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Technical Publication

Diesel Engine
8 V 2000 M72 / M92 / M93
10 V 2000 M72 / M92 / M93

Workshop Manual
M020127/02E
Printed in Germany
© 2005 Copyright MTU Friedrichshafen GmbH
Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung,
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

M020127/02E 05-08 © MTU


02 Table of Contents

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


2.1 Engine condition check before a major overhaul .............................. 53
2.2 Preface ................................................................ 54
2.3 Maintenance schedule matrix 2000 M72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.4 Maintenance schedule matrix 2000 M92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5 Maintenance schedule matrix 2000 M93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.6 Maintenance tasks ....................................................... 62
2.7 Engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.8 Engine – Disassembly .................................................... 66
2.9 Engine – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.10 Engine installation ....................................................... 72
2.11 Engine run-in ........................................................... 73
3 Task Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1 Crankcase and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1.2 Cylinder liner – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.1.3 Cylinder liner – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.1.4 Cylinder liner – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1.5 Cylinder liner – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.1.6 Cylinder liner – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.1.7 Cylinder liner – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.1.8 Oil pan – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.1.9 Oil pan – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.1.10 Oil pan – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.1.11 Oil pan – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.1.12 Oil pan – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.1.13 Engine lifting equipment – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.1.14 Engine lifting equipment – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.1.15 Engine lifting equipment – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.1.16 Engine lifting equipment – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.1.17 Engine lifting equipment – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.1.18 Crankcase breather – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.1.19 Crankcase breather – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.1.20 Hengst oil separator – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.1.21 Crankcase ventilation – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1.22 Crankcase breather – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.1.23 Hengst oil separator – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.1.24 Hengst oil separator – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.1.25 Crankcase ventilation – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

M020127/02E 05-08 © MTU


Table of Contents 03

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


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

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04 Table of Contents

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


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

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Table of Contents 05

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


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

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


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

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Table of Contents 07

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


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

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08 Table of Contents

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


3.13.1 Oil heat exchanger – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
3.13.2 Oil heat exchanger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
3.13.3 Oil heat exchanger – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
3.13.4 Oil heat exchanger – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
3.13.5 Oil heat exchanger – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
3.13.6 Exhaust turbocharger oil supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
3.13.7 Turbocharger oil supply – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
3.13.8 Turbocharger oil supply – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
3.13.9 Turbocharger oil supply – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
3.13.10 Turbocharger oil supply – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

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Table of Contents 09

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


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

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10 Table of Contents

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


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

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General 11

1 General

1.1 Important Information

1.1.1 Reman assemblies – Prerequisites for maintenance tasks


and general assembly instructions
These Maintenance Instructions are for technicians responsible for maintenance.
Contents:
• Scheduled W6 maintenance tasks
• Non-scheduled service operations on the individual assemblies.

Reman assemblies
The following assemblies are only available through the exchange procedure:

Series 2000 Series 4000

Vibration damper Vibration damper

Camshaft Camshaft

Injection pump High-pressure fuel pump

Injector

MDEC MDEC

Basic requirements for maintenance and service work


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

General assembly instructions


Assemblies that are exposed to contact with oil, fuel, coolant and combustion air must be clean. Assemblies with
the requirement ”Specially clean” (e.g. components carrying oil and fuel) should be cleaned in the appropriate
manner and checked for cleanness. Remove packaging of components immediately before assembly.
Elastomer components (e.g. rubber and similar) must not be washed with diesel fuel, solvent or cold cleaners.
• Remove oil or fuel coatings. The parts should be wiped with a dry cloth.
• Elastomer components such as engine mounts, damping elements, couplings and V-belts must not be painted.
They can only be installed after painting the engine or must be covered before painting work is carried out.
Radial-lip shaft seals treated by the manufacturer with oil show as a result definite signs of swelling when delivered.
They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before installation.
The surfaces of parts that slide against each other must be lubricated with SAE 30 engine
oil when installed, unless otherwise specified.
O-rings and surfaces moving against them during installation (bores and shafts) must be coated with petroleum
jelly, unless otherwise specified. When installing O-rings with counterrings in coolant pumps, always follow the
installation instructions. After installing O-rings in shaft grooves, pass a rounded marking tool under the O-ring in the
direction of the circumference if the O-ring diameter is sufficiently large. Make sure that the O-ring is not damaged.
Before shaft seal assembly:
• On the shaft, the sealing lip of the shaft seal must be coated with petroleum jelly and the shaft
running surface with thin-film lubricant or SAE 30 engine oil.

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12 General

• In the support bore, in the case of a metal outer jacket the outer surface must be coated with surface
sealant, unless otherwise specified in the drawing. For elastomer outer jackets or combined metal/elastomer
outer jackets, the outer surface must be coated with denatured ethanol.

This symbol applies to radial-lip shaft seals and its significance depends on its position. The
arrow indicates the position of the sealing lip.
Sealing paste must be used to fix the position of flat gaskets. Sealing paste is to be thinly applied in spots on the
flat gaskets or mating faces. Immediately after application of the sealing paste, the flat gaskets must be fitted to
the component and then (no more than 20 minutes later) the seal components screwed together. .
Before installing antifriction bearings, lubricate the bearing seats. Only remove the bearings from their
original packaging immediately before installation. Do not remove the corrosion inhibitor from the
bearings in the original packaging. Use petroleum spirit or acid-free kerosene to clean the antifriction
bearings. After cleaning, relubricate the bearings with engine oil.
• During assembly, do not apply (axial) forces to rolling elements and do not hit the bearing
rings with a hammer (use assembly aids).
• Do not use an open flame to heat bearing inner races.
• The temperature must be between 80 °C and 100 °C and never exceed 120 °C.
• Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate).
Do not oil dry bearings.
When installing gears, the splines must be lubricated with SAE 30 engine oil.
All support and mating surfaces of components (e.g. mating surfaces for centering devices, flange and sealing
surfaces, joint surfaces of press fits) must be clean, polished or provided with the specified surface protection and free
from warping and damage. Corrosion inhibitor (e.g. oil, grease) must be removed from the contact and mating faces.
After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate
must be removed and the parts coated with SAE 30 engine oil.
Sensors must be coated with long-life lubricant before installation in the immersion sleeves.
Cable connections with cutting ring unions must be preassembled and tightened in a vice, after
the threads have been previously coated with thin-film lubricant.
If components are to be marked by etching, after the etching is completed the solution must be removed by
means of neutralization agent. The affected parts must then be preserved with SAE 30 engine oil.
Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes) must be coated at the support
and mating surfaces with assembly paste, unless otherwise specified.
The assembly surfaces of screws, nuts, washers and of parts to be tensioned must be clean and
polished or provided with the specified surface protection and free from warping and damage. Corrosion
inhibitors (e.g. oil, grease) must be removed. Thread and screw contact surfaces must be coated with
lubricant before installation in accordance with tightening specifications.
Unless otherwise specified, use engine oil as a lubricant (SAE 30) and assembly paste in hot-part areas.
For threaded connections without tightening specifications, the tightening procedure can be selected
as required, i.e. mechanical tightening with screwdriver or normal manual tightening with an open-end
wrench or box wrench is possible. When machine-tightening is carried out, look up tightening torque
of thread size and strength class in the general tightening specifications.
Threaded connections with tightening specifications:
• The threaded connections must be tightened manually with a click wrench or angle-of-rotation torque
wrench. The specified tightening torques must be set without considering the specified tolerance
at the click wrench. When using an angle-of-rotation torque wrench, the torque indicated must be
within the torque specification limit value. Proceed in a similar manner with torsionally protected
threaded connections. This information also applies to checking torques.
• If no tolerance is specified for tightening torque, the tightening tolerance is + 10% of specified torque.
• Angleofrotation tightening:
The angles of further rotation specified in the tightening specifications must be achieved and may be
exceeded within the specified tolerance. If no tightening tolerance is specified, the following tolerances
must be observed: +5° for additional angle of rotation less than or equal to 90° +10° for additional

M020127/02E 05-08 © MTU


General 13

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

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14 General

1.2 General Conditions

1.2.1 General conditions

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

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General 15

1.2.2 Personnel and organizational requirements

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

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16 General

1.2.3 Safety precautions when working on the engine

Safety precautions when putting the equipment into operation


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

M020127/02E 05-08 © MTU


General 17

Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. When subjected to fire
or temperatures above 300 °C the material degenerates, giving off hydrogen fluoride gas. Hydrogen fluoride
vapors are released in this case. The resulting acid leads to serious burning if it contacts the skin. Do not touch
elastomeric seals if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!
Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!
Do not touch hot components of the compressor and the exhaust system ⇒ Risk of injury!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of injury!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable bonding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. The welding
current could be induced in the cable harnesses and could possibly damage the electrical plant.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.

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18 General

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

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General 19

1.2.4 Auxiliary materials, fire prevention and environmental protection

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

M020127/02E 05-08 © MTU


20 General

Compressed air
Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.
The pressure at which the air is kept can be read off at pressure gauges which must be connected
to the compressed air tanks and the compressed air lines.
When working with compressed air, safety precautions must be constantly observed:
• Pay special attention to the pressure level in the compressed air network and pressure vessel!
• Connecting devices and equipment must either be designed for this pressure or, if the permitted
pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose
coupling and connections must be securely attached!
• Always wear protective goggles when blowing off tools or extracting chips!
• The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents
air-borne particles being reflected and thereby prevents injury to eyes.
• First shut off compressed air lines before compressed air equipment is disconnected from the
supply line or before equipment or tool is to be replaced!
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII
and B) out of containers, results in a risk of explosion!
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass)
for drying purposes or to check for leaks, results in a risk of explosion!
• Do not blow dirty clothing with compressed air when being worn on the body.
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.

M020127/02E 05-08 © MTU


General 21

1.2.5 Standards for warning notices in the publication


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

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

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

M020127/02E 05-08 © MTU


22 General

1.2.6 General information regarding the Tolerances and Wear Limits List
The tolerances and wear limits are intended as a guide for the examination of engine components
as well as for engine inspection and repair.

Explanation of terms for dimensions of new components

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


the permissible dimensional deviation (e.g. 24 +0.013)

Basic size Designed size without fit symbol or permissible


dimensional deviation

Deviation Permissible deviation from the basic or tolerance size.


Deviation indicates the upper and lower limits of the
tolerance size/basic size.

Clearance Difference between bore and shaft diameter when bore


diameter is greater than shaft diameter

Interference Difference between bore and shaft diameter when bore


diameter is smaller than shaft diameter

Explanation of terms for reconditioning of components

Wear limit The wear limits specified do not represent the maximum
wear limits permissible for satisfactory component
operation. They indicate that the next major overhaul
can be reached safely. If a wear limit is exceeded, the
component must be replaced.

Reworking instructions If wear limits are exceeded or values are below


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

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

M020127/02E 05-08 © MTU


General 23

1.2.7 Engine side and cylinder designations


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

1 KGS = Free end 3 KS = Driving end


2 Right side 4 Left side

M020127/02E 05-08 © MTU


24 General

1.2.8 Torque specifications for screws, nuts and bolts

Crankcase
Designation Torque specification Lubricant

Screw for crankshaft bearing cap Engine oil


• Nominal length: 172.5 mm to 173.0 mm
• max. length: 176.0 mm

1 Pretightening torque 300 Nm + 30 Nm

2 Angle of further rotation 90° + 10°

Side screw for crankshaft bearing cap


• Nominal length: 84.5 mm to 85.0 mm

1 Tightening torque 140 Nm + 10 Nm

Plug screw 180 Nm

Screw for Hengst oil separator 6 Nm + 2 Nm

Gear train
Designation Torque specification Lubricant

Nut for drive gear (auxiliary drive) 285 Nm + 30 Nm Engine oil

M020127/02E 05-08 © MTU


General 25

Running gear
Designation Torque specification Lubricant

Screw for counterweight Engine oil


• Nominal length: 82.5 mm to 83.0 mm
• max. length: 84 mm

1 Pretightening torque 140 Nm + 20 Nm

2 Angle of further rotation 90° + 10°

Screw for flywheel 42 Nm +4 Nm

Screw for side on plate vibration damper 52 Nm

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

1 Pretightening torque 100 Nm + 15 Nm


Sequence:
a Short arm
b Long arm

2 Angle of further rotation 90° + 10°


Sequence:
a Short arm
b Long arm

Conrod screws can also be tightened together.

Cylinder head
Designation Torque specification Lubricant

Protective sleeve for injector 45 Nm + 5 Nm Engine oil

Screw for cylinder head.


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

Tightening sequence of screws: 1 to 4

Pretightening torque

1st stage 10 Nm

2nd stage 50 Nm

3rd stage 100 Nm

4th stage 200 Nm

Angle of further rotation

1st stage 90° + 10°

2nd stage 90° + 10°

M020127/02E 05-08 © MTU


26 General

Valve gear
Designation Torque specification Lubricant

Nut on adjusting screw for rocker 50 Nm Engine oil

Screw for rocker shaft support

1 Pretightening torque 60 Nm

2 Angle of further rotation 90 °

Screw for cylinder head cover 20 Nm

Fuel system – high-pressure


Designation Torque specification Lubricant

Breather valve 100 Nm ± 5 Nm Engine oil

Screw for hold-down clamp 40 Nm + 4 Nm

HP line from HP pump to fuel distributor 40 Nm + 5 Nm

HP line from fuel distributor to HP accumulator 40 Nm + 5 Nm

HP line from HP accumulator to injector 15 Nm + 5 Nm

Fuel system – low-pressure


Designation Torque specification Lubricant

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

M020127/02E 05-08 © MTU


General 27

Exhaust turbocharger
Designation Torque specification Lubricant

Screws on carrier housing 70 Nm + 7 Nm Engine oil

Threaded union on exhaust 35 Nm + 4 Nm


turbocharger

Clamp on turbine housing 18 Nm + 7 Nm

Clamp on compressor housing 18 Nm + 2 Nm

Clamp on center bearing 5 Nm + 1 Nm

Clamp on flap housing 5 Nm + 1 Nm

Screw for flange on compressor 21 Nm + 2 Nm


housing

Screw on retaining ring 28 Nm + 3 Nm

Magnetic nut on turbine wheel Ultra-Therm MTU

1 Pretightening torque 35 Nm + 3 m
(left-hand thread)

2 Loosen

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

4 Angle of further rotation 45° +5°

Intercooler
Designation Torque specification Lubricant

Screw for intercooler at connection 21 Nm Engine oil


housing (bottom)

Air intake / air supply


Designation Torque specification Lubricant

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


mounting plate

M020127/02E 05-08 © MTU


28 General

Exhaust system
Designation Torque specification Lubricant

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

Screw for exhaust diffuser 30 Nm + 3 Nm

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

Screw for slide on exhaust manifold 57 Nm + 6 Nm

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

Lube oil system


Designation Torque specification Lubricant

Screw for oil spray nozzle 25 Nm Engine oil

Coolant system
Designation Torque specification Lubricant

Screw for bearing housing on 8.5 Nm Engine oil


bearing housing engine coolant
pump and raw water pump

Nuts for bearing housing on volute 20.5 Nm


engine coolant pump and raw water
pump

Screw for bearing housing on 41.5 Nm


housing (raw water pump)

Impeller test torque for engine 300 Nm - 400 Nm


coolant pump and raw water pump

Plug screw for impeller (raw water 75 Nm Loctite 638


pump)

M020127/02E 05-08 © MTU


General 29

Power supply, engine side


Designation Torque specification Lubricant

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

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

Mount/support
Designation Torque specification Lubricant

Engine mount

Nut on threaded rod 400 Nm Valvoline Tectyl 472

Monitoring, control and regulation devices


Designation Torque specification Lubricant

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


• Charge air
• Engine coolant
• Lube oil
• Fuel
• Intake air

Temperature sensor PT 100 • Unions: 40 Nm ± 5 Nm


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

Pressure sensor for 20 Nm to 45 Nm


• Lube oil
• Charge air

Fuel pressure sensor after filter 20 Nm + 3 Nm

Pressure sensor 20 Nm to 45 Nm
• Engine coolant pressure
• Raw water pressure
• Refill oil pressure

Differential pressure monitor for lube 27 Nm


oil

Level probe max. 30 Nm


• Engine coolant level
• Leak-off fuel level

Fuel high-pressure 30 Nm + 5 Nm

Tightening specifications for setscrew and stud connections according


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

M020127/02E 05-08 © MTU


30 General

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


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

M020127/02E 05-08 © MTU


General 31

When tightening mechanically, the permitted assembly tolerance is +15 %.

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

M6 9 12 8 11

M8 21 31 20 28

M8 x 1 23 32 21 30

M10 42 60 40 57

M10 x 1.25 45 63 42 60

M12 74 100 70 92

M12 x 1.25 80 110 75 105

M12 x 1.5 76 105 72 100

M14 115 160 110 150

M14 x 1.5 125 180 120 170

M16 180 250 170 235

M16 x 1.5 190 270 180 255

M18 250 350 240 330

M18 x 1.5 280 400 270 380

M20 350 500 330 475

M2 x 1.5 390 550 350 520

M22 480 680 450 650

M22 x 1.5 520 730 490 700

M24 600 850 570 810

M24 x 1.5 680 950 640 900

M24 x 2 660 900 620 850

M27 900 1250 850 1175

M27 x 2 960 1350 900 1275

M30 1200 1700 1100 1600

M30 x 2 1350 1900 1250 1800

MA = tightening torques

Tightening specifications for stress bolt connections prescribed in standard MTN 5007
This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic
loads of strength class 10.9 and the corresponding nuts.
Shank and transition dimensions as per MMN 209 standard and material and machining as per
MMN 389 standard (bright surface or with phosphate coating).
The values in the table are based on a friction coefficient µtot.= 0.125. Precondition: Thread and mating
faces of screws and nuts must be coated in engine oil prior to assembly.

M020127/02E 05-08 © MTU


32 General

When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process - e.g. resulting from inaccurate readings and overtightening during assembly.
The values in the tables are for manual tightening with torque wrench.

Thread not torsionally protected MA(Nm) torsionally protected MA(Nm)

M6 9 12

M8 21 28

M8 x 1 24 30

M10 42 55

M10 x 1.25 46 60

M12 75 93

M12 x 1.5 78 99

M14 120 150

M14 x 1.5 135 160

M16 180 225

M16 x 1.5 200 245

M18 250 315

M18 x 1.5 300 360

M20 350 450

M20 x 1.5 430 495

M22 500 620

M22 x 1.5 560 675

M24 640 790

M24 x 2 700 850

M27 900 1170

M27 x 2 1000 1230

M30 1250 1575

*Protect shank against torsion when tightening.


MA = tightening torques

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


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

M020127/02E 05-08 © MTU


General 33

M020127/02E 05-08 © MTU


34 General

Tightening torques MA are specified for plug screws of steel (St), surface-protected with phosphate
coating and oiled or galvanically zinc-plated. Threads and mating faces under head must be coated
in engine oil, prior to assembly. An assembly tolerance of +10 % of the table values is permitted for
unavoidable deviations of the tightening torque from the table value during the tightening process -
e.g. resulting from inaccurate readings and overtightening during assembly.
Tightening torques for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed plug)

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

M10 x 1 15 15

M12 x 1.5 35 25

M14 x 1.5 35 25

M16 x 1.5 40 30

M18 x 1.5 50 35

M20 x 1.5 55 45

M22 x 1.5 60 50

M24 x 1.5 70 60

M26 x 1.5 80 70

M27 x 2 80 70

M30 x 1.5 100 90

M30 x 2 95 85

M33 x 2 120 110

M36 x 1.5 130 115

M38 x 1.5 140 120

M42 x 1.5 150 130

M45 x 1.5 160 140

M48 x 1.5 170 145

M52 x 1.5 180 150

M56 x 2 190 160

M64 x 2 205 175

MA = tightening torques

M020127/02E 05-08 © MTU


General 35

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

M8 x 1 10 10

M22 x 1.5 80 65

M26 x 1.5 105 90

M30 x 1.5 130 130

M38 x 1.5 140 120

M45 x 1.5 160 140

MA = tightening torques

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


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

M020127/02E 05-08 © MTU


36 General

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

Tightening specifications for banjo screws made of steel


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

M8 x 1 10

M10 x 1 15

M12 x 1.5 20

M14 x 1.5 25

M16 x 1.5 25

M18 x 1.5 30

M22 x 1.5 60

M26 x 1.5 90

M30 x 1.5 130

M38 x 1.5 140

M45 x 1.5 160

MA = tightening torques

M020127/02E 05-08 © MTU


General 37

Tightening specifications for banjo screws made of copper/aluminum alloys


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

M10 x 1 15

M16 x 1.5 30

MA = tightening torques

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


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

Tightening torques MA are given for male connectors made of steel (St) with surface protected
by a phosphate coating and oiled or galvanized.
Thread and mating faces beneath heads must be coated in engine oil prior to assembly.

M020127/02E 05-08 © MTU


38 General

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.

inserted in steel/gray cast iron MA


Thread
(Nm)

M10 x 1 10

M12 x 1.5 20

M14 x 1.5 40

M16 x 1.5 50

M18 x 1.5 60

M22 x 1.5 70

M26 x 1.5 100

M32 x 2 160

M42 x 2 260

M48 x 2 320

MA = tightening torques

Tightening specifications for union nuts on screwed plugs ISO 6149-3

1 Union nut
2 Union body
3 O-ring
4 Ball bush
Union nut: When installing the ball bush, the union nut should be tightened firmly by hand (noticeable
increase in force) a quarter of a turn (90°) beyond this point.

M020127/02E 05-08 © MTU


General 39

1.2.9 Settings

Firing order for 2000CR engines


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

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

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

16V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7

Direction of rotation, viewed on driving end


Component Direction of rotation

Crankshaft left

Camshaft right

High-pressure fuel pump left

Oil pump left

Engine coolant pump left

Raw water pump left

Battery-charging generator left

Valve clearance with cold engine


Inlet 0.30 mm

Exhaust 0.40 mm

M020127/02E 05-08 © MTU


40 General

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

No. Valve position Crank angle

1 Inlet opens 40.4° before TDC

2 Inlet closes 43.6° after BDC

3 Exhaust opens 67.6° before BDC

4 Exhaust closes 43.2° after TDC

5 Overlap 83.6 °

Start of delivery Performance-map controlled

I Top dead center (TDC)

II Bottom dead center (BDC)

Cam and valve lift for camshaft adjustment


Inlet Exhaust

Cam lift at TDC 1.60 mm 1.60 mm

Valve lift at TDC (zero valve 2.20 mm 2.20 mm


clearance)

M020127/02E 05-08 © MTU


General 41

1.2.10 Conversion tables

Length
Unit A multiplied by factor = Unit B

in 25.4 = mm

ft 0.3048 =m

yd 0.9144 =m

stat. mile 1.609 = km

yd 3 = ft

yd 36 = in

Unit B multiplied by factor = Unit A


mm 0.3937 = in
m 3.281 = ft

km 0.6215 = stat. mile

Area
Unit A multiplied by factor = Unit B

in2 645.16 = mm2

ft2 0.0929 = m2

yd2 0.8361 = m2

stat. mile2 2.5889 = km2

Unit B multiplied by factor Unit A


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

km2 0.3863 stat. mile2

M020127/02E 05-08 © MTU


42 General

Volume
Unit A multiplied by factor = Unit B

in3 16387 = mm3

ft3 0.02832 = m3

yd3 0.7646 = m3

gallon (US) 3.787 = dm3

gallon (Brit.) 4.546 = dm3

Unit B multiplied by factor = Unit A


cm3 0.06102 = in3
m3 35.31 = ft3

dm3 0.2642 = gallon (US)

dm3 0.22 = gallon (Brit.)

Speed
Unit A multiplied by factor = Unit B

ft/s 0.3048 = m/s

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

knot (Brit.) 1.852 = km/h

Unit B multiplied by factor = Unit B

m/s 3.281 = ft/s

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

km/h 0.54 = knot (Brit.)

M020127/02E 05-08 © MTU


General 43

Mass
Unit A multiplied by factor = Unit B

lb 0.4536 = kg
oz 28.35 =g

ton 1.016 =t

Unit B multiplied by factor = Unit A


g 0.03527 = oz

kg 2.205 = lb

t 0.9843 = ton

Force
Unit A multiplied by factor = Unit B

lb 0.4536 = kp

lb 4.4483 =N

Unit B multiplied by factor = Unit A

kp 2.205 = lb

N 0.101972 = kp

kp 9.80665 =N

Density
Unit A multiplied by factor = Unit B

lb s2/ft4 515.4 = kg/m3

Unit B multiplied by factor = Unit A

kg/m3 0.00194 = lb s2/ft4

M020127/02E 05-08 © MTU


44 General

Torque
Unit A multiplied by factor = Unit B

ft lb 1.3563 = Nm

Unit B multiplied by factor = Unit A

Nm 0.7373 = ft lb

Pressure
Unit A multiplied by factor = Unit B

lb/sq in (psi) 703.1 = kp/m2 (mm WS)

lb/sq in (psi) 0.06895 = bar

lb/sq ft 47.883 = Pa

in QS 0.03386 = bar

in QS 345.3 = kp/m2

Unit B multiplied by factor = Unit A

atm 760 = mm QS

atm 1.0133 = bar

atm 10332 = kp/m2 (mm WS)

atm 1.0332 = kp/cm2 (at)

atm 14.696 = lb/sq in

bar 14.503 = lb/sq in

Mass moment, 2nd grade


Unit A multiplied by factor = Unit B

ft lb s2 1.3563 = kg m2

Unit B multiplied by factor = Unit A

kg m2 0.7373 = ft lb s2

M020127/02E 05-08 © MTU


General 45

Energy
Unit A multiplied by factor = Unit B

ft lb 1.356 =J

kcal 4186.8 =J

BTU 1055 =J

CHU 1899 =J

Unit B multiplied by factor = Unit A

J 0.7376 = ft lb

J 0.0002389 = kcal

J 0.0009479 = BTU

J 0.00052656 = CHU

Power
Unit A multiplied by factor = Unit B

HP (horse power) 0.7355 = kW

HP 0.7457 = kW

BTU/s 1.055 = kW

kcal/h 1.163 =W

HP 550 = ft lb/s

Unit B multiplied by factor = Unit A

kW 1.36 = PS

kW 1.341 = HP

kW 0.9479 = BTU/s

W 0.8598 = kcal/h

ft lb/s 0.0018 = HP

M020127/02E 05-08 © MTU


46 General

Temperature
Celsius Kelvin Fahrenheit Réaumur

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

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

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


K

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

Fuel consumption
Unit A multiplied by factor = Unit B

mile/gal (US) 0.4251 = km/l

gal/mile (US) 2.3527 = l/km

Unit B multiplied by factor = Unit A

km/l 2.3527 = mile/gal (US)

l/km 0.4251 = gal/mile (US)

M020127/02E 05-08 © MTU


General 47

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


Data

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

M6 6.31/6.04 6.1–6.2–6.25

M8 8.35/8.04 8.1–8.2–8.25–8.3

M8x1 8.32/8.04 8.1–8.2–8.25–8.3

M 10 10.4/10.05 10.25

M 12 12.5/12.05 12.25–12.5

M 12 x 1.5 12.43/12.05 12.25

M 14 14.53/14.06 14.25–14.5

M 14 x 1.5 14.43/14.05 14.25

M 15 x 2 15.3/15.2 15.25

M 16 16.53/16.06 16.25–16.5

M 16 x 1.5 16.43/16.05 16.25

M 24 x 1.5 24.43/24.05 24.25

M 26 x 1.5 26.43/26.05 26.25

M 30 x 1.5 30.43/30.05 30.25

1. Remove thread insert with suitable removal


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

1 Snout
2 Spindle

M020127/02E 05-08 © MTU


48 General

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


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

1 Spindle
2 Thread insert

9. Use spindle to turn thread insert through snout


until it is flush at front (arrow).

10. Mount installation tool on threaded hole and install


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

M020127/02E 05-08 © MTU


General 49

1.2.12 Transport

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

M020127/02E 05-08 © MTU


50 General

1.2.13 Abbreviations

Abbrevia- Meaning Explanation


tion

AL Alarm

ANSI American National Standards Institute

ATL Abgasturbolader Exhaust Turbocharger

BDM Backup Data Module

BR Baureihe Engine Series

CAN Controller Area Network

CPP Controllable Pitch Propeller

CR Common Rail

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

DIS Display Unit

DL Default Lost Alarm: CAN bus failure

ECS Engine Control System

ECU Engine Control Unit Engine governor

EDM Engine Data Module

EMU Engine Monitoring Unit

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

FPP Fixed Pitch Propeller

GCU Gear Control Unit

GMU Gear Monitoring Unit

HI High Alarm: Measured value exceeds 1st maximum limit

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

HT High Temperature

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

IDM Interface Data Module

IMO International Maritime Organization

ISO International Organization for


Standardization

KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204

KS Kraftseite Engine driving end in accordance with DIN ISO 1204

M020127/02E 05-08 © MTU


General 51

Abbrevia- Meaning Explanation


tion

LCD Liquid Crystal Display, Liquid Crystal


Device

LCU Local Control Unit LOP subassembly

LED Light Emitting Diode

LMU Local Monitoring Unit LOP subassembly

LO Low Alarm: Measured value is lower than 1st minimum limit

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

LOP Local Operating Panel

LOS Local Operating Station

MCS Monitoring and Control System

MG Message

MPU Microprocessor Unit, Microprocessing


Unit

OT Oberer Totpunkt Top dead center (TDC()

P-xyz Pressure-xyz Pressure measuring point xyz

PAN Panel

PCU Propeller Control Unit

PIM Peripheral Interface Module

UPS Unit Pump System

RCS Remote Control System

RL Redundancy Lost Alarm: Redundant CAN bus failure

SAE Society of Automotive Engineers U.S. standardization organization

SD Sensor Defect Alarm: Sensor failure

SDAF Shut Down Air Flaps

SPC Spare Parts Catalog

SS Safety System Alarm initiated by safety system

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

T-xyz Temperature-xyz Temperature measuring point xyz

TC Tools Catalog

TD Transmitter Deviation Alarm: Deviation in transmitter values

UT Unterer Totpunkt Bottom dead center (BDC)

VS Voith Schneider Voith Schneider drive

WJ Water Jet Waterjet drive

M020127/02E 05-08 © MTU


52 General

M020127/02E 05-08 © MTU


Operation Schedules 53

2 Operation Schedules

2.1 Engine condition check before a major overhaul


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

Operations to be performed See

Put the engine into operation after a scheduled (→Operating Instructions)


out-of-service period.

Start engine at LOP. (→Operating Instructions)

Run engine until operating temperature is reached. -

Test engine at highest possible power. (→Acceptance test record)


If this is not possible, operate the engine at adjustable
upper and lower no-load speed.

Perform operational checks. (→Operating Instructions)

Take engine oil sample and analyze. (→Operating Instructions)

Take engine coolant sample and analyze. (→Operating Instructions)

Shut down engine at LOP. (→Operating Instructions)

Drain engine coolant. (→Operating Instructions)

If engine coolant sample is not OK, fill with cleaning (→Fluids and Lubricants Specification)
agent.

Start engine at LOP. (→Operating Instructions)

Flush engine cooling system. (→Fluids and Lubricants Specification)

Shut down engine at LOP. (→Operating Instructions)

M020127/02E 05-08 © MTU


54 Operation Schedules

2.2 Preface

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

MTU maintenance concept


The MTU maintenance concept is a preventive maintenance concept. Preventive maintenance enables
advance operational planning and secures high operational availability.
The maintenance schedule is base on the load profile specified below. The intervals after which maintenance
work is to be carried out as well as the prescribed inspection and maintenance work are the average result of
operational experience and therefore merely guide values. Specific operating conditions may require modifications
to the Maintenance Schedule. Exchange parts (reliabilt®) are available for components to be replaced.

Note
The maintenance task matrix covers all tasks up to a major overhaul. Maintenance work must
then be continued according to the specified intervals.
The task number specified in the task list is marked on the corresponding spare part and
is a reference for the required scope of parts.
The specification of the fluids and lubricants, the guidelines for maintenance and replacement intervals as well as
the list of recommended fluids and lubricants are to be found in the MTU Fluids and Lubricants Specifications
A001061 and in the fluids and lubricants specifications of the component manufacturers. Only use fluids and
lubricants that comply with the MTU specification or that are approved by the respective component manufacturer.
The user/customer must perform the following maintenance tasks:
• Fuel prefilter:
The maintenance interval depends on the fuel’s degree of contamination. Paper inserts of
fuel prefilters must be replaced after 2 years at the latest.
• Battery:
The maintenance of the batteries depends on their use and the ambient conditions. The
specifications of the battery manufacturer apply.
The manufacturer’s specifications are binding for the servicing of all components that are
not included in this maintenance schedule.

Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures
according to the Fluids and Lubricants Specifications, MTU Publication No. A001061.

Application group
1B Fast vessels with high load factors

M020127/02E 05-08 © MTU


Operation Schedules 55

Load profile
Load profile table

Power 100% < 15%

Corresponding operating time 75% 25%

Application group
1DS Fast vessels with low load factors

Load profile
Load profile table

Power 100% 70% < 10%

Corresponding operating time 10% 70% 20%

M020127/02E 05-08 © MTU


56 Operation Schedules

2.3 Maintenance schedule matrix 2000 M72

0-5,250 operating hours

Limit, years
Item Operating hours [h]

1,000
1,250
1,500
1,750
2,000
2,250
2,500
2,750
3,000
3,250
3,500
3,750
4,000
4,250
4,500
4,750
5,000
5,250
Daily
250
500
750
Engine oil filter 2

Engine operation - X

Crankcase ventilation - X X X X X X X X X X X X X X X X X X X X X

Crankcase ventilation - X X X X X X X X X X

Centrifugal oil filter - X X X X X X X X X X

Fuel filter 2 X X X X X X X X X X

Valve gear - X X X X X

Belt drive 2 X

Air filter 3 X

Fuel injectors -

Cylinder chambers -

Component maintenance -

Cylinder head -

Extended component 18
maintenance

M020127/02E 05-08 © MTU


Operation Schedules 57

5,500-10,750 operating hours

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

Centrifugal oil filter - X X X X X X X X X X X

Fuel filter 2 X X X X X X X X X X X

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

M020127/02E 05-08 © MTU


58 Operation Schedules

11,000-12,000 operating hours

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

Centrifugal oil filter - X X X

Fuel filter 2 X X X

Valve gear - X X

Belt drive 2 X

Air filter 3 X

Fuel injectors - X

Cylinder chambers - X

Component maintenance - X

Cylinder head - X

Extended component 18 X
maintenance

M020127/02E 05-08 © MTU


Operation Schedules 59

2.4 Maintenance schedule matrix 2000 M92

0-5,250 operating hours

Limit, years
Item Operating hours [h]

1,000
1,250
1,500
1,750
2,000
2,250
2,500
2,750
3,000
3,250
3,500
3,750
4,000
4,250
4,500
4,750
5,000
5,250
Daily
250
500
750
Engine oil filter 2

Engine operation - X

Crankcase ventilation - X X X X X X X X X X X X X X X X X X X X X

Crankcase ventilation - X X X X X X X X X X

Centrifugal oil filter - X X X X X X X X X X

Fuel filter 2 X X X X X X X X X X

Valve gear - X X X X X

Belt drive 2 X X

Air filter 3 X X

Fuel injectors -

Cylinder chambers -

Component maintenance -

Cylinder head -

Extended component 18
maintenance

M020127/02E 05-08 © MTU


60 Operation Schedules

5,500-6,000 operating hours

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

Centrifugal oil filter - X X

Fuel filter 2 X X

Valve gear - X

Belt drive 2 X

Air filter 3 X

Fuel injectors - X

Cylinder chambers - X

Component maintenance - X

Cylinder head - X

Extended component 18 X
maintenance

M020127/02E 05-08 © MTU


Operation Schedules 61

2.5 Maintenance schedule matrix 2000 M93

0-4,000 operating hours

Limit, years
Item Operating hours [h]

1,000
1,250
1,500
1,750
2,000
2,250
2,500
2,750
3,000
3,250
3,500
3,750
4,000
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

Centrifugal oil filter - X X X X X X X X

Fuel filter 2 X X X X X X X X

Valve gear - X X X X

Belt drive 2 X X

Air filter 3 X X

Fuel injectors - X

Cylinder chambers - X

Component maintenance - X

Cylinder head - X

Extended component 18 X
maintenance

M020127/02E 05-08 © MTU


62 Operation Schedules

2.6 Maintenance tasks

Qual- Interval Item Maintenance tasks Task


ifica-
tion [hours] [a]

QL1 - - Engine oil filter Replace engine oil filter after each oil change or after W1008
year limit at latest. (→Operating Instructions).

QL1 Daily - Engine operation Check engine oil level. (→Operating Instructions ). W0500

Visually check leak-tightness and general condition of W0501


the engine. (→Operating Instructions).

Check drain line of the intercooler (if fitted). W0502


(→Operating Instructions).

Check service indicator of air filter. (→Operating W0503


Instructions).

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


Instructions).

Check for abnormal running noises, exhaust gas color W0506


and vibrations. (→Operating Instructions).

Drain water and dirt on drain cock of fuel prefilter (if W0507
fitted). (→Operating Instructions).

Check reading at service indicator of fuel prefilter (if W0508


fitted). (→Operating Instructions).

QL1 Crankcase ventilation Replace paper or textile insert (if fitted) of oil separator. W1139
(→Operating Instructions)

QL1 Crankcase ventilation Clean wire meshes of crankcase breather. (→Operating W1140
Instructions)

QL1 Centrifugal oil filter Centrifugal oil filter (if fitted): Check layer thickness of W1009
oil residue, clean and replace filter sleeve (→Operating
Instructions).

QL1 Fuel filter Replace fuel filter or filter insert. (→Operating W1001
Instructions).

QL1 Valve gear Check valve clearance. (→Operating Instructions ). W1002

QL1 Belt drive Check condition and tension of drive belt, replace if W1003
required. (→Operating Instructions).

QL1 Air filter Replace air filter. (→Operating Instructions ). W1005

QL1 Fuel injectors Replace fuel injectors. (→Operating Instructions ). W1006

QL1 Cylinder chambers Endoscope cylinder chambers. (→Operating W1011


Instructions ).

QL3 Component Prior to maintenance work, drain coolant and flush W2000
maintenance coolant circuits.

Clean air supply line. (→ Page 403) W2002

Clean intercooler and check for leaks. (→ Page 392) W2003

M020127/02E 05-08 © MTU


Operation Schedules 63

Qual- Interval Item Maintenance tasks Task


ifica-
tion [hours] [a]

Check engine coolant thermostat and replace W2006


thermostat insert. (→ Page 498)

Check centrifugal oil filter for wear (if fitted). W2009

Check vibration damper. (→ Page 200) W2011

Replace diaphragm of crankcase breather. W2014


(→ Page 100)

Overhaul coolant pump. (→ Page 462) W2015

Overhaul raw water pump. (→ Page 506) W2015

Overhaul bilge pump (if fitted). (→ Page 540) W2015

Clean engine coolant cooler and, if possible, check for W2017


leaks. (→ Page 488)

Clean engine oil exchanger and check for leaks. W2018


(→ Page 449)

Check engine alignment. W2036

Clean fuel cooler. (→ Page 348) W2059

Check pushrods and ball joints for wear. (→ Page 303) W2074

Check rocker and valve bridge for wear. (→ Page 311) W2074

Overhaul exhaust turbocharger. (→ Page 367) W2075

Replace seals of all disassembled components. W2062

QL3 Cylinder head Overhaul cylinder heads, check piston crowns and W1063
running pattern of cylinder liners visually. (→ Page 258)

QL4 Extended component Perform complete engine disassembly. Check engine W3000
maintenance components in accordance with assembly instructions,
repair or replace as required. (→ Page 66)

Replace all elastomer components and seals. W3001

Replace piston rings. (→ Page 213) W3002

Replace conrod bearings. (→ Page 213) W3003

Replace crankshaft bearings. (→ Page 151) W3004

Replace cylinder liners. (→ Page 76) W3005

Replace aux. PTO antifriction bearing. W3006

Replace high-pressure fuel pump. (→ Page 332) W3007

Replace actuating cylinders of air flaps. W3011

Replace actuating cylinders of exhaust flaps. W3012


(→ Page 431)

Replace exhaust flap bearings. (→ Page 431) W3013

M020127/02E 05-08 © MTU


64 Operation Schedules

Qual- Interval Item Maintenance tasks Task


ifica-
tion [hours] [a]

Overhaul starter. (→ Page 443) W3041

Overhaul battery-charging generator. W3042

Replace fuel-pressure relief valve. (→ Page 558) W3043

Replace high-pressure fuel sensor. (→ Page 558) W3057

Replace water filter. W3058

Replace wire meshes of crankcase breather. W3056


(→ Page 100)

M020127/02E 05-08 © MTU


Operation Schedules 65

2.7 Engine removal

Operations to be performed See

Shut off fuel supply. –

Close raw water supply line. –

Drain engine oil at operating temperature. (→Operating Instructions)

Examine oil sludge for metallic residues. –

Drain engine coolant (coolant temperature < 60 °C) (→Operating Instructions)

Drain raw water. –

Wash machinery plant (as required, without chemical –


detergent).

Disconnect all connections. –

Install non-fibrous plugs and blanking plates to seal all –


open connections.

Release engine securing screws. –

Remove engine and place on stands. –

Attach engine to lifting device in accordance with (→Operating Instructions)


transportation regulations.

M020127/02E 05-08 © MTU


66 Operation Schedules

2.8 Engine – Disassembly


The sequence of the worksteps described as follows corresponds with the practical assembly
procedure. Prior to disassembling the engine, it is helpful to make photographs of all engine
sides or to mark components installed on the engine.

Operations to be performed See

Mark and disconnect electric cables. –

Remove ECU housing. (→Operating Instructions)

Remove air filter. (→ Page 400)

Remove crankcase breather. (→ Page 103)

Remove intake housing.

Remove control block and control line for air and exhaust
flaps.

Remove centrifugal oil filter (if installed).

Remove exhaust system for engine coolant cooler and (→ Page 483)
intercooler.

Remove coolant pipework, coolant pump.

Remove coolant pipework after coolant pump.

Remove preheating unit (if installed).

Remove coolant pipework from/to intercooler.

Remove exhaust system for engine coolant cooler and (→ Page 483)
intercooler.

Remove engine lifting attachment. (→ Page 96)

Remove air supply to the cylinders. (→ Page 404)

Remove intercooler.

Remove fuel supply from fuel delivery pump to filter.

Remove fuel duplex filter. (→ Page 355)

Remove belt drive.

Remove fuel supply to the fuel delivery pump. (→ Page 342)

Remove fuel line from fuel filter to low pressure line.

Remove engine wiring harnesses.

Remove engine coolant pump. (→ Page 464)

Remove raw water lines. (→ Page 520)

Remove raw-water pump. (→ Page 507)

Remove battery-charging generator.

Remove bilge pump (if installed). (→ Page 543)

Remove coolant cooler and fuel cooler. (→ Page 489)

M020127/02E 05-08 © MTU


Operation Schedules 67

Operations to be performed See

Remove oil pump connections.

Remove leak-off fuel pipework. (→ Page 363)

Remove exhaust gas compensator after engine.

Remove exhaust gas insulating molding / jacket after


engine.

Remove exhaust flap with actuators. (→ Page 434)

Remove exhaust system after exhaust turbocharger.

Remove constant-pressure manifold. (→ Page 412)

Remove turbocharger oil supply.

Remove oil return line from exhaust turbocharger.

Remove exhaust turbocharger. (→ Page 368)

Remove starter. (→ Page 444)

Remove vibration damper on PTO, free end (→ Page 202)

Remove oil filter with slide valve for oil filter switch.

Remove oil heat exchanger. (→ Page 450)

Remove coolant pipework with thermostat. (→ Page 500)

Remove cylinder head cover. (→ Page 325)

Remove HP line.

Remove injector.

Remove valve drive. (→ Page 313)

Remove pushrod. (→ Page 304)

Remove cylinder heads. (→ Page 260)

Remove roller tappet. (→ Page 304)

Remove HP pump. (→ Page 333)

Remove PTO flange, driving end – flywheel. (→ Page 191)

Remove auxiliary PTO.

Remove filling and measuring device.

Remove engine mounts. (→ Page 526)


(→ Page 534)

Install crankcase in crankcase rotation device.

Remove oil pan. (→ Page 89)

Remove lube oil pump with drive.

Remove piston and conrod. (→ Page 216)

M020127/02E 05-08 © MTU


68 Operation Schedules

Operations to be performed See

Remove gear case, free end. (→ Page 126)

Remove gear train, free end. (→ Page 142)

Remove flywheel housing. (→ Page 114)

Remove crankshaft. (→ Page 154)

Remove cylinder liners. (→ Page 77)

Remove oil system in crankcase.

Remove crankcase from crankcase rotation device.

Remove camshaft. (→ Page 290)

Remove plug screws and cover.

Remove camshaft bearing bush.

M020127/02E 05-08 © MTU


Operation Schedules 69

2.9 Engine – Assembly


The sequence of the worksteps described as follows corresponds with the practical assembly procedure.

Operations to be performed See

Clean crankcase.

Check crankcase.

Assemble crankcase

Install camshaft. (→ Page 297)

Install crankcase in crankcase rotation device.

Install cylinder liners. (→ Page 85)

Install oil system in crankcase.

Install crankshaft. (→ Page 182)

Install piston with conrod. (→ Page 249)

Install flywheel housing. (→ Page 119)

Install gear case, free end. (→ Page 133)

Install lube oil pump with drive.

Install oil pan. (→ Page 93)

Remove crankcase from crankcase rotation device.

Install roller tappet. (→ Page 304)

Install cylinder heads. (→ Page 286)

Install PTO flange, driving end – flywheel (→ Page 197)

Install vibration damper on PTO, free end. (→ Page 208)

Install fuel line from fuel filter to low pressure line.

Install HP pump. (→ Page 337)

Install pushrods. (→ Page 309)

Install valve gear. (→ Page 322)

Install cylinder head cover. (→ Page 328)

Install coolant pipework with thermostat. (→ Page 504)

Install oil heat exchanger. (→ Page 454)

Install oil filter with slide valve for oil filter switch.

Install belt drive.

Install HP line.

Install starter. (→ Page 448)

Install constant-pressure manifold. (→ Page 419)

Install filling and measuring device.

M020127/02E 05-08 © MTU


70 Operation Schedules

Operations to be performed See

Install intercooler. (→ Page 397)

Install engine wiring harnesses.

Install exhaust turbocharger. (→ Page 389)

Connect turbocharger oil supply.

Install oil return line from exhaust turbocharger.

Install exhaust flap with actuators. (→ Page 442)

Install exhaust system after exhaust turbocharger.

Install exhaust gas insulating molding / jacket after


engine.

Install exhaust gas compensator after engine.

Install oil pump connections.

Install leak-off fuel pipework. (→ Page 366)

Install battery-charging generator.

Install engine coolant pump. (→ Page 475)

Install raw water pump. (→ Page 518)

Install pipework at raw water pump. (→ Page 523)

Install bilge pump. (→ Page 555)

Install auxiliary PTO.

Install exhaust system for engine coolant cooler and (→ Page 486)
intercooler.

Install engine coolant lines.

Install coolant cooler and fuel cooler. (→ Page 494)

Install fuel filter. (→ Page 360)

Install fuel delivery pump.

Install fuel pipework.

Install intake housing.

Install control block and control line for air and exhaust
flaps.

Install centrifugal oil filter (if available).

Install intercooler.

Install air supply to the cylinders. (→ Page 407)

Install engine lifting attachment. (→ Page 99)

Install crankcase breather. (→ Page 111)

Install air filter. (→ Page 402)

M020127/02E 05-08 © MTU


Operation Schedules 71

Operations to be performed See

Install engine mount. (→ Page 529)


(→ Page 537)

Install and connect electric wiring. (→ Page 568)

Install ECU housing. (→Operating Instructions)

Install PTO systems, free and driving ends. –

M020127/02E 05-08 © MTU


72 Operation Schedules

2.10 Engine installation

Operations to be performed See

Open all connections, remove cover and rubber plugs. –

Attach engine only at transportation eyelets and install (→Operating Instructions)


as per transportation regulations.

Connect coolant lines, fuel lines and engine monitoring. –

Fill engine coolant system. (→Operating Instructions)

Fill oil system with engine oil. (→Operating Instructions)

Align engine. –

M020127/02E 05-08 © MTU


Operation Schedules 73

2.11 Engine run-in


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

Operations to be performed See

Install engine on test stand. –

Connect engine to dynamometer or generator. –

Connect air intake, exhaust, engine coolant, raw water –


and fuel pipework.

Connect dialog unit to ECU. –

Fill expansion tank with coolant with 2% corrosion (→Operating Instructions)


inhibitor oil up to max. mark.

Vent coolant lines until bubble-free coolant emerges. –

Check that fuel in service or supply tank is according (→Fluids and Lubricants Specification)
to specification.

Vent fuel system. (→Operating Instructions)

Fill oil system with engine oil. (→Operating Instructions)

Lubricate valve gear. (→Operating Instructions)

Check operation of engine governor before starting –


engine.

Check emergency shutdown system. –

Start engine. (→Operating Instructions)

After approx. 1 minute idling operation, shut down (→Operating Instructions) (→Operating Instructions)
engine and:
• Check engine oil level. If necessary, top up oil.
• Check valve gear lubrication.

Start engine and check idle speed. –

Check for leaks at coolant, oil and fuel lines, crankcase –


seals, air system and exhaust lines.

Run in engine in accordance with run-in program and (→Acceptance test record)
record measured values.

M020127/02E 05-08 © MTU


74 Operation Schedules

Operations to be performed See

Compare/check injection, temperatures, pressures and –


speeds at gauge dialogue units with Acceptance Test
Record.

Check exhaust gas color and enter. –

Enter barometric pressure and relative air humidity in (→Acceptance test record)
Test Record.

Check engine for abnormal running noises and leaks. –

Check engine monitoring. –

After running in, run down engine and switch off. (→Operating Instructions)

Cut open one oil filter and check for residues. –

Carry out acceptance test in accordance with MTU –


Engine Acceptance Test Record.

Enter operational data in Acceptance Test Record. (→Acceptance test record)

Compare values with measured values in MTU (→Acceptance test record)


Acceptance Test Record and evaluate.

After completion of acceptance test, run down engine (→Operating Instructions)


and switch off.

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


prolonged period.

Take protective measures for sea transportation. –

Remove sensors and measuring lines and seal –


measuring points.

Remove engine from test stand. –

Prepare engine for paint spraying and coat with –


protective paint.

M020127/02E 05-08 © MTU


Task Descriptions 75

3 Task Descriptions

3.1 Crankcase and Attachments

3.1.1 Engine layout


Deviations from illustrations are insignificant
The same applies analogously to 8/12/16V 2000CR

010 Crankcase and attachments 140 Exhaust system 500 Monitoring and control system,
020 Gear train (→ Page 125) 170 Starting system (→ Page 443) general electric devices
030 Running gear (→ Page 151) 180 Lube oil system (→ Page 558)
040 Cylinder head (→ Page 258) 200 Engine cooling system
050 Valve gear (→ Page 289) (→ Page 462)
070 High pressure fuel system 210 Power supply
(→ Page 329) 230 Mounting/support (→ Page 525)
080 Low pressure fuel system 250 PTO systems, driving and free
100 Exhaust turbocharger ends (coupling)
(→ Page 367) 360 Auxiliary systems and additional
110 Intercooler (→ Page 392) equipment (not illustrated)
120 Air intake / air supply (→ Page 540)

M020127/02E 05-08 © MTU


76 Task Descriptions

3.1.2 Cylinder liner – Overview

1 Sealing ring 3 Cylinder liner


2 Sealing ring 4 Scraper ring

M020127/02E 05-08 © MTU


Task Descriptions 77

3.1.3 Cylinder liner – Removal

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Removal tool for liner F6783773 1

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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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78 Task Descriptions

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


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

Removing carbon scraper ring


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

M020127/02E 05-08 © MTU


Task Descriptions 79

Cylinder liner – Removal


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

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


Note: Do not damage oil spray nozzle.

3. Set extraction plate at the lower collar of the


cylinder liner (2).
4. Engage captive washer (4) on threaded rod.
5. Turn nut (3) on removal tool (1) until cylinder
liner (2) becomes loose on crankcase bore.
6. Take off removal tool (1).
7. Extract cylinder liner (2) from crankcase.
8. Remove sealing rings from cylinder liner (2).

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80 Task Descriptions

3.1.4 Cylinder liner – Cleaning

Material
Designation / Use Part No. Qty.
Decarbonizer
Cleaning agent

Excessive reaction time of cleaning agents on components.


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

Remove cylinder liner (→ Page 77)

Cylinder liner – Cleaning


1. Clean cylinder liner with cleaning agent.
2. Clean the carbon scraper ring using decarbonizing agent.
3. Remove cleaning agent.

M020127/02E 05-08 © MTU


Task Descriptions 81

3.1.5 Cylinder liner – Check

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.

Clean cylinder liner (→ Page 80).

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82 Task Descriptions

Cylinder liner – Check

Item Findings Task

Using the magnetic crack-testing Signs of cracks Replace


method with fluorescent magnetic
powder, check the cylinder liner for
cracks.

Check outer wall for pitting. Pitting visible. Replace

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

Check carbon scraper ring for • Scores Replace


scoring and pitting. • Pitting
visible.

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

Check cylinder liner running surface • Scores Replace


for scores and pitting. • Pitting
visible.

Check reversal point of first piston Wear visible. Replace cylinder liner.
ring for wear.

Measure cylinder liner bore with Values exceeded Replace


bore gauge and dial gauge.
Measurement plane and values
(→ Page 83).

M020127/02E 05-08 © MTU


Task Descriptions 83

3.1.6 Cylinder liner – Tolerances

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Crankcase bore 0 157.500 0 +0.040 0.005 0.070


H7
- upper fit
1 158.000
H7

Cylinder liner 0 157.500 −0.030 −0.005


- upper fit
1 158.000

2 Crankcase bore 0 154.000 0 +0.040 0.025 0.090


H7
- lower fit
1 154.500
H7

Cylinder liner 0 154.000 −0.050 −0.025


- lower fit
1 154.500

3 Crankcase bore 170.500 −0.100 +0.300 0.300 0.900

Seal 170.000 −0.100 +0.100


outer Ø

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84 Task Descriptions

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

4 Liner bore 139.000 0 +0.040 0.014 0.094


H7

Carbon scraper 139.000 −0.054 −0.014


ring outer Ø g7

5 Carbon scraper 134.400 0 +0.063


ring bore H8

6 Cylinder liner 0 10.850 −0.020 0


Collar thickness

7 Sealing ring 0.150 −0.010 +0.010

8 Cylinder liner protrusion: 10.440 to 10.540

9 0 to 0.03 > actual dimension inner Ø

10 Plane of 30.000
measurement

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

M020127/02E 05-08 © MTU


Task Descriptions 85

3.1.7 Cylinder liner – Installation

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Check cylinder liner (→ Page 81).

M020127/02E 05-08 © MTU


86 Task Descriptions

Cylinder liner – Installation


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

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


5. Fix sealing ring (2) with petroleum jelly on
crankcase (3).
6. Insert cylinder liner (4) in crankcase (3).

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


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

Measuring cylinder liner ID


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

Measuring protrusion of cylinder liner


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

M020127/02E 05-08 © MTU


Task Descriptions 87

Installing carbon scraper ring


Note: Insert carbon-deposit scraper ring only after piston has been installed (→ Page 249) .

1. Spray cylinder liner and carbon scraper ring with engine oil.
2. Insert carbon scraper ring into fit of cylinder liner.
3. Remove safety rail for cylinder liners.

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 77)
– – X Fill with engine oil (→Operating Instructions)
– – X Fill with engine coolant (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


88 Task Descriptions

3.1.8 Oil pan – Overview

5 Oil pan 50 Washer


10 Gasket 60 Screw
25 Screw 65 Sealing ring
30 Washer 75 Washer
35 Screw 80 Flange
40 Screw 85 O-ring
45 Screw 90 Screw

M020127/02E 05-08 © MTU


Task Descriptions 89

3.1.9 Oil pan – Removal

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

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Drain engine oil (→Operating Instructions)
– X X Remove oil pump connections
– X X Remove filling and measuring device

M020127/02E 05-08 © MTU


90 Task Descriptions

Lowering oil pan


Note: The oil pan can be lowered for assembly
work with the engine installed.

1. Install lowering devices (1) on the right and left


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

Oil pan – Removal


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

M020127/02E 05-08 © MTU


Task Descriptions 91

3.1.10 Oil pan – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove oil pan (→ Page 89).

Oil pan – Cleaning


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow out oil pan and all threaded bores with compressed air.

M020127/02E 05-08 © MTU


92 Task Descriptions

3.1.11 Oil pan – Check

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.

Clean oil pan (→ Page 91).

Oil pan – Check

Item Findings Measure

Check oil pan with surface crack test Signs of cracks Replace
procedure and red dye penetrant for
cracks.

Check mating face of oil pan with Unevenness above 0.3 mm for 8, Rework contact surface.
crankcase for surface irregularities. 10, 12V

Unevenness above 0.5 mm for 16 V

Check sealing faces. Damaged • Recondition


• Replace

Check tapped holes for ease of Sluggish Replace thread inserts.


movement.

M020127/02E 05-08 © MTU


Task Descriptions 93

3.1.12 Oil pan – Installation

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.

Incorrect installation of components and lines.


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

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

Check oil pan (→ Page 92)

M020127/02E 05-08 © MTU


94 Task Descriptions

Installing lowered oil pan


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

Oil pan – Installation


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

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 89)
– – X Fill with engine oil (→Operating Instructions)
– – X Fill with engine coolant (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 95

3.1.13 Engine lifting equipment – Overview

10 Engine lifting equipment, free end 40 Engine lifting equipment, 60 Screw


20 Screw driving end 65 Washer
25 Washer 50 O-ring 70 Eyebolt
30 Eyebolt 55 O-ring

M020127/02E 05-08 © MTU


96 Task Descriptions

3.1.14 Engine lifting equipment – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)

Engine lifting equipment – Removal


1. Remove engine lifting equipment as shown in overview drawing (→ Page 95) .
2. Remove O-rings.
3. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


Task Descriptions 97

3.1.15 Engine lifting equipment – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove engine lifting equipment (→ Page 96).

Engine lifting equipment – Cleaning


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Blow out all parts with compressed air.

M020127/02E 05-08 © MTU


98 Task Descriptions

3.1.16 Engine lifting equipment – Check

Material
Designation / Use Part No. Qty.
Red penetrant dye for surface crack-testing procedure

Spare parts
Designation / Use Part No. Qty.
Engine lifting equipment

Clean engine lifting equipment (→ Page 97).

Engine lifting equipment – Check

Item Findings Task

Check engine lifting equipment for Damaged Replace


damage.

Check engine lifting equipment with Signs of cracks Replace


surface crack test procedure for
cracks.

Check mating and bolt-on faces for Damaged • Recondition: smooth with
damage. oilstone.
• Replace

Check threads in crankcase for ease Sluggish Recondition: Recut threads


of movement.

M020127/02E 05-08 © MTU


Task Descriptions 99

3.1.17 Engine lifting equipment – Installation

Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white

Spare parts
Designation / Use Part No. Qty.
Screw
Washer
O-ring

Check engine lifting equipment (→ Page 98).

Engine lifting equipment – Installation


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

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– – X Enable engine start –

M020127/02E 05-08 © MTU


100 Task Descriptions

3.1.18 Crankcase breather – Overview

15 Oil deflector plate 95 O-ring 150 Washer


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

M020127/02E 05-08 © MTU


Task Descriptions 101

Crankcase breather

220 Oil line 238 Screw 250 Screw


230 Sealing ring 239 Nut 255 Washer
235 Connection 240 Nut 260 Clamp
237 Clamp 241 Oil line

M020127/02E 05-08 © MTU


102 Task Descriptions

Oil separator

1 Diaphragm 2 Filter element 3 Gasket

M020127/02E 05-08 © MTU


Task Descriptions 103

3.1.19 Crankcase breather – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine. (→ Page 65)

X – – Disassemble engine. (→ Page 66)

Removing pipework and oil separator


1. Before removing the lines, take photos or label attachments and lines.
2. Remove pipework and oil separator as shown in overview drawings (→ Page 100).
3. Seal openings with suitable covers.
4. Protect oil separator from damage.

M020127/02E 05-08 © MTU


104 Task Descriptions

3.1.20 Hengst oil separator – Disassembly

Special tools
Designation / Use Part No. Qty.
Screwdriver (Torx 30)

Remove Hengst oil separator (→ Page 103).

Disassembling Hengst oil separator


1. Remove screws (2) for cover (1).
2. Remove cover (1) and O-ring.

3. Remove aerosol element (1) from oil separator


housing (2).

M020127/02E 05-08 © MTU


Task Descriptions 105

4. Remove screws for cover (1).


5. Remove cover (1), spring (2) and O-ring.
6. Remove diaphragm (3) from oil separator housing.

M020127/02E 05-08 © MTU


106 Task Descriptions

3.1.21 Crankcase ventilation – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove crankcase ventilation (→ Page 103).

Crankcase ventilation – Cleaning


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Clean pipes and all threads thoroughly with compressed air.

M020127/02E 05-08 © MTU


Task Descriptions 107

3.1.22 Crankcase breather – Check

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)

Compressed air is pressurized.


Hot testing liquid.
WARNING Risk of injury and scalding!
• Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Clean crankcase breather (→ Page 106).

Crankcase breather – Check

Item Findings Measure

Visually inspect components for Damaged Replace


damage and wear.

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


faces for damage and wear. oilstone
• Replace

Check movement of threads. Damaged • Recondition: recut threads


• Replace

Check pipes for leaks in water bath, Leaking • Recondition


using compressed air and corrosion • Replace
inhibitor.
• Test pressure: 0.5 bar (do not
exceed test pressure)

Check function of oil separator Malfunction Replace


(→ Page 108).

M020127/02E 05-08 © MTU


108 Task Descriptions

3.1.23 Hengst oil separator – Check

Spare parts
Designation / Use Part No. Qty.
Diaphragm
Oil separator

Compressed air is pressurized.


Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Clean Hengst oil separator (→ Page 106).

Hengst oil separator – Check

Item Findings Task

Visually inspect components for Damaged Replace


damage and wear.

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


faces for damage and wear. oilstone
• Replace

Check thread for ease of movement. Damaged • Recondition: recut threads


• Replace

Pressure-test oil separator for leaks Leaking • Replace


with air in water bath.
• Test pressure: 0.2 bar (do not
exceed test pressure)

Oil separator pressure control can only be checked when installed with engine running. Vacuum or overpressure
is measured (e.g. with water pressure gauge) over entire engine speed range. Values should lie between minus
10 mbar and plus 10 mbar (100 mm water column).

M020127/02E 05-08 © MTU


Task Descriptions 109

3.1.24 Hengst oil separator – Assembly

Special tools
Designation / Use Part No. Qty.
Screwdriver (Torx 30)

Material
Designation / Use Part No. Qty.
Petroleum jelly, white

Check Hengst oil separator (→ Page 108).

Assembling Hengst oil separator


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

4. Mount cover (1) on spring (2) in correct position.


5. Insert screws and tighten diagonally with
torque wrench to prescribed tightening torque
(→ Page 24).

M020127/02E 05-08 © MTU


110 Task Descriptions

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


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

8. Put cover (1) on to oil separator housing,


insert screws (2) and tighten diagonally with
torque wrench to prescribed tightening torque
(→ Page 24).
9. Check oil separator for leaks (→ Page 108).

M020127/02E 05-08 © MTU


Task Descriptions 111

3.1.25 Crankcase ventilation – Installation

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

Check crankcase ventilation (→ Page 107).

Crankcase ventilation – Installation


1. Prior to installation, remove all covers.
2. Coat O-rings with petroleum jelly.
3. Install oil separator and pipes as shown in overview drawings (→ Page 100).

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– – X Enable engine start –

M020127/02E 05-08 © MTU


112 Task Descriptions

3.2 Gear Train

3.2.1 Flywheel housing – Overview

25 Flywheel housing 99 Spacer bush 160 Sealing ring


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

M020127/02E 05-08 © MTU


Task Descriptions 113

Flywheel housing – Overview

5 Flywheel housing 25 Sleeve 35 Sleeve


20 Bearing flange 30 Flange

M020127/02E 05-08 © MTU


114 Task Descriptions

3.2.2 Flywheel housing – Removal

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


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

Flywheel housing – Removal


1. Insert eyebolts.
2. Use lightly pretensioned rope to attach flywheel housing to crane.
3. Mark all screws (different lengths) and remove (→ Page 112).
4. Remove flywheel housing from crankcase.

M020127/02E 05-08 © MTU


Task Descriptions 115

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


6. Seal openings with suitable covers.

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116 Task Descriptions

3.2.3 Flywheel housing – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove flywheel housing (→ Page 114).

Flywheel housing – Cleaning


1. Clean all parts with cleaning agent.
2. Remove cleaning agent.
3. Blow out all parts and all threads thoroughly with compressed air.

M020127/02E 05-08 © MTU


Task Descriptions 117

3.2.4 Flywheel housing – Check

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

Clean flywheel housing (→ Page 116).

Flywheel housing – Check

Item Findings Measure

Check flywheel housing with red dye Signs of cracks Replace


penetrant for cracks.

Check mating and bolt-on faces. Wear Smooth with oilstone.

Check threads for damage. Damaged Rework threads.

Check sleeve of sensor for damage. Damaged • Recondition with oilstone or


emery cloth.
• Replace (→ Page 124)

Check radial-lip shaft seal for Damaged Replace (→ Page 122)


damage.

M020127/02E 05-08 © MTU


118 Task Descriptions

3.2.5 Flywheel housing – Tolerances

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Flywheel housing 148.000 0 +0.063 0.187 0.450


bore H8

Shaft seal outer 148.000 +0.250 +0.450


Ø

M020127/02E 05-08 © MTU


Task Descriptions 119

3.2.6 Flywheel housing – Installation

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Check flywheel housing (→ Page 117).

M020127/02E 05-08 © MTU


120 Task Descriptions

Flywheel housing – Installation


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

9. Use crane to install flywheel housing (1) on


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

12. Insert all screws and washers and tighten evenly.


13. Remove ropes and eyebolts.
14. Check axial play of camshaft (→ Page 297).

M020127/02E 05-08 © MTU


Task Descriptions 121

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 114)
– – X Fill up with engine coolant (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


122 Task Descriptions

3.2.7 Radial-lip shaft seal – Replacement

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.

Incorrect installation of components and lines.


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

Removing shaft seal


Note: Use extraction tool only if flywheel housing is installed.

1. Install extraction tool for shaft seal.


2. Extract shaft seal from flywheel housing with extraction tool.

M020127/02E 05-08 © MTU


Task Descriptions 123

Installing shaft seal in seal carrier


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

3. Slide shaft seal (2) on to installation jig (3) with


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

M020127/02E 05-08 © MTU


124 Task Descriptions

3.2.8 Sensor sleeve – Removal and installation

Special tools
Designation / Use Part No. Qty.
Mandrel

Material
Designation / Use Part No. Qty.
Liquid nitrogen

Spare parts
Designation / Use Part No. Qty.
Sleeve

Nitrogen is liquid (at -200°C).


Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Wear protective clothing, gloves, and goggles / safety mask.
• Ventilate working area well.

Check sleeve (→ Page 117).

Removing sleeve
1. Place flywheel housing to the side on a suitable surface.
2. Use suitable mandrel and hammer to remove sleeve (→ Page 112) from flywheel housing.

Installing sleeve
1. Clean bore (→ Page 112) in flywheel housing.
2. Chill sleeve in liquid nitrogen.
3. Insert chilled sleeve in flywheel housing.

M020127/02E 05-08 © MTU


Task Descriptions 125

3.2.9 Gearcase, free end – Overview

1 Gearcase, free end 4 Hub 7 Idler gear


2 Plug screw 5 Idler gear
3 Self-aligning ball bearing 6 Hub

M020127/02E 05-08 © MTU


126 Task Descriptions

3.2.10 Gearcase, free end – Removal

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

M020127/02E 05-08 © MTU


Task Descriptions 127

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


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

– X X Remove engine mounting, free end (→ Page 526)

Gearcase, free end – Removal


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

M020127/02E 05-08 © MTU


128 Task Descriptions

13. Remove guide pin.


14. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


Task Descriptions 129

3.2.11 Gearcase, free end – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove gearcase, free end (→ Page 126).

Cleaning equipment carrier


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly clean equipment carrier, oil chambers and all oil bores by blowing out with compressed air.

M020127/02E 05-08 © MTU


130 Task Descriptions

3.2.12 Gearcase, free end – Check

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.

Disassemble gearcase, free end (→ Page 137).

M020127/02E 05-08 © MTU


Task Descriptions 131

Gearcase, free end – Check

Item Findings Measure

Check gearcase, free end with Signs of cracks Replace.


magnetic crack test procedure for
cracks.

Check crankshaft bearings for wear, • Scores Replace crankshaft bearing


scoring and indentation. • Indentations (→ Page 137).
visible

Check threads in gearcase for ease Sluggish Recut threads.


of movement.

Check screw threads and shafts for Damaged Replace.


damage.

Check all mating and sealing faces Damaged • Recondition with oilstone or
and fits. emery cloth.
• Replace.

Measure crankshaft bearing Values exceeded. Replace crankshaft bearing


in gearcase, free end. Values (→ Page 137).
(→ Page 132)

Measure crankshaft bearing bore in Values exceeded. Replace gearcase.


gearcase. Values (→ Page 132)

M020127/02E 05-08 © MTU


132 Task Descriptions

3.2.13 Gearcase, free end – Tolerances

No. Designation Stage Toleranced size Clearance Interference Wear


limit

lower upper min. max. min. max.

1 Gearcase bore 180.000 0 +0.063 0.237 0.550


H8

Replace radial-lip 180.000 +0.300 +0.550


shaft seal

2 Gearcase bore 160.000 0 0.025 0.100 0.155


H6

Bearing outer Ø 160.100 −0.030 0


removed

3 Bearing bore 150.107 0 +0.120 0.297 0.417


installed

Vibration damper 149.820 −0.010 +0.010


outer Ø

M020127/02E 05-08 © MTU


Task Descriptions 133

3.2.14 Gearcase, free end – Installation

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.

Incorrect installation of components and lines.


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

Check gearcase, free end.

M020127/02E 05-08 © MTU


134 Task Descriptions

Gearcase, free end – Installation


1. Coat O-ring (1) and sealing ring (2) with petroleum
jelly and insert in grooves on gearcase, free end.
2. Prior to installation, remove all covers.

3. Turn back jackscrew (1) of alignment tool (2).


Note: Marking (4) always faces upwards,
regardless of position of crankcase.

4. Install alignment tool (2) on crankshaft (3).


5. Screw eyebolts into gearcase, free end (5).
6. Attach gearcase, free end to crane with lightly
pretensioned rope.
7. Insert guide pin.
8. Install gearcase, free end (5) on crankcase above
alignment tool (2).

9. Align gearcase, free end (1) to crankcase.

M020127/02E 05-08 © MTU


Task Descriptions 135

Note: Observe markings / different screw lengths


and types.

10. Insert all screws and washers and tighten evenly.


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

Checking axial play and backlash


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

M020127/02E 05-08 © MTU


136 Task Descriptions

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 126)
– – X Fill up with engine oil (→Operating Instructions)
– – X Fill up with engine coolant (→Operating Instructions)
– – X Fill fuel system (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 137

3.2.15 Gearcase, free end – Removal and installation of crankshaft bearing

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

Nitrogen is liquid (at -200°C).


Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Wear protective clothing, gloves, and goggles / safety mask.
• Ventilate working area well.

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

Check crankshaft bearing bore (→ Page 130).

Removing crankshaft bearing


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

M020127/02E 05-08 © MTU


138 Task Descriptions

Installing crankshaft bearing


1. Place gearcase, free end on a suitable surface.
2. Chill crankshaft bearing in liquid nitrogen.
3. Insert chilled crankshaft bearing with installation jig in gearcase, free end.

M020127/02E 05-08 © MTU


Task Descriptions 139

3.2.16 Radial-lip shaft seal – Replacement

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.

Incorrect installation of components and lines.


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

Removing radial-lip shaft seal


Note: Use extraction tool only if gearcase, free end is installed.

1. Install extraction tool for radial-lip shaft seal.


2. Extract radial-lip shaft seal from gearcase, free end, with extraction tool.

M020127/02E 05-08 © MTU


140 Task Descriptions

Installing radial-lip shaft seal in seal carrier


1. Check bore for radial-lip shaft seal in gearcase,
free end (1). Values (→ Page 118).
2. If value is exceeded, replace gearcase, free
end (1).
Note: Use installation jig (3) only if gearcase,
free end (1), is installed.

3. Slide radial-lip shaft seal (2) onto installation jig (3)


with sealing lip facing downwards.
4. Clean sealing face for radial-lip shaft seal (2) in
gearcase, free end (1) until free of grease and dry.
5. Coat sealing face on radial-lip shaft seal (2)
with ethanol.
6. Press radial-lip shaft seal (2) with installation jig (3)
into gearcase, free end (1).
7. Remove installation jig (3).

M020127/02E 05-08 © MTU


Task Descriptions 141

3.2.17 Gear train – Overview

Item no. Designation Number of Circumferential backlash Axial play (mm)


teeth (mm)

1 Gear, camshaft 80 0.2 to 0.32 to gear 8 0.2 to 0.5

2 Gear, raw water pump 33

3 Idler gear 54

4 Gear, crankshaft 43 0.15 to 0.35

5 Idler gear 54

6 Gear, coolant pump with driver for 33


high-pressure fuel pump

7 Gear, oil pump 40

8 Gear, crankshaft 40 0.15 to 0.35

M020127/02E 05-08 © MTU


142 Task Descriptions

3.2.18 Gear train, free end – Removal

Special tools
Designation / Use Part No. Qty.
Extractor F30377999 1

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Drain engine coolant (→Operating Instructions)
– – X Drain or draw off engine oil (→Operating Instructions)
– X X Remove gearcase, free end (→ Page 126)

Removing idler gears


1. Set down gearcase, free end (4) on a clean, flat
surface.
2. Remove screws (1) and (3).
3. Insert extractor in thread (5) of hub (2).
4. Extract hub (2) evenly.
5. Remove idler gears.
6. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


Task Descriptions 143

3.2.19 Gear train, free end – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove gear train, free end (→ Page 142).

Gear train, free end – Cleaning


1. Clean idler gears.
2. Clean axle oil bores.
3. Remove cleaning agent.
4. Thoroughly clean gear train, free end, by blowing clear with compressed air.

M020127/02E 05-08 © MTU


144 Task Descriptions

3.2.20 Gear train, free end – Check

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

Clean gear train, free end (→ Page 143).

Gear train, free end – Check

Item Findings Task

Using the magnetic crack-testing Signs of cracks Replace idler gears.


method, check idler gears for cracks.

Check surface quality of idler gear Damaged Replace idler gear.


tooth flanks with magnifying glass.

Check running surface of axles, • Scores • Recondition: smooth with oilstone or


bearing bushes in idler gears and • Wear emery cloth.
axial friction faces of gears for wear Visible • Replace
and scores.

Check taper seat and bolt-on surface • Scores • Recondition


of axles for scoring and wear. • Wear • Replace
Visible

Check screws for damage and • Damaged Replace screws.


thread for ease of movement. • Tightness of movement

Measure bearing bush bore in idler Values exceeded Replace bearing bush (→ Page 149).
gear. Values (→ Page 145).

Using micrometer, measure outside Values exceeded Replace axle.


diameter of axles at running surface.
Values (→ Page 145).

Measure equipment carrier bore Values exceeded Replace equipment carrier.


of idler gear axles. Values
(→ Page 145).

M020127/02E 05-08 © MTU


Task Descriptions 145

3.2.21 Gear train, free end – Tolerances

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Web width 3.000 –0.050 +0.050

2 Gearcase bore 80.000 H7 0 +0.030 0.060 0.120

Hub outer Ø 80.000 e7 –0.090 –0.060

3 Bush bore

installed 70.000 H8 0 +0.046 0.060 0.125

removed 70.000 E6 +0.060 +0.079

Hub outer Ø 70.000 e7 –0.079 –0.060

4 Idler gear bore 75.000 H7 0 +0.030 0.029 0.078

Bush outer Ø 75.000 s6 +0.059 0.078

M020127/02E 05-08 © MTU


146 Task Descriptions

3.2.22 Gear train, free end – Installation

Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white

Spare parts
Designation / Use Part No. Qty.
O-ring

Incorrect installation of components and lines.


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

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

Check gear train, free end (→ Page 144).

M020127/02E 05-08 © MTU


Task Descriptions 147

Installing idler gear in equipment carrier


1. Coat O-ring (1) with petroleum jelly and insert in
gearcase (2).

2. Coat bearing bushes (1) in idler gear (3) with


engine oil.
3. Insert idler (3) in correct position through opening
in gearcase (2).

Installing hub
1. Coat O-ring (2) with petroleum jelly and insert in
groove on hub (3).
2. Insert hub (3) in gearcase (1).

M020127/02E 05-08 © MTU


148 Task Descriptions

3. Insert screws (1) and (2) and tighten evenly.

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 142)
– – X Fill with engine oil (→Operating Instructions)
– – X Fill with engine coolant (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 149

3.2.23 Bearing bush – Removal and installation

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

Nitrogen is liquid (at -200°C).


Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Wear protective clothing, gloves, and goggles / safety mask.
• Ventilate working area well.

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.

Incorrect installation of components and lines.


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

Check bearing bush bore (→ Page 144).

M020127/02E 05-08 © MTU


150 Task Descriptions

Removing bearing bush


1. Clean idler gear (2) (→ Page 143).
2. Using a hand press and ejection mandrel, remove
bearing bush (1) from idler gear (2).

Installing bearing bush


1. Measure bore in idler gear. Values (→ Page 145)
2. If limit values are exceeded, replace idler gear.
3. Place idler gear on a suitable surface.
4. Chill bearing bush in liquid nitrogen and heat idler gear to 80 °C.
5. Use ejection mandrel to insert chilled bearing bush in idler gear.

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Task Descriptions 151

3.3 Running Gear

3.3.1 Crankshaft – Overview

1 Crankcase 4 Screw 7 Crankshaft bearing


2 Thrust washer 5 Main bearing cap
3 Double hex bolt 6 Crankshaft

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152 Task Descriptions

Crankshaft

5 Crankshaft
10 Counterweight
15 Screw
20 Crankshaft gear
25 Crankshaft gear

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Task Descriptions 153

Crankshaft with thrust washer

30 Main bearing 35 Main bearing 45 Thrust washer

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154 Task Descriptions

3.3.2 Crankshaft – Removal

Special tools
Designation / Use Part No. Qty.
Assembly jig F6783027 1
Insertion shoe set F6783312 1

Removing main bearing caps


1. Check marking of main bearing caps to crankcase
and consecutive numbering of screws.
2. If marking is not present: Starting from the driving
end, emboss main bearing numbers making sure
they can be read from the same direction.

a Consecutive numbering of main bearings, starting


from driving end

Removing main bearing caps


1. Turn crankcase upside down in crankcase rotation
device with oil pan mating face horizontal and
facing upwards.
Note: Always loosen screws of one bearing in
one cycle.

2. Remove all lateral double-hex screws for main


bearing caps.

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Task Descriptions 155

Note: Always loosen screws of one bearing in


one cycle.

3. Remove screws for main bearing cap.

Removing main bearing caps, method 1


1. Withdraw all bearing caps carefully, i.e. without
canting, from crankcase.
2. Mark bearing shell to bearing shell and remove.
3. Protect bearing shells from damage.
4. Remove thrust washers.

Removing main bearing caps, method 2


1. Use assembly jig (2) to loosen main bearing
cap (2) from fit and remove.
2. Mark bearing shell to bearing shell and remove.
3. Protect bearing shells from damage.
4. Remove thrust washers.

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156 Task Descriptions

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.

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Task Descriptions 157

3.3.3 Crankshaft – Disassembly


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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Remove crankshaft (→ Page 154).

Removing counterweights
Note: If counterweights are to be removed, mark
relevant counterweight in its installation
position on the crankshaft prior to removal.

1. Determine and record distance A (web to


counterweight).
2. Draw mark b.
3. Check that counterweights are numbered
consecutively.
4. If consecutive numbering is not visible: Stamp
new numbers.

5. Remove counterweights with the crankshaft


supported in a firm assembly base.
6. Remove screws (2) and counterweight (1).

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158 Task Descriptions

Removing crankshaft gears on driving and free end


Note: Remove gear only if damaged.

1. Withdraw driving-end crankshaft gear (1) from


crankshaft.
2. Withdraw free-end crankshaft gear (2) from
crankshaft.

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Task Descriptions 159

3.3.4 Crankshaft – Cleaning

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Excessive reaction time of cleaning agents on components.


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

Disassemble crankshaft (→ Page 157).

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.

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160 Task Descriptions

3.3.5 Crankshaft – Check

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.

Clean crankshaft (→ Page 159).

Crankshaft – Check

Item Findings Measure

Check mating faces of Traces of wear found. Smooth with oilstone.


counterweights for wear.

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)

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Task Descriptions 161

Item Findings Measure

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 thrust washers for scores and • Scores Replace


damage. • Damage
visible

Using the magnetic crack-testing Signs of cracks Replace crankshaft counterweight


method with fluorescent magnetic (→ Page 171).
powder, check the crankshaft
counterweight for cracks.

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 for wear. Traces of wear found. • Recondition


• Replace (→ Page 157)

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.

Measure shaft length of screws with Dimension exceeded. Replace


depth gauge. Permissible shaft
length (→ Page 24)

Using the magnetic crack-testing Signs of cracks Replace


method with fluorescent magnetic
powder, check screws for cracks.

Make sure that threads are in perfect • Sluggish Replace


condition. • Damaged

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162 Task Descriptions

Checking crankshaft for cracks


1. Install crankshaft in longitudinal direction between
jaws of test device.
2. The specified magnetic field strength of 20 A/cm
to 60 A/cm must be applied at every part of
the component.
3. Check crankshaft with magnetic crack test
procedure for cracks. In doing so, also check oil
and pivot bores (3), transition radii of journals,
as well as mating faces on counterweights (2)
and tapped holes (1).
4. Demagnetize crankshaft after crack test. A
residual field strength of 2.5 A/cm to 4 A/cm
must not be exceeded.

Checking hardness of journals


Note: Check hardness of all journals when
not installed.

1. Check hardness of all journals using the Microdur


tester or other suitable hardness tester. Required
hardness: 49 HRC to 53 HRC.
2. Test hardness of each journal at four points at 90°
intervals around circumference.
Result: Values not attained, only to be carried
out in workshops authorized by MTU. Post cure
crankshaft.

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Task Descriptions 163

Checking crankshaft concentricity


1. Support crankshaft with roller blocks at the
following journals:
• 8V: Journals 1 and 5 supported by roller blocks
• 10V: Journals 1 and 6 supported by roller blocks
• 12V: Journals 1 and 7 supported by roller blocks
• 16V: Journals 2 and 8 supported by roller blocks
2. Check main bearing journal with adjustable
measuring stand and dial gauge for true running.
3. If wear across circumference of journal is irregular,
measure at transition from cylindrical section
of journal to radius.
Note: Crankshaft must not be straightened.

4. If measured values deviate, only to be carried


out in workshops authorized by MTU. Grind
main bearing journal to next stage. Values
(→ Page 164).
1 Fixed support (roller block, rigid version)
2 Dial gauge
3 Magnetic holder

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164 Task Descriptions

3.3.6 Crankshaft – Tolerances

Crankshaft bearing inner tolerance

No. Designation Stage Toler- Deviation Clearance Interference


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

1 Journal Ø 0 108.000 −0.020 0

1 Main bearing, upper 0 3.460 0 +0.012


and lower halves

Difference in wall thickness per bearing shell 0.006;


Theoretical clearance: 0.066-0.132

2 Expansion 115.000 +0.300 +1.300


dimension, upper
and lower halves
removed

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Task Descriptions 165

Crankshaft bearing outer tolerance

No. Designation Stage Toler- Deviation Clearance Interference Wear limit


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

1 Main bearing, 1-0 3.510 0 +0.012


upper and lower
halves 2-0 3.585 0

Difference in wall thickness within bearing shell 0.006;

2 Main bearing 1-0 108.066 0 +0.046 0.066 0.130


installed
2-0 108.066

Journal Ø 1-0 108.000 −0.020 0

2-0 108.000

3 Expansion 1-0 115.750 0 +1.000


dimension, upper
and lower halves 2-0 116.000
removed

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166 Task Descriptions

Crankshaft axial clearance

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Journal - width 0 42.000 H9 0 +0.062

2 42.500 H9

2 Crankcase, 0 34.500 −0.200 0


bearing cap -
width

3 Thrust washer 0 5.400 −0.025 +0.025

1 5.650

4 Crankshaft axial 0.150 0.350


clearance
Thrust washers of the same thickness must be installed on both crankshaft fit sides.

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Task Descriptions 167

Main bearing shells

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.

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168 Task Descriptions

Conrod bearings

No. Designation Stage Toleranced Deviation Clearance Interference Wear


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

1 Crankpin Ø 0 94.000 −0.020 0

1 93.900

2 93.750

3 93.500

Conrod bearing - 0 2.473 0 −0.010


upper half
1 2.523

2 2.598

3 2.723

Conrod bearing - 0 2.463 0 +0.010


lower half
1 2.513

2 2.588

3 2.713

Difference in wall thickness per bearing shell 0.006;


Theoretical clearance: 0.064 - 0.126

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Task Descriptions 169

No. Designation Stage Toleranced Deviation Clearance Interference Wear


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

2 Crankpin width 83.000 H10 0 +0.140

3 Expansion 99.600 0 +0.100


dimension, upper
and lower halves
removed

Crankshaft gear, driving end

No. Designation Stage Toleranced Deviation Clearance Interference Wear


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

1 Gear bore 100.300 N6 −0.016 −0.038 0.120 0.164

Shaft OD 100.300 t6 +0.104 +0.126

2 Clearance - gear 2.000 −0.200 +0.200


pressed on

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170 Task Descriptions

Crankshaft gear, free end

No. Designation Stage Toleranced Deviation Clearance Interference Wear


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

1 Gear bore 100.000 N6 −0.016 −0.038 0.120 0.164

Shaft OD 100.000 t6 +0.104 +0.126

2 Clearance - gear 77.500 −0.200 +0.200


pressed on

M020127/02E 05-08 © MTU


Task Descriptions 171

3.3.7 Crankshaft – Assembly

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Check crankshaft (→ Page 160).

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172 Task Descriptions

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.

5. Align counterweight to marking b and dimension A


and tighten screws with torque wrench to
prescribed pretightening torque (→ Page 24) .
6. Check that the installation position of the
counterweight matches the markings or measured
dimensions made before installation.

7. Mark screw heads.


8. Turn screws further to prescribed angle of further
rotation (→ Page 24) .
9. After installing counterweights, check identification
marks on counterweights and webs.
10. Starting from driving end, mark counterweights
with number punch.

M020127/02E 05-08 © MTU


Task Descriptions 173

Installing crankshaft gear, driving end


1. Clean surfaces of shaft stub and gear bore so that
they are free of grease and dry.
2. Place crankshaft gear, driving end (3) in the
alignment tool (1), aligning the spring-pin bore
in the crankshaft gear with the bore (arrow) of
the alignment tool.
3. Lock crankshaft gear with threaded pin (2) in its
position.
4. Heat driving-end crankshaft gear with heating
equipment to 210 °C +10 °C.

5. Insert guide pin (1) in crankshaft bore on free end.


6. Set spacing jig (arrow) down on to crankshaft and
slide heated crankshaft gear, driving end with
alignment tool on to crankshaft up to attachment.
7. Remove alignment tool and clearance gauge after
the components have cooled down to room
temperature .
8. Check clearance (arrow) between gear and
crankshaft collar with feeler gauge.
9. Specified clearance (→ Page 164).

Installing crankshaft gear, free end


1. Clean surfaces of shaft stub and gear bore so that
they are free of grease and dry.
2. Place free-end crankshaft gear (1) in assembly
jig (2) and secure in position with knurled nuts (3).
3. Pay attention to installation position of
chamfer (arrow).
4. Heat free-end crankshaft gear with heating
equipment to 230 °C +10 °C.

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174 Task Descriptions

5. Slide heated free-end crankshaft gear with


assembly jig onto crankshaft.
6. Adjust clearance (arrow) between crankshaft
and free-end crankshaft gear with feeler gauge.
Specified clearance (→ Page 164).
7. Remove assembly jig after the parts have cooled
down to room temperature.
8. Balance crankshaft dynamically (→ Page 175).

M020127/02E 05-08 © MTU


Task Descriptions 175

3.3.8 Crankshaft – Balancing

Special tools
Designation / Use Part No. Qty.
Master weights

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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Assemble crankshaft (→ Page 171).

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

Crankshaft (8V) Crankshaft (10V) Crankshaft (12V) Crankshaft (16V)

Maximum operating 2500 1/min 2500 1/min 2500 1/min 2500 1/min
speed

Support crankshaft 1 and 5 1 and 6 1 and 7 2 and 8


at shaft journals

Balancing assembly 180 kg 238 kg 218 kg 340 kg


mass

Balancing speed 200 1/min 200 1/min 200 1/min 200 1/min

Permissible residual 60 gcm 60 gcm 80 gcm 80 gcm


unbalance per
compensation level
for initial balancing

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

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176 Task Descriptions

Bore values for counterweights


1. To balance crankshaft, remove material from
counterweights by drilling with twist drill.
2. After balancing, recheck the numbering of the
counterweights, if necessary reapply.

A 25 mm (max.)
B 22 mm (max. Ø)
C 4 mm (min.)
D 72° (max.)
E 10.4 mm (min.)

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Task Descriptions 177

3.3.9 Main bearing shells – Check


Remove crankshaft (→ Page 154).

Main bearing shells – Check


Item Findings Task

In the case of reuse (e.g. Wear, scores, cracks, corrosion, Replace


non-scheduled removal), check erosion or damage visible
bearing shells for surface wear,
scores, cracks, corrosion, erosion
and damage.

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

Measure spread dimension Determined value exceeded Replace bearing shell.


(→ Page 164).

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.

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178 Task Descriptions

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.

M020127/02E 05-08 © MTU


Task Descriptions 179

3.3.10 Crankshaft bearing bore – Check

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Remove crankshaft (→ Page 154).

Note: The crankshaft bearing bore must first be checked without and subsequently with main bearings installed.

Measuring crankshaft bearing bore with main bearings installed

M020127/02E 05-08 © MTU


180 Task Descriptions

Installing bearing shells


1. Turn crankcase upside down in rotation device
with oil pan mating face horizontal.
2. Wipe bores (arrowed) for main bearing in
crankcase and bearing shells on both sides
with chamois leather.

Note: Top and bottom bearing shells have


different part numbers.

3. Check marking of repair stage and journal


diameter on new bearing shells and bearing
numbers on used bearing shells.
4. Compare crankcase data sheet and crankshaft
data sheet.
5. Insert bearing shells at housing side (bearing
shells with oil groove and oil bore) in housing bore
with pressure by hand so that they fit positively.
6. Locating lug (arrow) of the bearing shell must be in
crankcase groove.
7. Oil bores of bearing shells and crankcase must be
aligned.

Installing main bearing caps


1. Position engine in crankcase rotation device so that its oil pan mating face is facing upwards and in horizontal
position.
2. Install crankshaft bearing cap (→ Page 182).

M020127/02E 05-08 © MTU


Task Descriptions 181

Measuring crankshaft bore


1. Adjust bore gauge with adjusting ring or
micrometer to basic size of bearing bore.
2. Coat running surfaces of main bearing shells
with engine oil.
3. Measure crankshaft bearing bore ID with bore
gauge.
4. Record measured values in data sheet.
5. Compare planes of measurement and limit values
(→ Page 164).
6. If wear limits are exceeded, replace bearing shells
or work to next repair stage.
7. After measuring crankshaft bearing bores, if
necessary mark bearing shells according to
bearing point number.

Checking crankshaft bearing bore without main bearing installed


1. Remove crankshaft bearing cap (→ Page 154).
2. Remove bearing shells. Protect against damage.
3. Install crankshaft bearing cap (→ Page 182).
4. Measure crankshaft bearing bore ID in the same way as with installed bearing shells.

M020127/02E 05-08 © MTU


182 Task Descriptions

3.3.11 Crankshaft – Installation

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Incorrect installation of components and lines.


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

Check crankshaft (→ Page 160).

Check main bearing shells (→ Page 177).

Check main bearing bore (→ Page 179).

M020127/02E 05-08 © MTU


Task Descriptions 183

Determining wall thickness of thrust washers


1. In order to achieve the specified axial play
(→ Page 164) the wall thickness of the thrust
washers is determined as follows.
2. Determine wall thickness of thrust washers
according to the following formula: (A − B +
mean axial play) /2.
Note: Thrust washers of the same thickness must
be installed on both crankshaft fit sides.

3. Measure fit width (A) of crankshaft and record.

4. Measure crankcase wall thickness (B) and record


measured value.

5. Measure alignment bearing thickness (B) and


record measured value.

M020127/02E 05-08 © MTU


184 Task Descriptions

Installing bearing shells in crankcase


1. Turn crankcase upside down in crankcase rotation
device with oil pan mating face horizontal and
facing upwards.
2. Wipe both sides of bores for main bearing in
crankcase and bearing shells with chamois leather.

Note: Top and bottom bearing shells have


different part numbers.

3. Manually insert crankcase-side bearing shells


(with oil groove and oil bore) in accordance with
bearing point number in housing bore to form a
positive connection.
4. Check stage of main bearing bore and stage of
bearing shells. For data, see crankcase data sheet
and crankshaft data sheet.
5. Locating lug (arrowed) of the bearing shell must be
in crankcase groove.
6. Oil bores of bearing shells and crankcase must be
aligned.
7. Coat bearing surfaces of bearing shells (housing
side) with engine oil.

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.

M020127/02E 05-08 © MTU


Task Descriptions 185

4. With camshaft installed and before final position


of camshaft is reached, make sure that the
markings (arrows) on crankshaft gear and
camshaft gear match.
5. Slowly set down crankshaft in crankcase.
6. Remove insertion shoes.

7. Insert thrust washer (1) in crankcase (2) (both


sides).

Installing main bearing cap


1. Wipe bearing shell mating faces on main bearing
cap.
2. Wipe lower bearing shell (without oil bore) on both
sides with chamois leather and insert in the
bearing cap in accordance with the marking /
bearing number.
3. Locating lug (arrowed) of the bearing shell must
be in main bearing cap groove.

M020127/02E 05-08 © MTU


186 Task Descriptions

4. Assign bearing cap to respective bearing journal


according to marking to crankcase.

a Consecutive numbering of main bearings, starting


from driving end

5. Insert thrust washer (2) in main bearing cap (3)


(both sides).
6. Insert main bearing cap (3) with assembly jig (1)
in crankcase.
7. Coat threads and screw head mating face of
screws with engine oil.
8. Insert screws according to marking (see previous
figure) and tighten by hand.
9. Coat threads and screw head mating face of
double hex bolts with engine oil.
10. Insert double hex bolts and tighten by hand.

Note: Always tighten screws of one bearing in


one cycle.

11. Tighten screws for main bearing cap, starting


at alignment bearing, with torque wrench to
prescribed pretightening torque (→ Page 24).
12. Mark screw heads.
13. Tighten screws for main bearing cap to prescribed
additional angle of rotation (→ Page 24).

M020127/02E 05-08 © MTU


Task Descriptions 187

Note: Tighten lateral double-hex screws of one


bearing simultaneously.

14. Tighten double-hex screws at side, starting at


alignment bearing, in one cycle to prescribed
tightening torque (→ Page 24).

Measuring axial play of crankshaft


1. Mount magnetic dial gauge holder with dial gauge
(2) on crankcase.
2. Position dial gauge tip against front face of
crankshaft.
3. Using pry bar (1), press crankshaft axially as
far as it will go.
4. Set preloaded dial gauge to zero.
5. Move crankshaft from stop to stop (arrows) and
record measured value in data sheet.
6. If the determined value is outside the permissible
tolerance range (→ Page 164), remove crankshaft
and check cause.

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188 Task Descriptions

3.3.12 PTO flange, driving end, flywheel – Overview

20 Flywheel

M020127/02E 05-08 © MTU


Task Descriptions 189

Overview drawing

5 Flywheel 15 Timing wheel 25 Screw


10 Spacer ring 20 Ring gear 30 Coiled spring pin

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190 Task Descriptions

Arrangement of installation/removal device for flywheel

1 Pressure sleeve 4 Feed shaft a Push-on distance: 10.4 mm


2 Hydraulic nut A Reference dimension: 348 mm to 13.0 mm
3 Nut

M020127/02E 05-08 © MTU


Task Descriptions 191

3.3.13 PTO flange, driving end, flywheel – Removal

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.

Equipment can drop off.


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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start –

– X X Disconnect engine from gearbox –

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.

4. Screw hydraulic pressure testing device on to


crankshaft journal, driving end, according to
arrangement and tighten (→ Page 188).

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192 Task Descriptions

5. Insert and screw in hydraulic nut up to stop, then


turn back past push-on dimension value. push-on
dimension (→ Page 188).
6. Connect high-pressure line of hand pump for
hydraulic nut.
7. Fill hand pumps (1) and (2) with engine oil SAE10.
8. Vent hand pump (1) and line system, until
bubble-free oil emerges.
9. Tighten high-pressure line.
10. Operate hand pump (2) for hydraulic nut and
bring hydraulic press with minimum pressure p2
(beginning pressure increase) to contact point on
flywheel.
11. Read off maximum expansion pressure pmax at
flywheel.
12. Actuate hand pump (1) for expanding the flywheel,
until half of the maximum expansion pressure
p1 is reached.
13. Maintain pressure p1 for approx. 5 minutes.
14. Increase expansion pressure in stages of 0.1
x pmax, waiting approx. 2 minutes between
increases, until flywheel is released from
crankshaft. Do not exceed maximum permissible
expansion pressure pmax.
15. Continue to use hand pump (1) to keep falling
expansion pressure at constant level.
16. Monitor pressure p2 in hydraulic nut. The release
of the flywheel from the taper seat is indicated by
rising pressure p2.
17. Gradually drain oil from hydraulic nut, while at
the same time continuing to pump with the hand
pump (1).
18. Relieve hand pumps (1) and (2).
19. Screw carrying bracket on to flywheel and attach
to crane with lightly pretensioned rope.
20. Remove high-pressure line.
21. Remove removal device.
22. Insert locating pin.
23. Remove flywheel.
24. Place flywheel on a clean surface and secure.
25. Remove locating pin.

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Task Descriptions 193

3.3.14 PTO flange, driving end – Flywheel disassembly


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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

PTO flange, driving end – Remove flywheel (→ Page 191).

PTO flange, driving end – Flywheel disassembly


1. Set flywheel down on to assembly bench.
2. Remove screws and washers as shown in overview drawing (→ Page 188) .
3. Rotate flywheel on assembly bench by 180°.
4. Use crowbar to force ring gear off flywheel.
5. Remove spacer ring and timing wheel from flywheel.
6. Remove coiled spring pin if damaged.

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194 Task Descriptions

3.3.15 PTO flange, driving end – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Disassemble PTO flange, driving end (→ Page 193).

Cleaning PTO flange, driving end


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Blow out all threads thoroughly with compressed air.

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Task Descriptions 195

3.3.16 PTO flange, driving end – Flywheel check

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.

PTO flange, driving end – Clean flywheel (→ Page 194).

PTO flange, driving end – Flywheel check

Item Findings Measure

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 mating faces on flywheel for flatness, Signs of wear • Recondition


stress marks, scores and indentations. • Replace

Check taper with taper gauge. Not true to gauge. Replace taper.

Check thread of expanding bore. Damaged Rework thread.

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196 Task Descriptions

3.3.17 PTO flange, driving end – Flywheel assembly

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

PTO flange, driving end – Check flywheel (→ Page 195).

PTO flange, driving end – Flywheel assembly


1. Set flywheel (2) down on to assembly bench.
2. Drive coiled spring pin (1) into flywheel (2).
3. Assemble flywheel as shown in overview drawing
(→ Page 188).
4. Insert screws and washers and tighten diagonally
with torque wrench to prescribed tightening torque
(→ Page 24) .

M020127/02E 05-08 © MTU


Task Descriptions 197

3.3.18 PTO flange, driving end, flywheel – Installation

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.

Equipment can drop off.


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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Assemble flywheel on PTO flange, driving end (→ Page 196).

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.

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198 Task Descriptions

9. Install installation device as shown in overview


drawing (→ Page 188).
10. Set push-on travel (a) on hydraulic nut
(→ Page 188).
11. Insert high-pressure line and tighten by hand.
12. Connect high-pressure line for hydraulic nut.
13. Fill hand pumps (1) and (2) with engine oil SAE10.
14. Vent hand pump (1) and line system, until
bubble-free oil emerges.
15. Tighten high-pressure line from adapter.
16. Before fitting, taper fits must be moistened with
expansion fluid. To do so use hand pump (1) until
expansion fluid emerges at flywheel end.
17. Operate hand pump (2) for hydraulic nut and bring
hydraulic press to contact point on flywheel.
Note: Read off expansion pressure pmax at
flywheel.

18. Pump in expansion fluid until expansion


pressure (p1) can no longer be increased (do not
exceed expansion pressure Pmax ), then increase
push-on force by increasing force-on pressure (p2).
19. Select push-on force so that end position is
reached after approx. 5 steps.
20. Open valve screw on hand pump (1) to relieve
expansion pressure.
21. Maintain maximum force-on pressure for 60
minutes, to ensure that the expansion fluid is
expelled from the joint and static friction can build
up between the fixed components.
22. Remove high-pressure lines.
23. Remove locating pin.
24. Remove removal device after prescribed holding
time.
25. Insert grub screw in flywheel.
26. Do not subject press fitting to operating load
for at least 8 hours.

M020127/02E 05-08 © MTU


Task Descriptions 199

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– – X Connect engine to gearbox –

– – X Enable engine start –

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200 Task Descriptions

3.3.19 Vibration damper on PTO, free end – Overview

1 Belt drive
2 Crankshaft
3 Vibration damper
4 Gear case
5 Shaft seal

M020127/02E 05-08 © MTU


Task Descriptions 201

Layout of installation/removal tool for vibration damper

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


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

M020127/02E 05-08 © MTU


202 Task Descriptions

3.3.20 Vibration damper on PTO, free end – Removal

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.

Equipment can drop off.


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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– X X Remove belt drive

M020127/02E 05-08 © MTU


Task Descriptions 203

Vibration damper – Removal


1. Remove flange for barring gear.
2. Remove grub screw from expansion bore in
vibration damper.
3. Screw feed shaft (5) into crankshaft.
4. Check reference dimension ”A” of feed shaft
(→ Page 200).
5. Slide pressure sleeve (4) and hydraulic nut (2) on
to feed shaft.
6. Screw on nut (1).
7. Screw adapter (3) into vibration damper and
connect high-pressure line.
8. Connect high-pressure line for hand pump to
hydraulic nut.
9. Set hydraulic nut to initial position with zero stroke.
10. Turn nut back past push-on dimension value.
Push-on dimension ”a” see on vibration damper
11. Fill hand pumps (1) and (2) with engine oil SAE10.
12. Vent hand pump (1) and line system, until
bubble-free oil emerges.
13. Tighten high-pressure line.
14. Operate hand pump (2) for hydraulic nut and
use minimum pressure p2 (beginning pressure
increase) and bring to contact point on vibration
damper.
15. Read off maximum expansion pressure pmax
at vibration damper.
16. Operate hand pump (1) for expanding the hub,
until half of the maximum expansion pressure
p1 is reached.
17. Maintain pressure p1 for approx. 5 minutes.
18. Increase the expansion pressure in steps of 0.1 x
pmax, and hold each time for approx. 2 minutes,
until the vibration damper is released from the
crankshaft. Do not exceed maximum permissible
expansion pressure pmax.
19. Continue to use hand pump (1) to keep falling
expansion pressure at constant level.
20. Monitor pressure p2 in hydraulic nut. The
loosening of the vibration damper from the taper
seat is indicated by a rise in pressure p2 .
21. Gradually drain oil from hydraulic nut, while at
the same time continuing to pump with the hand
pump (1).
22. Relieve hand pumps (1) and (2).
23. Remove high-pressure line and adapter.
24. Remove nut, hydraulic nut and pressure bush.
25. Install lifting equipment.
26. Remove vibration damper from crankshaft.
27. Seal openings with suitable covers.

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204 Task Descriptions

3.3.21 Vibration damper on PTO, free end – Disassembly


Remove vibration damper (→ Page 202).

Vibration damper – Disassembly


Disassembly of this component is not planned.
This component is an exchange component (Reman) and is available through the usual exchange procedure.

M020127/02E 05-08 © MTU


Task Descriptions 205

3.3.22 Vibration damper on PTO, free end – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove vibration damper (→ Page 202).

Vibration damper – Cleaning


1. Clean vibration damper on PTO, free end, with cleaning agent.
2. Remove cleaning agent.
3. Clean vibration damper on PTO, free end, by blowing out with compressed air.

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206 Task Descriptions

3.3.23 Vibration damper on PTO, free end – Check

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Clean vibration damper (→ Page 205).

Checking vibration damper

Item Findings Measure

Visually inspect vibration damper for • Damage Replace vibration damper.


damage and stress marks. • Stress marks
visible

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)

Check thread of expansion bore. Damaged Recut thread.

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Task Descriptions 207

3.3.24 Vibration damper on PTO, free end – Tolerances

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Vibration damper 151.740 −0.050 +0.050


Outer Ø

2 Vibration damper 149.820 −0.010 +0.010 0.157 0.417


Outer Ø

Crankshaft 150.107 −0.120 +0.120


bearing
(installed)

3 Shaft seal flush press-fitted.

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208 Task Descriptions

3.3.25 Vibration damper on PTO, free end – Installation

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.

Equipment can drop off.


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

Check vibration damper on PTO, free end (→ Page 206).

M020127/02E 05-08 © MTU


Task Descriptions 209

Installing vibration damper


1. Prior to installation, remove all covers.
2. Clean and degrease tapers of crankshaft and
vibration damper.
3. Coat bearing surfaces of crankshaft bearing and
vibration damper with oil.
4. Coat sealing lip on shaft seal with petroleum jelly.
5. Slide vibration damper on to crankshaft taper.
6. To determine the push-on travel, measure distance
from crankshaft front end to vibration damper front
end with depth gauge.
7. Calculate difference value (=push-on travel)
between measured dimension and dimension (B)
(→ Page 200).
8. If measured distance is smaller than push-on travel
(a) (→ Page 200) , check taper for dimensional
accuracy.

9. Screw feed shaft (5) into crankshaft.


10. Check reference dimension ”A” (→ Page 200).
11. Mount pressure bush (4) and hydraulic nut (2) on
feed shaft and screw on nut (1).
12. Screw high-pressure line on to adapter (3) and
hand-tighten.
13. Connect high-pressure line for hydraulic nut.
14. Set hydraulic nut to initial position with zero stroke.

15. Fill hand pumps (1) and (2) with 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.

20. Pump in expansion fluid until expansion


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

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210 Task Descriptions

23. Maintain maximum force-on pressure for 60


minutes, to ensure that the expansion fluid is
expelled from the joint and static friction can build
up between the fixed components.
24. Remove high-pressure lines.
25. Allow specified retention time to elapse and
remove nut, hydraulic nut, pressure bush and
feed shaft.
26. Check push-on dimension ”B”. Value
(→ Page 200)
27. Install flange for barring gear.
28. Do not subject press fitting to operating load
for at least 8 hours.
Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 211

3.3.26 Vibration damper on PTO, free end – Replacement of track ring

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.

Check vibration damper on PTO, free end (→ Page 206).

Removing bearing race


1. Use puller to remove bearing race (2) from
vibration damper (1).
2. Measure outer diameter of vibration damper (1).
Values (→ Page 207)

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212 Task Descriptions

Installing bearing race


Note: Liner can either be press-fitted or fitted
by heating.

1. Heat liner (1) to 130 °C +30 °C.


2. Insert heated liner in assembly jig (2), with bevel
facing downwards (arrow).

3. Use assembly jig to knock bearing race on to


vibration damper.
4. Let bearing race cool to room temperature, then
remove assembly jig.
5. Check if entire circumference of bearing race
is flush.

M020127/02E 05-08 © MTU


Task Descriptions 213

3.3.27 Piston and conrod – Overview

50 Piston 150 Snap ring 250 Taper-face compression ring


100 Piston pin 200 Keystone ring 300 Oil control ring

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214 Task Descriptions

Overview drawing

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

M020127/02E 05-08 © MTU


Task Descriptions 215

Overview drawing

5 Conrod 15 Conrod screw


10 Conrod cap 20 Conrod bushing

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216 Task Descriptions

3.3.28 Piston and conrod – Removal

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.

M020127/02E 05-08 © MTU


Task Descriptions 217

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– X X Drain engine coolant (→Operating Instructions)
– X X Drain or draw off engine oil (→Operating Instructions)
– X X Remove ECU (→Operating Instructions)
– X X Disconnect electric wiring
– X X Remove air filter (→ Page 400)
– X X Remove intake housing
– X X Remove air supply to the (→ Page 404)
cylinders
– X X Remove leak-off fuel lines (→ Page 363)
– X X Remove cylinder head cover (→ Page 325)
– X X Remove valve drive (→ Page 313)
– X X Remove pushrod (→ Page 304)
– X X Remove injector
– X X Remove cylinder head (→ Page 260)
– X X Lower or remove oil pan (→ Page 89)

Removing piston with conrod with lowered oil pan


1. Remove combustion residues in cylinder liner.
2. Removing carbon scraper ring (→ Page 77).
3. Use socket and ratchet to loosen conrod screws
from below.
4. Install assembly jig (1) in piston (2) and switch
on compressed air.
5. After approx. 5 seconds, check assembly jig (1)
for correct fit.
6. For further removal, except for altered removal
position of crankcase: see “Removing pistons with
conrods in rotation device” in next section.

M020127/02E 05-08 © MTU


218 Task Descriptions

Removing piston with conrod in rotation device


1. Turn crankcase in rotation device so that the
pistons to be removed are in horizontal position.
2. Turn crankpin (2) of piston and conrod (1) to be
removed in removal position, as shown in drawing.

Note: Bearing cap and conrod are a single unit


and must not be interchanged.

3. Check marking (arrows) of conrod cap to conrod.


If necessary, mark components.

4. Use socket extension and ratchet to loosen


conrod screws.
5. Remove conrod screws (arrows) and take off
conrod cap (1).
6. Remove bearing shell from conrod cap (1).
7. Protect bearing shell and conrod cap from damage.

M020127/02E 05-08 © MTU


Task Descriptions 219

Note: Take care that the oil spray nozzle is not


damaged.

8. Pull piston (2) and conrod out of cylinder liner until


2nd piston ring (3) jumps up.
9. Switch off compressed air.
10. Remove assembly jig (1) from piston (2).
11. Remove bearing shell from conrod and protect
from damage.
12. Carefully place piston and conrod on to soft
surface.
13. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


220 Task Descriptions

3.3.29 Piston and conrod – Disassembly

Special tools
Designation / Use Part No. Qty.
Piston-ring pliers F30379877 1

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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Spring/circlip/tensioning roller preload.


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

Remove piston and conrod (→ Page 216).

Removing conrod from piston


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

M020127/02E 05-08 © MTU


Task Descriptions 221

Removing piston rings


1. Stretch piston rings until they can be removed
from the piston.
2. Remove piston rings with piston ring pliers in
sequence from top to bottom.

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222 Task Descriptions

3.3.30 Piston – Cleaning

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Excessive reaction time of cleaning agents on components.


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

Disassemble piston and conrod (→ Page 220).

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

1. Clean all components.


2. Clean area of piston ring grooves with rotating plastic brush.
3. Remove cleaning agent.
4. After cleaning, blow out oil chamber and oil bores with compressed air.

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Task Descriptions 223

3.3.31 Piston – Check

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Clean piston (→ Page 222).

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224 Task Descriptions

Piston – Check

Item Findings Measure

Ensure oil chamber and oil bores Uncleanness Clean


are particularly clean.

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

Measure piston pin boss. Values Values exceeded Replace piston.


(→ Page 226)

Check sliding surface of bronze • Stress marks Replace piston.


bush for stress marks and scoring. • Scores
visible

Check groove width with final Values exceeded Replace piston.


measurements. If no final dimension
is available, alternatively a new
piston ring can be inserted in
the groove and the axial play
checked with a feeler gauge. Values
(→ Page 226)

Check piston pin with magnetic Signs of cracks Replace piston pin.
crack test procedure for cracks.

Check condition of piston pin. • Traces of wear Replace piston pin.


• Score marks
• Impact points
visible

Measure piston pin outer diameter Values exceeded Replace piston pin.
with outside micrometer. Values
(→ Page 226)

Check piston rings. • Piston rings with burring, Replace


chipping or sharp edges
• If chrome layer shows scores,
cracks or burn marks.

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Task Descriptions 225

Checking piston rings


1. Place piston ring (1) in ring gauge (3) to measure
piston ring end clearance. Make sure that piston
ring fits evenly in ring gauge (3).
2. Check ring end clearance with feeler gauge (2).
Values (→ Page 226)
3. Values exceeded: Replace piston rings. Replace
piston rings only in sets.
4. After installation of new piston rings, replace
cylinder liners (→ Page 77).

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226 Task Descriptions

3.3.32 Piston – Tolerances

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Piston bore 52.000 +0.010 +0.016 0.012 0.024

Piston pin 52.000 −0.008 −0.002


Outer Ø

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Task Descriptions 227

Piston rings

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Groove width

Keystone-type
compression ring

2 Groove width

Taper-face 3.000 −0.030 0


compression ring

3 Groove width

Oil control ring 4.000 −0.030 0

4 Ring end clearance

Keystone-type 0.350 0.600


compression ring

Taper-face 0.800 1.050


compression ring

Oil control ring 0.400 0.750

Measure ring end clearance in ring gauge.

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

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228 Task Descriptions

Piston clearance in cylinder liner

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Piston recess 2.600 −0.500 +0.500

2 Liner Ø 135.000 −0.015 +0.015

Piston skirt Ø

3 Liner Ø 135.000 −0.015 +0.015

Piston skirt Ø

4 Liner Ø 135.000 −0.015 +0.015

Piston crown Ø

Dimensions 2 to 4 measured in vertical position to piston pin axis.

5 Piston skirt crowned-oval shape

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Task Descriptions 229

3.3.33 Conrod – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Disassemble conrod (→ Page 220).

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.

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230 Task Descriptions

3.3.34 Conrod – Check

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

Clean conrod (→ Page 229).

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Task Descriptions 231

Conrod – Check

Item Findings Measure

Check conrod main bore for blue Blue discoloration Replace conrod.
discoloration.

Check conrod bush for scores, dirt, Damaged • Recondition


stress marks and heat discoloration • Replace conrod bush.
marks.

Check conrod, conrod bearing cap Signs of cracks Replace


and screws with magnetic crack test
procedure for cracks.

Check threads of conrod and conrod Damaged • Replace conrod.


screw for damage. • Replace conrod screw.

Check conrod screw length. Values Value exceeded Replace


(→ Page 236)

Check mating face on conrod • Stress marks Replace


bearing cap for conrod screws for • Scores
stress marks and scores. visible

Check main bore for stress marks • Stress marks • Recondition


and scores. • Scores • Replace
visible

Inspect meshing for damage Damaged Replace


and check contact pattern with
engineer’s blue.

Measuring conrod main bore without bearing shells


1. Assemble conrod (→ Page 242).
2. Adjust bore gauge and measure main bore of conrod. Values (→ Page 236).
3. If values are exceeded, replace conrod.

Measuring conrod main bore with bearing shells


1. Assemble conrod (→ Page 242).
2. Coat running surface of bearing shells with engine oil.
3. Measure conrod bearing bore. Values (→ Page 236).
4. Record measured values in data sheet.
5. Replace bearing shells if limit values are not attained or exceeded.
6. Remove conrod screws, conrod cap and bearing shells.
7. Protect bearing shells from damage.

Measuring conrod bore and conrod 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.

Checking axial seating of conrod bush


1. Check conrod bush with hydraulic press for secure axial fit. Required test force (→ Page 236).
2. If test force is not reached, replace conrod.

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232 Task Descriptions

Checking conrod bore axial parallelism and twist

Test device layout


1 Dial gauge for axial parallelism
2 Test mandrel, small conrod bore
3 Dial gauge for conrod twist
4 Conrod
5 Test mandrel, large conrod bore
6 Prism
7 Base plate
8 Resilient stop
9 Adjustable dial gauge holder

Note: For checking axial parallelism and twist


of conrod bores, the conrod cap is
installed and conrod screws are only
inserted (10 to 20 Nm).

1. Clean large and small conrod bores.


2. Pay attention to installation position as shown
in illustration.
Note: Insert test mandrels in such a way that the
clamp pins (arrows) of the test mandrels
face outwards and lie in one plane.

3. Tighten test mandrels lightly with locking screw. In


doing so, do not twist test mandrel.

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Task Descriptions 233

Checking axial parallelism


1. Insert conrod with test mandrel (3) into prisms
(4) of testing device.
2. Place with the small test eye on to resilient stop (5).
3. Adjust fixed support on resilient stop so that the
axle of the test mandrel (2) lies approx. 2 mm
under the tracer pin of the dial gauges (1).
4. Adjust dial gauges so that their readings indicate
approx. 2 mm preload at highest point on test
mandrel axis, and set to zero.
5. Rotate conrod through 180° and carefully insert in
testing device.
6. Move the test mandrel over the sensing devices of
the dial gauges at the highest point of the test
mandrel axle.
7. Determine and note deviations from zero position
on the dial gauges.

Calculating axial parallelism


1. The testing device is set for measuring axial
parallelism at 200 mm intervals.
2. To obtain the correct value at a distance of 100
mm (→ Page 236) calculate the read-off value at
the dial gauges as shown in the following example.

Description Value

Left dial gauge A = –0.05 mm

Right dial gauge B = +0.03 mm

Result = 0.08 mm

Result: Axle parallelism: 0.08 mm : 4 = 0.02 mm


3. Compare calculated value with (→ Page 236) .
4. If the limit value is exceeded, replace conrod.

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234 Task Descriptions

Checking axial twist


1. Set both dial gauges (2) for axial twist with
adjusting gauge (1) above dial gauge anvil
(arrow) to zero.
2. Remove adjusting gauge from test device.

3. Insert conrod with test mandrel (2) into prisms of


testing device.
4. Fixed support of adjustable stop is set so that dial
gauge anvil travel is approx. 2 mm.
5. Press conrod at small conrod bore on fixed
support.
6. Read and record values on dial gauges (1).

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Task Descriptions 235

Measuring axial twist at conrod


1. In order to determine the axial twist of the conrod
bore, calculate the value measured at a distance
of 100 mm as shown in the following example.

Description Value

Left dial gauge A = -0.06 mm

Right dial gauge B = +0.04 mm

Result = 0.10 mm

Result: Axial twist A: 0.10 mm / 2 = 0.05 mm


2. Specified values (→ Page 236).
3. If the limit value is exceeded, replace conrod.

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236 Task Descriptions

3.3.35 Conrod – Tolerances

Conrod bearings

No. Designation Stage Toleranced Deviation Clearance Interference Wear


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

1 Conrod bore 99.000 H6 0 +0.022

2 Conrod width 41.500 −0.190 −0.120

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Task Descriptions 237

Conrod screw length, plane of measurement

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Screw length 67.500 −0.300 0 68.500


removed

Reassembly with bearing shells, measurement in the direction of a/b/c, smallest dimension must lie in the
direction of a.
Inner Ø with bearing shell: 94.064 mm +0.042 mm

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238 Task Descriptions

Conrod bore parallelism

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Conrod length 273.000 −0.020 +0.020


- with bush and
without bearing
shell

Conrod length - 273.000 −0.050 +0.050


without bushing
and without
bearing shell

2 Parallelism of 0.050 measured over a distance of 100 mm


axial inclination

3 Parallelism of 0.100 measured over a distance of 100 mm


axial twist

Conrod weight 3930 g −30 g +30 g


without bearing shells

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Task Descriptions 239

Conrod bore

No. Designation Stage Toleranced Deviation Clearance Interference Wear


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

1 Conrod bore 57.000 H6 0 +0.019 0.061 0.100

Conrod bushing 57.080 0 +0.020


outer- Ø

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

2 Conrod bushing 52.060 −0.005 +0.005


inner Ø - finish
machining

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240 Task Descriptions

3.3.36 Conrod – Repair

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

Nitrogen is liquid (at -200°C).


Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Wear protective clothing, gloves, and goggles / safety mask.
• Ventilate working area well.

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

Check conrod (→ Page 230).

Ejecting conrod bushing


1. Use ejection mandrel (1) and hydraulic press to
remove conrod bushing from conrod (2).
2. Measure conrod bore (→ Page 236).

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Task Descriptions 241

Inserting conrod bushing


Note: Observe matching of lube oil bores.

1. Chill new conrod bushing (1) in liquid nitrogen and


use shrinking tool without pressure to insert in
correct position in conrod bore (2).
2. Check if conrod bushing is securely positioned.
Values (→ Page 236)
3. Use fine boring machine to work conrod bushing to
finished dimension.
4. Deburr edges (A) after twisting out.
5. Round outer edges of conrod bushing (1) after
twisting out.

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242 Task Descriptions

3.3.37 Conrod – Assembly

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.

Incorrect installation of components and lines.


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

Check conrod (→ Page 230).

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).

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Task Descriptions 243

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


shell (2).

7. Carefully press conrod bearing cap by hand


onto conrod.
8. Coat threads of conrod bearing screw head
mating face and screw head seating surfaces
with engine oil.
Note: Thread must not be recut.

9. Screw conrod bearing screw in bore on conrod


bearing cap by hand three full circles without tool.
10. Install conrod bearing screws until screw heads
make contact and use socket wrench to tighten
firmly by hand. Ensure that conrod and conrod
parting groove is closed at short and long conrod
arms.
11. Tighten conrod bearing screws with torque wrench
to prescribed tightening torque (→ Page 24).

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244 Task Descriptions

3.3.38 Conrod bearing shells – Check

Item Findings Task

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

Measure spread dimension Value exceeded Replace bearing shell.


(→ Page 164).

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.

M020127/02E 05-08 © MTU


Task Descriptions 245

3.3.39 Piston and conrod – Assembly

Special tools
Designation / Use Part No. Qty.
Piston-ring pliers F30379877 1

Material
Designation / Use Part No. Qty.
Engine oil

Spare parts
Designation / Use Part No. Qty.
Snap ring

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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Check piston (→ Page 223).

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246 Task Descriptions

Installing piston rings


1. Turn coiled spring expander (2) in oil control ring
(1) in order to offset ring spring butting face (arrow)
to oil control ring butt by 180°.

Note: Make sure that new piston rings are


replaced in sets.

2. Prepare piston rings as per installation sequence.


3. Replace cylinder liners after renewal of piston
rings (→ Page 77).

1 Keystone-type compression ring


2 Taper-face compression ring
3 Oil control ring

M020127/02E 05-08 © MTU


Task Descriptions 247

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


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

Installing conrod in piston


1. Wipe down piston pin, conrod bush and piston pin
bore with chamois leather and coat with engine oil.
2. Insert conrod into the corresponding piston,
in accordance with the marking, so that the
longer side (A) of the angle-split conrod faces
the cavity (B).

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


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

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248 Task Descriptions

4. Insert second snap ring.


5. Check that both snap rings (arrows) fit well and are
in correct position.

M020127/02E 05-08 © MTU


Task Descriptions 249

3.3.40 Piston and conrod – Installation

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.

Assemble piston (→ Page 245).

Preparing piston for installation


1. Coat piston and piston rings with engine oil.
2. Arrange piston ring joints one after the other at 120° intervals around the circumference of the piston.
3. Center piston rings and oil control ring in grooves.

M020127/02E 05-08 © MTU


250 Task Descriptions

Preparing conrod bearing for installation


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

5. Check if markings (arrows) from conrod cap to


conrod match.

Installing piston and conrod in rotation device


Note: The piston must be installed by two persons, to guide the conrod and to avoid damage to the oil
spray nozzle.

1. Turn crankcase in rotation device so that cylinder liner is in horizontal position.


2. Rotate crankpin for crankshaft of piston with conrod to be installed to assembly position (→ Page 216).
3. Wipe crankpin and bearing surface on cylinder liner with chamois leather and coat with engine oil.
4. Insert assembly sleeve in fit for carbon scraper ring.
5. Coat assembly sleeve and cylinder liner with engine oil.
Note: The cavity for the oil spray nozzle on the piston must face towards the center of the engine

6. Insert piston and conrod with light twist in cylinder liner, so that the oil spray nozzle is not damaged.

M020127/02E 05-08 © MTU


Task Descriptions 251

Installing conrod bearing cover


1. Use assembly jig to align conrod bearing shell.
2. Coat thread and screw head mating face of conrod
screws (arrow) with engine oil.
3. Insert conrod screws (arrow) by hand into screw
bores on conrod cap (1), screw in for the first three
revolutions without using any tool.
4. Screw conrod screws (arrow) in up to contact
point on screw head and use socket wrench
to tighten by hand.
5. Insert conrod screws (arrow) and use torque
wrench to tighten to specified tightening torque
(→ Page 24).
6. Check that conrod has axial play.
7. Insert conrod screws (arrow) and use torque
wrench to tighten to specified tightening torque
(→ Page 24).
8. Check axial play of conrod.
9. Bar crankshaft and ensure that there is ease of
movement between oil spray nozzle, piston
and conrod.

Installing piston with conrod, with oil pan lowered


1. The installation is continued as in Installing piston and conrod in rotation device.
2. Install conrod bearing, conrod cap and conrod screws from below.

Installing carbon scraper ring


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

Determine TDC position (→ Page 300).

Measuring piston deck height


Note: Measure positive piston deck height between piston crown and top edge of cylinder liner without
cylinder-head gasket.

1. Clean deposits on piston and crankcase.


2. Rotate crankshaft in direction of engine rotation until piston to be measured is approx. 1 cm in front of top
dead center.
3. Attach preloaded dial gauge to bridge meter.
4. Set bridge meter down with dial-gauge anvil and set dial gauge to zero.
5. Continue to rotate crankshaft in direction of engine rotation until piston is at top dead center.
6. Measure positive piston deck height at dial gauge and record. Values (→ Page 226).
7. If tolerance deviation is not permissible, check conrod, replace if required.

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252 Task Descriptions

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)


– X X Assembly in reverse sequence to disassembly (→ Page 216)
– – X Fill up with engine oil (→Operating Instructions)
– – X Fill up with engine coolant (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 253

3.4 Cylinder Head

3.4.1 Valve-seat turning machine for cylinder head

Working principle of valve-seat turning machine

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.

M020127/02E 05-08 © MTU


254 Task Descriptions

Installing the solid pilot

Precondition:

Valve guide is installed and machined to finished dimension.

Valve guide was cleaned.

Cylinder head is securely clamped and valve guide accessible from both sides.

Mounting the supporting spider


To achieve maximum accuracy, the pilot must be supported by the supporting spider (7) below the valve seat. Slide
the supporting spider (7) over the pilot shaft to such position that the spring-loaded spider elements (1) rest just
below the valve seat level when the pilot is installed in the valve guide (4) and tighten the clamping screw (6).
Inserting the pilot into the valve guide
Remove clamping nut (3) from pilot and insert the threaded end of the pilot into the valve guide (4), until
the tapered portion (5) bears against the conical seating of the valve guide (4). The spring-loaded elements
(1) of the spider (7) will bear against the exhaust/inlet canal below the valve seat.
Locking the pilot
Screw clamping nut (3) onto the pilot and tighten with moderate force. Tighten the screws (6) on
top of the spider to lock the spring-loaded elements (1) of the spider (7). Apply standard machine
oil to the top and around the periphery of the pilot shaft.

M020127/02E 05-08 © MTU


Task Descriptions 255

Setting up valve turning machine

Mounting the cutter


Fit the appropriate tool holder of the cutter (8) with an indexable insert and attach to the tool slide (7).
Placing the valve-turning machine on the pilot
Take care that the cutter (8) does not bump against the cylinder head.
Slide the valve-seat cutting machine over the pilot (10) until either the depth stop (3) rests upon
the pilot (10) or the cutter (8) contacts the cylinder head.
Aligning the cutting edge with the valve-seat center
Turn rapid tool adjuster (11) to position cutting edge of cutter over the valve-seat center (9). Hold
the machine with one hand. Loosen screw (4) of depth stop (3) and allow machine to slide down
until the cutting edge contacts the valve seat (9) lightly. Push depth stop (3) slightly downward
against the pilot (10) and then tighten depth stop locking screw (4).
Connecting the machine to power supply
Insert the round plug of the outlet cable (6) of the power supply unit (5) into the corresponding socket
(1) on the driving assembly (2) and allow the securing latch to engage.

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256 Task Descriptions

Valve seat turning

Positioning the cutter at the inner valve-seat edge


Slightly lift machine with one hand and then turn rapid tool adapter (11) with the other hand until the
cutting edge is just clear of the inner edge of the valve seat (10).
Setting cutting depth
To set the depth of cut, turn depth feed (3) counterclockwise. One notch of the depth-feed scale (4) corresponds
to a depth feed of 0.025 mm. As the valve seat (10) usually shows unequal wear, the depth of the first turning
cycle must be selected (max. 0.2 mm) to ensure that the entire valve-seat surface is undercut.
If the cutting edge is just scraping along the surface instead of undercutting the hard surface zone,
there is a risk of premature wear and chipping of the cutting edge.
Lubricating the valve seat
Apply a few drops of metalworking lubricant on hard valve-seat surfaces before turning.
Valve seat turning
Make sure that the pivoted lever (8) is engaged in the groove of the feed actuator (12). Select proper speed by
shifting the switch (6) at the power supply unit (5). Speed can be increased by changing over from 30 VDC to 42 VDC.
Hold driving unit (2) with both hands at the motors (1) and press pushbutton switch (7) to start the cutting pass.
Release the pushbutton switch (7) as soon as the cutter has been traversed beyond the top edge of the valve seat (10).
Repeating the cutting pass
Repeat steps with a cutting depth between 0.05 mm and 0.1 mm until the valve seat surface (10) is plane all around.
To ensure a smooth valve-seat surface (10) finish, proceed with a final pass at high speed with 0.025 mm cutting depth.

M020127/02E 05-08 © MTU


Task Descriptions 257

Replacing the adapter head

Removing the adapter head


Unscrew the two screws (1) from the adapter head (2).
Turn adapter head (2) in the direction of the arrow until the back of the toothed rack (4) is no longer engaged with
the pinion (4) in the gear housing (6). Now the adapter head can be withdrawn off the gear housing (6).
Mounting the adapter head
Place adapter head (2) onto gear housing (6) so that the pinion (5) projecting from the gear housing (6)
is seated in the corresponding bore of the adapter head (2).
The adapter head (2) must be seated flush with the gear housing (6).
Screw the two screws (1) loosely into the gear housing so that the adapter head (2) can still be moved
to adjust proper clearance between toothed rack (4) and pinion.
Adjust the adapter head so that the gap between the toothed side of the rack (4) and the opposite side of
the recess (3) is approximately 0.3 mm to 0.5 mm. Tighten both screws (1).
Turn the rapid tool adjuster to move the tool slide back and forth. If tool slide does not
move freely, readjust the adapter head.

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258 Task Descriptions

3.4.2 Cylinder head – Overview

10 Cylinder head 50 Washer


20 Inlet valve 60 Valve-spring retainer
30 Exhaust valve 70 Valve collet
40 Valve spring 80 Gasket

M020127/02E 05-08 © MTU


Task Descriptions 259

Overview drawing

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


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

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260 Task Descriptions

3.4.3 Cylinder head – Removal

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Socket F30907150 1

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Drain engine coolant (→Operating Instructions)
– X X Remove constant-pressure manifold (→ Page 412)
– X X Remove air pipework to cylinders (→ Page 404)
– X X Remove cylinder head covers (→ Page 325)
– X X Remove valve drive (→ Page 313)
– X X Remove sensors, actuators and injectors (→ Page 563)
– X X Remove injector
– X X Remove leak-off fuel pipework (→ Page 362)

M020127/02E 05-08 © MTU


Task Descriptions 261

Cylinder head – Removal


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

M020127/02E 05-08 © MTU


262 Task Descriptions

3.4.4 Cylinder head – Disassembly

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Spring/circlip/tensioning roller preload.


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

Remove cylinder head (→ Page 260).

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).

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Task Descriptions 263

4. Remove valve collets (1) with bar magnet and


relieve valve spring of tension.
5. Remove valve lifter and retaining device.
6. Remove valve-spring retainer (2), washer (5) and
valve springs (3) and (4).
7. Lay cylinder head on its side.
8. Remove exhaust and inlet valves.

9. Place valves in storage rack (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.

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264 Task Descriptions

Removing protective sleeve


1. Unscrew protective sleeve (2) with socket (1)
from cylinder head (4).
2. Remove sealing ring (3) from cylinder head (4).

M020127/02E 05-08 © MTU


Task Descriptions 265

3.4.5 Cylinder head – Cleaning

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Excessive reaction time of cleaning agents on components.


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

Removing cylinder head (→ Page 260).

Cleaning cylinder head


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Remove carbon deposits with decarbonizer.
4. After cleaning with decarbonizer, rinse components in water until no further residues are washed off.
Note: Pay particular attention to the coolant bores in the bottom of the cylinder head!

5. Blow out all parts with compressed air.

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266 Task Descriptions

3.4.6 Cylinder head – Check

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.

Test liquid is hot and pressurized.


Risk of injury and scalding!
WARNING • Wear protective clothing, gloves, and goggles / safety mask.

Clean cylinder head (→ Page 265).

M020127/02E 05-08 © MTU


Task Descriptions 267

Cylinder head – Check

Item Findings Measure

Measure cylinder head height. Value Value not attained. Replace cylinder head.
(→ Page 268)

Check cylinder head mating face Damaged Replace cylinder head.


(combustion chamber side) for
evenness and damage.

Check mating face of protective • Scores Smoothen mating face.


sleeve in cylinder head for scores • Stress marks
and stress marks. visible

Measure valve guides with bore Not true to gauge. Recondition cylinder head
gauge. Values (→ Page 268) (→ Page 277).

Check valve springs for damage. • Damaged Replace valve springs


Check spring force and length of • Values exceeded.
valve springs. Values (→ Page 268)

Check all threads for ease of Sluggish • Recondition


movement. • Replace cylinder head.

Check valve seats on cylinder head • Pitting Recondition cylinder head


for pitting and wear. • Wear (→ Page 277).
visible

Check cylinder head screw threads, Damaged Replace


screw head mating faces and thrust
washer for damage.

Measure shank length of cylinder Values (→ Page 268) exceeded. Replace


head screws with depth gauge.

Check valves with red dye penetrant Signs of cracks Replace


for cracks.

Check valves for damage. • Chrome layer damaged Replace


Check valves for concentricity and • Valve keyways damaged or
dimensional accuracy. Values burnt
(→ Page 268) • Out-of-round

Replace spring retainer and valve collet.

Checking cylinder head for leaks


1. Install protective sleeve prior to leak test (→ Page 283)
2. Prepare water for water bath with corrosion inhibitor.
3. Install pressure testing device.
4. Place cylinder head in a water bath heated to 80 °C until cylinder head has warmed up.
5. Pressure-test cylinder head with 0.5 bar compressed air.
6. Pressure must be maintained with cylinder in water bath for at least 30 minutes. No air bubbles must emerge.
7. Remove hydraulic pressure testing device.
8. Replace leaky covers (→ Page 288).

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268 Task Descriptions

3.4.7 Cylinder head – Tolerances

Inlet and exhaust valve guides

No. Designation Stage Tolerance Deviation Clearance Interference Wear limit


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

1 Cylinder head 15.000 H7 0 +0.018 +0.010 +0.046


bore

Valve guide 15.000 s7 +0.028 +0.046


outer Ø

2 Exhaust

Valve guide bore 9.000 H8 0 +0.022 0.060 0.097


installed

Valve stem Ø 8.940 h7 −0.015 0

3 Valve guide 104.300 −0.350 +0.350


dimension

4 Valve clearance 0.700 to


Exhaust 1.150

Valve clearance 0.700 to


Inlet 1.150

M020127/02E 05-08 © MTU


Task Descriptions 269

No. Designation Stage Tolerance Deviation Clearance Interference Wear limit


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

5 Inlet

Valve guide bore 9.000 H8 0 +0.022 0.050 0.087


installed

Valve stem Ø 8.950 h7 −0.015 0

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

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270 Task Descriptions

Inlet and exhaust valve seats

No. Designation Stage Tolerance Deviation Clearance Interference Wear limit


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

Inlet

1 Valve seat 42.000 −0.010 +0.010


diameter

2 Valve seat depth 4.000 0 +0.150 up to min.


3.300

Exhaust

3 Valve seat 39.000 −0.010 +0.010


diameter

4 Valve seat depth 3.800 0 +0.150 up to min.


3.100

5 Roughness value: R3z 6.3

6 Concentricity: 0.04 to B

7 Concentricity: 0.04 to A

8 Roughness value: R3z 6.3

M020127/02E 05-08 © MTU


Task Descriptions 271

Inlet and exhaust valve seats

No. Designation Stage Tolerance Deviation Clearance Interference Wear limit


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

Inlet

1 Cylinder head 47.300 H7 0 +0.025 0.065 0.110


bore

Valve-seat insert 47.400 −0.010 +0.010


Outer Ø

2 Cylinder head 11.000 −0.100 +0.100


Bore depth

3 Valve seat ring 7.700 −0.100 +0.100


height

Exhaust

4 Cylinder head 43.000 H7 0 +0.025 0.055 0.090


bore

Valve-seat insert 43.090 −0.010 0


Outer Ø

5 Cylinder head 11.000 −0.100 +0.100


Bore depth

6 Valve seat ring 8.100 −0.100 0


height

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272 Task Descriptions

Exhaust valve

No. Designation Stage Tolerance Deviation Clearance Interference Wear limit


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

1 Valve head 41.100 −0.200 +0.200


Outer Ø

2 Reference 39.000
dimension
Valve seat Ø

3 Reference 3.100 −0.300 0 up to min.


dimension 2.400
Valve seat height

4 Valve seat width 3.500

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

M020127/02E 05-08 © MTU


Task Descriptions 273

Inlet valve

No. Designation Stage Tolerance Deviation Clearance Interference Wear limit


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

1 Valve head 45.600 −0.200 +0.200


Outer Ø

2 Reference 42.000
dimension
Valve seat Ø

3 Reference 3.300 −0.300 0 up to min.


dimension 2.600
Valve seat height

4 Valve seat width 3.500

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.

M020127/02E 05-08 © MTU


274 Task Descriptions

Mating face – protective sleeve

No. Designation Stage Tolerance Deviation Clearance Interference Wear limit


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

1 Cylinder head 114.000 −0.150 +0.150


height

2 Protective sleeve 15.700 −0.100 +0.100


mating surface

3 Protective sleeve 26.000 H7 0 +0.021 0.100 0.173


bore

Protective sleeve 25.900 h9 −0.052 0


Outer Ø

4 Thread M14 x 1

5 Flatness: 0.020/150

6 Roughness value: R3z / lm40 Wt 10

M020127/02E 05-08 © MTU


Task Descriptions 275

Inlet and exhaust valve springs

No. Designation Stage Tolerance Deviation Clearance Interference Wear limit


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

1 Spring length 69.700


released

2 Spring length 49.000


compressed

2.1 Spring tension, 400.000 N -18 N +18 N


loaded spring
length 49.0

3 Spring length 37.000


compressed

3.1 Spring tension, 675.000 N -31 N +31 N


loaded spring
length 37.0

4 Spring length 47.700


compressed

4.1 Spring tension, 722.000 N


loaded spring
length 35.3

5 Winding Ø 28.900

6 Wire Ø 4.200

M020127/02E 05-08 © MTU


276 Task Descriptions

No. Designation Stage Tolerance Deviation Clearance Interference Wear limit


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

e1 Permitted deviation of generating line from vertical position with spring unloaded max. 2.090

e2 Spring seat, permitted parallelism deviation max. 0.740

Cylinder head screws

No. Designation Stage Tolerance Deviation Clearance Interference Wear limit


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

1 Cylinder head 210.000 −0.500 0 max.


screw length:
212.00

2 Concentricity: 0.8/AB

3 Concentricity: 0.8/AB

M020127/02E 05-08 © MTU


Task Descriptions 277

3.4.8 Cylinder head – Repair

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

M020127/02E 05-08 © MTU


278 Task Descriptions

Nitrogen is liquid (at -200°C).


Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Wear protective clothing, gloves, and goggles / safety mask.
• Ventilate working area well.

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.

Incorrect installation of components and lines.


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

Check cylinder head (→ Page 266).

Removing valve-seat insert


1. Clean valve guide using bottle brush.
2. Insert pilot (1) into valve guide of cylinder head (2)
and secure.

M020127/02E 05-08 © MTU


Task Descriptions 279

3. Fit tool head (2) with turning tool on valve-seat


turning machine (1).
4. Set up valve-seat turning machine (→ Page 253).
5. Fit valve-seat turning machine (1) on the pilot and
mount steady rest.
6. Machine valve seat to facilitate installation of
valve-seat insert removal tool.
7. Remove steady rest, valve-seat turning
machine (1) and pilot.

8. Mount valve-seat insert extractor (1) on the


valve-seat insert (2) to be removed.
9. Remove valve-seat insert (2) using extractor (1).
10. Check valve-seat bore (2) in cylinder head. Values
(→ Page 268). Fit new cylinder head in the event
of dimensional deviation.

Removing valve guide


1. Place cylinder head on hydraulic press. Ensure
correct cylinder head side mating.
2. From the combustion side, press valve guide out
of cylinder head with removal tool.
3. Check valve guide bore in cylinder head. Values
(→ Page 268). Rework to next stage in the event
of dimensional deviation.
4. Clamp cylinder head in boring mill.
5. Ream valve guide bores in cylinder head with
chucking reamer.

M020127/02E 05-08 © MTU


280 Task Descriptions

Installing valve guide


1. Prepare water for water bath with corrosion
inhibitor.
2. Place cylinder head (3) in water bath heated to 80
°C until cylinder head (3) has warmed up.
3. Chill valve guide (2) in liquid nitrogen for approx.
20 to 30 minutes.
4. Place heated cylinder head (3) onto installation
device (4).
5. Use mandrel (1) to install chilled valve guide (2)
in cylinder head bore (3) up to the stop of the
installation device (4).

Installing valve-seat insert


1. Prepare water for water bath with corrosion
inhibitor.
2. Place cylinder head (1) in water bath heated to 80
°C until cylinder head (1) has warmed up.
3. Chill valve-seat insert (2) in liquid nitrogen for
approx. 20 to 30 minutes.
4. Place heated cylinder head (1) on a suitable
surface.
5. Use installation mandrel (3) to insert chilled
valve-seat insert (2) in cylinder-head bore (1)
up to the stop.

M020127/02E 05-08 © MTU


Task Descriptions 281

Machining valve guides to finished dimension


Note: Do not displace the cylinder head after
alignment.

1. Clamp cylinder head (1) in boring mill and align the


valve guide (2) to be machined with centering tip.
2. Remove centering tip and install
reamer (3) Ø8.8 mm with floating tool holder (4)
in boring mill.
3. Machine valve guide (2) with reamer (3) Ø8.8 mm.
4. Remove reamer (3) Ø8.8 mm and install reamer
Ø9.0 mm with floating tool holder (4) in boring mill.
5. Machine valve guide (2) with reamer Ø9.0 mm.
6. Remove reamer Ø9.0 mm.
Note: Go-end plug gauge must move easily
through the whole valve guide. Insertion of
the no-go-end must not be possible.

7. Check valve guides (2) with plug gauge.

Machining valve-seat insert


1. Clean valve guide using bottle brush.
2. Insert pilot (3) with supporting spider (2) in valve
guide of cylinder head (1) and secure.
3. Machine valve-seat insert. The sequence is the
same as for removing the valve-seat insert, but
with the corresponding unscrew button.
4. Remove pilot (3) and supporting spider (2) from
valve guide.
5. Machine valve-seat insert with the appropriate
countersink.

M020127/02E 05-08 © MTU


282 Task Descriptions

Checking concentricity of valve seat


1. Insert pilot into valve guide.
2. Mount clamp ring (2) over the inserted pilot and
secure firmly in position.
3. Mount the testing device (1) on the clamp ring.
4. Set feeler of preloaded testing device on valve
seat center (arrowed).
5. Check concentricity of valve seat in relation to
valve guide. Values (→ Page 268).
6. In event of deviation from test values, rework
valve seat again.
7. Remove testing device (1), clamp ring (2) and pilot.
8. Clean cylinder head after machining.

Measuring valve seat depths


1. Set the distance between plug gauge (2) and
ring gauge (3).
2. Set scale on dial gauge (1) to zero.
3. Measure valve seat depths.
4. Values (→ Page 268) are exceeded, fit new
cylinder head.

Regrinding valve seats on valve heads


1. Mount valve (1) as directly as possible behind
valve head in valve grinding machine (2).
2. Set valve seat grinding angle on valve grinding
machine.
3. Grind valve seat with slight advance until valve
seat is smooth and free from chatter marks over
the entire circumference.
4. Measure height of outside edge of valve seat and
width of valve seat. Values (→ Page 268) Fit new
valve in the event of dimensional deviation.

M020127/02E 05-08 © MTU


Task Descriptions 283

3.4.9 Cylinder head – Assembly

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

Spring/circlip/tensioning roller preload.


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

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.

Repair cylinder head (→ Page 266).

M020127/02E 05-08 © MTU


284 Task Descriptions

Installing protective sleeve


1. Clamp cylinder head firmly.
2. Clean sealing faces.
3. Coat O-rings (3) with petroleum jelly and insert
into cylinder head groove (4).
4. Use socket (1) to screw protective sleeve (2) into
cylinder head and tighten with torque wrench to
prescribed tightening torque. (→ Page 24).

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.

4. Insert cylinder head in retaining device.


5. Insert gasket (2).
6. Use expander (1) and drift to press in manually
up to stop on valve guide (3).
7. Check if gasket (2) is positioned securely.
8. Remove expander (1).

M020127/02E 05-08 © MTU


Task Descriptions 285

9. Place washer (5) on valve guide.


10. Place valve springs (3) and (4) on to washer (5)
with colored marking facing upwards.
11. Place spring plate (2) on to valve spring.
12. Install valve lifter.
13. Insert valve collets (1) into spring plate (2) and
center.
14. Ensure that valve collet lip (1) is securely
positioned.
15. Relieve valve spring (4) of tension.
16. Remove holding plate and valve lifter.

17. Lay cylinder head on its side.


18. Make sure valves move freely.
19. Hit valve stem lightly with plastic mallet.
Result: Valve collets are in groove of valve neck.

Measuring valve clearance to cylinder head


1. Install dial gauge (4) in dial-gauge holder (5).
2. Place preloaded dial gauge (4) on to end face
of cylinder head (4).
3. Set dial gauge to zero.
4. Place tracer pin on valve heads of valves (2)
and (3) and measure clearance between valve
and end face.
5. If recorded value is out of tolerance range then
check valve seat on cylinder head and valve head.
Values (→ Page 268)

M020127/02E 05-08 © MTU


286 Task Descriptions

3.4.10 Cylinder head – Installation

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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

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

Contamination in blind hole.


Damage to component!
CAUTION • Inspect and clean blind hole.

Assemble cylinder head (→ Page 283).

M020127/02E 05-08 © MTU


Task Descriptions 287

Installing cylinder head


1. Drive clamping sleeves (1) into crankcase up to
stop.
2. Install cylinder head gasket (2).
3. Position cylinder head (3) on cylinder head
gasket (2).
4. Coat threads, head mating face and shaft of
double-hex screw (4) with engine oil.
5. Install double-hex screw (4) by hand into
crankcase.
Note: To check the angle of rotation, mark screw
head of double-hex screw with paint
following pre-tightening.

6. Evenly tighten double-hex screw (4). Ensure


correct tightening sequence and tightening torque
(→ Page 24).

Final steps

For these steps a distinction must be made as to whether


1 the engine has been completely disassembled
2 the engine has been removed but not disassembled
3 the engine has remained installed

1 2 3 Operations See

X – – Assemble engine. (→ Page 69)

X – – Install engine. (→ Page 72)


– X X Perform installation in reverse sequence of work steps as (→ Page 260)
described for removal.
– – X Fill with engine coolant. (→Operating instructions)
– – X Fill with fuel. (→Operating instructions)
– – X Enable engine start. –

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288 Task Descriptions

3.4.11 Cylinder head seals – Repair

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Check cylinder head (→ Page 266).

Replacing plug
Note: Replace plug only if necessary.

1. Twist plug off using a boring mill.


2. Clean water chambers.
3. Blow out water chambers with compressed air and check for dirt.
4. Degrease and dry mating surface on new plug and cylinder head bore.
5. Coat plug mating surface with Loctite.
6. Use drift to hit plug evenly into cylinder head bore.
7. Check cylinder head for leaks (→ Page 266).

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Task Descriptions 289

3.5 Valve Gear

3.5.1 Camshaft – Overview

5 Camshaft 15 Timing wheel 25 Washer


10 Camshaft gear 20 Screw 30 Coiled spring pin

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290 Task Descriptions

3.5.2 Camshaft – Removal

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

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– X X Removal not scheduled –

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) .

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Task Descriptions 291

3.5.3 Camshaft – Cleaning

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.

Remove camshaft (→ Page 290).

Camshaft – Cleaning
1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow out camshaft and threads with compressed air.

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292 Task Descriptions

3.5.4 Camshaft – Check

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

Clean camshaft (→ Page 291).

Camshaft – Check

Item Findings Task

Using the magnetic crack-testing Signs of cracks Replace camshaft.


method, check camshaft for cracks.

Crack-test thrust bearing flange Signs of cracks Replace camshaft.


using surface crack-test method.

Check mating face of camshaft gear. Wear visible • Recondition: smooth with
oilstone or emery cloth.
• Replace

Check axial sliding surface, journal • Scores Replace camshaft.


faces and roller tracks of cams for • Wear
scoring, wear and indentations. • Indentations
Visible

Check tooth flank of camshaft gear Damaged Replace camshaft gear.


with magnifying glass.

Check hex screws for damage. Damaged Replace hex screws.

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Task Descriptions 293

Checking hardness of cam and journal


1. Use hardness testing unit to test cam hardness
(inlet/exhaust rocker arms) and journals. Required
hardness: 60 HRC ±2 HRC
2. Test hardness of each journal at four points at 90°
intervals around circumference.
3. Replace camshaft if values are not attained.

Checking concentricity and cam lift


1. Set camshaft at outer journals on V-blocks (2) or
roller stands.
2. Place supporting mount (3) at center journal.
3. Measure radial runout of cam base circle and
bearings with dial gauge (1). Values (→ Page 294).

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294 Task Descriptions

3.5.5 Camshaft – Tolerances

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Crankcase bore 0–0 71.000 H6 0 +0.019 0.101 0.121

1–0 71.400 H6

2–0 71.800 H6

Camshaft 0–0 71.000 +0.120 +0.140


bearing outer
dia. 1–0 71.400
removed 2–0 71.800

2 Camshaft outer 67.000 e7 −0.079 −0.060


dia.

3 Wall thickness at 0 1.995 0 +0.015


camshaft bearing
bush, measured 1 2.195
at the carrying
parts 2 2.395

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Task Descriptions 295

Concentricity of bearings

Max. permissible deviation of New Wear limit


concentricity

During the concentricity check, provide supports for and align the following bearings.
• 8V:
• 10V: bearing 3 beginning at driving end
• 12V:
• 16V:

a all cams on the base circle 0.050 / A-B

a over 3 bearings 0.025 / A-B


The basis in each case are left and
right bearings

c all bearings 0.050 / A-B

d concentricity of gear mating 0.050 / A-B


surface

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296 Task Descriptions

Camshaft gear

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Bearing 5 beginning at
driving end

2 Distance: 740.300 −0.100 +0.100


Gear fitted

3 Gear bore 60.000 0 +0.012 0.054 0.085


H6

Shaft outer dia. 60.000 +0.066 +0.085


t6

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Task Descriptions 297

3.5.6 Camshaft – Installation

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.

Check camshaft (→ Page 292)

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.

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298 Task Descriptions

3. Screw locating pin (1) on to end face of


camshaft (2) (arrow).

4. Attach camshaft (2) to crane in the middle with


lightly pretensioned rope (1) and wipe with
chamois leather.
5. Coat camshaft (2), camshaft bearing,
installation/removal tool, support guide and
locating pin with engine oil.

6. Insert camshaft in such a way that the


markings (arrow) match at the meshings of
camshaft gear and crankshaft gear.
7. Remove installation/removal tool, support guide
and locating pin.
8. Until flywheel housing is installed, fix camshaft
axially or secure against falling out.

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Task Descriptions 299

Measuring backlash (with flywheel housing


installed)
1. Mount magnetic dial gauge holder with dial gauge
on crankcase.
2. Place lightly preloaded dial-gauge anvil on
a tooth flank.
3. Set dial gauge to zero.
4. Check backlash by turning camshaft gear back
and forth. Backlash (→ Page 141).

Measuring axial play of camshaft (with flywheel


housing installed)
1. Mount magnetic dial gauge holder with dial gauge
(1) on crankcase (free end).
2. Position dial-gauge anvil at end face (arrow).
3. Press camshaft on camshaft gear axially as
far as it will go.
4. Set preloaded dial gauge to zero.
5. Move camshaft from stop to stop and record
measurement value (axial clearance). Axial
play (→ Page 141).

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– – X Enable engine start –

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300 Task Descriptions

3.5.7 Camshaft timing – Check

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

Check camshaft (→ Page 292)

Installing pointer, graduated disk and barring tool


1. Set piston cylinder A1 to top dead center.
2. Install pointer (1) on flywheel housing.
3. Install respective graduated disk (2) with barring
tool, set to TDC mark of A1 and tighten.
4. Attach ratchet (3) to barring tool.

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Task Descriptions 301

Determination of TDC position of piston


Note: With cylinder head and valve drive
installed:

1. Insert preloaded dial gauge (2) in measuring


device (4) and clamp tight with screw (1) clamp.
2. Install measuring device (4) in cylinder head and
fasten with knurled-head screw (3).
3. Set dial gauge (2) to zero.
4. Using the barring tool, bar the engine until the
piston of cylinder A1 is in the firing TDC.
Result: The piston is at firing TDC when both
rocker arms are unloaded, i.e. have clearance.
5. Move piston in TDC up and down several times
and then position it in such a way that the pointer
of the dial gauge (2) indicates the highest value.
6. Set dial gauge (2) to zero.
7. Turn back crankshaft in opposite direction of
rotation by approx. 10°.
8. Set crankshaft in direction of rotation to 0.3 mm
(dial gauge indicator) before TDC.
9. Apply exact line mark to graduated disk opposite
TDC pointer tip.
10. Turn crankshaft further in direction of
rotation approx. 10° past TDC (bearing play
compensation).
11. Bar crankshaft in direction opposite to normal
direction of rotation to 0.3 mm after TDC and
make a second mark.
12. Apply third line mark exactly in the middle between
the line marks.
13. Align graduated disk in such a way that the line
mark for cylinder A1 matches the pointer.
14. Check TDC position.
15. Remove measuring tool (4) with dial gauge (2).

Measuring valve lift


Note: With cylinder head and valve drive
installed.

1. Set cylinder A1 to firing TDC.


2. Loosen locknut (arrow).
3. Screw in adjusting screws until there is no more
valve clearance, then tighten locknut lightly.
4. Attach measuring stand with dial gauge to
cylinder A1.
5. Place dial-gauge anvil with light preload on to
valve bridge of inlet valve and set scale of dial
gauge to zero.
6. Slowly turn crankshaft in direction of engine
rotation another 360° and set exactly to
overlap-TDC (line mark of graduated disk).
7. Read valve stroke from dial gauge and record
readings in Data Sheet.

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302 Task Descriptions

8. Place dial-gauge anvil on to valve bridge of outlet


valve and set scale of dial gauge to zero.
9. Further rotate crankshaft slowly in engine direction
of rotation until pointer of dial gauge no longer
moves.
10. Read valve stroke from dial gauge and record
readings in Data Sheet.
11. Check that specified values are observed.
Specified values (→ Page 39).
12. If the specified value is not attained, contact
Service.
13. Remove measuring stand with dial gauge, TDC
pointer and graduated disk.
14. Set valve clearance at cylinder A1 (→Operating
Instructions ).

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– – X Enable engine start –

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Task Descriptions 303

3.5.8 Valve roller tappet, pushrod – Overview

35 Pushrod 45 Roller tappet

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304 Task Descriptions

3.5.9 Roller tappet and pushrod – Removal

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Pliers F30378037 1

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– X X Remove cylinder head cover (→ Page 325)
– X X Remove valve drive (→ Page 313)

Removing pushrod
1. Rotate pushrod so that the roller tappet is loosened
2. Remove pushrod

M020127/02E 05-08 © MTU


Task Descriptions 305

Removing roller tappet


1. Remove cylinder head (→ Page 260).
2. Remove roller tappets with pliers from crankcase.
3. Mark roller tappet to crankcase.

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306 Task Descriptions

3.5.10 Roller tappet, pushrod – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Roller tappet, remove pushrod (→ Page 304).

Roller tappet, pushrod – Cleaning


1. Clean all parts with cleaning agent.
2. Remove cleaning agent.
3. Blow out all parts with compressed air.

M020127/02E 05-08 © MTU


Task Descriptions 307

3.5.11 Roller tappet, pushrod – Check

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.

Clean roller tappet, pushrod (→ Page 306).

Check

Item Findings Task

Using the magnetic crack-testing Signs of cracks Replace


method, check following
components for cracks:
• Roller tappet
• Pushrod

Check pushrod ball seat and ball • Wear Replace


end for wear. • Indentations
• Scores
visible

Measure outer Ø of roller tappet Dimensions not as specified Replace


with outside micrometer. Values
(→ Page 308)

Check tappet roller for ease of Sluggish Replace roller tappet.


movement and excessive play. Excessive play

Check roller tappet for damage and Damaged Replace


wear. Wear

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308 Task Descriptions

3.5.12 Roller tappet, pushrod – Tolerances

Roller tappet, pushrod

No. Designation Stage Toler- Deviation Clearance Interference Wear limit


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

1 Housing bore 0 30.000 30.021 0.035 0.077

1 30.500 30.525 0.035 0.085

Tappet outer Ø 0 29.944 29.965

1 30.440 30.465

M020127/02E 05-08 © MTU


Task Descriptions 309

3.5.13 Roller tappet, pushrod – Installation

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.

Check roller tappet, pushrod (→ Page 307).

Installing roller tappet


1. Coat roller tappet and bore in crankcase with
engine oil.
2. Use pliers to insert roller tappet; in doing so
observe guide slot.
3. Check ease of movement of roller tappet in
guide bore.

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310 Task Descriptions

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

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assembly in reverse disassembly sequence (→ Page 304)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 311

3.5.14 Valve drive – Overview

100 Rocker arm with rocker shaft


support
105 Valve bridge
115 Plug-in pipe
120 O-ring

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312 Task Descriptions

Rocker, shaft support

5 Rocker shaft support 25 Nut


10 Rocker arm, exhaust 35 Washer
15 Rocker arm, inlet 40 Snap ring
20 Adjusting screw 50 Screw

M020127/02E 05-08 © MTU


Task Descriptions 313

3.5.15 Valve drive – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Drain engine coolant (→Operating Instructions)
– X X Remove turbocharger oil supply (→ Page 457)
– X X Remove crankcase breather (→ Page 103)
– X X Remove air filter (→ Page 400)
– X X Remove intake housing
– X X Remove cylinder head cover (→ Page 325)

Removing rocker arms


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

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314 Task Descriptions

Removing valve bridge


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

M020127/02E 05-08 © MTU


Task Descriptions 315

3.5.16 Valve drive – Disassembly


Remove valve drive (→ Page 313)

Disassembling rocker arm


1. Clamp rocker shaft support in vice with aluminium
jaws.
2. Use circlip pliers to remove snap ring (1) from
shaft.
3. Remove washer (2).

4. Remove rocker arm (1).


5. Remove nut (2) and adjusting screw (3).

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316 Task Descriptions

3.5.17 Valve drive – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove valve drive (→ Page 313).

Cleaning valve drive


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Blow out all parts with compressed air.

M020127/02E 05-08 © MTU


Task Descriptions 317

3.5.18 Valve drive – Check

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.

Disassemble valve drive (→ Page 315).

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318 Task Descriptions

Valve drive – Check

Item Findings Measure

Check the following parts with Signs of cracks Replace


magnetic crack test procedure for
cracks.
• Rocker shaft support
• Rocker arm, exhaust
• Rocker arm, inlet
• Nut
• Screws
• Adjusting screws

Check bearing surfaces on shaft • Wear • Recondition


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

Check mating faces on rocker shaft Damaged • Recondition


support. • Replace

Check condition of snap ring Damaged • Recondition


grooves of axles. • Replace

Check screws, nuts and adjusting Damaged Replace component.


screws for damage.

Measure diameter of bush bore in Value exceeded Replace


rocker arm. Value (→ Page 319)

Measure diameter of shaft support Value exceeded Replace


axle. Value (→ Page 319)

Measure screws for rocker shaft Value exceeded Replace


support. Value (→ Page 319)

M020127/02E 05-08 © MTU


Task Descriptions 319

3.5.19 Valve drive – Tolerances

Rocker shaft support, inlet and exhaust

No. Designation Level Tol. size Deviation Clearance Interference Wear


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

1 Rocker arm 25.000 +0.005 +0.021 0.025 0.054


bush bore

Rocker shaft 25.000 f6 –0.033 -0.020


support outer
Ø

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320 Task Descriptions

Screw

No. Desig- Level Tol. Deviation Clearance Interference Wear limit


nation size
lower upper min. max. min. max.
Basic
size

1 Screw 90.000 -0.200 0 91.000


length —
removed

M020127/02E 05-08 © MTU


Task Descriptions 321

3.5.20 Valve drive – Assembly

Material
Designation / Use Part No. Qty.
Engine oil

Spring/circlip/tensioning roller preload.


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

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

Check valve drive (→ Page 317).

Assembling rocker arm


1. Insert adjusting screw (1) into rocker arm (3).
2. Fit nut (2) on adjusting screw (1), do not tighten!
3. Coat axles on rocker shaft support and bushes of
rocker arm (3) with engine oil.
4. Clamp rocker shaft support in vice with aluminium
jaws.
5. Place rocker arm (3) on axle.

6. Fit washer (2) and secure with snap ring (1).


7. Check whether snap ring (1) is correctly seated.
8. Install second rocker arm in the same way.

M020127/02E 05-08 © MTU


322 Task Descriptions

3.5.21 Valve drive – Installation

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.

Assemble valve drive (→ Page 321).

Installing valve bridge and rocker arm


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

M020127/02E 05-08 © MTU


Task Descriptions 323

3. Coat ball seat of pushrod with engine oil.


4. Set piston with barring tool to firing TDC.
5. Loosen nut of adjusting screws on rocker shaft
support (2) and turn back adjusting screws.
6. Place rocker shaft support (2) on to cylinder
head, in doing so, check position of the ball in
the pushrod.
7. Coat thread and screw head mating face of
screw (1) with engine oil.
8. Insert screw (1) and tighten with torque wrench to
specified tightening torque (→ Page 24).
9. Adjust valve clearance (→Operating Instructions).

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assembly in reverse disassembly sequence (→ Page 313)
– – X Enable engine start –

M020127/02E 05-08 © MTU


324 Task Descriptions

3.5.22 Cylinder head cover – Overview

10 Cylinder head cover, lower part 30 Cylinder head cover, upper part
15 Screw 35 Screw
20 Washer 40 Gasket
25 Gasket 45 Washer

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Task Descriptions 325

3.5.23 Cylinder head cover – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)

Cylinder head cover – Removal


1. Remove cylinder head cover as shown in overview drawing (→ Page 324).
2. Remove gaskets.
3. Seal openings with suitable covers.

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326 Task Descriptions

3.5.24 Cylinder head cover – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove cylinder head cover (→ Page 325).

Cleaning cylinder head cover


1. Clean cylinder head cover with cleaning agent.
2. Remove cleaning agent.
3. Blow out cylinder head cover with compressed air.

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Task Descriptions 327

3.5.25 Cylinder head cover – Check

Spare parts
Designation / Use Part No. Qty.
Cylinder head cover

Clean cylinder head cover (→ Page 326).

Cylinder head cover – Check

Item Findings Measure

Check cylinder head cover for Damaged • Recondition: Smooth with


damage. emery cloth or oilstone.
• Replace

Seal Damaged Replace

Check thread of screws for ease of Sluggish • Recondition: Recut thread.


movement. • Replace

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328 Task Descriptions

3.5.26 Cylinder head cover – Installation

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.

Check cylinder head cover (→ Page 327).

Cylinder head cover – Installation


1. Prior to installation, remove all covers.
2. Insert gaskets in cylinder head cover.
3. Install cylinder head cover with centering device as shown in overview drawing (→ Page 324) .

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Task Descriptions 329

3.6 HP Fuel System

3.6.1 High-pressure fuel system – Tightening

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.

Incorrect installation of components and lines.


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

Installing high-pressure accumulator in charge-air


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

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330 Task Descriptions

Installing high-pressure lines


1. Hand-tighten high-pressure line (5) on fuel
distributor.
2. Hand-tighten high-pressure line (5) on
high-pressure pump.
3. Hand-tighten high-pressure lines (1) and (2) on
high-pressure accumulator.
4. Hand-tighten high-pressure lines (1) and (2) on
fuel distributor.
5. Tighten all high-pressure lines in the same
sequence with torque wrench to specified
tightening torque (→ Table Tightening torque
on page 331) .
6. Tighten fuel distributor (3).
7. Tighten all screws on high-pressure
accumulator (4) with torque wrench to specified
tightening torque (→ Table Tightening torque
on page 331).
8. Install pipe half-clamps (6).

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

Installing high-pressure line to injector


1. Install union nut (3) of high-pressure line on
high-pressure accumulator and hand-tighten.
2. Install union nut (2) of high-pressure line on
injector (1) and hand-tighten.
3. Tighten hold-down clamp on injector (1) with
torque wrench to specified tightening torque
(→ Table Tightening torque on page 331).
4. Tighten union nut (3) on high-pressure line with
torque wrench to specified tightening torque
(→ Table Tightening torque on page 331).
5. Tighten union nut (2) of high-pressure line on
high-pressure accumulator with torque wrench to
specified tightening torque (→ Table Tightening
torque on page 331).
6. Tighten flanges.

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Task Descriptions 331

Tightening torque for high-pressure fuel system

Tightening torque

Designation Tightening specifications Lubricant

High-pressure line on fuel distributor 40 Nm +5 Nm Engine oil

High-pressure line on high-pressure pump 40 Nm +5 Nm

High-pressure line on high-pressure 40 Nm +5 Nm


accumulator

High-pressure line on injector 20 Nm +5 Nm

High-pressure line of injector on 30 Nm +5 Nm


high-pressure accumulator

Screw on hold-down clamp 40 Nm +4 Nm

Pressure relief valve on fuel distributor 100 Nm +5 Nm

High-pressure sensor on fuel distributor 30 Nm +5 Nm

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332 Task Descriptions

3.6.2 HP fuel pump – Overview

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

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Task Descriptions 333

3.6.3 HP fuel pump – Removal

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Lifting device T80091650 1
Support bracket T80091665 1

Fuels are combustible.


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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– X X Remove fuel lines (low pressure)
– X X Remove fuel lines (high pressure)
– X X Remove sensors, actuators and injectors (→ Page 563)

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334 Task Descriptions

HP fuel pump – Removal


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

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


HP pump (1).
4. Remove HP fuel pump (1).
5. Seal openings with suitable covers.
6. Remove O-ring.

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Task Descriptions 335

3.6.4 High-pressure pump – Disassembly


Disassembly of this component is not planned.
This assembly is a replacement part (Reman). It is available within the scope of the service-exchange scheme.

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336 Task Descriptions

3.6.5 HP fuel pump – Check

Spare parts
Designation / Use Part No. Qty.
HP pump
Screw

Remove HP pump (→ Page 333).

HP fuel pump – Check

Item Findings Measure

Check screws for damage. Damaged Replace

Check drive gear for damage. Damaged Replace HP pump.

Check sealing faces for damage. Damaged • Recondition


• Replace

M020127/02E 05-08 © MTU


Task Descriptions 337

3.6.6 High-pressure fuel pump – Installation

Special tools
Designation / Use Part No. Qty.
Lifting device T80091650 1
Carrying bracket T80091665 1
Alignment tool F6783244 1
Guide pin F30450460 2

Material
Designation / Use Part No. Qty.
Engine oil
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.

Check high-pressure fuel pump (→ Page 336).

High-pressure fuel pump – Installation


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

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338 Task Descriptions

6. Mount alignment tool (2) on high-pressure


pump (1) in correct position.
7. Use socket (3) to align high-pressure pump
meshing in such a way that the marked lines
(4) match.
8. Remove alignment tool (2).

9. Coat O-rings with petroleum jelly and insert in


grooves.
10. Install lifting device (2) and carrying bracket (3) for
high-pressure pump (1).
11. Insert high-pressure fuel pump (1) in bore.

12. Insert screws (2) and tighten.


13. Mount clamps (1).
14. Remove lifting device and carrying bracket for
high-pressure pump.

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Task Descriptions 339

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assembly in reverse sequence to disassembly (→ Page 333)
– – X Fill and vent fuel system (→Operating Instructions)
– – X Enable engine start –

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340 Task Descriptions

3.7 LP Fuel System

3.7.1 Fuel supply to fuel delivery pump – Overview

200 Fuel line 2500 Screw 3530 Washer


400 O-ring 2600 Washer 3600 Clamp
500 Screw 2610 O-ring 3700 Screw
600 Washer 2800 Holder 3800 Washer
800 Fuel line 2900 Screw 3900 Spacer bush
1000 Clamp 3000 Washer 4100 Clamp
1200 Clamp 3020 Cable clamp 4200 Screw
1400 Clamp 3200 Banjo screw 4300 Washer
1500 Fuel line 3300 Sealing ring 4400 Fuel line
1700 O-ring 3320 Banjo screw 4600 Clamp
1800 Screw 3330 Sealing ring 4700 Screw
1900 Washer 3400 Fuel line 4800 Washer
2100 Fuel line 3510 Holder 5000 Clamp
2300 Fuel cooler 3520 Screw

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Task Descriptions 341

Fuel priming pump

1 Fuel priming pump 2 Pump housing 3 Sealing ring

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342 Task Descriptions

3.7.2 Fuel supply to fuel delivery pump – Removal

Preconditions
• Engine is stopped and starting disabled.

Fuels are combustible.


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

Preparatory steps

A distinction must be made as to whether


1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)

Removing fuel supply to fuel delivery pump


1. Before disconnecting the lines, take photographs or mark attachments and lines.
2. Release threaded union on fuel lines and catch fuel emerging.
3. Remove fuel supply to fuel delivery pump and hand pump in accordance with overview drawing (→ Page 340).
4. Seal all openings with suitable covers.

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Task Descriptions 343

3.7.3 Fuel supply to fuel delivery pump – Disassembly


Fuels are combustible.
Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.

Remove fuel supply to fuel delivery pump (→ Page 342).

Disassembling fuel priming pump


Note: Handle is locked with screw locking liquid.

1. Unscrew handle (6) from piston rod (2).


2. Remove cover (5).
3. Remove sleeve (7) from housing (1).
4. Withdraw piston rod (2).
5. Take off O-ring (4) and seal (3).

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344 Task Descriptions

3.7.4 Fuel supply to fuel delivery pump – Cleaning

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.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Excessive reaction time of cleaning agents on components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Disassemble fuel supply to fuel delivery pump (→ Page 343).

Cleaning fuel supply to fuel delivery pump


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow all parts clean with compressed air.

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Task Descriptions 345

3.7.5 Fuel supply to fuel delivery pump – Check

Spare parts
Designation / Use Part No. Qty.
Fuel delivery pump
Pump housing
Retainer
Fuel line

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Compressed air is pressurized.
Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Clean fuel supply to fuel delivery pump . (→ Page 344)

Checking fuel supply to fuel delivery pump

Item Findings Task

Check fuel lines visually for damage. Damaged • Recondition


• Replace

Pressure-test fuel line for leaks Leaking Replace


with air in water bath. A water
temperature of min. = 30 °C or
max. = 40 °C at a test pressure of
0.5 bar must be observed.

Check sealing and mating faces for Damaged • Recondition: smooth with
damage. oilstone.
• Replace

Check threads of union nuts and Sluggish • Recondition: Recut threads


threaded connections for ease of • Replace
movement.

Check mounting parts of fuel lines Damaged Replace


for damage.

Check operation of check valve. Malfunction Replace


Opening pressure and flow direction
are to be found on check valve.

Check sealing, mating and sliding • Wear • Recondition: smooth with


surfaces on hand pump for wear. • Wear oilstone.
visible • Replace

Check pump housing for damage. Damaged Replace

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346 Task Descriptions

3.7.6 Fuel supply to fuel delivery pump – Assembly

Material
Designation / Use Part No. Qty.
Engine oil
Loctite 270
Petroleum jelly, white

Spare parts
Designation / Use Part No. Qty.
O-ring
Seal

Fuels are combustible.


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

Check fuel supply to fuel delivery pump (→ Page 345).

Assembling fuel priming pump


1. Coat O-ring (4) with petroleum jelly and insert into
groove on the piston rod (2).
2. Insert seal (3) into housing (1).
3. Insert piston rod (2) into housing.
4. Install cover (5).
5. Clean threads of piston rod (2) and handle (6) so
that they are dry and free of grease.
6. Coat thread of piston rod (2) with Loctite.
7. Screw on handle (6) and tighten hand-tight.
8. Check operation of fuel priming pump.
9. Assemble handle (6) with sleeve (7).

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Task Descriptions 347

3.7.7 Fuel supply to fuel delivery pump – Installation

Material
Designation / Use Part No. Qty.
Engine oil

Spare parts
Designation / Use Part No. Qty.
Sealing ring
Clamp

Fuels are combustible.


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

Assemble fuel supply to fuel delivery pump (→ Page 345).

Fuel supply to fuel delivery pump – Installation


1. Prior to installation, remove all covers.
2. Tighten fuel priming pump on pump housing with torque wrench to prescribed tightening torque (→ Page 24).
3. Install fuel supply to fuel delivery pump in accordance with overview drawing (→ Page 340).

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 342)
– – X Fill fuel system (→Operating Instructions)
– – X Enable engine start –

– – X After engine start, visually inspect fuel lines for leaks. –

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348 Task Descriptions

3.7.8 Fuel cooler – Overview

2300 Fuel cooler 2500 Screw 2600 Washer

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Task Descriptions 349

3.7.9 Fuel cooler – Removal

Preconditions
• Engine is stopped and starting disabled.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Fuels are combustible.


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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Drain engine coolant (→Operating Instructions)

Fuel cooler – Removal


1. Remove screws and washers as shown in overview drawing (→ Page 348) .
2. Collect emerging fuel.
3. Remove fuel cooler.
4. Remove O-rings.
5. Seal openings with suitable covers.

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350 Task Descriptions

3.7.10 Fuel cooler – Cleaning

Material
Designation / Use Part No. Qty.
Cleaning agent

High-pressure water jet.


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

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

Excessive reaction time of cleaning agents on components.


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

Remove fuel cooler (→ Page 349).

Cleaning the coolant side


1. Prior to cleaning the coolant side, check fuel cooler for contamination.
2. If encrustation of the coolant side is visible (intake area), caused by hardness components and dirt deposits,
clean with suitable cleaning agent.
Note: Dwell time depends on the condition and temperature of the solution and the nature and stubbornness
of the deposits.

3. Fill fuel cooler with cleaning agent.


4. After cleaning, flush fuel cooler with water. pH value difference between fresh water and flushing liquid
max. 1 pH.
5. If fuel cooler is not put into operation again immediately, dry it and then treat with preservative.
6. After treating with preservative, seal all openings with suitable covers.

Cleaning the fuel side


Note: Flushing with a cleaning agent must be carried out in the opposite direction of the direction of flow
when in operation.

1. Prepare cleaning agent in accordance with the manufacturer’s instructions.


2. After cleaning, flush fuel cooler with water. pH value difference between fresh water and flushing liquid
max. 1 pH.
3. If fuel cooler is not put into operation again immediately, dry it and then treat with preservative.

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Task Descriptions 351

3.7.11 Fuel cooler – Check

Spare parts
Designation / Use Part No. Qty.
Fuel cooler

Equipment can drop off.


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

Clean fuel cooler (→ Page 350)

Fuel cooler – Check

Item Findings Measure

Check fuel cooler visually for Damaged Replace


damage

Check fuel and water chambers of Leaking Replace


fuel cooler for leaks.
• Test pressure fuel side: 6 bar
• Test pressure coolant side: 9
bar

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

M020127/02E 05-08 © MTU


352 Task Descriptions

3.7.12 Fuel cooler – Installation

Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil

Spare parts
Designation / Use Part No. Qty.
O-ring

Fuels are combustible.


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

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

Check fuel cooler (→ Page 351).

Fuel cooler – Installation


1. Prior to installation, remove all covers.
2. Coat O-rings with petroleum jelly and insert in grooves.
3. Install fuel cooler with screws and washers as shown in overview drawing (→ Page 348) .

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– – X Fill up with engine coolant (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 353

3.7.13 Fuel duplex filter – Overview

4000 Fuel filter 4700 Intermediate piece 5100 Washer


4200 Retainer 4800 Screw 5300 Union
4400 Screw 4900 Washer 5400 Sealing ring
4500 Washer 5000 Screw

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354 Task Descriptions

Fuel duplex filter

5 Threaded bush 25 Screw


10 Sealing ring 30 Screw
15 Threaded vent plug 35 Cover
20 Sealing ring 40 Sealing ring

M020127/02E 05-08 © MTU


Task Descriptions 355

3.7.14 Fuel duplex filter – Removal

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Filter wrench F30379104 1

Fuels are combustible.


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

Preparatory steps

A distinction must be made as to whether


1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– X X Remove fuel lines

Removing fuel duplex filter


1. Unscrew filter elements using strap wrench (1).
2. Collect emerging fuel.
3. Remove filter head and bracket in accordance with
overview drawing (→ Page 353).

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356 Task Descriptions

3.7.15 Fuel duplex filter – Disassembly


Fuels are combustible.
Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

Remove fuel duplex filter (→ Page 355).

Disassembling fuel duplex filter


1. Disassemble filter head in accordance with overview drawing (→ Page 353).
2. Remove threaded vent plugs and sealing rings.
3. Remove cylinder screws.
4. Remove change-over valve with cover from filter head.

M020127/02E 05-08 © MTU


Task Descriptions 357

3.7.16 Fuel duplex filter – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Disassemble fuel duplex filter (→ Page 356).

Fuel duplex filter – Cleaning


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow out all parts with compressed air.

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358 Task Descriptions

3.7.17 Fuel duplex filter – Check


Compressed air is pressurized.
Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Clean fuel duplex filter (→ Page 357).

Fuel duplex filter – Check

Item Findings Task

Visually inspect fuel duplex filter for Damaged Replace


damage and condition.

Pressure-test fuel duplex filter with Leaking • Replace blanking plug.


air in water bath for leaks. A water • Replace fuel duplex filter.
temperature of min = 30 °C or
max = 40 °C at a test pressure of
0.5 bar must be observed.
Install filter inserts before carrying
out leak check.

Check sealing and bolt-on faces for Damaged • Smooth with oilstone.
damage. • Replace

M020127/02E 05-08 © MTU


Task Descriptions 359

3.7.18 Fuel duplex filter – Assembly

Material
Designation / Use Part No. Qty.
Engine oil

Spare parts
Designation / Use Part No. Qty.
CU sealing rings

Fuels are combustible.


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

Check fuel duplex filter (→ Page 358).

Fuel duplex filter – Assembly


1. Coat sealing ring (1) with engine oil.
2. Insert sealing ring (1) in groove on change-over
valve.
3. Insert change-over valve with cover (3) in filter
head.
4. Screw in cylinder head screws (2) and (4) and
tighten diagonally and evenly.
5. Insert all vent plugs and sealing rings.

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360 Task Descriptions

3.7.19 Fuel duplex filter – Installation

Spare parts
Designation / Use Part No. Qty.
Copper sealing ring

Fuels are combustible.


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

Assemble fuel duplex filter (→ Page 359).

Installing fuel duplex filter


1. Remove all plugs.
2. (→ Page 353)Install fuel duplex filter in accordance with overview drawing.

Fuel filter – Installation


1. Coat filter sealing ring (arrow) with fuel.
2. Install filter and tighten by hand.

M020127/02E 05-08 © MTU


Task Descriptions 361

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence (→ Page 355)
– – X Fill fuel system (→Operating Instructions)
– X X Enable engine start –

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362 Task Descriptions

3.7.20 Leak-off fuel system – Overview

200 Holder 2000 Clamp 4600 Clamp


300 Screw 2100 Screw 4700 Screw
400 Washer 2200 Washer 4800 Washer
420 Cable clamp 2400 Clamp 5000 Clamp
600 Distributor piece 2600 Clamp 5100 Screw
610 Plug screw 2700 Screw 5200 Washer
615 Sealing ring 2800 Washer 5210 Nut
625 Connection 2900 Spacer bush 5800 Clamp
630 Sealing ring 2950 Fuel line 5900 Screw
800 Screw 3100 Pipe half-clamps 6000 Washer
900 Washer 3200 Grommet 6020 Cable clamp
1100 Holder 3300 Screw 6200 Clamp
1200 Screw 3400 Washer 6300 Screw
1300 Nut 3800 Fuel line 6400 Washer
1400 Washer 4000 Grommet 6500 Nut
1600 Fuel line 4400 Fuel line

M020127/02E 05-08 © MTU


Task Descriptions 363

3.7.21 Leak-off fuel system – Removal

Preconditions
• Engine is stopped and starting disabled.

Fuels are combustible.


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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– X X Remove charge air manifold (if necessary) (→ Page 404)

Leak-off fuel system – Removal


1. Take photos or mark attachments and lines before removing them.
2. Release threaded union on fuel line and catch fuel emerging.
3. Remove fuel lines with securing elements as shown in overview drawing (→ Page 362) .
4. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


364 Task Descriptions

3.7.22 Leak-off fuel line – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove leak-off fuel pipework (→ Page 363).

Leak-off fuel line – Cleaning


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow out all parts with compressed air.

M020127/02E 05-08 © MTU


Task Descriptions 365

3.7.23 Leak-off fuel line – Check

Spare parts
Designation / Use Part No. Qty.
Sealing rings

Compressed air is pressurized.


Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Clean leak-off fuel line (→ Page 364).

Leak-off fuel line – Check

Item Findings Task

Visually inspect all leak-off fuel lines Damaged • Recondition


for damage. • Replace

Pressure-test leak-off fuel lines with Leaking Replace


air in water bath for leaks. A water
temperature of min. = 30 °C or
max. = 40 °C at a test pressure of
0.5 bar must be observed.

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

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366 Task Descriptions

3.7.24 Leak-off fuel system – Installation

Spare parts
Designation / Use Part No. Qty.
Sealing ring
Grommet

Fuels are combustible.


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

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

Check leak-off fuel system (→ Page 365)

Leak-off fuel system – Installation


1. Prior to installation, remove all covers.
2. Blow out leak-off fuel lines with compressed air.
3. Install leak-off fuel lines as shown in overview drawing (→ Page 362) and/or photographs or markings.

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assembly in reverse disassembly sequence (→ Page 363)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 367

3.8 Exhaust Turbocharger

3.8.1 Exhaust turbocharger – Overview

15 Exhaust turbocharger 50 O-ring 80 O-ring


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

M020127/02E 05-08 © MTU


368 Task Descriptions

3.8.2 Exhaust turbocharger – Removal

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

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine. (→ Page 65)

X – – Disassemble engine. (→ Page 66)


– – X Disable engine start. (→ Page 16)
– – X Drain engine coolant. (→Operating Instructions)
– X X Remove carrier housing cover. (→ Page 424)

M020127/02E 05-08 © MTU


Task Descriptions 369

Exhaust turbocharger – Removal


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

2. Remove threaded union (5) on exhaust


turbocharger (3).
3. Remove screws (1) and take off ring (2).
4. Remove screws (4).

5. Attach lifting equipment (1) to exhaust


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

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370 Task Descriptions

3.8.3 Exhaust turbocharger – Disassembly

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

Equipment can drop off.


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

Spring/circlip/tensioning roller preload.


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

Exhaust turbocharger – Disassembly


1. Remove center bearing.
2. Mark position of clamps (4) and (5).
3. Make marks (lines) between bearing housing (2)
and turbine housing (3), as well as between
bearing housing (2) and compressor housing (1).
4. Release clamp (5) on compressor housing (1)
and remove.

M020127/02E 05-08 © MTU


Task Descriptions 371

5. Insert exhaust turbocharger (4) in assembly jig (5).


6. Remove magnetic nut (left-hand thread) from
compressor wheel (3) using two-armed wrench.
7. Screw installation/removal tool (2) on to turbine
shaft.
8. Connect SKF hand pump (1).
Note: Expansion pressure: max. 800 bar

9. Use SKF hand pump (1) to expand hub of


compressor wheel (3) until compressor wheel (3)
jumps off turbine shaft.
10. Remove installation/removal tool (2).
11. Remove compressor wheel (3).

12. Install extracting fixture for retaining ring (4).


13. Remove retaining ring (4).
14. Remove extracting fixture for retaining ring ().
15. Remove washer (3), thrust bearing (2) and thrust
washer (1) on compressor side.

16. Remove O-ring (1), ring carrier (3) and piston


rings (2).

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372 Task Descriptions

17. Release clamp on turbine housing (2) and remove.


18. Remove bearing housing (1) on turbine
housing (2).

19. Remove turbine wheel (4) from bearing


housing (1).
20. Remove piston ring (3) from turbine wheel (4).
21. Remove heat shield (5) from bearing housing (1).
22. Remove snap rings (6), bearing bushes (2) and
washer from bearing housing (1).
23. Remove all O-rings.

M020127/02E 05-08 © MTU


Task Descriptions 373

3.8.4 Turbocharger cleaning

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.

Fuels are combustible.


Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Excessive reaction time of cleaning agents on components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Remove turbocharger (→ Page 368).

Turbocharger cleaning
1. Clean turbocharger externally with cleaner.
2. Remove cleaner.
3. Thoroughly blow all components with compressed air.

M020127/02E 05-08 © MTU


374 Task Descriptions

3.8.5 Exhaust turbocharger – Check

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

Clean turbocharger (→ Page 373).

M020127/02E 05-08 © MTU


Task Descriptions 375

Exhaust turbocharger – Check

Item Findings Measure

Check shaft of turbine wheel, Signs of cracks Replace


housing and compressor wheel with
magnetic crack test procedure for
cracks.

Check turbine housing, bearing • Abrasion • Recondition: smooth with


housing, compressor housing, shaft • Scores oilstone.
of turbine wheel and compressor visible • Replace
wheel for scores and gear wipe.

Measure bearing housing bore, Values exceeded or not attained. Replace


bearing bush bore, retaining ring
bore, compressor wheel bore,
bearing bush outer Ø, turbine shaft
outer Ø. Values (→ Page 379)

Check retaining ring, nut, ring Wear visible Replace


carrier, thrust bearing and thrust
washer for wear.

Check thread of screws. Damaged Replace

Check coolant channels and Deposits visible Clean or replace


housing cover of bearing housing
for deposits.

Bearing bushes, O-rings and piston Replace


rings

M020127/02E 05-08 © MTU


376 Task Descriptions

Checking turbine wheel concentricity


1. Support shaft of turbine wheel at bearings (see
arrows) in a roller V-block.
2. Check shaft runout.

Item Tolerance value


a 0.008 A-B

b 0.02 A-B
c 0.008 A-B

Result: Shaft runout > a, b or c, replace turbine


wheel.

M020127/02E 05-08 © MTU


Task Descriptions 377

Check balancing of turbine wheel


1. Support turbine wheel (1) at bearings (see arrows).
2. Permissible residual imbalance per balancing
level, see table below

Turbo- d1 d2 d3 a t permissible permissible


charger dia. dia. dia. (mm) (mm) residual imbalance
type imbalance per
(mm) (mm) (mm)
per balancing
balancing level (gmm)
level (gmm) when
procedure
is repeated

CB 125 67 53 50 10 1 1 –

Checking turbine housing


1. Check turbine housing for cracks.
2. Crack length more than max. crack length: (e =
2/3 L) stop-drilled with 3 mm permitted (arrow),
replace turbine housing.

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378 Task Descriptions

Checking compressor housing


1. Check compressor housing for cracks.
2. Crack length more than max. crack length: (e =
2/3 L) stop-drilled with 3 mm permitted (arrow),
replace compressor housing.

M020127/02E 05-08 © MTU


Task Descriptions 379

3.8.6 Exhaust turbocharger – Tolerances

No. Designation Stage Toler- Deviation Clearance Interference Wear limit


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

1 Compressor 10.400 0 +0.011 0.004 0.018


wheel bore H6

Turbine shaft OD 10.400 +0.007 +0.018


m6

2 Compressor 11.000 0 +0.018 0.004 0.018


wheel bore H7

Turbine shaft OD 11.000 +0.007 +0.018


m6

Fit length 11.0 H7 min. 13.0 mm

3 Bracket bore 27.900 0 +0.021


H7

4 Bearing housing 24.000 0 +0.013 0.072 0.095


bore H6

Bearing bush OD 24.000 −0.082 −0.072

M020127/02E 05-08 © MTU


380 Task Descriptions

No. Designation Stage Toler- Deviation Clearance Interference Wear limit


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

5 Bearing housing 17.000 0 +0.011 0.032 0.053


bore H6

Turbine shaft OD 17.000 −0.042 −0.032

6 Turbine shaft OD 27.400 0 −0.052


h9

Exhaust turbocharger

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

1 Measure ring end clearance in corresponding housing

Piston ring compressor side 0.350 0.450

Piston ring turbine side 0.350 0.450

2 Turbine wheel 4.000 C9 +0.070 +0.100 0.070 0.130


groove width

Piston ring turbine 4.000 h9 −0.030 0


side (1X)

M020127/02E 05-08 © MTU


Task Descriptions 381

No. Designation Stage Toler- Deviation Clearance Interference Wear


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

3 Ring carrier groove 4.000 D9 +0.030 +0.060 0.030 0.085


width

Piston ring 2.000 h9 −0.025 0


compressor side
(2X)

Gap clearance between Specified value (mm)

Check gap clearances with wire feeler gauges


a Axial play compressor wheel to compressor 0.25 to 0.563
housing

b Axial play turbine wheel to turbine housing 0.55 to 1.074


c Radial play turbine wheel to turbine housing 0.45 to 0.65

d Axial play 0.088 to 0.112


e Radial play turbine wheel to turbine housing 0.20 to 0.40

M020127/02E 05-08 © MTU


382 Task Descriptions

3.8.7 Exhaust turbocharger – Assembly

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

Equipment can drop off.


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

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

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

Spring/circlip/tensioning roller preload.


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

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

Check exhaust turbocharger (→ Page 374).

M020127/02E 05-08 © MTU


Task Descriptions 383

Exhaust turbocharger – Assembly


1. Insert snap rings (2) and (3) with snap ring pliers in
bearing housing (1).
Note: Broad bearing bush, turbine side

2. Coat bearing bush (4), inside and outside, with


engine oil and insert in bearing housing (1).
3. Insert snap ring (5) with snap ring pliers in
bearing housing (1).

4. Insert piston ring (2) for checking up to installation


in bearing housing (1).
5. Check piston ring gap with feeler gauge (3).
Values (→ Page 379)

6. Remove piston ring (1) from bearing housing and


insert in groove on turbine wheel (2).

M020127/02E 05-08 © MTU


384 Task Descriptions

7. Mount heat shield (2) on bearing housing.


8. Insert turbine wheel (1) in bearing housing (2).
9. Coat O-rings (4) with petroleum jelly and insert in
grooved on bearing housing (3).

10. Insert bearing housing (3) with turbine wheel (2)


in turbine housing.
11. Coat washer (1) with engine oil and insert in
bearing housing (3).

12. Coat bearing bush (1) with engine oil and insert in
bearing housing (2).

M020127/02E 05-08 © MTU


Task Descriptions 385

13. Insert thrust washer (1) up to installation on


bearing housing (2).

14. Insert thrust bearing (2) and washer (1) in correct


position in bearing housing (3).

15. In order to measure ring end clearance, insert


piston rings (2) one after the other in the retaining
ring (1), twisted by 180 °.
16. Measure ring end clearance with feeler gauge.
Values (→ Page 379).

M020127/02E 05-08 © MTU


386 Task Descriptions

17. Coat O-ring with petroleum jelly and insert in


groove on retaining ring (2).
18. Mount retaining ring (2) on bearing housing (4)
and tighten screws (3) to specified tightening
torque (→ Page 24) .
19. Insert ring carrier (1) in retaining ring (2).

Option A: Mounting compressor wheel (Al and


titanium) by press-fitting
1. Take up exhaust turbocharger (4) in assembly
jig (5).
2. Coat bearing surfaces on turbine shaft and
compressor wheel bore with oil.
3. Push compressor wheel (3) on to turbine shaft.
4. Screw installation/removal tool (2) on to turbine
shaft.
5. Connect SKF hand pump (1).
Note: Expansion pressure: max. 800 bar

6. Use SKF hand pump (1) to expand hub of


compressor wheel (3) and at the same time press
on compressor wheel (3) with installation/removal
tool (2) up to the stop.
7. Relieve pressure.
8. Remove SKF hand pump (1) and
installation/removal tool (2).

Option B: Mounting compressor wheel (Al) by heating


1. Degrease and dry clean bearing surfaces on turbine shaft and compressor wheel bore.
2. Heat compressor wheel to 150 °C.
3. Push heated compressor wheel on up to the installation and hold until shrink connection between shaft
and compressor wheel is firm.

M020127/02E 05-08 © MTU


Task Descriptions 387

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).

4. Align clamp (5) with compressor housing (1)


according to marks made prior to installation.
5. Align clamp (4) with turbine housing (3) according
to marks made prior to installation
6. Align compressor housing (1) with alignment tool.
7. Tighten clamps (4) and (5) with torque wrench to
specified tightening torque (→ Page 24) .

Measuring axial play


1. Mount tool (2) with dial gauge (4) on compressor
housing (1).
2. Slide rotor assembly (3) in both directions and
measure axial play. Value (→ Page 379).

M020127/02E 05-08 © MTU


388 Task Descriptions

Measuring gap clearance with feeler gauge


1. Slide rotor assembly (1) in both directions up to
stop and in doing so, check axial play and radial
play with feeler gauge (2). Values (→ Page 379).
2. Install center bearing on compressor housing.

M020127/02E 05-08 © MTU


Task Descriptions 389

3.8.8 Exhaust turbocharger – Installation

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.

Incorrect installation of components and lines.


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

Assemble exhaust turbocharger (→ Page 382).

Exhaust turbocharger – Installation


1. Prior to installation, remove all covers.
2. Clean mating face on carrier housing (2).
3. Coat O-ring (1) with petroleum jelly and insert in
groove on carrier housing (2).

M020127/02E 05-08 © MTU


390 Task Descriptions

4. Attach lifting equipment (1) to exhaust


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

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


tighten to specified tightening torque with torque
wrench (→ Page 24) .
8. Install ring halves (2) with screws (1) on exhaust
turbocharger (3) and tighten.
9. Insert threaded union (5) for exhaust
turbocharger (3) and tighten to specified tightening
torque (→ Page 24) with torque wrench.

10. Coat O-ring with petroleum jelly and insert


in groove.
11. Insert screws (2) in flange (1) and tighten to
specified tightening torque (→ Page 24) with
torque wrench.

M020127/02E 05-08 © MTU


Task Descriptions 391

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assembly in reverse disassembly sequence (→ Page 368)
– – X Fill up with engine coolant (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


392 Task Descriptions

3.9 Intercooler

3.9.1 Intercooler – Overview

5 Intercooler 25 Spacer sleeve 60 Screw


11 Screw 30 O-ring 70 Washer
15 Screw 35 O-ring
20 Washer 50 Retainer

M020127/02E 05-08 © MTU


Task Descriptions 393

3.9.2 Intercooler – Removal

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

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine. (→ Page 65)

X – – Disassemble engine. (→ Page 66)


– – X Disable engine start. (→ Page 16)
– X X Remove ECU. (→Operating Instructions)
– X X Remove engine coolant and charge-air coolant ventilation.
– X X Remove coolant pipework from – to intercooler.

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.

M020127/02E 05-08 © MTU


394 Task Descriptions

3.9.3 Intercooler – Cleaning


Remove intercooler (→ Page 393).
The intercooler must always only be cleaned by qualified personnel.
The following instructions are for the cleaning company.
Cleaning the air-side
Grease and oil contamination of the intercooler’s air-side is to be removed in a closed cleaning unit. The
cleaning agent must circulate in opposite direction to the cooling-air direction of flow.
It is imperative to avoid damaging the cooler, especially the cooling fins.
To remove the deposits, only use a cleaning agent that does not corrode metal surfaces
(→Fluids and Lubricants Specifications ).
Dwell time depends on the condition and temperature of the solution and the nature and stubbornness of the deposits.
Cleaning the waterside
It is recommended that the waterside be cleaned in a closed cleaning unit with forced flushing and filter.
The waterside can also be cleaned in an immersion- or ultrasonic bath.
To remove the deposits, only use a cleaning agent that does not corrode metal surfaces
(→Fluids and Lubricants Specifications ).
Dwell time depends on the condition and temperature of the solution and the nature and stubbornness of the deposits.
Flushing the intercooler
After cleaning the intercooler, flush coolant and air sides with fresh water, until the pH values of fresh water
and flushing liquid are almost the same (permitted pH value difference: 1 pH).
Intercooler drying and preservation
If the cooler is not to be put into operation immediately after cleaning, the cooler must be dried in
a drying oven for approx. 3 hours at a temperature of 110 to 120 °C.
After drying, the cooler must be preserved with a preservation agent.

M020127/02E 05-08 © MTU


Task Descriptions 395

3.9.4 Intercooler – Check

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.

Compressed air is pressurized.


Hot testing liquid.
WARNING Risk of injury and scalding!
• Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

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

Clean the intercooler (→ Page 394).

M020127/02E 05-08 © MTU


396 Task Descriptions

Intercooler – Check

Item Findings Measure

Visually inspect all components for Damaged • Recondition


damage. • Replace

Check shroud with surface crack test Cracks visible Replace


procedure using red dye penetrant
for cracks (only marine application).

Check air and coolant chambers of Leaking Replace


intercooler for leaks.
• Test pressure: air side: 4.8 bar
• Test pressure: coolant side: 8
bar

Check all sealing, mating and • Damaged • Recondition:


contact surfaces for damage and • Uneven smooth with oilstone or emery
unevenness. cloth.
• Replace

Check movement of thread in Sluggish Recondition


shroud (only marine application).

M020127/02E 05-08 © MTU


Task Descriptions 397

3.9.5 Intercooler – Installation

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.

Incorrect installation of components and lines.


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

Check intercooler (→ Page 395).

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.

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398 Task Descriptions

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 393)
– – X Fill up with engine coolant (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 399

3.10 Air Intake/Air Supply

3.10.1 Air filter – Overview

5 Air filter 15 Clamp

M020127/02E 05-08 © MTU


400 Task Descriptions

3.10.2 Air filter – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)

Removing air filter


1. Remove service indicator and air filter in accordance with overview drawing (→ Page 399).
2. After removal, close all openings with suitable covers.

M020127/02E 05-08 © MTU


Task Descriptions 401

3.10.3 Air filter – Check

Special tools
Designation / Use Part No. Qty.
Inspection lamp

Spare parts
Designation / Use Part No. Qty.
Air filter
Service indicator
Clamp

Remove air filter (→ Page 400).

Item Findings Task

Check air filter with inspection lamp • Damaged Replace


for damage and contamination. • Contaminated

Check clamps for damage. Damaged Replace

Check operation of service indicator. Malfunction Replace

M020127/02E 05-08 © MTU


402 Task Descriptions

3.10.4 Air filter – Installation


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

Check air filter (→ Page 401).

Air filter – Installation


1. Remove all covers.
2. Install air filter with clamp on intake housing in accordance with overview drawing (→ Page 399).
3. Install service indicator with signal ring pushed back.

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 403

3.10.5 Air supply system to cylinders – Overview

10 Clamp 90 Sealing ring 159 Cable clamp


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

M020127/02E 05-08 © MTU


404 Task Descriptions

3.10.6 Air supply to the cylinders – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– X X Remove engine control (→Operating Instructions)
– X X Remove air filter (→ Page 400)
– X X Remove intake housing
– X X Remove engine lifting equipment (if required) (→ Page 96)
– X X Remove emergency-air shutoff flap

Charge-air manifold removal


1. Install charge air manifold as shown in overview drawing (→ Page 403) .
2. Remove gaskets and O-rings.
3. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


Task Descriptions 405

3.10.7 Air supply system to cylinders – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove air supply system to cylinders (→ Page 404).

Cleaning air supply system to cylinders


1. Clean air lines to cylinders with cleaning agent.
2. Remove cleaning agent.
3. Blow out air lines to cylinders thoroughly with compressed air.

M020127/02E 05-08 © MTU


406 Task Descriptions

3.10.8 Air supply system to cylinders – Check

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.

Clean air supply system to cylinders (→ Page 405).

Checking air supply system to cylinders

Item Findings Task

Check charge-air manifold with Signs of cracks Replace


fluorescent dye penetrant for cracks.

Pressure-test charge-air manifold Leaking: • Replace blanking plug.


for leaks with air in water bath at a • at blanking plugs • Replace charge-air manifold.
max. barometric pressure of 0.5 bar. • at charge-air manifold

Check sealing and bolt-on faces for • Uneven • Recondition: smooth with
evenness and damage. • Damaged oilstone.
• Replace

Check threads for ease of Sluggish • Recut threads


movement. • Replace thread inserts.

Check screws and plugs for damage. Damaged Replace

M020127/02E 05-08 © MTU


Task Descriptions 407

3.10.9 Air supply to the cylinders – Installation

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.

Incorrect installation of components and lines.


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

Check air supply to the cylinders (→ Page 406).

Air supply to the cylinders – Installation


1. Prior to installation, remove all covers.
2. Place seals on cylinder heads.
3. Install air supply to the cylinders as shown in overview drawing (→ Page 403) .

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assembly in reverse disassembly sequence (→ Page 404)
– – X Enable engine start –

M020127/02E 05-08 © MTU


408 Task Descriptions

3.11 Exhaust System

3.11.1 Constant-pressure manifold – Overview

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

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Task Descriptions 409

Exhaust system

55 Exhaust pipework housing, left 245 Plug screw 300 Washer


88 Heat shield 255 Screw 310 Elbow
150 Exhaust manifold, left 260 Screw 315 Gasket
200 Sliding piece 265 O-ring 320 Screw
205 Bush 270 Washer 325 Screw
210 Washer 275 O-ring 330 Washer
215 Screw 280 O-ring 340 Plug-in pipe
225 Cover, left 290 Flange 350 O-ring
240 Sealing ring 295 Screw

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410 Task Descriptions

Exhaust system

95 Exhaust elbow 145 O-ring 345 Plug-in pipe


105 Plug screw 165 Plate 360 Exhaust pipe bellows
110 Sealing ring 170 Intermediate piece 370 Screw
120 Stud 175 Screw 375 Washer
125 O-ring 180 Screw 380 O-ring
130 Washer 185 Washer 385 O-ring
135 Nut 190 Washer
140 O-ring 230 Cover, right

M020127/02E 05-08 © MTU


Task Descriptions 411

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

M020127/02E 05-08 © MTU


412 Task Descriptions

3.11.2 Constant-pressure manifold – Removal

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

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine. (→ Page 65)

X – – Disassemble engine. (→ Page 66)


– – X Disable engine start. (→ Page 16)
– – X Drain engine coolant. (→Operating Instructions)
– X X Remove fuel line.
– X X Remove battery-charging generator.

Removing exhaust pipework housing


1. Release exhaust pipe bellows from carrier
housing, lower part.
2. Remove connecting piece of coolant pipe as
shown in overview drawing.
3. Remove nuts and heat shield.
4. Screw hooks (1) on to bores in exhaust pipework
housing (2).
5. Attach exhaust system housing (2) with lightly
pretensioned rope to crane.
6. Remove screws.
7. Remove exhaust pipework housing (2).
8. Set exhaust system housing (2) on to suitable
surface.
9. Remove hook (1).

M020127/02E 05-08 © MTU


Task Descriptions 413

Removing intermediate flange


1. Remove screws (2) and (3) and remove
intermediate flange with exhaust diffuser.
2. Remove O-ring (4) and gasket.
3. Screw two nuts onto grub screws (1) and lock.
4. Remove grub screw (1).
5. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


414 Task Descriptions

3.11.3 Constant-pressure manifold – Disassembly


Remove constant-pressure manifold (→ Page 412).

Disassembling exhaust system housing


1. Mark individual components of exhaust system housing.
2. Disassemble exhaust system housing in accordance with overview drawing (→ Page 408).
3. Remove O-rings, rings and gaskets.

M020127/02E 05-08 © MTU


Task Descriptions 415

3.11.4 Constant-pressure manifold – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Disassemble constant-pressure manifold (→ Page 414).

Constant-pressure manifold – Cleaning


1. Clean constant-pressure manifold with cleaning agent.
2. Place parts with carbon deposits in container with decarbonizer. Duration of immersion in cleaning bath
depends on thickness of deposit layer.
3. After cleaning with decarbonizer, rinse components in water until no further residues are washed off.
4. If deposits are stubborn, use synthetic shot-blasting pellets (nominal size 16 to 20) to help cleaning.
5. Remove cleaning agent.
6. Thoroughly blow out constant-pressure manifold with compressed air.

M020127/02E 05-08 © MTU


416 Task Descriptions

3.11.5 Constant-pressure manifold – Check

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

Compressed air is pressurized.


Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Clean constant-pressure manifold (→ Page 415).

M020127/02E 05-08 © MTU


Task Descriptions 417

Constant-pressure manifold - Check

Item Findings Measure

Check exhaust pipe bellows, Signs of cracks Replace


exhaust elbow and exhaust manifold
with fluorescent dye penetrant for
cracks.

Check exhaust pipes for Deformation Replace


deformation.

Check sealing and mating faces for Damaged • Recondition: smooth with
damage. oilstone or emery cloth.
• Replace

Check exhaust pipework housing Leaking Replace


and cover for leaks and stability, to
do so force off cooling chambers
with prepared water.

Check thread for ease of movement. Sluggish • Recondition: Recut thread.


• Replace

Check screws for damage. Damaged Replace

M020127/02E 05-08 © MTU


418 Task Descriptions

3.11.6 Constant-pressure manifold – Assembly

Material
Designation / Use Part No. Qty.
Assembly paste Ultra-Therm MTU

Spare parts
Designation / Use Part No. Qty.
Screw

Check constant-pressure manifold (→ Page 416).

Constant-pressure manifold – Assembly


1. Coat slides, O-rings, screw head mating faces and threads of screws with assembly paste prior to installation.
2. Prior to installation, clean cover and sealing faces until free of grease and dry.
3. Assemble exhaust pipework housing as shown in overview drawing (→ Page 408) and according to markings
made prior to removal.

M020127/02E 05-08 © MTU


Task Descriptions 419

3.11.7 Constant-pressure manifold – Installation

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.

Incorrect installation of components and lines.


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

Assemble constant-pressure manifold (→ Page 418).

M020127/02E 05-08 © MTU


420 Task Descriptions

Installing intermediate flange


1. Prior to installation, remove all covers.
2. Insert grub screws (1) in intermediate flange
with insertion tool or with the help of two nuts
and tighten.
3. Install intermediate flange with gasket and use
torque wrench to tighten screws (2) and (3) to
specified tightening torque (→ Page 24).
4. Coat threads of grub screws (1) with assembly
paste.
5. Coat O-ring (4) with petroleum jelly and insert in
groove on intermediate flange.

Constant-pressure manifold – Installation


1. Clean mating and sealing faces on exhaust system
housing and on intermediate flanges.
2. Screw hooks () on to bores in exhaust pipework
housing ().
3. Attach exhaust system housing () with lightly
pretensioned rope to crane.
4. Raise exhaust pipework housing () up to contact
point on intermediate flange.
5. Attach exhaust pipework housing () with screws.
6. Install heat shield for exhaust pipework housing ()
with nuts and washers.
7. Remove hook (1).
8. Install exhaust pipe bellows on carrier housing,
lower part.
9. Install connecting piece of coolant pipe.

M020127/02E 05-08 © MTU


Task Descriptions 421

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 412)
– – X Fill up with engine coolant (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


422 Task Descriptions

3.11.8 Carrier housing – Overview

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


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

M020127/02E 05-08 © MTU


Task Descriptions 423

3.11.9 Carrier housing – Removal

Preconditions
• Engine is stopped and starting disabled.

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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine. (→ Page 65)

X – – Disassemble engine. (→ Page 66)


– – X Disable engine start. (→ Page 16)
– – X Drain engine coolant. (→Operating Instructions)
– X X Remove turbocharger oil supply. (→ Page 457)
– X X Remove coolant pipework from/to exhaust turbocharger. (→Operating Instructions)
– X X Remove crankcase breather. (→ Page 103)
– X X Remove sensors, actuators and injectors. (→ Page 563)
– X X Remove exhaust flap actuator. (→ Page 434)

Carrier housing – Removal


1. Remove screws (2) on carrier housing (1).
2. Insert lifting eyes on carrier housing (1).
3. Attach carrier housing (1) with lightly pretensioned
rope to crane.
4. Remove carrier housing (1) and set down on
suitable surface.

M020127/02E 05-08 © MTU


424 Task Descriptions

3.11.10 Carrier housing – Disassembly

Preconditions
• Engine is stopped and starting disabled.
Remove carrier housing (→ Page 423).

Carrier housing – Disassembly


1. Remove all screws (2).
2. Remove flange (1) with gasket.
3. Remove all screws (4).
4. Remove carrier housing cover (3).

5. Remove exhaust turbocharger (1) (→ Page 368).


6. Remove flap housing (2).
7. Remove dowel pin (3) if damaged.
8. Remove all O-rings.

M020127/02E 05-08 © MTU


Task Descriptions 425

3.11.11 Carrier housing – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Disassemble carrier housing (→ Page 424).

Carrier housing – Cleaning


1. Clean carrier housing with cleaning agent.
2. Place parts with carbon deposits in container with decarbonizer. Duration of immersion in cleaning bath
depends on thickness of deposit layer.
3. After cleaning with decarbonizer, rinse components in water until no further residues are washed off.
4. If deposits are stubborn, use synthetic shot-blasting pellets (nominal size 16 to 20) to help cleaning.
5. Remove cleaning agent.
6. Blow out carrier housing thoroughly with compressed air.

M020127/02E 05-08 © MTU


426 Task Descriptions

3.11.12 Carrier housing – Check

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

Clean carrier housing (→ Page 425).

Carrier housing – Check

Item Findings Measure

Check carrier housing with Signs of cracks Replace


fluorescent penetrant for cracks.

Check sealing and mating faces for Damaged • Recondition: smooth with
damage. oilstone or crocus cloth.
• Replace

Check threads for ease of Sluggish • Recondition: Recut threads


movement. • Replace

Check screws for damage. Damaged Replace

M020127/02E 05-08 © MTU


Task Descriptions 427

3.11.13 Carrier housing – Assembly

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

Incorrect installation of components and lines.


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

Check carrier housing (→ Page 426).

Carrier housing – Assembly


1. Coat O-rings with petroleum jelly.
2. Insert O-rings in grooves on upper part of carrier
housing.
Note: Observe position of dowel pin (3) to
flap housing (2).

3. Install flap housing (2).


4. Install exhaust turbocharger (1) (→ Page 389).

M020127/02E 05-08 © MTU


428 Task Descriptions

5. Coat screws (2) and (4) with engine oil.


6. Install carrier housing cover (3).
7. Insert screws (4) and tighten.
8. Install flange (1) and gasket.
9. Insert screws (2) and tighten.

M020127/02E 05-08 © MTU


Task Descriptions 429

3.11.14 Carrier housing – Installation

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.

Assemble carrier housing (→ Page 427).

Carrier housing – Installation


1. Prior to installation, remove all covers.
2. Coat O-rings with petroleum jelly.
3. Insert O-rings and gasket in annular groove.
4. Coat sealing face with silicone rubber.
5. Insert lifting eyes on carrier housing (1).
6. Attach carrier housing (1) with rope and crane
and lift it.
7. Install carrier housing (1) on bottom part of carrier
housing.
8. Coat screws (2) with engine oil.
9. Insert screws (2) and tighten them diagonally.

M020127/02E 05-08 © MTU


430 Task Descriptions

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine. (→ Page 69)

X – – Install engine. (→ Page 72)


– X X Assemble in reverse sequence to disassembly. (→ Page 423)
– – X Fill up with engine coolant. (→Operating Instructions)
– – X Enable engine start. –

M020127/02E 05-08 © MTU


Task Descriptions 431

3.11.15 Exhaust flap with actuators – Overview

15 Flap housing 236 Retainer 274 Screw


75 Multi-piece oil ring 237 Screw 275 O-ring
80 Ring 238 Washer 285 Sealing ring
90 Bushing 240 Clamp 290 Sleeve
95 R-ring 241 Screw 300 Gasket
100 Flange 242 Washer 305 Screw
110 Screw 255 Gasket 310 Screw
115 Gasket 260 Screw 315 Screw
125 Spring pin 265 Washer 320 O-ring
135 Screw 271 Gasket 325 Washer
140 Sealing ring 272 Screw 330 O-ring
230 Carrier housing 273 Washer 331 Washer

M020127/02E 05-08 © MTU


432 Task Descriptions

Overview drawing

30 Exhaust flap 165 Flange 215 Cylinder


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

M020127/02E 05-08 © MTU


Task Descriptions 433

Overview drawing

333 Bracket 396 Washer 455 Union


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

M020127/02E 05-08 © MTU


434 Task Descriptions

3.11.16 Exhaust flap with actuators – Removal

Preconditions
• Engine is stopped and starting disabled.

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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine. (→ Page 65)

X – – Disassemble engine. (→ Page 66)


– – X Disable engine start. (→ Page 16)
– X X Remove exhaust pipe bellows.
– X X Remove exhaust elbow.

Exhaust flap with actuators – Removal


1. Before removing the lines, take photos or label attachments and lines.
2. Remove actuator from exhaust flap as shown in overview drawing (→ Page 431).
3. Remove flap housing with exhaust flap (→ Page 424).
4. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


Task Descriptions 435

3.11.17 Exhaust flap with actuators – Disassembly


Remove exhaust flap with actuators (→ Page 434).

Disassembling exhaust flap


1. Remove bushing, R-ring and multi-piece oil ring as
shown in overview drawing (→ Page 431).
2. Remove screws for bearing bushings (1) and (3).
3. Remove bearing bushings (1) and (3).
4. Remove exhaust flap (2).
5. Remove screw for stop on exhaust flap (2).

M020127/02E 05-08 © MTU


436 Task Descriptions

3.11.18 Exhaust flow control flap with actuators – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Disassemble exhaust flow control flap with actuators (→ Page 435).

Exhaust flow control flap – Cleaning


1. Clean all components with cleaning agent.
2. Place parts displaying soot deposits in a bath containing carbon-deposit remover. Dwell time depends on
thickness of deposits.
3. After cleaning with decarbonizer, rinse components in water until no further residues are washed off.
4. If deposits are stubborn, use synthetic shot-blasting pellets (nominal size 16 to 20) to help cleaning.
5. Remove cleaning agent.
6. Thoroughly blow out constant-pressure manifold with compressed air.

M020127/02E 05-08 © MTU


Task Descriptions 437

3.11.19 Exhaust flap with actuators – Check

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

Clean exhaust flap with actuators (→ Page 436).

Exhaust flap with actuators – Check

Item Findings Measure

Using the crack-testing method with Signs of cracks Replace


fluorescent magnetic powder, test
shaft and bearing bushings.

Check flap housing and flap with red Signs of cracks Replace
dye penetrant for cracks.

Check parts for stress marks, wear • Stress marks Replace


and damage. • Wear
• Damage
visible

Check sealing and mating faces. Damaged • Recondition: smooth with


oilstone or crocus cloth.
• Replace

Check threads for ease of Sluggish • Recondition: Recut threads


movement. • Replace

Check bore for bearing bushings in • Pitting • Recondition: smooth with


flap housing for pitting and wear. • Wear oilstone.
visible • Replace

Check register bores and diameters Dimensions not as specified Replace


for dimensional accuracy. Values
(→ Page 438)

Check operation of cylinder. Malfunction Replace

M020127/02E 05-08 © MTU


438 Task Descriptions

3.11.20 Exhaust flap with actuators – Tolerances

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic
lower upper min. max. min. max.
size

1 Shaft OD 14.000 H10 −0.070 0

2 Bushing inner Ø 23.000 H8 0 +0.033 0.065 0.131

Shaft OD 23.000 d8 −0.065 −0.098

3 Flap housing 37.000 F8 +0.025 +0.064 0.050 0.128


bore

Bearing bushing 37.000 f8 –0.064 –0.025


OD

4 Bearing bushing 23.000 H10 0 +0.084 0.300 0.468


bore

Exhaust flap 22.700 H10 0 –0.084


outer Ø

5 Exhaust flap 16.000 H9 0 +0.043 0.400 0.495


bore

Bearing bushing 15.600 h9 0 −0.052


OD

M020127/02E 05-08 © MTU


Task Descriptions 439

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic
lower upper min. max. min. max.
size

6 Exhaust flap 28.000 F8 +0.020 +0.053 0.040 0.106


bore

Bearing bushing 28.000 f8 –0.020 −0.053


outer Ø

M020127/02E 05-08 © MTU


440 Task Descriptions

3.11.21 Exhaust flap with actuators – Assembly

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.

Incorrect installation of components and lines.


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

Check exhaust flap with actuators (→ Page 437).

M020127/02E 05-08 © MTU


Task Descriptions 441

Exhaust flap with actuators – Assembly


1. Coat sliding surface of bearing bushings (1), (3)
and exhaust flap (2) with assembly paste.
2. Install exhaust flap (2) in flap housing.
3. Install bearing bushings (1) and (3).
4. Insert screw for stop on exhaust flap (2).
5. Coat screws with assembly paste.
6. Insert screw for bearing bushings (1) and (3)
and tighten.
7. Check exhaust flap (2) for ease of movement.

8. Coat multi-piece oil ring (1) and R-ring (3) with


assembly paste.
9. Insert multi-piece oil ring (1) and R-ring (3) in
annular groove on flap housing (2).

10. Install flap housing (1) in retaining plate (4).


11. Install assembly sleeve for R-ring on bushing (3) at
rear.
12. Pull bushing (3) with assembly sleeve over
R-ring at rear.
13. Remove assembly sleeve.
14. Install assembly sleeve (2) for R-ring on
bushing (3) at front.
15. Pull bushing (3) with assembly sleeve (2) over
R-ring at front.
16. Remove assembly sleeve (2).

M020127/02E 05-08 © MTU


442 Task Descriptions

3.11.22 Exhaust flap with actuators – Installation

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.

Incorrect installation of components and lines.


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

Assemble exhaust flap with actuators (→ Page 440).

Exhaust flap with actuators – Installation


1. Prior to installation, remove all covers.
2. Install flap housing with exhaust flap (→ Page 429).
Note: Exhaust flap closed, position of bore on shaft 11 o’clock

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

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 434)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 443

3.12 Starting System

3.12.1 Electric starter – Overview

1 Starter 3 Nut 5 Stud


2 Flange 4 Washer

M020127/02E 05-08 © MTU


444 Task Descriptions

3.12.2 Starter – Removal

Preconditions
• Engine is stopped and starting disabled.

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

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

Preparatory steps

A distinction must be made as to whether


1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)

Disconnecting and removing starter


1. Prior to disconnecting, mark all cables with writable adhesive tape.
2. Disconnect all cables from starter.
3. Protect all cables from damage.
4. Unscrew nuts on starter in accordance with overview drawing (→ Page 443).
5. Remove starter.
6. Protect starter against damage.

M020127/02E 05-08 © MTU


Task Descriptions 445

3.12.3 Starter – Disassembly


Remove starter (→ Page 444).

Disassembling starter
See separate Publication No. M060710.

M020127/02E 05-08 © MTU


446 Task Descriptions

3.12.4 Starter – Cleaning


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

Disassemble starter (→ Page 445).

Starter – Cleaning
1. Clean starter with compressed air; do not wet-clean.
2. Protect starter against moisture.

M020127/02E 05-08 © MTU


Task Descriptions 447

3.12.5 Starter – Inspection

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.

Clean starter (→ Page 446).

Starter – Inspection

Item Findings Task

Check tooth flanks of drive gear for • Wear • Recondition


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

Check nuts and studs for condition No ease of movement Replace


and check threads for ease of
movement.

Check mating face on end housing Wear traces are found. Recondition Re-surface with crocus
for wear. cloth or oil stone.

M020127/02E 05-08 © MTU


448 Task Descriptions

3.12.6 Starter – Installation

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.

Check starter (→ Page 447).

Installing starter
1. Coat starter pinion with long-life grease.
2. Install starter as in accordance with overview drawing (→ Page 443).

Connecting starter electrically


1. Connect lines according to markings.
2. Check operation of starter.

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 449

3.13 Lube Oil System

3.13.1 Oil heat exchanger – Overview

1 Oil heat exchanger 3 Washer


2 Screw 4 O-ring

M020127/02E 05-08 © MTU


450 Task Descriptions

3.13.2 Oil heat exchanger – Removal

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Carrying bracket T80091765 1

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine. (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Drain engine coolant (→Operating Instructions)
– X X Remove fuel duplex filter (→ Page 355)

Oil heat exchanger – Removal


1. Remove screws (arrows) and washers.
2. Install carrying bracket on oil heat exchanger.
3. Attach oil heat exchanger to crane with rope
slightly pretensioned.
4. Remove oil heat exchanger from coolant
distribution housing.
5. Protect oil heat exchanger from damage and
remove carrying bracket.
6. Remove O-rings.
7. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


Task Descriptions 451

3.13.3 Oil heat exchanger – Cleaning

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.

High-pressure water jet.


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

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

Excessive reaction time of cleaning agents on components.


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

Remove oil heat exchanger (→ Page 450).

Cleaning water side


1. Prior to cleaning the water side, inspect oil heat exchanger for dirt.
2. If encrustation is visible on the water side (entry zone), caused by hardness components, dirt or oil deposits,
then clean with suitable cleaning agent, e.g. Porodox or Porozink.
Note: Dwell time depends on the condition and temperature of the solution and the nature and stubbornness
of the deposits.

3. Fill cleaning agent into oil heat exchanger .


4. After cleaning, flush oil heat exchanger thoroughly with water. Difference in pH value between fresh water
and rinsing water should be max. 1 pH.
5. If the oil heat exchanger is not immediately put into operation, it should be dried and then treated with
preservative.
5.1. Drying should be carried out in a drying oven.
• Temperature: 110 °C to 120 °C.
• Drying time: 3 hours.
5.2. Treat oil heat exchanger with preservative.
• Preservative: Branol 32/10.
• Dosage: 2 ml Branorol 32/10 per liter coolant volume.
6. After preserving treatment, close all openings with suitable covers.

M020127/02E 05-08 © MTU


452 Task Descriptions

Cleaning oil side


1. Replace oil heat exchanger if swarf has penetrated engine oil system, e.g. in the case of piston seizure or
damage caused during storage.
2. Connect oil side to a closed-circuit rinsing device.
• Mesh size of filter unit: 0.05 mm
Note: The rinsing procedure with a cleaning agent must be carried out in operating mode and in opposite
direction to direction of oil flow.

3. Prepare cleaning agent according to manufacturer’s instructions. Cleaning agent: 3 to 5% P3 FD solution


• Rinsing pressure: 3 to 4 bar at 150 liters/minute to 300 liters/minute
• Cleaning can additionally be improved ultrasonic waves.
4. After cleaning, flush oil heat exchanger thoroughly with water. Difference in pH value between fresh water
and rinsing water max. 1 pH.
5. If the oil heat exchanger is not immediately put into operation, it should be dried and then treated with
preservative. (see Cleaning water side)

M020127/02E 05-08 © MTU


Task Descriptions 453

3.13.4 Oil heat exchanger – Check

Spare parts
Designation / Use Part No. Qty.
Oil heat exchanger

Equipment can drop off.


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

Clean oil heat exchanger (→ Page 451).

Checking oil heat exchanger

Item Findings Task

Check oil heat exchanger visually Damaged Replace


for damage.

Check oil and water chambers of oil Leaking Replace


heat exchanger for leaks.
• Test pressure: oil side: 25 bar
• Test pressure: coolant side: 8
bar

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

M020127/02E 05-08 © MTU


454 Task Descriptions

3.13.5 Oil heat exchanger – Installation

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.

Check oil heat exchanger (→ Page 453).

Oil heat exchanger – Installation


1. Prior to installation, remove all covers.
2. Coat O-rings with petroleum jelly.
3. Insert O-rings in grooves on coolant distribution
housing.
4. Install carrying bracket on oil heat exchanger.
5. Attach oil heat exchanger to crane with rope
slightly pretensioned.
6. Install oil heat exchanger on coolant distribution
housing.
7. Insert screws (arrow) and washers and tighten
diagonally.
8. Remove carrying bracket.

M020127/02E 05-08 © MTU


Task Descriptions 455

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assembly in reverse sequence to disassembly (→ Page 450)
– – X Fill up with engine coolant (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


456 Task Descriptions

3.13.6 Exhaust turbocharger oil supply – Overview

20 4/2-way directional control valve 210 Union 390 Oil line


30 Plate 220 Sealing ring 410 Clamp
50 Screw 250 Oil line 430 Retainer
80 Union 260 Oil line 450 Screw
90 Sealing ring 280 Oil line 460 Washer
110 Retainer 290 Oil line 480 Screw
130 Screw 310 Oil line 490 Nut
140 Washer 330 Oil line 500 Washer
160 Screw 350 Clamp 510 Washer
170 Washer 360 Screw 600 Cover
190 Oil line 370 Washer

M020127/02E 05-08 © MTU


Task Descriptions 457

3.13.7 Turbocharger oil supply – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


1 The engine is to be completely disassembled
2 The engine is removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)

Removing turbocharger oil supply


1. Remove oil lines, connecting and mounting parts from engine in accordance with overview drawing
(→ Page 456).
2. Remove all sealing elements.
3. After removal, close all openings with suitable covers.
4. Protect oil lines from damage.

M020127/02E 05-08 © MTU


458 Task Descriptions

3.13.8 Turbocharger oil supply – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove turbocharger oil supply (→ Page 457).

Cleaning turbocharger oil supply


1. Clean exhaust turbocharger oil supply with cleaning agent.
2. Remove cleaning agent.
3. Then blow dry turbocharger oil system with compressed air.

M020127/02E 05-08 © MTU


Task Descriptions 459

3.13.9 Turbocharger oil supply – Check

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.

Compressed air is pressurized.


Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Clean turbocharger oil supply (→ Page 458).

Checking turbocharger oil supply

Item Findings Task

Check oil lines visually for damage. Damaged Replace

Pressure-test oil return lines for Leaking Replace


leaks with air in water bath. Maintain
a water temperature of min. = 30 °C
or max. = 40 °C at a test pressure
of 0.5 bar.

Check connecting and mounting Damaged Replace


parts of connections for damage.

Check sealing and bolt-on faces. Damaged • Recondition: smooth with


oilstone or emery cloth.
• Replace

Check thread for freedom of Sluggish • Recondition: Recut threads


movement. • Replace

M020127/02E 05-08 © MTU


460 Task Descriptions

3.13.10 Turbocharger oil supply – Installation

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.

Incorrect installation of components and lines.


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

Check turbocharger oil supply (→ Page 459).

Turbocharger oil supply – Installation


1. Prior to installation, remove all covers.
2. Blow out oil lines with compressed air.
3. Install oil lines with connecting and mounting parts as shown in overview drawing (→ Page 456).
4. After engine start, visually inspect oil lines for leaks.

M020127/02E 05-08 © MTU


Task Descriptions 461

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Install SOLAS covers (if required) (→Operating Instructions)
– – X Enable engine start. –

M020127/02E 05-08 © MTU


462 Task Descriptions

3.14 Coolant System

3.14.1 Engine coolant pump – Overview

10 Engine coolant pump 25 Nut


20 Stud 30 Washer

M020127/02E 05-08 © MTU


Task Descriptions 463

Overview drawing

100 Engine coolant pump 600 Bearing housing 1000 Washer


300 O-ring 800 Stud
400 Taper ring 900 Nut

M020127/02E 05-08 © MTU


464 Task Descriptions

3.14.2 Engine coolant pump – Removal

Preconditions
• Engine is stopped and starting disabled.

Coolant is hot and under pressure.


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

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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Drain engine coolant (→Operating Instructions)
– X X Remove protective cover and holder (→ Page 114)
– X X Remove catch basin for fuel filter –

– X X Remove sensor cable for sensor B16 –

– X X Remove fuel line from hand pump to HP pump –

Engine coolant pump – Removal


1. Remove nuts from engine coolant pump (→ Page 462) .
2. Loosen engine coolant pump with crowbar and remove.
3. Remove elbow.
4. Remove follower for HP pump.
5. Seal openings with suitable covers.
6. Remove O-ring.

M020127/02E 05-08 © MTU


Task Descriptions 465

3.14.3 Engine coolant pump – Disassembly

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.

Spring/circlip/tensioning roller preload.


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

Equipment can drop off.


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

Remove engine coolant pump (→ Page 464).

Engine coolant pump – Disassembly


1. Mark bearing housing (5) to bearing housing (6)
and bearing housing (6) to volute (1).
2. Remove all nuts (2) on bearing housing (6).
3. Use crowbar to loosen volute (1) from bearing
housing (6) and take off.
4. Remove screws (3).
5. Press bearing housing (5) with screws over forcing
thread on bearing housing (6).
6. Remove snap ring (4) with snap ring pliers from
bearing housing (5).

M020127/02E 05-08 © MTU


466 Task Descriptions

7. Use ejection mandrel (1) to press cylindrical roller


bearing (2) out of bearing housing (3).

8. Take up engine coolant pump with adapter (7) in


bench vise (6).
9. Remove plug screw from impeller (9).
10. Use hydraulic spindle and extracting fixture (1) to
force impeller (9) off water pump shaft (2).
11. In doing so hold gear (5) in adapter (7).
12. Remove impeller (9) from engine coolant pump.
13. Remove rotary seal (8) from water pump shaft (2).
14. Remove adapter (3) from bearing housing (4).
15. Remove engine coolant pump from adapter (7).

16. Use ejection mandrel (1) to press counterring (2)


out of adapter (3).

M020127/02E 05-08 © MTU


Task Descriptions 467

17. Remove snap ring (1) with snap ring pliers.


18. Remove spacer ring (5) from bearing housing (3).
19. Remove shaft seal (4) from bearing housing (3).
20. Remove snap ring (2) with snap ring pliers from
bearing housing (3).

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).

M020127/02E 05-08 © MTU


468 Task Descriptions

3.14.4 Coolant pump – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Disassemble coolant pump (→ Page 465).

Cleaning coolant pump


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow all parts clean with compressed air.

M020127/02E 05-08 © MTU


Task Descriptions 469

3.14.5 Engine coolant pump – Check

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Clean engine coolant pump (→ Page 468).

M020127/02E 05-08 © MTU


470 Task Descriptions

Engine coolant pump – Check

Item Findings Measure

Check volute and impeller for Cavitation visible. Replace


cavitation.

Check bearing housing, impeller, Signs of cracks Replace


adapter and volute with red dye
penetrant for cracks.

Check water pump shaft with Signs of cracks Replace


fluorescent magnetic powder for
cracks.

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

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


of wear and damage. • Indentations oilstone or emery cloth.
• Damage • Replace.
visible

Check spacer ring for damage. Damaged Replace

M020127/02E 05-08 © MTU


Task Descriptions 471

3.14.6 Engine coolant pump – Assembly

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.

Spring/circlip/tensioning roller preload.


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

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

Incorrect installation of components and lines.


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

Check engine coolant pump (→ Page 469).

M020127/02E 05-08 © MTU


472 Task Descriptions

Engine coolant pump - Assembly


1. Heat angular-contact ball bearing (2) and track
ring (1) to 120 °C and slide on to water pump
shaft (3).
2. Insert water pump shaft (3) in bearing housing (7).
Note: Snap ring (8) opening must lie on relief
groove of bearing housing (7).

3. Use snap ring pliers to insert snap ring (8) in


groove on bearing housing (7).
4. Heat gear (6) to 180 °C and slide on to water pump
shaft (3) until dimension (a = 63.5 mm).
5. Heat inner ring (4) with warm-up device to 120 °C
and slide on to water pump shaft (3).
6. Use snap ring pliers to insert snap ring (5) in
groove on water pump shaft (3).

7. Degrease and dry clean shaft seal surface on


bearing housing (3).
8. Coat sealing lips on shaft seal (2) with petroleum
jelly
Note: Make sure shaft seal (2) is in correct
position.

9. Use press-in tool (1) to install shaft seal (2) in


bearing housing (3).
10. Install spacer ring and snap ring.

11. Check rotary seal for damage.


12. Clean counterring surface on adapter (1) with
ethanol.
13. Coat outer surface of new counterring (2) with
ethanol.
14. Use installation/removal jig to press counterring (2)
up to stop in adapter (1).
15. Insert adapter (1) in bearing housing.
16. Degrease and dry rotary seal (3) and push on
to water pump shaft up to the installation on
the counterring, with rotary seal surface facing
the counterring (2).

M020127/02E 05-08 © MTU


Task Descriptions 473

17. Coat O-ring with petroleum jelly and insert


in groove (2).
18. Heat impeller (3) to 250 °C.
19. Place two sensor plates (gap clearance a = 0.8
mm), at intervals of 180°, on to adapter (1).
20. Push heated impeller up to the installation and
hold until shrink connection between shaft and
impeller is firm.
21. Use feeler gauge to check gap between
impeller (3) and adapter (1).
Result: If gap clearance (0.8 mm) is out of
tolerance, determine the cause and replace
components, if necessary.

22. Use adapter (1) and torque wrench to check if


impeller (2) is seated correctly on shaft. Checking
torque (→ Page 24).
23. Impeller (2) must not twist when powering the
shaft; if it does, remove impeller (2) and check
cause.
24. Insert plug screw for impeller (2).

M020127/02E 05-08 © MTU


474 Task Descriptions

25. Coat cylindrical roller bearing in bearing


housing (3) with engine oil.
Note: Apply press-in pressure to bearing
outer ring.

26. Use hydraulic press and installation mandrel to


press cylindrical roller bearing (3) into bearing
housing (4).
27. Use snap ring pliers to insert snap ring (2) in
groove on bearing housing (4).
28. Coat O-ring with petroleum jelly and insert in
groove on bearing housing (4).
29. Set bearing housing (4) on to bearing housing
(5) according to the installation position marking
made before removal.
30. Use torque wrench to tighten screws to specified
tightening torque (→ Page 24) .
31. Set volute (6) onto bearing housing (5) according
to the installation position marking made before
removal.
32. Use torque wrench to tighten nuts to specified
tightening torque (→ Page 24) .
33. Turn water pump shaft to check freedom of
rotation.
34. Use feeler gauge to check gap (a = 0.4 mm to 1.0
mm) between impeller and volute (6).
35. If measured value is out of tolerance, determine
the cause and replace components, if necessary.

M020127/02E 05-08 © MTU


Task Descriptions 475

3.14.7 Engine coolant pump – Installation

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.

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Assemble engine coolant pump (→ Page 471).

Engine coolant pump – Installation


1. Prior to installation, remove all covers.
2. Coat O-ring with petroleum jelly and insert in groove on bearing housing.
3. Install follower for HP pump on water pump shaft.
Note: Make sure that gears are correctly meshed and that follower fits.

4. Insert engine coolant pump in correct position in bore (→ Page 462).


5. Screw on nuts with washers and tighten evenly.

M020127/02E 05-08 © MTU


476 Task Descriptions

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assembly in reverse disassembly sequence (→ Page 464)
– – X Fill up with engine coolant (→Operating Instructions)
– – X Vent fuel system (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 477

3.14.8 Coolant pipework from/to exhaust turbocharger – Overview

430 Coolant line 540 Coolant line 610 Sealing ring


440 Banjo screw 550 Banjo screw 630 Clamp
450 Sealing ring 560 Sealing ring 640 Spacer sleeve
470 Clamp 566 Clamp 660 Coolant line
480 Screw 567 Screw 680 Banjo screw
490 Washer 568 Washer 690 Sealing ring
510 Union 590 Coolant line
520 Sealing ring 600 Banjo screw

M020127/02E 05-08 © MTU


478 Task Descriptions

3.14.9 Coolant pipework from/to exhaust turbocharger – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Drain engine coolant (→Operating Instructions)

Coolant pipework from/to exhaust turbocharger – Removal


1. Before removing the lines, take photos or label add-on components and lines.
2. Remove coolant lines as shown in overview drawing (→ Page 477).
3. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


Task Descriptions 479

3.14.10 Coolant pipework from/to exhaust turbocharger – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Unsuitable cleaning tools.


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

Remove coolant pipework from/to exhaust turbocharger (→ Page 478).

Coolant pipework from/to exhaust turbocharger – Cleaning


1. Clean coolant lines with cleaning agent and brush.
2. Remove cleaning agent.
3. Blow coolant lines dry with compressed air and preserve in oil bath.

M020127/02E 05-08 © MTU


480 Task Descriptions

3.14.11 Coolant pipework from/to exhaust turbocharger – Check

Spare parts
Designation / Use Part No. Qty.
Coolant line
Clamp
Banjo screw
Union

Compressed air is pressurized.


Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Clean coolant pipework from/to exhaust turbocharger (→ Page 479).

Coolant pipework from/to exhaust turbocharger – Check

Item Findings Measure

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

Check clamp and banjo screw for Damaged Replace


damage.

Pressure-test coolant lines with air Leaking Replace


in water bath for leaks as necessary.
Maintain a coolant temperature of
min. = 30 °C or max. = 40 °C at a
test pressure of 0.5 bar.

M020127/02E 05-08 © MTU


Task Descriptions 481

3.14.12 Coolant pipework from/to exhaust turbocharger – Installation

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.

Incorrect installation of components and lines.


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

Check coolant pipework from/to exhaust turbocharger (→ Page 480).

Coolant pipework from/to exhaust turbocharger – Installation


1. Prior to installation, remove all covers.
2. Blow out coolant lines with compressed air.
3. Install coolant lines as shown in overview drawing (→ Page 477).

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Fill up with engine coolant (→Operating Instructions)
– X X Enable engine start –

M020127/02E 05-08 © MTU


482 Task Descriptions

3.14.13 Engine coolant and charge-air coolant ventilation – Overview

20 Vent line 100 Screw 240 Union


40 Union 110 Washer 250 Sealing ring
50 Sealing ring 130 Vent line 300 Vent line
51 Union 150 Union 320 Clamp
52 Sealing ring 160 Sealing ring 330 Screw
70 Vent line 180 Clamp 340 Washer
72 Union 190 Screw 350 Spacer sleeve
73 Sealing ring 200 Washer
90 Clamp 220 Vent line

M020127/02E 05-08 © MTU


Task Descriptions 483

3.14.14 Engine coolant and charge-air coolant ventilation – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Drain engine coolant (→Operating Instructions)

Engine coolant and charge-air coolant ventilation – Removal


1. Before removing the lines, take photos or label attachments and lines.
2. Remove lines as shown in overview drawing (→ Page 482).
3. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


484 Task Descriptions

3.14.15 Engine coolant and charge-air coolant ventilation – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Unsuitable cleaning tools.


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

Remove engine coolant and charge-air coolant ventilation (→ Page 483).

Engine coolant and charge-air coolant ventilation – Cleaning


1. Clean lines with cleaning agent and brush.
2. Remove cleaning agent.
3. Blow lines dry with compressed air and preserve in oil bath.

M020127/02E 05-08 © MTU


Task Descriptions 485

3.14.16 Engine coolant and charge-air coolant ventilation – Check

Spare parts
Designation / Use Part No. Qty.
Line
Banjo screw

Clean engine coolant and charge-air coolant ventilation (→ Page 484).

Engine coolant and charge-air coolant ventilation – Check

Item Findings Measure

Check line and banjo screw for Damaged Replace


stress marks and damage.

Pressure-test coolant lines with air Leaking Replace


in water bath for leaks as necessary.
Maintain a coolant temperature of
min. = 30 °C or max. = 40 °C at a
test pressure of 0.5 bar.

M020127/02E 05-08 © MTU


486 Task Descriptions

3.14.17 Engine coolant and charge-air coolant ventilation – Installation

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.

Incorrect installation of components and lines.


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

Check engine coolant and charge-air coolant ventilation (→ Page 485).

Engine coolant and charge-air coolant ventilation – Installation


1. Prior to installation, remove all covers.
2. Blow out lines with compressed air.
3. Install lines with new sealing rings and screw on with clamps.

M020127/02E 05-08 © MTU


Task Descriptions 487

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Fill up with engine coolant (→Operating Instructions)
– X X Enable engine start –

M020127/02E 05-08 © MTU


488 Task Descriptions

3.14.18 Coolant cooler – Overview

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

Engine Plate Initial Coolant cooler End Tense state


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

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


M93

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


M93

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


M93

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


M93

M020127/02E 05-08 © MTU


Task Descriptions 489

3.14.19 Coolant cooler – Removal

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Threaded pin 5362030462 2

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Drain engine coolant (→Operating Instructions)
– – X Drain raw water –

– X X Remove raw water lines (→ Page 520)

Removing coolant cooler


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

M020127/02E 05-08 © MTU


490 Task Descriptions

3.14.20 Coolant cooler – Cleaning

Special tools
Designation / Use Part No. Qty.
High-pressure cleaner
Soft cleaning brush

Material
Designation / Use Part No. Qty.
Sodium hydroxide
Sodium carbonate
Nitric acid
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.

High-pressure water jet.


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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Excessive reaction time of cleaning agents on components.


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

Cleaning agents containing chlorine and hydrochloric acid attack metal surfaces.
Risk of damage due to corrosion!
CAUTION • Do not use hydrochloric acid with stainless steel.
• Chlorine concentration in water solution must not exceed 300 ppm for cleaning purposes.
If a higher chlorine concentration is required, contact MTU.
• Protect aluminum components against chemicals.

Unsuitable cleaning tools.


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

Note: Do not use the following solvents:


• Ketones (e.g. acetone, methyl ethyl ketone, methyl isobutyl ketone)
• Esters (e.g. ethyl acetate, butyl acetate)
• Halogenated hydrocarbons (e.g. chlorothene, carbon tetrachlorides, Freon)
• Aromatic substances (e.g. benzene, toluene)

M020127/02E 05-08 © MTU


Task Descriptions 491

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

Removing aluminum/metal oxides and boiler deposit


Note: Mechanical or chemical cleaning, with open device, for:
• Calcium carbonate
• Calcium sulfate
• Silicates

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.

M020127/02E 05-08 © MTU


492 Task Descriptions

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

Removing calcium carbonate


1. Clean plates with 10% nitric acid and a soft brush.
2. Rinse plates with water and dry with cloth.

Oil residues, tars and fats


Note: Mechanical or chemical cleaning, with open device, for:
• Oil residues
• Tars
• Fats

1. Clean plates with kerosene and soft brush.


2. Dry plates with cloth or rinse with water.

Cleaning cover plate


Note: Protect aluminum components from chemicals.

1. Clean cover plate with cold cleaner and soft brush.


2. Remove cleaning agent.
3. Blow off cover plate with compressed air.

M020127/02E 05-08 © MTU


Task Descriptions 493

3.14.21 Coolant cooler – Check

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

Clean coolant cooler (→ Page 490).

Coolant cooler – Check

Item Findings Measure

Check cooler plates and cover Signs of cracks Replace


plate with red dye penetrant for
surface crack test procedure or with
fluorescent penetrant for cracks.

Check thread inserts of cover plate Sluggish Replace thread inserts


for ease of movement.

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

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

M020127/02E 05-08 © MTU


494 Task Descriptions

3.14.22 Coolant cooler – Installation

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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Check coolant cooler (→ Page 493).

Coolant cooler – Installation


1. Prior to installation, remove all covers.
Note: Tighten clamps for sleeve only when
coolant cooler has been installed.

2. Insert elbow (5) in coolant distribution housing


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

M020127/02E 05-08 © MTU


Task Descriptions 495

8. Coat thread and screw head mating face of screws


with thin-film lubrication.
9. Insert screws with tab washers and washers
and tighten alternately to dimension (a), see
(→ Page 488).
10. Select tightening sequence, so that a deflection of
the plate of max. 1 mm (in relation to plate length)
and a non-parallelism of the plate package of
max. 2 mm are not exceeded.
11. Remove threaded pin.
12. Secure screws with tab washers.

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 489)
– – X Fill up with engine coolant (→Operating Instructions)
– – X Enable engine start –

– – X Vent fuel system (→Operating Instructions)

M020127/02E 05-08 © MTU


496 Task Descriptions

3.14.23 Engine coolant cooler – Replacement of gasket

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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Excessive reaction time of cleaning agents on components.


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

Adhesives to be used

Manufacturer Type

Bostik 1782

3M Scotch Gripp 1099

Bond Spray 77

Castrol Pliobond 20/30

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.

2. Apply adhesive with a brush on gasket groove.


3. Insert new gasket in correct position in gasket groove.

M020127/02E 05-08 © MTU


Task Descriptions 497

4. Hold down inserted gasket with a plate for 30 minutes.


5. When the adhesive has dried, treat gasket with talc.

M020127/02E 05-08 © MTU


498 Task Descriptions

3.14.24 Coolant pipework with thermostat – Overview

360 Thermostat housing 380 Thermostat insert 390 Screw


370 Flow restrictor 385 Gasket 405 Washer

M020127/02E 05-08 © MTU


Task Descriptions 499

Plug screws for thermostat housing

10 Thermostat housing 30 Plug screw 50 Sealing ring


20 Plug screw 40 Sealing ring 60 Sealing ring

M020127/02E 05-08 © MTU


500 Task Descriptions

3.14.25 Coolant pipework with thermostat – Removal

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

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Drain engine coolant (→Operating Instructions)
– – X Extract or drain off engine oil (→Operating Instructions)
– X X Remove V-belt guard and V-belt
– X X Remove fuel line before fuel pump (→ Page 342)
– X X Remove fuel line from pump to filter
– X X Remove fuel filter (→ Page 355)
– X X Fuel line from Filter to injection pump
– X X Remove centrifugal oil filter
– X X Remove oil heat exchanger (→ Page 450)
– X X Remove oil filter
– X X Remove engine coolant lines
– X X Remove coolant cooler (→ Page 489)
– X X Remove raw water line (→ Page 520)
– X X Remove battery-charging generator
– X X Disconnect electrical lines and remove

Removing thermostat housing


1. Remove thermostat housing as shown in overview drawing (→ Page 498) .
2. Remove gaskets and flow restrictor from coolant distribution housing.
3. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


Task Descriptions 501

3.14.26 Coolant pipework with thermostat – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Remove coolant pipework with thermostat (→ Page 500).

Cleaning coolant pipework with thermostat


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow out all parts using compressed air.

M020127/02E 05-08 © MTU


502 Task Descriptions

3.14.27 Coolant pipework with thermostat – Check

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.

Clean coolant pipework with thermostat (→ Page 501).

Coolant pipework with thermostat – Check

Item Findings Measure

Using red dye penetrant, check the Signs of cracks Replace


coolant distribution housing and
thermostat housing for cracks.

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

Check locating bores of thermostat Damaged • Recondition: smooth with


inserts for damage. oilstone.
• Replace

Check threads in coolant distribution Sluggish Replace thread inserts.


housing for ease of movement.

Check coolant and oil chambers Leaking Replace


of coolant distribution housing with
air and corrosion inhibitor in water
bath for leaks. A water temperature
of min = 30 °C or max = 40 °C at
a test pressure of 0.5 bar must be
observed.

M020127/02E 05-08 © MTU


Task Descriptions 503

Checking thermostat insert


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

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


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

3. Check thermostat insert for start of opening


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

M020127/02E 05-08 © MTU


504 Task Descriptions

3.14.28 Coolant pipework with thermostat – Installation

Special tools
Designation / Use Part No. Qty.
Drive-in tool F30378672 1
Drive-in tool F30450050 1

Material
Designation / Use Part No. Qty.
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.

Check coolant pipework with thermostat (→ Page 502).

Installing thermostat housing


1. Prior to installation, remove all covers.
2. Install sealing rings in thermostat housing with drive-in tool.
3. Mount gaskets, restrictor and thermostat inserts on thermostat housing.
4. Install thermostat housing as shown in overview drawing (→ Page 498).

M020127/02E 05-08 © MTU


Task Descriptions 505

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly (→ Page 500)
– X X Fill up with engine coolant (→Operating Instructions)
– – X Fill up with engine oil (→Operating Instructions)
– – X Fill fuel system (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


506 Task Descriptions

3.14.29 Raw water pump – Overview

1 Screw 11 Bearing housing 21 Intermediate piece


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

M020127/02E 05-08 © MTU


Task Descriptions 507

3.14.30 Raw water pump – Removal

Preconditions
• Engine is stopped and starting disabled.

Coolant is hot and under pressure.


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

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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Close raw water supply –

– – X Drain raw water –

– X X Remove protective cover and holder –

– X X Remove elbow –

Raw water pump – Removal


1. Remove nuts for raw water pump as shown in overview drawing (→ Page 506) .
2. Remove screws from sleeve.
3. Loosen raw water pump with crowbar and remove.
4. Remove O-ring.
5. Seal openings with suitable covers.

M020127/02E 05-08 © MTU


508 Task Descriptions

3.14.31 Raw water pump – Disassembly

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.

Equipment can drop off.


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

Spring/circlip/tensioning roller preload.


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

Remove raw water pump (→ Page 507).

Raw water pump – Disassembly


1. Mark bearing housing (4) to bearing housing (5)
and bearing housing (5) to volute (6).
2. Remove all nuts (1) on bearing housing (5).
3. Use crowbar to loosen volute (6) from bearing
housing (5) and take off.
4. Remove screws (2).
5. Press bearing housing (4) with screws over forcing
thread off bearing housing (5).
6. Remove snap ring (3) with snap ring pliers from
bearing housing (4).

M020127/02E 05-08 © MTU


Task Descriptions 509

7. Use ejection mandrel (1) to press cylindrical roller


bearing (2) out of bearing housing (3).

8. Take up raw water pump with adapter (5) in


bench vise (6).
9. Remove plug screw from impeller (8).
10. Use hydraulic spindle and extracting fixture (1) to
force impeller (8) off water pump shaft (2).
11. In doing so hold gear firmly (4) in adapter (5).
12. Remove impeller (8) from raw water pump.
13. Remove rotary seal (3) from water pump shaft (2).
14. Remove adapter (7) from bearing housing.
15. Remove raw water pump from adapter (5).

16. Use ejection mandrel (1) to press counterring (2)


out of adapter (3).

M020127/02E 05-08 © MTU


510 Task Descriptions

17. Remove snap ring (1) with snap ring pliers.


18. Remove spacer ring (5) from bearing housing (3).
19. Remove shaft seal (4) from bearing housing (3).
20. Remove snap ring (2) with snap ring pliers from
bearing housing (3).

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).

M020127/02E 05-08 © MTU


Task Descriptions 511

3.14.32 Raw water pump – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Disassemble raw water pump (→ Page 508).

Cleaning raw water pump


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow all parts clean with compressed air.

M020127/02E 05-08 © MTU


512 Task Descriptions

3.14.33 Raw water pump – Check

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

Components have sharp edges.


Risk of injury!
WARNING • Wear protective gloves.

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

Clean raw water pump (→ Page 511).

M020127/02E 05-08 © MTU


Task Descriptions 513

Raw water pump – Check

Item Findings Measure

Check volute and impeller for Cavitation visible. Replace


cavitation.

Check bearing housing, impeller Signs of cracks Replace


and volute with red dye penetrant
for cracks.

Check water pump shaft with Signs of cracks Replace


fluorescent magnetic powder for
cracks.

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

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


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

Check spacer ring for damage. Damaged Replace

M020127/02E 05-08 © MTU


514 Task Descriptions

3.14.34 Raw water pump – Assembly

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.

Spring/circlip/tensioning roller preload.


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

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

Incorrect installation of components and lines.


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

Check raw water pump (→ Page 512).

M020127/02E 05-08 © MTU


Task Descriptions 515

Raw water pump – Assembly


1. Heat angular-contact ball bearing (2) and track
ring (1) to 120 °C and slide on to water pump
shaft (3).
2. Insert water pump shaft (3) in bearing housing (7).
Note: Snap ring (8) opening must lie on relief
groove of bearing housing (7).

3. Use snap ring pliers to insert snap ring (8) in


groove on bearing housing (7).
4. Heat gear (6) to 180 °C and slide on to water pump
shaft (3) until dimension (a = 67.5 mm).
5. Heat inner ring (4) to 120 °C and slide on to
water pump shaft (3).
6. Use snap ring pliers to insert snap ring (5) in
groove on water pump shaft (3).

7. Degrease and dry clean shaft seal surface on


bearing housing (3).
8. Coat sealing lips on shaft seal (2) with petroleum
jelly
Note: Make sure shaft seal (2) is in correct
position.

9. Use press-in tool (1) to install shaft seal (2) in


bearing housing (3).
10. Install spacer ring and snap ring.

11. Check rotary seal for damage.


12. Clean counterring surface on adapter (1) with
denatured ethanol.
13. Coat outer surface of new counterring (2) with
denatured ethanol.
14. Use installation/removal jig to press counterring (2)
up to stop in adapter (1).
15. Insert adapter (1) in bearing housing.
16. Degrease and dry rotary seal (3) and push on to
water pump shaft up to the installation, with rotary
seal surface facing the counterring (2).

M020127/02E 05-08 © MTU


516 Task Descriptions

17. Coat O-ring with petroleum jelly and insert


in groove (2).
18. Heat impeller to 210 °C.
19. Place two sensor plates (gap clearance a = 1.0 mm)
at intervals of 180° on adapter (1).
20. Push heated idler gear up to the installation
and hold until shrink connection between shaft
and idler gear is firm.
21. Use feeler gauge to check gap between idler
gear (3) and adapter (1).
Result: If gap clearance (a) is out of tolerance,
determine the cause and replace components,
if necessary.

22. Use adapter (2) and torque wrench (1) to check


if idler gear (3) is seated correctly on shaft.
Checking torque (→ Page 24)
23. Idler gear (3) must not twist when powering
the shaft; if it does, remove idler gear (3) and
check cause.
24. Coat plug screw for idler gear (3) with Loctite.
25. Tighten plug screw for idler gear (3) with torque
wrench to specified tightening torque (→ Page 24) .

M020127/02E 05-08 © MTU


Task Descriptions 517

26. Coat cylindrical roller bearing in bearing


housing (4) with engine oil.
Note: Apply press-in pressure to bearing
outer ring.

27. Use hydraulic press and installation mandrel to


press cylindrical roller bearing (6) into bearing
housing (4).
28. Use snap ring pliers to insert snap ring in groove
on bearing housing (4).
29. Coat O-ring with petroleum jelly and insert
in groove (3).
30. Set bearing housing (4) onto bearing housing (2)
according to the installation position marking
made before removal.
31. Use torque wrench to tighten screws to specified
tightening torque (→ Page 24) .
32. Set volute (1) onto bearing housing (2) according
to the installation position marking made before
removal.
33. Use torque wrench to tighten nuts to specified
tightening torque (→ Page 24) .
34. Turn pump shaft to check freedom of rotation.
35. Use feeler gauge to check gap (0.4 mm to 1.0 mm)
between idler gear and volute (1).
36. If measured value is out of tolerance, determine
the cause and replace components, if necessary.

M020127/02E 05-08 © MTU


518 Task Descriptions

3.14.35 Raw water pump – Installation

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.

Assemble raw water pump (→ Page 514).

Raw water pump – Installation


1. Prior to installation, remove all covers.
2. Coat O-ring with petroleum jelly and insert in groove on bearing housing.
Note: Make sure that gears are correctly meshed.

3. Insert raw water pump in correct position in bore (→ Page 462).


4. Screw on nuts with washers and tighten evenly.

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assembly in reverse disassembly sequence (→ Page 507)
– – X Open raw water supply –

– – X Fill raw water pump –

– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 519

3.14.36 Coolant pipework to raw water pump – Overview

15 Elbow 65 Restrictor 120 Nut


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

M020127/02E 05-08 © MTU


520 Task Descriptions

3.14.37 Raw water pump pipe system – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Close raw water supply –

– – X Drain raw water –

Removing raw water pump pipe system


1. Remove raw water pipe system and attachments in accordance with overview drawing (→ Page 519).
2. Take off O-rings, gasket and sealing rings.
3. Seal all openings with suitable covers.

M020127/02E 05-08 © MTU


Task Descriptions 521

3.14.38 Raw water pump pipe system – Cleaning

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.

Unsuitable cleaning tools.


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

Excessive reaction time of cleaning agents on components.


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

Remove raw water pump pipe system (→ Page 520).

Cleaning raw water pump pipe system


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow out all parts using compressed air.

M020127/02E 05-08 © MTU


522 Task Descriptions

3.14.39 Raw water pump pipe system – Check

Spare parts
Designation / Use Part No. Qty.
Elbow
Clamping element half

Clean raw water pump pipe system (→ Page 521).

Item Findings Task

Check connections and annular • Wear • Recondition: with oilstone or


grooves on elbows and connecting • Pitting emery cloth.
lines visually for wear, pitting and • Cavitation • Replace
cavitation. visible

Check thread for freedom of Sluggish Recut threads


movement.

Check sealing surfaces for Uneven • Recondition: with oilstone or


irregularities. emery cloth.
• Replace

M020127/02E 05-08 © MTU


Task Descriptions 523

3.14.40 Raw water pump pipe system – Installation

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.

Check raw water pump pipe system (→ Page 522).

Installing raw water pump pipe system


1. Prior to installation, remove all covers.
2. Coat O-rings with petroleum jelly.
3. Install lines with new O-rings, sealing rings, gasket and mounting parts, without tension, in accordance with
overview drawing (→ Page 519).

M020127/02E 05-08 © MTU


524 Task Descriptions

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence (→ Page 520)
– X X Fill engine coolant system (→Operating Instructions)
– – X Fill with engine oil (→Operating Instructions)
– – X Fill fuel system (→Operating Instructions)
– – X Enable engine start –

M020127/02E 05-08 © MTU


Task Descriptions 525

3.15 Mounting/Support

3.15.1 Engine mount – Overview

1 Engine mount 2 Engine mounting bracket

M020127/02E 05-08 © MTU


526 Task Descriptions

3.15.2 Engine mount – Removal

Preconditions
• Engine is stopped and starting disabled.

Engine can tilt over.


Danger to life!
DANGER • Use appropriate lifting devices and appliances.

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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Close and drain raw water supply. –

– – X Remove raw water supply and return lines from –


engine.
– X X Separate engine from gearbox or shaft –

– X X Attach engine to lifting device. (→ Page 65)

Engine mount – Removal


1. Remove threaded foundation connection (4) on
resilient mount (5) to be removed.
2. Contract resilient mount (5) evenly with blocking
screws (3) until engine mount can be removed.
3. Remove all screws (1) with washers on engine
mounting bracket (2).
4. Remove engine mounting bracket (2).
5. Remove nut (6) from resilient mount (5).
6. Remove resilient mount (5) from engine mounting
bracket (2).

M020127/02E 05-08 © MTU


Task Descriptions 527

3.15.3 Engine mount – Cleaning


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

Remove engine mount (→ Page 526).

Cleaning engine mount


Note: Do not allow rubber mounts to come into contact with oil and fuel.

1. Wipe rubber surfaces with dry cloth only; do not clean with organic detergents.
2. Thoroughly blow all parts clean with compressed air.

M020127/02E 05-08 © MTU


528 Task Descriptions

3.15.4 Engine mount – Check

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

Clean engine mount (→ Page 527).

Checking engine mount

Item Findings Task

Check engine mounting brackets Signs of cracks Replace


with red penetrant dye for cracks.

Check rubber mounts for cracks and • Damage Replace


deformation (visual inspection). • Cracks
• Deformation
visible

Check thread for freedom of Sluggish • Recondition: Recut threads


movement. • Replace

Check bolt-on faces for flatness. Uneven • Recondition: smooth with


oilstone.
• Replace

M020127/02E 05-08 © MTU


Task Descriptions 529

3.15.5 Engine mount – Installation

Special tools
Designation / Use Part No. Qty.
Alignment tool F6782161 1

Material
Designation / Use Part No. Qty.
Engine oil
Loctite 518
Tectyl 472

Engine can tilt over.


Danger to life!
DANGER • Use appropriate lifting devices and appliances.

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

Nitrogen is liquid (at -200°C).


Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Wear protective clothing, gloves, and goggles / safety mask.
• Ventilate working area well.

Check engine mount (→ Page 528).

Overview of resilient mounts


Note: Condition when supplied, preloaded
to 100 ±0.5 mm.

1. Prior to installation, check presettings of resilient


mount. Readjust if necessary.
2. Degrease engine mounting bracket and flanging
face.

a Unloaded 103 mm ±0.5 mm


b Adjusting range 103 mm +8/−5
c Initial dimension for height adjustment 5 mm
d Max. clamp length 37 mm

M020127/02E 05-08 © MTU


530 Task Descriptions

Installing engine mounting bracket with resilient


mount
1. Seal marked area (2) with Loctite.
2. Coat marked area (1) with Tectyl, after installation.

3. Install resilient mount (5) on engine mounting


bracket (2).
4. Screw on nut (6) by hand.
5. Install engine mounting bracket (2) with screws (1)
and washers.
6. Use torque wrench to tighten screws to specified
tightening torque (→ Page 24) .
7. Align base mounts of resilient mount (5) in
longitudinal direction.
8. Lower engine on to foundation.
9. Remove blocking screws (3) and store.
10. Check engine alignment; realign engine if
necessary
11. Screw resilient mount (5) with screws (4) on
to foundation.
12. Tighten nut (6) with torque wrench to specified
tightening torque (→ Page 24) .

M020127/02E 05-08 © MTU


Task Descriptions 531

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Install engine (→ Page 72)

X – – Assemble engine (→ Page 69)


– – X Open raw water supply –

– – X Install raw water supply and return lines of engine. –

– – X Connect engine to gearbox and shaft –



– – X Enable engine start –

M020127/02E 05-08 © MTU


532 Task Descriptions

3.15.6 Engine mounting/support – Overview

1 Engine mounting bracket 3 Screw


2 Screw 4 Washer

M020127/02E 05-08 © MTU


Task Descriptions 533

Resilient engine mount

1 Resilient engine mount

M020127/02E 05-08 © MTU


534 Task Descriptions

3.15.7 Engine mount – Removal

Preconditions
• Engine is stopped and starting disabled.

Engine can tilt over.


Danger to life!
DANGER • Use appropriate lifting devices and appliances.

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

Preparatory steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Close raw water supply line and drain –

– – X Remove raw water supply and return lines from engine –

– X X Disconnect engine from gearbox / shaft. –

– X X Attach engine with lifting device (→ Page 65)

Removing engine mount


1. Remove base screws (5) at resilient element
to be removed (4).
2. Contract resilient element (4) with locking
screws (3) evenly until removal of engine mount is
possible.
3. Remove screws (1) with washer on engine
mounting bracket (6).
4. Remove engine mounting bracket (6) from
crankcase.
5. Unscrew nut (2) from resilient element (4).
6. Remove resilient element (4) from engine
mounting bracket (6).

M020127/02E 05-08 © MTU


Task Descriptions 535

3.15.8 Engine mount – Cleaning


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

Remove engine mount (→ Page 534).

Cleaning engine mount


Note: Do not allow resilient mounts to come into contact with oil and fuel.

1. Wipe rubber surfaces with dry cloth only; do not clean with organic detergents.
2. Thoroughly blow all parts clean with compressed air.

M020127/02E 05-08 © MTU


536 Task Descriptions

3.15.9 Engine mount – Check

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

Clean engine mount (→ Page 535).

Checking engine mount

Item Findings Task

Check engine mounting brackets Signs of cracks Replace


with red penetrant dye for cracks.

Check resilient mounts for cracks • Damage Replace


and deformation (visual inspection). • Cracks
• Deformation
visible

Check thread for freedom of Sluggish • Recondition: Recut threads


movement. • Replace

Check bolt-on faces for flatness. Uneven • Recondition: smooth with


oilstone.
• Replace

M020127/02E 05-08 © MTU


Task Descriptions 537

3.15.10 Engine mount – Installation

Special tools
Designation / Use Part No. Qty.
Alignment tool F6782161 2

Material
Designation / Use Part No. Qty.
Engine oil

Engine can tilt over.


Danger to life!
DANGER • Use appropriate lifting devices and appliances.

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

Nitrogen is liquid (at -200°C).


Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Wear protective clothing, gloves, and goggles / safety mask.
• Ventilate working area well.

Check engine mount (→ Page 536).

Overview of resilient mounts


Note: Resilient mounts are preset and blocked
on delivery.

1. Prior to installation, check presettings of resilient


mount. Readjust if necessary.
2. Degrease engine mounting bracket and flanging
face.

a Unloaded 152 mm
b Initial dimension for height adjustment 5 mm
c Max. clamp length 35 mm

M020127/02E 05-08 © MTU


538 Task Descriptions

Installing engine mounting bracket with resilient


mount
1. Install resilient mount (4) on engine mounting
bracket (6).
2. Screw on nut (2) by hand.
3. Install engine mounting bracket (6) with screws (1)
and washers.
4. Tighten screws (1) with torque wrench to specified
tightening torque (→ Page 24).
5. Align base mounts of resilient mount (4) in
longitudinal direction.
6. Lower engine on to foundation.
7. Remove blocking screws (3) and store.
8. Check engine alignment; realign engine if
necessary
9. Screw resilient mount (4) on to foundation.
10. Tighten nut (2) with torque wrench to prescribed
tightening torque (→ Page 24).

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Install engine (→ Page 72)

X – – Assemble engine (→ Page 69)


– – X Open raw water supply –

– – X Install raw water supply and return lines of engine. –

– – X Connect engine to gearbox and shaft –



– – X Enable engine start. –

M020127/02E 05-08 © MTU


Task Descriptions 539

3.16 Auxiliary Systems/Accessory Equipment

3.16.1 Auxiliary systems / accessory equipment – Overview

1 Connecting cable 3 V-belt B Inlet


2 Bilge pump A Outlet

M020127/02E 05-08 © MTU


540 Task Descriptions

3.16.2 Bilge pump – Overview

1 Bilge pump 3 Nut 5 Threaded adapter


2 Screw 4 Washer 6 Sealing tape

M020127/02E 05-08 © MTU


Task Descriptions 541

Carrier and clamping fixture

1 Carrier 8 Sleeve 15 Screw


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

M020127/02E 05-08 © MTU


542 Task Descriptions

Bilge pump

1 Screw 9 Screw 17 Belt pulley


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

M020127/02E 05-08 © MTU


Task Descriptions 543

3.16.3 Bilge pump – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– X X Disable engine start (→ Page 16)
– X X Remove protective cover
– X X Remove suction and pressure lines –

– X X Mark electrical cable on bilge pump and disconnect –

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

Bilge pump – Removal


1. Remove clamping jig as shown in overview drawing (→ Page 540) .
2. Remove bilge pump and bracket as shown in overview drawing (→ Page 540) .

M020127/02E 05-08 © MTU


544 Task Descriptions

3.16.4 Bilge pump – Disassembly


Spring/circlip/tensioning roller preload.
Risk of injury!
WARNING • Only use specified tool and equipment.

Remove bilge pump (→ Page 543).

Disassembling bilge pump


1. Remove screws and washers for belt pulley (1).
2. Pull belt pulley off shaft.

3. Remove screws (1) for coil (2).


4. Remove coil from adapter.

M020127/02E 05-08 © MTU


Task Descriptions 545

5. Remove screws (1) for cover (2).


6. Remove cover and seal (3) from housing.

7. Carefully pull pump gear wheel (1) off


shaft (arrows).
8. Pull plate off shaft.

9. Remove screw (2) and cam (1).

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546 Task Descriptions

10. Pull rotary seal (1) off shaft (2).

11. Remove screws (1) for adapter (2).


12. Remove adapter.
13. Remove sealing.

14. Press shaft (1) with ball bearing out of housing.


15. Remove washer (2).

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Task Descriptions 547

16. Remove snap ring (1) from shaft.


Note: Exert press-out pressure on ball bearing
inner race.

17. Support ball bearing inner race with sleeve (2).


Using manual press, remove shaft from
bearing (arrow).

M020127/02E 05-08 © MTU


548 Task Descriptions

3.16.5 Bilge pump – Cleaning

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.

Excessive reaction time of cleaning agents on components.


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

Disassemble bilge pump (→ Page 544).

Cleaning bilge pump


1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Thoroughly blow all parts clean with compressed air.

M020127/02E 05-08 © MTU


Task Descriptions 549

3.16.6 Bilge pump – Check

Spare parts
Designation / Use Part No. Qty.
Housing
Cover
Belt pulley
Impeller
Cam
Plate
Coil
V-belt
Adapter

Clean bilge pump (→ Page 548).

Checking bilge pump

Item Findings Task

Check housing and cover for Cavitation visible. Replace


cavitation.

Check belt pulley for wear, • Wear Replace


deformation and damage. • Deformation
• Damage
visible

Check condition of keyway in belt Damage visible Replace


pulley.

Check all attachment and mating Wear • Recondition: with oilstone or


faces. emery cloth
• Replace

Check screws for damage. Damage visible Replace

Check thread for ease of movement. Sluggish • Recondition: Recut threads


• Replace

Use ohmmeter to check coil of Resistance < 10 Ohm Replace


magnetic clutch for continuity.

If re-using, check V-belt for cracks, • Cracks • Clean


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

Replace cover screws, gasket and rotary seal after each disassembly of pump.

Replace ball bearing and V-belt at W6.

M020127/02E 05-08 © MTU


550 Task Descriptions

3.16.7 Bilge pump – Assembly

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

Spring/circlip/tensioning roller preload.


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

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

Check bilge pump (→ Page 549).

Assembling bilge pump


1. Support ball bearing inner race with sleeve (3).
Using manual press, push shaft (1) into ball
bearing (2) (arrow).
2. Insert snap ring in shaft groove, with flat side
facing ball bearing.

M020127/02E 05-08 © MTU


Task Descriptions 551

3. Insert washer (2) in housing.


4. Insert shaft (1) and ball bearing with shaft toothing
facing housing.
Note: Exert insertion pressure only on bearing
outer race.

5. Using manual press, push shaft and press-in


sleeve all the way into housing.

6. Coat sealing (3) with grease and press evenly


into housing (arrow).
7. Install adapter (2) with screws (1) on housing.
8. Tighten screws crosswise.

9. Insert ceramic ring in bore over shaft (2).


10. Coat rotary seal (1) bore with denatured ethanol.
11. Degrease and dry sliding surface on ceramic ring
and opposite surface of rotary seal (1).
12. Slide rotary seal (1) (with slide surface facing
ceramic ring) into position until it touches ceramic
ring.

M020127/02E 05-08 © MTU


552 Task Descriptions

Note: Observe grooved pin fit (arrow).

13. Insert plate (1) in housing.

14. Degrease and dry mating face on cam (1), mating


face (arrow) and threads in housing (2) as well as
screw thread.
15. Coat mating face and thread with sealing agent.

16. Insert cam (1) in housing and tighten with


screw (2).

M020127/02E 05-08 © MTU


Task Descriptions 553

17. Apply thin petroleum jelly film to pump housing


interior.
18. By turning pump gear wheel, press gear wheel in
running direction (arrow) in housing.

19. Install cover (2) and sealing (3) with screws (1) on
housing.
20. Tighten screws crosswise.

21. Attach coil (2) with screws (1) to adapter (arrow).

M020127/02E 05-08 © MTU


554 Task Descriptions

22. Insert key in shaft (2).


23. Put belt pulley (1) on to shaft.

24. Insert and tighten screw and washer for belt


pulley (arrow).

M020127/02E 05-08 © MTU


Task Descriptions 555

3.16.8 Bilge pump – Installation

Special tools
Designation / Use Part No. Qty.
Alignment tool F6784786 1
Preloading force measuring device Y20097429 1

Material
Designation / Use Part No. Qty.
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.

Assemble bilge pump (→ Page 550).

Bilge pump – Installation


1. Install clamping jig (3), bilge pump (2) and bracket
as shown in overview drawing (→ Page 540).
2. Mount V-belt (1) on belt pulley.
3. Set parallelism of both belt pulleys with alignment
tool.

M020127/02E 05-08 © MTU


556 Task Descriptions

Adjsuting V-belt tension


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

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


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

Settings

New V-belt 450 N ±50 N

Run V-belt 400 N ±50 N

M020127/02E 05-08 © MTU


Task Descriptions 557

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Install engine (→ Page 72)


– X X Assemble in reverse sequence to disassembly. (→ Page 543)
– X X Connect electrical cable to bilge pump. –

– – X Install suction and pressure lines. –

– – X Enable engine start. –

M020127/02E 05-08 © MTU


558 Task Descriptions

3.17 Monitoring, Control and Regulation Equipment

3.17.1 Sensors, actuators and injectors – Overview

No. Designation For monitoring

1 B9 Charge air temperature

2 B10 Charge air pressure

3 B7 Lube oil temperature

4 B3 Intake air temperature

M020127/02E 05-08 © MTU


Task Descriptions 559

Free end side V 2000CR

No. Designation For monitoring

1 B34 Fuel line pressure after filter

2 B5.3 Lube oil pressure before filter

3 B5.2 Lube oil pressure

4 B5 Lube oil pressure

5 F33 Coolant pressure

6 B21 Raw water pressure

7 B16 Coolant pressure

8 B6.2 Coolant temperature

9 B6 Coolant temperature

M020127/02E 05-08 © MTU


560 Task Descriptions

Driving end side V 2000CR

No. Designation For monitoring

1 B4.22 Exhaust gas temperature

2 B1 Camshaft speed

M020127/02E 05-08 © MTU


Task Descriptions 561

Right engine side V 2000CR

No. Designation For monitoring

1 B44 Turbocharger speed

2–6 Y39.x Injector

7 B33 Fuel temperature

8 B48 Fuel pressure in the rail

9 M8 HP pump

10 B13.2 Crankshaft speed

11 B13 Crankshaft speed

12 F46 Leak-off fuel level

M020127/02E 05-08 © MTU


562 Task Descriptions

Left engine side V 2000CR

No. Designation For monitoring

1–5 Y39.x Injector

6 B4.21 Exhaust gas temperature A

7 Y27 Exhaust gas temperature B

System sensors
The sensors are mounted on the engine exterior.

Designation For monitoring

B19 Starting-air pressure

B70 Water level in fuel prefilter

B41 Exhaust back pressure

S37 Start interlock, switch status

M020127/02E 05-08 © MTU


Task Descriptions 563

3.17.2 Sensors, actuators and injectors – Removal

Preconditions
• Engine is stopped and starting disabled.

Fuels are combustible.


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

Coolant is hot and under pressure.


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

Preparatory steps

A distinction must be made as to whether


1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (→ Page 65)

X – – Disassemble engine (→ Page 66)


– – X Disable engine start (→ Page 16)
– – X Drain engine coolant (only when removing coolant (→Operating Instructions)
sensors)

M020127/02E 05-08 © MTU


564 Task Descriptions

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


B33)
1. Always note:
• The sensors are identical with regard to
design and electrical function. Removal is
also identical.
• Arrangement and position of sensors
(→ Page 558).
2. Observe the following prior to removal:

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

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

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

3. Release bayonet lock (1) and remove connector


(2).
4. Remove sensor via nut (3).

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


1. Always note:
• The sensors are identical with regard to
design and electrical function. Removal is
also identical.
• Arrangement and position of sensors
(→ Page 558).
2. Release bayonet lock (1) and remove connector
(2).
3. Remove union nut (3) from temperature sensor.
4. Remove temperature sensor from union (4).

M020127/02E 05-08 © MTU


Task Descriptions 565

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


1. Always note:
• The sensors are identical with regard to
design and electrical function. Removal is
also identical.
• Arrangement and position of sensors
(→ Page 558).
• During removal of sensor B5 (oil pressure),
small amounts of engine oil may emerge. Catch
engine oil in a suitable container.
2. Release bayonet lock (1) and remove connector
(2).
3. Remove sensor via nut (3).

Removing pressure sensors (B34, B48)


1. Always note:
• Arrangement and position of sensor
(→ Page 558).
• During removal of sensors, small amounts of
fuel may emerge. Catch fuel in a suitable
container.
2. Release bayonet lock (1) and remove connector
(2).
3. Remove sensor via nut (3).

Removing speed sensors (B1, B13)


1. Always note:
• The sensors are identical with regard to
design and electrical function. Removal is
also identical.
• Arrangement and position of sensors
(→ Page 558).
2. Release bayonet lock (1) of speed sensor (2) and
remove connector (3) from engine wiring system.
3. Remove screw (4).
4. Remove speed sensor (2).

M020127/02E 05-08 © MTU


566 Task Descriptions

Speed sensors (B44.1, B44.2)


1. Always note:
• The sensors are identical with regard to
design and electrical function. Removal is
also identical.
• Arrangement and position of sensors
(→ Page 558).
2. Release bayonet lock of speed sensor and remove
connector from engine wiring system.
3. Remove speed sensor from turbocharger.

Level probe (F33)


1. Always note:
• Arrangement and position of sensors
(→ Page 558).
2. Release bayonet lock (2) and remove connector
(1).
3. Remove sensor (3) via nut.

Level probe (F46)


1. Always note:
• Arrangement and position of sensors
(→ Page 558).
2. Release bayonet lock and remove from connector.
3. Remove sensor via nut (1).

M020127/02E 05-08 © MTU


Task Descriptions 567

3.17.3 Sensors, actuators and injectors – Check

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

Remove sensors, actuators and injectors (→ Page 563).

Sensors, actuators and injectors – Check


1. Always note:
• The engine governor identifies defective electrical assemblies, cable breaks, short circuits or deviating
sensor values.
2. Carry out the following checks:

Item Findings Measure

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.

Check sensors, actuators and Damaged Replace


plug-in connections for mechanical
damage.

Check sensors, actuators Contamination visible. Clean affected assembly with


and plug-in connections for isopropyl alcohol.
contamination (e.g. oil sludge).

M020127/02E 05-08 © MTU


568 Task Descriptions

3.17.4 Sensors, actuators and injectors – Installation

Material
Designation / Use Part No. Qty.
Petroleum jelly, white

Spare parts
Designation / Use Part No. Qty.
O-ring
Sealing ring
Adjusting shim

Check sensors, actuators and injectors (→ Page 567).

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


1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
• Arrangement and position of sensors
(→ Page 558).
2. Coat O-ring of sensor with petroleum jelly.
3. Insert sensor in bore by hand.
4. Tighten nut (3) with torque wrench to specified
tightening torque (→ Page 24) .
5. Fit connector (2) and tighten bayonet lock (1).

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


1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
• Arrangement and position of sensors
(→ Page 558).
2. Coat O-ring of sensor with petroleum jelly.
3. Insert sensor in bore by hand.
4. Tighten nut (3) with torque wrench to specified
tightening torque (→ Page 24) .
5. Fit connector (2) and tighten bayonet lock (1).

M020127/02E 05-08 © MTU


Task Descriptions 569

Installing pressure sensors (B34, B48)


1. Always note:
• Arrangement and position of sensor
(→ Page 558).
2. Coat O-ring of sensor with petroleum jelly.
3. Insert sensor in bore by hand.
4. Tighten nut (3) with torque wrench to specified
tightening torque (→ Page 24) .
5. Fit connector (2) and tighten bayonet lock (1).

Installing speed sensors (B1; B13)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
• Arrangement and position of sensors
(→ Page 558).
2. Coat O-ring of sensor with petroleum jelly.
3. Fit sensor in bore and press in.
4. Tighten sensor (2) with screw (4).
5. Check clearance dimension “A”, see table below.

"A" (clearance between sensor and graduated disc)

Speed sensor B1 0.1 mm to 1.6 mm

Speed sensor B13 0.45 mm to 1.45 mm

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


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

M020127/02E 05-08 © MTU


570 Task Descriptions

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


1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
• Arrangement and position of sensors
(→ Page 558).
2. Insert temperature sensor in union (2).
3. Screw on union nut (1) for temperature sensor.

Speed sensors (B44.1, B44.2)


1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
• Arrangement and position of sensors
(→ Page 558).
2. Insert speed sensor on turbocharger in bore
and press in.

Installing level probe (F33)


1. Always note:
• Arrangement and position of sensors
(→ Page 558).
2. Coat O-ring with petroleum jelly.
3. Insert sensor in bore by hand.
4. Tighten sensor nut (3) with torque wrench to
specified tightening torque (→ Page 24) .
5. Fit connector (1) and tighten bayonet lock (2).

M020127/02E 05-08 © MTU


Task Descriptions 571

Installing level probe (F46)


1. Always note:
• Arrangement and position of sensors
(→ Page 558).
2. Coat O-ring with petroleum jelly.
3. Insert sensor in bore by hand.
4. Tighten nut (1) with torque wrench to specified
tightening torque (→ Page 24) .
5. Fit connector and tighten bayonet lock.

Final steps

A distinction must be made as to whether


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

1 2 3 Operations See

X – – Assemble engine (→ Page 69)

X – – Engine installation (→ Page 72)


– – X Fill up with engine coolant (→Operating Instructions)
– – X Check secure and exact fit of all plug-in connections –

– – X Enable engine start –

M020127/02E 05-08 © MTU


572 Task Descriptions

M020127/02E 05-08 © MTU


Special Tools 573

4 Special Tools

4.1 Standard tools – Overview

Order no. Designation Quan-


Use tity

8205891159/00 General tool kit 1

M020127/02E 05-08 © MTU


574 Special Tools

4.2 Special tools – Overview

Part No. Designation / Use Qty.

Bore gauge

Dial gauge

Micrometer or adjusting ring

F6783773 Removal tool for liner 1

F6783388 Installation tool for cylinder 1


liner

M020127/02E 05-08 © MTU


Special Tools 575

Part No. Designation / Use Qty.

F6555715 Safety rail 2

Red dye penetrant for surface


crack test procedure

VM59210 Crankcase rotation device 1

M020127/02E 05-08 © MTU


576 Special Tools

Part No. Designation / Use Qty.

F6783180 Support 1

F6554710 Frame 1

M020127/02E 05-08 © MTU


Special Tools 577

Part No. Designation / Use Qty.

F6784104 Lowering device 3

Screwdriver (Torx 30)

Bore gauge

Micrometer

000580016002 Eyebolt 4

B80525907 Load frame 2

F6555162 Locating pin 2

M020127/02E 05-08 © MTU


578 Special Tools

Part No. Designation / Use Qty.

F6782161 Alignment tool 2

Mandrel

F30379303 Extraction tool 1

F6782568 Installation jig 1

M020127/02E 05-08 © MTU


Special Tools 579

Part No. Designation / Use Qty.

B80141628 Nut 1

F6555797 Feed shaft 1

Adjusting ring

F6558527 Guide pin 4

M020127/02E 05-08 © MTU


580 Special Tools

Part No. Designation / Use Qty.

F6557158 Axial fixation camshaft 1

F6783790 Drive-out mandrel for bearings 1

F6783789 Drive-out mandrel for shaft 1

M020127/02E 05-08 © MTU


Special Tools 581

Part No. Designation / Use Qty.

F6783001 Alignment tool 1

F30450344 Drive-in tool shaft seal 1

F30450345 Drive-in tool shaft seal 1

F6784844 Extraction device 1

5555890063/00 SKF hand pump 1

B80144155 Hydraulic nut 1

M020127/02E 05-08 © MTU


582 Special Tools

Part No. Designation / Use Qty.

F6783214 Installation jig 1

F6783178 Installation jig 1

Magnifying glass

M020127/02E 05-08 © MTU


Special Tools 583

Part No. Designation / Use Qty.

F30377999 Extractor 1

Hand press

F30450850 Ejection mandrel 1

M020127/02E 05-08 © MTU


584 Special Tools

Part No. Designation / Use Qty.

F30450851 Ejection mandrel 1

F30275611 Support 1

M020127/02E 05-08 © MTU


Special Tools 585

Part No. Designation / Use Qty.

F6555514 Support 1

Bottle brush

Master weights

Y20097353 Endoscope

Taper gauge 1:50

Microdur testing device

Depth gauge

Measuring stand

M020127/02E 05-08 © MTU


586 Special Tools

Part No. Designation / Use Qty.

F6783027 Assembly jig 1

F6783312 Insertion shoe set 1

M020127/02E 05-08 © MTU


Special Tools 587

Part No. Designation / Use Qty.

F6552506 Alignment tool crankshaft 1


gear, driving end

Y4341111 Spacing jig crankshaft gear, 1


driving end

F6554711 Assembly jig crankshaft gear, 1


free end

Y4341107 Spacing jig crankshaft gear, 1


free end

M020127/02E 05-08 © MTU


588 Special Tools

Part No. Designation / Use Qty.

Y20010128 Feeler gauge 1

Magnetic holder

T80091511 Carrying bracket 1

F0140565 Installation/removal device 1

5505890163/00 Hydraulic unit 1

M020127/02E 05-08 © MTU


Special Tools 589

Part No. Designation / Use Qty.

F6780523 Protective sleeve 1

Outside micrometer

F0140560 Installation/removal tool 1

M020127/02E 05-08 © MTU


590 Special Tools

Part No. Designation / Use Qty.

T80091619 Lifting gear 1

F30379133 Puller 1

M020127/02E 05-08 © MTU


Special Tools 591

Part No. Designation / Use Qty.

F6554708 Assembly jig 1

T80090974 Carrying bracket for unit-pump 1


system

M020127/02E 05-08 © MTU


592 Special Tools

Part No. Designation / Use Qty.

T80091511 Carrying bracket for CR

Decarbonizer

Synthetic rotary brush

Y4345226 Ring gauge 1

F6783914 Barring tool 1

Lowering device

F6783791 Assembly jig 1

M020127/02E 05-08 © MTU


Special Tools 593

Part No. Designation / Use Qty.

F30379877 Piston-ring pliers 1

F6784287 Assembly sleeve 1

M020127/02E 05-08 © MTU


594 Special Tools

Part No. Designation / Use Qty.

F6557995 Assembly jig 1

Y4341492 Testing device 1

M020127/02E 05-08 © MTU


Special Tools 595

Part No. Designation / Use Qty.

Y4341915 Test mandrel 1

Y4341916 Test mandrel 1

M020127/02E 05-08 © MTU


596 Special Tools

Part No. Designation / Use Qty.

F6780557 Assembly jig hydraulic press 1

F6781639 Press-in device 1

F6347932 Retainer small boss 1

F6376294 Fit small boss 1

M020127/02E 05-08 © MTU


Special Tools 597

Part No. Designation / Use Qty.

F6554737 Retainer large boss 1

F30377859 Shrinking tool 1

Torque wrench

Cleaning agent

Y20098136 Limit plug gauge 1

Y4346861 Gauge for exhaust valve seat 1

Y4346862 Gauge for inlet valve seat 1

M020127/02E 05-08 © MTU


598 Special Tools

Part No. Designation / Use Qty.

Y4341042 Pressure testing device 1

F30907150 Socket 1

4425890031/00 Valve lifter 1

F30450454 Removal tool for valve guide 1

F30377657 Socket for BR 2000 unit-pump 1


system

M020127/02E 05-08 © MTU


Special Tools 599

Part No. Designation / Use Qty.

F30450351 Socket for BR 2000 CR 1

F6554686 Retaining device 1

M020127/02E 05-08 © MTU


600 Special Tools

Part No. Designation / Use Qty.

8205892961/00 Magnetic pickup 1

F30450845 Pliers for valve stem seal 1

M020127/02E 05-08 © MTU


Special Tools 601

Part No. Designation / Use Qty.

F6783844 Assembly tool kit 1

F6784110 Tool kit 1

M020127/02E 05-08 © MTU


602 Special Tools

Part No. Designation / Use Qty.

F30543151 Reamer for valve guide 1


Ø8.8 mm

F30543150 Reamer for valve guide 1


Ø9.0 mm

F70007011 Floating tool holder MK2 1

M020127/02E 05-08 © MTU


Special Tools 603

Part No. Designation / Use Qty.

F70000966 Centering tip MK3 1

F70000417 Extension sleeve MK3/MK3 1

F70001021 Taper reduction sleeve 1


MK4/MK2

F70000146 Taper reduction sleeve 1


MK4/MK3

F70000073 Taper reduction sleeve 1


MK3/MK2

M020127/02E 05-08 © MTU


604 Special Tools

Part No. Designation / Use Qty.

F70000199 Drift key MK1/MK2 1

F70000200 Drift key MK3 1

M020127/02E 05-08 © MTU


Special Tools 605

Part No. Designation / Use Qty.

F70000637 Drift key MK4 1

0005891853/00 Reamer for valve guide in 1


cylinder head

M020127/02E 05-08 © MTU


606 Special Tools

Part No. Designation / Use Qty.

F30378880 Punch for inlet valve seat 1

F30378881 Punch for exhaust valve seat 1

M020127/02E 05-08 © MTU


Special Tools 607

Part No. Designation / Use Qty.

F30378896 Valve seat countersink for 1


exhaust valve

F30450549 Valve seat countersink for 1


inlet valve

0005892816/01 Handle for turning handle 1

8205890451/00 Turning handle 1

M020127/02E 05-08 © MTU


608 Special Tools

Part No. Designation / Use Qty.

F30450454 Removal tool 1

Y4341935 Testing device 1

M020127/02E 05-08 © MTU


Special Tools 609

Part No. Designation / Use Qty.

F6784237 Mounting plate for valve 1


guides

Y4346861 Gauge for exhaust valve 1

Y4346862 Gauge for inlet valve 1

F30377883 Drift 1

M020127/02E 05-08 © MTU


610 Special Tools

Part No. Designation / Use Qty.

F30377930 Expander 1

3435890040/00 Dial-gauge holder 1

Y20044010 Rotation angle measuring 1


device

F30378878 Drift 1

M020127/02E 05-08 © MTU


Special Tools 611

Part No. Designation / Use Qty.

F6557929 Barring tool 1

F6557932 Pointer 1

M020127/02E 05-08 © MTU


612 Special Tools

Part No. Designation / Use Qty.

Y4345595 Graduated disk for 8V 1

Y4345536 Graduated disk for 10V 1

M020127/02E 05-08 © MTU


Special Tools 613

Part No. Designation / Use Qty.

Y4345886 Graduated disk for 12V 1

Y4345887 Graduated disk for 16V 1

M020127/02E 05-08 © MTU


614 Special Tools

Part No. Designation / Use Qty.

5415890121/00 Bridge meter 1

0015890321/00 Measuring stand 1

0015895321/00 Dial gauge 1

M020127/02E 05-08 © MTU


Special Tools 615

Part No. Designation / Use Qty.

Y4345888 Measuring device 1

Hardness test unit (e.g.


Microdur test unit)

F6782990 Installation/removal device 1

M020127/02E 05-08 © MTU


616 Special Tools

Part No. Designation / Use Qty.

F6782991 Support guide 1

F6782980 Locating pin 1

M020127/02E 05-08 © MTU


Special Tools 617

Part No. Designation / Use Qty.

F30378037 Pliers 1

Depth gauge

F6557932 Pointer for barring tool 1

M020127/02E 05-08 © MTU


618 Special Tools

Part No. Designation / Use Qty.

Y4345595 Graduated plate for 8V 1

Y4345536 Graduated plate for 10V 1

M020127/02E 05-08 © MTU


Special Tools 619

Part No. Designation / Use Qty.

Y4345886 Graduated plate for 12V 1

Y4345887 Graduated plate for 16V 1

M020127/02E 05-08 © MTU


620 Special Tools

Part No. Designation / Use Qty.

F6783025 Centering device 1

F6784160 Extraction tool 1

0005896803/00 Socket wrench 1

M020127/02E 05-08 © MTU


Special Tools 621

Part No. Designation / Use Qty.

F30450342 Assembly sleeve 1

T80091650 Lifting device 1

M020127/02E 05-08 © MTU


622 Special Tools

Part No. Designation / Use Qty.

T80091665 Support bracket 1

T80091665 Carrying bracket 1

M020127/02E 05-08 © MTU


Special Tools 623

Part No. Designation / Use Qty.

F6783244 Alignment tool 1

F30450460 Guide pin 2

M020127/02E 05-08 © MTU


624 Special Tools

Part No. Designation / Use Qty.

F30379104 Filter wrench 1

T80091621 Lifting gear 1

F0099975 Installation/removal tool 1

M020127/02E 05-08 © MTU


Special Tools 625

Part No. Designation / Use Qty.

F6783898 Extracting fixture 1

F6783845 Assembly jig 1

Snap ring pliers

M020127/02E 05-08 © MTU


626 Special Tools

Part No. Designation / Use Qty.

5115890021/00 Feeler gauge 1

F30372701 Insertion tool 1

M020127/02E 05-08 © MTU


Special Tools 627

Part No. Designation / Use Qty.

F6783880 Alignment tool 1

Measuring device for axial


play

Oilstone

000580008001 Eyebolt 2

Inspection lamp

T80091769 Hook 1

M020127/02E 05-08 © MTU


628 Special Tools

Part No. Designation / Use Qty.

T80090943 Hook-ended chain sling 1

T80091769 Hook-ended chain sling 1

M020127/02E 05-08 © MTU


Special Tools 629

Part No. Designation / Use Qty.

T80091312 Hook 1

F6784266 Retaining plate 1

F6784265 Assembly sleeve 1

F6784264 Assembly sleeve 1

Flushing device

T80091765 Carrying bracket 1

M020127/02E 05-08 © MTU


630 Special Tools

Part No. Designation / Use Qty.

F0140588 Tool kit 1

F6781539 Hydraulic spindle 1

F6780562 Extracting fixture 1

F30275611 Support 1

Screw tap M20 x 1.5

Cleaning brush

High-pressure cleaner

Soft cleaning brush

M020127/02E 05-08 © MTU


Special Tools 631

Part No. Designation / Use Qty.

5362030462 Threaded pin 2

F30378672 Drive-in tool 1

M020127/02E 05-08 © MTU


632 Special Tools

Part No. Designation / Use Qty.

F30450050 Drive-in tool 1

Precision bore gauge

F0140587 Tool kit 1

M020127/02E 05-08 © MTU


Special Tools 633

Part No. Designation / Use Qty.

F6781600 Extracting fixture 1

Screw tap M18 x 1.5

M020127/02E 05-08 © MTU


634 Special Tools

Part No. Designation / Use Qty.

F6784786 Alignment tool 1

Y20097429 Preloading force measuring 1


device

M020127/02E 05-08 © MTU


Special Tools 635

4.3 General workshop equipment – Overview

Order no. Designation Quan-


Use tity

F30004455 Open-end wrench 1

F30006068 Double open-end 1


wrench

M020127/02E 05-08 © MTU


636 Special Tools

Order no. Designation Quan-


Use tity

F30025896 Open end wrench 1


bit

F30028338 Open end wrench 1


bit

M020127/02E 05-08 © MTU


Special Tools 637

Order no. Designation Quan-


Use tity

F30029815 Open end wrench 1


bit

F30029816 Open end wrench 1


bit

M020127/02E 05-08 © MTU


638 Special Tools

Order no. Designation Quan-


Use tity

F30047446 Torque wrench 1

F30450902 Ratchet bit 1

M020127/02E 05-08 © MTU


Special Tools 639

Order no. Designation Quan-


Use tity

F30501631 Starter wrench 1

Y20097353 Endoscope 1

M020127/02E 05-08 © MTU


640 Special Tools

Order no. Designation Quan-


Use tity

5505890921/00 Compression 1
pressure recorder

5505890921/06 Diagram sheets 1

M020127/02E 05-08 © MTU


Special Tools 641

4.4 Measuring tools – General overview

Order no. Designation Quan-


Use tity

Y20000088 Outside micrometer 1

Y20000085 Outside micrometer 1

M020127/02E 05-08 © MTU


642 Special Tools

Order no. Designation Quan-


Use tity

Y20000665 Adjusting ring 1


(9 mm)

Y20000918 Depth gauge 1

M020127/02E 05-08 © MTU


Special Tools 643

Order no. Designation Quan-


Use tity

Y20001743 Caliper gauge 1

Y20016482 Bore gauge 1

M020127/02E 05-08 © MTU


644 Special Tools

Order no. Designation Quan-


Use tity

Y20091481 Bore gauge 1

M020127/02E 05-08 © MTU


Special Tools 645

Order no. Designation Quan-


Use tity

Y20091482 Bore gauge 1

Y20091483 Bore gauge 1

M020127/02E 05-08 © MTU


646 Special Tools

M020127/02E 05-08 © MTU


Annex 647

5 Annex

5.1 Manufacturer’s documentation


See manufacturer’s documentation.

M020127/02E 05-08 © MTU


648 Annex

5.2 MTU contact/service partner


You can find the MTU contacts/service partners for your region under www.mtu-online.com
on the left-hand navigation bar under worldwide.

M020127/02E 05-08 © MTU


Annex 649

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

M020127/02E 05-08 © MTU


650 Annex

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