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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,
Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten.
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und
Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.
Printed in Germany
© 2005 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU
Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic
systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.
Imprimé en Allemagne
© 2005 Copyright MTU Friedrichshafen GmbH
Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen
GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le
traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant
de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.
Modifications réservées.
Impreso en Alemania
© 2005 Copyright MTU Friedrichshafen GmbH
Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su
reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen
bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal
de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.
Stampato in Germania
© 2005 Copyright MTU Friedrichshafen GmbH
Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione, alla
diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici, comprese
banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto alla
manutenzione e alla condotta.
Con riserva di modifiche.
Impresso na Alemanha
© 2005 Copyright MTU Friedrichshafen GmbH
A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorização
prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e
a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line.
Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente
consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores.
Salvo alterações.
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
1 General
Reman assemblies
The following assemblies are only available through the exchange procedure:
Camshaft Camshaft
Injector
MDEC MDEC
• 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
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.
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.
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.).
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.
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.
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.
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.
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!
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.
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.
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.
Crankcase
Designation Torque specification Lubricant
Gear train
Designation Torque specification Lubricant
Running gear
Designation Torque specification Lubricant
Conrod screw
• Nominal length: 67.2 mm to 67.5 mm
• max. elongation: 68.5 mm
Cylinder head
Designation Torque specification Lubricant
Pretightening torque
1st stage 10 Nm
2nd stage 50 Nm
Valve gear
Designation Torque specification Lubricant
1 Pretightening torque 60 Nm
Exhaust turbocharger
Designation Torque specification Lubricant
1 Pretightening torque 35 Nm + 3 m
(left-hand thread)
2 Loosen
3 Pretightening torque 15 Nm + 1 Nm
(left-hand thread)
Intercooler
Designation Torque specification Lubricant
Exhaust system
Designation Torque specification Lubricant
Starting system
Designation Torque specification Lubricant
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
Coolant system
Designation Torque specification Lubricant
Pin for lever on clamping jig 100 Nm + 10 Nm Assembly paste MTH 5109
Mount/support
Designation Torque specification Lubricant
Engine mount
Pressure sensor 20 Nm to 45 Nm
• Engine coolant pressure
• Raw water pressure
• Refill oil pressure
Fuel high-pressure 30 Nm + 5 Nm
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
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.
When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process - e.g. resulting from inaccurate readings and overtightening during assembly.
The values in the tables are for manual tightening with torque wrench.
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
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 2 95 85
MA = tightening torques
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
MA = tightening torques
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.
When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process - e.g. resulting from inaccurate readings and overtightening during assembly.
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
MA = tightening torques
M10 x 1 15
M16 x 1.5 30
MA = tightening torques
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.
When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process - e.g. resulting from inaccurate readings and overtightening during assembly.
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
M32 x 2 160
M42 x 2 260
M48 x 2 320
MA = tightening torques
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.
1.2.9 Settings
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
Crankshaft left
Camshaft right
Exhaust 0.40 mm
5 Overlap 83.6 °
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
yd 3 = ft
yd 36 = in
Area
Unit A multiplied by factor = Unit B
ft2 0.0929 = m2
yd2 0.8361 = m2
Volume
Unit A multiplied by factor = Unit B
ft3 0.02832 = m3
yd3 0.7646 = m3
Speed
Unit A multiplied by factor = Unit B
Mass
Unit A multiplied by factor = Unit B
lb 0.4536 = kg
oz 28.35 =g
ton 1.016 =t
kg 2.205 = lb
t 0.9843 = ton
Force
Unit A multiplied by factor = Unit B
lb 0.4536 = kp
lb 4.4483 =N
kp 2.205 = lb
N 0.101972 = kp
kp 9.80665 =N
Density
Unit A multiplied by factor = Unit B
Torque
Unit A multiplied by factor = Unit B
ft lb 1.3563 = Nm
Nm 0.7373 = ft lb
Pressure
Unit A multiplied by factor = Unit B
lb/sq ft 47.883 = Pa
in QS 0.03386 = bar
in QS 345.3 = kp/m2
atm 760 = mm QS
ft lb s2 1.3563 = kg m2
kg m2 0.7373 = ft lb s2
Energy
Unit A multiplied by factor = Unit B
ft lb 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU
Power
Unit A multiplied by factor = Unit B
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
Temperature
Celsius Kelvin Fahrenheit Réaumur
Fuel consumption
Unit A multiplied by factor = Unit B
M6 6.31/6.04 6.1–6.2–6.25
M8 8.35/8.04 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 14 14.53/14.06 14.25–14.5
M 15 x 2 15.3/15.2 15.25
M 16 16.53/16.06 16.25–16.5
1 Snout
2 Spindle
1 Spindle
2 Thread insert
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.
1.2.13 Abbreviations
AL Alarm
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")
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
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
LOLO Low Low Alarm: Measured value is lower than 2nd minimum limit
MG Message
PAN Panel
TC Tools Catalog
2 Operation Schedules
If engine coolant sample is not OK, fill with cleaning (→Fluids and Lubricants Specification)
agent.
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.
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
Load profile
Load profile table
Application group
1DS Fast vessels with low load factors
Load profile
Load profile table
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
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
Limit, years
Item Operating hours [h]
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
Fuel filter 2 X X X X X X X X X X X
Valve gear - 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 -
Extended component 18
maintenance
Limit, years
Item Operating hours [h]
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
Fuel filter 2 X X X
Valve gear - X X
Belt drive 2 X
Air filter 3 X
Fuel injectors - X
Cylinder chambers - X
Component maintenance - X
Cylinder head - X
Extended component 18 X
maintenance
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
Fuel filter 2 X X X X X X X X X X
Valve gear - X X X X X
Belt drive 2 X X
Air filter 3 X X
Fuel injectors -
Cylinder chambers -
Component maintenance -
Cylinder head -
Extended component 18
maintenance
Limit, years
Item Operating hours [h]
5,500
5,750
6,000
Engine oil filter 2
Engine operation -
Crankcase ventilation - X X X
Crankcase ventilation - X X
Fuel filter 2 X X
Valve gear - X
Belt drive 2 X
Air filter 3 X
Fuel injectors - X
Cylinder chambers - X
Component maintenance - X
Cylinder head - X
Extended component 18 X
maintenance
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
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
Crankcase ventilation - 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 chambers - X
Component maintenance - X
Cylinder head - X
Extended component 18 X
maintenance
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
Drain water and dirt on drain cock of fuel prefilter (if W0507
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 Belt drive Check condition and tension of drive belt, replace if W1003
required. (→Operating Instructions).
QL3 Component Prior to maintenance work, drain coolant and flush W2000
maintenance coolant circuits.
Check pushrods and ball joints for wear. (→ Page 303) W2074
Check rocker and valve bridge for wear. (→ Page 311) W2074
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)
Remove control block and control line for air and exhaust
flaps.
Remove exhaust system for engine coolant cooler and (→ Page 483)
intercooler.
Remove exhaust system for engine coolant cooler and (→ Page 483)
intercooler.
Remove intercooler.
Remove oil filter with slide valve for oil filter switch.
Remove HP line.
Remove injector.
Clean crankcase.
Check crankcase.
Assemble crankcase
Install oil filter with slide valve for oil filter switch.
Install HP line.
Install exhaust system for engine coolant cooler and (→ Page 486)
intercooler.
Install control block and control line for air and exhaust
flaps.
Install intercooler.
Align engine. –
Check that fuel in service or supply tank is according (→Fluids and Lubricants Specification)
to specification.
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.
Run in engine in accordance with run-in program and (→Acceptance test record)
record measured values.
Enter barometric pressure and relative air humidity in (→Acceptance test record)
Test Record.
After running in, run down engine and switch off. (→Operating Instructions)
3 Task Descriptions
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)
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.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Decarbonizer
Cleaning agent
Special tools
Designation / Use Part No. Qty.
Bore gauge
Dial gauge
Micrometer or adjusting ring
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack-testing method
Spare parts
Designation / Use Part No. Qty.
Cylinder liner
Carbon scraper ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Check sealing and mating faces for • Wear • Recondition: Smooth with
wear and damage. • Damage oilstone.
visible. • Replace
Check floating mount of the carbon Signs of jamming • Measure cylinder liner.
scraper ring in the cylinder liner. • Replace carbon scraper ring.
Check reversal point of first piston Wear visible. Replace cylinder liner.
ring for wear.
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
Special tools
Designation / Use Part No. Qty.
Installation tool for cylinder liner F6783388 1
Safety rail F6555715 2
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
Sealing rings
Scraper ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
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 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
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!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Designation / Use Part No. Qty.
Red dye penetrant for surface crack test procedure
Spare parts
Designation / Use Part No. Qty.
Oil pan
Screw
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
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
Material
Designation / Use Part No. Qty.
Engine oil
Loctite 5970
Loctite 586
Spare parts
Designation / Use Part No. Qty.
Gasket
Screw
Union
Sealing ring
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Material
Designation / Use Part No. Qty.
Red penetrant dye for surface crack-testing procedure
Spare parts
Designation / Use Part No. Qty.
Engine lifting equipment
Check mating and bolt-on faces for Damaged • Recondition: smooth with
damage. oilstone.
• Replace
Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white
Spare parts
Designation / Use Part No. Qty.
Screw
Washer
O-ring
Final steps
1 2 3 Operations See
Crankcase breather
Oil separator
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Screwdriver (Torx 30)
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Material
Designation / Use Part No. Qty.
Corrosion inhibitor
Spare parts
Designation / Use Part No. Qty.
Pipe
Oil separator
Clamp
Holder
Carrier
Intake pipe
Cover (if fitted)
Housing (if fitted)
Strap (if fitted)
Spare parts
Designation / Use Part No. Qty.
Diaphragm
Oil separator
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).
Special tools
Designation / Use Part No. Qty.
Screwdriver (Torx 30)
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
Gasket
O-ring
Sealing ring
Clamp
Union
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Eyebolt 000580016002 4
Load frame B80525907 2
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Designation / Use Part No. Qty.
Bore gauge
Micrometer
Material
Designation / Use Part No. Qty.
Red dye penetrant for surface crack test procedure
Spare parts
Designation / Use Part No. Qty.
Flywheel housing
Plug
Special tools
Designation / Use Part No. Qty.
Eyebolt 000580016002 4
Locating pin F6555162 2
Load frame B80525907 2
Alignment tool F6782161 2
Material
Designation / Use Part No. Qty.
Loctite 573
Engine oil
Petroleum jelly, white
Spare parts
Designation / Use Part No. Qty.
Gasket
Screws
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Extraction tool F30379303 1
Installation jig F6782568 1
Nut B80141628 1
Feed shaft F6555797 1
Material
Designation / Use Part No. Qty.
Denatured ethanol
Spare parts
Designation / Use Part No. Qty.
Radial-lip shaft seal
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Special tools
Designation / Use Part No. Qty.
Mandrel
Material
Designation / Use Part No. Qty.
Liquid nitrogen
Spare parts
Designation / Use Part No. Qty.
Sleeve
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.
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
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!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Designation / Use Part No. Qty.
Bore gauge
Adjusting ring
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack test procedure
Spare parts
Designation / Use Part No. Qty.
Gearcase, free end
Idler gears
Hub
Crankshaft bearing
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Check all mating and sealing faces Damaged • Recondition with oilstone or
and fits. emery cloth.
• Replace.
Special tools
Designation / Use Part No. Qty.
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
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white
Spare parts
Designation / Use Part No. Qty.
O-ring
Sealing ring
Retainer
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Extraction device F6784844 1
SKF hand pump 5555890063/00 1
Hydraulic nut B80144155 1
Installation jig F6783214 1
Material
Designation / Use Part No. Qty.
Liquid nitrogen
Spare parts
Designation / Use Part No. Qty.
Crankshaft bearing
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Extraction tool F30379303 1
Installation jig F6783178 1
Material
Designation / Use Part No. Qty.
Denatured ethanol
Spare parts
Designation / Use Part No. Qty.
Radial-lip shaft seal
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
3 Idler gear 54
5 Idler gear 54
Special tools
Designation / Use Part No. Qty.
Extractor F30377999 1
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Designation / Use Part No. Qty.
Bore gauge
Micrometer
Magnifying glass
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack-testing method
Spare parts
Designation / Use Part No. Qty.
Idler gears
Axle
Measure bearing bush bore in idler Values exceeded Replace bearing bush (→ Page 149).
gear. Values (→ Page 145).
3 Bush bore
Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white
Spare parts
Designation / Use Part No. Qty.
O-ring
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Installing hub
1. Coat O-ring (2) with petroleum jelly and insert in
groove on hub (3).
2. Insert hub (3) in gearcase (1).
Final steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Hand press
Ejection mandrel F30450850 1
Ejection mandrel F30450851 1
Support F30275611 1
Support F6555514 1
Material
Designation / Use Part No. Qty.
Liquid nitrogen
Spare parts
Designation / Use Part No. Qty.
Bush
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Crankshaft
5 Crankshaft
10 Counterweight
15 Screw
20 Crankshaft gear
25 Crankshaft gear
Special tools
Designation / Use Part No. Qty.
Assembly jig F6783027 1
Insertion shoe set F6783312 1
Crankshaft – Removal
1. To protect crankshaft (1), install insertion shoes (3)
at first and last bearing.
2. Attach crankshaft (1) with lightly pretensioned
rope (2) to crane and lift out of crankcase.
3. Make sure that crankshaft (1) is in horizontal
position when lifted.
4. Set down crankshaft (1) on a firm assembly block.
5. Remove insertion shoes (3).
6. Mark bearing shells (housing side) to main bearing
cap and remove from crankcase.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Removing counterweights
Note: If counterweights are to be removed, mark
relevant counterweight in its installation
position on the crankshaft prior to removal.
Special tools
Designation / Use Part No. Qty.
Bottle brush
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Crankshaft – Cleaning
1. Clean crankshaft using cleaning agent and bottle brush.
2. Remove cleaning agent.
3. Thoroughly clean crankshaft and all threads with compressed air.
Special tools
Designation / Use Part No. Qty.
Endoscope Y20097353
Micrometer
Taper gauge 1:50
Microdur testing device
Depth gauge
Measuring stand
Bore gauge
Dial gauge
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack test procedure
Spare parts
Designation / Use Part No. Qty.
Crankshaft
Counterweight
Screw
Crankshaft gear
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Crankshaft – Check
Measure diameter and roundness Values not attained. To be carried out only in workshops
of main bearing and crankpin with authorized by MTU.
micrometer. Record measured Grind crankshaft to next stage.
values in data sheet. Values
(→ Page 164)
Check thrust washer sliding surfaces Wear visible. • Recondition: smooth with
of first main bearing for wear. Values oilstone.
(→ Page 164) • To be carried out only in
workshops authorized by MTU.
Grind main bearing to next
stage.
Check taper surfaces for scores and Scores visible. • Recondition: smooth with
damage. oilstone.
• To be carried out only in
workshops authorized by MTU.
Rework taper.
Check tapers with taper gauge. Not true to gauge To be carried out only in workshops
authorized by MTU. Rework taper.
Check crankshaft mating face to Traces of wear found. • To be carried out only in
counterweights for traces of wear. workshops authorized by MTU.
Recondition: grind with
grinding machine.
• Replace
Check crankshaft gear with magnetic Signs of cracks Replace (→ Page 157)
crack test procedure for cracks.
Using engineer’s blue, check that Uneven contact. Level mating face.
screw head mating face is in good
contact with counterweight surface.
2-0 108.000
2 42.500 H9
1 5.650
Install bearing shells and bearing caps and tighten as per specification.
Measure main bearing bores in crankcase:
• Determine diameters a, b1 and b2 in the measuring planes 1 and 2 and calculate the average for a, b1 and b2.
• Check bore roundness:
Deviations from roundness can be determined from the average values for a, b1 and b2 as follows: 0.5 (b1+b2)-a
Replace bearing shells if:
• roundness deviation >0.040
• b1 : b2 is above/below 0.040
• vertical ovality -a>0.5 (b1+b2), which is not permitted.
Conrod bearings
1 93.900
2 93.750
3 93.500
2 2.598
3 2.723
2 2.588
3 2.713
Special tools
Designation / Use Part No. Qty.
Alignment tool crankshaft gear, driving end F6552506 1
Spacing jig crankshaft gear, driving end Y4341111 1
Assembly jig crankshaft gear, free end F6554711 1
Spacing jig crankshaft gear, free end Y4341107 1
Feeler gauge Y20010128 1
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Crankshaft gears, driving and free end
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Installing counterweights
1. Measure shank lengths of counterweight screws.
Max. shank length (→ Page 24).
2. Clean the mating faces of crankshaft and
counterweight (1) so that they are dry and free
of grease.
3. Coat threads and screw head mating faces of
screws (2) with engine oil.
4. Position counterweight on crankshaft according to
markings and slightly tighten screws.
Special tools
Designation / Use Part No. Qty.
Master weights
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1. Prior to balancing, seal all oil bores.
2. Depending on stroke position (free residual moment), master weights must be used for dynamic balancing to
simulate the rotating and oscillating mass of conrod and piston.
Dynamic balancing
Maximum operating 2500 1/min 2500 1/min 2500 1/min 2500 1/min
speed
Balancing speed 200 1/min 200 1/min 200 1/min 200 1/min
Permissible residual 180 gcm 180 gcm 240 gcm 240 gcm
unbalance per
compensation level
in other clamp or
balancing machine
(comparison)
Minimum wall 4 mm 4 mm 4 mm 4 mm
thickness around
bore
A 25 mm (max.)
B 22 mm (max. Ø)
C 4 mm (min.)
D 72° (max.)
E 10.4 mm (min.)
Check bearing shell butt and bearing Fretting corrosion visible Replace and determine cause.
rear side for damage and fretting Possible causes:
corrosion (pitting).
• Insufficient screw pretension
• Assembly error
• Spread dimension of bearing
shell outside tolerance
• Faulty bearing support bore
1 Slide layer
2 Barrier layer
3 Intermediate layer
4 Protective steel shell
Assessment
An important indicator for assessing the extent of wear on the bearing shell is the shape
and extent of the barrier layer areas exposed.
Wear of the bearing running surfaces starts at the galvanized slide layer (1).
A reduction of the slide layer contact surface to 70% significantly limits the usability of the bearing shell!
It is often difficult to differentiate between the nickel barrier and softer slide layer.
If in doubt, consult a bearing specialist.
Damage to bearing
Damage to bearings occurs mainly through foreign body scoring, impressions and embedding,
cavitation and corrosion, pitting, fatigue and installation faults.
Bearings showing such damage must be replaced.
Special tools
Designation / Use Part No. Qty.
Bore gauge
Dial gauge
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Crankshaft bearing shells
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Note: The crankshaft bearing bore must first be checked without and subsequently with main bearings installed.
Special tools
Designation / Use Part No. Qty.
Insertion shoe set F6783312 1
Assembly jig F6783027 1
Magnetic holder
Dial gauge
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Installing crankshaft
1. Wipe main bearing surfaces with chamois leather.
2. Attach insertion shoes (3) at first and last bearing.
3. Attach crankshaft (1) with lightly pretensioned
rope (2) to crane.
20 Flywheel
Overview drawing
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Carrying bracket T80091511 1
Installation/removal device F0140565 1
SKF hand pump 5555890063/00 1
Hydraulic unit 5505890163/00 1
Protective sleeve F6780523 1
Locating pin F6555162 2
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Preparatory steps
1 2 3 Operations See
Removing flywheel
1. Remove grub screw from flywheel.
2. Insert feed shaft in crankshaft.
3. Check reference dimension (A) (→ Page 188).
Note: On screwing in the nut up to the stop,
hydraulic nut must be in its initial zero
stroke position.
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Designation / Use Part No. Qty.
Taper gauge 1:50
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack test procedure
Spare parts
Designation / Use Part No. Qty.
Flywheel
Spacer ring
Ring gear
Timing wheel
Coiled spring pin
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Check flywheel and ring gear with magnetic Signs of cracks Replace
crack test procedure for cracks.
Check ring gear for wear and stress marks. Signs of wear • Recondition
• Replace
Check taper with taper gauge. Not true to gauge. Replace taper.
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Coiled spring pin
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Special tools
Designation / Use Part No. Qty.
Carrying bracket T80091511 1
Installation/removal device F0140565 1
SKF hand pump 5555890063/00 1
Hydraulic unit 5505890163/00 1
Protective sleeve F6780523 1
Locating pin F6555162 2
Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Installing flywheel
1. Clean taper surface on crankshaft and flywheel
with cleaning agent and lint-free cloth until free
of grease and dry.
2. Coat bearing surface on flywheel for shaft seal
with engine oil.
3. Coat shaft seal lip with petroleum jelly.
4. Insert feed shaft in crankshaft.
5. Check reference dimension (A) (→ Page 188).
6. Insert locating pin.
7. Screw carrying bracket on to flywheel and attach
to crane with lightly pretensioned rope.
8. Slide flywheel onto crankshaft taper.
Final steps
1 2 3 Operations See
1 Belt drive
2 Crankshaft
3 Vibration damper
4 Gear case
5 Shaft seal
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Installation/removal tool F0140560 1
SKF hand pump 5555890063/00 1
Hydraulic unit 5505890163/00 1
Lifting gear T80091619 1
Protective sleeve F6780523 1
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Designation / Use Part No. Qty.
Taper gauge 1:50
Outside micrometer
Bore gauge
Spare parts
Designation / Use Part No. Qty.
Vibration damper
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Check taper with taper gauge. Not true to gauge. Replace vibration damper.
Measure outer Ø of vibration damper Value not attained. Replace vibration damper.
. Value (→ Page 207)
Special tools
Designation / Use Part No. Qty.
Installation/removal tool F0140560 1
Lifting gear T80091619 1
SKF hand pump 5555890063/00 1
Hydraulic unit 5505890163/00 1
Protective sleeve F6780523 1
Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white
Spare parts
Designation / Use Part No. Qty.
O-ring
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
15. Fill hand pumps (1) and (2) with engine oil SAE10.
16. Vent hand pump (1) and line system, until
bubble-free oil emerges.
17. Tighten high-pressure line for adapter.
18. Before fitting, taper fits must be moistened with
expansion fluid. To do so, operate hand pump (1),
until expansion fluid emerges at hub end.
19. Operate hand pump (2) for hydraulic nut and use
minimum pressure to bring to contact point on hub.
Note: Read off expansion pressure Pmax at hub.
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Puller F30379133 1
Assembly jig F6554708 1
Carrying bracket for unit-pump system T80090974 1
Carrying bracket for CR T80091511
Spare parts
Designation / Use Part No. Qty.
Track ring
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Overview drawing
Overview drawing
Preconditions
• Engine is stopped and starting disabled
Special tools
Designation / Use Part No. Qty.
Barring tool F6783914 1
Lowering device
Assembly jig F6783791 1
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Piston-ring pliers F30379877 1
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Special tools
Designation / Use Part No. Qty.
Decarbonizer
Synthetic rotary brush
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Piston – Cleaning
Note: The graphite layer on the piston skirt must not be mechanically removed or treated with strong cleaners!
Special tools
Designation / Use Part No. Qty.
Ring gauge Y4345226 1
Material
Designation / Use Part No. Qty.
Fluorescent dye penetrant for surface crack test procedure
Fluorescent magnetic powder for magnetic crack test procedure
Spare parts
Designation / Use Part No. Qty.
Piston
Piston pin
Oil control ring
Taper-face compression ring
Keystone-type compression ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Piston – Check
Check piston with red dye penetrant Signs of cracks Replace piston.
for cracks.
Check piston for wear. • Contact erosion at piston edge Replace piston.
and valve clearance pockets
• Large area of polish wear on
piston skirt (appears matt)
• Concentrated occurrence of
scores
• Pitting
Check piston pin with magnetic Signs of cracks Replace piston pin.
crack test procedure for cracks.
Measure piston pin outer diameter Values exceeded Replace piston pin.
with outside micrometer. Values
(→ Page 226)
Piston rings
1 Groove width
Keystone-type
compression ring
2 Groove width
3 Groove width
5 Measure groove width / keystone-type compression ring thickness for 1.500 mm recess.
Piston skirt Ø
Piston skirt Ø
Piston crown Ø
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Conrod – Cleaning
1. Clean conrod and conrod screws with cleaning agent.
2. Remove cleaning agent.
3. Blow out conrod and conrod screws with compressed air.
4. Clean meshing on separating plates of conrod and conrod bearing cap with brass brush and blow dry with
compressed air.
5. Clean conrod oil bore with hole brush and blow out with compressed air.
Special tools
Designation / Use Part No. Qty.
Testing device Y4341492 1
Test mandrel Y4341915 1
Test mandrel Y4341916 1
Bore gauge
Dial gauge
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack test procedure
Spare parts
Designation / Use Part No. Qty.
Conrod
Conrod screw
Conrod bush
Conrod – Check
Check conrod main bore for blue Blue discoloration Replace conrod.
discoloration.
Measuring conrod bore and conrod bush from conrod small end
1. Adjust bore gauge to zero dimension of conrod bush bore and measure conrod bush bore. Values
(→ Page 236).
2. If values are exceeded, replace conrod bush (→ Page 240)
3. After removing the conrod bush, measure main bore in conrod with bore gauge. Values (→ Page 236)
4. If values are exceeded: Replace conrod.
Description Value
Result = 0.08 mm
Description Value
Result = 0.10 mm
Conrod bearings
Reassembly with bearing shells, measurement in the direction of a/b/c, smallest dimension must lie in the
direction of a.
Inner Ø with bearing shell: 94.064 mm +0.042 mm
Conrod bore
Special tools
Designation / Use Part No. Qty.
Assembly jig hydraulic press F6780557 1
Press-in device F6781639 1
Retainer small boss F6347932 1
Fit small boss F6376294 1
Retainer large boss F6554737 1
Shrinking tool F30377859 1
Material
Designation / Use Part No. Qty.
Liquid nitrogen
Spare parts
Designation / Use Part No. Qty.
Conrod bushing
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Special tools
Designation / Use Part No. Qty.
Torque wrench
Assembly jig F6557995 1
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Preparing conrod
1. Blow out separation planes (arrows) on conrod and
conrod bearing cap with compressed air and clean.
2. Wipe bearing shell mating faces on conrod and
conrod bearing cap.
3. Before installing bearing shells, compare repair
stage entries on conrod and on crankshaft data
sheet.
4. Use aluminum jaws to mount conrod in bench vise
under conrod large end in horizontal position.
5. Insert upper conrod bearing (2) in conrod (1).
Check conrod bearing shells for Wear, scores, corrosion, erosion or Replace
wear, scoring, corrosion, erosion damage visible
and damage.
Check conrod bearing shell butt and Fretting corrosion visible Replace and determine cause.
bearing rear side for damage and Possible causes:
fretting corrosion . • Insufficient screw pretension
• Assembly error
• Spread dimension of bearing
shell out of tolerance
• Faulty bearing support bore
1 Slide layer
2 Barrier layer
3 Intermediate layer
4 Steel support shell
Assessment
An important indicator for assessing the extent of wear on the bearing shell is the shape
and extent of the blocking layer areas exposed.
Use of bearing shell is already restricted in friction area once the sliding layer is reduced to 70%!
It is often difficult to differentiate between the nickel barrier and softer slide layer.
If in doubt, consult a bearing specialist.
Damage to bearing
Damage to bearings occurs mainly through impressions and embedding, cavitation and
corrosion, pitting, fatigue and installation faults.
Bearings showing such damage must be replaced.
Special tools
Designation / Use Part No. Qty.
Piston-ring pliers F30379877 1
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Snap ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Special tools
Designation / Use Part No. Qty.
Barring tool F6783914 1
Assembly sleeve F6784287 1
Assembly jig F6557995 1
Material
Designation / Use Part No. Qty.
Engine oil
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
6. Insert piston and conrod with light twist in cylinder liner, so that the oil spray nozzle is not damaged.
Final steps
1 2 3 Operations See
The valve-seat turning machine is an inside turning device. While the cutter (3) rotates around the valve-seat
(5), a feed gear mechanism ensures a continuous outward feed motion (1). The feed motion under the proper
valve-seat angle (4) is defined by an inclined slideway in the exchangeable adapter head.
Precondition:
Cylinder head is securely clamped and valve guide accessible from both sides.
Overview drawing
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Socket F30907150 1
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Valve lifter 4425890031/00 1
Removal tool for valve guide F30450454 1
Socket for BR 2000 unit-pump system F30377657 1
Socket for BR 2000 CR F30450351 1
Retaining device F6554686 1
Magnetic pickup 8205892961/00 1
Pliers for valve stem seal F30450845 1
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Removing valves
1. Insert cylinder head in retaining device.
2. Install valve lifter (1).
3. Use valve lifter to press down valve-spring
retainer (1).
Removing gaskets
1. Place cylinder head on to cylinder head base.
2. Remove gasket from valve guide with two
screwdrivers; be careful not to damage valve
guide.
Special tools
Designation / Use Part No. Qty.
Decarbonizer
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Special tools
Designation / Use Part No. Qty.
Limit plug gauge Y20098136 1
Gauge for exhaust valve seat Y4346861 1
Gauge for inlet valve seat Y4346862 1
Pressure testing device Y4341042 1
Material
Designation / Use Part No. Qty.
Fluorescent dye penetrant for surface crack test procedure
Spare parts
Designation / Use Part No. Qty.
Cylinder head
Screw
Cover
Valve-seat inserts
Sealing ring
Protective sleeve
Cylinder-head gasket
Spring sleeve
Valve
Valve spring
Washer
Valve-spring retainer
Valve collet
Gasket
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Measure cylinder head height. Value Value not attained. Replace cylinder head.
(→ Page 268)
Measure valve guides with bore Not true to gauge. Recondition cylinder head
gauge. Values (→ Page 268) (→ Page 277).
2 Exhaust
5 Inlet
Re After press-fitting it into cylinder head, finish work on valve guide bore.
2
and
3:
Re Permitted difference: Valve clearance to cylinder head underside per cylinder: up to −0.200 mm
4
Inlet
Exhaust
6 Concentricity: 0.04 to B
7 Concentricity: 0.04 to A
Inlet
Exhaust
Exhaust valve
2 Reference 39.000
dimension
Valve seat Ø
Only rework valve seat height until a satisfactory surface has been achieved.
5 Roundness: 0.010
6 Concentricity: 0.030 to A
7 Concentricity: 0.200 to A
Inlet valve
2 Reference 42.000
dimension
Valve seat Ø
Only rework valve seat height until a satisfactory surface has been achieved.
5 Roundness: 0.010
6 Concentricity: 0.045 to A
7 Concentricity: 0.200 to A
Rework instruction:
• Re 2 and 3: Only rework valve seat height until a satisfactory surface has been achieved.
4 Thread M14 x 1
5 Flatness: 0.020/150
5 Winding Ø 28.900
6 Wire Ø 4.200
e1 Permitted deviation of generating line from vertical position with spring unloaded max. 2.090
2 Concentricity: 0.8/AB
3 Concentricity: 0.8/AB
Special tools
Designation / Use Part No. Qty.
Assembly tool kit F6783844 1
Tool kit F6784110 1
Reamer for valve guide Ø8.8 mm F30543151 1
Reamer for valve guide Ø9.0 mm F30543150 1
Floating tool holder MK2 F70007011 1
Centering tip MK3 F70000966 1
Extension sleeve MK3/MK3 F70000417 1
Taper reduction sleeve MK4/MK2 F70001021 1
Taper reduction sleeve MK4/MK3 F70000146 1
Taper reduction sleeve MK3/MK2 F70000073 1
Drift key MK1/MK2 F70000199 1
Drift key MK3 F70000200 1
Drift key MK4 F70000637 1
Reamer for valve guide in cylinder head 0005891853/00 1
Punch for inlet valve seat F30378880 1
Punch for exhaust valve seat F30378881 1
Valve seat countersink for exhaust valve F30378896 1
Valve seat countersink for inlet valve F30450549 1
Handle for turning handle 0005892816/01 1
Turning handle 8205890451/00 1
Removal tool F30450454 1
Testing device Y4341935 1
Limit plug gauge Y20098136 1
Mounting plate for valve guides F6784237 1
Gauge for exhaust valve Y4346861 1
Gauge for inlet valve Y4346862 1
Bottle brush
Material
Designation / Use Part No. Qty.
Liquid nitrogen
Corrosion inhibitor
Spare parts
Designation / Use Part No. Qty.
Valve guide, inlet
Valve guide, exhaust
Valve-seat insert, inlet valve
Valve-seat insert, exhaust valve
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Special tools
Designation / Use Part No. Qty.
Socket for BR 2000 unit-pump system F30377657 1
Socket for BR 2000 CR F30450351 1
Valve lifter 4425890031/00 1
Retaining device F6554686 1
Drift F30377883 1
Expander F30377930 1
Dial-gauge holder 3435890040/00 1
Dial gauge
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-ring
Sealing ring
Heavy object.
Damage to equipment due to falling components!
WARNING • Ensure that all components are secured during removal and installation work.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Installing valves
1. Lay cylinder head on its side (A).
2. Wipe valves (1) and (2) with chamois leather and
coat valve stems with engine oil.
3. Insert valves into valve guides. Observe correct
valve arrangement.
Special tools
Designation / Use Part No. Qty.
Rotation angle measuring device Y20044010 1
Socket F30907150 1
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Clamping sleeve
Gasket
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Drift F30378878 1
Material
Designation / Use Part No. Qty.
Cleaning agent
Loctite 270
Spare parts
Designation / Use Part No. Qty.
Plug
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Replacing plug
Note: Replace plug only if necessary.
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Installation/removal device F6782990 1
Support guide F6782991 1
Locating pin F6782980 1
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Camshaft – Removal
1. Screw locating pin (2) on to end face of camshaft
(3) that is installed in crankcase (4).
2. Make sure it fits perfectly.
3. Pull camshaft (3) approx. 500 mm out of
crankcase (4).
4. Install installation/removal device (1) and support
guide.
5. Pull camshaft (3) out of crankcase (4) until a rope
can be attached to the middle of the camshaft (3).
6. Attach lightly pretensioned rope to crane and
extract camshaft (3) from crankcase (4).
7. Remove installation/removal device (1) and
support guide.
8. If required, remove timing wheel (e.g. if damaged)
as shown in overview drawing (→ Page 289) .
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Camshaft – Cleaning
1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow out camshaft and threads with compressed air.
Special tools
Designation / Use Part No. Qty.
Hardness test unit (e.g. Microdur test unit)
Magnifying glass
Dial gauge
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack-testing method
Red penetrant dye for surface crack-testing procedure
Spare parts
Designation / Use Part No. Qty.
Camshaft
Camshaft gear
Measuring wheel
Hex screw
Clamping washer
Camshaft – Check
Check mating face of camshaft gear. Wear visible • Recondition: smooth with
oilstone or emery cloth.
• Replace
1–0 71.400 H6
2–0 71.800 H6
Concentricity of bearings
During the concentricity check, provide supports for and align the following bearings.
• 8V:
• 10V: bearing 3 beginning at driving end
• 12V:
• 16V:
Camshaft gear
1 Bearing 5 beginning at
driving end
Special tools
Designation / Use Part No. Qty.
Installation/removal device F6782990 1
Support guide F6782991 1
Locating pin F6782980 1
Barring tool F6783914 1
Measuring stand 0015890321/00 1
Dial gauge 0015895321/00 1
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Loctite 270
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Camshaft – Installation
1. Install timing wheel as follows:
1.1. Coat screws with Loctite.
1.2. Install timing wheel on flywheel with
screws as shown in overview drawing
(→ Page 289) .
2. Screw installation/removal device (2) and support
guide (1) on to end face of crankcase (3) and
center to camshaft bearings with locating pin.
Final steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Barring tool F6557929 1
Barring tool F6783914 1
Pointer F6557932 1
Graduated disk for 8V Y4345595 1
Graduated disk for 10V Y4345536 1
Graduated disk for 12V Y4345886 1
Graduated disk for 16V Y4345887 1
Bridge meter 5415890121/00 1
Measuring stand 0015890321/00 1
Dial gauge 0015895321/00 1
Measuring device Y4345888 1
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Pliers F30378037 1
Preparatory steps
1 2 3 Operations See
Removing pushrod
1. Rotate pushrod so that the roller tappet is loosened
2. Remove pushrod
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Designation / Use Part No. Qty.
Bore gauge
Outside micrometer
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack-testing
Spare parts
Designation / Use Part No. Qty.
Roller tappet
Pushrod
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Check
1 30.440 30.465
Special tools
Designation / Use Part No. Qty.
Pliers F30378037 1
Material
Designation / Use Part No. Qty.
Engine oil
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Installing pushrod
1. Install cylinder head (→ Page 286).
2. Coat pushrod with engine oil.
3. Insert pushrod with ball head side, in doing so
observe correct fit in roller tappet.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Designation / Use Part No. Qty.
Bore gauge
Depth gauge
Outside micrometer
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack test procedure
Spare parts
Designation / Use Part No. Qty.
Snap ring
Washer
Rocker shaft support
Rocker arm, exhaust
Rocker arm, inlet
Valve bridge
Screw
Adjusting screw
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Screw
Material
Designation / Use Part No. Qty.
Engine oil
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Special tools
Designation / Use Part No. Qty.
Barring tool F6783914 1
Pointer for barring tool F6557932 1
Graduated plate for 8V Y4345595 1
Graduated plate for 10V Y4345536 1
Graduated plate for 12V Y4345886 1
Graduated plate for 16V Y4345887 1
Material
Designation / Use Part No. Qty.
Engine oil
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
10 Cylinder head cover, lower part 30 Cylinder head cover, upper part
15 Screw 35 Screw
20 Washer 40 Gasket
25 Gasket 45 Washer
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Designation / Use Part No. Qty.
Cylinder head cover
Special tools
Designation / Use Part No. Qty.
Centering device F6783025 1
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Gasket
Screw
Washer
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Extraction tool F6784160 1
Socket wrench 0005896803/00 1
Assembly sleeve F30450342 1
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Installing injector
1. Install injector (1) in cylinder head and align.
2. Install hold-down clamp (2) and hand-tighten
screw.
Tightening torque
10 HP pump 57 Washer
15 O-ring 58 Screw
25 Follower 59 Clamping element
35 Screw 60 Washer
40 Washer 61 Screw
50 O-ring 62 Screw
56 Retainer 63 Washer
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Lifting device T80091650 1
Support bracket T80091665 1
Preparatory steps
1 2 3 Operations See
Spare parts
Designation / Use Part No. Qty.
HP pump
Screw
Special tools
Designation / Use Part No. Qty.
Lifting device T80091650 1
Carrying bracket T80091665 1
Alignment tool F6783244 1
Guide pin F30450460 2
Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white
Spare parts
Designation / Use Part No. Qty.
O-ring
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Designation / Use Part No. Qty.
Fuel delivery pump
Pump housing
Retainer
Fuel line
Check sealing and mating faces for Damaged • Recondition: smooth with
damage. oilstone.
• Replace
Material
Designation / Use Part No. Qty.
Engine oil
Loctite 270
Petroleum jelly, white
Spare parts
Designation / Use Part No. Qty.
O-ring
Seal
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Sealing ring
Clamp
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Designation / Use Part No. Qty.
Fuel cooler
Check all sealing and mating faces • Damage • Recondition: smooth with
for stress marks and damage • Stress marks oilstone or emery cloth.
visible • Replace
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-ring
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Filter wrench F30379104 1
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Check sealing and bolt-on faces for Damaged • Smooth with oilstone.
damage. • Replace
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
CU sealing rings
Spare parts
Designation / Use Part No. Qty.
Copper sealing ring
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Designation / Use Part No. Qty.
Sealing rings
Check banjo screws for damage and • Damaged • Recondition: recut threads.
threads for ease of movement. • Threads sluggish. • Replace
Check sealing and bolt-on faces for Damaged • Recondition: smooth with
damage. oilstone.
• Replace
Spare parts
Designation / Use Part No. Qty.
Sealing ring
Grommet
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Lifting gear T80091621 1
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Hydraulic unit 5505890163/00 1
Installation/removal tool F0099975 1
Extracting fixture F6783898 1
Assembly jig F6783845 1
Snap ring pliers
Material
Designation / Use Part No. Qty.
Cleaner
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Turbocharger cleaning
1. Clean turbocharger externally with cleaner.
2. Remove cleaner.
3. Thoroughly blow all components with compressed air.
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack test procedure
Spare parts
Designation / Use Part No. Qty.
Exhaust turbocharger
Magnetic nut
Retaining ring
Turbine housing
Turbine wheel
Bearing housing
Thrust bearing
Compressor wheel
Compressor housing
Ring carrier
b 0.02 A-B
c 0.008 A-B
CB 125 67 53 50 10 1 1 –
Exhaust turbocharger
Special tools
Designation / Use Part No. Qty.
Assembly jig F6783845 1
Installation/removal tool F0099975 1
Feeler gauge 5115890021/00 1
Insertion tool F30372701 1
Alignment tool F6783880 1
Feeler gauge Y20010128 1
Measuring device for axial play
Material
Designation / Use Part No. Qty.
Assembly paste MTN5128
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
Snap ring
O-ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
12. Coat bearing bush (1) with engine oil and insert in
bearing housing (2).
Options A and B
1. Coat magnetic nut (1) with assembly paste.
2. Tighten magnetic nut (1) (left-hand thread) with
torque wrench to specified tightening torque
(→ Page 24) .
3. Coat O-ring (3) with assembly paste and mount on
bearing housing (2).
Special tools
Designation / Use Part No. Qty.
Lifting gear T80091621 1
Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white
Spare parts
Designation / Use Part No. Qty.
O-ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
3.9 Intercooler
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Eyebolt 000580008001 1
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Intercooler – Removal
1. Remove shroud.
2. Release flange from exhaust turbocharger to intercooler.
3. Remove intercooler as shown in overview drawing (→ Page 392).
4. Remove O-rings.
5. Seal openings with suitable covers.
6. Protect intercooler from damage. Cover cooler meshes.
Special tools
Designation / Use Part No. Qty.
Oilstone
Material
Designation / Use Part No. Qty.
Emery cloth
Red dye penetrant for surface crack test procedure
Spare parts
Designation / Use Part No. Qty.
O-rings
Sealing rings
Gaskets
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Intercooler – Check
Special tools
Designation / Use Part No. Qty.
Eyebolt 000580008001 2
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Thin-film lubrication Molykote G-n plus
Spare parts
Designation / Use Part No. Qty.
O-ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Intercooler – Installation
1. Prior to installation, remove all covers.
2. Before installing the intercooler, clean both
mating faces.
3. Coat mating face (2) with thin-film lubrication.
4. Prior to installation, coat O-rings with assembly
paste.
5. Insert O-ring in annular grooves (1).
6. Install intercooler and tighten screws with torque
wrench to specified tightening torque (→ Page 24).
7. Screw on flange from exhaust turbocharger
to intercooler.
8. Install shroud.
9. Install drain line with mounting parts.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Inspection lamp
Spare parts
Designation / Use Part No. Qty.
Air filter
Service indicator
Clamp
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Material
Designation / Use Part No. Qty.
Red penetrant dye for surface crack-testing procedure
Spare parts
Designation / Use Part No. Qty.
Charge-air manifold
Rubber sleeve
Clamp
Screws
Plug
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Check sealing and bolt-on faces for • Uneven • Recondition: smooth with
evenness and damage. • Damaged oilstone.
• Replace
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
Seal
Sealing ring
O-ring
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
20 Flange 70 Stud
25 Gasket 75 Washer
30 O-ring 76 Washer
35 Screw 80 Nut
45 Fire tube 85 Screw
50 Screw 87 Heat shield
60 Exhaust pipework housing, right 155 Exhaust manifold, right
Exhaust system
Exhaust system
Exhaust system
395 Carrier housing, lower part 435 Gasket 470 Exhaust elbow, left
410 Screw 440 O-ring 475 Exhaust elbow, right
415 Screw 442 Bracket 485 Plate
420 Screw 444 Screw 490 Screw
425 Washer 445 Washer 495 Conical spring washer
430 Washer 447 Cable clamp
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Hook T80091769 1
Hook-ended chain sling T80090943 1
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Material
Designation / Use Part No. Qty.
Red dye penetrant for surface crack test procedure
Spare parts
Designation / Use Part No. Qty.
Exhaust pipework housing
Elbow
Exhaust elbow
Plug-in pipe
Cover
Exhaust pipe bellows
Exhaust manifold
Exhaust elbow
Heat shield
Flange
Fire tube
Sliding piece
Check sealing and mating faces for Damaged • Recondition: smooth with
damage. oilstone or emery cloth.
• Replace
Material
Designation / Use Part No. Qty.
Assembly paste Ultra-Therm MTU
Spare parts
Designation / Use Part No. Qty.
Screw
Special tools
Designation / Use Part No. Qty.
Hook-ended chain sling T80091769 1
Hook T80091312 1
Material
Designation / Use Part No. Qty.
Assembly paste Ultra-Therm
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-ring
Grub screw
Screw
Gasket
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Remove carrier housing (→ Page 423).
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Material
Designation / Use Part No. Qty.
Red dye penetrant for surface crack test procedure
Spare parts
Designation / Use Part No. Qty.
Carrier housing, upper part
Carrier housing cover
Check sealing and mating faces for Damaged • Recondition: smooth with
damage. oilstone or crocus cloth.
• Replace
Preconditions
• Engine is stopped and starting disabled.
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-ring
Gasket
Material
Designation / Use Part No. Qty.
Silicone rubber Loctite 5970
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-ring
Gasket
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Final steps
1 2 3 Operations See
Overview drawing
Overview drawing
Preconditions
• Engine is stopped and starting disabled.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Decarbonizer
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Material
Designation / Use Part No. Qty.
Fluorescent magnetic powder for magnetic crack test procedure
Red dye penetrant for surface crack test procedure
Spare parts
Designation / Use Part No. Qty.
Bushing
Flap housing
Exhaust flap
Lever
Flange
Retainer
Cylinder
Check flap housing and flap with red Signs of cracks Replace
dye penetrant for cracks.
No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic
lower upper min. max. min. max.
size
No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic
lower upper min. max. min. max.
size
Special tools
Designation / Use Part No. Qty.
Retaining plate F6784266 1
Assembly sleeve F6784265 1
Assembly sleeve F6784264 1
Material
Designation / Use Part No. Qty.
Assembly paste Ultra-Therm
Spare parts
Designation / Use Part No. Qty.
R-ring
Multi-piece oil ring
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Material
Designation / Use Part No. Qty.
Assembly paste Ultra-Therm
Spare parts
Designation / Use Part No. Qty.
Gasket
Grub screws
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
3. Install actuator from exhaust flap as shown in overview drawing (→ Page 431).
4. Direct compressed air at cylinder and check operation of exhaust flap.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Electrical voltage.
Risk of serious injury - danger to life!
DANGER • Make certain that the power supply to the engine is switched off before starting to work.
Ensure that the power supply cannot be switched on unintentionally!
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Disassembling starter
See separate Publication No. M060710.
Starter – Cleaning
1. Clean starter with compressed air; do not wet-clean.
2. Protect starter against moisture.
Spare parts
Designation / Use Part No. Qty.
Starter
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Starter – Inspection
Check mating face on end housing Wear traces are found. Recondition Re-surface with crocus
for wear. cloth or oil stone.
Material
Designation / Use Part No. Qty.
Long-life grease
Electrical voltage.
Risk of serious injury - danger to life!
DANGER • Make certain that the power supply to the engine is switched off before starting to work.
Ensure that the power supply cannot be switched on unintentionally!
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Installing starter
1. Coat starter pinion with long-life grease.
2. Install starter as in accordance with overview drawing (→ Page 443).
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Carrying bracket T80091765 1
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Flushing device
Material
Designation / Use Part No. Qty.
Porozink from Parobe-Chemie company
Porodox from Henkel company
Branol 32/10 from Brangs u. Heinrich company
3-5% P3 FD solution from Henkel company.
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Designation / Use Part No. Qty.
Oil heat exchanger
Check all sealing and mating faces • Damage • Recondition: smooth with
for wear and damage • Wear oilstone or emery cloth.
visible • Replace
Special tools
Designation / Use Part No. Qty.
Carrying bracket T80091765 1
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Designation / Use Part No. Qty.
Oil line
Retainer
Union
Clamp
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
Clamp
Gasket
Sealing ring
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Overview drawing
Preconditions
• Engine is stopped and starting disabled.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Tool kit F0140588 1
Hydraulic spindle F6781539 1
Extracting fixture F6780562 1
Support F30275611 1
Snap ring pliers
Screw tap M20 x 1.5
Material
Designation / Use Part No. Qty.
Thin-film lubrication Molykote G-n plus
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
21. Place two pads (2) under gear (1) and place
bearing housing (3) on suitable support (4).
22. Press water pump shaft (7) with angular-contact
ball bearing (6) and inner rings (5) and (8) out of
gear and bearing housing (3).
23. Press water pump shaft (7) out of inner ring (5)
and angular-contact ball bearing (6).
24. Remove all O-rings.
25. Inner ring (8) can not be exchanged. If a spare
part is required, replace cylindrical roller bearing
with water pump shaft (7).
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Material
Designation / Use Part No. Qty.
Red dye penetrant for surface crack-testing procedure
Fluorescent magnetic powder for magnetic crack test procedure
Spare parts
Designation / Use Part No. Qty.
Impeller
Bearing housing
Volute
Gear
Intermediate piece
Water pump shaft
Spacer ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Check coolant pump shaft for traces • Wear • Recondition: smooth minor
of wear and damage. • Damage traces of wear with emery cloth.
visible • Replace
Visually inspect sealing surfaces for • Stress marks • Recondition: smooth with
stress marks, pitting and cavitation. • Pitting oilstone or emery cloth.
• Cavitation • Replace
visible
Special tools
Designation / Use Part No. Qty.
Tool kit F0140588 1
Feeler gauge Y20010128 1
Snap ring pliers
Material
Designation / Use Part No. Qty.
Denatured ethanol
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
Shaft seal
Rotary seal
O-ring
Angular-contact ball bearing
Cylindrical roller bearing
Snap ring
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Cleaning brush
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Designation / Use Part No. Qty.
Coolant line
Clamp
Banjo screw
Union
Check sealing and mating faces for Damaged • Recondition: smooth with
stress marks and damage. oilstone or emery cloth.
• Replace
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Sealing ring
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Cleaning brush
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Designation / Use Part No. Qty.
Line
Banjo screw
Material
Designation / Use Part No. Qty.
Engine oil
Spare parts
Designation / Use Part No. Qty.
Sealing ring
Clamp
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
1 Coolant distribution housing 4 Cooler plate A Position of code letter (bottom left)
2 Initial plate 5 End plate B Position of gasket (to the
3 Cooler plate 6 Cover plate cover plate)
Preconditions
• Engine is stopped and starting disabled.
Special tools
Designation / Use Part No. Qty.
Threaded pin 5362030462 2
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
High-pressure cleaner
Soft cleaning brush
Material
Designation / Use Part No. Qty.
Sodium hydroxide
Sodium carbonate
Nitric acid
Sulfamic acid
Citric acid
Phosphoric acid
Kerosene
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Cleaning agents containing chlorine and hydrochloric acid attack metal surfaces.
Risk of damage due to corrosion!
CAUTION • Do not use hydrochloric acid with stainless steel.
• Chlorine concentration in water solution must not exceed 300 ppm for cleaning purposes.
If a higher chlorine concentration is required, contact MTU.
• Protect aluminum components against chemicals.
Preparatory steps
1. Remove cooler plates (→ Page 489).
2. Place cooler plates for cleaning on a suitable surface.
Gross fouling
Note: Mechanical cleaning, with open device, for:
• Algae
• Pieces of wood/fibers
• Shellfish
1. Clean plates with soft brush and running water. Avoid damage to gasket.
2. Clean plates with high-pressure hose.
3. Dry gaskets with a cloth.
Biological growth
Note: Mechanical or chemical cleaning, with open device, for:
• Bacteria
• Nematodes
• Protozoa
1. Clean plates with soft brush and running water. Avoid damage to gasket.
2. Clean plates with high-pressure hose.
3. Clean plates using alkaline cleaning agents, such as:
• Sodium hydroxide
• Sodium carbonate
Concentration Temperature
max. 4% max. 60 °C
1. Clean plates with soft brush and running water. Avoid damage to gasket.
2. Clean plates with high-pressure hose.
3. Clean plates using acid cleaning agents, such as:
• Nitric acid
• Sulfamic acid
• Citric acid
• Phosphoric acid
Concentration Temperature
max. 4% max. 60 °C
4. The addition of a synthetic cleaning agent can improve the cleaning effect.
Sediment (deposits)
Note: Mechanical or chemical cleaning, with open device, for:
• Corrosion products
• Metal oxides
• Boiler deposit
• Alumina
• Diatom organisms
1. Clean plates with soft brush and running water. Avoid damage to gasket.
2. Clean plates with high-pressure hose.
3. Clean plates using chemical cleaning agents, such as:
• Nitric acid
• Sulfamic acid
• Citric acid
• Phosphoric acid
Concentration Temperature
max. 4% max. 60 °C
Material
Designation / Use Part No. Qty.
Red dye penetrant for surface crack test procedure
Surface crack test procedure and fluorescent penetrant
Spare parts
Designation / Use Part No. Qty.
Cover plate
Initial plate
Cooler plate
End plate
Threaded pin
Check mating faces and sealing • Stress marks • Recondition: smooth with
surfaces of cover plate for stress • Damage oilstone or crocus cloth.
marks and damage. visible • Replace
Check threaded pin for damage and • Stress marks • Recondition: recut threads
stress marks. • Damage • Replace
visible
Special tools
Designation / Use Part No. Qty.
Threaded pin 5362030462 2
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Thin-film lubrication Molykote G-n plus
Spare parts
Designation / Use Part No. Qty.
O-ring
Tab washer
Nipple
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Material
Designation / Use Part No. Qty.
Adhesive (see table)
Acetone
Talc
Brush
Spare parts
Designation / Use Part No. Qty.
Gasket
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Adhesives to be used
Manufacturer Type
Bostik 1782
Bond Spray 77
Removing gasket
1. Place plate on suitable surface.
2. Strip damaged gasket from plate.
Installing gasket
1. Degrease and dry clean gasket groove with chlorine-free solvent (e.g. acetone).
Note: Drying time 30 seconds after application.
Preconditions
• Engine is stopped and starting disabled.
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Preparatory steps
1 2 3 Operations See
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Material
Designation / Use Part No. Qty.
Red dye penetrant for surface crack-testing procedure
Spare parts
Designation / Use Part No. Qty.
Coolant distribution housing
Thermostat housing
Thermostat insert
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Check all sealing and mating faces • Stress marks • Recondition: smooth with
for stress marks and damage. • Damage oilstone or emery cloth.
visible • Replace
Special tools
Designation / Use Part No. Qty.
Drive-in tool F30378672 1
Drive-in tool F30450050 1
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-rings
Sealing ring
Screws
Union
Gasket
Restrictor
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preparatory steps
1 2 3 Operations See
– X X Remove elbow –
Special tools
Designation / Use Part No. Qty.
Tool kit F0140587 1
Hydraulic spindle F6781539 1
Extracting fixture F6781600 1
Support F30275611 1
Snap ring pliers
Screw tap M18 x 1.5
Material
Designation / Use Part No. Qty.
Thin-film lubrication Molykote G-n plus
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
21. Place two pads (2) under gear (1) and place
bearing housing (3) on suitable support (4).
22. Press water pump shaft (7) with angular-contact
ball bearing (6) and inner rings (5) and (8) out of
gear and bearing housing (3).
23. Press water pump shaft (7) out of inner ring (5)
and angular-contact ball bearing (6).
24. Remove all O-rings.
25. Inner ring (8) can not be exchanged. If a spare
part is required, replace cylindrical roller bearing
with water pump shaft (7).
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Designation / Use Part No. Qty.
Precision bore gauge
Outside micrometer
Material
Designation / Use Part No. Qty.
Red dye penetrant for surface crack-testing procedure
Fluorescent magnetic powder for magnetic crack test procedure
Spare parts
Designation / Use Part No. Qty.
Raw water pump
Water pump shaft
Impeller
Bearing housing
Intermediate piece
Volute
Gear
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Check coolant pump shaft for wear • Wear • Recondition: smooth minor
and damage. • Damage traces of wear with emery cloth.
visible • Replace
Visually inspect sealing surfaces for • Stress marks • Recondition: smooth with
stress marks, pitting and cavitation. • Pitting oilstone or emery cloth.
• Cavitation • Replace
visible
Special tools
Designation / Use Part No. Qty.
Tool kit F0140587 1
Feeler gauge Y20010128 1
Snap ring pliers
Material
Designation / Use Part No. Qty.
Denatured ethanol
Petroleum jelly, white
Engine oil
Loctite 638
Spare parts
Designation / Use Part No. Qty.
Shaft seal
Rotary seal
O-ring
Angular-contact ball bearing
Cylindrical roller bearing
Snap ring
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-ring
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
Special tools
Designation / Use Part No. Qty.
Cleaning brush
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Designation / Use Part No. Qty.
Elbow
Clamping element half
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-rings
Gasket
Sealing ring
Clamp
Rubber sleeve
Screws
Blanking cone
Nut
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Final steps
1 2 3 Operations See
3.15 Mounting/Support
Preconditions
• Engine is stopped and starting disabled.
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Preparatory steps
1 2 3 Operations See
1. Wipe rubber surfaces with dry cloth only; do not clean with organic detergents.
2. Thoroughly blow all parts clean with compressed air.
Material
Designation / Use Part No. Qty.
Red penetrant dye for surface crack-testing procedure
Spare parts
Designation / Use Part No. Qty.
Engine mounting bracket
Damping element
Special tools
Designation / Use Part No. Qty.
Alignment tool F6782161 1
Material
Designation / Use Part No. Qty.
Engine oil
Loctite 518
Tectyl 472
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Final steps
1 2 3 Operations See
Preconditions
• Engine is stopped and starting disabled.
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Preparatory steps
1 2 3 Operations See
1. Wipe rubber surfaces with dry cloth only; do not clean with organic detergents.
2. Thoroughly blow all parts clean with compressed air.
Material
Designation / Use Part No. Qty.
Red penetrant dye for surface crack-testing procedure
Spare parts
Designation / Use Part No. Qty.
Engine mounting bracket
Resilient mount
Special tools
Designation / Use Part No. Qty.
Alignment tool F6782161 2
Material
Designation / Use Part No. Qty.
Engine oil
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
a Unloaded 152 mm
b Initial dimension for height adjustment 5 mm
c Max. clamp length 35 mm
Final steps
1 2 3 Operations See
Bilge pump
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
V-belt – Removal
1. Loosen screw (3) for clamp (2).
2. Loosen clamping nut until V-belt (1) can be
removed.
Material
Designation / Use Part No. Qty.
Cleaning agent
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Designation / Use Part No. Qty.
Housing
Cover
Belt pulley
Impeller
Cam
Plate
Coil
V-belt
Adapter
Replace cover screws, gasket and rotary seal after each disassembly of pump.
Material
Designation / Use Part No. Qty.
Grease
Sealing agent Curil
Petroleum jelly, white
Denatured ethanol
Spare parts
Designation / Use Part No. Qty.
Ball bearing
Rotary seal
Sealing
Wedge
Snap ring
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
19. Install cover (2) and sealing (3) with screws (1) on
housing.
20. Tighten screws crosswise.
Special tools
Designation / Use Part No. Qty.
Alignment tool F6784786 1
Preloading force measuring device Y20097429 1
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Spare parts
Designation / Use Part No. Qty.
O-ring
Snap ring
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Settings
Final steps
1 2 3 Operations See
9 B6 Coolant temperature
2 B1 Camshaft speed
9 M8 HP pump
System sensors
The sensors are mounted on the engine exterior.
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1 2 3 Operations See
B7 (oil temperature) During removal, small amounts of engine oil may emerge. Catch engine
oil in a suitable container.
B33 (fuel temperature) During removal, small amounts of fuel may emerge. Catch fuel in a
suitable container.
Material
Designation / Use Part No. Qty.
Isopropyl alcohol
Spare parts
Designation / Use Part No. Qty.
Pressure sensor
Pressure monitor
Engine speed sensor
Temperature sensor
Level monitor
Check if sensors and actuators are Sensors and actuators loose. Retighten securing screws.
loose.
Check if plug-in connections are Plug-in connections loose. Insert plug-in connections properly
loose. and tighten.
Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Spare parts
Designation / Use Part No. Qty.
O-ring
Sealing ring
Adjusting shim
Final steps
1 2 3 Operations See
4 Special Tools
Bore gauge
Dial gauge
F6783180 Support 1
F6554710 Frame 1
Bore gauge
Micrometer
000580016002 Eyebolt 4
Mandrel
B80141628 Nut 1
Adjusting ring
Magnifying glass
F30377999 Extractor 1
Hand press
F30275611 Support 1
F6555514 Support 1
Bottle brush
Master weights
Y20097353 Endoscope
Depth gauge
Measuring stand
Magnetic holder
Outside micrometer
F30379133 Puller 1
Decarbonizer
Lowering device
Torque wrench
Cleaning agent
F30907150 Socket 1
F30377883 Drift 1
F30377930 Expander 1
F30378878 Drift 1
F6557932 Pointer 1
F30378037 Pliers 1
Depth gauge
Oilstone
000580008001 Eyebolt 2
Inspection lamp
T80091769 Hook 1
T80091312 Hook 1
Flushing device
F30275611 Support 1
Cleaning brush
High-pressure cleaner
Y20097353 Endoscope 1
5505890921/00 Compression 1
pressure recorder
5 Annex
5.3 Index
A C
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . 50 Camshaft – Check . . . . . . . . . . . . . . . . . . . . . 292
Air filter – Check . . . . . . . . . . . . . . . . . . . . . . . 401 Camshaft – Cleaning . . . . . . . . . . . . . . . . . . . 291
Air filter – Installation . . . . . . . . . . . . . . . . . . . 402 Camshaft – Installation . . . . . . . . . . . . . . . . . . 297
Air filter – Overview . . . . . . . . . . . . . . . . . . . . . 399 Camshaft – Overview . . . . . . . . . . . . . . . . . . . 289
Air filter – Removal . . . . . . . . . . . . . . . . . . . . . 400 Camshaft – Removal . . . . . . . . . . . . . . . . . . . 290
Air Intake/Air Supply . . . . . . . . . . . . . . . . . . . . 399 Camshaft – Tolerances . . . . . . . . . . . . . . . . . . 294
Air filter – Check . . . . . . . . . . . . . . . . . . 401 Camshaft timing – Check . . . . . . . . . . . . . . . . 300
Air filter – Installation . . . . . . . . . . . . . . 402
Carrier housing – Assembly . . . . . . . . . . . . . . 427
Air filter – Overview . . . . . . . . . . . . . . . . 399
Air filter – Removal . . . . . . . . . . . . . . . . 400 Carrier housing – Check . . . . . . . . . . . . . . . . . 426
Air supply system to cylinders – Carrier housing – Cleaning . . . . . . . . . . . . . . . 425
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 406 Carrier housing – Disassembly . . . . . . . . . . . . 424
Air supply system to cylinders –
Carrier housing – Installation . . . . . . . . . . . . . 429
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 405
Air supply system to cylinders – Carrier housing – Overview . . . . . . . . . . . . . . 422
Overview . . . . . . . . . . . . . . . . . . . . . . . . 403 Carrier housing – Removal . . . . . . . . . . . . . . . 423
Air supply to the cylinders – Conrod – Assembly . . . . . . . . . . . . . . . . . . . . 242
Installation . . . . . . . . . . . . . . . . . . . . . . 407
Conrod – Check . . . . . . . . . . . . . . . . . . . . . . . 230
Air supply to the cylinders –
Removal . . . . . . . . . . . . . . . . . . . . . . . . 404 Conrod – Cleaning . . . . . . . . . . . . . . . . . . . . . 229
Air supply system to cylinders – Check . . . . . . 406 Conrod – Repair . . . . . . . . . . . . . . . . . . . . . . . 240
Air supply system to cylinders – Cleaning . . . . 405 Conrod – Tolerances . . . . . . . . . . . . . . . . . . . . 236
Air supply system to cylinders – Overview . . . 403 Conrod bearing shells – Check . . . . . . . . . . . . 244
Air supply to the cylinders – Installation . . . . . 407 Constant-pressure manifold – Assembly . . . . 418
Air supply to the cylinders – Removal . . . . . . . 404 Constant-pressure manifold – Check . . . . . . . 416
Auxiliary materials, fire prevention and Constant-pressure manifold – Cleaning . . . . . 415
environmental protection . . . . . . . . . . . . . . . . . 19 Constant-pressure manifold – Disassem-
Auxiliary systems / accessory equipment – bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539 Constant-pressure manifold – Installation . . . . 419
Auxiliary Systems/Accessory Equipment . . . . 539 Constant-pressure manifold – Overview . . . . . 408
Auxiliary systems / accessory equipment Constant-pressure manifold – Removal . . . . . 412
– Overview . . . . . . . . . . . . . . . . . . . . . . 539
Conversion tables . . . . . . . . . . . . . . . . . . . . . . 41
Bilge pump – Assembly . . . . . . . . . . . . 550
Bilge pump – Check . . . . . . . . . . . . . . . 549 Coolant cooler – Check . . . . . . . . . . . . . . . . . . 493
Bilge pump – Cleaning . . . . . . . . . . . . . 548 Coolant cooler – Cleaning . . . . . . . . . . . . . . . . 490
Bilge pump – Disassembly . . . . . . . . . . 544 Coolant cooler – Installation . . . . . . . . . . . . . . 494
Bilge pump – Installation . . . . . . . . . . . . 555
Coolant cooler – Overview . . . . . . . . . . . . . . . 488
Bilge pump – Overview . . . . . . . . . . . . . 540
Bilge pump – Removal . . . . . . . . . . . . . 543 Coolant cooler – Removal . . . . . . . . . . . . . . . . 489
Coolant pipework from/to exhaust turbocharger
– Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
B Coolant pipework from/to exhaust turbocharger
Bearing bush – Removal and installation . . . . 149 – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Bilge pump – Assembly . . . . . . . . . . . . . . . . . 550 Coolant pipework from/to exhaust turbocharger
Bilge pump – Check . . . . . . . . . . . . . . . . . . . . 549 – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 481
Bilge pump – Cleaning . . . . . . . . . . . . . . . . . . 548 Coolant pipework from/to exhaust turbocharger
Bilge pump – Disassembly . . . . . . . . . . . . . . . 544 – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Bilge pump – Installation . . . . . . . . . . . . . . . . . 555 Coolant pipework from/to exhaust turbocharger
Bilge pump – Overview . . . . . . . . . . . . . . . . . . 540 – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Bilge pump – Removal . . . . . . . . . . . . . . . . . . 543 Coolant pipework to raw water pump –
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
Coolant pipework with thermostat – Check . . . 502 Raw water pump – Check . . . . . . . . . . . 512
Coolant pipework with thermostat – Raw water pump – Cleaning . . . . . . . . . 511
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501 Raw water pump – Disassembly . . . . . . 508
Raw water pump – Installation . . . . . . . 518
Coolant pipework with thermostat –
Raw water pump – Overview . . . . . . . . 506
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Raw water pump – Removal . . . . . . . . . 507
Coolant pipework with thermostat – Raw water pump pipe system –
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498 Check . . . . . . . . . . . . . . . . . . . . . . . . . . 522
Coolant pipework with thermostat – Raw water pump pipe system –
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 521
Coolant pump – Cleaning . . . . . . . . . . . . . . . . 468 Raw water pump pipe system –
Installation . . . . . . . . . . . . . . . . . . . . . . 523
Coolant System . . . . . . . . . . . . . . . . . . . . . . . 462
Raw water pump pipe system –
Coolant cooler – Check . . . . . . . . . . . . 493
Removal . . . . . . . . . . . . . . . . . . . . . . . . 520
Coolant cooler – Cleaning . . . . . . . . . . 490
Coolant cooler – Installation . . . . . . . . . 494 Crankcase and Attachments . . . . . . . . . . . . . . 75
Coolant cooler – Overview . . . . . . . . . . 488 Crankcase breather – Check . . . . . . . . 107
Coolant cooler – Removal . . . . . . . . . . 489 Crankcase breather – Overview . . . . . . 100
Coolant pipework from/to exhaust Crankcase breather – Removal . . . . . . 103
turbocharger – Check . . . . . . . . . . . . . . 480 Crankcase ventilation – Cleaning . . . . . 106
Coolant pipework from/to exhaust Crankcase ventilation – Installation . . . 111
turbocharger – Cleaning . . . . . . . . . . . . 479 Cylinder liner – Check . . . . . . . . . . . . . . 81
Coolant pipework from/to exhaust Cylinder liner – Cleaning . . . . . . . . . . . . 80
turbocharger – Installation . . . . . . . . . . 481 Cylinder liner – Installation . . . . . . . . . . 85
Coolant pipework from/to exhaust Cylinder liner – Overview . . . . . . . . . . . 76
turbocharger – Overview . . . . . . . . . . . 477 Cylinder liner – Removal . . . . . . . . . . . . 77
Coolant pipework from/to exhaust Cylinder liner – Tolerances . . . . . . . . . . 83
turbocharger – Removal . . . . . . . . . . . . 478 Engine layout . . . . . . . . . . . . . . . . . . . . 75
Coolant pipework to raw water pump – Engine lifting equipment – Check . . . . . 98
Overview . . . . . . . . . . . . . . . . . . . . . . . . 519 Engine lifting equipment – Cleaning . . . 97
Coolant pipework with thermostat – Engine lifting equipment –
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 502 Installation . . . . . . . . . . . . . . . . . . . . . . 99
Coolant pipework with thermostat – Engine lifting equipment – Overview . . . 95
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 501 Engine lifting equipment – Removal . . . 96
Coolant pipework with thermostat – Hengst oil separator – Assembly . . . . . 109
Installation . . . . . . . . . . . . . . . . . . . . . . 504 Hengst oil separator – Check . . . . . . . . 108
Coolant pipework with thermostat – Hengst oil separator – Disassembly . . . 104
Overview . . . . . . . . . . . . . . . . . . . . . . . . 498 Oil pan – Check . . . . . . . . . . . . . . . . . . 92
Coolant pipework with thermostat – Oil pan – Cleaning . . . . . . . . . . . . . . . . 91
Removal . . . . . . . . . . . . . . . . . . . . . . . . 500 Oil pan – Installation . . . . . . . . . . . . . . . 93
Coolant pump – Cleaning . . . . . . . . . . . 468 Oil pan – Overview . . . . . . . . . . . . . . . . 88
Engine coolant and charge-air coolant Oil pan – Removal . . . . . . . . . . . . . . . . 89
ventilation – Check . . . . . . . . . . . . . . . . 485 Crankcase breather – Check . . . . . . . . . . . . . 107
Engine coolant and charge-air coolant Crankcase breather – Overview . . . . . . . . . . . 100
ventilation – Cleaning . . . . . . . . . . . . . . 484
Crankcase breather – Removal . . . . . . . . . . . 103
Engine coolant and charge-air coolant
ventilation – Installation . . . . . . . . . . . . 486 Crankcase ventilation – Cleaning . . . . . . . . . . 106
Engine coolant and charge-air coolant Crankcase ventilation – Installation . . . . . . . . . 111
ventilation – Overview . . . . . . . . . . . . . . 482 Crankshaft – Assembly . . . . . . . . . . . . . . . . . . 171
Engine coolant and charge-air coolant
Crankshaft – Balancing . . . . . . . . . . . . . . . . . . 175
ventilation – Removal . . . . . . . . . . . . . . 483
Engine coolant cooler – Replacement of Crankshaft – Check . . . . . . . . . . . . . . . . . . . . 160
gasket . . . . . . . . . . . . . . . . . . . . . . . . . . 496 Crankshaft – Cleaning . . . . . . . . . . . . . . . . . . 159
Engine coolant pump – Assembly . . . . . 471 Crankshaft – Disassembly . . . . . . . . . . . . . . . 157
Engine coolant pump – Check . . . . . . . 469
Crankshaft – Installation . . . . . . . . . . . . . . . . . 182
Engine coolant pump – Disassem-
bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 Crankshaft – Overview . . . . . . . . . . . . . . . . . . 151
Engine coolant pump – Installation . . . . 475 Crankshaft – Removal . . . . . . . . . . . . . . . . . . 154