws and nuts must be coated in engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values
is permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process - e.g. resulting from inaccurate readings and overtightening during assembly.
M020127/02E 05-08 © MTU

General 31
When tightening mechanically, the permitted assembly tolerance is +15 %.
Hand-tightened Machine-tightened
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M2 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA = tightening torques
Tightening specifications for stress bolt connections prescribed in standard MTN 5007
This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic
loads of strength class 10.9 and the corresponding nuts.
Shank and transition dimensions as per MMN 209 standard and material and machining as per
MMN 389 standard (bright surface or with phosphate coating).
The values in the table are based on a friction coefficient µtot.= 0.125. Precondition: Thread and mating
faces of screws and nuts must be coated in engine oil prior to assembly.
M020127/02E 05-08 © MTU

32 General
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
The values in the tables are for manual tightening with torque wrench.
Thread not torsionally protected MA(Nm) torsionally protected MA(Nm)
M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
*Protect shank against torsion when tightening.

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

This standard applies to plug screws as per DIN 908, DIN 910 and DIN 7604 with screwed plug
DIN 3852, model A (sealed by sealing ring DIN 7603-Cu).
M020127/02E 05-08 © MTU

General 33
M020127/02E 05-08 © MTU

34 General
Tightening torques MA are specified for plug screws of steel (St), surface-protected with phosphate
coating and oiled or galvanically zinc-plated. Threads and mating faces under head must be coated
in engine oil, prior to assembly. 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 for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed plug)
inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 35 25
M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
M22 x 1.5 60 50
M24 x 1.5 70 60
M26 x 1.5 80 70
M27 x 2 80 70
M30 x 1.5 100 90
M30 x 2 95 85
M33 x 2 120 110
M36 x 1.5 130 115
M38 x 1.5 140 120
M42 x 1.5 150 130
M45 x 1.5 160 140
M48 x 1.5 170 145
M52 x 1.5 180 150
M56 x 2 190 160
M64 x 2 205 175
M020127/02E 05-08 © MTU

General 35
Tightening specifications for plug screws as per DIN 7604C (with long screwed plug)
inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
Tightening specifications for banjo screws as per MTN 5183-2 standard

This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603-Cu
M020127/02E 05-08 © MTU

36 General
Tightening torques MA are given for banjo screws made of steel (St) with surface protected by a phosphate
coating and oiled or galvanized and for banjo screws made of copper-aluminum alloys.
Thread and mating faces beneath heads must be coated in engine oil prior to assembly.
Tightening specifications for banjo screws made of steel

inserted in steel/gray cast iron/Al alloy MA
Thread
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
M020127/02E 05-08 © MTU

General 37
Tightening specifications for banjo screws made of copper/aluminum alloys

inserted in steel/gray cast iron/Al alloy MA
Thread
(Nm)
M10 x 1 15
M16 x 1.5 30
Tightening specifications for male connectors as per MTN 5183-3 standard

This standard applies to male connectors DIN 2353, row L with screwed plug DIN 3852,
model A (sealed by sealing ring DIN 7603-Cu)
Tightening torques MA are given for male connectors made of steel (St) with surface protected
by a phosphate coating and oiled or galvanized.
Thread and mating faces beneath heads must be coated in engine oil prior to assembly.
M020127/02E 05-08 © MTU

38 General
inserted in steel/gray cast iron MA

Thread
(Nm)
M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
Tightening specifications for union nuts on screwed plugs ISO 6149-3
1 Union nut
2 Union body
3 O-ring
4 Ball bush
Union nut: When installing the ball bush, the union nut should be tightened firmly by hand (noticeable
increase in force) a quarter of a turn (90°) beyond this point.
M020127/02E 05-08 © MTU

General 39
1.2.9 Settings
Firing order for 2000CR engines

8V A1-B4-A4-A2-B3-A3-B2-B1
10V A1-B4-A4-B3-A3-B2-A2-B5-A5-B1
12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1
16V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7
Direction of rotation, viewed on driving end

Component Direction of rotation
Crankshaft left
Camshaft right
High-pressure fuel pump left
Oil pump left
Engine coolant pump left
Raw water pump left
Battery-charging generator left
Valve clearance with cold engine

Inlet 0.30 mm
Exhaust 0.40 mm
M020127/02E 05-08 © MTU

40 General
Valve timing with valve clearance adjusted (viewed on free end)
No. Valve position Crank angle
1 Inlet opens 40.4° before TDC
2 Inlet closes 43.6° after BDC
3 Exhaust opens 67.6° before BDC
4 Exhaust closes 43.2° after TDC
5 Overlap 83.6 °
Start of delivery Performance-map controlled
I Top dead center (TDC)
II Bottom dead center (BDC)
Cam and valve lift for camshaft adjustment

Inlet Exhaust
Cam lift at TDC 1.60 mm 1.60 mm
Valve lift at TDC (zero valve 2.20 mm 2.20 mm

clearance)
M020127/02E 05-08 © MTU

General 41
1.2.10 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km
yd 3 = ft
yd 36 = in
Unit B multiplied by factor = Unit A

mm 0.3937 = in
m 3.281 = ft
km 0.6215 = stat. mile
Area
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.5889 = km2
Unit B multiplied by factor Unit A

mm2 0.00155 = in2
m2 10.7643 = ft2
m2 1.1960 = yd2
km2 0.3863 stat. mile2
M020127/02E 05-08 © MTU

42 General
Volume
in3 16387 = mm3
ft3 0.02832 = m3
yd3 0.7646 = m3
gallon (US) 3.787 = dm3
gallon (Brit.) 4.546 = dm3

cm3 0.06102 = in3
m3 35.31 = ft3
dm3 0.2642 = gallon (US)
dm3 0.22 = gallon (Brit.)
Speed
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (Brit.) 1.852 = km/h
Unit B multiplied by factor = Unit B
m/s 3.281 = ft/s
km/h 0.6215 = stat. mile/h (mph)
km/h 0.54 = knot (Brit.)
M020127/02E 05-08 © MTU

General 43
Mass
lb 0.4536 = kg
oz 28.35 =g
ton 1.016 =t

g 0.03527 = oz
kg 2.205 = lb
t 0.9843 = ton
Force
lb 0.4536 = kp
lb 4.4483 =N
kp 2.205 = lb
N 0.101972 = kp
kp 9.80665 =N
Density
lb s2/ft4 515.4 = kg/m3
kg/m3 0.00194 = lb s2/ft4
M020127/02E 05-08 © MTU

44 General
Torque
ft lb 1.3563 = Nm
Nm 0.7373 = ft lb
Pressure
lb/sq in (psi) 703.1 = kp/m2 (mm WS)
lb/sq in (psi) 0.06895 = bar
lb/sq ft 47.883 = Pa
in QS 0.03386 = bar
in QS 345.3 = kp/m2
atm 760 = mm QS
atm 1.0133 = bar
atm 10332 = kp/m2 (mm WS)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lb/sq in
bar 14.503 = lb/sq in
Mass moment, 2nd grade

ft lb s2 1.3563 = kg m2
kg m2 0.7373 = ft lb s2
M020127/02E 05-08 © MTU

General 45
Energy
ft lb 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU
Power
HP (horse power) 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.055 = kW
kcal/h 1.163 =W
HP 550 = ft lb/s
kW 1.36 = PS
kW 1.341 = HP
kW 0.9479 = BTU/s
W 0.8598 = kcal/h
ft lb/s 0.0018 = HP
M020127/02E 05-08 © MTU

46 General
Temperature
Celsius Kelvin Fahrenheit Réaumur
x°C = x + 273.15 K = 9/5x + 32 °F = (4/5x) °R
xK = x − 273.15 °C = 9/5(x − 273.15) + 32 °F = 4/5 (x − 273.15) °R
x°F = 5/9(x − 32) °C =5/9 (x − 32) + 273.15 = 4/9 (x − 32) °R

K
x°R = 5/4x °C = (5/4x) + 273.15 K = (9/4x) + 32 °F
Fuel consumption
mile/gal (US) 0.4251 = km/l
gal/mile (US) 2.3527 = l/km
km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)
M020127/02E 05-08 © MTU

General 47
1.2.11 Repairing threaded bores with threaded inserts (Heli-Coil)

Data
Thread Core hole diameter (max./min.) Twist drill diameter
M6 6.31/6.04 6.1–6.2–6.25
M8 8.35/8.04 8.1–8.2–8.25–8.3
M8x1 8.32/8.04 8.1–8.2–8.25–8.3
M 10 10.4/10.05 10.25
M 12 12.5/12.05 12.25–12.5
M 12 x 1.5 12.43/12.05 12.25
M 14 14.53/14.06 14.25–14.5
M 14 x 1.5 14.43/14.05 14.25
M 15 x 2 15.3/15.2 15.25
M 16 16.53/16.06 16.25–16.5
M 16 x 1.5 16.43/16.05 16.25
M 24 x 1.5 24.43/24.05 24.25
M 26 x 1.5 26.43/26.05 26.25
M 30 x 1.5 30.43/30.05 30.25
1. Remove thread insert with suitable removal

tool from bore (left).
2. Bore core hole with suitable twist drill - see table.
3. Cut thread with special tap.
4. Do not countersink hole!
5. Mount spindle (2) and snout (1) corresponding
with thread.
6. Groove on snout must be aligned with markings on
installation tool (arrows).
1 Snout
2 Spindle
M020127/02E 05-08 © MTU

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

installation tool.
8. Driver journal of the thread insert must be in
groove (arrow).
1 Spindle
2 Thread insert
9. Use spindle to turn thread insert through snout

until it is flush at front (arrow).
10. Mount installation tool on threaded hole and install

thread insert without applying pressure to spindle.
11. Insert thread insert 1/2 to 1 1/2 turns deeper than
the threaded hole surface.
12. Use screw shearer to remove driver journals up
to M 14. With threaded inserts over M14, use
pointed pliers to move driver journal up and
down and remove.
M020127/02E 05-08 © MTU

General 49
1.2.12 Transport
Transport
Lift the engine only with the lifting eyes provided.
Use only the transport and lifting equipment approved by MTU.
Take note of the engine center of gravity.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
In the case of special packaging with aluminium foil, suspend the engine on the lifting eyes of the
transport pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transport locking devices for crankshaft and engine mounts.
Secure the engine against tilting during transportation. The engine must be especially secured
against slipping or tilting when going up or down inclines and ramps.
Setting the engine down after transport
Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.
M020127/02E 05-08 © MTU

50 General
1.2.13 Abbreviations
Abbrevia- Meaning Explanation

tion
AL Alarm
ANSI American National Standards Institute
ATL Abgasturbolader Exhaust Turbocharger
BDM Backup Data Module
BR Baureihe Engine Series
CAN Controller Area Network
CPP Controllable Pitch Propeller
CR Common Rail
DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards (DIN = "Deutsche
Industrie-Norm")
DIS Display Unit
DL Default Lost Alarm: CAN bus failure
ECS Engine Control System
ECU Engine Control Unit Engine governor
EDM Engine Data Module
EMU Engine Monitoring Unit
FLS Fluids and Lubricants Specifications MTU publication no. A01061/..
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
ICFN ISO - Continuous rating - Fuel stop power Power specifications acc. to DIN-ISO 3046-7
- Net
IDM Interface Data Module
IMO International Maritime Organization
ISO International Organization for

Standardization
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
M020127/02E 05-08 © MTU

General 51
Abbrevia- Meaning Explanation

tion
LCD Liquid Crystal Display, Liquid Crystal

Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value is lower than 1st minimum limit
LOLO Low Low Alarm: Measured value is lower than 2nd minimum limit
LOP Local Operating Panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing

Unit
OT Oberer Totpunkt Top dead center (TDC()
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
UPS Unit Pump System
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps
SPC Spare Parts Catalog
SS Safety System Alarm initiated by safety system
SSK Schnellschlussklappe(n) Emergency Air Shutoff Flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TC Tools Catalog
TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom dead center (BDC)
VS Voith Schneider Voith Schneider drive
WJ Water Jet Waterjet drive
M020127/02E 05-08 © MTU

52 General
M020127/02E 05-08 © MTU

Operation Schedules 53
2 Operation Schedules
2.1 Engine condition check before a major overhaul

Before the engine is removed, a brief test should be conducted to assist in evaluating
its condition and running behavior.
Deviations from the Engine Acceptance Test Record Data found during the test run provide
valuable information for subsequent overhaul services.
Operations to be performed See
Put the engine into operation after a scheduled (→Operating Instructions)

out-of-service period.
Start engine at LOP. (→Operating Instructions)
Run engine until operating temperature is reached. -
Test engine at highest possible power. (→Acceptance test record)

If this is not possible, operate the engine at adjustable
upper and lower no-load speed.
Perform operational checks. (→Operating Instructions)
Take engine oil sample and analyze. (→Operating Instructions)
Take engine coolant sample and analyze. (→Operating Instructions)
Shut down engine at LOP. (→Operating Instructions)
Drain engine coolant. (→Operating Instructions)
If engine coolant sample is not OK, fill with cleaning (→Fluids and Lubricants Specification)
agent.
Start engine at LOP. (→Operating Instructions)
Flush engine cooling system. (→Fluids and Lubricants Specification)
Shut down engine at LOP. (→Operating Instructions)
M020127/02E 05-08 © MTU

2.2 Preface
General information
Operational availability, operational reliability and minimum operational and maintenance costs can only
be achieved if maintenance and repair work are carried out in accordance with MTU specifications.
The entire system into which the engine is integrated must be serviced in such a way that satisfactory
engine operation is guaranteed. This includes above all:
• fuel quality and quantity
• dry, clean combustion air
Preventive maintenance instructions:
• Always keep the machine system clean so that any leaks are detected in time, thus
preventing consequential damage.
• Protect rubber and synthetic parts from oil and fuel, never treat with organic detergents, only wipe with dry cloth.
• Always replace all seals and gaskets.
Your service partner is available at all times with support and advice if required.
MTU maintenance concept

The MTU maintenance concept is a preventive maintenance concept. Preventive maintenance enables
advance operational planning and secures high operational availability.
The maintenance schedule is base on the load profile specified below. The intervals after which maintenance
work is to be carried out as well as the prescribed inspection and maintenance work are the average result of
operational experience and therefore merely guide values. Specific operating conditions may require modifications
to the Maintenance Schedule. Exchange parts (reliabilt®) are available for components to be replaced.
Note
The maintenance task matrix covers all tasks up to a major overhaul. Maintenance work must
then be continued according to the specified intervals.
The task number specified in the task list is marked on the corresponding spare part and
is a reference for the required scope of parts.
The specification of the fluids and lubricants, the guidelines for maintenance and replacement intervals as well as
the list of recommended fluids and lubricants are to be found in the MTU Fluids and Lubricants Specifications
A001061 and in the fluids and lubricants specifications of the component manufacturers. Only use fluids and
lubricants that comply with the MTU specification or that are approved by the respective component manufacturer.
The user/customer must perform the following maintenance tasks:
• Fuel prefilter:
The maintenance interval depends on the fuel’s degree of contamination. Paper inserts of
fuel prefilters must be replaced after 2 years at the latest.
• Battery:
The maintenance of the batteries depends on their use and the ambient conditions. The
specifications of the battery manufacturer apply.
The manufacturer’s specifications are binding for the servicing of all components that are
not included in this maintenance schedule.
Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures
according to the Fluids and Lubricants Specifications, MTU Publication No. A001061.
Application group
1B Fast vessels with high load factors
M020127/02E 05-08 © MTU

Load profile
Load profile table
Power 100% < 15%
Corresponding operating time 75% 25%
Application group
1DS Fast vessels with low load factors
Load profile
Load profile table
Power 100% 70% < 10%
Corresponding operating time 10% 70% 20%
M020127/02E 05-08 © MTU

2.3 Maintenance schedule matrix 2000 M72
0-5,250 operating hours
Limit, years
Item Operating hours [h]
1,000
1,250
1,500
1,750
2,000
2,250
2,500
2,750
3,000
3,250
3,500
3,750
4,000
4,250
4,500
4,750
5,000
5,250
Daily
250
500
750
Engine oil filter 2
Engine operation - X
Crankcase ventilation - X X X X X X X X X X X X X X X X X X X X X
Crankcase ventilation - X X X X X X X X X X
Centrifugal oil filter - X X X X X X X X X X
Fuel filter 2 X X X X X X X X X X
Valve gear - X X X X X
Belt drive 2 X
Air filter 3 X
Fuel injectors -
Cylinder chambers -
Component maintenance -
Cylinder head -
Extended component 18
maintenance
M020127/02E 05-08 © MTU

5,500-10,750 operating hours
Limit, years
10,000
10,250
10,500
10,750
5,500
5,750
6,000
6,250
6,500
6,750
7,000
7,250
7,500
7,750
8,000
8,250
8,500
8,750
9,000
9,250
9,500
9,750
Engine oil filter 2
Engine operation -
Crankcase ventilation - X X X X X X X X X X X X X X X X X X X X X X
Crankcase ventilation - X X X X X X X X X X X
Centrifugal oil filter - X X X X X X X X X X X
Fuel filter 2 X X X X X X X X X X X
Belt drive 2 X X
Air filter 3 X X
Fuel injectors - X
Cylinder chambers - X
Component maintenance - X
Cylinder head -
maintenance
M020127/02E 05-08 © MTU

Limit, years
12,000
11,000
11,250
11,500
11,750
Engine oil filter 2
Engine operation -
Crankcase ventilation - X X X X X
Crankcase ventilation - X X X
Centrifugal oil filter - X X X
Fuel filter 2 X X X
Valve gear - X X
Belt drive 2 X
Air filter 3 X
Fuel injectors - X
Cylinder head - X
Extended component 18 X
maintenance
M020127/02E 05-08 © MTU

Limit, years
1,000
1,250
1,500
1,750
2,000
2,250
2,500
2,750
3,000
3,250
3,500
3,750
4,000
4,250
4,500
4,750
5,000
5,250
Daily
250
500
750
Engine oil filter 2
Crankcase ventilation - X X X X X X X X X X X X X X X X X X X X X
Crankcase ventilation - X X X X X X X X X X
Centrifugal oil filter - X X X X X X X X X X
Fuel filter 2 X X X X X X X X X X
Belt drive 2 X X
Air filter 3 X X
Fuel injectors -
Cylinder chambers -
Component maintenance -
Cylinder head -
maintenance
M020127/02E 05-08 © MTU

Limit, years
5,500
5,750
6,000
Engine oil filter 2
Engine operation -
Crankcase ventilation - X X X
Crankcase ventilation - X X
Centrifugal oil filter - X X
Fuel filter 2 X X
Valve gear - X
Belt drive 2 X
Air filter 3 X
Fuel injectors - X
Cylinder head - X
maintenance
M020127/02E 05-08 © MTU

Limit, years
1,000
1,250
1,500
1,750
2,000
2,250
2,500
2,750
3,000
3,250
3,500
3,750
4,000
Daily
250
500
750
Engine oil filter 2
Crankcase ventilation - X X X X X X X X X X X X X X X X
Crankcase ventilation - X X X X X X X X
Centrifugal oil filter - X X X X X X X X
Fuel filter 2 X X X X X X X X
Valve gear - X X X X
Belt drive 2 X X
Air filter 3 X X
Fuel injectors - X
Cylinder head - X
maintenance
M020127/02E 05-08 © MTU

2.6 Maintenance tasks
Qual- Interval Item Maintenance tasks Task

ifica-
tion [hours] [a]
QL1 - - Engine oil filter Replace engine oil filter after each oil change or after W1008
year limit at latest. (→Operating Instructions).
QL1 Daily - Engine operation Check engine oil level. (→Operating Instructions ). W0500
Visually check leak-tightness and general condition of W0501

the engine. (→Operating Instructions).
Check drain line of the intercooler (if fitted). W0502

(→Operating Instructions).
Check service indicator of air filter. (→Operating W0503

Instructions).
Check relief bores of water pump(s). (→Operating W0505

Instructions).
Check for abnormal running noises, exhaust gas color W0506

and vibrations. (→Operating Instructions).
Drain water and dirt on drain cock of fuel prefilter (if W0507
fitted). (→Operating Instructions).
Check reading at service indicator of fuel prefilter (if W0508

fitted). (→Operating Instructions).
QL1 Crankcase ventilation Replace paper or textile insert (if fitted) of oil separator. W1139
(→Operating Instructions)
QL1 Crankcase ventilation Clean wire meshes of crankcase breather. (→Operating W1140
Instructions)
QL1 Centrifugal oil filter Centrifugal oil filter (if fitted): Check layer thickness of W1009
oil residue, clean and replace filter sleeve (→Operating
Instructions).
QL1 Fuel filter Replace fuel filter or filter insert. (→Operating W1001
Instructions).
QL1 Valve gear Check valve clearance. (→Operating Instructions ). W1002
QL1 Belt drive Check condition and tension of drive belt, replace if W1003
required. (→Operating Instructions).
QL1 Air filter Replace air filter. (→Operating Instructions ). W1005
QL1 Fuel injectors Replace fuel injectors. (→Operating Instructions ). W1006
QL1 Cylinder chambers Endoscope cylinder chambers. (→Operating W1011

Instructions ).
QL3 Component Prior to maintenance work, drain coolant and flush W2000
maintenance coolant circuits.
Clean air supply line. (→ Page 403) W2002
Clean intercooler and check for leaks. (→ Page 392) W2003
M020127/02E 05-08 © MTU


ifica-
tion [hours] [a]
Check engine coolant thermostat and replace W2006

thermostat insert. (→ Page 498)
Check centrifugal oil filter for wear (if fitted). W2009
Check vibration damper. (→ Page 200) W2011
Replace diaphragm of crankcase breather. W2014

(→ Page 100)
Overhaul coolant pump. (→ Page 462) W2015
Overhaul raw water pump. (→ Page 506) W2015
Overhaul bilge pump (if fitted). (→ Page 540) W2015
Clean engine coolant cooler and, if possible, check for W2017

leaks. (→ Page 488)
Clean engine oil exchanger and check for leaks. W2018

(→ Page 449)
Check engine alignment. W2036
Clean fuel cooler. (→ Page 348) W2059
Check pushrods and ball joints for wear. (→ Page 303) W2074
Check rocker and valve bridge for wear. (→ Page 311) W2074
Overhaul exhaust turbocharger. (→ Page 367) W2075
Replace seals of all disassembled components. W2062
QL3 Cylinder head Overhaul cylinder heads, check piston crowns and W1063
running pattern of cylinder liners visually. (→ Page 258)
QL4 Extended component Perform complete engine disassembly. Check engine W3000
maintenance components in accordance with assembly instructions,
repair or replace as required. (→ Page 66)
Replace all elastomer components and seals. W3001
Replace piston rings. (→ Page 213) W3002
Replace conrod bearings. (→ Page 213) W3003
Replace crankshaft bearings. (→ Page 151) W3004
Replace cylinder liners. (→ Page 76) W3005
Replace aux. PTO antifriction bearing. W3006
Replace high-pressure fuel pump. (→ Page 332) W3007
Replace actuating cylinders of air flaps. W3011
Replace actuating cylinders of exhaust flaps. W3012

(→ Page 431)
Replace exhaust flap bearings. (→ Page 431) W3013
M020127/02E 05-08 © MTU


ifica-
tion [hours] [a]
Overhaul starter. (→ Page 443) W3041
Overhaul battery-charging generator. W3042
Replace fuel-pressure relief valve. (→ Page 558) W3043
Replace high-pressure fuel sensor. (→ Page 558) W3057
Replace water filter. W3058
Replace wire meshes of crankcase breather. W3056

(→ Page 100)
M020127/02E 05-08 © MTU

2.7 Engine removal
Shut off fuel supply. –
Close raw water supply line. –
Drain engine oil at operating temperature. (→Operating Instructions)
Examine oil sludge for metallic residues. –
Drain engine coolant (coolant temperature < 60 °C) (→Operating Instructions)
Drain raw water. –
Wash machinery plant (as required, without chemical –

detergent).
Disconnect all connections. –
Install non-fibrous plugs and blanking plates to seal all –

open connections.
Release engine securing screws. –
Remove engine and place on stands. –
Attach engine to lifting device in accordance with (→Operating Instructions)

transportation regulations.
M020127/02E 05-08 © MTU

2.8 Engine – Disassembly

The sequence of the worksteps described as follows corresponds with the practical assembly
procedure. Prior to disassembling the engine, it is helpful to make photographs of all engine
sides or to mark components installed on the engine.
Mark and disconnect electric cables. –
Remove ECU housing. (→Operating Instructions)
Remove air filter. (→ Page 400)
Remove crankcase breather. (→ Page 103)
Remove intake housing.
Remove control block and control line for air and exhaust
flaps.
Remove centrifugal oil filter (if installed).
Remove exhaust system for engine coolant cooler and (→ Page 483)
intercooler.
Remove coolant pipework, coolant pump.
Remove coolant pipework after coolant pump.
Remove preheating unit (if installed).
Remove coolant pipework from/to intercooler.
Remove exhaust system for engine coolant cooler and (→ Page 483)
intercooler.
Remove engine lifting attachment. (→ Page 96)
Remove air supply to the cylinders. (→ Page 404)
Remove intercooler.
Remove fuel supply from fuel delivery pump to filter.
Remove fuel duplex filter. (→ Page 355)
Remove belt drive.
Remove fuel supply to the fuel delivery pump. (→ Page 342)
Remove fuel line from fuel filter to low pressure line.
Remove engine wiring harnesses.
Remove engine coolant pump. (→ Page 464)
Remove raw water lines. (→ Page 520)
Remove raw-water pump. (→ Page 507)
Remove battery-charging generator.
Remove bilge pump (if installed). (→ Page 543)
Remove coolant cooler and fuel cooler. (→ Page 489)
M020127/02E 05-08 © MTU

Remove oil pump connections.
Remove leak-off fuel pipework. (→ Page 363)
Remove exhaust gas compensator after engine.
Remove exhaust gas insulating molding / jacket after

engine.
Remove exhaust flap with actuators. (→ Page 434)
Remove exhaust system after exhaust turbocharger.
Remove constant-pressure manifold. (→ Page 412)
Remove turbocharger oil supply.
Remove oil return line from exhaust turbocharger.
Remove exhaust turbocharger. (→ Page 368)
Remove starter. (→ Page 444)
Remove vibration damper on PTO, free end (→ Page 202)
Remove oil filter with slide valve for oil filter switch.
Remove oil heat exchanger. (→ Page 450)
Remove coolant pipework with thermostat. (→ Page 500)
Remove cylinder head cover. (→ Page 325)
Remove HP line.
Remove injector.
Remove valve drive. (→ Page 313)
Remove pushrod. (→ Page 304)
Remove cylinder heads. (→ Page 260)
Remove roller tappet. (→ Page 304)
Remove HP pump. (→ Page 333)
Remove PTO flange, driving end – flywheel. (→ Page 191)
Remove auxiliary PTO.
Remove filling and measuring device.
Remove engine mounts. (→ Page 526)

(→ Page 534)
Install crankcase in crankcase rotation device.
Remove oil pan. (→ Page 89)
Remove lube oil pump with drive.
Remove piston and conrod. (→ Page 216)
M020127/02E 05-08 © MTU

Remove gear case, free end. (→ Page 126)
Remove gear train, free end. (→ Page 142)
Remove flywheel housing. (→ Page 114)
Remove crankshaft. (→ Page 154)
Remove cylinder liners. (→ Page 77)
Remove oil system in crankcase.
Remove crankcase from crankcase rotation device.
Remove camshaft. (→ Page 290)
Remove plug screws and cover.
Remove camshaft bearing bush.
M020127/02E 05-08 © MTU

2.9 Engine – Assembly

The sequence of the worksteps described as follows corresponds with the practical assembly procedure.
Clean crankcase.
Check crankcase.
Assemble crankcase
Install camshaft. (→ Page 297)
Install crankcase in crankcase rotation device.
Install cylinder liners. (→ Page 85)
Install oil system in crankcase.
Install crankshaft. (→ Page 182)
Install piston with conrod. (→ Page 249)
Install flywheel housing. (→ Page 119)
Install gear case, free end. (→ Page 133)
Install lube oil pump with drive.
Install oil pan. (→ Page 93)
Remove crankcase from crankcase rotation device.
Install roller tappet. (→ Page 304)
Install cylinder heads. (→ Page 286)
Install PTO flange, driving end – flywheel (→ Page 197)
Install vibration damper on PTO, free end. (→ Page 208)
Install fuel line from fuel filter to low pressure line.
Install HP pump. (→ Page 337)
Install pushrods. (→ Page 309)
Install valve gear. (→ Page 322)
Install cylinder head cover. (→ Page 328)
Install coolant pipework with thermostat. (→ Page 504)
Install oil heat exchanger. (→ Page 454)
Install oil filter with slide valve for oil filter switch.
Install belt drive.
Install HP line.
Install starter. (→ Page 448)
Install constant-pressure manifold. (→ Page 419)
Install filling and measuring device.
M020127/02E 05-08 © MTU

Install intercooler. (→ Page 397)
Install engine wiring harnesses.
Install exhaust turbocharger. (→ Page 389)
Connect turbocharger oil supply.
Install oil return line from exhaust turbocharger.
Install exhaust flap with actuators. (→ Page 442)
Install exhaust system after exhaust turbocharger.
Install exhaust gas insulating molding / jacket after

engine.
Install exhaust gas compensator after engine.
Install oil pump connections.
Install leak-off fuel pipework. (→ Page 366)
Install battery-charging generator.
Install engine coolant pump. (→ Page 475)
Install raw water pump. (→ Page 518)
Install pipework at raw water pump. (→ Page 523)
Install bilge pump. (→ Page 555)
Install auxiliary PTO.
Install exhaust system for engine coolant cooler and (→ Page 486)
intercooler.
Install engine coolant lines.
Install coolant cooler and fuel cooler. (→ Page 494)
Install fuel filter. (→ Page 360)
Install fuel delivery pump.
Install fuel pipework.
Install intake housing.
Install control block and control line for air and exhaust
flaps.
Install centrifugal oil filter (if available).
Install intercooler.
Install air supply to the cylinders. (→ Page 407)
Install engine lifting attachment. (→ Page 99)
Install crankcase breather. (→ Page 111)
Install air filter. (→ Page 402)
M020127/02E 05-08 © MTU

Install engine mount. (→ Page 529)

(→ Page 537)
Install and connect electric wiring. (→ Page 568)
Install ECU housing. (→Operating Instructions)
Install PTO systems, free and driving ends. –
M020127/02E 05-08 © MTU

2.10 Engine installation
Open all connections, remove cover and rubber plugs. –
Attach engine only at transportation eyelets and install (→Operating Instructions)

as per transportation regulations.
Connect coolant lines, fuel lines and engine monitoring. –
Fill engine coolant system. (→Operating Instructions)
Fill oil system with engine oil. (→Operating Instructions)
Align engine. –
M020127/02E 05-08 © MTU

2.11 Engine run-in

Run in engine after component replacement.
• When pistons, piston rings or cylinder liners are replaced, the engine must be run in
accordance with the applicable running-in schedule. Correct running in is decisive for the
service life and operational reliability of the engine.
• To destroy the braking energy, use the alternator or brake.
• Power must be transmitted from the engine to the brake by means of a resilient coupling.
Set engine operational values.
• Set temperatures, fuel and intake air in accordance with the temperature values in the
MTU Acceptance Test Record. Note the following:
• The coolant temperature depends on the operating range of the coolant thermostat.
• The fuel temperature depends on the volume of the service tank insofar as there is
no fuel-cooling device on the test stand.
• Record readings for power, fuel, 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
Run-in” in “MTU Diesel Engine Factory Test” record.
Install engine on test stand. –
Connect engine to dynamometer or generator. –
Connect air intake, exhaust, engine coolant, raw water –

and fuel pipework.
Connect dialog unit to ECU. –
Fill expansion tank with coolant with 2% corrosion (→Operating Instructions)

inhibitor oil up to max. mark.
Vent coolant lines until bubble-free coolant emerges. –
Check that fuel in service or supply tank is according (→Fluids and Lubricants Specification)
to specification.
Vent fuel system. (→Operating Instructions)
Fill oil system with engine oil. (→Operating Instructions)
Lubricate valve gear. (→Operating Instructions)
Check operation of engine governor before starting –

engine.
Check emergency shutdown system. –
Start engine. (→Operating Instructions)
After approx. 1 minute idling operation, shut down (→Operating Instructions) (→Operating Instructions)
engine and:
• Check engine oil level. If necessary, top up oil.
• Check valve gear lubrication.
Start engine and check idle speed. –
Check for leaks at coolant, oil and fuel lines, crankcase –

seals, air system and exhaust lines.
Run in engine in accordance with run-in program and (→Acceptance test record)
record measured values.
M020127/02E 05-08 © MTU

Compare/check injection, temperatures, pressures and –

speeds at gauge dialogue units with Acceptance Test
Record.
Check exhaust gas color and enter. –
Enter barometric pressure and relative air humidity in (→Acceptance test record)
Test Record.
Check engine for abnormal running noises and leaks. –
Check engine monitoring. –
After running in, run down engine and switch off. (→Operating Instructions)
Cut open one oil filter and check for residues. –
Carry out acceptance test in accordance with MTU –

Engine Acceptance Test Record.
Enter operational data in Acceptance Test Record. (→Acceptance test record)
Compare values with measured values in MTU (→Acceptance test record)

Acceptance Test Record and evaluate.
After completion of acceptance test, run down engine (→Operating Instructions)

and switch off.
Preserve engine if it is to be out of service for a (→Fluids and Lubricants Specifications)

prolonged period.
Take protective measures for sea transportation. –
Remove sensors and measuring lines and seal –

measuring points.
Remove engine from test stand. –
Prepare engine for paint spraying and coat with –

protective paint.
M020127/02E 05-08 © MTU

Task Descriptions 75
3 Task Descriptions
3.1 Crankcase and Attachments
3.1.1 Engine layout

Deviations from illustrations are insignificant
The same applies analogously to 8/12/16V 2000CR
010 Crankcase and attachments 140 Exhaust system 500 Monitoring and control system,
020 Gear train (→ Page 125) 170 Starting system (→ Page 443) general electric devices
030 Running gear (→ Page 151) 180 Lube oil system (→ Page 558)
040 Cylinder head (→ Page 258) 200 Engine cooling system
050 Valve gear (→ Page 289) (→ Page 462)
070 High pressure fuel system 210 Power supply
(→ Page 329) 230 Mounting/support (→ Page 525)
080 Low pressure fuel system 250 PTO systems, driving and free
100 Exhaust turbocharger ends (coupling)
(→ Page 367) 360 Auxiliary systems and additional
110 Intercooler (→ Page 392) equipment (not illustrated)
120 Air intake / air supply (→ Page 540)
M020127/02E 05-08 © MTU

76 Task Descriptions
3.1.2 Cylinder liner – Overview
1 Sealing ring 3 Cylinder liner

2 Sealing ring 4 Scraper ring
M020127/02E 05-08 © MTU

3.1.3 Cylinder liner – Removal
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Removal tool for liner F6783773 1
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Components have sharp edges.

Risk of injury!
WARNING • Wear protective gloves.
M020127/02E 05-08 © MTU

Preparatory steps
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 (→ Page 65)
X – – Disassemble engine (→ Page 66)

– – X Disable engine start (→ Page 16)
– – X Drain engine coolant (→Operating Instructions)
– – X Drain or draw off engine oil (→Operating Instructions)
– X X Remove air filter (→ Page 400)
– X X Remove intake housing
– X X Remove control block and control line for air and exhaust flaps
– X X Remove engine control (→Operating Instructions)
– X X Remove charge-air manifold (→ Page 404)
– X X Remove cylinder head cover (→ Page 325)
– X X Remove constant-pressure manifold (→ Page 412)
– X X Remove high-pressure line
– X X Remove leak-off fuel line. (→ Page 363)
– X X Remove valve drive (→ Page 313)
– X X Remove pushrods (→ Page 304)
– X X Remove cable connection
– X X Remove cylinder head (→ Page 260)
– X X Lower or remove oil pan (→ Page 89)
– X X Remove piston and conrod (→ Page 216)
Removing carbon scraper ring

1. Extract carbon scraper ring from fit of cylinder liner.
2. Protect carbon scraper ring from damage.
M020127/02E 05-08 © MTU

Cylinder liner – Removal

1. Mark installation position of cylinder liner to
crankcase with a marking pen (arrow).
2. Insert removal tool (1) in cylinder liner (2).

Note: Do not damage oil spray nozzle.
3. Set extraction plate at the lower collar of the

cylinder liner (2).
4. Engage captive washer (4) on threaded rod.
5. Turn nut (3) on removal tool (1) until cylinder
liner (2) becomes loose on crankcase bore.
6. Take off removal tool (1).
7. Extract cylinder liner (2) from crankcase.
8. Remove sealing rings from cylinder liner (2).
M020127/02E 05-08 © MTU

3.1.4 Cylinder liner – Cleaning
Material
Decarbonizer
Cleaning agent
Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.
Remove cylinder liner (→ Page 77)
Cylinder liner – Cleaning

1. Clean cylinder liner with cleaning agent.
2. Clean the carbon scraper ring using decarbonizing agent.
3. Remove cleaning agent.
M020127/02E 05-08 © MTU

3.1.5 Cylinder liner – Check
Special tools
Bore gauge
Dial gauge
Micrometer or adjusting ring
Material
Fluorescent magnetic powder for magnetic crack-testing method
Spare parts
Cylinder liner
Carbon scraper ring
Heavy object.
Risk of crushing!
Clean cylinder liner (→ Page 80).
M020127/02E 05-08 © MTU

Cylinder liner – Check
Item Findings Task
Using the magnetic crack-testing Signs of cracks Replace

method with fluorescent magnetic
powder, check the cylinder liner for
cracks.
Check outer wall for pitting. Pitting visible. Replace
Check sealing and mating faces for • Wear • Recondition: Smooth with
wear and damage. • Damage oilstone.
visible. • Replace
Check carbon scraper ring for • Scores Replace

scoring and pitting. • Pitting
visible.
Check floating mount of the carbon Signs of jamming • Measure cylinder liner.
scraper ring in the cylinder liner. • Replace carbon scraper ring.
Check cylinder liner running surface • Scores Replace

for scores and pitting. • Pitting
visible.
Check reversal point of first piston Wear visible. Replace cylinder liner.
ring for wear.
Measure cylinder liner bore with Values exceeded Replace

bore gauge and dial gauge.
Measurement plane and values
(→ Page 83).
M020127/02E 05-08 © MTU

3.1.6 Cylinder liner – Tolerances
No. Designation Stage Toler- Deviation Clearance Interference Wear

anced limit
size
lower upper min. max. min. max.
Basic
size
1 Crankcase bore 0 157.500 0 +0.040 0.005 0.070

H7
- upper fit
1 158.000
H7
Cylinder liner 0 157.500 −0.030 −0.005

- upper fit
1 158.000
2 Crankcase bore 0 154.000 0 +0.040 0.025 0.090

H7
- lower fit
1 154.500
H7
Cylinder liner 0 154.000 −0.050 −0.025

- lower fit
1 154.500
3 Crankcase bore 170.500 −0.100 +0.300 0.300 0.900
Seal 170.000 −0.100 +0.100

outer Ø
M020127/02E 05-08 © MTU


anced limit
size
Basic
size
4 Liner bore 139.000 0 +0.040 0.014 0.094

H7
Carbon scraper 139.000 −0.054 −0.014

ring outer Ø g7
5 Carbon scraper 134.400 0 +0.063

ring bore H8
6 Cylinder liner 0 10.850 −0.020 0

Collar thickness
7 Sealing ring 0.150 −0.010 +0.010
8 Cylinder liner protrusion: 10.440 to 10.540
9 0 to 0.03 > actual dimension inner Ø
10 Plane of 30.000
measurement
Reconditioning instructions:
Re 1 and 2:
If there is cavitation on the upper and/or lower fit of the crankcase bore:
Introduce next repair stage and install cylinder liner of corresponding stage.
To be carried out only in workshops authorized by MTU.
Re 4 and 5:
Check scraper ring OD and ID when fitted.
Re A Cylinder liner without groove: stage 0
Cylinder liner with groove: stage 1
M020127/02E 05-08 © MTU

3.1.7 Cylinder liner – Installation
Special tools
Installation tool for cylinder liner F6783388 1
Safety rail F6555715 2
Material
Petroleum jelly, white
Engine oil
Spare parts
Sealing rings
Scraper ring
Heavy object.
Risk of crushing!

Risk of injury!
Contamination of components.
• Check components for special cleanness.
Check cylinder liner (→ Page 81).
M020127/02E 05-08 © MTU

Cylinder liner – Installation

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

5. Fix sealing ring (2) with petroleum jelly on
crankcase (3).
6. Insert cylinder liner (4) in crankcase (3).
7. Install press-in tool (3) on crankcase (1).

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

1. Adjust bore gauge and dial gauge with micrometer or gauge ring to basic size for cylinder liner. Value and
measurement planes (→ Page 83).
2. Measure cylinder liner bore with bore gauge.
3. Record measured values in data sheet.
4. If out-of-round is measured:
4.1. Remove cylinder liner.
4.2. Remeasure cylinder liner bore and outer diameter.
4.3. Check correct fit of sealing rings.
Measuring protrusion of cylinder liner

1. Measure protrusion of cylinder liner collar to crankcase. Record protrusion. Carry out 4 x 90° offset
measurements.
2. For each measurement, set the scale of the dial gauge to zero. The difference of the 4 measured points per
cylinder liner must not exceed max. 0.02 mm. Protrusion (→ Page 83).
3. If the test values deviate, remove cylinder liner and check cause.
M020127/02E 05-08 © MTU

Installing carbon scraper ring

Note: Insert carbon-deposit scraper ring only after piston has been installed (→ Page 249) .
1. Spray cylinder liner and carbon scraper ring with engine oil.
2. Insert carbon scraper ring into fit of cylinder liner.
3. Remove safety rail for cylinder liners.
Final steps

1 the engine was completely disassembled
2 the engine was removed but not disassembled
3 the engine is still installed
X – – Assemble engine (→ Page 69)
X – – Install engine (→ Page 72)

– X X Assemble in reverse sequence to disassembly (→ Page 77)
– – X Fill with engine oil (→Operating Instructions)
– – X Fill with engine coolant (→Operating Instructions)
– – X Enable engine start –
M020127/02E 05-08 © MTU

3.1.8 Oil pan – Overview
5 Oil pan 50 Washer

10 Gasket 60 Screw
25 Screw 65 Sealing ring
30 Washer 75 Washer
35 Screw 80 Flange
40 Screw 85 O-ring
45 Screw 90 Screw
M020127/02E 05-08 © MTU

3.1.9 Oil pan – Removal
Preconditions
Special tools
Crankcase rotation device VM59210 1
Support F6783180 1
Frame F6554710 1
Lowering device F6784104 3
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Heavy object.
Risk of crushing!
Preparatory steps


– – X Drain engine oil (→Operating Instructions)
– X X Remove oil pump connections
– X X Remove filling and measuring device
M020127/02E 05-08 © MTU

Lowering oil pan

Note: The oil pan can be lowered for assembly
work with the engine installed.
1. Install lowering devices (1) on the right and left

engine sides.
2. Remove all screws (3) for oil pan (4).
3. Lower oil pan (4) by evenly turning the threaded
rods (2) of the lowering devices (1).
Oil pan – Removal

1. Seal openings with suitable covers.
2. Install engine in rotation device and rotate by 180°.
3. Remove screws for oil pan.
4. Attach oil pan to crane with lightly pretensioned rope and set down on suitable surface.
5. Remove gasket.
M020127/02E 05-08 © MTU

3.1.10 Oil pan – Cleaning
Material
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Remove oil pan (→ Page 89).
Oil pan – Cleaning

1. Clean all components with cleaning agent.
3. Thoroughly blow out oil pan and all threaded bores with compressed air.
M020127/02E 05-08 © MTU

3.1.11 Oil pan – Check
Special tools
Red dye penetrant for surface crack test procedure
Spare parts
Oil pan
Screw
Heavy object.
Risk of crushing!
Clean oil pan (→ Page 91).
Oil pan – Check
Item Findings Measure
Check oil pan with surface crack test Signs of cracks Replace
procedure and red dye penetrant for
cracks.
Check mating face of oil pan with Unevenness above 0.3 mm for 8, Rework contact surface.
crankcase for surface irregularities. 10, 12V
Unevenness above 0.5 mm for 16 V
Check sealing faces. Damaged • Recondition

• Replace
Check tapped holes for ease of Sluggish Replace thread inserts.

movement.
M020127/02E 05-08 © MTU

3.1.12 Oil pan – Installation
Material
Engine oil
Loctite 5970
Loctite 586
Spare parts
Gasket
Screw
Union
Sealing ring
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Incorrect installation of components and lines.

CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
Check oil pan (→ Page 92)
M020127/02E 05-08 © MTU

Installing lowered oil pan

1. Clean mating faces on oil pan (3) and
crankcase (4) so that they are dry and free
of grease.
2. Coat contact surfaces around the interstices of
crankcase - flywheel housing and crankcase -
gearcase with Loctite 5970.
3. Set gasket on to sealing face of oil pan.
4. Attach oil pan (3) to crankcase (4) by evenly turning
the threaded rods (2) of the lowering devices (1).
5. Insert screws and washers for oil pan (3) and
tighten evenly.
6. Remove lowering devices (1), insert and tighten
remaining screws and washers.
Oil pan – Installation

1. Prior to installation, remove all covers.
2. Turn crankcase in rotation device until oil pan attachment surface is horizontal and facing upwards.
3. Clean mating faces on oil pan and crankcase so that they are dry and free of grease.
4. Coat contact surfaces around the interstices of crankcase - flywheel housing and crankcase - gearcase
with Loctite 5970.
5. Set gasket on to sealing face.
6. Attach oil pan to crane with lightly pretensioned rope and set down carefully on mating face of crankcase. In
doing so, align oil pan to bores of crankcase mating face.
7. Insert all screws and washers for oil pan and tighten evenly.
8. Coat plug screws with Loctite 586 and screw into oil pan.
Final steps


– – X Fill with engine oil (→Operating Instructions)
– – X Fill with engine coolant (→Operating Instructions)
M020127/02E 05-08 © MTU

3.1.13 Engine lifting equipment – Overview
10 Engine lifting equipment, free end 40 Engine lifting equipment, 60 Screw

20 Screw driving end 65 Washer
25 Washer 50 O-ring 70 Eyebolt
30 Eyebolt 55 O-ring
M020127/02E 05-08 © MTU

3.1.14 Engine lifting equipment – Removal
Preconditions
Preparatory steps


– – X Disable engine start (→ Page 16)
Engine lifting equipment – Removal

1. Remove engine lifting equipment as shown in overview drawing (→ Page 95) .
2. Remove O-rings.
M020127/02E 05-08 © MTU

3.1.15 Engine lifting equipment – Cleaning
Material
Cleaning agent
Compressed air.
Risk of injury!

Remove engine lifting equipment (→ Page 96).
Engine lifting equipment – Cleaning

3. Blow out all parts with compressed air.
M020127/02E 05-08 © MTU

3.1.16 Engine lifting equipment – Check
Material
Red penetrant dye for surface crack-testing procedure
Spare parts
Engine lifting equipment
Clean engine lifting equipment (→ Page 97).
Engine lifting equipment – Check
Item Findings Task
Check engine lifting equipment for Damaged Replace

damage.
Check engine lifting equipment with Signs of cracks Replace

surface crack test procedure for
cracks.
Check mating and bolt-on faces for Damaged • Recondition: smooth with
damage. oilstone.
• Replace
Check threads in crankcase for ease Sluggish Recondition: Recut threads

of movement.
M020127/02E 05-08 © MTU

3.1.17 Engine lifting equipment – Installation
Material
Engine oil
Spare parts
Screw
Washer
O-ring
Check engine lifting equipment (→ Page 98).
Engine lifting equipment – Installation

1. Coat O-rings with petroleum jelly and insert in grooves.
2. Install engine lifting equipment with screws and washers as shown in overview drawing (→ Page 95) .
Final steps


M020127/02E 05-08 © MTU

3.1.18 Crankcase breather – Overview
15 Oil deflector plate 95 O-ring 150 Washer

20 Cover 105 Oil separator 160 Intake pipe
30 Gasket 110 Screw 165 Clamp
40 Screw 115 Washer 175 Screw
50 Washer 125 Oil line 180 Washer
65 Rubber sleeve 127 Intake pipe 185 O-ring
70 Clamp 128 Clamp 200 Clamp
75 Pipe 130 Oil line 205 Screw
85 Screw 140 Clamp 210 Washer
90 Washer 145 Screw
M020127/02E 05-08 © MTU

Crankcase breather
220 Oil line 238 Screw 250 Screw

230 Sealing ring 239 Nut 255 Washer
235 Connection 240 Nut 260 Clamp
237 Clamp 241 Oil line
M020127/02E 05-08 © MTU

Oil separator
1 Diaphragm 2 Filter element 3 Gasket
M020127/02E 05-08 © MTU

3.1.19 Crankcase breather – Removal
Preconditions
Preparatory steps

X – – Remove engine. (→ Page 65)
X – – Disassemble engine. (→ Page 66)
Removing pipework and oil separator

1. Before removing the lines, take photos or label attachments and lines.
2. Remove pipework and oil separator as shown in overview drawings (→ Page 100).
4. Protect oil separator from damage.
M020127/02E 05-08 © MTU

3.1.20 Hengst oil separator – Disassembly
Special tools
Screwdriver (Torx 30)
Remove Hengst oil separator (→ Page 103).
Disassembling Hengst oil separator

1. Remove screws (2) for cover (1).
2. Remove cover (1) and O-ring.
3. Remove aerosol element (1) from oil separator

housing (2).
M020127/02E 05-08 © MTU

4. Remove screws for cover (1).

5. Remove cover (1), spring (2) and O-ring.
6. Remove diaphragm (3) from oil separator housing.
M020127/02E 05-08 © MTU

3.1.21 Crankcase ventilation – Cleaning
Material
Cleaning agent
Compressed air.
Risk of injury!

Remove crankcase ventilation (→ Page 103).
Crankcase ventilation – Cleaning

3. Clean pipes and all threads thoroughly with compressed air.
M020127/02E 05-08 © MTU

3.1.22 Crankcase breather – Check
Material
Corrosion inhibitor
Spare parts
Pipe
Oil separator
Clamp
Holder
Carrier
Intake pipe
Cover (if fitted)
Housing (if fitted)
Strap (if fitted)
Compressed air is pressurized.

Hot testing liquid.
WARNING Risk of injury and scalding!
• Pressure must not exceed 0.5 bar.
Clean crankcase breather (→ Page 106).
Crankcase breather – Check
Visually inspect components for Damaged Replace

damage and wear.
Check sealing surfaces and bolt-on Damaged • Recondition: smooth with

faces for damage and wear. oilstone
• Replace
Check movement of threads. Damaged • Recondition: recut threads

• Replace
Check pipes for leaks in water bath, Leaking • Recondition

using compressed air and corrosion • Replace
inhibitor.
• Test pressure: 0.5 bar (do not
exceed test pressure)
Check function of oil separator Malfunction Replace

(→ Page 108).
M020127/02E 05-08 © MTU

3.1.23 Hengst oil separator – Check
Spare parts
Diaphragm
Oil separator
Compressed air is pressurized.

Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
Clean Hengst oil separator (→ Page 106).
Hengst oil separator – Check
Item Findings Task
Visually inspect components for Damaged Replace

damage and wear.
Check sealing surfaces and bolt-on Damaged • Recondition: smooth with

faces for damage and wear. oilstone
• Replace
Check thread for ease of movement. Damaged • Recondition: recut threads

• Replace
Pressure-test oil separator for leaks Leaking • Replace

with air in water bath.
• Test pressure: 0.2 bar (do not
exceed test pressure)
Oil separator pressure control can only be checked when installed with engine running. Vacuum or overpressure
is measured (e.g. with water pressure gauge) over entire engine speed range. Values should lie between minus
10 mbar and plus 10 mbar (100 mm water column).
M020127/02E 05-08 © MTU

3.1.24 Hengst oil separator – Assembly
Special tools
Screwdriver (Torx 30)
Material
Check Hengst oil separator (→ Page 108).
Assembling Hengst oil separator

1. Coat O-ring (arrow) with petroleum jelly and insert
into groove provided on oil separator housing (3).
2. Insert diaphragm (2) in oil separator housing (3)
ensuring it is correctly positioned (curvature
facing up).
3. Fit spring (1) on diaphragm (2), ensuring spring (1)
is correctly seated at diaphragm (2).
4. Mount cover (1) on spring (2) in correct position.

5. Insert screws and tighten diagonally with
torque wrench to prescribed tightening torque
(→ Page 24).
M020127/02E 05-08 © MTU

6. Coat O-ring with petroleum jelly and insert into

groove (arrow) provided on oil separator housing
(2).
7. Insert aerosol element (1) in oil separator
housing (2), ensuring it is correctly positioned.
8. Put cover (1) on to oil separator housing,

insert screws (2) and tighten diagonally with
torque wrench to prescribed tightening torque
(→ Page 24).
9. Check oil separator for leaks (→ Page 108).
M020127/02E 05-08 © MTU

3.1.25 Crankcase ventilation – Installation
Material
Engine oil
Spare parts
Gasket
O-ring
Sealing ring
Clamp
Union
Check crankcase ventilation (→ Page 107).
Crankcase ventilation – Installation

2. Coat O-rings with petroleum jelly.
3. Install oil separator and pipes as shown in overview drawings (→ Page 100).
Final steps

1 The engine was completely disassembled
2 The engine was removed but not disassembled
3 The engine is still installed

M020127/02E 05-08 © MTU

3.2 Gear Train
3.2.1 Flywheel housing – Overview
25 Flywheel housing 99 Spacer bush 160 Sealing ring

35 Sleeve 100 Screw 170 Plug
40 Seal, left 101 Washer 175 Sealing ring
45 Seal, right 105 Holder 180 Screw
50 Screw 110 Screw 185 Washer
55 Screw 115 Washer 190 Plug
80 Plug 125 Screw 195 Sealing ring
85 Seal 130 Sealing ring 200 Screw
90 Screw 140 Radial-lip shaft seal 205 Washer
95 Washer 150 Screw
97 Holder 155 Adapter union
M020127/02E 05-08 © MTU

Flywheel housing – Overview
5 Flywheel housing 25 Sleeve 35 Sleeve

20 Bearing flange 30 Flange
M020127/02E 05-08 © MTU

3.2.2 Flywheel housing – Removal
Preconditions
Special tools
Eyebolt 000580016002 4
Load frame B80525907 2
Suspended load.
Danger to life!

Risk of injury!
Preparatory steps


– X X Remove crankcase breather (→ Page 103)
– X X Remove exhaust turbocharger (→ Page 368)
– X X Remove oil supply line for exhaust turbocharger (→ Page 457)
– X X Remove oil return line for exhaust turbocharger
– X X Remove carrier housing (→ Page 423)
– X X Remove flywheel (→ Page 191)
– X X Remove starter (→ Page 444)
– X X Remove engine mounting, driving end (→ Page 526)
(→ Page 534)
Flywheel housing – Removal

1. Insert eyebolts.
2. Use lightly pretensioned rope to attach flywheel housing to crane.
3. Mark all screws (different lengths) and remove (→ Page 112).
4. Remove flywheel housing from crankcase.
M020127/02E 05-08 © MTU

5. Remove attachments on flywheel housing as shown in overview drawing (→ Page 112).

M020127/02E 05-08 © MTU

3.2.3 Flywheel housing – Cleaning
Material
Cleaning agent
Compressed air.
Risk of injury!

Remove flywheel housing (→ Page 114).
Flywheel housing – Cleaning

1. Clean all parts with cleaning agent.
3. Blow out all parts and all threads thoroughly with compressed air.
M020127/02E 05-08 © MTU

3.2.4 Flywheel housing – Check
Special tools
Bore gauge
Micrometer
Material
Red dye penetrant for surface crack test procedure
Spare parts
Flywheel housing
Plug
Clean flywheel housing (→ Page 116).
Flywheel housing – Check
Check flywheel housing with red dye Signs of cracks Replace

penetrant for cracks.
Check mating and bolt-on faces. Wear Smooth with oilstone.
Check threads for damage. Damaged Rework threads.
Check sleeve of sensor for damage. Damaged • Recondition with oilstone or

emery cloth.
• Replace (→ Page 124)
Check radial-lip shaft seal for Damaged Replace (→ Page 122)

damage.
M020127/02E 05-08 © MTU

3.2.5 Flywheel housing – Tolerances

anced limit
size
1 Flywheel housing 148.000 0 +0.063 0.187 0.450

bore H8
Shaft seal outer 148.000 +0.250 +0.450

Ø
M020127/02E 05-08 © MTU

3.2.6 Flywheel housing – Installation
Special tools
Eyebolt 000580016002 4
Locating pin F6555162 2
Load frame B80525907 2
Alignment tool F6782161 2
Material
Loctite 573
Engine oil
Spare parts
Gasket
Screws
Suspended load.
Danger to life!

Risk of injury!
Check flywheel housing (→ Page 117).
M020127/02E 05-08 © MTU

Flywheel housing – Installation

2. Install attachments on flywheel housing as shown
in overview drawing (→ Page 112).
3. Screw locating pin (3) into crankcase.
4. Degrease and dry sealing face between flywheel
housing and crankcase.
5. Apply Loctite evenly around bores (arrow).
6. Attach seal (2) on both sides.
7. Screw eyebolts into flywheel housing.
8. Use lightly pretensioned rope to attach flywheel
housing to crane.
9. Use crane to install flywheel housing (1) on

crankcase (3).
10. Insert two screws and screw in.
11. Remove locating pins (2).
Note: Observe different screw lengths and types.
12. Insert all screws and washers and tighten evenly.

13. Remove ropes and eyebolts.
14. Check axial play of camshaft (→ Page 297).
M020127/02E 05-08 © MTU

Final steps


– – X Fill up with engine coolant (→Operating Instructions)
M020127/02E 05-08 © MTU

3.2.7 Radial-lip shaft seal – Replacement
Preconditions
Special tools
Extraction tool F30379303 1
Installation jig F6782568 1
Nut B80141628 1
Feed shaft F6555797 1
Material
Denatured ethanol
Spare parts
Radial-lip shaft seal

Removing shaft seal

Note: Use extraction tool only if flywheel housing is installed.
1. Install extraction tool for shaft seal.

2. Extract shaft seal from flywheel housing with extraction tool.
M020127/02E 05-08 © MTU

Installing shaft seal in seal carrier

1. Check bore for sealing ring in flywheel housing.
Values (→ Page 118).
2. If values are exceeded, replace flywheel housing.
Note: Use installation jig (3) only if flywheel
housing is installed.
3. Slide shaft seal (2) on to installation jig (3) with

sealing lip facing downwards.
4. Clean sealing face for shaft seal (2) in flywheel
housing (1) until free of grease and dry.
5. Coat sealing face on shaft seal (2) with ethanol.
6. Screw installation jig (3) into crankshaft (4).
7. Remove installation jig (3).
M020127/02E 05-08 © MTU

3.2.8 Sensor sleeve – Removal and installation
Special tools
Mandrel
Material
Liquid nitrogen
Spare parts
Sleeve
Nitrogen is liquid (at -200°C).

Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Ventilate working area well.
Check sleeve (→ Page 117).
Removing sleeve
1. Place flywheel housing to the side on a suitable surface.
2. Use suitable mandrel and hammer to remove sleeve (→ Page 112) from flywheel housing.
Installing sleeve
1. Clean bore (→ Page 112) in flywheel housing.
2. Chill sleeve in liquid nitrogen.
3. Insert chilled sleeve in flywheel housing.
M020127/02E 05-08 © MTU

3.2.9 Gearcase, free end – Overview
1 Gearcase, free end 4 Hub 7 Idler gear

2 Plug screw 5 Idler gear
3 Self-aligning ball bearing 6 Hub
M020127/02E 05-08 © MTU

3.2.10 Gearcase, free end – Removal
Preconditions
Special tools
Eyebolt 000580016002 4
Guide pin F6558527 4
Axial fixation camshaft F6557158 1
Drive-out mandrel for bearings F6783790 1
Drive-out mandrel for shaft F6783789 1
Suspended load.
Danger to life!

Risk of injury!
M020127/02E 05-08 © MTU

Preparatory steps


– – X Drain or draw off engine oil (→Operating Instructions)
– X X Disconnect and remove electric wiring
– X X Remove coolant pipework after coolant pump
– X X Remove engine coolant pump (→ Page 464)
– X X Remove raw water pump (→ Page 507)
– X X Remove vibration damper (→ Page 202)
– X X Remove belt drive
– X X Remove bilge pump (if installed) (→ Page 543)
– X X Remove oil pump connections
– X X Remove battery-charging generator
– X X Lower or remove oil pan (→ Page 89)
– X X Connect engine to lifting device –
– X X Remove engine mounting, free end (→ Page 526)
Gearcase, free end – Removal

1. Check radial-lip shaft seal (3) for damage, replace
if required (→ Page 139).
2. Check self-aligning ball bearing (1) and radial-lip
shaft seal of battery-charging generator for
damage, replace if required.
3. Screw eyebolts into gearcase, free end (4).
4. Attach gearcase, free end to crane with lightly
pretensioned rope.
5. Remove plug screws (2).
6. Unscrew and remove screws through hole borings
of idler gears. If screws are not visible, rotate
crankshaft accordingly.
7. Mark all screws on gearcase, free end (4) (different
lengths and types).
8. Insert guide pin.
9. Remove gearcase, free end (4) from crankcase.
10. Remove O-rings and gasket.
11. Protect gearcase, free end (4) from damage.
12. Install axial fixation for camshaft.
M020127/02E 05-08 © MTU

13. Remove guide pin.

M020127/02E 05-08 © MTU

3.2.11 Gearcase, free end – Cleaning
Material
Cleaning agent
Compressed air.
Risk of injury!

Remove gearcase, free end (→ Page 126).
Cleaning equipment carrier

3. Thoroughly clean equipment carrier, oil chambers and all oil bores by blowing out with compressed air.
M020127/02E 05-08 © MTU

3.2.12 Gearcase, free end – Check
Special tools
Bore gauge
Adjusting ring
Material
Fluorescent magnetic powder for magnetic crack test procedure
Spare parts
Gearcase, free end
Idler gears
Hub
Crankshaft bearing
Heavy object.
Risk of crushing!
Disassemble gearcase, free end (→ Page 137).
M020127/02E 05-08 © MTU

Gearcase, free end – Check
Check gearcase, free end with Signs of cracks Replace.

magnetic crack test procedure for
cracks.
Check crankshaft bearings for wear, • Scores Replace crankshaft bearing

scoring and indentation. • Indentations (→ Page 137).
visible
Check threads in gearcase for ease Sluggish Recut threads.

of movement.
Check screw threads and shafts for Damaged Replace.

damage.
Check all mating and sealing faces Damaged • Recondition with oilstone or
and fits. emery cloth.
• Replace.
Measure crankshaft bearing Values exceeded. Replace crankshaft bearing

in gearcase, free end. Values (→ Page 137).
(→ Page 132)
Measure crankshaft bearing bore in Values exceeded. Replace gearcase.

gearcase. Values (→ Page 132)
M020127/02E 05-08 © MTU

3.2.13 Gearcase, free end – Tolerances
No. Designation Stage Toleranced size Clearance Interference Wear

limit
1 Gearcase bore 180.000 0 +0.063 0.237 0.550

H8
Replace radial-lip 180.000 +0.300 +0.550

shaft seal
2 Gearcase bore 160.000 0 0.025 0.100 0.155

H6
Bearing outer Ø 160.100 −0.030 0

removed
3 Bearing bore 150.107 0 +0.120 0.297 0.417

installed
Vibration damper 149.820 −0.010 +0.010

outer Ø
M020127/02E 05-08 © MTU

3.2.14 Gearcase, free end – Installation
Special tools
Eyebolt 000580016002 4
Alignment tool F6783001 1
Guide pin F6558527 1
Drive-in tool shaft seal F30450344 1
Drive-in tool shaft seal F30450345 1
Material
Engine oil
Spare parts
O-ring
Sealing ring
Retainer
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!

Check gearcase, free end.
M020127/02E 05-08 © MTU

Gearcase, free end – Installation

1. Coat O-ring (1) and sealing ring (2) with petroleum
jelly and insert in grooves on gearcase, free end.
3. Turn back jackscrew (1) of alignment tool (2).

Note: Marking (4) always faces upwards,
regardless of position of crankcase.
4. Install alignment tool (2) on crankshaft (3).

5. Screw eyebolts into gearcase, free end (5).
6. Attach gearcase, free end to crane with lightly
pretensioned rope.
7. Insert guide pin.
8. Install gearcase, free end (5) on crankcase above
alignment tool (2).
9. Align gearcase, free end (1) to crankcase.
M020127/02E 05-08 © MTU

Note: Observe markings / different screw lengths

and types.
10. Insert all screws and washers and tighten evenly.

11. Insert plug screws (2) into gearcase, free end (3)
and tighten.
12. Remove alignment tool from crankshaft with
jackscrew.
13. Install self-aligning ball bearing (1) and radial-lip
shaft seals.
Checking axial play and backlash

1. Attach magnetic-base holder with dial gauge to gearcase.
2. Measure axial play:
2.1. Attach preloaded dial-gauge anvil to lateral collar of idler gear.
2.2. Set dial gauge to zero.
2.3. Check axial play by moving idler gear back and forth in axial direction. Values (→ Page 141).
3. Measure backlash:
3.1. Attach preloaded dial-gauge anvil to tooth flank of idler gear.
3.2. Set dial gauge to zero.
3.3. Measure backlash by moving idler gear in radial direction.
3.4. Compare with specified values in table (→ Page 141).
4. If limit values are exceeded, replace idler gears.
M020127/02E 05-08 © MTU

Final steps


– – X Fill up with engine oil (→Operating Instructions)
– – X Fill up with engine coolant (→Operating Instructions)
– – X Fill fuel system (→Operating Instructions)
M020127/02E 05-08 © MTU

3.2.15 Gearcase, free end – Removal and installation of crankshaft bearing
Special tools
Extraction device F6784844 1
SKF hand pump 5555890063/00 1
Hydraulic nut B80144155 1
Installation jig F6783214 1
Material
Liquid nitrogen
Spare parts
Crankshaft bearing
Nitrogen is liquid (at -200°C).

Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Ventilate working area well.
Component is hot.
Risk of burning!
Check crankshaft bearing bore (→ Page 130).
Removing crankshaft bearing

1. Install extraction device (1) and hydraulic nut (2)
on gearcase.
2. Remove crankshaft bearing (3) with extraction
device (1) and hydraulic nut (2) from gearcase, free
end.
3. Measure main bore in gearcase, free end. Values
(→ Page 132).
4. If limit values are exceeded, replace gearcase,
free end.
M020127/02E 05-08 © MTU

Installing crankshaft bearing

1. Place gearcase, free end on a suitable surface.
2. Chill crankshaft bearing in liquid nitrogen.
3. Insert chilled crankshaft bearing with installation jig in gearcase, free end.
M020127/02E 05-08 © MTU

3.2.16 Radial-lip shaft seal

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M020127/02E 05-08 © MTU

2 Operation Schedules ........................................................... 53

M020127/02E 05-08 © MTU

3.2 Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

M020127/02E 05-08 © MTU

3.3 Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

M020127/02E 05-08 © MTU

3.4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

M020127/02E 05-08 © MTU

3.7 LP Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

M020127/02E 05-08 © MTU

3.10 Air Intake/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

M020127/02E 05-08 © MTU

3.13 Lube Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449

M020127/02E 05-08 © MTU

3.14 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462

M020127/02E 05-08 © MTU

3.15 Mounting/Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525

M020127/02E 05-08 © MTU

1.1 Important Information

1.1.1 Reman assemblies – Prerequisites for maintenance tasks

Series 2000 Series 4000

Vibration damper Vibration damper

Injection pump High-pressure fuel pump

Basic requirements for maintenance and service work

General assembly instructions

M020127/02E 05-08 © MTU

M020127/02E 05-08 © MTU

M020127/02E 05-08 © MTU

1.2 General Conditions

1.2.1 General conditions

M020127/02E 05-08 © MTU

1.2.2 Personnel and organizational requirements

M020127/02E 05-08 © MTU

1.2.3 Safety precautions when working on the engine

Safety precautions when putting the equipment into operation

M020127/02E 05-08 © MTU

M020127/02E 05-08 © MTU

M020127/02E 05-08 © MTU

1.2.4 Auxiliary materials, fire prevention and environmental protection

M020127/02E 05-08 © MTU

M020127/02E 05-08 © MTU

1.2.5 Standards for warning notices in the publication

M020127/02E 05-08 © MTU

Explanation of terms for dimensions of new components

Tolerance size Designed size followd by a fit symbol (e.g. 24 H6) or by

Basic size Designed size without fit symbol or permissible

Deviation Permissible deviation from the basic or tolerance size.

Clearance Difference between bore and shaft diameter when bore

Interference Difference between bore and shaft diameter when bore

Explanation of terms for reconditioning of components

Reworking instructions If wear limits are exceeded or values are below

M020127/02E 05-08 © MTU

1.2.7 Engine side and cylinder designations

1 KGS = Free end 3 KS = Driving end

M020127/02E 05-08 © MTU

1.2.8 Torque specifications for screws, nuts and bolts

Screw for crankshaft bearing cap Engine oil

1 Pretightening torque 300 Nm + 30 Nm

2 Angle of further rotation 90° + 10°

Side screw for crankshaft bearing cap

1 Tightening torque 140 Nm + 10 Nm

Plug screw 180 Nm

Screw for Hengst oil separator 6 Nm + 2 Nm