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Technical Documentation
Diesel Engine
12 V 2000 M84 (Common Rail)
16 V 2000 M84 (Common Rail)
12 V 2000 M94 (Common Rail)
16 V 2000 M94 (Common Rail)
1 General Information
Graphical symbol applies to radial shaft seals and depends on the position. Dimension
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Prior to installing antifriction bearings, lubricate the bearing seats. Only take bearings out of their
original packaging immediately before installation. Do not remove corrosion inhibitor from bearings
in original packaging. To clean the antifriction bearings, use denatured spirit or acid-free kerosene.
After cleaning, lubricate bearings with SAE 30 engine oil.
• Do not apply assembly forces (axial) over rolling elements and do not knock bearing
rings with hammers (use assembly aids).
• Do not use naked flames to heat inner bearing races!
• The temperature should be between 80°C and 100°C and may not exceed 120°C.
• Freezing as a method for the assembly of anti-friction bearings is not permitted (danger
of cracks, rust formation due to condensate).
Do not lubricate dry bearings with oil.
When installing gears, use SAE 30 engine oil to moisten teeth.
Prior to assembly, mating and contact surfaces of components (e.g. contact surfaces for centering,
flange and sealing faces, joint surfaces of interference fit assembles) must be clean, bright or have
the specified surface protection and also be free of surface irregularities and damage. Remove any
corrosion inhibitor (e.g. oil, grease) from mating and contact surfaces.
After joining components that are chilled with liquid nitrogen, remove any condensate
and preserve with SAE 30 engine oil.
Prior to installation in immersion sleeves, coat the sensor area of measuring sensors with long-life lubricant.
Preassemble line links with cutting ring union in the bench vise and tighten; coat thread with thin-film lubricant first.
If components need to be marked by means of etching, use neutralization agent to remove the marking
solution afterwards. Preserve the relevant areas with SAE 30 engine oil.
The mating/contact surfaces of components used in the hot-component area (e.g. V-belt clamps, bellows,
plug-in pipes), should be coated with assembly paste, if not otherwise specified.
The assembly surfaces of screws, nuts, washer components and parts to be tensioned must be clean,
bright or have surface protection and also be free of surface irregularities and damage. Remove
any corrosion inhibitors (e.g. oil, grease). Prior to assembly according to tightening specifications,
coat threads and screw bearing surfaces with lubricant.
If not otherwise specified, use SAE 30 engine oil as lubricant and in the hot-component area assembly paste.
Screw connections without tightening specification can be tightened freely, i.e. machine-tightening with
screwdriver or hand-tightening with open-end wrench or box wrench. For machine-tightening, take the torque
specification for thread size and property class from the general tightening specifications.
Screw connections with tightening specification:
• Establish the screw connections by hand-tightening with snap wrench or torque indicator wrench. Apply
tightening torque without taking the tolerance specified on the snap wrench into account. If a torque
indicator wrench is used, the torque must be within the tightening torque limit range. Proceed in the same
way for connections protected against torsion. This information also applies to test torques.
• If no tolerance is specified for the tightening torque, the tightening tolerance is +10 % of the specified torque.
• Rotation angle tightening:
The angles of further rotation specified in the torque specification must be established. They may be exceeded
within the specified tolerance range. If no tightening torque is specified, maintain the following tolerances: +5 °
for angle of further rotation below/equal 90 ° +10 ° for angle of further rotation above 90 °. Prior to rotation angle
tightening, apply a color line mark to each screw head to allow the inspection of the correct angle of rotation after
tightening (exception: the color line mark is not required for tightening using self-monitoring NC screwdrivers).
• Elongation tightening:
Tighten according to tightening specification, taking the tightening tolerance into account.
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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
Unauthorized engine modifications compromise 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
During repair or engine overhaul reworking can be carried out in 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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Personnel requirements
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).
Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. When subjected to fire
or temperatures above 300 °C the material degenerates, giving off hydrogen fluoride gas. Hydrogen fluoride
vapors are released in this case. The resulting acid leads to serious burning if it contacts the skin. Do not touch
elastomeric seals if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of burning!
Note cooling period for components which are heated for installation or removal ⇒ Risk of burning!
Do not touch hot components of the compressor and the exhaust system ⇒ Risk of burning!
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 burning!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable binding 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.
Observe special cleanness when conducting maintenance and repair work on the engine plant. After completion
of maintenance and repair work, make sure that no loose objects are in/on the engine plant.
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
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Fire prevention
Rectify any fuel or oil leakage immediately; even quantities of oil or fuel on hot parts can cause fires,
so keep the engine clean at all times. Do not leave cloths saturated with fluids or lubricants lying on
or near the engine. Do not store inflammable material near the engine.
Do not carry out welding work on pipes or components containing oil or fuel! Prior to welding,
clean components using a non-inflammable liquid.
When starting the engine with an external power source, connect the ground cable last and remove it first.
In order to avoid sparks in the proximity of the batteries, connect the ground cable of the external power
source to the ground cable of the engine or to the ground clamp on the starter.
Always have adequate extinguishing devices (fire extinguishers) ready and make sure you know how to use them.
Noise
Noise can result in an increased risk of accidents, if it affects the perception of acoustic signals,
shouts of warning or noises indicating danger.
Wear ear protectors at all workplaces with a sound pressure level exceeding 85 dB(A)
(protective cotton pads, plugs or capsules)!
Environmental protection
Modification or removal of mechanical or electronic components or the installation of additional components
as well as the execution of calibration processes that might affect the emission characteristics of the engine
are prohibited by emission regulations. Emission control units/systems may only be maintained, exchanged
or repaired if the components used for this purpose are approved by MTU or equivalent components.
Noncompliance with these guidelines might represent a violation of the Clean Air Act and could involve
the termination of the operating license by the emission authorities. MTU does not accept any liability for
violations of the emission regulations. MTU will provide assistance and advice if emission-relevant components
are intended to be modified. The MTU Maintenance Schedules ensure the reliability and performance of
MTU engines and must be complied with over the entire life cycle of the engine.
Only fuel of prescribed quality may be used to comply with emission limit values.
In Germany the VAwS (regulation for installations concerning how to handle water-polluting substances)
applies, i.e. work may only be carried out by specialists (such as MTU).
Dispose of used fluids, lubricants and filters in accordance with national regulations.
Auxiliary materials, fluids and lubricants
Only use auxiliary materials, fluids and lubricants that have been checked and approved by MTU.
Store auxiliary materials, fluids and lubricants in suitable containers with appropriate labeling! When
handling fluids, lubricants and other chemical substances, observe the safety regulations that
apply. Caution when handling hot, chilled or aggressive substances. When handling inflammable
substances, avoid contact with easily ignitable sources, do not smoke!
Lead
• When working with lead or pastes containing lead, avoid direct contact, do not inhale lead fumes.
• Avoid the formation of lead dust!
• Switch on extraction fan!
• Clean hands after making contact with lead or lead-containing substances!
Acid and alkaline solutions
• When working with acid and alkaline solutions, wear goggles or face protection
shield, gloves and protective clothing.
• In the case of acid or alkali burns, remove contaminated clothing immediately!
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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!
Wear limit The wear limits do not denote the max. permissible
wear for correct functioning of the component. They
are to be regarded as indications that the next required
major overhaul will be reached safely. A component
must be replaced if its wear limit is exceeded.
Deviations from roundness, cylindricity, parallelism and coaxiality must be within wear limits unless
specifically indicated. All dimensions are given in “mm” unless otherwise specified.
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Crank drive
Designation Torque specification Lubricant
Conrod screw
• Nominal length: 67.2 mm to 67.5 mm
• Max. elongation: 68.5 mm
Cylinder head
Designation Torque specification Lubricant
Pretightening torque
1st stage 10 Nm
2nd stage 50 Nm
Valve gear
Designation Torque specification Lubricant
1 Pretightening torque 60 Nm
Exhaust turbocharger
Designation Torque specification Lubricant
1 Pre-application torque 35 Nm +3 Nm
(left-hand thread)
2 Loosening
3 Pre-application torque 15 Nm +1 Nm
(left-hand thread)
Charge-air cooling
Designation Torque specification Lubricant
Exhaust system
Designation Torque specification Lubricant
Starting equipment
Designation Torque specification Lubricant
Terminal 30 28 Nm ±4 Nm
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Terminal 31 M10 16 Nm - 20 Nm
Terminal 45 28 Nm ±4 Nm
Terminal 50 2.4 Nm - 3 Nm
Cooling system
Designation Torque specification Lubricant
Pin for lever for clamping jig 100 Nm +10 Nm Assembly paste MTH 5109
Mounting / support
Designation Torque specification Lubricant
Engine mounting
Pressure sensor 20 Nm to 45 Nm
• engine coolant pressure
• raw water pressure
• refill oil pressure
Tightening specifications for setscrew and stud connections as per MTN 5008 standard
This 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 for
studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and to the corresponding nuts.
It does not apply to heat-resistant screws in the hot-component area.
Tightening torques MA are specified for screws of strength class 8.8 (surface condition bright, phosphatized
or galvanically zinc-plated) and 10.9 (surface condition bright or phosphatized).
The table values are based on a friction coefficient of µtotal= 0.125. Precondition: prior to assembly, threads
and screw-mating faces of screws and nuts need to be lubricated with engine oil.
When tightening by hand, due to unavoidable deviations of the tightening torques from the
table value during tightening, e.g. due to reading inaccuracies and overtightening, an assembly
tolerance of +10 % of the table values is permitted.
For machine-tightening, the permissible assembly tolerance is +15 %.
Hand-tightening Machine-tightening
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
Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
MA=tightening torques
Tightening specifications for stress bolt connections as per MTN 5007 standard
This standard applies to stress bolt connections subjected to static and dynamic loads of
strength class 10.9 and for the corresponding nuts.
Shaft and transition dimensions as per MMN 209 and material and production as per MMN 389
(surface condition bright or phosphatized).
The table values are based on a friction coefficient of µges.= 0.125. Precondition: prior to assembly, threads
and screw-mating faces of screws and nuts need to be lubricated with engine oil.
For unavoidable deviations of the tightening torques from the table value during tightening, e.g. due to reading
inaccuracies and overtightening, an assembly tolerance of +10 % of the table values is permitted.
The table values are for tightening by hand with a torque wrench.
Thread not protected from torsion MA(Nm) protected from torsion MA(Nm)
M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
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M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
Thread not protected from torsion MA(Nm) protected from torsion MA(Nm)
Tightening torques MA are specified for plug screws made of steel (St) with surface protection: phosphatized and
oiled or galvanically zinc-plated. Threads and screw-mating surfaces under head need to be lubricated with engine
oil prior to assembly. For unavoidable deviations of the tightening torques from the table value during tightening, e.g.
due to reading inaccuracies and overtightening, an assembly tolerance of +10 % of the table values is permitted.
Tightening torques for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed end)
inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 35 25
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M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M22 x 1.5 60 50
M24 x 1.5 70 60
M26 x 1.5 80 70
M27 x 2 80 70
M30 x 2 95 85
MA=tightening torques
Tightening specifications for plug screws as per DIN 7604C (with long screwed end)
inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
MA=tightening torques
Tightening torques MA are specified for banjo screws made of steel (St) with surface protection: phosphatized
and oiled or galvanically zinc-plated and of copper/aluminum alloys.
Prior to assembly, threads and screw-mating surfaces under head need to be lubricated with engine oil.
For unavoidable deviations of the tightening torques from the table value during tightening, e.g. due to reading
inaccuracies and overtightening, an assembly tolerance of +10 % of the table values is permitted.
M8 x 1 10
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M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
MA=tightening torques
M10 x 1 15
M16 x 1.5 30
MA=tightening torques
Tightening torques MA are specified for male connectors made of steel (St) with surface protection:
phosphatized and oiled or galvanically zinc-plated.
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Prior to assembly, threads and screw-mating surfaces under head need to be lubricated with engine oil.
For unavoidable deviations of the tightening torques from the table value during tightening, e.g. due to reading
inaccuracies and overtightening, an assembly tolerance of +10 % of the table values is permitted.
M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M32 x 2 160
M42 x 2 260
M48 x 2 320
MA=tightening torques
1 Union nut
2 Junction block
3 O-ring
4 Linear ball bearing
Union nut: On installing the linear ball bearing, after tightening the union nut firmly by hand (noticeable
increase in force), it should be tightened another 1/4 turn (90°) past this point.
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Tightening specifications for screwed ends with O-ring as per ISO 6149-2
M8 x 1 10
M10 x 1 20
M12 x 1.5 35
M14 x 1.5 45
M16 x 1.5 55
M18 x 1.5 70
M20 x 1.51) 80
M27 x 2 170
M33 x 2 310
M42 x 2 330
M48 x 2 420
M60 x 2 500
1)Only for locks for installation spaces for screw-in valves (see ISO 7789)
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Tightening specifications for screwed ends with O-ring as per ISO 6149-3
M8 x 1 8
M10 x 1 15
M12 x 1.5 25
M14 x 1.5 35
M16 x 1.5 40
M18 x 1.5 45
M22 x 1.5 60
M27 x 2 100
M33 x 2 160
M42 x 2 210
M48 x 2 260
inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 20 10+ 2
M60 x 2 1) 200+ 20
1) Value is still to be determined
Assembly instructions and tightening specifications for hose fittings with union nut
To connect hose fittings to sealing heads and the corresponding adapters, assembly must be carried out as follows,
as opposed to the instructions for pipe unions (these instructions do not apply to ORFS fittings).
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Hose fitting, metallic sealing with union nut: tighten union nut by hand, then use wrench
to tighten by a maximum of a 1/4 turn.
Hose fitting with O-ring and union nut: tighten union nut by hand, then use wrench
to tighten by a maximum of a 1/2 turn.
Prior to tightening the union nuts, the hose lines need to be aligned accordingly.
M12 x 1.5 6 20
M14 x 1.5 8 38
M16 x 1.5 8 45
10
M18 x 1.5 10 51
12
M20 x 1.5 12 58
M22 x 1.5 14 74
15
M24 x 1.5 16 74
M30 x 2 20 135
22
M36 x 2 25 166
28
M42 x 2 30 240
M45 x 2 35 290
M52 x 2 38 330
42
G1/4 20
G3/8 34
G1/2 60
G5/8 69
G3/4 115
G1 140
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G1.1/4 210
G1.1/2 290
G2 400
7/16–20 –4 15
1/2–20 –5 20
9/16–18 –6 30
3/4–16 –8 50
7/8–14 –10 69
1.1/16–12 –12 98
9/16–18 –4 14+ 2
11/16–16 –6 24+ 3
13/16–16 –8 43+ 4
1.2.9 Settings
10V A1-B4-A4-B3-A3-B2-A2-B5-A5-B1
12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1
16V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7
Crankshaft left
Camshaft right
Exhaust 0.40 mm
5 Overlap 83.6 °
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
yd 3 = ft
yd 36 = in
Area
Unit A multiplied by factor = Unit B
ft2 0.0929 = m2
yd2 0.8361 = m2
Volume
Unit A multiplied by factor = Unit B
ft3 0.02832 = m3
yd3 0.7646 = m3
Speed
Unit A multiplied by factor = Unit B
Mass
Unit A multiplied by factor = Unit B
lb 0.4536 = kg
oz 28.35 =g
ton =t
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1.016
kg 2.205 = lb
t 0.9843 = ton
Force
Unit A multiplied by factor = Unit B
lb 0.4536 = kp
lb 4.4483 =N
kp 2.205 = lb
N 0.101972 = kp
kp 9.80665 =N
Density
Unit A multiplied by factor = Unit B
Torque
Unit A multiplied by factor = Unit B
ft lb 1.3563 = Nm
Nm 0.7373 = ft lb
Pressure
Unit A multiplied by factor = Unit B
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lb/sq ft 47.883 = Pa
in QS 0.03386 = bar
in QS 345.3 = kp/m2
atm 760 = mm QS
atm 1.0133 = bar
atm 10332 = kp/m2 (mm WS)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lb/sq in
ft lb s2 1.3563 = kg m2
kg m2 0.7373 = ft lb s2
Energy
Unit A multiplied by factor = Unit B
ft lb 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU
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Power
Unit A multiplied by factor = Unit B
HP 0.7457 = kW
BTU/s 1.055 = kW
kcal/h 1.163 =W
HP 550 = ft lb/s
kW 1.36 = PS
kW 1.341 = HP
kW 0.9479 = BTU/s
W 0.8598 = kcal/h
ft lb/s 0.0018 = HP
Temperature
Celsius Kelvin Fahrenheit Réaumur
Fuel consumption
Unit A multiplied by factor = Unit B
M6 6.31/6.04 6.1–6.2–6.25
M8 8.35/8.04 8.1–8.2–8.25–8.3
M 10 10.4/10.05 10.25
M 12 12.5/12.05 12.25–12.5
M 14 14.53/14.06 14.25–14.5
M 15 x 2 15.3/15.2 15.25
M 16 16.53/16.06 16.25–16.5
1 Snout
2 Spindle
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1 Spindle
2 Thread insert
1.2.12 Abbreviations
AL Alarm
CR Common Rail
DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards (DIN = "Deutsche
Industrie-Norm")
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
ICFN ISO - Continuous rating - Fuel stop power Power specifications acc. to DIN-ISO 3046-7
- Net
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
LOLO Low Low Alarm: Measured value is lower than 2nd minimum limit
MG Message
PAN Panel
TC Tools Catalog
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2 Task Descriptions
010 Crankcase and externally mounted 100 Exhaust turbocharger 250 PTO systems, driving end and
components (→ Page 46) (→ Page 158) free end (coupling)
(→ Page 56) 110 Intercooler 360 Auxiliary systems and
020 Gear train 120 Air intake/air supply supplementary equipment (not
030 Crank drive (→ Page 74) 140 Exhaust system shown) (→ Page 228)
040 Cylinder head (→ Page 105) 170 Starting equipment (→ Page 182) 500 Monitoring and control devices,
050 Valve drive (→ Page 113) 180 Lube oil system / lube oil circuit general electric equipment
(→ Page 120) 200 Coolant system (→ Page 192) (→ Page 238)
070 HP fuel system (→ Page 132) 210 Power supply
080 LP fuel system (→ Page 149) 230 Mounting/support
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Preconditions
• Engine shut down and starting disabled.
Preparatory steps
1. Remove cylinder head (→ Page 108).
2. Remove piston and conrod (→ Page 78).
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Special tools
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Spare parts
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Check sealing and mating faces for • Wear • Recondition: smooth with
wear and damage. • Damage oilstone.
visible • Replace
Check floating mount of the carbon Signs of jamming • Measure cylinder liner.
scraper ring in the cylinder liner. • Replace carbon scraper ring.
1 154.500
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 0Cylinder liner with groove: stage 1
Special tools
Material
Spare parts
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
1. Spray cylinder liner and carbon scraper ring with engine oil.
2. Insert carbon scraper ring into fit of cylinder liner.
3. Remove safety rail for cylinder liners.
TIM ID: 0000020536 – 002
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Observe safety regulations.
2. Drain or extract engine oil (→ Operating Instructions).
TIM ID: 0000020537 – 002
Special tools
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.
Spare parts
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Check mating face of oil pan on Unevenness exceeding 0.3 mm on Recondition mating face.
crankcase for surface irregularities. 8, 10, 12V engines
Material
Spare parts
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.
Preconditions
• Preparatory steps have been completed.
Removing oil lines and oil separator
1. Take pictures prior to removal or mark installed components and lines.
2. Remove oil lines and oil separator as per overview drawings.
3. Seal openings with suitable covers.
4. Protect oil separator from damage.
TIM ID: 0000039489 – 001
Special tools
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
11. Fill hand pumps (1) and (2) with SAE 10 engine oil.
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 with holding times of approx. 2 minutes,
until the vibration damper is released from the
crankshaft. In doing so, do not exceed the
maximum 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 sleeve.
25. Install lifting gear.
26. Remove vibration damper from crankshaft.
27. Seal openings with suitable covers.
TIM ID: 0000020853 – 002
Special tools
Material
Spare parts
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.
CAUTION
• Ensure correct installation position of components.
15. Fill hand pumps (1) and (2) with SAE 10 engine oil.
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.
TIM ID: 0000020854 – 002
Material
Overview drawing
Overview drawing
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Drain or extract engine oil (→ Operating Instructions ).
3. Remove ECU (→ Operating Instructions ).
4. Remove air filter (→ Operating Instructions ) .
5. Remove cylinder head (→ Page 108).
6. Lower oil pan (→ Page 58).
TIM ID: 0000020541 – 003
Special tools
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Special tools
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Piston cleaning
Note: The graphite layer on the piston skirt must not be mechanically removed or treated with strong cleaners!
Special tools
Spare parts
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Piston – Check
Piston rings
5 Measure groove width / keystone-type compression ring thickness for 1.500 mm recess.
Special tools
Spare parts
Conrod – Check
Check conrod main bore for blue Blue discoloration Replace conrod.
discoloration.
Conrod bearings
Reassembly with bearing shells, measurement in the direction of a/b/c, smallest dimension must lie in the
direction of a.
Inner Ø with bearing shell: 94.064 mm +0.042 mm
Conrod bore
Special tools
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Preparing conrod
1. Blow out joint faces (arrowed) on conrod and
conrod bearing cap with compressed air and clean.
2. Leather off bearing shell contact surfaces on
conrod and conrod bearing cap.
3. Before installing bearing shells, compare repair
stage entries on conrod and on crankshaft data
sheet.
4. Using aluminum jaws, mount conrod in bench vise
under conrod big end in horizontal position.
5. Insert upper conrod bearing (2) in conrod (1).
TIM ID: 0000020842 – 004
Special tools
Material
Spare parts
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Special tools
Material
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.
Check the conrod bearing shells for Wear, scores, corrosion, erosion or Replace
wear, scores, corrosion, erosion and damage visible
damage.
Check conrod bearing shell butt and Fretting corrosion visible Replace and determine cause.
bearing rear side for damage and Possible causes:
fretting corrosion. • insufficient screw pretension
• assembly error
• spread dimension of bearing
shell out of tolerance
• faulty bearing support bore
1 Slide layer
2 Barrier layer
3 Intermediate layer
4 Steel support shell
Assessment
An important indicator for assessing the extent of wear on the bearing shell is the shape
and extent of the blocking layer areas exposed.
Use of bearing shell is already restricted in friction area once the sliding layer is reduced to 70%!
It is often difficult to differentiate between the nickel barrier and softer slide layer.
If in doubt, consult a bearing specialist.
Damage to bearing
Damage to bearings occurs mainly through impressions and embedding, cavitation and
TIM ID: 0000038970 – 001
Overview drawing
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Remove cylinder head covers . (→ Operating Instructions ) .
3. Remove injector (→ Operating Instructions ).
4. Remove constant-pressure manifold (→ Page 173).
5. Remove air pipework to cylinders (→ Page 169).
6. Remove valve drive (→ Page 123).
TIM ID: 0000039500 – 001
Preconditions
• Preparatory steps have been completed.
Special tools
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Special tools
Material
Spare parts
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.
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Remove cylinder head cover (→ Operating Instructions).
2. Remove valve drive (→ Page 123).
Preconditions
• Preparatory steps have been completed.
Pushrod – Removal
1. Rotate pushrod so that the roller tappet is loosened.
2. Remove pushrod.
TIM ID: 0000020552 – 001
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Installing pushrod
1. Coat pushrod with engine oil.
2. Insert pushrod with ball head side, in doing so
make sure that it fits correctly in roller tappet.
100 Rocker arm with rocker shaft 105 Valve bridge 120 O-ring
support 115 Plug-in pipe
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions).
2. Remove air filter (→ Operating Instructions).
3. Remove cylinder head cover (→ Operating Instructions).
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Special tools
Material
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.
Preconditions
• Engine is stopped and starting disabled.
Special tools
Material
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Installing HP lines
1. Hand-tighten HP line (5) on fuel distributor.
2. Hand-tighten HP line (5) on HP pump.
3. Hand-tighten HP lines (1) and (2) on HP
accumulator.
4. Hand-tighten HP lines (1) and (2) on fuel distributor.
5. Use torque wrench to tighten all HP lines in
the same order to specified tightening torque
(→ Table Tightening torque on page 131).
6. Tighten fuel distributor (3).
7. Use torque wrench to tighten all screws on HP
accumulator (4) to specified tightening torque
(→ Table Tightening torque on page 131).
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.
Tightening torque
HP line on HP pump 40 Nm +5 Nm
HP line on HP accumulator 40 Nm +5 Nm
HP line on injector 20 Nm +5 Nm
TIM ID: 0000020868 – 003
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Remove fuel lines (low pressure) (→ Page 147).
2. Remove fuel lines (high pressure) (→ Page 141).
3. Remove sensors, actuators and injectors (→ Page 244).
TIM ID: 0000020569 – 001
Special tools
Spare parts
Special tools
Material
Spare parts
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.
Preconditions
• Engine is stopped and starting disabled.
HP line – Removal
1. Take pictures prior to removal or mark installed components and lines.
2. Remove lines as per overview drawing (→ Page 140).
3. Seal openings with suitable covers.
TIM ID: 0000020866 – 003
Special tools
HP line – Installation
1. Install HP line as shown in overview drawing, photos taken or marks made prior to removal (→ Page 140).
2. Use torque wrench to tighten screws for HP line to specified tightening torque (→ Page 129).
2.6.1 Fuel pipework from fuel delivery pump to fuel filter – Overview
2.6.2 Fuel pipework from fuel delivery pump to fuel filter – Removal
Preconditions
• Disable engine start.
2.6.3 Fuel pipework from fuel delivery pump to fuel filter – Installation
Spare parts
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Observe safety regulations.
2. Drain engine coolant (→ Operating Instructions ).
Spare parts
Check all sealing and mating faces • Damage • Recondition: smooth with
for stress marks and damage. • Stress marks oilstone or emery cloth.
visible • Replace
Material
Spare parts
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Preconditions
• Preparatory steps have been completed.
Spare parts
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Overview drawing
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Remove carrier housing cover (→ Page 180).
Special tools
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Special tools
Material
Spare parts
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.
Preconditions
• Preparatory steps have been completed.
Removing charge-air pipe
1. Remove charge-air pipe as shown in overview drawing (→ Page 168).
2. Remove gaskets and O-rings.
3. Seal openings with suitable covers.
TIM ID: 0000020728 – 001
Material
Spare parts
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Remove oil supply pipework for exhaust turbochargers (→ Page 190).
3. Remove coolant pipework from/to exhaust turbochargers (→ Operating Instructions ).
4. Remove crankcase breather (→ Page 63).
5. Remove sensors, actuators and injectors (→ Page 244).
6. Remove exhaust flap actuator (→ Page 178).
Special tools
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Preconditions
• Engine is stopped and starting disabled.
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 and flap housing.
Valid for 10V 12V 16V (12V/16V one turbocharger and exhaust flap additionally)
Overview drawing
Overview drawing
Material
Spare parts
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Preconditions
• Engine is stopped and starting disabled.
Removing carrier housing cover
1. Remove oil lines (4) from turbocharger.
2. Remove coolant lines (3).
3. Disconnect clevis head (6) from actuating cylinder.
4. Remove flange (7).
5. Remove union from oil supply to turbocharger.
6. Remove flange (1) with gasket.
7. Remove all screws (5).
8. Remove carrier housing cover (2).
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.
Cleaning starter
1. Do not wet-clean. Clean starter with compressed air only.
2. Protect starter from moisture.
Spare parts
Inspecting starter
Check mating face on end housing Wear traces are found. Rework: Smooth with crocus cloth
for wear. or oilstone.
TIM ID: 0000020603 – 003
Material
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.
Starter – Installation
1. Coat starter pinion with lubricating grease.
2. Install starter according to overview drawing (→ Page 182).
Overview drawing
40 4/2-way directional control valve 280 Oil supply line 553 Washer
60 Plate 320 Union 554 Nut
100 Screw 340 Sealing ring 580 Screw
160 Union 400 Oil line 600 Washer
180 Sealing ring 420 Oil line 620 Washer
210 Retainer 460 Oil line 630 Nut
220 Screw 480 Oil line 650 Oil return line
240 Washer 510 Retainer, left side 660 Clamp
251 Bracket 520 Screw 665 Screw
252 Screw 540 Washer 670 Washer
253 Washer 551 Retainer, left side 700 Union
254 Washer 552 Screw 720 Sealing ring
TIM ID: 0000039522 – 001
Overview drawing
1220 4/2-way directional control valve 1640 Oil line 1830 Nut
1240 Plate 1660 Oil line 1831 Clamp
1280 Screw 1700 Retainer 1832 Screw
1340 Union 1720 Screw 1833 Washer
1360 Sealing ring 1740 Washer 1834 Retainer
1400 Screw 1751 retainer, right side 1835 Screw
1420 Washer 1752 Screw 1836 Washer
1460 Oil supply line 1753 Washer 1850 Oil return line
1500 Union 1754 Nut 1900 Union
1520 Sealing ring 1780 Screw 1920 Sealing ring
1580 Oil line 1800 Washer
1600 Oil line 1820 Washer
TIM ID: 0000039522 – 001
Preconditions
• Engine is stopped and starting disabled.
Exhaust turbocharger oil supply – Removal
1. Before removing the lines, take photos or mark attachments and lines.
2. Remove oil lines, connecting and mounting parts as shown in overview drawing (→ Page 187).
3. Remove all sealing elements.
4. Seal openings with suitable covers.
5. Protect oil lines from damage.
Material
Spare parts
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.
Overview drawing
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Remove sensor cable for sensors B6, B6.2 and B16 (→ Operating Instructions).
3. Remove protective cover (→ Page 67).
4. Release coolant line from coolant pump elbow.
5. Remove fuel line from hand pump to high-pressure pump.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Material
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Spare parts
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
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 traces • Recondition: smooth with
of wear and damage. • Indentations oilstone or emery cloth.
• Damage • Replace.
visible
Material
Spare parts
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
1 Coolant distribution housing 4 Cooler plate A Position of code letter (bottom left)
2 Initial plate 5 End plate B Position of gasket (to the
3 Cooler plate 6 Cover plate cover plate)
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Drain raw water.
3. Remove raw water lines (→ Page 226).
TIM ID: 0000020613 – 001
Special tools
Special tools
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Cleaning agents containing chlorine and hydrochloric acid attack metal surfaces.
Risk of damage due to corrosion!
CAUTION • Do not use hydrochloric acid with stainless steel.
• Chlorine concentration in water solution must not exceed 300 ppm for cleaning purposes.
If a higher chlorine concentration is required, contact MTU.
• Protect aluminum components against chemicals.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Use appropriate cleaning tool.
Preparatory steps
1. Remove cooler plates (→ Page 202).
2. Place cooler plates on a suitable surface for cleaning.
Heavy fouling
Note: Mechanically clean open unit to remove:
• Algae
• Pieces of wood/fiber
• Shellfish
1. Clean plates under running water with a soft brush. Avoid damaging the seal.
2. Clean plates with high-pressure hose.
3. Dry seals with a cloth.
Biological fouling
Note: Mechanically or chemically clean open unit to remove:
• Bacteria
• Nematodes
• Protozoa
1. Clean plates under running water with a soft brush. Avoid damaging the seal.
2. Clean plates with high-pressure hose.
3. Clean plates with alkaline cleaning agents e.g.:
• Sodium hydroxide
• Sodium carbonate
Concentration Temperature
1. Clean plates under running water with a soft brush. Avoid damaging the seal.
2. Clean plates with high-pressure hose.
3. Clean plates with acidic cleaning agents e.g.:
• Nitric acid
• Sulphamic acid
• Citric acid
TIM ID: 0000020615 – 002
• Phosphoric acid
Concentration Temperature
Sediments (deposits)
Note: Mechanically or chemically clean open unit to remove:
• Corrosion products
• Metal oxides
• Sludge
• Loam
• Diatom organisms
1. Clean plates under running water with a soft brush. Avoid damaging the seal.
2. Clean plates with high-pressure hose.
3. Clean plates with chemical cleaning agents e.g.:
• Nitric acid
• Sulphamic acid
• Citric acid
• Phosphoric acid
Concentration Temperature
Special tools
Spare parts
Check mating faces and sealing • Stress marks • Recondition: smooth with
surfaces of cover plate for stress • Damage oilstone or emery cloth
marks and damage. visible • Replace
Check threaded pin for damage and • Stress marks • Recondition: recut thread
stress marks. • Damage • Replace
visible
Special tools
Material
Spare parts
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Drain engine coolant (→ Operating Instructions ).
2. Remove sensor cable for sensor B6.2 (→ Operating Instructions).
3. Remove protective cover (→ Page 67).
4. Disconnect coolant line from coolant pump elbow.
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Special tools
Spare parts
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Component is hot.
Risk of burning!
WARNING • Wear protective gloves.
Check all sealing and mating faces • Stress marks • Recondition: smooth with
for stress marks and damage. • Damage oilstone or emery cloth.
visible • Replace
Special tools
Material
Spare parts
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.
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Close raw water supply.
2. Drain raw water.
3. Remove protective cover and holder.
4. Remove elbow.
TIM ID: 0000020632 – 001
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Visually inspect sealing surfaces for • Stress marks • Recondition: smooth with
stress marks, pitting and cavitation. • Pitting oilstone or emery cloth.
• Cavitation • Replace
visible
Material
Spare parts
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Preconditions
• Preparatory steps have been completed.
Coolant pipework on raw water pump – Removal
1. Remove raw water lines and securing parts as per overview drawing (→ Page 225).
2. Remove Orings, gaskets and sealing rings.
3. Seal openings with suitable covers.
Material
Spare parts
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Bilge pump
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Remove protective cover (→ Page 67).
2. Remove suction and pressure lines.
3. Mark electrical cable on bilge pump and disconnect it.
TIM ID: 0000020642 – 001
Material
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Spare parts
Check all contact and mating Stress marks visible. • Recondition: smooth with
surfaces. oilstone or emery cloth.
• Replace
Special tools
Material
Spare parts
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
Settings
9 B6 Coolant temperature
TIM ID: 0000020654 – 001
2 B1 Camshaft speed
9 M8 HP pump
System sensors
The sensors are mounted on the engine exterior.
Preconditions
• Engine is stopped and starting disabled.
Preparatory steps
1. Observe safety regulations.
2. Drain engine coolant (only if coolant sensors are to be removed) (→ Operating Instructions).
TIM ID: 0000020656 – 001
B7 (oil temperature) During removal, small amounts of engine oil may emerge. Catch engine
oil in a suitable container.
B33 (fuel temperature) During removal, small amounts of fuel may emerge. Catch fuel in a
suitable container.
Material
Spare parts
3 Special Tools
F30005947 Socket 1
TIM ID: 0000020700 – 001
F30005947-1-b Socket 1
F30907150 Socket 1
TIM ID: 0000020700 – 001
T80091769 Hook 1
8205893261/00 Oilstone 1
TIM ID: 0000020700 – 001
Y20097353 Endoscope 1
TIM ID: 0000020701 – 001
5505890921/00 Compression 1
pressure recorder
4 Appendix
Service
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and customer
service centers ensure fast and direct support on site and ensure the high availability of our products.
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For our locally available support, go to MTU’s Internet site: http://www.mtu-online.com/mtu/mtu-worldwide/
24h Hotline
With our 24h hotline and high flexibility, we’re your contact around the clock: during each operating
phase, preventive maintenance and corrective operations in case of a malfunction, for information
on changes in conditions of use and for supplying spare parts.
Your contact at Headquarters: Service-support@mtu-online.com
Spare Parts Service
Fast, simple and correct identification of spare parts for your drive system or vehicle fleet.
The right spare part at the right time at the right place.
To this end we offer worldwide networked parts logistics
– a central depot at Headquarters, as well as decentralized depots among our subsidiaries,
representatives and contractual workshops.
Your contact at Headquarters:
e-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908779
Fax.: +49 7541 908102
4.3 Index
A Carrier housing – Final steps . . . . . . . . . . . . . 181
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . 43 Carrier housing – Overview . . . . . . . . . . . . . . 171
Air Intake / Air Supply . . . . . . . . . . . . . . . . . . . 168 Carrier housing – Preparatory steps . . . . . . . . 172
Air pipework to cylinders – Conrod – Assembly . . . . . . . . . . . . . . . . . . . . 95
Installation . . . . . . . . . . . . . . . . . . . . . . 170
Conrod – Check . . . . . . . . . . . . . . . . . . . . . . . 89
Air pipework to cylinders – Removal . . . 169
Air supply system to cylinders – Conrod – Tolerances . . . . . . . . . . . . . . . . . . . . 91
Overview . . . . . . . . . . . . . . . . . . . . . . . . 168 Conrod bearing shells – Check . . . . . . . . . . . . 104
Air pipework to cylinders – Installation . . . . . . 170 Constant-pressure manifold – Removal . . . . . 173
Air pipework to cylinders – Removal . . . . . . . . 169 Conversion tables . . . . . . . . . . . . . . . . . . . . . . 36
Air supply system to cylinders – Overview . . . 168 Coolant cooler – Check . . . . . . . . . . . . . . . . . . 206
Auxiliary materials, fire prevention and Coolant cooler – Cleaning . . . . . . . . . . . . . . . . 203
environmental protection . . . . . . . . . . . . . . . . . 12 Coolant cooler – Final steps . . . . . . . . . . . . . . 209
Auxiliary Systems / Supplementary Coolant cooler – Installation . . . . . . . . . . . . . . 207
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Coolant cooler – Overview . . . . . . . . . . . . . . . 200
Bilge pump – Check . . . . . . . . . . . . . . . 234
Bilge pump – Cleaning . . . . . . . . . . . . . 233 Coolant cooler – Preparatory steps . . . . . . . . . 201
Bilge pump – Final steps . . . . . . . . . . . 237 Coolant cooler – Removal . . . . . . . . . . . . . . . . 202
Bilge pump – Installation . . . . . . . . . . . . 235 Coolant pipework on raw water pump –
Bilge pump – Overview . . . . . . . . . . . . . 228 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Bilge pump – Preparatory steps . . . . . . 231
Coolant pipework on raw water pump –
Bilge pump – Removal . . . . . . . . . . . . . 232
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Coolant pipework on raw water pump –
B Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Bilge pump – Check . . . . . . . . . . . . . . . . . . . . 234 Coolant pipework with thermostat – Check . . . 214
Bilge pump – Cleaning . . . . . . . . . . . . . . . . . . 233 Coolant pipework with thermostat –
Bilge pump – Final steps . . . . . . . . . . . . . . . . . 237 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Bilge pump – Installation . . . . . . . . . . . . . . . . . 235 Coolant pipework with thermostat – Final
Bilge pump – Overview . . . . . . . . . . . . . . . . . . 228 steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Bilge pump – Preparatory steps . . . . . . . . . . . 231 Coolant pipework with thermostat –
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Bilge pump – Removal . . . . . . . . . . . . . . . . . . 232
Coolant pipework with thermostat –
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
C Coolant pipework with thermostat – Preparatory
Carrier housing – Cover removal and steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Carrier housing – Disassembly . . . . . . . . . . . . 174
TIM ID: 0000020688 – 004
Engine coolant pump – Overview . . . . . . . . . . 192 Fuel pipework from fuel delivery pump to fuel
Engine coolant pump – Preparatory steps . . . 194 filter – Installation . . . . . . . . . . . . . . . . . . . . . . 148
Engine coolant pump – Removal . . . . . . . . . . 195 Fuel pipework from fuel delivery pump to fuel
filter – Overview . . . . . . . . . . . . . . . . . . . . . . . 143
Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fuel pipework from fuel delivery pump to fuel
Engine side and cylinder designations . . . . . . 16
filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . 147
Exhaust flap with actuator . . . . . . . . . . . . . . . . 175
Exhaust flap with actuators – Installation . . . . 179
G
Exhaust flap with actuators – Removal . . . . . . 178
General information on the Tolerances and Wear
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . 171 Limits List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Carrier housing – Cover removal and
installation . . . . . . . . . . . . . . . . . . . . . . . 180 General Instructions . . . . . . . . . . . . . . . . . . . . 07
Carrier housing – Disassembly . . . . . . . 174 General Provisions . . . . . . . . . . . . . . . . . . . . . 07
Carrier housing – Final steps . . . . . . . . 181 Abbreviations . . . . . . . . . . . . . . . . . . . . 43
Carrier housing – Overview . . . . . . . . . 171 Auxiliary materials, fire prevention and
Carrier housing – Preparatory steps . . . 172 environmental protection . . . . . . . . . . . 12
Constant-pressure manifold – Conversion tables . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . 173 Engine side and cylinder designa-
Exhaust flap with actuator . . . . . . . . . . . 175 tions . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exhaust flap with actuators – General information on the Tolerances
Installation . . . . . . . . . . . . . . . . . . . . . . 179 and Wear Limits List . . . . . . . . . . . . . . . 15
Exhaust flap with actuators – General Instructions . . . . . . . . . . . . . . . 07
Removal . . . . . . . . . . . . . . . . . . . . . . . . 178 Personnel and organizational
Exhaust Turbocharger . . . . . . . . . . . . . . . . . . 158 requirements . . . . . . . . . . . . . . . . . . . . . 08
Exhaust turbocharger – Check . . . . . . . 164 Repairing threaded bores with threaded
Exhaust turbocharger – Cleaning . . . . . 163 inserts (Heli-Coil) . . . . . . . . . . . . . . . . . 41
Exhaust turbocharger – Final steps . . . 167 Safety precautions when working on the
Exhaust turbocharger – Installation . . . 165 engine . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Exhaust turbocharger – Overview . . . . . 158 Settings . . . . . . . . . . . . . . . . . . . . . . . . . 34
Exhaust turbocharger – Preparatory Standards for warning notices in the
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 publication . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust turbocharger – Removal . . . . . 161 Tightening specifications for screws, nuts
and bolts . . . . . . . . . . . . . . . . . . . . . . . . 17
Exhaust turbocharger – Check . . . . . . . . . . . . 164
General workshop equipment – Overview . . . 283
Exhaust turbocharger – Cleaning . . . . . . . . . . 163
Exhaust turbocharger – Final steps . . . . . . . . 167
Exhaust turbocharger – Installation . . . . . . . . . 165
H
High Pressure Fuel System . . . . . . . . . . . . . . 129
Exhaust turbocharger – Overview . . . . . . . . . . 158
HP fuel pump – Check . . . . . . . . . . . . . 135
Exhaust turbocharger – Preparatory steps . . . 160 HP fuel pump – Installation . . . . . . . . . . 136
Exhaust turbocharger – Removal . . . . . . . . . . 161 HP fuel pump – Overview . . . . . . . . . . . 132
Exhaust turbocharger oil supply – HP fuel pump – Preparatory steps . . . . 133
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 HP fuel pump – Removal . . . . . . . . . . . 134
HP fuel system – Tightening
Exhaust turbocharger oil supply –
procedure . . . . . . . . . . . . . . . . . . . . . . . 129
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
HP line – Installation . . . . . . . . . . . . . . . 142
Exhaust turbocharger oil supply – HP line – Overview . . . . . . . . . . . . . . . . 140
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 HP line – Removal . . . . . . . . . . . . . . . . 141
HP pump – Final steps . . . . . . . . . . . . . 139
F HP fuel pump – Check . . . . . . . . . . . . . . . . . . 135
HP fuel pump – Installation . . . . . . . . . . . . . . . 136
TIM ID: 0000020688 – 004
Sensors, actuators and injectors – Preparatory Roller tappet, pushrod – Check . . . . . . 117
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Roller tappet, pushrod – Installation . . . 118
Sensors, actuators and injectors – Roller tappet, pushrod – Preparatory
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Roller tappets, pushrod – Final
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Special tools – Overview . . . . . . . . . . . . . . . . . 254 Valve drive – Check . . . . . . . . . . . . . . . 125
Standard tools – Overview . . . . . . . . . . . . . . . 253 Valve drive – Final steps . . . . . . . . . . . . 128
Standards for warning notices in the Valve drive – Installation . . . . . . . . . . . . 126
publication . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Valve drive – Overview . . . . . . . . . . . . . 120
Valve drive – Preparatory steps . . . . . . 122
Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . 184
Valve drive – Removal . . . . . . . . . . . . . 123
Starter – Inspection . . . . . . . . . . . . . . . . . . . . . 185 Valve gear – Cleaning . . . . . . . . . . . . . . 124
Starter – Installation . . . . . . . . . . . . . . . . . . . . 186 Valve roller tappet, pushrod –
Starter – Removal . . . . . . . . . . . . . . . . . . . . . . 183 Overview . . . . . . . . . . . . . . . . . . . . . . . . 113
Starting Equipment . . . . . . . . . . . . . . . . . . . . . 182 Valve drive – Check . . . . . . . . . . . . . . . . . . . . 125
Electric starter – Overview . . . . . . . . . . 182 Valve drive – Final steps . . . . . . . . . . . . . . . . . 128
Starter – Cleaning . . . . . . . . . . . . . . . . . 184 Valve drive – Installation . . . . . . . . . . . . . . . . . 126
Starter – Inspection . . . . . . . . . . . . . . . . 185
Valve drive – Overview . . . . . . . . . . . . . . . . . . 120
Starter – Installation . . . . . . . . . . . . . . . 186
Starter – Removal . . . . . . . . . . . . . . . . . 183 Valve drive – Preparatory steps . . . . . . . . . . . 122
Valve drive – Removal . . . . . . . . . . . . . . . . . . 123
T Valve gear – Cleaning . . . . . . . . . . . . . . . . . . . 124
Tightening specifications for screws, nuts and Valve roller tappet, pushrod – Overview . . . . . 113
bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Vibration damper on PTO, free end –
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Vibration damper on PTO, free end –
V Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Vibration damper on PTO, free end –
Pushrod – Cleaning . . . . . . . . . . . . . . . 116
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Pushrod – Removal . . . . . . . . . . . . . . . 115
TIM ID: 0000020688 – 004