Tolerances and Wear Limits TE 4

Technical Publication
Diesel Engine
V 396 TE.4
V 396 TC.4
Tolerances and Wear

Limits Lits
M070026/00E
Edition 95--04
Version
556.943--01, 558.943--01, 559.943--01
DaimlerChrysler Off-Highway
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Contents Page 1
Contents
General Information
01 Crankcase
02 Gear train
03 Running gear
05 Cylinder head
06 Valve gear
10 Combustion air / Exhaust gas system)
11 Fuel injetion equipment group
13 Coolant pump
15 Oil pump
16 Oil system
20 Hydraulic fan drive
88 Accessories (mechanical)
70026/0 95-04
Page 2 Contents
General Information
The tolerances and wear limits are intended as a guide for the examination of engine components during inspection and
repair.
Explanation of terms for dimensions of new components

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

Wear limit The limit dimensions specified do not represent the absolute maximum values permissible for
satisfactory engine operation.
They indicate that the next basic overhaul can be reached safely.
If a limit value is exceeded, the component must be replaced.
Reconditioning If values exceed or drop below limit values, the components must be reconditioned in
instructions accordance with the relevant reconditioning instructions or replaced.
Deviations from roundness, cylindricity, parallelism and coaxiality must be within specified limit values, unless exceptions are
specifically indicated.
All dimensions are given in "mm", unless alternative units of measurement are specifically indicated.
70026/0 95-04
Crankcase Group 01
Page 1
Cylinder Liner
No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic size lower upper min. max. min. max.
1 Crankcase bore 0 189.000 H6 0 + 0.029 0.025 0.024 clearance
- upper fit 1 189.000 H6 mean
H6
2 189.000 0.120
3 189.300 H6 max. 0.150
4 189.300 H6
5 189.600 H6
Cylinder liner 0-0 189.000 k5 + 0.004 + 0.024
- upper fit 0-1 189.000 k5
0-2 189.000 k5
1-1 189.300 k5
1-2 189.300 k5
2-2 189.600 k5
2 Crankcase bore 0 185.000 H6 0 + 0.029 0.040 0.099 clearance
H6
- lower fit 1 185.000 max. 0.150
H6
2 185.000
H6
3 185.300
H6
4 185.300
5 185.600 H6
Cylinder liner 0-0 185.000 - 0.070 - 0.040
- lower fit 0-1 185.000
0-2 185.000
1-1 185.300
1-2 185.300
2-2 185.600
Reconditioning instructions:
Ref. 1 and 2: If cavitation at the upper and lower fits cannot be removed by reconditioning, bore out the crankcase bore to the
next repair stage or replace the liners.
70026/0 92-10
Group 01 Crankcase
Page 2
Cylinder Liner
1 Liner bore 165.000 + 0.025 + 0.060
2 Liner bore min.
165.100
max.
165.130
3 Liner bore max.
165.150
Ref. 1: Cylinder liner installed, permissible ovality max. 0.100 with tightened main bearing caps.
Check in engine longitudinal and transverse directions; enter results in assembly / data sheet.
Ref. 2: With a min. operational limit of 165.100, the cylinder linder can be rehoned to a max. of 165.130.
Ref. 3: Absolute operational limit of cylinder liner.
70026/0 90-08
Crankcase Group 01
Page 3
Cylinder Liner Seat
a Crankcase see Page 1 Deviation
max. 0.080
b Crankcase see Page 1 Deviation
mean 0.120
max. 0.150
c Housing 0 -
- Indent OD 1÷5 203.500 0 + 0.200
d Housing 0 -
- Deep indent 1 0.200 0 + 0.020
2 0.400 0 + 0.020
3 0.200 0 + 0.020
4 0.400 0 + 0.020
5 0.400 0 + 0.020
e Cylinder liner 0-0 8.060 - 0.020 0
- Collar thickness 0-1 8.260 - 0.020 0
0-2 8.460 - 0.020 0
1-1 8.260 - 0.020 0
1-2 8.460 - 0.020 0
2-2 8.460 - 0.020 0
Note: Ref. a and b: Measured in crankcase longitudinal (A) and transverse (B) directions
Assignment of crankcase stage to cylinder liner stage and support plate

Crankcase Cylinder liner to be installed Collar projection (f) Support plate (g) to be installed
Stage 0 Stage 0-0 8.040 ÷ 8.060 7.970 - 0.020
1 0-1
2 0-2 8.020 ÷ 8.040 7.950 - 0.020
3 1-1 8.040 ÷ 8.060 7.970 - 0.020
4 1-2
5 2-2
70026/0 92-10
Group 01 Crankcase
Page 4
Cylinder Liner Seat
1 Identification on 1 + 0.200 punch -in with punch numerals
crankcase at 2 + 0.400 punch-in with punch numerals
3 + 0.200 / dia. + 0.300 punch-in with punch numerals
2 Edge slightly rounded
3 Identification of 0-0 No groove
cylinder liners 0-1 One groove
0-2 One groove
1-1 One groove
1-2 One groove
2-2 One groove
70026/0 90-08
Crankcase Group 01
Page 5
Crankcase Main Bearing Bores
1 Screw projection 169.000 - 0.500 + 0.500 max.
173.000
Note:
Main bearing caps tightened according to specification.
Measure main bearing bores in direction a - b1 and a - b2.
Ovality results from the difference between the inner dia. b1 and a, or b2 and a.
A When replacing bearing cap studs
− measure the thread flank dia. in the crankcase
− use studs with a dimension * .
allowing flank clearance of 0 - 0.030 mm.
* The dimension is shown on the stud’s head as a code number
Example: Dimension 22.01 mm = Code No. 1
Reconditioning instruction:
Ref. 1: Operational limit is exceeded: replace screws
70026/0 90-08
Group 01 Crankcase
Page 6
70026/0 90-08
Gear Train Group 02
Page 1
Idler Gear, Coolant Pump Drive
1 Housing bore 72.000 - 0.030 - 0.010 0.003 0.030
Bearing OD 72.000 - 0.013 0
2 Bearing bore 30.000 - 0.010 0 0.015 0.034
Shaft OD 30.000 n5 + 0.015 + 0.024
3 Cover bore 72.000 - 0.030 - 0.010 0.003 0.030
Bearing OD 72.000 - 0.013 0
4 Gear bore 46.000 H6 0 + 0.016 0.021 0.011
Shaft OD 46.000 j6 - 0.005 + 0.011
5 Axial clearance 0.300 0.840
70026/0 90-08
Group 02 Gear Train
Page 2
Idler Gear, Oil Pump Drive 8, 12 V 396
1 Gear bore 72.000 P6 - 0.045 - 0.026 0.013 0.045
Bearing OD 72.000 - 0.013 0
2 Bearing bore 35.000 - 0.012 0 0.005 0.018
Pin OD 35.000 j5 - 0.005 + 0.006
3 Housing bore 30.000 H7 0 + 0.021 0.013 0.021
Pin OD 30.000 m6 + 0.008 + 0.021
4 Axial clearance 0 0.030
70026/0 90-08
Gear Train Group 02
Page 3
Idler Gear, Oil Pump Drive 16 V 396
1 Gear bore 85.000 P6 - 0.052 - 0.030 0.015 0.052
Bearing OD 85.000 - 0.015 0
2 Bearing bore 45.000 - 0.012 0 0.005 0.018
Pin OD 45.000 j5 + 0.005 + 0.006
3 Housing bore 45.000 H7 0 + 0.025 0.030 0.006
Pin OD 45.000 j5 - 0.005 + 0.006
70026/0 90-08
Group 02 Gear Train
Page 4
Idler Gear, Generator Drive
1 Housing bore 90.000 M6 - 0.028 - 0.006 0.009 0.028
Bearing OD 90.000 - 0.015 0
2 Bearing bore 40.000 - 0.012 0 0.017 0.040
Shaft OD 40.000 n5 + 0.017 + 0.028
3 Cover bore 100.000 M6 - 0.028 - 0.006 0.009 0.028
Bearing OD 100.000 - 0.015 0
4 Bearing bore 45.000 - 0.012 0 0.017 0.040
Shaft OD 45.000 n5 + 0.017 + 0.028
H6
5 Gear bore 68.000 0 + 0.019 0.026 0.012
Shaft OD 68.000 j6 - 0.007 + 0.012
70026/0 90-08
Running Gear Group 03
Page 1
Crankshaft Bearings, Main Journals
1 Housing bore ***** 0* 150.000 H6 0 + 0.025
1** 150.500 H6
2*** 151.000 H6
2 Main bearing bore 0-0 141.107 0 + 0.054 0.121 0.200
****** 0-1**** 140.857
(bearing shells 0-2 140.607
installed) 0-3 140.357
0-4 140.107
1-0 141.107
1-1**** 140.857
1-2 140.607
1-3 140.357
1-4 140.107
2-0 141.107
2-1 140.857
2-2 140.607
2-3 140.357
2-4 140.107
Main bearing 0 141.000 g6 - 0.039 - 0.014
journal - dia. I**** 140.750 g6
II 140.500 g6
III 140.250 g6
IV 140.000 g6
Ref. 1: Heavy wear (cold shots); recondition crankcase bore and install new bearing shells (introduce next repair stage)
Ref. 2: Ovality exceeds 0.100, clearance exceeds 0.230: replace bearing shells (introduce repair stage)
Note:
Ref. 1 and 2: see Group 03 Page 2
70026/0 95-04
Group 03 Running Gear
Page 2
Note:
Ref. 1 and 2: Assignment of main bearing journal stage to bearing shell stage
Main bearing journal Bearing shells to be installed
Stage 0 Stage 0-0 1-0 2-0
I 0-1 1-1 2-1
II 0-2 1-2 2-2
III 0-3 1-3 2-3
IV 0-4 1-4 2-4
* applicable for stages 0 - 0 to 0 - 4

** applicable for stages 1 - 0 to 1 - 4
*** applicable for stages 2 - 0 to 2 - 4
**** also permissible for new engines
***** Measuring instructions, see Group 01, Page 5
****** Measuring instructions, see Group 03, Page 9
70026/0 95-04
Gear Train Group 03
Page 3
1 Clearance between counterweight and crankcase, at least 2.100
2 Housing bore 8.000 H7 0 + 0.015 0.014 0.010
Pin OD 8.000 k7 + 0.001 + 0.010
3 Main bearing 8V: with crankshaft supported on main journals II and IV max. 0.030
journal 12V: with crankshaft supported on main journals II and VI
16V: with crankshaft supported on main journals II and VIII
Note:
Dynamic balancing of the crankshaft:
- permissible residual imbalance at the support journals 300 cmg each
- crankshaft must only be balanced when new counterweights habe been installed
For dynamic balancing, support the crankshaft as follows:

- 8V main journals II and IV
- 12V main journals II and VI
- 16V main journals II and VIII
70026/0 90-08
Page 4
Crankshaft Bearings, Axial Bearing
1 Housing bore 260.000 J6 - 0.007 + 0.025 0.060 0.007
Bearing OD 260.000 - 0.035 0
2 Crankshaft 0 8.800 - 0.020 + 0.020
Collar width I* 8.500
II 8.200
III 7.900
Axial bearing width 0 41.500 - 0.050 0
I* 41.200
II 40.900
III 40.600
Note:
* also permissible for new engines
X Mark of axial bearing width without groove = Stage 0
with 1 groove = Stage I
with 2 grooves = Stage II
with 3 grooves = Stage III
XX Basic size of crankshaft collar (2) punched in here.
Ref. 2: Dimensions 2.920 -0.020. 120.500 -0.050 and 0.500+0.300x45° establish.
70026/0 92-10
Gear Train Group 03
Page 5
Crankshaft Axial Clearance - for engines with F56 Geislinger coupling
1 Axial bearing clearance 0.286 0.476
2 Clearance between grooved ball bearing 0.080 0.250
and bearing race
3 Total axial clearance of crankshaft greater 0.740
No. 2
70026/0 90-08
Page 6
Crankshaft Axial Clearance - for engines with E48 and E56 Geisligner coupling
1 Axial bearing clearance 0.286 0.476
2 Clearance between grooved ball bearing 0.080 0.250
and bearing race
3 Total axial clearance of crankshaft greater 0.730
No. 2
70026/0 90-08
Gear Train Group 03
Page 7
Crankshaft Bearing Shells
1 Spreading 0-0 150.500 0 + 0.700
dimension 0-1 150.500
Upper bearing shell 0-2 150.500
removed 0-3 150.500
0-4 150.500
1-0 151.000
1-1 151.000
1-2 151.000
1-3 151.000
1-4 151.000
2-0 151.500
2-1 151.500
2-2 151.500
2-3 151.500
2-4 151.500
Note:
Ref. 2: see Group 03 Page 8
70026/0 90-08
Page 8
2 Spreading 0-0 149.700 0 + 0.700
dimension 0-1 149.700
Lower bearing shell 0-2 149.700
removed 0-3 149.700
0-4 149.700
1-0 150.200
1-1 150.200
1-2 150.200
1-3 150.200
1-4 150.200
2-0 150.700
2-1 150.700
2-2 150.700
2-3 150.700
2-4 150.700
Note:
Ref. 1: see Group 03 Page 7
70026/0 90-08
Gear Train Group 03
Page 9
Note:
Crankshaft bearings tightened according to specification.
Measure ID of crankshaft bearings in direction a - b1 and a - b2
Ensure that the bearing ID measured in b1 and b2 direction is equal to, or greater than, that measured in direction a,
max. a + 0.075
Ovality results from the difference between the IDs measured in directions b1 and a or b2 and a.
70026/0 90-08
Page 10
Connecting Rod Bearing
1 Connecting rod 0* 112.000 H6 0 + 0.022 max. 0.030
bore **** 1** 112.500 H6
2 Bearing ID***** 0-0 105.065 0 + 0.046 0.077 0.145 devtn. frm.
(bearing shells 0-1*** 104.865 round.
installed) 0-2 104.665 0.050
0-3 104.465 Clearance
0.170
1-0 105.065
1-1*** 104.865
1-2 104.665
1-3 104.465
Bearing journal 0 105.000 g6 - 0.034 - 0.012
diameter I*** 104.800 g6
II 104.600 g6
III 104.400 g6
3 Journal length 98.000 - 0.050 + 0.050 0.210 0.510 Clearance
Connecting rod 49.000 c10- 0.230 - 0.130 max. 0.600
width
Assignment of bearing journal stage to bearing ID stage
Bearing journal Bearing shells to be installed Bearing journal Bearing shells to be installed
Stage 0 Stage 0-0 1-0 Stage II Stage 0-2 1-2
I 0-1 1-1 III 0-3 1-3
Note:
* applicable for stages 0 - 0 to 0 - 3 **** for measuring instructions, see Group 03. Page 12
** applicable for stages 1 - 0 to 1 - 3 ***** for measuring instructions, see Group 03. Page 13
*** also permissible for new engines
Ref. 1: Heavy wear (cold shots): recondition the connecting rod bore and replace bearing shells.
Ref. 2: Clearance greater than 0.170: replace bearing shells, introduce next repair stage if necessary.
70026/0 90-08
Gear Train Group 03
Page 11
Crankshaft Bearing
1 Locating pin bore 0 7.000 H7 0 + 0.015 0.004 0.028
1* 7.300 H7
2 7.600 H7
Locating pin OD 0 7.000 r6 + 0.019 + 0.028
1* 7.300 r6
2 7.600 r6
Note:
70026/0 92-10
Group 03 Gear Train
Page 12
Connecting Rod Bearing Bore
1 Screw length 84.000 - 0.400 0 max.
85.000
Note:
Connecting rod cap tightened according to specification
Measure connecting rod bearing bore in directions a - b1 and a - b2
Ovality results from the difference between the IDs measured in directions b1 and a or b2 and a.
Ref. 1: Operational limit exceeded: replace screw
70026/0 90-08
Gear Train Group 03
Page 13
Connecting Rod Bearing Shells
1 Spreading 0-0 112.600 0 + 0.500
dimensions, 0-1 112.600
Bearing shell 0-2 112.600
removed 0-3 112.600
1-0 113.100
1-1 113.100
1-2 113.100
1-3 113.100
Note:
Connecting rod bearings tightened according to specification.
Measure ID of connecting rod bearing in direction a - b1 and a - b2.
Ensure that the bearing ID measured in direction b1 or b2 is equal to, or greater than, that measured in the direction a,
max. a + 0.075
Ovality results from the difference between the IDs measured in direction b1 and a or b2 and a.
70026/0 90-08
Group 03 Gear Train
Page 14
Parallelity of Connecting Rod Bores
Dim. Parallelity of the Deviation measured at intervals of 100 mm: 0.100 0.120
a axes of piston pin
and connecting rod
bearing bores
Dim. Parallelity of the Deviation measured at intervals of 100 mm: 0.030 0.040
b axes of piston pin
and connecting rod
bearing bores
Dim. Mean distance 341.000 - 0.050 + 0.050
c between piston pin
and connecting rod
bores in new
condition
Connecting rod 6380 g - 40 g + 40 g
weight
70026/0 90-08
Gear Train Group 03
Page 15
Piston Pin Bore
1 Connecting rod 0 66.000 H6 0 + 0.019 0.083 0.121 Interference
bore 1* 66.200 H6 min. 0.070
2 66.400 H6
Bush OD 0 66.000 u6 + 0.102 + 0.121
1* 66.200 u6
2 66.400 u6
2 Bush ID 60.000 + 0.070 + 0.080 0.070 0.085 Clearance
max.
Piston pin OD 60.000 - 0.005 0 a: 0.150
b: 0.100
3 Bush ID 60.000 + 0.008 + 0.016 0.008 0.021 Clearance
max.
Piston pin OD 60.000 - 0.005 0 a: 0.040
b: 0.030
Piston weight
Z 23 9020 g - 50 g + 50 g
Z 24 9120 g - 50 g + 50 g
Note:
Z Piston crown code number
X Marking Conrod bush without groove = Stage 0
Conrod bush with 1 groove = Stage 1
Conrod bush with 2 grooves = Stage 2
Ref. 1: If interference is less than 0.07 or the bush is loose at a test load of 12000 N, increase the connecting rod bore to the
next repair stage.
Ref. 2:If the max. clearance for dimension a is greater than 0.15 and for dimension b greater than 0.10, replace bush and
piston pin, dimension b may be less than the lower permissible deviation by up to 0.02 mm.
70026/0 90-08
Group 03 Gear Train
Page 16
Piston Clearance in Cylinder Liner
1 Cylinder liner bore 165.000 + 0.025 + 0.060 0.432 0.497
Piston crown dia. 164.588 - 0.020 + 0.025
Piston crown dia. 164.717 - 0.020 + 0.020
Piston crown dia. 164.805 - 0.020 + 0.020
Piston skirt dia. 164.782 - 0.010 + 0.010
Piston skirt dia. 164.835 - 0.011 + 0.011
A = Piston crown, oval
B = Piston skirt, falling oval
Ref. 1 to 5: Measure piston crown and piston skirt diameters in piston pin transverse direction.
70026/0 90-08
Gear Train Group 03
Page 17
Piston Crown Security
1 Screw length 50.000 - 0.100 + 0.100 max.
- M10 Hex. head 51.000
2 Screw length 50.000 - 0.100 + 0.100 max.
- M10 Hex. socket 51.000
Note:
Discoloration of the screw at the head and in the upper shank area is caused by operation. Screws can be reused.
Ref. 1 and 2: If screw length exceeds operational limit, replace screw.
70026/0 90-08
Group 03 Gear Train
Page 18
Piston Rings
1 Groove width 3.500 + 0.095 + 0.115 0.135 0.170 Clearance
Compression ring 3.470 - 0.025 - 0.010 max. 0.230
Taper - faced ring 3.480 - 0.025 - 0.010 max. 0.200
max. 0.180
Oil control ring 5.950 - 0.025 - 0.010 Clearance
min. 0.060
4 Gap * * Clearance**
Compression ring 0.400 0.600 max. 1.000
Taper - faced ring 0.600 0.800 max. 1.150
Oil control ring 0.450 0.650 max. 1.000
Ref. 1 and 2: Gap clearance of compression ring must be smaller than that of taper-faced ring.
Ref. 3: If clearance is less than 0.060: Replace the piston
If clearance exceeds 0.180: Replace oil control ring
Ref. 4: If clearance exceeds 1.000: Replace compression ring
If clearance exceeds 1.150: Replace taper-faced ring
If clearance exceeds 1.000: Replace oil control ring
Use new piston rings with new or rehoned cylinder liners.
Make certain the top compression ring is barrel-faced.
Replace compression ring before its upper edge becomes sharp.
* Measured in the reference ring; accuracy to comply with ring-gauge tolerance.

** Measured in the installed cylinder liner in which the ring/piston will be installed.
70026/0 97-04
Gear Train Group 03
Page 19
Crankshaft Gear
1 Gear bore 95.000 P7 - 0.059 - 0.024 Selective pairing
Shaft OD 95.000 t6 + 0.091 + 0.113 0.135 0.155
2 Space 0.200 0 + 0.100
- Gear pushed on
70026/0 90-08
Group 03 Gear Train
Page 20
Counterweight Security
1 Screw length 140.000 - 0.400 0 max.
143.000
Ref. 1: If screw length exceeds operational limit, replace screw
70026/0 90-08
Gear Train Group 03
Page 21
Crankshaft Outlet - in engines with E48 and E56 Geislinger Coupling
1 Friction ring OD 200.000 h8 - 0.072 0
Ref. 1: If friction surface is worn, metal spray friction ring and regrind to new dimension or replace ring.
70026/0 90-08
Group 03 Gear Train
Page 22
Crankshaft Bearings
1 Bearing mounting 0* 150.000 H6 0 + 0.025 0.135 0.180
bore 1** 150.500 H6
Bearing bush 0* 150.180 - 0.020 0
OD-removed 1** 150.680
2 Bearing bore 0-0 141.107 0 + 0.054 0.121 0.200
(bearing shells 0-1*** 140.857
installed) 0-2 140.607
0-3 140.357
0-4 140.107
1-0 141.107
1-1*** 140.857
1-2 140.607
1-3 140.357
1-4 140.107
Flange OD or 0 141.000 g6 - 0.039 - 0.014
Support ring OD I*** 140.750 g6
II 140.500 g6
III 140.250 g6
IV 140.000 g6
Ref. 1: If heavy wear (cold shots) is found, recondition the housing boring and replace bearing shells
(introduce next repair stage).
Ref. 2: If ovality is more than 0.100, clearance more than 0.230: replace bearing shells
(introduce next repair stage).
Note:
70026/0 90-08
Gear Train Group 03
Page 23
Crankshaft Bearings
Assignment of flange stage or support ring stage to bearing A = without vibration damper
shells stage B = with vibration damper
Flange or support ring Bearing shells to be installed * valid for stages 0 - 0 to 0 - 4
Stage 0 Stage 0-0 1-0 ** valid for stages 1 - 0 to 1 - 4
I 0-1 1-1 *** also permissible for new engines
II 0-2 1-2
III 0-3 1-3
IV 0-4 1-4
Note:
70026/0 90-08
Group 03 Gear Train
Page 24
Crankshaft Vibration Damper
1 Carrier bore 184.000 H8 0 + 0.072 0.400 0.672
Flange OD 183.600 - 0.200 0
2 Carrier bore 114.000 G7 + 0.012 + 0.047 0.012 0.069
Flange OD 114.000 h6 - 0.022 0
3 Spring pack bore in 70.000 H9 0 + 0.074
carrier
Balancer ring
4 Stroke limiter pin 20.000 h12 - 0.210 0 max. wear
0.500
5 Outer spring pack
H11
6 Carrier 22.000 0 + 0.130
Slot width
7 Screw length 66.300 - 0.200 0 max.
68.000
Ref. 4: If operational limit is exceeded, replace stroke limiter pins.
Ref. 5: Outer spring pack worn: replace entire spring pack
Ref. 7: If operational limit is exceeded, replace screw
70026/0 90-08
Gear Train Group 03
Page 25
Crankshaft Vibration Damper
1 Spring pack bore in 70.000 H9 0 + 0.074
carrier
Balancer ring
2 Stroke limiter pin 20.000 h12 - 0.210 0 max. wear
0.500
3 Outer spring pack
4 Carrier 22.000 H11 0 + 0.130
Slot width
Ref. 2: If operational limit is exceeded, replace stroke limiter pins.
Ref. 3: Outer spring pack worn: replace entire spring pack.
70026/0 90-08
Group 03 Gear Train
Page 26
70026/0 90-08
Cylinder Head Group 05
Page 1
Valve Guide, exhaust
1 Cylinder head bore 0 19.000 H7 0 + 0.021 0.014 0.048 Interfe-
1 19.100 H7 rence min.
1a 19.250 H7 0.014
2 19.500 H7
Valve guide OD 0 19.000 s6 + 0.035 + 0.048
1 19.100 s6
1a 19.250 s6
2 19.500 s6
H7
2 Valve guide ID 14.000 0 + 0.018 0.060 0.088 A max: 14.040*
Bronze B max. 14.040*
- Reaming and /or C max: 14.090*
honing A max: 14.080**
Valve stem dia. 13.940 - 0.010 0 B max: 14.100**
C max: 14.500**
2 Valve guide ID 14.000 H9 0 + 0.043 0.060 0.113 A max: 14.060*
Gray cast iron B max. 14.060*
- Complete guide C max: 14.100*
A max: 14.080**
C max: 14.500**
Ref. 1: If interference is less than 0.014, introduce the next repair stage.
Ref. 2: If chrome plating of exhaust valve is damaged or worn, replace valve.
* Limit dimension to ensure operational reliability to next scheduled W5

** Absolute limit dimension
70026/0 96-02
Group 05 Cylinder Head
Page 2
Valve Guide, inlet
1 Cylinder head bore 0 19.000 H7 0 + 0.021 0.014 0.048 Interfe-
1 19.100 H7 rence min.
1a 19.250 H7 0.014
2 19.500 H7
Valve guide OD 0 19.000 s6 + 0.035 + 0.048
1 19.100 s6
1a 19.250 s6
2 19.500 s6
H7
2 Valve guide ID 14.000 0 + 0.018 0.040 0.068 A max: 14.040*
Bronze B max. 14.040*
- Reaming and /or C max: 14.090*
honing A max: 14.080**
C max: 14.500**
2 Valve guide ID 14.000 H9 0 + 0.043 0.040 0.093 A max: 14.060*
Gray cast iron B max. 14.060*
Complete guide C max: 14.100*
A max: 14.080**
C max: 14.500**
Ref. 1: If interference is less than 0.014, introduce the next repair stage.
Ref. 2: If chrome plating of exhaust valve is damaged or worn, replace valve.
* Limit dimension to ensure operational reliability to next scheduled W5

** Absolute limit dimension
70026/0 96-02
Page 3
Exhaust Valve Seats in Cylinder Head
1 Cylinder head bore 0 59.000 H6 0 + 0.019 0.068 0.106
1 59.500 H6
Valve seat insert 0 59.000 u6 + 0.087 + 0.106
OD 1 59.500 u6
2 Cylinder head 0 12.500 0 + 0.100
Bore depth 1 12.800
3 Valve seat 0 9.200 - 0.100 0
Insert height 1 9.500
Dim. Valve seat insert 3.300 0 + 0.200
A depth
Dim. Exhaust valve max. 5.100
A1
Dim. Valve seat dia. 54.400 0 + 0.100
B
Ref. 1: If interference is less than 0.068, replace valve seat inserts, if necessary introduce next repair stage.
Ref. A and A1: Only recondition valve seat insert face until correct seating is achieved.
70026/0 91-12
Page 4
Inlet Valve Seats in Cylinder Head
1 Cylinder head bore 0 64.000 H6 0 + 0.019 0.068 0.104
1 64.500 H6
Valve seat insert 0 64.000 u6 + 0.087 + 0.106
OD 1 64.500 u6
2 Cylinder head 0 12.500 0 + 0.100
Bore depth 1 12.800
3 Valve seat insert 0 8.500 - 0.100 0
height 1 8.800
Dim. Valve seat insert 4.000 0 + 0.200
A depth
Dim. Inlet valve max. 5.100
A1
Dim. Valve seat dia. 57.000 0 + 0.100
B
Ref. 1: If interference is less than 0.068, replace valve seat inserts, if necessary introduce next repair stage.
Ref. A and A1: Only recondition valve seat insert face until correct seating is achieved.
70026/0 91-12
Page 5
Exhaust and Inlet Valves
Dim. 3.500 - 0.300 0
a
Dim. min. 2.800
b
Dim. Permissible reconditioning area
c
Inlet valves
Dim. Valve head dia. 57.000 - 0.200 0 max.
d 57.000
Exhaust valve
Dim. Valve head dia. 54.000 - 0.200 0 max.
d 54.000
Ref. dim. b: Only recondition to the minimum necessary.
If dimension b is smaller than 2.80, replace valve.
Ref. dim. d: If valve head diameter is greater than 54.0 or 57.0, regrind valve to basic size.
70026/0 90-08
Page 6
Valve Springs with Rotocap
Dim. Outer valve spring (right-hand pitch)
a Spring length 56.800
b Spring length 47.000
c Spring length 33.500
d Spring diameter 5.300
e1 Permissible deviation of generatrix from the vertical with unloaded spring, max. 2.500
e2 Spring face Permissible deviation from the parallel, less than 1.300
x Blocked length 31.800
B Spring force 347 N 0 0
C Spring force 843 N - 50 + 50
D Spring diameter 38.700
Dim. Inner valve spring (left-hand pitch)
B Spring force 140 N 0 0
Signs of wear caused by the spring centering devices at the shaped end spirals (top of spring: spring retainer, bottom of
spring: spring collar or Rotocap).
- below 0.200 mm: Smooth down signs of wear
- above 0.200 mm: Replace valve spring
70026/0 90-08
Page 7
Piston Clearance at TDC
Dim. Cylinder head 2.000 - 0.080 + 0.080
A gasket
Dim. Projection piston at 8.160 to
B TDC 8.520
Dim. Piston clearance 1.420 to
C 1.980
70026/0 90-08
Page 8
Cylinder Head Height/Valve Recession
1 Cylinder head 143.000 - 0.100 0 142.000
height
2 Rotocap mating 99.000 - 0.200 0 98.000
face
3 Recess to cylinder 27.900 0 + 0.200
head - valve
pushrod guide
Inlet valve
4 Recess to cylinder 0.500 - 0.150 + 0.100 max.
head 2.4000
Exhaust valve
5 Recess to cylinder 0 - 0.150 + 0.100 max.
head 2.6000
Ref. 1: If wear traces or corrosion is visible: recondition the cylinder head mating face.
CAUTION!
- Recondition cylinder head mating face only to the extent absolutely necessary.
- After reconditioning, check valve recession and remachine valve seats and possibly valves, if necessary.
- The maximum height difference between adjacent cylinder heads or covers must not exceed 0.5 mm.
Ref. 3: If the cylinder head has been reconditioned/refaced, machine housing depth to basic size.
Ref. 4 and 5: If recession is greater than 2.4 or 2.6 mm, install new valve seat inserts.
70026/0 90-08
Page 9
Cylinder Head Protective Sleeve
1 Cylinder head M 16x1 4H5H
thread
Protective M 16x1
sleeve thread
2 Protective 13.400 - 0.200 + 0.200 13.000
sleeve support
70026/0 92-02
Page 10
70026/0 92-02
Valve Gear Group 06
Page 1
Camshaft Bearings
1 Housing bore 0-0 71.000 H7 0 + 0.030 0.010 0.059
1-0 71.400 H7
2-0 71.800 H7
0-1 71.000 H7 0 + 0.030 0.010 0.059
1-1 71.400 H7
2-1 71.800 H7
Bearing OD 0-0 71.000 g6 - 0.029 - 0.010
1-0 71.400 g6
2-0 71.800 g6
0-1 71.000 g6 - 0.029 - 0.010
1-1 71.400 g6
2-1 71.800 g6
2 Bearing bore 0* 57.000 H7 0 + 0.030 0.060 0.109 Clearance
1** 56.600 H7 max. 0.130
Shaft OD 0* 57.000 e6 - 0.079 - 0.060
1** 56.600 e6
H8
3 Journal length 27.100 0 + 0.033 0.100 0.166 Clearance
Bush length 27.000 h8 - 0.033 0 max. 0.500
Note:
* Applicable for stages 0 - 0 to 2 - 0
** Applicable for stages 0 - 1 to 2 - 1
70026/0 90-08
Group 06 Valve Gear
Page 2
Camshaft Bearings
1 Housing bore 0 - 0 71.000 H6 0 + 0.019 0.101 0.140 Interference
1 - 0 71.400 H6 min. 0.100
2 - 0 71.800 H6
0 - 1 71.000 H6 0 + 0.019 0.101 0.140 Interference
1 - 1 71.400 H6 min. 0.100
2 - 1 71.800 H6
Bush OD 0 - 0 71.000 + 0.120 + 0.140
1 - 0 71.400
2 - 0 71.800
0 - 1 71.000 + 0.120 + 0.140
1 - 1 71.400
2 - 1 71.800
2 Bush bore max. 0* 67.000 H8 0 + 0.046 0.060 0.125 Clearance
1** 66.600 H8 max. 0.150
Shaft OD 0* 67.000 e6 - 0.079 - 0.060
1** 66.600 e6
3 Cams If there is evidence of damaged or pitting: regrind (up to max. 0.300 / surface)
4 Flane and out-of-round deviation max. 0.02
Note:
Ref. 2: Bore diameter 67 - 0.020/+ 0.029 with installed bush.
If clearance is greater than 0.15, replace bush.
Reface bearing areas, if necessary by metal spraying.
70026/0 90-08
Valve Gear Group 06
Page 3
Rocker Arm Bearing, inlet
1 Rocker arm bore 32.000 H7 0 + 0.025 0.018 0.059 Interference
Bush OD 32.000 s6 + 0.043 + 0.059 min. 0.018
2 Bush bore 28.000 H7 0 + 0.021 0.020 0.062 Clearance
Axis OD 28.000 f7 - 0.041 - 0.020 max. 0.100
70026/0 90-08
Group 06 Valve Gear
Page 4
Rocker Arm Bearing, exhaust
1 Rocker arm bore 32.000 H7 0 + 0.025 0.018 0.059 Interference
Bush OD 32.000 s6 + 0.043 + 0.059 min. 0.018
2 Bush bore 28.000 H7 0 + 0.021 0.020 0.062 Clearance
Axis OD 28.000 f7 - 0.041 - 0.020 max. 0.100
70026/0 90-08
Valve Gear Group 06
Page 5
Tappet Guide
1 Housing bore 46.000 H7 0 + 0.025 0.009 0.050 Interference
Bush OD 46.000 r6 + 0.034 + 0.050 min. 0.009
2 Bush bore 40.000 E7 + 0.050 + 0.075 0.075 0.125 Clearance
Tappet OD 40.000 f7 - 0.050 - 0.025 max. 0.160
3 Tappet bore 14.000 R6 - 0.031 - 0.020 0.012 0.031
Pin OD 14.000 h5 - 0.008 0
4 Roller bore 21.040 0 + 0.020 0.040 0.081 Clearance
Bush OD 21.000 - 0.021 0 max. 0.100
5 Bush bore 14.000 + 0.053 + 0.070 0.053 0.078 Clearance
Pin OD 14.000 h5 - 0.008 0 max. 0.100
Ref. 3: Tes load for interference fit of the pin in the tappet is min. 3800 N.
70026/0 90-08
Group 06 Valve Gear
Page 6
70026/0 90-08
Combustion Air / Exhaust Gas Systems Group 10
Page 1
Emergency Air Shut-off Flaps
1 Cover bore 34.000 H7 0 + 0.025 0.018 0.059
Bush OD 34.000 s6 + 0.043 + 0.059
2 Cover bore 26.000 H8 0 + 0.033 0 0.066
Bush OD 26.000 h8 - 0.033 0
3 Bush bore 17.000 F8 + 0.016 + 0.043 0.032 0.088
Shaft OD 17.000 f8 - 0.043 - 0.016
4 Flap bore 17.500 H7 0 + 0.018 0.006 0.020
Shaft OD 17.500 n5 + 0.012 + 0.020
5 Shaft OD 17.000 f8 - 0.043 - 0.016
70026/0 90-08
Group 10 Combustion Air / Exhaust Gas Systems
Page 2
Exhaust Flow Control Flap
1 Exhaust manifold 25.000 H9 0 + 0.052 0.020 0.124
bore
Bearing bush OD 25.000 f9 - 0.072 - 0.020
2 Flap bore 21.000 H8 0 + 0.033 0 0.485
Bearing bush OD 20.600 h9 - 0.052 0
3 Guide housing 35.000 H7 0 + 0.021 0 0.060
bore
Bearing bush OD 35.000 h8 - 0.039 0
H10
4 Bearing bush bore 20.400 0 + 0.084 0.379 0.476
Shaft OD 20.000 m6 + 0.008 + 0.021
70026/0 90-08
Combustion Air / Exhaust Gas Systems Group 10
Page 3
Air Flow Control Flap
1 Intake housing 30.000 H7 0 + 0.021 0.007 0.049
bore
Flanged bush OD 30.000 g7 - 0.028 - 0.007
2 Flanged bush bore 20.000 F8 + 0.020 + 0.053 0.027 0.081
Shaft OD 20.000 g7 - 0.028 - 0.007
3 Flap bore 20.000 H7 0 + 0.021 0.007 0.049
Shaft OD 20.000 g7 - 0.028 - 0.007
70026/0 90-08
Group 10 Combustion Air / Exhaust Gas Systems
Page 4
70026/0 90-08
Fuel Injection Equipment Group Group 11
Page 1
Fuel Injection Pump Drive
1 Housing bore 100.000 H6 0 + 0.022 0.029 0.073
Bearing bush OD 100.000 r6 + 0.051 + 0.073
2 Bearing bush bore 90.000 F6 + 0.036 + 0.058 0.036 0.073
Bearing OD 90.000 - 0.015 0
3 Beraing bore 40.000 - 0.012 0 0.019 0.015
Shaft OD 40.000 h6 - 0.016 0
4 Drive gear bore 56.000 H6 0 + 0.019 0.030 0.068
Shaft OD 56.000 f6 - 0.049 - 0.030
5 Stress bolt OD 25.000 h11 - 0.130 0
6 Axial clearance of 0.114 0.169
drive gear
7 Screw length 163.000 - 0.300 0 max.
165.000
Ref. 5: If worn, replace stress bolt
Ref. 7: Operational limit exceeded: replace screw
A = with injection timer

B = without injection timer
70026/0 90-08
Group 11 Fuel Injection Equipment Group
Page 2
Fuel Injection Pump Drive
1 Housing bore 0-0 71.000 H6 0 + 0.019 0.101 0.140
1-0 71.400 H6
2-0 71.800 H6
0-1 71.000 H6 0 + 0.019 0.101 0.140
1-1 71.400 H6
2-1 71.800 H6
Bearing bush OD 0-0 71.000 + 0.120 + 0.140
1-0 71.400
2-0 71.800
0-1 71.000 + 0.120 + 0.140
1-1 71.400
2-1 71.800
2 Bearing bush bore 0* 67.000 H8 0 + 0.046 0.060 0.125 clearance
1** 66.600 H8 max. 0.150
Shaft OD 0* 67.000 e6 - 0.079 - 0.060
1** 66.600 e6
3 Gear backlash 0 0.080
Note:
Ref. 1: If seating security is less than 400 kp, replace bearing bush, introduce repair stage if necessary.
Ref. 2: If clearance is greater than 0.150, replace bearing bush.
70026/0 90-08
Fuel Injection Equipment Group Group 11
Page 3
Injection Timer
1 Curved elements, friction surface
2 Counterflange friction surface
3 Governor weight 57.000 - 0.100 0
OD
4 Governor weight 0.160 0.343
axial clearance
5 Screw length 37.500 - 0.300 0 max.
38.000
Ref. 1 and 2: If heavy wear traces are found, replace curved elements, counterflange and governor
Ref. 5: Operational limit exceeded; replace screw
70026/0 90-08
Group 11 Fuel Injection Equipment Group
Page 4
Injection Timer Springs
Dim. Springs for injection timer, radial
B Spring force 10 N - 3 +3
C Spring force 105 N - 8 +8
Dim. Springs for injection timer, tangential
B Spring force 105 N - 15 + 15
70026/0 90-08
Coolant Pump Group 13
Page 1
Engine Coolant Pump
1 Housing bore 108.000 H7 0 + 0.035 0.044 0.013
Bearing housing 108.000 j6 - 0.009 + 0.013
OD
2 Bearing housing 72.000 J6 - 0.006 + 0.013 0.026 0.006
bore
Bearing OD 72.000 - 0.013 0
3 Bearing bore 35.000 - 0.012 0 0.002 0.030
Shaft OD 35.000 k6 + 0.002 + 0.018
70026/0 90-08
Group 13 Coolant Pump
Page 2
Engine Coolant Pump
1 Housing bore 52.000 H8 0 + 0.046 0.204 0.450
Sealing ring OD 52.000 + 0.250 + 0.450
2 Pump shaft OD 32.000 - 0.100 0
3 Housing bore 57.000 H8 0 + 0.046 0.024 0.116
Gasket OD 57.070 k8 0 + 0.046
4 Impeller bore 46.000 F8 + 0.025 + 0.064 0.025 0.089
Thrust ring OD 46.000 h7 - 0.025 0
5 Clearance between 0.600 1.500
impeller and
connecting element
Ref. 1: Always renew shaft seal during pump assembly
Ref. 2: If running surface is worn, metal spray pump shaft and regrind to new dimension
Ref. 3 and 4: Always renew axial/slip ring gasket and complete thrust ring during pump assembly
70026/0 90-08
Coolant Pump Group 13
Page 3
Engine Coolant Pump Drive
1 Housing bore 108.000 H7 0 + 0.035 0.044 0.013
Bearing housing OD 108.000 j6 - 0.009 + 0.013
2 Housing bore 108.000 H7 0 + 0.035 0.044 0.013
Bearing flange OD 108.000 j6 - 0.009 + 0.013
3 Bearing flange bore 80.000 M6 - 0.024 - 0.005 0.008 0.024
Roller bearing OD 80.000 - 0.013 0
4 Roller bearing bore 40.000 - 0.012 0 0.002 0.030
Pump shaft OD 40.000 k6 + 0.002 + 0.018
70026/0 90-08
Group 13 Coolant Pump
Page 4
Raw Water Pump
1 Bearing housing 90.000 M6 - 0.028 - 0.006 0.009 0.028
bore
Bearing OD 90.000 - 0.015 0
2 Bearing bore 50.000 - 0.012 0 0.002 0.030
Shaft OD 50.000 k6 + 0.002 + 0.018
4 Pump shaft OD 48.000 - 0.100 0
5 Impeller clearance to the inlet elbow 0.500 1.000
- shaft displaced as arrowed
70026/0 90-08
Oil Pump Group 15
Page 1
Engine Oil Pump, 8V
Bearing bush OD 36.000 + 0.045 + 0.070 min. 0.029
2 Bearing bush bore 32.000 + 0.010 + 0.040 0.060 0.106 Clearance
Shaft OD 32.000 e6 - 0.066 - 0.050 max. 0.200
3 Housing bore 65.000 H8 0 + 0.046 0.200 0.276
Gear OD 64.800 - 0.030 0
4 Housing fit width 80.000 H8 0 + 0.046 0.260 0.346 Clearance
Gear fit width 79.740 - 0.040 0 max. 0.420
Note:
Ref. 1: Replace bearing bushes during major overhaul W6 at latest.
Ref. 2: Basic size with bearing bush installed in housing
70026/0 90-08
Group 15 Oil Pump
Page 2
Engine Oil Pump, 12V
Shaft OD 32.000 e6 - 0.066 - 0.050 max. 0.200
3 Housing bore 65.000 H8 0 + 0.046 0.200 0.276
Gear OD 64.800 - 0.030 0
4 Housing fit width 100.000 H8 0 + 0.054 0.200 0.308 Clearance
Gear fit width 99.800 h8 - 0.054 0 max. 0.750
Reconditiong instructions:
Ref. 1: Replace bearing bushes during major overhaul W6 at the latest
70026/0 90-08
Oil Pump Group 15
Page 3
Engine Oil Pump, 16V
Shaft OD 32.000 e6 - 0.066 - 0.050 max. 0.200
3 Housing bore 65.000 H8 0 + 0.046 0.200 0.276
Gear OD 64.800 - 0.030 0
4 Housing bore 97.000 H8 0 + 0.054 0.200 0.284
Gear OD 96.800 - 0.030 0
H8
5 Housing fit width 100.000 0 + 0.054 0.200 0.308 Clearance
Gear fit width 99.800 h8 - 0.054 0 max. 0.750
Reconditining instructions:
Ref. 1: Replace bearing bushes during major overhaul W6 at the latest
70026/0 90-08
Group 15 Oil Pump
Page 4
70026/0 90-08
Oil System Group 16
Page 1
Pressure Relief Valve
1 Housing bore 35.000 H10 0 + 0.100 0.100 0.300
Housing OD 34.900 - 0.100 0
2 Housing bore 27.000 H9 0 + 0.052 0.110 0.195
Valve piston OD 27.000 c8 - 0.143 - 0.110
3 Housing bore 28.000 H7 0 + 0.021 0 0.042
Valve seat insert 28.000 h7 - 0.021 0
OD
70026/0 90-08
Group 16 Oil System
Page 2
Pressure Limiting Valve
1 Housing bore 36.000 H7 0 + 0.025 0.021 0.066
Valve housing OD 36.000 f6 - 0.041 - 0.021
2 Valve housing bore 26.000 H7 0 + 0.021 0.040 0.113
Guide bush OD 26.000 e9 - 0.092 - 0.040
3 Valve housing bore 26.000 H7 0 + 0.021 0.020 0.062
Valve piston OD 26.000 f7 - 0.041 - 0.020
4 Housing bore 22.000 H7 0 + 0.021 0.050 0.091
Valve piston OD 22.000 - 0.070 - 0.050
H10
5 Valve housing bore 25.000 0 + 0.084 0.020 0.127
Plug OD 25.000 f8 - 0.053 - 0.020
70026/0 90-08
Hydraulic Fan Drive Group 20
Page 1
Drive Gear
1 Cover bore 100.000 M6 - 0.028 - 0.006 0.009 0.028
Bearing OD 100.000 - 0.015 0
2 Bearing bore 45.000 - 0.012 0 0.002 0.030
Shaft OD 45.000 k6 + 0.002 + 0.018
3 Intermediate 100.000 J6 - 0.006 + 0.016 0.031 0.006
housing bore
Bearing OD 100.000 - 0.015 0
4 Bearing bore 55.000 - 0.015 0 0.002 0.036
Shaft OD 55.000 k6 + 0.002 + 0.021
70026/0 90-08
Group 20 Hydraulic Fan Drive
Page 2
Idler Gear
1 Cover bore 100.000 M6 - 0.028 - 0.006 0.009 0.028
Bearing OD 100.000 - 0.015 0
2 Bearing bore 45.000 - 0.012 0 0.002 0.030
Shaft OD 45.000 k6 + 0.002 + 0.018
3 Intermediate housing 100.000 M6 - 0.028 - 0.006 0.009 0.028
bore
Bearing OD 100.000 - 0.015 0
4 Bearing bore 45.000 - 0.012 0 0.002 0.030
Shaft OD 45.000 k6 + 0.002 + 0.018
70026/0 90-08
Page 3
Fan Wheel Shaft
1 Fan wheel bore 152.000 H7 0 + 0.040 0.014 0.079
Flange OD 152.000 g6 - 0.039 - 0.014
2 Fan flange OD 80.000 h11 - 0.190 0
3 Cover bore 140.500 0 + 0.300 0.500 0.815
Bearing OD 140.000 - 0.015 0
4 Bearing bore 65.000 - 0.015 0 0.011 0.039
Shaft OD 65.000 m5 + 0.011 + 0.024
M6
5 Cover bore 140.000 - 0.033 - 0.008 0.010 0.033
Shaft OD 140.000 - 0.018 0
6 Bearing bore 65.000 - 0.015 0 0.011 0.039
Shaft OD 65.000 m6 + 0.011 + 0.024
7 Intermediate 100.000 M6 - 0.028 - 0.006 0.009 0.028
housing bore
Bearing OD 100.000 - 0.015 0
8 Bearing bore 45.000 - 0.012 0 0.009 0.032
Shaft OD 45.000 m5 + 0.009 + 0.020
70026/0 90-08
Page 4
Control Unit
1 Housing bore 33.000 H6 0 + 0.016 0.025 0.057
Control piston OD 33.000 f6 - 0.041 - 0.025
2 Housing bore 33.000 H6 0 + 0.016 0.025 0.057
Control piston OD 33.000 f6 - 0.041 - 0.025
3 Housing bore 26.200 0 + 0.200 0.200 0.500
Socket OD 26.000 - 0.100 0
4 Socket bore 18.200 H8 0 + 0.027 0.200 0.337
Thermally responsive 18.000 h11 - 0.110 0
element OD
H8
5 Housing bore 31.000 0 + 0.039 0.025 0.089
Socket OD 31.000 f7 - 0.050 - 0.025
70026/0 90-08
Page 5
Compression Spring for Control Unit
Dim. Compression spring (right-hand pitch)
B Spring force 110 N - 10 + 10
Dim. Compression spring (left-hand pitch)
c Permissible non-paralellity of the spring faces less than 0.5
B Spring force 100 N - 5 +5
70026/0 90-08
Page 6
70026/0 90-08
Accessories (Mechanical) Group 88
Page 1
E48 and E56 Geislinger Coupling
1 Bearing housing 260.000 P6 - 0.079 - 0.047 0.012 0.079
bore
Bearing OD 260.000 - 0.035 0
Ref. 2: If friction ring surface is worn, metal spray friction ring and regrind to new dimension or replace ring.
70026/0 90-08
Group 88 Accessories (Mechanical)
Page 2
F56 Geislinger Coupling
1 Bearing housing 290.000 P6 - 0.079 - 0.047 0.012 0.079
bore
Bearing OD 290.000 - 0.035 0
2 Bearing bore 190.000 - 0.030 0 0.031 0.090
Flange OD 190.000 n6 + 0.031 + 0.060
3 Bearing carrier bore 260.000 P6 - 0.079 - 0.047 0.012 0.079
Bearing OD 260.000 - 0.035 0
Ref. 4: If friction surface is worn, metal spray friction ring and regrind to new dimension or replace ring.
70026/0 90-08
Accessories (Mechanical) Group 88
Page 3
Auxiliary Drive
2 Friction ring bore 100.000 H6 0 + 0.022 0.049 0.093
Intermediate flange 100.000 s6 + 0.071 + 0.093
OD
3 Screw length 80.000 - 0.200 0 max.
81.500
Recondition instructions:
Ref. 1: When replacing radial-lip oil seal: install friction ring to collar.
If there are double grooves on the surface: metal spray friction ring and regrind to new dimension, or replace ring.
Ref. 3: Operational limit exceeded: remplace screw.
70026/0 90-08
Group 88 Accessories (Mechanical)
Page 4
70026/0 90-08

Tolerances and Wear Limits TE 4

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Technical Publication

Tolerances and Wear

MTU Friedrichshafen GmbH

Please use block capitals!

Receipt Amendment No. 1. 12.91

j Update as (PDF) file as CD--ROM 3. 07.94

j Update in hardcopy form 4. 04.95

Fax Telephone 11.

(Postal code) City 15.

10 Combustion air / Exhaust gas system)

11 Fuel injetion equipment group

20 Hydraulic fan drive

Explanation of terms for dimensions of new components

Explanation of terms for reconditioning and operational limits

Cylinder Liner Seat

Assignment of crankcase stage to cylinder liner stage and support plate

Cylinder Liner Seat

Crankcase Main Bearing Bores

Idler Gear, Coolant Pump Drive

Idler Gear, Oil Pump Drive 8, 12 V 396

Idler Gear, Oil Pump Drive 16 V 396

Idler Gear, Generator Drive

Crankshaft Bearings, Main Journals

Crankshaft Bearings, Main Journals

* applicable for stages 0 - 0 to 0 - 4

Crankshaft Bearings, Main Journals

For dynamic balancing, support the crankshaft as follows:

Crankshaft Bearings, Axial Bearing

Crankshaft Axial Clearance - for engines with F56 Geislinger coupling

Crankshaft Bearing Shells

Crankshaft Bearing Shells

Crankshaft Bearing Shells

Connecting Rod Bearing

Connecting Rod Bearing Bore

Connecting Rod Bearing Shells

Parallelity of Connecting Rod Bores

Piston Pin Bore

Piston Clearance in Cylinder Liner

Piston Crown Security

* Measured in the reference ring; accuracy to comply with ring-gauge tolerance.

Crankshaft Outlet - in engines with E48 and E56 Geislinger Coupling

Crankshaft Vibration Damper

Crankshaft Vibration Damper

Valve Guide, exhaust

* Limit dimension to ensure operational reliability to next scheduled W5

Valve Guide, inlet

* Limit dimension to ensure operational reliability to next scheduled W5

Exhaust Valve Seats in Cylinder Head

Inlet Valve Seats in Cylinder Head

Exhaust and Inlet Valves

Valve Springs with Rotocap

Piston Clearance at TDC

Cylinder Head Height/Valve Recession

Cylinder Head Protective Sleeve

Rocker Arm Bearing, inlet

Rocker Arm Bearing, exhaust

Emergency Air Shut-off Flaps

Exhaust Flow Control Flap

Air Flow Control Flap

Fuel Injection Pump Drive

A = with injection timer

Fuel Injection Pump Drive

Injection Timer Springs